ME8361 - MANUFACTURING TECHNOLOGY LABORATORY I

Laboratory Manual

Department of Mechanical Engineering

Revision Date Prepared by Approved by

Name Designation Signature Name Designation Signature
Rev 1. 12-08.2020 Mr. S. RAJAMANICKAM AP Dr. P. VIJAYASARATHI Prof.
VISION OF THE INSTITUTE

 Pursuit of excellence in technical education to create civic responsibility with

competency.

MISSION OF THE INSTITUTE

 To impart the attributes of global engineers to face industrial challenges with social
relevance.
 To indoctrinate as front runners through moral practices.
 To attain the skills through lifelong learning.

VISION OF THE DEPARTMENT

 To produce industry ready, innovative and creative Mechanical Engineers to meet societal
challenges with moral values and research knowledge.

MISSION OF THE DEPARTMENT

 To impart high quality of Mechanical Engineering knowledge to students and enhance

their skills to fit for industrial practices.
 To inspire dynamic potential minds to think innovatively and involve them in research
and consultancy.
 To confer the right extent of morals, ethical values and lifelong learning to empower the
general public and to make noteworthy commitments
 PROGRAM EDUCATIONAL OBJECTIVES (PEOS)

Our graduates will,

 Have the potential to work effectively as individual and as well as in teams in the field of
Chemical Engineering and allied disciplines.
 Have the ability to pursue higher studies and research through continuous and lifelong
learning.
 Engage in career development through entrepreneurial skills with a sense of social
responsibility considering ethical, economical, environmental factors.

PROGRAM SPECIFIC OUTCOMES (PSOS):

After completing B.E., Mechanical Engineering program, graduates will be able to

PSOs Program Specific Outcomes (PSOs)

Design, develop and establish newer mechanical system using emerging techniques such as ANSYS,
PSO1
3D Printing and Smart Materials to enhance the productivity with international standards.

Provide sustainable, cost effective and eco friendly methodologies for improving existing Mechanical
PSO2
system.

Use modern analysis and design tools such as CATIA, ANSYS, and Solid Works, to enhance quality
PSO3
in Mechanical Engineering domains.
 PROGRAM OUTCOMES (POs)

POs PROGRAM OUTCOMES (POs)

Engineering knowledge : Apply the knowledge of mathematics, science, engineering fundamentals, and an
PO1
engineering specialization to the solution of complex engineering problems.
Problem analysis: Identify, formulate, review research literature, and analyze complex engineering
PO2 problems reaching substantiated conclusions using first principles of mathematics, natural sciences, and
engineering sciences.
Design/development of solutions : Design solutions for complex engineering problems and design system
PO3 components or processes that meet the specified needs with appropriate consideration for the public health
and safety, and the cultural, societal, and environmental considerations.
Conduct investigations of complex problems: Use research-based knowledge and research methods
PO4 including design of experiments, analysis and interpretation of data, and synthesis of the information to
provide valid conclusions.
Modern tool usage: Create, select, and apply appropriate techniques, resources, and modern engineering
PO5 and IT tools including prediction and modeling to complex engineering activities with an understa nding of
the limitations.
The engineer and society: Apply reasoning informed by the contextual knowledge to assess societal,
PO6 health, safety, legal and cultural issues and the consequent responsibilities relevant to the professional
engineering practice.
Environment and sustainability: Understand the impact of the professional engineering solutions in
PO7 societal and environmental contexts, and demonstrate the knowledge of, and need for sustainable
development.
Ethics: Apply ethical principles and commit to professional ethics and responsibilities and norms of the
PO8
engineering practice.

Individual and team work: Function effectively as an individual, and as a member or leader in diverse
PO9
teams, and in multidisciplinary settings.
Communication: Communicate effectively on complex engineering activities with the engineering
PO10 community and with society at large, such as, being able to comprehend and write effective reports and
design documentation, make effective presentations, and give and receive clear instructions.
Project management and finance: Demonstrate knowledge and understanding of the engineering and
PO11 management principles and apply these to one’s own work, as a member and leader in a team, to manage
projects and in multidisciplinary environments.
Life-long learning: Recognize the need for, and have the preparation and ability to engage in independent
PO12
and life-long learning in the broadest context of technological change.
 SYLLABUS

ME8361 MANUFACTURING TECHNOLOGY LABORATORY – I LTPC

0042

OBJECTIVE:
To Study and practice the various operations that can be performed in lathe, shaper,
drilling, milling machines etc. and to equip with the practical knowledge required in the core
industries.

