P.H.

O
MRC SMME NUST
EDM DIE-SINKING PRACTICE
Ref: Advance Workshop Practice Level: UG Mode: Practical

Time: 03 Hours Course: ME-223 Semester:

TITLE
1. Die-Sinking Setup and Operations.

Introduction
2. Die sinking machine has a unique
Servocontrol
servomotor

capability to create a cavity in the work

piece using Electric Discharge between 1ool head

dielectricum-
anode and cathode. The work piece is a COniOiner

work piece
onero1or

workplece-
cathode which an anode of a special shape electroade
overflo
iel
treatme
is brought in close vicinity to the cathode contoiner
power supply
Filter
thus generating a controlled electrical sporcgop

Pume cross fable

discharge resulting in work piece erosion

current voltage (Voltage 0- 300 (Ampere 0
-

60). The shape of the anode will determine the shape of the erosion taking place on the work piece,
hence the shape of cavity is achieved.

3. The die sinking method has certain advantages over the other machining processes:

Pulse
a. Special and complicated shapes Geuerator
Spark
can be generated through this
[Flushng
method. Power Supply Too
Dielectic Leve
. High precision can be achieved.
Wo
Flxture
Anode of special shape has to be
manufactured once Lter

through other machining Puuny

:Sum
techniques or through use of
EDM Wire-Cut and is used over

and over again.

Obiective
4. Students are required to learn the methods and operations of the Die- Sinking EDM including its

safety precautions.
equirements
the
Following are the basic requirements for 6c DcCrler
. Tool eectrode
experiment:

Ls
Anode of special shape. lWork Tank
Work piece on which negative cavity of c ED
C assisting
power sp
electrode
discharge shape is to be created.

Drawings and technical details of the Kerosene

work piece.
Chag
Power sapp pAel
Measuring instruments.

Machine ait

Procedure
The procedure is to be followed in the following sequence:

a. Study the given drawing (copy attached).

Anode is already assumed to be available so
b.
select the right anode.

Fix the work piece appropriately. Tool Eectrode

electrode
Now fix the anode in the right position. Pump

E. Set machine parameters like current, setting,

Workpiece
feed rate, cutting fluid flow etc. Machining Tank

Program the machine from zero set position.

Decide the depth to which machining is to be carried out.

h. Start operation under observation.

i. Remove and inspect the part for shape and depth.

Safety Precautions
Following safety precautions must be followed:

a.
Correct parameters shall be selected according to types of work/operation.

b Check program and parameters.

If a stored program is selected make sure it in the right program (Dry run the program

when in doubt).

d. Do not change / disturb setting during operations.

e. Always use coolant/ cutting fluid.

Never leave the machine un-attended.

 Watch where you work.

h. Do not play or fiddle with machine.

. Remain alert and vigilant.

Use safety apron and goggles/ Face Mask.

k. Focus the spot light on the work zone.

. Always have the fire extinguishing system ready for use.

m. Exhaust system must operate when working.

Instructions:
work done during the practical, on which
7. All students will submit written report/ account of the
the grading of work will be done.
 L i
L iLuL LU LLL
un

-SMME
32.5

75
Manufacturer: OgSON AMO MANUFACTURING RESOURCE CENTRE,SMME NUST 1SLAMABAD Part Name:
Matenal
Project Name: PROJECT coDE PART CODE DRAWING NO REV:
Name SIgn. ate

Drawn b MAbbas
Scale:Same Units: mm Sheet: 1 of 1
Size. 4
Checked by : Wajid Ali khan
Projection: 3rd Angle
Approvesby :M Naweed Hassan folerance s according to ISO 2768/Coarse , uniess other wise Speched
 P.H.O
MRCSMME NUST
WELDING INSPECTION PRACTICE

UG Mode: Practical
Advance Workshop Practice
Level:
Ref:
Course: ME-223 Semester:
Time: 03 Hours

TITLE
Drawbacks and Defects.
Joints against
1. Inspection of Welding

Introduction
out work piece, it needs inspection for quality. Many defects and
2. When welding is carried on

need to be detected and rectified.

drawbacks occurs during welding. These

a. Crack

b. Cavity
C. Under Cut

d. Spatters

Objective
The objective of the practical is to understand the inspection procedure for a welded joint.
3.

Requirements
4. Following are the requirements:

Welded work piece.

b. Cleaning Spray
C Inspection-Spray(2 Types

Procedure (Part-1)
5. Following steps are to be taken by students.

a. After welding, chipping hammer will be used to remove slags.

b. After removing slag, the work piece will be cleaned using wire brush. To clean the

surface of the work piece.

C. Meta Clean: Use to clean the surface of welding area. Spray it on the welding area

and clean with cotton.

 d.
Pentrix: Apply this spray on work piece, leave it for 30 minutes, then wash it
with water. Clean it with Cotton.

e Rivelex: After using of pentrix, then Rivelex will be used on cracks and holes, by
applying the spray the holes and cracks will be visible clearly.

