MANUFACTURING PROCESS

LAB MANUAL
 MANUFACTURING PROCESS

LIST OF EXPERIMENTS

S.NO LATHE PAGE NO.

1 Study of Lathe 01
2 Plain turning and facing 09
3 Step turning, grooving, chamfering and knurling 11
4 Taper turning by swiveling the compound rest and V-thread cutting 13
MILLING MACHINE
5 Study of Milling machine 15
6 Cube milling 23
GRINDING OPERATIONS
7 Study of grinding machine 25
8 Surface grinding of cylindrical shafts 28
FOUNDRY
9 Study of Foundry 30
10 Face Plate (Solid Pattern) 36
11 Pipe Flange (Split Pattern) 38

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EX.NO: 01 STUDY OF LATHE

AIM

To study about major components and the accessories of the lathe, their working principles and different types
of Lathe.

Introduction
Lathe is called the father of machine tools. The main function of lathe is to remove metals from
work piece to give a required shape and size. In the lathe the work piece is held in a chuck. The tool is moved at
an angle 90_ to the axis. Various operations such as straight turning, taper turning, and chamfering, facing,
knurling, grooving, thread cutting, taper turning are carried out. When the operations above set are done
automatically, then the lathe is called automatic lathe.

Working principle of lathe:

In a lathe, the work piece is held in chuck and rotates about its axis by means of power. A single
point cutting tool is mounted in tool post. When the chuck rotated the work piece also rotated. The tool moves
parallel to the axis of rotation of work piece to produce a cylindrical surface, where as the tool moves
perpendicular to the work piece to produce a flat surface. The tool moves at an angle to the axis of work piece
to produce a turn surface. The material is removed in the form of chip from the work piece by giving proper
feed and depth of cut. So, the required size and shape of the work is obtained.
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Main parts of lathe:
The lathe consists of various parts. Their parts and function are discussed below.

Bed
Bed is the base of the lathe. The headstock is mounted on the left end; the carriage is in the
middle and the tailstock at the right end of bed. The bed is made up of cast iron, alloyed with nickel, chromium.
The bed is made up of cast iron to observe shock and vibration created during machining. The guide ways of
the bed may be flatter inverted ‘V’ shape.

Headstock
It is mounted on the left end of the bed. It carries a hollow spindle. The live center can
be attached in the spindle. The spindle nose is threaded. In chuck faceplates can be attached to the spindle. The
headstock may be back threaded type. The headstock has two types of driving mechanism
• Back geared mechanism
• Belt driven mechanism

Tailstock
It is located on the bed at the right end. It is used for supports right end of work and also for
holding drills, reamer tools for drilling, reaming and such other operations. The tailstock can be moved along
the bed and clamped at any position, to support the different length work.

Carriage
Carriage is used for giving various feed to the tool by hand or by power. The carriage is attached
with the saddle.

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Saddle
It is a H shaped casting fitted on the bed and moves along the guide ways. It carries the cross
slide, Compound rest and a tool post.

i) Cross slide
It is attached to the upper side of saddle and carries compound slide and tool post. The
cross slide can be moved cross wise by hand or power. The micrometer dial is mounted on the cross slide hand
wheel, with an accuracy of 0.05mm.

ii) Compound Rest

It is attached over the cross slide. It is used during the taper turning opening operations to set
the tool for angular cuts. Here the micrometer dial is mounted to show the depth of cut.

iii) Tool post

The tool is clamped over the tool post. It is fixed over the compound rest. There are
four types of tool post
a. Single screw tool post
b. Open side tool post
c. Four bolt tool post
d. Four way tool post

Apron
Apron is attached to the saddle and hangs in front of the bed. It has gears, levers, clutches for
moving the carriage automatically. A split nut is attached for engaging and disengaging the carriage from the
lead screw. It is used in thread cutting work.

Lead Screw
It is a longer screw with standard ACME square threads and used for transmitting power for
automatic feed for thread cutting operation.

Feed rod
The feed rod is the long shaft used for the movement of carriage along the axis of bed. It is
used for operations like facing, turning and boring.

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Work holding devices:
This is used to hold the work piece firmly during the operation. Following are the commonly
used work holding devices in lathe.
Three-Jaw Chuck:

It is also called universal chuck (or) self-centering chuck. A chuck key is engaged and rotated
in one of the jaws, which simultaneously moves the other jaws to grip the work piece.

