Vidya Vikas Educational Trust (R),

Vidya Vikas Polytechnic

27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028

Department of Mechanical [General]

Laboratory Manual

Subject : Manufacturing Processes

Subject Code : 20ME33P

Semester : 3rd Semester

Name of the Student: …………………………………………….

Register Number: …………………………………………….

Praperd by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore 1 |T o t a l P a g e ’ s ( 4 4 )

 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
APPENDIX 5 (Certificate issued by guide)

Name of the Institution: VIDYA VIKAS POLYTECHNIC

Address with pin code: 27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028

Department: MECHANICAL ENGINEERING (General)

CERTIFICATE

Certified that this Practical Record entitled “Manufacturing Processes 20ME33P” which is being submitted

by Mr.………………………….……………………bearing Reg.No…..………………………, is a bonafide

student of Mechanical Engineering Department, studying in Third Semester in our Institution and has

fulfilment the Laboratory prescribed by Department of Technical Education, Bangalore during the year 2021-

2021.

It is certified that all corrections/suggestions indicated for internal Assessment have been incorporated in the

Report.

Signature of the Staff In-charge

Signature of H.O.D

CIE (Internal Assessment Marks Obtained in Words):…………..……………………………………………

Name and signature

External Examiner 1:………………………………

Dept. …………………………College…….…………………

External Examiner 2:………………………………

Dept. …………………………College…….…………………

Praperd by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore 2 |T o t a l P a g e ’ s ( 4 4 )

 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028

Praperd by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore 3 |T o t a l P a g e ’ s ( 4 4 )

 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028

Praperd by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore 4 |T o t a l P a g e ’ s ( 4 4 )

 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028

Praperd by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore 5 |T o t a l P a g e ’ s ( 4 4 )

 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Contents

UNIT 1: FOUNDRY

UNIT 2: FORGING

UNIT 3: SHEET METAL

Praperd by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore 6 |T o t a l P a g e ’ s ( 4 4 )

 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
UNIT 1: FOUNDRY
FOUNDRY Introduction: Foundry is a process of shaping the metal components in their molten stage. It is
the also called as metal casting the shape and size of the metal casting is obtained depends on the shape and
size of the cavity produced in sand mould by using wooden/ metal pattern.

Practical application
a) Casting is the cheapest and most direct way of producing the shape of the component
b) Casting is best suited to work where components required is in low quantity.
c) Complicated shapes having internal openings and complex section variation can be produced quickly and
cheaply by casting since liquid metal can flow into any form/ shape.
d) Electric motor housing
e) Bench vice, Irrigation pumps etc.
f) Heavy equipment such as machine beds of lathe, milling machine, shaping, drilling plaining machine etc.
can be cast/easily
g) Casting is best suited for composite components,

Steps in foundry process

The Foundry process involves three steps.
(a) Making the required pattern
(b) Moulding process to produce the cavity in sand using pattern.
(c) Pouring the molten metal into the cavity to get casting.

Classification of foundries;
 Steel foundry
 C.I foundry
 Light alloy foundry
 Brass foundry
 Shell Moulding foundry
 Die casting foundry (using permanent metal or dies for high volume of low and pressure die)

Pattern:
A pattern is normally a wooden/ metal model or thermosetting plastic which is facsimile of the cast product
to be made, there are many types of pattern and are either one piece, two piece or three piece, split pattern,
loose piece pattern, Gated and match plate pattern etc. Pattern size: Actual casting size + shrinkage allowance
+ shake allowance + finish allowance
1. Shrinkage allowance: The liquid metal shrinks during solidification and it contraction to its room
temperature, so that the pattern must be made larger than the casting to provide for total contraction.
2. Finishing allowance: The casting is to be machined at some points then the casting should be provided
with excess metal for machining.
Praperd by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore 7 |T o t a l P a g e ’ s ( 4 4 )
 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028

Types of patterns
Single piece pattern
Split piece pattern
Match piece pattern
Cope and drag pattern
Solid pattern
Loose piece pattern
Sweep pattern
Skeleton pattern
Segmental pattern
Shell pattern.

