MT I Lab Manual

7/29/2019 MT I Lab Manual

1/20

National College Of Engineering

MARUTHAKULAM, TIRUNELVELI - 627151

MANUFACTURING TECHNOLGY - I

LABORATORY MANUAL

DEPARTMENT OF MECHANICAL ENGINEERING


2/20

Ex. No : 1 FACING, PLAIN TURNING, STEP TURNING AND CHAMFERINGDate :

Aim

To perform turning, facing and step turning on a cylindrical work piece.

Material used

Mild steel rod.

Tools required

Lathe

Three-jaw chuck

Chuck key

Vernier caliper

Single-point cutting tool

Procedure

1. First loosen the jaw in the chuck key to position the work piece, and then tighten thejaws.

2. Fix the cutting tool in the toolpost.3. Switch on the lathe and move the carriage near to the workpiece. Give it a small cross

feed, and then move carriage longitudinally to the required length slowly.

4. Bring the carriage to the original position, give a small cross feed and move carriagelongitudinally. Repeat this step until required diameter is obtained.

5. To get smooth surface give a very small feed when the diameter is nearing the requiredvalue.

6. To face the end surface of the workpiece, move the carriage to make the tool touch theend surface of the work piece.

7. Give a small feed in longitudinal direction, and then move the tool towards the axis of theworkpiece using the cross slide to complete the workpiece.

8. The turning operation is done with cutting tool to reduce the diameter upto the requireddimension for the two steps of various diameters.

9. The workpiece is removed from the chuck and the dimensions of workpiece are checkedfor the requirements.

Result

Thus the required shape and size is obtained by Facing, plain turning and step turning.


3/20

Ex. No : 2 TAPER TURNING USING COMPOUND REST

Date :

Aim

To get a required shape and size from a given workpiece by taper turning operations in the lathe.

Material used

Mild steel rod.

Tools required

Single point cutting tool

Lathe

Vernier caliper

Try square

Chuck key

Procedure

1. First loosen the jaw in the chuck key to position the work piece, and then tighten thejaws.

2. Fix the cutting tool in the toolpost.3. Switch on the lathe and move the carriage near to the workpiece. Give it a small cross

feed, and then move carriage longitudinally to the required length slowly.

4. Bring the carriage to the original position, give a small cross feed and move carriagelongitudinally. Repeat this step until required diameter is obtained.

5. To get smooth surface give a very small feed when the diameter is nearing the requiredvalue.

6. To face the end surface of the workpiece, move the carriage to make the tool touch theend surface of the work piece.

7. Then the taper turning operation is done on the workpiece according to the taper anglecalculated. The compound rest base is swirled and set a calculated taper angle, for this the

tool is moved by 45_ to the lathe axis.

8. The workpiece is removed from the chuck and the dimensions of workpiece are checkedfor the requirements.

Result

Thus the required shape and size is obtained by taper turning operation.


4/20

HORIZONTAL WELDING


5/20

Ex. No : 3 HORIZONTAL WELDING

Date :

Aim

To make the butt joint in the horizontal position using arc welding on the given workpiece.

Material Required

Welding Transformer Electrode (12 gauge) Safety Gloves Welding Shield Chipping hammer Tongs

Procedure

1. First of all, the work pieces must be thoroughly cleaned to remove rust, scale and otherforeign materials.

2. Then the given workpieces are placed on the table in such a way that the two workpiecesare brought close to each other in a horizontal position.

3. Appropriate power supply should be given to the electrode and the workpieces.4. When current is passed, arc is produced between the electrode and workpieces.5. Tag welding is done on the ends of the workpieces and then hold it on a clamp.6. Then the welding is carried throughout the length.7. As soon as the welding process is finished, switch off the current supply and allow the

workpiece to cool.

8. Slags are removed by chipping process with the help of chipping hammer.9. Finally using wire brush, welded portions are cleaned.

Result:

Thus the butt joint in vertical position using arc welding is done on the given workpiece.


