GENERAL SAFETY INSTRUCTIONS

• Always wear proper uniform in the workshop

• Never wear loose clothes.

• Never work bare-footed inside the workshop.

• Use of closed shoe is recommended.

• Never operate any machine unless you do not know how to operate it.

• Never touch moving parts, belts or rotating tools etc.

• Never touch any switch, knob, lever of the machine without knowing it.

• Silky clothes catch fire soon, so never come workshop wearing silky clothes.

• Do not touch any live wire inside the workshop.

• In case of any fire, the electric supply should be disconnected.

• Always keep in mind about the position of the fire extinguisher and the first- aid - box.

• Always read the first – aid chart carefully while beginning the workshop.

• Make sure that your work is not affecting anybody in the workshop.

• Always try to learn sincerely from the instruction and try to follow their instruction properly.

• Always keep your mind concentrated on the job.

• Always wear safety glasses when required when machines are in running condition.

• Always ask the workshop supervisor before operating any unknown machine , instrument or tool.

• Be careful while using compressed air.

• Keep machines in cleaned condition after finishing the specified task .

• Hearing protection should be used while using noisy machines.

 FITTING
Fitting is related to assembly of parts, after bringing the dimension or shape to the required size or form, in order to
secure the necessary fit. The operations required for the same are usually carried out on a work bench, hence the
term bench work is also added with the name fitting. The bench work and fitting plays an important role in
engineering.The person working in the fitting shop is called fitter.

FITTING TOOLS:

Fitting shop tools are classified as below:

•Work Holding Devices/ Clamping Tools.

•Measuring and Marking Tools.

•Cutting Tools.

•Striking Tools.

•Drilling Tools.

•Threading Tools.

WORK HOLDING DEVICES/CLAMPING TOOLS:

1. WORK BENCH:
A fitting process can be done at various
places, but most of the important
operations of fitting are generally carried out on
a table called work bench. The work bench is a
strong, heavy and rigid table made up of hard
wood.

2. BENCH VICE:
It is firmly fixed to the bench with the help of nuts and bolts. It consists of a cast Iron body and cast iron jaws. Two
jaw plates are fitted on both the jaws. The holding surface of the jaw plates is knurled in order to increase the
gripping. One jaw is fixed to the body and the second slideson a square threaded screw with the help of a handle.
Handle is used to move the movable jaw.

3. V BLOCK:
.
In V Block, V grooves are provided to hold the round
objects longitudinally. The screw of the clamp applies
the holding pressure. When the handle is rotated
there is movement in the screw

MEASURING TOOLS

1. STEEL RULE:
These are made up of stainless steel and are available in many sizes ranging from 1/2 ft. to 1 ft. These are marked in
inches or millimeters. All the faces are machined true. The edges of steel rule should be protected from rough
handling.

2.CALIPERS:
These are generally used to measure the inside or outside diameters. Different types are:

I .OUTSIDE CALIPER: It is used to measure the outside dimensions.

II .INSIDE CALIPER: It is used to measure the inside dimensions. III. ODD LEG
CALIPER: One leg is bent at the tip inwardly and the other has a straight pointed end. It is used to scribe lines parallel
to the straight edges.

MARKING TOOL:
SURFACE PLATE:
It is used for testing the flatness, trueness of the surfaces. It is made up of cast iron or graphite. Its upper face is
planed to form a very smooth surface. It is also used in scribing work. While not in use, it should be covered with a
wooden cover.

ANGLE PLATE:
It is made up of cast iron in different sizes; it has two planed surfaces at right angles to each other and has various
slots in each surface to hold the work by means of bolts and clamps. Never do hammering on the angle plate to
fasten (lighten) the nuts and bolts.

SCRIBER AND SURFACE GAUGE:

It consists of a cast iron bass on the center of which a steel rod is fixed vertically. Scriber is made up of high carbon
steel and is hardened from the front edge. It is used for locating the centers of round bars or for marking of the lines.

PUNCH:
Punches are used for marking purposes. Prick punches are used for marking dotted line and centre punch is used to
mark the centre of hole before drilling. Punches are made up of high carbon steel or high speed steels. One end is
sharpened. Hammering is done on the second end while working.

CENTER PUNCH PRICK PUNCH

For Prick punch, angle of the punching end is 60 degree

While in center punch; angle of punching end is 90 degree

TRY SQUARE:
It is used for checking squareness of two surfaces. It consists of a blade made up of steel, which is attached to a base
at 90 degree. The base is made up of cast iron or steel. It is also used to mark the right angles and measuring
straightness of surfaces. Never use try square as a hammer.

HACKSAW BLADE:
Depending upon the direction of cut, blades are classified as
1.Forward cut 2. Backward cut.

Depending upon the pitch of the teeth (Distance between the two consecutive teeth) blades is classified as:
•Coarse (8-14 teeth per Inch) •Medium (16-20 teeth per inch) •Fine (24-32 teeth per inch)

FILES
Files are multi points cutting tools. It is used to remove the material by rubbing it on the metals.

Files are available in a number of sizes, shapes and degree of coarseness.

CLASSIFICATION OF FILES:

ON THE BASIS OF LENGTH: 4”, 6”, 8”, 12”

ON THE BASIS OF GRADE:

•Rough (R) (20 teeth per inch)

•Bastard (B) (30 teeth per inch)

•Second cut (Sc) (40 teeth per inch)

•Smooth file (S) (50 teeth per inch)

•Dead smooth (DS) (100 teeth per inch)

Rough and bastard files are the big cut files. When the material removal is more, these files are used. These files have
bigger cut but the surface produced is rough.