LIST OF EXPERIMENTS
Machining and Machining time estimations for:
1. Taper Turning
2. External Thread cutting
3. Internal Thread Cutting
4. Eccentric Turning
5. Knurling
6. Square Head Shaping
7. Hexagonal Head Shaping
8. Fabrication of simple structural shapes using Gas Metal Arc Welding
9. Joining of plates and pipes using Gas Metal Arc Welding/ Arc Welding /Submerged arc
welding
10. Preparation of green sand moulds
11 Manufacturing of simple sheet metal components using shearing and bending operations.
12. Manufacturing of sheet metal components using metal spinning on a lathe
TOTAL: 60 PERIODS

COURSE OUTCOMES:

Upon the completion of this course the students will be able to

CO1 Demonstrate the safety precautions exercised in the mechanical

workshop.
CO2 Make the workpiece as per given shape and size using Lathe.
CO3 Join two metals using arc welding.
CO4 Use sheet metal fabrication tools and make simple tray and funnel.
CO5 Use different moulding tools, patterns and prepare sand moulds.
 GENERAL INSTRUCTIONS AND SAFETY RULES
1. Students should wear the uniform and closed foot wear. (Students inappropriately dressed for lab, at the
instructor’s discretion, be denied access).

2. When you handle chemicals wear eye protection (chemical splash goggles or full face shield).

3. When you work with welding equipment you should use special gloves to protect your hands.

4. To protect clothing from chemical damage or other dirt, wear a lab apron or lab coat. Long hair should be tied
back to keep it from coming into contact with lab chemicals or flames.

5. In case of injury (cut, burn, fire etc.) notify the instructor immediately.

6. In case of a fire or imminently dangerous situation, notify everyone who may be affected immediately; be sure the
lab instructor is also notified.

7. If chemicals splash into someone's eyes act quickly and get them into the eye wash station, do not wait for the
instructor.

8. In case of a serious cut, stop blood flow using direct pressure using a clean towel, notify the lab instructor
immediately.

9. Eating, drinking and smoking are prohibited in the laboratory at all times.

10. Never work in the laboratory without proper supervision by an instructor.

11. Except the scientific calculator, any other electronic devices are not permitted to use inside the Laboratory.

12. Any damage to any of the equipment/instrument/machine caused due to carelessness, the cost will be fully
recovered from the individual (or) group of students.
 CONTENTS

Ex. No. Name of the Experiment Page No.

EXPERIMENTS

1 Taper turning 1

2 External thread cutting 3

3 Drilling, boring and internal thread Cutting 5

4 Eccentric turning 7

5 Knurling 9

6 Square head shaping 11

7 Hexagonal head shaping 13

8 Fabrication of simple structural shapes using Gas Metal Arc Welding 15

9 Joining of plates and pipes using Gas Metal Arc Welding/ Arc Welding 17
/Submerged arc welding

10 Preparation of green sand moulds 19

11 Manufacturing of simple sheet metal components using shearing and 26

bending operations.

12 Manufacturing of sheet metal components using metal spinning on a 32

lathe

ADDITIONAL EXPERIMENTS BEYOND THE SYLLABUS

13 Capstan lathe 33

14 Planner Machine 34
 TAPER TURNING
Ex.No.: 1
Date:
Aim:
To produce the component by performing taper turning using lathe

Materials required:
Mild steel Φ 32 mm X 100 mm long

Tools required:
1. Chuck key
2. Tool post spanner
3. Verneir caliper
4. Steel rule
5. Single point cutting tool

Specimen drawing:

All dimensions are in mm

1
Procedure:
1. Check the size of raw material given and ensure the size.
2. Hold the workpiece in the chuck and tight it properly.
3. Clamp the tool on post properly and check the centre of work piece with cutting tool tip.
4. Do the facing operation by giving cross feed to the cross slide and reduce length.
5. Do the turning operation by giving longitudinal feed to the carriage and reduce the diameter of the
work piece.
6. Two or three pass can be given for turning operation.
7. Remove the work piece and hold in chuck on other side and do the turning operation for the remaining
portion of the work piece.
8. Calculate the taper angle and swivel the compound rest and clamp it properly.
9. Do the taper turning operation by giving angular feed to the compound rest as per the dimension.
10. Do the facing operation and get the required length.
11. Remove the component carefully and check the dimension.