Types of foundry sand

a) Natural sand: Sand containing the silica grains and clay bond as found. It varies in grain size and clay
content collected from natural recourses.
b) Synthetic sand: It is an artificial sand obtained by mixing relatively clay free sand, binder (water and
bentonite). It is better moulding sand as its properties can be easily controlled.
c) Facing sand: It is the fine grade sand used against the face of the pattern and finally governs the surface
finish of the casting.
d) Parting sand: It is fine dry sand + brick dust used to preserve the joint face between the cope and the
drag.
e) Green sand: moulding is the most common moulding process
Natural Greensand= sand+ clay+ moisture (10to15%) (7 to9%)
Synthetic Greensand= sand+ clay+ moisture (5to7%) (4 to8%)
f) Dry sand mould: Dry sand mould refers to a mould which is artificially dried before the molten metal is
poured into it. Dry sand moulds are costly, stronger, used for complicated castings, i.e. avoid casting
defects, casting gets smoother surface.

Ingredient of Moulding sand

(a) Sand (e) Potash
(b)Binding material (Clay) (f) Saw dust
(c) Chime (g) Coal dust etc.
(d) Magnesia

Preparation of Moulding sand

a) Mixing of sand: Mixing of Moulding material should ensure uniform distribution of clay, moisture and
other constituents between grains. It makes uniform distribution.
b) Tempering of sand: The process by which sufficient moisture is added to the Moulding sand is known as
sand tempering.
c) Sand conditioning: Sand conditioning accomplishes uniform distribution of binder among the sand grains,
controls the moisture contents, eliminate foreign particles and suitable for ramming in the flask.

Praperd by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore 8 |T o t a l P a g e ’ s ( 4 4 )

 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Moulding methods:
a) Bench moulding: In this method the moulding is carried out on convenient bench and moulds are
relatively small.
b) Floor moulding: In this method the moulding is carried out in medium and large moulds are carried out
on the floor.
c) Plate moulding: For large quantity production and for very heavy casting two plates may be used with
pattern.
d) Pit moulding: In this method the moulding is carried out in the pits and generally very large moulds are
made.
e) Machine moulding: A machine is used to prepare moulds of small and medium. This method is faster
and gives uniform moulding.

Nomenclature of a Mould
A model of a Mould used in sand casting is shown in Figure 20.2. Moulding material—material that is packed
around the pattern to provide the Mould cavity is green sand. The various parts of Mould can be defined as
below:

Flask: It is a rigid box opens at top and bottom that holds the complete Mould. Flask may be divided into
three parts—the upper, middle, and lower; these three parts are known as cope, cheek, and drag, respectively.
Core: A sand or metal shape that is inserted into the mould to create internal hole or recess.
Mould Cavity: It is a cavity of casting shape in the mould connected to runner and riser. It is used to pour the
molten metal in which metal solidifies and gets the shape of the cavity.
Riser: An additional opening in the mould that provides additional metal to compensate for shrinkage and
also helps to remove gas or vapor formed during pouring the molten metal into the cavity.
Gating System: It is a network of channels that delivers the molten metal to the mould cavity.
Pouring Cup/Basin: It is located at the top surface of the mould and connected to an upper part of down sprue.
It prevents the splitting of molten metal.
Down sprue: It is a vertical portion of the gating system. It facilitates the streamline flow of molten metal.
Runners: It is a horizontal channel which connects the down sprue and gates.
Gate: It controls the amount of flow of molten metal at the entrance of cavity.
Parting Line: It is dividing a line of Cope and drag.
FOUNDRY TOOLS & EQUIPMENT’S
Praperd by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore 9 |T o t a l P a g e ’ s ( 4 4 )
 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Foundry or casting is a process of forming metallic products by melting the metal and pouring into a cavity
known as the mould, and allowing it to solidify. When it is removed from the mould it will be of the same
shape as the mould. Almost any article can be cast with proper technic and design and there is practically no
limit as to the size and shape of the casting that may be made.
Foundry tools and mouldes uses are fairly numerous. A brief description of the most important tools is given
here.
Shovel: Shovel is used for mixing and tempering moulding sand and for moving the sand from the pile to the
flask.

Riddle: A riddle is a wire mesh fitted into a wooden or metal frame. It is used for screening the moulding
sand and to scatter the fine moulding sand over the pattern.

Rammers: Rammers are used for packing the sand around the pattern in a flask. The rammer is generally
made of hard wood or metal with one end flat and another peen(wedge). Peen rammer is used for pressing the
sand.

