EXPERIMENT NUMBER:-

Aim:- Taper turning in a lathe.

Introduction:- Lathe is the oldest machine tool invented, started with Egyptian tree-lathes. In the
Egyptian tree-lathe one end of the rope wound round the workpiece is attached to a flexible branch
of a tree while the other end is pulled by the operator thus giving rotary motion to the workpiece.
The principal form of surface produced in a lathe is the cylindrical surface. This is achieved by
rotating the workpiece while the single-point cutting tool removes the material by traversing in a
direction parallel to the axis of rotation.

Types of lathe:- Lathes of various designs and constructions have been developed to suit the
various conditions of metal machining. But all of them employ the same fundamental principal of
operation and perform the same function. The types generally used are:-
1. Speed lathe:-
a. wood working.
b. Centering.
c. Spinning.
2. Engine lathe:-
a. Belt drive.
b. Individual motor drive.
c. Gear head lathe.
3. Bench lathe.
4. Tool room lathe.
5. Capstan and turret lathe.
6. Automatic lathe.
7. Special purpose lathe:-
a. wheel lathe.
b. Gap bed lathe.
Principal parts:- figure illustrates different parts of a standard lathe. Following are the principal
parts:-
1. Bed.
2. Headstock.
3. Tailstock.
4. Carriage.
5. Feed mechanism.
6. Lead screw.
7. Spindle.
8. Toolpost.
9. Cross slide.

Operations:- operations which are performed in a lathe are:-

1. Turning.
2. Chamfering.
3. Facing.
4. Knurling.
5. Thread cutting.
6. Taper turning.
7. Drilling.
8. Boring.
9. Reaming.
10. Counterboring.

Taper may be defined as a uniform increase or decrease in diameter of a piece of work

measured along its length. In lathe taper means to produce a conical surface by gradual reduction
in diameter from a cylindrical workpiece. This tapering of a part has wide applications in the
construction of machines. Almost all machine spindles have taper holes which receive taper shank
of various tools and work holding devices.

D = large diameter of taper in mm.

d = small diameter of taper in mm.
l = length of tapered part in mm.
2α = full taper angle.
α = angle of taper or half taper angle.
The amount of taper in a workbook is usually specified by the ratio of difference in diameter of
taper to its length. This is termed as the conicity and its designated by the letter K.
D−d
K=
l
A taper turning may be turned in a lathe by feeding the tool at an angle to the axis of rotation of
the workpiece. The angle formed by the path of the tool with the axis of workpiece should
correspond to the half taper angle.

Taper turning methods:-

1. By a broad nose form tool.
2. By setting over the tail stock.
3. By swivelling the compound rest.
 4. By a taper turning attachment.
Taper turning by a form tool:- A broad nose tool having straight cutting edge is set on to
the work at half taper angle and is fed straight into the work to generate a tapered surface. The half
angle of taper will correspond to 90 minus side cutting edge angle of the tool. In this method the
tool angle should be properly checked before use. This method is limited to turn short length of
taper only. This is due to the reason that the metal is removed by the entire cutting edge and any
increase in length of the taper will necessitate the use of a wider cutting edge. This require
excessive cutting pressure which may distort the work due to vibration and spoil the work surface.

Taper turning by setting over the tailstock:- The principle of turning taper by this method is
to shift the axis of rotation of the workpiece at an angle to the lathe axis and feeding the tool
parallel to the lathe axis. The angle at which the axis of rotation of the workpiece is shifted is
equal to half angle of the taper. This is done when the body of the tailstock is made to slide on its
base towards or away from the operator by a setover screw. The amount of setover being limited
this method is suitable for small taper on long jobs. The main disadvantage of this method is that
the live and dead centres are not equally stressed and the wear is not uniform.