Result:
Thus the component is produced as per the given drawing using lathe.

Viva - voce

1. What is meant by lathe?

2. What are the various operations can be performed on a lathe?
3. What are principle parts of the lathe?
4. What are the types of headstock?
5. What are the various parts mounted on the carriage?
6. What are the four types of tool post?
7. What is the purpose of three jaw chuck?
8. Define – Conicity
9. What are the different operations performed on the lathe?
10. What are the holding devices?
11. What are the various feed mechanisms used for obtaining automatic feed?
12. What is copying lathe?
13. What are the advantage of capston lathe & turret lathe?
14. What is meant by tooling?
15. What are the three stage of a tool-layout?
16. What are the different drives used in copying lathe?

2
 EXTERNAL THREAD CUTTING
Ex.No.: 2
Date:
Aim:
To produce the component by performing threads cutting operation using lathe

Material required:
Mild steel Φ 32 mm X 100 mm long

Tools required:
1. Chuck key
2. Tool post spanner
3. Verneir caliper
4. Steel rule
5. Single point cutting tool
6. V thread cutting tool
7. Pitch gauge
8. Grooving tool
9. Drill chuck with centre drill bit

Specimen drawing:

All dimensions are in mm

3
 Procedure:
1. Check the size of raw material given and ensure the size.
2. Hold the work pieces in the chuck and tight it properly.
3. Clamp the tool on tool post properly and check the centre of work piece with cutting tool tip.
4. Do the facing operation by giving cross feed to the cross slide and reduce the length.
5. Do the turning operation by giving longitudinal feed to the carriage and reduce the length.
6. Two or three pass can be given for the turning operation.
7. Remove the work piece and hold in chuck on the other side and do the turning operation for the
remaining work piece.
8. Engage the back gear mechanism to reduce the speed of the work piece.
9. Check the pitch required, calculate the tumbler gear, and engage it with head stock.
10. Move the carriage towards tail stock and make a mark on the dial.
11. Give small depth of cut and engage the half nut so that the carriage will move automatically towards
head stock and cut the v-thread on the work piece.
12. After reaching the required length of thread, release the tool by rotating cross slide in opposite to the
depth of cut by counting the number of rotation.
13. Move the carriage towards tail stock, give depth of cut and engage the half nut.
14. Repeat the procedure to produce complete form of v-thread. After finishing remove the work piece
from the chuck.

Result:
Thus the component is produced as per the given drawing using lathe.

Viva - voce

1. What are the components that can be turned on a copying lathe?

2. What is meant by shaper?
3. What are the four important parts of a shaper?
4. How the feed & depth of cut is given to the shaper?
5. What are the four-shaper specifications?
6. How does the planer differ from the shaper?
7. What is the use of planer?
8. What are the various types of planners?
9. Name the various parts of a double housing planer?
10. Distinguish between square and V type thread
11. Write down different types of thread.

4
 DRILLING, BORING AND INTERNAL THREAD CUTTING
Ex.No.: 3
Date:
Aim:
To produce the component by performing drilling, boring and thread cutting using lathe
Material required:
Mild steel Φ 50 mm X 45 mm long

Tools required:
1. Chuck key
2. Tool post spanner
3. Verneir caliper & Steel rule
4. Single point cutting tool & Boring tool
5. Drill chuck with drill bits
6. Internal thread cutting tool

Specimen drawing:

All dimensions are in mm

5
Procedure:
1. Check the size of raw material given and ensure the size.
2. Hold the workpiece in the chuck and tight it properly.
3. Clamp the tool on tool post properly and check the centre of work piece with cutting tool tip.
4. Do the facing operation by giving cross feed to the cross slide and reduce the length.
5. Hold the drill bit on the tail stock and unclamp the tail stock, then move it towards the head stock and
ensure the centre coincidence with work piece centre.

