Practical Workbook

Manufacturing Processes-I Lab

(ME-220)

Name : _________________________________
Year : _________________________________
Batch : _________________________________
Roll No. : ________________________________
Department : ____________________________________

Department of Mechanical Engineering

NED University of Engineering & Technology
Karachi 75270, Pakistan
 Practical Workbook
Manufacturing Processes-I Lab
(ME-220)

Prepared by: Mr. Syed Muhammad Hassan Liaqat

(Lecturer)

Mr. Osama Anis

(Lecturer)

This is certified that this Practical Workbook contains 60 pages.

October 2022
Chairman

Department of Mechanical Engineering

NED University of Engineering &
TechnologyKarachi – 75270, Pakistan
 Certificate
Of Laboratory Work Completion
This is to certify that Mr./Miss. s/o, d/o
bearing roll number , student of Spring/Fall semester has
successfully completed the lab work for the course of (course code) and the
assessment done for OBE based practicals in this workbook comply with the set OBE
rules.

Verified By: Course Coordinator

Name:

Signature:

Date:
Manufacturing Processes-I
NED University of Engineering & Technology - Department of Mechanical Engineering

Course learning outcome of Manufacturing processes I

Taxonomy
No. CLO PLO
Level
Discuss in detail the processes of manufacturing of PLO – 1
1 C2
metallic and plastic parts
Compare different types of metal forming processes and PLO – 2
2 C4
their output characteristics
Describe various manufacturing processes using the PLO – 7
3 C2
concept of sustainable manufacturing
Perform various metal forming and joining processes on PLO – 4
4 P3
job piece as per the guidelines
Adopt safety protocols as per the Health Safety and PLO - 6
5 A4
Environment (HSE) guidelines

CLO Mapping on Experiments

CLO E1 E2 E3 E4 E5 E6 E7 E8 E9 E10 E11 E12 E13 E14
1
2
3
4
5
Summary of Marks Obtained
Sr. Marks
Components Max. Marks
no. Obtained

1 P3 (Psychomotor Domain) rubric-based evaluation 20

A4 (Affective Domain) rubric-based evaluation

2 05

3 Miscellaneous (Attendance, Workbook, etc.) 05

Total Marks 30

Marks Awarding Scheme:

 𝑀𝑎𝑟𝑘𝑠 𝑓𝑜𝑟 (𝑃𝑠𝑦𝑐ℎ𝑜𝑚𝑜𝑡𝑜𝑟 𝐷𝑜𝑚𝑎𝑖𝑛) 𝑂𝐵𝐸 𝑏𝑎𝑠𝑒𝑑 𝑝𝑟𝑎𝑐𝑡𝑖𝑐𝑎𝑙 =
𝑆𝑢𝑚 𝑜𝑓 𝑚𝑎𝑟𝑘𝑠 𝑜𝑏𝑡𝑎𝑖𝑛𝑒𝑑 𝑓𝑟𝑜𝑚 𝑟𝑢𝑏𝑟𝑖𝑐 𝑓𝑜𝑟𝑚
× 20 (P3)
𝑀𝑎𝑥. 𝑚𝑎𝑟𝑘𝑠 𝑓𝑟𝑜𝑚 𝑟𝑢𝑏𝑟𝑖𝑐 𝑓𝑜𝑟𝑚
 𝑀𝑎𝑟𝑘𝑠 𝑓𝑜𝑟 (𝐴𝑓𝑓𝑒𝑡𝑖𝑣𝑒 𝐷𝑜𝑚𝑎𝑖𝑛) 𝑂𝐵𝐸 𝑏𝑎𝑠𝑒𝑑 𝑝𝑟𝑎𝑐𝑡𝑖𝑐𝑎𝑙 =
𝑆𝑢𝑚 𝑜𝑓 𝑚𝑎𝑟𝑘𝑠 𝑜𝑏𝑡𝑎𝑖𝑛𝑒𝑑 𝑓𝑟𝑜𝑚 𝑟𝑢𝑏𝑟𝑖𝑐 𝑓𝑜𝑟𝑚
× 05 (A4)
𝑀𝑎𝑥. 𝑚𝑎𝑟𝑘𝑠 𝑓𝑟𝑜𝑚 𝑟𝑢𝑏𝑟𝑖𝑐 𝑓𝑜𝑟𝑚
Manufacturing Processes-I
NED University of Engineering & Technology - Department of Mechanical Engineering

Table of Contents

S. No. Experiment Page Initial

1 To carry out sand casting of non-ferrous metals 2-6

To carry out cold rolling of non-ferrous metal and study

2 7-9
its effect on properties

To carry out injection molding of plastics using hand

3 10-12
operated injection molding machine
To perform the Electric Arc Welding for butt joint &
4 13-17
Corner Joint using mild steel electrode
To perform the Electric Arc Welding for Lap joint & T
5 18-21
Joint using mild steel electrode
To perform the Electric Arc Welding Edge Joint of cast
6 22-24
iron using iron powder electrode
7 To perform the Electric Arc Welding of Stainless steel 26-29

8 To perform the spot welding 30-34

9 To perform the Gas Tungsten Arc Welding (GTAW) 35-38

10 To perform the oxy-acetylene gas welding 39-44

11 To perform the oxy-acetylene gas cutting. 45-48

To perform the sheet metal shearing for mild steel using

12 49-52
Edward True cut power shear

To calculate various parameters of Upset forging with

13 53-56
hydraulic press using interactive simulation bench

To calculate various parameters of direct extrusion in

14 57-60
cold working using interactive simulation bench

01
Manufacturing Processes-I
NED University of Engineering & Technology - Department of Mechanical Engineering

EXPERIMENT 1
1.1 OBJECTIVE
To carry out sand casting of non-ferrous metals.

1.2 APPARATUS
Furnace, sand, pattern, mold box, gloves, tong, binder

1.3 THEORY
Metal casting is the process in which molten metal is poured into a mold and allowed to solidify
into an object. The object that results from this process is also called a casting. In sand casting,
sand is used to define the cavity inside a mold. In addition, sand is used to make any cores that
are contained in the mold. The molten metal solidifies in the cavity between the interior of the
mold and the exterior of the core. There are five basic steps to creating a sand casting.

1.3.1 Patternmaking
The first step in sand casting is pattern making. The pattern is a replica of the exterior of the
casting with dimensional allocation for shrinkage and finishing. If the casting is hollow,
additional patterns called cores are used to create these cavities in the finished product. Patterns
are usually made of wood, plastic, metal, or plaster; however, other materials or combinations
of materials are used if there are additional specific properties required of the pattern. The
number of castings to be made from the mold and the specifications required of the finished
casting are two criteria that determine which material is selected for the creation of the pattern.

1.3.2 Core-making
The next step in the process is core making. Cores are forms which are placed into the mold to
create the interior contours of the casting. They are typically made of a sand mixture- sand
combined with water and organic adhesives called binders- baked to form the core. This allows
the cores to be strong yet collapsible, so they so that be easily removed from the finished
casting. Since cores are made in molds, they require a pattern and mold, called a core box. The
core pattern is made in the same fashion as the casting pattern, but the core box is created from
a durable material like metal or wood. Since the cores are made of sand, the moldcannot also be
made of sand.

1.3.3 Molding
Molding is the multi-step process in which molds are created. In horizontal casting, the mold
is contained in a two-piece frame, called a flask. The upper portion of the flask is called a cope
and the lower portion is a drag. First, molding sand is packed into a flask around the pattern.
After the pattern is removed, gating and runner arrangements are positioned in the drag half of
the mold cavity and the sprue is placed the cope portion. Gating systems are necessary for the
molten metal to flow into the mold cavity. Cores are also placed in the drag portion of the mold

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Manufacturing Processes-I
NED University of Engineering & Technology - Department of Mechanical Engineering

if they are needed. To finish the mold, the cope (top) section is placed on the drag (bottom)
section, and the mold is closed and clamped together.

1.3.4 Melting & Pouring

Melting is the preparation of the metal for casting, and its conversion from a solid to a liquid
state in a furnace. It is then transferred in a ladle to the molding area of the foundry where it is
poured into the molds. After the metal has solidified, the molds are vibrated to remove the sand
from the casting, a process called shakeout.

1.3.5 Cleaning
Cleaning generally refers to the removal of all materials that are not part of the finished casting.
Rough cleaning is the removal of the gating systems from the casting. Initial finishing removes
any residual mold or core sand that remains on the piece after it is free of the mold. Trimming
removes any superfluous metal. In the last stages of finishing, the surface of the casting is
cleaned for improved appearance. In addition, at this point, the casting is inspected for defects
and adherence to quality standards. This inspection may include nondestructive testing to
determine whether the part will adequately perform for its intended use.

1.3.6 Sprues and Runners

The molten material is poured in the pouring cup, which is part of the gating system that
supplies the molten material to the mold cavity. The vertical part of the gating system connected
to the pouring cup is the sprue, and the horizontal portion is called the runners and finally to
the multiple points where it is introduced to the mold cavity called the gates. Additionally, there
are extensions to the gating system called vents that provide the path for the built-up gasesand
the displaced air to vent to the atmosphere.
The cavity is usually made oversize to allow for the metal contraction as it cools down to room
temperature. This is achieved by making the pattern oversize. To account for shrinking, the
pattern must be made oversize by these factors, on the average. These are linear factors and
apply in each direction. These shrinkage allowances are only approximate, because the exact
allowance is determined the shape and size of the casting. In addition, different parts of the
casting might require a different shrinkage allowance.

1.4 PROCEDURE
Make a mold in sand with the help of pattern. Put the solid material in the crucible. With the
help of tong place the crucible inside the furnace. Set the temperature and turn on the furnace.
When the required temperature is reached wait for required time. Take out the crucible with
the help of tong and pour the molten metal into the mold cavity. Clean the newly cast specimen.

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Manufacturing Processes-I
NED University of Engineering & Technology - Department of Mechanical Engineering

Fig 1.1 Typical Components of Sand-Casting Mold

1.5 QUESTIONS
1. If pure aluminum was used in your lab, what was the pouring temperature of aluminum

2. Based on the pouring temperature calculate the total heat supplied to the
aluminum
3. What was the length of the down sprue _ cm.
4. What would be the velocity of molten aluminum at the base of the sprue .
5. Depending upon the area of sprue at its base, calculate the volumetric flow rate .

04
 NED University of Engineering & Technology F/OBEM 01/07/00
Department of Mechanical Engineering

Course Code & Title: ME-220 Manufacturing Processes-I

Psychomotor Domain Assessment Rubric-Level P3

Extent of Achievement
Skill Sets
0 1 2 3 4
Equipment Identification Not able to identify -- -- -- Able to identify
Sensory skill to identify the equipment. equipment as well
equipment and/or its as its components.
component for a lab work.
Equipment Use Doesn't Slightly Somewhat Moderately demon Fully
Sensory skills to demonstrate the demonstrates the demonstrates the strates the use of demonstrates the
demonstrate the use of the use of equipment. use of equipment. use of equipment. equipment. use of equipment.
equipment for the lab
work.
Procedural Skills Not able to either Able to slightly Able to somewhat Able to moderately Able to fully
Displays skills to act upon learn or perform understand lab understand lab understand lab understand lab
sequence of steps in lab lab work work procedure work procedure work procedure work procedure
work. procedure. and perform lab and perform lab and perform lab and perform lab
work. work. work. work.
Response Not able to imitate Able to slightly Able to somewhat Able to moderately Able to fully
Ability to imitate the lab the lab work. imitate the lab imitate the lab imitate the lab imitate the lab
work on his/her own. work. work. work. work.
Observation’s Use Not able to use Slightly able to Somewhat able to Moderately able to Fully able to use
Displays skills to use the the observations use the use the use the the observations
observations from lab from lab work for observations observations from observations from from lab work for
work for experimental experimental from lab work for lab work for lab work for experimental
verifications and verifications and experimental experimental experimental verifications and
illustrations. illustrations. verifications and verifications and verifications and illustrations.
illustrations. illustrations. illustrations.
Safety Adherence Doesn’t adhere to Slightly adheres Somewhat Moderately adheres Fully adheres to
Adherence to safety safety procedures. to safety adheres to safety to safety safety procedures.
procedures. procedures. procedures. procedures.
Equipment Handling Doesn’t handle Rarely handles Occasionally Often handles Handles
Equipment care during the equipment with equipment with handles equipment with equipment with
use. required care. required care. equipment with required care. required care.
required care.
Group Work Doesn't Slightly Somewhat Moderately Fully participates
Contributes in a group participate and participates and participates and participates and and contributes.
based lab work. contribute. contributes. contributes. contributes.

