1

LABORATORY MANUAL

MANUFACTURING PRATICE

ME 218 E














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LIST OF PRACTICALS


Page No Sr. No Name of Practical
From To
1 To make the pattern for a given casting with all the necessary
allowances, parting line running system details. Prepare the
mould and make the casting. Investigate the casting defects and
suggest the remedial measures.

01 03
2 To make a component involving horizontal and vertical welding
and study the welding defects and suggests their remedies.

04 07
3 To prepare a job on surface Grinder / Cylindrical Grinder and
measure the various parameters of the finished piece.

08 09
4 To Cut external threads on a lathe.

10 11
5 Manufacturing and assembly of a unit consisting of 2 & 3
components to have the concept of tolerances and fits (shaft and
bush assembly or shaft key or bush assembly or any suitable
assembly).

12 13
6 Leveling of machine tools and testing their accuracy.

14 14
7 Disassembly and assembly of small assembles such as tail stock,
bench vice and screw jack etc.

15 16
8 Development and manufacture of complex sheet metal
components such as funnel etc.

17 18
9 Multi slot cutting on Milling machine by indexing.(Cutting of
slots on a circular piece at 90)

19 19
10 To drill and tap holes on a metal plate and investigate the
accuracy of tapping holes.

20 21




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EXPERIMENT NO.1

Aim: - To make a pattern for a given casting with all necessary allowances, parting line,
running system details. Prepare the mould and make the casting. Investigate the casting
defects and suggest the remedial measures.

Tools required: -
Steel scale, try square, saw, rasp, hand drilling machine, mould box, shovel, hand riddle,
vent wire, trowel, lifter, gate cutter, Strike of bar, runner, riser, sprue pin, licks, rammers
swab, crucible tong furnace.

Material required: -
Kellwood of required size, green sand mixture.

Procedure: -
1. Two wooden pieces of required size are to be cut.
2. Length, width and height for pattern are marked on both pieces.
3. One piece is clamped in vice and unwanted material is removed as per marking using
saw and rasp file and finish it.
4. The process is repeated on the second piece.
5. Mark the center line on both blocks for drilling holes.
6. Do the drilling according to marking both the pieces up to half of thickness of the
pattern.
7. J oin the pattern with the help of dowels.
8. Then a mould box suitable for the pattern should be selected.
9. Lower part of pattern is placed in the middle of drag.
10. Drag is filled with the moulding sand and rammed properly.
11. Parting sand is sprinkled over the top surface of the mould.
12. The cope is placed over the drag in proper position.
13. Then the top part of the pattern is assembled in position
14. Runner and riser are placed in position and the cope is filled with sand and rammed.
15. Then the cope is separated from drag and the pattern is removed.
16. The gate is made using gate cutter and mould cavity.
17. The cope is placed in position and locked.
18. The mould is allowed drying.
19. The mould is ready for pouring.
20. Metal is melted in crucible to correct temperature.
21. The crucible is held with a tong and metal is poured in the mould and allowed to
solidify and cool.
22. After cooling the casting is extracted by breaking the mould.
23. Cut of the gate.
24. The entire surface is cleaned using wire brush.

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Precautions: -
1. Wear apron, shoes and tight fitted clothes.
2. Be careful and attentive while working on this job.
3. Use proper tools for each operation.
4. Dont keep any sharp tool in your pocket.
5. Tools being used should be well sharpened.
6. Runner and riser should be placed at the right place.
7. Sand should be mixed properly.
8. Always use gloves when doing casting.

Defects in casting and there remedial measures: -

The chief defects in casting are: Blow holes, shrinkage cavity metal penetration and rough
surfaces, hot tears, displaced cores etc.

Blow holes: - Blow holes are internal porosity or surface depression as a result of excessive
gasses material that cannot escape. They are caused by low permeability, excessive
moisture, hard ramming and excessive organic material. They can be controlled by taking
care of above points.
Shrinkage cavity: - When ever feeding is inadequate internal unsoundness is usually
indicated by some external imperfection either the wall deformation by dishing at the
weakest point. Remedial of the cause proper design of gates and runners.
Metal penetration and rough surfaces: -
It refers to the condition of penetration of metal in the interstices of the sand grains. It causes
a fused aggregate of metal and sand on the surface of casting which results in rough surface
finish. It is caused by sft ramming, too coarse mould and core sand and excessive metal
temperature.
Hot Tears: - It is caused by excessive mould, hardness by ramming, high dry and hot
strength, improper metallurgical and pouring temperature controls and provision of
insufficient fillets or bracket at the junction of sections.
Displaced cores: - These occur due to the buoyancy of cores in molten metal. Cores should
be firmly anchored. In long cores, bending can be taken care of by using stiff core irons and
chaplets placed correctly.










