Bansilal Ramnath Agarwal Charitable Trust’s
Vishwakarma Institute of Technology, Pune-48
(An Autonomous Institute affiliated to Savitribai Phule Pune University)
Department of Mechanical Engineering
Second Year B. Tech. Mechanical Engineering
Manufacturing Processes (ME2302)
Prepared by: Dr. Satish Chinchanikar (Course Owner)
LAB WORK
Job 1: Sand moulding and pattern making
Job 2: Composite Job involving different operations such as turning, milling, drilling,
grinding, etc.
Jobs 3-5: Demonstrations and assignments (Case studies): Plastic moulding, Sheet metal
working, and Joining processes
Job 6: 3-D printing of a simple geometry
A case study supported with industrial visit: EDM/AJM/ECM/3-D printing
Course Project: Presentation, evaluation, and Submission of a research paper or filing a
patent on Case studies/Course project
Job 1: Sand moulding
Select any one from the following given objects and answer the following questions.
1. Compute the amount of heat that must be added to the metal to heat it from room temperature
to the pouring temperature which is 1000C above its melting temperature.
2. Assuming suitable dimensions for height of the pouring basin and height (length) of sprue,
calculate the diameter of the sprue base for avoiding aspiration. Also obtain velocity of the
molten metal at the base of the sprue, volume rate of flow and time to fill the mould.
3. Previous observations indicated that for a casting of the same shape, material and with
increase in all the dimensions by 10% for the selected casting, the total solidification time for
casting is 12 min. Obtain the total solidification time for the selected casting under similar
conditions.
4. Design a cylindrical riser for a selected sand casting mould if the riser will have a diameter to
height ratio as unity. Consider the total solidification time of riser is 20% higher than the
total solidification time for the selected casting.
5. Design a pattern for the selected casting considering a suitable pattern material and pattern
allowances.
6. Sketch the pattern considering allowances. Also, comment on the core and core print
requirement. Comment on the probable casting defects and their remedies.
1
2
3
4
Plastic Processing (Demonstration and Assignment 1)
1. Compare thermoplastic and thermosetting plastics.
2. Categorize the following applications of thermoplastic and thermosetting plastics:
Telephone receivers, electric plugs, radio and T.V. cabinets, camera bodies, circuit breaker,
switch panels, gears, knobs, handles, dishes, container taps and fittings, washing machine
agitators and housings, electronic components with moulded terminals, pins, studs,
connectors, toys, combs, toilet goods, photographic films, insulating tapes, hoses electrical
insulation.
3. State the classification of processing of plastics.
4. State the appropriate plastic processing method(s) for manufacturing of following
applications: Cups, chairs, toys, containers, knobs, car dash board, car handles, air
conditioner parts, plumbing fittings, radiator fan, cosmetic packaging, food and water bottles,
doll bodies, pipes, automobile fuel tanks, hollow containers, luggage bags, refrigerator inner
panels, tubes of U, Y, or J sections, pipes or tubes, drinking straws, plumbing pipes, optical
fibers, plastic coated wires, window frames, garbage bags, flat window glazing, ATM cards,
rainwear, tapes, trays, floor tiles, laminations and transparent film used for packaging, hollow
profiles like tubes and pipes, coating of wires and cables.
5. Explain the most appropriate manufacturing process for manufacturing of plastic bathtubs,
buckets, chairs, and hollow containers with sketches (Any two).
Joining Processes (Demonstration and Assignment 2)
6. Compare TIG, MIG, Plasma arc welding, Submerged arc welding, shielded metal arc
welding, flux cored arc welding, Electroslag welding and electrogas welding processes in
terms of a) Source of heat,
b) Type of electrode used,
c) Weldable metals,
d) Cost of welding equipments,
e) Flux material,
f) Thickness of workpiece to be welded and
g) Major applications.
2) Determine the melting efficiency in the case of arc welding of steel with a potential of 22V
and current of 230 A. The cross-sectional area of the joint is 25 mm 2 and the travel speed is 6
mm/s. Heat required to melt steel may be taken as 10 J/mm 3 and the heat transfer efficiency as
86 percent.
3) It is required to weld a low carbon steel plate by the manual metal arc welding process using a
linear V.I. characteristic D.C. power source. The following data are available:
a) Open circuit voltage for power source = 62 V
b) Short circuit current = 130 A
5
c) Arc length = 4 mm
c) Transverse speed of welding = 15 cm/min
d) Voltage is given as, V = 20 + 1.5 L (L being arc length in mm)
e) Efficiency of heat input = 84 percent
Calculate the heat input to the workpiece.
Questions for Practice
Compare:
A.C. and D.C. welding process,
Leftward and rightward welding technique,
Soldering, brazing and braze welding,
Arc welding, gas welding and resistance welding.
Sheet Metal Working (Demonstration and Assignment 3)
Parts shown below are to be made from mild steel sheet 2 mm thickness. Ultimate
shear strength of M.S. is 200 N/mm2. Determine (a) Strip layout and percent
utilization (Strip utilization factor, SUF), b) Punch and die dimensions (c) Centre of
Pressure and (d) Total cutting force required if no shear is provided either on the
punch or the die. (e) Draw a sketch press and die tool and comment how you will
reduce the force required on punching and blanking. (All dimensions mentioned in
Figures are in mm). Solve any one problem.
6
Practice problems
1. A washer of inner diameter 14 mm and outside diameter 35 mm with ultimate shearing
strength of 290 N/mm2 is used. (a) Find the total cutting force if both punches act at the same
time and no shear is provided on the die or punch, (b) What will be the cutting force, if the
punches are staggered so that only one punch acts at a time? (c) Taking 65% penetration and
shear on punch 1 mm, what will be the cutting force if both punches act together. Take sheet
thickness as 1.5 mm.
7
2. A hole of 65 mm diameter is to be produced in steel plate of 3 mm thick. The ultimate
shearing strength of the plate material is 450 MPa. Find the amount of shear on the punch
if the punching force is to be reduced to half of the force required when operation carried
using a punch without shear. Take percentage penetration of 45%.
3. A part shown below is to be made from mild steel sheet 2 mm thick. Ultimate shear
strength of M.S. is 200 N/mm2. Determine (a) Strip layout and percent utilization, b)
Punch and die dimensions (c) Centre of Pressure and (d) Total cutting force required if no
shear is provided either on the punch or the die. (All dimensions mentioned in Figure are
in mm).