Laboratory Session No. _____________ Date: ______________________

Weighted CLO (Psychomotor Score)

Remarks

Instructor’s Signature with Date:

05
 F/OBEM 01/07/00

NED University of Engineering & Technology

Department of Mechanical Engineering

Course Code & Title: ME-220 Manufacturing Processes-I

PLO 6 The Engineer and Society – Rubric for Affective Domain Assessment (A-4)
Level of Attainment
Criterion 0 1 2 3 4
Acknowledges responsibilities Doesn’t acknowledge Partially acknowledges Fairly acknowledges Satisfactorily acknowledges Fully acknowledges
and attitudes, relevant to responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes,
practice of engineering relevant to practice of relevant to practice of relevant to practice of relevant to practice of relevant to practice of
including; societal, health, engineering including; engineering including; engineering including; engineering including; engineering including;
safety, legal and cultural societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal
issues. and cultural issues. and cultural issues. and cultural issues. and cultural issues. and cultural issues.
Doesn’t practice Partially practices Fairly practices Satisfactorily practices Fully practices
Practices responsibilities and
responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes,
attitudes, relevant to practice
relevant to practice of relevant to practice of relevant to practice of relevant to practice of relevant to practice of
of engineering including;
engineering including; engineering including; engineering including; engineering including; engineering including;
societal, health, safety, legal
societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal
and cultural issues.
and cultural issues. and cultural issues. and cultural issues. and cultural issues. and cultural issues.
Doesn’t value Partially values Fairly values responsibilities Satisfactorily values Fully values responsibilities
Values responsibilities and
responsibilities and attitudes, responsibilities and attitudes, and attitudes, relevant to responsibilities and attitudes, and attitudes, relevant to
attitudes, relevant to practice
relevant to practice of relevant to practice of practice of engineering relevant to practice of practice of engineering
of engineering including;
engineering including; engineering including; including; societal, health, engineering including; including; societal, health,
societal, health, safety, legal
societal, health, safety, legal societal, health, safety, legal safety, legal and cultural societal, health, safety, legal safety, legal and cultural
and cultural issues.
and cultural issues. and cultural issues. issues. and cultural issues. issues.
Doesn’t display Partially displays Fairly displays Satisfactorily displays Fully displays
Displays responsibilities and
responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes,
attitudes, relevant to practice
relevant to practice of relevant to practice of relevant to practice of relevant to practice of relevant to practice of
of engineering including;
engineering including; engineering including; engineering including; engineering including; engineering including;
societal, health, safety, legal
societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal
and cultural issues.
and cultural issues. and cultural issues. and cultural issues. and cultural issues. and cultural issues.

Student’s Name: ___________________ Seat No.: _____________ Assignment Title: ______________________________

Total Score = ___________________________ Weighted Score (%) = _____________________
Instructor’s Signature: ____________________
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Manufacturing Processes-I
NED University of Engineering & Technology - Department of Mechanical Engineering

EXPERIMENT 2
2.1 OBJECTIVE
To carry out cold rolling of non-ferrous metal and study its effect on properties
2.1 APPARATUS
Mini rolling mill, nonferrous metal, hardness tester, Metallurgical microscope
2.2 THEORY
Cold rolling is a process by which the sheet metal or strip stock is introduced between rollers
and then compressed and squeezed. Cold rolling is done below recrystallization temperature.
After cold working its grains are in a distorted condition. Plastic deformation or cold working
affects all the properties of a metal that are dependent on the lattice structure. The amount of
strain introduced determines the hardness and other material properties of the finished product.
By cold rolling tensile strength, yield strength and hardness are increased, while ductility is
decreased. Distortion of the lattice structure hinders the passage of electrons and decreases
electrical conductivity in alloys. The increase in internal energy, particularly at the grain
boundaries, makes the material more susceptible to inter granular corrosion, thereby reducing
its corrosion resistance.
The advantages of cold rolling are good dimensional accuracy and surface finish. However
more power is required in cold rolling to deform higher strength starting material and overcome
the additional resistance caused by strain hardening

Fig. 2.1 Schematic diagram of rolling process

Cold rolled sheet can be produced in various conditions such as skin-rolled, quarter hard, half
hard, full hard depending on how much cold work has been performed. This cold working
(hardness) is often called temper, although this has nothing to do with heat treatment temper.
2.3 PROCEDURE
Take the hardness of the material before rolling. Set the gap between the two rollers with the
help of the adjusting knob. Turn ON the mini rolling mill. Enter the material from the inlet side

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NED University of Engineering & Technology - Department of Mechanical Engineering

of the roller and collect the rolled material from the other side. Again, measure the hardness of
the rolled metal. The procedure is repeated at different reduction percentages.
2.4 OBSERVATIONS

Material used: , Flow stress (K):

Initial dimensions: Thickness: , Width: , Length: .

Thickness Width Length

Initial

Final

Table 2.1 Observation

2.5 QUESTIONS

1. The reduction ratio was:

2. Prove that volume was constant:
3. Determine the true strain:
4. Calculate The approximate rolling force:
5. Maximum draft possible in a single draft was:
6. Determine the contact length:
7. The torque exerted by each roll was:

08
 F/OBEM 01/05/00
NED University of Engineering & Technology
Department of Mechanical Engineering

Course Code & Title: ME-220 Manufacturing Processes-I

Psychomotor Domain Assessment Rubric-Level P3

Extent of Achievement
Skill Sets
0 1 2 3 4
Equipment Identification Not able to identify -- -- -- Able to identify
Sensory skill to identify the equipment. equipment as well
equipment and/or its as its components.
component for a lab work.
Equipment Use Doesn't Slightly Somewhat Moderately demon Fully
Sensory skills to demonstrate the demonstrates the demonstrates the strates the use of demonstrates the
demonstrate the use of the use of equipment. use of equipment. use of equipment. equipment. use of equipment.
equipment for the lab
work.
Procedural Skills Not able to either Able to slightly Able to somewhat Able to moderately Able to fully
Displays skills to act upon learn or perform understand lab understand lab understand lab understand lab
sequence of steps in lab lab work work procedure work procedure work procedure work procedure
work. procedure. and perform lab and perform lab and perform lab and perform lab
work. work. work. work.
Response Not able to imitate Able to slightly Able to somewhat Able to moderately Able to fully
Ability to imitate the lab the lab work. imitate the lab imitate the lab imitate the lab imitate the lab
work on his/her own. work. work. work. work.
Observation’s Use Not able to use Slightly able to Somewhat able to Moderately able to Fully able to use
Displays skills to use the the observations use the use the use the the observations
observations from lab from lab work for observations observations from observations from from lab work for
work for experimental experimental from lab work for lab work for lab work for experimental
verifications and verifications and experimental experimental experimental verifications and
illustrations. illustrations. verifications and verifications and verifications and illustrations.
illustrations. illustrations. illustrations.
Safety Adherence Doesn’t adhere to Slightly adheres Somewhat Moderately adheres Fully adheres to
Adherence to safety safety procedures. to safety adheres to safety to safety safety procedures.
procedures. procedures. procedures. procedures.
Equipment Handling Doesn’t handle Rarely handles Occasionally Often handles Handles
Equipment care during the equipment with equipment with handles equipment with equipment with
use. required care. required care. equipment with required care. required care.
required care.
Group Work Doesn't Slightly Somewhat Moderately Fully participates
Contributes in a group participate and participates and participates and participates and and contributes.
based lab work. contribute. contributes. contributes. contributes.

Laboratory Session No. _____________ Date: ______________________

Weighted CLO (Psychomotor Score)

Remarks

Instructor’s Signature with Date:

09
Manufacturing Processes-I
NED University of Engineering & Technology - Department of Mechanical Engineering

EXPERIMENT 3
3.1 OBJECTIVE
To carry out injection molding of plastics using hand operated injection molding machine
3.2 APPARATUS
Injection molding machine, die, plastic granules
3.3 THEORY
Injection molding is one of the most important processing methods used for forming
thermoplastic materials. The modern injection-molding machine utilizes a reciprocating screw
mechanism for melting the plastic and injecting it into a mold. Older type injection molding
machines use a plunger for melt injection. One of the main advantages of the reciprocating
screw method over plunger type is that the screw drive delivers a more homogeneous melt for
injection.
In injection molding process plastic granules from a hopper is fed through an opening in the
injection cylinder onto the surface of a rotating screw drive, which carries them forward toward
the mold. The rotation of the screw forces the granules against the heated wall of the cylinder,
causing them to melt due to the heat of compression, friction, and the hot walls of the cylinder.
When sufficient plastic is melted at the mold end of the screw, the screw stops and by plunger
like motion injects a “shot” of melted plastic through a runner gate system and then into the
closed mold cavities.
3.3.1 Advantages
 High quality parts can be produced at a high production rate.
 The process has relatively low labor cost.
 Good surface finishes can be produced on molded part.
 The process can be highly automated
 Intricate shapes can be produced.
3.3.2 Disadvantages
High cost of the machine means that a large volume of parts must be made to pay for the
machine. The process must be closely controlled to produce a quality product.

3.4 PROCEDURE
Pour required quantity of plastic granules inside the hopper of injection molding machine. Place
the mold just below the cylinder such that exiting hole of the cylinder match with the entering
hole of the die. Turn on the machine. As temperature rises and reaches to the meltingpoint of
the plastic it starts melting. Pressure is applied manually so that the melted plastic enters the
mold and acquires the engraved shape. Then mold is removed from the molding machine and
parts are ejected from the die.

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Manufacturing Processes-I
NED University of Engineering & Technology - Department of Mechanical Engineering

3.5 RESULT

3.6 QUESTIONS

1. The injection molding is generally done for .

2. Main advantages of injection molding by the reciprocating screw method over plunger type
is
.
3. Injection molding machine used in the experiment is .
4. Write the name of various types of thermoplastics .
5. Which type of plastic is reusable .
6. The operating current and voltage are and respectively.

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 F/OBEM 01/05/00
NED University of Engineering & Technology
Department of Mechanical Engineering

Course Code & Title: ME-220 Manufacturing Processes-I

Psychomotor Domain Assessment Rubric-Level P3

Extent of Achievement
Skill Sets
0 1 2 3 4
Equipment Identification Not able to identify -- -- -- Able to identify
Sensory skill to identify the equipment. equipment as well
equipment and/or its as its components.
component for a lab work.
Equipment Use Doesn't Slightly Somewhat Moderately demon Fully
Sensory skills to demonstrate the demonstrates the demonstrates the strates the use of demonstrates the
demonstrate the use of the use of equipment. use of equipment. use of equipment. equipment. use of equipment.
equipment for the lab
work.
Procedural Skills Not able to either Able to slightly Able to somewhat Able to moderately Able to fully
Displays skills to act upon learn or perform understand lab understand lab understand lab understand lab
sequence of steps in lab lab work work procedure work procedure work procedure work procedure
work. procedure. and perform lab and perform lab and perform lab and perform lab
work. work. work. work.
Response Not able to imitate Able to slightly Able to somewhat Able to moderately Able to fully
Ability to imitate the lab the lab work. imitate the lab imitate the lab imitate the lab imitate the lab
work on his/her own. work. work. work. work.
Observation’s Use Not able to use Slightly able to Somewhat able to Moderately able to Fully able to use
Displays skills to use the the observations use the use the use the the observations
observations from lab from lab work for observations observations from observations from from lab work for
work for experimental experimental from lab work for lab work for lab work for experimental
verifications and verifications and experimental experimental experimental verifications and
illustrations. illustrations. verifications and verifications and verifications and illustrations.
illustrations. illustrations. illustrations.
Safety Adherence Doesn’t adhere to Slightly adheres Somewhat Moderately adheres Fully adheres to
Adherence to safety safety procedures. to safety adheres to safety to safety safety procedures.
procedures. procedures. procedures. procedures.
Equipment Handling Doesn’t handle Rarely handles Occasionally Often handles Handles
Equipment care during the equipment with equipment with handles equipment with equipment with
use. required care. required care. equipment with required care. required care.
required care.
Group Work Doesn't Slightly Somewhat Moderately Fully participates
Contributes in a group participate and participates and participates and participates and and contributes.
based lab work. contribute. contributes. contributes. contributes.

Laboratory Session No. _____________ Date: ______________________

Weighted CLO (Psychomotor Score)

Remarks

Instructor’s Signature with Date:

12
Manufacturing Processes-I
NED University of Engineering & Technology - Department of Mechanical Engineering

EXPERIMENT 4
4.1 OBJECTIVE
To perform the Electric Arc Welding for butt joint & Corner Joint using mild steel electrode
4.2 APPARATUS
Electric arc welding machine
4.3 THEORY
Arc welding
The term arc welding applies to a large and varied group of processes that use an electric arc
as the source of heat to melt and join metals. In arc welding processes, the joining of metals or
weld is produced by the extreme heat of an electric arc drawn between an electrode and the
work piece. The arc is struck between the work piece and an electrode that is mechanically or
manually moved along the joint. The metal wire not only carried the welding current, but as it
melted in the arc, it also supplied the necessary filler.
All arc-welding process employs the same basic circuit. If distinct current is used and the work
is made positive (the anode of the circuit), the condition is known as straight polarity. When
the cork is negative & the electrode is positive, reverse polarity is employed.

