PREPARATION OF GREEN SAND MOULD BY USING SOLID PATTERN
PREPARATION OF GREEN SAND MOULD BY USING SOLID PATTERN
AIM:
To make the mould of solid pattern
MATERIAL REQUIRED:
Molding sand, Parting sand, facing sand, Solid pattern, molding boxes etc.
TOOLS REQUIRED:
1. Shovel
2. Sieve
3. Trowel
4. Rammers
5. Sprue pin
6. Strike off bar
7. Lifter
8. Gate cutter
9. Runner
10. Riser
11. Vent rod
12. Draw spike
13. Bellow
SEQUENCE OF OPERATIONS:
1. Sand preparation
2. Core preparation
3. Placing the pattern on the moulding board.
4. Ramming of drag
5. Placing runner and riser
6. Ramming of cope
7. Removal of pattern, runner, riser
8. Gate cutting.
WORKING STEPS:
1. The solid pattern is placed on the moulding board.
2. A suitable core is prepared and placed in the hole of the
gearpattern.
3. Clay washing is done inside the drag surface.
4. Parting sand is applied over the pattern.
5. Box is filled with smooth moulding sand and proper
ramming isdone using flat and peen rammer.
6. Excess sand is removed using the strike off bar.
7. The drag is turned upside down.
8. The cope is placed on the drag after doing clay wash.
9. The runner and riser are placed over the pattern.
10. After applying parting sand, moulding, sand is filled
over thepart ten.
11. Ramming is done to get a rigid mould.
12. Using strike off bar excess sand is removed.
13. Vent holes are made using vent rod.
14. Runner and riser are removed and a funnel shape is made on
therunner hole.
15. Cope is kept aside and the pattern is removed using draw spike
16. The cope is placed on the drag.
RESULT:
Thus the mould is prepared and ready for casting.
PREPARATION OF GREEN SAND MOULD BY USING SPLIT PATTERN
PREPARATION OF GREEN SAND MOULD BY USING SPLIT PATTERN
AIM:
To prepare a sand mould using a split pattern.
MATERIAL REQUIRED:
Moulding sand, Parting sand, Facing sand, Gear pattern, Moulding boxes etc.
TOOLS REQUIRED:
1. Showel
2. Sieve
3. Trowel
4. Rammers
5. Sprue pin
6. Strike off bar
7. Lifter
8. Gate cutter
9. Runner
10. Riser
11. Vent rod
12. Draw spike
13. Bellow
SEQUENCE OF OPERATIONS:
1. Sand preparation
2. Core preparation
3. Placing the pattern on the moulding board
4. Ramming of drag
5. Placing runner and riser
6. Ramming of cope
7. Removal of pattern, runner, riser
8. Gate cutting.
WORKING STEPS:
1. The mould box, pattern, tools, and the table /floor are cleaned.
2. The drag is filled with green sand after positioning lower part
of thepattern on the table.
3. The green sand is rammed carefully and the excess sand is
struckoff.
4. Till the drag upside down and sprinkle river sand on top of it.
5. The cope is positioned on the top of the drag and upper part of
thepattern is positioned carefully.
6. Position the sprue pin and riser pin, then the fill cope with
sandramming is done and the excess sand is struck off.
7. Remove the sprue pin and the riser pin carefully
8. Apply water on the edges of the pattern and remove them
carefullyusing the draw spike, then finish the cavity.
9. Vent holes are made using vent wire.
10.A funnel – shaped opening and gate is made to pour the
moltenmetal.
RESULT:
Thus the mould cavity of the given split pattern is obtained.
LAP JOINT
PERFORM LAP JOINT USING ELECTRIC ARC WELDING
AIM
To join the given two work pieces as a lap joint by arc welding.
MATERIAL USED
Mild Steel plates.
