Manufacturing Process Manual Final (Repaired)

FACULTY OF ENGINEERING SCIENCES AND TECHNOLOGY
Hamdard Institute of Engineering & Technology

Hamdard University
Manufacturing Processes
Experiments Manual
ME-313
FALL-2019
Name: _______________________________________
Roll Number: ____________________________________
Mechanical Engineering Department

Hamdard University Karachi
Hamdard Institute of Engineering & Technology, Hamdard University

Sharae Madinat Al-Hikmah, Muhammad Bin Qasim Avenue, Karachi 74600, Pakistan.
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Index
Exp No. Experiment Signature
1 To Observe various safety rules for a machining shop.
2 To Observe various parts and cutting tools used for center lathe
machine.
3 To conduct an experiment to make bush of the given size
4 To conduct an experiment to make a hexagonal headed bolt of 12

TPI BSW Threading on Lathe Machine
5 To execute the given material into the shape required through
machining as per given specification.
6(a) To conduct an experiment to make coupling joint pair using drill
machine and lathe machine
6(b) Open Ended Lab
7 To conduct an experiment to make square from a circular specimen
using milling machine
8 To conduct an experiment on milling to produce a Hexagon.
9 To conduct an experiment on electric arc welding with five types of

basic weld joints.
10 To conduct an experiment on the working of oxy-acetylene gas
welding.
11 To Conduct an experiment on the oxy-acetylene gas cutting.
12(a) To Conduct an experiment on Sand-Casting Process.
12(b) Open Ended Lab
13 To Observe the Die Casting and Centrifugal Casting Process.
14 To Observe the Brazing Process.

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Marks Evaluation
Marks
Experiment No.
C.P(0.3) E.P(0.5) E.R(0.2)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Final
________________________
Instructor Signature

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Introduction to the Manufacturing Process Laboratory
Purpose
The goals of the Manufacturing Process laboratory are:
1. To allow the students to perform experiments that demonstrate the theory of

Manufacturing Process that is discussed in the theory course.
2. The goal of the laboratory is to educate students through practical experiences in the
manufacturing of the mechanical parts also familiar with the mechanical manufacturing
machines and the operations that are performed on them and to remain on the competitive
edge of new developments.
3. To familiarize the students with proper laboratory procedure, including precise record-
keeping, logical troubleshooting, safety, and learning about the capabilities and limitations of
your equipment.
Introduction
Objectives: where the expected achievements by the end of the experiment are stated.
Theoretical Background: Where the theory of the subject is reviewed. The introduction is
kept brief, assuming the student has covered the material in detail in class, or can refer to the
theory textbook for further reading.
Learning outcomes: What will be the learning outcome after the student has successfully
completed the tasks in the Lab experiment?
General Laboratory Procedure
While there is no specific document to be submitted at the beginning of the Lab –unless your
instructor advises you otherwise-, you are expected to read the experiment fully before you
come to the laboratory? Interestingly, you can even try parts of the experiment at home. Here
is a list of programs that will equip you with a virtual lab at your home:
Matlab® Simulation Tool http://www.mathworks.com/
Troubleshooting
Things will not always go as expected; this is the nature of the learning process. While
conducting the Experiment think before you do anything. If you do so you will avoid
wasting time going down dead-end streets. Be logical and systematic. First, look for obvious
errors that are easy to fix. Is your measuring device correctly set and connected? Are you
looking at the proper scale? Is the power supply set for the correct voltage? Is the signal
generator correctly set and connected? How are the variables in the code set? Is there a syntax
error? And so on. Next, check for obvious misconnections or broken connections, at least in
simple circuits.

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As you work through your circuit, use your Lab Manual record tests and changes that you
make as you go along; don't rely on your memory for what you have tried. Identify some test
points in the system at which you know what the signal should be and work your way
backwards from the output through the test points until you find a good signal.
Neatness
When you have finished for the day, return all modules to their proper storage bins, return all
test leads and probes to their storage racks, return all equipment to its correct location, and
clean up the lab station. If appropriate switch off the unneeded equipment. Save your files in
the Computer and on any USB device for your records because you might not get the same
PC System again for the next experiment. Also email your file contents to your email address
as a backup.
Laboratory Safety
Always pay attention to what you are doing and you’re surrounding during the experiments
and notify the Instructor for any unlikely event or mishap and leave the Laboratory with the
permission of Instructor immediately.
All students must read and understand the information in this document with regard to
laboratory safety and emergency procedures prior to the first laboratory session. Your
personal laboratory safety depends mostly on YOU. Effort has been made to address
situations that may pose a hazard in the lab but the information and instructions provided
cannot be considered all-inclusive.
Students must adhere to written and verbal safety instructions throughout the academic term.
Since additional instructions may be given at the beginning of laboratory sessions, it is
important that all students arrive at each session on time. With good judgement, the chance
of an accident in this course is very small. Nevertheless, research and teaching workplaces
(labs, shops, etc.) are full of potential hazards that can cause serious injury and or damage to
the equipment. Working alone and unsupervised in laboratories is forbidden if you are
working with hazardous substances or equipment. With prior approval, at least two people
should be present so that one can shut down equipment and call for help in the event of an
emergency. Safety training and/or information should be provided by a faculty member,
teaching assistant, lab safety contact, or staff member at the beginning of a new assignment
or when a new hazard is introduced into the workplace.

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Emergency Response
1. It is your responsibility to read safety and fire alarm posters and follow the
instructions during an emergency
2. Know the location of the fire extinguisher, eye wash, and safety shower in your lab
and know how to use them.
3. Notify your instructor immediately after any injury, fire or explosion, or spill.
4. Know the building evacuation procedures.
Common Sense
Good common sense is needed for safety in a laboratory. It is expected that each student will
work in a responsible manner and exercise good judgement and common sense. If at any time
you are not sure how to handle a situation, ask your Teaching Assistant or Instructor for
advice. DO NOT TOUCH ANYTHING WITH WHICH YOU ARE NOT
COMPLETELY FAMILIAR!!! It is always better to ask questions than to risk harm to
yourself or damage to the equipment.
Personal and General laboratory safety
1. Never eat, drink, or smoke while working in the laboratory.

2. Read labels carefully.
3. Do not use any equipment unless you are trained and approved as a user by your
supervisor.
4. Wear safety glasses or face shields when working with hazardous materials and/or
equipment.
5. Wear gloves when using any hazardous or toxic agent.
6. Clothing: When handling dangerous substances, wear gloves, laboratory coats, and
safety shield or glasses. Shorts and sandals should not be worn in the lab at any time.
Shoes are required when working in the machine shops.
7. If you have long hair or loose clothes, make sure it is tied back or confined.
8. Keep the work area clear of all materials except those needed for your work. Coats
should be hung in the hall or placed in a locker. Extra books, purses, etc. should be
kept away from equipment, which requires air flow or ventilation to prevent
overheating.
9. Disposal - Students are responsible for the proper disposal of used material if any in
appropriate containers.
10.Equipment Failure - If a piece of equipment fails while being used, report it
immediately to your lab assistant or tutor. Never try to fix the problem yourself
because you could harm yourself and others.
11.If leaving a lab unattended, turn off all ignition sources and lock the doors.
12.Never pipette anything by mouth.
13.Clean up your work area before leaving.
14.Wash hands before leaving the lab and before eating.
15.Unauthorized person(s) shall not be allowed in a laboratory for any reason

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Electrical safety
1. Obtain permission before operating any high voltage equipment.

