MANUFACTURING TECHNOLOGY LAB I MANUAL

ME-2207

CONTENTS S.NO DATE EXPERIMENT MARKS SIGNATURE OF THE STAFF

Ex. No: 1 Date:

STUDY OF BASIC MACHINING LATHE

SAFETY PRECAUTIONS FOR MACHINING WORK Job should be tightly held in the chuck. If the job is held in between the centres, then apply grease on the nose of dead centre,

otherwise it will burnt out due to excess heat. Do not measure the job while the work piece is rotating. Do not leave the chuck key in the chuck. Do not try to stop the lathe chuck or job with hands. Do not handle metal chips by hand. Do not give more depth of cut while the job is rotating at high speed. Tighten the tool in the tool post. Do not stand close to the rotating work piece and do not bring your face close it. Do not reduce or increase the speed when the lathe operation is going on.

PRINCIPLE OF LATHE In lathe the work piece is held in the chuck, a work holding device. The cutting tool is mounted in the tool post. The chuck is rotated by means of electric power. When the chuck rotates the work piece also rotates. The tool is moved against the rotating work piece by giving small amount of depth of cut. Here the material is removed in form of chips. Lathe machine has the following parts as shown in figure: Bed Head stock Carriage Saddle Cross slide Compound rest Tool post Apron Lead screw Tailstock

BED It is the base of the machine on its left side the head stock is mounted. A movable casing called tail stock is mounted on the right side.

HEAD STOCK It consists of a spindle, gears and speed change levers. It is used to transmit the motion of the job.

CARRIAGE Carriage is used to carry a tool to bring it in contact with the rotating work piece or to with draw from such a contact.

SADDLE It is H shaped part fitted on the lathe bed. There is a hand wheel to move it on the bed way. Cross slide, compound rest and tool post are fitted on this saddle.

CROSS SLIDE It is on the upper side of saddle in the form of dove tail. A band wheel is provided to drive the cross slide.

COMPOUND REST It is fitted over the cross slide on a turn table. It permits both parallel and angular movements to the cutting tool.

TOOL POST It is fitted on the top most part of compound rest. Tool is mounted on this tool post. Cutting tool is fixed in it with the help of screw.

APRON It is the hanging part in front of the carriage. It accommodates the mechanism of hand and power feed to the cutting tool for carrying out different operations.

HEAD SCREW It is a long screw with ACME threads. It is used for transmitting power for automatic feed or feed for thread cutting operating.

TAIL STOCK

It is located at the right end of the lathe bed and it can be positioned anywhere in the bed. It is used for supporting lengthy jobs and also carries tool to carry out operations such as tapping, drilling and reaming.

LATHE OPERATIONS Simple Turning It is operation for reducing the diameter of the work piece. The turning tool is used for this operation. More feed of tool is given for rough turning. Then, less feed is given for finishing. In this operation, work is held in chuck and tool is set to the centre height of the work piece. Taper Turning Taper is defined as the uniform change in the diameter of a work piece measured along its length. Calculation for taper turning Taper = (D d) / 2L Where, D = larger diameter d = smaller diameter L = length of taper Taper turning operation shown in figure. This can be done by the following methods: 1. Compound rest method 2. Tail stock set over method 3. Using form tool 4. Taper attachment method. Drilling Drilling is the operation of making a hole on the work piece. Here the job is held in the tail stock sleeve. Feed is given by rotating the hand wheel in the tail stocks which pushes the tailstock sleeve Facing

It is done for getting fine finish on the face of the job. Facing tool is set at an angle to the work piece. In this operation the tool is fed from the centre of work piece towards the outer surface against the rotating work piece. Depth of cut is low for the facing operation.

Step turning It is similar to the process of turning but in this case different diameter in step of various

sizes are taken on the work piece roughing tool i.e. used for rough turning and the knife tool is used for finishing cut. Boring It is the process of enlarging a drilled hole. A special type of boring tool is used for this purpose.

