PRODUCTION TECHNOLOGY LAB

II B.TECH -I Semester

CMR ENGINEERING COLEGE

UGC Autonomous Institution

(Approved by AICTE, New Delhi & Affiliated JNTU, Hyderabad)

Kandlakoya (V), Medchal Road, RR.Dist – 501401

DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE

ACADEMIC YEAR: 2020-21

This is to certify that the bonafide record work done by

Mr./Ms.__________________________________________________________
Bearing H.T No _________________of II-B.Tech-I Semester in the
Production technology Laboratory is satisfactorily completed.

Faculty In-Charge Head of the Department

VISION OF THE INSTITUTE

• To be recognized as a premier institution in offering value based and futuristic quality technical
education to meet the technological needs of the society

MISSION OF THE INSTITUTE

1. To impart value based quality technical education through innovative teaching and learning methods
2. To continuously produce employable technical graduates with advanced technical skills to meet the
current and future technological needs of the society
3. To prepare the graduates for higher learning with emphasis on academic and industrial research.

VISION OF THE DEPARTMENT

To be a center of excellence in offering value based and futuristic quality technical education in the field of
mechanical engineering.

MISSION OF THE DEPARTMENT

M1. To impart quality technical education imbibed with values by providing state of the art laboratories and
effective teaching and learning process.

M2. To produce industry ready mechanical engineering graduates with advanced technical and lifelong learning
skills.

M3. To prepare graduates for higher learning and research in mechanical engineering and its allied areas.

PROGRAM EDUCATIONAL OBJECTIVES (PEOS):

PEO 1: The Graduates will exhibit strong knowledge in mathematics, sciences and engineering for successful
employment or higher education in mechanical engineering.
PEO 2: The Graduates will design and implement complex modeling systems, conduct research and work with
multi disciplinary teams.
PEO 3: The Graduates will be capable of communicating effectively with lifelong learning attitude and
function as responsible members of global society.
PROGRAM OUTCOMES (POS):

1. Engineering knowledge: Apply the knowledge of mathematics, science, engineering fundamentals, and an
engineering specialization to the solution of complex engineering problems.

2. Problem analysis: Identify, formulate, review research literature, and analyze complex engineering problems
reaching substantiated conclusions using first principles of mathematics, natural sciences, and engineering
sciences.
3. Design/development of solutions: Design solutions for complex engineering problems and design system
components or processes that meet the specified needs with appropriate consideration for the public health and
safety, and the cultural, societal, and environmental considerations.
4. Conduct investigations of complex problems: Use research-based knowledge and research methods
including design of experiments, analysis and interpretation of data, and synthesis of the information to provide
valid conclusions.
5. Modern tool usage: Create, select, and apply appropriate techniques, resources, and modern engineering and
IT tools including prediction and modeling to complex engineering activities with an understanding of the
limitations.
6. The engineer and society: Apply reasoning informed by the contextual knowledge to assess societal, health,
safety, legal and cultural issues and the consequent responsibilities relevant to the professional engineering
practice.
7. Environment and sustainability: Understand the impact of the professional engineering solutions in societal
and environmental contexts, and demonstrate the knowledge of, and need for sustainable development.
8. Ethics: Apply ethical principles and commit to professional ethics and responsibilities and norms of the
engineering practice.
9. Individual and team work: Function effectively as an individual, and as a member or leader in diverse
teams, and in multidisciplinary settings.
10. Communication: Communicate effectively on complex engineering activities with the engineering
community and with society at large, such as, being able to comprehend and write effective reports and design
documentation, make effective presentations, and give and receive clear instructions.
11. Project management and finance: Demonstrate knowledge and understanding of the engineering and
management principles and apply these to one’s own work, as a member and leader in a team, to manage
projects and in multidisciplinary environments.
12..Life-long learning: Recognize the need for, and have the preparation and ability to engage in independent
and life-long learning in the broadest context of technological change
.
PROGRAM SPECIFIC OUTCOMES(PSOS):

PSO.1 Design a Pattern for efficiency improvement as per industrial needs.

PSO.2 Design and manufacture mechanical components using advanced manufacturing technology as per the
industrial needs.
Course Name: PRODUCTION TECHNOLOGY LAB

CO No.
Course Outcome (CO’s)

Make different types of patterns with consideration of design parameters

CO1
using wood working lathe.

CO2 Making use of Arc, Butt, Spot, Gas and Tig welding joints.

Develop plastic components making use of plastic injection & blow

CO3
moulding machine.

CO4 Develop sheet metal components using Hydraulic press.

CO5 Produce a casting of any machine component

CO6 Make welded joints using TIG welding

CO’s/PO’s PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11 PO12

CO1 3 - 3 3 - - 2 - - - - -

CO2 3 - 3 3 - - 2 - - - - -

CO3 3 - 3 3 - - 2 - - - - -

CO4 3 - 3 3 - - 2 - - - - -

CO5 3 - 3 3 - - 2 - - - - -

CO6 3 - 3 3 - - 2 - - - - -

CO’s/PSO’s PSO1 PSO2

CO1 - 3

CO2 - 3
CO3 - 3
CO4 - 3
CO5 - 3
CO6 - 3
 GENERAL INSTRUCTIONS FOR LABORATORY CLASSES
1. All the students must follow the prescribed dress code (apron, formals, shoes) wear their ID cards

2. All the students should sign in login register.

3. All students must carry their observation books and records without fail.

4. Students must take the permission of the laboratory staff before handling the machines in order to avoid any
injury.

5. The students must have basic understanding about the theory and procedure of the experiment to be
conducted.

6. Power supply to the test table/test rig should be given in the presence of only through the lab technician.

7. Do not LEAN on and do not come CLOSE to the equipment.

8. Instruments like TOOLS, APPARATUS and GUAGE sets should be returned before leaving the lab.

9. Every student is required to handle the equipment with care and follow proper precautions

10. Students should ensure that their work areas are clean.

11. At the end of each experiment, the student must take initials from the staff on the data / observations taken
after completing the necessary calculations.

12. The record should be properly written with following section in each experiment:
a) Aim of the experiment
b) Apparatus / Tools / Instruments required
c) Procedure / Theory
d) Model Calculations
e) Schematic Diagram
f) Specifications / Designs Details
g) Tabulations.
h) Graph
i) Result and discussions.

13. Students should attend regularly to all lab classes.

14. Day- to- day evaluation of student performance is carried out and recorded for finalizing internal marks.
 SCHEME OF EVALUATION FOR EXTERNAL LABS

Correctness of Conduct Model Calculations Results and Graphs Viva

Write up and Experiment &
Precautions observations

Marks: 10 Marks: 20 Marks: 15 Marks: 15 Marks: 15

Total Marks: 75 Marks

SCHEME OF EVALUATION FOR INTERNAL LABS

Day to Day Evaluation ------15 Marks Internal Exam------10 Marks

Uniform Observation Performance Results Viva Correctness Conduct Model Results and Viva Voce
of Voce of Write up Experiment Calculations Graphs
&Record and &
experiment Precautions observations

Marks:2 Marks:3 Marks:3 Marks:4 Marks:3 Marks:2 Marks:2 Marks:2 Marks:2 Marks:2

Total Marks: 15+10=25 Marks

 LIST OF EQUIPMENT

1 Universal Strength Machine(hydraulic)

2 Sand Rammer

3 Permeability Tester

Hydraulic Plastic Injection Moulding Machine

4
Model

5 Pneumatically Operated Blow Molding Machine

6 Injection Machine

7 Spot Welding machine

8 Wood Turning lathe machine

9 Floor with electrical and tools

Hydraulic Press with deep

10
drawing die

11 Mechanical fly press with blanking and piercing

12 Brazing setup with cylinder

13 Electrical Melting furnace

14 Tig welding machine

15 Plasma welding & cutting machine

 INDEX
I. METAL CASTING

1. PREPARATION MOULD CAVITY USING SINGLE PIECE PATTERN

2. PREPARATION MOULD CAVITY USING SPLIT PATTERN

3. PATTERNMAKING

4. MELTING PRACTICE

II. WELDING

ARC WELDING

5. BUTT JOINT.

6. LAP JOINT

7. SPOT WELDING

8. TIG WELDING

9. BRAZING

III. PRESS WORKING OPERATIONS

10. FLY SCREW PRESS

11. HYDRAULIC PRESS

IV. PROCESSING OF PLASTICS

12. INJECTION MOULDING

13. BLOW MOULDING

V. Manufacturing of 24 teeth aluminum gear using modeling/casing methodology

 METAL CASTING

PREPARATION OF A MOULD CAVITY USING SINGLE PIECE PATTERN

Aim:

To prepare a mould for a given single piece pattern

Materials Required:

Moulding sand, Facing sand, Banking sand, Parting sand, Core, pattern, cope box, Drug box,
bottom board.