Dead smooth and smooth files have smaller teeth and used for finishing work. Second cut file has degree of finish in
between bastard and smooth file.

 ON THE BASIS OF NUMBER OF CUTS:

•Single cut files.
•Double cut files

In single cut files the teeth are cut in parallel rows at an angle of 60 degree to the face. Another row of teeth is added
in opposite direction in case of double cut files. Material removal is more in case of double cut files.

 ON THE BASIS OF SHAPE AND SIZE:

The length of the files varies from 4” to 14”. The various shapes of cross-section available are hand file, flat file,
triangular, round; square, half round, knife-edge, pillar, needle and mill file.

1. FLAT FILE:
This file has parallel edges for about two-thirds of the length and then it tapers in width and thickness. The faces are
double cut while the edges are single cut.

2. HAND FILE:
For a hand file the width is constant throughout, but the thickness tapers as given in flat file. Both faces are double
cut and one edge is single cut. The remaining edge is kept uncut in order to use for filing a right-angled corner on one
side only.

3. SQUARE FILE:
It has a square cross-section. It is parallel for two-thirds of its length and then tapers towards the tip. It is double cut
on all sides. It is used for filing square corners and slots.

4. ROUND FILE:
It has round cross-section. It carries single cut teeth all round its surface. It is normally made tapered towards the tip
and is frequently known as rat-tail file. Parallel round files having same diameter throughout the length are also
available. The round files are used for opening out holes, producing round comers, round-ended slots etc.

5. HALF-ROUND FILE:
Its cross-section is not a true half circle but is only about one-third of a circle. The width of the file is either parallel
throughout or up to middle and then tapered towards the tip. The flat side of this file is always a double cut and
curved side has single cut. It is used for filing curved surfaces.

6.TRIANGULAR FILE:
It has width either parallel throughout or up to middle and then tapered towards the tip. Its section is triangular
(equilateral) and the three faces are double cut and the edges single cut. It is used for filing square shoulders or
comers and for sharpening wood working saws.

METHODS OF FILING:
The following are the two commonly used methods of filing:

1. Cross-filing 2. Draw filing.

1. CROSS-FILLING:
This method is used for efficient removal of maximum amount of metal in the shortest possible time. It may be noted
that the file must remain horizontal throughout the stroke (long, slow and steady) with pressure only applied on the
forward motion

2. DRAW FILING:
This method is used to remove file marks and for finishing operations. Here, the file is gripped as close to the work as
possible between two hands. In this filing method, a fine cut file with a flat face should be used.

Experiment No 1: To make T-Fitting from the given two M.S Plate as instructed.

SQUARE (T) - FITTING

 EXPERIMENTNO:01 DATE:

Aim: - To make T-Fitting from the given two M.S Plate a specified in the diagram

Tools required: -

1. Benchvice
2. Steelrule
3. Trysquare
4. Ball peenhammer
5. Scriber
6. Hack saw withblade
7. Dot punch and Centrepunch
8. Surfaceplate
9. Venire heightgauge
10. Rough and smooth flatfiles
11. Flat chisel and triangularfile
Materials required: - Mild steel (M.S) plate of size (75 x 50 x 5)x2Nos.
Sequence of Operations: -
1. Filing
2. Checking flatness and squareness
3. Marking andmeasuring
4. Punching
5. Sawing
6. Chipping
7. Finishing
Fig: SQUARE (T) - FITTING
Procedure: -
1. The burrs in the pieces are removed and the dimensions are checked with
a steelrule.
2. The pieces are clamped one after the other and the outer mating edges are
filed by using rough and smoothfiles.
3. The flatness, straightness and square ness i.e. right angle between
adjacent sides are checked with help ofTry-square.
4. Chalk is then applied on the surfaces of the twopieces.
5. The given dimensions of the T-fitting are marked with help of vernier
height gaugecarefully.
6. Using the dot punch, dots are punched along the above scribedlines.
7. Using the hack saw, the unwanted portions areremoved.
8. Using the flat chisel, the unwanted material in the piece Y isremoved.
9. The cut edges are filed by the half roundfile.
10. The corners of the stepped surfaces are filed by using a square or triangular
file to get the sharpcorners.
11. The pieces (X and Y) are fitted together and the mating is checked for
the correctness of thefit.

Result: - T-fit is made as per the required dimensions.

 V - FITTING

EXPERIMENTNO:02 DATE:

Aim: - To make V-fitting from the given M.S Plate as

specified in the diagram.

Tools required: -
1. Benchvice
2. Steelrule
3. Trysquare
4. Ball peenhammer
5. Scriber
6. Hack saw withblade
7. Dot punch and Centrepunch
8. Surfaceplate
9. Vernier heightgauge
10. Rough and smooth flatfiles
11. Flat chisel and triangularfile
Material required: - Mild steel (M.S) plate of size 48 x 34–2 Nos.

