Name: Muhammad Aizaz

Roll No: 2022-BSMLE-01

Lab: Manufacturing Processes Lab

Submitted to: Engr. Syed Masood Arif

 Experiment.No.1:
Title:
Machining Operations on Drill Machine
Background:
1.Description:
Drill Machines:
A drill machine also called a drill press, is used to cut holes into or through metal, wood or other
materials. Drilling machines use a drilling tool that has cutting edges at its point. This cutting tool is
held in the drill press by a chuck and is rotated and fed into the work at variable speeds.

Main Parts of Drill Machines:

Following are the main parts of a Drill machine:

1.Spindle:
The spindle holds the drill or cutting tools and revolves in a fixed position in a sleeve. In most drilling
machines, the spindle is vertical and the work is supported on a horizontal table.

2.Sleeve or Quill:
The sleeve or quill assembly does not revolve but may slide in its bearing in a direction parallel to
its axis. When the sleeve carrying the spindle with a cutting tool is lowered, the cutting tool is fed
into the work: and when it is moved upward, the cutting tool is withdrawn from the work. Feed
pressure applied to the sleeve by hand or power causes the revolving drill to cut its way.

3.Head of Drill:
The head of the drill press is composed of the sleeve, spindle, electric motor and feed mechanism.
The head is bolted to the column.

4.Column:
The column of most drill presses is circular and built rugged and solid. The column supports the
head and the sleeve or quill assembly.

Drilling Operations:
Following are the operations which are performed by drilling machine:

1.Drilling:
Drilling is the operation of producing a circular hole in a work piece by forcing a rotating drill into it.
2.Counter boring:
Counter boring is an operation of enlarging one end of a drilled hole.

3.Boring:
Boring is an operation of enlarging hole that has already been drilled.

4.Counter sinking:
Counter sinking is an operation of making a cone shaped enlargement of the end of the hole.

Types of Drills:
1.Straight Flute Drills:
It has straight cutting edge with straight flute. It is designed for cutting brass and other soft
materials. It is also known as gun drill.

2.Twist Drill:
It is a common type of drill having two flutes and a cutting edge as its name implies the flutes are
twisted in a helical way.

objective:
 To determine the parts and working of drill machine
 To understand the process of drilling holes
 To make a hole of 4,6,8 mm in a steel strip

Material and method:

Materials:
 Hammer
 Steel strip
 Prick punch
 Inch tape
 Drill bits (4,6,8 mm)

Method/procedure:
 First of all, take the steel stripe and then clean it.
 Now take an inch tape and measure the length width and height of the steel stripe.
 Now point out the center of the steel stripe by using hammer and prick punch.
 Now fix a drill bit of in drill spindle and then fixed the work piece on working table of column
drill machine.
 Now start the drill machine and slowly apply drilling operation on the steel stripe by using the
sleeve.

Observation:
Conclusion:
Drill Machine is an easy to operate machine for cutting operations.

Experiment.No.2:

Title:
Electric Arc Welding
objective:
This lab exercise aims to familiarize students with the fundamentals of welding equipment,
processes, and safety measures.

Background:
Metals are firmly joined via welding, an essential industrial operation. In order to form a solid bond,
the base metal and a filler substance are melted together. One of the most used welding techniques
is arc welding, which produces the necessary heat using an electric arc.

Materials, Machines and Methods:

Materials:
 Chipping hammer
 Welding gloves
 Mild steel plates
 Welding electrodes
 Safety glasses

Machines:
 Welding machine
 Welding helmet with a dark visor
 Welding apron

Tools Used:
 Clamps
 Measuring tape
 Squares

Methodology:
  Measure and note the location of the next welding junction.
 Clamps should be used to hold the workpieces in the desired welding position.
 Following the manufacturer's instructions, assemble the welding machine.
 Determine which welding wire or electrode is best for the material being welded and the
welding procedure.
 The welding parameters (current, voltage, and wire speed) should be adjusted as necessary.

Conclusion:
 Students have gained practical welding skills thanks to this lab project. Now that arc welding
procedures, tools, and safety precautions have been covered, students should have a basic
grasp of them. The value of quality control in welding has also become clearer to them.

Safety Measures:
 Do not weld in a confined or poorly ventilated space.
 Follow all safety precautions and wear appropriate.
 Keep the welding area clean and free from flammable materials.

Experiment.No.3:

Title:
Types of Welding
objective:
This lab exercise aims to familiarize students with of different types of welding, there equipment,
processes, and safety measures.