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EXPERIMENT NO.2

Aim: - To make the component involving horizontal and vertical welding and study the
welding defects and suggests there remedies.

Tool required: - Scale, scriber, hand hack saw, flat file, welding m/c, eye shield, gloves,
wire brush, chipping hammer, welding rod etc.

Material required: - mild steel plates of 8mm thickness.

Procedure: -
1. Two pieces are cut to size and surface to be welded are cleaned properly.
2. Electrode is held in electrode holder and earth clamp is clamped to the work piece.
3. The pieces are positioned first for horizontal welding. The two work pieces rest one
over the other with flat faces in vertical plane. As shown in fig. Then tack weld is done at
two end points.
4. 2 -3mm spark gap is maintained and horizontal welding is done smoothly.
5. For vertical welding the two pieces to be positioned so the axis of weld remain
vertical and tack weld is done at two points.
6. The welding should be started from the bottom and proceeds up words.
7. Slag is removed using chipping hammer and weld is cleaned using wire brush.

Precautions: -
1. Wear apron, shoes, gloves, nose mask and tight clothes.
2. Be careful and attentive while working on welding job.
3. During welding dont see the welding light rays directly without the goggles / face
shield.
4. Do not cool the welding piece in the water.
5. Dont keep electrode holder on the welding m/c.
6. No inflammable material should be present in welding shop.

Defects in welding and their remedial measures: -

Porosity and blow holes: - Porosity is a group of small voids, which will be generated in the
weld bead, when gases will get entrapped in the weld bead. Remedies of this are reduce
welding speed, to allow time for gases to escape, clean the base properly and proper arc
length, welding current, welding techniques and electrode should be used.

Slag Inclusion: - Flux used in welding reacts with impurities and for a slag. If this slag is
mixed with weld bead that defects is called slage inclusion so slag inclusion are compounds
such as oxides flux and electrode coating materials that are trapped weld zone. It remedies
are clean surface and previous weld bead properly. Use proper arc length, angle and speed.
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Incomplete fusion and penetration: - If the molten metal does not (fuse) mix properly with
the base metal that defects is called incomplete fusion or lack of fusion. It remedies are use
proper arc current, less arc travel speed, shorter arc length and use small electrode and
design of joint well.

Cracks: - Cracks may occur in various location and direction in the weld area. Cracks may
appear in crater, under bead, base metal or in the root. Its remedies are cooling rate should be
reduced. Use fresh and baked electrode. Increase welding current and electrode size and
reduce travel speed. Use preheats, anneal the base metal.

Spatter: - Spatter refers to small particles of metals which are scattered around the weld
along its length. Its remedies are use proper welding current arc length and lower arc
voltage. And use fresh or baked electrodes and reduce arc blow.






























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EXPERIMENT NO.3

Aim: - To prepare a job on Surface Grinder / Cylindrical Grinder and measure the various
parameters of the finished piece.

Tool & Instruments required: - Straight disc grinding wheel, roughness checking gauge,
steel scale and micrometer.

Material required: - 1005015mm mild steel plate.

Procedure: -
1. Work piece is to be cut to size.
2. Work piece held on magnetic chuck of the machine and set as per wheel position.
3. Longitudinal feed to the work is given by reciprocating the table.
4. Cross feed is given by moving the wheel head in and out.
5. A rough cut over the whole surface is completed by giving small in feed of 0.02mm.
6. Then finish cut is completed by giving in feed 0.01mm.
7. Repeat the operation for opposite surface.
8. The piece is cleaned and thickness is measured.
9. Surface finish is checked with roughness checking gauge.

Precautions:-
1. Suitable coolant to be used in grinding.
2. Use of higher feed and slow speed for rough work and low feed and higher speed for
finishing operation is always recommended.
3. Nut for tightening the wheel on spindle should always be in opposite direction of
wheel rotation.
4. Wear apron, shoes and tight fitted clothes.
5. Be careful and attentive while working on the machine.














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EXPERIMENT NO.4

Aim: - To cut external threads on a lathe.

Tool & Instruments required: - Longitudinal turning tool, Threading tool, steel rule,
vernier caliper, out side caliper, micrometer, thread gauge etc.

Material required: - Round M.S bar of 50mm dia.