Sequence of Operations: -
1. Filing
2. Checking flatness and squareness
3. Marking andmeasuring
4. Punching
5. Sawing
6. Chipping
7. Finishing
Procedure: -
1. The burrs in the pieces are removed and the dimensions are checked with
a steelrule.
2. The pieces are clamped one after the other and the outer mating edges are
filed by using rough and smoothfiles.
3. The flatness, straightness and square ness i.e. right angle between
adjacent sides are checked with help ofTry-square.
4. Chalk is then applied on the surfaces of the twopieces.
5. The given dimensions of the V-fitting are marked with help of vernier height
gaugecarefully.
6. Using the dot punch, dots are punched along the above scribedlines.
7. Using the hack saw, the unwanted portions areremoved.
8. Using the flat chisel, the unwanted material in the piece Y isremoved.
9. The cut edges are filed by the half roundfile.
10. The corners of the stepped surfaces are filed by using a square or triangular
file to get the sharpcorners.
11. The pieces (X and Y) are fitted together and the mating is checked for
the correctness of thefit.
Safety precautions: -
1. Care is taken to see that the marking dots are not crossed, which is indicated
by the half of the punch dots left on thepieces.
2. Apply pressure in forward direction during hacksawing.
3. Don’t rub steel rule on thejob.
4. Fix blade in hack saw frame with correcttension.
5. During hack sawing the coolant like water or lubricating oil is to beused.
6. Use precision instruments like vernier calipers and vernier height
gauge carefully.
7. Files are to be cleaned properly afterusing.

Result: - V- fit is made as per the required dimensions.

 INTRODUCTION

Welding is the process of joining similar metals by the application of heat, with or without
application of pressure or filler metal, in such a way that the joint is equivalent in composition
andcharacteristics of the metals joined. In the beginning, welding was mainly used for repairing
all kinds ofworn or damaged parts. Now, it is extensively used in manufacturing industry,
construction industry(construction of ships, tanks, locomotives and automobiles) and
maintenance work, replacing rivetingand bolting, to a greater extent.

The various welding processes are:

1. Electric arcwelding,
2. Gaswelding
3. Thermalwelding
4. Electrical Resistance weldingand
5. Frictionwelding

Electric arc welding

Arc welding is the welding process, in which heat is generated by an electric arc struck between
an electrode and the work piece. Electric arc is luminous electrical discharge between two
electrodesthrough ionized gas.

Any arc welding method is based on an electric circuit consisting of the following parts:
a. Power supply (AC orDC);
b. Weldingelectrode;
c. Workpiece;
d. Welding leads (electric cables) connecting the electrode and work piece to the powersupply.
 Fig:1 Arc welding set up

Electric arc between the electrode and work piece closes the electric circuit. The arc
temperature may reach 10000°F (5500°C), which is sufficient for fusion the work piece edges
and joining them. When a long joint is required the arc is moved along the joint line. The front
edge of the weld pool melts the welded surfaces when the rear edge of the weld pool solidifies
forming the joint.
Transformers, motor generators and rectifiers’ sets are used as arc welding machines.
These machines supply high electric currents at low voltage and an electrode is used to produce
the necessary arc. The electrode serves as the filler rod and the arc melts the surface so that, the
metals to be joined are actually fixed together.
Sizes of welding machines are rated according to their approximate amperage capacity at
60% duty cycle, such as 150,200,250,300,400,500 and 600 amperes. This amperage is the rated
current output at the working terminal.
Transformers
The transformers type of welding machine produces A.C current and is considered to be theleast
expensive. It takes power directly from power supply line and transforms it to the voltage
required for welding. Transformers are available in single phase and three phases in the market.
Motor generators
These are D.C generators sets, in which electric motor and alternator are mounted on the same
shaft to produce D.C power as pert the requirement for welding. These are designed to produce
D.C current in either straight or reversed polarity. The polarity selected for welding depends
upon the kind of electrode used and the material to be welded.
Rectifiers
These are essentially transformers, containing an electrical device which changes A.C into D.C
by virtue of which the operator can use both types of power (A.C or D.C, but only one at a
time).In addition to the welding machine, certain accessories are needed for carrying out the
welding work.
Welding cables
Two welding cables are required, one from machine to the electrode holder and the other,
from the machine to the ground clamp. Flexible cables are usually preferred because of the case
of usingand coiling the cables. Cables are specified by their current carrying capacity, say 300 A,
400 A, etc.
Electrodes
Filler rods are used in arc welding are called electrodes. These are made of metallic wire called
core wire, having approximately the same composition as the metal to be welded. These are
coated uniformly with a protective coating called flux. While fluxing an electrode; about 20mm
of length is left at one end for holding it with the electrode holder. It helps in transmitting full
current from electrode holder to the front end of the electrode coating. Flux acts as an insulator
of electricity. In general, electrodes are classified into five main groups; mild steel, carbon steel,
special alloy steel, cast iron and non‐ferrous. The greatest range of arc welding is done with
electrodes in the mild steel group. Various constituents like titanium oxide, potassium oxide,
cellulose, iron or manganese, Ferro silicates, carbonates, gums, clays, asbestos, etc., are used as
coatings on electrodes. While welding, the coating or flux vaporizes and provides a gaseous
shield to prevent atmospheric attack. The size of electrode is measured and designated by the
diameter of the core wire in SWG andlength, apart from the brand and code names; indicating
the purpose for which there are most suitable
Electrodes may be classified on the basis of thickness of the coated flux. As
1. Dust coated or lightcoated
2. Semi or medium coatedand
3. Heavily coated orshielded
Electrodes are also classified on the basis of materials, as
1. Metallicand
2. Non‐metallic orcarbon
Metallic arc electrodes are further sub‐divided into
1. Ferrous metal arc electrode (mild steel, low/medium/high carbon steel, cast iron, stainless
steel, etc)
2. Non‐ferrous metal arc electrodes (copper, brass, bronze, aluminum,etc).
In case of non‐metallic arc electrodes, mainly carbon and graphite are used to make the
electrodes.
Fig :3Electrodeholder Fig :4 Ground Clamp