In one large group of arc welding process, the electrode is consumed (consumable electrode
pressure) and thus supplies the metal needed to fill the voids in the joints. Consumable
electrodes have a melting temperature below the temperature of the arc. Small droplets are
melted from the end of the electrode and pass to work piece. The size of these droplets varies
greatly and the mechanism of the transfer depends on the type of electrode welding current and
other process parameters. As the electrode melts, the arc length and the electrical resistances
of the arc path will vary. To maintain a stable arc and satisfactory welding condition, the
electrode must be towards the work at controlled rate. Manual arc welding is almost always
performed with shielded electrodes.
Continuous bare-metal wire can be used as the electrode in automatic or semiautomatic arc
welding, but this is always in conjunction with a separate shielding and arc stabilizing medium
and automatic feed controlling devices that maintain the proper arc length.
Because of the wide variety of processes available, arc welding has become a widely used
means of joining material. Each process and application however require the selections and
specification of the welding voltage, welding current, arc polarity, arc length, welding speed,
arc atmosphere, electrodes or filler metal and flux. Filler materials must be selected to match
the base metal with respect to properties and / or alloy content. For many of the processes, the
quality of the weld also depends on the strikes of the operator.
Type of joint
There are five basic types of joints for bringing two members together for welding. These
joint types or deigns are also used by other skilled trades:
1. B, Butt joint - parts in approximately the same plane.
2. C, Corner joint – parts are approximately right angle and at the edge of both parts.

13
Manufacturing Processes-I
NED University of Engineering & Technology - Department of Mechanical Engineering

3. L, Lap joint – between overlapping parts.

4. T, T joint - parts are approximately right angles, not at the edge of one part.
5. E, Edge joint – an edge of two or more parallel parts.

Fig. 4.1 Types of weld joints

Welding positions
General
Welding is often done on structures in position in which they are found. Techniques have been
developed to allow welding in any position. Some welding processes have all-position
capabilities, while others may be used in only one or two positions. All welding can be
classified according to the position of the work piece ·or the position of the welded joint on the
plates or sections being welded. There are four basic welding positions, which are illustrated
in figure.

Fig. 4.2 Welding positions

Flat position welding
In this position, the welding is performed on the upper side of the joint, and the face of the
weld is approximately horizontal. Flat welding is the preferred term; however, the same
position is sometimes called down hand.
Horizontal position welding
Fillet weld
In this position, welding is performed on the upper side of an approximately horizontal
surface and against an approximately vertical surface.
Groove weld
In this position, the axis of the weld lies in an approximately horizontal plane and the face of
the weld lies in an approximately vertical plane

15
Manufacturing Processes-I
NED University of Engineering & Technology - Department of Mechanical Engineering

Horizontal fixed weld

In this pipe welding position, the axis of the pipe is approximately horizontal, and the pipe is
not rotated during welding.
Horizontal rolled weld
In this pipe welding position, welding is performed in the flat position by rotating the pipe.
Vertical position welding
a. In this position, the axis of the weld is approximately vertical. Vertical welding positions.
b. In vertical position pipe welding, the axis of the pipe is vertical, and the welding is
performed in the horizontal position.
Overhead position welding
In this welding position, the welding is performed from the underside of a joint.
Covered Electrodes
When molten metal is exposed to air, it absorbs oxygen and nitrogen, and becomes brittle or is
other was adversely affected. A slag cover is needed to protect molten or solidifying weld metal
from the atmosphere. This cover can be obtained from the electrode coating. The composition
of the electrode coating determines its usability, as well as the composition of the deposited
weld metal and the electrodes specification. The formulation of electrode coatings is based on
well-established principle of metallurgy, chemistry, and physics. The coating protects the metal
from damage, stabilizes the arc, and improves the weld in other ways, which includes.
1. The smooth weld metal surface with even edges.
2. Minimum spatter adjacent to the weld.
3. A stable welding arc.
4. Penetration control.
5. A strong, tough coating.
6. Easier slag removal.
7. Improve deposition rate.
The type of electrode used depends upon the specific properties req. in the weld deposited.
These include corrosion, resistance, ductility, high tensile strength, the type of base metal to be
welded, the position of the weld (flat, horizontal, vertical, or overhead); and the type of current
and polarity required.
4.4 REVIEW QUESTIONS
Q1. Explain the basic principles of Arc Welding process?

Q2. Describe the functions and characteristics of electrodes. What functions do coatings
have?

Q3. Explain E6013

Q4. Enlist and briefly explain the arc-welding processes that do not use consumable
electrodes.

15
 F/OBEM 01/05/00
NED University of Engineering & Technology
Department of Mechanical Engineering

Course Code & Title: ME-220 Manufacturing Processes-I

Psychomotor Domain Assessment Rubric-Level P3

Extent of Achievement
Skill Sets
0 1 2 3 4
Equipment Identification Not able to identify -- -- -- Able to identify
Sensory skill to identify the equipment. equipment as well
equipment and/or its as its components.
component for a lab work.
Equipment Use Doesn't Slightly Somewhat Moderately demon Fully
Sensory skills to demonstrate the demonstrates the demonstrates the strates the use of demonstrates the
demonstrate the use of the use of equipment. use of equipment. use of equipment. equipment. use of equipment.
equipment for the lab
work.
Procedural Skills Not able to either Able to slightly Able to somewhat Able to moderately Able to fully
Displays skills to act upon learn or perform understand lab understand lab understand lab understand lab
sequence of steps in lab lab work work procedure work procedure work procedure work procedure
work. procedure. and perform lab and perform lab and perform lab and perform lab
work. work. work. work.
Response Not able to imitate Able to slightly Able to somewhat Able to moderately Able to fully
Ability to imitate the lab the lab work. imitate the lab imitate the lab imitate the lab imitate the lab
work on his/her own. work. work. work. work.
Observation’s Use Not able to use Slightly able to Somewhat able to Moderately able to Fully able to use
Displays skills to use the the observations use the use the use the the observations
observations from lab from lab work for observations observations from observations from from lab work for
work for experimental experimental from lab work for lab work for lab work for experimental
verifications and verifications and experimental experimental experimental verifications and
illustrations. illustrations. verifications and verifications and verifications and illustrations.
illustrations. illustrations. illustrations.
Safety Adherence Doesn’t adhere to Slightly adheres Somewhat Moderately adheres Fully adheres to
Adherence to safety safety procedures. to safety adheres to safety to safety safety procedures.
procedures. procedures. procedures. procedures.
Equipment Handling Doesn’t handle Rarely handles Occasionally Often handles Handles
Equipment care during the equipment with equipment with handles equipment with equipment with
use. required care. required care. equipment with required care. required care.
required care.
Group Work Doesn't Slightly Somewhat Moderately Fully participates
Contributes in a group participate and participates and participates and participates and and contributes.
based lab work. contribute. contributes. contributes. contributes.

Laboratory Session No. _____________ Date: ______________________

Weighted CLO (Psychomotor Score)

Remarks

Instructor’s Signature with Date:

16
 F/OBEM 01/07/00
NED University of Engineering & Technology
Department of Mechanical Engineering

Course Code & Title: ME-220 Manufacturing Processes-I

PLO 6 The Engineer and Society – Rubric for Affective Domain Assessment (A-4)
Level of Attainment
Criterion 0 1 2 3 4
Acknowledges responsibilities Doesn’t acknowledge Partially acknowledges Fairly acknowledges Satisfactorily acknowledges Fully acknowledges
and attitudes, relevant to responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes,
practice of engineering relevant to practice of relevant to practice of relevant to practice of relevant to practice of relevant to practice of
including; societal, health, engineering including; engineering including; engineering including; engineering including; engineering including;
safety, legal and cultural societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal
issues. and cultural issues. and cultural issues. and cultural issues. and cultural issues. and cultural issues.
Doesn’t practice Partially practices Fairly practices Satisfactorily practices Fully practices
Practices responsibilities and
responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes,
attitudes, relevant to practice
relevant to practice of relevant to practice of relevant to practice of relevant to practice of relevant to practice of
of engineering including;
engineering including; engineering including; engineering including; engineering including; engineering including;
societal, health, safety, legal
societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal
and cultural issues.
and cultural issues. and cultural issues. and cultural issues. and cultural issues. and cultural issues.
Doesn’t value Partially values Fairly values responsibilities Satisfactorily values Fully values responsibilities
Values responsibilities and
responsibilities and attitudes, responsibilities and attitudes, and attitudes, relevant to responsibilities and attitudes, and attitudes, relevant to
attitudes, relevant to practice
relevant to practice of relevant to practice of practice of engineering relevant to practice of practice of engineering
of engineering including;
engineering including; engineering including; including; societal, health, engineering including; including; societal, health,
societal, health, safety, legal
societal, health, safety, legal societal, health, safety, legal safety, legal and cultural societal, health, safety, legal safety, legal and cultural
and cultural issues.
and cultural issues. and cultural issues. issues. and cultural issues. issues.
Doesn’t display Partially displays Fairly displays Satisfactorily displays Fully displays
Displays responsibilities and
responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes,
attitudes, relevant to practice
relevant to practice of relevant to practice of relevant to practice of relevant to practice of relevant to practice of
of engineering including;
engineering including; engineering including; engineering including; engineering including; engineering including;
societal, health, safety, legal
societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal
and cultural issues.
and cultural issues. and cultural issues. and cultural issues. and cultural issues. and cultural issues.

Student’s Name: ___________________ Seat No.: _____________ Assignment Title: ______________________________

Total Score = ___________________________ Weighted Score (%) = _____________________

Instructor’s Signature: ____________________

17
Manufacturing Processes-I
NED University of Engineering & Technology - Department of Mechanical Engineering

EXPERIMENT 5
5.1 OBJECTIVE
To perform the Electric Arc Welding for Lap joint & T Joint using mild steel electrode
5.2 APPARATUS
Electric Arc machine
5.3 THEORY
E6013 Mild steel electrode
Description:
E6013 has fast freeze characteristics that make it the perfect choice for welding applications
that have poor fit-up conditions. This electrode produces a very stable arc with good weld bead
appearance. E6013 is an excellent choice for sheet metal welding, general purpose fabrication,
machine parts, metal buildings, and shaft build-up.
Features
 Excellent arc stability
 Fast-freeze
 Slag removes easily
 All-position
Benefits
 Welding accuracy and efficiency
 Excellent for poor fit-up

Type of current:
Direct Current Electrode Positive (DCEP), AC, or Direct Current Electrode Negative
(DCEN)

Diameters: 3.2 mm

Recommended welding techniques

Arc Length - Average length (1/8” to 1/4”)
Flat - Angle electrodes 10-15° from 90° with higher heat than E6011 electrodes
Vertical Up - Reduce amperage from flat position
Vertical Down - Use higher amperage and faster travel, staying ahead of puddle
Overhead - Use slight whipping motion, multi-pass for build-up

Chemical composition of melting metal (%)

C Mn Si S P
≤ 0.12 ≤ 1.60 ≤ 0.75 ≤ 0.035 ≤ 0.040

18
Manufacturing Processes-I
NED University of Engineering & Technology - Department of Mechanical Engineering

Table 5.1 Welding electrode classification.

(Ref. Specification for carbon steel electrodes. American welding society, AWS -A-5.1 )
5.4 REVIEW QUESTIONS
1. Using the above table, what is the coating on your electrode?

2. What is the tensile strength of the material you are depositing?

3. Differentiate between DCEP and DCEN.

19
 F/OBEM 01/05/00
NED University of Engineering & Technology
Department of Mechanical Engineering

Course Code & Title: ME-220 Manufacturing Processes-I

Psychomotor Domain Assessment Rubric-Level P3

Extent of Achievement
Skill Sets
0 1 2 3 4
Equipment Identification Not able to identify -- -- -- Able to identify
Sensory skill to identify the equipment. equipment as well
equipment and/or its as its components.
component for a lab work.
Equipment Use Doesn't Slightly Somewhat Moderately demon Fully
Sensory skills to demonstrate the demonstrates the demonstrates the strates the use of demonstrates the
demonstrate the use of the use of equipment. use of equipment. use of equipment. equipment. use of equipment.
equipment for the lab
work.
Procedural Skills Not able to either Able to slightly Able to somewhat Able to moderately Able to fully
Displays skills to act upon learn or perform understand lab understand lab understand lab understand lab
sequence of steps in lab lab work work procedure work procedure work procedure work procedure
work. procedure. and perform lab and perform lab and perform lab and perform lab
work. work. work. work.
Response Not able to imitate Able to slightly Able to somewhat Able to moderately Able to fully
Ability to imitate the lab the lab work. imitate the lab imitate the lab imitate the lab imitate the lab
work on his/her own. work. work. work. work.
Observation’s Use Not able to use Slightly able to Somewhat able to Moderately able to Fully able to use
Displays skills to use the the observations use the use the use the the observations
observations from lab from lab work for observations observations from observations from from lab work for
work for experimental experimental from lab work for lab work for lab work for experimental
verifications and verifications and experimental experimental experimental verifications and
illustrations. illustrations. verifications and verifications and verifications and illustrations.
illustrations. illustrations. illustrations.
Safety Adherence Doesn’t adhere to Slightly adheres Somewhat Moderately adheres Fully adheres to
Adherence to safety safety procedures. to safety adheres to safety to safety safety procedures.
procedures. procedures. procedures. procedures.
Equipment Handling Doesn’t handle Rarely handles Occasionally Often handles Handles
Equipment care during the equipment with equipment with handles equipment with equipment with
use. required care. required care. equipment with required care. required care.
required care.
Group Work Doesn't Slightly Somewhat Moderately Fully participates
Contributes in a group participate and participates and participates and participates and and contributes.
based lab work. contribute. contributes. contributes. contributes.