Trowel: These are used for cleaning, smoothing and patching the flat surface of the mould. The blade is made
with steel fitted with a wooden handle. These are made in different forms and sizes to suit the particular job.

Slick: The common form of slick

is an oval spoon. It has a flat one on one end and spoon on the other end. It is used for patching and smoothing
the mould after the pattern has been withdrawn.

Lifter: These are usually made of mild steel. It is used for removing the sand particles from the mould. It may
also be used to repair the mould.

Strike off bar: It is made either from wood or metal with straight edge. This is used to cutting of extra sand
after ramming and bringing it level with the moulding box.

Praperd by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore 10 |T o t a l P a g e ’ s ( 4 4 )

 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Sprue pin: Sprue pin or rod is a tapered wooden peg. It forms the vertical passage in the cope through which
the molten metal enters the mould. Pin used to make riser hole is called riser pin.

Bellow: Bellows are used to blow excess parting sand from the pattern and also to blow loose sand particles
from the mould.

Bulb swab: This is the soft brush used for moisturizing the sand around the pattern. This strengthens the
sand and prevents the edge from breaking when the pattern is removed.

Gate cutter: It is a piece of sheet metal bent in the form of a u shape as given in the figure and is used to cut
the gate.

Mallet: A rawhide mallet is used to loosen the pattern in the mould so that it can be withdrawn without damage
to the mould.

Vent wire: It is a steel wire or rod with sharp pointed end. It is used to make a series of small holes in the
sand mould. This permits the gases to escape while the molten metal is being poured.

Draw spike (screw): Draw spike are used to lift the pattern from the sand mould. Two types of draw spike
are shown in the figure. Draw pin is inserted into a wooden pattern while thread end of draw spike screws
into a wooden pattern draw plate fastened to the large wooden plate or tapped hole of metal pattern.

Praperd by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore 11 |T o t a l P a g e ’ s ( 4 4 )

 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Moulding flask: A flask is a wooden or metal frame in which
a mould is generally made. It is generally made in two parts, the
cope (top section) and drag (bottom section). These two are held
in position by dowel pins. If the flask is made in three sections
(to increase the depth of mould for complicated castings) the
center one is called cheek.A flask must be strong and rigid so
as to protect the mould against damage during assembly, transportation and pouring. Steel flasks are
considered more durable than wooden flasks.

Laddle: Laddle is used to collect the molten metal from the

furnace and to pour the metal in the mould cavity. It is made up
of sheet metal and is coated with refractory material inside to
withstand the temperature of molten metal

Defects in Casting Process

1. Gas Porosity: Blowholes, open holes, pinholes

2. Shrinkage defects: Shrinkage cavity

Cut and washes, swell, drops,
3. Mould material defects:
metal penetration, rat tail
4. Pouring metal defects: Cold shut, misrun, slag inclusion

5. Metallurgical defects: Hot tears, hot spot.

Steps in Sand Casting

The entire casting process can be represented as a chain as shown in Figure below.

a) A green sand Mould is prepared with the help of a pattern.

b) The green sand Mould is a mixture of green sand, binders, and water.
c) The pattern is made of wood plastics, metal, wax, etc. The selection of pattern materials is based on the
type of casting process.
d) After pattern/Mould making, metal is melted in the cupola or in another suitable furnace.
e) The molten metal is poured into the Mould cavity.
f) The solidification process allows the product to gain the desired properties and strength.
g) The shrinkage in casting is controlled by the riser and proper design of the Mould.
h) After solidification, casting is removed from the Mould and sent to cleaning, finishing, and inspection.
Finally, the casting defects are rectified.
Praperd by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore 12 |T o t a l P a g e ’ s ( 4 4 )
 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028

Practical Steps in the Laboratory:

i. Place the pattern on the turn overboard.

ii. Place the drag around the pattern with upside and sprinkle the parting sand at the bottom.

iii. Fill the Moulding sand over the pattern pack, Ram, Jolt &squeeze.

iv. Level the bottom drag surface by leveler& turn over the drag.

v. Sprinkle the parting sand, place the cope on the drag to suit the drag slot.

vi. Select the in and out gate in the drag, Place the sprue pins.

vii. Fill the moulding sand around the sprue pins pack, Ram, Jolt and Squeeze & level the surface.

viii. Make vent holes on both the boxes with the help of vent wire.

ix. Remove the sprue pin & Separate cope from drag.

x. Remove the pattern carefully with the help of draw pin, cut gate ways to flow the molten metal.

xi. From the funnel shape on runner & riser, Hole to pour the molten metal on the top of the cope box.

xii. Join the two boxes with clamps, Now the mould is ready to pour the molten metal.