6/20

VERTICAL WELDING


7/20

Ex. No : 4 VERTICAL WELDING

Date :

Aim

To make the butt joint in the vertical position using arc welding on the given work piece.

Material Required

Welding Transformer Electrode (12 gauge) Safety Gloves Welding Shield Chipping Hammer Tongs

Procedure

1. First of all, the work pieces must be thoroughly cleaned to remove rust, scale and otherforeign materials.

2. Then the given workpieces are placed on the table in such a way that the two workpiecesare brought close to each other in a vertical position.

3. Appropriate power supply should be given to the electrode and the workpieces.4. When current is passed, arc is produced between the electrode and workpieces.5. Tag welding is done on the ends of the workpieces and then hold it on a clamp.6. Then the welding is carried throughout the length.7. As soon as the welding process is finished, switch off the current supply and allow the

workpiece to cool.

8. Slags are removed by chipping process with the help of chipping hammer.9. Finally using wire brush, welded portions are cleaned.

Result:

Thus the butt joint in vertical position using arc welding is done on the given workpiece.


8/20

STEPPED PULLEY SPLIT PATTERN MOULDING


9/20

Ex. No : 5 MOULD WITH SPLIT PATTERN (STEPPED CONE)Date :

Aim

To make the mould for the given stepped cone.

Material required

Moulding board Riser pin

Moulding box Sprue pin

Green sand Rammer

Trowel Lifter

Riddle Draw spike

Gate cutter Bellow

Vent rod

Procedure

1. Place the moulding board on a horizontal surface.2. A suitable core is prepared with the help of core box.3. The drag box is placed above the moulding board. Now the pattern is kept at center of

drag.

4. Now parting sand in sprinkled before we keep pattern.5. Facing sand is sprinkled over the pattern to a depth of 5mm. then green sand is filled over

it.

6. Proper ramming is done on the green sand to get a air tight packing.7.

Excess sand is removed by strike off bar.

8. The drag box is inverted upside down.9. The cope box is placed over the drag box and locked.10.The riser pin sprue pin placed at right position and green sand is filled over the

pattern.

11.Proper ramming is done on the green sand to get air tight packing with strike off barleaving is done.

12. Now riser pin and sprue pin get removed from the green sand mould. The pattern isremoved by draw spike tool.

13.Gate is prepared using gate cutter and core is placed vertically inside the cavity.14.The vent holes are made with vent rod and cope.

Result

Thus the mould is created for given stepped cone.


10/20

Ex. No : 6 MOULD WITH SOLID PATTERN

Date :

Aim

To make the mould for the given stepped cone.

Material required

Moulding board Riser pin

Moulding box Sprue pin

Green sand Rammer

Trowel Lifter

Riddle Draw spike

Gate cutter Bellow

Vent rod

Procedure

1. Place the moulding board on a horizontal surface.2. A suitable core is prepared with the help of core box.3. The drag box is placed above the moulding board. Now the pattern is kept at center of

drag.

4. Now parting sand in sprinkled before we keep pattern.5. Facing sand is sprinkled over the pattern to a depth of 5mm. then green sand is filled over

it.

6. Proper ramming is done on the green sand to get a air tight packing.7. Excess sand is removed by strike off bar.8. The drag box is inverted upside down.9. The cope box is placed over the drag box and locked.10.The riser pin sprue pin placed at right position and green sand is filled over the

pattern.

11.Proper ramming is done on the green sand to get air tight packing with strike off barleaving is done.

12. Now riser pin and sprue pin get removed from the green sand mould. The pattern isremoved by draw spike tool.

13.Gate is prepared using gate cutter and core is placed vertically inside the cavity.14.The vent holes are made with vent rod and cope.

Result

Thus the mould is created for given stepped cone.


11/20

Ex. No : 7Date :

SHEET METAL TRAY

Aim.

To make a rectangular tray from the given sheet metal.

