RUNGTA COLLEGE OF ENGINEERING & TECHNOLOGY(R1), BHILAI-RAIPUR, C.G.

RUNGTA COLLEGE OF ENGINEERING & TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING

LAB MANUAL

Manufacturing Science Lab

SEMESTER 4th

RUNGTA COLLEGE

Prepared By
Dr. Sameer Singh
Assistant Professor

RCET(R1), BHILAI-RAIPUR, C.G. DEPARTMENT OF MECHANICAL ENGINEERINGPage 1

RUNGTA COLLEGE OF ENGINEERING & TECHNOLOGY (R1), BHILAI-RAIPUR, C.G.
RUNGTA COLLEGE OF ENGINEERING & TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING

LAB MANUAL

Manufacturing Science Lab

SEMESTER 4th

PREPARED AS PER THE SYLLABUS PRESCRIBED BY

CHHATTISGARH SWAMI VIVEKANAND TECHNICAL UNIVERSITY,

BHILAI

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RUNGTA COLLEGE OF ENGINEERING & TECHNOLOGY (R1), BHILAI-RAIPUR, C.G.
List of DOs & DON’Ts

DOs:

 For any abnormal working of the machine consult the Faculty In-charge/Lab
Assistant.
 Shut down the machine and switch off the power supply after performing the
experiment.
 Maintain silence and proper discipline in the lab.
 Enter your machine number in the Login register.

DON’Ts :

 Do not eat or drink anything in the lab.

 Do not tamper the instruments in the Lab and do not disturb their settings.

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RUNGTA COLLEGE OF ENGINEERING & TECHNOLOGY (R1), BHILAI-RAIPUR, C.G.
LIST OF EXPERIMENTS
AS PER THE SYLLABUS PRESCRIBED BY THE UNIVERSITY

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RUNGTA COLLEGE OF ENGINEERING & TECHNOLOGY (R1), BHILAI-RAIPUR, C.G.
LIST OF EXPERIMENTS
AS PER RUNGTA COLLEGE OF ENGINEERING & TECHNOLOGY
(MINIMUM 10% MORE THAN THE PRESCRIBED SYLLABUS)

Exp. Name of Experiment Pg. No.

No.
1 Moulding of a multi-piece pattern by green sand moulding.

2 Making a Mould with core and casting

3 Taper turning in a Lathe

4 Thread cutting in Lathe

5 Alignment testing of Lathe

6 Drilling, boring and reaming of a hole.

7 Study of turning tool of Lathe

8 Joining MS plates by arc welding (SMAW,MIG)

9 Joining metal sheet by resistance welding

10 Inspection of casting defect and welding defects

Course Outcomes:
On successful completion of the course, the student will be able to:

1. Demonstrate the use of green sand molding process for casting.

2. Demonstrate the use of various machine tools for important machining operations.
3. Explain the tool geometry of single point cutting tool and twist drill.
4. Explain the practicability of various metal joining processes like arc welding, resistance
welding, soldering and brazing.
5. Obtain practical skills in inspection and testing of casting and welding defects.

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RUNGTA COLLEGE OF ENGINEERING & TECHNOLOGY (R1), BHILAI-RAIPUR, C.G.
Experiment No. 1
Aim: Moulding of a multi-piece pattern by green sand
moulding.
Material Required: Moulding sand

TOOLS REQUIRED: Pattern, Shovel, Riddle, Rammer, Trowel, Slick, Lifter, Strike – Off bar, draw – spike, Mallet,
Moulding Boxes, Vent rod, Runner, Riser, and Swab.

THEORY: MOULDING SAND: The principal material used in the foundry shop for moulding is the sand. This is
because it possesses the properties vital for foundry purposes. Sources: All sands are formed by the breaking up of
rocks due to the action of natural sources such as frost, wind, rain, heat and water currents. Rocks however are very
complex in their composition and sands contain most of the elements of the rocks of which they fragment. For this
reason, sands in different parts of the world vary considerably. Today, sand is obtained from places which probably
once were bottoms and banks of rivers and sand dunes. PRINCIPAL INGREDIENTS: The principal ingredients of
moulding of sands are:

1. Silica sand grains

2. Clay

3. Moisture and

4. Miscellaneous materials

Silica in the form of granular quartz, itself sand is the chief constituent of moulding sand. Silica sand contains from 80
to 90 percent silicon dioxide and is characterized by a high softening temperature and decomposition of granite,
which is composed of feldspar and quartz. The feldspar, when decomposed, becomes clay (hydrous aluminium
silicate). However, silica sand grains impart refractoriness, chemical resistivity, and permeability to the sand. They
are specified according to their average size and shape. Clay is defined as those particles of sand (under 20 microns
in diameter) that fail to settle at a rate of 25mm per minute, when suspended in water. Clay consists of two
ingredients: fine silt and true clay. Fine silt is a sort of foreign matter or mineral deposit and has no bonding power. It
is the true clay which imparts the necessary bonding strength to the mould sand, so that the mould does not lose its
shape after ramming. True clay is found to be made up of extremely minute aggregates of crystalline, usually flake-
shaped, particles called clay minerals. Most moulding sands for different grades of work contain 5-20 percent clay.
Moisture, in requisite amount furnishes the bonding action of clay; it penetrates the mixture and forms a microfilm
which coats the surface of flake-shaped clay particles. The bonding quality of clay depends on the maximum
thickness of water film it can maintain The bonding action is considered best if the water added is the exact quantity
to form the film.

