LABORATORY MANUAL

MEC 317 MANUFACTURING TECHNOLOGY LABORATORY

TABLE OF CONTENTS

S. No. Title of the Experiment 1 2 3 4 5 6 7 8

Page No. 2 5 8 10 13

Moisture testing of the sand using speedy moisture tester. To prepare the mould and make the Aluminium sand casting Surface finish analysis using different types of moulding sands.
To join the given two work pieces Square butt joint using TIG welding

To join the given two work pieces Tee fillet joint using MIG welding.

Manufacturing of a gear on milling machine and Inspection of PCD, tooth 16 profile and run out of Manufacturing and analyzing a flat surface on surface grinding and shaper 19 machine. 22 To prepare a job as per sketch using Capstan and Turret Lathe Machines.

To Prepare Spur Gear using Milling machine with different indexing methods.

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Foundry Shop
1. Experiment: 1 Moisture testing of the sand using speedy moisture tester Machine/Equipment used:Speedy Moisture testing apparatus Material required:Calcium Carbide 2. Learning Objectives: 1) To practice how to check the moisture percentage of the prepared sand to control the manufacturing process & reduce the casting defects due to variation of moisture. 3. Outlines of the Procedure: 1) Take a batch of prepared green sand. 2) Weigh it with standard weighing scale of the apparatus. 3) Add the measured quantity as per the apparatus. 4) Shake the mixture by making a tight fitting of the apparatus lid & get the reading of the moisture. 4. Required results 1. Analysis of the variation in the moisture percentage in green sand process. 2. Analyzing casting defects produced due to that variation. 5. Cautions: 1. Wear apron, shoes and tight fitted clothes. 2. Be careful and attentive while working on this job. 3. Use proper tools for each operation.
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4. Dont keep any sharp tool in your pocket. 5. Tools being used should be well sharpened. 6. Always use gloves when doing casting 7. Make sure the lid of the moisture teller to be opened slowly & carefully.

Date of Performance

Worksheet of the student

Registration Number:

Aim: Moisture testing of the sand using speedy moisture tester

Learning Outcomes (what I have learnt):

To be filled in by Faculty S.No. 1 Parameter Understanding of the student about the procedure/apparatus. Marks obtained Max. Marks 20

Accuracy level of job dimensions

20

Completion of experiment, Discipline and Cleanliness

10

Signature of Faculty

Total marks obtained 4

1. Experiment: 2 To prepare the mould and make the Aluminium sand casting Machines/Equipments/tools to be used: Tilting pit furnace, Aluminium, Moulding box, shovel, hand rammer, strike off bar, vent wire, trowel, lifter, sprue and flow off pin swab, hand riddle Material Required Moulding sand, silica sand, bentonite, dextrine, soap stone powder, Aluminium scrap 10 kg. 2. Learning Objectives To study the sand casting process to produce complex shaped parts with the low tooling and equipment cost. Scrap can be recycled. 3. Outline of the Procedure: 1. Place a pattern in sand to create a mold. 2. Incorporate a gating system. 3. Remove the pattern. 4. Fill the mold cavity with molten metal. 5. Allow the metal to cool. 6. Break away the sand mold and remove the casting. 4. Scope of results expected: 1. Analysis of the process of aluminium sand casting. 2. Preparing sand mould and hence casting. 3. Investigate the casting defects and suggest the remedial measures. 5. Cautions: 1. Wear apron, shoes and tight fitted clothes. 2. Be careful and attentive while working on this job. 3. Use proper tools for each operation. 4. Dont keep any sharp tool in your pocket. 5. Tools being used should be well sharpened.
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6. Runner and riser should be placed at the right place. 7. Sand should be mixed properly. 8. Always use gloves while doing casting.

