KJIT-Mechanical Department ‘Manufacturing Technology (3151912) SEMESTER V LIST OF EXPERIMENTS SR) NO) PRACTICAL NAME DATE | SIGN Study and classify various manufacturing processes. 2 | Study of Casting Processes. 3 | Hands on experience on pattern making. 4 | Study of various welding processes. 5 | Perform Arc Welding Process. 6 | Study of Forging process 7 | Study of Plastic Processing 8 | Study of Ceramic and Glass Manufacturing. ‘Scanned with CamScannerKJIT-Mechanical Department ‘Manufacturing Technology (3151912) SEMESTER V EXPERIMENT NO 1 AIM:Study and Classify Various Manufacturing Processes, INTRODUCTION ‘The word “Manufacturing” is derived from Latin, manus=hand and factus=made, that is, he literal meaning is “made by hand” However, in the broad sense, the word manufacturing ‘means the making of goods and articles by hand or machinery. Thus manufacturing deals with the study of various process required to produce parts. When one thinks as to how the various parts are produced, many techniques come to the mind, for e.g. Casting, forging, rolling, machining etc. The manufacturing are so varied that there is no simple and universal criteria for classifying these. However all manufacturing process may be grouped into following two categories [1]Non cutting (Non-material removal) - e.g. casting, rolling, drawing, forging, shearing. [2]Cutting (Material removal) - e.g. sawing, drilling, turning, planning, milling etc. ut of these we should study casting process and machine tools in this subject. In casting process, the metal in the molten state is poured into a mould and allowed to solidify into a shape. The mould may be expendable or permanent. In machining process, metal removal can be obtained by relative motion between cutting tool & job. Such motion is produced by combination of rotary and translating movements either of job or of the tool or of both. REVIEW QUESTIONS 1, Define and classify the manufacturing processes. 2. Explain in brief about different manufacturing processes. 3. Explain importance of manufacturing ‘Scanned with CamScannerKJIT-Mechanical Department ‘Manufacturing Technology (3151912) SEMESTER V EXPERIMENT NO 2 AIM: Study of Casting Processes. INTRODUCTION Casting is a process in which molten metal flows by gravity or other force into a mold where it solidifies in the shape of the mold cavity. The term casting is also applied to the part that is made by this process. The principle of casting seems simple: melt the metal, pour it into a mold, and let it cool and solidify; yet there are many factors and variables that must be considered in order to accomplish a successful casting operation. Pouring ladle Molten metal ‘Sprue and runner (to be trimmed) —— Parting Solid casting line Mold (sand) () (2) Advantages of Casting + Casting can be used to create complex part geometries, including both external and internal shapes. + Some casting processes are capable of producing parts to net shape. No further manufacturing. + Operations are required to achieve the required geometry and dimensions of the parts. + Other casting processes are near net shape, for which some additional shape processing is required (usually machining) in order to achieve accurate dimensions and details. + Casting can be used to produce very large parts. Castings weighing more than 100 tons have been ‘made. + The casting process can be performed on any metal that can be heated to the liquid state. + Some casting methods are quite suited to mass production. ‘Scanned with CamScannerKJIT-Mechanical Department ‘Manufacturing Technology (3151912) SEMESTER V Disadvantages of Casting Limitations on mechanical properties porosity ete. poor dimensional accuracy and surface finish for some casting processes, safety hazards to humans when processing hot molten metals, environmental problems REVIEW QUESTIONS 1, Define following: Casting process, pattem, core, mould. 2. Classify the casting process. 3. Explain elements and its function in sand casting process. ‘Scanned with CamScannerKJIT-Mechanical Department ‘Manufacturing Technology (3151912) SEMESTER V EXPERIMENT NO 3 AIM: Hands on experience on pattern making, selection of material, types of pattern & function of patterns, Allowances. INTRODUCTION: 4 A Patter is a model or the replica of the object to be cast. & Except for the various allowances a pattern exactly resembles the casting to be made. ‘Patterns may be in two or three pieces, where as casting are in a single piece. ‘© A pattem is required even if one object has to be ‘ The quality of casting and the final product will be effected to a great extent by the planning of pattern. Functions of Patterns: = A Pattern prepares a mould cavity for the purpose of making a casting. * A Pattern may contain projections known as core prints if the casting requires a core and need to be made hollow, = Risers, runners and gates may form a part of the pattern. = Patterns properly made and having finished and smooth surfaces reduce casting defects. Properly constructed patterns minimize overall cost of the casting. Selection of Pattern Materials: The pattern material should be: 1, Easily worked, shaped and joined. 