Tools Required:

Sprue, Riser, Chaplets, Gate cutter, Trowel, Vent rod, sleek, Bellow

Terminology of casting:

Flask: A moulding flask is one which holds the sand mould intact .Depending upon the position of
the flask in the mould structure it is referred to by various names as drag cope and check .It is made
up of wood for temporary application or more generally of metal for long term use.

Drag: lower moulding flask.

Cope: Upper moulding flask used in three moulding.

Pattern: Intermediate is a replica of the object to be made with some modifications. The mould casting
is made with the help of the pattern.

Parting Line: This is the dividing line between the two moulding flasks that makes up the sand mould .
In split pattern is also the diving line between the two halves of the pattern.

Bottom Board: This is a board normally made of wood which is used at the start if the moulding
making. The pattern is first kept on the bottom board sand is poured on it and then the ramming is
done in the drag.
Facing Sand: This is specially prepared sand which is placed around the pattern which has
superior properties with regards to refractoriness permeability etc. This will ensure better surface
ion the castings.

Coal Dust: The small amount of carbonaceous materials sprinkled on the inner surface of the
moulding cavity to give better finish to castings.

Moulding Sand: It is a mixture of silica ,clay and moisture in appropriate proportions to get the
desired results and it surrounds the pattern facing sand while making the mould .The moulding
sand is the mixture

Backing sand: It is chat constitutes most of the refractory material found in the mould. This
made up of used and burnt sand.

Core: It is used for making hallow cavities in castings.

Sprue: The passage through which the molten metal from the pouring basin reaches the mould
cavity. In many cases it controls the flow of metal into the mould.

Runner: the passageways on parting plane through which molten metal flow id regulated before the
reach the mould cavity through the In-Gate.

In-Gate : The actual entry point through when molten metal enter mould cavity.

Riser: It is a reservoir of molten metal provided in the casting. So that hot metal can flow into the
casting when there is a reduction in volume of metal to solidification

Chill: Chill are metallic objects which are placed in the mould to increase the cooling rate of
molten metal.

Moulding Procedure:

1 The drag is first placed upside down a moulding.

2 The drag is filled with moulding sand and rammed suitably with the help of a rammer
3 After sand is rammed a strike off bar is used to remove the excess sand and the surface is made half
4 The drag is turned over and cope is placed on it. The two flasks are held together rigidly with the help
of sprue pins
5 The above procedure is repeated again after placing the sprue pin and riser at right place.
6 After proper ramming the sprue and riser are removed from cope, vent holes are made using vent rod
7 Now the cope and drag are separated and pattern is removed using draw spike from drag
8 With the help of gate cutter the runner is prepared in the casting
Diagram :

Precautions:

1. There should be enough clearance between the pattern and the walls of the flask.

2. The ramming of the sand should be done properly so as not to compact it too hard,
which makes the escape of gases difficult.

Result:

Viva Questions

1. What is mean by casting process and types of casting processes ?

_____________________________________________________________________

_____________________________________________________________________

____________________________________________________________

2. What are the different types of materials can be used for making of pattern?

_____________________________________________________________________

_____________________________________________________________________

____________________________________________________________
3. Explain the core making process?

_____________________________________________________________________

_____________________________________________________________________

____________________________________________________________

4. Explain the composition and properties of moulding sand?

_____________________________________________________________________

_____________________________________________________________________

____________________________________________________________

5. Describe the types of patterns

_____________________________________________________________________

_____________________________________________________________________

____________________________________________________________
 2. PREPARTIONMOULDCAVITYUSINGSPLITPATTERN
Aim: To prepare a green mould for casting using only two boxes

Tools And Pattern:

Wood pattern made in two halves , dowelled together ,the division passing through the
centre of the grooves, cope and drag moulding tools parting sand, brick dust etc.

Stage Sketches:

The mould can be prepared by using tree boxes without any difficulty .However the same can be
prepared using two boxes using an ingenious method known as false-core method

Procedure:

1. One half of the pattern is molded in the bottom box, the parting being cut an incline as shown .the
other half pattern is then placed in portion and band poured and rammed to form the second parting
with a slope down wards from the upper flange of pulley

2. The top box is next placed in the bottom box and properly located .Sand is poured and
rammed without damaging the false core.

3. The top box is gently removed the upper half pattern is gently taken out from the top box.

4. The top box is replaced on the drag and the entire mould is turned upside down .The bottom box,
which now is at the top , is gently lifted and the remaining half of the pattern is withdrawn.

5. The bottom box is replaced and the mould id inverted .the spruces are removed , pouring basin
is cut and the mould is finished after piercing holes (vents)

Observations:

1. After ramming using moulds hardness tester check the moulds hardness on all the four sides
of the pattern
2. Locate the rumen and riser 90 degree exactly.
Precautions :

1. Ramming should be uniform strength to the mould.

2. Apply parting sand at the partitions for easy separation of boxes.

3. Locate the two halves of pattern properly to avoid mismatch.

Result:

Viva Questions
1. Explain Casting Defects.

_____________________________________________________________________

_____________________________________________________________________

____________________________________________________________

2. Describe the various moulding methods.

_____________________________________________________________________

_____________________________________________________________________

____________________________________________________________

3. List the components used in moulding process?

_____________________________________________________________________

_____________________________________________________________________

____________________________________________________________
 3. PATTERN MAKING
Aim: To prepare a pattern using design of pattern allowances.

Tools Equipment & Material:

Steel rule, outside caliper, Mortise Chisel, inside chisel , peering Chisel, Firmer Chisel wood
rasp half round file outside gauge ,outside Chisel, Try square , handsaw, Mallet, Sand Paper,
Teak Wood given size

Procedure:

Match the two rectangular Wood pieces of stock and fix them together by wood screws at either end
in the excess portion of wood. This must give a firm clamping of the wood pieces to turn into single
piece.

In body portion of the pattern mark a center link using marking gauge and extend it to the dressed
end Using the race with counter sunk make indentations at the center of each and to form locations
for the head stock and tail stock center

The wood stock is turned on the wood turning lathe using appropriate gauge and finally finished the
dimensions.

Sanding paper No.1/2 or No.0 does smooth finishing

The sand paper should be moved laterally on the rotating work.

1 DESIGN OF A PATTERN FOR SAMPLE CASTING:

The pattern drawing with required dimensions taking shrinkage into account is shown in Fig.1

Before Allowance Casting Part

 After Allowance Casting
Part Fig : 1

Shrinkage Allowance:
From Table for steel the shrinkage allowance is 21.0mm/m
For dimension ,allowance is x / =
For dimension ,allowance is x / =
For dimension ,allowance is x / =
For dimension ,allowance is x / =

Draft Allowance:
Assume 1degree taper for external details and 3 degree for internal details. For
102.1 size the paper required is,
External = x tan ( )=
Internal = x tan ( )=

After providing for this taper the pattern drawing is as shown in Fig compared to which has been
before providing the draft allowance.

Finish or Machining Allowance: Machining allowance of 2 mm is provided The

dimension x =
The dimensions – x =
The final dimensions are shown in Fig.1

Precautions:

1. The tools are kept sharp to cut freely without burning and without much pressure to
cause chipping.

2. Maintain proper turning angles.

3.Be alert to avoid accidents.

Results:
Viva Questions

1. What are the different types of allowances ?

_____________________________________________________________________

_____________________________________________________________________

____________________________________________________________

2. What are the different types of materials available for making pattern?

_____________________________________________________________________

_____________________________________________________________________

____________________________________________________________

3. What is the main function of shrinkage allowance?

_____________________________________________________________________

_____________________________________________________________________

____________________________________________________________

4. What are the different types of tools used in making pattern?

_____________________________________________________________________

_____________________________________________________________________

____________________________________________________________
 4. MELTING PRACTICE
Aim:- To observe the melting of metals to prepare the casting.

Material Required And Apparatus :-

Oil furnace, Ladle to stir ,Metal.
Specifications :- Capacity – 10
kgs
Crucible – Graphite of Dia 1 ‘ X height
1.5” Burner – 0 Number
Blower – 1 HP 2880
rpm. Oil tank – 100 lts.
Oil consumption – 2-4
Hrs. Insulation – Fire
bricks
Outer Casting – Mild steel duly painted.
Melting Procedure For Aluminum Alloys :-
The charge materials, chemicals should be free from moisture, oil and corrosion powder and
should be preheated before charging .The calculation of charge should be done considering the
melting loss of each element in the melting furnace for final desired analysis.