2. Maintain an unobstructed access to all electrical panels.
3. Wiring or other electrical modifications must be referred to the Electronics Shop or
the Building Coordinator.
4. Avoid using extension cords whenever possible. If you must use one, obtain a heavy-
duty one that is electrically grounded, with its own fuse, and install it safely.
Extension cords should not go under doors, across aisles, be hung from the ceiling, or
plugged into other extension cords.
5. Never, ever modify, attach or otherwise change any high voltage equipment.
6. Always make sure all capacitors are discharged (using a grounded cable with an
insulating handle) before touching high voltage leads or the "inside" of any equipment
even after it has been turned off. Capacitors can hold charge for many hours after the
equipment has been turned off.
7. When you are adjusting any high voltage equipment or a laser which is powered with
a high voltage supply, USE ONLY ONE HAND. Your other hand is best placed in a
pocket or behind your back. This procedure eliminates the possibility of an accident
where high voltage current flows up one arm, through your chest, and down the other
arm.
8. Discard damaged cords, cords that become hot, or cords with exposed wiring.
9. Before equipment is energized ensure, (1) circuit connections and layout have been
checked by a Teaching Assistant (TA) and (2) all colleagues in your group give their
assent.
10. Know the correct handling, storage and disposal procedures for batteries, cells,
capacitors, inductors and other high energy-storage devices.
11. Experiments left unattended should be isolated from the power supplies. If for a
special reason, it must be left on, a barrier and a warning notice are required.
12. Equipment found to be faulty in any way should be reported to the Lab Engineer
immediately and taken out of service until inspected and declared safe.
13. Voltages above 50 V rms AC and 120 V DC are always dangerous. Extra precautions
should be considered as voltage levels are increased.
14. Never make any changes to circuits or mechanical layout without first isolating the
circuit by switching off and removing connections to power supplies.
15. Know what you must do in an emergency.
16. Emergency Power Off: Every lab is equipped with and Emergency Power Off
System.
17. Only authorized personnel are permitted to reset power once the Emergency Power
Off system has been engaged.
Electrical Emergency Response
The following instructions provide guidelines for handling two types of electrical
emergencies:
1. When someone suffers serious electrical shock, he or she may be knocked

unconscious. If the victim is still in contact with the electrical current, immediately
turn off the electrical power source. If you cannot disconnect the power source,
depress the Emergency Power Off switch.

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2. Do not touch a victim that is still in contact with a live power source; you could be
electrocuted.
3. Have someone call for emergency medical assistance immediately. Administer first-
aid, as appropriate.
4. If an electrical fire occurs, try to disconnect the electrical power source, if possible. If
the fire is small and you are not in immediate danger; and you have been properly
trained in fighting fires, use the correct type of fire extinguisher to extinguish the fire.
When in doubt, push in the Emergency Power Off button.
5. NEVER use water to extinguish an electrical fire.
Mechanical safety
1. When using compressed air, use only approved nozzles and never directs the air
towards any person.
2. Guards on machinery must be in place during operation.
3. Exercise care when working with or near hydraulically- or pneumatically-driven
equipment. Sudden or unexpected motion can inflict serious injury.
Additional Safety Guidelines
1. Never do unauthorized experiments.

2. Never work alone in laboratory.
3. Keep your lab space clean and organized.
4. Do not leave an on-going experiment unattended.
5. Always inform your instructor if you break a thermometer. Do not clean mercury
yourself!!
6. Never taste anything. Never pipette by mouth; use a bulb.
7. Never use open flames in laboratory unless instructed by TA.
8. Check your glassware for cracks and chips each time you use it. Cracks could cause
the glassware to fail during use and cause serious injury to you or lab mates.
9. Maintain unobstructed access to all exits, fire extinguishers, electrical panels,
emergency showers, and eye washes.
10. Do not use corridors for storage or work areas.
11. Do not use corridors for storage or work areas.
12. Do not store heavy items above table height. Any overhead storage of supplies on
top of cabinets should be limited to lightweight items only. Also, remember that a
36" diameter area around all fire sprinkler heads must be kept clear at all times.
13. Areas containing lasers, biohazards, radioisotopes, and carcinogens should be posted
accordingly. However, do not post areas unnecessarily and be sure that the labels are
removed when the hazards are no longer present.
14. Be careful when lifting heavy objects. Only shop staff may operate forklifts or
cranes.
15. Clean your lab bench and equipment, and lock the door before you leave the
laboratory.

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Clothing
1. Dress properly during a laboratory activity.
2. Long hair, dangling jewelry, and loose or baggy clothing are a hazard in the
laboratory.
3. Long hair must be tied back, and dangling jewelry and baggy clothing must be
secured.
4. Shoes must completely cover the foot.
5. No sandals allowed on lab days.
6. A lab coat or smock should be worn during laboratory experiments.
Accidents and Injuries
1. Do not panic.
2. Report any accident (spill, breakage, etc.) or injury (cut, burn, etc.) to the teacher
immediately, no matter how trivial it seems.
3. If you or your lab partner is hurt, immediately (and loudly) yell out the teacher's name
to get the teacher's attention.

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General Warning Signs

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Practical No: 01
Objective:
To observe various safety rules for a machining shop
SAFETY RULES:
DO's
1. Immediately report any accident even if it is small.

2. Wear your overalls buttoned up to protect your clothes and prevent loose and ties
becoming caught in the moving part of the machine.
3. Either roll up your overall sleeves or button up the cuffs.
4. Keep your hair short or wear a cap, net or hair band.
5. Keep machine and all equipment clean and in good condition.
6. Before starting machine ensure that you know how to stop it.
7. Switch off the machine immediately if anything goes wrong.
8. Keep the machine and surrounding area tidy.
9. Check oil level before first starting machine.
10. Switch off machine at the main at the end of each day.
11. Check that chucks or clutches rotate in the correct directions before commencing cutting
operations.
12. Use the correct tool or cutter for the job.
13. Replace tool that are worn or damaged.
14. Keep tools and cutter in boxes or racks when not in use.
15. Report immediately to your instructor any mechanical or electrical fault.
16. Ensure that all machine parts are in position before starting the machine.
17. Check that the work area is clean before starting the machine.
18. Ensure that everything is properly secured before starting the machine.
19. Ensure that feed mechanisms are not engaged before starting the machine.
DON'Ts
1. Don't wear rings or watches while operating a machine.

2. Don't keep sharp tools in your overall.
3. Don't remove swarf with your bare hand, use a brush.
4. Don't manually lift heavy equipment.
5. Don't lean on the machine.
6. Don't attempt to operate a machine until know how to correctly use the machine.
7. Don't temper with the machine.
8. Don't remove any stop in an effort to obtain a greater cutting range or the machine may
severely damage.
9. Don't try to reverse the direction of the motion of the machine during motion.
10. Don't try to change the spindle speed while in motion.
11. Don't throw things.
12. Don't walk away and leave your machine running.
13. Don't direct compressed air at yourself or workmates it can kill.