Date of Performance

Worksheet of the student

Registration Number:

Aim: To prepare the mould and make the Aluminium sand casting Learning Outcomes (what I have learnt):

To be filled in by Faculty S.No. 1 Parameter Understanding of the student about the procedure/apparatus. Marks obtained Max. Marks 20

Accuracy level of job dimensions

20

Completion of experiment, Discipline and Cleanliness

10

Signature of Faculty

Total marks obtained 7

1. Experiment: 3 Surface finish analysis using different types of moulding sands. Material required: Green sand, Mollasis Sand, Co2 Binder sand, bentonite powder, Sodium silicate and Co2 Gas, Silica and ordinary river sand. Tools required: Shovels, Trowels, Hand sieve riddle, Sprue pipe, Sprue cutter, Gaggers, Heart and Square shape lifters, Rammers, Vents, Swabs, Draw skew, Roller, Strike of bar. 2. Learning Objectives: To know the variations of different sand during the molding. 3. Outline of the Procedure: 1) First of all we take three types of molding sand green sand, Mollasis sand & Co2 binder sand in prepared conditions with silica as well as ordinary river sand and will prepare the moulds for the same. 2) Then we pour the molten metal in the moulds and after decoring will check the surface finish of the castings produced from different mould and compares them. 4. Scope of the results expected: To analysis the surface finish due to verity of the moulding processes using different sands. 5. Cautions: 1. Wear apron, shoes and tight fitted clothes. 2. Be careful and attentive while working on this job. 3. Use proper tools for each operation. 4. Dont keep any sharp tool in your pocket. 5. Tools being used should be well sharpened. 6. Runner and riser should be placed at the right place. 7. Sand should be mixed properly. 8. Always use goggles while doing castings. 9. Proper moisture content should be maintained. 10. Follow the operative instructions clearly.
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Date of Performance

Worksheet of the student

Registration Number:

Aim: Surface finish analysis using different types of moulding sands.

Learning Outcomes (what I have learnt):

To be filled in by Faculty S.No. 1 Parameter Understanding of the student about the procedure/apparatus. Marks obtained Max. Marks 20

Accuracy level of job dimensions

20

Completion of experiment, Discipline and Cleanliness

10

Signature of Faculty

Total marks obtained 9

Welding Shop
1. Experiment: 4 To join the given two work pieces Square butt joint using TIG welding.

All the dimensions are in mm Material required: M.S flat Tools required: Welding power supply Welding rod Electrode holder Gloves and apron Shield and goggles

2. Learning Objectives: The objective of this work is to join the work pieces using TIG welding and compare with other weld joints. 3. Procedure 1. The given work pieces are thoroughly cleaned, i.e. rust, scales are removed and edges are filed. 2. The electrode is held in an electrode holder and ground clamp is clamped to the welding plates and the power is supplied. 3. The work pieces are positioned on the table form a square butt joint. 4. The tag weld is done on the both the ends of joining plates to avoid the movement of work pieces during welding. 5. The welding is carried throughout the length of the work pieces on both sides by maintaining 3mm gap between plates and welding rod.
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6. The welded plates are allowed for air cooling after the slag is removed. 7. The weld joint portions are cleaned by wire brush. 4. Cautions: 1. Check the ground connection and insulation of all the wires. 2. They are should be observed only through a shield or goggles. 3. Always wear the safety hand gloves, apron and leather shoes. 4. Use proper capacity current cables. 5. Switch off the welding machines when leaving from the work. 6. Remove the slag by chipping hammer only. 7. To relieve strain or irritation on the eyes, eye drops may be applied.

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Date of Performance

Worksheet of the student

Registration Number:

Aim: To join the given two work pieces Square butt joint using TIG welding.
Learning Outcomes (what I have learnt):

To be filled in by Faculty S.No. 1 Parameter Understanding of the student about the procedure/apparatus. Marks obtained Max. Marks 20

