K.S.

K COLLEGE OF ENGINEERING AND TECHNOLOGY

KUMBAKONAM-612702

DEPARTMENT OF MECHANICAL ENGINEERING

GE3271- ENGINEERING PRACTICES LABORATORY MANUAL

GROUP B (MECHANICAL)

SECOND SEMESTER B.E / [Link]

(Common to All Branches)

NAME OF THE STUDENT:

BRANCH / SECTION :
REG. NUMBER :
 SYLLABUS
ENGINEERING PRACTICES LABORATORY

GROUP B (MECHANICAL)

MECHANICAL ENGINEERING PRACTICE

Welding:
 Preparation of arc welding of butt joints, lap joints and tee joints.
 Gas welding practice

Basic Machining:
 Simple Turning
 Taper turning
 Drilling Practice

Sheet Metal Work:

 Making a square Tray

Machine assembly practice:

 Assembling a centrifugal pump
 Assembling a air conditioner
 Assembling a household mixer

Demonstration on:

 Foundry operations like mould preparation for gear and step cone pulley.
 GE3271-ENGINEERING PRACTICES LAB MANUAL
(Group B –Mechanical)

INDEX

Marks Staff
[Link] Date Name of the Exercise Page No. Obtained Sign
 SAFETY PRECAUTIONS

Definition of Workshop:

It is a place where human efforts, machines, materials and tools together manufacture the
products.

Safety Aspects:

1) The shop floor should be kept clean and free from dirt of any kind.
2) Always wear tight fit clothing with tucked in.
3) Never wear chapels in the workshop. Always wear leather shoes.
4) Do not wear watches, metallic bangles, neck chains and any ornaments while working in the
workshop.
5) Never operate the machines without taking prior permission.
6) Always walk in the Aisle space provided in the workshop.
7) Do not keep the tools at the edge of the table.
8) All the tools should be handled with proper precautions.
9) Tools which are not used should be kept proper places.
10) Ensure sufficient lightning and ventilation to avoid accidents.
11) Never carry any sharp tool in the pocket.
12) Use safety devices like Apron, Goggles, Gloves, Shields and Tongs while welding.
13) Do not spill the oil and grease. If it is spilled, it should be cleaned immediately to avoid
slipping.
14) Always operate machines at a safe distance.
15) Use Scissors and Cutters properly while working with the sheet metal.
16) Avoid unnecessary talking and discussions while working and concentrate on the work.
17) Incase if you find any difficulty of any nature, report immediately to the workshop supervisor.
18) Do not shift the speed gears while machine is functioning.
19) Use coolant while machining and wherever necessary.
GAS WELDING SET UP
[Link]:
STUDY OF WELDING
DATE:

Introduction

Welding is a fabrication or sculptural process that joins materials, usually metals or

thermoplastics, by causing coalescence. This is often done by melting the work pieces and adding a
filler material to form a pool of molten material (the weld pool) that cools to become a strong joint,
with pressure sometimes used in conjunction with heat, or by itself, to produce the weld. This is in
contrast with soldering and brazing, which involve melting a lower-melting-point material between the
work pieces to form a bond between them, without melting the work pieces

Types of Welding:
The two types of welding most prevalently in use are
1. Arc welding 2. Gas Arc welding.

1. Gas welding—the use of a combustible mixed with oxygen to create a flame for welding—is used
extensively in repair and maintenance work.

2 .Arc welding—the use of a conductive arc to create heat and accomplish a weld—is the most basic
and often used form of welding in industry.

Gas welding produces a wide, imprecise flame that can result in poor quality welds. In Arc
welding, an electric current creates an arc between a conductor called an electrode that is contained in
the welder's torch tip and the material to be welded. This arc generates the heat necessary to complete
the weld and gives the welder greater control over the welding process.

Welding Applications

Welding has traditionally been viewed as a heavy manufacturing process. The shipbuilding,
automobile manufacturing, construction and oil industries have benefited greatly from the expediency
of welding. These industrial applications still employ the majority of welding practices in use today.
ARC WELDING
 From welding thick steel beams together to repairing the hulls of ocean tankers, welding is the
join technology of choice. Welding has also branched out into areas like electronics, aerospace, medical
device manufacture, instrumentation, and photonics. Welding is being used on rocket fuel tanks, glass
sealing of electronic packages, nano-wire assemblies and glass to metal or silicon joining of sensors.
Today's welding processes involve plastic, glass, fiberglass, and ceramic in addition to metal.

GAS WELDING
Oxy Acetylene Welding Principle of Operation:
When acetylene is mixed with oxygen in correct proportions in the welding torch and ignited,
the flame resulting at the tip of the torch is sufficiently hot to melt and join the parent metal. The
oxyacetylene flame reaches a temperature of about 3200°C and thus can melt all commercial metals
which, during welding, actually flow together to form a complete bond.
A filler metal rod is generally added to the molten metal pool to build up the seam slightly for
greater strength. Oxyacetylene welding does not require the components to be forced together under
pressure until the weld forms and solidifies.

Gas welding equipment:

The apparatus used in gas welding consists basically of an oxygen source and a fuel gas source
(usually cylinders), two pressure regulators and two flexible hoses (one of each for each cylinder), and
a torch. The cylinders are often carried in a special wheeled trolley.
1. Oxygen Cylinder:
Oxygen cylinder is usually painted in black colour. In this cylinder, oxygen is stored under a
pressure of 1550 N/m2. The common cylinder is 1.8 m3, 3.5 m3, 7 m3, etc.,
2. Acetylene Cylinder:
Acetylene cylinder is usually painted in maroon colour. In this cylinder, acetylene is stored
under a pressure of 175 N/m2. The common cylinder is 1.6 m3, 2.8 m3, 8.4 m3, etc.,
3. Regulator:
The regulator is used to control pressure from the tanks by reducing pressure and regulating
flow rate.
4. Gas hoses:
 The hose is usually a double-hose design, meaning that there are two hoses joined together. The
oxygen hose is green and the fuel hose is red. The type of gas the hose will be carrying is important
because the connections will have different threads for different types of gas. Fuel gases (red) will use
left-hand threads and a groove cut into the nut, while the oxygen (green) will use right-hand threads.
This is a safety precaution to prevent hoses from being hooked up the wrong way.
5. Non-return valve:
Between the regulator and hose, and ideally between hose and torch on both oxygen and fuel
lines, a flashback arrestor and/or non-return valve should be installed to prevent flame or
Oxygen-fuel mixture being pushed back into either cylinder and damaging the equipment or
making a cylinder explodes.
6. Check valve:
A check valve lets gas flow in one direction only. A check valve is usually a chamber
containing a ball that is pressed against one end by a spring: gas flow one way pushes the ball out of the
way, and no flow or flow the other way lets the spring push the ball into the inlet, blocking it.
7. Torches:
The torch is the part that the welder holds and manipulates to make the weld. It has a connection
and valve for the fuel gas and a connection and valve for the oxygen, a handle for the welder to grasp, a
mixing chamber (set at an angle) where the fuel gas and oxygen mix, with a tip where the flame forms.
The top torch is a welding torch and the bottom is a cutting torch
a) Welding torch:
A welding torch head is used to weld metals. It can be identified by having only one or two
pipes running to the nozzle and no oxygen-blast trigger and two valve knobs at the bottom of the handle
letting the operator adjust the oxygen flow and fuel flow.
b) Cutting torch:
A cutting torch head is used to cut metal. It is similar to a welding torch, but can be identified
by having three pipes that go to a 90 degree nozzle and by the oxygen-blast trigger. Only iron and steel
can be cut using this method.
8. Other Accessories:
a) Filler rod / Welding rod: Filler rod is a metal which is used in gas welding to supply additional metal
to make the joint.