Types of Welding:

Gas welding
By burning the combination gasses entering through the torch tip, a very hot flame is created. In
order to finish welding, the edges that need to be welded are heated until they melt, and then filer
metal is added to the melted metal to fill the hollow. In gas welding, a variety of gas combinations are
utilized, but the most popular combination is oxygen and acetylene. This molten metal mixture
solidifies upon cooling to form welded seams.
Air acetylene:
In order to create a high-temperature flame, acetylene gas mixture atmospheric air is used in the air
acetylene welding process. Strong and long-lasting bonds are formed when metals or other materials
are melted and joined together using this flame.
Oxy hydrogen
When hydrogen and oxygen combine in oxy-hydrogen welding, steam is produced and the flame
temperature rises to about 28000C. However, when the torch itself provides all of the oxygen
needed for combustion, the weld pool is not shielded from the environment. Therefore, the torch
provides oxygen in an amount that is marginally less than what is needed for complete
combustion, while atmospheric oxygen is responsible for burning the remaining hydrogen. As a
result, the main flame is surrounded by a preheating flame that serves as protection. However,
this somewhat lowers the flame temperature.

2. Resistance welding
Resistance welding is generally used to join two plain metal work pieces together. An electric
current is delivered to the metal sheets (or any work pieces being joined) through weld electrodes
which apply force to the sheets. This force is then converted to heat. The heat is generated so
that it melts the metal at the point where they join – the point of ‘resistance’ between the faying
surfaces. The electrode then extracts heat from the molten weld area which forms a weld nugget
at the point where it solidifies. A force is applied before, during and after a current is applied,
which confines the contact area.

Butt welding
A butt weld is one of the simplest and versatile types of weld joint designs. The joint is formed simply by
placing two pieces of metal end-to-end and then welding along the join. Importantly, in a butt joint, the
surfaces of the work pieces being joined are on the same plane and weld metal remains within the planes of the
surfaces. Thus, work pieces are nearly parallel and do not overlap, unlike lap joints.

spot welding
Spot welding (also known as resistance spot welding) is a resistance welding process. This welding process is
used primarily for welding two or more metal sheets together by applying pressure and heat from an electric
current to the weld area. It works by contacting copper alloy electrodes to the sheet surfaces, whereby pressure
and electric current are applied and heat is generated by the passage of current through resistive materials
such as low carbon steels.

Seam welding
Seam welding is the joining of work pieces made of similar or dissimilar materials along a continuous seam.
Seam welding can be broken down into two main techniques, resistance seam welding and friction seam
welding.

projection welding
Projection welding is the resistance welding process which joins the metal pieces together by using the heat
generated by an electric current. In this welding process, different projections are formed on the work pieces
for effective welding. Projection welding does not use electrodes for concentration of heat, instead the
projection on the work piece is used for this purpose. Actually, projection welding is a modified version of spot
welding.

Arc welding
Arc welding is a type of welding process using an electric arc to create heat to melt and join metals. A
power supply creates an electric arc between a consumable or nonconsumable electrode and the base
material using either direct (DC) or alternating (AC) currents.
 Carbon arc
Carbon arc welding is used for welding copper and its alloys. In this method, the carbon electrode is used
which is kept negative with respect to work if DC supply is used. It is because, if the carbon electrode is
made positive, the carbon particles have a tendency to go into the welded joint and make it brittle.
Therefore, the electrode in carbon arc welding is always kept negative and the work positive

metal arc
Metal arc welding also known as shielded metal arc welding flux shielded arc welding or stick welding, is a
process where the arc is struck between an electrode flux coated metal rod and the work piece. Both the rod
and the surface of the work piece melt to create a weld.

plasma arc welding

Plasma welding is very similar to TIG as the arc is formed between a pointed tungsten electrode and the work
piece. However, by positioning the electrode within the body of the torch, the plasma arc can be separated
from the shielding gas envelope. Plasma is then forced through a fine-bore copper nozzle which constricts the
arc.

Gas metal arc (MIG)

Gas metal arc welding (GMAW), sometimes referred to by its subtypes metal inert gas (MIG) and
metal active gas (MAG) is a welding process in which an electric arc forms between a consumable
MIG wire electrode and the work piece metal(s), which heats the work piece metal(s), causing them
to fuse (melt and join).

gas tungsten arc (TIG)

Tungsten Inert Gas (TIG) welding, also known as Gas Tungsten Arc Welding (GTAW) is an arc welding
process that produces the weld with a nonconsumable tungsten electrode.