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Questions:
1. Detect different practices that are used in machine shop to promote general safety?
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2. Recognize personal safety protection devices or clothing must you wear while working in
the shop?
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4. Detect the procedure should you follow if you see an accident happen?
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5. Recognize the instructions that are given for handling and storage of your job's material?
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Practical No: 02
Objective:
To observe various parts and cutting tools used for center lathe machine
Lathe Machine:
Definition:
Lathe is the most versatile and commonly used among all machine tools. The work piece is
held in a holding device (e.g. chuck) and rotated on the axis, while the cutting tool is
advanced along the line of the desired cut. Lathe size is determined by the "SWING" and
"BED LENGTH". Swing indicates the largest diameter that can be turned. Bed length is the
entire length of the ways and should not be mistaken for the maximum length of the metal
that can be turned.
Operations performed on lathe:
A lathe machine is extremely versatile and with suitable attachments the lathe maybe used for
performing a very large number of machining operations. Typical machining operations that
are performed on a lathe are turning, facing, tapering, and taper turning, drilling, boring,
spinning, grinding, threading, tapping and polishing operation.
Major Parts of Lathe Machine:
Each of the lath part falls into one of the three functional divisions:
1. Driving the lathe.
2. Holding and rotating the work.
3. Holding and moving the cutting tool.
Main parts of a center lathe are:
1. The bed and ways.

2. The head Stock.
3. The quick-change gear box.
4. The carriage assembly.
5. The tail stock.
1. BED:
The bed is a heavy, rugged casting made to support the working parts of the lathe. On its top
section are machined ways that guide and provide for precise alignment of the headstock' and
tail stock.
2. The Head Stock:
The headstock is clamped on the left-hand side of the bed. Hollow spindle supported by the
bearings, provides a drive through the gears from the motors to the work holding devices.
The spindle is usually fitted with one of two standardized taper spindle noses, or with a

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threaded spindle nose. 3- Jaw or 4- Jaw chucks can be fitted on to the spindle in order to hold
and drive the workpiece, which would allow the cutting tool to perform various operations.
3. Feed Mechanism:
The feed mechanism transmits power through a gear train to the quick-change gear box
which in tum regulates the distance of tool travel per revolution of the spindle. The LEAD
SCREW transmits the power to the carriage through a gearing and clutch arrangement in the
apron. Feed change levers on the apron controls the operation of power feeds and, when
placed in neutral, permits the half nuts to be engaged for threading operations.
4. Carriage Assembly:
The Carriage Assembly consists of three main parts.

1. The saddle
2. Apron
3. Cross slide.
4.1 The Saddle:
It is used to move the cutting tool along the lathe bed. The saddle is an H-shaped casting
mounted on the top of the lathe ways, provides a mean of mounting the cross slide & the
apron.
4.2 Apron:
It is the part of carriage assembly on the side of the operator. It contains levers for engaging
and dis-engaging the feed rod and lead screw via a half nut. Apron fastened to the saddle
houses the gears and mechanism required to move the carriage or cross side automatically.
The apron hand wheel can be turned manually to move the carriage along the lathe bed. This
hand wheel connected to a gear that meshes on a rack fastener to the lathe bed.
4.3 The cross slide:
The cross slide mounted on top of the saddle, provides a manual or automatic cross
movement for the cross movement of cutting tools. The compound rest, fitted on the top of
the cross slide is used to support the cutting tool.
5. Tail Stock:
It consists of the upper and lower castings. It can be adjusted along the lathe ways to
accommodate works of different lengths. The tailstock can be locked in any position along
the bed of the lathe by the tail stock clamp. The tail stock spindle has an internal taper to
receive the dead center, which provides support for the right-hand end of the work. Other
standard tapered shank tool such as reamer and drill can be held in the tail stock spindle. A
Spindle clamp is used to hold the tail stock spindle in or out of the tail stock casting. It can be
used to provide a hand feed for drilling and reaming operations.

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Lathe Tools:
The tools used for common machining operations on a lathe are single point cutting tools i.e.
they have only one cutting edge that must be re-sharpened when becomes dull or worn out
after a certain period of machining. The most commonly used tool material is High speed
steel, although carbides and ceramics tool inserts are gaining increased usage due to their
many superior characteristics over HSS tools. Refer to figure for various configurations of
lathe tools.
Lathe Machine
Discussions:
1. Detect lathe machine to illustrate different parts?

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2. Detect lathe machine to define tail stock quill?

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Practical No: 03
Objective:
To conduct an experiment to make bush of given size
Lathe Machine:
Definition:
that can be turned.
Procedure:
 Place the job in the chuck to hold tightly
 Face the both sides of the job
 Process turning to required diameter.
Processes:
1. Turning
2. Facing
3. Drilling
4. Chamfering
Figure 1: Bush

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Learning Outcome:

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Practical No: 04
Objective:
To conduct an experiment to make a hexagonal headed bolt of 12 TPI BSW Threading on
Lathe Machine
Material:
M.S Hexagonal 3/4" rod and 2" in length
Tools & Equipments:

Lathe Machine, Cutting tool, V-Type threading tool, and Vernier caliper
Theory:
that can be turned.
Lathe Threading
Thread cutting on the lathe is a process that produces a helical ridge of uniform section on the
workpiece. This is performed by taking successive cuts with a threading toolbit the same
shape as the thread form required.
The formula below will give you the single depth for undertaking unified threads:
d = P x 0.750
Where d = Single Depth
P = Pitch
n = Number of threads per inch (TPI)
Infeed Depth = .75 / n

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Procedure for threading:
1. Set the speed to about one quarter of the speed used for turning.
2. Set the quick change gearbox for the required pitch in threads. (Threads per inch)
3. Set the compound rest at 29 degrees to the right for right hand threads.
4. Install a 60 degree threading tool bit and set the height to the lathe center point.
5. Set the tool bit and right angles to the work, using a thread gage.
6. Using a layout solution, coat the area to be threaded.
7. Move the threading tool up to the part using both the compound and the cross
feed. Set the micrometer to zero on both dials
Learning Outcome:
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Practical No: 05
Objective:
To execute the given material into the shape required through machining as per given
specification
Material:
Mild Steel Solid Bar 37mm in diameter and 60mm in length.
Measuring tool:
Vernier Caliper.
Cutting tool:
Single edge HSS Cutting Tool.
Operations:
1. Facing.
2. Turning.
3. Step Turning.
4. Chamfering.
Job assignment

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Figure 2: Stepped Shaft (step Turning)
Procedure:
Learning Outcome:
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Practical No: 06
Objective:
To conduct an experiment to make coupling joint pair using drill machine and lathe machines
Introduction:
Drilling holes is one of the most basic of machining operations, and probably is the one
which produces maximum chip volume. Drilling often is not the ultimate operation in hole
production. Because the finishing is not very good, and there may be tapering of hole
diameter with depth, therefore, drilling is most often followed by finishing operations like
reaming, boring and honing. Various other hole modification operations are also performed
subsequent to drilling that include counter-boring, counter-sinking and spot-facing.
Required:
Figure 3 Coupling oriented view Figure 4: Coupling Side View
Figure 5: Coupling Size