2. Light in weight. 3. Strong, hard and durable, 4. Resistant to wear and abrasion. 5. Resistant to corrosion, and to chemical reactions. 6. Dimensionally stable and unaffected by variations in temperature and humidity. 7. Available at low cost. ‘Scanned with CamScannerKJIT-Mechanical Department ‘Manufacturing Technology (3151912) SEMESTER V Materials for making patterns: a. Wood b. Metal c. Plastic 4. Plaster of paris fe. Wax. ‘Types of Patterns: 1. Single piece pattern. Split piece pattern. Loose piece pattern. Match plate pattern. Sweep pattern. Gated pattern Skeleton pattern Follow board pattern ypaenanawn Cope and Drag pattern ‘Types of Pattern Allowances: 1. Shrinkage or contraction allowance. 2. Machining or finish allowance. 3. Draft of tapper allowances. 4, Distortion or chamber allowance. 5. Shake or rapping allowance. QUESTIONS: 1, Explain functions, types of patterns with neat sketch, Explain types of materials used in making patterns with their advantages disadvantages. Explain various types of allowances used in making patterns with its importance. ‘Scanned with CamScannerKJIT-Mechanical Department ‘Manufacturing Technology (3151912) SEMESTER V EXPERIMENT NO 5 AIM: Study of Gas Welding process INTRODUCTIO! Gas metal are welding (GMAW) Uses an are between a continuous filler metal (consumable) electrode and the weld pool. Shielding is provided by an externally supplied shielding gas. This process is also known as MIG welding or MAG welding. MIG (Metal Inert Gas) welding means the use of an inert (Le. non active) gas. MAG (Metal Active Gas) welding requires the use of an active gas (i.e. carbon dioxide and oxygen). CO2 is a more commonly used shortening of MAG welding gas. ‘The process consists of a DC arc burning between a thin bare metal wire electrode and the piece. ‘The arc and weld area are enveloped in a protective gas shield. ‘The wire electrode is fed from a spool, through a welding torch which is connected to the positive terminal into the weld zone. MIG/MAG welding is the most widely used process in the world today. It is a versatile method which offers a lot of advantages. The technique is easy to use and there is no need for slag cleaning. Another advantage is the extremely high productivity that MIG/MAG welding makes possible, MIG/MAG welding is used on all thicknesses of steels, aluminum, nickel, stainless steels etc. The MAG process is suitable both for steel and unalloyed, low-alloy and high-alloy based ‘materials. The MIG process, on the other hand, is used for welding aluminum and copper metals Flux Cored Arc Welding Flux cored are welding (FCAW) is an electric are welding process that uses an are between a Continuously fed flux-filled electrode and the weld pool. The process is used with shielded gas from a flux contained within the tubular electrode with or without additional shielding from an externally supplied gas. ‘The FCAW process utilizes the heat of an arc between a continuously fed consumable flux cored electrode and the work. The heat of the arc melts the surface of the base metal and the end of the electrode. ‘The metal melted off the electrode is transferred across the are to the work piece, where it becomes the deposited weld metal. Shielding is obtained from the disintegration of ingredients Contained within the flux cored electrode. Additional shielding is obtained from an envelope of gas supplied through a nozzle to the arc area. Ingredients within the electrode produce gas for shielding and also provide deoxidizers, ionizers, purifying agents and, in some cases, alloying elements bmerged Arc Welding (SAW) ‘Submerged are welding is an arc welding process that fuses together the parts to be welded by heating them with one or more electric arcs between one or more bare electrodes and the work piece. The submerged are welding process utilizes the heat of an arc between a continuously fed electrode and the work. The heat of the are melts the surface of the base metal and the end of the electrode, ‘Scanned with CamScannerKJIT-Mechanical Department ‘Manufacturing Technology (3151912) SEMESTER V The metal melted off the electrode is transferred through the arc to the work piece, where it becomes the deposited weld metal. Shielding is obtained from a blanket of granular flux, which is laid directly over the weld area, ‘The flux close to the arc melts and intermixes with the molten weld metal and helps purify and fortify it. The flux forms a glasslike slag that is lighter in weight than the deposited weld metal and floats on the surface as a protective cover. The weld is submerged under this layer of flux and slag- hence the name submerged arc welding. ‘Tungsten inert gas welding (TIG) In TIG an are is created between a no consumable tungsten electrode and the metal being welded. The arc produces the heat needed to melt the work. The shielding gas keeps oxygen in the air away from the molten weld pool and the hot tungsten. Gas is fed through the torch in order to shield the electrode and the molten weld pool. The shielding gas used is pure argon. There may or may not be filler metal added to the molten weld pool during the process. ‘Tungsten