National College Of Engineering

MARUTHAKULAM, TIRUNELVELI - 627151

MANUFACTURING TECHNOLGY - I LABORATORY MANUAL

DEPARTMENT OF MECHANICAL ENGINEERING

Ex. No : 1 Date : Aim

FACING, PLAIN TURNING, STEP TURNING AND CHAMFERING

To perform turning, facing and step turning on a cylindrical work piece. Material used Mild steel rod. Tools required Lathe Three-jaw chuck Chuck key Vernier caliper Single-point cutting tool Procedure 1. First loosen the jaw in the chuck key to position the work piece, and then tighten the jaws. 2. Fix the cutting tool in the toolpost. 3. Switch on the lathe and move the carriage near to the workpiece. Give it a small cross feed, and then move carriage longitudinally to the required length slowly. 4. Bring the carriage to the original position, give a small cross feed and move carriage longitudinally. Repeat this step until required diameter is obtained. 5. To get smooth surface give a very small feed when the diameter is nearing the required value. 6. To face the end surface of the workpiece, move the carriage to make the tool touch the end surface of the work piece. 7. Give a small feed in longitudinal direction, and then move the tool towards the axis of the workpiece using the cross slide to complete the workpiece. 8. The turning operation is done with cutting tool to reduce the diameter upto the required dimension for the two steps of various diameters. 9. The workpiece is removed from the chuck and the dimensions of workpiece are checked for the requirements.

Result Thus the required shape and size is obtained by Facing, plain turning and step turning.

Ex. No : 2 Date : Aim

TAPER TURNING USING COMPOUND REST

To get a required shape and size from a given workpiece by taper turning operations in the lathe. Material used Mild steel rod. Tools required Single point cutting tool Lathe Vernier caliper Try square Chuck key Procedure 1. First loosen the jaw in the chuck key to position the work piece, and then tighten the jaws. 2. Fix the cutting tool in the toolpost. 3. Switch on the lathe and move the carriage near to the workpiece. Give it a small cross feed, and then move carriage longitudinally to the required length slowly. 4. Bring the carriage to the original position, give a small cross feed and move carriage longitudinally. Repeat this step until required diameter is obtained. 5. To get smooth surface give a very small feed when the diameter is nearing the required value. 6. To face the end surface of the workpiece, move the carriage to make the tool touch the end surface of the work piece.

7. Then the taper turning operation is done on the workpiece according to the taper angle calculated. The compound rest base is swirled and set a calculated taper angle, for this the tool is moved by 45_ to the lathe axis. 8. The workpiece is removed from the chuck and the dimensions of workpiece are checked for the requirements. Result Thus the required shape and size is obtained by taper turning operation.

HORIZONTAL WELDING

Ex. No : 3 Date : Aim

HORIZONTAL WELDING

To make the butt joint in the horizontal position using arc welding on the given workpiece.

Material Required Welding Transformer Electrode (12 gauge) Safety Gloves Welding Shield Chipping hammer Tongs

Procedure 1. First of all, the work pieces must be thoroughly cleaned to remove rust, scale and other foreign materials. 2. Then the given workpieces are placed on the table in such a way that the two workpieces are brought close to each other in a horizontal position. 3. Appropriate power supply should be given to the electrode and the workpieces. 4. When current is passed, arc is produced between the electrode and workpieces. 5. Tag welding is done on the ends of the workpieces and then hold it on a clamp. 6. Then the welding is carried throughout the length. 7. As soon as the welding process is finished, switch off the current supply and allow the workpiece to cool. 8. Slags are removed by chipping process with the help of chipping hammer. 9. Finally using wire brush, welded portions are cleaned. Result: Thus the butt joint in vertical position using arc welding is done on the given workpiece.

VERTICAL WELDING

Ex. No : 4 Date : Aim

VERTICAL WELDING

To make the butt joint in the vertical position using arc welding on the given work piece.

Material Required Welding Transformer Electrode (12 gauge) Safety Gloves Welding Shield Chipping Hammer Tongs

Procedure 1. First of all, the work pieces must be thoroughly cleaned to remove rust, scale and other foreign materials. 2. Then the given workpieces are placed on the table in such a way that the two workpieces are brought close to each other in a vertical position. 3. Appropriate power supply should be given to the electrode and the workpieces. 4. When current is passed, arc is produced between the electrode and workpieces. 5. Tag welding is done on the ends of the workpieces and then hold it on a clamp. 6. Then the welding is carried throughout the length. 7. As soon as the welding process is finished, switch off the current supply and allow the workpiece to cool. 8. Slags are removed by chipping process with the help of chipping hammer. 9. Finally using wire brush, welded portions are cleaned.

Result: Thus the butt joint in vertical position using arc welding is done on the given workpiece.