Taper turning by swivelling the compound rest:- This method employs the principle of
turning taper by rotating the workpiece on the lathe axis and feeding the tool at an angle to the axis
of rotation of the workpiece. The tool mounted on the compound rest is attached to a circular base
graduated in degree which may be swivelled and clamped at any desired angle. Once the
compound rest is set at the desired half taper angle rotation of the compound slide screw will
cause the tool to be fed at that angle and generate a corresponding taper. This method is limited to
turn a short taper owing to the limited movement of the compound rest. The compound rest may
be swivelled at 45° on either side of the lathe axis enabling it to turn a steep taper.

Drawing of workpiece:-

Procedure:- (Students have to write procedure in their own words after completing their job/
workpiece in workshop/ laboratory.)
Precautions:- (Students have to write the precautions which they took during completing
their job/ workpiece.)
 EXPERIMENT NUMBER:-

Aim:- Thread cutting in a lathe.

Introduction:- Lathe is the oldest machine tool invented, started with Egyptian tree-lathes. In the
Egyptian tree-lathe one end of the rope wound round the workpiece is attached to a flexible branch
of a tree while the other end is pulled by the operator thus giving rotary motion to the workpiece.
The principal form of surface produced in a lathe is the cylindrical surface. This is achieved by
rotating the workpiece while the single-point cutting tool removes the material by traversing in a
direction parallel to the axis of rotation.

Types of lathe:- Lathes of various designs and constructions have been developed to suit the
various conditions of metal machining. But all of them employ the same fundamental principal of
operation and perform the same function. The types generally used are:-
1. Speed lathe:-
a) wood working.
b) Centering.
c) Spinning.
2. Engine lathe:-
a) Belt drive.
b) Individual motor drive.
c) Gear head lathe.
3. Bench lathe.
4. Tool room lathe.
5. Capstan and turret lathe.
6. Automatic lathe.
7. Special purpose lathe:-
a) wheel lathe.
b) Gap bed lathe.
Principal parts:- Figure illustrates different parts of a standard lathe. Following are the principal
parts:-
1. Bed.
2. Headstock.
3. Tailstock.
4. Carriage.
5. Feed mechanism.
6. Lead screw.
7. Spindle.
8. Toolpost.
9. Cross slide.

Operations:- Operations which are performed in a lathe are:-

1. Turning.
2. Chamfering.
3. Facing.
4. Knurling.
5. Thread cutting.
6. Taper turning.
7. Drilling.
8. Boring.
9. Reaming.
10. Counterboring.

Drawing of workpiece:-

Procedure:- (Students have to write procedure in their own words after completing their job/
workpiece in workshop/ laboratory.)
Precautions:- (Students have to write the precautions which they took during completing
their job/ workpiece.)
 EXPERIMENT NUMBER:-

Aim:- Slot cutting in a shaper.

Introduction:- The shaper is a reciprocating type of machine tool intended primarily to produce
flat surfaces. These surfaces may be horizontal, vertical or inclined. In general the shaper can
produce any surfaces composed of straight line elements.
In shaping, the tool has a reciprocating movement, the cutting taking place on the forward
stroke along the whole length of the surface being generated, while the reverse stroke is made
with the tool lifted clear, to avoid damage to the tool or the work. The next stroke is made when
the work has been moved by the feed distance, which may be either horizontal or vertical.

Types of shaper:- Shapers are classified in a number of ways depending upon the general features
of design or the purpose for which they are intended. Shapers are classified under the following
headings:-
1. according to the type of mechanism used for giving reciprocating motion to the
ram:
a. crank type
b. geared type
c. hydraulic type
2. according to the position and travel of ram:
a. horizontal type
b. vertical type
c. travelling head type
3. according to the type of design of the table:
a. standard shaper
b. universal shaper
4. according to the type of cutting stroke;
a. push type
b. draw type
Principal parts:- Figure illustrates different parts of a standard shaper.
1. Base.
2. Column.
3. Crossrail.
4. Ram.
5. Tool head.
6. Table.

Shaper mechanism:- In a shaper, rotary movement of the drive is converted into reciprocating
movement by the mechanism contained within the column of the machine. The ram holding the
tool gets the reciprocating movement. In a standard shaper metal is removed in the forward cutting
stroke while the return stroke goes idle and no metal is removed during this period. The
reciprocating movement of the ram and the quick return mechanism of the machines are usually
obtained by any of the following methods:-
1. Crank and slotted link mechanism.
2. Whitworth quick return mechanism.

