Lab Manual Manufacturing Proccesses II

MANUFACTURING PROCESS-II
Department of Industrial and Manufacturing Engineering

University of Engineering and Technology Lahore
Laboratory Manual of
IME-322 Manufacturing Processes II
w.e.f 22-12-2016
IME-14
Page 1 of 80
Experiment No.1
1.1 Title
Resistance Spot Welding of Uncoated Magnetic Material(s)
1.2 Problem Statement
Determining electrode tip diameter in relation to the type of magnetic material(s) and
combined thickness of the material strip.
1.3 Objective(s)
1.3.1 Identify key variables for spot welding operation
1.3.2 Determine electrode tip size for good quality weld
1.4 Apparatus
1.4.1 MS Strips of known thickness
1.4.2 Spot Welding Equipment
1.4.3 Pair of electrodes
1.4.4 Vernier Calliper
1.5 Theory [1]
Resistance welding (RW) is a group of fusion-welding processes that uses a
combinationof heat and pressure to accomplish coalescence, the heat being generated by
electrical resistance to current flow at the junction to be welded.
1.5.1 Principal
Resistance welding is accomplished when current is caused to flow through electrode tips
and the separate pieces of metal to be joined. The resistance of the base metal to
electrical current flow causes localized heating in the joint, and the weld is made.
1.5.2 Schematic
Fig. No. 1 Working Principle for Resistance Spot Welding
IME-14
Page 2 of 80
1.5.3 Electrode Tip Size
It is through the electrode that the welding current is permitted to flow into the work
piece, it is logical that the size of the electrode tip point controls the size of the resistance
spot weld. Actually, the weld nugget diameter should be slightly less than the diameter of
the electrode tip point.
The formula generally used for low carbon steel is as follows:
Electrode tip diameter = 0.100 in. + 2t
1.5.4 Spot Weld [`1]
A spot weld is a small fused section between the surfaces of two sheets or plates.
1.6 Procedure:
1.6.1 Close tongs and measure space between electrode tip contact surfaces.
1.6.2 Measure the thickness of the total weldment.
1.6.3 Adjust tong gap to measurement of Step 2 less 1/2 the thickness of the thinnest
workpiece to be welded.
1.6.4 Insert the parts to be welded between the electrode tips and bring tips to
welding pressure. There should be a slight deflection of the tongs. This may be
measured with a straight edge set on the tong longitudinal axis.
1.6.5 Energize the spot welding machine and make a sample weld.
1.6.6 Test the weld by visual and mechanical means.
1.7 Observation(s)
1.7.1 They are as follows:
i. The contact point between the electrode and top workpiece.
ii. The top workpiece.
iii. The interface of the top and bottom workpieces.
iv.
The bottom workpiece.
1.8 Calculation(s) [2]
For example, if two pieces of 0.062 in. sheet metal are to be joined, the electrode tip
diameter would be the same for both sides of the joint. The calculation would be as
follows:
Electrode tip dia. = 0.100 + 2t
= 0.100 + 2 x 0.062 in.
= 0.100 + 0.124 in.
Electrode tip dia. = 0.224 in.
IME-14
Page 3 of 80
1.9 Conclusion(s)
1.9.1 Appearance and quality of finished weld was acceptable / not acceptable.
1.9.2 Above stated relationship holds / does not hold for the presented case due to
following reasons:
a. Pressure control
b. Time cycle management
c. human element
d. Type and condition of welder
e. Condition of electrodes and condition of surface.
1.10 Recommendation(s)
Solutions to above mentioned reasons, for example,
1.10.1 Welding variables need to be determined and minimized using good process
design and by keeping in view general purpose use of the equipment for
demonstration and practice purpose.
1.10.2 Consideration must be given to surface preparation for better results.
1.11 Precaution(s)
1.11.1 Ensure that welding equipment is properly ground.
1.11.2 Do not touch live electrical parts.
1.11.3 Do not weld where the atmosphere may contain flammable dust,gas, or liquid
vapors (such as gasoline).
1.11.4 People with implants must be aware of magnetic and electric fields effect.
1.11.5 Do not weld on containers that have held combustibles, or onclosed containers
such as tanks, drums, or pipes unless they areproperly prepared according to
AWS F4.1 and AWS A6.0
1.12 Proposed Mini Project(s)
1.12.1 Updating the spot welder for time and pressure control measures and display.
1.12.2 Incorporation of current varying elements in the spot welder circuit
1.13 Reference(s)
1. Mikell P. Groover, Fundamentals of Modern Manufacturing: materials,
processes, and systems - Fourth Edition, John Wiley & Sons, Inc., New York,
2010
2. Handbook forResistance SpotWelding, miller, 2012.
IME-14
Page 4 of 80
Experiment No.2
2.1 Title
V-I Relationship in Resistance Spot Welding
Determining the heat generated in the spot welding
2.3 Objective(s)
Impact of larger/smaller current on the welding pool
2.4 Apparatus
MS Strips of known thickness
Spot Welding Equipment
Pair of electrodes
2.5 Theory [1]
Resistance welding (RW) is a group of fusion-welding processes that uses a combination
of heat and pressure to accomplish coalescence, the heat being generated by electrical
resistance to current flow at the junction to be welded.
2.5.1 Principal
Resistance welding is accomplished when current is caused to flow through electrode tips
and the separate pieces of metal to be joined. The resistance of the base metal to
electrical current flow causes localized heating in the joint, and the weld is made.
Schematic
Fig. No. 1 Working Principle for Resistance Spot Welding
IME-14
Page 5 of 80
2.5.2 Parameters in resistance welding:[2]
The principle of resistance welding is the Joule heating law where the heat Q is
generated depending on three basic factors as expressed in the following formula:
Joule heating law
Where I is the current passing through the metal combination, R is the resistance of
the base metals and the contact interfaces, and t is the duration/time of the current
flow.
The most influential parameters are following:
Welding current:
Welding time:
Welding force:
2.5.3 Processing of spot welding

Resistance spot welding involves three stages
The first of all the electrodes being brought to the surface of the metal and
applying a slight amount of pressure
The current from the electrodes is then applied briefly after which the current is
removed but the electrodes remain in place for the material to cool
Weld times range from 0.01 sec to 0.63 sec depending on the thickness of the
metal, the electrode force and the diameter of the electrodes themselves
2.5.4 Spot Weld [1]

A spot weld is a small fused section between the surfaces of two sheets or plates.
2.6 Procedure:
Clean the metal strip.
Place the metal strip between electrodes.
Put pressure through paddle.
Indent is produced at metal strip.
IME-14
Page 6 of 80
2.7 Observation(s)
Current will be produced when two point of contact will met.
Heat will generate and produce weld pool.
2.9 Calculation(s)
Resistance can be calculated through Ohms law.
V=IR
Heat generated can be calculated by formula given below:
Q=I2RT
2.10 Conclusion(s)
Total heat generated in the process can be known.
Keep knob at 2 which is at right side which will give appropriate
current and proper welding pool
2.12 Precaution(s)
Ensure that welding equipment is properly ground.
Do not touch live electrical parts.
Do not weld where the atmosphere may contain flammable dust, gas, or liquid
People with implants must be aware of magnetic and electric fields effect.
Do not weld on containers that have held combustibles, or on closed containers

such as tanks, drums, or pipes unless they are properly prepared according to
AWS F4.1 and AWS A6.0

Verify Joules law and ohms law in different equipments.
2.14 Reference(s)
[1] Mikell P. Groover, Fundamentals of Modern Manufacturing: materials,
processes, and systems - Fourth Edition, John Wiley & Sons, Inc., New York, 2010
[2] https://www.swantec.com/technology/resistance-welding/. (22-12-2016)
IME-14
Page 7 of 80
Experiment No.3
3.1 Title
To investigate the effect of thicknesses of strips on weld nugget in resistance spot welding
Determination of weld nugget diameter for steel strips of different gauges.
3.3Objective(s)
3.3.1Determineweld diameter size for good quality weld
3.5 Theory [3]
3.5.1 Welding Variables: [5]
There are 3 welding variables in RSW.
Time (cycles)
Current (K Amp)
Force (tip force in pounds)
3.5.2 Welding limitations:
1. The equipment cost is high so it can have an effect on the initial cost.
2. Skilled welders or technicians are needed for the maintenance and controlling.
3. Some metals need special surface preparation for making the RSW a success.
4. The thick jobs are not easy to weld
3.6 Procedure [2]
Close tongs and measure space between electrode tip contact surfaces through
vernier caliper.
Now take the steel strips of different gauges
First takes two strips, put them between the electrodes and presses the paddle of the
machine and measures the diameter of the weld nugget created
Now repeats the same things by taking three strips
Repeat the process for other strips of different gauges
IME-14
Page 8 of 80
3.7 Observation(s)
There is few main points of keen observation in the work area. They are as follows:
The contact point between the bottom work piece and the electrode.
Weld nugget formed was weak and small / was found with gas pockets / voids. But
by using proper size of tip diameter weld nugget was good.
3.8 Table(s):
Thickness of metal sheet in this experiment is 2mm. Time is 0.53 sec. Current is
34 A. Voltage is 4V.Material of strip is mild steel.
weld spacing
STEEL GAUGES (SAE 1060)
2
pieces
3
pieces
weld
diameter
GAUGE
in
mm
in
in
In
16
0.060
1.524
1.06
1.31
0.22
18
0.048
1.219
0.94
1.18
0.2
20
0.036
0.914
0.72
1.06
0.17
22
0.030
0.762
0.62
0.88
0.16
24
0.024
0.610
0.38
0.62
0.15
3.9Conclusion(s)
3.9.1Appearance and quality of finished weld was acceptable.
3.10Recommendation(s) [1]
1) Welding variables need to be determined and minimized using good process design
and by keeping in view general purpose use of the equipment for demonstration and
practice purpose.
2) Consideration must be given to surface preparation for better results.
IME-14
Page 9 of 80
Standards: [6]
Standard and/or project
ISO 669:2016
Resistance welding -- Resistance welding equipment -- Mechanical and electrical requirements
ISO 693:1982
Dimensions of seam welding wheel blanks
ISO 865:1981
Slots in platens for projection welding machines
ISO 1089:1980
Electrode taper fits for spot welding equipment Dimensions
ISO 5182:2016
Resistance welding -- Materials for electrodes and ancillary equipment
ISO 5183-1:1998
Resistance welding equipment -- Electrode adaptors, male taper 1:10 -- Part 1: Conical fixing, taper 1:10
ISO 5183-2:2000
Resistance spot welding -- Electrode adaptors, male taper 1:10 -- Part 2: Parallel shank fixing for end-thrust electrodes
3.12Proposed Mini Project(s)

Making weld joints on different metallic strips.
3.13 Reference(s)
[1] http://www.titespot.com/spot-welding-technical-information/ (last seen 3/10/16)
[2 ]http://www.amadamiyachi.com/servlet/servlet.FileDownload?retURL=%2Fapex%2F
educationalresources_articles&file=01530000000Jybm (last seen 3/10/16)
[3] Mikell P. Groover, Fundamentals of Modern Manufacturing: materials, processes,
and systems - Fourth Edition, John Wiley & Sons, Inc., New York, 2010
[5] https://app.aws.org/forum/topic_show.pl?tid=18252 (last seen 7/11/16)
[6]http://www.iso.org/iso/iso_catalogue/catalogue_tc/catalogue_tc_browse.htm?commid
=48622 (last seen 3/10/16)
IME-14
Page 10 of 80
Experiment No.4
4.1 Title
Metal inert gas welding of strips of different material(s)