b) Flux is used in oxy-acetylene gas welding to prevent oxidation and also to remove impurities. The
flux may be either in powder or liquid form.
9. Safety devices:
a) Goggles b) Leather goggles c) Apron

ARC WELDING
Principle of Operation:
In arc welding, the intense heat needed to melt metal is produced by an electric arc. The arc is
formed between the actual work and an electrode (stick or wire) that is manually or mechanically
guided along the joint. The electrode can either be a rod with the purpose of simply carrying the current
between the tip and the work. Or, it may be a specially prepared rod or wire that not only conducts the
current but also melts and supplies filler metal to the joint. Most welding in the manufacture of steel
products uses the second type of electrode.
An arc is created across the gap when the energized circuit and the electrode tip touches the
work piece and is withdrawn, yet still with in close contact. The arc produces a temperature of about
6000ºC at the tip. This heat melts both the base metal and the electrode, producing a pool of molten
metal sometimes called a "crater." The crater solidifies behind the electrode as it is moved along the
joint. The result is a fusion bond.
Arc Welding Equipment:
a) Power Supply:
The Main equipment used for electric arc welding is the transformer. It may be AC/ DC. Arc
welding may be done with direct current (DC) with the electrode either positive or negative or
alternating current (AC). The choice of current and polarity depends on the process, the type of
electrode, the arc atmosphere, and the metal being welded. The figure shows AC arc welding set up
using transformer. The transformer steps down the usual supply voltage (220 v to 440 v) to the open
circuit voltage required for the welding which is 40 v to 80 v.
b) Electrode:
If an electrode is consumable, the tip melts under the heat of the arc and molten droplets are
detached and transported to the work through the arc column. This type of electrodes is made up of
steel, copper, brass bronze or aluminum.
If an electrode is non consumable, the tip of the electrode may not get melted. This type of
electrodes is made up of carbon and graphite. Here filler rod has to be used.
c) Electrode Holder:
It is used to hold or secure the electrode. It should be light, strong and easy to handle. It allows
the shortest electrode possible to be used, ensuring rigidity and lack of deflection

d) Ground Clamp:
It is connected to the end of the ground cable and is clamped to the work or welding table to
complete the electric circuit.
e) Chipping Hammer:
It is chisel shaped one and it is used to remove slag from the weld beads.
f) Wire Brush:
It is used to clean the surface to be welded and it is also used to clean the weld.
g) Face Shield or Screen:
It is used to protect the eyes of the welder from the radiations. There are two types (i) Hand type
and (ii) Helmet type.
h) Goggles:
It is used to protect eyes of the welder from the light sparks produced during welding.
i) Hand Gloves:
It is used to protect the hands of the welder from the effect of ultra violet rays, infra red rays,
heat and sparks.
 SQUARE BUTT JOINT

All dimensions are in mm

[Link]: SQUARE BUTT JOINT
DATE:

Aim:
To join two given metal plates by a square butt joint using arc welding.

Material Supplied:
Mild Steel Plate of Size 75x50x6 mm

Tools required:
Power supply, (AC /DC), earthing clamp, welding electrode, welding torch, tongs, bench vice,
wire brush, gloves, shield, apron, safety goggles, steel rule, flat file, chipping hammer

Sequence of Operation:
a. Edge preparation (removal of rust, scale, etc)
b. Tacking
c. Welding
d. Cooling
e. Chipping
f. Cleaning

Working Steps:
1. The given metal plates are cleaned to remove rust and scale formation by using a wire
brush.
2. Then edge preparation is done to the required dimensions with the aid of bench vice and a
file for a square butt joint.
3. Based on the thickness of the metal plates to be welded, the amperage and correct voltage is
selected.
4. Two metal plates are placed as shown in the figure with a suitable gap of 2mm between
them and tag weld is done on the ends to avoid the movement of the plates while welding.
5. Then welding is started from one end of the plates and is continued till the other end by
maintaining 3 mm gap between the welding rod and the plates to be welded.
6. While welding goggles, gloves and shield are used for the safety of eyes and hand.
7. The electric arc produced by the transformer melts the electrode and joins the two metal
plates.
8. Then cool the welded metal plates
9. Finally the welded portion is chipped to remove slag using chipping hammer and wire
brush.

Result:
Hence the two given metal plates are joined by square butt joint using arc welding.
 .
LAP JOINT

All dimensions are in mm

[Link]:
LAP JOINT
DATE:

Aim:
To join two given metal plates by a lap joint using arc welding.

Tools required:
Power supply, (AC /DC), Earthling clamps, welding electrode, welding torch, tongs, bench
vice, wire brush, gloves, shield, apron, safety goggles, steel rule, flat file and chipping
hammer.

Material Supplied:
Mild Steel Plate of Size 75x50x6 mm

Sequence of Operation:
a. Edge preparation (removal of rust, scale, etc)
b. Tacking
c. Welding
d. Cooling
e. Chipping
f. Cleaning

Working Steps:
1. The given metal plates are cleaned to remove rust and scale formation, by using a wire
brush.
2. Then edge preparation is done to the required dimensions, with the aid of bench vice.
3. Based on the thickness of the metal plates to be welded the amperage and correct voltage is
selected.
4. Two metal plates are placed in the over lapped position using a support piece and tag weld
is done on the ends to avoid the movement of the plates while welding.
5. Then welding is started from one end of the plates and is continued till the other end by
maintaining 3 mm gap between the welding rod and the plates to be welded.
6. While welding goggles, gloves and shield are used for the safety of eyes and hand.
7. The electric arc produced by the transformer melts the electrode and joins the two metal
plates.
8. Then cool the welded metal plates
9. Finally the welded portion is chipped to remove slag using chipping hammer and wire
brush.

