GWALIOR INSTITUTE OF INFORMATION TECHNOLOGY
A
Practical File on
MANUFACTURING PROCESS (ME-305)
Session:…………………
Submitted To: Submitted By:
Name:
Semester:
Enrollment No:
Branch:
EXPERIMENT-1
MOLD MAKING & CASTING
Objective
1. To prepare a pattern for given object for lost form casting.
2. To prepare a Green sand mold from the prepared pattern.
3. To melt and pour Aluminum metal into the mold.
Equipment and Materials
Pattern, core box, molding flasks, molding tools, sand muller, riddle, sand, bentonite, core baking oven,
thermocole, melting furnace, fluxes, pouring ladle, pyrometer, hacksaw, file.
Procedure
Pattern for lost form casting
Fig. 3: Foam pattern and the corresponding cast object.
Mold Making
(i) Place the drag part of the molding flask and riddle molding green sand to a depth of 2 cm in
the drag.
(ii) Place the pattern at the centre of the drag (flask)
(iii) Pack the sand carefully around the pattern as shown in figure 4. Heap more molding sand in
the drag and ram with rammer carefully
(iv) Place the core half of the pattern over the drag pattern matching the guide pins and also place
the gating system with sprue and riser in proper positions.
(v) Complete the cope half by repeating steps 3. Remove the extra sprue and riser pins and make
a pouring basin.
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Fig. 4: Equipment for sand mixing and a prepared mold.
Melting and Pouring
(i) Melt the metal in the furnace. Use appropriate fluxes at proper stages and measure metal
temperature from time to time.
(ii) Pour the molten metal into the pouring ladle at a higher temperature (say 100oC higher) than
the pouring temperature. As soon as the desired pouring temperature is reached, pour the
liquid metal into the mold in a steady stream with ladle close to the pouring basin of the
mold. Do not allow any dross or slag to go in.
(iii) Allow sufficient time for the metal to solidify in the mold. Break the mold carefully and
remove the casting.
(iv) Cut-off the riser and gating system from the casting and clean it for any sand etc.
(v) Inspect the casting visually and record any surface and dimensional defects observe.
Fig. 5: Furnace for melting metal for pouring into mold.
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INTRODUCATION TO METAL FORMING
SHEET METAL FORMING
Many products are manufactured from sheet metal involving combination of processes such as shearing,
bending, deep drawing, spinning etc. These processes are characterized by localized deformation and
configuration changes and are together called “Sheet Metal Forming”. These processes do not result in
bulk shape change of the parts, but lead to configurational changes. Sheets have high surface area to
volume ratio of starting metal which distinguishes these from bulk deformation. Sheet metal forming is
often called ‘press working’ as presses are required to perform these operations. Parts are usually called
stampings and usual tools involve punches and dies. Sheet metal operations can involve combination of
stresses, eg.
Stretching of the metal (tensile stresses)
Bending of the metal (tensile and compressive stresses)
Cutting of the metal (shear stresses)
Fig. 6: Schematic of some sheet metal working operations (top) shearing (bottom) bending.
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(a)
(b)
(c)
Fig. 7: Some of the apparatus available in engineering metallurgy lab to perform sheet metal forming
(a) Shearing equipment (b) Bending equipment (c) Folding equipment.
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EXPERIMENT-2
SHEET METAL FORMING
Objective
(i) To prepare a sheet metal product (Funnel).
(ii) Report the various parameters for the various passes during the rolling of the given metal piece.
Equipment & material
Mallet, Hand Snip, Bench Vice, Grooving Tool, Scriber, Scale, Marker, Light Weight Hammer, Divider
and Metal Sheet
Demonstration
Self secured sheet metal joints
(a) Internal grooved joint
Mark out portions of given sheets near edges to be joined with a marker.
Fold the sheets at edges in the portion marked, first at right angles to the plane of the sheet
and then at 180० to the plane.
Insert one folded sheet into the other.
Groove the seam using grooving die.
(b) Double grooved joint
Fold sheets after making them as per the instructions given.
Cut a piece of sheet (called strap) of required width.
Strap width = (4x size of marked edges) + (4 x thickness of sheet).
Close the edges of the strap slightly.
Slip the strap on the bent edges of the sheets after bringing them.
(c) Knocked-up joint
Fold one sheet and close edges slightly.
Bend one sheet to form a right angles band.
Slip the second sheet in the folded one.
Close the right angled sheet using a mallet.