To study the different parts, advantages, disadvantages & applications of MIG machine.
4.3 Objective(s)
4.3.1
Identify the parts, knobs and mechanism of welding machine.
4.4 Apparatus
4.4.1
MIG welding machine.
4.5 Theory [1]

Gas metal arc welding or MIG welding is a welding process in which two metals are joined
together by heating them to their melting point with an electric arc and a wire of filler material is
constantly fed to join the molten metal. An inert gas is used to protect the electric arc from
contaminants present in atmosphere.
It can be done in three different ways
Hand held
Semiautomatic.
Automatic.
4.5.1 Principal [1]

A continuous consumable wire is fed through a suitable torch or gun which is used as both
electrode and filler the gun embodies with the gas cylinder consisting of inert gas. The gun is
positive electrode and the work place is negative electrode , when gun is brought closer to the
workplace a large quantity of current flows through the electrodes producing that much quantity
of heat causing metal to melt.
IME-14
Page 11 of 80
4.6 Schematic
4.7 Parts of machine [2]

4.7.1
Torch: Torch is the major part of welding machine its life depends upon how much
welder use it.
4.7.2
Gas Regulator: There are two types of gas regulator one that measures the amount of
remaining gas in cylinder and one that measures both the remaining gas and the flow
rate
Wire Feeding system: The performance of the wire feed system can be crucial to the stability and
reproducibility of MIG welding. As the system must be capable of feeding the wire smoothly,
attention should be paid to the feed rolls and liners. There are three types of feeding systems:
pinch rolls
push-pull
spool on gun
IME-14
Page 12 of 80
4.7.3
Power source: MIG is operated usually with a DC power source. The source is termed
a flat, or constant voltage, characteristic power source, which refers to the
voltage/welding current relationship. In MIG, welding current is determined by wire feed
speed, and arc length is determined by power source voltage level (open circuit voltage).
4.7.4
Shielding gas: There are two shielding gases used in the MIG welding argon and
helium but most commonly used is argon.
4.8 Applications:[3]
i.
ii.
iii.
iv.
It is used in automotive repair.

It can produce a strong weld even down to 0.5mm thick metal sheet.
It can be used to reinforce the worn out railroad tracks.
It is also used in maintenance and in the construction of bridges and buildings.
4.9 Advantages: [4]

i.
ii.
iii.
iv.
High productivity because you dont have to stop to change the rods and chips.
Can weld on stainless steel Mild steel and aluminum.
Minimum weld splash is produced.
Metals as thin as 0.5842mm can be welded.
4.10 Disadvantages: [4]

i.
ii.
iii.
iv.
v.
Requires cumbersome bottle of shielding gases.

Costs money for consumables like tips ad nozzles.
Isnt worth or paints, dirty and rusty surfaces.
Not good for too much thick steel because of less penetration power.
Use of inert gas makes it less portable.
IME-14
Page 13 of 80
4.11 References:
1- http://www.twi-global.com/technical-knowledge/job-knowledge/equipment-for-migwelding-015/ (11-10-16)
2- American Welding Society (2004). Welding Handbook, Welding Processes, Part 1.
Miami: American Welding Society. ISBN 0-87171-729-8 (11-10-16)
3- http://www.bakersgas.com/weldmyworld/2011/01/26/mig-welding-applications (11-10-16)
4- http://www.bakersgas.com/mig-welding-advantages-disadvantages.php (11-10-16)
IME-14
Page 14 of 80
Experiment No.5
5.1 Title
Optimizing Process Conditions in MIG welding of aluminum alloys through factorial design
experiments.

Determining the factors that effect the strength of weld joint.
5.3 Objective(s)
5.3.1
Identification and optimization of main factors that have significant effect on weld joint
strength through factorial design experiments.
5.4 Apparatus
5.4.1
MIG welding apparatus
5.4.2
Pair of electrodes
5.4.3
Wire roll
5.4.4
Argon gas
5.4.5 Aluminium strips
5.5 Theory
The Metal Inert Gas (MIG) welding process, also known as Gas Metal Arc Welding (GMAW) is
much faster, more versatile, requires less skill and training, and can be used for welding thicker
sections. In addition, MIG welds are generally stronger than TIG welds due to better penetration.
5.5.1 Principal
In the metal inert gas (MIG) welding process, an electric arc is struck between the filler wire and
the work piece while a shroud of inert gas shields the electrode and protects the molten pool
against oxidation.
Generally, a smoothed direct current power source is used. To ensure the removal of the oxide
film (alumina) and the fusion of the consumable wire electrode the negative pole is connected to
the work piece. If the oxide film is thick (oxidised aluminium work pieces), the film has to be
removed mechanically with stainless steel brush.
MIG welding is suitable for thickness above 2.5 mm.
IME-14
Page 15 of 80
5.5.2 Schematic
5.6 Procedure [1]

Procedure for MIG welding is as follows. (Pal, K. and Pal, S.K., 2010)
5.6.1
A filler wire with 1.2 mm in diameter was used as a consumable electrode and a
shielding gas used was 100% pure Argon.
5.6.2
Test specimens were composed of two pieces each having dimensions of 100mm x 50mm
x 8mm in size and were made of aluminum alloy.
5.6.3
The specimens were prepared according to the joint geometry as shown
IME-14
Page 16 of 80
5.6.4
Joint spacing between the specimens was fixed at 2mm during welding experiments.
5.6.5
Prior to the welding, specimens were degreased using an aerosol degreaser to remove
contaminants and surface oxides were removed with a stainless wire brush used only on
aluminium as shown
5.6.6
Once a specimen is welded, a wrap-around bending test was used to determine the
strength of the welded joint in which a V-shaped line load is applied against the weld line
of the specimen.
5.6.7
The maximum load registered by the machine during bending is used to indicate the
strength of the weld joint.
5.7 Factorial Design Experiments [2]

Factorial design experiments refer to the implementation of design of experiments
methodology to the design and analysis of experiments with multiple factors being studied.
Although in MIG welding of aluminum alloys numerous factors have an effect on weld
joint strength and quality, few of these effects can be considered significant. (singla, M.,
Singh, D. and Deepak, D., 2010)
5.7.1 Screening Phase

Five factors were screened in this phase as shown in table below. These factors are arc
voltage (Volt V), filler feed rate (in/s), gas flow rate (cubic foot per hour, cfh), specimen
edge angle (deg) and preheat temperature (oC.)
Factor
Level
IME-14
Arc
voltage
Filler feed
rate
Gas flow
rate
Edge
angle
Preheat
temperature
Page 17 of 80
Low (-)
High (+)
(v)
21
27
(in/s)
4
6
(cfh)
24
32
(o)
60
90
(oC)
25
70
5.7.2 Optimization Phase

In this phase two factors were further studied since they have significant effects on weld
joint strength. The two factors were arc voltage and filler feed rate. The gas flow rate,
specimen edge angle and preheat temperature were fixed at 24 cfh, 90o and 25oC,
respectively.
Level
1
2
3
4
Arc
voltage
(v)
21
24
27
30
Filler feed
rate
(in/s)
4
5
6
7
5.8 Results and Discussion

5.8.1 Screening Phase Results [3]
The weld strength results of the screening phase experiments are summarized in table
below. Based on Daniels method, if all the effects of a factor fall approximately close to
the fitted line then this factor is considered insignificant. (Karadeniz, E., Ozsarac, U. and
Yildiz, C., 2007)
Arc
voltage
(v)
27
27
27
21
21
27
27
27
IME-14
Filler feed
rate
(in/s)
4
4
4
4
6
6
4
6
Gas flow
rate
(cfh)
24
24
32
24
32
32
32
24
Edge
angle
(o)
60
90
60
60
90
60
60
60
Preheat
temperature
(oC)
25
70
70
25
25
70
25
70
Weld
strength
(N)
2490
2685
2180
2895
9820
2735
2235
4120
Page 18 of 80
5.8.2 Optimization Phase Results

The weld strength results of the optimisation phase experiments are summarized in table
below. It can be noted from table that the maximum mean weld strength occurs when arc
voltage and filler feed rate are set at 24 V and 7 in/s, respectively.
Arc
voltage
Filler feed
rate
Weld
strength
(v)
27
24
21
30
24
24
21
(in/s)
4
4
4
5
6
4
6
(N)
2685
5040
3720
5190
9620
5310
10120
5.9 Calculation(s)
Weld Strength= W = 69931271V + 3272F
5.10 Weld Procedure Sequence

Weld Procedure Number
Qualifying Welding Procedure (WPAR)
Manufacturer: Industrial and
Manufacturing
engineering department
Location:
Welding
Process:
Joint Type:
IME-14
Workshop
Manual MIG
Single Sided Butt Weld
30 P1 MIG 01 Issue A
WP T17/A
Method Of
Preparation
and Cleaning:
Parent Metal
Specification:
Parent Metal
Thickness
Pipe Outside
Diameter
Welding Position:
Welding
Machine and
Degrease
Grade 304L
Stainless Steel
3 to 8mm Wall
25 to 100mm
All Positions
Upwards
Page 19 of 80
Progression:
Joint Design
Run Process
1
2
MIG
MIG
Welding Sequences
Size Of
Filler
Metal
Current
A
Voltage
V
Type Of
Current/Polarity
1.2mm
1.6mm
N/A
21
DCDC-
Welding Consumables:Type, Designation Trade Name:

Any Special Baking or Drying:
BS 2901 Part 2 : 308S92

No
Gas Flux:
Gas Flow Rate - Shield:
- Backing:
Argon 99.99% Purity

8 - 12 LPM
5 LPM
Details of Back Gouging/Backing:
Gas Backing
Preheat Temperature:
Interpass temperature:
25C Min
200C Max
Post Weld Heat Treatment

Time, temperature, method:
Heating and Cooling Rates*:
Not Required
IME-14
Filler
Feed
Speed
(in/s)
4
4
Travel
Speed
Heat
Input
(oC)
N/A
25
27
Production Sequence
1. Clean weld and
25mm borders to
bright metal using
approved solvent.
2. Position items to be
welded ensuring
good fit up and apply
purge
3. Tack weld parts
together using MIG,
tacks to at least 5mm
min length
4. Deposit root run
using 1.2mm
dia. wire.
5. Inspect root run
internally
6. Complete weld
using 1.2mm
dia wire.
7. 100% Visual
inspection of
completed weld
Page 20 of 80
5.11 Conclusion(s).
5.11.1 Factorial design experiments have shown, based on Daniels method, that arc voltage
and filler feed rate are the only significant factors of the five. These factors include arc
voltage, filler feed rate, specimen edge angle and preheat temperature.
5.11.2 It was determined that arc voltage and filler rate at 24 V and 7 in/s, respectively, yields
the maximum mean weld strength.
5.12.1 Welding variables need to be determined and minimized using good process design and
by keeping in view general purpose use of the equipment for demonstration and practice
purpose.
5.12.2 Consideration must be given to surface preparation for better results.
5.13 Precaution(s)
5.13.2 Do not weld where the atmosphere may contain flammable dust, gas, or liquid vapors
(such as gasoline)..
5.13.3 Additional safety precautions are required when any of the following electrically
hazardous conditions are present: in damp locations or while wearing wet clothing; or
when there is a high risk of unavoidable or accidental contact with the work piece or
ground. For these conditions, see ANSI Z49.1 listed in Safety Standards.