1. The furnace crucible should be clean and red hot for charging.
2. Aluminum alloys get readily oxidized and from dross, using proper covering top with
flux and chemicals help to reduce this. Different proprietary chemicals are available for
different alloys.
3. Melting should be done under steady conditions without agitation. Stirring is doe to
 reduce gas pickup.
4. Once melting is complete, degassing using solid chemicals like hexa chloro-ethane
which evolves chlorine by purging with nitrogen or argon gas is done to remove the
dissolved hydrogen. Hydrogen is evolved from moisture.
3H2O+2Al Al203+6H

Hydrogen absorbed by liquid metal causes serious porosity in casting during solidification.
Degassing should be done in the temperature range 730 0 C to 7500 C .
5. Liquid metal after degassing is treated with sodium containing chemicals to improve
mechanical properties.
6. Liquid metal once ready should be super heated. Agitated or kept long in the furnace
which will cause dressing and gas pickup. Dross should be skimmed properly before
pouring.

7. Alloys containing magnesium should be melting carefully as it is highly reacting.

Special fluxes and chemical like sulphur are used to inhibit the reactivity and prevent
spontaneous ignition , melting loss and dross.

Casting Defects Due To Improper Melting:-

1. Improper chemical analysis : Incorrect charge, calculations, including wrong

estimates of melting losses, metal recovery, excessive losses due to improper fluxing
and slogging operations, improper covering of nonferrous melt causes this defect.
2. Gassy metal/hydrogen pickup/pinhole porosity : Unclean melting causes formation and
forms cavities inside casting.
3. Oxygen absorption : Excessive oxygen furnace operations in atmosphere following
oxidation during melting cause this defect. It also causes loss of costly metal added in
charge.
4. Slag inclusions : Improper fluxing and slag particles to be mixed in the metal being
poured. Careless pouring, lip pouring for alloys with fluid slag particles to enter casting.
5. Cold shut, misrun, unfilled castings : Low pouring temp, delay in pouring, due to many
folds being poured, loss of heat from ladle , due to improper covering failure of ladle
opening in the bottom pouring cause premature solidification of metal causing defects.
6. Sand fusion, metal penetration, rough surface : excessive pouring temp of liquid causes
damage to the casting surface by attacking mould surface.
7. Sand erosion sand inclusions : Uncontrolled high pouring rate from ladle into mould leads
 to erosion of mould/core

PRECAUTIONS:

1. The furnace crucible should be clean and red hot for charging
2. Charge material should be free from oil, moisture etc.,
3. Melting must be done under steady condition to reduce gas pickup.

RESULT:

Viva Questions

1. Define melting process?

_____________________________________________________________________

_____________________________________________________________________

____________________________________________________________

2. Explain the different types of furnaces?

_____________________________________________________________________

_____________________________________________________________________

____________________________________________________________

3. What is the working principle of cupola furnace?

_____________________________________________________________________

_____________________________________________________________________

____________________________________________________________
 WELDING

Arc Welding
Introduction to Electric Arc Welding:

Arc welding is joining of two metals together with the aid of a filler rod and heat. In electric arc
welding the heat is supplied by electricity from a welding transformer.

A socket supplies electricity with a high voltage to the welding transformer. The transformer changes
the electricity to a low voltage which is not harmful and can be used for welding. This electricity
however has a high current strength which is essential for obtaining a strong flaming arc.

Electric Arc Welding Equipment:

A-ON/OFF switch, B-Socket, C-PLUG,D-Welding Transformer(A.C),E-Current control, F-

Earth clamp, G-Welding table, H-Work piece, I-Electrode, J-Electrode holder, K- Apron, L-Welding
shield, M-Gloves, N-Chipping hammer, O-Wire brush

Welding Transformer:

A welding power supply is a device that provides an electric current to perform welding.
Welding usually requires high current (over 80 amperes) and it can need above 12,000 amperes in spot
welding. Low current can also be used; welding two razor blades together at 5 amps with gas tungsten
arc welding is a good example. A welding power supply can be as simple as a car battery and as
sophisticated as a high-frequency inverter using IGBT technology, with computer control to
assist in the welding process. A transformer-style welding power supply converts the moderate
voltage and moderate current electricity from the utility mains (typically 230 or 115 VAC) into a high
current and low voltage supply, typically between 17 to 45 (open-circuit) volts and 55 to 590
amperes. A rectifier converts the AC into DC on more expensive machines. An Arc Welding machine
is shown in Fig

Fig 1: A.C. Arc Welding Equipment

 This design typically allows the welder to select the output current by variously moving a primary
winding closer or farther from a secondary winding, moving a magnetic shunt in and out of the core of
the transformer, using a series saturating reactor with a variable saturating technique in series with the
secondary current output, or by simply permitting the welder to select the output voltage from a set of
taps on the transformer's secondary winding. These transformer style machines are typically the least
expensive.
The trade off for the reduced expense is that pure transformer designs are often bulky and massive
because they operate at the utility mains frequency of 50 or 60 Hz. Such low frequency transformers
must have a high magnetizing inductance to avoid wasteful shunt currents. The transformer may also
have significant leakage inductance for short circuit protection in the event of a welding rod becoming
stuck to the workpiece. The leakage inductance may be variable so the operator can set the output
current.
Current Controls:
The current is set with a handle or a wheel on the welding transformer. The
current and the diameter of the electrode depend on the thickness the material to be welded together,
the length of the cables and the size of the whole workplace which may take much of the heat away
during welding. Thick electrodes need a higher current than thin electrodes.
Earth Clamp (Ground Clamp):

The ground clamp connects the ground cable to the work. It is an important device
because without proper grounding, one fails to get a stable arc and the required heat for welding. A
ground clamp should be designed to provide a strong positive electrical contact, to be capable of
easy attachment and detachment and to with stand rough use.

Electrode:

Both welding rods and consumable welding electrodes and filler metal to the weld. In arc welding
,the filler metal is called as electrode. Most electrodes used are mild steel and vary only in the flux
covering. Since almost all electrodes are mild steel, welding with them varies only because the flux
has different characteristics in our workshop we are using E 6013 electrode

E 6013:

It is widely used on sheet metal when appearance and ease of operation are more important than
speed. It is also used for general purpose welding with smaller, limited input, low open- circuit
voltage welders. Spatter loss is low, and the beads are bright, smooth and flat with easily removed
slag

E---indicates electrode extruded and is used for arc welding 60---

-indicates the minimum tensile strength

1----indicates the electrode can be used in all positions

 3---indicates this electrode has a soft arc, producing only shallow penetration with slightly convex
beads.

AC current or either polarity DC current may be used with this electrode to produce medium to
high quality deposits

The E 6013 electrode covered with Ructile-potassium flux. Rutile(titanium dioxide)

causes slag formation and potassium (potassium oxalate or potassium silicate) stabilizes the arc.
According to I.S 2879-1975 The mild steel electrode core wires have the
following

% of elements in composition

Carbon ------------- --0.1%

Silicon ------------- --0.03%

Manganese-----------0.38 to 0.62%
Sulphur -----------------0.03%

Phosphorus ------------ --0.03%

Copper ---------------- --0.15%

Iron -------------------- remaining%

Choosing an electrode:
Basically an electrode should be chosen by looking at these
qualities of the welding job:

A) Properties of the base metal

B) position of the joint

C) Type of joint

D) Amount of welding required

E) Tightness of the joint's fit-up

F) Type of welding current available

Electrode Holder:

The electrode holder is used to grip the electrode and provide it with the welding
current. A holder can be partly or fully insulated. A properly designed holder is light in weight, grips
the electrode securely in position receives and ejects the electrodes easily, and resists over heating in
continuous use. Holders are available in various sizes according to their current- carrying capacities,
 their weight increasing with increasing capacity. Electrode holders should never be immersed in
water for cooling.

Apron:

This protects the cloths of operator from dirt and spatter. It is made of soft leather(cow).

Welding shield:

Arc welding demands that a welder use a hand shield or a head shield. The head
shield also called a helmet, is used only when the welder needs his other hand to be free while
welding. Both the hand shield and head shield are meant to protect the face, head and eyes from the
blinding rotation of the arc and hot spatter and are provided with colored filter glasses through which
the arc must be observed
Gloves:

These are essential to protect hands. It is made of leather

Chipping hammer:

The welder needs a chipping hammer to remove the slag which

Covers the deposited weld bead before the next bead is laid. Unless the slag is completely removed,
the finished weld joint is likely to have slag inclusions. The chipping hammer is made of hardened
steel and is usually double-ended. One end is shaped like a chisel for general chipping, while the
other end has a sharp point to deslag the corners.

