CASTING DRAWINGS

5.1 Sand casting practice: A pattern is required to prepare a sand casting. Machining is
carried out on the casting thus obtained, to finally at the required job. The pattern drawing
is prepared by considering the shrinkage of the material of the casting and a draft
allowance has to be to withdraw the pattern from the mould easily. Core prints are added
to this drawing to facilitate the location of cores, if any, to obtain the recesses. In addition
to the above, machining allowance also is to be provided, if a particular surface of the
casting requires a better finish than the sand casting finish. Figure 5.1a illustrates the
pattern drawing, incorporating al the allowances (shrinkage, machining and draft) to the
final shape of the object. Figure 5.1a represents the final shape of the job after the sand
casting is machined. It may also be noted that thus figure shows the size and shape of the
casting obtained from the pattern, illustrated in figure 5.1a.
5.2 Die casting practice: Drafts are provided on die castings, just as it is done on other
castings; although the amount is often less than for sand castings. Die tolerances should
be carefully chosen. Under-cuts should be avoided and fillets and radii are provided.
Figure 5.1b illustrates the die casting of the job with required allowances and machining
drawing. The two holes (one through hole and one blind hole) and the end faces are
machined.
5.3 Forging drawings: In preparing forging drawings we have to consider dimensioning,
draft angles and parting lines, corner and fillet radii, forging tolerances, allowances for
machining, material specification, heat treatment, location of trade mark, part number etc.
figure 5.2 illustrates all these considerations. The machining drawing of the forging
indicates dimensions wherever machining is required, whereas forging drawing gives the
dimensions that are required for designing the dies.
5.4 Press working tools: Figure 5.4a shows clearance c for blanks of given size, making
die to size and punch smaller by a total clearance 2C. Figure 5.4b shows clearance for the
hole of given size, making the punch to size and die larger by the amount of the total
clearance 2C. The application of clearances for holes of an irregular shape is shown in
figure 5.4c. Different clearance values are suggested for different materials: (a) 4.5% of
material thickness for all aluminium alloys, (b) 6%of material thickness for brass, cold
rolled steel and soft stainless steel, (c) 7.5% of material tickness for hard, cold rolled steel
stainless steel, etc. Angular clearance is 1/40 to 11/20 per side.
5.5 Scrap strip layout: In designing and producing blanked parts from strip material,
economical stock utilization is of high importance. The goal should be atleast 75%
utilization. A simple scrap-strip layout is shown in fig 5.5a, in which,
B- is the space between the part and edge of strip,
C- is the lead of the die, i.e., the distance from a point on one part to the corresponding
point on the next part,
L- is the length of the part,
H- is the part width,
W- is the width of the scrap strip, and

t- is the thickness of the stock.

The following formulae are used in calculating scrap-strip dimensions for all
strips over 0.75 mm thick.
B = 1.125t, when C is < 65mm
B= 1.5t, when C is > 65mm
C= L+B
Minimum scrap-strip allowances for material thickness, less than 0.75 mm, are
given below:
Strip width, W mm
Dimension, B mm
0-75
0.25
75-150
2.32
150- 300
3.12
Over300
3.40
Other scrap-strip allowances are:
(a) For work with curved outlines, B=70%t (fig 5.5b).
(b) For straight edge blanks and C<65 mm, B=t, and
when C is over 200mm, B=1.5t (fig 5.5c).
for work with parallel curves, the same formulae as above are used (fig 5.5d).
(d) for layout with parallel curves of adjacent blanks, B=1.125 t ( fig 5.5e).

4.1 Tappet in guide: The assembly of the tappet in guide is shown in fig 4.1a. This
consists of the body (cylinder head), bush and tappet valve as shown in fig 4.1b. The bush
has to guide the tappet valve and hence there should be clearance fit between them.
However, it must provide a leak proof motion, whereas the bush and the body should not
have any relative motion. However, they can be assembled without without much force.
It may be noted that the fit suggested between the body and the bush is interference,
medium press fit H7/p6. The suggested fit between the bush and the valve stem is
clearance, easy running fit H8/e8. The surface finish values are also indicate accordingly.
4.2 Pump impeller on shaft: The fitting of a centrifugal pump impeller on shaft is
shown in Fig 4.2a. The fit suggested between them is interference, press fit H7/r6. They
are press fitted with a taper key. The tolerances and surface finish values are indicated on
the working drawings of the mating components as shown in fig 4.2b. It may be noted
that a key is provided between the impeller and the shaft, though there is an interference
fit between them, for a positive drive.
4.3 Valve seat: Figure 4.3 shows an assembly of a valve seat in the cylinder head of an
I.C Engine. There should not be any relative motion between the valve seat and the head.
The suggested fit between them is interference fit.

