MANUFACTURING TECHNOLOGY

GUJARAT TECHNOLOGICAL UNIVERSITY

C.K.PITHAWALA COLLEGE OF ENGINEERING AND
TECHNOLOGY, SURAT.

LABORATORY MANUAL
Name of Student
Enrollment No.
Subject Name MANUFACTURING TECHNOLOGY
Subject Code 3151912
Student Class 3rd year (5th semester)
Division A&B
Academic Year 2022-23

MECHANICAL ENGINEERING DEPARTMENT

LABORATORY MANUAL Page 1

MANUFACTURING TECHNOLOGY

C. K. PITHAWALLA COLLEGE OF ENGINEERING AND

TECHNOLOGY, SURAT
INDEX
Sr. Page
Date Title Signature CO
No. No.
Basic understanding of Different
Manufacturing Processes: concepts,
1 CO-1
application, advantage and future
aspects
Hands on Exercise on Pattern
2 CO-2
Making
Practice for making sand samples
3 CO-2
using sand rammer.
Determination of permeability of
4 given sand sample using CO-2
permeability tester.
Performance on Metal Casting of
5 CO-2
Simple component
Performance on Welding of simple
6 CO-3
workpiece
Exercise problems on Sheet Metal
7 CO-4
Works

LABORATORY MANUAL Page 2

MANUFACTURING TECHNOLOGY

CO and PEOs
Course Outcome (CO)

Course Outcome CO Statement

1 To understand the fundamentals of manufacturing process.
2 Interpret foundry practices like pattern making, mold making,
Core making and Inspection of defects.
3 Select appropriate metal joining Processes to join similar or
dissimilar metals.
4 Differentiate various metal forming processes.
5 Classify different plastic molding processes and application
6 Distinguish different Super Finishing Technology.

Program Specific Outcome (PEOs)

Program Outcome PEOs Statement

Preparation Develop the students to cultivate Mechanical Engineering to
excel in professional career, post graduate studies and innovative
research.
Core Competence To develop competence in the field of Design, Production and
Thermal fluid sciences to analyse and solve engineering
problems.
Breadth Generate ability to use modern engineering tools, techniques,
skills and contemporary engineering practice to take up
multidisciplinary projects.
Professionalism To learn concepts and intellectual skills, courage and integrity
and aspirations of the society.
Learning To make a significant contribution towards the development of
Environment skilled technical manpower to take up emerging needs of
society.

LABORATORY MANUAL Page 3

MANUFACTURING TECHNOLOGY

PRACTICAL –1
AIM: Basic understanding of Different Manufacturing Processes: concepts,
application, advantage and future aspects
INTRODUCTION
Manufacturing is the backbone of any industrialized nation. Manufacturing and
technical staff in industry must know the various manufacturing processes, materials
being processed, tools and equipments for manufacturing different components or
products with optimal process plan using proper precautions and specified safety rules
to avoid accidents.
It should provide the knowledge of basic workshop processes namely bench work and
fitting, sheet metal, carpentry, pattern making, mould making, foundry, smithy,
forging, metal working and heat treatment, welding, fastening, machine shop, surface
finishing and coatings, assembling inspection and quality control..
MANUFACTURING PROCESS
Manufacturing process is that part of the production process which is directly
concerned with the change of form or dimensions of the part being produced. It does
not include the transportation, handling or storage of parts, as they are not directly
concerned with the changes into the form or dimensions of the part produced.
CLASSIFICATION OF MANUFACTURING PROCESSES
For producing of products materials are needed. It is therefore important to know the
characteristics of the available engineering materials.
Raw materials used manufacturing of products, tools, machines and equipments in
factories or industries are extracted from ores.
Primary Shaping Processes Primary shaping processes are manufacturing of a product
from an amorphous material. Some processes produces finish products or articles into
its usual form whereas others do not, and require further working to finish component
to the desired shape and size.
Castings need re-melting of scrap and defective ingots in cupola or in some other
melting furnace and then pouring of the molten metal into sand or metallic moulds to
obtain the castings. Thus the intricate shapes can be manufactured. Typical examples
of the products that are produced by casting process are machine beds, automobile
engines, carburetors, flywheels etc. The parts produced through these processes may
or may not require to under go further operations.
Some of the important primary shaping processes is: (1) Casting, (2) Powder
metallurgy, (3) Plastic technology, (4) Gas cutting, (5) Bending and (6) Forging.
shape using a cutting tool is known as machining.