6. Start the motor and give depth of cut to the drill bit by rotating the tail stock wheel and make complete
hole.
7. Clamp the boring tool on the tool post to perform the boring operation.
8. Clamp the internal thread tool on the tool post to perform internal threading operation,
9. Engage the back gear mechanism to reduce the speed of the work piece.
10. Check the pitch required, calculate the tumbler gear and engage it with head stock.
11. Move the carriage towards tailstock and make marking on the dial.
12. Give small depth of cut and engage the half nut so that the carriage will move automatically towards
headstock and cut the v thread on the work piece.
13. Release the tool by rotating cross slide in opposite to the depth of cut by counting number of rotation
after reaching the required length of thread.
14. Move the carriage toward the tail stock and give depth of cut and engage the half nut.
15. Repeat the procedure to produce complete form of v thread. After finishing remove the work piece
from the chuck.

Result:
Thus the component is produced as per the given drawing using lathe

Viva - voce

1. What is meant by drilling?

2. What is meant by gang -drilling machine?
3. What are the specifications of drilling machine?
4. What are the machining operations that can be performed on a drilling machine?
5. What are the different ways to mount the drilling tool?
6. What is meant by broaching?
7. What are the specifications of a broaching machine?
6
 ECCENTRIC TURNING
Ex.No.: 4
Date:

Aim:
To turn a given work piece eccentrically in a lathe machine as per the given dimensions
Material required:
Mild steel Φ 32 mm X 75 mm long
Tools required:
1. Steel rule
2. Dot punch
3. Ball pen hammer
4. Single point cutting tool
5. Surface gauge
6. Drill bit
7. Drill chuck
8. Boring tool
Specimen drawing:

All dimensions are in mm

7
Procedure:
1. Check the size of raw material given and ensure the size.
2. The work piece is fixed in the four jaw chuck using surface gauge.
3. The cutting tool is fixed in the tool post to the lathe axis.
4. Facing operation has been done on both sides of given work pieces.
5. Marking and punching is to be done on the given work pieces as per the dimension.
6. Then the work piece is fixed in the chuck such that the offset point coincides with spindle axis.
7. Using the turning tool, turning operation has been performed.
8. The same procedure is also carried out to the other side of the work piece for the given offset
distance.
9. Thus the eccentric turning would be finished.

Result:
Thus the work piece is turned eccentrically as per the given dimensions .

Viva - voce

1. What is meant by eccentricity?

2. What is meant by effect of back rake angle? Mention the types.
3. What is meant by side rake angle? Mention its effects.
4. What are all the conditions for using positive rake angle?
5. When will the negative rake angles be used?
6. Define – Orthogonal cutting
7. What is meant by cutting force?
8. What is meant by chip thickness ratio?
9. What are the purposes of chip breakers?
10. Define – Machinability of metal
11. Define – Oblique cutting
12. Differentiate between orthogonal and oblique cutting.
13. Which type of chuck used for eccentric turning?
14. What are the applications of eccentric components?
15. What is meant by tool signature?

8
 KNURLING AND GROOVING
Ex.No.: 5
Date:
Aim:
To produce the component by performing knurling and grooving operation using lathe

Material required:
Mild steel rod size of dia. 32 mm and length 100 mm

Tools required:
1. Single point cutting tool
2. Knurling tool
3. Pitch gauge
4. Grooving tool
5. Drill chuck with centre drill bit

Specimen drawing:

All dimensions are in mm

Procedure:
1. Check the size of raw material given and ensure the size.
2. Held the work pieces in the chuck and tight it properly.
3. Clamp the tool on tool post properly and check the centre of work piece with cutting tool tip.
4. Do the facing operation by giving cross feed to the cross slide and reduce the length.
5. Do the turning operation by giving longitudinal feed to the carriage and reduce the length.

9
 6. Two or three passes can be given for the turning operation.
7. The grooving tool is fixed in the tool holder on lathe.
8. The work piece is fixed in the machine vice. Then switch on the machine.
9. Make the grooving operation as per the dimension using grooving tool.
10. Then place a knurling tool in the tool holder of lathe.
11. Make the knurling operation as per the dimension using knurling tool.
12. Make the chamfer at the end of the component.
13. Remove the component and inspect its size.