On the other hand the bonding action is reduced

and the mould gets weakened if the water is in
excess. The water should be between 2-8percent.
Miscellaneous materials that are found in addition
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RUNGTA COLLEGE OF ENGINEERING & TECHNOLOGY (R1), BHILAI-RAIPUR, C.G.
to silica and clay, in mouding sand are oxide of iron,
limestone, magnesia, soda, and potash .The
impurities should be below 2 percent. Gating
system: Gating system refers to all those elements
which are connected with the flow of molten metal
from the ladle to the mould cavity. The various
elements that are connected with a gating system
are:
1. Pouring basin
2. Sprue
3. Sprue base well
4. Runner
5. Runner extension
6. Ingate
7. Riser
Gates: Also called the ingates, these are the
openings through which the molten metal enters
the mould cavity. Depending on the application,
various types of gates are used in the casting design.
They are:
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RUNGTA COLLEGE OF ENGINEERING & TECHNOLOGY (R1), BHILAI-RAIPUR, C.G.
1. Top Gate
2. Bottom Gate
3. Parting Gate
Top Gate: This is the type of gating through which
the molten metal enters the mould cavity from the
top as shown in fig. since the first metal entering
the gate reaches the bottom and hotter metal is at
the top, a favorable temperature gradient towards
the gate is achieved. Also the mould is filled very
quickly. But as the metal falls directly into the
mould cavity through a height, it is likely to cause
mould erosion. Also because it causes turbulence in
the mould cavity it is prone to form dross and as
such top gate is not advisable for those materials
which are likely to form excessive dross. It is not
suggested for non – ferrous alloys and is suggested
only for ferrous alloys. It is suitable only for simple
casting shapes which are essentially shallow in
nature.

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RUNGTA COLLEGE OF ENGINEERING & TECHNOLOGY (R1), BHILAI-RAIPUR, C.G.

Bottom Gate: When molten metal enters the

mould cavity slowly as shown in fig., it would not
cause any mould erosion. Bottom gate is generally
used for very deep moulds. It takes higher time for
filling the mould and also generates a very
unfavorable temperature gradient.

PROCEDURE:
1. First the pattern is placed with its larger
diameter side is on a mould board.
2. The drag section of the flask is set over the
pattern on same board.
3. After powdering the pattern with
lycopodium, talc or graphite, a 15 to 20
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RUNGTA COLLEGE OF ENGINEERING & TECHNOLOGY (R1), BHILAI-RAIPUR, C.G.
mm layer of facing sand is riddled over the
pattern.
4. The drag is then filled by layers of green
sand mixture from 70 to 100 mm thick,
compacting each layer with rammer.
5. The top of the mould is rammed with the
butt end of a rammer. The object of
ramming the sand is to consolidate it,
thereby preventing the cavity of the mould
from being enlarged by the metal.
6. After the sand is rammed a strickle is used
to scrape off the excess sand level with the
top of the flask.
7. The mould is then vented by sticking it
with a fine stiff wire at numerous places
(The vent holes should not reach the
pattern by 15 to 20 mm as otherwise they
may spoil the mould. Moreover, the metal
may run in to the vent holes during
pouring. These vent holes permit the
escape of gases generated in the mould
when the molten metal comes in contact
with moist sand).
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RUNGTA COLLEGE OF ENGINEERING & TECHNOLOGY (R1), BHILAI-RAIPUR, C.G.
8. A small amount of loose sand is sprinkled
over the mould and bottom board is placed
on the top. The drag is rolled over, the
moulding board is removed, and the upper
surface is sprinkled with parting sand (The
parting sand is used to prevent the joints
between the halves of a mould from
adhering to one another when the two
parts of the moulding box are separated).
9. The cope section of the flask is then
assembled.
10. Tapered wooden pegs to serve as sprue
and riser are placed in proper position as
shown in figure on the pattern which is
riddled over with facing sand and then
cope is filled with green sand.
11. The operation of filling, ramming and
venting of the cope proceed in the same
manner as in the drag.
12. A funnel shaped opening is scooped out at
the top of the sprue to from the pouring
basin.

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RUNGTA COLLEGE OF ENGINEERING & TECHNOLOGY (R1), BHILAI-RAIPUR, C.G.
13. Next the cope is lifted off and placed on a
board with the parting line upward.
14. An iron bar is now pushed down to the
pattern and rapped sideways .So as to
loosen the pattern and prevents any sand
from sticking to the pattern.
15. Next pattern is drawn out using draw
spike.
16. Runners are cut in the cope according to
the dimensions shown in fig.
17. Cut the gates in the drag according to the
dimensions shown ( Use Top Gating
System).
18. If needed all the cavity edges are repaired.
19. Finally the mould is assembled, the cope
being carefully placed on the drag so that
the flask pins fit into the bushes.
20. The mould is then ready for pouring.
21. Molten metal (Aluminium) is prepared in
the high frequency electrical induction
furnace.
22. Take the molten metal from crucible in to
the ladle.
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RUNGTA COLLEGE OF ENGINEERING & TECHNOLOGY (R1), BHILAI-RAIPUR, C.G.
23. Pour the molten metal from the ladle into
the pouring basin so that the molten metal
will enter into the mould cavity through
the sprue, runner and gate.
24. Allow the molten metal to solidify.
25. Then break the mould to obtain desired
casting.
PRECAUTIONS:
1. Care must be taken to have proper alignment
of the pattern as well as moulding boxes.
2. Sand should be rammed properly and evenly.
3. The pattern should be rapped gently and
withdrawn carefully without damaging the
mould cavity.
4. Care should be taken to avoid over cuts and
corners.
5. Care should be taken while pouring the molten
metal in to the cavity.
6.

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RUNGTA COLLEGE OF ENGINEERING & TECHNOLOGY (R1), BHILAI-RAIPUR, C.G.
Experiment No. 2
Aim :

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