Laboratory Session No. _____________ Date: ______________________

Weighted CLO (Psychomotor Score)

Remarks

Instructor’s Signature with Date:

20
 F/OBEM 01/07/00
NED University of Engineering & Technology
Department of Mechanical Engineering

Course Code & Title: ME-220 Manufacturing Processes-I

PLO 6 The Engineer and Society – Rubric for Affective Domain Assessment (A-4)
Level of Attainment
Criterion 0 1 2 3 4
Acknowledges responsibilities Doesn’t acknowledge Partially acknowledges Fairly acknowledges Satisfactorily acknowledges Fully acknowledges
and attitudes, relevant to responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes,
practice of engineering relevant to practice of relevant to practice of relevant to practice of relevant to practice of relevant to practice of
including; societal, health, engineering including; engineering including; engineering including; engineering including; engineering including;
safety, legal and cultural societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal
issues. and cultural issues. and cultural issues. and cultural issues. and cultural issues. and cultural issues.
Doesn’t practice Partially practices Fairly practices Satisfactorily practices Fully practices
Practices responsibilities and
responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes,
attitudes, relevant to practice
relevant to practice of relevant to practice of relevant to practice of relevant to practice of relevant to practice of
of engineering including;
engineering including; engineering including; engineering including; engineering including; engineering including;
societal, health, safety, legal
societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal
and cultural issues.
and cultural issues. and cultural issues. and cultural issues. and cultural issues. and cultural issues.
Doesn’t value Partially values Fairly values responsibilities Satisfactorily values Fully values responsibilities
Values responsibilities and
responsibilities and attitudes, responsibilities and attitudes, and attitudes, relevant to responsibilities and attitudes, and attitudes, relevant to
attitudes, relevant to practice
relevant to practice of relevant to practice of practice of engineering relevant to practice of practice of engineering
of engineering including;
engineering including; engineering including; including; societal, health, engineering including; including; societal, health,
societal, health, safety, legal
societal, health, safety, legal societal, health, safety, legal safety, legal and cultural societal, health, safety, legal safety, legal and cultural
and cultural issues.
and cultural issues. and cultural issues. issues. and cultural issues. issues.
Doesn’t display Partially displays Fairly displays Satisfactorily displays Fully displays
Displays responsibilities and
responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes,
attitudes, relevant to practice
relevant to practice of relevant to practice of relevant to practice of relevant to practice of relevant to practice of
of engineering including;
engineering including; engineering including; engineering including; engineering including; engineering including;
societal, health, safety, legal
societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal
and cultural issues.
and cultural issues. and cultural issues. and cultural issues. and cultural issues. and cultural issues.
Student’s Name: ___________________ Seat No.: _____________ Assignment Title: ______________________________

Total Score = ___________________________ Weighted Score (%) = _____________________

Instructor’s Signature: ____________________

21
Manufacturing Processes-I
NED University of Engineering & Technology - Department of Mechanical Engineering

EXPERIMENT 6
6.1 OBJECTIVE
To perform the Electric Arc Welding Edge Joint of cast iron using iron powder electrode
6.2 APPARATUS
Electric Arc machine
6.3 THEORY
E7018 Mild steel electrode
Description:
E7018/E7018-1 is a high deposition rate iron powder electrode designed for DC reverse
polarity or AC operation in all positions. It provides excellent operator appeal with a quiet arc,
minimal spatter, and good restrike capabilities. It offers good slag removal and an easily
controlled weld puddle that allows outstanding ease when welding in either the vertical or
overhead position. E7018/E7018-1 is an excellent choice for out-of-position tacking, welding
low alloy structural, steel structures, field erections, offshore rigs, and power plants.
Features
 Excellent starts and restarts
 Extra low moisture
 Stable arc
 Low spatter
Benefits
 Great for tacking, increases productivity
 Prevents starting porosity
 Easy to control, operates well in all positions
 Easy clean up

Type of current: Direct Current Electrode Positive (DCEP) or AC

Diameters: 3/32”, 1/8”, 5/32”, 3/16”, 7/32”, 1/4”
Recommended welding techniques:
Arc Length - Very short (less than half the diameter of the electrode)
Flat - Angle electrode 10-15° from 90°
Horizontal - Angle electrode slightly toward top plate
Vertical Up - Use weaving technique
Vertical Down - Not recommended
Overhead - Use slight weaving motion within the puddle

Chemical composition of melting metal (%)

C Mn Si S P Cr Ni S
≤ 0.15 ≤ 1.60 ≤ 0.75 ≤ 0.035 ≤ 0.035 ≤ 0.20 ≤ 0.30 ≤ 0.08

22
Manufacturing Processes-I
NED University of Engineering & Technology - Department of Mechanical Engineering

Table 6.1 Welding electrode classifications

(Ref. Specification for carbon steel electrodes. American welding society, AWS -A-5.1 )
6.4 REVIEW QUESTIONS
Q1. Using the above table, what is the coating on your electrode?

Q2. What is the tensile strength of the material you are depositing?

Q3. Which polarity gives higher rate of deposition?

Q4. Explain E7018

23
 F/OBEM 01/05/00
NED University of Engineering & Technology
Department of Mechanical Engineering

Course Code & Title: ME-220 Manufacturing Processes-I

Psychomotor Domain Assessment Rubric-Level P3

Extent of Achievement
Skill Sets
0 1 2 3 4
Equipment Identification Not able to identify -- -- -- Able to identify
Sensory skill to identify the equipment. equipment as well
equipment and/or its as its components.
component for a lab work.
Equipment Use Doesn't Slightly Somewhat Moderately demon Fully
Sensory skills to demonstrate the demonstrates the demonstrates the strates the use of demonstrates the
demonstrate the use of the use of equipment. use of equipment. use of equipment. equipment. use of equipment.
equipment for the lab
work.
Procedural Skills Not able to either Able to slightly Able to somewhat Able to moderately Able to fully
Displays skills to act upon learn or perform understand lab understand lab understand lab understand lab
sequence of steps in lab lab work work procedure work procedure work procedure work procedure
work. procedure. and perform lab and perform lab and perform lab and perform lab
work. work. work. work.
Response Not able to imitate Able to slightly Able to somewhat Able to moderately Able to fully
Ability to imitate the lab the lab work. imitate the lab imitate the lab imitate the lab imitate the lab
work on his/her own. work. work. work. work.
Observation’s Use Not able to use Slightly able to Somewhat able to Moderately able to Fully able to use
Displays skills to use the the observations use the use the use the the observations
observations from lab from lab work for observations observations from observations from from lab work for
work for experimental experimental from lab work for lab work for lab work for experimental
verifications and verifications and experimental experimental experimental verifications and
illustrations. illustrations. verifications and verifications and verifications and illustrations.
illustrations. illustrations. illustrations.
Safety Adherence Doesn’t adhere to Slightly adheres Somewhat Moderately adheres Fully adheres to
Adherence to safety safety procedures. to safety adheres to safety to safety safety procedures.
procedures. procedures. procedures. procedures.
Equipment Handling Doesn’t handle Rarely handles Occasionally Often handles Handles
Equipment care during the equipment with equipment with handles equipment with equipment with
use. required care. required care. equipment with required care. required care.
required care.
Group Work Doesn't Slightly Somewhat Moderately Fully participates
Contributes in a group participate and participates and participates and participates and and contributes.
based lab work. contribute. contributes. contributes. contributes.

Laboratory Session No. _____________ Date: ______________________

Weighted CLO (Psychomotor Score)

Remarks

Instructor’s Signature with Date:

24
 F/OBEM 01/07/00
NED University of Engineering & Technology
Department of Mechanical Engineering

Course Code & Title: ME-220 Manufacturing Processes-I

PLO 6 The Engineer and Society – Rubric for Affective Domain Assessment (A-4)
Level of Attainment
Criterion 0 1 2 3 4
Acknowledges responsibilities Doesn’t acknowledge Partially acknowledges Fairly acknowledges Satisfactorily acknowledges Fully acknowledges
and attitudes, relevant to responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes,
practice of engineering relevant to practice of relevant to practice of relevant to practice of relevant to practice of relevant to practice of
including; societal, health, engineering including; engineering including; engineering including; engineering including; engineering including;
safety, legal and cultural societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal
issues. and cultural issues. and cultural issues. and cultural issues. and cultural issues. and cultural issues.
Doesn’t practice Partially practices Fairly practices Satisfactorily practices Fully practices
Practices responsibilities and
responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes,
attitudes, relevant to practice
relevant to practice of relevant to practice of relevant to practice of relevant to practice of relevant to practice of
of engineering including;
engineering including; engineering including; engineering including; engineering including; engineering including;
societal, health, safety, legal
societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal
and cultural issues.
and cultural issues. and cultural issues. and cultural issues. and cultural issues. and cultural issues.
Doesn’t value Partially values Fairly values responsibilities Satisfactorily values Fully values responsibilities
Values responsibilities and
responsibilities and attitudes, responsibilities and attitudes, and attitudes, relevant to responsibilities and attitudes, and attitudes, relevant to
attitudes, relevant to practice
relevant to practice of relevant to practice of practice of engineering relevant to practice of practice of engineering
of engineering including;
engineering including; engineering including; including; societal, health, engineering including; including; societal, health,
societal, health, safety, legal
societal, health, safety, legal societal, health, safety, legal safety, legal and cultural societal, health, safety, legal safety, legal and cultural
and cultural issues.
and cultural issues. and cultural issues. issues. and cultural issues. issues.
Doesn’t display Partially displays Fairly displays Satisfactorily displays Fully displays
Displays responsibilities and
responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes,
attitudes, relevant to practice
relevant to practice of relevant to practice of relevant to practice of relevant to practice of relevant to practice of
of engineering including;
engineering including; engineering including; engineering including; engineering including; engineering including;
societal, health, safety, legal
societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal
and cultural issues.
and cultural issues. and cultural issues. and cultural issues. and cultural issues. and cultural issues.

Student’s Name: ___________________ Seat No.: _____________ Assignment Title: ______________________________

Total Score = ___________________________ Weighted Score (%) = _____________________

Instructor’s Signature: ____________________

25
Manufacturing Processes-I
NED University of Engineering & Technology - Department of Mechanical Engineering

EXPERIMENT 7
7.1 OBJECTIVE
To perform the Electric Arc Welding of Stainless steel
7.2 APPARATUS
Electric Arc machine
7.3 THEORY
E308-16 Mild steel electrode
Description:
E308-16/E308H-16 has a nominal composition (wt.-%) of 19.5 Cr and 10 Ni. This electrode
has a restricted carbon content of 0.04%-0.08%. This provides for higher tensile and creep
strengths at elevated temperatures. These electrodes are used for welding Type 304H base
metal as well as similar alloys in wrought or cast form, such as AISI grades 301, 302, 304, and
305. The weld metal ferrite content is normally targeted for 5 FN to minimize the effect of
sigma embrittlement in high-temperature service. This wire features a smooth arc transfer with
very little spatter and easy slag removal. E308-16/E308H-16 is particularly suited for welding
food processing equipment and in petroleum and chemical processing plants.
Features
 Excellent starts and restarts
 Extra low moisture
 Stable arc
 Low spatter
Benefits
 Great for tacking, increases productivity
 Prevents starting porosity
 Easy to control, operates well in all positions
 Easy cleanup

Type of current: Direct Current Electrode Positive (DCEP) or AC

Diameters: 3/32”, 1/8”, 5/32”, 3/16”
Chemical composition:

C Mn Si Mo P Cr Ni S
≤ 0.08 0.5-2.5 ≤ 1.00 ≤ 0.75 ≤ 0.04 ≤ 18.0 ≤ 9.0 ≤ 0.03

26
Manufacturing Processes-I
NED University of Engineering & Technology - Department of Mechanical Engineering

7.4 REVIEW QUESTIONS

Q1. Using the above table, what is the coating on your electrode?

Q2. What is the tensile strength of the material you are depositing?

Q3. Explain E30816

27
 F/OBEM 01/05/00

NED University of Engineering & Technology

Department of Mechanical Engineering

Course Code & Title: ME-220 Manufacturing Processes-I

Psychomotor Domain Assessment Rubric-Level P3

Extent of Achievement
Skill Sets
0 1 2 3 4
Equipment Identification Not able to identify -- -- -- Able to identify
Sensory skill to identify the equipment. equipment as well
equipment and/or its as its components.
component for a lab work.
Equipment Use Doesn't Slightly Somewhat Moderately demon Fully
Sensory skills to demonstrate the demonstrates the demonstrates the strates the use of demonstrates the
demonstrate the use of the use of equipment. use of equipment. use of equipment. equipment. use of equipment.
equipment for the lab
work.
Procedural Skills Not able to either Able to slightly Able to somewhat Able to moderately Able to fully
Displays skills to act upon learn or perform understand lab understand lab understand lab understand lab
sequence of steps in lab lab work work procedure work procedure work procedure work procedure
work. procedure. and perform lab and perform lab and perform lab and perform lab
work. work. work. work.
Response Not able to imitate Able to slightly Able to somewhat Able to moderately Able to fully
Ability to imitate the lab the lab work. imitate the lab imitate the lab imitate the lab imitate the lab
work on his/her own. work. work. work. work.
Observation’s Use Not able to use Slightly able to Somewhat able to Moderately able to Fully able to use
Displays skills to use the the observations use the use the use the the observations
observations from lab from lab work for observations observations from observations from from lab work for
work for experimental experimental from lab work for lab work for lab work for experimental
verifications and verifications and experimental experimental experimental verifications and
illustrations. illustrations. verifications and verifications and verifications and illustrations.
illustrations. illustrations. illustrations.
Safety Adherence Doesn’t adhere to Slightly adheres Somewhat Moderately adheres Fully adheres to
Adherence to safety safety procedures. to safety adheres to safety to safety safety procedures.
procedures. procedures. procedures. procedures.
Equipment Handling Doesn’t handle Rarely handles Occasionally Often handles Handles
Equipment care during the equipment with equipment with handles equipment with equipment with
use. required care. required care. equipment with required care. required care.
required care.
Group Work Doesn't Slightly Somewhat Moderately Fully participates
Contributes in a group participate and participates and participates and participates and and contributes.
based lab work. contribute. contributes. contributes. contributes.