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Fig. 8: Approximate dimensions of the funnel to be fabricated.
Procedure for funnel:
Draw the elevation on full scale
Complete the cone by extending the lines A and G
Choose a point Z and draw curves with Z as a center, and ZA and ZX as radius
Draw the vertical line Z3, meeting the internal curve at D, and external curve at 3
Starting from D mark lengths DC, CB, BA, DE, EF and FG, each equal to nd/6.
Again starting from 3 mark length 3-2, 2-1, 1-0, 3-4, 4-5 and 5-6, each equal to πd/6. (D and d
are major and minor diameters)
Draw another curve with Z as a center and ZX+5 mm as radius.
Joint AO and G6 and extend it to cut the outer curve at points H and I, respectively.
Provide a margin of 5 mm on one side, and 10 mm on another side for joint.
Cut out the required portion and form the conical portion.
Make the bottom half of the funnel.
Fig. 9: Final form of funnel to be fabricated in the lab.
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INTRODUCTION TO JOINING PROCESSES
Objective
To study and observe the welding and brazing techniques through demonstration and practice (ARC,
MAG, Brazing)
Background
Solid materials need to be joined together in order that they may be fabricated into useful shapes for
various applications such as industrial, commercial, domestic, art ware and other uses. Depending on
the material and the application, different joining processes are adopted such as, mechanical (bolts,
rivets etc.), chemical (adhesive) or thermal (welding, brazing or soldering). Thermal processes are
extensively used for joining of most common engineering materials, namely, metals. This
EXPERIMENT is designed to demonstrate specifically: gas welding, arc welding, resistance welding,
brazing.
WELDING PROCESSES
Welding is a process in which two materials, usually metals, and is permanently joined together by
coalescence, resulting from temperature, pressure, and metallurgical conditions. The particular
combination of temperature and pressure can range from high temperature with no pressure to high
pressure with any increase in temperature. Thus, welding can be achieved under a wide variety of
conditions and numerous welding processes have been developed and are routinely used in
manufacturing.
Fig. 10: Schematic of a welding process
To obtain coalescence between two metals following requirements need to be met: (1) perfectly smooth, flat
or matching surfaces, (2) clean surfaces, free from oxides, absorbed gases, grease and other contaminants,
(3e) metals with no internal impurities. These are difficult conditions to obtain. Surface roughness is
overcome by pressure or by melting two surfaces so that fusion occurs. Contaminants are removed by
mechanical or chemical cleaning prior to welding or by causing sufficient metal flow along the interface so
that they are removed away from the weld zone friction welding is a solid state welding technique. In many
processes the contaminants are removed by fluxing agents.
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The production of quality welds requires (1) a satisfactory heat and/or pressure source, (2) a means of
protecting or cleaning the metal, and (3) caution to avoid, or compensate for, harmful metallurgical
effects.
Arc Welding
In this process a joint is established by fusing the material near the region of joint by means of an
electric arc struck between the material to be joined and an electrode. A high current low voltage
electric power supply generates an arc of intense heat reaching a maximum temperature of
approximately 5500OC. The electrode held externally may act as a filler rod (consumable electrode) or
it is fed independently of the electrode (nonconsumable electrode). Due to higher levels of heat input,
joints in thicker materials can be obtained by the arc welding process. It is extensively used in a variety
of structural applications.
There are so many types of the basic arc welding process such as shielded metal arc welding (SMAW), gas
metal arc welding (GMAW), gas tungsten arc welding (GTAW), submerged arc welding
Fig. 11: Schematic of a shielded metal arc welding process.
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EXPERIMENT-3
ARC WELDING
Objective
To prepare a butt joint with mild steel strip using MAG & MMAW technique.
Equipment and materials
Welding unit, consumable mild steel wire, mild steel flats (100 x 25 x 5 mm), protecting gas, Wire
Brush, Tongs etc.
Procedure
Clean the mild steel flats to be joined by wire brush.
Arrange the flat pieces properly providing the gap for full penetration for butt joint(gap ½
thicknesses of flats).
Practice striking of arc, speed and arc length control
Set the welding current, voltage according to the type of metal to be joined.
Strike the arc and make tacks at the both ends to hold the metal pieces together duringthe
welding process
Lay beads along the joint maintaining proper speed and arc length (Speed 100-150 mm/min).
Clean the welded zone and submit.
Fig. 12: Welding equipment and operation available in the Engineering Metallurgy Lab.