Shaper operations:- A shaper is a versatile machine tool primarily designed to generate a flat
surface by a single point cutting tool. But it may also be used to perform many other operations.
The different operations which a shaper can perform are as follows:-
1. Machining horizontal surface.
2. Machining vertical surface.
3. Machining angular surface.
4. Cutting slots, grooves and keyways.
5. Machining irregular surfaces.
6. Machining splines or cutting gears.

Drawing of workpiece:-

Procedure:- (Students have to write procedure in their own words after completing their job/
workpiece in workshop/ laboratory.)
Precautions:- (Students have to write the precautions which they took during completing
their job/ workpiece.)
 EXPERIMENT NUMBER:-

Aim:- Gear cutting in milling machine using indexing head.

Introduction:- A milling machine is a machine tool that removes metal as the work is fed against
a rotating multipoint cutter. The cutter rotates at a high speed and because of the multiple cutting
edges it removes metal at a very fast rate. The machine can also hold one or more number of
cutters at a time.

Types of milling machine:- The milling machine can be classified in several form covering a
wide range of work and capacities, but the choice of any particular machine is determined
primarily by the nature of the work to be undertaken both in relation to the size and operation to be
performed. The usual classifications according to the general design of the milling machines are:
1. Column and knee type:-
a. hand milling machine.
b. Plain milling machine.
c. Universal milling machine.
d. Vertical milling machine.
2. Manufacturing of fixed bed type:-
a. Simplex milling machine.
b. Duplex milling machine.
c. Triplex milling machine.
3. Planer type.
4. Special type:-
a. Rotary table milling machine.
b. Drum milling machine.
c. Planetary milling machine.

Principal parts:- The principal parts of a column and knee type milling machine illustrated in
figure are:
1. Column.
2. Base.
3. Knee.
 4. Table.
5. Overarm.
6. Saddle.
7. Arbor.

Milling machine operations:- The following are different operations performed in a milling
machine:
1. Plain milling.
2. Face milling.
3. Side milling.
4. Straddle milling.
5. Angular milling.
6. Gang milling.
7. Form milling.
8. End milling.
9. Gear cutting.

Safety measures in milling:- Milling machine operators must be extremely careful in running this
machine tool. The following safe-working practices must be followed:-
1. Learn to operate controls before operating the machine.
2. Workpiece must be rigidly held on the worktable.
3. Do not change spindle speed when the machine is running.
4. Do not remove or tighten the milling machine arbor nut with power on.
5. Keep hands and body away from the revolving cutter.
6. Do not measure work while the cutter is cutting or revolving near the
workpiece.
7. Remove chips with a suitable brush. Do not remove chips when the machine
is running.
8. Do not lean on the machine when it is running.

Drawing of workpiece:-

Procedure:- (Students have to write procedure in their own words after completing their job/
workpiece in workshop/ laboratory.)
Precautions:- (Students have to write the precautions which they took during completing
their job/ workpiece.)
 EXPERIMENT NUMBER:-

Aim:- Study of turning tool of lathe (Tool signature).

Introduction:- Metal cutting processes are industrial processes in which metal parts are shaped by
the removal of unwanted material. we will only consider turning from various traditional chip-
forming processes such as turning, boring, drilling, and milling. In these operations, metal is
removed as a plastically deformed chip of appreciable dimensions.
Cutting-tool design has a strong impact on machining performance. Properly designed
tools produce parts of consistent quality and have long and predictable useful lives. An improperly
designed tool may wear or chip rapidly or unpredictably, reducing productivity, increasing costs,
and producing parts of deteriorating quality. Tooling thus has a major influence on the productivity
and economics of a process. It is important to consider all tooling geometries and material
options for a given application, and especially the range of speeds and feeds for which each can be
applied and their typical failure modes.
Cutting tools may be broadly classified as single point tools, which have one active cutting
edge, and multipoint, multifunctional, or multitasking tools, which have multiple active cutting
edges. Single point tools are commonly used for turning and boring, while multipoint tools are
used for drilling, milling, and in special purpose tooling. Multifunctional or multitasking tools are
used to machine multi-step holes or several features with one tool.