4 Newer welding
Newer welding applications and methods, such as laser and electron beam welding, use less heat and produce fewer
fumes than traditional welding processes. This creates a safer welding environment with limited emissions of harmful
particles and toxic gases.

4.1 electron beam welding

Electron beam welding is a fusion welding process whereby electrons are generated by an electron gun and
accelerated to high speeds using electrical fields. This high speed stream of electrons is tightly focused using magnetic
fields and applied to the materials to be joined. The beam of electrons creates kinetic heat as it impacts with the work
pieces, causing them to melt and bond together.

laser welding
Laser welding is a process used to join together metals or thermoplastics using a laser beam to form a weld. Being
such a concentrated heat source, in thin materials laser welding can be carried out at high welding speeds of
metres per minute, and in thicker materials can produce narrow, deep welds between square-edged parts.

solid state welding

Solid-state welding is a group of joining processes, in which coalescence of the joining surface is achieved
without melting by applying pressure with or without the application of heat
 friction
Friction welding (FRW) is a class of solid-state welding processes, in which heat is generated by mechanical
friction between a moving component and a stationary one, and at the same time a lateral force called 'upset' is
applied to the parts, in order to plastically displace and fuse the material.

ultrasonic welding
Ultrasonic welding is an industrial process whereby high-frequency ultrasonic acoustic vibrations are locally
applied to work pieces being held together under pressure to create a solid-state weld. It is commonly used
for plastics and metals, and especially for joining dissimilar materials. When used to join metals, the
temperature stays well below the melting point of the involved materials, preventing any unwanted
properties which may arise from high temperature exposure of the metal.

diffusion welding
Diffusion bonding or diffusion welding is a solid-state welding technique used in metalworking, capable of joining
similar and dissimilar metals. It operates on the principle of solid-state diffusion, wherein the atoms of two solid,
metallic surfaces intersperse themselves over time.

Explosive welding
Explosion welding, also called explosive welding or shockwave welding, is a solid state welding process that
involves accelerating one of the components at a high speed with the use of chemical explosives. The
process uses the merging principle, which occurs in milliseconds and eliminates bulk heating or metal
weakening.

Experiment.No.4:
Title:
Forging and Its Types
Objective:
The objective of this lab is to familiarize students with the fundamentals of Forging, its
types and some safety measures regarding this process.

Background:
1.Description:
Forging:
Forging is a manufacturing process that involves shaping metal with localized compressive forces.
The blows are delivered with a hammer or a die. Forging is frequently classified according to the
temperature at which it is performed: cold forging and hot forging.

Components of Forging:
Anvil:
An anvil is a metalworking tool consisting of a large block of metal, with a flattened top surface, upon
which another object is struck.

Hammer:
Four types of Hammers are used in Forging.

Tongs:
Tongs are used to hold and turn metal pieces in forging process.

Chisels:

Chisel, cutting tool with a sharpened edge at the end of a metal blade.

Types of Forging:
 Cold Forging
 Hot Forging
 Press Forging
 Impact Forging
Cold Forging:
Cold forging, unlike hot forging, deforms metal below its recrystallization point - near or at room
temperature. Cold forging is a preferred method for softer metals (such as aluminum), is less
expensive and has the ability to produce forged parts that require little finishing. A cold machining
process, cold forging involves placing bar material in a die and then pressing it with a second closed
die. Similar to the cold press process the workpiece is pressed between two dies until it assumes the
desired shape of the die.

Hot Forging:
Hot forging can be defined as “a metal shaping process in which a malleable metal part, known as
a billet or workpiece, is worked to a predetermined shape by one or more processes such as
hammering, upsetting, pressing and so forth where the workpiece is heated up to about 75% of its
melting temperature”.

Press Forging:
Press forging may be defined as the process of shaping a metal that is placed between two dies
by applying mechanical or hydraulic pressure. Press forging is usually done on a forge press - a
machine that applies gradual pressure on the forging dies. The shape of the metal is usually
accomplished by a single stroke of the press for each die station.

Impact Forging:
Impact forging is essentially hammer forging in which both dies are moved horizontally, converging
on the workpiece. Counterblow forging is similar, except that the dies converge vertically.

Conclusion:
Forging is a process for shaping metals using compressive force. Forging under different conditions
boosts the process.

Experiment.No.5:

Title:
Plastic Moulding
Objective:
This lab exercise aims to familiarize students with the fundamentals of Plastic
Moulding, processes, and safety measures. Students will comprehend the basics of Plastic Moulding
and its types.

