ESTD

MANUFATURING TECHNOLOGY LAB
ESTD: 1995 R. G. M COLLEGE OF ENGG. &TECH. NANDYAL-518501, KURNOOL DIST. A. P. (AUTONOMOUS) OFFERING B.TECH & M.TECH COURSES APPROVED BY AICTE NEW DELHI- AFFILIATED TO JNTU, ANANTAPUR. ACCREDITED BY NBA, NEW DELHI. PARTICIPATED INSTITUTUE IN WORLD BANK AIDED TEQIP-I MANUFACTURING TECHNOLOGY LAB MANUAL
NAME YEAR REGD. No
: : :
SCHOOL OF MECHANICAL ENGINEERING
School of Mechanical Engineering
R.G.M.C.E.T, Nandyal

PREFACE Manufacturing technology provides basic knowledge in manufacturing engineering. The Manufacturing Technology Lab manual has been written to provide a good foundation in all the principal areas of various process techniques like casting, welding, forming etc. in the manufacturing engineering. AIM OF MANUFACTURING TECHNOLOGY LAB Imparting the basic knowledge of processing techniques in the field of Manufacturing Technology. The students are exposed with hands of practice on process of Production Techniques. I have paid careful attention to the organization of the contents and it is suspected that this manual will be well received by the student. Any suggestion for improvement is always welcome.
LAB IN CHARGE
R. G. M COLLEGE OF ENGG. &TECH. SCHOOL OF MECHANICAL ENGINEERING
MANUFACTURING TECHNOLOGY LAB
Date
Exp. No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 A B C D E F G H I J K L M N B C D E F G H I J K L M N A C D E F G H I J K L M N A B D E F G H I J K L M N A B C E F G H I J K L M N A B C D F G H I J K L M N A B C D E G H I J K L M N A B C D E F H I J K L M N A B C D E F G I J K L M N A B C D E F G H J K L M N A B C D E F G H I K L M N A B C D E F G H I J L M N A B C D E F G H I J K M N A B C D E F G H I J K L N A B C D E F G H I J K L M
INDEX
S.NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 DATE NAME OF EXPERIMENT PAGE .NO MARKS REMARKS
PROPER DRESS CODE FOR MANUFACTURING TECHNOLOGY LAB Enter lab with khaki color dress (tucked) with shoes. Loose clothing, Jackets & long sleeves should not be worn in the Shop area. Rings, watches, Bracelets etc should not be worn while operating the machines. Neck ties and necklaces should be tucked inside your shirt. Avoid Nylon or synthetic clothing which can burn or melt.
Long hair must be secured in a Apron.