5.14.1 Incorporation of varying current in order to test the strength of the weld joint.
5.15 Reference(s)
1. Pal, K. and Pal, S.K. (2010) Study of weld joint strength using sensor signals for various
torch angles in pulsed MIG welding, CIRP Journal of Manufacturing Science and
Technology, Vol. 3, No. 1, pp.5565.
2.
Singla, M., Singh, D. and Deepak, D. (2010) Parametric optimization of Gas Metal Arc
Welding processes by using factorial design approach, Journal of Minerals & Materials
Characterization & Engineering, Vol. 9, No. 4,pp.353363.
3. Karadeniz, E., Ozsarac, U. and Yildiz, C. (2007) The effect of process parameters on
penetration in gas metal arc welding processes, Materials and Design, Vol. 28, No. 2,
pp.649656.
IME-14
Page 21 of 80
Experiment No: 6
6.1 Title
Metal inert Gas (MIG) Welding of Materials
Basic Problems and there solutions in MIG Welding
6.3 Objective(s)
6.3.1 Identify key variables for MIG welding operation
6.4 Apparatus
I. DC output power source
II. Wire feed unit
III. Torch
IV.
Work return welding lead
V.
Shielding gas supply, (normally from cylinder)
6.5 Theory
MIG (Metal Inert Gas) welding, also known as MAG (Metal Active Gas) and in the USA
as GMAW (Gas Metal Arc
Welding), is a welding process that is now widely used for welding a variety of materials,
ferrous and non ferrous. [1]
6.5.1 Principal
The principal of the process is that he small diameter electrode wire, which is fed
continuously into the arc from
a coil. As a result this process can produce quick and neat welds over a wide range of
joints.[1]
6.5.2 Schematic [2]
IME-14
Page 22 of 80
IME-14
Page 23 of 80
IME-14
Page 24 of 80
6.6 Reference(s)
2010
2. Weldability , Intro to MIG welding : www.weldabilitysif.com/media/docs/Intro_MIG_Welding.pdf / 11/15/2016/09 : 30 pm
IME-14
Page 25 of 80
Experiment No: 7
7.1 Title
Metal Inert Gas (MIG) Welding
Parametric analysis of MIG welding of aluminum and safety measures
7.3 Objective(s)
To determine the suitable parameters of MIG welding for Al strips
7.4 Apparatus
7.4.1
Al strips of known thickness
7.4.2
MIG Welding Equipment
7.5 Theory [1]
7.5.1 Selection of Inert Gas
7.5.1.1
Inert gases are used for welding of Stainless steels and Aluminum
7.5.1.2
100% Argon is used for Al
7.5.1.3
CO2 is used for low and medium Carbon Steels
7.5.2 Application(s)
MIG Welding is being used in following industries
Automotive
Piping
7.6 Procedure [3]
7.6.1 Measure the thickness of strips
7.6.2 Keep the strips in the position of being welded.
7.6.3 Bring the welding gun close to joint and initiate it
7.6.4 Travel the gun in the direction of joint
7.6.5 On completion, clean the welded joint with brus
7.7
Observation(s) [2]
Following parameters can be observed for a good joint.

Selection of voltage and Current
S/N
1
2
3
4
5
6
7
IME-14
Strip thickness
(mm)
3.2
4.8
6.4
7.9
9.5
11.1
12.7 or up
Voltage
(V)
21-22
23-24
24-25
26-27
26-28
28-29
29-30
Current
(A)
110-130
140-150
180-224
200-230
220-250
280
300
Page 26 of 80
Table 2.1
Selection of electrode thickness according to strip thickness
Strip thickness
(mm)
3.2
4.8
6.4
7.9
9.5
11.1
12.7 or up
Electrode wire Diameter
Mm
Electrode wire feed speed

(Imp)
350-400
240-270
425-450
300-325
Not feasible
350-375
Not feasible
400-425
Not feasible
450-480
Not feasible
Not feasible
Not feasible
Not feasible
Not feasible
Not feasible
170-185
200-210
220-280
240-270
290-300
0.9
1.6
1.2
Table 2.2
7.8
Conclusion(s)
7.8.1 Amount of current and voltage increases as thickness of weld material
7.8.2 By changing the thickness of weld material, current & voltage changes over a
specific range to give a better weld
7.9
Recommendation(s)
For aluminum, the most common wire type is ER4043 for all-purpose work. ER5356 is a
stiffer wire (easier to feed), and is used when more rigid, higher-strength weld properties
are needed. The best feeding of wire for aluminum is done with a spool gun. If you can't
use a spool gun, use the shortest gun possible and keep the gun as straight as possible.
Use Argon only for shielding gas.
With aluminum, pushing the gun away from the weld puddle rather than pulling it will
result in better cleaning action, reduced weld contamination, and improved shielding-gas
coverage
7.10 Precaution(s) [4]
7.10.1 ELECTRIC AND MAGNETIC FIELDS:
7.10.1.1 Electric current flowing through any conductor causes localized Electric and
Magnetic Fields (EMF). Welding current creates EMF fields around welding
cables and welding machines
7.10.1.2 EMF fields may interfere with some pacemakers, and welders having a
pacemaker should consult their physician before welding.
7.10.1.3 Connect the work cable to the work piece as close as possible to the area
being welded.
7.10.2 ARC RAYS:
7.10.2.1 Use a shield with the proper filter and cover plates to protect your eyes from
sparks and the rays of the arc when welding or observing open arc welding.
Head shield and filter lens should conform to ANSI Z87. I standards.
IME-14
Page 27 of 80
7.10.2.2
7.10.2.3
Use suitable clothing made from durable flame-resistant material to protect

your skin and that of your helpers from the arc rays.
Protect other nearby personnel with suitable, non-flammable screening
and/or warn them not to watch the arc nor expose themselves to the arc rays
or to hot spatter or metal.
7.10.3 FUMES AND GASES:

Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes
and gases. When welding, keep your head out of the fume. Use enough ventilation and/or
exhaust at the arc to keep fumes and gases away from the breathing zone. When welding
with electrodes which require special ventilation such as stainless or hard facing
instructions on container or MSDS) or on lead or cadmium plated steel and other metals
or coatings which produce highly toxic fumes, keep exposure as low as possible and
below Threshold Limit Values (TLV) using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a respirator may be required.
Additional precautions are also required when welding on galvanized steel.
7.10.4 WELDING SPARKS
7.10.4.1 Remove fire hazards from the welding area.
7.10.4.2 Where compressed gases are to be used at the job site, special precautions
should be used to prevent hazardous situations. Refer to Safety in Welding
and Cutting (ANSI Standard Z49.1) and the operating information for the
equipment being used.
7.10.4.3 Do not heat, cut or weld tanks, drums or containers until the proper steps
have been taken to insure that such procedures will not cause flammable or
toxic vapors from substances inside. They can cause an explosion even though
they have been cleaned. For information, purchase Recommended Safe
Practices for the Preparation for Welding and Cutting of Containers and
Piping That Have Held Hazardous Substances, AWS F4.1 from the
American Welding Society
7.10.4.4 Sparks and spatter are thrown from the welding arc. Wear oil free protective
garments
7.10.4.5 Connect the work cable to the work as close to the welding area as practical.
7.10.5 FOR ELECTRICALLY:
7.10.5.1 Turn off input power using the disconnect switch at the fuse box before
working on the equipment.
7.10.5.2 Install equipment in accordance with the U.S. National Electrical Code, all
local codes and the manufacturers recommendations.
7.10.5.3 Ground the equipment in accordance with the U.S. National Electrical Code
and the manufacturers recommendations.
7.10.6 Additional safety precautions are required when any of the following electrically
hazardous conditions are present: in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings, or scaffolds; when in
cramped positions such as sitting, kneeling, or lying; or when there is a high risk
of unavoidable or accidental contact with the work piece or ground. For these
conditions, see ANSI Z49.1 listed in Safety Standards. And, do not work alone!
IME-14
Page 28 of 80
7.11.1 Study of MIG Welding of steel based materials
7.11.2 Practical advantages and cost benefits using advanced pulse MIG welding over
traditional MIG welding
7.12 Reference(s)
2010
2. Miller Calculator for weld parameters
3. General safety precautions
http://www.arcraftplasma.com/welding/weldingdata/generalsafety.htm
/11/15/2016/ 8:45
4. Lincoln Electric, Gas Metal Arc Welding Product and Procedure Selection.
IME-14
Page 29 of 80
Experiment No.8
8.1 Title
Study of Tungsten Inert Gas Welding Machine (TIG) to understand its principle of
working and basic parameters.

Studying different parts, working, commercial applications, advantages and limitations of
Tungsten Inert Gas Welding Machine
8.3 Objective(s)
8.3.1 To study the fitting and placement of different parts in TIG welding machine
8.3.2 To study the practical applications of TIG welding process
8.4 Apparatus
8.4.1 TIG Welding Equipment
8.5 Theory [1]

In TIG welding an arc is formed between a non-consumable tungsten electrode and the
metal being welded. Gas is fed through the torch to shield the electrode and molten weld
pool. If filler wire is used, it is added to the weld pool separately.
8.5.1 Principal [1]

Gas tungsten arc welding (GTAW) is a process in which the joining of metals is produced
by heating therewith an arc between a tungsten (non-consumable) electrode and the
work. A shielding gas is used, normally argon.
8.5.2 Schematic [1]
Fig. No. 1 Working Principle for Tungsten Inert Gas Welding
IME-14
Page 30 of 80
8.5.3 TIG Shielding Gas [1]
Shielding Gas is defined as the gas which acts as protective shield against atmospheric
contaminants. Such as oxygen, nitrogen and moisture.
8.5.4 Current Parameters
Fig. No. 4 Graph of Currents on Tungsten Inert Gas Welding Power Supply
8.5.5 Starting Current [2]
This is current which uses ionized gas molecule to initiate the arc at a specific distance
between base metal and torch. It depends upon the size gas molecule. The starting
current is inversely proportional to the size of gas molecule which used as shielding.
Fig. No. 5 Starting Current Controller of Tungsten Inert Gas Welding Power Supply
8.5.6 Base Current [2]
This is a welding current. The current which stays in work piece throughout the welding
process is base current. Area of weld pool is controlled by base current. Base current is
set at level sufficient to maintain stable arc.
IME-14
Page 31 of 80
Fig. No. 6 Base Current Controller of Tungsten Inert Gas Welding Power Supply
8.5.7 Pulse Current [2]
It is the peak value of current which flows through work piece. It is used to melt the weld
spot. Its control is also set from remote control like of base current. It controls the state
of weld pool.
Fig. No. 8 Pulse Current Controller of Tungsten Inert Gas Welding Power Supply
8.6 Working Procedure

The working of TIG welding is as follows:
8.6.1 Welding starts from starting current which is used to ionize the gasses present in
shield of shielding gasses.
8.6.2 Then there is slope up in which starting current shifts to base current
8.6.3 Then after base current, comes the cycle of welding or pulse current. Pulse current
is that current which is used to melt the weld spot.
8.6.4 After cycle of impulse current there is again base current and then comes the down
slope timing, during down slope timing the base current shifts to crater current which is
low than base current.
8.6.5 When the whole cycle is completed the cycle again starts from starting current and
the cycle is repeated again and again until the welding ends.
8.6.6 One way, the current goes from the workpiece, up into your electrode, which makes
your electrode hotter, and the workpiece cooler.
IME-14
Page 32 of 80
8.7 Advantage(s)[2]
1.7.1 Welds are of High quality.
1.7.2 Welds nearly all metal and alloys.
1.7.3 All weld positions are possible
1.7.4 No slag developed
8.8 Limitation(s)[2]
1.8.3 Equipment is more complex and expensive than other more productive processes.
[1]
8.9 Conclusion(s)
TIG welding is one of the finest and high quality welding used in industries at present.
8.10 Precaution(s)[2]
1.10.3 Do not weld where the atmosphere may contain flammable dust, gas, or liquid

1.15.1 To study the relationship between the tungsten rod diameter and weld penetration
for mild steel plates.
1.15.2 To compare the pattern of beads formed on butt and lap joints after TIG welding.
8.12 Reference(s)
3. JWOLTE, Guidelines to Gas Tungsten Arc Welding, July, 2003
4. Welders Handbook For Gas Shielded Arc Welding, Oxy Fuel Cutting & Plasma
Cutting, Air Products PLC, 3rd Edition, 1999.
IME-14
Page 33 of 80
Experiment No.9
9.1 Title
To study the Tungsten Inert Gas Welding (TIG) parameters for mild steel plates of
different thickness.