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Operations:
1. Facing.
2. Turning.
3. Step Turning.
4. Chamfering.
Procedure:
Learning Outcome:
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___________________________________________________________________________
___________________________________________________________________________

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Practical No: 06 (b)
Open Ended Lab

(Freedom to develop own experiment without guidelines)
Objective:
Observation:
Learning Outcomes:

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Practical No: 07
Objective:
To conduct an experiment to make square from a circular specimen using milling machine
Introduction:
Milling machine is probably the most versatile of all traditional machine tools. It has been
said that a milling machine is capable of reproducing itself. With an extremely wide range of
attachments and cutters, almost every machining operation can he performed on a milling
machine. But the main disadvantage is the cost and skill requirement for operating a milling
machine.
Milling machine is well known for gear manufacturing and production of dies and molds.
Although the latter application has been snatched by non-traditional machines like EDM and
wire-EDM, nevertheless modern milling machines with computer controls are an important
part of today’s industry.
Procedure:
 Fix the given material on milling machine
 Mark the points on round job
 Set the position of the cutter
 Start the machine and proceed in x-direction, y-direction and z-direction respectively
Given:
Figure 6: Circular Job with D=55mm
Required:
Figure 7: 30 mm square

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Learning Outcome:

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Practical No: 08
Objective:
To conduct an experiment on milling to produce a Hexagon
Introduction:
Milling machine is probably the most versatile of all traditional machine tools. It has been
said that a milling machine is capable of reproducing itself. With an extremely wide range of
attachments and cutters, almost every machining operation can he performed on a milling
machine. But the main disadvantage is the cost and skill requirement for operating a milling
machine.
Milling machine is well known for gear manufacturing and production of dies and molds.
Although the latter application has been snatched by non-traditional machines like EDM and
wire-EDM, nevertheless modern milling machines with computer controls are an important
part of today’s industry.
Procedure:
 Fix the given material on milling machine
 Mark the points on round job
 Set the position of the cutter
 Start the machine and proceed in x-direction
Given:
Figure 8: Circular Specimen with D=55mm
Required:
Figure 9: Hexagon

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Learning Outcome:

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Practical No: 09
Objective:
To conduct an experiment on electric arc welding with five basic types of welds joints.
Introduction:
ELECTRIC ARC WELDING:
The term arc welding applies to a large and varied group of processes that use an electric arc
as the source of heat to melt and join metals. In arc welding processes, the joining of metals
or weld is produced by the extreme heat of an electric arc drawn between an electrode and the
work piece. The arc is struck between the work piece and an electrode that is mechanically or
manually moved along the joint. The metal wire not only carried the welding current, but as it
melted in the arc, it also supplied the necessary filler.
All arc-welding process employs the same basic circuit. If distinct current is used and the
work is made positive (the anode of the circuit), the condition is known as straight polarity.
When the cork is negative & the electrode is positive, reverse polarity is employed.
In one large group of arc welding process, the electrode is consumed (consumable electrode
pressure) and thus supplies the metal needed to fill the voids in the joints. Consumable
electrodes have a melting temperature below the temperature of the arc. Small droplets are
melted from the end of the electrode and pass to workpiece. The size of these droplets varies
greatly and the mechanism of the transfer depends on the type of electrode welding current
and other process parameters. As the electrodes melts, the arc length and the electrical
resistances of the arc path will vary. To maintain a stable arc and satisfactory welding
condition, the electrode must be towards the work at controlled rate. Manual arc welding is
almost always performed with shielded electrodes.
Continuous bare-metal wire can be used as the electrode in automatic or semiautomatic arc
welding, but this is always in conjunction with a separate shielding and arc stabilizing
medium and automatic feed controlling devices that maintain the proper arc length.
Because of the wide variety of processes available, arc welding has become a widely used
means of joining material. Each process and application however requires the selections and
specification of the welding voltage, welding current, arc polarity, arc length, welding speed,
arc atmosphere, electrodes or filler metal and flux. Filler materials must be selected to match
the base metal with respect to properties and / or alloy content. For many of the processes, the
quality of the weld also depends on the strikes of the operator.
Types of Joint:
There are five basic types of joints for bringing two members together for welding. These
joint types or deigns are also used by other skilled trades. These five basic types of joints are:
1) Butt joint (B):

Parts in approximately the same plane.
2) Corner joint (C):

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Parts at approximately right angle and at the edge of both parts.
3) Edge joint (E):

An edge of two or more parallel parts.
4) Lap joint (L):

Between overlapping parts.
5) Tee joint (T):

Parts are approximately right angles, not at the edge of one part.
Several types of Weld Joints
Welding Positions:
Welding is often done on structures in position in which they are found. Techniques have
been developed to allow welding in any position. Some welding processes have all-position
capabilities, while others may be used in only one or two positions. All welding can be
classified according to the position of the work piece or the position of the welded joint on
the plates or sections being welded. There are four basic welding positions, which are
illustrated in figure:

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Welding positions—Groove weld—Plates
Flat position welding:

In this position, the welding is performed on the upper side of the joint, and the face of the
weld is approximately horizontal. Flat welding is the preferred term; however, the same
position is sometimes called down hand.
Horizontal position welding:

Fillet weld:
In this position, welding is performed on the upper side of an approximately horizontal
surface and against an approximately vertical surface.
Groove weld:
In this position, the axis of the weld lies in an approximately horizontal plane and the face of
the weld lies in an approximately vertical plane.
Horizontal fixed weld:
In this pipe welding position, the axis of the pipe is approximately horizontal, and the pipe is
not rotated during welding.
Horizontal rolled weld:
In this pipe welding position, welding is performed in the flat position by rotating the pipe.
Vertical position welding:

a) In this position, the axis of the weld is approximately vertical. Vertical welding positions.
b) In vertical position pipe welding, the axis of the pipe is vertical, and the welding is
performed in the horizontal position.
Overhead position welding:

In this welding position, the welding is performed from the underside of a joint.
Covered Electrodes:
When molten metal is exposed to air, it absorbs oxygen and nitrogen, and becomes brittle or
is otherwise adversely affected. A slag cover is needed to protect molten or solidifying weld
metal from the atmosphere. This cover can be obtained from the electrode coating. The
composition of the electrode coating determines its usability, as well as the composition of
the deposited weld metal and the electrodes specification. The formulation of electrode
coatings is based on well-established principle of metallurgy, chemistry, and physics. The

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coating protects the metal from damage, stabilizes the arc and improves the weld in other
ways, which includes:
1. The smooth weld metal surface with even edges.