Material properties:- Cutting tools must be made of materials capable of withstanding the high
stresses and temperatures generated during chip formation. Ideally, tool materials should have the
following properties:
1. High deformation resistance to prevent the edge from deforming or collapsing
under the stresses produced by chip formation.
2. High fracture toughness to resist edge chipping and breakage, especially in
interrupted cutting.
3. Chemical inertness (low chemical affnity) with respect to the work material to resist
diffusion and chemical wear.
4. High thermal conductivity to reduce cutting temperatures near the tool edge.
5. High fatigue resistance, especially for tools used in interrupted cutting.
6. High thermal shock resistance to prevent tool breakage in interrupted cutting.

Turning tool:- Turning is carried out primarily using single-point cutting tools, or tools with a
single active cutting surface. Together with planing and shaping, turning is the most basic cutting
process; an understanding of the cutting action and geometry of single-point turning tools
therefore provides insight into the basic cutting action and geometry of more complex tools. In the
past, solid single-point tools ground from a HSS blank were most commonly used for turning. At
present, however, turning is most commonly carried out using indexable inserts.

Tool geometry:-
1. Rake angles (back and side):-They can be positive, zero or negative. Shear angle is directly
affected by the rake angle. Larger rake angles are beneficial for machining efficiency
giving rise to the lower cutting force and power. However increasing to a very high value
decreases the strength of the tool tip. Small rake angles are used for cutting hard materials
while large angles are used for cutting soft and ductile.
2. Side cutting edge angle:- Side cutting edge angle (SCEA) prevents the sudden engagement
of the entire depth of cut when the tool enters the work material. As a result it affects the
resulting tool life and surface finish. It can vary from 0 0 to 900. when it is zero the entire
cutting edge will engage at the same time with the workpiece. When the SCEA is increased
the entry of the tool is smooth to the start cut since the depth of cut will gradually increase
untill the entire cutting edge is in contact with the workpiece. The chip produced is thinner
and wider with increased SCEA.

3. End cutting edge angle :- The purpose of the End cutting edge angle (ECEA) is to relieve
the trailing end of the cutting edge to prevent rubbing the machined surface. To that extent
only a small angle is sufficient for this purpose. It is not desirable to have a large ECEA as
it takes away material that supports the cutting edge and hinders the conduction of heat
away from the point.
4. Relief angles (side and end):- The function of the relief angles is to prevent the rubbing of
the flank of the tool with the machined surface. In general turning relief angles ranging
from 50 to 150 are used. Similar to ECEA small relief angles give strength to the cutting
edge when machining hard and strong materials. Increased values of relief angles allow the
tool to penetrate and cut the workpiece materials more efficiently, thereby reducing the
cutting forces.
 EXPERIMENT NUMBER:-

Aim:- Study of twist drill.

Introduction:- Machining is the most versatile and accurate of all manufacturing processes in its
capability to produce a diversity of part geometries and geometric features. Casting can also
produce a variety of shapes, but it lacks the precision and accuracy of machining.