4.4 V-belt drive: Belt drive is used when power is to be transmitted between shafts
which are at a considerable distance apart. Figure 4.4 shows the assembly drawing of a Vbelt drive arrangement. Here, the power is received from an external source, through Vbelt drive and is transmitted to a gear drive at its output end.
The unit consists of ball bearings 6, one of which is fitted to the body 5, on the
gear end of the shaft 10. The sleeve 3 is placed on the shaft and the second ball bearing is
then fitted. The grease seal 11 and the bearing retainers 12 are then placed in position.
The gear 8 is fitted on the shaft, by means of sunk key 7 and retained by the hexagonal
slotted nut 9 and locked with a split pin. The V-pulley 2 is fixed to the shaft by a
woodruff key 13 and retained by the nut 1. The whole assembly is fitted to the machine
frame by means of six hexagonal cap screws 4.
4.5 Vernier caliper: Vernier calipers are used for measuring external and internal
dimensions, to a greater accuracy than ordinary spring caliper. The accuracy which is
referred to as least count depends on the type of mechanism and adjustment provided. A
fine adjustment type vernier caliper assembly is shown in fig 4.5. The least count of this
instrument is 0.02 mm. It has also a depth bar to measure depths.
The assembly consists of the main blade 1, and slide 2, which has jaws, suitable to
measure external dimensions on one side and internal dimensions on the other. The slider
is placed on the main blade, after fitting the depth bar 7, from underneath, slider knob 11
and positioning the slider jib 14. The jib is held in position by the jib pressing screws 12.
The slider can be moved to any position, by pushing the slider knob with thumb and
clamped by means of clamping screw 3.
For fine adjustment, a fine adjustment slider 6 is provided, which has a knurled
nut 10. It has a jib 4, fine adjustment screw 9, and clamping screw 5. At the end of the
bar, a stopper 13 is fitted with screws 8.
4.6 Lathe tail-stock: Lathe tail-stock is a sub assembly of a lathe, which may be
mounted at any position on the lathe bed. It is used to hold the tools such as drills,
reamers, drill chucks, etc., with a morse taper shank or to support the work on a centre.
Figure 4.6 shows the assembly drawing of a lathe tail-stock. The feather 1 is
placed in the hole, provided in the tail-stock body 7, such that, its head lies along the
longitudinal groove of the barrel 3. This arrangement prevents the rotation of the barrel.
The spindle 4 is then screwed into the barrel, through its threaded end.
The cap 5, acting as a spindle bearing, is threaded into the tail-stock body. The
hand wheel 9 is then fitted at the end of the spindle and retained in position by nut 6. the
hand wheel and collar on the spindle, restrict the free axial movement of the spindle.
With this arrangement, when the hand wheel is turned, the rotation of the spindle makes
the barrel move axially in the tail-stock body. The centre 2, with standard morse taper is
inserted in the barrel. After adjustment the barrel to the desired position, it may be
clamped by tightening the screw 8. The entire unit is clamped on the lathe bed, by means
of a clamping plate and bolt with nut.