Mark Allocation Performance Observation Attendance Viva Total 05 05 05 05 20

Ex. No: 2 Date:

FACING, PLAIN TURNING AND STEP TURNING

AIM: To obtain the required shape and size of the given work piece by facing, plain turning and step turning. MATERIAL SUPPLIED: Mild Steel round rod of size ____________________mm TOOLS REQUIRED: Single point cutting tool Vernier calliper Steel rule Outside calliper Marking gauge SEQUENCE OF OPERATIONS: Facing Turning Step turning

PROCEDURE: 1. The given work piece is checked for its dimensions by using measuring devices. 2. Loosen the jaws in the chuck using the chuck key to position the work piece, and then tighter the jaws 3. Check the center of the job using marking gauge. If the center of the job is not in the lathe axis readjust the chuck and fix the job in the lathe axis 4. Fix the single point cutting tool in the tool post
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5. Select the corresponding spindle speed and feed the before starting the operation 6. Switch ON the lathe and do the facing operation on the one side of the job 7. Move the carriage near the work piece. Give it small cross feed and then move the carriage 8. Then stop the machine, release the chuck, mark the length, invert the job and refax in the chuck 9. Do the facing operation on the other side of the job. 10. Then the plain turning is done to reduce the diameter of the work piece 11. Finally, the dimensions of work piece are again checked

Mark Allocation Performance Observation Attendance Viva Total RESULT: Thus the required size and shape of the given work piece is detained 05 05 05 05 20

Ex. No: 3 Date: AIM: To perform taper turning, thread cutting and knurling operation on a given cylindrical work piece.

TAPER TURNING, THREAD CUTTING AND KNURLING

MATERIAL SUPPLIED: Mild Steel round rod of size ____________________mm

TOOLS REQUIRED: Single point cutting tool Vernier calliper Steel rule Outside calliper Marking gauge Thread cutting tool Thread pitch gauge Knurling tool SEQUENCE OF OPERATIONS: Taper turning Thread cutting Knurling

CALCULATION:

Taper turning:
The angle is determined by using the formula, Tana= (D-d)/2L Where D=Larger diameter of the work piece d=smaller dia of the work piece L=taper length of the work piece

Thread Cutting:
(Driver teeth)/ (Driven teeth) = (Pitch of the work)/ (Pitch of the lead screw)

PROCEDURE: 1. The given work piece is checked for its dimensions by using measuring devices. 2. Loosen the jaws in the chuck using the chuck key to position the work piece. 3. Check the center of the job using marking gauge. 4. Fix the single point cutting tool in the tool post. 5. Select the corresponding spindle speed and feed the before starting the operation 6. Work the taper length on the job 7. Calculate the taper angle and then the compound rest is received to the required angle 8. Cutting tool is moved at an angle to the lathe axis 9. The gear ratio of no of teeth required on change gear are calculated

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10. The current size of gears in the change gear train is fixed 11. Rotation of spindle should be sent out fourth of speed 12. The cutting tool height is set which is equal to the centre of work piece 13. The cross slide hand wheel is rotated tilled tool touches the work piece 14. The half nut is engaged when any one making on the dial coincides with reference mark on chasing dial 15. Now the tool will move in helical path on the work piece to form thread 16. Fix the knurling tool in the tool post 17. Then the tool is held in tool post and passed again checked

Mark Allocation Performance Observation Attendance Viva Total RESULT: Thus the taper turning thread cutting and knurling operation of required dimensions was determined 05 05 05 05 20

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Ex. No: 4 Date: AIM:

BOARING AND INTERNAL THREAD CUTTING

To perform Boaring and internal thread cutting operation on a given cylindrical work piece MATERIAL SUPPLIED: Mild Steel round rod of size ____________________mm

TOOLS REQUIRED: Single point cutting tool Vernier calliper Steel rule Outside calliper Marking gauge Thread cutting tool Thread pitch gauge Boaring tool SEQUENCE OF OPERATIONS: Boaring Internal Thread cutting

CALCULATION:

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Thread Cutting:
(Driver teeth)/ (Driven teeth) = (Pitch of the work)/(Pitch of the lead screw)

PROCEDURE: 1. The given work piece is checked for its dimensions by using measuring devices. 2. Loosen the jaws in the chuck using the chuck key to position the work piece. 3. Check the center of the job using marking gauge. 4. Fix the single point cutting tool in the tool post. 5. Select the corresponding spindle speed and feed the before starting the operation 6. The drill is fitted in the tail stock spindle 7. The tail stock is moved over the bed and chambered near the work piece 8. When the job rotates, the drill bit is fed into work by turning tail stock hand wheel upto required path 9. Then Boaring tool is fitted on the tool post and fed parallel to the axis of lathe 10. Boar the work piece to required dia 11. The gear ratio and no teeth required on change gears are calculated 12. The current size of gears in the change gear train is fixed 13. The rotation of the spindle should be sent one fourth of the speed required for turning 14. The cross slide hand wheel is rotated till the tool touches the work piece 15. Now the tool will move in helical path on work piece to form thread 16. After one pass the half nut is dischanged and the tool is withdrawn simultaneously