2. Minimum spatter adjacent to the weld.
3. A stable welding arc.
4. Penetration control.
5. A strong, tough coating.
6. Easier slag removal.
7. Improve deposition rate.
The type of electrode used depends upon the specific properties required in the weld
deposited. These include corrosion resistance, ductility, high tensile strength, the type of base
metal to be welded, the position of the weld (flat, horizontal, vertical, or overhead) and the
type of current and polarity required.
Questions:
1. Explain the basic principles of Arc Welding process?
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2. Describe the functions and characteristics of electrodes. What functions do coatings

have?
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3. Enlist and explain briefly the arc-welding processes that do not use consumable
electrodes.
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Practical No: 10
Objective:
To conduct an experiment on the working of oxy-acetylene gas welding.
Introduction:
GAS WELDING:
Gas welding processes are a group of welding processes in which a weld is made by heating
with a gas flame or fares. Pressure and/or filler metal may or may not be used. Also referred
to as oxyfuel gas welding, the term gas welding is used to describe any welding process that
uses a fuel gas combined with oxygen, or in rare cases, with air, to produce a flame having
sufficient energy to melt the base metal. The fuel gas and oxygen are mixed in the proper
proportions in a chamber, which is generally a part of the welding tip assembly. The torch is
designed to give the welder complete control of the welding flare allowing the welder to
regulate the melting of the base metal and the filler metal. The molten metal from the plate
edges and the filler metal intermix in a common molten pool and join upon cooling to form
one continuous piece. Manual welding methods are generally used. Acetylene was originally
used as the fuel gas in oxyfuel gas welding, but other gases, such as MAPP gas, have also
been used. The flames must provide high localized energy to produce and sustain a molten
pool. The flames can also supply a protective reducing atmosphere over the molten metal
pool which is maintained during welding. Hydrocarbon fuel gases such as propane, butane
and natural gas are not suitable for welding ferrous materials because the heat output of the
primary flame is too low for concentrated heat transfer or the flame atmosphere is too
oxidizing.
Oxy-Acetylene Gas Welding Equipment

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TYPES OF FLAME:
The two-stage combustion process produces a flame having two distinct regions. The
maximum temperature occurs near the end of the inner cone, where the first stage of
combustion is completed. Most welding should be performed with the torch positioned so
that the point of maximum temperature is just above the metal being welded. The outer
envelope of the flame serves to preheat the metal, end at the same time, provides shielding
from oxidation, since oxygen from the surrounding air is used in the secondary combustion.
Three different types of flames can be obtained by varying the oxygen / acetylene (or oxygen
/ fuel gas) ratio. If the ratio is about 1:1 to 1.15:1, all reactions are carried to completion and a
neutral flame is produced. Most welding is done with a neutral flame, since it will have the
least chemical effect on the heated metal.
A higher ratio, such as 1.5:1 produces an oxidizing flame, hotter than the neutral flame (about
6000oF) but similar in appearance. Such flames are used when welding copper and copper
alloys but are generally considered harmful when welding still because the excess oxygen
react with the carbon, decarburizing the region around the weld.
Excess fuel, on the other hand, produces a carburizing flame. The excess fuel decomposes to
carbon & hydrogen and the flame temperature is not as great (about 5550 oF). Flames with a
slight excess of fuel are reducing flames. No carburization occurs, but the metal is well
protected from oxidation. Flames of these types are used in welding Monel, high carbon steel
and some alloy steels, and for applying some types of hard-facing materials.
For welding purpose, the oxygen is usually supplied in relatively pure form from pressurized
tanks, but in rare cases, air can also be used. The acetylene is usually obtained in portable
storage tanks that hold up to 300 cubic ft. (8.5 m3) at 250 psi (1.7 MPa) pressure. Because
acetylene is not safe when stored as a gas at pressure above 15 psi (0.1 MPa), it is usually
dissolved in acetone. The storage cylinders are fitted with porous filler such as balsa-wood
chips or infusion earth. Acetone is absorbed in to the voids in the filler material and serves as
a medium for dissolving the acetylene.
The pressure used in a gas-flame welding range from 1 to 15 psi (7 to 105 MPa) and is
controlled by pressure regulators on each tank. Because mixture of acetylene and oxygen are
highly explosive, precaution must be taken to avoid mixing the gases improperly or by

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accident. All acetylene fitting has left hand threads, while those for oxygen are equipped with
right hand threads.
The tip size (or orifice diameter) of the torch can be varied to control the shape of inner cone
and the flow rate of the gases. Larger tip permits greater flow of gases, resulting in greater
heat input without the higher gas velocities that might blow the molten metal from the weld
pedal. Larger torch tips are required for welding thicker metal and operate with higher gas
pressure.
EQUIPMENTS:
Oxygen Cylinder:
A typical oxygen cylinder is shown. It is made of steel and has a capacity of 220 cu-ft. at a
pressure of 2000-psi (13,790 kPa) and a temperature of 70°F (21°C). Attached equipment
provided by the oxygen supplier consists of an outlet valve, a removable metal cap for the
protection of the valve, and a low melting point safety fuse plug and disk. The cylinder is
fabricated from a single plate of high grade steel so that it will have no seams and is heat
treated to achieve maximum strength. Because of their high pressure, oxygen cylinders
undergo extensive testing prior to their release for work and must be periodically tested
thereafter.
Acetylene Cylinders:
Acetylene cylinders are equipped with safety plugs which have a small hole through the
center. This hole is filled with a metal alloy which melts at approximately 212F (100C) or
releases at 500 psi (3448 kPa). When a cylinder is overheated the plug will melt and permit

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the acetylene to escape before dangerous pressures can be developed. The plug hole is too
small to permit a flame to burn back into the cylinder if escaping acetylene is ignited.
Oxygen and Acetylene Regulators:

Regulators reduce pressure and control the flow of gases from the cylinders. The pressure in
an oxygen cylinder can be as high as 2200 psi (15,169 kPa); which must be reduced to a
working pressure of 1 to 25 psi (6.90 to 172.38 kPa). The pressure of acetylene in an
acetylene cylinder can be as high as 250 psi (1724 kPa).
Oxy-acetylene Welding Torch:

The oxyacetylene welding torch is used to mix oxygen and acetylene in definite proportions.
It also controls the volume of these gases burning at the welding tip, which produces the
required type of flame. The torch consists of a handle or body which contains the hose
connections for the oxygen and the fuel gas. The torch also has two needle valves, one for
adjusting the flow of oxygen and one for acetylene, and a mixing head.