Laboratory Session No. _____________ Date: ______________________

Weighted CLO (Psychomotor Score)

Remarks

Instructor’s Signature with Date:

28
 F/OBEM 01/07/00
NED University of Engineering & Technology
Department of Mechanical Engineering

Course Code & Title: ME-220 Manufacturing Processes-I

PLO 6 The Engineer and Society – Rubric for Affective Domain Assessment (A-4)
Level of Attainment
Criterion 0 1 2 3 4
Acknowledges responsibilities Doesn’t acknowledge Partially acknowledges Fairly acknowledges Satisfactorily acknowledges Fully acknowledges
and attitudes, relevant to responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes,
practice of engineering relevant to practice of relevant to practice of relevant to practice of relevant to practice of relevant to practice of
including; societal, health, engineering including; engineering including; engineering including; engineering including; engineering including;
safety, legal and cultural societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal
issues. and cultural issues. and cultural issues. and cultural issues. and cultural issues. and cultural issues.
Doesn’t practice Partially practices Fairly practices Satisfactorily practices Fully practices
Practices responsibilities and
responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes,
attitudes, relevant to practice
relevant to practice of relevant to practice of relevant to practice of relevant to practice of relevant to practice of
of engineering including;
engineering including; engineering including; engineering including; engineering including; engineering including;
societal, health, safety, legal
societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal
and cultural issues.
and cultural issues. and cultural issues. and cultural issues. and cultural issues. and cultural issues.
Doesn’t value Partially values Fairly values responsibilities Satisfactorily values Fully values responsibilities
Values responsibilities and
responsibilities and attitudes, responsibilities and attitudes, and attitudes, relevant to responsibilities and attitudes, and attitudes, relevant to
attitudes, relevant to practice
relevant to practice of relevant to practice of practice of engineering relevant to practice of practice of engineering
of engineering including;
engineering including; engineering including; including; societal, health, engineering including; including; societal, health,
societal, health, safety, legal
societal, health, safety, legal societal, health, safety, legal safety, legal and cultural societal, health, safety, legal safety, legal and cultural
and cultural issues.
and cultural issues. and cultural issues. issues. and cultural issues. issues.
Doesn’t display Partially displays Fairly displays Satisfactorily displays Fully displays
Displays responsibilities and
responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes,
attitudes, relevant to practice
relevant to practice of relevant to practice of relevant to practice of relevant to practice of relevant to practice of
of engineering including;
engineering including; engineering including; engineering including; engineering including; engineering including;
societal, health, safety, legal
societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal
and cultural issues.
and cultural issues. and cultural issues. and cultural issues. and cultural issues. and cultural issues.
Student’s Name: ___________________ Seat No.: _____________ Assignment Title: ______________________________

Total Score = ___________________________ Weighted Score (%) = _____________________

Instructor’s Signature: ____________________

29
Manufacturing Processes-I
NED University of Engineering & Technology - Department of Mechanical Engineering

EXPERIMENT 8
8.1 OBJECTIVE
To perform the spot welding.

8.2 THEORY
Resistance welding is a process used to join metals with electric current. There are several
forms of resistance welding, including spot welding, seam welding, projection welding, and
butt welding. In all forms of resistance welding, the parts are locally heated until a molten pool
form. The parts are then allowed to cool, and the pool freezes to form a weld nugget. On a
typical machine, the operator has control over the current setting, electrode force and weld time.
To create heat, copper electrodes an electric current through the work pieces. The heat
generated depends on the electrical resistance and thermal conductivity of the metal, and the
time that the current is applied. The heat generated is expressed by the equation.

𝐻 = 𝐼2 × 𝑅 × 𝑡

Where H is the heat energy, r is the current, R is the electrical resistance and t is the time that
the current is applied.
Copper is used for electrodes because it has low resistance and high thermal conductivity. This
ensures that heat is generated in the work piece instead of the electrodes. When the electrodes
are too hot, heat marks on the surface of the work piece can form.
The electrodes are held under controlled force during welding. The amount of force affects the
resistance across the interface’s b/w the work piece and the electrodes. The force is adjusted to
the immediately create heat at the interface b/w the work piece.

Spot welding
A spot weld is made by applying pressure to two pieces of overlapping metal, then passing an
electrical current through a localized contact area, for very specific time period, to heat the area
till a weld nugget form. Force is continued to be applied after the weld time until the weld has
solidified and forged. To minimize heat dissipation the weld is formed very quickly. This
requires very large electrical transformer.

30
Manufacturing Processes-I
NED University of Engineering & Technology - Department of Mechanical Engineering

Fig. 8.1 Spot welding schematic diagram

Using schedules to setup machine

PCT (pressure, current, time) are the factors used to construct a weld schedule. To use the
schedule, you look up the size of the thinnest piece of the metal being welded. Looking acres,
you will see values for the correct amount of force, the proper weld time value, and the amount
of amperage necessary to weld. Also, you will typically see values for electrode diameter,
electrode size and weld strengths.
The relationship b/w the factors can be expressed as:

𝐻 =× 𝐼 2 × 𝑅 × 𝑇 × 𝐾
H = heat R= resistance
I = current T = time

K = heat losses through

Components
The three main components of the welding machine are the control, transformer, and secondary
conductor.
Control
The purpose of the weld control is to accurately time the functions involved ion resistance
welding. The various tasks that timed as squeeze, weld, hold and off.

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Manufacturing Processes-I
NED University of Engineering & Technology - Department of Mechanical Engineering

Transformer

Transformer takes a primary voltage of 220 V and current of 800 amps. and gives off a
secondary amount of 2 - 15 V with a current of 100,000 amps.
Secondary Conductor
This includes everything that is attached to the secondary winding of the transformer. The weld
arms, holders, and tips are all parts of the secondary circuit. We will talk about this later as a
maintenance item.
Procedure and Operation of Equipment
Cooling system should be inspected for flow periodically. An adequate flow would be
approximately 3 to 5 gallons per minute for average size machine being run at a normal duty
cycle (large machine or high duty cycles can necessitate higher flow rates). If you observe a
flow rate significantly below this, maintenance is required. Because many water channels are
very small, a little mineral scale can have a significant impact. Also, water cooled cables tend
to fray and release small pieces of fire into the cooling system. These can accumulate into a
"hair ball" forming blockage. Operators have the best opportunity to spot these problems before
they cause a machine shutdown. Excess heat should always be reported and investigated.
When properly set up resistance welding machines should produce no flash. Weld flash is a
tire hazard and requires that any flammable substances be properly protected. Weld flash is
also an abrasive. Moving parts should be protected from exposure to weld flash whenever
possible. Also, since weld flash is made of metal (steel) it can be conductive. If allowed to
accumulate across platen and fixture insulation, Hash will cause a slow burning, gradually
extending back to inacces5ible areas. Eventually this will interfere with the welding process,
and a major repair and cleaning are called for. Transformers should also be protected from weld
flash. Flash can get in the winding causing a short in the windings.
Electrodes require regular maintenance. The size and shape of the electrode largely determines
the quality of the weld. 'Therefore, it is of primary importance that the weld face remains
constant. Because of this, tips should be frequently changed or dressed. Several dressing
devices are available. They might be air operated cutters or manual files. Electrodes sometime
will "pickup" the material being welded. When this happens, it should be moved as soon as
possible. However, when welding coated materials this pickup continually occurs and it is not
reasonable to clean the electrodes after each weld. Care should be exercised when handling
electrodes that the tip tapers are not damaged. Damaged tapers can cause poor electrical contact
and water leakage. A conductive copper lube should be used on tip tapers to ease in removal
and ensure a good electrical connection

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Manufacturing Processes-I
NED University of Engineering & Technology - Department of Mechanical Engineering

8.3 REVIEW QUESTIONS

Q.1. What are the two major roles of applied pressure in resistance welding?

Q.2. What are the three components that contribute to the total resistance between the
electrodes?

Q.3. What measures can be taken to reduce the resistance between the electrodes and the
work pieces?

Q.4. What are the possible consequences of too little pressure during the cycle? Too much
pressure?

Q.5. What is the typical size of a spot-weld nugget?

33
 F/OBEM 01/05/00
NED University of Engineering & Technology
Department of Mechanical Engineering

Course Code & Title: ME-220 Manufacturing Processes-I

Psychomotor Domain Assessment Rubric-Level P3

Extent of Achievement
Skill Sets
0 1 2 3 4
Equipment Identification Not able to identify -- -- -- Able to identify
Sensory skill to identify the equipment. equipment as well
equipment and/or its as its components.
component for a lab work.
Equipment Use Doesn't Slightly Somewhat Moderately demon Fully
Sensory skills to demonstrate the demonstrates the demonstrates the strates the use of demonstrates the
demonstrate the use of the use of equipment. use of equipment. use of equipment. equipment. use of equipment.
equipment for the lab
work.
Procedural Skills Not able to either Able to slightly Able to somewhat Able to moderately Able to fully
Displays skills to act upon learn or perform understand lab understand lab understand lab understand lab
sequence of steps in lab lab work work procedure work procedure work procedure work procedure
work. procedure. and perform lab and perform lab and perform lab and perform lab
work. work. work. work.
Response Not able to imitate Able to slightly Able to somewhat Able to moderately Able to fully
Ability to imitate the lab the lab work. imitate the lab imitate the lab imitate the lab imitate the lab
work on his/her own. work. work. work. work.
Observation’s Use Not able to use Slightly able to Somewhat able to Moderately able to Fully able to use
Displays skills to use the the observations use the use the use the the observations
observations from lab from lab work for observations observations from observations from from lab work for
work for experimental experimental from lab work for lab work for lab work for experimental
verifications and verifications and experimental experimental experimental verifications and
illustrations. illustrations. verifications and verifications and verifications and illustrations.
illustrations. illustrations. illustrations.
Safety Adherence Doesn’t adhere to Slightly adheres Somewhat Moderately adheres Fully adheres to
Adherence to safety safety procedures. to safety adheres to safety to safety safety procedures.
procedures. procedures. procedures. procedures.
Equipment Handling Doesn’t handle Rarely handles Occasionally Often handles Handles
Equipment care during the equipment with equipment with handles equipment with equipment with
use. required care. required care. equipment with required care. required care.
required care.
Group Work Doesn't Slightly Somewhat Moderately Fully participates
Contributes in a group participate and participates and participates and participates and and contributes.
based lab work. contribute. contributes. contributes. contributes.

Laboratory Session No. _____________ Date: ______________________

Weighted CLO (Psychomotor Score)

Remarks

Instructor’s Signature with Date:

34
Manufacturing Processes-I
NED University of Engineering & Technology - Department of Mechanical Engineering

EXPERIMNT 9
9.1 OBJECTIVE
To perform the Gas Tungsten Arc Welding (GTAW)

9.2 THEORY
In gas tungsten-arc welding (GTAW), formerly known as TIG (for “tungsten inert gas”)
welding, the filler metal is supplied from a filler wire as shown in figure to provide the strength
to the weld joint. Because the tungsten electrode is not consumed in this operation, a constant
and stable arc gap is maintained at a constant current level. The filler metals are similar to the
metals to be welded, and flux is not used. The shielding gas is usually argon or helium (or a
mixture of the two). Tungsten is a good electrode material due to its high melting point of
3410oC (6170oF). This type of welding can be done with either AC or with DC power supply.
Straight polarity is used with DC power during the welding and more heat will generate at the
base metal. The TIG welding is slower than the consumable electrode welding GMAW.

Fig. 9.1 Welding gun for GTAW

Equipment
1- Mains connection
2- Power source
3- Hose pack
4- Grounding cable
5- Welding torch
6- Ground terminal
7- Work piece
8- Filler metal
9- Shielding gas
Fig. 9.2 Welding plant

35
Manufacturing Processes-I
NED University of Engineering & Technology - Department of Mechanical Engineering

9.3 PROCEDURE
 Clean the surface of the base metals using emery paper or with wire brush.
 Place the work pieces on the worktable in the required position.
 Set the AC current of the machine up to 500amps but it also depends upon the thickness
of the material.
 Fix the tungsten electrode to the electrode holder.
 Required size of the nozzle is selected and it is fixed to the torch. Adjust the inert gas
flow rate to the required rate.

 Select the filler rod (aluminum) of required diameter.

 Touch the electrode to the work, so that current flow will be established and then
separated by a small distance and the arc will be generated.