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INTRODUCTION TO JOINING PROCESSES
Gas Welding
In this process, a joint is established by fusing the material near the region of joint by means of a gas flame.
The common gas used is mixture of oxygen and acetylene which on burning gives a flame temperature of
3500OC. Hence this is also termed as Oxy Acetylene Welding (OAW). A filler rod is used to feed molten
material in the gap at the joint region and establish a firm weld. The flame temperature can be controlled
by changing the gas composition i.e. ratio of oxygen to acetylene. The color of flame changes from
oxidizing to neutral to reducing flame.
Fig. 13: Oxyfuel gas welding flame used for gas welding as well as for Brazing.
BRAZING
In this process metal parts to be joined are heated to a temperature below the melting point of the parts
but sufficient to melt the lower fusion point filler material which is used to fill the gap at the joint and
establish a bond between the edges through the filler material. The filler metal is drawn through the
joint through the capillarity action to create joint between the two pieces.
In this process, the base metal does not melt and hence the metallurgy of the base metal is not disturbed
much. However, this also implies that the joints made by this process are not as strong as those made
by welding. On the other hand, this process can establish joint between two dissimilar metals, through a
proper choice of filler material. Unlike in welding the filler rod differs widely in composition from the
parent material(s). Gas (oxy-acetylene mixture) is usually used for heating.
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Fig. 14: Schematic of brazing operation.
Fig. 15: Various kind of joints that can be obtained using brazing.
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EXPERIMENT-4
BRAZING
Objective
To prepare a butt joint with mild steel strips using brazing technique.
Equipment & materials
Gas welding set, brazing wire, fluxes, mild steel strips (100 x 25 x 3 mm), wirebrush, tongs etc.
Procedure for Brazing
Clean the mild steel strip removing the oxide layer and flatten it.
Keep the metal strip in butt position.
Tack at the two ends.
Lay brazing metal at the joint maintaining proper speed and feed.
Clean the joint and submit
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Fig. 16: Brazing operation and equipment available in the Engineering Metallurgy Lab.
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INTRODUCTION TO ROLLING, SWAGING, POWDER METALLURGY
PROCESSES
Part -1: ROLLING
Objective
To study and observe the plain and grooved Rolling techniques through demonstration.
Rolling is the process of plastic deformation of metals by squeezing action as it passes between a pair
of rotating rolls, either plane or grooved. The process may be carried out hot or cold. The most
common rolling mill is the two -high rolling mill, which consists of two rolls usually mounted
horizontally in bearings at their ends and vertically above each other. The rolls may be driven through
couplings at their ends by spindles, which are coupled, to pinions (or gears), which transmit the power
from the electric motor.
To control the relative positioning of rolls, a roll positioning system is employed on the mill stand.
In small mills, such as the one in the laboratory, the roll positioning system called the ‘mill screw’ is
hand driven, while in commercial mills they are motor driven.
The two-high mills could be either reversing or non-reversing type. In the reversing type, which is
the most common one, the direction of motion of the rolls can be reversed, and therefore the work can
be fed into the mill from both sides by reversing the direction of rotation of rolls.
For rolling to take place the roll separation or roll gap must be less than the in going size of the
stock. After rolling, the height of the stock is reduced and length is increased. The difference in height
of ingoing and outgoing is called ‘draught’. Fig. 17 shows a flat piece of metal of thickness h1, through
a pair of rolls of radius R. The AC is called the ‘arc of contact’. The angle θ subtended at the roll center
by the arc of contact is called the ‘angle of contact’ and can be evaluated from
Cos θ = [1 – (ho – h1) /2R]
If there is no elastic deflection of rolls during rolling, the final thickness of metal h 1 is same as the roll
gap. If elastic deflection of rolls occur, the final thickness of metal after rolling h1, is greater than the
roll gap fixed before rolling.
Depending upon the condition under which the metal is introduced into the roll gap, two situations can
occur:
The metal is gripped by the rolls and pulled along into the roll gap.
The metal slips over the roll surface.
The process of rolling depends upon the frictional forces acting between the surfaces of the roll and the
metal. The condition of biting or gripping of metals into rolls is μ ≥ tan θ, where μ is the coefficient of
friction between the roll and metal surfaces. The maximum value of θ (θmax = tan-1λ) is often called the
angle of bite. The average coefficient of friction can now be estimated as μ = tan θmax.
Rolling of a metal plate on a two high rolling mill will be demonstrated. The demonstration of the
situations when (a) metal slips on the roll surface, and (b) metal is gripped by the rolls, would also be
shown to you.