Fig:5Wirebrush Fig :6Chippinghammer

Fig:7Handgloves Fig :8Faceshield

Fig :9Weld positions

 WELDING TOOLS
Electrode holder
The electrode holder is connected to the end of the welding cable and holds the electrode.
Itshould be light, strong and easy to handle and should not become hot while in operation. Figure
shows one type of electrode holder. The jaws of the holder are insulated, offering protection
from electricshock.
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 a low resistance
connection.
Wire brush and chipping hammer
A wire brush is used for cleaning and preparing the work for welding. A chipping hammer is
used for removing slag formation on welds. One end of the head is sharpened like a cold chisel
and the other, to a blunt, round point. It is generally made of tool steel. Molten metal dispersed
around the welding heads, in the form of small drops, is known as spatter. When a flux coated
electrode is used in welding process, then a layer of flux material is formed over the welding
bead which contains the impurities of weld material. This layer is known as slag. Removing the
spatter and slag formed on and around the welding beads on the metal surface is known as
chipping.
Welding table and cabin
It is made of steel plate and pipes. It is used for positioning the parts to be welded properly.
Welding cabin is made‐up by any suitable thermal resistance material, which can isolate the
surrounding by the heat and light emitted during the welding process. A suitable draught should
also be provided for exhausting the gas produced during welding.
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 wherever 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 fitted with dark glasses to filter out the
Harmful rays of the arc. In some designs, a cover glass is fitted in front of the dark lens to protect
it from spatter.
Hand gloves
These are used to protect the hands from electric shocks and hot spatters

TECHNIQUES OF WELDING
Preparation of work
Before welding, the work pieces must be thoroughly cleaned of rust, scale and other foreign
material. The piece for metal generally welded without beveling the edges, however, thick work
pieceshould be beveled or veed out 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. Before commencing the welding process, the following must be
considered
a) Ensure that the welding cables are connected to proper powersource.
b) Set the electrode, as per the thickness of the plate to bewelded.
c) Set the welding current, as per the size of the electrode to beused.

WELDING POSITIONS
Depending upon the location of the welding joints, appropriate position of the electrode and
hand movement is selected. The figure shows different welding positions.
Flat position welding
In this position, the welding is performed from the upper side of the joint, and the face of the
weld is approximately horizontal. Flat welding is the preferred term; however, the same position
is sometimes called down hand.
Horizontal position welding
In this position, welding is performed on the upper side of an approximately horizontal surface
and against an approximately vertical surface.
Vertical position welding
In this position, the axis of the weld is approximately vertical as shown in figure.
Overhead position welding
In this welding position, the welding is performed from the underside of a joint
 WELDING

BUTT JOINT

EXPERIMENTNo:05 DATE:

Aim: Preparation of butt joint as shown in figure using Shielded Metal Arc Welding process.

Material required: M.S Plates – (75 x 50 x 5) mm3 −¿2 Nos

Tools required:
1. weldingtransformer,
2. connectingcables,
3. electrodeholder,
4. ground clamp,
5. electrodes,
6. hippinghammer,
7. Welding shieldetc.
 MACHINE SHOP

V – butt
joint

INTRODUCTION
 In a machine shop, metals are cut to shape on different machine tools. A lathe is used to cut and
shape the metal by revolving the work against a cutting tool. The work is clamped either in a
chuck,fitted on to the lathe spindle or in‐between the centers. The cutting tool is fixed in a tool
post, mountedon a movable carriage that is positioned on the lathe bed. The cutting tool can be
fed on to the work,either lengthwise or cross‐wise. While turning, the chuck rotates in counter‐
clockwise direction, whenviewed from the tail stock end.
principal parts of a Lathe
Figure 4.1 shows a center lathe, indicating the main parts. The name is due to the fact that work
pieces are held by the centers.

Bed

It is an essential part of a lathe, which must be strong and rigid. It carries all parts of the
machine and resists the cutting forces. The carriage and the tail stock move along the guide ways
provided on the bed. It is usually made of cast iron.
Head stock
It contains either a cone pulley or gearings to provide the necessary range of speeds and feeds.
It contains the main spindle, to which the work is held and rotated.
Tail stock
It is used to support the right hand end of a long work piece. It may be clamped in any position
along the lathe bed. The tail stock spindle has an internal Morse taper to receive the dead center
thatsupports the work. Drills, reamers, taps may also be fitted into the spindle, for performing
operationssuch as drilling, reaming and tapping.
Carriage or Saddle
It is used to control the movement of the cutting tool. The carriage assembly consists of the
longitudinal slide, cross slide and the compound slide and apron. The cross slide moves across
the lengthof the bed and perpendicular to the axis of the spindle. This movement is used for
facing and to providethe necessary depth of cut while turning. The apron, which is bolted to the
saddle, is on the front of thelathe and contains the longitudinal and cross slide controls.
Procedure:
1. The given metallic pieces filled to the desiredsize.
2. On both pieces beveled in order to have Vgroove.
3. The metallic pieces are thoroughly cleaned from rust grease, oil,etc.
4. The metallic pieces are connected to terminals of Transformer.
5. Select electrode dia based on thickness of work piece and hold it on the
electrodeholder. Select suitable range of current for selecteddia.
6. Switch on the power supply and initiates the arc by either striking arc method or touch
and dragmethod.
7. Take welding to be done before fullwelding.
8. In full welding process after completion one part before going to second part. Slag is
removed from the weld bed. With the metal wire brush or chippinghammer.
9. Then the above process will be repeated until to fill the groove with weld bed
orweld metal.
Precautions:
1. Use goggles, gloves in order to protect the human body.
2. Maintain the constant arclength.
Result: butt joint is prepared as shown infigure by using arc-welding process.
 FOUNDRY