is used for the electrode because of its high melting temperature and good electrical characteristics. The main advantage of TIG welding is the wide range of materials that it can weld. TIG welding is used to a great extent for welding different kinds of alloys of aluminum and stainless steel, especially when quality is of great importance. This technique is mainly used in aeronautical constructions and in the chemical and the nuclear power industry. Electro slag welding Electro slag welding is a very efficient, single p s carried out in the vertical or near vertical position and used for joining stee! plates/sections in thicknesses of 25mm and above. It was developed by the Paton Institute in the Ukraine in the early 1950s and superseded the very high current submerged are process for making longitudinal welds in thick-walled pressure vessels. Unlike other high current fusion processes, electro slag welding is not an are process. Heat required for melting both the welding wire and the plate edges is generated through a molten slag's resistance to the passage of an electric current. In its original form, plates are held vertically approximately 30mm apart with the edges of the plate. Brericarmotion — HE oscisation ‘Scanned with CamScannerKJIT-Mechanical Department ‘Manufacturing Technology (3151912) SEMESTER V Current status In the fabrication industry, the process continues to be used for thick walled pressure vessels which are post-weld normalized and for structures such as blast furnace shells and steel ladles which are used at above ambient temperatures. The process is also extensively used for the welding of railway poin Important current issues Considerable interest was shown in electro slag welding during the 1970s when ideas for increasing welding speed were investigated. This was seen as an important parameter for increasing productivity and as a way of reducing heat input to improve HAZ and weld metal impact properties. However, since that time little has been done by way of development. Those developments that have taken place have been limited to the tuning of parameters and tailoring techniques for specific applications. Benefits ‘The principal benefits of the process are: + speed of joint completion; typically 1 hour per meter of seam, irrespective of thickness + lack of angular distortion + lateral angular distortion limited to 3mm per meter of weld + high quality welds produced + simple joint preparation, ie. flame-cut square edge + major repairs can be made simply by cutting out total weld and re-welding ‘Scanned with CamScannerKJIT-Mechanical Department ‘Manufacturing Technology (3151912) SEMESTER V Electro slag welding is not one of the major welding processes because the high heat input generates large, coarse grained weld metal and HAZs which lead to poor fracture toughness properties in these areas. Toughness improvements can only be achieved by post-weld normalizing treatment. Additionally, the near parallel-sided geometry of the weld, combined with the coarse grains, can make it difficult to identify defects at the fusion boundary by standard ultrasonic NDT techniques. The process has considerable potential for increasing productivity. However, its use has been limited because of relatively poor understanding of the process and, for specific applications, the significance of the fracture toughness values. As a result, use of the process has been restricted to a few niche applications. QUESTIONS: 1. Explain various types of flames obtained in gas welding, State their specific applications. 2. Differentiate between gas welding and gas cutting processes. 3. Oxidizing flame makes a roaring sound, why? 4. State the functions of flux used in welding process. 5. Define Welding. (All the definitions) 6. Classify welding process. 7. __ Differentiate following: Tig welding — Mig welding Soldering ~ Brazing 8. Explain Tig welding with neat sketch, REVIEW QUESTIONS 1.Define and Classify welding process. 2.Explain types of welded joints. 3.Differentiate between gas welding and gas cutting processes. 4.State the functions of flux used in welding process. 5.Explain TIG and MIG welding with neat sketch. ‘Scanned with CamScannerKJIT-Mechanical Department ‘Manufacturing Technology (3151912) SEMESTER V EXPERIMENT NO 6 AIM: Study of Forming Processes. INTRODUCTION Metal formingis a general term for manufacturing processes in that the metal being processed is plastically deformed to shape it into a desired geometry. In order to plastically deform a metal, a force must be applied that will exceed the yield strength of the material. The magnitude of the amount will be directly proportional to the force applied. Also the material will return to its original geometry once the force is released. Once the stress on a metal inereases past a certain point, it no longer deforms elastically, but starts to undergo plastic deformation. In plastic deformation, the geometric change in the material is no longer directly proportional to stress and geometric changes remain after the stress is released; meaning that the material does not recover its shape. Cold working is a metal forming