STEPPED PULLEY SPLIT PATTERN MOULDING

Ex. No : 5 Date : Aim

MOULD WITH SPLIT PATTERN (STEPPED CONE)

To make the mould for the given stepped cone. Material required Moulding board Moulding box Green sand Trowel Riddle Gate cutter Vent rod Procedure 1. Place the moulding board on a horizontal surface. 2. A suitable core is prepared with the help of core box. 3. The drag box is placed above the moulding board. Now the pattern is kept at center of drag. 4. Now parting sand in sprinkled before we keep pattern. 5. Facing sand is sprinkled over the pattern to a depth of 5mm. then green sand is filled over it. 6. Proper ramming is done on the green sand to get a air tight packing. 7. Excess sand is removed by strike off bar. 8. The drag box is inverted upside down. 9. The cope box is placed over the drag box and locked. 10. The riser pin sprue pin placed at right position and green sand is filled over the pattern. 11. Proper ramming is done on the green sand to get air tight packing with strike off bar leaving is done. 12. Now riser pin and sprue pin get removed from the green sand mould. The pattern is removed by draw spike tool. 13. Gate is prepared using gate cutter and core is placed vertically inside the cavity. 14. The vent holes are made with vent rod and cope. Result Thus the mould is created for given stepped cone. Riser pin Sprue pin Rammer Lifter Draw spike Bellow

Ex. No : 6 Date : Aim

MOULD WITH SOLID PATTERN

To make the mould for the given stepped cone. Material required Moulding board Moulding box Green sand Trowel Riddle Gate cutter Vent rod Procedure 1. Place the moulding board on a horizontal surface. 2. A suitable core is prepared with the help of core box. 3. The drag box is placed above the moulding board. Now the pattern is kept at center of drag. 4. Now parting sand in sprinkled before we keep pattern. 5. Facing sand is sprinkled over the pattern to a depth of 5mm. then green sand is filled over it. 6. Proper ramming is done on the green sand to get a air tight packing. 7. Excess sand is removed by strike off bar. 8. The drag box is inverted upside down. 9. The cope box is placed over the drag box and locked. 10. The riser pin sprue pin placed at right position and green sand is filled over the pattern. 11. Proper ramming is done on the green sand to get air tight packing with strike off bar leaving is done. 12. Now riser pin and sprue pin get removed from the green sand mould. The pattern is removed by draw spike tool. 13. Gate is prepared using gate cutter and core is placed vertically inside the cavity. 14. The vent holes are made with vent rod and cope. Result Thus the mould is created for given stepped cone. Riser pin Sprue pin Rammer Lifter Draw spike Bellow

Ex. No : 7 Date : SHEET METAL TRAY Aim. To make a rectangular tray from the given sheet metal. Material Required G.I Sheet Tools required Steel rule Mallet Scriber Divider Protractor Snips Stakes Ball peen hammer Procedure 1. The size of the given sheet is checked for its dimension using steel rule. 2. Then the sheet is leveled on the leveling plate using a mallet. 3. The dimensions are marked as shown in figure. 4. The sheet is cut as per the marked dimensions by straight snips. 5. Then a single hemming is made on the four sides of the tray as shown in figure. 6. The four sides of the tray bent to 90 using the stakes anvil. 7. Finally all the corners of the tray are joined.

Result Thus desired square tray is made from the given sheet metal.

Ex. No : 8 Date : Aim.

SINGLE AND MULTISTART V-THREAD CUTTING AND KNURLING

To machine a work piece by facing, plain turning, knurling and external thread cutting operations using a lathe. Tools required Lathe machine Outside Caliper Turning tool Steel Rule Knurling tool Vernier Caliper External V thread cutting tool

Calculation The number of teeth on change gears is calculated using the following formula Driver teeth/ Driven teeth = Pitch of the work ------------------------------pitch of the lead screw.

Procedure 1. The given work piece is held firmly in a lathe chuck. 2. The cutting tool is set in a tool post such that the point of the cutting tool coincides with the lathe axis. 3. The machine is switched on to revolve the work piece at the selected speed. 4. By giving Cross feed and longitudinal feed to the cutting tool, the facing and turning operations are done respectively. 5. The speed of the work piece is reduced. 6. The knurling operation is done using knurling tool. 7. The machine is switched off and the change gears of calculated teeth (as per calculation) are connected. 8. Again the machine is switched on. 9. The external thread cutting operation is done using external V thread cutting tool by engaging thread cutting mechanism. The machine is switched off. 10. The work piece is removed from the chuck and all the dimensions are measured and checked. Result Thus the given work piece is subjected to facing, plain turning, knurling and external thread cutting operations.

Ex No: 9 Date : Aim.

BORING AND INTERNAL THREAD CUTTING

To perform the facing, plain turning, drilling, boring and internal thread cutting operations on the given job. Material Required 27 mm diameter x 50 mm length of mild steel cylindrical rod. Tools required Single point cutting tool Single point boring tool Internal thread cutting tool Chuck key Spanner Steel rule Vernier Caliper

Calculation The number of teeth on change gears is calculated using the following formula Driver teeth/ Driven teeth = Pitch of the work ------------------------------pitch of the lead screw.