TOOLS REQUIRED
[Link] [Link]
[Link] [Link] hammer
[Link] [Link]
[Link] [Link] clamps
[Link] andgoggles
PROCEDURE
1. First of all, the work pieces must be thoroughly cleaned to remove rust, scale and
other foreignmaterials.
2. Then the given work pieces are placed on the table in such a way that one work
piece is placed on the other work piece like the LAP joint is formed.
3. Appropriate power supply should be given to the electrode and the work pieces.
4. Now the welding current output may be adjusted.
5. When current is passed, arc is produced between the electrode andwork pieces.
6. Then the welding is carried out throughout the length.
7. As soon as the welding process is finished, switch off the current supply and allow
the work piece tocool.
8. Slag is removed by chipping process with the help of chipping hammer.
9. Finally using wire brush, welded portions are cleaned.
RESULT
The Lap joint was successfully prepared using Electric Arc welding, and a uniform weld bead was obtained.
PERFORM SINGLE V BUTT JOINT USING ELECTRIC ARC WELDING
AIM
To join the given two work pieces as a single ‘v’ butt joint by arc
welding.
MATERIAL USED
Mild Steel plates.
TOOLS REQUIRED
1. Welding power supply [Link] rod [Link] holder 4. Gloves and Apron [Link] and Goggles
6. Flat File [Link] hammer [Link] brush [Link] clamps
PROCEDURE
1. First of all, the work pieces must be thoroughly cleaned to remove rust, scale and other
foreign materials.
2. Then the given work pieces are placed on the table in such a way that work pieces are
brought close to close to each other so that it forms a V shapes when the plates butt each other.
3. Appropriate power supply should be given to the electrode and the work pieces.
4. Now the welding current output may be adjusted.
5. When current is passed, arc is produced between the electrode and work pieces.
6. Now set the two work pieces in correct position and maintain the gap 3mm and tag at both
ends of the work pieces as shown in figure.
7. Then the welding is carried out throughout the length.
8. As soon as the welding process is finished, switch off the current supply and allow the work
piece to cool.
9. Slag is removed by chipping process with the help of chipping hammer.
10. Finally using wire brush, welded portions are cleaned.
RESULT
The butt joint was successfully prepared using Electric Arc welding, and a uniform weld bead was obtained.
PERFORM T-JOINT USING ELECTRIC ARC WELDING
AIM
To join the given two work pieces as a ‘T’ joint by arc welding
MATERIAL USED
Mild Steel plates.
TOOLS REQUIRED
1. Welding power supply [Link] rod [Link] Hammer [Link] Holder
5. Gloves and Apron 6. Flat File [Link] brush [Link] clamps
PROCEDURE
1. First of all, the work pieces must be thoroughly cleaned to remove rust, scale and other
foreign materials.
2. Now the work pieces are placed on the table in such a way that two work pieces are abroad
close to each other T shapes are formed as shown in figure.
3. Appropriate power supply should be given to the electrode and the work pieces.
4. Now the welding current output may be adjusted.
5. When current is passed, arc is produced between the electrode and work pieces.
6. Now set the two work pieces in correct position like T joint and tag at both ends of the
work pieces as shown in figure.
7. The joint is placed on a welding table in a flat position by keeping the tag side down.
8. Then the welding is carried out throughout the work piece.
9. As soon as the welding process is finished, switch off the current supply and allow the
work piece to cool.
10. Slag is removed by chipping process with the help of chipping hammer.
11. Finally using wire brush, welded portions are cleaned.
RESULT
The T joint was successfully prepared using Electric Arc welding, and a uniform weld bead was obtained.
