Assignment No: Title: Aim: Raw Material:

ME 192/292/01 Manufacture a gauge from MS plate as per given drawing by performing different Fitting and Bench Work operations To obtain basic knowledge about different Fitting and Bench Work operations Mild steel Plate

Raw Material Size: Tools required: 1. 12 Steel Rule. 2. 4 Parallel-Jaw Bench vice 3. 6 Odd leg caliper 4. 6 Try square 5. 6 Scriber 6. 6 Divider 7. 12 Hacksaw Frame 8. 12- 18 TPI High Carbon Hacksaw Blade 9. 4 Prick punch 10. 4 Centre Punch 11. 250 gm Ball Peen Hammer 12. 12 Flat Bastard File 13. 6 Smooth File 14. 6 Half round File 15. 6 Triangular File 16. 13mm Bench Drilling Machine with drilling vice 17. 9mm HSS Twist drill bit 18. M10 x 1.5 HSS tap set 19. Tap handle 20. 500 gm Ball Peen Hammer 21. Lettering and numbering Punch 22. Safety Goggles Procedure: 1. 2. 3. Check the size of raw material by using steel rule whether it is acceptable for performing the job as per drawing. Hold the MS plate in the bench vice. Make two adjacent sides of the MS plate right angle with the help of bastard file and try square so that the performing adjacent sides can act as datum reference lines for making measurement and marking lines. Layout the flat surface by marking media chalk and water.

4.

Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292)

5.

6. 7. 8. 9. 10. 11. 12.

13. 14.

15.

Marking is done as per drawing on the laid out surface of the metal plate using different marking instruments like steel rule, odd Leg caliper, try square, surface plate and scriber. Punch the scribed lines for make the line permanent with the help of prick punch, centre punch and ball Peen Hammer. Cut the work piece as per marking to bring the approximate size by removing extra metal with the help of Hacksaw and Bench vice. Calculate the Tap size drill according to the internal thread (M10 x 1.5 mm). Here it is 8mm. Hold proper drill bit into the drill chuck and the job in the drilling vice. Then centering of job to the proper position is performed by adjusting the table. Switch on the drilling machine and feed the Drill Bit manually to produce the 8 mm hole. Apply cutting fluid during the drilling operation as per requirement. Switch off the Drill Machine and remove the job from Drill Vice and Drill Bit from the drill chuck. Then hold the drilled plate in the bench vice rigidly with the hole in the upright position. Then to produce the internal thread as per drawing tapping operation is performed by using Tap Set according to chronological order i.e. rougher tap, intermediate tap and lastly finisher tap by turning the tap two or three rotation in the forward direction followed by a half rotation in backward direction for breaking and removal of chips by Tap Wrench until the entire length of the tap enter the hole. Pour oil during tapping as a lubricant. Finally the job is brought to accurate size as per drawing with the help of Bastard File, Smooth File, Triangular file, Half round file and Try Square. Check and note the final dimensions of the job to ascertain whether it is finished according to drawing or not by using Steel Rule, Try square, and Vernier Caliper. Also verify the right angles of all adjacent sides by Try Square. Punch roll number and branch code on the job for proper identification with the help of numbering punch lettering punch and ball peen hammer.

Precautions: 1. Never place sharp material such as scriber, punch etc on the floor. 2. Always use safety goggles.

Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292)

Scale: 1:1

All Dimensions are in mm

JOB DRAWING

Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292)

Assignment No: Title: Aim: Raw material:

ME 192/292/02 Join two thick (6mm) MS plates as per given drawing by performing V-Butt joint by MMA welding To acquire basic knowledge about MMA welding Two nos. Mild Steel Plates