 First tack weld is done on the work pieces.

 Move the electrode slowly along the length of the joint with the filler rod, so that the
filler metal will be deposited in the joint.
 Repeat the operation for the second pass, so that required amount of filler metal will be
deposited on the work pieces.

9.4 PRECAUTIONS
 Never look at the arc with the naked eye. Always use a shield while welding.
 Always wear the safety hand gloves, apron and leather shoes.
 Ensure proper insulation of the cables and check for openings.
 Select the parameters of the machine properly based on the metals to be welded.
 Set these parameters properly before performing the operation.
 Inflammable and combustible materials are removed from the vicinity of welding
operations.

9.5 REVIEW QUESTION

1- What is the function of using shielding gas during the TIG welding?

2- What type of DC polarity is used to perform the TIG welding and why it is used?

3- Why filler is added into the molten pool in TIG welding process?

4- What is the purpose of flux? Why is it not needed in gas tungsten-arc welding

36
 F/OBEM 01/05/00
NED University of Engineering & Technology
Department of Mechanical Engineering

Course Code & Title: ME-220 Manufacturing Processes-I

Psychomotor Domain Assessment Rubric-Level P3

Extent of Achievement
Skill Sets
0 1 2 3 4
Equipment Identification Not able to identify -- -- -- Able to identify
Sensory skill to identify the equipment. equipment as well
equipment and/or its as its components.
component for a lab work.
Equipment Use Doesn't Slightly Somewhat Moderately demon Fully
Sensory skills to demonstrate the demonstrates the demonstrates the strates the use of demonstrates the
demonstrate the use of the use of equipment. use of equipment. use of equipment. equipment. use of equipment.
equipment for the lab
work.
Procedural Skills Not able to either Able to slightly Able to somewhat Able to moderately Able to fully
Displays skills to act upon learn or perform understand lab understand lab understand lab understand lab
sequence of steps in lab lab work work procedure work procedure work procedure work procedure
work. procedure. and perform lab and perform lab and perform lab and perform lab
work. work. work. work.
Response Not able to imitate Able to slightly Able to somewhat Able to moderately Able to fully
Ability to imitate the lab the lab work. imitate the lab imitate the lab imitate the lab imitate the lab
work on his/her own. work. work. work. work.
Observation’s Use Not able to use Slightly able to Somewhat able to Moderately able to Fully able to use
Displays skills to use the the observations use the use the use the the observations
observations from lab from lab work for observations observations from observations from from lab work for
work for experimental experimental from lab work for lab work for lab work for experimental
verifications and verifications and experimental experimental experimental verifications and
illustrations. illustrations. verifications and verifications and verifications and illustrations.
illustrations. illustrations. illustrations.
Safety Adherence Doesn’t adhere to Slightly adheres Somewhat Moderately adheres Fully adheres to
Adherence to safety safety procedures. to safety adheres to safety to safety safety procedures.
procedures. procedures. procedures. procedures.
Equipment Handling Doesn’t handle Rarely handles Occasionally Often handles Handles
Equipment care during the equipment with equipment with handles equipment with equipment with
use. required care. required care. equipment with required care. required care.
required care.
Group Work Doesn't Slightly Somewhat Moderately Fully participates
Contributes in a group participate and participates and participates and participates and and contributes.
based lab work. contribute. contributes. contributes. contributes.

Laboratory Session No. _____________ Date: ______________________

Weighted CLO (Psychomotor Score)

Remarks

Instructor’s Signature with Date:

37
 F/OBEM 01/07/00
NED University of Engineering & Technology
Department of Mechanical Engineering

Course Code & Title: ME-220 Manufacturing Processes-I

PLO 6 The Engineer and Society – Rubric for Affective Domain Assessment (A-4)
Level of Attainment
Criterion 0 1 2 3 4
Acknowledges responsibilities Doesn’t acknowledge Partially acknowledges Fairly acknowledges Satisfactorily acknowledges Fully acknowledges
and attitudes, relevant to responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes,
practice of engineering relevant to practice of relevant to practice of relevant to practice of relevant to practice of relevant to practice of
including; societal, health, engineering including; engineering including; engineering including; engineering including; engineering including;
safety, legal and cultural societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal
issues. and cultural issues. and cultural issues. and cultural issues. and cultural issues. and cultural issues.
Doesn’t practice Partially practices Fairly practices Satisfactorily practices Fully practices
Practices responsibilities and
responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes,
attitudes, relevant to practice
relevant to practice of relevant to practice of relevant to practice of relevant to practice of relevant to practice of
of engineering including;
engineering including; engineering including; engineering including; engineering including; engineering including;
societal, health, safety, legal
societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal
and cultural issues.
and cultural issues. and cultural issues. and cultural issues. and cultural issues. and cultural issues.
Doesn’t value Partially values Fairly values responsibilities Satisfactorily values Fully values responsibilities
Values responsibilities and
responsibilities and attitudes, responsibilities and attitudes, and attitudes, relevant to responsibilities and attitudes, and attitudes, relevant to
attitudes, relevant to practice
relevant to practice of relevant to practice of practice of engineering relevant to practice of practice of engineering
of engineering including;
engineering including; engineering including; including; societal, health, engineering including; including; societal, health,
societal, health, safety, legal
societal, health, safety, legal societal, health, safety, legal safety, legal and cultural societal, health, safety, legal safety, legal and cultural
and cultural issues.
and cultural issues. and cultural issues. issues. and cultural issues. issues.
Doesn’t display Partially displays Fairly displays Satisfactorily displays Fully displays
Displays responsibilities and
responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes,
attitudes, relevant to practice
relevant to practice of relevant to practice of relevant to practice of relevant to practice of relevant to practice of
of engineering including;
engineering including; engineering including; engineering including; engineering including; engineering including;
societal, health, safety, legal
societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal
and cultural issues.
and cultural issues. and cultural issues. and cultural issues. and cultural issues. and cultural issues.

Student’s Name: ___________________ Seat No.: _____________ Assignment Title: ______________________________

Total Score = ___________________________ Weighted Score (%) = _____________________

Instructor’s Signature: ____________________

38
Manufacturing Processes-I
NED University of Engineering & Technology - Department of Mechanical Engineering

EXPERIMENT 10
10.1 OBJECTIVE
To perform the oxy-acetylene gas welding

10.2 THEORY
OXY-ACETYLENE gas welding refers to a group of welding processes that uses, as thin heat
source, the flame produced by the combustion of a fuel gas and oxygen. The combustion of
oxygen and acetylene by means of a welding torch of the type produces a temperature of about
5850° F (3250° C) in a two-stage reaction.
Types of flame
The two-stage combustion process produces a flame having two distinct regions. The maximum
temperature occurs near the end of the inner cone, where the first stage of combustion is
complete. Most welding should be performed with the torch positioned so that the point of
maximum temperature is just above the metal being welded. The outer envelope of the flame
serves to preheat the metal, and at the same time, provides shielding from oxidation, since
oxygen from the surrounding air is used in the secondary combustion.
Three different types of flames can be obtained by varying the oxygen / acetylene (or oxygen
/ Fuel gas) ratio.

 If the ratio is about 1:1 to 1.15:1, all reactions are carried to completion and a neutral
flame is produced. Most welding is done with a neutral flame, since it will have the
least chemical effect on the heated metal.
 A higher ratio, such as 1.5:1 produces an oxidizing flame, hotter than the neutral flame
(about 6000 f) but similar in appearance. Such flames are used when welding copper
and copper alloys but are generally considered harmful when welding steel because the
excess oxygen react with the carbon, decarburizing the region around the weld.
 Excess fuel on the other hand, produces a carburizing flame.
 The excess fuel decomposes to carbon & hydrogen, and the flame temperature is not as
great (about 5550° F). Flames with a slight excess of fuel are reducing flames. No
carburization occurs, but the metal is well protected from oxidation. Flames of these
types are used in welding Monel, high carbon steel and some alloy steels, and for
applying some types of hard-facing materials.
For welding purpose, the oxygen is usually supplied in relatively pure form from pressurized
tanks, but in rare cases, air can also be used. The acetylene is usually obtained in portable
storage tanks that hold up to 300 cubic ft (8.5 m3) at 250-psi (1.7 MPa) pressure. Because
acetylene is not safe when stored as a gas at pressure above 15 psi (0.1 MPa), it is usually
dissolved in acetone. The storage cylinders are fitted with porous filler such as balsa-wood, or
infusion earth. Acetone is absorbed in to the voids in the filler material and serves as a medium
for dissolving the acetylene.

39
Manufacturing Processes-I
NED University of Engineering & Technology - Department of Mechanical Engineering

The pressure used in a gas-flame welding range from 1 to 15 psi (7 to 105 MPa) and is
controlled by pressure regulators on each tank. Because mixture of acetylene and oxygen are
explosive, precaution must be taken to avoid mixing the gases improperly or by accident. All
acetylene fitting has left hand threads, while those for oxygen are equipped with right hand
threads.
The tip size (or orifice diameter) of the torch can be varied to control the shape of inner cone
and the flow rate of the gases. Larger tips permit greater flow of gases, resulting in greater
heat input without the higher gas velocities that might blow the molten metal from the weld
pedal. Larger torch tips are required for welding thicker metal and operate with higher gas
pressure.

10.3 EQUIPMENT
Oxygen & Acetylene Cylinder

It is made of steel and has a capacity of 200 cu ft at a pressure of 2000 psi (13,790 KPa) and a
temperature of 70°F (21°C). Attached equipment consists of an outlet valve, a removable metal
cap for the protection of the valve, and a low melting point safety fuse plug and disk.

Fig. 10.1 Oxy-fuel gas welding

40
Manufacturing Processes-I
NED University of Engineering & Technology - Department of Mechanical Engineering

Oxygen and Acetylene Regulators

Regulators reduce pressure and control the flow of gases from the cylinders. The pressure in
an oxygen cylinder can be as high as 2200 psi (15,169 kPa), which must be reduced to a
working pressure of I to 25 psi (6.90 to 172.38 kPa). The pressure of acetylene in an acetylene
cylinder can be as high as 250 psi (1724 kPa).
Oxyacetylene Welding Torch
The oxyacetylene welding torch is used to mix oxygen and acetylene in definite proportions. It
also controls the volume of these gases burning at the welding tip, which produces the required
type of flame. The torch consists of a handle or body which contains the hose connections for
the oxygen and the fuel gas. The torch also has two needle valves, one for adjusting the flow
of oxygen and one for acetylene, and a mixing head.
Hose
The hoses used to make the connection between are made especially for this purpose. They
are built to with stand high internal; regulator and torch; pressures.

10.4 PROCEDURE
When setting up the welding and cutting equipment, it is important that all operations be
performed systematically to avoid mistakes trouble.
Cylinders

 Place the oxygen and acetylene cylinders on a level floor and tie them firmly to a
work bench, post, wall, or other secure anchorage to prevent their being knocked
or pulledover.

 Remove the valve protecting cap.

 “Crack” both cylinders valves by opening first the acetylene and then oxygen valve
slightly for an instant to blow out any dirt matter that may have accumulated during
shipmentor storage.

 Close the valves and wipe the connection seat with a clean cloth.
Pressure regulators

 Check the regulator fitting for dirt and obstruction. Also check threads of cylinders
and regulators for imperfection.

 Connect the respective regulators to the oxygen and acetylene cylinders.

 Connect the red hose to the acetylene regulator and the green one to the oxygen.

 Open the cylinder valve slowly. Read the high-pressure gages to check the cylinder
gage pressure. Blow out the oxygen hose by turning the regulator screw in and then
release the regulator screw. Flash back suppressors must be attached to the torch
whenever possible.
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Manufacturing Processes-I
NED University of Engineering & Technology - Department of Mechanical Engineering

Adjustment of work pressure

Adjust the acetylene work pressure by opening the acetylene needle valve on the torch and
turning the regulator screw to the right. Then adjust the acetylene regulator to the required
pressure for the tip size to be used. Close the needle valve. Adjust the oxygen working
pressure in the same manner.

10.5 REVIEW QUESTIONS

Q. 1. What are some of the problems that might occur when high temperatures are used in
welding?

Q.2. Why does an oxyfuel gas-welding torch usually have a flame with two distinct
regions?

Q.3. What three types of flames varying the oxygen/fuel ratio can produce?

Q.4. What is the location of the maximum temperature in an oxyacetylene flame?

Q.5. What function or functions are served by outer zone of the welding flame?