There are two basic types of molds used in castings, namely, expendable molds (sand
casting and investment casting) that are destroyed to remove the part, and permanent
molds (die casting). Expendable molds are created using either a permanent pattern
(sand casting) or an expendable pattern (investment casting). Permanent molds, of
course, do not require a pattern. Two of the major advantages for selecting casting as

LABORATORY MANUAL Page 4

MANUFACTURING TECHNOLOGY

the process of choice for creating a part are the wide selection of alloys available and
the ability, as in injection molding, to create complex shapes. However, not all alloys
can be cast by all processes. The nature of the molds used and the method for
removing the part from the mold differs for the various processes. The tolerances and
surface finishes achievable are also different.
CASTING PROCESS
Sand casting is a process in which a sand mold is formed by packing a mixture of
sand, a clay binder, and water around a wood or metal pattern that has the same
external shape as the part to be cast. A pattern can come in two halves: a top half
(called a cope) and a bottom half (called a drag)

Rough Machine

Each half is placed in a molding box, and the sand mixture is then poured all around
the pattern. After the sand is packed, holes, which are used to pour the molten metal
into the mold (sprue) and to be used as a reservoir of molten metal (risers), are formed
in the sand. Vents are also created in order to allow the escape of gases from the melt.
Then the pattern is removed and a runner system or small 1 passageway is created
inside the die through which the melt can flow and be distributed. Gates are the
sections where the melt enters the impression. Thus, sprues feed the runners, and the
runners feed the gates.

LABORATORY MANUAL Page 5

MANUFACTURING TECHNOLOGY

FORGING PROCESS

Forging is produced by using heavy mechanical presses or hammering heated bars of

metal between dies.
Advantages of forging over sand casting are that forged parts are much stronger and
less brittle

WELDING PROCESS

Welding is the fusion or joining of two pieces of metal by means of heat, with or
without the application of pressure.

Welded
Cast Plastics Processing

The plastics industry represents one of the major manufacturing segments.

Thermosetting – becoming permanently hard and unmoldable when once subjected to
heat. Thermoplastic – becoming or
remaining soft and moldable when subjected to heat.

LABORATORY MANUAL Page 6

MANUFACTURING TECHNOLOGY

Extruding

The process of producing shapes by forcing hot metal through a die that has and opening of
the desired shape.

Blow Molding

Used in the production of bottles, automotive ductwork, hollow toy components, and door
panel

QUESTIONS:
1. Define manufacturing and give types of different manufacturing process.
2. Explain the importance of manufacturing process.
3. Write application and advantages of manufacturing process.

LABORATORY MANUAL Page 7

MANUFACTURING TECHNOLOGY

PRACTICAL –2
AIM: Hands on Exercise on Pattern Making

Theory:
The Pattern: A full-sized model of the part, slightly enlarged to account for shrinkage and
machining allowances in the casting
Pattern materials: − Wood - common material because it is easy to work, but it warps
− Metal - more expensive to make, but lasts much longer
− Plastic - compromise between wood and metal.

Material and dimension:

Job Drawing:

Procedure:
LABORATORY MANUAL Page 8
MANUFACTURING TECHNOLOGY

Conclusion:

QUESTION:

1. Can finished casting be used as a pattern for making a mould? Explain?

2. List the properties of good pattern material?
3. Compare wood, metals and plastics as pattern materials in the lights of
desired properties of pattern material.
4. Explain the use of following types of patterns
(1) Loose piece pattern (2) Sweep

(3) Match plate pattern (4) Follow boar

LABORATORY MANUAL Page 9

MANUFACTURING TECHNOLOGY

PRACTICAL –3

AIM: Practice of Making Sand Samples Using Sand Rammer

Overview:
The sand rammer is a machine for preparing specimens for testing of the permeability and
strength of moulding sand and is comprised mainly of a base, ram, tamping bar and lever.