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17. The tool is adjusted to the required depth of cut and rearranged the half nut for repeating the same
procedure till the required depth is obtained

18. Finally, the dimensions of work piece are again checked

Mark Allocation Performance Observation Attendance Viva Total RESULT: Thus the Boaring and internal thread cutting operation of required dimension was determined 05 05 05 05 20

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Ex.No: 5 Date:

STUDY OF WELDING
SAFETY PRECAUTIONS FOR ARC WELDING Check the ground connection and insulation of all the wires. They are should be observed only through a shield or goggles. Always wear the safety hand gloves, apron and leather shoes. Use proper capacity current cables. Switch off the welding machines when leaving from the work. Remove the slag by chipping hammer only. To relieve strain or irritation on the eyes, eye drops may be applied.

SAFETY PRECAUTIONS FOR GAS WELDING As far as possible use a spark lighter for igniting the flame. Oil, petrol, gaseous and other explosive materials should be kept away from the

welding location. Goggles face shields and gloves must be used while welding. Dont keep the blow pipe on a wooden blank during the course of welding. Oil and petrol tanks and tanks with inflammable materials should be perfectly

emptied and cleaned before welding them. Secure cylinder- in-use against falling, which may knock off the valve. Any repairable parts of the welding equipment should be sent to the manufacturer for

necessary repairs.

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INTRODUCTION Arc welding is one of several fusion processes for joining metals. By applying intense heat, metal at the joint between two parts is melted and caused to intermix-directly, or more commonly, with an intermediate molten filler metal. Upon cooling and solidification, a metallurgical bond is created. In arc welding, the intense heat needed to melt metal is produced by an electric arc. When the circuit is energized, the flow of electric current through the electrode heats the electrode by virtue of its electric resistance. When the electrode tip is touched to the work piece and then withdrawn to leave a gap between the electrode and work piece, the arc jumping the short gap presents a further path of high electric resistance, resulting in the generation of an extremely high temperature in the region of the sustained arc. The temperature reaches about 6000oC, which is more than adequate to melt. This heat melts both the base metal and the electrode, producing a pool of molten metal sometimes called a crater.

WELDING TOOLS Chipping hammer Electrode holder Wire brush Helmet Goggle Leather gloves Hand screen Tongs

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1. CHIPPING HAMMER A chipping hammer is chisel shaped one and it is used to remove the slag from the weld bead.

2. ELECTRODE HOLDER It is device used for mechanically holding the electrode and conducting current to it. Jaws are made to hold the bare end of the electrode in either vertical or an angular position. These are fully insulated and the jaws are made of metals having high heat conductivity. 3. WIRE BRUSH A wire brush made up of shift steel wire, embedded in wood, removes small particles of slag from the weld bead after the chipping hammer is used.

4. HELMET It is used shield provide better protection to face and neck of the welder. It is fitted with suitable fitter lens. 5. GOGGLE This is protective clothing for the eyes. It is worn to avoid radiation, spatter and hot slag. 6. LEATHER GLOVES This is a flame-retardant outfits worn by a welder to protect the under clothing and the body from the sparks, the metal and the hot metal being welded. 7. HAND SCREEN It is a protective device used in arc welding. A hand shield is held in the hand of the welder and it is fitted with a suitable fitter lens. 8. TONGS Tongs are used to handle the hot metal- welding job while cleaning; they are also used to hold the metal for hammering. TYPES OF WELD JOINTS There are two major classes of weld fillet and butt. Fillet welds. These welds are roughly triangular in cross section and between two

surfaces not in the same plane and the weld metal are substantially placed alongside the components being joined.
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Butt welds. A butt weld is made between two pieces of metal usually in the same

plane, the weld metal maintaining continuity between the sections. The most common welds are given below. Lap joint Butt joint T-joint and the Edge joint