Twist drill structural properties:- The structural properties of the drill have a direct bearing on
drilling performance. From a structural viewpoint, several features of a twist drill are significant as
illustrated in figure.
1. Shank or drive type:- The butt end of the drill is generally held in a holder or the spindle
and driven. Straight shank drills with or without ground flats are mounted in end mill
holders, collets, chucks, or special hydraulically or mechanically clamped holders. Tapered
shank drills are mounted directly into the spindle with or without
intermediate sleeves or adapters.
2. Helix angle. The helix angle is the angle between the leading edge of the land and the
drill axis. Standard helix drills have a helix angle of approximately 30° and are used for
drilling malleable and cast irons, carbon steels, stainless steels, hard aluminum alloys,
brass,
and bronze. Low (slow) helix drills have helix angles of approximately 12°. They have
increased cutting edge strength and are used for drilling high temperature alloys and other
hard-to-machine materials. Zero helix (straight flute) drills have a 0° helix angle. They are
used for materials that produce short chips such as brass, other non ferrous materials, and
cast iron.
3. Hand or direction of rotation. The vast majority of drills are right-handed and rotate in a
clockwise direction when viewed from the shank end.
4. Number of flutes. The number of flutes may vary from one to four, with two being the most
common choice. The optimum number of flutes on a drill depends on the drill diameter,
the work material, required hole quality, and hole exit conditions.
5. Coolant hole(s). Solid drills without coolant holes are used for shallow holes (up to two
diameters deep) and for conventional tool penetration rates (using feeds in the range of
0.008–0.011 mm per cutting edge per mm of drill diameter). Solid drills with coolant
feeding hole(s), called coolant-fed or oil-hole drills, have passages that run through the
drill
body. Cutting fluid is fed through these passages to improve chip ejection and cool the
cutting edges, which permits use of higher cutting speeds and penetration rates.
6. Web and flute geometry. The strength of a drill is largely determined by its web and flute
sizes. The two main conflicting parameters in drill body design are adequate flute area for
efficient chip disposal and high drill rigidity to reduce deflection and increase dynamic
stability. The ratio of the web thickness to the drill diameter directly affects the drill’s
torsional and bending strength.
 EXPERIMENT NUMBER:-

Aim:- Drilling, boring and reaming of a hole.

Drilling:- Drilling is a machining operation used to create a round hole in a workpart. Drilling is
usually performed with a rotating cylindrical tool that has two cutting edges on its working end.
The tool is called a drill or drill bit. The most common drill bit is the twist drill. The rotating drill
feeds into the stationary workpart to form a hole whose diameter is equal to the drill diameter.
Drilling is customarily performed on a drill press, although other machine tools also perform this
operation.

Reaming:- Reaming is used to slightly enlarge a hole, to provide a better tolerance on

its diameter, and to improve its surface finish. The tool is called a reamer, and it usually
has straight flutes. Reamer is a multi-tooth cutter which rotates and moves linearly into an already
existing hole. The previous operation could be drilling or boring. Reaming will provide smooth
surface as well as close tolerance on the diameter of the hole. Generally the reamer follows the
already existing hole and therefore will not be able to correct the hole allignment.

Boring:- Boring is an operation of enlarging a hole. The single point cutting tool used for boring
operation. Generally the single point tool bit is mounted in the boring bar of suitable diameter. It is
possible to carry out the boring operation in a lathe for limited applications while in drilling and
milling machines a large range of holes can be bored using the multiple point cutting tool in
addition to the single point tool.

Drawing of workpiece:-

Procedure:- (Students have to write procedure in their own words after completing their job/
workpiece in workshop/ laboratory. Use the same workpiece for boring which is used for drilling
in a continuous operation.)
Precautions:- (Students have to write the precautions which they took during completing
their job/ workpiece.)
 EXPERIMENT NUMBER:-

Aim:- Joining MS plate by arc welding (SMAW, MIG).

Introduction:- Welding is a materials joining process in which two or more parts are coalesced at
their contacting surfaces by a suitable application of heat and/or pressure. Many welding
processes are accomplished by heat alone, with no pressure applied; others by a combination of
heat and pressure; and still others by pressure alone, with no external heat supplied. In some
welding processes a filler material is added to facilitate coalescence. The assemblage of parts that
are joined by welding is called a weldment.

Its commercial and technological importance derives from the following:

1. Welding provides a permanent joint. The welded parts become a single entity.
2. The welded joint can be stronger than the parent materials if a filler metal is used
that has strength properties superior to those of the parents, and if proper welding
techniques are used.
3. Welding is usually the most economical way to join components in terms of
material usage and fabrication costs.
4. Welding is not restricted to the factory environment. It can be accomplished ‘‘in the
field.’’