The machine is so constructed that the ram is brought up by the crank and is then caused to
drop to strike and drive down the tamping bar at the lower end of which is fixed a tamping
plate which slides into a sand tube to press the sand tube into a certain size with certain
energy.

Equipment:
A. Sand Rammer
B. Sand Tube

LABORATORY MANUAL Page 10

MANUFACTURING TECHNOLOGY

Operating Procedure:

 Preparation of Strength Test Specimen:

1. Set the sand tube in the tube rest for about 15 mm, and holding it by hand, introduce
about 140 g to 175 g of the test sand gently so that the sand surface is level.
2. Next, pull the handle toward you to force the tamping bar up, then load the sand tube
having the sand charged together with the rest of the base, introduce the ramming
head quietly into the sand tube until it is held by the sand surface.
3. Then, turning the lever forward, perform ramming three times.
4. With the sand thus rammed, if the pointer provided on the tamping bar stops within
the tolerable range on the scale, the compactable sand is usable as a test specimen of a
standard size (height 50 mm).
5. The tolerances ±1mm graduated above and below the base line, and if the pointer
does not remain within the tolerable range, such specimen is not usable as a test
specimen, so that it should be discarded.
6. Then, adjusting the quantity of sand to be introduced in the sand tube properly, repeat
the foregoing procedure.
7. When a specimen of standard size is obtained, raise the ramming plate, remove the
sand tube and set it over the sand stripping bar to withdraw the standard sand
specimen from the sand tube.

LABORATORY MANUAL Page 11

MANUFACTURING TECHNOLOGY

PRACTICAL –4

AIM: Determination of Permeability of Given Sand Sample Using

Permeability Tester

Overview:
Permeability is that property which allows gas and moisture to pass through the moulding
sand. It is determined by measuring the rate of flow of air through A.F.S. standard rammed
specimen under a standard pressure. The volume of air in ⁄ . passing through a
specimen of length 1 cm and cross sectional area of 1 under a pressure difference of 1
cm water gauge is called Permeability Number.

 Permeability Number:
The volume of air passing through a sand specimen 1 sq. cm area and 1 cm in height at a
pressure of 1 gram per square centimeter in 1 min is called the Permeability Number and is
computed by the formula:

( )⁄( )

Where,

P = Permeability Number
v = Volume of air passing through the specimen (cubic centimeter or in mil)
h = Height of specimen (centimeters)
p = Pressure difference between upper and lower test surfaces of the test
specimen (in centimeter of water column)
a = Cross-sectional area of specimen (square centimeter)
t = time (minutes)

LABORATORY MANUAL Page 12

MANUFACTURING TECHNOLOGY

 Pemeability Meter:
The body of the permeability meter is an aluminum casting of a water tank and base. Inside
water tank floats a balanced air drum carefully weighed and designed to maintain constant
pressure of 10 cm during its fall.

The outlet from the air drum is connected to a center post in the base via three way air
valve. The centre post incorporates a pipe for measuring pressure, which is connected to the
water manometer and an expansible “O” ring for sealing the specimen tube. It also
accommodates the orifices.

Equipment:
A. Sand Permeability Tester
B. Testing sand specimens

Sand Permeability Tester

LABORATORY MANUAL Page 13

MANUFACTURING TECHNOLOGY

Standard Permiability Test

 Test Procedure:
(A.F.S. Standard Time and Pressure Method)

1. Check the open orifice is in the position in the centre

2. Prepare an A.F.S. standard specimen of sand. Before stripping from the tube place in
position on the centre post and seal by rotating the knurled ring anti-clockwise.
3. Check water level in the tank. Turn air valve to “NENT” and slowly raise drum until
it is out of water.
4. Allow the air drum to descend by turning the air valve to a position midway between
“CLOSED” and “VENT”.
5. Time the descend of air drum between zero and 2000 ml mark with a stop watch and
record the pressure indicated on the manometer during the descend of the drum.
6. Calculate the permeability by applying the given formula.