Accuracy level of job dimensions

20

Completion of experiment, Discipline and Cleanliness

10

Signature of Faculty

Total marks obtained 12

1. Experiment: 5 To join the given two work pieces Tee fillet joint using MIG welding.

All the dimensions are in mm

Material required: M.S flat Tools required: Welding power supply Welding rod Electrode holder Gloves and apron Shield and goggles 2. Learning Objectives: The objective of this work is to join the work pieces using MIG welding and compare with other weld joints. 3. Procedure: 1. The given work pieces are thoroughly cleaned, i.e. rust, scales are removed and edges are filed. 2. The electrode is held in an electrode holder and ground clamp is clamped to the welding plates and the power is supplied. 3. The work pieces are positioned on the table form a Tee fillet joint. 4. The tag weld is done on the both the ends of joining plates to avoid the movement of work pieces during welding.
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5. The welding is carried throughout the length of the work pieces on both sides by maintaining 3mm gap between plates and welding rod. 6. The welded plates are allowed for airs cooling after the slag are removed. 7. The weld joint portions are cleaned by wire brush. 4. Cautions: 1. Check the ground connection and insulation of all the wires. 2. They are should be observed only through a shield or goggles. 3. Always wear the safety hand gloves, apron and leather shoes. 4. Use proper capacity current cables. 5. Switch off the welding machines when leaving from the work. 6. Remove the slag by chipping hammer only. 7. To relieve strain or irritation on the eyes, eye drops may be applied.

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Date of Performance

Worksheet of the student

Registration Number:

Aim: To join the given two work pieces Tee fillet joint using MIG welding.
Learning Outcomes (what I have learnt):

To be filled in by Faculty S.No. 1 Parameter Understanding of the student about the procedure/apparatus. Marks obtained Max. Marks 20

Accuracy level of job dimensions

20

Completion of experiment, Discipline and Cleanliness

10

Signature of Faculty

Total marks obtained 15

Machine Shop
1. Experiment: 6 Manufacturing of a gear on milling machine and Inspection of PCD, tooth profile and run out of PCD in respect to bore. Equipment required: Vernier Calliper, Steel scale, outside callipers, inside callipers, Lathe machine equipped with different tools, Mandrels and milling cutters etc. Material required: Raw material of specific dimension 2. Learning Objectives: A) To learn indexing method, B) To learn Bore, Turning procedures. 3. Outline of the Procedure: a) Take a blank of the required dimension, turn it for the outer dimensions and make a bore in it to be fitted on the mandrel using lathe machines. b) Then fixing the piece on the mandrel of the indexing head on the milling machine c) Adjust the indexing head for the required profile of the gear. 4. Scope of the result expected: The tooth profile and PCD should be accurate. Indexing method help in the generation of different gears which are used in almost all the industrial applications. 5. Cautions: 1. Always wear shoes while performing the practical 2. Do not wear bangles, bracelets, rings, chains and even neck tie. 3. Always wear lab coat (white). 4. Always wear safety goggles. 5. Do not wear loose clothes while working on machine. 6.Do not even try to touch anything unknown. 7. Do not let anybody to stand on the left side of the operator. 8. Do not lean on to the machine.
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9. Follow the operative instructions given strictly. 10. Check the alignment of the bed of the machine.

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Date of Performance

Worksheet of the student

Registration Number:

Aim: Manufacturing of a gear on milling machine and Inspection of PCD, tooth profile and run
out of PCD in respect to bore. Learning Outcomes (what I have learnt):

To be filled in by Faculty S.No. 1 Parameter Understanding of the student about the procedure/apparatus. Marks obtained Max. Marks 20

Accuracy level of job dimensions

20

Completion of experiment, Discipline and Cleanliness

10

Signature of Faculty

Total marks obtained

18

1. Experiment: 7 Manufacturing and analyzing a flat surface on surface grinding and shaper machine. Equipment required: Vernier Calliper, Steel scale, Outside callipers, Inside callipers, Surface grinding machine & Shaping machine equipped with different tools, cutters etc. Material required: Raw material of specific dimensions (Rectangular in shape) 2. Learning Objectives: To find out difference in the roughness of surfaces generated on Grinding & Shaper machine 3. Outline of Procedure: 1. Fixing the blank on the clamping device of the shaping machine and performing operations accordingly to flatten the all surfaces of the rectangular blank by changing the feed and speed of the machine for different sides for the reference. 2. Fixing the blank on the clamping device of the lathe machine and performing operations accordingly to flatten the all surfaces of the rectangular blank by changing the feed and speed of the machine for different sides for the reference. After wards fixing that particular piece to the surface grinding machine for the further operations to make it in the comparable state. 4. Scope of the result expected: This will help the student in find out use of proper machining process to be used for different industrial applications. 5. Cautions: 1. Always wear shoes while performing the practical 2. Do not wear bangles, bracelets, rings, chains and even neck tie. 3. Always wear lab coat (white). 4. Always wear safety goggles. 5. Do not wear loose clothes while working on machine. 6. Do not even try to touch anything unknown 7. Do not let any body to stand on the left side of the operator.
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8. Do not lean on to the machine. 9. Follow the operative instructions given strictly. 10. Make sure not to make contact of the grinding wheel with a sudden impact. 11. Make sure the feed of the grinding wheel should be in microns only. 12. Tighten the tools on the shaping machine properly.