THE WELDING CURRENT Both direct and alternating currents may be used for arc welding. However, most work on mild steel is done using AC. AC welding machines have several advantages over DC machines, among them being a lower purchase cost, higher operating efficiency and negligible maintenance. The quality of welds produced using AC is equally as good as when DC is used. However, AC is limited in that it will not satisfactorily run many of the non-ferrous types of electrodes. GAS WELDING Welding is a way of joining metals by means of heat liberated by burning the gas like oxyacetylene and acetylene. The oxygen and acetylene is obtained under high pressure in cylinders which are fitted with pressure regulators. Each cylinder is connected to the blowpipe by flexible hoses. The oxygen cylinders are painted black and acetylene cylinders are painted maroon. When acetylene is mixed with oxygen in correct proportions in the welding torch, ignition is taking place. The flame resulting at the tip of the torch is sufficiently hot to melt and join the parent metal. The flame temperature is about 3200 C. The filler metal rod is generally added to the molten metal pool to build up the seam for greater strength. TYPES OF FLAMES Neutral Flame (Oxygen, Acetylene in equal proportions) Oxidizing Flame(excess of Oxygen) Reducing Flame(excess of Acetylene)
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NEUTRAL FLAME A neutral flame is produced when approximately equal volumes of oxygen and acetylene are mixed in the welding torch and burnt at the torch tip. The temperature of the neutral flame is of the order of about 3260 C. The flame has inner cone which is light blue in colour.
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OXIDIZING FLAME If the volume of the oxygen supplied to the neutral flame is increased, then resulting flame will be oxidizing flame (i.e., rich in oxygen). The temperature of oxidizing flame is of the order of about 3482 C. Normally the outr flame envelope is much shorter. It has very small white inner cone. REDUCING FLAME If the volume of the oxygen supplied to the neutral flame is reduced, the resulting flame will be a carburizing or reduced flame (i.e., rich in acetylene). In this case, flame is recognized by acetylene feather which exists between the inner cone and outer envelope. The outer flame envelope is longer than that of the neutral flame and is usually much brighter in color. It has appropriate temperature of 3038 C.
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APPLICATIONS OF WELDING Today, almost all the commonly employed metals and their alloys can be welded by

the arc welding process. Shielded metal arc welding is used both as a fabrication process and for maintenance

and repair jobs. The process finds application in Air receiver, tank, boiler, structural and pressure vessel fabrications. Ship building. Arc welding is used in building and bridge Mark Allocation Performance Observation Attendance Viva Total
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05 05 05 05 20

construction.

Ex. No: 6 Date: AIM: To join two given metal plates by a square butt joint in arc welding. MATERIAL SUPPLIED: Mild Steel Plate of size TOOLS REQUIRED: Welding transformer Welding rods Safety gloves Goggle Tong Chipping hammer Flat file Try square, etc.,

SQUARE BUTT JOINT

SEQUENCE OF OPERATIONS:

Edge preparation (Removal of rust, scale etc.,) Tacking Welding Cooling Chipping Cleaning

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PROCEDURE: 1. The surface to be welded is cleaned and the edges of the plates may be filed for perfect joint and more strength. 2. The welding rod is held in the electrode holder and the ground clamp is clamped to the plate to be welded. 3. The plates to be welded are positioned touching each other (butting) and tag weld is done on the ends to avoid the movement of the plates during welding. 4. Now start welding from one end of the plates. 5. The electric arc produced melts the welding rod and joints the two metal plates. Maintain a gap of 3 mm between the plate and the welding rod. 6. The welding process is completed by removing slag using chipping hammer. Mark Allocation Performance Observation Attendance Viva Total RESULT: Thus the two metal plates were joined by square butt weld. 05 05 05 05 20

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Ex. No: 7 Date:

LAP JOINT
AIM: To join two given metal plates by a Lap joint in arc welding. MATERIAL SUPPLIED: Mild Steel Plate of size TOOLS REQUIRED: Welding transformer Welding rods Safety gloves Goggle Tong Chipping hammer Flat file Try square, etc.,

SEQUENCE OF OPERATIONS: Edge preparation (Removal of rust, scale etc.,) Tacking Welding Cooling Chipping Cleaning

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PROCEDURE: 1. The surface to be welded is cleaned and the edges of the plates may be filed for perfect joint and more strength. 2. The welding rod is held in the electrode holder and the ground clamp is clamped to the plate to be welded. 3. The plates to be welded are positioned touching each other (butting) and tag weld is done on the ends to avoid the movement of the plates during welding. 4. Now start welding from one end of the plates. 5. The electric arc produced melts the welding rod and joints the two metal plates. Maintain a gap of 3 mm between the plate and the welding rod. 6. The welding process is completed by removing slag using chipping hammer.