PROCESS PLANNING:
Process planning is one of the important activities in a manufacturing company. It
represents the link between engineering design and shop floor manufacturing an
determining the manufacturing operations required to transform a part from a rough to
the finished state specified on the engineering drawing. The first step involves an analysis
of the parts engineering design. The geometric features, dimensional sizes, tolerances,
and material specifications of the parts must be evaluated in order to select an appropriate
sequence of processing operations and specific machines. The next step involves
determining the specific processing details. In the case of machining process, this step
would include determining the depth of cuts, cut planning sequence, cutting speeds, feeds
tooling etc. in the present unit the student is expected to complete the process sheet for
individual components as specified. In addition the student is required to evaluate the
machining time assuming suitable operating parameters. Also, the specific operation to be
carried out has to be represented by a drawing depicting the process.
For problem 3.3 (shifting gear lever) the sample process sheet is not provided.
The student is expected to take up this as exercise problem.
METAL CUTTING TOOLS:
Material removal process is one of the important one in manufacturing processes.
Material removal process require the design of certain tools with the help of which the
production process can be carried out.
S c t:
Single point cutting tools are provided in two categories by the manufacturing
point of view. HSS tools are provided as single pieces, where as carbide tools are
provided as inserts.
The student has to draw three views of the tool indicating different tool angles and
hence mention the tool signature.
MILLING CUTTER:
Milling is perhaps the most versatile machining operation and most of the shapes
can be generated by this operation. The nomenclature of the angles of the face milling
cutter with inserted teeth are illustrated in fig..
Reamer: Reaming is an accurate way of sizing and finishing a hole which has been
previously drilled. The tool used for reaming is known as reamer which has multiple
cutting edges. Figure 3.5b shows a reamer with nomenclature.
NC:
A milling tool is to be used in CNC machine tool is an assembly of a number of
parts besides the actual cutting tool. Figure 3.6a shows the complete tool assembly of end
mill. The assembly consists of the adopter to suit the spindle taper such as ISO40 or 50, a
collet for holding the straight shank of the end mill, a retention knob which is used by the
hydraulic draw bar in the spindle housing for retaining or releasing the tool from the
spindle, besides the actual cutting tool, end mill.

The actual point to be programmed in a CNC part program is the tip of the tool
where the axes will be moving with respect to a known point in the spindle, e.g. the
centre of the spindle in case of machining centre. It is therefore becomes necessary to
know precisely the deviation of the tool tip from the gauge point on the spindle. Hence
the tool setting equipment is generally used. A simple mechanical type tool setting device
is shown in fig 3.6b.
A wide range of standard tool holders are available. NC tooling offered by a
typical manufacturer to meet various machining requirements is shown in fig 3.7.
Shell mill adaptor is to suit different cutter dimensions, collect chucks and
extensions are used to hold drills and end mills and other parallel shank cutters, end mill
adaptor is used whereas sufficient frictional grip is required. Morse taper shank drills are
hold by morse taper adaptor, boring bars are available in rough or finish boring versions.
Screwed shank end mill holders, tapping head and adjustable boring heads are the some
other typical spindle tooling available.
Working drawing: Production drawing, also called as working drawing is normally
prepared for a single component, giving the necessary details. It is the drawing used on
the shop floor by the workman to manufacture the part. The inspection is carried out
during the manufacture of individual components and also at the end of the production, to
check the design requirements when assembled. A satisfactory function is possible,if the
assembled parts are fitted with proper relation between each other.
GATING SYSTEM:
The gating system for a casting is a series of channels, which lead molten metal into
mould cavity. A gating system includes pouring basin, sprue, sprue base, runner, ingate
and riser as shown I fig.
Pouring basin acts as a reservoir for molten metal from which metal flows
smoothly into the sprue. This will be at the top of the sprue to minimize splash and
turbulence and promote the entry of clean metal into the sprue.
Sprue is a vertical passage that passes through the cope and connects the pouring
basin with the runner.
The stream of metal traveling at a high velocity from the bottom of the sprue
changes its velocity and direction of flow in the sprue well.
The molten metal is usually carried from sprue well to several gates through a
passage called runner. Abrupt changes in runner section should be avoided to ensure that
metal enter the mould cavity at low speed.
Gate is the passage through which molten metal flows from the runner to the
mould cavity.
In gating system the choke area should be A = (M )/ d.t.2.g.h
Where, M- casting mass in kg, d is density of molten metal in kg/mm 3 , t is pouring time
in sec, h is effective height of metal head in mm.
Gating ratio is one of the important factor in gating system, i.e. gating ratio is the ratio of
the cross sectional area between the sprue, runner and gate.
Gating ratio required is 1:3:3.
In gating system riser serves as a reservoir for molten metal to compensate the shrinkage
in solidified metal.

Parting line is the dividing line between the two moulding flasks that makes up the sand
mould. In split pattern it is also the diving line between the two kalves of the pattern.