process that is carried out at room temperature or a little above it. In cold working, plastic deformation of the work causes strain hardening as discussed earlier. The yield point of a metal is also higher at the lower temperature range of cold forming. Hence, the force required to shape a partis greater. Hot workingis a metal forming process that is carried out at a temperature range that is higher than the recrystallization temperature of the metal being formed. The behavior of the metal is significantly altered, due to the fact that itis above its recrystallization temperature. Different Types Of Metal Forming Processes: (DBulk Deformation Rolling: Rolling is a metal forming process that deforms the work by the use of rolls. Rolling processes include flat rolling, shape rolling, ring rolling, thread rolling, gear rolling, and the production of seamless tube and pipe by rotary tube piercing or roll piercing, Forging: Forging is characteristic in the use of dies to compress and shape a work piece. The die may be flat or may contain an impression of a certain geometry, Extrusion; Extrusion involves forming by forcing metal through a die opening, producing work of variable length and constant cross section. Drawing: Drawing is similar to extrusion, in that a length of metal is made to flow through a die opening ‘and forming is done over its cross section. The difference between drawing and extrusion is the application of force to the work piece. In extrusion the work is pushed through the die opening, in drawing the work is pulled through the die opening. (ID) Sheet Metal Working ‘Scanned with CamScannerKJIT-Mechanical Department ‘Manufacturing Technology (3151912) SEMESTER V Shearing: Shearing is the cutting of the work piece, this would include punching holes. Technically shearing does not involve shaping by plastic deformation, but it is a critical process in sheet metal working operations and should be understood along with metal forming processes. Bending: Bending involves the deformation of the work by way of bending about a certain axis. ‘Deep Drawing: Deep drawing is a metal forming process in which a flat piece of plate or sheet is forced into a die cavity to take a shape, such as a cup. REVIEW QUESTIONS State the various material properties which are important in metal Forming process. Classify metal Forming process. Differentiate between hot working and cold working, How the pipes and tubes are manufacturing? Explain various press working operations. gaens ‘Scanned with CamScannerKJIT-Mechanical Department ‘Manufacturing Technology (3151912) SEMESTER V EXPERIMENT NO 7 AIM: Study of Plastic Processing. INTRODUCTION Plastics refer to a group of synthetic organic materials which becomes plastic on heating and can be formed to desired shape with or without the application on pressure. The plastics are high polymers which have excellent combination of properties suitable for many engineering applications. Some of its advantages are ease of fabrication, good dimensional accuracy, excellent electrical insulation, resistance to heat, sufficient hardness ete. ‘Thermo plastic and thermo setting plastics are basic classification of plastics. Questions: 1) Define and classify plastics 2) Write short note on Thermoplastic and Thermo setting plastics 3) Explain compression moulding with neat sketch. 4) What is laminating? Explain in brief 5) Explain joining of plastic in bref. ‘Scanned with CamScannerKJIT-Mechanical Department ‘Manufacturing Technology (3151912) SEMESTER V EXPERIMENT NO 8 AIM: Study of Ceramic and Glass Manufacturing. INTRODUCTION (Ceramics are defined as inorganic, non-metallic materials. Ceramics are hard materials that are resistant to high temperatures and are not deformed plastically, as well as having good resistance to corrosion and low electrical conductivity. Ceramies are manufactured by compacting powder to a body which is then sintered at high temperatures. The geometry, production volume and characteristic requirements for the component govern the choice of manufacturing process. Glass is fluid at high temperature and its fluidity decreases as the temperature is reduced. In other words, its viscosity decreases as the temperature increases. Unlike water, which turns from a liquid to solid at a specific temperature, glass has no specific melting or freezing point, but is gradually changed from a stiff solid to a liquid mass as the temperature is increased. It is this property of “variable viscosity,” which is used in forming a mass of glass into articles of beauty or utility. The different methods for forming a variety of different types of glasses either by hand forming, or machine forming, are: + Container Glass Manufacture; + Flat Glass Manufacture; + Domestic Glassware Manufacture; Glass Blowing; Glass Fibre Manufacture; Optical Fibre Manufactu Glass Tubing Manufacture; Glass manufacturing has also secondary processes, such as the processes of annealing, toughening, coating and decoration. Questions: 41) Explain various ceramic matrix composites processing techniques. 2) Explain glass melting and glass forming process in detail. ‘Scanned with CamScanner