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Oxy-Acetylene Gas Welding Torch
Hose:
The hoses used to make the connection between are made especially for this purpose. They
are built to withstand high internal; regulator and torch; pressures.
Procedure:
When setting up the welding and cutting equipment, it is important that all operations be
performed systematically to avoid mistakes trouble.
Cylinders
• Place the oxygen and acetylene cylinders on a level floor and tie them firmly to a work
bench, post, wall or other secure anchorage to prevent their being knocked or pulled over.
• Remove the valve protecting caps.
• "Crack" both cylinders valves by opening first the acetylene and then the oxygen valve
slightly for an instant to blowout any dirt matter that may have accumulated during shipment
or storage.
• Close the valves and wipe the connection seat with a clean cloth.
Pressure Regulators:
• Check the regulator fitting for dirt and obstruction. Also check threads of cylinders and
regulators for imperfection.
• Connect the respective regulators to the oxygen and acetylene cylinders.
• Connect the red hose to the acetylene regulator and the green one to the oxygen.
• Open the cylinder valve slowly. Read the high-pressure gages to check the cylinder gage
pressure. Blowout the oxygen hose by turning the regulator screw in and then release the
regulator screw. Flash back suppressors must be attached to the torch whenever possible.
Adjustment of Work Pressure:

Adjust the acetylene work pressure by opening the acetylene needle valve on the torch and
turning the regulator screw to the right. Then adjust the acetylene regulator to the required
pressure for the tip size to be used. Close the needle valve. Adjust the oxygen working
pressure in the same manner.
Shutting Down Welding Apparatus:

a. Shut off the gases. Close the acetylene valve first, then the oxygen valve on the torch. Then
close the acetylene and oxygen cylinder valves.
b. Drain the regulators and hoses by the following procedures:

(1) Open the torch acetylene valve until the gas stops flowing and the gauges read zero, then
close the valve.
(2) Open the torch oxygen valve to drain the oxygen regulator and hose. When gas stops
flowing and the gauges read zero, close the valve.

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(3) When the above operations are performed properly, both high and low-pressure gauges on
the acetylene and oxygen regulators will register zero.
c. Release the tension on both regulator screws by turning the screws to the left until they
rotate freely.
d. Coil the hoses without kinking them and suspend them on a suitable holder or hanger.
Avoid upsetting the cylinders to which they are attached.
Discussions:
Q.1. What are some of the problems that might occur when high temperatures are used in
welding?
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Q.2. Why does an oxyfuel gas-welding torch usually have a flame with two distinct regions?
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Q.3. What three types of flames varying the oxygen fuel ratio can produced?
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Q.4. What is the location of the maximum temperature in an oxyacetylene flame?

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Hamdard University
Practical No: 11
Objective:
To conduct an experiment on the oxy-acetylene gas cutting.
Introduction:
OXY-ACETYLENE GAS CUTTING:

For many years, metal sheets and plates have been cut by means of oxyfuel torches.
Basically, a thermal cutting is done by oxyfuel gas cutting. In nonferrous, the metal is melted
by the flame of the torch and a gap known as kerf is produced. However, in ferrous metals it
becomes a rapid oxidation(burning) of iron at high temperature.
Cutting torch and other cutting equipment:

The cutting torch like the welding torch has a tube for oxygen and one for acetylene. In
addition, there is a tube for high pressure oxygen, along with a cutting tip or nozzle. The tip is
provided with a center hole through which a jet of pure oxygen passes. Mixed oxygen and
acetylene pass through holes surrounding the center holes for the preheating flames. The
number of orifices for oxyacetylene flames ranges from 2 1to 6, depending on the purpose for
which the tip is used. The cutting torch is controlled by a trigger or lever operated valve. The
cutting torch is furnished with interchangeable tips for cutting steel from less than 1/4 in. (6.4
mm) to more than 12.0 in. (304.8 mm) in thickness.
Oxy-Acetylene Gas Cutting Torch

Operation of Cutting Equipment:
a) Attach the required cutting tip to the torch and adjust the oxygen and acetylene pressure.
b) Adjust the preheating flame to neutral.
c) Hold the torch so that the cutting oxygen lever or trigger can be operated with one hand.
Use the other hand to steady and maintain the position of the torch head to the work. Keep

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the flames at a 90-degree angle to work in the direction of travel. The inner cones of
preheating flames should be about 1/16 in. (1.6 mm) above the end of the line to be cut. Hold
this position until the spot has been raised to a bright red heat, and then slowly open the
cutting oxygen valve.
d) If the cut has been started properly, a shower of sparks will fall from the opposite side of
the work. Move the torch at a speed which allows the cut to continue penetrating the work. A
good cut will be clean and narrow.
e) When cutting billets, round bars, or heavy sections, time and gas are saved if a burr is
raised with a chisel al the point where the cut is to start. This small portion will heat quickly
and cutting will start immediately. A welding rod can be used to start a cut on heavy sections.
When used, it is called a starting rod.
Precautions:
1) Always have suitable fire extinguishing equipment at hand when doing any welding.
2) Do not stand facing cylinder valve outlets of oxygen, acetylene, or other compressed gases
when opening them.
3) Purge both acetylene and oxygen lines (hoses) prior to igniting torch. Failure to do this can
causes serious injury to personnel and damage to the equipment.
4) Oxygen and gas should be stored separately. Always chain store cylinders. Acetylene
cylinders may explode unless store upright.
5) Cylinders regulators should be correctly used.
6) Leaks- ensure no gas is escaping from any part of equipment.
Personal Protection:
1) Use proper gloves, overalls and industrial type footwear, especially when cutting or
welding overhead.
2) Eyes - protect them with a helmet and visor of a grade designed for the type of welding,
wear eyes protect during slag removal or chipping and grinding.
Discussions:
1. Produce a difference between torch cutting of ferrous metals & cutting non-oxidizing
metals?
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2. Produce a difference between an oxyacetylene cutting torch and an oxyacetylene welding

torch?
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Hamdard University
Practical No: 12
Objective:
To conduct an experiment on Sand-Casting Process.
Introduction:
SAND CASTING:
Sand casting is used to make large parts (typically cast iron, but also bronze, brass,
aluminum). Molten metal is poured into a mold cavity formed out of sand (natural or
synthetic). The main components of the mold are included patterns, sprues and runners.
Patterns:
The cavity in the sand is formed by using a pattern (an approximate duplicate of the real
part), which are typically made from wood, sometimes metal. The cavity is contained in an
aggregate housed in a box called the flask. Core is a sand shape inserted into the mold to
produce the internal features of the part such as holes or internal passages. Cores are placed
in the cavity to form holes of the desired shapes. Core print is the region added to the pattern,
core, or mold that is used to locate and support the core within the mold. A riser is an extra
void created in the mold to contain excessive molten material. The purpose of this is to feed
the molten metal to the mold cavity as the molten metal solidifies and shrinks, and thereby
prevents voids in tile main casting.
Typical Components of a Two-Part Sand Casting Mold
In a two-part mold, which is typical of sand castings, the upper half, including the top half of
the pattern, flask, and core is called cope and the lower half is called drag. The parting line or
the parting surface is line or surface that separates the cope and drag. The drag is first filled
partially with sand, and the core print, the cores, and the gating system are placed near the
parting line. The cope is then assembled to the drag, and the sand is poured on the cope half,
covering the pattern, core and the gating system. The sand is compacted by vibration and
mechanical means. Next the cope is removed from the drag, and the pattern is carefully
removed. The object is to remove the pattern without breaking the mold cavity. This is

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facilitated by designing a draft, a slight angular offset from the vertical to the vertical surfaces
of the pattern usually a minimum of 1 or 1.5 mm, whichever is greater. The rougher the
surface of the pattern, the more the draft to be provided.
Sprues and Runners:

The molten material is poured in the pouring cup, which is part of the gating system that
supplies the molten material to the mold cavity. The vertical part of the gating system
connected to the pouring cup is the sprue, and the horizontal portion is called the runners and
finally to the multiple points where it is introduced to the mold cavity called the gates.
Additionally, there are extensions to the gating system called vents that provide the path for
the built-up gases and the displaced air to vent to the atmosphere.
The cavity is usually made oversize to allow for the metal contraction as it cools down to
room temperature. This is achieved by making the pattern oversize. To account for shrinking,
the pattern must be made oversize by these factors, on the average. These are linear factors
and apply in each direction. These shrinkage allowances are only approximate, because the
exact allowance is determined from the shape and size of the casting. In addition, different
parts of the casting might require a different shrinkage allowance.
Sand castings generally have a rough surface sometimes with surface impurities, and surface
variations. A machining (finish) allowance is made for this type of defect.
Steps involved in processing a sand casting

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Discussions:
1. Execute sand casting process to define the function of a Core & Core print.
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2. Execute sand casting process to define the function of a riser.