Procedure: -
1. Round bar is cut to size.
2. Work piece is hold in lathe chuck in such a way that 120mm bar is projected out side
the check.
3. Single point cutting tool is fixed in the tool post and facing operation is completed.
4. A rough cut is used to turn the outer periphery.
5. Set the control levers in the positions as indicated on the instructions plate, under the
supervision of shop instructor for cutting the given lead of threads.
6. For positive movement of the carriage, the main spindle is connected with the lead
screw by the gears and then by closing the split nut tightly upon the lead screw.
7. A properly ground threading tool should be set in the tool post.
8. The process should be repeated a number of times to achieve the required depth of
thread.

Precautions: -
1. Work piece should be firmly gripped in the lathe chuck.
2. Coolant should be used.
3. Closing of split nut should coincide with the initial starting point as marked on the
thread dial for repeated operation.
4. Tool withdrawal at the end of each cutting should be done quickly to avoid the
overshooting of tool.
5. Threading tool is ground to a prefect angle for cutting the required profile of the
thread should be ensured.
6. Threading should be done at medium r.p.m.
7. Wear apron, shoes and tight fitted clothes.
8. Be careful and attentive wile working on the machine.








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EXPERIMENT NO.5

Aim: - Manufacturing and assembly of unit consisting of 2 &3 components to have the
concept of tolerances and fits (shift and bush assembly or shaft key or bush assembly or any
suitable assembly)

Tool & Instrument required: - Longitudinal turning tool, twist drill, boring tool, vernier
scale, micrometer etc.

Material Required: - M.S. bar 35mm dia.

Procedure of bush making: -
1. A round bar is cut to size.
2. Work is held in the chuck, aligned and centre is located.
3. A through hole of 10mm dia is drilled by fixing a 10mm dia drill in the tail stock.
4. The dia of hole is enlarged to 20mm by using 15mm and then 20mm drill.
5. A boring bar is set in the tool post.
6. The hole is bored by using boring tool.
7. The hole size of 22
0.2
is achieved in 2 3 cuts at medium speed and feed.
8. Finally the bore size is checked and the piece is unloaded.

Procedure of shaft making: -
1. Work piece is held in chuck and aligned.
2. Tool is fixed in tool post and facing operation is done.
3. Similarly step turning operation is done.
4. The size of shaft dia 22
0.2
is achieved in 3 4 cuts.
5. Final cut is taken cautiously so the size is maintained.
6. Burrs and sharp edge are removed from both the pieces.
7. Bush and shaft should be assembled with normal hand pressure.

Precautions: -
1. Work piece should be firmly gripped in the chuck.
2. Coolant to be used.
3. When taking finish cut to achieve the required size, care should be taken in selecting
the required speed and feed.
4. Wear apron, shoes and tight fitted clothes.
5. Be careful and attentive while working on the machine.






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EXPERIMENT NO.6

Aim: - Leveling of machine tools and testing their accuracy.

Tool & Instrument required: - Straight edge, sprit level, steel wedges, test mandrel
600mm long, dial gauge, spanner set, hammer etc.

Procedure of leveling of machine (lathe)
1. Machine is placed on foundation.
2. Wedges are driven at each corner of both the legs of the machine.
3. Wedges are driven at there position till they are tight.
4. A precision sprit level is used to check the level, by keeping the level on the machine
bed in longitudinal transverse direction.
5. Deviation from zero reading is corrected by adjusting the wedges.
6. After ensuring that the machine has been properly leveled, the base is properly
secured by tightening those nuts over the foundation both and the m/c is left for few days to
settle down.
7. After few days of setting, the machine given the final check and grouting operation is
competed.

Acceptance Test
True running of spindle
1. A test mandrel 300mm long is taken and set in the spindle of the machine.
2. A dial indicator is set such a way that the plunger of the dial indicator touches the
cylindrical surface of the mandrel.
3. Spindle is rotated slowly and the readings of dial indicator are noted.
4. Deviation should be within 0.01mm.
5. The test should be repeated at mandrel close to spindle bore as well as extreme end of
the test mandrel.

Parallelism & perpendicularity test
(Parallelism between two axes is two surfaces are normally measured in two planes,
horizontal and vertical.)
1. The test mandrel is mounted in the spindle of lathe.
2. Dial indicator is mounted on saddle or carriage. So that the plugs of dial indicator
touches the mandrel surface.
3. The saddle is moved to a specified distance and dial reading is noted.
4. The test is repeated in the horizontal direction also.





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EXPERIMENT NO.7

Aim: - Disassembly and assembly of small assembles such as tail stock, bench vice and
screw jack etc.

Tool & Instruments required: - Vernier scale, hammer, spanner set, pliers, screw driver,
spring setting pliers.