Procedure 1) The given work piece is held firmly in a lathe chuck. 2) The cutting tool is set in a tool post such that the point of the cutting tool coincides with the lathe axis. 3) The machine is switched on to revolve the work piece at the selected speed. 4) By giving Cross feed and longitudinal feed to the cutting tool, the facing and turning operations are done respectively. 5) The speed of the work piece is reduced. 6) The boring operation is done using boring tool. 7) The machine is switched off and the change gears of calculated teeth (as per calculation) are connected. 8) Again the machine is switched on. 9) The internal thread cutting operation is done using internal V thread cutting tool by engaging thread cutting mechanism. 10) The machine is switched off. 11) The work piece is removed from the chuck and all the dimensions are measured and checked. Result Thus the given work piece is subjected to facing, plain turning, boring and internal thread cutting operations

Ex. No : 10 Date : Aim

OVERHEAD WELDING

To make the butt joint in the overhead position using arc welding on the given workpiece.

Material Required Welding Transformer Electrode (12 gauge) Safety Gloves Welding Shield Chipping hammer Tongs

Procedure
1. The mild steel plates to be joined are first cleaned. 2. The edge and surface to be welded are then filled or ground to get the required dimension. 3. Now the metal plates to be welded are placed in position on metal plate. 4. The welding electrode is held using an electrode holder and tack welds at two places are made such that the position of the plates do not change while welding. 5. Now the electrode is made to touch the metal plates and then electrodes is separated to leave a small gap. (3 to 4 mm) between its tips and the metal plates. 6. This initiates an arc. 7. Once the arc is initiated, the electrode is moved along the length of the metal pieces. For completing the welding process on one side. 8. Using tongs, the metal plates welded on one side is over turned. Welding is now carried out on the other side. 9. After welding, the plates are allowed to cool for some time. Using a chipping hammer, oxides are removed to complete the exercise.

Result:
Thus the two mild steel plates are welded to get the Overhead Welding.

GAS WELDING

GAS CUTTING

40

40

100

100

80

Ex. No : 11 Date : Aim

GAS WELDING AND GAS CUTTING

To join the given two work pieces as required type of joint by gas welding. Material used Mild steel plate. Tools used Oxygen and acetylene gas cylinder with the equipments (pressure gauge, regulators) Gas welding torch Filler rod Safety goggles, gloves Chipping hammer Wire brush Procedure For Gas Welding : 1. The given workpiece are thoroughly cleaned, i.e., rust, scales are removed. 2. The joining workpieces are positioned properly. 3. Acetylene and Oxygen cylinder valves are opened then the Acetylene torch valve is opened. 4. Light the tip of torch using lighter. 5. Oxygen and Acetylene torch valves are adjusted and the required flame is obtained. 6. The welding torch and the filler rod are moved along the line of weld and welding is done by maintaining 3mm gap between plate and inner cone of flame. For Gas Cutting : 1. The given workpiece is thoroughly cleaned, i.e., rust, scales are removed and positioned properly 2. Acetylene and Oxygen cylinder valves are opened then the Acetylene torch valve is opened. 3. Light the tip of torch using lighter. 4. Oxygen and Acetylene torch valves are adjusted and the required flame for gas cutting is obtained. 5. The torch is moved along the line of cut and cutting is done by maintaining 3mm gap between plate and inner cone of flame. Result Thus the required welding and cutting is obtained by gas welding and gas cutting process respectively.

Ex. No : 12 Date :

MAKING OF A CONE FUNNEL

Aim To make a funnel from the given sheet metal. Tools required Steel rule Mallet Scriber Divider Protractor Snips Stakes Ball peen hammer Solder Procedure 1. The size of the given sheet is checked for its dimension using steel rule. 2. The required development of surface is being made on the white paper which is overlapped on the sheet metal. 3. The marking is done on the sheet metal as per the development being done on the paper. 4. Now using straight snips, unwanted material are removed. 5. Now fold and bend the workpiece to make the funnel shape and joint is made on the workpieces. 6. Then using a groove, a locked grooved joint is made for about 5mm. also; hemming is done in the bottom of the funnel. 7. In between top face and bottom face, a butt joint is made using a solder. 8. Finally, trimming and finishing operations are carried out.

Result Thus desired cone funnel is made from the given sheet metal.

BRAZING

Ex. No : 13 Date :

BRAZING

Aim

To join the given two work pieces as required type of joint by brazing.

Material used Mild steel plate. Tools used Filler rod Safety goggles, gloves Brazing torch Procedure 1. The given workpiece are thoroughly cleaned, i.e., rust, scales are removed. 2. The joining workpieces are positioned properly. 3. A flux is applied to all surfaces where the filler material is flow. 4. After that the joint is heated to the proper brazing temperature. 5. Solid filler metal may be replaced on the metal pieces and thus melted as the metal pieces are heated. 6. Only small amount of filler metal is needed to fill the joint completely.

Result Thus the required welding is obtained by brazing process.

Ex. No : 14 Date :

INJECTION MOULDING

Aim To study about the injection moulding. Material required Dies Polymers Injection Moulding machine.

Procedure 1. Initially the polymer is filled in a hopper 2. Then it goes to the heating section where the polymer is melted and the pressure is increased. 3. The heated material is injected by the pushing along with the heated reciprocating screw. 4. So, the heated material is forced to fill in mould cavity through the nozzle to get the required shape of the plastic. Result Thus the required plastic is obtained by the injection moulding process.