Material Required

G.I Sheet

Tools required

Steel rule

Mallet

Scriber

Divider

Protractor

Snips Stakes

Ball peen hammer

Procedure

1. The size of the given sheet is checked for its dimension using steel rule.2. Then the sheet is leveled on the leveling plate using a mallet.3. The dimensions are marked as shown in figure.4. The sheet is cut as per the marked dimensions by straight snips.5. Then a single hemming is made on the four sides of the tray as shown in figure.6. The four sides of the tray bent to 90 using the stakes anvil.7. Finally all the corners of the tray are joined.

Result

Thus desired square tray is made from the given sheet metal.


12/20

Ex. No : 8 SINGLE AND MULTISTART V-THREAD CUTTING AND KNURLING

Date :

Aim.

To machine a work piece by facing, plain turning, knurling and external thread cutting operationsusing a lathe.

Tools required

Lathe machine Outside Caliper Turning tool Steel Rule Knurling tool Vernier Caliper External Vthread cutting tool

Calculation

The number of teeth on change gears is calculated using the following formula

Driver teeth/ Driven teeth = Pitch of the work

-------------------------------

pitch of the lead screw.Procedure

1. The given work piece is held firmly in a lathe chuck.2. The cutting tool is set in a tool post such that the point of the cutting tool

coincides with the lathe axis.

3. The machine is switched on to revolve the work piece at the selected speed.4. By giving Cross feed and longitudinal feed to the cutting tool, the facing and

turning operations are done respectively.

5. The speed of the work piece is reduced.6. The knurling operation is done using knurling tool.7. The machine is switched off and the change gears of calculated teeth (as per

calculation) are connected.

8. Again the machine is switched on.9. The external thread cutting operation is done using external V thread cuttingtool by engaging thread cutting mechanism. The machine is switched off.10.The work piece is removed from the chuck and all the dimensions are measured

and checked.

Result

Thus the given work piece is subjected to facing, plain turning, knurling and external

thread cutting operations.


13/20

Ex No: 9 BORING AND INTERNAL THREAD CUTTINGDate :

Aim.

To perform the facing, plain turning, drilling, boring and internal thread cutting

operations on the given job.

Material Required

27 mm diameter x 50 mm length of mild steel cylindrical rod.

Tools required

Single point cutting tool Single point boring tool Internal thread cutting tool Chuck key Spanner Steel rule Vernier Caliper

Calculation

The number of teeth on change gears is calculated using the following formula

Driver teeth/ Driven teeth = Pitch of the work

-------------------------------

pitch of the lead screw.Procedure

1) The given work piece is held firmly in a lathe chuck.2) The cutting tool is set in a tool post such that the point of the cutting tool coincides with

the lathe axis.

3) The machine is switched on to revolve the work piece at the selected speed.4) By giving Cross feed and longitudinal feed to the cutting tool, the facing and turning

operations are done respectively.

5) The speed of the work piece is reduced.6) The boring operation is done using boring tool.7) The machine is switched off and the change gears of calculated teeth (as per calculation)

are connected.

8) Again the machine is switched on.9) The internal thread cutting operation is done using internal V thread cutting tool by

engaging thread cutting mechanism.

10) The machine is switched off.11)The work piece is removed from the chuck and all the dimensions are measured and

checked.

Result

Thus the given work piece is subjected to facing, plain turning, boring and internal thread

cutting operations


14/20

Ex. No : 10 OVERHEAD WELDINGDate :

Aim

To make the butt joint in the overhead position using arc welding on the given workpiece.

Material Required

Welding Transformer Electrode (12 gauge) Safety Gloves Welding Shield Chipping hammer Tongs

Procedure

1. The mild steel plates to be joined are first cleaned.2. The edge and surface to be welded are then filled or ground to get the required dimension.3. Now the metal plates to be welded are placed in position on metal plate.4. The welding electrode is held using an electrode holder and tack welds at two places are

made such that the position of the plates do not change while welding.

5. Now the electrode is made to touch the metal plates and then electrodes is separated to leavea small gap. (3 to 4 mm) between its tips and the metal plates.

6. This initiates an arc.7. Once the arc is initiated, the electrode is moved along the length of the metal pieces. For

completing the welding process on one side.