Raw Material Size: Machine: AC Welding Machine

Specification of the Machine: Tools and Accessories: 1. 12 Steel Rule. 2. 4 Parallel-Jaw Bench vice 3. 6 Odd leg caliper 4. 6 Try square 5. 12 Flat Bastard File 6. 4 Prick punch 7. 6 Scriber 8. Earthing clamp 9. Electrode holder 10. Electrode ( 3.15 mm x 450 mm) 11. Welding Table 12. Flat Tong 13. Safety Gears ( Apron, Gloves, Leg guard, and Helmet) 14. Welding shield 15. Chipping hammer 16. Anvil (25 kg / 50 kg) 17. Wire Brush 18. 8 Bench Grinder 19. Safety Goggles 20. Lettering and numbering punch 21. 500 gm ball peen hammer 22. Emery Cloth (100) Procedure: 1. 2. 3. 4. Check the size of raw material by using steel rule and try square. Clean the surface and edges of the plates using flat bastard file, emery paper and wire brush. Marking the metal plates as per drawing using steel rule, try square odd leg caliper and Scriber. Edge preparation is performed as per drawing (beveling of edges) using flat bastard file, bench vice and bench grinder.
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Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292)

5.

Set the metal plates on the welding table (face to face making a root-gap of 1-2 mm) with proper support. 6. Put the welding electrode into the electrode holder and fit the earthing clamp to the welding table. Then switch on the welding machine and set the proper arc length by adjusting voltage / current. 7. Tack both ends of the metal plates at the sides to be joined to avoid distortion using welding machine and electrode. 8. Welding is performed by maintaining proper arc speed and arc length (2-3 mm). 9. Cool the job in natural air. 10. Then hold the job on the anvil by using tong and after that de-slugging is done by rapid striking of the job by the chipping hammer. 11. Clean the job by wire brush. 12. Test the joint by visual observation. 13. Finish the job by using file and bench grinder. 14. Punch roll number and branch code on the job for proper identification using lettering punch, numbering punch and ball peen hammer. Precautions: 1. 2. 3. 4. Always perform welding after wearing all the safety gears. Do not perform welding operation with bare eye. Always use welding shield. Do not touch the electrode or job with bare hand. Always use flat tong. Always wore safety goggles during the chipping operation.

Scale: 1:1

All Dimensions are in mm

JOB DRAWING

Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292)

Assignment No: Title: Aim: Raw material:

ME 192/292/03 Join two thin (3mm) metal sheets as per given drawing by performing Lap joint by Oxy-Acetylene Welding To get basic knowledge about Oxy- Acetylene gas welding Two nos. Mild Steel Sheets

Raw Material Size: Tools and Accessories: 12 Steel rule 2. 6Try Square 6 Scriber 4. 4 Prick Punch 4 Parallel-Jaw Bench vice 6. 12 Flat Bastard File 8 Bench Grinder Oxygen and Acetylene Cylinders fitted with pressure regulators and pressure gauges 9. Hoses (Blue or Black for Oxygen and Maroon or Red for Acetylene) 10. Welding Torch 11. Cylinder Valve Opening Key 12. Tip Cleaner 13. Spark Lighter 14. Nozzle (No. 13) of Welding Torch 15. C.C.M.S Welding Rod 16. Flat Tong 17. Safety Guards (Apron, Gloves, Leg Guard, Welding Goggles, and Helmet) 18. Safety Goggles 19. Welding Table 20. Hose Protector and Flash Back Arrester 21. Anvil (25 kg/50 kg) 22. Chipping Hammer 23. Wire Brush 24. Numbering & Lettering Punch 25. 500 gm Ball Peen Hammer 26. Metal Bucket 27. Emery Cloth (100) Procedure: 1. 2. 3. 4. 5. Check the size of raw material by using steel rule and try square. Clean the surface and edges of the sheets using flat bastard file, emery paper and wire brush. Marking the metal sheets as per drawing using steel rule, try square and Scriber. Punching Roll No. and Branch Code in any piece of metal by using Punch and Hammer. Edge preparation is performed as per drawing using flat bastard file, bench vice emery cloth.
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1. 3. 5. 7. 8.

Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292)

6.