Four-Jaw Chuck:

Each of the four jaws of the chucks can be actuated independently by roatating the screw which
meshes with the corresponding teeth (thread) cut on the backside of the jaw.It is used for clamping irregularly
shaped work pieces.

Feed mechanism:
The movement of the tool relative to the work is termed as “feed”. A lathe tool may have three
types of feed-longitudinal, cross, and angular. When the tool moves parallel to the lathe axis, the movement is
termed as longitudinal feed and is effected by the movement of carriage. When the tool moves at right angles to
the lathe axis with the help of the cross slide the movement is termed as cross feed, while the movement of the
tool by compound slide when it is swiveled at an angle to the lathe axis is termed as angular feed. Cross and
longitudinal feed is both hand and power operated, but angular feed is only hand operated.

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Operations performed on Lathe:

The various operations performed on lathe are

• Turning
• Facing
• Step turning
• Taper turning
• Thread cutting
• Grooving
• Chamfering
• Knurling

Turning:

Turning is the process of removing excess material from a work piece to produce a cylindrical surface
and to reduce the diameter of the work piece.

Facing:

Facing is done to remove material at the end of a work piece to produce a flat surface and to reduce the
length of the work piece.

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Step turning :

Step turning creates two surfaces with an abrupt change in diameters between them.

Taper Turning:

Taper turning produces a ramp transition between the two surfaces with different diameters due to the
angled motion between the workpiece and a cutting tool.

Thread cutting:

Thread cutting is a process for generating a thread. It's used for the production of threads on the outer
surface of a cylinder or on the inner surface of a bore.

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Grooving:

Grooving removes a small length (2mm or 3mm) of material from a work piece.

Chamfering:

Chamfering is the process of leveling the extreme ends of a work piece.

Knurling:

The process of embossing a diamond shaped pattern on a work piece having a cylindrical surface is
called knurling.

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Cutting tool:

Metal cutting takes place due to relative motion between work and cutting tool. During cutting , the
metal is removed in the form of chips. The chips are removed by the cutting edge of tools. If the tools have one
cutting edge it is called single point cutting tool. This tool is made by High Speed Steel(HSS).

Cutting tool Materials :

Cutting is done by the hard and shape edge of the cutting tool.

Different cutting tool materials are given below,

• Carbon steel(Medium and High)

• Alloy
• High speed steels
• Cemented carbides
• Ceramics
• Diamonds

RESULT :

Thus the working principle, major components & parts of lathe and their operations are studied.

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EX.NO: 02 PLAIN TURNING AND FACING

AIM

To perform the facing and plain turning operation in the given work piece as per the given dimensions.

TOOLS REQUIRED:

Vernier caliper

Steel rule

Dead centre

Chuck key

Tool post key

Cutting tool

MATERIALS REQUIRED:

Mild steel workpiece of dimensions 25 mm diameter and 100 mm length.

PROCEDURE:

• The work piece is held in the lathe chuck.

• The cutting tool is held in the tool post and its cutting point is set to lathe axis.
• The carriage is moved to the bed and it is clamped at the required place.
• By giving cross feed, the tool is feed perpendicular to lathe axis.
• The facing operation of the work piece is machined to the required dimensions.
• By repeating the same procedure the next face of the work piece is machined.
• Then the tool is feed parallel to lathe axis with suitable depth of cut.
• Two or more cuts are given to obtain the required size diameter.
• Both ends of the work piece are chamfered by using chamfering tool.

RESULT :

Thus the plain turning and facing operation is performed in the given job as per the dimensions.

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EX.NO: 03 STEP TURNING, GROOVING, CHAMFERING AND KNURLING

AIM

To perform the Step turning, Grooving, chamfering and knurling operations in the given work piece as
per the given dimensions.