Introduction: Foundry practice deals with the process of making castings in molds, formed in either
sand or some other material. The process involves the operations of pattern making, sand preparation,
moulding, melting of metals, pouring in molds, cooling, shake-out, heat treatment, finishing, and
inspection.

Pattern:Pattern is the principal tool during the casting process. It may be defined as a model of
anything, so constructed that it may be used for forming an impression called would in damp sand or
other suitable material.When this mold is filled with molten metal and the metal is allowed to solidify
it forms a reproduction of the pattern and is known as casting. The process of making pattern is
known as pattern making.

Mould: Mould is cavity formed by the pattern. It is similar in shape and size to that of the actual
casting plus some allowances for shrinkage, machining etc. Molds are classified as temporary and
permanent. Temporary molds are made of refractory sand and other binding materials and may be
produced either through hand molding or machinemolding.

Molding Sand: Sand is the principal material used in foundry. The principal ingredients of molding
sands are: Silica sand, clay, moisture, and miscellaneous materials. Silica sand withstands very high
temperatures and doesn’t react with the molten metal.

Properties of Molding Sand:

 Porosity or Permeability
 Flowability
 Collapsibility
 Adhesiveness
 Cohesiveness or Strength
 Refractoriness
Types of Molding Sand:
Green Sand: It is a mixture of silica sand with 18 to 30 % clay having a total water of 6 to 8 %.
Dry Sand: Green sand that has been dried or baked after the mold is made is called dry sand.
Loam Sand:Loam sand is high in clay, as much as 50 %.
Parting Sand: Parting sand is used to keep the green sand from sticking to the pattern and also to allow the
sand on the parting surface of the cope and drag to separate without clinging. This is clean clay free silica
sand which serves the same purpose as parting dust.
 Core Sand: The sand used for making cores is called as core sand and sometimes it is called as oil
sand. This is silica sand mixed with core oil which is composed of linseed oil. Resin light mineral oil
and other binding materials.

Pattern Materials:

The selection of pattern materials depends primarily on the following factors.

1. Service requirement, e.g. quantity, quality, and intricacy of casting i.e. minimum
thickness, desired degree of accuracy, and finishrequired
2. Type of production of castings and the type of moldingprocess
3. Possibility of designchanges
4. Number of castings to be produced, i.e. possibility of repeatorders

To be good of its kind, pattern material shouldbe:

a. Easily worked, shaped, andjoined

b. Light inweight
c. Strong, hard, and durable, so that it may be resistant to wear and abrasion, corrosion, and
to chemicalaction
d. Dimensionally stable in allsituations
e. Easily available at lowcost
f. Repairable and reused
g. Able to take good surfacefinish

The wide variety of pattern materials which meet these characteristics are wood and wood
products; metal and alloys; plasters; plastics and rubber; and waxes.
Types of Patterns:

Single Piece or Solid Pattern: In a simple solid pattern, one side is made flat which serves as a
parting surface. In this case, the mould cavity will be entirely in the drag, and requires the more
number of manual operations such as cutting the gating system and repairing of the mold. The shape
of the single piece pattern is exactly same as that of casting. Single piece patterns are inexpensive and
best suited for limited production
 MRCET ENGINEERING WORKSHOP MANUAL B.TECH 1ST

Tools and Equipment:

Moulding Board
A molding board is a smooth wooden board on which the flask and pattern are placed when the
mould is being made. The figure is shown below:

Fig: Moulding Boxes

Moulding Boxes: Sand moulds are prepared in specially constructed boxes called flasks. The purpose of
flask is to impart the necessary rigidity and strength to the sand in molding. They are usually made in two
parts, held in alignment by dowel pins. The top part is called the cope and the lower part the drag.

Shovel
A shovel is used for mixing and tempering molding sand and for moving the sand from the pile
to the flask as shown in figurebelow:
Riddle
A riddle sometimes called a screen consists of a circular or square wooden frame fitted with a
standard wire mesh at the bottom as shown in figure below. It is used to remove coarse sand
particles and other foreign material from the foundry sand.

Fig:Shovel Fig:Riddle Fig: Rammers

Rammer: A hand rammer is used for packaging or ramming the sand into the mould. One of its ends,
called the peen end, is wedge shaped and is used for packing sand in spaces, pockets and corners, in
the early stages of ramming.
Strike Edge or Strike-Off Bar: It is a piece of metal or wood with straight edge as shown in below
figure. It is used to remove excess sand from the mould after ramming, to provide a level surface.
Riser Pin:It is a straight wooden pin used to make a hole in the cope over the mold cavity for the
molten metal to rise-in and feed the casting to compensate the shrinkage that may take place during
solidification.
 MRCET ENGINEERING WORKSHOP MANUAL B.TECH 1ST

Sprue Pin: It is a tapered wooden pin, as shown in below figure. It is used to make a hole in the cope
through which the molten metal is poured into themould.