Praperd by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore 13 |T o t a l P a g e ’ s ( 4 4 )

 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Experiment Number 01:
M= Mass of the Product
M1=Mass of the Hexagonal
prism
M2= Mass of the Square

M1=Volume x Density

a=30mm=3cm
h=25mm=2.5cm
ρ = 2.70 gm/cm3

M1 =157.95gms

M2=Volume x Density
M2 =l x b x h
l=100mm=10cm
b=100mm=10cm
h=25mm=2.5cm
ρ = 2.70gm/cm3
M2 =10 x 10 x 2.5x2.70
=675gms
M=M1 + M2
M = 157.95 + 675 = 832.95gms
Add 30% Extra
30% of 832.95 is =249.89
Total Mass =832.95+249.89
M =1082.83gms
Evaluation Index
Parameter Maximum Marks Marks Obtained
Procedure Writing & Calculation 5 Marks
Pattern Making 5 Marks
Accuracy & Finishing 5 Marks
Viva 5 Marks
Total 20 Marks

Date……………. Signature of the Faculty

Praperd by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore 14 |T o t a l P a g e ’ s ( 4 4 )

 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Experiment Number 02:
M= Mass of the Product
M1=Mass of the Cylinder
M2= Mass of the Square

M1=Volume x Density
M1=A x L x ρ
d=100mm=10cm
A = 𝜋d2/4
ρ = 2.70 gm/cm3
L=30mm=3cm
M1 =A x L x ρ =636.17gms

M2=Volume x Density
M2 =l x bx h x ρ
l=20mm=2cm
b=50mm=5cm
h=50mm=5cm
ρ = 2.70gm/cm3
M2 = =2 x 5 x 5 x 2.70
M2 =135gms

M= M1 + M2
M = 636.17 + 135 =771.17gms
Add 30% Extra=231.35
=771.17+231.35
Total Mass M =1002.52gms
Evaluation Index
Parameter Maximum Marks Marks Obtained
Procedure Writing & Calculation 5 Marks
Pattern Making 5 Marks
Accuracy & Finishing 5 Marks
Viva 5 Marks
Total 20 Marks

Date……………. Signature of the Faculty

Praperd by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore 15 |T o t a l P a g e ’ s ( 4 4 )

 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Experiment Number 03:

Evaluation Index
Parameter Maximum Marks Marks Obtained
Procedure Writing &
5 Marks
Calculation
Pattern Making 5 Marks
Accuracy & Finishing 5 Marks
Viva 5 Marks
Total 20 Marks

Date……………. Signature of the Faculty

Praperd by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore 16 |T o t a l P a g e ’ s ( 4 4 )

 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Experiment Number 04:

Evaluation Index
Parameter Maximum Marks Marks Obtained
Procedure Writing & Calculation 5 Marks
Pattern Making 5 Marks
Accuracy & Finishing 5 Marks
Viva 5 Marks
Total 20 Marks

Date……………. Signature of the Faculty

Praperd by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore 17 |T o t a l P a g e ’ s ( 4 4 )
 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Experiment Number 05:

Evaluation Index
Parameter Maximum Marks Marks Obtained
Procedure Writing & Calculation 5 Marks
Pattern Making 5 Marks
Accuracy & Finishing 5 Marks
Viva 5 Marks
Total 20 Marks

Praperd by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore 18 |T o t a l P a g e ’ s ( 4 4 )

 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Date……………. Signature of the Faculty

Estimation of Material Costs

In this chapter the material cost means the direct material cost. The frequently used
materials are: Aluminum, Copper, Gunmetal, Brass, Iron, Tin, Magnesium, Mild steel, Alloy steel
& Lead etc.
The generalized procedure to calculate the Material Cost:
1. Observe the component drawings, break up the drawing into simple parts as per convenience.
2. Using formulae calculate area & Volume of each part. Scrap should be taken into Account while
calculating the volume.
3. Add the Volume of all the parts.
4. Multiply the component volume & density of material. It will be weight of the component. Density
X Volume =Weight.
5. Multiply the weight of the component with the cost of material per unit weight.