SPECIMEN DIAGRAM:

TOOLS REQUIRED:

Vernier caliper

Steel rule

Dead centre

Chuck key

Cutting tool

Try square

Flat file

Vice handle

Vernier height gauge

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PROCEDURE:

1) Check the size of raw material given and ensure the size.
2) Hold the workpiece in the chuck and tight it properly.
3) Clamp the tool on post properly and check the centre of work piece with cutting tool tip.
4) Plain turning is done to a diameter of 18 mm upto length of 55 mm
5) After that again a length of 30 mm is plain turned to the diameter of 14 mm from the edge.
6) The chamfering is done on either of the finished work piece.
7) Knurling is done on the work piece for the required dimensions.
8) Grooving is done on the work piece for 2mm as per the specimen diagram.
9) Remove the component carefully and check the dimensions.

RESULT :

Thus the component is produced as per the given drawing using lathe.

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EX.NO: 04 Taper turning by swiveling the compound rest and V-thread cutting

AIM

To perform the taper turning by swiveling the compound rest and V-thread cutting.

SPECIMEN DIAGRAM:

TOOLS REQUIRED:

Vernier caliper

Steel rule

Dead centre

Chuck key

Tool post key

Cutting tool

PROCEDURE:

1) Check the size of raw material given and ensure the size.
2) Hold the workpiece in the chuck and tight it properly.
3) Clamp the tool on post properly and check the centre of work piece with cutting tool tip.
4) Do the facing operation by giving cross feed to the cross slide and reduce length.
5) Do the turning operation by giving longitudinal feed to the carriage and reduce the diameter of
the work piece.
6) Two or three passes can be given for turning operation.
7) Remove the work piece and hold in chuck on other side and do the turning operation for the
remaining portion of the work piece.
8) Calculate the taper angle and swivel the compound rest and clamp it properly.

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 9) Do the taper turning operation by giving angular feed to the compound rest as per the
dimension.
10) Do the facing operation and get the required length .
11) Engage the back gear mechanism to reduce the speed of the work piece.
12) Check the pitch required, calculate the tumbler gear, and engage it with head stock.
13) Move the carriage towards tail stock and make a mark on the dial.
14) Give small depth of cut and engage half nut so that the carriage will move automatically
towards head stock and cut the v-thread on the work piece.
15) After reaching the required length of thread, release the tool by rotating cross slide in opposite
to the depth of cut by counting the number of rotation.
16) Move the carriage towards tail stock, give depth of cut and engage the half nut.
17) Repeat the procedure to produce complete form of v-thread.
18) After finishing remove the work piece from the chuck.

RESULT

Thus the component is produced as per the given drawing using lath

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EX.NO: 05 STUDY OF MILLING MACHINE

AIM

To study about major components and accessories of milling machine and their working principles.

INTRODUCTION

A milling machine is a machine tool, which machines a material when the work piece material is
directed against a multipoint cutter. This machine can also hold more cutters at once and hence it is
widely used for production work, which requires accuracy and better surface finish.
There are various types of milling machines that can be classified based on the nature of the work and
operations that is to be carried out. The types are as follows: -

1. Column & Knee Type: - This type of milling machine is commonly used nowadays in the
workshops. It may be further subdivided into different types such as Hand milling machine in
which the table feeding movement is provided by hand control, Plain milling machine which is
heavier than the Hand milling machine for accommodating heavier work pieces and the table feed
may be given by hand or power. Universal milling machine so called owing to its capacity to
perform wide range of milling operations. It has a circular swivel base table which can be
swiveled up to 45 degrees and it can also be swiveled in a vertical axis other than 90 degrees to
the spindle. Omniversal milling machine similar to a universal milling machine except the table
can be tilted in a vertical plane with the help of a swivel arrangement at the knee, Vertical milling
machine in which the spindle is perpendicular to the worktable.

2. Manufacturing or Fixed Bed Type: - It is very heavy and rigid compared to column and knee
type milling machine. The table movement is restricted to reciprocation at right angles to the
spindle axis with no facility for cross or vertical adjustment. It is again subdivided into simplex,
duplex and triplex types, which mean the machine, may be provided with single, double or triple
spindle heads respectively.

3. Planer Type: - It is a heavy machine made for heavy duty work which has spindle heads
adjustable in vertical and traverse directions. It resembles a planer and hence the name Plano-
miller.

4. Special Type: - These are non conventional types built to suit special purposes. The types are
Rotary table machine, Drum milling machine, Planetary milling machine, Pantograph milling
machine etc all of which have in common are the spindle for rotating the cutter and facility for
moving the tool or work piece in different directions.