To study the process parameters of TIG welding
9.3 Objective
9.3.1 To analyze the parameters that affects the quality and the output of TIG welding
process
9.4 Apparatus
TIG welding apparatus
9.5 Weld Current [1]

9.5.1 Higher current in TIG welding can lead to splatter and work piece become damage
9.5.2 Lower current setting in TIG welding lead to sticking of the filler wire
9.6 Weld Voltage [1]

9.6.1 This is the electrical potential difference between the tip of the welding wire and the
surface of the molten weld pool
9.6.2 It determines the shape of the fusion zone and weld reinforcement
9.7 Welding Speed [2]

9.7.1 Speed of welding = Travel of electrode/Arc time mm/min
9.7.2 Heat input rate or arc energy = V I 60/v joules per mm where, V is arc voltage
in volts, I is welding current in ampere and v is speed of welding in mm/min
9.8 Inert Gas [2]

9.8.1 The choice of shielding gas depends on the working metals and effects on the
welding cost, weld temperature, arc stability, weld speed, splatter, electrode life etc.
9.8.2 Pure helium may be used for aluminium and copper. Helium argon mixtures may be
used for low alloy steels, aluminium and copper.
9.9 Working Procedure

The working of TIG welding for different material plates is as follows:
9.9.1 Select the current type as AC and then starting current, for the MS plates, which is
used to ionize the gasses present in shield of shielding gasses.
IME-14
Page 34 of 80
9.9.2 Then set the base current which stays throughout the welding and prevents the
solidification of weld spot.
9.9.3 Then after base current, comes the cycle of weld or pulse current. Pulse current is
use to melt the weld spot. Set it according to the rod diameter and dimensions of plates.
9.9.4 After setting the weld current set the crater current and down slope timing. The
purpose of down slope timing is to with draw the current from weld spot uniformly.
9.9.5 After these settings, start the welding keeping the distance of at least 3mm between
the tip and the plates to be welded. When the whole cycle is completed the cycle again
starts from starting current and the cycle is repeated again and again until the welding
ends.
9.10 Limitations[3]
9.10.1 Less economical than consumable electrode processes for sections thicker than
3/8 inch
9.10.2 Lowest deposition rate of all arc processes
9.11 Observation(s)
Plate
Material
Plate
Dimensions
(mm)
Rod
Diameter
(mm)
Base
Current
(A)
Pulse
Current
(A)
Current
Type
Distance
of tip
from
weld
Starting
Current
(A)
Crater
Current
(A)
Gas
Flow
Rate
(1/mi
n)
Down
Slope
timing
(s)
MS
MS
MS
120*50*3
120*50*3
120*50*3
1.6
1.6
1.6
30
35
40
100
105
110
AC
AC
AC
3mm
3mm
3mm
25
30
35
60
70
80
8-10
8-10
8-10
3
5
8
9.12 Conclusion(s)
9.11.1 By carefully controlling the above mentioned parameters, weld of fine quality can
be produced
9.13.1 The beads formed by more base current are wide and can be reduced by keeping
the base current optimum
9.13.2 Tip of the tungsten rod should be clean after each welding cycle to achieve better
quality weld.
9.14 Precaution(s)
IME-14
Page 35 of 80
9.15 Reference(s)
1- Raveendra, A., & Kumar, B. R.(2013). Experimental study on Pulsed and Non Pulsed
Current TIG Welding of Stainless Steel sheet (SS304). International Journal
of Innovative Research in Science, Engineering and Technology, 2(6)
2- Hussain, A. K., Lateef, A., Javed, M., & Pramesh, T. (2010). Influence of Welding
Speed on Tensile Strength of Welded Joint in TIG Welding Process. International
Journal of Applied Engineering Research, Dindigul, 1(3), 518-527
3- Tseng, K. H., & Hsu, C. Y. (2011). Performance of activated TIG process in
austenitic stainless steel welds. Journal of Materials Processing Technology, 211(3),
503-512.
Weld Procedure Specification(s)

Weld Procedure Number
Qualifying Welding Procedure
(WPAR)
Manufacture Industrial and
r:
Manufacturing
engineering
department
Location:
Welding
Process:
Joint Type:
Welding Workshop
Manual TIG
Single Sided Butt
Weld
Joint Design
Run
Process
TIG
IME-14
30 P1 TIG 01 Issue A
WP T17/A
Method Of
Preparation
and Cleaning:
Parent Metal
Specification:
Parent Metal
Thickness
Pipe Outside
Diameter
Welding Position:
Welding
Progression:
Machine and
Degrease
Mild Steel
3 to 8mm Wall
All Positions
Upwards
Welding Sequences
Size Of
Filler
Metal
1
Curre
nt
A
N/A
Voltage
V
N/A
Type Of
Current/P
olarity
AC-
Travel
Speed
N/A
Heat
Input
(oC)
25
Page 36 of 80
2
TIG
AC-
Welding Consumables:Type, Designation Trade Name:

Any Special Baking or Drying:
Gas Flux:
Gas Flow Rate - Shield:
- Backing:
BS 2901 Part 2 :
308S92
No
Argon 99.99% Purity
8 - 12 LPM
5 LPM
Details of Back
Gouging/Backing:
Gas Backing
Preheat Temperature:
Interpass temperature:
25C Min
200C Max
Post Weld Heat Treatment

Time, temperature, method:
Heating and Cooling Rates*:
Not Required
Revision History
Date
Issu
e
5/11/201
A
6
IME-14
Changes
27
Production
Sequence
1 Clean weld and
. 25mm borders to
bright metal
using approved
solvent.
2 Position items to
. be welded
ensuring good fit
up and apply
purge
3 Tack weld parts
. together using
TIG, tacks to at
least 5mm min
length
4 Deposit root run
. using 1.2mm
dia. wire.
5 Inspect root run
. internally
6 Complete weld
. using 1.2mm
dia wire.
7 100% Visual
. inspection of
completed weld
Authorization
First Issue
Page 37 of 80
Experiment No.10
10.1 Title
Identification of Oxyacetylene Gas Welding Process.

Determine the use of Oxy-acetylene flame and different parts of the equipment used for
gas welding.
10.3 Objective(s)
10.3.1 Purpose of Using Oxyacetylene Gas Welding Process
10.3.2 Advantages and Disadvantages of Oxy-acetylene Gas Welding
10.4 Apparatus
10.4.1 MS Strips of known thickness
10.4.2 Oxyacetylene Gas Welding Apparatus
10.5 Theory [1]

Oxyacetylene Gas welding (OAGW) is a fusion-welding process performed by a hightemperature flame from combustion of acetylene and oxygen. The flame is directed by a
welding torch. A filler metal is sometimes added, and pressure is occasionally applied in
OAW between the contacting part surfaces.
10.5.1 Principal
Oxyacetylene Gas Welding is accomplished at high temperature flame from combustion
of acetylene and oxygen gas. Sometimes a filler metal is also added and pressure is also
applied between the contacting part surface, shown in fig 1
Fig 1. Oxyacetylene Welding Operation
IME-14
[2]
Page 38 of 80
10.5.2 Schematic
The schematic diagram of the gas welding apparatus is as follow.
Fig No. 2 Basic Part in Oxy-acetylene Gas Welding Apparatus
[3]
10.5.3 Filler Metal

When filler metal is used, it is typically in the form of a rod with diameters ranging
from1.6 to 9.5mm (1/163/8in).Composition of the filler must be similar to that of the
base metals. The filler is often coated with a flux that helps to clean the surfaces and
prevent oxidation, thus creating a better weld joint.
10.5.4 Gas Cylinders
Oxygen bottle color = black and has right hand thread.
Acetylene bottle color = maroon and has left hand thread.
10.5.5 Pressure Regulators
These regulators are used to control pressure of Oxygen and acetylene during the
process. Some parts of this illustration are labeled. It is important to learn the names of
these equipment components.
IME-14
Page 39 of 80
Fig No. 3 Two Stage Regulators [4]
10.5.6 Economizer
The Economizer is used to save oxygen and fuel gas when the welding or cutting torch is
not being used. When the torch is rested on the lever rod of the gas saver the flame is
automatically extinguished. The
10.5.7 Adjusting an Acetylene Flame [5]
There are three ways to control Acetylene Flame.
10.5.7.1 Neutral Flame
This flame burns equal quantities of oxygen and acetylene. Neutral Flame-Cone Tip
Hottest Part Approx.3100C.
10.5.7.2 Carburizing Flame
This flame has an excess of acetylene which results in a carbon-rich zone extending
around and beyond the cone.
10.5.7.3 Oxidizing Flame
This flame has an excess of oxygen which results in an oxygen-rich zone just beyond the
cone. This flame is obtained by setting to neutral and then turning the fuel gas down.
10.6 Procedure
Take the MS strips

Clean them with sand paper
Turn on the welding apparatus
First open the valve of acetylene gas
Adjust it with respect to thickness
Open the valve of oxygen gas
Take a fillet of material mild steel
Before performing the experiment check the gauges and regulators
IME-14
Page 40 of 80
The gauge should show the pressure needle on zero

Perform horizontal gas welding
10.7 Observation(s)
Sr.no Plate
Cutting tip Oxygen Acetylene
Thickness (size no.)
(psi)
(psi)
(in)
1
0
30
3
Hand Cutting
Speed
(in/min)
16-18
3/8
30
14-16
40
12-14
40
12-14.5
50
8.5-11.5
4
5
10.8 Conclusion(s)
10.8.1 Above stated relationship holds / does not hold for the presented case due to
following reasons:
f. Controlling Pressure properly
g. Little use of Oxygen Gas
h. Proper Size of Nozzle
i. Composition of Filler Material
IME-14
Welding variables like depth of penetration of weld, current etc need to be

determined and minimized using good process design and by keeping in view
general purpose use of the equipment for demonstration and practice purpose.
Page 41 of 80
10.10 Safety Precaution(s) [7]
Always wear the correct eye goggles.
Always have the spindle key in the acetylene cylinder valve.
10.11 Mini Project(s)

1.13.1 Preparation of butt joint using oxyacetylene brazing process
10.12 Reference(s)
2010
2010
3. http://navyaviation.tpub.com/14018/css/Oxyacetylene-Welding-639.htm/20th
October 2016, 7:34pm
4. http://www.asge-online.com/Regpg20.html/20th October 2016, 7:46pm
5. www.weldguru.com/welding-flames.html/20th October 2016, 8:20pm
6. Black, Bruce J, Workshop processes, practices and materials, Third Edition,
Elsevier Science & Technology , 2004
7. www.labour.gov.hk/eng/public/os/B/welding2.pdf/20th October 2016, 9:01pm
IME-14
Page 42 of 80
Experiment No.12
12.1 Title
To study the process planning and manufacturing of film by using blow extrusion.