The following table gives the densities of various materials:

Praperd by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore 19 |T o t a l P a g e ’ s ( 4 4 )

 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028

Praperd by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore 20 |T o t a l P a g e ’ s ( 4 4 )

 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028

Praperd by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore 21 |T o t a l P a g e ’ s ( 4 4 )

 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028

UNIT – 2 FORGING

Praperd by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore 22 |T o t a l P a g e ’ s ( 4 4 )

 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028

Praperd by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore 23 |T o t a l P a g e ’ s ( 4 4 )

 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028

Praperd by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore 24 |T o t a l P a g e ’ s ( 4 4 )

 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028

Anvil: It is used as a mount for pairs of tools between which the work is forged by hammer blows. The main
body of the anvil is made of mild steel with a hardened top face welded on. The beak is soft and with an
increasing diameter of cross section. Beak is useful for producing bends of different radii. The ledge between
the beak and the anvil face is soft and can be used as a base for cutting operation with hot chisels.

Praperd by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore 25 |T o t a l P a g e ’ s ( 4 4 )

 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Sledge hammer: It is a very heavy hammer with a long handle. It may weigh from 4 to 16 kg. These are
used for heavy work. The length of the handle increases with the weight.

Chisel: It is fitted with a long handle. The chisel is held on the work and struck with a hammer.
Cold chisel: It is used for cutting cold metal.
Hot chisel: It is used for cutting hot metal.

Fullers: These are blunt nosed chisels and are used to reduce the thickness of hot metal. They may be held
with hand or fitted with a rod handle. Bottom fullers may be inserted in the square hole of the anvil. For
occasional use, fullers can be improvised from round mild steel bar.

Praperd by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore 26 |T o t a l P a g e ’ s ( 4 4 )

 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Hardie: This is a chisel fitted in to a hole in the anvil with its cutting edge at the top. There is usually one for
hot and another for cold use.

Swages: These are used in pairs to shape hot metal. They are supplied in pairs, top and bottom

Tongs: These are used to hold hot metal pieces. Various shapes of blacksmith’s tongs are available

Flatter: This is used to flatten and smooth the metal. It is used under a sledge hammer to flatten and smoothen
the metal, particularly after its thickness has been reduced using fullers.

Praperd by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore 27 |T o t a l P a g e ’ s ( 4 4 )

 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
WORKING STEPS IN MAKING THE FORGING JOB

Procedure:

1) Calculate the final length of the model to be forged of the given round rod of 12mmdiameter.

2) Place the given round rod in the Hearth furnace in suitable place.

3) Switch on the blower and set the temperature range up to 900-10000C in control panel.

4) The job is heated to red hot temperature.

5) Place the heated job in between open-faced Bottom & Top Die, which is set on Anvil.

6) Draw down the heated work piece to calculated length with the help of hammer, tong &flatter.

7) The process is carried approximately until the circular rod is transformed into desired shape and with desired

dimensions.

8) The work piece is re-heated to carry out bending operation.

9) Bending is carried out on Leg vice as per dimensions.

10) With the help of flatter, open faced dies finish the work piece to the final dimension and surface finish,

cool the specimen by dipping in water (Quenching).

Praperd by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore 28 |T o t a l P a g e ’ s ( 4 4 )

 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Experiment Number 01:

Evaluation Index
Parameter Maximum Marks Marks Obtained
Procedure Writing & Calculation 5 Marks
Pattern Making 5 Marks
Accuracy & Finishing 5 Marks
Viva 5 Marks

Total 20 Marks

Date……………. Signature of the Faculty

Praperd by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore 29 |T o t a l P a g e ’ s ( 4 4 )

 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Experiment Number 02:

Evaluation Index
Parameter Maximum Marks Marks Obtained
Procedure Writing & Calculation 5 Marks
Pattern Making 5 Marks
Accuracy & Finishing 5 Marks
Viva 5 Marks
Total 20 Marks

Date……………. Signature of the Faculty

Praperd by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore 30 |T o t a l P a g e ’ s ( 4 4 )

 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028

Experiment Number 03:

Evaluation Index
Parameter Maximum Marks Marks Obtained
Procedure Writing & Calculation 5 Marks
Pattern Making 5 Marks
Accuracy & Finishing 5 Marks
Viva 5 Marks
Total 20 Marks