Result:
Hence the two given metal plates are joined by lap joint using arc welding.
 TEE - JOINT

All dimensions are in mm

[Link]:
TEE FILLET JOINT
DATE:

Aim:
To join two given metal plates, by T-fillet joint using arc welding.

Tools required:
Power supply, (AC /DC), earthing clamps, welding electrode, welding torch, tongs, bench vice,
Wire brush, gloves, shield, apron, safety goggles, steel rule, flat file and chipping hammer.

Material Supplied:
Mild Steel Plate of Size 75x50x6 mm

Sequence of Operation:
a. Edge preparation (removal of rust, scale, etc)
b. Tacking
c. Welding
d. Cooling
e. Chipping
f. Cleaning

Working Steps:
1. The given metal plates are cleaned to remove rust and scale formation by using a wire
brush.
2. Then edge preparation is done to the required dimensions, with the aid of bench vice and a
file to get perfect joint and good strength.
3. Based on the thickness of the metal plates to be welded, the amperage and correct voltage is
selected.
4. One of the plates to be welded is kept at right angles to the surface of the other plate by
using tongs.
5. The tag weld is made on the ends to aviod the movement of the plates while welding.
6. Then welding is started from one end of the plates and is continued till the other end on both
sides by maintaining a gap of 3mm between welding rod and the plates to be welded.
7. While welding goggles, gloves and shield are used for the safety of eyes and hand.
8. The electric arc produced by the transformer melts the electrode and joins the two metal
plates.
9. Then cool the welded metal plates
10. Finally the welded portion is chipped to remove slag using chipping hammer and wire
brush.

Result:
Hence the two given metal plates are joined by T-fillet joint using arc welding.
.
 [Link]:
STUDY OF BASIC MACHINING LATHE
DATE:

The lathe is an ancient tool, dating at least to the Egyptians and known and used in Assyria,
Greece, the Roman and Byzantine Empires. The origin of turning dates to around 1300BC when the
Egyptians first developed a two-person lathe. One person would turn the wood work piece with a rope
while the other used a sharp tool to cut shapes in the wood.
During the industrial revolution, mechanized power was applied to the lathe via steam engines
and line shafting, allowing faster and easier work. The design of lathes diverged between woodworking
and metalworking to a greater extent than in previous centuries. Metalworking lathes evolved into
heavier machines with thicker, more rigid parts. The application of lead screws, slide rests, and gearing
produced commercially practical screw-cutting lathes. Between the late 19th and mid 20th centuries,
individual electric motors at each lathe replaced line shafting as the power source. Beginning in the
1950s, servomechanisms were applied to the control of lathes and other machine tools via numerical
control (NC), which often was coupled with computers to yield computerized numerical control (CNC).
Today manually controlled and CNC lathes coexist in the manufacturing industries.
Working Principle:
In a lathe work piece is held and rotated about its axis. A cutting force is applied on the work
piece by a single point cutting tool and hence the material is removed from the work piece. The amount
of material removed from the work piece, in unit time is based on the depth of cut and feed. The single
point cutting tool used in a lathe is made up of High Speed Steel (HSS), cemented carbides and poly-
crystalline diamonds (PCD).
Parts of Lathe:
a) Lathe Bed
b) Head stock
c) Tail stock
d) Carriage : (i) Apron (ii) Saddle (iii) Cross slide (iv) Compound rest (v) Tool post
e) Feed rod
f) Lead screw.

[Type text] [Type text] [Type text]

FACING OPERATION

TURNING OPERATION
a) Lathe Bed:
It is the base of the machine. On its left side, the head stock is mounted. The tail stock which is
moveable on the bed, mounted on the right side. The bed is made up of cast iron in order to resist the
vibrations occurring during the machining operations.
b) Head stock:
The head stock is permanently fastened on the inner ways at the left hand end of the bed. It
serves to support the spindle and driving arrangements. All lathes receive their power through the head
stock, which may be equipped with a step-cone pulleys or a geared head drive. The modern lathe is
provided with all-geared head stock to get large variation of spindle speeds.
c) Tail stock:
The tail stock is the counter part of the head stock and is situated at the right hand end of the
bed. It is used for supporting the work when turning on centers or when a long component is to be held
in a chuck. It is also used for holding and feeding the tools such as drills, reamers, taps, etc.,
d) Carriage:
In its simplest form the carriage holds the tool bit and moves it longitudinally (turning) or
perpendicularly (facing) under the control of the operator. The operator moves the carriage manually
via the hand wheel or automatically by engaging the feed shaft with the carriage feed mechanism. This
provides some relief for the operator as the movement of the carriage becomes power assisted.
(i)Apron: It is fastened to the saddle and hangs over the front of the bed. It contains gears, clutches and
levers for operating the carriage by hand and power feeds. The apron had wheel can be turned to move
the carriage longitudinally back and forth by hand.

(ii) Saddle: It is an H-shaped casting that fits over the bed and slides along the ways between the head
stock and tail stock.

(iii) Cross slide: The cross-slide stands atop the carriage and has a feed screw that travels perpendicular
to the main spindle axis. This permits facing operations to be performed, and the depth of cut to be
adjusted. This feed screw can be engaged, through a gear train, to the feed shaft to provide automated
'power feed' movement to the cross-slide. On most lathes, only one direction can be engaged at a time
as an interlock mechanism will shut out the second gear train.
TAPER TURNING OPERATION

TURNING OPERATION
(iv) Compound rest: The compound rest (or top slide) is the part of the machine where the tool post is
mounted. It provides a smaller amount of movement along its axis via another feed screw. The
compound rest axis can be adjusted independently of the carriage or cross-slide. It is utilized when
turning tapers, to control depth of cut when screw cuts or precision facing, or to obtain finer feeds
(under manual control) than the feed shaft permits.