To study the working, commercial applications and advantages of extruded blown film.
12.3 Objective(s)
To gain the practical knowledge and critical parameters involved in blow extrusion of
film.
12.4 Apparatus
Blow film extrusion set up
12.5 Theory
Roshan Packages is one of the well-known Packages Company in Lahore. It is one of the
small packaging organizations in Pakistan. Its owner establishes their business with the
corrugating box making facilities in Pakistan.
12.5.1 Extrusion[1]
Extrusion is a process in which material is shaped by pushing by some external force
through a die or a hole.
Extruder is recently installed and is used frequently for the production of plastic sheets
and oil films.
12.5.2 Blow Extrusion[2]

Extruder that is used in Roshan Packages is Varex 2 (W &H).
Its speed is 600-650 kg/hour and the material that is used for extrusion is
LDPE
HDPE
LLDPE
Polyamide
12.5.3 Basic Stages in Film Extrusion[2]

There are three basic stages in the overall film extrusion process:
Materials Conditioning/Handling
Film Extrusion
Film Takeoff
12.5.4 Material Handling[2]

IME-14
Page 43 of 80
Roshan packages have extensive systems, such as filters, etc. to prevent resin
contamination during production, storage, loading and shipment. Since polyolefin resins
are non-hygroscopic (they absorb virtually no water), they do not require drying prior to
extrusion. However, precautions should be taken to ensure the cleanliness of the
polyolefin pellets as they are handled at the processors facilities.
12.5.5 Extruder
The extruder consists of a resin
Feeding hopper
Heated barrel
Rotating screw
[3]
12.5.6 Hopper[2]
Polyolefin resins are dropped into the extruder feed throat through a round or square
funnel, called the hopper. An automatic loader on top of the hopper periodically feeds
resin into it.
[3]
IME-14
Page 44 of 80
12.5.7 Barrel
Most barrels have smooth bores. However, for making HMW-HDPE and LLDPE film at
high throughput rates, the feed section of the barrel may be water-cooled and have as
many as 12 helical grooves (Figure 18). This configuration permits low melt index
HMW-HDPE, HMW-LDPE and LLDPE resins to be processed at high extrusion rates.
Barrels with high wear-resistant metal liners, such as tungsten carbide, generally wear
better than extruder screws.
[4]
12.5.8 Blown Film Tower

The blown film bubble rising up from the die is pulled into a complex takeoff system,
generally referred to as a multidecked tower. Commercial blown film towers consist of
one or more decks. The decks provide easy access to different stages of the blown film
process, e.g., deck 1 is at the cooling device, deck 2 at the collapsing frame, and deck 3 at
the nip roll and film pull-off assembly. From the top of the tower, the collapsed film
bubble passes through a corona treatment device and down through a series of guide
rolls to a windup unit.
IME-14
Page 45 of 80
12.5.9
Guide Bars
The bubble should not vibrate from unequal air distribution or too high an air velocity.
On its path between the die and the nip rolls, the bubble can be supported and prevented
from swaying by means of one or more pairs of guide bars, generally set parallel or at
right angles to each other and/or a bubble stabilizing cage.
12.5.10 Nip Rolls

At the top of the tent, there are several nip rolls set at fixed, narrow distances from one
another. The nip rolls collapse the bubble, confine the air within the bubble and assist in
pulling the film web upward. One of the nip rolls normally is a water-cooled (or
occasionally, refrigerated-air cooled), driven plated steel roll, and the other is elastomercovered.
12.5.11 Web Slitters

When a film roll reaches its preset size a slitter cuts the web. High-speed, in-line slitters
use either a razor blade or a rotating cutting knife. After being cut, the film web is fed
onto a new core.
12.6 Advantage(s) [2]
Optical clarity & gloss

Sealing strength
Water vapor barrier
Oxygen transmission barrier
Shelf Life
12.7 Commercial Application(s) [2]
Instant drinks
Cosmetics
Shampoo
Pesticide bags
IME-14
Page 46 of 80
Pickles
Spices
Soup bags
12.8 References:
1. Mikell P. Groover.2010. Fundamentals of Modern Manufacturing: materials,
processes, and systems - Fourth Edition. John Wiley & Sons, Inc. New York.
(21-12-2016)
2. Roshan Packages.Ltd
3. http://www.russellproducts.com/polybags.html(22-12-16)
(21-12-2016)
IME-14
Page 47 of 80
Experiment No.13
13.1 Title
Plastic Extrusion of PVC plastics pipes

Determining the volume drag flow rate of the PVC (plasticized) plastics of 3m pipes
13.3 Objective(s)
13.3.1 Determining the effect of volume drag flow rate during the manufacturing of pipes
of desired dimensions and shape
13.4 Apparatus
13.4.1 Granules of PVC plastics
13.4.2 Plastic extrusion machine
13.4.3 Appropriate die
13.4.4 Pipe cutter
13.5 Theory [1]

Extrusion is the compression process in which material is forced to flow through die
orifice to provide long continuous product whose cross sectional shape is determined by
the shape of the orifice
13.5.1 Principle [3]
The basic mechanics of extrusion are simple a screw turns in a barrel and pushes the
plastic forward to form pipes and other similar shapes like it
13.5.2 Schematic
IME-14
Page 48 of 80
13.5.3 Process [1]

In plastic extrusion the PVC in the form of the granules is fed into the extrusion barrel
through hopper where is melted, compressed and pressurized and forced to flow through
the die opening by means of a rotating screw to form the desired shape of the plastic
13.5.4 Key components of the extrusion process:

Extruder
Heating
Cooling
Screw
Barrel
Die
Land length critical to control final memory of polymer as it exits die
Draw down oversize of die in relation to finished part
Saw
In-line knife cutter

Punch
13.5.5 Flow Analysis [4]

There are two types of flow:
1. Pressure flow.
2. Drag flow.Procedure
13.5.6 Procedure:
13.5.7 Prepare or take the initial stock of PVC in the form of granules
13.5.8 Attach the die of the desire shape to produce particular shape of the pipe
13.5.9 Now start the machine and start the heaters to achieve the uniform temperature
inside the barrel
13.5.10Now start adding the PVC granules inside the barrel with the help of hopper
through gravity feed
13.5.11Cool down the hot product at room temperature by falling water on the product
continuously through water trough
13.5.12Now cut the pipe into the desired length by the help of cutter
IME-14
Page 49 of 80
13.6 Observation(s)
There are basically two parameters which should be observable
1) Design parameters (Helix angle, Channel depth etc.)
2) Operating parameters (Rotational speed, Melt viscosity etc.)
13.7 Calculation(s)
The volume drag flow rate of the PVC can be obtained from the following equation
Qd = 0.5vdw (1)
Where,
V= velocity m/s), D= distance separating the two plates (m), W= width of the plates.
Qd= (0.5)(0.239)(0.06)(0.286)
Qd= 2.050610-3 (m3/s)
13.8 Conclusion(s)
13.8.1 By knowing this value of volume drag flow rate we can become save from various
defects occurred in the plastic extrusion process
13.9 Precaution(s) [5]

1
Do not wear loose clothes.
Die temperatures should range from 350 to 600F.
13.10 Advantages
A great advantage of extrusion is that pipes can be made to any length.

1.12.1 Determine the back pressure flow of the PVC or some other plastics
13.12 Reference(s)
2010
6. https://en.wikipedia.org/wiki/Plastics_extrusion ( last seen 8/11/16)
7. http://www.plasticstoday.com/content/words-wisdom-10-11-key-principlesextrusion/408736320326 (last seen 8/11/16)
8. https://www.theseus.fi/bitstream/handle/10024/32570/Kirubel%20Bogale.pdf (last
seen 8/11/16)
9. http://www.streamlineextrusion.com/2011/extrusion-line-safety/ (last seen 8/11/16)
IME-14
Page 50 of 80
Experiment # 14
14.1Title
Plastic Extrusion of PVC plastic pipes

Effect on plastic extrusion by changing different form of plastics
14.3 Objective(s)
Determining the effect of changing forms of plastic in manufacturing (plastic extrusion)
of PVC pipes.
14.4 Apparatus
Granules and powder of PVC plastics
Plastic extrusion machine
Appropriate die
Pipe cutter
14.5 Theory[1]
Extrusion is the compression process in which material is forced to flow through die
orifice to provide long continuous product whose cross sectional shape is determined by
the shape of the orifice. (Groover, 2010)
14.6 Schematic
IME-14
Page 51 of 80
14.7 Process [1]

In plastic extrusion the PVC in the form of the granules is fed into the extrusion barrel
through hopper where is melted, compressed and pressurized and forced to flow through
the die opening by means of a rotating screw to form the desired shape of the plastic.
(Groover, 2010)
14.8 Key components of the extrusion process:
Extruder
Heating
Cooling
Screw
Barrel
14.9 Die
Land length critical to control final memory of polymer as it exits die
Swell factor takes into consideration shear rate of material at differing fpm (feet per
minute)
14.10 Procedure
Prepare or take the initial stock of PVC in the form of granules
Attach the die of the desire shape to produce particular shape of the pipe
Now start the machine and start the heaters to achieve the uniform temperature
inside the barrel
Now start adding the PVC granules inside the barrel with the help of hopper
through gravity feed
Cool down the hot product at room temperature by falling water on the product
continuously through water trough
Now cut the pipe into the desired length by the help of cutter
Now take the initial stoke of PVC in form of powder
Repeat the above steps for powder form
14.11 Observation(s)
Following parameters are observed
Temperature
Flow of polymer melt
IME-14
Page 52 of 80
Quality of pipe
Change in screw of different pitch
14.12 Conclusion(s)[2]
Powder form should be preferred due to following reasons
I.
II.
III.
IV.
More temperature is required while using granular form.