LIST OF EXPERIMENTS: 1. Preparation of stepped pulley pattern of given dimensions. 2. Determination of strength of a given molding sand 3. Determination of permeability of a given molding sand 4. Preparation of a Double welded lap joint by Shielded Metal Arc Welding. 5. Preparation of a Double welded butt joint by Shielded Metal Arc Welding of given dimensions 6. Preparation of a T- joint by Shielded Metal Arc Welding of given dimensions. 7. Prepare a welded model using Spot welding. 8. 9. Preparation of a metal welding using Plasma Arc Welding. 10 Preparation of a metal welding using Brazing operation. 11. Prepare a model by using Deep Drawing. 12. Prepare a model using Pipe Bending machine. 13. Prepare a model using Injection Molding. 14. Prepare a model using Blow Molding.
Prepare a stepped pulley pattern
Exp.No:
Date:
PREPARATION OF STEPPED PULLEY PATTERN AIM: Prepare a stepped pulley pattern of given dimensions as shown in fig. using wood turn lathe. TOOLS REQUIRED: Gauge, skew chisel, parting tool, scraping tools. DESCRIPTION OF LATHE: Wood turning lathe is also called lathe. It is simple in construction having three basic parts bed, head stock and tail stock. The head stock is permanently fixed on the left side of the bed. On the top of the bed guide way tail stock is mounted and it is free to slide and it can be clamped in any position. The work piece is held between centers (head stock and tail stock) and revolved on its own axis. The tool is fed manually to remove UN wanted material from rotating work piece. From this machine any axis symmetric component can be produced. PROCEDURE: 1. Take the work piece of required length and size. 2. Check the end faces weather they are perpendicular or not with the rectangular faces. 3. Mark the centers on both end faces. 4. Fix the work piece between centers. That is live center and dead center. 5. Rotate the work piece in anti clock wise direction. 6. Feed the tools manually to get the desired shape. PRECAUTIONS: Use goggles to protect the eyes from dust. CONCLUSIONS:
TABLE S. No. 1 2 3 4 5 6 GRAPH: %moisture /%Bentonite/ number of rams Compression strength (Kg/cm2 ) Shear strength (Kg/cm2 )
Exp.No:
Date:
DETERMINATION OF STRENGTH OF A GIVEN MOLDING SAND AIM: To determine the effect of moisture content / bentonite content /number of rams on green compression strength / Shear strength of a given moulding sand . APPARATUS: Universal sand strength testing machine( hydraulic type), Compression heads, shear heads, Muller, sand rammer, Weighing balance, water measuring jar etc. THEORY: The green compression strength of sand is the maximum compression stress which a tempered sand mixture is capable of developing when prepared, rammed and tested according to the standard procedure. The green shear strength of sand is the maximum shear stress which a tempered sand mixture is capable of developing when prepared, rammed and tested according to the standard procedure. PROCEDURE: An ISI standard specimen is rammed with desired percentage of moisture and bentonite. 1. The specimen is stripped from the tube by using the stripper post. 2. The specimen is placed between the compression heads or shear heads on universal sand testing machine. 3. The hand wheel is rotated slowly and steadily till the specimen fails. 4. The active needle comes back leaving the idle needle at the maximum breaking strength achieved. The reading is noted at the needle on the compression scale/shear scale. 5. The same procedure is repeated for different percentages of water for a given percentage of bentonite. 6. Results are recorded in tabular column and corresponding graph is also drawn.
The % of moisture may be kept constant at 1.5/2.0/2.5/3.0. The % of Bentonite may be kept constant at 4/6/8/10/12 The number of rams may be kept constant at 3/4/5/6. Note: Each batch of students may conduct the experiment by varying one of the variable keeping the other two constant. RESULTS: Effect of moisture content / bentonite content /number of rams on green compression strength / Shear strength of a given moulding sand is measured. CONCLUSIONS:
Exp.No:
Date:
LAP JOINT AIM: Preparation of double welded lap joint as shown in fig using shielded metal arc welding. MATERIAL REQUIRED: 2 M.S. flat of given size. TOOLS REQUIRED: Welding transformer, connecting cables, electrode holder, ground clamp, electrodes, chipping hammer, welding shield etc. THEORY: Arc welding is fusion welding process. Arc welding is a process of joining two metallic pieces by the application of heat is obtained from the electric arc between two electrodes. In this process two metallic pieces will act as base metal or parent metal
School of Mechanical Engineering R.G.M.C.E.T, Nandyal
and electrode will act as filler metal. The electrode is coated with flux which prevents oxidation of parent metals. LAP JOINT: The lap joint is used in joining two overlapping plates so that edge of each plate is welded to the surface of the other. The overlapping portion is called lap. The width of lap may be 3 to 5 times the thickness of the plates to be welded. Welds usually run each side of the lap. No edge preparation is required for a lap joint. PROCEDURE: 1. The given metallic pieces are prepared to given sizes by filling. 2. The metallic pieces are thoroughly cleaned from rest, grease, oil etc. 3. Now given metallic pieces were assembled as shown in fig. select the electrodes, based on thickness of metal piece and hold it in the electrode holder. 4. Switch on the supply and initiate the arc by either striking arc method or drag. 5. Tack welding to be done before full welding. 6. The full welding process is carried after completion of one pass slag is removed from the full weld bed with help of chipping hammer and metallic wire brush. 7. Then the above process is repeated until to reach desired height of the weld. PRECAUTIONS: 1. Use goggles, gloves in order to protect the human being. 2. Maintain constant arc length to have uniform weld bead. RESULT: Lap joint is prepared as shown in fig by using arc welding process.
CONCLUSIONS:
Exp.No: BUTT JOINT
Date:
AIM: preparation of butt joint as shown in figure using shielded metal arc welding process. MATERIAL REQUIRED: 2M.S Flat pieces of given size. TOOLS REQUIRED: welding transformer, connecting cables, electrode holder, ground clamp, electrodes, hipping hammer, welding shield etc. THEORY: Arc welding is a fusion welding process. Arc welding is the process of joining two metallic pieces by the application of heat, where heat is obtained from the electric arc between two electrodes. In this process two metallic pieces will act as base metal or parent metal and School of Mechanical Engineering R.G.M.C.E.T, Nandyal
electrode will act filler metal. The electrode is coated with flux which prevents oxidation of parent metals. Butt joint: The butt joint is join the ends or edges of plates or surfaces located approximately in the same plate with each other. Preparation of edge varies according to the thickness of the material and welding process used. Light gauge section requires only 90 sheared edges with no spacing between them. Materials ranging from 9 to 13mm thick that can be welded only from one side should be reduced either as a single V or single U. However thicker plates are prepared from both sides. The U shaped type of joint is more satisfactory and requires less filler material than V type groove. How ever it is more expensive to prepare U shape. Procedure: 1. The given metallic pieces filled to the desired size. 2. On both pieces beveled in order to have V groove. 3. The metallic pieces are thoroughly cleaned from rust grease, oil, etc. 4. The metallic pieces are connected to terminals of Trans former. 5. Select electrode dia based on thickness of work piece and hold it on the electrode holder. Select suitable range of current for selected dia. 6. Switch on the power supply and initiates the arc by either striking arc method or touch and drag method. 7. Tak welding to be done before full welding. 8. In full welding process after completion one part before going to second part. Slag is removed from the weld bed. With the metal wire brush or chipping hammer. 9. Then the above process will be repeated until to fill the groove with weld bed . PRECAUTIONS: 1. Use goggles, gloves in order to protect the human body. 2. Maintain the constant arc length. RESULT: butt joint is prepared as shown in figure by using arc-welding process. CONCLUSIONS:
Exp.No:
Date:
T-JOINT AIM: preparation of T-joint as shown in figure using shielded metal arc welding process. MATERIAL REQUIRED: two mild steel flats of given size. TOOLS REQUIRED: welding transformer, connecting cables, electrode holder, ground clamp, electrodes, chipping hammer, welding shield, wire brush etc. THEORY: Arc welding is a fusion welding process. Arc welding is the process of joining two metallic pieces by the application of heat, where heat is obtained from the electric arc.
In this process the two metallic pieces will act as base metal or parent metal. Electrode will act as filler metal. The electrode is coated with flux, which prevents oxidation of parent metal. T-JOINT: joint are used to weld two plates or sections whose surfaces are at approximately right angles to each other. Plates or surfaces should have good fit up in order to ensure uniform penetration and fusion. Edge preparation of vertical member is come as that of the butt joint. PROCEDURE: 1. Required edge preparation is made over the given metallic pieces. 2. The work pieces are cleaned properly from rust, grease, oil etc. 3. Place the electrode in the holder and ensure that all connections are given properly or not. 4. Assemble the given work pieces as shown in fig. 5. Switch on the power supply and initiate the arc. 6. first tack welding is done. 7. now full welding is carried after one pass, slag is removed from the weld bed by using chipping hammer and wire brush. 8. then second, third passes will be carried until to get the desired height of weld. PRECAUTIONS: 1. To protect the welder make use of welding shield, goggles, gloves, apron etc. 2. Maintain uniform arc length to have uniform weld bed. RESULT: T-joint is prepared as shown in fig by using by shielded metal arc welding CONCLUSIONS:
Designing of spot weld parameters are essentially based on the sheet thickness being welded. The typical equations for welding mild steel up to a thickness of 3.2 mm are given below. Electrode tip diameter: 2.54 + (t1 + t2) mm Weld time : 2.36 (t1 + t2) cycles Current : 3937 (t1+t2) A Electrode force : 876 (t1 + t2 ) N Where t1 = thickness of the first plate, mm t2 = thickness of the second plate, mm
Exp.No:
Date:
RESISTANCE SPOT WELDING AIM: Prepare a welded model using Spot welding TOOLS REQUIRED: spot welding machine , pneumatic cylinder& piston Arrangement, hose pipes. MATERIAL REQUIRED: sheet metal DESCRIPTION: The process description made so far is called the resistance spot welding (RSW)or simply spot welding. This is the most common resistance welding process. This is essentially done to join two sheet metal jobs in lap joint forming a smaller nugget at the interface of the two plates, as shown in fig. it essentially consists of two electrodes, out of which one is fixed. The other electrode is fixed to a rocker arm (to provide mechanical advantage) for transmitting the mechanical force from a pneumatic cylinder. This is the simplest type of arrangement. The other position is that of a pneumatic or hydraulic cylinder being directly connected to the electrode without any rocker arm. PROCEDURE: 1. Close tongs and measure space between electrode tip contact surfaces. 2. Measure the thickness of the total well-ment. 3. Adjust tong gap to measurement of Step 2 less 1/2 the thickness of the thinnest weld number. 4.Insert the parts to be welded between the electrode tips and bring tips to welding pressure. 5.There should be a slight deflection of the tongs. This may be measured with a straight edge set on the tong longitudinal axis. 6. Energize the spot welding machine and make a sample weld. 7. Test the weld by visual and mechanical means. Check the electrode tip for deformation and contamination 8. Adjust tong pressure as required 9.A typical welding schedule whose time elements are measured in terms of the time unit for a cycle of AC these welding schedules can be precisely controlled with the modern programmable electronic controllers PRECAUTIONS: 1. Flying sparks and hot metal are often thrown off from the weld joint and can burn or injure eyes and skin.
2 .Electric shock from wiring is a possible hazard. 3. Hot metal and parts can cause burns. 4. Moving parts, such as tongs, tips, and linkages, can injure fingers and hands. RESULT:
CONCLUSIONS:
Bend allowance
B = (R +Kt)
Where =bend angle, in radians R=inside radius of the bend, in mm K=location of neutral axis from bottom surface = 0.33 when R<2t = 0.5 when R>2t t = sheet thickness, in mm Minimum bend radius = 0.5 t soft materials = t other materials = 3 t spring materials 2 Fb= KLst /W Where Fb=bending force, N K= 1.33 for die opening of 8t = 1.20 for die opening of 16t = 0.67 for U bending = 0.33 for a wiping die L = Length of the bent part, mm s = ultimate tensile strength, MPa t = blank thickness, mm W = width between the contact points, mm
Exp.No: PIPE BENDING MACHINE Date: AIM : Prepare a model using Pipe bending machine TOOLS REQUIRED: Bending machine , pneumatic cylinder& piston Arrangement, hose pipes. MATERIAL REQUIRED: sheet metal DESCRIPTION: o Bending refers to the operation of deforming a flat sheet around a straight axis where the neutral plane lies. o The disposition of the stresses in a bent specimen is shown in fig . o Here, due to the applied forces, the top layers are in tension and bottom layers are in compression as shown. The plane with no stresses is called the neutral axis. o The neutral axis should be at the centre when the material is elastically deformed.But when the material reaches the plastic stage, the neutral axis moves downward, since the materials oppose compression much better than tension PROCEDURE: since neutral axis remains constant, it is the required length. Beyond the bend lines, the material is not affected. Hence to calculate the length required, it is necessary to find out the bend allowance which is the arc length of the neutral axis between the bend lines.. The outer layers which are under tension should not be stretched too much; otherwise there is likelihood of rupture taking place. The amount of stretching depends on the sheet thickness and the radius. Lower the bend radius. Lower the bend radius, higher is the strain in this zone. Hence there is a minimum bend radius to be specified, depending on the material characteristics. The other aspect to be considered in designing parts from bending is the grain orientation of the sheet which is bent. As far as possible, the bending is to be done in a direction perpendicular to the grain direction in the metal. By virtue of the rolled sheets being used for bending, the grain direction usually is along the length axis, being the direction of rolling. There is a possibility of cracks appearing at the time of bending if the bending is done along the grains But if two bending are to be done on
the same sheet at right angles, then it may be desirable to make them at 450 to the grain direction so that the risk of cracking is minimized. Spring back in bending is difficult to estimate theoretically .but it is essential to compensate it, because the bend geometry gets affected by the spring back directly. RESULT:
CONCLUSIONS:
INJECTION MOULDING
Exp.No: INJECTION MOULDING AIM: Prepare a model using Injection Molding
Date:
TOOLS REQUIRED: Blow Molding Machine, Press working die, pneumatic cylinder& piston Arrangement, hose pipes MATERIAL REQUIRED: Granular Rubber DESCRIPTION: The injection molding process and the plastics industry has become a multi-billion dollar industry, with 32% of all plastics, by weight, processed by injection molding. Injection molding has made possible the cheap and durable construction of many consumer and industrial items that have had a profound impact on society. PROCEDURE: Granulated or powdered thermoplastic plastic is fed from a hopper into the Injection Molding machine. The Injection Molding machine consists of a hollow steel barrel, containing a rotating screw (Archemidial Screw). The screw carries the plastic along the barrel to the mould. Heaters surround the barrel melt the plastic as it travels along the barrel. The screw is forced back as the melted plastic collects at the end of the barrel. Once enough plastic has collected a hydraulic ram pushes the screw forward injecting the plastic through a sprue into a mould cavity. The mould is warmed before injecting and the plastic is injected quickly to prevent it from hardening before the mould is full. .Pressure is maintained for a short time (dwell time) to prevent the material creeping back during setting (hardening). This prevents shrinkage and hollows, therefore giving a better quality product. .The molding is left to cool before removing (ejected) from the mould. The molding takes on the shape of the mould cavity
PRECAUTIONS: 1. Use goggles, gloves in order to protect the human being. 2. Maintain uniform pressure to have uniform mould RESULT:
CONCLUSIONS:

Exp.No: Date:
BLOW MOULDING AIM: Prepare a model using Blow Molding TOOLS REQUIRED: blow Molding Machine, Press working die, pneumatic cylinder& piston Arrangement, hose pipes MATERIAL REQUIRED: Granular Rubber. DESCRIPTION: Blow molding process for the fabrication of plastic containers is similar to that used for blowing glass bottles. Blow molding is a manufacturing method used in the plastics and polymers industries to create hollow but strong containers for their clients. Plastic beverage bottles and fuel tanks are commonly created through blow molding. A typical blow molding machine set-up uses an extruded plastic pre form and compressed air to fill the chamber of a divided Plastic molds. The two halves of the mold separate and the finished container is released. PROCEDURE: First a length of polymer tubing is extruded. While still in a semi molten state, the length is placed in to a two piece mould having the desired container configuration. The hallow piece is formed by blowing or steam under pressure in to the parsion, forcing the tube walls to conform to the counters of the mould. Sometimes referred to as Molding Technique Actually an extrusion process, since the material is shaped by being forced through an extruder Casting like metals, polymeric materials may be cast, as when a molten plastic material is poured in to a mould and allowed to solidify. Both thermoplastic and thermosetting plastics may be cast .For thermoplastics, solidification occurs upon cooling from the molten state; however, for thermosetting, Harding is a consequence of the actual polymerization or curing process.
PRECAUTIONS: Use goggles, gloves in order to protect the human being. Maintain uniform air flow to have uniform mould RESULT:
CONCLUSIONS:

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MANUFATURING TECHNOLOGY LAB

NAME YEAR REGD. No

School of Mechanical Engineering

MANUFATURING TECHNOLOGY LAB

School of Mechanical Engineering

MANUFATURING TECHNOLOGY LAB

R. G. M COLLEGE OF ENGG. &TECH. SCHOOL OF MECHANICAL ENGINEERING

MANUFACTURING TECHNOLOGY LAB

School of Mechanical Engineering

MANUFATURING TECHNOLOGY LAB

School of Mechanical Engineering

MANUFATURING TECHNOLOGY LAB

Long hair must be secured in a Apron.

School of Mechanical Engineering

MANUFATURING TECHNOLOGY LAB

School of Mechanical Engineering

MANUFATURING TECHNOLOGY LAB

Prepare a stepped pulley pattern

School of Mechanical Engineering

MANUFATURING TECHNOLOGY LAB

School of Mechanical Engineering

MANUFATURING TECHNOLOGY LAB

School of Mechanical Engineering

MANUFATURING TECHNOLOGY LAB

School of Mechanical Engineering

MANUFATURING TECHNOLOGY LAB

School of Mechanical Engineering

MANUFATURING TECHNOLOGY LAB

School of Mechanical Engineering

MANUFATURING TECHNOLOGY LAB

School of Mechanical Engineering

MANUFATURING TECHNOLOGY LAB

School of Mechanical Engineering

MANUFATURING TECHNOLOGY LAB

School of Mechanical Engineering

MANUFATURING TECHNOLOGY LAB

MANUFATURING TECHNOLOGY LAB

School of Mechanical Engineering

MANUFATURING TECHNOLOGY LAB

Exp.No: BUTT JOINT

MANUFATURING TECHNOLOGY LAB

School of Mechanical Engineering

MANUFATURING TECHNOLOGY LAB

MANUFATURING TECHNOLOGY LAB

School of Mechanical Engineering

MANUFATURING TECHNOLOGY LAB

School of Mechanical Engineering

MANUFATURING TECHNOLOGY LAB

MANUFATURING TECHNOLOGY LAB

School of Mechanical Engineering

MANUFATURING TECHNOLOGY LAB

School of Mechanical Engineering

MANUFATURING TECHNOLOGY LAB

School of Mechanical Engineering

MANUFATURING TECHNOLOGY LAB

School of Mechanical Engineering

MANUFATURING TECHNOLOGY LAB

School of Mechanical Engineering

MANUFATURING TECHNOLOGY LAB

School of Mechanical Engineering

MANUFATURING TECHNOLOGY LAB

MANUFATURING TECHNOLOGY LAB

School of Mechanical Engineering

MANUFATURING TECHNOLOGY LAB