Although welding has the advantages indicated above, it also has certain limitations and
drawbacks:
1. Most welding operations are performed manually and are expensive in terms of
labour cost. Many welding operations are considered ‘‘skilled trades,’’ and the
labour to perform these operations may be scarce.
2. Since welding accomplishes a permanent bond between the components, it does not
allow for convenient disassembly. If the product must occasionally be disassembled
(e.g., for repair or maintenance), then welding should not be used as the assembly
method.
3. The welded joint can suffer from certain quality defects that are difficult to detect.
The defects can reduce the strength of the joint.

Types of welding:- We can divide the welding processes into two major groups:
1. Fusion welding.
2. Non-fusion welding.
Fusion-welding processes use heat to melt the base metals. In many fusion welding
operations, a filler metal is added to the molten pool to facilitate the process and provide bulk and
strength to the welded joint. A fusion-welding operation in which no filler metal is added is
referred to as an autogenous weld. Examples are arc welding, oxy-fuel gas welding etc..
Solid-state welding refers to joining processes in which coalescence results from
application of pressure alone or a combination of heat and pressure. If
heat is used, the temperature in the process is below the melting point of the metals being
welded. No filler metal is utilized. Examples are friction welding, forge welding etc..

Shielded Metal Arc Welding (SMAW) :- The shielded metal arc welding (SMAW)process is also
known as the stick welding process. Metal coalescence is produced by the heat from an electric arc
that is maintained between the tip of flux-coated (or “coated” or “covered”), discontinuous
consumable (or “stick”) electrode and the surface of the base metal being welded. A core wire
conducts the electric current from a constant current power supply to the arc and provides most of
the filler metal to the joint.
The covering, coating, or flux on an SMAW electrode performs many functions. First, it
provides a gaseous shield to protect the molten metal of the weld from the air. The second thing a
coating does is provide deoxidizers and fluxing or reducing agents as molten metal compounds to
deoxidize or denitrify and cleanse the molten weld metal, as in metallurgical refining. Once
solidified, the slag that is formed from the flux protects the already solidified, but still hot and
reactive, weld metal from oxidation. It also aids out-of-position welding by providing a shell or
mould in which molten weld metal can solidify. The third thing a coating does is provide arc
stabilizers in the form of readily ionized compounds (e.g., potassium oxalate or lithium carbonate)
to help initiate the arc and keep the arc steady and stable by helping to conduct current by
providing a source of ions and electrons.

Metal Inert Gas Welding (MIG) :- The gas-metal arc welding (GMAW) (or metal-inert gas,
MIG) process employs a continuous consumable (usually) solid wire electrode and an externally
supplied inert shielding gas. The consumable wire electrode produces an arc with a workpiece
made part of the electric circuit and provides filler to the weld joint. The wire is fed to the arc by
an automatic wire feeder. The externally supplied shielding gas plays dual roles in GMAW. First, it
protects the arc and the molten or hot, cooling weld metal from air. Second, it provides desired arc
characteristics through its effect on ionization.
 Constant voltage (CV) DC welding power supplies can be used. Either DCSP (DCEN) or
DCRP (DCEP) may be used, depending on the particular wire and desired mode of molten metal
transfer, but the DCRP (DCEP) mode is far more common. The reason is that in the RP mode,
electrons from the negative workpiece strike the positive wire to give up their kinetic energy in the
form of heat to melt and consume the wire.

Drawing of workpiece:-

Procedure:- (Students have to write procedure in their own words after completing their job/
workpiece in workshop/ laboratory.)
Precautions:- (Students have to write the precautions which they took during completing
their job/ workpiece.)
 EXPERIMENT NUMBER:-

Aim:- Moulding of a multi piece pattern by green sand moulding.

Introduction:- Casting is a process in which molten metal flows by gravity or other force into a
mould where it solidifies in the shape of the mould cavity. The term casting is also applied to the
part that is made by this process. The principle of casting seems simple: melt the metal, pour it
into a mould, and let it cool and solidify; yet there are many factors and variables that must be
considered in order to accomplish a successful casting operation.
As a production process, casting is usually carried out in a foundry. A foundry is a factory
equipped for making moulds, melting and handling metal in molten form, performing the
casting process, and cleaning the finished casting. The mould contains a cavity whose geometry
determines the shape of the cast part. The actual size and shape of the cavity must be slightly
oversized to allow for shrinkage that occurs in the metal during solidification and cooling.