(v) Tool post: The tool bit is mounted in the tool post which may be of the American lantern style,
traditional 4 sided square style, or in a quick change style such as the multifix arrangement pictured.
The advantage of a quick change set-up is to allow an unlimited number of tools to be used (up to the
number of holders available) rather than being limited to 1 tool with the lantern style, or 3 to 4 tools
with the 4 sided type.

e) Feed rod: Feed rod is long shaft which gets power from the head stock spindle through large number
of gears located in the feed box. It is used for the longitudinal movement of the carriage (or) cross feed
movement of the cross slide

f) Lead screw: A lead screw also known as a power screw or translation screw, is a screw designed to
translate radial motion into motion. It is a long threaded shaft which is used during thread cutting
operations.
Lathe Operations
a) Turning: It is the operation of reducing the diameter of the work piece.
b) Facing: It is the operation of reducing the length of the work piece.
c) Chamfering: It is the operation of removing the sharp corners of the work piece to protect the edges
of the job from getting damaged. It is done by keeping the tool at an angle of 45 degree to the lathe
axis.
d) Taper Turning: It is the operation of making uniform change in the diameter of the work piece
along its length or producing conical surface on the work piece.
e) Drilling: It is the operation of making hole in the work piece. This can be achieved by fixing the
drill bit in tail stock and fed in to the rotating work piece.
f) Boring: It is operation of enlarging the already drilled hole.
g) Knurling: It is the operation of making rough surface to get the get grip on the work piece.
FACING, TURNING AND CHAMFERING

BEFORE MACHINING

AFTER MACHINING

All dimensions are in mm

[Link]:
TURNING, FACING AND CHAMFERING
DATE:

Aim:
To make turning, facing and chamfering on the given metal work piece to get the required
dimension.

Material Supplied:
Mild Steel rod of 25 mm diameter x 75 mm length

Tools required:
Single point cutting tool, vernier caliper, steel rule, chuck key, tool post key and wire brush.

Sequence of Operation:
a. Checking
b. Work piece setting
c. Tool setting
d. Facing
e. Turning
f. Chamfering

Working Steps:
1. The given work piece is checked for its given dimensions.
2. The work piece is held in the three jaw chuck. Chuck key is used to tighten the job rigidly
ensuring centering of the work piece.
3. The single point cutting tool is fixed in the tool post of the lathe machine using tool post key
and spanners. Sometimes the packing material like hacksaw blade pieces, thick sheet paper
materials can be used to set the tool appropriately pointing towards the centre of the job.
4. Facing operation is done to obtain the required length of the job.
5. Turning operation is done to obtain the required diameter of the job.
6. Chamfering is done to remove sharp edges and corners of the work piece by keeping the
tool at an angle of 45 º to the lathe axis.
7. Finally the work piece dimensions are checked to conform to the specification given in the
drawing.

Result:
Hence the required shape and size are obtained using turing, facing and chamfering operations
on the given work piece.
 .

TAPER TURNING

BEFORE MACHINING

AFTER MACHINING

All dimensions are in mm.

[Link]:
TAPER TURNING
DATE:

Aim:
To make turning, facing and taper turning operations on the given metal work piece to get the
required dimension.

Material Supplied:
Mild Steel rod of 25 mm diameter x 75 mm length

Tools required:
Single point cutting tool, vernier caliper, steel rule, chuck key, tool post key, wire brush and
scriber.

Sequence of Operation:
a. Checking
b. Workpiece setting
c. Tool setting
d. Facing
e. Turning
f. Taper Turning

Working Steps:
1. The given work piece is checked for its given dimensions.
2. The workpiece is held in the three jaw chuck. Chuck key is used to tighten the job rigidly,
ensuring centering of the workpiece.
3. The single point cutting tool is fixed in the tool post of the lathe machine using tool post
key. Sometimes the packing material like hacksaw blade pieces, thick sheet paper materials
can be used to set the tool appropriately pointing towards the centre of the job.
4. Facing operation is done to obtain the required length of the job.
5. Turning operation is done to obtain the required diameter of the job.
6. Next the taper turing operation is carried out as per the taper angle calculated using the
formula, tan θ = (D-d)/2L. Then compound rest base is swiveled and set at half taper angle.
Cutting tool is moved at set angle to the lathe axis by rotating the cross slide till the required
taper is obtained.
7. Finally the work piece dimensions are checked to conform to the specification given in the
drawing.

Result:
Hence the required shape and size is obtained using turing, facing and taper turing operations
on the given work piece.
 DRILLING

All dimensions are in mm.

[Link]:
DRILLING
DATE:

Aim:
To drill holes on the given MS-plate as per the specification given in the drawing.

Material Supplied:
Mild Steel plate of 75x50x6 mm

Tools required:
Drilling Machine, Drill Bit, Drill chuck key, steel rule, wire brush, Dot Punch, Hammer, Flat
file.

Sequence of Operation:
a. Checking
b. Marking
c. Workpiece setting
d. Tool setting
e. Drilling

Working Steps:
1. Mark the workpiece as per the specification given in the drawing.
2. Holes centers are marked using dot punch and hammer.
3. Keep the workpiece in the fixture.
4. Bring the tool nearer the workpiece where it has to be drilled. This can be done by
adjusting the work table.
5. Perform drilling operation on the Workpiece.
6. Repeat the process, till the required numbers of holes are drilled.
7. Using the flat file remove the unwanted materials like burrs, chips etc.,
8. Check the dimensions of the finished workpiece

Result:
Hence the required number of holes are drilled using drilling machine on the given work piece.
STRAIGHT SNIP CURVED SNIP

BENCH SHEAR

BALL PEEN HAMMER CROSS PEEN HAMMER

MALLET
[Link]:
SHEET METAL
DATE:

Introduction:
Sheet metal is simply metal formed into thin and flat pieces. It is one of the fundamental forms
used in metalworking, and can be cut and bent into a variety of different shapes. Thicknesses can vary
significantly, although extremely thin thicknesses are considered foil or leaf, and pieces thicker than
6 mm (0.25 in) are considered plate. The thickness of the sheet metal is called its gauge. The gauge of
sheet metal ranges from 30 gauge to about 8 gauge. The higher the gauge, the thinner the metal is.
There are many different metals that can be made into sheet metal, such as: Aluminum, brass,
copper, steel, tin, nickel and titanium. For decorative uses, important sheet metals include silver, gold,
and platinum.
Sheet metal has applications in car bodies, airplane wings, medical tables, roofs for building and
many other things. Historically, an important use of sheet metal was in plate armor worn by cavalry,
and sheet metal continues to have many decorative uses, including in horse tack.

Specification of Sheet Metal:

The sheets specified by standard gauge numbers. Each gauge designates a definite thickness.
The gauge number can be identified by Standard Wire Gauge (S.W.G) .