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The constructional features of a vertical milling machine are shown in figure below.

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 It consists of a Base, Column, Knee, Saddle, Table, Overhanging Arm, Front Brace, Spindle & Arbor,
which are explained below.

Base: - It is a iron casting machined on it’s top and bottom surface which provides the foundation for
all the other parts that rest over it. It has a column on one end and in some cases its base is hollow to
act as a reservoir for the cutting fluid.

Column: - It is the main supporting frame mounted vertically on the base. It is box shaped and
encloses the driving mechanisms for the spindle and table feed. The front vertical face of the column
is machined and consists of dovetail guide ways for supporting the knee. From the top of the column
an overhanging arm extends outward.

Knee: - It slides up and down on the guide ways situated on the column face. The height can be
adjusted with the help of an elevating screw mounted on the base and connected to the knee. The knee
also houses the feed mechanism for the table and controls to operate it.

Saddle: - It is placed over the knee, which slides on the guide ways provided for it. A cross feed
screw at the top of the knee engages a nut at the bottom of the saddle in order to move it horizontally
to provide cross feed. The saddle is provided with guide ways on it’s top for mounting the table.

Table: - The table is mounted on the guide ways of the saddle, which travels longitudinally. The table
is also machined with T-slots to facilitate the clamping of work pieces or fixtures. A lead screw below
the table engages a nut on the saddle in order to move the table horizontally.

Overhanging Arm: - It extends from the top of the column face and provides a bearing support for
the other end of the arbor.

Front Brace: - It is an additional support fitted between the knee and the over arm in order to provide
rigidity to the arbor and the knee.

Spindle: - It is situated at the top of the column and obtains power from the motor through the belts or
gears and transmits it to the arbor.

Arbor: - It is the extension of the machine spindle on which the milling cutters are mounted and
rotated in order to properly align with the machine spindle the arbors are made with taper shanks.

Note the direction of rotation of the milling cutter

a. The cutting edge of the tooth can be seen cutting in an upward direction
b. As the cutter is rotating in an anti – clockwise direction, the work is fed from the right
against the cut
c. The direction of rotation will determine which side of the cutter the work should be
fed into
d. Conventional milling tends to lift the work away that the work is secure
e. Rigidity is of great importance for efficient machining

Climb Milling:
a. Should never be attempted except under skilled supervision. The machine should
specially be equipped for this technique. The cutter tends to climb over the work.
b. The advantage of this method is that when taking heavy cuts the work is forced down
on to the machine table the feed force is also reduced.

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 Milling Cutters: Milling cutters are grouped under the following headings

a. Plain or Cylindrical Cutters: Used in machining flat surfaces, Cutting only

with their sides.
b. Face Cutters: Face cutters cut with teeth formed on the ends.
c. Side & Face Cutters: These cutters cut on both periphery and on face.
d. Saws & Slotting Cutters: These cutters produce plain, the lee and dovetail slots.
e. Form Cutters: Form cutters are used to produce rounded corners, hollows, and
gear
– teeth.
f. Inserted – Tooth Cutters: These cutters are usually made in larger sizes of
face and cylindrical mills.

Cylindrical Cutter:

Slab or Rolling Milling Cutler: This is a cylindrical cutter. This is made in a variety 01
diameters and widths. This has 16 teeth on the circumference only. This is used to produce flat
surfaces. Usually it is mounted on a horizontal arbore. To prevent vibration helical teeth are
preferred.

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Side & Face Cutter: This cutter is used for light facing operations and for cutting slots. This is
a narrow cylindrical cutter. It has teeth on both faces and on the periphery. This cutter can be
used for side cutting as well as for edge cutting.

Metal Slitting Saws: This has teeth on the periphery only. It is a thin cylindrical cutter. The width is
0.25 to 6 mm wide. This is used for cutting-off operations. This is also used for producing deep
narrow slots, or as a slitting saw. It is mounted on a shaft of arbor in a horizontal milling
machine

Single Angle Cutter: This cutter is used for cutting angular surfaces e.g. chamfers, dovetail
slots, vee-notches, serrations and for cutting reamer teeth. It is a cylindrical cutter with teeth on
the conical surface

Double Angle Cutter: This is a cylindrical cutter. The teeth are on the two-conical surfaces
forming vee-shaped teeth. Some cutters have equal angels between the conical faces. Other
cutters have unequal angles. The included angles are 45 , 60 or 90 . This cutter is used for
milling angular grooves and for milling helical flutes in cutter blanks.