Set the metal sheets on the welding table by overlapping one edge of one sheet over the surface of the other sheet at proper place as per drawing with proper support. 7. Open the O2 Cylinder and move the O2 regulator to flow gases through the hose and use Tip cleaner to clean the carbon particle and asses from hose and Tip and then close it. 8. Open both the Gas Cylinders slowly one by one (chronological order) with gas opening key to check internal pressure of the cylinders and then set proper welding pressure by moving the regulator cap up to the required level. 9. Then ignite the flame by spark lighter. Set the flame as per requirement by adjusting the acetylene and oxygen valves of the welding torch. 10. Tack both ends of the metal sheets at the sides to be joined to avoid distortion. 11. Welding is performed by the proper flame and also maintains required welding speed. The Torch and Filler Rod are moved backwards along the line to be welded. 12. After welding first close the C2H2 gas and then O2. 13. Close the cylinder tightly with cylinder key. 14. Release the internal gases of both the hoses by opening both the valves of blow pipe. 15. Cool the job in the natural air. 16. Then hold the job on the anvil by using tong and after that de-slugging is done by rapid striking of the job by the chipping hammer. 17. Clean the job by wire brush. 18. Test the joint by visual observation. 19. Finish the job by using file and bench grinder. 20. Punch roll number and branch code on the job for proper identification using lettering punch, numbering punch and ball peen hammer. Precautions: 1. Before welding check the leakage test of Gas Welding set up with soap water and brush, if there is any leakage take preventive measure like tightening and using Teflon Tape in the position of threaded area and close it. 2. Always perform welding after wearing all the safety gears. 3. Do not touch the job with bare hand. Always use flat tong. 4. Always wore safety goggles during the cleaning operation. 5. Maintain a safe distance from the burning flame. 6. Cool the welding nozzle by dipping it in the water contained in the metal bucket intermittently to avoid back fire. 7. Always transfer gas cylinders from one place to other with the help of welding trolley. 8. Never lay down the acetylene cylinder.

Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292)

Scale: 1:1

All Dimensions are in mm

JOB DRAWING

Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292)

Assignment No: Title: Aim: Raw material:

ME 192/292/04 Manufacture a component as per given drawing by performing different machining operations on an Engine Lathe To gain knowledge about operation of Engine Lathe and also about different machining operations of Engine lathe Mild Steel Rod

Raw Material Size: Machine: Engine Lathe

Specification of Machine: Tools and Accessories: 1. 3 or 4 Jaw Independent/Universal Chuck 2. Chuck Key 3. 12 Steel Rule 4. 12Vernier Caliper 5. 6Outside Caliper 6. 12Adjustable Marking Gauge 7. Tool Holder 8. Tool Holder Key 9. Tool Post Wrench 10. Facing Tool 11. Turning Tool 12. 6Flat Smooth File 13. Emery Cloth (100) 14. Hand Gloves 15. Marker Pen Procedure: 1. 2. 3. 4. 5. 6. Check the size of Raw Material by using Steel Rule and Outside Caliper. Hold the job firmly inside the jaws of the Chuck by tightening the jaws screw with the Chuck key. Centre the job with the help of Adjustable Marking Gauge by slowly rotating the chuck manually. Check the nomenclature of the tool (tool angles, sharpness of the cutting edges etc.) Fix the Cutting Tool inside the tool way of the Tool Holder firmly by tightening screw with the help of Tool holder key. Place the tool holder inside the Tool Post and centre the tool with respect to dead centre by using metal seams and finally fix the position by tightening the bolts of Tool Post with the tool post wrench. Calculate the cutting speed (r.p.m.), feed and depth of cut for different operations required.
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7.

Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292)

8.

9.

10. 11. 12. 13. 14. 15. 16. 17. 18.

19. 20.