Wire brush:

After chipping, the weld bead needs to be brushed vigorously with a wire brush to remove the
last traces of slag. The wire brush is also used to remove rust and dirt from joint surfaces before
starting to weld.

Cables:

Large, heavy cables carry the current needed for good working heat. These are connected to the
positive and negative terminals on the welding machines.

Most cables are made of woven, hair like strands of copper wire covered with insulated rubber. The
rubber allows the woven wire to flex, protects it during use under rough conditions, and insulates it
from shorts. Copper connectors fasten the free end of each cable to different kinds of holders

Face Shield:

A face shield is used to protect the eyes and face from the rays of the arc and from spatter or
flying particles of hot metal. It is available either in hand or helmet type. The hand type is convenient
to use, where ever the work can be done with one hand. The helmet type, though not comfortable to
wear, leaves both hands free for the work Shields are made of light weight non-reflecting fiber and
fired with dark glass to filter out the harmful rays of the arc. A cover glass is fitted in front of the dark
lens to protect it from spatter.

Weld Joints

Figure shows some common types of weld joints. Wherever possible, it is better to
weld by placing the parts in the flat

Preparation of work

Before welding, the work pieces must be thoroughly cleaned of rust,

Scale and other foreign materials. Thin pieces of metal are generally welded without beveling the
edges. However, thick work pieces should be beveled to ensure adequate penetration and fusion of all
parts of the weld. But, in either case the parts to be welded must be separated slightly to allow better
penetration of the weld
Electrodes

Filler rods used in arc welding are called electrodes. They are generally made of a rod of
alloying elements suitable for the job, coated with a flux. They are specified y the diameter in SWG
and length, apart from the brand and code names, indicating the purpose for which they are most
suitable

Electrode holder

The electrode holder is connected to the end of the welding cable and holds the electrode. It
should be light, strong and easy to handle and should not become hot while in operation. Figure
shows one type of electric holder. The jaws of the holder are insulated, offering protection from
electric shock.

Ground clamp

It is connected to the end of the ground cable and is clamped to the work or welding table
to complete the electric circuit It should be strong and durable and give low resistance connection.

Chipping Hammer and Wire Brush

A chipping hammer is used for removing slag formationon welds. One end of the head is
sharpened like a cold chisel and the other, to a blunt, round point. A wire brush is used for
cleaning and preparing the work for welding.
Safety Rules:

Before starting to weld, you must be aware of the dangers involved

A) The bright light of the arc

B) Hot metal and flying sparks

C) Electric shocks

Precautions:

1) Use a proper welder's eye shield with dark glass when you look into the arc. Never use
regular safety goggles instead. They do not give your eyes and your face enough protection

2) If you do not use the eye shield, your eyes will become very painful. Do not your eyes
when this happens. If necessary ask for medical help.
3) Always wear safety goggles when you remove slag from a weld with a chipping
hammer

4) Keep your skin covered as far as possible. Radiation from the bright light of the arc can
cause skin injuries. Protect your skin against flying sparks. Wear leather welding area. Don't carry
matches or a lighter in your pocket

5) Keep electric cables in good condition. Repair the insulation if it is damaged.

6) Do not use welding equipment in wet or damp areas, it will increase the danger of electric
shocks

7) Shut off the electricity when you stop welding. Do not forget this in case you use your
own power unit.

8) Never works on the welding transformer unless you hae pulled the plug out of the socket.

9) Be extremely careful when you weld fuel tanks or containers. Take the necessary
precautions.
 5. SINGLE V-BUTT JOINT
Aim: To make a single V-butt joint, using the given two M.S. pieces and by arc welding.

Tools and Equipment required: Rough and smooth files, protractor, arc welding machine
(transformer type), mild steel electrode and electrode holder, ground clamp, tongs, face shield,
apron and chipping hammer.

Sequence of operations:

1. The given M.S pieces are thoroughly cleaned of rust and scale.

2. One edge of each piece is beveled, to an angle of 30°, leaving nearly 1/4th of the flat
thickness, at one end.

3. The two pieces are positioned on the welding table such that, they are separated slightly for
better penetration of the weld.

4. The electrode is fitted in the electrode holder and the welding current is set to a proper value.

5. The ground clamp is fastened to the welding table.

6. Wearing the apron and using the face shield, the arc is struck and holding the two pieces
together, first run of the weld is done to fill the root gap.

7. Second run of the welding is done with proper weaving and with uniform movement. During
the process of welding, the electrode is kept at 15° to 25° from vertical and in the direction of
welding.

8. The scale formation on the welds is removed by using the chipping hammer.

9. Filling is done to remove any spatter around the weld.

Precautions:

1. Edge preparation should be done carefully.

2. Before welding ensures that the surfaces are extremely clean.

3. While welding always use face shields or goggles.

Result:
Viva Questions

1. What is the difference between arc welding and gas welding?

_____________________________________________________________________

_____________________________________________________________________

____________________________________________________________

2. What are the components of arc welding machine?

_____________________________________________________________________

_____________________________________________________________________

____________________________________________________________

3. What is electrode and give its purpose?

_____________________________________________________________________

_____________________________________________________________________

____________________________________________________________

4. Define welding process

_____________________________________________________________________

_____________________________________________________________________

____________________________________________________________

5. What is consumable and non-consumable electrode?

_____________________________________________________________________

_____________________________________________________________________

____________________________________________________________
 6 LAP JOINT
Aim: To make a Lap joint, using the given two M.S. pieces and by arc welding.

Tools and Equipment required: Rough and smooth files, protractor, arc welding machine
(transformer type), mild steel electrode and electrode holder, ground clamp, tongs, face
shield, apron and chipping hammer.

Sequence of operations:

1. The given M.S pieces are thoroughly cleaned of rust and scale.

2. Given 2 M.S plates are filled at an angle of 45° at 2 surfaces to be joined.

3. The electrode is fitted in the electrode holder and the welding current is set to a proper
value.

4. The ground clamp is fastened to the welding table.

5. Connections to be given such that electrode-negative and work piece positive. 6.Wearing

the apron and using the face shield, the arc is struck and holding the two
pieces together, first run of the weld is done to fill the root gap.
7. Second run of the welding is done with proper weaving and with uniform movement. During
the process of welding, the electrode is kept at 15° to 25° from vertical and in the direction
of welding.

8. The scale formation on the welds is removed by using the chipping hammer.

9.Filling is done to remove any spatter around the weld.

Precautions:

1. Edge preparation should be done carefully.

2. Before welding ensures that the surfaces are extremely clean.

3. While welding always use face shields or goggles.

Result:
Viva Questions

1. What is the difference between arc welding and gas welding?

_____________________________________________________________________

_____________________________________________________________________

____________________________________________________________

2. What are the components of arc welding machine?

_____________________________________________________________________

_____________________________________________________________________

____________________________________________________________

3. What is electrode and give its purpose?

_____________________________________________________________________

_____________________________________________________________________

____________________________________________________________

4. Define welding process

_____________________________________________________________________

_____________________________________________________________________

____________________________________________________________

5. What is consumable and non-consumable electrode?

_____________________________________________________________________

_____________________________________________________________________

____________________________________________________________
 7. SPOT WELDING
Aim: To study the effect of the current on weld strength using spot welding process

Equipment: Spot welding machine

Material Required: Two metal pieces of size 4” X 2”

Description of the Equipment:

A typical resistance spot welding machine essentially consists of two electrodes, out
of which one is fixed. The other electrode is fixed to a rocker arm (to provide mechanical
advantage) for transmitting mechanical force from a pneumatic cylinder. This is the simplest type
of arrangement. The other possibility is that of a pneumatic or hydraulic cylinder being directly
connected to the electrode without any rocker arm. A portable spot welding machine is shown in
figure.

For welding large assemblies such as car bodies, portable spot welding machines are used.
Here the electrode holder and the pneumatic pressurizing system is present in the form of a
portable assembly, which is taken to the place, where the spot is to be made. The electric current,
compressed air and the cooling water needed for the electrodes is supplied through cable and
hoses from the main welding machine to the portable unit.

In spot welding, a satisfactory weld is obtained when a proper current density (A/Sqmm) is
maintained. The current density depends on the contact area between the electrode and the work
piece. With the continuous use, if the tip becomes upset and the contact area increases, the current
density will be lowered and consequently weld is obtained over a large area. This would not but
able to melt the metal and hence there would be no proper fusion.