Fig:Sprue Pin Fig: Slick

Slick: It is a small double ended tool having a flat on one end and a spoon on the other end as shown
in below figure. Slicks are used for repairing and finishing small surfaces of the mould.

Lifter: Lifters are made of thin sections of steel of various widths and lengths with one end bent at
right angles as shown in below figure. They are used to clean and finish the bottom and sides of deep,
narrow openings in moulds.
Gate Cutter: It is a small piece of tin plate shape as shown in below figure. This serves as a tool for
cutting gates and runners in the mould.

Fig:GateCutters Fig: Vent Rod

A vent rod or wire, as shown in below figure is used to make a series of small holes to permit
gases to escape while the molten in being poured.
 MRCET ENGINEERING WORKSHOP MANUAL B.TECH 1ST

Slick
It is a small double ended tool having a flat on one end and a spoon on the other end as shown in
below figure. Slicks are used for repairing and finishing small surfaces of the mould.

Lifter
Lifters are made of thin sections of steel of various widths and lengths with one end bent at right
angles as shown in below figure. They are used to clean and finish the bottom and sides of deep,
narrow openings in moulds.

Gate Cutter
It is a small piece of tin plate shape as shown in below figure. This serves as a tool for cutting
gates and runners in the mould.

Fig:GateCutters Fig: Vent Rods

Fig: Draw Spikes
Vent Rod
A vent rod or wire, as shown in below figure is used to make a series of small holes to permit
gases to escape while the molten in being poured.
Drawspike or Screw

The draw spike is appointed steel rod, with a loop at one end. It is used to rap a draw patterns
from the sand. Below figure shows two kinds of draw spikes. The draw spike is threaded on the
end to engage metal patterns.
 MRCET ENGINEERING WORKSHOP MANUAL B.TECH 1ST

FOUNDRY
(SINGLE PIECE PATTERN)

EXPERIMENTNo: DATE:

Aim: - To prepare a sand mould cavity using One Stepped Shaft (single piece pattern).
Tools required: -
1. Moldingboard
2. Moldingflask
3. Shovel
4. Riddle
5. Rammer
6. Strike-off bar or StrikeEdge
7. Spruepin
8. Riserpin
9. Trowel
10. Spike or Drawpin
11. Slick
12. Lifters
13. Gatecutter
14. Bellows
15. Ventrod
Material required: -
1. Moldingsand
2. Partingsand
3. Dum-Bell
Sequence of operation: -
1. Sandpreparation
2. Sandmixing
3. Pouring
4. Finishing
MRCET ENGINEERING WORKSHOP MANUAL B.TECH 1ST
 MRCET ENGINEERING WORKSHOP MANUAL B.TECH 1ST

Procedure: -
1. Place the pattern on the molding board, with its flat side on theboard.
2. Place the drag over the board, after giving a clay washinside.
3. Sprinkle the pattern and molding board, with parting sand.
4. Allow loose sand, preferably through a riddle over the pattern, unit it is
covered to a depth of 2 to 3cm.
5. Pack the molding sand around the pattern and into the corners of the flask,
with fingers.
6. Place some more sand in the flask and pack the pattern with a rammer, using
first the peen end and then buttend.
7. Strike-off the excess sand from the top surface of the drag with the strike-offbar.
8. Turn the drag upsidedown.
9. Blow-off the loose sand particles with the bellows and smoothen the upper
surface.
10. Place the cope on to the drag in position. Locate riser pin on the highest point
of the pattern.
11. Place the sprue pin at about 5 to 6 cm from the pattern on the other side of
the riserpin.
12. Sprinkle the upper surface with partingsand.
13. Repeat steps 3 to 7,approximately.
14. Make holes with the vent rod to about 1 cm from thepattern.
15. Remove the sprue and riser pins by carefully drawing them out. Funnel
shaped hole is made at the top of the sprue hole, called the pouringcup.
16. Lift the cope and place it aside on itsedge.
17. Insert the draw pin into the pattern. Wet the edges around the pattern.
Loosen the pattern by rapping. Then draw the pattern straightup.
18. Adjust and repair the mold by adding bits of sand, ifnecessary.
19. Cut gate in the drag from the sprue to the mold. Blow off any loose sand
particles in themold.
20. Close the mold by replacing the cope and placing weights onit.
Precautions:-
1. Do not get the sand too wet. Water is an enemy of moltenmetals.
2. Provide adequate ventilation to remove smoke andfumes.
3. Never stand near or look over the mold during the pouring because of the
molten metal might be too hot.
4. Do not shake out a casting too hastily, which may result in second and third
degreeburns.
 MRCET ENGINEERING WORKSHOP MANUAL B.TECH 1ST
Result: - A sand mold cavity is prepared by using one–Stepped Shaft.