Background:
1.Description:
Plastic Moulding:
Plastic moulding is the process of pouring liquid plastic into a certain container or mould so that it
hardens in that customized shape. These plastic moulds can then be used for a wide range of
purposed. There are 5 types of plastic moulding that is considered to be the most effective and most
popular.
These 5 types are extrusion moulding, compression moulding, blow moulding, injection moulding and
rotational moulding. We will look at the details pertaining to each of these methods so that you can
decide which one will be the most effective for you to use.

Types of Plastic Moulding:

1. Extrusion Moulding
With extrusion moulding, hot melted plastic is pressed through a shaped hole to create a lengthy
shaped plastic part. This customizable shape that the liquid plastic gets pressed through is called a
die. This die is custom made for the particular outcome that is desired. It is almost like pressing
dough through a press to make shaped cookies. The other forms of plastic moulding also use
extrusion so get the raw liquid into the moulds, the difference here is that other methods use the
moulds to make the desired shape and here the extrusion itself is making the shape with the use of
the die’s shape.

2. Compression Moulding
This method involves the raw liquid plastic being poured into a heated mould and then being
compressed together to form the desired shape. The high temperature of the entire process ensures
good strength in the final product. The process is finished off by cooling the liquid plastic so that it
keeps its form before being trimmed and removed from the mould.

3. Blow Moulding
With blow moulding, the custom plastic parts come out hollow and thin-walled. This method is ideal
for when the plastic part has to have uniform wall thickness. This is very similar to the process of
glass blowing. The machine heats up the raw plastic until it becomes liquid and then injects air into it
like a balloon. The plastic is blown into a shaped mould and as it gets bigger it presses against the
mould walls and it starts to take its shape. After the liquid balloon fills the mould it is cooled to keep
its shape. The process is very fast and can produce up to 1400 pieces in a 12-hour work day.

4. Injection Moulding
Injection Moulding is fairly similar to extrusion moulding. The difference here is that with injection
moulding the melted plastic is injected directly into a custom mould. The injection is under high
pressure so that the mould is filled and a solid part is made. As with the other methods, after the
mould is filled, the plastic is cooled as to keep its new shape and then the mould is opened. This can
be compared to a Jello mould when the mould is filled and then cooled to create the final product.

5. Rotational Moulding
Also sometimes called roto-moulding, this method involves the resin or liquid being placed inside the
mould and then being rotated at high speeds. The liquid then evenly covers the entire surface of the
mould to create a hollowed part with all the walls evenly thick. After the mould is cooled and the liquid
plastic has taken its new form it is then taken out of the mould. This method is very material efficient
and very little goes to waste making it more economical and environmentally friendly.

6. Thermoforming
Thermoforming is a process of heating a thermoplastic sheet to its softening point. The sheet is
stretched across a single-sided mold and then manipulated. Then, it cools into the desired shape.
The most common methods to get the sheet to conform to its final shape are vacuum-forming,
pressure-forming, and mechanical forming. Thermoforming has innumerable applications and can be
used by several different industries. Here is a brief overview of thermoforming, its benefits, and its
applications.

Conclusion:
Plastic molding is a highly productive and efficient method in fabricating plastic products. The
injection molding cycle involves an injection of molten plastic into a mold, then cooling it to form
the solidified part. The mold is customized tooling that produces identical parts consistently.

Experiment.No.6:
Title:
Heat Treatment and Its Processes

Objective:
This lab exercise aims to familiarize students with the fundamentals of Heat Treatment,
processes, and safety measures. Students will comprehend the basics of Heat Treatment and its
types and processes.

Background:
1.Description:
Heat Treatment:
Heat treatment is a process that is used to change the physical properties of a material in a beneficial
way. During a heat treatment process, a material is typically heated to a target temperature at which
its physical properties change then soaking is done in which material is heated at specific
temperature for specific time and then it is then cooled at a controlled rate.

Types of Heat Treatment:

1. ANEALING:
It is one of the most important processes of heat treatment. It is one of the most widely used
operations in the heat treatment of iron and metal and is defined as the softening process. In this
process metal is heated up to its recrystallization temperature and cooling it at a very slow rate by
seeking the metal into the furnace. The main aim of annealing is to make metal more ductile and
malleable and to remove internal stresses. This process makes the metal soft so that it can be
easily machined. The other advantage of this process are.