A resistance welding schedule is the sequence of events that normally take place in each of
 the welds. The events are the squeeze time that is the time required for the electrodes to align and
clamp the two work pieces together under them and provides the necessary electrical contact. The
weld time is the time of the current flow through the work pieces till they are heated to the
melting temperature. The hold time is the time whne the pressure is to be maintained on the
molten metal without the electric current. During this time, the pieces are to be forge welded. The
off time is time during which, the pressure on the electrode is taken off so that the plates can be
positioned for the next spot. The off time is not normally specified for simple spot welding, but
only when a series of spots are to be made in a predetermined pitch.

PROCEDURE:

1. Switch on the machine and set the current in the machine to 2 Ampere.

2. Set the timer to two seconds

3. Over lap the two metal pieces to the requires size and place them between the two
electrodes.

4. Apply pressure by foot on the lever such that two electrodes come into contact if the over
lapped metals.

5. After 2 seconds remove the pressure on the lever slowly.

6. Now the joint is ready for use.

7. Repeat the same procedure at various amperes.

8. Test the strength of the joints using universal testing machine.

PRECAUTIONS:

1. Ensure that the electrodes should not be touched.

2. Don’t touch the welded portion by hand immediately after the welding is done.

Result:
Viva Questions

1. Explain friction welding and its advantages?

_____________________________________________________________________

_____________________________________________________________________

____________________________________________________________

2. Explain thermit welding

____________________________________________________________________

_____________________________________________________________________

____________________________________________________________

3. Explain EBW?

____________________________________________________________________

_____________________________________________________________________

____________________________________________________________

4. Explain LBW?

____________________________________________________________________

_____________________________________________________________________

____________________________________________________________

5. Explain PAW?

____________________________________________________________________

_____________________________________________________________________

____________________________________________________________
 8. TIG WELDING
AIM:

To sturdy the effect of arc current on weld strength and heat effected zone in TIG welding.

EQUIPMENT AND MATERIAL REQUIRED:

TIG welding machine ADORTIG 11/20 ( input supply 230 volts, single phase, 50
hertz frequency, maximum welding current @ 60% duty cycle AC/DC is 110/200 amps ), bench
vice, universal testing machine, metallurgical microscope, m.s plates of 250*50*5mm.

TOOLS REQUIRED:

Hack saw, chipping hammer, wire brush, safety goggles, hand gloves, face shield,
files.

DESCRIPTION OF EQUIPMENT:

Tungsten inert gas (TIG) welding or gas tungsten arc welding (GTAW) isan inert gas
shielding arc welding process using non consumable electrode. The electrodes may also contain 1%
to 2% thoria (thorium oxide ) mixed along with the core tungsten or tungsten with 0.15% to
0.40% zirconia (zirconium oxide). The pure tungsten electrode are less expensive but carry less
current. The thoriated tungsten electrodes carry high currents and are more desired because they
can strike and maintain a stable arc with relative case. They zirconia added tungsten electrodes are
better than pure tungsten but inferior to thoriated tungsten electrodes
A typical tungsten inert gas welding setup is shown in fig: 14.1. it consists of a
welding torch at the centre of which of which, is the tungsten electrode. The inert gas is
supplied to the welding zone through the annular path surrounding the tungsten electrode to
effectively displace the atmosphere around the weld puddle. The smaller weld torches may not
be provided with any cooling devices for the electrodes, as in fig: 1 but larger ones are
provided with circulated cooling water.
The TIG welding process can be used for the joining of a number of materials
though the most common ones are aluminium, magnesium and stainless steel. The typical
combination of TIG set ups to be used with these and other metals are presented in table 1
MATERIAL ELECTRODES POWERSUPPLY USED PREFERRED
SHIELDING GAS
Aluminium All types AC ARGON
Stainless steel Thoriated tungsten DECEN ARGON
Magnesium Tungsten AC ARGON
Deoxidized copper, Thoriated tungsten DECEN ARGON
monel high carbon steel
Cast iron Thoriated tungsten AC or DCEN ARGON

TABLE: 1
PROCEDURE:

1. Given two ms plates are filled at an angle of 45 degrees at the surfaces to be joined.
2. Beads on plates are laid on given plates by using various currents by selecting at least 5
current values.
3. After welding the beads are cross sectioned and polished, etched with two percent initial
solution.
4. Now the beads are viewed under the microscope of magnification factor x 10 to
observe heat effected zone.
5. The strength of weld joints is found using a tensile testing machine.
6. The observation are recorded in tabular column and plotted for analysis.

RESULT:
Viva questions

1. Explain MIG and TIG?

____________________________________________________________________

_____________________________________________________________________

____________________________________________________________

2. Explain SAW?

____________________________________________________________________

_____________________________________________________________________

____________________________________________________________

3. Define heat affected zone?

____________________________________________________________________

_____________________________________________________________________

____________________________________________________________

4. What is tack weld?

____________________________________________________________________

_____________________________________________________________________

____________________________________________________________

5. What gas is used in TIG welding?

____________________________________________________________________

_____________________________________________________________________

____________________________________________________________
 9. PLASMA ARC WELDING
AIM: To study the features of plasma arc welding machine and conduct experiment on the given
specimen (stainless Steel specimens preferably) of thickness 6mm

EQUIPMENT: Plasma welding equipment set, specimen for doing the job and cleaning
materials

THEORTY: Working Principle of PAM

In this process gases are heated and charged to plasma state. Plasma state is the superheated and
electrically ionized gases at approximately 5000oC. These gases are directed on the work piece in the
form of high velocity stream. Working principle and process details are shown in Figure below

Work piece Nozzle

(anode) Machining zone

Flow of gases

Tungsten electrode (cathode) - ve Work

piece + ve

Dc power Supply

Process Details of PAM

Plasma Gun

Gases are used to create plasma like, nitrogen, argon, hydrogen or mixture of these gases. The plasma
gun consists of a tungsten electrode fitted in the chamber. The electrode is given negative polarity and
nozzle of the gun is given positive polarity. Supply of gases is maintained into the gun. A strong arc is
established between the two terminals anode and cathode. There is a collision between molecules of
gas and electrons of the established arc. As a result of this collision gas molecules get ionized and heat
is evolved. This hot and ionized gas called plasma is directed to the work piece with high velocity. The
established arc is controlled by the supply rate of gases.
Power Supply and Terminals
Power supply (DC) is used to develop two terminals in the plasma gun. A tungsten electrode is
inserted to the gun and made cathode and nozzle of the gun is made anode. Heavy potential difference

38
 is applied across the electrodes to develop plasma state of gases.
Cooling Mechanism
As we know that hot gases continuously comes out of nozzle so there are chances of its overheating. A
water jacket is used to surround the nozzle to avoid its overheating.
Tooling
There is no direct visible tool used in PAM. Focused spray of ho0t, plasma state gases works as a
cutting tool.
Work piece
Work piece of different materials can be processed by PAM process. These materials are aluminium,
magnesium, stainless steels and carbon and alloy steels. All those material which can be processed by
LBM can also be processed by PAM process.
Applications of PAM
The chief application of this process is profile cutting as controlling movement of spray focus point is
easy in case of PAM process. This is also recommended for smaller machining of difficult to
machining materials.
Advantages of PAM Process
Advantages of PAM are given below:
(a) It gives faster production rate.
(b)Very hard and brittle metals can be machined.
(c) Small cavities can be machined with good dimensional accuracy.

Disadvantages of PAM Process

(a) Its initial cost is very high.
(b) The process requires over safety precautions which further enhance the initial cost of the
setup.
(c) Some of the work piece materials are very much prone to metallurgical changes on excessive
heating so this fact imposes limitations to this process.
(d)It is uneconomical for bigger cavities to be machined

What is Plasma?
Plasma can be defined as a partially or wholly ionized gas with a roughly equal number of positively
and negatively charged particles. Some scientists have dubbed plasma the “fourth state of matter”
because while plasma is neither gas nor liquid, its properties are similar to those of both gases and
liquids.
There are two types of plasma – high temperature and low temperature. A good example of naturally
occurring high temperature plasma is lightning. This type of plasma can be artificially generated using a
high voltage, high temperature arc, which is the basis for the corona discharge process and for the
plasma torch used to vaporize and redeposit metals.

Low temperature plasmas, used in surface modification and organic cleaning, are ionized gases
generated at pressures between 0.1 and 2 torr. These types of plasmas work within a vacuum chamber
where atmospheric gases have been evacuated typically below 0.1 torr. Low pressure allows for a
relatively long free path of accelerated electrons and ions. Since the ions and neutral particles are at or
near ambient temperatures and the long free path of electrons, which
are at high temperature or electron volt levels, have relatively few collisions with molecules at this
pressure the reaction remains at low temperature.