Safety Precautions

6 Following safety precautions must be followed:

a. Use proper safety gears including Apron, Shield and gloves.

b Adjust the parameters properly as per requirement of the job.

C. Attend the work.

Instructions:
Students are required to make a report on welding inspection.
 P.H. O
MRC SMME NUST
ELECTRICALSPOT WELDING PRACTICE
Ref: Advance Workshop Practice
Level UG Mode: Practical
Time: 03 Hours
Course: ME-223 Semester:
TITLE
1. Electrical Spot welding of Thin
Sheet Metal.

Introduction
2 One of the
very simple and convenient way of
welding is through heavy electrical current flow
through a conductor which generate heat due to
resistance offered by the conductor itself. This method
involves flow of heavy DC currents at low (safe) voltages.
3 Resistance welding can be seam like welding or spot welding. It has
advantages of being quick
and clean. Heat Effected Zone
(HEZ) is minimum and set up is
comparatively simple. It is also an
environmental friendly method. It is convenient for bulk production of industries like automotive
industry etc.

Objective
4. The objective of the practical is to learn the method and
procedure involved in electrical spot
welding

Procedure
5. Following procedure is to be adopted.
a. Select the work piece.
b. Clean the surface to be
joined together for electrical conduction.
Mark theposition where the work piece has to be spot welded.
Clamp the two pieces using appropriate clamping devices
(e.g. C- clamps).
e. Set the current rating and timing (if available) on the plant.
f. Switch ON the plant.
Place the work piece between the electrodes of the
plant.
. Press pedal and leaves as soon as the weld has taken
place.
Continue the process where spots are to be carried out.
Inspect the work piece for quality of weld.
K.
afety Precautions
6. Following safety precautions
must be
a.
Adjust the jaws and
followed
electrodes for alignment. Check
b.
Adjust current rating as before starting procedure.
per the work piece
C.
Ensure that thickness.
cooling system of the plant is switched on.
d.
Always use wooden/ insulated
wooden board.
e
Pay attention to work.
f. Long work piece must be supported in position
Instructions:
7. Students are required to write a report on the method adopted for the given piece. Special
emphasis given on the parameter adjustment/ setting
 P.H. O
NUST SMME
Induction Furnace Practice
subject: Masfacluvr oaej Level: UG Mode: Practical

Time: 0 Hours Course: ME-oS(A 6 ) Semester: F a l 2 o

TITLE
1. Melting of Metal through Induction Furnace and Pouring to Manufacturing an Article in a DIE
Fixed Mold.

Introduction
2 For foundry work the metals have to be melted. Different techniques can be used to melt like

coal/gas fired furnaces. In induction furnace a heavy current is flown through conductor coils around
the crucible. This causes induction within the metal pieces placed inside the crucible which itself is laying
in the centre of the copil.! The heat generated results into melting. The process is clean, environmental
friendly and quick. On comparative basis it is also economical. The process of induction melting can be

used for ferrous and non-ferrous metals. Induction furnace are designed on 50 Hz frequency of 60 Hz

frequency

Objective
Students are required to learn setting up of preparatory work before and during melting of
3.

metal in an Induction Furnace.

Requirements
Metal Scrap is required (Quantity as per object to be casted).

Drawing of the required article.

b.
LPG for pre heating of the ladle.

Shoes etc).
d. Safety gears (Specially Helmet, Googles, Apron, Safety
e. Pre fixed mold.

f. Ceramic Rod.

Pyrometer

Procedure Induction Heating Machine

4. The following procedure is to adopted:

Prepare mold of required job.

D. Cut the scrap in specific shape for crucible.

C.
Put the scrap in crucible in crucible vertically.

d. Ensure the cooling system is in working mode.

 Switch on the controller.
. Set the temperature and time parameters as per requirements (Material)
Observe the melting stages and temperature using pyrometer.
In parallel pre-heat the ladle using LPG before pouring molten material.

i. Remove the slags during melting from molten metal.

Pour the molten metal in ladle then in mold OR directly in the mold.
Remove the casted part from mold and finish the job.

Safety Precautions
5. Following safety precautions must be followed:
a. Use all safety gears during work.

b. Watch where you work.

Do not play or fiddle with machine.

Remain alert and vigilant.
to observe molten.
e Use special coated glass / shield
etc.
combustible materials like wood,
chemical, papers, oil, gasses
Remove all types of
mode.
Ensure the cooling system is in working
melted.
Do not over heat the materials once it has been
h.
crucible.
i. Be extra careful while pouring molten metal in a mold/
with molten
concrete which can explode when in contact
Avoid spilling molten metal on
metal.

K. Do not touch the casted part/job with bare hands.

Instructions:

written report/ account ofthe work

done during the practical,
All students will submita

which the grading of work will

be done.
on