S.W.G 10 12 14 16 18 20 22 24 26 30
Thickness
3.2 2.6 2.0 1.6 1.2 0.9 0.7 0.6 0.4 0.3
(mm)

Sheet Metal Tools:

1. Cutting Tools
2. Striking Tools
3. Supporting Tools
4. Marking and Measuring Tools
5. Bending and Folding Tools
6. Other Tools
 FLAT CHISEL

HALF ROUND CHISEL

BEAK HORN STAKE

HALF MOON STAKE FUNNEL STAKE

1. Cutting Tools: (Chisels, Snips or Shears)
a) Chisels:
This is used to cut the sheets. It is also used to remove the unwanted metal form the surface of a
job by chipping. Mostly flat type and round nose type chisels are used. Flat chisel are used to obtain flat
surface and its cutting edge is V-shape. Its cutting angle is 60° and the cutting edge varies from 20 to
25 mm in width. But the cutting edge of the round nose chisel is round in shape and used for making
grooves. Its cutting angle varies from 35° to 40°.
b) Snips (or) Shears:
The tool similar to scissors used for cutting or shearing thin metal sheets is called snip. Its
length varies from 200 mm to 600 mm. Mainly Straight Snip and Curved Snip is used. Bench shear is
used to cut the sheet metal of 3 mm thickness.

2. Striking Tools: (Hammers and Punches)

a) Hammers:
These are used on the sheet metal for straightening, bending, leveling, riveting, removing nails,
forging, chipping etc., with the application of impact load exerted manually. Mainly Ball peen hammer,
Cross peen hammers and Mallet used in practice.
b) Punch:
This is used for marking out work, locating centres etc. There are four types Dot punch Centre
punch, Letter punch and Number punch.
3. Supporting Tools: (Stakes, Anvils, Swage Block)
a) Stakes:
The stakes are used for doing various operations like forming, bending, hemming, seaming, etc.
There are different shapes of stakes available but based upon the purpose, the required shape of stake is
selected. They are Beak Horn stake, Funnel stake, Half moon stake etc.
b) Anvil:
The anvil acts as a base for smithy work while hammering. The body of the anvil is made of
mild steel (MS), wrought iron or cast iron (CI). The weight of the anvil varies from 100 to 150 kg.
c) Swage Block:
It is a CI block having number of slots of different shapes and sizes along its four side faces. It
also contains number of through holes of different size and shape from its top to bottom face. This
 BENCH PLATE

GROOVING TOOL

COMBINATION PLIERS PIPE PLIERS

DOT PUNCH
block can be used for bending, punching and shaping of metals.

4. Marking and Measuring Tools: (Steel rule, Scriber, Trammel, Divider, Swing Blade Protractor,
Wire Gauge)
a) Steel rule: It is used for linear measurements up to the accuracy of 0.5 mm.
b) Scribers: It is made up of hardened steel with pointed end used for marking lines on the sheet.
c) Trammel (or) beam compass: It is a big size compass used for marking large arcs and circles.
d) Divider: It is used for dividing straight and curvilinear lines, marking circles and arcs.
e) Swing Blade Protractor: It is used for marking and measuring angles.
f) Wire Gauge: It is used for measuring the thickness of sheet metal.

5. Bending and Folding Tools: (Pliers, Folding Bars)

a) Pliers:
The pliers are mainly used for bending the sheet metal to the required shape. It is also used for
holding and cutting the sheet metal. There are mainly two types – Pipe pliers and Combination pliers.
b) Folding Bars:
The folding bars are used for bending and folding operation of the sheet metal.
6. Other Tools:

a) Grooving Tools: It is used for making locked joints in sheets like wired edges, slots etc.
b) Bench Plate: It is plate having the holes of different shapes and sizes.

Sheet Metal Operations:

1. Shearing: (Parting, Blanking, Punching, Notching, Slitting, Lancing, Trimming)
2. Bending
3. Drawing
4. Squeezing

1. Shearing Operation:
Shearing is a metalworking process which cuts stock without the formation of chips or the use
of burning or melting. Strictly speaking, if the cutting blades are straight the process is called Shearing;
if the cutting blades are curved then they are shearing-type operations.
SOLID TYPE FOLDING BAR

SPLIT TYPE FOLDING BAR

WIRE GAUGE

SWING BLADE PROTRACTOR

The most commonly sheared materials are in the form of sheet metal or plates, however rods can also
be sheared.
a) Parting: It signifies that scrap is removed between the two pieces to part them.
b) Blanking: It means cutting a whole piece from sheet metal.
c) Puching: It is the operation of producing circular holes on a sheet metal by punch and die.
d) Notching: It is the process of removing the metal from the side or edge of a sheet.
e) Slitting: It is the process of conducting shearing between the rotary blades.
f) Lancing: It is the process of cutting sheet metal lengthwise.
g) Trimming: It the process cutting away the excess metal in a flange or flash from a piece.
2. Bending:
In this metal is stressed beyond the elastic limit, so that the metal is bent into right angle and
forming occurs when complete items or parts are shaped. It incorporates angle bending, roll bending,
and roll forming and seaming.
3. Drawing:
It is the process of producing cup shaped components from the sheet metal by required number
of punching strokes. It is done by placing the metal blank over a stationary die and exerting required
pressure from a punch against the blank.
4. Squeezing:
Squeezing is the one of the methods of forming ductile material. Riveting, cold heading and
rotary swaging are very common process of squeezing.
Sheet Metal Joints:
There are mainly two types: Hem and Seam
a) Hem: A hem is an edge or border made by folding. There are mainly three types of hem they are;
(i) Single Hem: It is made by a single folding of the edge in the sheet metal to make it smooth &
stiff.
(ii) Double Hem: The double hem is made by double folding of the edge in the sheet metal, to
make it smooth & stiff.
(iii) Wired Edge Hem: It is made by rolling the sheet metal to certain distance. This hem is
smooth and strong.
b) Seam: A seam is a joint made by fastening two edges of the sheet metal together.
SPRING DIVIDER WING DIVIDER

TRAMMEL

DOUBLE POINT SCRIBER

DEVELOPMENT OF RECTANGULAR TRAY

RECTANGULAR TRAY

All dimensions are in mm.

[Link]:
RECTANGULAR TRAY
DATE:

Aim:
To make the rectangular tray from the given sheet metal.

Material Required:
26 gauge Galvanized Iron (G.I) Sheet [150x110mm]

Tools required:
Steel Rule, Scriber, Try-Square, Ball Peen Hammer, Mallet, Stacks, Straight Snip, Grover,
Pliers and Compass.

