LABORATORY MANUAL

MANUFACTURING PRATICE
ME 218 E

LIST OF PRACTICALS

Sr. No

Name of Practical

Page No
From To
01
03

To make the pattern for a given casting with all the necessary
allowances, parting line running system details. Prepare the
mould and make the casting. Investigate the casting defects and
suggest the remedial measures.

To make a component involving horizontal and vertical welding

and study the welding defects and suggests their remedies.

04

07

To prepare a job on surface Grinder / Cylindrical Grinder and

measure the various parameters of the finished piece.

08

09

To Cut external threads on a lathe.

10

11

Manufacturing and assembly of a unit consisting of 2 & 3

components to have the concept of tolerances and fits (shaft and
bush assembly or shaft key or bush assembly or any suitable
assembly).

12

13

Leveling of machine tools and testing their accuracy.

14

14

Disassembly and assembly of small assembles such as tail stock,

bench vice and screw jack etc.

15

16

Development and manufacture of complex sheet metal

components such as funnel etc.

17

18

Multi slot cutting on Milling machine by indexing.(Cutting of

slots on a circular piece at 90)

19

19

10

To drill and tap holes on a metal plate and investigate the

accuracy of tapping holes.

20

21

EXPERIMENT NO.1
Aim: - To make a pattern for a given casting with all necessary allowances, parting line,
running system details. Prepare the mould and make the casting. Investigate the casting
defects and suggest the remedial measures.
Tools required: Steel scale, try square, saw, rasp, hand drilling machine, mould box, shovel, hand riddle,
vent wire, trowel, lifter, gate cutter, Strike of bar, runner, riser, sprue pin, licks, rammers
swab, crucible tong furnace.
Material required: Kellwood of required size, green sand mixture.
Procedure: 1. Two wooden pieces of required size are to be cut.
2. Length, width and height for pattern are marked on both pieces.
3. One piece is clamped in vice and unwanted material is removed as per marking using
saw and rasp file and finish it.
4. The process is repeated on the second piece.
5. Mark the center line on both blocks for drilling holes.
6. Do the drilling according to marking both the pieces up to half of thickness of the
pattern.
7. Join the pattern with the help of dowels.
8. Then a mould box suitable for the pattern should be selected.
9. Lower part of pattern is placed in the middle of drag.
10. Drag is filled with the moulding sand and rammed properly.
11. Parting sand is sprinkled over the top surface of the mould.
12. The cope is placed over the drag in proper position.
13. Then the top part of the pattern is assembled in position
14. Runner and riser are placed in position and the cope is filled with sand and rammed.
15. Then the cope is separated from drag and the pattern is removed.
16. The gate is made using gate cutter and mould cavity.
17. The cope is placed in position and locked.
18. The mould is allowed drying.
19. The mould is ready for pouring.
20. Metal is melted in crucible to correct temperature.
21. The crucible is held with a tong and metal is poured in the mould and allowed to
solidify and cool.
22. After cooling the casting is extracted by breaking the mould.
23. Cut of the gate.
24. The entire surface is cleaned using wire brush.
3

Precautions: 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 gloves when doing casting.
Defects in casting and there remedial measures: The chief defects in casting are: Blow holes, shrinkage cavity metal penetration and rough
surfaces, hot tears, displaced cores etc.
Blow holes: - Blow holes are internal porosity or surface depression as a result of excessive
gasses material that cannot escape. They are caused by low permeability, excessive
moisture, hard ramming and excessive organic material. They can be controlled by taking
care of above points.
Shrinkage cavity: - When ever feeding is inadequate internal unsoundness is usually
indicated by some external imperfection either the wall deformation by dishing at the
weakest point. Remedial of the cause proper design of gates and runners.
Metal penetration and rough surfaces: It refers to the condition of penetration of metal in the interstices of the sand grains. It causes
a fused aggregate of metal and sand on the surface of casting which results in rough surface
finish. It is caused by sft ramming, too coarse mould and core sand and excessive metal
temperature.
Hot Tears: - It is caused by excessive mould, hardness by ramming, high dry and hot
strength, improper metallurgical and pouring temperature controls and provision of
insufficient fillets or bracket at the junction of sections.
Displaced cores: - These occur due to the buoyancy of cores in molten metal. Cores should
be firmly anchored. In long cores, bending can be taken care of by using stiff core irons and
chaplets placed correctly.