Result:
Thus the component is produced by performing knurling and grooving operation using lathe.

Viva - voce
1. What is the purpose of knurling?
2. What are the various types of knurling tool?
3. Which machine used for knurling operation?
4. What is meant by Machinability index?
5. What is the purpose of grooving?
6. What are various types of grooving tool?
7. Write the tailor’s tool life equation.
8. What are the purposes of gear grinding process?
9. What is meant by gear lapping?
10. What is meant by cutting shaping process?
11. Define – Tool life
12. What are the factors affecting tool life?
13. What are the factors affecting the machinability?
14. Define – Machinability of metal
15. What are the purposes of chip breakers?

10
 SQUARE HEAD SHAPING
Ex.No.: 6
Date:
Aim:
To make round work piece to square by using shaper

Material required:
Mild steel Φ 50 mm x 25 mm long

Tools required:
Steel rule, dot punch, hammer, verneir height gauge, T-square, scriber, surface plate, single point cutting
tool, tool holder.

Specimen drawing:

All dimensions are in mm

Procedure:
1. Check the size of raw material given and ensure the size.
2. The work piece is fixed in the three jaw chuck.
3. The cutting tool is fixed in the tool post to the lathe axis.
4. Facing operation has been done on both sides of given work pieces.
5. Chalk is applied uniformly on the face of the work piece.
6. Marking and punching is to be done on the given work pieces as per the dimension.

11
 7. The cutting tool is fixed in the tool holder in shaper machine.
8. The work piece is fixed in the machine vice, then switch on the machine.
9. At the end of each stroke give the feed to the work piece.
10. Shaping operation has been done on four sides in the work piece till the round work piece is turned
into square shaped as per the given dimension.

Result:
Thus the round work piece is machined to square work piece by shaper machine.

Viva - voce

1. What is meant by shaper?

2. What are the various types of shaper?
3. What are the specifications of shaper?
4. W hat are the operations of shaper?
5. What is the application of square head?
6. What is meant by indexing?
7. What are the three types dividing heads?
8. What is cam milling?
9. What are the different types of thread milling?
10. What are the other forming methods for manufacturing gears?
11. Write any ten nomenclature of plain milling cutter?
12. What are the various milling operations?
13. What are the advantages of milling process?
14. What are the down milling processes?
15. What is the various type of milling attachment?

12
 HEXAGONAL HEAD SHAPING
Ex.No.: 7
Date:
Aim:
To make a round work piece to hexagonal shape by using shaper

Material required:
Mild steel rod size of dia. 32 mm and length 50 mm

Tools required:
Steel rule, dot punch, hammer, verneir height gauge, T-square, scriber, surface plate, single point cutting
tool, tool holder.

Specimen drawing:

All dimensions are in mm

Procedure:

13
 1. Check the size of raw material given and ensure the size.
2. The work piece is fixed in the three jaw chuck.
3. The cutting tool is fixed in the tool post to the lathe axis.
4. Facing operation has been done on both sides of given work pieces.
5. Chalk is applied uniformly on the face of the work piece.
6. Marking and punching is to be done on the given work pieces as per the dimension.
7. The cutting tool is fixed in the tool holder in shaper machine.
8. The work piece is fixed in the machine vice, then switch on the machine.
9. At the end of each stroke give the feed to the work piece.
10. Follow the same procedure to the other side of the work piece.
11. Shaping operation has been done on six sides in the work piece till the round work piece is turned into
hexagonal shaped as per the given dimension.

Result:
Thus the round work piece is machined to hexagonal shape by shaper machine.

Viva-voce

1. What is the function of cutting fluids?

2. What are the properties of cutting fluid?
3. What are the causes of wear?
4. What are the specifications of the milling machine?
5. What are the various movements of universal milling machine table?
6. Distinguish between plain and universal milling machine?
7. What are the cutter holding devices?
8. What are the various type of milling attachment?
9. Write any ten nomenclature of plain milling cutter?
10. What are the advantages of milling process?
11. What are the applications of hexagonal head?
12. Differentiate shaper from planner.
13. What are the operations of planner?
14. What are the work holding devices used in shaper?
15. What are the tool holding devices used in shaper?