Material required: - A Bench voice

Procedure: -
1. Moveable slide is taken out by rotating the spindle antic lock wise till the end.
2. Spring is loosened by pulling out the split pin with plier.
3. Screwed shaft is separated by taking out the spring.
4. Both jaws are unscrewed by screw driver.
5. All the parts are cleaned and washed in kerosene oil.
6. Allow the parts to dry.
7. Apply grease in bushes and all screw shafts.
8. The spring with washers both sides is fitted at its place using spring setter and locked
with split pin.
9. The moveable slide with screw is locked in their position.
10. The slide is moved forwarded and positioned by rotating screw clockwise.
11. Both the jaws are screwed and fitted tightly by using screw driver.

Precautions: -
1. Proper tools should be used.
2. Dissembled parts should not be mishandled.
3. Tights nuts or faster should be open properly. Use of hammer to open the nuts should
be avoided.
4. Wear apron, shoes and tight fitted clothes.
5. Be careful and attentive wile working on the job.











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EXPERIMENT NO.8

Aim: - Development and manufacture o f complex sheet metal components such as funnel
etc.

Tools required: - scale, scriber, snip, surface plate, rail line, bench or hand shearing
machine, mallet, funnel stake, composition plier, solder, soldering iron, flux.

Material required: - G.I. (galvanized iron) sheet 26 SWG.

Procedure: -
1. Sheet of required size is cut (according to pattern) and smoothened by using mallet on
surface plate.
2. Layout of funnel is drawn on the sheet as per template using the scriber.
3. Cutting is done as per marking using snip.
4. Bending is done on the funnel stake using mallet.
5. Make the second smaller piece in a similar way.
6. After making both the pieces soldering is done using solder and soldering iron.
7. J ob is finished using mallet and file.

Precautions: -
1. Wear apron, shoes, gloves, nose mask and tight clothes.
2. Be careful and attentive while working on sheet metal job.
3. Use proper tool for each operation.
4. Dont touch hotter place when doing soldering.
5. Dont keep any sharp tool in your pocket.

















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EXPERIMENT NO.9

Aim: - Multi slot cutting on milling mach8ine by indexing. (Cutting of slots on a circular
piece at 90).

Material required: - M.S. 50mm dia. & 70mm length.

Procedure: -
1. An indexing head is mounted on the milling table.
2. A plain slot cutter is set in the machine spindle.
3. Centers on both faces of the job is marked and punched.
4. The job is to be mounted between centers using center of the indexing head and that of
tail stock.
5. The position of the job and the tool is set properly.
6. The slot is made3 at medium rpm of the cutter and medium feed of the table.
7. The job is brought back to the original position by backward feed to the table.
8. The job is indexed to the desired degree by using crank and indexing pin of the
indexing head.
9. The tool is set again in position and the second slot is made in the similar way.
10. The process is repeated for the third and fourth slot.
11. The job is unloaded from the machine burs and coroners of the slots are removed
using fine file and checked.

Precautions: -
1. Understanding of indexing head is very important.
2. Where ever indexing head is set for desired position ensure that indexing pin and
plunger are set properly.
3. Light used of file is required for removing the burs.
4. Coolant should be used.
5. Wear apron, shoes and tight fitted clothes.
6. Be careful and attentive while working on the machine.












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EXPERIMENT NO.10

Aim: - To drill and tap holes on a metal plate and investigate the accuracy of tapping holes.

Tools & Instrument required: - Drilling machine, drill chuck, tap handle & tap set,
machine vice, twist drill bits, flat file, try square, center punch, scriber, vernier caliper.

Material required: - Mild steel flat

Procedure: -
1. A flat piece of required dimension is to be cut using hacksaw.
2. Both ends are filed and checked for square ness using try square.
3. Chalk solution is applied on the surface of metal and left to dry.
4. Dried metal piece is marked as per dimension given in the drawing using steel rule
and scriber.
5. Center of the hole is marked using center punch and hammer.
6. J ob is clamped in the vice of drilling machine keeping the marked surface upward and
enlarges the centers of the holes using center drill in the machine.
7. The center drill is taken out and the drills of required sizes are fitted in the drill chuck
of the machine and drill the job.
8. After drilling, the work piece is clam0ped in a vice and roughing tap, secured in the
tap wrench is inserted in the hole vertically.
9. Tap is rotated clockwise and hand pressure is applied till the tap cuts a few threads.
10. After each clockwise revolution, tap should be rotated by a half revolution in antic
lock wise direction.
11. The process is repeated for intermediate tap and finishing tap.

Precautions: -
1. Always cut the threads with the whole set of taps using the three taps in proper order
i.e. first, second and finishing tap.
2. Always tapping is done perpendicular to the work piece.
3. Always use good and proper cutting fluid.
4. Wear apron, shoes and tight fitted clothes.
5. Be careful and attentive while working on the machine.