Flow of polymeric melt is smooth when we use powder form.
When we use powder form of PVC we get pipe of better quality. (Plant engineer in
polopipes, 2016)
For using granular form, screw should be designed as required. (Plant engineer in
polopipes, 2016)
14.13References:
(21-12-2016)
2. http://www.polopipes.com.pk/
(15-11-2016,5:30pm)
3. https://en.wikipedia.org/wiki/Plastics_extrusion (15-12-2016,8:30pm)
IME-14
Page 53 of 80
Experiment # 15
15.1 Title
Injection molding of General Purpose Polystyrene (GPPS)
Determining the different parameters of injection molding of GPPS
15.3 Objective(s)
15.3.1 Study the molding parameters of jug lid caps
15.4 Apparatus
15.4.1 Injection molding machine (Techmation 150 TON)
15.4.2 Pallets of GPPS (raw material)
15.5 Theory
Injection molding is a manufacturing process for producing parts by injecting
material into a mold. It lies under the category of Solidification process.
15.5.1 Principal
Injection molding is a process in which a polymer is heated to a highly plastic
state and forced to flow under high pressure into a mold cavity, where it
solidifies. The molded part, called a molding, is then removed from the cavity.
15.5.2 GPPS
The GPPS (General Purpose, aka crystal) polystyrene is a polymer obtained from
the styrene monomer: clear, rigid, non-toxic.
15.5.3 Properties[1]
I. Tensile Strength 60MPa
II. Shear modulus 800 MPa
III. Coefficient of thermal expansion 80 * 10-6 /K
IV.
Max Use Temp 85 oC
V.
Glass transition temperature 80-90C
VI.
Density 1.05 g/cm3
VII. Solidification shrinkage 0.3-0.7%
15.5.4 Market price
3700 Rs. Per 25 kg bag.
15.5.5 Applications
Toys, rigid packaging, refrigerator trays and boxes, cosmetic packs and costume
jewelry, lighting diffusers, audio cassette and CD cases.
15.5.6 Injection Molding Parameters
There are various parameters that must be established and controlled to achieve
proper injection molding of a plastic part. A few of them are discussed below.
15.5.6.1 Pressure
Pressure is found primarily in the injection area, but there is also pressure found
in the clamp unit of the molding machine. Following pressures are included in
molding process.
IME-14
Page 54 of 80
I.
Back pressure
The resistance of the molten plastic material to forward flow. In molding, back
pressure increases the temperature of the melt, and contributes to better mixing of
colors and homogeneity of the material.
II.
Injection pressure
This is the primary pressure for injecting the molten plastic into the closed mold.
Normally, the highest pressure and fastest fill rate are the best condition.
However, high pressure will increase molded-in stress. The greater the pressure,
the greater the stress, and the greater the reaction when it is released. So the
minimum amount of pressure necessary to fill the mold should be determined, and
then use all of it.
III.
Holding pressure[2]
Once the majority of the plastic has been injected using standard injection
pressure, the machine should drop into hold pressure. Hold pressure is required
until the gate freezes off. If hold pressure is released before the gate freezes, the
material in the cavity is still molten and will be sucked back out of the cavity.
IV.
Clamping pressure[2]
At the other end of the machine, we have clamp pressure. The only reason to have
clamp pressure is to keep the mold closed.
15.5.6.2 Switch over position and Cushion distance[2]
The switch-over position is the ram position where the filling (injection) stage
switches to the post-filling (packing or holding) stage.
The cushion distance is the distance from the switch-over position to the farthest
position that the end of the screw can reach.
15.6 Procedure
15.6.1 Plastic material in the form of granules is melted until soft enough to be injected
under pressure to fill a mold. The result is that the shape is exactly copied. Once
the plastic moulding has cooled sufficiently to harden the injection mould opens
releasing the part. The whole injection moulding process then repeats.
15.6.2 CLAMPING - the moving and fixed platens of the injection molding machine
holds the mold tool together under pressure.
IME-14
Page 55 of 80
15.6.3 INJECTION - the molten plastic that has been melted from pellet form in the
barrel of the molding machine is injected under pressure into the mold.
15.6.4 DWELLING - after the molten plastic has been injected into the mold, pressure is
applied to ensure all cavities are filled.
15.6.5 COOLING - the plastic parts are then allowed to solidify in the mold.
15.6.6 OPENING - the moving platen moves away from the fixed platen separating the
mold.
15.6.7 EJECTION - rods, a plate or air blast then aids ejection of the completed plastic
molding from the injection mold tool.
15.7 Observation(s)
Raw material geometry
Pallets (2-2.5mm)
Temperature
190-210-230C
L/D
125
Clamping force
140 ton
Cycle time
36 sec
Screw speed
172 rpm
Nozzle dia
2 mm
Mold temperature
50C
Plunger pressure
40 bar
Back pressure
8-10 bar
Production
6000 parts/ 25kg
Total shots / bag
378
Waste
10g /shot
15.8 Conclusion(s)
15.8.1 The process was running under precisely controlled parameters.
15.8.2 Dimensions and surface finish of molded parts were accurate.
IME-14
Page 56 of 80

15.9.1 Modify the mold geometry to reduce the wastage of material.
15.10 Reference(s)
1. Manufacturing Processes for Engineering Materials, 5th ed. Kalpakjian
Schmid.
2. www.plastictroubleshooter.com (online plastic troubleshooting site) : 22
Nov,2016.
IME-14
Page 57 of 80
Experiment No.16
16.1 Title
steel wire drawing

Reduction of diameter of steel wire from 12mm to 6mm
16.3 Objective(s)
Obtaining the wire of diameter 6mm.
16.4 Apparatus
16.4.1 wire drawing machine
16.4.2 steel wire coil
16.4.3 Lubricants
16.4.4 Vernier Calliper
16.5 Theory
Wire drawing is a metalworking process used to reduce the cross-section of a wire by
pulling the wire through a single, or series of, drawing die(s).
16.5.1 Principal
The wire drawing process is quite simple in concept. The wire is prepared by
shrinking the beginning of it, by hammering, filing, rolling or swaging, so that it will
fit through the die; the wire is then pulled through the die. As the wire is pulled
through the die, its volume remains the same, so as the diameter decreases, the
length increases. Usually the wire will require more than one draw, through
successively smaller dies, to reach the desired size.
IME-14
Page 58 of 80
schematic.
16.5.2 Types of machines

16.5.2.1 Continuous machine
16.5.2.2 Single step machine
IME-14
Page 59 of 80
16.6 Procedure
16.6.1 Take a coil of 12mm diameter made of mild steel.
16.6.2 One end of wire is made pointed and then inserted in die hole.
16.6.3 Then it is firmly attached with a dog from the other end for holding purpose.
16.6.4 After that lubricant is applied inside the die. Wet soap is used as lubricant.
16.6.5 After lubrication the end of the wire is wrapped on the drawing roller.
16.6.6 Then the machine is set ON and the wire is continuously drawn from the die with
the reduced diameter.
16.7 Observation(s)
16.7.1 Obsevations are as follows:
v.
lubrication can be changed depending on material type.
vi.
holding mechanism can be changed
vii. RPM depends on the material of wire.
16.8 Calculation(s)
AREA REDUCTION:
D = wire diameter
Dl = beginning wire diameter
Ds = ending wire diameter
AR = reduction in area
N = number of dies
Df = finished diameter of the die
A = die angle
%ELONGATION=
16.9 Conclusion(s)
16.9.1 finished quality is acceptable / not acceptable.
16.9.2 required dia is obtained or not.
IME-14
Page 60 of 80
16.10 Precaution(s)
16.10.1 RPM should not be too fast
16.10.3 lubrication must be used
16.10.4 Do not stand in front of drawing wire because of back lash
16.11 Reference(s)
10. Mikell P.GROOVER Fundamentals of Modern Manufacturing. [Pg2,1]
11. Mikell P.GROOVER Fundamentals of Modern Manufacturing. [Pg4,2]
12. http://www.diequip.com/formulas.html [Pg3,3]
13. https://www.unb.ca/fredericton/engineering/depts/mechanical/_resources/pdf/sop/
wire-drawing-experiment.pdf [Pg6,1]
IME-14
Page 61 of 80
Experiment No.17
17.1Title
Bendable and Flexible drinking straws
17.2Problem Statement
Producing bending in a pre-made drinking straw
17.3Objective(s)
Impact of bending on the drinking straws
17.4 Apparatus
A flat metal plate
Pre-made the straw
A series of steel pins
Crimping jaws
17.5 Theory
A bendable straw or bendy straw" (known in the industry as an "articulated straw") has
a concertina-type hinge near the top for convenience. This variation was invented
by Joseph Friedman in 1937
17.6 Principal
Bending can be produced in drinking straws on the account of applied external forces
which forces the premade straw to be flexible. It follows the groves present in the metal
flat plates and acquires its shape. At the end crimping jaws make bends by creating
tension as well as compression portion on the premade drinking straws.
[1] Bending
[2] variety of straws
17.7 Schematic
[3] Working of bending producing setup
IME-14
Page 62 of 80
17.8 Parameters in Straw Bending:
The parameters that involve in the process of bending the pre-made drinking straw for
getting more comfort are as mention and briefly explained below:
17.8.1 Straw length:
The length of drinking straw is the most important parameter in
making bendable straws which determines the physical as well as chemical properties.
The size of the bend increases very rapidly as the length of the drinking straw increases
and vice versa. The more length of drinking straw, the more wide and large bend will
have to be produced in it.
17.8.2 Bending time:
If the bending time is kept more, the desire bend would not be shaped
up. As the bending time increases, it increases the tension and compression region that
are accountable for giving a drastically different result (bend)
17.8.3 Bending force:
The work pieces must be kept in normal or optimal range as it is
the foremost factor that is dealt with great accuracy as well as sensitivity. Too much
force to bend a premade drinking straw may fail the straw. So we should have to avoid
taking different and non-uniform fluctuations and value of bending forces.
17.8.4 Bending pressure:
As it is mentioned earlier that we have to use steel pins to
bend and remove our final product. So pressure must be in suitable range so that it may
not damage raw material and it may result of improper bend.
17.8.5 Materials properties:
i. Polyethylene is used as a raw material in manufacturing of different drinking
straw
ii. Similar to polyethylene, especially in solution behavior and electrical properties
polypropylene is normally tough andflexible,especiallywhen copolymerized with ethylene.
iii. This allows polypropylene to be used as an engineering plastic, competing with
materials such as acrylonitrile butadiene styrene (ABS).
iv.
Polypropylene is reasonably economical.
17.9 Processing of producing bends
Straw can bend in the middle and is made using a special device:
i. That creates a series of grooves that allow the straw to flex.
ii. These grooves can be crimped into the straws in a two-step process.
iii. First, it is first necessary to "pick up" the straw so it can be manipulated. This can
be accomplished by spreading the straws across a flat plate, which has slots cut
in it.
iv.
The straws will tend to roll into the slots and remain there. The slots are evenly
spaced and are adjacent to a separate metal plate, which has a series of metal
pins extending from it.
v.
The pins are aligned in a parallel fashion with the slots on the plate.
vi.
Once the straws have come to rest in the slots, the pins can be easily inserted into
the straws. The straws can then be easily lifted up and moved around in any
orientation by simply manipulating the plate that holds the pins.
IME-14
Page 63 of 80
17.10Conclusion(s)
Bends in drinking straws can be made easily as it facilitates its user. Bends
are often made in large products then it requires large flat plate as well as large steel
pins.
Keep the raw material at right of the grooves which are slotted in flat plate. It is done
because it will impart a decent look to bend and will improve its physical and chemical
properties and flexibility as well.
17.12Precaution(s)
Ensure that bending equipment is properly ground.
Do not touch steel pins.
Do not use this apparatus where the atmosphere may contain contaminations,
different gas, or liquid vapors (such as gasoline).
People with implants must be aware of magnetic and electric fields effect.
Do not apply too much force to bend the drinking straw. Bending force and
pressure must be in optimal and suitable range.
17.13Proposed Mini Project(s)
To discuss and experimentally analysis of materials properties when it is
subjected to different grooves shapes.
17.14 Reference(s)
17.14.1 Figure(s)
[1]
[2]
[3]
http://rawnori.com/products
(22-12-2016)
www.dreamstime.com
(22-12-2016)
http://www.madehow.com/Volume-4/Drinking-Straw (22-12-2016)
17.14.2 Context(s)
1. http://www.madehow.com/Volume-4/Drinking-Straw
2. www.florida-drinking-straws.com
IME-14
(22-12-2016)
(22-12-2016)
Page 64 of 80
xperiment No.18
5.16 Title:
Sheet metal v-bending of mild steel sheet.
5.17 Problem statement:

Determine the bending force in relation with thickness, width, tensile strength and die
opening.
Determine the bend allowance in relation with bend radius and bend angle.
Determine the spring back.
5.18 Apparatus:
5.18.1 Mild steel sheet.
5.18.2 Bending machine.
5.18.3 Measuring tape.
5.19 Theory:
5.19.1 Bending:
Bending in sheet-metal work is defined as the straining of the metal around a straight
axis.
Fig:
(a) V-bending
IME-14
(b) Edge Bending
[11]
Page 65 of 80
5.19.2 Types of bending
5.19.2.1 V-bending
5.19.2.2 Edge bending
18.4.2.1 V-bending:
In V-bending, the sheet metal is bent between a V-shaped punch and die. Included angles
ranging from very obtuse to very acute can be made with V-dies. V-bending is generally
used for low-production operations. It is often performed on a press brake and the
associated V-dies are relatively simple and inexpensive.
[1]
18.4.2.2 Edge bending:
Edge bending involves cantilever loading of the sheet metal. A pressure pad is used to
apply a force Fh to hold the base of the part against the die, while the punch forces the
part to yield and bend over the edge of the die. In the setup shown in above figure (b),
edge bending is limited to bends of 90or less. More complicated wiping dies can be
designed for bend angles greater than 90. Because of the pressure pad, wiping dies are
more complicated and costly than V-dies and are generally used for high-production
work.
[2]
5.19.3 Principle:
The bending machine used for bending operations has two parts to perform this
operation, a punch and a die. Punch presses the sheet metal in die to make bend in the
sheet. The force applied depends upon the thickness and width of the sheet.
Fig:
IME-14
Bending machine
[12]
Page 66 of 80
5.19.4 Bend angle:

Some of the important terms in sheet-metal bending are identified. The metal of thickness
t is bent through an angle called the bend angle a. This results in a sheet-metal part with
an included angle a0, where a + a0 =180. The bend radius R is normally specified on the
inside of the part, rather than at the neutral axis, and is determined by the radius on the
tooling used to perform the operation. The bend is made over the width of the work piece
w.
[3]
5.19.5 Bend Allowance:
If the bend radius is small relative to stock thickness; the metal tends to stretch during
bending. It is important to be able to estimate the amount of stretching
That occurs, if any, so that the final part length will match the specified dimension. The
problem is to determine the length of the neutral axis before bending to account for
stretching of the final bent section. This length is called the bend allowance, and it can be
estimated as follows:
Ab=2/360(Rt + K)
Where Ab = bend allowance, mm (in); a = bend angle, degrees; R = bend radius, mm
(in); t = stock thickness, mm (in); and Kbais factor to estimate stretching. The following
design values are recommended for Kba [3]: if <2t, Kba= 0.33; and if R! 2t, Kba= 0.50.
The values of Kba predict that stretching occurs only if bend radius is small relative to
sheet thickness.
[4]
5.19.6 Spring back:

When the bending pressure is removed at the end of the deformation operation, elastic
energy remains in the bent part, causing it to recover partially toward its original shape.
This elastic recovery is called spring back, defined as the increase in included angle of
the bent part relative to the included angle of the forming tool after the tool is removed.
This is illustrated in Figure 20.13 and is expressed:
SB=-/
Where SB = spring back; a0 = included angle of the sheet-metal part, degrees; and a0 t=
included angle of the bending tool, degrees. Although not as obvious, an increase in the
bend radius also occurs due to elastic recovery. The amount of spring back increases
with modulus of elasticity E and yield strength Y of the work metal. Compensation for
IME-14
Page 67 of 80
spring back can be accomplished by several methods.
[5]
5.19.7 Bending Force:

The force required to perform bending depends on the geometry of the punch-and-die
and the strength, thickness, and length of the sheet metal. The maximum
F=K bf (TS) wt/D
Where F = bending force, N (lb); TS = tensile strength of the sheet metal, MPa (lb/in 2);
w =width of part in the direction of the bend axis, mm (in); t = stock thickness, mm (in);
and D = die opening dimension as defined in Figure 20.14, mm (in). Eq. (20.8) is based
on bending of a simple beam in mechanics, and Kbf is a constant that accounts for
differences encountered in an actual bending process. Its value depends on type of
bending: for V-bending, Kbf = 1.33; and for edge bending, Kbf = 0.33.
[6]
5.20 Procedure:
5.20.1 Take a sheet of mild steel of 6.35mm thickness
5.20.2 Mark the points where we have to make bends. .
5.20.3 Apply the force through press, when bend is made load is removed.
5.20.4 Remove the sheet when bend is made.
5.21 Observations and calculations:

Sheet thickness = t= 6.35mm
Sheet width =w= 8t= 86.35
Die opening = D =12t=126.35
Bend angle = 90
K bf =1.33
IME-14
Page 68 of 80
5.22 Conclusions:
5.22.1 Relatively easy process
5.22.2 Low cost than other forming processes
5.22.3 Relatively low accuracy
5.22.4 Time consuming process
5.22.5 Require three workers on a single machine
5.22.6 Can bend maximum angle of 90
5.23 Recommendations:
5.23.1 The control should be made so that it is easily operated by the workers.
5.23.2 Maintenance of machine should be done after regular intervals so that its
performance can be improved.
5.24 Precautions:
5.24.1 Wear safety gloves
5.24.2 Care should be taken while operating the machine
5.25 References:
[1]
Mikell P. Groover, Fundamentals of Modern Manufacturing: materials,

2010
9-12-2016
[2]
IME-14
https;//www3.nd.edu/-manufact/MPEM_pdf_file/Cho7.pdf 9-12-2016.
Page 69 of 80
Experiment No.19
19.1 Title
To study the process planning and manufacturing of pallets by using injection molding.

To study the structural foam molding process and to observe main causes of shrinkage in
injection molding process
19.3 Objective(s)
To gain the practical knowledge and critical parameters involved in injection molding
19.4 Apparatus
Structural Foam molding set up
19.5 Theory
The most common method is a variation of injection molding called Low Pressure
Structural Foam Molding
19.5.1 Injection Molding [1]

Shape-forming process in which molten metal or plastic is injected into aluminum,
ceramic, or steel molds (shaped like the end product) and squeezed under high pressure
19.5.2 Structural Foam Molding [2]

The Structural Foam process is similar to conventional injection molding with the
exception that a foaming agent, typically nitrogen gas, is mixed with the melted polymer
and injected into a mold at low pressures.
19.5.3 Structural Foam Molding Setup [2]

Structural Foam molding set up consists of the following parts:
Feed hopper
Heaters
Barrel
Reciprocating screw
SCF feeding machine for supplying N2 gas
Water circulator
Clamping unit
19.5.4 Steps in Structural Foam Molding [2]

The following steps are involved in Structural foam molding process:
Clamping
Injection
Dwelling
IME-14
Page 70 of 80
Addition of N2 Gas
Cooling
Opening
Ejection
19.5.5 Foaming agent [2]

Structural foam molded products have cellular cores surrounded by rigid, integral skins.
Foaming agent (N2, CO2 or CBA) is introduced into the polymer melt stream, creating
a homogenous mixture of polymer and gas
19.5.5 Materials used in Pallet manufacturing [3]

Following materials are usually use in pallet manufacturing
High Density Polyethylene (HDPE)
Polypropylene (PP)
Advanced Composite Material (ACM)
19.5.6 Effective factors and levels [3]

Effective factors in structural foam molding are:
Factor
Level 1
Level 2
Level 3
Melting
Temperature
Injection Pressure
Packing Pressure
Cooling time
180C
190C
200C
40 bar
25 bar
20 s
50 bar
30 bar
30 s
60 bar
35 bar
40 s
19.6 Shrinkage [4]

Shrinkage is the difference between the size of the mold cavity and the size of the finished
part divided by the size of the mold. Usually it is expressed in percentage. Four points
are selected on the pallet, measurements are made with micrometer screw gauge. For
each specimen, the average thickness is calculated as arithmetic mean of three points.
Shrinkage is calculated as follows:
S=(Dm-Dp/Dm)100%
19.6.1 Shrinkage and Machine settings [4]

All molders know that shrinkage and consequently warpage is affected by processing
Conditions, Figure shows some of the classic relationships between machine settings and
shrinkage, also shown is the effect of wall thickness. These curves apply only to a
particular mold and material combination.
IME-14
Page 71 of 80
19.6.2 How shrinkage is effected by time and pressure [4]

The magnitude of pressure and the time for which pressure is applied greatly affect the
shrinkage of material in the cavity. The actual pressure to which the material is subjected
is determined not only by machine settings, but also by the viscosity of the material and
the geometry of the cavity. Although a complicated matter, it is possible to restrict
attention to two important regions: close to the gate and at the end of flow.
19.6.2.1 Shrinkage near the Gate [4]
Areas near the gate are easier to pressurize (and depressurize) than areas at the
end of flow and generally the relationship between pressure, time and shrinkage
is simple.
High packing pressure gives lower shrinkages as long as the pressure is kept on
until the gate has frozen. In this case the shrinkage around the gate will generally
be lower than that at the end of flow.
If the packing pressure is not held on until the gate or runner system has frozen,
then the pressure in the cavity will cause plastic to reverse flow back into the
runner system. This can result in a higher shrinkage around the gate area than in
the rest of the cavity.
19.6.2.2 Shrinkage at the end of the flow [4]
A high packing pressure results in a high initial flow as the pressure is quickly
distributed throughout the cavity
A low packing pressure may give the opposite effect. Initially the flow rate will be
much smaller than with the high pressure
IME-14
Page 72 of 80
However as the material cools the volumetric change (from high to low
temperature) is much greater at low pressures so the flow rate due to
compensation will be greater than for the higher pressure
High packing pressures do not automatically mean that there will be less
shrinkage at the end of flow. This is because the plastic will freeze off in the
upstream section earlier in the cycle, thus preventing the pressure packing out the
area at the end of flow
19.7 Observations
Raw material geometry
Temperature
Plunger pressure
Clamping force
Cycle time
Screw speed
Mold temperature
Back pressure
Nozzle Dia
Foaming agent
Injection pressure
Packing pressure
Cooling time
Powdered form (0.25-2mm)

140-160 C
30 bar
ton
45 sec approximately
172 rpm
35 C
5-6 bar
2.5 mm
N2
40-60 bar
25-35 bar
20-40 sec
19.8 Conclusion(s)
Density reduction in structural foam molding is more, hence it reduces the overall
production cost
Shrinkage may occur in structural foam molding
Pallets being formed ,have high strength to weight ratio
19.9 Proposed mini project(s)
Optimization of Injection Molding Process Parameter for Reducing Shrinkage by