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Date of Performance

Worksheet of the student

Registration Number:

Aim: Manufacturing and analyzing a flat surface on surface grinding and shaper machine.
Learning Outcomes (what I have learnt):

To be filled in by Faculty S.No. 1 Parameter Understanding of the student about the procedure/apparatus. Marks obtained Max. Marks 20

Accuracy level of job dimensions

20

Completion of experiment, Discipline and Cleanliness

10

Signature of Faculty

Total marks obtained

21

1. Experiment: 8 To prepare a job as per sketch using Capstan and Turret Lathe Machines. Equipment Required: Scriber, engineering steel scale, vernier Calliper, Marking Chalk, Power hacksaw, Bench grinder, Capstan and Turret Lathe Machines, Cutting Tool bit, Hammer, Marking gauge. Material Required: Raw material of specific dimensions (Rectangular in shape)

2. Learning Objectives:
To practice & learn how to perform different operations in machine shop using Capstan and Turret Lathe machine like Facing, Turning, Step Turning, Grooving, Centre making and Chamfering.

3. Outline of the Procedure:

a) Fix the specimen in the chuck / Collet of the machine. b) Perform the different operations as per the sketch of job required.

4. Scope of results to be reported:

To get different experience from the conventional machining and experiencing the production machines. 22

5. Precautions:
1. Always wear shoes while performing the practical. 2. Do not wear bangles, bracelets, rings, chains, and even neck tie. 3. Always wear Lab coat (white). 4. Always wear safety goggles. 5. Do not wear loose clothes while working on machines. 6. Do not even try to touch anything unknown. 7. Do not let anybody to stand on the left side of the operator. 8. Do not lean on to the machines. 9. Follow the operative instructions given strictly.

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Date of Performance

Worksheet of the student

Registration Number:

Aim: To prepare a job as per sketch using Capstan and Turret Lathe Machines.
Learning Outcomes (what I have learnt):

To be filled in by Faculty S.No. 1 Parameter Understanding of the student about the procedure/apparatus. Marks obtained Max. Marks 20

Accuracy level of job dimensions

20

Completion of experiment, Discipline and Cleanliness

10

Signature of Faculty

Total marks obtained 24

1. Experiment: 9 To Prepare Spur Gear using Milling machine with different indexing methods. Equipment Required: Scriber, Engineering steel scale, Vernier caliper, Marking chalk, Milling Machine, Milling cutters, Cutting oil, Hammer, mandrills, Marking gauge. Material Required: Mild steel bar or as per availability in lab. 2. Learning objectives: To practice spur gear manufacturing on milling machine with indexing. 3. Procedure: Hold the work piece on the mandrill of the milling machine Starting operation by setting the indexing for the particular teethes in the rotation as per sketch to maintain the dimensional accuracy. 4. Required Results: 1. Reading practice and preparation of job as per sketch with detail dimensions. 2. Recognition and practice for the usage of the equipments and tools. 3. Operations performed and their significance. 5. Cautions: 1 .Always wears shoes while performing the practical 2. Do not wear bangles, bracelets, rings, chains and even neck tie. 3. Always wear lab coat (white). 4. Always wear safety goggles. 5. Do not wear loose clothes while working on machine. 6. Do not even try to touch anything unknown. 7. Do not let anybody to stand on the left side of the operator.

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Date of Performance

Worksheet of the student

Registration Number:

Aim: To Prepare Spur Gear using Milling machine with different indexing methods.
Learning Outcomes (what I have learnt):

To be filled in by Faculty S.No. 1 Parameter Understanding of the student about the procedure/apparatus. Marks obtained Max. Marks 20

Accuracy level of job dimensions

20

Completion of experiment, Discipline and Cleanliness

10

Signature of Faculty

Total marks obtained

26