Mark Allocation Performance Observation Attendance Viva Total RESULT: Thus the two metal plates were joined by Lap weld. 05 05 05 05 20

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Ex. No: 8 Date:

TEE FILLET JOINT

AIM: To join two given metal plates by a Tee Fillet joint in arc welding. MATERIAL SUPPLIED: Mild Steel Plate of size TOOLS REQUIRED: Welding transformer Welding rods Safety gloves Goggle Tong Chipping hammer Flat file Try square, etc.,

SEQUENCE OF OPERATIONS:

Edge preparation (Removal of rust, scale etc.,) Tacking Welding Cooling Chipping
Cleaning 24

PROCEDURE:

1. The surface to be welded is cleaned and the edges of the plates may be filed for perfect joint and more strength. 2. The welding rod is held in the electrode holder and the ground clamp is clamped to the plate to be welded. 3. The plates to be welded are positioned touching each other (butting) and tag weld is done on the ends to avoid the movement of the plates during welding. 4. Now start welding from one end of the plates. 5. The electric arc produced melts the welding rod and joints the two metal plates. Maintain a gap of 3 mm between the plate and the welding rod. 6. The welding process is completed by removing slag using chipping hammer.

Mark Allocation Performance Observation Attendance Viva Total RESULT: Thus the two metal plates were joined by Tee Fillet weld. 05 05 05 05 20

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Ex. No: 9 Date:

STUDY OF SHEET METAL

SAFETY PRECAUTIONS OF SHEET METAL Heavy sheet must be handled by using gloves. Check whether head portion of the mallet and hammer should be tightly fixed to the handle. Respective snips should be selected according to the sheet metal thickness. Burrs should be removed in the edges of the sheet metal after the cutting process. Do not let sheet metal slip through your hands. While cutting operation, blade should be perpendicular to the job and along the marking line. Adequate care should be taken while folding, hamming or scaming operations. Waste materials should be cleaned by using wire brush. Necessary sheet metal working tools should be collectively selected and handled because that

avoids confusion. High force should not be applied while leveling the plate.

GENERAL PROCEDURE FOR SHEET METAL WORK

The exact size and shape of the sheet to be cut is given by the development of the concerned

object. The development is drawn on a flat sheet metal and then the sheet is cut. The cut sheet is folded or rolled to the required shape before the joints are made by welding

or any other form of fastening.

SPECIFICATION OF SHEET METAL The sheets are specified by standard gauge numbers. Each gauge designates a definite thickness. The gauge number can be identified by standard wire gauge (or) S.W.G. The following table shows gauge numbers and their corresponding thicknesses of sheet. The larger the gauge numbers, the lesser the thickness and vice versa.

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S.W.G.

10

12 2.6

14 2.0

16 1.6

18 1.2

20 0.9

22 0.7

25 0.6

26 0.4

30 0.3

Thickness 3.2

TOOLS USED IN SHEET METAL WORK SNIPS (OR) SHEARS Snips are hand sheets, varying in length from 200mm to 600mm. 200mm and 250mm lengths are most commonly used. Curved snips or bend snips are used for trimming along inside curves. STRIKING TOOLS HAMMERS Hammers are used in sheet metal work for following: stretching, leveling, riveting, strengthening of sheet metal joints, etc. PUNCHES In sheet metal work, punch is used foe making out work, locating centers etc. there are two types of punches. SUPPORTING TOOLS STAKES Stakes are nothing but anvils of sheet metal workers, used for bending, hamming, scaming, forming, etc. using hammers or mallet. BENDING TOOLS Flat nose pliers and round nose pliers are used in sheet metal work for forming and holding work.

LAYOUT TOOLS SCRIBER It is a long wire of steel with its one end sharply pointed and hardened, to scratch a line on the sheet metal for laying out patterns.

DIVIDERS Dividers are used for drawing circles or arcs on sheet metal. They are used to mark a desired distance between two points and to divide lines into equal parts.
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TRAMMELS It is used for making of arcs and circles. Maximum size of the arc that can be described depends on the length of the beam in scriber.

GROOVER GROOVING In order to join the sheet metal jobs, their ends are grooved with the help of grooving tools. This process is called grooving.

SHEET METAL OPERATIONS shearing bending

SHEARING The following are the basic shearing operations. Cutting off Parting Blanking Punching Notching Slitting Lancing Nabbing Trimming

BENDING It means that the metal is stressed beyond the elastic limit, so that the metal is bent into right angle and forming occurs when complete items or parts are shaped. It incorporates angle bending, roll forming and scaming.

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Ex. No: 10 Date:

MODEL MAKING SQUARE TRAY

AIM: To make a square tray from a given metal sheet.

TOOLS REQUIRED:

Mallet Snip Stake Steel Rule Ball peen hammer Straight edge Rivets
Scriber, etc.,

PROCEDURE: 1. The given metal sheet is smoothed using mallet. 2. The development of square tray is drawn on the sheet with given dimensions using the scriber. 3. The unmarked and excess portions in the sheet are removed using snip. 4. Folding is done as per the given order using mallet and stake. 5. Bending is done as per the given dimension using the stake and mallet. 6. The tray is riveting using the given rivets and hammer.