LABORATORY MANUAL Page 14

MANUFACTURING TECHNOLOGY

PRACTICAL –5
AIM: Performance on Metal Casting of Simple component

Theory:
In casting, the liquid material is poured into a cavity (die or mould) corresponding to the
desired geometry. The shape obtained in the liquid material is now stabilized, usually by
solidification, and can be removed from the cavity as a solid component.
The main stages, which are not confined to metallic materials alone but are also applicable to
some plastics, porcelain, and so on, are: production of a suitable mould cavity; the melting of
the material; pouring the liquid material into the cavity; stabilization of the shape by
solidification, chemical hardening, evaporation, and so on; removal or extraction of the solid
component from the mould; and cleaning the component.

Normally, the term" casting" is applied to metals, but in general, the principal stages and
many of the characteristic problems are the same for most materials which can be shaped
from the liquid state. The term “casting” should be treated more broadly, allowing the
carryover of new ideas from one field to another (foundry industry, glass industry, plastic
industry, etc.).

The differences between the many casting processes are due mainly to the mechanical and
thermal properties of the work and mould material, the acceptable working temperature of the
mould, the cooling method and cooling rate of the workpiece, the radiation of heat from the
work and the mould material, the chemical reactions between the molten metal and the
mould, the solubility of gas in the work material, and the functional requirements of the
component.

Casting processes are important and extensively used manufacturing methods, enabling the
production of very complex or intricate parts in nearly all types of metals with high
production rates, average to good tolerances and surface roughness, and good material
properties.

LABORATORY MANUAL Page 15

MANUFACTURING TECHNOLOGY

Sand Casting Steps

Material and dimension:

LABORATORY MANUAL Page 16

MANUFACTURING TECHNOLOGY

Job Drawing:

Procedure:

Conclusion:

LABORATORY MANUAL Page 17

MANUFACTURING TECHNOLOGY

QUESTION:
1. Give typical composition of foundry green sand .
2. Explain different type of sand.
3. What is the function of chaplet.
4. Define grain fineness number(GFN) and give importance of it.
5. Explain the terms (a) Permeability (b) Green strength
6. Differentiate between parting sand and facing sand.
7. Explain the steps in sand preparation.
8. What are the basic steps in making a mould by hand moulding.
9. What is meant by core? Why and when cores are used in foundry.
10. List the basic characteristics of good core.

LABORATORY MANUAL Page 18

MANUFACTURING TECHNOLOGY

PRACTICAL –6
AIM: Performance on Welding of simple workpiece

Theory:
Welding is a materials joining process which produces coalescence of materials by heating
them to suitable temperatures with or without the application of pressure or by the application
of pressure alone, and with or without the use of filler material.
It is used in the manufacture of automobile bodies, aircraft frames, railway wagons, machine
frames, structural works, tanks, furniture, boilers, general repair work and ship building.
Arc welding safety equipment's

Shoes Gloves Helmet Goggles

Types of joints, welds and welding position

GAS WELDING EQUIPMENT

LABORATORY MANUAL Page 19

MANUFACTURING TECHNOLOGY

1. Gas Cylinders Pressure

2. Regulators

3. Pressure Gauges

4. Hoses

5. Welding torch

6. Check valve

7. Non return valve

LABORATORY MANUAL Page 20

MANUFACTURING TECHNOLOGY

QUESTION:
1. Define welding and give the name of different arc welding equipment’s
used for the welding process.
2. Give the name of different gas welding equipment’s used for the
welding process.
3. How arc is generated? Define the necessary condition for that.
4. Give different types of weld and weld joints.
5. Give different types of weld position

LABORATORY MANUAL Page 21

MANUFACTURING TECHNOLOGY

PRACTICAL –7

AIM: Exercise problems on Sheet Metal Works

Material and dimension:

Job Drawing:

Procedure:

Conclusion:

LABORATORY MANUAL Page 22

MANUFACTURING TECHNOLOGY

LABORATORY MANUAL Page 23