Sequence of Operation:
a. Marking
b. Cutting
c. Hemming
d. Bending
e. Finishing

Working Steps:
1. The given GI sheet is marked as per the given dimensions shown in the drawing.
2. The unwanted portion of the sheet is cut by using the straight snip along the marked lines.
3. Then the sheet is levelled for the perfect flatness using the mallet.
4. The position of the hemming operation is marked at the edges with the help of the steel rule
and a scriber.
5. By holding the sheet in the bench vice the hemming operation is done on four sides of the
tray using ball peen hammer.
6. The sides of the tray are bent to 90 degree as per the given sketch by using the required
stacks, anvil and mallet.
7. Finally all the corners of the tray are joined by rivetting and finishing operations.

Result:
Hence the rectangular tray is made on the given GI sheet to the required size.
DEVELOPMENT OF FUNNEL

CONE

NECK

All dimensions are in mm.

[Link]:
FUNNEL
DATE:

Aim:
To make the funnel from the given sheet metal.

Material Required:
26 gauge Galvanized Iron (G.I) Sheet [200x100mm]

Tools required:
Steel Rule, Scriber, Try-Square, Ball Peen Hammer, Mallet, Stacks, Straight Snip,
Grover, Pliers and Compass.

Sequence of Operation:
a. Marking
b. Cutting
c. Hemming
d. Bending
e. Finishing

Formula Used:
Angle , φ = (R/ L ) 360º

Where , R = radius of the top circle of the funnel

L = Slanting length
Working Steps:
1. Funnel is splitted into cone and cylinder
2. The development of cone and cylinder are drawn on the given GI sheet, using steel rule,
scriber and compass.
3. The unwanted portion of the sheet is cut by using the straight snip along the marked lines.
4. Then the sheet is leveled for the perfect flatness using the mallet.
5. The position of the hemming operation is marked at the top edge of the cone and also at the
bottom edge of the cylinder, with the help of the steel rule and a scriber as per the
specification given in the sketch.
6. The cone and the cylinder are joined together by seaming operation and soldering is done
around the joint.
7. Hemming is done at the top and bottom of the funnel by using required stacks and mallets
8. Finally finishing operation is done to avoid ups and downs of the funnel
 FUNNEL

All dimensions are in mm.

Result:
Hence the funnel is made on the given GI sheet to the required size.
DEVELOPMENT OF WINNOWING PAN

WINNOWING PAN

All dimensions are in mm

[Link]:
WINNOWING PAN
DATE:

Aim:
To make a winnowing pan from the given sheet metal.

Material Required:
26 gauge Galvanized Iron (G.I) Sheet [130x110mm]

Tools required:
Steel Rule, Scriber, Try-Square, Ball Peen Hammer, Mallet, Stacks, Straight Snip, Grover,
Pliers, Compass.

Sequence of Operation:
a. Marking
b. Cutting
c. Hemming
d. Bending
e. Finishing

Working Steps:
1. The given GI sheet is marked as per the dimensions shown in the drawing.
2. The unwanted portion of the sheet is cut by using the straight snip along the marked lines.
3. Then the sheet is leveled for the perfect flatness using the mallet.
4. The position of the hemming operation is marked at the edges with the help of the steel rule
and a scriber.
5. Hemming is done at the top and bottom of the funnel by using required stacks and mallets.
6. By holding the sheet in the bench vice, the hemming operation is done on the three sides of
the dust pan using ball peen hammer and pliers.
7. The sides of the dust pan are bent to 90 degree by using the required stacks anvil and mallet.
8. Finally all the corners of the tray are joined by riveting and finishing operations.

Result:
Hence the winnowing pan is made on the given GI sheet to the required size.
 .Window Air Conditioner

Split Type Air Conditioner

.
[Link]:
AIR CONDITIONER
DATE:

Introduction:
Air conditioner is a device used to condition the air according to human comfort. Air is
consisting of humidity, temperature, dust etc. The presence of these constituents makes the people to
feel discomfort and reduces the efficiency of persons. Therefore air has to be conditioner depending
upon the requirement. Generally in coastal areas the humidity level is more hence wet air prevails, so
air has to be dehumidified using air conditioner. In the tropical areas dry air prevails hence air has to be
humidified using air conditioner. Thus air conditioner may be classified according to season as Summer
Air Conditioner & Winter Air Conditioner.
Types of Air Conditioner:
1. Window Air Conditioner
2. Spilt type Air Conditioner

WINDOW AIR CONDITIONER:

Working Principle:
The refrigerant vapour at high pressure and temperature is supplied by the compressor to the
condenser. A propeller type fan is used to draw air from atmosphere and to circulate through the
condenser coil. The air cools the refrigerant vapour and it becomes liquid.
Refrigeration cycle
The refrigeration cycle consists of the following processes.
1) Condensing coil 2) Expansion valve, 3) Evaporator coil, 4) Compressor.
Initially, a heat pump transfers heat from a lower-temperature heat source into a higher-
temperature heat sink. Heat would naturally flow in the opposite direction. This is the most common
type of air conditioning. A refrigerator works in much the same way, as it pumps the heat out of the
interior and into the room in which it stands.
The most common refrigeration cycle uses an electric motor to drive a compressor. Since
evaporation occurs when heat is absorbed, and condensation occurs when heat is released, air
conditioners use a compressor to cause pressure changes between two compartments, and actively
condense and pump a refrigerant around. A refrigerant is pumped into the cooled compartment (the
evaporator coil), where the low pressure causes the refrigerant to evaporate into a vapor, taking heat
with it. In the other compartment (the condenser), the refrigerant vapor is compressed and forced
Through another heat exchange coil, condensing into a liquid, rejecting the heat previously absorbed
from the cooled space. Air conditioning equipment usually reduces the humidity of the air processed by
the system and hence produces the effect.
COMPONENTS:
The refrigeration systems consists of :
a) Compressor
The compressor used in window air conditioner is of hermetic type. The refrigerant vapour is
compressed to high pressure and temperature in the condenser.
b) Air-cooled condenser
It is used to cool the high pressure high temperature refrigerant vapour. It is continuous coil
made of copper tubing. A propeller type fan is used to draw the necessary air from atmosphere to cool
the refrigerant.
c) Capillary tube
It is an expansion device. It is used to reduce the pressure and temperature of the refrigerant.
d) Evaporator
It is cooling coil made of copper. A centrifugal blower is installed behind the coil to deliver cool
air from the evaporator to the room. The blower also sucks warm air from the room and sends it to the
evaporator through a Filter.
Applications:
1) Used in offices, hotels, buses, cars, aero planes for human comfort.
2) Used in textile industries to control moisture.
3) Used in printing press, food industries, chemical plants etc.,