14
 Fabrication of simple structural shapes using Gas Metal Arc Welding
Ex.No.: 8.A
Date:
BUTT JOINT
Aim:
To join two given metal plates by a single 'V' butt joint in arc welding

Tools Required:
1. Welding transformer
2. welding rods
3. Safety gloves
4. Goggle
5. Chipping hammer
6. Flat file
Diagram:

All dimensions are in mm

PROCEDURE:
1. Check the surface to be welded and file the edge of the plates for perfect joint and more strength.
2. Hold the welding rod in the electrode holder and clamp the ground clamp to the plate to be welded.
3. Position the plates to be welded touching each other (butting) and tag weld on the ends to avoid
the movement of the plates during welding.
4. Now start welding one end of the plates.
5. The electric arc produced melts the welding rod and joints the two metal plates. Maintain a gap of
3 mm between the plate and the welding rod.
6. Complete the welding process by removing slag using chipping hammer.

Result:
Thus the two metal plates are welded in single 'V' butt joint.

15
 LAP JOINT
Ex.No.: 8.B
Date:
Aim:
To join two given metal plates by a lap joint in arc welding

Tools Required:
1. Welding transformer
2. welding rods
3. Safety gloves
4. Goggle
5. Chipping hammer
6. Flat file
Diagram:

All the dimensions are in 'mm'

Procedure:

1. Clean the surface to be welded and file the edge of the plates for perfect joint and more strength.
2. Hold the welding rod in the electrode holder and clamp the ground clamp to the plate to be welded.

3. Position the plates to be welded overlapping and tag weld on the ends to avoid the movement of the
plates during welding.
4. Now start welding one end of the plates.
5. The electric arc produced melts the welding rod and joints the two metal plates. Maintain a gap of
3 mm between the plate and the welding rod.
6. Complete the welding process by removing slag using chipping hammer.

Result:
Thus the two metal plates are welded in lap joint.

16
 Joining of plates and pipes using Metal Arc Welding
Ex.No.: 9
Date:
Aim:
To join two given metal plates by a tee fillet joint in arc welding
Tools Required:
1. Welding transformer
2. welding rods
3. Safety gloves
4. Goggle
5. Chipping hammer
6. Flat file
Diagram:

All dimensions are in 'mm'

17
Procedure:
1. Clean the surface to be welded and file the edge of the plates for perfect joint and more strength.
2. Hold the welding rod in the electrode holder and clamp the ground clamp to the plate to be
welded.
3. Position one of the plates to be welded perpendicularly on the surface of the other plate. Tag weld
on the ends to avoid the movement of the plates during welding.
4. Now start welding one end of the plates.
5. The electric arc produced melts the welding rod and joints the two metal plates. Maintain a gap of
3 mm between the plate and the welding rod.
6. Complete the welding process by removing slag using chipping hammer.

Result:
Thus the two metal plates are welded in tee fillet joint.

18
 PREPARATION OF GREEN SAND MOULDS
Ex.No.: 10.A
Date:
Aim:
To prepare a sand mould using a gear pattern
Tools required:
1. Shovel
2. Sieve
3. Mould box
4. Rammer
5. Trowel
6. Strike off bar
7. Lifter
8. Gate cutter
9. Runner
10. Riser
11. Vent rod
12. Draw spike
13. Swap etc.
Gear pattern:

19
Procedure:
1. Clean the mould box, pattern, tools and table/floor.
2. Fill the drag with green sand after positioning the gear pattern on the table.
3. Ram the green sand carefully and the excess sand is struck off.
4. Tilt the drag upside down and sprinkle river sand on top of it.
5. Position the cope on top of the drag.
6. Position the sprue pin and riser pin, then fill the cope with sand and ramming 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 it carefully using the draw spike, and then finish
the cavity.
9. Vent holes are made using vent wire.
10. A funnel-shaped opening and gate is made to pour the molten metal.

Result:
Thus the mould of the given gear pattern is obtained.