PERFORM SINGLE V BUTT JOINT USING GAS WELDING
AIM
To perform a butt joint on mild steel plates using Oxy-Acetylene gas welding
APPARATUS / EQUIPMENT REQUIRED
• Oxy-acetylene welding unit
• Gas cylinders (Oxygen & Acetylene)
• Pressure regulators
• Gas hoses (Red – acetylene, Blue – oxygen)
• Welding torch
• Filler rod
• Spark lighter
• Welding goggles
• Gloves & apron
• Mild steel plates (100 mm × 50 mm × 3 mm)
• Wire brush
• Chipping hammer
PROCEDURE
1. Clean the edges of the plates using a wire brush.
2. Align the plates in a butt joint configuration with a small root gap (~1–2 mm).
3. Install oxygen and acetylene cylinders and adjust pressures using regulators.
4. Connect gas hoses to the welding torch (Blue – O₂, Red – C₂H₂).
5. Open the acetylene valve slightly and ignite using a spark lighter.
6. Slowly open the oxygen valve and adjust the flame to a neutral flame.
7. Preheat the joint area until the metal becomes red hot.
8. Add the filler rod while moving the torch along the joint.
9. Maintain uniform speed and torch angle (~45°).
10. After completing welding, allow the job to cool naturally.
11. Clean slag and inspect the weld bead.
RESULT
The butt joint was successfully prepared using oxy-acetylene gas welding, and a uniform weld
bead was obtained.
LAP JOINT
PERFORM LAP JOINT USING GAS WELDING
AIM
To perform a lap joint on mild steel plates using Oxy-Acetylene gas welding
APPARATUS / EQUIPMENT REQUIRED
• Oxy-acetylene welding unit
• Oxygen and Acetylene cylinders
• Pressure regulators
• Gas hoses (Blue – oxygen, Red – acetylene)
• Welding torch
• Filler rod
• Spark lighter
• Welding goggles, gloves, apron
• Mild steel plates (100 mm × 50 mm × 3 mm)
• Wire brush & chipping hammer
PROCEDURE
1. Clean the surfaces and edges of the plates using a wire brush.
2. Place the plates in an overlapped position (10–15 mm overlap).
3. Fix the plates using clamps to avoid movement.
4. Connect oxygen and acetylene cylinders to the welding torch using appropriate hoses.
5. Open the acetylene valve slightly and ignite using a spark lighter.
6. Slowly open the oxygen valve and adjust to a neutral flame.
7. Preheat the overlap region until it becomes red hot.
8. Move the torch steadily along the joint, adding filler rod where needed.
9. Maintain a torch angle of 45°–60° for uniform heating.
10. After completing the weld, allow the job to cool gradually.
11. Clean slag and inspect the weld bead quality.
RESULT
The lap joint was successfully made using oxy-acetylene gas welding, and a proper weld bead
was formed along the overlapping edges.
PERFORM T JOINT USING GAS WELDING
AIM
To prepare a T-joint on mild steel plates using Oxy-Acetylene gas welding
APPARATUS / EQUIPMENT REQUIRED
• Oxy-acetylene welding unit
• Oxygen and Acetylene cylinders
• Pressure regulators
• Gas hoses (Blue – O₂, Red – C₂H₂)
• Welding torch
• Filler rod
• Spark lighter
• Welding goggles, gloves, apron (PPE)
• Mild steel plates (100 mm × 50 mm × 3 mm)
• Wire brush
• Chipping hammer
• Clamps / fixtures
PROCEDURE
1. Clean the plates using a wire brush to remove dirt, grease, and rust.
2. Position the plates in a T-shape using clamps/fixtures.
3. Connect oxygen and acetylene cylinders to the welding torch.
4. Open the acetylene valve slightly and ignite with a spark lighter.
5. Adjust the flame to neutral flame by adding oxygen.
6. Preheat the intersection of the plates until the metal reaches red-hot condition.
7. Start welding by adding filler rod while moving the torch uniformly along the joint.
8. Maintain a proper torch angle (~45°) for both plates for good penetration.
9. After completing the weld, allow the joint to cool naturally.
10. Clean slag and inspect the weld for uniformity and penetration.
RESULT
The T-joint was successfully prepared using Oxy-Acetylene gas welding, and a continuous
weld bead was obtained at the intersection of the plates.