42
 F/OBEM 01/05/00
NED University of Engineering & Technology
Department of Mechanical Engineering

Course Code & Title: ME-220 Manufacturing Processes-I

Psychomotor Domain Assessment Rubric-Level P3

Extent of Achievement
Skill Sets
0 1 2 3 4
Equipment Identification Not able to identify -- -- -- Able to identify
Sensory skill to identify the equipment. equipment as well
equipment and/or its as its components.
component for a lab work.
Equipment Use Doesn't Slightly Somewhat Moderately demon Fully
Sensory skills to demonstrate the demonstrates the demonstrates the strates the use of demonstrates the
demonstrate the use of the use of equipment. use of equipment. use of equipment. equipment. use of equipment.
equipment for the lab
work.
Procedural Skills Not able to either Able to slightly Able to somewhat Able to moderately Able to fully
Displays skills to act upon learn or perform understand lab understand lab understand lab understand lab
sequence of steps in lab lab work work procedure work procedure work procedure work procedure
work. procedure. and perform lab and perform lab and perform lab and perform lab
work. work. work. work.
Response Not able to imitate Able to slightly Able to somewhat Able to moderately Able to fully
Ability to imitate the lab the lab work. imitate the lab imitate the lab imitate the lab imitate the lab
work on his/her own. work. work. work. work.
Observation’s Use Not able to use Slightly able to Somewhat able to Moderately able to Fully able to use
Displays skills to use the the observations use the use the use the the observations
observations from lab from lab work for observations observations from observations from from lab work for
work for experimental experimental from lab work for lab work for lab work for experimental
verifications and verifications and experimental experimental experimental verifications and
illustrations. illustrations. verifications and verifications and verifications and illustrations.
illustrations. illustrations. illustrations.
Safety Adherence Doesn’t adhere to Slightly adheres Somewhat Moderately adheres Fully adheres to
Adherence to safety safety procedures. to safety adheres to safety to safety safety procedures.
procedures. procedures. procedures. procedures.
Equipment Handling Doesn’t handle Rarely handles Occasionally Often handles Handles
Equipment care during the equipment with equipment with handles equipment with equipment with
use. required care. required care. equipment with required care. required care.
required care.
Group Work Doesn't Slightly Somewhat Moderately Fully participates
Contributes in a group participate and participates and participates and participates and and contributes.
based lab work. contribute. contributes. contributes. contributes.

Laboratory Session No. _____________ Date: ______________________

Weighted CLO (Psychomotor Score)

Remarks

Instructor’s Signature with Date:

43
 F/OBEM 01/07/00
NED University of Engineering & Technology
Department of Mechanical Engineering

Course Code & Title: ME-220 Manufacturing Processes-I

PLO 6 The Engineer and Society – Rubric for Affective Domain Assessment (A-4)
Level of Attainment
Criterion 0 1 2 3 4
Acknowledges responsibilities Doesn’t acknowledge Partially acknowledges Fairly acknowledges Satisfactorily acknowledges Fully acknowledges
and attitudes, relevant to responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes,
practice of engineering relevant to practice of relevant to practice of relevant to practice of relevant to practice of relevant to practice of
including; societal, health, engineering including; engineering including; engineering including; engineering including; engineering including;
safety, legal and cultural societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal
issues. and cultural issues. and cultural issues. and cultural issues. and cultural issues. and cultural issues.
Doesn’t practice Partially practices Fairly practices Satisfactorily practices Fully practices
Practices responsibilities and
responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes,
attitudes, relevant to practice
relevant to practice of relevant to practice of relevant to practice of relevant to practice of relevant to practice of
of engineering including;
engineering including; engineering including; engineering including; engineering including; engineering including;
societal, health, safety, legal
societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal
and cultural issues.
and cultural issues. and cultural issues. and cultural issues. and cultural issues. and cultural issues.
Doesn’t value Partially values Fairly values responsibilities Satisfactorily values Fully values responsibilities
Values responsibilities and
responsibilities and attitudes, responsibilities and attitudes, and attitudes, relevant to responsibilities and attitudes, and attitudes, relevant to
attitudes, relevant to practice
relevant to practice of relevant to practice of practice of engineering relevant to practice of practice of engineering
of engineering including;
engineering including; engineering including; including; societal, health, engineering including; including; societal, health,
societal, health, safety, legal
societal, health, safety, legal societal, health, safety, legal safety, legal and cultural societal, health, safety, legal safety, legal and cultural
and cultural issues.
and cultural issues. and cultural issues. issues. and cultural issues. issues.
Doesn’t display Partially displays Fairly displays Satisfactorily displays Fully displays
Displays responsibilities and
responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes,
attitudes, relevant to practice
relevant to practice of relevant to practice of relevant to practice of relevant to practice of relevant to practice of
of engineering including;
engineering including; engineering including; engineering including; engineering including; engineering including;
societal, health, safety, legal
societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal
and cultural issues.
and cultural issues. and cultural issues. and cultural issues. and cultural issues. and cultural issues.

Student’s Name: ___________________ Seat No.: _____________ Assignment Title: ______________________________

Total Score = ___________________________ Weighted Score (%) = _____________________

Instructor’s Signature: ____________________

44
Manufacturing Processes-I
NED University of Engineering & Technology - Department of Mechanical Engineering

EXPERIMENT 11
11.1 OBJECTIVE
To perform the oxy-acetylene gas cutting

11.2 THEORY
Oxy-Acetylene gas cutting:
For many years, metal sheets and plates have been cut by means of oxyfuel torches. Basically,
a thermal cutting is done by oxyfuel gas cutting. In nonferrous, the metal is melted by the flame
of the torch and a gap known as kerf is produced. However, in ferrous metals it becomes a
rapid oxidation (Burning) of iron at high temperature.
Cutting torch and other cutting equipment:
The cutting torch like the welding torch has a tube for oxygen and one for acetylene. In addition,
there is a tube for high pressure oxygen, along with a cutting tip or nozzle. The tip is provided
with a center hole through which a jet of pure oxygen passes. Mixed oxygen and acetylene pass
through holes surrounding the center holes for the preheating flames. The number of orifices
for oxyacetylene flames ranges from 2 to 6, depending on the purpose for which the tip is used.
The cutting torch is controlled by a trigger or lever operated valve. The cutting torch is furnished
with interchangeable tips for cutting steel from less than 1/4 in. (6.4 mm) to more than 12.0 in.
(304.8 mm) in thickness.
Operation of cutting equipment
a) Attach the required cutting tip to the torch and adjust the oxygen and acetylene pressure.
b) Adjust the preheating flame to neutral.
c) Hold the torch so that the cutting oxygen lever or trigger can be operated with one hand. Use
the other hand to steady and maintain the position of the torch head to the work. Keep the
flames at a 90-degree angle to work in the direction of travel. The inner cones of preheating
flames should be about 1/16 in. (1.6 mm) above the end of the line to be cut. Hold this position
until the spot has been raised to a bright red heat, and then slowly open the cutting oxygen
valve.
d) If the cut has been started properly, a shower of sparks will fall from the opposite side of the
work. Move the torch at a speed which allows the cut to continue penetrating the work. A good
cut will be clean and narrow.
e) When cutting billets, round bars, or heavy sections, time and gas are saved if a burr is raised
with a chisel at the point where the cut is to start. This small portion will heat quickly and
cutting will start immediately. A welding rod can be used to start a cut on heavy sections. When
used, it is called a starting rod.

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Manufacturing Processes-I
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11.3 PRECAUTIONS
I) Always have suitable fire extinguishing equipment at hand when doing any welding.
2) Do not stand facing cylinder valve outlets of oxygen, acetylene, or other compressed gases
when opening them,
3) Purge both acetylene and oxygen lines (hoses) prior to igniting torch. Failure to do this can
causes serious injury to personnel and damage to the equipment.
4) Oxygen and gas should be stored separately. Always chain store cylinders. Acetylene
cylinders may explode unless store upright.
5) Cylinders regulators - should be correctly used.

6) Leaks - ensure no gas is escaping from any part of equipment.

Personal protection

Use proper gloves, overalls and industrial type footwear, especially when cutting or welding
overhead.
Eyes - protect them with a helmet and visor of a grade designed for the type of welding; wear
eyes protect during slag removal or chipping and grinding.

11.4 REVIEW QUESTIONS

Q.l. In what Way does the torch cutting of ferrous metals differ from cutting no oxidizing
metals?

Q.2. Why might it be possible to cut cast steel standards continuously as they emerge from
the casting operation using only an oxygen lance?

Q.3. How does an oxyacetylene cutting torch differ from an oxyacetylene welding torch?

Q.4. What are some of the ways in which cutting torches can be mechanically
manipulated?

Q.5. What modification must be incorporated into a cutting torch to permit it to cut metal
Under

46
 F/OBEM 01/05/00
NED University of Engineering & Technology
Department of Mechanical Engineering

Course Code & Title: ME-220 Manufacturing Processes-I

Psychomotor Domain Assessment Rubric-Level P3

Extent of Achievement
Skill Sets
0 1 2 3 4
Equipment Identification Not able to identify -- -- -- Able to identify
Sensory skill to identify the equipment. equipment as well
equipment and/or its as its components.
component for a lab work.
Equipment Use Doesn't Slightly Somewhat Moderately demon Fully
Sensory skills to demonstrate the demonstrates the demonstrates the strates the use of demonstrates the
demonstrate the use of the use of equipment. use of equipment. use of equipment. equipment. use of equipment.
equipment for the lab
work.
Procedural Skills Not able to either Able to slightly Able to somewhat Able to moderately Able to fully
Displays skills to act upon learn or perform understand lab understand lab understand lab understand lab
sequence of steps in lab lab work work procedure work procedure work procedure work procedure
work. procedure. and perform lab and perform lab and perform lab and perform lab
work. work. work. work.
Response Not able to imitate Able to slightly Able to somewhat Able to moderately Able to fully
Ability to imitate the lab the lab work. imitate the lab imitate the lab imitate the lab imitate the lab
work on his/her own. work. work. work. work.
Observation’s Use Not able to use Slightly able to Somewhat able to Moderately able to Fully able to use
Displays skills to use the the observations use the use the use the the observations
observations from lab from lab work for observations observations from observations from from lab work for
work for experimental experimental from lab work for lab work for lab work for experimental
verifications and verifications and experimental experimental experimental verifications and
illustrations. illustrations. verifications and verifications and verifications and illustrations.
illustrations. illustrations. illustrations.
Safety Adherence Doesn’t adhere to Slightly adheres Somewhat Moderately adheres Fully adheres to
Adherence to safety safety procedures. to safety adheres to safety to safety safety procedures.
procedures. procedures. procedures. procedures.
Equipment Handling Doesn’t handle Rarely handles Occasionally Often handles Handles
Equipment care during the equipment with equipment with handles equipment with equipment with
use. required care. required care. equipment with required care. required care.
required care.
Group Work Doesn't Slightly Somewhat Moderately Fully participates
Contributes in a group participate and participates and participates and participates and and contributes.
based lab work. contribute. contributes. contributes. contributes.

Laboratory Session No. _____________ Date: ______________________

Weighted CLO (Psychomotor Score)

Remarks

Instructor’s Signature with Date:

47
 F/OBEM 01/07/00
NED University of Engineering & Technology
Department of Mechanical Engineering

Course Code & Title: ME-220 Manufacturing Processes-I

PLO 6 The Engineer and Society – Rubric for Affective Domain Assessment (A-4)
Level of Attainment
Criterion 0 1 2 3 4
Acknowledges responsibilities Doesn’t acknowledge Partially acknowledges Fairly acknowledges Satisfactorily acknowledges Fully acknowledges
and attitudes, relevant to responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes,
practice of engineering relevant to practice of relevant to practice of relevant to practice of relevant to practice of relevant to practice of
including; societal, health, engineering including; engineering including; engineering including; engineering including; engineering including;
safety, legal and cultural societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal
issues. and cultural issues. and cultural issues. and cultural issues. and cultural issues. and cultural issues.
Doesn’t practice Partially practices Fairly practices Satisfactorily practices Fully practices
Practices responsibilities and
responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes,
attitudes, relevant to practice
relevant to practice of relevant to practice of relevant to practice of relevant to practice of relevant to practice of
of engineering including;
engineering including; engineering including; engineering including; engineering including; engineering including;
societal, health, safety, legal
societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal
and cultural issues.
and cultural issues. and cultural issues. and cultural issues. and cultural issues. and cultural issues.
Doesn’t value Partially values Fairly values responsibilities Satisfactorily values Fully values responsibilities
Values responsibilities and
responsibilities and attitudes, responsibilities and attitudes, and attitudes, relevant to responsibilities and attitudes, and attitudes, relevant to
attitudes, relevant to practice
relevant to practice of relevant to practice of practice of engineering relevant to practice of practice of engineering
of engineering including;
engineering including; engineering including; including; societal, health, engineering including; including; societal, health,
societal, health, safety, legal
societal, health, safety, legal societal, health, safety, legal safety, legal and cultural societal, health, safety, legal safety, legal and cultural
and cultural issues.
and cultural issues. and cultural issues. issues. and cultural issues. issues.
Doesn’t display Partially displays Fairly displays Satisfactorily displays Fully displays
Displays responsibilities and
responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes, responsibilities and attitudes,
attitudes, relevant to practice
relevant to practice of relevant to practice of relevant to practice of relevant to practice of relevant to practice of
of engineering including;
engineering including; engineering including; engineering including; engineering including; engineering including;
societal, health, safety, legal
societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal societal, health, safety, legal
and cultural issues.
and cultural issues. and cultural issues. and cultural issues. and cultural issues. and cultural issues.