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Fig. 17: Schematic of rolling operation that reduces the thickness of the work piece while
simultaneously increasing its strength.
Fig. 18: Rolling mill in the Engineering Metallurgy Lab.
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Part-2: SWAGING
Objective
To study and observe the Swaging techniques through demonstration.
In this process, the diameter of a rod or a tube is reduced by forcing it into a confining die. A set of
reciprocation dies provides radial blows to cause the metal to flow inward and acquire the form of the die
cavity. The die movements may be of in – and – out type or rotary. The latter type is obtained with the
help of a set of rollers in a cage, in a similar action as in a roller bearing. The workpiece is held stationary
and the dies rotate, the dies strike the workpiece at a rate as high as 10 - 20 strokes per second.
In tube swaging, the tube thickness and / or internal dia of tube can be controlled with the use of internal
mandrels. For small – diameter tubing, a thin rod can be used as a mandrel; even internally shaped tubes
can be swaged by using shaped mandrels and shows the process.
Fig. 19: Swaging mechanism.
(a) Swaging of tubes without a mandrel. Wall thickness is more in the die gap.
(b) Swaging with a mandrel. The final wall thickness of the tube depends on the mandrel diameter.
(c) Examples of cross-sections of tubes produced by swaging on shaped mandrels.
The process is quite versatile. The maximum diameter of work piece that can be swaged is limited
to about 150 mm; work pieces as small as 0.5 mm diameter have been swaged. The production rate can be
as high as 30 parts per minute depending upon the complexity of the part shape and the part handling
means adopted.
The parts produced by swaging have tolerance in the range ± 0.05 mm to ± 0.5 mm and improved
mechanical properties. Use of lubricants helps in obtaining better work surface finish and longer die life.
Materials, such as tungsten and molybdenum are generally swaged at elevated temperatures as they have
low ductility at room temperature. Hot swaging is also used to form long or steep tapers, and for large
reductions.
Swaging is a noisy operation. The level of noise can be, however, reduced by proper mounting of the
machine or by the use of enclosure.
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Part-3: POWDER METALLURGY
Objective
To study and observe the Powder Metallurgy techniques through demonstration.
Powder Metallurgy comprises a family of production technologies, which process a feedstock in
powder form to manufacture components of various types. These production technologies generally
involve all or most of the following process steps:
Powder production: Virtually all iron powders for PM structural part production are manufactured
using either the sponge iron process or water atomization. Non ferrous metal powders used for other
PM applications can be produced via a number of methods.
Mixing of powders: This can often involve the introduction of alloying additions in elemental
powder form or the incorporation of a pressing lubricant.
Forming of the mixed powder into a compact: The dominant consolidation process involves
pressing in a rigid toolset, comprising a die, punches and, possibly, mandrels or core rods. However,
there are several other consolidation processes that are used in niche applications.
Sintering of the compact to enhance integrity and strength: This process step involves heating of
the material, usually in a protective atmosphere, to a temperature that is below the melting point of
the major constituent. In some cases, a minor constituent can form a liquid phase at sintering
temperature; such cases are described as liquid phase sintering. The mechanisms involved in solid
phase and liquid phase sintering are discussed briefly in a later section.
Secondary operations: The application of finishing processes to the sintered part. In the Powder
Metallurgy industry, such processes are often referred to as “secondary operations”.
Fig. 20: Components for powder metallurgy.
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EXPERIMENT-5
Demonstration with few EXPERIMENTs
Objective
To prepare a spring, square frame, ring, hemisphere and rivet joint with using various technique.
Equipment:
Ball peen hammer, Bench vice, Pliers, Hole punch, supporting rod & file etc.
Materials:-
Steel Rod, Wire and G I sheet.
1. Rolling
2. Swaging
3. Powder metallurgy
4. To learn a hole on a flat using drill machine.
5. To learn a surface grinding techniques on a flat job using grinding machine.
6. To learn pipe cutting using horizontal machine.
Student’s part: (These EXPERIMENTs are part of your project)
To make a ring with the help of mild steel rod (4.0 mm)
To make a spring with the help of mild steel wire copper coated (0.8 mm)
To bend a mild steel rod in a square frame.
To make a rivet having both fixed and movable joints using G I Sheet.
To make a hemisphere using GI Sheet with the help of anvil and ball pen hammer
Fig. 21: Demo EXPERIMENT components.
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