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Shell End Mill Cutters: This cutter has teeth on the periphery and end face. The length of teeth
on periphery is greater than diameter. The teeth are of helical form. These cutters are not
reversible. This cutter is used for face milling and for generating surface. It provides one of the
most accurate methods of producing a flat surface on a milling machine.

Face Mill: This cutter is of larger diameter than the shell end mill. Diameter is greater than the
tooth length

Gear Cutters: Involute gear cutters are made in a range of eight cutter numbered 1 – 8 for each
different module and pressure angle. The range, number, pressure angle, and module is clearly
stamped on each cutter.

Straddle Milling: It is a common form of production milling. In this more than one face is
called milled

Gang Milling: In this a number of cutters of different diameters, lengths and shapes are
mounted on the arbor at the same time. Several cutters may be ‘ganged’ together to produce
complicated profiles.

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 Contour Milling Cutter: Contour Milling Cutters have special profiles such as concave or
convex, circular arcs. These cutters are used for producing internal and external radii etc.

Form Cutting: Formed Milling Cutters are used in milling contours of various shapes. They are
made in many shapes and sizes and play important part in milling

Woodruff Cutters: Woodruff Cutters are used for producing woodruff key-seats. The cutters are
made in the form of a slot cutter. It has no side cutting teeth. To produce the key-seat, the cutter is
positioned over the work and sunk directly to the required depth.

Face Milling Cutter: This cutter can be fed along its own axis in the same way as drill. It is
used to produce keyways and blind slots with the cutter sunk into the material like a drill and
fed longitudinally

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 Dovetail Cutter: A special type of cutter produces a dovetail. Machines the base surface with
its end teeth and the angled surfaces with its inclined cutting face. These cutters are designed for
milling dovetail slides of machines. The cutters are available in a variety of size up to 38mm
diameter with 45 and 60 angles.

Vertical Milling Operations: Vertical milling operation is quicker, and smoother, uses less
power and produces a superior finish. Vertical milling operation is preferred to horizontal
milling on most production line.

End Milling Cutter: End milling cutter has helical teeth on the circumference and teeth on one
end. These cutters are used for light operations such as milling.

RESULT:

Thus the working principle, major components & parts of milling machine and their operations
are studied.

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EX.NO: 06 CUBE MILLING

AIM

To perform cube milling on the given job as per the required dimensions.

TOOLS REQUIRED

Vernier caliper

Vernier height gauge

Parallel bar

Try square

Milling cutter

Flat file

Vice handle

MATERIALS REQUIRED

A mild steel of cube of dimensions 40*40*40 mm

Procedure:

1. The job was fixed in the vice cutter.

2. The speed was selected according to the materials used.

3. Give fine cut of approximately 2 mm of three adjusted sides

4. With the help of height gauge mark the dimensions.

5. Finish the job according to the dimensions marked.

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 6. Check the flatness of square and perpendicularity of surfaces using the square.

7. Fix the edge to get clear and smooth finish.

GIVEN JOB FINISHED JOB

All dimensions shown in the drawings are in “mm”.

RESULT

Thus cube milling was performed on the given work piece.

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Ex No:07 STUDY OF GRINDING MACHINE

• Grinding is the process of removing metal by the application of abrasives which are
bonded to form a rotating wheel.

• When the moving abrasive particles contact the work piece, they act as tiny cutting tools,
each particle cutting a tiny chip from the work piece.

• It is a common error to believe that grinding abrasive wheels remove material by a

rubbing action.

• Actually, the process is as much a cutting action as drilling, milling, and lathe turning.

• A schematic of grinding operation is shown below

Types of Grinding Machines:

. The various types of grinding machines are described as follows

• Utility grinding machine

• Cylindrical grinding machine
• Surface grinding machine.
• Angle Grinder
• Tool Grinding machine

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Construction of Grinding Machine and wheel

The construction of grinding machine and grinding wheel are described in figure as
follows

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Applications
The grinding operations are mainly used for the applications are described as follows:
1) Surface finishing
2) Slitting & parting
3) De scaling, de burring
4) Stock removal finishing of flat as well as cylindrical surface.