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3. Produce a list to write different types of sand used in sand casting process?
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Practical No: 12 (b)
Open Ended Lab

(Freedom to develop own experiment without guidelines)
Objective:
Observation:
Learning Outcomes:

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Practical No: 13
Objective:
To Observe the Die Casting and Centrifugal Casting Process.

Introduction:
DIE CASTING:
Die-casting is a permanent mold casting process wherein the molten metal is injected into the
mold under high pressure of 10-210 MPa (1450-30500 Psi). This results in a more uniform
part, generally good surface finish and good dimensional accuracy, as good as 0.2% of
casting dimension. For many parts, post-machining can be eliminated, or very light
machining may be required to bring dimensions to size.
Die-casting can be done using a cold chamber or hot chamber processes:
Cold Chamber Process:

In a cold chamber process, the molten metal is ladled into the cold chamber for each shot.
There is less time exposure of the melt to the plunger walls or the plunger. This is particularly
useful for metals such as Aluminum and Copper (and its alloys) that alloy easily with Iron at
the higher temperatures.
Hot Chamber Process:

In a hot chamber process the pressure chamber is connected to the die cavity is immersed
permanently in the molten metal. The inlet port of the pressurizing cylinder is uncovered as
the plunger moves to the open (unpressurized) position. This allows a new charge of molten
metal to fill the cavity and thus can fill the cavity faster than the cold chamber process. The
hot chamber process is used for metals of low melting point and high fluidity such as tin,
zinc, and lead that tend not to alloy easily with steel at their melt temperatures.
Die casting molds (called dies in the industry) tend to be expensive as they are made from
hardened steel, also the cycle time for building these tend to be long. Also, the stronger and
harder metals such as iron and steel cannot be die-cast.
Common Alloys in Die Casting:

Aluminum, Zinc and Copper alloys are the materials predominantly used in die-casting. On
the other hand, pure Aluminum is rarely cast due to high shrinkage, and susceptibility to hot
cracking. It is alloyed with Silicon, which increases melt fluidity, reduces machinability.
Copper:
Copper is another alloying element, which increases hardness, reduces ductility, and reduces
corrosion resistance.
Aluminum:

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Aluminum is cast at a temperature of 650˚C (1200 ˚F). It is alloyed with Silicon 9% and
Copper about 3.5% to form the Aluminum Association 380 alloy (UNS A03800). Silicon
increases the melt fluidity, reduces machinability, Copper increases hardness and reduces the
ductility. By greatly reducing the amount of Copper (less than 0.6%) the chemical resistance
is improved; thus AA 360 (UNS A03600) is formulated tor use in marine environments. A
high silicon alloy is used in automotive engines for cylinder castings, AA 390 (UNS A03900)
with 17% Silicon for high wear resistance. Common aluminum alloys for die casting are
summarized as follows:
Material Silicon Copper Tensile Strength

MPa (kpsi)
AA 380 8.5% 3.5% 324
(UNS A03800) (47)
AA 384 11% 4% 331
(UNS A03840) (48)
AA 386 9.5% 0.6% 317
(UNS A03860) (46)
AA 390 17% 4.5% 283
(UNS A03900) (41)
Zinc:
Zinc can be made to close tolerances and with thinner walls than Aluminum, due to its high
melt fluidity. Zinc is alloyed with Aluminum (4%), which adds strength and hardness. The
casting is done at a low temperature of 425°C (800 ˚F) so the part does not have to cool much
before it can be ejected from the die. This, in combination with the fact that Zinc can be run
using a hot chamber process allows for a fast fill, fast cooling (and ejection) and a short cycle
time. Zinc alloys are used in making precision parts such as sprockets, gears, and connector
housings.
Copper alloys are used in plumbing, electrical and marine applications where corrosion and
wear resistance is important.
Minimum wall thickness and minimum draft angles for die casting are:
Material Min. Thickness Min. Draft Angle (⁰)

mm (in)
Aluminum Alloys 0.9 mm 0.5
(0.035 in)
Zinc Alloys 0.6 mm 0.25
(0.025 in)
Copper Alloys 1.25 mm 0.7
(Brass) (0.050 in)
Die-castings are typically limited from 20 kg (55 Ib) max. for Magnesium, to 35 kg (77 Ib)
max. for Zinc. Large castings tend to have greater porosity problems, due to entrapped air,

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and the melt solidifying before it gets to the furthest extremities of the die-cast cavity. The
porosity problem can be somewhat overcome by vacuum die casting.
From a design point of view, it is best to design parts with uniform wall thickness and cores
of simple shapes. Heavy sections cause cooling problems, trapped gases causing porosity. All
corners edges should be avoided to avoid stress concentration. Draft allowance should be
provided to all for releasing the parts-these are typically 0.25° to 0.75° per side depending on
the material.
CENTRIFUGAL CASTING:
Centrifugal casting: In centrifugal casting, a permanent mold is rotated about its axis at high
speeds (300 to 3000 rpm) as the molten metal is poured. The molten metal is centrifugally
thrown towards the inside mold wall, where it solidifies after cooling. The casting is usually a
fine grain casting with a very fine-grained outer diameter which is resistant to atmospheric
corrosion, a typical situation with pipes. The inside diameter has more impurities and
inclusions, which can be machined away.
Centrifugal Casting
Only cylindrical shapes can be produced with this process. Size limits are up to 3 m (10 feet)
diameter and 15 m (50 feet) length. Wall thickness can be 2.5 mm to 125 mm (0.I - 5.0 in).
The tolerances that can be held on the OD can be as good as 2.5 mm (0.1 in) and on the ID,
can be 3.8 mm (0.15 in). The surface finish ranges from 2.5 mm t6 12.5 mm (0.1 - 0.5 in)
rms.
Typical materials that can be cast with this process are iron, steel, stainless steels, and alloys
of aluminum, copper and nickel. Two materials can be cast by introducing a second material
during the process. Typical parts made by this process are pipes, boilers, pressure vessels,
flywheels, cylinder liners and other parts that are axis-symmetric.

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Discussions:
1. Detect the method for venting provided in the permanent molds of die-casting?
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2. Detect the different advantages and limitations of die-casting?