Using High Density Polyethylene (HDPE) Material
19.10 Reference(s)
processes, and systems - Fourth Edition. John Wiley & Sons, Inc. New York. (21-122016)
2. horizonplastics.com/our-processes/structural-foam-molding
3. Arco Plastics(Pvt.) Ltd
4. www.dc.engr.scu.edu/cmdoc/dg_doc/develop/process/physics/b3500001.htm
IME-14
Page 73 of 80
EXPERIMENT: 20
20.1 TITLE:
Electric arc welding of mild steel plates of different thickness using different diameter of
copper electrode.
20.2 PROBLEM STATEMENT:
Determining the electrode size in relation to the plate thickness and amount of current
and voltage required to perform a welding.
20.3 OBJECTIVES:
20.3.1 To learn how to operate electric arc welding machine.
20.3.2 To learn the relationship between plate thickness and electrode size.
20.3.3 To study the limitation of electric arc welding.
20.3.4 To study about main parts of electric arc welding machine.
20.4 APPARATUS:
20.4.1 Electric arc welding machine
20.4.2 Cables and electrode holder
20.4.3 Electrode of various sizes
20.4.4 plates of mild steel
20.5 THEORY:
20.5.1 Introduction
Welding is the process of joining similar metals by the application of heat, with or
without application of pressure or filler metal, in such a way that the joint is equivalent
in composition and characteristics of the metals joined. Various welding processes are
electric arc welding, gas welding, thermal welding, electric resistance welding, friction
welding etc. However here we will only study about electric arc welding.
20.5.2 Electric arc welding
Arc welding is the welding process, in which heat is generated by an electric arc struck
between an electrode and the work piece. Electric arc is luminous electrical discharge
between two electrodes through ionized gas.
20.5.3 Schematic
[1]
20.5.4 Technique of welding
20.5.4.1
Preparation of work
Before welding, the work pieces must be thoroughly cleaned of rust, scale and other
foreign material. The piece for metal generally welded without beveling the edges,
however, thick work piece should be beveled out to ensure adequate penetration and
fusion of all parts of the weld. But, in either case, the parts to be welded must be
separated slightly to allow better penetration of the weld.
Before commencing the welding process, the following must be considered
IME-14
Page 74 of 80
a) Ensure that the welding cables are connected to proper power source.
b) Set the electrode, as per the thickness of the plate to be welded.
[2]
20.6 PROCEDURE:
20.6.1 Clean the metal before welding
20.6.2 Set the joint
20.6.3 Strike a welding arc
20.6.4 Build up a weld pool
20.6.5 Start moving the weld pool across the metal
20.6.6 Finish the weld
20.6.7 Clean the slag
20.6.8. Examine the weld
20.6.9 Allow the metal to cool
20.7 OBSERVATIONS:
20.7.1 I observe that electric arc depends upon following given conditions
I. Distance between electrode tip and plates to be weld
II. Depends on amperes of given current
III. Ionization of air
IV.
Holding time of electrode upon one place
20.7.2 Number of electrodes may have to be used while welding long joints.
20.7.3 A defect (slag inclusion or insufficient penetration) may occur at the place where
welding is restarted with a fresh electrode.
20.8 TABLE
Electrode current vs. electrode size vs. plate thickness.
Plate thickness ,mm
Electrode size ,mm
Electrode current range ,amp
1.6
2.5
4.0
6.0
8.0
25.0
1.6
2.5
3.2
4.0
5.0
6.0
40-60
50-80
90-130
120-170
180-270
300-400
20.9 CONCLUSION:
20.9.1 Surface appearance and quality of weld is controlled by following variables.
I. Cleanliness of plates to be weld
II. Amount of current supplied
III. How much distance is kept of electrode tip and parts to be welded
20.9.2 Slag is formed on the surface of weld due to oxidation of weld pool
20.10 RECOMMENDATIONS:
Solutions to the above problems are as following:20.10.1 Clean the plates properly and maintain the distance of near about 1mm between
plates and electrode tips.
20.10.2 Protect the electrode tip, weld area, arc and adjacent areas of the work piece
from atmospheric contamination by gaseous shield obtained from combustion and
decomposition of the flux covering.
IME-14
Page 75 of 80
20.11 PRECAUTIONS:
Always weld in a well-ventilated place. Fumes given off from welding are
unpleasant and in some cases may be injurious, particularly from galvanized or zinc
coated parts.
20.11.1 .Do not weld around combustible or inflammable materials, where sparks may
cause a fire.
20.11.2. Never weld containers, which have been used for storing gasoline, oil or similar
materials, without first having them thoroughly cleaned.
20.11.3. Check the welding machine to make sure that it is properly grounded and that
all leads properly insulated.
20.11.4. Never look at the arc with the naked eye. The arc can burn your eyes severely.
Always use a face shield while welding.
20.11.5. Prevent welding cables from coming in contact with hot metal, water, oil, or
grease. Avoid dragging the cables around sharp corners.
20.11.6. Ensure proper insulation of the cables and check for openings.
20.11.7. Always wear the safety hand gloves, apron and leather shoes.
20.11.8. Always turn off the machine when leaving the work.
20.11.9. Apply eye drops after welding is over for the day, to relieve the strain on the
eyes.
20.11.10. While welding, stand on dry footing and keep the body insulated from the
electrode, any other parts of the electrode holder and the work.
20.12 PROPOSED MINI PROJECT:
20.12.1 Study the depth of seam by varying the amount of current.
20.12.2 Study the effect on welding by changing the polarity of electrode current
20.13 REFRENCES:
1. Welding Handbook, 9th ed., Vol. 1, Welding Science and Technology. American
Welding Society, Miami, Florida, 2007.
2. Mikael P. Grover, Fundamentals of Modern Manufacturing: materials,
2010 .
IME-14
Page 76 of 80
Experiment No.21
21.1 Title
Study of Rotational Molding Process

Determining the cycle time of water tanks of different sizes made by Rotational Molding
Process
21.3 Objective(s)
Determine the optimum cycle time for best quality water tanks
21.4 Apparatus
21.4.1
21.4.2
21.4.3
21.4.4
Rotational Molding Machine

LLDPE (Linear Low Density Polyethylene) in powder form
Molds of different sizes
Stop Watch
21.5 Theory [1]

Rotational molding (Roto-molding) is an alternative to blow molding for making large,
hollow shapes. It is used principally for thermoplastic polymers, but applications for
thermosets and elastomers are becoming more common. Roto-molding tends to favor
more complex external geometries, larger parts, and lower production quantities than
blow molding.
21.5.1 Principle [1]
Rotational molding uses gravity inside a rotating mold to achieve a hollow form.
21.5.2 Cycle Time [2]
It is the time from loading of LLDPE in the mold till the removal of tank from the mold. It
includes loading time of LLDPE, heating and processing of LLDPE in the mold, cooling
of mold after processing and the removal time of product.
21.5.3 Schematic [1]
IME-14
Page 77 of 80
Fig. No. 1 Rotational molding cycle performed on a three-station indexing machine:

(1) unloadload station; (2) heat and rotate mold; (3) cool the mold.
21.6 Procedure
21.6.1 Take LLDPE in final powdered form, different amount for different sizes of
molds as explained below.
30-40 kg for 500 gallons tank
21.6.2 Insert the mold of desired size in the machine
21.6.3 Open the mold and load the LLDPE powder in the mold
21.6.4 Close the mold
21.6.5 Start the burner and the blower and close the door of machine
21.6.6 Note the total cycle time i.e. from loading of LLDPE to removal of finished
tanks from the mold
21.7 Observation(s)
21.7.1 Cycle time includes:
i. Time of loading LLDPE in the mold
ii. Processing time
iii. Cooling time of mold
iv.
Unloading time
v.
Total time of the process
IME-14
Page 78 of 80
21.8 Table(s)
S/N
Size of the tank Loading Time

(gallons)
(Minutes)
1
2
3
4
5
500
300
200
100
50
2
2
2
2
2
Processing
time X
(Minutes)
25
20
15
10
4
Cooling
Time Y
(Minutes)
10
8
6
4
2
Unloading
Time Z
(Minutes)
3
3
3
2
2
Total
Time T
(Minutes)
40
33
26
18
10
21.9 Calculation(s)
T = X+Y+Z
Average cycle time for different sizes of tanks are:
i. 500 gallons = 40 minutes
ii. 300 gallons = 33 minutes
iii. 200 gallons = 26 minutes
iv.
100 gallons = 18 minutes
v.
50 gallons = 10 minutes
21.10
Conclusion(s)
21.10.1Surface finish of the product was acceptable using above mentioned cycle time.
21.11
Precaution(s)
21.11.1Ensure the mold is properly fixed in the machine

21.11.2Do not touch the mold right after the removal
21.11.3Do not overheat the mold
21.12
22
23
Reference(s)
Mikell P. Groover, Fundamentals of Modern Manufacturing: materials, processes,

and systems - Fourth Edition, John Wiley & Sons, Inc., New York, 2010
Taj Water Tanks, Darogha Wala, Lahore.
IME-14
Page 79 of 80
IME-14
Page 80 of 80

Lab Manual Manufacturing Proccesses II

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Lab Manual Manufacturing Proccesses II

Uploaded by

Copyright:

Available Formats

MANUFACTURING PROCESS-II

Department of Industrial and Manufacturing Engineering

Fig. No. 1 Working Principle for Resistance Spot Welding

Fig. No. 1 Working Principle for Resistance Spot Welding

2.5.3 Processing of spot welding

2.5.4 Spot Weld [1]

Ensure that welding equipment is properly ground.

Do not touch live electrical parts.

Do not weld on containers that have held combustibles, or on closed containers

2.13 Proposed Mini Project(s)

Now take the steel strips of different gauges

Now repeats the same things by taking three strips

Repeat the process for other strips of different gauges

3.12Proposed Mini Project(s)

4.2 Problem Statement

Identify the parts, knobs and mechanism of welding machine.

MIG welding machine.

4.5 Theory [1]

4.5.1 Principal [1]

4.7 Parts of machine [2]

It is used in automotive repair.

4.9 Advantages: [4]

4.10 Disadvantages: [4]

Requires cumbersome bottle of shielding gases.

5.2 Problem Statement

MIG welding apparatus

5.4.5 Aluminium strips

5.6 Procedure [1]

The specimens were prepared according to the joint geometry as shown

5.7 Factorial Design Experiments [2]

5.7.1 Screening Phase

5.7.2 Optimization Phase

5.8 Results and Discussion

5.8.2 Optimization Phase Results

5.10 Weld Procedure Sequence

Welding Consumables:Type, Designation Trade Name:

BS 2901 Part 2 : 308S92

Argon 99.99% Purity

Details of Back Gouging/Backing:

Post Weld Heat Treatment

5.14 Proposed Mini Project(s)

Following parameters can be observed for a good joint.

Electrode wire feed speed

Use suitable clothing made from durable flame-resistant material to protect

7.10.3 FUMES AND GASES:

8.2 Problem Statement

8.5 Theory [1]

8.5.1 Principal [1]

Fig. No. 1 Working Principle for Tungsten Inert Gas Welding

8.5.4 Current Parameters

8.6 Working Procedure

8.11 Proposed Mini Project(s)

9.2 Problem Statement

9.5 Weld Current [1]

9.6 Weld Voltage [1]

9.7 Welding Speed [2]

9.8 Inert Gas [2]

9.9 Working Procedure

Weld Procedure Specification(s)

Welding Consumables:Type, Designation Trade Name:

Post Weld Heat Treatment

10.2 Problem Statement

10.5 Theory [1]

Fig 1. Oxyacetylene Welding Operation