39
 Types of arcs

Working principle of Plasma Arc Welding:

The Plasma arc welding consists of a conventional DC power source. The ampere rating of these
machines is generally higher. The plasma arc welding process is started by initiating a low current
pilot arc between the electrode and the constricting arc. This ionizes the plasma gas flowing through
the nozzle. The high temperature of the plasma gas provides a low resistance path to start an arc
between the electrode and the work piece.

The plasma gas introduced surrounding the electrode in the plasma torch serves to shield the body of
the torch from the extreme heat of the cathode. Cathodes are not affected by gas or mixture of gas
other than Argon or Argon hydrogen mixture. Because of its low pressure the plasma gas cannot
provide enough shielding to protect the weld.

Therefore a large volume of an inert shielding gas is supplied through the outer gas nozzle
surrounding the inner nozzle. The inert gas supplied is: Argon, Helium, or mixture of hydrogen.

Equipment:

1. Power supply

2. High frequency generator and current limiting resistors

40
3. Plasma torch

4. Shielding gas or inert gas

5. Voltage control

6. Current and gas decay control

7. Fixture (for clamping work piece)

Advantages of Plasma Arc Welding:

1. Making manual welding is easier in PAW

2. The process provides a complete penetration on a single pass (about 6 mm thickness for butt
weld). So welding is faster and saving cost and time.

3. The heat affected zone is smaller and the shape of the welds is more desirable.

4. It has a parallel welds and it won’t scatter.

5. The plasma arc is more stable and the process is able to join practically all the commercially
available metals

6. Greater distance between the electrode tip and the work piece facilitates easy application of
filler metal rod without contamination of the electrode

7. Filler metal required is lesser in plasma arc welding because lesser number of runs needed to
complete the weld.
Disadvantages of Plasma Arc Welding:

1. Infra-red and ultraviolet radiations make it necessary to provide – special protection devices

2. Higher equipment cost

3. Need to frequently replace the nozzle surrounding the electrode

4. Welders need ear plugs because of unpleasant, disturbing and damaging noise

41
 5. More chances of electrical hazards are associated with this process

6. The process is limited to metal thickness of 25 mm and lower for Butt weld
PAW or Plasma arc welding (PAW) is where the joining of metals or coalescence takes place by
heating with a constricted arc between the work piece (transfer arc) and an electrode or the
constricting nozzle and the electrode (non-transfer arc).

Narrow and deep welds can be made using this process at high welding speeds.

The way shielding occurs is related to the hot ionized gas that issues from the orifice. It can also be
supplemented by another source of shielding gas. The shielding gas can be a mixture of gases or an
inert gas. Pressure can be used (or not used). You can also supply or not supply a filler metal.

The objective of the plasma arc welding process is to increase the energy level of the arc plasma in a
controlled manner. It is achieved by providing a special gas nozzle around a tungsten electrode
operating on a DCEN power source. The constricted plasma formed is concentrated and highly
ionized.

The process is detailed in the diagram below

Experimental procedure:

1. The student has to take all the instructions from lab assistant/in charge
2. Check all the connections are made as per standard practice
3. Keep the drawing of work pieces to be welded handy
4. Collect the work pieces from lab assistant
5. Prepare the edges for obtaining correct weld on the job
6. Wear the safety gear
7. Avoid touching the electrical connections during the experiment
8. Follow the below guide lines personally
• Connect the torch to power supply
• The torch acts as anode and work piece as cathode
• Fix the electrode (filler metal ) holder to power supply
• Press the start button slowly allow the torch to produce arc between cathode and anode
• In mode one the power supply switches automatically to the desired voltage
• Direct the arc towards work pieces to be joined along with electrode holder (filler metal
)see the filler metal is inserted in the electrode holder
• Conduct the experiment that is joining of work pieces by moving electrode slowly to get
good welding

42
 • After the completion of experiment dip the torch in water to bring down temperature of
torch to room temperature
• Colour code for connections: black for phase, neutral for white , yellow for ground

Precautions:

Please ware the safety gear. Protect eyes from plasma arc by wearing goggles
Conduct the experiment in presence of lab instructor/in-charge only.
Switch of all the power supply after the experiment TESTING OF WELDS

Result:

Viva Questions:

1. What do you mean by plasma?

____________________________________________________________________

_____________________________________________________________________

____________________________________________________________
2. How many types of plasma torches are used?
____________________________________________________________________

_____________________________________________________________________

____________________________________________________________
3. What gas is used in plasma arc welding?
____________________________________________________________________

_____________________________________________________________________

____________________________________________________________
4. What is the temperature obtained with plasma arc welding?
____________________________________________________________________

_____________________________________________________________________

____________________________________________________________
5. Explain the use of water plasma for cutting?
____________________________________________________________________

_____________________________________________________________________

43
 10.BRAZING
Aim: To make brazed joint on the two given sheets.

Equipment: Oxygen Cylinder, Acetylene Tank, Brazing Torch, Brazing rod and fluxes.

Theory: Brazing is a metal joining process in which two or more metal items are joined together by
melting and flowing a filler metal into the joint, the filler metal having a lower melting point than the
adjoining metal. Brazing differs from welding in that it does not involve melting the work pieces and
from soldering in using higher temperatures for a similar process. The filler metal flows into the gap
between close-fitting parts by capillary action. The filler metal is brought slightly above its melting
(liquids) temperature while protected by a suitable atmosphere, usually a flux.. It then flows over the
base metal (known as wetting) and is then cooled to join the work pieces together. It is similar to
soldering, except the temperatures used to melt the filler metal are higher for brazing. A major
advantage of brazing is the ability to join the same or different metals with a considerable strength.

Brazing, which utilises a wide variety of heat sources, is often classified by the heating method used.
To achieve brazing temperature, some methods heat locally (only the joint area), others heat the entire
assembly (diffuse heating). The type of brazing method used here is torch brazing to join two sheets.

Torchbrazing
In this method, the heat required to melt and flow filler metal is supplied by a fuel gas flame. The
fuel gas can be acetylene, hydrogen, or propane and is combined with oxygen or air to form a flame.
This process is readily automated and requires low capital investment. Torch brazing requires the use
of a flux, so a post-braze clean is often required.

Procedure:

1. It must be ensured that the proper clearance and fit is to be maintained between two base
metals.
2. The metals to be cleaned properly before brazing

3. Release of gases through cylinders like oxygen and acetylene

4. Adjust the flame in nozzle of Gas torch.

5. Arrangement of flux before brazing process begins.

6. A fixture is to be arranged for correct brazing

7. Brazing process starts

8. Cleaning of the new brazed joint

44
Precautions:

1. Before handling the gases, see that there is no leakage from all the cylinders

2. Safety goggles are to be used for doing brazing

3. After completion of brazing, the entire cylinder valves to be closed.

Result:

Viva Questions:

1. State the function of flux in brazing?

2. What is the difference between brazing and soldering?

3. What are the different types of soldering methods?

4. The filler metal employed in brazing is

5. Melting point of solder is in the range of

45
 PRESS WORKINGOPERATIONS

10. FLY SCREW PRESS

Aim: To make blanking and piercing operations on a given work piece.

Apparatus:
Fly screw press, work piece.

Description:
Press work is defined as a method of mass production involving the cold working of metals
usually in form of thin sheet (or) strip. This makes use of large forces by press tools for a short time
interval which results in cutting (or) shaping the sheet metal.

Figure (1) shows a fly press and its different parts.

1. A RAM (or) SLIDE which has a punch fitted at its bottom moves up and down and is
powered from a crank (or) eccentric driver by an electric derive motor.
2. FLY WHEEL stores energy and delivers it at the working stroke.
3. PUNCH will do the necessary operation during the downward stroke of the Ram.
4. DIE will hole the work piece and produce finished work piece. Die is of progressive type
which is than in Fig(2).
5. A progressive die is a multi station die which perform number of sheet metal
operations at two (or ) more stations during each stroke of the press.

Theory:
Blanking is defined as the operation of producing cutout blanks. Cutout blank is required portion
where as the remaining part is scrap. Piercing is defined as production of cutting holes on already
cutout blanks in this operation. Hole is the required portion and remaining portion of this operation is
shown in fig. 2

Procedure:
1) Keep the work piece in the first work station and at progressive die.
2) Operate fly wheel so that the ram pushed the punch in forward direction.
3) Operate blanking punch to cut the blanks at first work station.
4) After the blank is cutout more the work piece to next work station.
5) Then operate punching on piercing porch to cut the holes.
6) Remove the finished work piece from the die.