8. Using tongs, the metal plates welded on one side is over turned. Welding is now carried outon the other side.

9. After welding, the plates are allowed to cool for some time. Using a chipping hammer, oxidesare removed to complete the exercise.

Result:

Thus the two mild steel plates are welded to get the Overhead Welding.


15/20

GAS WELDING

GAS CUTTING

80

100

40 40

100


16/20

Ex. No : 11 GAS WELDING AND GAS CUTTINGDate :

Aim

To join the given two work pieces as required type of joint by gas welding.

Material used

Mild steel plate.

Tools used

Oxygen and acetylene gas cylinder with the equipments (pressure gauge,

regulators)

Gas welding torch

Filler rod

Safety goggles, gloves

Chipping hammer

Wire brush

Procedure

For Gas Welding :

1. The given workpiece are thoroughly cleaned, i.e., rust, scales are removed.2. The joining workpieces are positioned properly.3. Acetylene and Oxygen cylinder valves are opened then the Acetylene torch valve is

opened.

4. Light the tip of torch using lighter.5. Oxygen and Acetylene torch valves are adjusted and the required flame is obtained.6. The welding torch and the filler rod are moved along the line of weld and welding is done

by maintaining 3mm gap between plate and inner cone of flame.

For Gas Cutting :

1. The given workpiece is thoroughly cleaned, i.e., rust, scales are removed and positionedproperly

2. Acetylene and Oxygen cylinder valves are opened then the Acetylene torch valve isopened.

3. Light the tip of torch using lighter.4.

Oxygen and Acetylene torch valves are adjusted and the required flame for gas cutting isobtained.

5. The torch is moved along the line of cut and cutting is done by maintaining 3mm gapbetween plate and inner cone of flame.

Result

Thus the required welding and cutting is obtained by gas welding and gas cutting process

respectively.


17/20

Ex. No : 12 MAKING OF A CONE FUNNEL

Date :

Aim

To make a funnel from the given sheet metal.

Tools required

Steel rule

Mallet

Scriber

Divider

Protractor

Snips

Stakes

Ball peen hammer Solder

Procedure

1. The size of the given sheet is checked for its dimension using steel rule.2. The required development of surface is being made on the white paper which is

overlapped on the sheet metal.

3. The marking is done on the sheet metal as per the development being done on the paper.4. Now using straight snips, unwanted material are removed.5. Now fold and bend the workpiece to make the funnel shape and joint is made on the

workpieces.

6. Then using a groove, a locked grooved joint is made for about 5mm. also; hemming isdone in the bottom of the funnel.

7. In between top face and bottom face, a butt joint is made using a solder.8. Finally, trimming and finishing operations are carried out.

Result

Thus desired cone funnel is made from the given sheet metal.


18/20

BRAZING


19/20

Ex. No : 13 BRAZING

Date :

Aim

To join the given two work pieces as required type of joint by brazing.

Material used

Mild steel plate.

Tools used

Filler rod

Safety goggles, gloves

Brazing torch

Procedure

1. The given workpiece are thoroughly cleaned, i.e., rust, scales are removed.2. The joining workpieces are positioned properly.3. A flux is applied to all surfaces where the filler material is flow.4. After that the joint is heated to the proper brazing temperature.5. Solid filler metal may be replaced on the metal pieces and thus melted as the metal

pieces are heated.

6. Only small amount of filler metal is needed to fill the joint completely.

Result

Thus the required welding is obtained by brazing process.


20/20

Ex. No : 14 INJECTION MOULDINGDate :

Aim

To study about the injection moulding.

Material required

Dies Polymers Injection Moulding machine.

Procedure

1. Initially the polymer is filled in a hopper2. Then it goes to the heating section where the polymer is melted and the pressure is

increased.

3. The heated material is injected by the pushing along with the heated reciprocating screw.4. So, the heated material is forced to fill in mould cavity through the nozzle to get the

required shape of the plastic.

Result

Thus the required plastic is obtained by the injection moulding process.

MT I Lab Manual

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