Date……………. Signature of the Faculty

Praperd by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore 31 |T o t a l P a g e ’ s ( 4 4 )
 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
UNIT 3

Praperd by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore 32 |T o t a l P a g e ’ s ( 4 4 )

 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028

Praperd by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore 33 |T o t a l P a g e ’ s ( 4 4 )

 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028

Praperd by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore 34 |T o t a l P a g e ’ s ( 4 4 )

 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028

Praperd by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore 35 |T o t a l P a g e ’ s ( 4 4 )

 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028

Praperd by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore 36 |T o t a l P a g e ’ s ( 4 4 )

 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028

Sequence of operations or procedure for preparing Hexagonal Prism

1) Draw the top and front view of the Object with the given dimensions.
2) Draw a stretch out line A1A1 and mark off the sides of the base along this line
3) Erect perpendiculars through these points and mark the edges AA1, B B1, CC1, …. and AA1 and
height of the body.
4) Add 5mm extra adjacent to AA1 for seam joint.
5) Cut the development to shape on lines by using paper cutting scissor.
6) Place and fix the development on gives G.P sheet by using sticker.
7) Punch two points on each bending line.
8) Mark the boundary line by using marking pen.
9) Remove the paper development join the two points by scriber or marking pen.
10) Shear the boundary lines by hand snip.
11) Flatten the sheet by using mallet on flatter.
12) Always bend the seaming line first and then the remaining lines to get desired shape.
13) Finish the surface keeping on stake to shape.
14) Solder the joint.
15) Finish the surface finishing and complete the job.
Praperd by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore 37 |T o t a l P a g e ’ s ( 4 4 )
 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Experiment Number 01:

Evaluation Index
Parameter Maximum Marks Marks Obtained
Procedure Writing & Calculation 5 Marks
Pattern Making 5 Marks
Accuracy & Finishing 5 Marks
Viva 5 Marks
Total 20 Marks

Date……………. Signature of the Faculty

Praperd by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore 38 |T o t a l P a g e ’ s ( 4 4 )

 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Experiment Number 02:

Evaluation Index
Parameter Maximum Marks Marks Obtained
Procedure Writing & Calculation 5 Marks
Pattern Making 5 Marks
Accuracy & Finishing 5 Marks
Viva 5 Marks
Total 20 Marks

Date……………. Signature of the Faculty

Praperd by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore 39 |T o t a l P a g e ’ s ( 4 4 )

 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Experiment Number 03:

Evaluation Index
Parameter Maximum Marks Marks Obtained
Procedure Writing & Calculation 5 Marks
Pattern Making 5 Marks
Accuracy & Finishing 5 Marks
Viva 5 Marks
Total 20 Marks

Date……………. Signature of the Faculty

Praperd by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore 40 |T o t a l P a g e ’ s ( 4 4 )

 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Experiment Number 04:

Evaluation Index
Parameter Maximum Marks Marks Obtained
Procedure Writing & Calculation 5 Marks
Pattern Making 5 Marks
Accuracy & Finishing 5 Marks
Viva 5 Marks
Total 20 Marks

Date……………. Signature of the Faculty

Praperd by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore 41 |T o t a l P a g e ’ s ( 4 4 )

 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028

Experiment Number 05:

Evaluation Index
Parameter Maximum Marks Marks Obtained
Procedure Writing & Calculation 5 Marks
Pattern Making 5 Marks
Accuracy & Finishing 5 Marks
Viva 5 Marks
Total 20 Marks

Date……………. Signature of the Faculty

Praperd by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore 42 |T o t a l P a g e ’ s ( 4 4 )
 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028

Experiment Number 06:

Evaluation Index
Parameter Maximum Marks Marks Obtained
Procedure Writing & Calculation 5 Marks
Pattern Making 5 Marks
Accuracy & Finishing 5 Marks
Viva 5 Marks
Total 20 Marks

Date……………. Signature of the Faculty

Praperd by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore 43 |T o t a l P a g e ’ s ( 4 4 )
 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Rubrics for Assessment of Activity (Qualitative Assessment)
Name of the Student :………………………………………………………..….
Register Number :………………………………………………………..….
Subject :………………………………………………………..….

Average Total in Words:………………………………………………………..

Signature of the Student Signature of Staff

Praperd by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore 44 |T o t a l P a g e ’ s ( 4 4 )