Window air conditioner is also known as room air conditioner, and is usually fitted in the window or
any opening made in the wall of suitable dimensions. This is then packed with insulating material like
thermo coal to achieve better efficiency.
SPLIT TYPE AIR CONDITONER:
Introduction:
Split air conditioners are used for rooms and halls, usually in places where window air
conditioners cannot be installed. However, these days many people prefer split air conditioner units
even for places where window air conditioners can be fitted.
The split type room air conditioner is comprised of two parts.
1) The outdoor unit,
The outdoor unit, fitted outside the room, houses components like the compressor,
condenser and expansion valve.
2) The indoor unit.
The indoor unit comprises the evaporator or cooling coil and the cooling fan. The split air
conditioner can be used to cool one or two rooms.
OUTDOOR UNIT :
This unit houses important components of the air conditioner like the compressor, condenser
coil and also the expansion coil or capillary tubing. This unit is installed outside the room or office
space which is to be cooled.
It consists of the following parts :
a) Compressor is the main component of the system and is used to compress the refrigerant.
b) Condenser Coil is used to reject heat from the refrigerant to the out side air.
c) Condenser Fan is used in air-cooled condenser to help move the air molecules over the surface
of the condensing coil, hence rejecting the heat form the indoor to the space outside the
building.
d) Condenser Motor is located here. The motor usually has two to three speeds. Smaller unit may
have only one speed of control and turns on/off simultaneously with the compressor.
INDOOR UNIT :
The indoor unit houses the evaporator coil or the cooling coil, a long blower and the filer. After
passing from the expansion coil, the chilled Freon fluid enters the cooling coil. The blower sucks the
hot, humid and filtered air from the room and it blows over the cooling coil. As the air passes over
cooling coiling its temperature reduces drastically and also loses the excess moisture comfortable
conditions of around 25  to 27  C as per the standard requirements. It can be mounted on the ceiling,
wall or simply as a console unit on the floor.
It consists of the following parts :
a) Evaporator coil is where the heat exchange is done with the room. It consists of fins and tubes.
b) Control Panel is where user controls the functions of the air conditioner. Displays at the panel
may indicate the mode of operation, timer, on/off status, fan speed and other special functions.
Most newer units have remote control feature built into the system
c) Air Filter is located in front of the evaporator coil to trap any dust or particles before going into
the evaporator. This is usually washable and re-useable. Users are advised to clean it at least
once in three months or more regularly if the environment is dirty.
d) Supply and Return Air Grills are where the air enters and discharge from the indoor unit.
e) Fan blower together with its motor are used to control the fan speed of the unit. High, medium.
Low and Ultra low speeds are usually designed for users to select.
f) Capillary tube is used as an expansion device where the flow of the refrigerant depends on the
tube internal diameter, shape and its length. The tube is usually used in smaller units. Larger
units use thermostatic expansion valve which has a controlling valve to regulate the flow of
refrigerant with greater precision.
WORKING :
 A copper connection pipe and electrical wiring connects the indoor unit to the outdoor unit of
the split air conditioning.
 Gas refrigerant is pumped from the outdoor condenser coil and compressor through the
connection pipe to the indoor unit(s).
 A fan then quietly distributes cool air drawn across the unit’s evaporator coil.
[Link]:
CENTRIFUGAL PUMP
DATE:

Introduction:
The centrifugal pump is a hydraulic machine which converts the mechanical energy into
hydraulic energy in the form of pressure energy, by means of the centrifugal force of a rotating element,
known as impeller.
The components of the centrifugal pump are:
1. Suction Pipe:
The pipe whose one end is connected to the inlet of the pump and the other end is below the
water surface in the sump is known as Suction pipe. A foot valve (a non return valve) is fitted at the
lower end of the suction pipe. The length of the suction pipe should be maintained as low as possible
and the number bends along the pipeline should be kept to a minimum.
2. Impeller:
The rotating part of the centrifugal pump is known as impeller. It has curved vanes arranged on
it. The impeller is mounted on a shaft, which is powered by an electric motor.
3. Casing:
Casing is an air tight passage surrounding the impeller. The casing has a gradual decrease in
cross sectional area, so that kinetic energy may be converted into pressure energy. The different types
of casings are,
A) Volute casing:
This is spiral in nature and facilitates the conversion of kinetic energy into pressure energy, by
the gradual decrease in cross sectional area. For larger pumps the increase in efficiency is not very
large, because of formation of eddies. Because of formation of eddies in the flowing water,
considerable energy is lost.
B) Vortex casing:
Here, a circular chamber is introduced between the impeller and the casing, to reduce the
formation of eddies. Thus loss of energy is prevented and as such the pumps have better efficiency.
C) Diffuser casing:
Here, the impeller is surrounded by a diffuser. The diffuser has a series of guide vanes. The
function of the diffuser is to transmit the water without shock. Hence the vibration of the pump is
reduced. The presence of diffuser decreases the area of cross section, which helps in reducing the flow,
consequently enhancing the pressure of the water.
4. Delivery pipe:
A pipe whose one end is connected to the outlet of the pump and the other end to the delivery
tank is known as the delivery pipe.

Working principle:
The centrifugal pump works on the principle of Forced Vortex Flow, according to which, if a
certain mass of the fluid is rotated by an external torque, the rise in pressure head of the rotating liquid
takes place. The rise in pressure head at any point of the rotating liquid is proportional to the square of
tangential velocity of the liquid at that point.
Thus at outlet of the impeller where radius is more, the rise in pressure head will be more. This
increase in pressure head is responsible for raising the fluid to high level.
Types of impeller:
The different types of impellers are
A) Open impeller:
An open impeller is characterized by impeller blades that are supported almost entirely by the
impeller hub. This is the simplest impeller style and it is primarily applied to clean, non-abrasive, low
horsepower applications.
B) Closed impeller
A closed impeller incorporates a full front and back shroud. Fluid flows through the internal
impeller passages without hydraulic interaction with the stationary casing walls. In a well designed
enclosed impeller, the relative velocity between the impeller and the fluid at any given radius is quite
small. This results in less wear than other impeller styles.
C) Semi open impeller:
A semi-open impeller is a compromise between an open and an enclosed impeller. It
incorporates a single shroud, usually located on the back of the impeller. A semi-open impeller has a
solids passing capability similar to that found in an open impeller. With only a single shroud a semi-
open impeller is easy to manufacture and completely accessible for applying surface hardening
treatments. For moderately abrasive slurries, especially if plugging is a concern, a semi-open impeller
is a good choice.
Priming of Centrifugal pump:
Before starting the pump, the air from suction pipe, impeller, casing and a part of the delivery
pipe are is removed and replaced by water. This operation is known as Priming.
If priming operation is not done, then the torque of the impeller will not be transmitter to the
water, due to lack of contact, and as such water will not rise in the deliver pipe.