EXPERIMENT NO.2
Aim: - To make the component involving horizontal and vertical welding and study the
welding defects and suggests there remedies.
Tool required: - Scale, scriber, hand hack saw, flat file, welding m/c, eye shield, gloves,
wire brush, chipping hammer, welding rod etc.
Material required: - mild steel plates of 8mm thickness.
Procedure: 1. Two pieces are cut to size and surface to be welded are cleaned properly.
2. Electrode is held in electrode holder and earth clamp is clamped to the work piece.
3. The pieces are positioned first for horizontal welding. The two work pieces rest one
over the other with flat faces in vertical plane. As shown in fig. Then tack weld is done at
two end points.
4. 2 -3mm spark gap is maintained and horizontal welding is done smoothly.
5. For vertical welding the two pieces to be positioned so the axis of weld remain
vertical and tack weld is done at two points.
6. The welding should be started from the bottom and proceeds up words.
7. Slag is removed using chipping hammer and weld is cleaned using wire brush.
Precautions: 1. Wear apron, shoes, gloves, nose mask and tight clothes.
2. Be careful and attentive while working on welding job.
3. During welding dont see the welding light rays directly without the goggles / face
shield.
4. Do not cool the welding piece in the water.
5. Dont keep electrode holder on the welding m/c.
6. No inflammable material should be present in welding shop.
Defects in welding and their remedial measures: Porosity and blow holes: - Porosity is a group of small voids, which will be generated in the
weld bead, when gases will get entrapped in the weld bead. Remedies of this are reduce
welding speed, to allow time for gases to escape, clean the base properly and proper arc
length, welding current, welding techniques and electrode should be used.
Slag Inclusion: - Flux used in welding reacts with impurities and for a slag. If this slag is
mixed with weld bead that defects is called slage inclusion so slag inclusion are compounds
such as oxides flux and electrode coating materials that are trapped weld zone. It remedies
are clean surface and previous weld bead properly. Use proper arc length, angle and speed.
5

Incomplete fusion and penetration: - If the molten metal does not (fuse) mix properly with
the base metal that defects is called incomplete fusion or lack of fusion. It remedies are use
proper arc current, less arc travel speed, shorter arc length and use small electrode and
design of joint well.
Cracks: - Cracks may occur in various location and direction in the weld area. Cracks may
appear in crater, under bead, base metal or in the root. Its remedies are cooling rate should be
reduced. Use fresh and baked electrode. Increase welding current and electrode size and
reduce travel speed. Use preheats, anneal the base metal.
Spatter: - Spatter refers to small particles of metals which are scattered around the weld
along its length. Its remedies are use proper welding current arc length and lower arc
voltage. And use fresh or baked electrodes and reduce arc blow.

EXPERIMENT NO.3
Aim: - To prepare a job on Surface Grinder / Cylindrical Grinder and measure the various
parameters of the finished piece.
Tool & Instruments required: - Straight disc grinding wheel, roughness checking gauge,
steel scale and micrometer.
Material required: - 1005015mm mild steel plate.
Procedure: 1. Work piece is to be cut to size.
2. Work piece held on magnetic chuck of the machine and set as per wheel position.
3. Longitudinal feed to the work is given by reciprocating the table.
4. Cross feed is given by moving the wheel head in and out.
5. A rough cut over the whole surface is completed by giving small in feed of 0.02mm.
6. Then finish cut is completed by giving in feed 0.01mm.
7. Repeat the operation for opposite surface.
8. The piece is cleaned and thickness is measured.
9. Surface finish is checked with roughness checking gauge.
Precautions:1. Suitable coolant to be used in grinding.
2. Use of higher feed and slow speed for rough work and low feed and higher speed for
finishing operation is always recommended.
3. Nut for tightening the wheel on spindle should always be in opposite direction of
wheel rotation.
4. Wear apron, shoes and tight fitted clothes.
5. Be careful and attentive while working on the machine.