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Mark Allocation Performance Observation Attendance Viva Total 05 05 05 05 20

RESULT: Thus the square tray with required dimensions is obtained.

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Ex. No: 11 Date: MODEL MAKING RECTANGULAR TRAY AIM: To make a rectangular tray from a given metal sheet.

TOOLS REQUIRED:

Mallet Snip Stake Steel Rule Ball peen hammer Straight edge Rivets
Scriber, etc.,

PROCEDURE: 1. The given metal sheet is smoothed using mallet. 2. The development of the rectangular tray is drawn on the sheet with given dimensions using the scriber. 3. The unmarked and excess portions in the sheet are removed using snip. 4. Folding is done as per the given order using mallet and stake. 5. Bending is done as per the given dimension using the stake and mallet. 6. The tray is riveting using the given rivets and hammer.

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Mark Allocation Performance Observation Attendance Viva Total 05 05 05 05 20

RESULT: Thus the rectangular tray with required dimensions is obtained.

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Ex. No: 12 Date: MODEL MAKING FRUSTUM OF A CONE FUNNEL AIM: To make a funnel from a given metal sheet.

TOOLS REQUIRED:

Mallet Snip Stake Steel Rule Ball peen hammer Straight edge Rivets
Scriber, etc.,

PROCEDURE: The given metal sheet is smoothed using mallet. The development of the funnel is drawn on the sheet with given dimensions using the

scriber. The unmarked and excess portions in the sheet are removed using snip. Folding is done as per the given order using mallet and stake. Bending is done as per the given dimension using the stake and mallet. The tray is riveting using the given rivets and hammer.

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Mark Allocation Performance Observation Attendance Viva Total 05 05 05 05 20

RESULT: Thus the funnel with required dimensions is obtained.

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Ex. No: 13 Date: STUDY OF FOUNDRY

A foundry is a factory that produces metal castings. Metals are cast into shapes by melting them into a liquid, pouring the metal in a mould, and removing the mould material or casting after the metal has solidified as it cools. The most common metals processed are aluminium and cast iron. However, other metals, such as bronze, steel, magnesium, copper, tin, and zinc, are also used to produce castings in foundries. Process: In metalworking, casting involves pouring liquid metal into a mold, which contains a hollow cavity of the desired shape, and then allowing it to cool and solidify. The solidified part is also known as a casting, which is ejected or broken out of the mold to complete the process. Casting is most often used for making complex shapes that would be difficult or uneconomical to make by other methods. Melting: Melting is performed in a furnace. Virgin material, external scrap, internal scrap, and alloying elements are used to charge the furnace. Virgin material refers to commercially pure forms of the primary metal used to form a particular alloy. Alloying elements are either pure forms of an alloying element, like electrolytic nickel, or alloys of limited composition, such as ferroalloys or master alloys. External scrap is material from other forming processes such as punching, forging, or machining. Internal scrap consists of gates, risers, defective castings, and other extraneous metal oddments produced within the facility. The process includes melting the charge, refining the melt, adjusting the melt chemistry and tapping into a transport vessel. Refining is done to remove deleterious gases and elements from the molten metal to avoid casting defects. Material is added during the melting process to bring the final chemistry within a specific range specified by industry and/or internal standards. Certain fluxes may be used to separate the metal from slag and/or dross and degassers are used to remove dissolved gas from metals that readily dissolve certain gasses. During the tap, final chemistry adjustments are made.