Smithy

Forging is defined as the plastic deformation of metals at elevated temperatures into a predetermined size
or shape using compressive forces exerted through some means of hand hammers, small power hammers,
die, press or upsetting machine. It consists essentially of changing or altering the shape and section of
metal by hammering at a temperature of about 980°C, at which the metal is entirely plastic and can be
easily deformed or shaped under pressure. The shop in which the various forging operations are carried
out is known as the smithy or smith’s shop.

COMMON HAND FORGING TOOLS

For carrying out forging operations manually, certain common hand forging tools are employed.
These are also called blacksmith’s tools, for a blacksmith is one who works on the forging of metals
in their hot state. The main hand forging tools are as under.
Tongs
The tongs are generally used for holding work while doing a forging operation.

Flatter
Flatter is commonly used in forging shop to give smoothness and accuracy to articles which have
already been shaped by fullers and swages.
 Swage Block
Swage is used for forging work which has to be reduced or finished to round,
square ,hexagonal or other forms.

Punch
Punch is used in forging shop for making holes in metal part when it is at forging heat.

Chisels
Chisels are used for cutting metals and for nicking prior to breaking. They may be hot or
cold depending on whether the metal to be cut is hot or cold. A hot chisel generally used
in
forging shop is shown in Fig. 14.7. The main difference
between the two is in the edge. The edge of a cold chisel is
hardened and tempered with an angle of about 60°, whilst the
edge of a hot chisel is 30° and the hardening is not necessary.
The edge is made slightly rounded for better cutting action.

Hand hammers
There are two major kinds of hammers are used in hand forging:
a. The hand hammer used by the smith himself and
b. The sledge hammer used by the striker.

Hand hammers may further be classified as (a) ball peen hammer, (b) straight peen hammer,
and (c) cross peen hammer.
Sledge hammers may further be classified as (a) Double face hammer, (b) straight peen hammer,
and (c) cross peen hammer.
 Set hammer
A set hammer generally used in forging shop is shown in Fig. 14.9. It is used for
finishing corners in shouldered work where the flatter would be inconvenient. It is also
used for drawing out the gorging job.

Anvil
An anvil is a
most
commonly
tool used in
forging shop Page
which is
shown in. It
acts as a
FORGING OPERATIONS:
The following are the basic operations that may be performed by hand forging:

1. Drawing-down
2. Upsetting
3. Fullering
4. Flattering
5. Swaging
6. Bending
7. Twisting
8. Cutting

SAFE PRACTICES:
1. Hold the hot work downwards close to the ground, while transferring from the hearth to
anvil, to minimize danger of burns; resulting from accidental collisions with others.
2. Use correct size and type of tongs to fit the work. These should hold the work securely to
prevent its bouncing out of control from repeated hammer blows.
3. Care should be exercised in the use of the hammer. The minimum force only should be
used and the flat face should strike squarely on the work; as the edge of the hammer will
produce heavy bruising on hot metal.
4. Water face shield when hammering hot metal.
5. Wear gloves when handling hot metal.
6. Wear steel-toed shoes.
7. Ensure that hammers are fitted with tight and wedged handles.
EXP: 2 Square Rod Date

Aim: To make a Square rod from a given round rod, by following hand forging operation.

Tools required:
Smith’s forge, Anvil, 500gm and I kg ball-peen hammers, Flatters, Swage block, Half
round tongs, Pick- up tongs, Cold chisel.

Sequence of operations:
1. Take the raw material from stock
i.e., mild steel 10 mm round
shaped, cut the length of 50 mm.
2. Handle specimen with round
tong and heat in blacksmith’s
forge upto the part appears as
red cherry color code.
3. The required piece heated upto
it gets the recrystalization
temperature.
4. The part is taken out from the
forge and blow with sledge
hammer for obtaining the
square shape on all edges.
5. The hammering is done on the anvil.
6. The above mentioned all steps
are done, after the specimen
bent in required shape.
7. Check the dimensions after cooling the job by quenching process.

NOTE: In-between the above stage, the bar is heated in the smith’s forge, to facilitate
forging operations.
Result:
The square rod is thus made from the given round rod.

Precautions:
1. Hold the job carefully while heating and hammering
2. Job must be held parallel to the face of the anvil.
3. Wear steel-toed shoes.
4. Wear face shield when hammering the hot metal
5. Use correct size and type of tongs to fit the work.
 MACHINE SHOP
In a machine shop, metals are cut to shape on different machine tools. A lathe is used to cut and shape the metal
by revolving the work against a cutting tool. The work is clamped either in a chuck,fitted on to the lathe spindle or in‐
between the centers. The cutting tool is fixed in a tool post, mounted on a movable carriage that is positioned on the
lathe bed. The cutting tool can be fed on to the work, either lengthwise or cross ‐wise. While turning, the chuck
rotates in counter‐clockwise direction, when viewed from the tail stock end.
Principal parts of a Lathe are as follows:
1. Bed
2. Head stock
3. Tail stock
4. Carriage or Saddle
5. Compound Rest
6. Tool Post
7. Lead Screw
8. Centers

Parts of a center Lathe

WORK‐HOLDING DEVICES
1. Three jaw chuck
2. Face plate
3. Lathe dogs and driving plate

Three jaw and four jaw chuck

LATHE OPERATIONS

1. Turning
2.Boring
3.Facing
4.Taper Turning
5.Drilling
6.Knurling
7.Chamfering
8.Threading
 Experiment No: Date:
To make a pin from a mild steel rod as specified in lathe.