Applications
1) It is used to fill the overhead tank, in houses and offices.
2) In agricultural sector centrifugal pumps is used to deliver the water from the well.
3) Large size centrifugal pump are used in industries.
4) Centrifugal pumps play an important role in marine engineering, chemical engineering and
other fields of engineering also.
5) Centrifugal pumps are utilized to feed water to boilers in industries.
 BELLOWS RAMMERS

MOULDING BOX SHOVEL

TROWELS
[Link]: STUDY OF FOUNDRY
DATE:

Introduction:
A foundry is a factory which produces metal castings from either ferrous or non-ferrous alloys.
Metals are turned into parts by melting the metal into a liquid, pouring the metal in a mold, and then
removing the mold material or casting. The most common metal alloys processed are aluminum and
cast iron. However, other metals, such as steel, magnesium, copper, tin, and zinc, can be processed.

Casting
Casting is a manufacturing process by which a liquid material is usually poured into a mold,
which contains a hollow cavity of the desired shape, and then allowed to solidify. The solidified part is
also known as a casting, which is ejected or broken out of the mold to complete the process. Casting
materials are usually metals or various cold setting materials that cure after mixing two or more
components together; examples are epoxy, concrete, plaster and clay. Casting is most often used for
making complex shapes that would be otherwise difficult or uneconomical to make by other methods.
Components Required for Moulding:
1. Moulding Sand (Green Sand)
2. Moulding Boxes
3. Pattern
4. Moulding Tools

1. Moulding Sand:
Green sand is an aggregate of sand, bentonite clay, pulverized coal and water. Its principal use
is in making molds for metal casting. The largest portion of the aggregate is always sand, which can be
either silica or olivine.
Green sand (and other casting sands) is usually housed in what casters refer to as flasks which
are nothing other than boxes without a bottom or lid. The box is split into two halves which are stacked
together in use. The halves are referred to as the top (cope) and bottom (drag) flask respectively.
Green sand is not green in color, but "green" in the sense that it is used in a wet state (akin to
green wood).
 SLICK SPRUE

VENT ROD RIDDLE

2. Moulding Box:
It is also called moulding flask. It is frame or box of wood or metal. Wood is cheaper and boxes
can be made quickly. Wood wears out quickly. It is destroyed by contact with hot metal. A metal box is
steel, cast iron and aluminum alloys are used in mass production. Moulding boxes are used for making
sand moulds.
3. Pattern:
In casting, a pattern is a replica of the object to be cast, used to prepare the cavity into which
molten material will be poured during the casting process. Patterns used in sand casting may be made
of wood, metal, plastics or other materials The making of patterns, called patternmaking (sometimes
styled pattern-making or pattern making), is a skilled trade that is related to the trades of tool and die
making and mold making, but also often incorporates elements of fine woodworking.
4. Moulding Tools:
a) Shovel:
It is one of the foundry tools which have a broad metal blade with a long wooden handle. It is
used to carry moulding sand from the sand pit to the moulding box and is also used for mixing and
tempering (adding sufficient water) the sand.
b) Riddle:
It is a metal sieve used for removing foreign materials such as stones, nails etc., from the
moulding sand.
c) Rammer:
It is used for packing or ramming the moulding sand in the moulding box.
d) Trowels:
It is used for smoothening the surfaces of mould and also to repair the damaged portion of
mould.
e) Slick:
It is used for repairing and finishing surfaces and to round corners of the mould.
f) Lifter:
It is used to remove the loose sand from the mould. It is also used to finish the bottom and sides
of the mould.
g) Strike off bar:
It is used to remove excessive sand from the mould after tempering.
h) Sprue pin:
It is used to make sprue hole to pour the molten metal in the mould.
i) Vent rod:
It is used for making vent holes in the sand mould so that the molten gases released during
casting process, can easily escape from mould.
j) Bellows:
It is used to blow off loose sand particles from the mould and pattern.
k) Gate cutter:
It is used for cutting gates and runners in the mould.
[Link]:
STEPPED CONE PULLEY
DATE:

AIM:
To make the mould using stepped cone pulley.

Material Supplied:
Moulding sand, Parting sand, Facing sand, stepped cone pulley pattern and Moulding boxes
Tools Required:
Showel, Sieve, Trowel,. Rammers, Sprue pin, Strike off bar, Lifter, Gate cutter, Runner, Riser, Vent
rod, Draw spike, Bellow.
Sequence of Operation:
a) Sand Preparation
b) Core preparation
c) Placing the pattern on the moulding board
d) Ramming of drag
e) Placing runner and riser
f) Ramming of cope
g) Removal of pattern, runner, riser
h) Gate cutting

Working Steps:
1. The stepped cone pulley pattern is placed on the moulding board.
2. A suitable core is prepared and placed in the hole of the flange pattern.
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 is done using flat and peen
rammers.
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 is placed over the pattern.
10. After applying parting sand, moulding sand is filled over the pattern.
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 moved on the runner hole.
15. Cope is kept aside and the pattern is removed using draw pin.
16. Gate is prepared using gate cutter.
17. The cope is placed on the drag.

RESULT:
Hence the stepped cone pulley mould is prepared.
[Link]:
GEAR
DATE:

AIM:
To make the mould of a gear pattern.

Material Supplied:
Moulding sand, Parting sand, Facing sand, stepped cone pulley pattern and Moulding boxes
Tools Required:
Showel, Sieve, Trowel,. Rammers, Sprue pin, Strike off bar, Lifter, Gate cutter, Runner, Riser, Vent
rod, Draw spike, Bellow.
Sequence of Operation:
a) Sand Preparation
b) Core preparation
c) Placing the pattern on the moulding board
d) Ramming of drag
e) Placing runner and riser
f) Ramming of cope
g) Removal of pattern ,runner, riser
h) Gate cutting

Working Steps:
1. The gear pattern is placed on the moulding board.
2. A suitable core is prepared and placed in the hole of the flange pattern.
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 is done using flat and peen
rammers.
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 the pattern.
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 moved on the runner hole.
15. Cope is kept aside and the pattern is removed using draw pin.
16. Gate is prepared using gate cutter.
17. The cope is placed on the drag.
RESULT:
Hence the gear mould is prepared.