46
Precautions:
Operate fly wheel in such a way that the material should not cling to punch and carried way along
with the porch.

Result:

Viva Questions:

a. Plastic deformation in metals is achieved by?

b. What is recovery, recrystallisation and grain growth?

c. What is the difference between hot working and cold working process?

d. What is the effect of hot rolling on grain structure?

e. What is strain hardening?

47
 11. HYDRAULIC PRESS
Aim:
To make mosquito coil stand/washer/lid using Hydraulic press.

Equipment:
Hydraulic press, compound die, progressive die, deep drawing die.

RAW MATERIALS:
Mild steel: CR-SHEET T.K. (0.4) mm.

Description of the equipment:

Presses are classified in various ways. They may be classified according to

i) Source of power
ii) Method of actuation of the rams (slides)
iii) Number of Slides
iv) Types of frames
v) The type of work for which the press has been designed.

Source of power:

Two kinds of sources of power supply to the ram: Mechanical and Hydraulic.

Mechanical presses, the energy of fly wheel is utilized which is transmitted to the work piece
by gears, cranks, eccentrics or levers.

The fly wheel rotates freely on the crank shaft and is driven from an electric motor through
gears or V-Belts. The motor runs continuously and stores energy in the fly wheel. When the operator
presses a foot treadle or actuates a button, the clutch gets engages and the fly wheel is connected to
the crank shaft. Drive shaft starts rotating and the stored up energy in the fly wheel is transmitted to
the ram on its downward stroke. The clutch to engage and disengaged the fly wheel to the drive shaft
can be; a jaw clutch and the air operated clutch or an electromagnetic clutch. In manually operated
mechanical presses, the clutch is disengaged to each cycle. But in automatic presses in which the
metal strip is fed to the die automatically, there is no need of single stroke clutch, disengaging
mechanism and the ram moves up and down continuously. These presses can be classified as plain
and geared press, the fly wheel is carried on an auxiliary shaft which is connected to the main shaft.
Through one or more gear reduction, depending upon size and energy needed. In this arrangement,
the fly wheel stores considerably more energy than the plain as its speed is higher than the main
drive shaft.
In Hydraulic press, the ram is actuated by oil pressure on a piston in a cylinder.
Mechanical presses have following advantages over the hydraulic presses.

1. Run faster
2. Lower maintenance cost.

48
 3. Lower capital cost.

Advantages of hydraulic presses are:

1. More versatile and easier to operate

2. Tonnage adjustable of zero to maximum
3. Constant pressure can be maintained throughout the stroke.
4. Force and speed can be adjusted throughout the stroke.
5. Safe as it will stop at a pressure setting.
6. The main disadvantages of hydraulic press are that it is slower than a mechanical press.

A press is rated in tones of force; it is able to apply without under strain. To keep the deflections
small, it is a usual practice to choose a press rated 50 to 100 % higher than the force required for an
operation.

Procedure:

1. Set the compound die or progressive die or deep drawing die in the required position.
2. Switch on the motor to start the machine.
3. Press the MS sheet into the progressive die / compound die. In case of deep drawing.
4. Apply injection pressure using direction control valve.
5. The plunger punches the sheet into the mosquito coil stand / washer lid shape.
6. Release injection pressure.
7. Take out the finished product from the die.
8. Switch off the motor.

Precautions:

1. Do not apply too high injection pressure

2. Proper lubrication must be done between moving parts of die and press.
3. Operate the hydraulic press carefully.

49
Result:

Viva Questions:

a. Differentiate between blanking and piercing?

b. What do you mean by deep drawing?

c. What is forming limit diagram?

d. What are the different types of dies used in press tools?

e. What is the purpose of drawing?

50
 PROCESSING OF PLASTICS
General:

Plastics belong to the family of organic materials. Organic materials are those materials which are
directly from carbon. They consist of carbon chemically combined with hydrogen, oxygen and other
non-metallic substances, and their Structure, in most cases, are fairly complex. The large and diverse
organic group Includes the natural materials: wood, coal, petroleum, natural rubber, animals fibers and
food, which have biological origins. Synthetics include theY are group of solvent, adhesive, synthetic
fibers, rubber, plastics, explosive, Lubricants, dyes, soaps and cutting oils etc. which have no biological
origins. Of them, plastics and synthetic rubber are termed as “polymer”

Polymers

The team “polymer” is the derived from the two Greek words: poly, meaning “many”, and
meros meaning “parts” or “units”. Thus polymers are composed of a large number of repeating units
(small molecules) Called monomers. The monomers are joining together end- to-end in a
polymerization reaction. A polymer is, therefore , made up of thousands of monomers jointed together
to form a large molecule of colloidal dimensions are called macromolecule. The unique characteristics
of a polymer is that each molecule is either a long chain or a network of repeating unit all covalently
bounded together. polymers are molecular materials and are generally non crystalline soilds at
originary temperature, but pass through a viscous stage in course of their formation when, shaping is
readily carried out.

The most common polymers are those made from compounds of carbon, but Polymers can also
be made from inorganic chemicals such as silicates and silicones.

The naturally occuring polymers include: protein, cellulose, resins, starch, Shellac and lignin.
They are commonly found in leather, fur, wool, cotton, silk, rubber, Rope, wood and many others.
There are also synthetic polymers such as polyethylene, polystyrene, nylon, terylene, dacron etc.,
termed under plastics fibers and elastomers. Their properties are superior to those of the naturally
occuring counterparts.

Polymerization

The process of linking together of monomers, that is, of obtaining macromolecules is called
“polymerization”.

Plastics

Polymers can be divided into three broad divisions: plastics, fibers and elastomers.

(Polymers of high elasticity , for example, rubber) .synthetic resins are usually referred to as plastics.
Plastics derive their name from the fact that in a certain phase of their manufacture, they are present
in a plastic stage (that is, acquire plasticity), which makes it possible to imparts any desired shape to
the product

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Plastics fall into a category known chemically as high polymers.

Thus, “plastics” is a team applied to compositions consisting of a mixture of high molecular

compounds (synthetic polymer) and fillers, plasticizers, stains and pigments, lubricating and other
substance. Some of the plastics can contain nothing but resin (for instance, polyethylene, polystyrene).

Type of plastics

Plastics are classified on the broad basis of whether heat causes them to set (thermosetting) or causes
them to soften and melt (thermoplastic).

1. Thermosetting plastics:
These plastics under go a number of chemical changes on heating and cure to infusible and
practically insoluble articles. The chemical change is not reversible thermosetting plastics do
not soften on reheating and can be reworked. They rather become harder due to completion of
any left-over
polymerization reaction. Eventually, at high temperatures, the useful properties of the
plastics get destroyed. This is called degradation. The commonest thermosetting plastics are:
alkyds, epoxids, melamines, polyesters, phenolics, and ureas.
2. Thermoplastic plastics:
There plastics soften under heat, harden on cooling, and can be resoftened under heat. Thus
they retain their fusibility, solubility and capability of being repeatedly shaped. The
mechanical properties of these plastics are rather sensitive to temperature and to sunlight and
exposure to temperature may cause thermal degradation. Common thermoplastic plastics are :
acrylics, poly tetra fluoro ethylene (PTFE), polyvinyl chloride (PVC), nylons, polyethylene,
polypropylene, etc.
Thermosetting plastics are cross-linked polymers and the thermo-plastics are linear
and branched-linear polymers. The method of processing a plastics is determined largely by
whether a plastic is thermosetting or thermoplastic.

Properties of plastic:
Their great variety of physico-chemical and mechanism properties, and the ease with which
they can be made into various articles have found plastic their wide application in the engineering
and other industries.
1. Their comparatively low density (1 to 2 g/cm^3), substantial mechanical strength
higher strength –to-weight ratio and high anti friction properties have enabled pastics
to efficiently used as substitute for metals, for example, non- ferrous metals and
alloys-bronze, babbit etc., for making bearing.
2. With certain special properties (silent operation, corrosion resistance etc.), plastic
sometimes replace ferrous metals.
3. From the production point of view, their main advantage is their relatively low melts
points and their ability to flow into a mould.
4. Simple processing to obtain machine parts. Generally there is only one product
operation required to convert the chemically manufactured plastic intlo a finished
article.