20
 STEPPED CONE PULLEY
Ex.No.: 10.B
Date:
Aim:
To make the mould for the given stepped cone pulley
Tools required:
1. Trowel
2. Rammer
3. Strike off bar
4. Lifter
5. Runner
6. Riser
7. Gate cutter
8. Vent wire
9. Draw spike
10. Swap
11. Riddle
12. Sprue pin
13. Bellow
14. Moulding
Materials required:
1. Moulding sand
2. Parting sand
3. Facing sand
Procedure:
1. Clean the mould box, pattern, tools and the table / floor.
2. Prepare a suitable core with the help of core box.
3. Place the drag box above the moulding board. Now keep the pattern at center of the drag.
4. Sprinkle now parting sand before keeping the pattern.
5. Sprinkle facing sand over the pattern to a depth of 5 mm. Then fill the green sand over it.
6. Ram the green sand to get a air tight packing. Remove excess sand is removed by strike off bar.
7. Invert the drag box upside down. Place the cope box over the d rag box and locked.
8. Place the raiser pin and sprue pin at right position and fill the green sand over the pattern.
9. The green sand to get air tight packing with strike off bar leveling is done.
21
10. Now remove riser pin and sprue pin from the green sand mould.
11. Remove the pattern by drag spike tool.

22
 12. Prepare gate using gate cutter and place the core is placed vertically inside the cavity.
13. Mark the vent holes are made with vent wire on the cope.
Stepped cone pulley:

Result:
Thus the mould of the stepped cone pulley is obtained

23
 Viva - voce
1. What is foundry?
2. What is meant by casting?
3. What is meant by pattern?
4. What are the materials used for making patterns?
5. Name the various types of pattern.
6. What are the types of allowances used for making pattern?
7. What is the name of the binder used to mix with moulding sand?
8. Name the different types of sand used in foundry work.
9. What are the ingredients of good moulding sand?
10. What are the types of casting used in foundry?
11. List the foundry tools?
12. What is gate?
13. What is vent rod?
14. Name the types of moulding boxes.
15. Give the application of casting.
16. What do you mean by green sand?
17. Why ramming is done?
18. What is the use of sprue pin?
19. What is the function of gate cutter?
20. What is the function of riser?

24
 RECTANGULAR TRAY
Ex.No.: 11.A
Date:
Aim:
To make a rectangular tray from the given sheet metal
Material supplied:
22 gauge Galvanized Iron (GI) sheet
Tools required:
1. Steel rule
2. Mallet
3. Scriber
4. Divider
5. Protractor
6. Snips
7. Stakes
8. Rivet set
9. Ball pein hammer
Sequence of operation:
1. Checking
2. Levelling
3. Marking
4. Cutting
5. Bending
6. Hemming
7. Riveting
Procedure:
1. Check the size of the given sheet for its dimensions using a steel rule.
2. Level the sheet on the levelling plate using a mallet.
3. Follow the development procedure same as square taper tray.
4. Mark the dimensions.
5. Mark a single hemming on the four sides of the tray.

6. Bend this four sides of the tray to 90o using stakes anvil.
7. Finally join all the corners of the tray by riveting.

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Development of rectangular tray:

Result:
Thus the desired rectangular tray is made from the given sheet metal.

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 FUNNEL
Ex.No.: 11.B
Date:
Aim:
To make a funnel from the given sheet metal
Material supplied:
22 gauge Galvanized Iron (GI) sheet
Tools required:
1. Steel rule
2. mallet
3. Ball pein hammer
4. scriber
5. white paper
6. straight snips
7. groover
8. solder
Sequence of operation:
1. Checking
2. Leveling
3. Marking on paper
4. Marking on sheet metal
5. Cutting
6. Folding
7. Hemming
8. Soldering
Formula used:
Angle , φ = (R/ L )× 360º
Where , R = radius of the top circle of the funnel
L = Slanting length
Procedure:
1. Check the size of the given sheet metal is checked for its dimensions using steel rule.
2. Mark the required development of surface on the white paper which is over lapped on the sheet
metal.

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3. Mark on the sheet metal as per the development being done on the paper.
4. Now using straight snips, remove unwanted materials.

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 5. Now fold and bend the work piece to make the funnel shape and joint is made on the work pieces
6. Then using groover, make locked grooved joint for about 5 mm. Also, do hemming in the bottom of
the funnel.
7. In between top face and bottom face, make butt joint using solder.
8. Finally, carrying out trimming and finishing operation.
Development of funnel:

Cone Neck

Funnel
Result:
Thus the funnel of the required dimensions is made from the given sheet metal.