JOB FIGURE:-
 OPERATING INSRTUCTIONS IN LATHE:

The operating instructions are as follows:

a) At first hold the work piece/job in chuck / face plate

b) After holding the job, centering must be properly done for secured machining process.

c) Turn the chuck or faceplate by hand to ensure there is no binding or danger of the
work striking any part of the lathe.

d) Check to ensure the cutting tool will not run into the chuck. If possible, feed away
from the chuck.

e) Before starting the lathe, ensure the spindle work has the cup center imbedded; tail
stock and tool rests are securely clamped; and there is proper clearance for the
rotating stock.

f) Prior to starting the lathe, ensure that small diameter stock does not project too far
from the chuck without support from the tail stock center.

g) The operator must always be aware of the direction and speed of the carriage or cross
feed prior to engaging the automatic feed.

h) Select turning speed carefully. Large diameter stock must be turned at a very low
speed. Always use the lowest speed to rough out the stock prior to final machining.

i) The correct speed and feed for the specific material and cutting tool must be used.
Stop the machine before making adjustments or measurements.

j) After finished the work on the lathe, the power must be shut off and the machine must come
to a complete stop.
 Safety Precautions:

a) Do not remove metal chips from the table or stock by hand. Use a brush or other tool
to properly remove chips or shavings from the table or stock.

b) Never leave the key in the chuck. Do not let go of the key until it is free of the chuck
and secured in its proper holding place.
c) Never attempt to run the chuck on or off the spindle head by engaging the power.

d) Do not stop the rotation of the chuck by reversing the power to the lathe unless tapping

holes.

e) Do not leave tools, bits or excess pieces of stock on the lathe bed. All belts and pulleys

must be guarded.

c) Stop the machine immediately if odd noise or excessive vibration occurs.

Experiment No: Date:

To make rectangular and Vee slot in a block of cast iron or mild steel in a shaping and / or milling machine.
 Aim: To make butt-welding using gas welding equipment.

Equipment And Material Required:

Oxy – acetylene welding outfit, MS Sheets 150x50x3 mm3 (2No)

Tools Required: Wire brush, hand gloves, and chipping hammer, spark lighter.

Procedure:
1. Acetylene valve on the torch is opened slightly and lightened with the help of a spark lighter.
2. Now acetylene valve is opened to get required the flow of acetylene.
3. Oxygen valve is opened till the intermediate flame feather reduces into inner cone to get a
neutral flame.
4. The torch tip is to be positioned above the plates so that white cone is at a distance of
1.5mm to 3mm from the plates.
5. Torch is to be held at an angle of 300 to 450 to the horizontal plane.
6. Now filler rod is to be held at a distance of 10mm from the flame and 1.5 mm to 3 mm
from the surface of the weld pool.
7. As the backward welding allows better penetration, back ward welding is to be used.
8. After the completion of welding, slag is to be removed by means of chipping hammer, wire
brush.

Precautions:
1. Ensure that torch movement is uniform.
2. See that the joints are extremely clean.

Result: A butt joint is prepared using gas welding process.

Injection molding

Injection molding is a method to obtain molded products by injecting plastic materials molten by heat into a mold, and
then cooling and solidifying them.
The method is suitable for the mass production of products with complicated shapes, and takes a large part in the
area of plastic processing.
Injection molding machine
Injection molding machine is divided into 2 units i.e. a clamping unit and an injection unit.
The functions of the clamping unit are opening and closing a die, and the ejection of products.
There are 2 types of clamping methods, namely the toggle type shown in the figure below
and the straight-hydraulic type in which a mold is directly opened and closed with a hydraulic
cylinder.
The functions of the injection unit are to melt plastic by heat and then to inject molten
plastic into a mould.

Experiment No. Date:

INJECTION MOULDING

Objective:
To Prepare a Plastic product using Injection Molding machine as specified.
Equipment:
Injection molding machine Setup.
Material Required:
High grade poly ethylene
Procedure:
 Pour the raw material in the hopper.
 Place the die in such a way that its hole coin sides with the central axis of the cylinder.
 Heat the cylinder by pouring plastic pallets in it.
 When the metal is heated at 800C to 1000C it is converted into molten metal.
 Press the lever so that the softened plastic will enter into the die and gets the desired shape of the
mould.
 Allow it to cool for some time.
 Open the die and eject the article.

Precautions:
1. Align the opening of the die and an orifice of the cylinder carefully.
2. Use gloves while holding die.

Experiment No: Date:

Aim: To make glass pieces as specified using diamond cutter.

A glass cutter is a tool used to make a shallow score in one surface of a piece of glass that is to be broken in two
pieces. The scoring makes a split in the surface of the glass which encourages the glass to break along the
score. Regular, annealed glass can be broken apart this way but not tempered glass as the latter tends to shatter
rather than breaking cleanly into two pieces.

Fig: A Typical Glass Cutter

Glass cutters are manufactured with wheels of varying diameters. [6] One of the most popular has a diameter of
5.5 mm (7⁄32 in). The ratio between the arc of the wheel and the pressure applied with the tool has an important
bearing on the degree of penetration. Average hand pressure with this size wheel often gives good results. For a
duller wheel on soft glass a larger wheel (e.g., 6 mm (1⁄4 in) will require no change in hand pressure. A smaller wheel
(3 mm (1⁄8 in)) is appropriate for cutting patterns and curves since a smaller wheel can follow curved lines without
dragging.