2. NORMALIZING:
The main aim of normalizing is to remove the internal stresses developed after the cold working
process. In this process metal is heated at its critical temperature and then metal is allowed cool
in still air at room temperature.

3. QUENCHING:
The main aim of the hardening process is to make metal hard tough. The metal is heated above
its critical temperature range. It is held at that temperature for a definite period of time. The metal
is then rapidly cooled in a medium of quenching. The quenching medium is selected according to
the degree of hardness desired. The air, water, oils and Nacl (brine solution) are used as
quenching mediums. Water is widely used medium but it results in the formation of bubbles on the
surface of the metal. Hence oil is used when there is a risk of distortion on cracks on metal. 
Brittleness increase

4. TEMPERING:
When the hardening process hardens a metal it becomes brittle and has high residual stress. It is
an operation used to modify the properties of metal hardened by quenching for the purpose of
increasing its usefulness. The metal after being quenched in the hardening process is reheated to
a temperature slightly near the critical temperature. It is held at that temperature for a definite
period of time and then slowly cooled in the air.

5. CASE HARDENING:
The process of hardening the surface of a metal by infusing the elements on to the metal surface
forming a thin layer of harden alloy. In this process the metal is heated until it converted into its
red hot form then carbon is fused in surface and then metal is undergoing through a quickly
quenching process. At the end a case is formed on the surface of metal.

6. SURFACE HARDENING:
Surface hardening increases the hardness of the metal’s surface while keeping the core soft. In
this process the metal is heated in such a way that its outer surface is converted into its red hot
form keeping the core at a lower temperature. Once the surface comes to the desired
temperature, it gets quenched.
 7. AUSFORMING:
A type of hardening process which integrates tempering, rapid cooling, deforming and quenching.
It is a modified steel heat treatment process in which plastic deformation of metastable austenite
is done. In the ausforming process first the material is heated to a particular temperature soaked
at that temperature for some time then the material is rapidly cooled below nose of curve. After
cooling up to particular temperature the mechanical work is done on material by forging and
rolling, the temperature is maintained constant during mechanical working. Then again it is
cooled. The water or salt bath is used as quenching/ cooling medium.

Experiment.No.7:
Title:
Grinding Machine and its Operation
Objective:
 To demonstrate different parts of Grinding machine.

 To understand basic of grinding machine.

Background:

The grinding machine is an machine that have grinding wheel that is used for fine finish and
light cuts on metals. It is used for removing of material to gain dimensional accuracy, and
surface finish. In grinding machine the motor rotate the grinding wheel. The grinding wheel is
made up of abrasive material and when a high speed rotating grinding wheel is strike with any
metal it starts to remove metal.

PARTS OF DRILL MACHINE:

BASE:
It is a lower part of grinding machine that is made up of cast iron. The base supports motor of
the Grinding machine. The base of the machine can be fixed on the flour by using nut and
bolts.

Motor:
The motor is used to rotate grinding wheel of grinding machine. The grinding wheel are
connected with shafts that are connected with motor. Thus motor rotate the shafts and shafts
rotate the grinding wheel.
Shafts:
Two shafts are connected with the motor and at the end these shafts are connected with the
grinding wheels. Thus the function of shafts is to provide rotations to grinding wheels.

Grinding wheels:
It is mounted at the end of the shafts and its rotates to produces cuts and surface finish on metal.
Grinding wheel are made up of abrasive material.

Wheel guard:
A grinding machine have a wheel guard. The purpose of wheel guard is to protect user from any
accident. It increases the safety of the machine.

OPERATIONS OF GRINDING MACHINE:

 cutting
 grinding
 metal removing.

MATERIAL:

 safety googles, gloves and apron

 water
 scriber
 grinding machine
 cast steel rod

METHOD:

 First of all, wear the safety googles, gloves and apron.

 Now clean the work piece, and grinding machine and ready all the equipment’s used during
experiment.
 Now use scriber to make lines on work piece and turn on the grinding machine.
 Now hold the work piece and slowly touch the work piece with the grinding wheel of grinding
machine. To remove excess metal, we use coarse grain wheel and to remove less metal we
use fine grain wheel.
 Now dipped the hot tool inside the water to make it cool. If tool is not cooled, then the tool will
be broke.
 After the operation is completed the grinding machine is switched off and safety goggles ,
gloves and apron are removed.

CONCLUSION:
From this experiment it is conclude that if the metal is not cooled after an specific time then it may
be broke or case accident moreover for surface finish we use fine grain size grinding wheel while for
removing metal we use coarse grinding wheel.