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EX.NO: 08 CYLINDRICAL GRINDING

Aim:
To grind the cylindrical surface of the given work piece by cylindrical grinding

Apparatus Required:

• Grinding machine

• Cylindrical grinding wheel setup

• Steel Rule.

• Vernier Calliper

Materials Required:

• Cast iron work piece

Procedure:

• First the given work piece is preliminarily finished to the pre-required dimensions on a
lathe
before beginning the grinding process.
• Now the work piece is fitted in the chuck of the cylindrical grinding machine.
• The grinding wheel is just touched with the work piece and is taken as the zero reference.
• Coolant circulation is switched on and the grinding wheel is engaged with the work
piece.
• Both the work piece and the grinding wheel roll on contact with each other like two gears
in
mesh.
• Now slowly the wheel is moved over the entire length of the work piece to get the
grinded
finish.
• After one feed is over, the grinding wheel is moved further towards the axis of the work
piece and the process is repeated until the required dimensions are achieved.
• Finally the dimensions are checked using a Vernier caliper.

Result
Thus cylindrical grinding is performed on the given work piece to the given dimensions

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29
EX.NO: 09 STUDY OF FOUNDRY

Aim:

To understand the basic concepts of foundry by carrying out simple exercises relevant to its
principles

Introduction:

Foundry is a process of forming different shapes and sizes of metals in their molten state. It is
also called as metal casting. The shape of the metal cast obtained depends on the shape and size
of the cavity produced in sand mould by using a wooden model. This wooden model is called a
pattern

The foundry process involves three steps:

a. Making the required pattern

b. Moulding process to produce the cavity in sand using the patter
c. Pouring the molten metal into the cavity to get the casing

Pattern:

A pattern is normally a wooden model which is the facsimile of the cast/product to be made.
There are many types of patterns and are either one piece or two-pieces.

Moulding Box:

A moulding box is normally a rectangular wooden/metal box with bottom and top surfaces
open. The upper part (cope) and the lower part (drag) are aligned property.

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Sieve:

A sieve is used to remove foreign materials from the moulding sand. A sieve is a rectangular
or circular frame with a wire mesh.

Rammer:

A rammer is used to press or ram the moulding sand uniformly into the moulding box.

Strike-off Bar:

A strike off bar is a flat-edged rectangular bar made of wood. It is used to remove excess sand on
top of the mould box after ramming.

Vent wire:

A vent wire is a steel wire used to produce holes in sand fill after ramming. This enables
the gases to escape out to the atmosphere when the molten metal is poured into the cavity of the
mould.

Draw spike:
A draw spike is a steel spike with sharp pointed end. This is used to pick the pattern from
the mould after ramming.

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Mallet:

A mallet is used to give light blow to the draw spike to drive it into the pattern in order to it
the pattern with the help of draw spike. It is round or rectangular and is made of hard wood

Lifter:

A lifter is used to remove the loose sand in the cavity produced in moulding. It is also used to
finish the walls of the cavity after removing the pattern.

Trowel:

A trowel is used to finish the cavity obtained in the mould. Trowels of various shapes and
sizes are used in moulding process.

Sprue Pin:

A sprue pin is a cylindrical and tapered wooden piece used to make a hole through which the
molten metal poured into the mould cavity.

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Core:

The core is used to make a hole or hollow casting. The core is normally made of core sand.
The core sand can be removed easily after the casting. The core sand is having 90% silica sand
and the remaining is binding materials (saw dust, asbestos, linseed cil, molasses etc.)

Shovel:
It is used to mix and move the mould sand from one place to another in the foundry shop. It
consists of a broad iron pan fitted with a long wooden handle.

Bellow:

It is used to blow out sand particles and dust on the surface of the mould

Swab:

It is used to apply water on the edges of the pattern before removing it from the mould. It is
easy to remove the moisturized pattern, otherwise mould sand sticks along with the pattern.

Slick:

It is used to repair and smoothen the mould surface after removing the pattern. It consists of
spoon shaped double ended trowel

Gate cutter

It is used to cut gates in the mould. The gate is connecting the runner hole and the mould cavity.