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Furnace: Several specialized furnaces are used to melt the metal. Furnaces are refractory lined vessels that contain the material to be melted and provide the energy to melt it. Modern furnace types include electric arc furnaces (EAF), induction furnaces, cupolas, reverberatory, and crucible furnaces. Furnace choice is dependent on the alloy system and quantities produced. For ferrous materials, EAFs, cupolas, and induction furnaces are commonly used. Reverberatory and crucible furnaces are common for producing aluminium, bronze, and brass castings. Furnace design is a complex process, and the design can be optimized based on multiple factors. Furnaces in foundries can be any size, ranging from small ones used to melt precious metals to furnaces weighing several tons, designed to melt hundreds of pounds of scrap at one time. They are designed according to the type of metals that are to be melted. Furnaces must also be designed based on the fuel being used to produce the desired temperature. For low temperature melting point alloys, such as zinc or tin, melting furnaces may reach around 500 C. Electricity, propane, or natural gas are usually used to achieve these temperatures. For high melting point alloys such as steel or nickel based alloys, the furnace must be designed for temperatures over 1600 C. The fuel used to reach these high temperatures can be electricity (as employed in electric arc furnaces) or coke. The majorities of foundries specializes in a particular metal and have furnaces dedicated to these metals. For example, an iron foundry (fore cast iron) may use a cupola, induction furnace, or EAF, while a steel foundry will use an EAF or induction furnace. Bronze or brass foundries use crucible furnaces or induction furnaces. Most aluminium foundries use either electric resistance or gas heated crucible furnaces or reverberatory furnaces. Degassing: In the case of aluminium alloys, a degassing step is usually necessary to reduce the amount of hydrogen dissolved in the liquid metal. If the hydrogen concentration in the melt is too high, the resulting casting will be porous as the hydrogen comes out of solution as the aluminium cools and solidifies. Porosity often seriously deteriorates the mechanical properties of the metal. An efficient way of removing hydrogen from the melt is to bubble argon or nitrogen through the melt. To do that, several different types of equipment are used by foundries. When the bubbles go up in the melt, they catch the dissolved hydrogen and bring it to the top surface. There are various types of equipment which measure the amount of hydrogen present in it. Alternatively, the density of the aluminium sample is calculated to check amount of hydrogen dissolved in it.

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Mould making: In the casting process a pattern is made in the shape of the desired part. This pattern is made out of wax, wood, plastic, or metal. Simple designs can be made in a single piece or solid pattern. More complex designs are made in two parts, called split patterns. A split pattern has a top or upper section, called a cope, and a bottom or lower section called a drag. Both solid and split patterns can have cores inserted to complete the final part shape. Cores are used to create hollow areas in the mould that would otherwise be impossible to achieve. Where the cope and drag separates is called the parting line. When making a pattern it is best to taper the edges so that the pattern can be removed without breaking the mould. This is called draft. The opposite of draft is an undercut where there is part of the pattern under the sand making it impossible to remove the pattern without damaging the mould. The moulds are constructed by several different processes dependent upon the type of foundry, metal to be poured, quantity of parts to be produced, size of the casting and complexity of the casting. These mould processes include: Sand casting Green or resin bonded sand mould. Lost-foam casting Polystyrene pattern with a mixture of ceramic and sand mould. Investment casting Wax or similar sacrificial pattern with a ceramic mould. Ceramic mould casting Plaster mould. V-process casting Vacuum is used in conjunction with thermoformed plastic to form sand moulds. No moisture, clay, or resin is needed for sand to retain shape. Die casting metal mould. Billet (ingot) casting Simple mould for producing ingots of metal normally for use in other foundries. Pouring: Bronze poured from a ladle into a mould, using the ancient lost-wax casting process In a foundry, molten metal is poured into moulds. Pouring can be accomplished with gravity, or it may be assisted with a vacuum or pressurized gas. Many modern foundries use robots or automatic pouring machines for pouring molten metal. Traditionally, moulds were poured by hand using ladles.

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Shakeout: The solidified metal component is then removed from its mould. Where the mould is sand based, this can be done by shaking or tumbling. This frees the casting from the sand, which is still attached to the metal runners and gates - which are the channels through which the molten metal travelled to reach the component itself. Degating: Degating is the removal of the heads, runners, gates, and risers from the casting. Runners, gates, and risers may be removed using cutting torches, band saws or ceramic cut off blades. For some metal types, and with some gating system designs, the sprue, runners, and gates can be removed by breaking them away from the casting with a sledge hammer or specially designed knockout machinery. Risers must usually be removed using a cutting method (see above) but some newer methods of riser removal use knockoff machinery with special designs incorporated into the riser neck geometry that allow the riser to break off at the right place. The gating system required producing castings in a mould yields leftover metal, including heads, risers, and sprue, sometimes collectively called sprue, that can exceed 50% of the metal required to pour a full mould. Since this metal must be remelted as salvage, the yield of a particular gating configuration becomes an important economic consideration when designing various gating schemes, to minimize the cost of excess sprue, and thus melting costs.