Switch on the Machine and making a flat surface at the end of the job, perform facing operation by advancing the facing tool perpendicular to the axis of rotation of the job (cross feed). Reduce the diameter of the job up to requisite length as per drawing by performing rough turning followed by finish turning by advancing the turning tool along the axis of rotation of the job (longitudinal feed). Produce the required Chamfer at the end of the job by performing Chamfering operation. Take out the job from the chuck by loosening the jaws screw. Fit the opposite end of the job into chuck in a similar manner as described in 2-3. Make the end of the job flat by performing facing operation. Reduce diameters up to requisite length at different position by performing step turning operation. Produce the required Chamfer at the end of the job by performing Chamfering operation. Finish the job for getting better surface finish by using smooth file and fine emery cloth. Switch off the Machine and take out the job from the chuck by loosening the jaws screw. Check and note the final dimensions of the job whether it is finished according to drawing or not using steel rule, out Side Caliper, Vernier Caliper and record the deviation. Mark the Roll No. and Branch Code on the job with the Marker Pen for proper identification. Clean the Machine properly with Brush and Cotton Thread.

Precautions: 1. Do not put your hands and finger inside the movable parts. 2. Do not wear loose garments. 3. Hold the job into chuck tightly. 4. Do not touch the cutting tools and chips during the operation. 5. Do not use too much depth and feed in the time of cutting operation.

Scale: 1:1

All Dimensions are in mm

JOB DRAWING
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Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292)

Assignment No: Title:

ME 192/292/05 Generate two parallel planes opposite to each other from a MS rod as per given drawing by performing shaping operation on shaping machine. To acquire knowledge about the operation of Shaping machine. Mild steel rod.

Aim: Raw material:

Raw Material Size: mm Machine: Plain horizontal Cone Pulley Type Shaping Machine

Specification of the Machine: Tools and Accessories: 1. 12 Steel Rule 3. 2x 2 Surface plate 4. 12 Vernier Height Gauge 5. V block 6. 6 Try Square 7. 6 Out Side Caliper 8. 4 Prick Punch 9. 250 gm Ball Peen Hammer 10. Scriber 11. Machine Vice & Vice Handle 12. Tool Holder & Tool Key 13. Single Point Shaping Tool 14. Spirit Level 15. Double Ended Spanner 16. Adjustable Spanner 17. Lettering & Numbering Punch 18. 500 gm Ball Peen Hammer 19. Hand Gloves Procedure: 1. 2. 3. 4. 5. 6. Check the size of raw material by using Steel Rule, Out Side Caliper and Vernier Caliper. Mark the job as per drawing keeping it on the Surface Plate using Steel Rule, Try square, Vernier Height Gauge and Scriber. Make the marking permanent by Prick Punch and Ball peen Hammer. Fix the job rigidly on the Machine Vice of the Shaping Machine and level it by spirit level. Check nomenclature of the cutting tool (tool angles, sharpness of the cutting edges etc.). Fix the cutting tool into the tool holder with the help of tool key and after that hold the tool holder into the tool head of the Clapper Box rigidly.
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2. 12 Vernier Caliper

Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292)

7. 8. 9. 10. 11. 12. 13. 14. 15.

Adjust the length of stroke and position of ram with the help of ram control lever according to job length. Align the job with respect to the table by moving the table horizontally and vertically. Adjust the depth of cut by moving down the feed screw of the tool slide. Switch on the machine and enter the feed to the job under the reciprocating cutting tool by moving the table manually/automatically and complete the cut. Repeat the above operations (9-10) until required depth is achieved as per marking. After generation of one plane, generate the other one by following the same operations mentioned above (4-11). After competition of the machining as per drawing switch off the machine and remove the job from machine vice. Check and note the final dimensions of the job whether it is finished according to drawing or not using Try Square and Vernier Caliper. Punch roll number and branch code on the job for proper identification using lettering punch, numbering punch and ball peen hammer.

Precautions: 1. 2. 3. 4. Do not put your hands and finger inside the movable parts. Do not wear loose garments. Hold the job into Vice tightly. Always use hand gloves.