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Melting furnaces:

The melting furnaces are used to melt the metal to be cast. Furnaces used to melt ferrous or non-
ferrous metals are

1. Coke fired crucible furnace

2. Oil fired crucible furnace

3. Gas fired crucible furnace

4. Cupola furnace

5. Electric furnace

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Shank Ladder:

The ladle is used to collect the molten metal from the crucible and pour it to the mould
cavity.

RESULT:

Thus the various aspects of foundry and different moulding tools used in foundry shops are
studied.

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EX.NO: 10 FACE PLATE (SOLID PATTERN)

AIM

To make a green sand mould using a solid pattern.

TOOLS REQUIRED

Moulding boxes, Solid pattern, Peen end hammer, Flat end hammer, Shovel, Trowel ,Gate cutter,
Sprue pin, Strike off bar,etc

MATERIALS REQUIRED

Solid pattern and a mixture of green sand .

PROCEDURE

• Moulding sand was prepared with proper amount of moisture and clay content.
• The solid pattern was kept on the table such that the flat face of the pattern touches the
table and it was centered inside the drag.
• Dry sand was uniformly poured inside the drag including the pattern.
• Moulding sand was uniformly poured inside the drag including the pattern.
• It was rammed using peen end rammer by applying constant pressure till one third of the
drag was filled with sand.
• The flat end rammer was used for ramming the sand until the drag gets filled.
• Then the excess sand was leveled by a strike off bar.
• Small vent holes were made through the sand using vent pin, so that when the molten
metal was powered, the gas and steam so generated could escape out.
• The drag was tilted down .

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 • Dry sand was applied over the surface and pattern .It was placed correctly in position on
the drag & aligned using dowel pins.
• The sprue pin was placed vertically beside the pattern for making holes for pouring the
molten metal.
• The riser pin was placed inside vertically over the pattern so that the gases and the steam
in the molten metal would escape.
• The operations of filling the sand , ramming and venting of the cope were done in the
same manner as in the drag.
• The runner and the riser were removed. A funnel shaped opening called pouring basin
was cut all the top to facilitate easy pouring of the material.
• The cope was lifted, turned over and placed on the floor.
• The solid pattern was carefully removed from the drag by using draw screw.
• Gate was then cut by using gate cutter.
• Also the cope might be set in left by the pattern in the drag.
• Loose particles of sand were removed by a jet of air and the surface of moulding were
cleaned so as to give a smooth surface for the casting.
• Finally the moulding was assembled, the cope being carefully placed on the drag so that
the box was fitted using the pins.

RESULT

Thus a green sand mould was prepared using a solid pattern.

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EX.NO: 11 PIPE FLANGE (SPLIT PATTERN)

AIM

To make a green sand mould using a Split pattern.

TOOLS REQUIRED

Moulding boxes, Solid pattern, Peen end hammer, Flat end hammer, Shovel, Trowel ,Gate cutter,
Sprue pin, Strike off bar, vent pin etc

MATERIALS REQUIRED

Split pattern and a mixture of green sand .

PROCEDURE

• Moulding sand was prepared with proper amount of moisture and clay content.
• One piece of split pattern was kept on the table such that the flat surface of the pattern
touches the table and it was centered inside the drag.
• Dry sand was uniformly poured inside the drag including the pattern.
• Moulding sand was uniformly poured inside the drag including the pattern.
• It was rammed using peen end rammer by applying constant pressure till one third of the
drag was filled with sand.
• The flat end rammer was used for ramming the sand until the drag gets filled.
• Then the green sand was travelled by a strike off bar.
• The drag was tilted down .
• The top half of the pattern was placed correctly in position over the just half.
• Dry sand was applied over the surface and pattern .It was placed correctly in position on
the drag & aligned using trowel pins.
• The sprue pin was placed vertically beside the pattern for making holes for pouring the
molten metal.
• The riser pin was placed inside vertically over the highest point.
• The operations of filling the sand , ramming and venting of the cope were done in the
same manner as in the drag.
• The cope was lifted, turned over and placed on the floor.
• Gate was then cut by using gate cutter.
• Also the cope might be set in left by the pattern in the drag.

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 • Loose particles of sand were removed by a jet of air and the surface of moulding were
cleaned so as to give a smooth surface for the casting.

RESULT

Thus a green sand mould was prepared using a split pattern.

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