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5. In mass production, plastics substituted for ferrous metals allow the production cost
be reduced by fractor of 1.5 to 3.5 and for non-ferros metals by a fractor of 5 to 20.
6. Good damping capacity and good surface finish of the product.
7. The high heat and electric insulation of plastic prmits them to be applied and
electrical engineering industries as dielectrics and as substituts for porcelain, ebonite,
mica, natural rubber, etc.
8. Their good chemical stability, when subjected to the action of solvents and
ceroxidizing agents, water resistance, gas and steam-proof properties, enable pastics
to be used as valuable engineering materials in the automobile and tractor, ship
building and other industries.

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 12. INJECTION MOULDING
Aim:
To prepare a plastic product using injection moulding machine.

Equipment:
Injection Moulding Machine

Material Required:

High grade Poly ethylene

Description of The Equipment:

Hydraulic Plastic Injection Moulding machine, Model JIM-1HD has been designed for
moulding variety components upto 45 Gms capacity in polystyrene. The machine is robustly built to
ensure consistent high quality and volume production of precision components. Operator fatigue due
to injection process is completely eliminated by use of hydraulic power for both the injection and
releases operations.

Locking Unit:

This locking is made by hydraulic cylinder.

Injection Unit:

Injection Unit consists of two guide rods, nuts, top and bottom plates with injection
cylinder and barrel. Injection cylinder is designed to develop 3 Tons load. Barrel diameter 30 mm is
attached with the machine as standard.

Hydraulics:

Hydraulic pump is driven by 3 HP Induction motor for a rated delivery of 14 lp, at

1440 rpm and at 80 kg/cm2. The maximum pressure in the hydraulic system is present in our works
and is not to be altered. The oil tank capacity is 60 litres. All hydraulic system manufacturers safety
precautions are provided to hydraulic system by using section strainer, which will prevent the
contamination entering into the system.

Oil Cooler:

Oil cooler provided to keep the oil temperatures below 50oC which will give more
life to hydraulic oil in continuous use.

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Electricals: Electrical control panel with automatic blind temperature controller is fixed on the right
hand side of the machine for clear viewing of the temperature and for easy to operate the switches.
Designed with safety measure, which will protect the motor from over load.

Working Procedures:

Injection Moulding makes use of heat softening characteristics of thermo plastic materials.
These materials soften when heated and re harden when cooled. No chemical change takes place when
the material is heated or cool. For this rason the softening and rehardening cycle can be repeated any
no. of times.

1. The granular moulding material is loaded hopper where it is metered out in a heating cylinder
by a feeding device.
2. The exact amount of material is delivered to a cylinder, which is required to fill the mould
completely.
3. Set the die in position Provide spacing plates if necessary. Clamping the Die using
hydraulic operate ram.
4. Set the injection pressure by rotating (clockwise) the regulator knob to suit the
requirement of moulding the container.
5. Switch on the heater. Set the required timings to the timers, for top and middle.

Heater, Set the temperature by adjusting automatic temperature controller to control the bottom heater.
Allow sufficient time to stabilizer. When temperature reached, operate the hand lever valve to inject the
material.

Precautions:
1. Apply injection pressure on the heated material using plunger rod.
2. The injection ram pushes the material into the heating cylinder and in doing so pushes a small
amount of heated material out of the other end of the cylinder through the nozzle and screw
bushing and into the cavity of closed mould.

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 3. The material is cooled in a rigid state in the mould.
4. Release the injection pressure. In clamp the Die suing hydraulic operated ram.
5. The mould is then opened and piece is ejected out.

Result:

Viva Questions:

1. What are the advantages of plastics over other materials?

2. What is the difference between thermo plastics and thermo-setting plastics?

3. What is injection moulding?

4. What are the different additive agents in plastics?

5. How are plastics extruded?

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 13. BLOW MOULDING
Aim: To prepare a bottle of 200ml using blow mouling machine

Equipment: Blow moulding machine.

Operating instruction:

a) Install the machine on leveled strong flooring near the compressor (within 2 meters)
b) The machine must be placed in a positive where all parts are accessible readily.
c) Check for loose any loose electrical connection with the help of certified electrician and
with the electrical circuit enclosed.
d) Fill the lubricator with SAE 20 grade oil to the level indicated. The lubrication has been set to
allow one drop of oil for every 5 strokes of air cylinder (oil) drop is factory set, no need to
adjust.
e) Connect the air filter to the compressor by rubber/nylon hose (Min inside dia 10mm), pressure
with standing capacity 20kg/cm^2
f) Set the pressure switch in the compressor as per the compressor manual to switch on 7
kg/cm^2 pressure & switch off at 10kg/cm^2 (NOTE: The air pressure should not exceed
10cm^2).
g) Set air pressure in machine by adjusting the injection & release regular (18).
h) Set release pressure 2kg/cm^2 by adjusting release regulator.
i) Operate the hand lever valve (13) and check for smooth functioning of plunger.
j) Set the blow pressure in regulator (15) and operate the hand lever valve (14) to check flow of
air throw blow nozzle.
k) Eletrical connection should be given as indicated on the main plug phase, neutral and
earth.
l) Proper earting should be done.
m) Check the incoming voltage (230VAC, 50Hz) now the machine is ready for operation.

Working principle: The process is applied to only thermo plastics, which are used for producing
hollow objects such as bottle, and flow table objects by applying air pressure to the sheet material
when it is in heated and in soft pliable condition. Blow moulding can be accomplished in two
manners, one is direct blow

moulding and other indirect blow mouling.in the former case, a measured amount of material in form
of tube is either injected or extruded in a split cavity die. The split mould is closed around the tube,
sealing off the lower end. The air under pressure is blow into the
tube, which causes the tube to expand to the walls of cavity. In the latter case, a uniformly softened sheet
material by heat is clamped at the edges between the die and cover, which causes the sheet to attain a
hemispherical shape or the configuration of mould whatever it may be parts obtained by indirect blow
moulding have excellent appearance but they are more costly as only to percent of the sheet stock is
utilized and also there is a tendency for excessive thinning of sheet at the deepest point.

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Procedure:

1) Set the die in position. Adjust the guide rod nuts to suit die height. Align the tapered face of
the die for sealing the parison while blowing also checks for the face opening and closing of
the die.
2) Ensure minimum die height is 80mm. provide spacing plates if necessary.
3) Set the injection, release and blow pressure by rotating (clock wise) the regulator knob
to suit the requirement of moulding the container.
4) Feed correct quantity & quality of plastic material and switch on the power supply.
5) Switch on the heater.
6) Set the requred timings controller to control the bottom heater.
7) Allow sufficient time to stabilizer.
8) When temperature reached, operate the hand level valve.
9) Extrude the parison (Tubular form) to the required length and close the two die halves
release the injection cyclinder.
10) Operate the hand lever valve and blow the air so that the parison to form the shape of the
container as designed in the die.
11) Allow the component to cool.
12) Open the die & take the product of the die.
13) Now the machine is ready for nest cycle.

Result:

Viva Questions:

1. What do you mean by blow moulding?

2. Can plastics be welded?

3. What are the different types of blow moulding?

4. What is the air pressure required in blow moulding?

5. What is the temperature required to melt the plastic in blow moulding process?

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 LEAD EXPERIMENT
Manufacturing of 24 teeth aluminum gear using modeling/casing methodology
Aim: The aim of the Lead Experiment is to manufacture 24 teeth Aluminum Gear using Moulding
/Casting Methodology.

Apparatus: Moulding Sand Testing Equipment, Permeability Tester, Hardness equipment, Melting
Furnace, Pattern Making Tools, Casting dies, wood turning lathe, gear driven or belt driven lathe.
Materials Required: Moulding Sand, Bentonite Powder, Clay, Water, Aluminum Ingot material,
Wood Pattern material

Description of the Process:

The process is used to make a gear having 24 teeth suitable to petrol engine or Diesel engine. This
gear making involves the operation start with sand preparation. It is followed by Sand testing and
hardness testing. This sand is mixed with different ingredients like clay, bentonite and other
materials in order make mould for gear making. This mould cavity is used for aluminum melt which
comes from Melting furnace. This gear will be sent for machining process.
Operation of the Process:

First the gear material is selected and pattern is made using wood turning lathe after calculating
pattern allowances.
After the pattern is prepared, then it must be rammed with the moulding sand which is already
prepared and tested.
After ramming is over, mould cavity is made using different pattern making tools.
Then melting furnace is made ready with pre maintenance is completed.
This furnace is pre heated and it is ready for melting aluminum material
Once the melting process is over after 4 hours, the liquid is poured into casting dies for making cast
objects.
This liquid is poured directly into mould cavity suitable for gear making process.
This gear casting is allowed for solidification to about 2 hours.
Once solidified, gear will be sent for final machining process to remove risers and runners.

Result: The Final Component of Gear is ready for inspection.

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