Scale: 1:1

All Dimensions are in mm

JOB DRAWING
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Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292)

Assignment No: Title:

ME 192/292/06 Make a slot (6 mm) on one parallel plane of the MS rod generated earlier as per given drawing by performing milling operation on a milling machine To acquire knowledge about the operation of Milling machine and also production of slots by milling machine Mild steel rod

Aim: Raw material:

Raw Material Size: .. mm Machine: Column and Knee type Universal Milling Machine

Specification of the Machine: Tools and Accessories: 1. 12 Steel Rule 2. 12 Vernier Caliper 3. 6 Try Square 4. 6 Out Side Caliper 5. 4 Prick Punch 6. 250 gm Ball Peen Hammer 7. Scriber 8. 2x 2 Surface plate 9. 12 Vernier Height Gauge 10. Spirit Level 11. Machine Vice & Vice Handle 12. Double Ended Spanner 13. Adjustable Spanner 14. 3.5X0.25X1 Plain Side Milling Cutter 15. Lettering & Numbering Punch 16. 500 gm Ball Peen Hammer 17. Hand Gloves Procedure: 1. 2. 3. 4. 5. 6. 7. Check the size of raw material by using Steel Rule, Out Side Caliper and Vernier Caliper. Mark the job as per drawing keeping it on the Surface Plate using Steel Rule, Try square, Vernier Height Gauge and Scriber. Make the marking permanent by Prick Punch and Ball peen Hammer. Fix the job rigidly on the Machine Vice of the Milling Machine and level it by spirit level. Check the sharpness of the Milling Cutter. Insert the Milling Cutter into the arbor & fix it by tightening the nut. Place the job below the cutter and place it appropriate position by adjusting the table by rotating cross feed handle and longitudinal feed wheel.
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Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292)

Set the desired depth of cut by adjusting the knee by rotating the knee elevating handle. 9. Switch on the Machine and coolant Pump and give required feed to the job under the rotating cutter by moving the table manually /automatically and complete the cut. 10. Repeat the above operations (8-9) until the required depth is achieved. 11. After completion of the milling operation, switch off the Machine and remove the job from the Milling Vice. 12. Check and note the final dimensions of the job whether it is finished according to drawing or not using Try Square and Vernier Caliper. 13. Punch roll number and branch code on the job for proper identification using lettering punch, numbering punch and ball peen hammer. Precautions: 8. 1. Do not put your hands and finger inside the movable parts. 2. Do not wear loose garments. 3. Hold the job into Vice tightly.

Scale: 1:1

All Dimensions are in mm

JOB DRAWING
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Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292)

Assignment No: Title: Aim: Raw material:

ME 192/292/07 Forming a cone as per given drawing by performing different sheet forming and soldering operations To acquire essential knowledge about Sheet metal working and soldering. G.I. Sheet

Raw Material Size: mm X mm X SWG Tools and Accessories: 1. Mallet 2. 6Scriber 3. 4 Parallel-Jaw Bench vice 4. 12Steel Rule 5. 25 mm Outside Micrometer 6. 6Try Square 7. 6Divider 8. 6Pliers 9. 18Straight Snip 10. Funnel Stake 1. 250 gm. Ball Peen Hammer 2. 240W,220-230V Soldering Iron 3. 5 mt. Extension Cord 4. Hand Gloves 5. Marker Pen 6. Solder 7. Flux (ZnCl2) Procedure: 1. 2. Flatten the GI Sheet by Mallet Check the Dimensions of GI Sheet by steel rule. Also measure the thickness by outside micrometer and find out the corresponding Standard Wire Gauge number (SWG) from standard table. Develop the pattern of the cone) on the GI sheet, providing allowances for bending and forming, by Steel Rule, Try Square, Divider, and Scriber. Cutting the GI Sheet as per developed surface (laid out pattern) by shearing with the help of snip. Fold edges of the sheared sheet and then bend the sheet according to the development of surface with the help of funnel stake and ball point hammer. Join (Double Seam) the folded edges of the funnel. Solder the joint of the cone by using soldering iron, solder and requisite amount of flax. Clean the job properly. Check the final Dimension of the Funnel whether it is finished according to
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3. 4. 5. 6. 7. 8. 9.

Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292)

drawing using Steel Rule and record the deviation. 10. Mark Roll Number on the job with the help of Marker Pen for proper identification. Precautions: 1. 2. Do not handle the cut pieces with bare hand. Always use hand gloves Do not forget to straighten the sheet metal pieces (Laid out pattern) after shearing.