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3. Recognize the different factors on which the life of the die depends in die-castings?
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___________________________________________________________________________
___________________________________________________________________________

Hamdard University
Practical No: 14
Objective:
To Observe the Brazing Process.
Introduction:
BRAZING PROCESS:
Brazing is the joining of metals using heat and a filler metal whose melting temperature is
above 840⁰F (150 ⁰C), but below the melting point of the metals being joined.
ln comparison with welding, the brazing process is different in many ways:
1. The composition of the brazing alloy is significantly different from that of the base metal.
2. The strength of the brazing alloy is substantially lower than that of the base metal.
3. Bonding requires capillary action; the specific flow being related to the viscosity of the
liquid and the geometry of the joint.
Because of these differences, the brazing process has several distinct advantages:
1. Virtually all metals can be joined by some type of brazing metal.

2. The process is ideally suited for dissimilar metals, such as the joining of ferrous to non-
ferrous, or metals with widely different melting points.
3. Since less heating is required than for welding, the process can be performed quickly and
economically.
4. The lower temperatures reduce problems associated with heat-affected zones, warping, or
distortion. Thinner and more complex assemblies can be joined successfully.
5. Brazing is highly adaptable to automation and performs well when mass producing delicate
assemblies. A strong permanent joint is formed.
A major disadvantage of brazing is that subsequent heating of the assembly can cause
inadvertent melting of the braze metal, weakening or destroying the joint. Too often brazed-
joints fail when people apply heat to straighten or repair damaged assemblies.
Although this is certainly not the result of defective brazing, the consequences are still most
unfortunate.
Another concern with brazed joints is their enhanced susceptibility to corrosion. Since the
filler metal is of different composition than the materials being joined, the brazed joint is a
localized galvanic corrosion cell. This effect can often be minimized by proper selection of
the filler metal.
Brazing Metals:
Brazing materials should be selected based on a variety of criteria, including compatibility
with the base materials, brazing temperature restrictions, restrictions due to service or
subsequent processing temperatures, the brazing process to be used, the joint design,
anticipated service environment, desired appearance, desired mechanical properties (such as

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strength, ductility., and toughness), desired physical properties (such as electrical, magnetic,
or thermal) and cost. In addition, the materials must can flow through small capillaries,
"wetting" the joint surfaces, and partially alloying with the base metals. The most commonly
used brazing metals are copper and copper alloys, silver and silver alloys, and aluminum
alloys. Following Table shows some common braze metal families, the metals they are used
to join, and the typical brazing temperatures.
Braze Metal Family Materials Commonly Jointed Typical Brazing

Temperature (0C)
Aluminum – silicon Aluminum alloys 1050 – 1150
Copper and copper Various ferrous metals as well as 1700 – 2100
alloys copper and nickel alloys and
stainless steel
Copper – phosphorus Copper and copper alloys 1300 – 1700
Silver alloys Ferrous and non-ferrous metals, 1150 – 1800
except aluminum and magnesium
Precious metals (Gold Iron, nickel and cobalt alloys 1650 – 2000
based)
Magnesium Magnesium alloys 1100 – 1150
Nickel alloys Stainless steel, nickel and cobalt 1700 – 2200
alloys
Procedure:
A common source of heat for brazing is a gas-flame torch, in the torch-brazing procedure,
oxyacetylene, oxy-hydrogen, or other gas-flame combinations can be used. Most repair
brazing is done in this manner because of its flexibility and simplicity, but the process is also
widely used in production applications. Local heating permits the retention of most of the
original material strength and permits large components to be joined with little or no
distortion. The major drawbacks are the difficulty in controlling the temperature, maintaining
uniformity of heating, and meeting the cost of skilled labor. A protective flux is required and
the flux residue must be removed after brazing. In production-type torch brazing, specially
shaped torches are often used to speed the heating and aid in reducing the amount of skill
required.
Methods of applying Braze metal and Positioning or Fixturing various joints

Hamdard University
Discussions:
1. Recognize the difference between Brazing and Welding?
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2. Recognize a reason for Brazing as an appropriate method for joining dissimilar metal
with widely different melting point?
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3. Recognize Brazed joints more prone to corrosion problem than welded joint?
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________


Manufacturing Process Manual Final (Repaired)

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FACULTY OF ENGINEERING SCIENCES AND TECHNOLOGY

Hamdard Institute of Engineering & Technology

Roll Number: ____________________________________

Mechanical Engineering Department

Hamdard Institute of Engineering & Technology, Hamdard University

1 To Observe various safety rules for a machining shop.

4 To conduct an experiment to make a hexagonal headed bolt of 12

9 To conduct an experiment on electric arc welding with five types of

12(a) To Conduct an experiment on Sand-Casting Process.

12(b) Open Ended Lab

13 To Observe the Die Casting and Centrifugal Casting Process.

14 To Observe the Brazing Process.

Hamdard Institute of Engineering & Technology, Hamdard University

Hamdard Institute of Engineering & Technology, Hamdard University

The goals of the Manufacturing Process laboratory are:

1. To allow the students to perform experiments that demonstrate the theory of

General Laboratory Procedure

Matlab® Simulation Tool http://www.mathworks.com/

Hamdard Institute of Engineering & Technology, Hamdard University

Hamdard Institute of Engineering & Technology, Hamdard University

Personal and General laboratory safety

1. Never eat, drink, or smoke while working in the laboratory.

Hamdard Institute of Engineering & Technology, Hamdard University

1. Obtain permission before operating any high voltage equipment.

Electrical Emergency Response

1. When someone suffers serious electrical shock, he or she may be knocked

Hamdard Institute of Engineering & Technology, Hamdard University

1. Never do unauthorized experiments.

Hamdard Institute of Engineering & Technology, Hamdard University

1. Dress properly during a laboratory activity.

4. Shoes must completely cover the foot.

5. No sandals allowed on lab days.

6. A lab coat or smock should be worn during laboratory experiments.

Accidents and Injuries

Hamdard Institute of Engineering & Technology, Hamdard University

Hamdard Institute of Engineering & Technology, Hamdard University

1. Immediately report any accident even if it is small.

1. Don't wear rings or watches while operating a machine.

Hamdard Institute of Engineering & Technology, Hamdard University

Hamdard Institute of Engineering & Technology, Hamdard University

Operations performed on lathe:

Major Parts of Lathe Machine:

Main parts of a center lathe are:

1. The bed and ways.

2. The Head Stock:

Hamdard Institute of Engineering & Technology, Hamdard University

The Carriage Assembly consists of three main parts.

4.1 The Saddle:

4.3 The cross slide:

Hamdard Institute of Engineering & Technology, Hamdard University

1. Detect lathe machine to illustrate different parts?

2. Detect lathe machine to define tail stock quill?

Hamdard Institute of Engineering & Technology, Hamdard University

 Face the both sides of the job

 Process turning to required diameter.

Hamdard Institute of Engineering & Technology, Hamdard University

Hamdard Institute of Engineering & Technology, Hamdard University

Tools & Equipments:

Where d = Single Depth

n = Number of threads per inch (TPI)

Infeed Depth = .75 / n

Hamdard Institute of Engineering & Technology, Hamdard University

6. Using a layout solution, coat the area to be threaded.

Hamdard Institute of Engineering & Technology, Hamdard University