Sand casting moulds:- Sand casting is by far the most important casting process. A sand-casting
mould will be used to describe the basic features of a mould. Figure shows the cross-sectional
view of a typical sand-casting mould, indicating some of the terminology. The mould consists of
two halves: cope and drag. The cope is the upper half of the mould, and the drag is the bottom
half. These two mould parts are contained in a box, called a flask, which is also divided into two
halves, one for the cope and the other for the drag. The two halves of the mould separate at the
parting line.

In sand casting (and other expendable-mould processes) the mould cavity is formed by
means of a pattern, which is made of wood, metal, plastic, or other material and has the shape of
the part to be cast. The cavity is formed by packing sand around the pattern, about half each in the
cope and drag, so that when the pattern is removed, the remaining void has the desired shape of
the cast part. The pattern is usually made oversized to allow for shrinkage of the metal as it
solidifies and cools. The sand for the mould is moist and contains a binder to maintain its shape.
The cavity in the mould provides the external surfaces of the cast part. In addition, a
casting may have internal surfaces. These surfaces are determined by means of a core, a form
placed inside the mould cavity to define the interior geometry of the part. In sand casting, cores
are generally made of sand, although other materials can be used, such as metals, plaster, and
ceramics.

Drawing of workpiece:-

Procedure:- (Students have to write procedure in their own words after completing their job/
workpiece in workshop/ laboratory.)
Precautions:- (Students have to write the precautions which they took during completing
their job/ workpiece.)
 EXPERIMENT NUMBER:-

Aim:- Making a mould with core and casting.

Introduction:- Casting is a process in which molten metal flows by gravity or other force into a
mould where it solidifies in the shape of the mould cavity. The term casting is also applied to the
part that is made by this process. The principle of casting seems simple: melt the metal, pour it
into a mould, and let it cool and solidify; yet there are many factors and variables that must be
considered in order to accomplish a successful casting operation.
As a production process, casting is usually carried out in a foundry. A foundry is a factory
equipped for making moulds, melting and handling metal in molten form, performing the
casting process, and cleaning the finished casting. The mould contains a cavity whose geometry
determines the shape of the cast part. The actual size and shape of the cavity must be slightly
oversized to allow for shrinkage that occurs in the metal during solidification and cooling.

Sand casting moulds:- Sand casting is by far the most important casting process. A sand-casting
mould will be used to describe the basic features of a mould. Figure shows the cross-sectional
view of a typical sand-casting mould, indicating some of the terminology. The mould consists of
two halves: cope and drag. The cope is the upper half of the mould, and the drag is the bottom
half. These two mould parts are contained in a box, called a flask, which is also divided into two
halves, one for the cope and the other for the drag. The two halves of the mould separate at the
parting line.

In sand casting (and other expendable-mould processes) the mould cavity is formed by
means of a pattern, which is made of wood, metal, plastic, or other material and has the shape of
the part to be cast. The cavity is formed by packing sand around the pattern, about half each in the
cope and drag, so that when the pattern is removed, the remaining void has the desired shape of
the cast part. The pattern is usually made oversized to allow for shrinkage of the metal as it
solidifies and cools. The sand for the mould is moist and contains a binder to maintain its shape.
The cavity in the mould provides the external surfaces of the cast part. In addition, a
casting may have internal surfaces. These surfaces are determined by means of a core, a form
placed inside the mould cavity to define the interior geometry of the part. In sand casting, cores
are generally made of sand, although other materials can be used, such as metals, plaster, and
ceramics.

Drawing of workpiece:-

Procedure:- (Students have to write procedure in their own words after completing their job/
workpiece in workshop/ laboratory.)
Precautions:- (Students have to write the precautions which they took during completing
their job/ workpiece.)