Scale: 1:1

All Dimensions are in mm

JOB DRAWING
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Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292)

Assignment No: Title: Aim: Raw material:

ME 192/292/08 Make a wooden pattern by performing different pattern making operation. To obtain basic knowledge about pattern making. Gamari Wood

Raw Material Size: mm Machine: Belt and Disc Sander HP: RPM:

Specification of Machine: Size: Tools and Accessories: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

2 Four Fold wooden Rule / 12 Steel Rule 9 Carpentry Vice 12 Iron Jack Plane 6 Try square Marking Gauge Pencil 18 Cross-cut Hand Saw 12 Tenon Saw 1 Firmer Chisel Mallet Sand Paper Marker Pen

Procedure: 1. Check the initial dimensions of the wooden piece by four fold wooden rule /steel rule. 2. Hold the wooden piece in the carpentry vice and all the surfaces excepting two ends are planned as per drawing and are also right angled to each other by using jack plane, steel rule and try square. 3. Marking is done on the plane surface according to drawing with the marking gauge, steel rule, pencil and try square. 4. Sawing and chiseling wooden piece according to the drawing using Cross-cut Hand Saw, Tenon Saw, Firmer Chisel and Mallet. 5. Using belt sander machine finish the tapered portions. 6. Final finishing and polishing of the job is done by using sand paper. 7. Check the accuracy of final dimensions as per drawing 8. Mark roll number for proper identification using marker pen. Precaution: 1. Wood is a softer material so during handling the job during its operations care should be taken so that job surface is not damaged by different hand tools
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Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292)

Assuming: Shrinkage Allowance: 1.3% Machining Allowance: 2.5% Draft Allowance: 1

Scale: 1:1

All Dimensions are in mm

JOB DRAWING

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Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292)

Assignment No: Title: Aim:

ME 192/292/09 Making a sand mould with the pattern developed earlier by performing sand mould making operations. To gather knowledge regarding different mould making tools, gating system design, core making and green sand moulding The pattern developed earlier as per drawing, Green Sand, Bentonite Powder, Coal Dust, Yellow Dextrin, Facing Sand, Parting Sand, French chalk and Water.

Raw Materials:

Tools and Accessories: 1. Riddle 2. Shovel 3. Moulding Board 4. Moulding Flask (Cope and Drag parts) 5. Rammer 6. Strike off Bar 7. Bellow 8. Sprue Pin 9. Riser Pin 10. Vent Rod 11. Draw Spike 12. Gate Cutter 13. Lifter 14. Slick 15. Trowels 16. Cleaning Brush 17. Water Mug Procedure: 1. Green sand for moulding is prepared by mixing Silica sand with 8-12% bentonite and 2-3% water. To improve bonding strength, 5-6% coal dust and 2-3% yellow dextrin are added as additives. All mixing is done with the help of shovel. 2. Then the prepared green sand is screened by Riddle fitted with coarse and medium mesh size wire mesh in order to remove the impurities. During this process to avoid dryness of the green sand suitable amount of water is added. 3. Drag part of the moulding flask is placed on the moulding board. The half portion of the given Split Pattern is placed at a convenient position within the moulding flask keeping space around all the sides. Facing sand is sprinkled over the board and pattern. Then the box is filled with the prepared green sand by using shovel. 4. During filling the green sand is rammed properly with the Rammer to facilitate the adherence of the sand to the surfaces of the box. 5. Upper surface of the drag box is smoothened and leveled with the edges of the
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Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292)