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 Viva - voce
1. Define - Sheet Metal
2. What is the application of sheet metal?
3. What are the metals used for sheet metal work?
4. Name the various types of tool used for sheet metal?
5. Explain the different types of operations in sheet metal?
6. What are the methods are used in sheet metal?
7. What is the formula used to make a cone from sheet metal?
8. What is the sequence of operations?
9. What is the use of snips?
10. What is bending?
11. What is the tool is used to measure the thickness of sheet metal?
12. What do you mean by gauge?
13. What is the application of sheet metal?
14. What is punching?
15. Why anvil is needed?
16. What is hem? What is seam?
17. What is the use of rivet set?
18. What is stake? List the different types of stakes?
19. List the different types of cutting tools used in sheet metal?
20. List the various marking tools used in sheet metal?

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 MANUFACTURING OF SHEET METAL COMPONENTS USING METAL
SPINNING ON A LATHE
Ex. No. : 12
Date :

Aim:
To machine a cup as shown in the sketch out of the sheet metal provided using Lathe machine.

Procedure:

 A disc of metal is revolved at controlled speed on a lathe machine.

 Hold the work piece in a four jaw chuck and machine the surface shown in the sketch.

 Spinning tools are forced against the rotating blank either by hand or by auxiliary power.
 Employing a serious of axial and radial strokes.
 The blank is spun onto the material causing the metal to flow to the shape of the desired part.

Results:
Thus the job was performed on the Lathe machine.

Viva-voce
1. What is metal spinning?
2. What is the requirement of metal spinning?
3. What is the mechanism involved in spinning?
4. What is speed of spinning?
5. Why lubricant is essential in metal spinning?

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 CAPSTAN LATHE

Ex.No.: 13
Date:
Aim:
To machine the work piece to the given dimensions using capstan lathe

Tools and equipments required:

Capstan Lathe, stopper, drill chuck, counter sink bit, drill bit, turning tool, parting off tool, Verneir Caliper.

Specimen drawing:

All dimensions are in mm

Procedure:
1. Prepare the tooling layout for the given workpiece.
2. Set the tools in their respective positions of the tool stations.
3. The workpiece is chucked and checked for the rotation.
4. The adjustment to the length of feed for each tool is adjusted by rotating the adjustment screws.
5. Feed the tools in the required sequence to machine the given workpiece.

Result:
Thus the given workpiece is machined to the given dimensions using capstan lathe.

Viva-voce
1. What is meant by drilling?
2. What is meant by gang -drilling machine?
3. What are the specifications of drilling machine?
4. What are the machining operations that can be performed on a drilling machine?
5. What are the different ways to mount the drilling tool?
6. What is meant by broaching?
7. What are the specifications of a broaching machine?
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 PLANER MACHINE
Ex. No. : 14
Date :

Aim:
To machine a V-block as shown in the sketch out of the workpiece provided using planner machine.

Descriptions:
 A planer is a type of metalworking machine tool that uses linear relative motion between the work piece
and a single-point cutting tool to machine a linear tool path.
 Its cut is analogous to that of a lathe, except that it is linear instead of helical. (Ad ding axes of motion can
yield helical tool paths; see "Helical planing" below.)
 A planer is analogous to a shaper, but larger, and with the entire work piece moving on a table beneath
the cutter, instead of the cutter riding a ram that moves above a stationary work piece.
 The table is moved back and forth on the bed beneath the cutting head either by mechanical means,
such as a rack and pinion drive or a lead screw, or by a hydraulic cylinder.

Procedure:
1. Hold the work piece in a vice and machine the bottom surface shown in the sketch.
2. Invert the casting in the vice and machine the top surface till the desired height is obtained.
3. Machine the inclined faces using right and left hand tools.
4. Finally machine the groove.

Results:
Thus the job was performed on the planner machine.

Viva-voce
1. What are the advantages and limitation of broaching?
2. What are the different operations that can be performed on a broaching machine?
3. What is meant by boring?
4. Differentiate between drilling and boring
5. What is meant by counter boring?

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