Heat treating: Heat treating is a group of industrial and metalworking processes used to alter the physical, and sometimes chemical, properties of a material. The most common application is metallurgical. Heat treatments are also used in the manufacture of many other materials, such as glass. Heat treatment involves the use of heating or chilling, normally to extreme temperatures, to achieve a desired result such as hardening or softening of a material. Heat treatment techniques include annealing, case hardening, precipitation strengthening, tempering, and quenching. It is noteworthy that while the term heat treatment applies only to processes where the heating and cooling are done for the specific purpose of altering properties intentionally, heating and cooling often occur incidentally during other manufacturing processes such as hot forming or welding. Surface cleaning: After degating and heat treating, sand or other moulding media may adhere to the casting. To remove this surface is cleaned using a blasting process. This means a granular media will be propelled against the surface of the casting to mechanically knock away the adhering sand. The media may be blown with compressed air, or may be hurled using a shot wheel. The media
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strikes the casting surface at high velocity to dislodge the moulding media (for example, sand, slag) from the casting surface. Numerous materials may be used as media, including steel, iron, other metal alloys, aluminium oxides, glass beads, walnut shells, baking powder among others. The blasting media is selected to develop the colour and reflectance of the cast surface. Terms used to describe this process include cleaning, bead blasting, and sand blasting. Shot peening may be used to further work-harden and finish the surface. Finishing: The final step in the process usually involves grinding, sanding, or machining the component in order to achieve the desired dimensional accuracies, physical shape and surface finish. Removing the remaining gate material, called a gate stub, is usually done using a grinder or sanding. These processes are used because their material removal rates are slow enough to control the amount of material. These steps are done prior to any final machining. After grinding, any surfaces that require tight dimensional control are machined. Many castings are machined in CNC milling centres. The reason for this is that these processes have better dimensional capability and repeatability than many casting processes. However, it is not uncommon today for many components to be used without machining. A few foundries provide other services before shipping components to their customers. Painting components to prevent corrosion and improve visual appeal is common. Some foundries will assemble their castings into complete machines or sub-assemblies. Other foundries weld multiple castings or wrought metals together to form a finished product. More and more the process of finishing a casting is being achieved using robotic machines which eliminate the need for a human to physically grind or break parting lines, gating material or feeders. The introduction of these machines has reduced injury to workers, costs of consumables whilst also reducing the time necessary to finish a casting. It also eliminates the problem of human error so as to increase repeatability in the quality of grinding. With a change of tooling these machines can finish a wide variety of materials including iron, bronze and aluminium.

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FOUNDRY TOOLS

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Mark Allocation Performance Observation Attendance Viva Total 05 05 05 05 20

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Ex. No: 14 Date: AIM:

MOULD WITH SOLID PATTERN

To make the mould of flange pattern

MATERIAL SUPPLIED: Mild Steel round rod of size ____________________mm

TOOLS REQUIRED:
Moulding boxes Moulding board Shovel Sand rammer Strike off bar Vent wire Riser pin Draw spike

SEQUENCE OF OPERATIONS: Boaring Internal Thread cutting

PROCEDURE: 1. The flange pattern is placed on the moulding board 2. A suitable core is prepared and placed in the hold of flange pattern 3. Clay wishing is done inside the drag surface 4. Parting sand is applied over the pattern 5. Box is filled with smooth moulding sand and proper ramming is done using flat and peen rammer 6. Excess sand is removed using the strike of bar
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7. Drag is teered upside down 8. The cope is placed on the drag after doing clay wash 9. The runner and riser are placed over the pattern 10. Ramming is done to get a rigid mould 11. Using strike off bar excess sand is removed 12. Vent holes are mark using vent rod 13. Cope is kept circle and pattern is removed using draw pin 14. Gate is prepared using gate cutter 15. Cope and drag are assembled and the mould is ready for casting

Mark Allocation Performance Observation Attendance Viva Total RESULT: Thus the flange moulding is prepared and ready for casting. 05 05 05 05 20

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Ex. No: 15 Date: AIM:

MOULD WITH SPLIT PATTERN

To make green sand mould tumblers

MATERIAL SUPPLIED: Mild Steel round rod of size ____________________mm

TOOLS REQUIRED:
Moulding boxes Moulding board Shovel Sand rammer Strike off bar Vent wire Riser pin Draw spike

SEQUENCE OF OPERATIONS: Boaring Internal Thread cutting PROCEDURE: 1. Moulding sand should prepared by mixing thoroughly silica sand with required suck amount of powder and water 2. Tumblers is placed on the moulding board and come parting sand should be sprinkled to prevent sticking of moulding sand to the board 3. Drag box is placed on the moulding board with its dual pins facing downwards such that the pattern should be approximately at the center of the box 4. Now the drag is rolled over on the bottom board and the cope box is assembled with the legs engaging dowels is on the drag box parting sand should be sprinkled inside the box
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5. Cope is separated from the drag and the pattern is drawn out carefully by using draw spike 6. Cope and drag are assembled

Mark Allocation Performance Observation Attendance Viva Total 05 05 05 05 20

RESULT: The green sand mould for tumbles pattern is made.

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