drag box by removing excess sand by using the Strike- off Bar. 6. Then by using a Vent Rod, small holes are created in the rammed sand for providing paths for removal of gases. 7. Then another moulding board is placed on the drag box and the box is turn upside down with bottom board. 8. Then the upper board is removed and the upper surface is cleaned by removing loose sand particles by blowing air by using Bellow 9. Then parting sand is sprinkled over the cleaned upper surface. 10. Then the other half portion of the Pattern is placed on the first half portion of the Pattern already fitted in the drag box. 11. Then the Cope part of the moulding flask is placed properly on the drag part. Sprue pin and Riser pin is placed at proper place for forming the sprue and riser. 12. Then the cope box is also filled with green sand in a similar way like the drag box (Step 3-6). 13. Then Sprue and Riser Pin are removed carefully. Then a funnel shaped hole (called pouring basin/cup) is made at the top of the Sprue hole. 14. Then the cope is separated from the drag and any loose sand on the cope and drag interface of the drag is blown off with the help of bellow. 15. Then the cope and drag pattern halves are withdrawn by using Draw Spike after shaking properly. 16. Then the defective part, if any, of the mould is properly repaired with the help of slick and lifter. 17. Then water is gently spread over the repaired portion and the portions adjacent to the pattern of the mould carefully without damaging the mould 18. Then using Gate Cutter, gates and runners are cut in the drag part of the mould. 19. Then any excess or loose sand in the runners and mould are lifted up by lifter and then blown off by Bellow. 20. Then French chalk dust is spread all over the mould cavity and runners. 21. Then the cope part is placed on the drag part taking care of the alignment of the two by means the pins. Thus the sand mould for a pattern is made, which is ready for pouring the molten metal. Precautions: 1. Ramming should be done properly to get the required rigidity of the sand mould. 2. Care should be taken during removal of pattern, sprue and riser pins so that any portion of the mould is not damaged during removal.

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Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292)

Assignment No: Title:

ME 192/292/10 Cast the aluminum block as per given drawing by using the sand mould prepared earlier by performing different sand mould casting operations To obtain basic knowledge about sand casting Aluminium Ingots and Scraps Coverall 11 Flux Electrically Heated Pit Furnace Capacity: 10 kg of aluminium melting Max Temperature: 900C

Aim: Raw Material: Consumable: Machine:

Make: PSP Traders Power: 4.5 kW, 400V, 3ph, 50 Hz Tools and Accessories:

1. Crucible 2. Slotted steel spoon 3. Flat Tong 4. Refractory Bricks 5. 12 Hacksaw Frame fitted with 12- 18 TPI High Carbon Hacksaw Blade 6. 8 Bench Grinder 7. 12Vernier Caliper 8. 12Steel Rule 9. Hand Gloves. 10. Safety Goggles 11. Leather Apron 11. Numbering , Lettering punch 12. 500 gm Ball Peen Hammer. Procedure: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Put required amount of Aluminum ingots and scraps inside of the Crucible. Cover the charge within the crucible with the requisite amount of coverall flux. Open the lid of the furnace and place the crucible into the furnace. Then close the furnace with its lid and switch on the furnace. Set the furnace temperature at 750 0C and set the furnace heating regulator at 100. Wait until the furnace temperature rise up to 750 0C and it is indicated by a glowing yellow light. Then reset the furnace heating regulator at 80. Open the lid of the furnace and check the melting conditions of the charge and extent the melting if required. When melting is complete then remove lid, scoop off slag, which is floating on top, with a slotted steel spoon and turn off the furnace. Take out the crucible with the help of flat tong. Then Pour the molten metal into the pouring basin and metal flow into the mould cavity through gate via sprue and runners. Pouring is continued till riser is filled up with molten metal. Wait for a considerable time of at least 1 hr for solidification of molten metal within the mould cavity. Then crush the mould and taking out the casting.
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Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292)

15. After that necessary fettling operation, that is removal of gates, riser and other unnecessary projections by using hacksaw blade and cleaning of the surfaces by grinding, is performed. 16. Checking of final dimensions by steel rule and vernier caliper according to drawing. 17. Punch roll number on the job for proper identification with the help of numbering and lettering punch. Precautions: 1. 2. 3. 4. Always use leather apron and hand gloves. During pouring keep mould on the refractory brick to prevent leaking. Always keep safe distance from the heat of the Furnace. During pouring handle molten metal carefully.

Scale: 1:1

All Dimensions are in mm

JOB DRAWING

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