Student’s Name: ___________________ Seat No.: _____________ Assignment Title: ______________________________

Total Score = ___________________________ Weighted Score (%) = _____________________

Instructor’s Signature: ____________________

48
 Manufacturing Processes-I
NED University of Engineering & Technology - Department of Mechanical Engineering

EXPERIMENT 12
12.1 OBJECTIVE
To perform the sheet metal shearing for mild steel using Edward Truecut power shear

12.2 TOOL:
Edwards 2.5 / 1250 DD Truecut Power Guillotine Shear

12.3 THEORY
Sheet metal operations: They are metal forming and cutting operations mostly performed on
sheets, coils and strips. It is also called as Press-working. Product obtained is called Stamping.
The stamping presses are used to perform sheet metal operation. Mostly performed as cold
working process. Performed by the tools called Punch (Positive part) and die (Negative part
of the assembly) Cutting and forming operations performed on relatively thin sheets of metal.
Thickness of sheet metal = 0.4 mm (1/64 in) to 6 mm (1/4 in) Thickness of plate stock > 6 mm
Cutting of sheet metal is accomplished by a shearing action between two sharp cutting edges.
Sheet metal cutting operation along a straight line between two cutting edges. Machinesused is
called power or squaring shears. Upper blade is often inclined to reduce required cuttingforce. It
is typically used to cut large sheets.

Fig. 12.1 Inclined shearing blade

Shearing of sheet metal between two cutting edges:

1. Just before the punch contacts work part.
2. Punch begins to push into work part, causing plastic deformation.
3. Punch compresses and penetrates into work causing a smooth cut surface (1/3rd of sheet
thickness);
4. Fracture is initiated at the opposing cutting edges which separates the sheet.

Fig. 12.2 Steps of sheet metal shearing

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Manufacturing Processes-I
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The sheared edges of the sheet have some features:

 Rollover: Depression made by the punch in the work prior to cutting.

 Burnish: Penetration of the punch into the work before fracture began.
 Fractured zone: A relatively rough surface of the cut edge where fracture of the metal
occurs.
 Burr: A sharp corner of the edge caused by elongation of the metal during final
separation of two pieces

Fig. 12.3 Features of sheared edge

Clearance The clearance c in a shearing operation is the distance between the punch and die.
Typical clearances in conventional pressworking range between 4% and 8% of the sheet-metal
thickness t. The correct clearance depends on sheet-metal type and thickness. The
recommended clearance can be calculated by the following formula:
𝑐 = 𝐴𝑐 × 𝑡
where c =clearance, mm (in); Ac =clearance allowance; and t = stock thickness, mm (in). The
clearance allowance is determined according to type of metal.
12.4 PROCEDURE
 Select sheet metal of mild steel based on thickness
 Place the sample in the shearing machine and align it using the scope
 Apply force using the paddle
 Analyze the sheared edge.
Estimates of cutting force are important because this force determines the size (tonnage) of the
press needed. Cutting force F in sheet metalworking can be determined by
𝐹 =𝑆×𝑡×𝐿
Where;
S= Shear strength
T= Stock thickness
L= length of cutting edge
Note:
- Clearance Allowance (A) for mild steel =0.060

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Manufacturing Processes-I
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12.5 REVIEW QUESTIONS

Q1: What is the difference between sheet metal and plate?

Q2. Why clearance is important in sheet metal cutting operations?

Q3. How do we reduce shearing force for a given material?

51
 F/OBEM 01/05/00
NED University of Engineering & Technology
Department of Mechanical Engineering

Course Code & Title: ME-220 Manufacturing Processes-I

Psychomotor Domain Assessment Rubric-Level P3

Extent of Achievement
Skill Sets
0 1 2 3 4
Equipment Identification Not able to identify -- -- -- Able to identify
Sensory skill to identify the equipment. equipment as well
equipment and/or its as its components.
component for a lab work.
Equipment Use Doesn't Slightly Somewhat Moderately demon Fully
Sensory skills to demonstrate the demonstrates the demonstrates the strates the use of demonstrates the
demonstrate the use of the use of equipment. use of equipment. use of equipment. equipment. use of equipment.
equipment for the lab
work.
Procedural Skills Not able to either Able to slightly Able to somewhat Able to moderately Able to fully
Displays skills to act upon learn or perform understand lab understand lab understand lab understand lab
sequence of steps in lab lab work work procedure work procedure work procedure work procedure
work. procedure. and perform lab and perform lab and perform lab and perform lab
work. work. work. work.
Response Not able to imitate Able to slightly Able to somewhat Able to moderately Able to fully
Ability to imitate the lab the lab work. imitate the lab imitate the lab imitate the lab imitate the lab
work on his/her own. work. work. work. work.
Observation’s Use Not able to use Slightly able to Somewhat able to Moderately able to Fully able to use
Displays skills to use the the observations use the use the use the the observations
observations from lab from lab work for observations observations from observations from from lab work for
work for experimental experimental from lab work for lab work for lab work for experimental
verifications and verifications and experimental experimental experimental verifications and
illustrations. illustrations. verifications and verifications and verifications and illustrations.
illustrations. illustrations. illustrations.
Safety Adherence Doesn’t adhere to Slightly adheres Somewhat Moderately adheres Fully adheres to
Adherence to safety safety procedures. to safety adheres to safety to safety safety procedures.
procedures. procedures. procedures. procedures.
Equipment Handling Doesn’t handle Rarely handles Occasionally Often handles Handles
Equipment care during the equipment with equipment with handles equipment with equipment with
use. required care. required care. equipment with required care. required care.
required care.
Group Work Doesn't Slightly Somewhat Moderately Fully participates
Contributes in a group participate and participates and participates and participates and and contributes.
based lab work. contribute. contributes. contributes. contributes.

Laboratory Session No. _____________ Date: ______________________

Weighted CLO (Psychomotor Score)

Remarks

Instructor’s Signature with Date:

52
Manufacturing Processes-I
NED University of Engineering & Technology - Department of Mechanical Engineering

EXPERIMENT 13
13.1 OBJECTIVE
To calculate various parameters of Upset forging with hydraulic press using interactive
simulation bench.

13.2 TOOL
Online simulation bench (http://msvs-dei.vlabs.ac.in/msvs-dei/Hydraulic.php).

13.3 THEORY
Hammer Forging
Hammer forging may be defined as an open-die hot forging in which billet is compressed and
deformed by continuous blows of upper die. In this process, the billet remains stationary over
the lower die. The upper die continuously strikes the billet till the required reduction in the
height and desired shape is obtained.
With the hammer forging process, the material undergoes large plastic (permanent)
deformation, resulting in an appreciable change in shape and cross section. During the hammer
forging the grain structure of the material break into more uniform structure and hence the
mechanical properties of the materials greatly improved. . As a result, forging offers potential
savings in energy and material, especially in medium and large production quantities, where
tool costs can be easily amortized. In addition, for a given weight, parts produced by forging
exhibit better mechanical and metallurgical properties and reliability than do those
manufactured by casting or machining.
GRAVITY DROP HAMMER PRESS
In the operation of this hammer, the energy is derived from the free-falling ram. The available
energy of the hammer is the product of the ram's weight and the height of its drop. Ram weights
range from 180 kg to 4500kg, with energy capacities ranging up to 120kJ.

Fig. 13.1 Forging hammer

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Manufacturing Processes-I
NED University of Engineering & Technology - Department of Mechanical Engineering

POWER DROP HAMMER:

In this hammer, the ram's downstroke is accelerated by the steam, air, or hydraulic pressure at
about 750 kPa. Ram weights range from 225 kg to as much as 22,500 kg, with energy capacities
ranging up to 1150 KJ.

13.4 PROCEDURE
 Open the simulation bench link (http://msvs-dei.vlabs.ac.in/msvs-dei/Hydraulic.php)
 Material: Aluminum
 L/D ratio of workpiece= 1
 Workpiece temperature: Cold.
 Coefficient of friction: Medium (0.1)
 Velocity of Upper die: 1 mm/sec
 Initial Volume of this solid cylinder mm^3
 The initial height and Diameter of the workpiece is 100 mm (As shown in the simulation)
Observe the graph between forging force and height of work part at hf=80 mm and hf= 50
mm, find out the parameters mentioned in the table 13.1. Also Show all the calculations in
the section 13.5 given below.

Parameters Value Values

(at hf=80 mm) (at hf= 50 mm)
Engineering Strain
True Strain
Flow stress (MPa)
Cross sectional Area (mm2)
Diameter (mm)
Kf
Forging Force (Tons)
Table 13.1 Observation
Note:
-Flow curve for Aluminum (K)= 175 MPa
-Strain hardening Exponent= 0.2
-1 ton = 9806.65 N
-1 MPa= 1 N/mm2

13.5 CALCULATIONS

At hf= 80 mm At hf= 50 mm

54
Manufacturing Processes-I
NED University of Engineering & Technology - Department of Mechanical Engineering

13.5 REVIEW QUESTIONS

Q1. Why is flash desirable in impression-die forging?

Q2. What are the two basic types of forging equipment?

55
 NED University of Engineering & Technology
Department of Mechanical Engineering

Course Code & Title: ME-220 Manufacturing Processes-I

Software Use Rubric (P3)

Extent of Achievement
Skill Sets
0 1 2 3 4
Identification and usage Does not use Rarely uses software Occasionally Often uses Uses software
of correct software software menus at menus correctly. uses software software menus menus correctly and
menus all. menus correctly. correctly. effectively.
Skills to use basic options Not able to use Uses basic options Uses basic Uses basic Exhibits all basic
any basic with detailed options with options without options effectively.
options. supervision. some guidance. guidance .
Skills to use Not able to use Uses Uses Uses Exhibits all
advanced/associated any advanced/associated advanced/associa advanced/associa advanced/associated
features advanced/associ features with ted features with ted features features effectively.
ated features. detailed supervision. some guidance. without guidance
Performing the assigned Can not use the Uses the software Uses the Uses the software Uses the software
task using software software for with below-average software with with above- with proficient
assigned task expertise average average expertise
expertise expertise
Extraction of required Does not extract Rarely extract Occasionally Often extract Effectively extract
output from software requried output requried output from extract requried requried output requried output
at all. software. output from from software. from software.
software.

Laboratory Session No. _____________ Date: ______________________

Weighted CLO (Psychomotor Score)

Remarks

Instructor’s Signature with Date:

56
Manufacturing Processes-I
NED University of Engineering & Technology - Department of Mechanical Engineering

EXPERIMENT 14
14.1 OBJECTIVE
To calculate various parameters of direct extrusion in cold working using interactive
simulation bench

14.2 TOOL
Online simulation bench (http://msvs-dei.vlabs.ac.in/msvs-dei/Aluminium.php)

14.3 THEORY
Compression forming process in which the work metal is forced to flow through a die opening
to produce a desired cross‑sectional shape. Process is similar to squeezing toothpaste out of a
toothpaste tube. In general, extrusion is used to produce long parts of uniform cross-sections
Two basic types of extrusion:

 Direct extrusion
 Indirect extrusion
 Hot, Warm, and cold extrusion
 Continuous and Discrete extrusion
Direct & Indirect Extrusion
Direct Extrusion Also called forward extrusion

As ram approaches die opening, a small portion of billet remains that cannot be forced through
die opening, this extra portion, called the butt, must be separated from extruded product by
cutting it just beyond the die exit. Starting billet cross section usually round, but final shape is
determined by die opening

Fig. 14.1 Schematic diagram of Extrusion process

In Direct Extrusion Also called Backward Extrusion

Limitations of indirect extrusion are imposed by the lower rigidity of hollow ram and difficulty
in supporting extruded product as it exits die.

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Fig. 14.2 Types of Extrusion process

Hot & Cold Extrusion

Hot extrusion prior heating of billet to above its recrystallization temperature. This reduces
strength and increases ductility of the metal, permitting more size reductions and more complex
shapes
Cold extrusion generally used to produce discrete parts. The term impact extrusion is used to
indicate high speed cold extrusion

Discrete & Continuous Extrusion

Continuous Extrusion a true continuous process operates in a steady state mode for an indefinite
period. This make very long section in one cycle, but its length is limited bythe amount of
material that can be fed in the ram. So generally, it is termed as semi continuousextrusion

Discrete Extrusion Single part is produced in each cycle. The term impact extrusion is an
example for this.

14.4 PROCEDURE
 Open the simulation bench link (http://msvs-dei.vlabs.ac.in/msvs-dei/Aluminium.php)
 Select the parameters as given below:
Extrusion: Solid Shaft.
Die Angle: 45o
Extrusion Die curvature: Without Curvature.
Coefficient of friction: Medium (0.1)
Workpiece temperature: Cold
Velocity of ram: 1 mm/sec

Note:
Friction is only considered between the billet and die surface; no friction is considered between
billet and container.
-Flow curve for Aluminum (K) = 175 MPa
-Strain hardening Exponent= 0.2
-1 ton = 9806.65 N
-1 Mpa= 1 N/mm^2

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Manufacturing Processes-I
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Fig. 14.3 Schematic for the simulation workpiece

Observe the graph between extrusion force and billet length at L=70 mm and L= 50 mm, find
out the parameters mentioned in the table 14.1. Also Show all the calculations in the section
14.5 given below.

Parameters Value Value

(at L=70 mm) (at L=50 mm)
Extrusion Ratio
True Strain
Extrusion strain (a=0.8 & b=1.5)
Flow Stress (Yf)
Pressure (Mpa)
Extrusion Force (Tons)

Table 14.1 Observation

14.5 CALCULATIONS

14.6 REVIEW QUESTIONS

Q1. Distinguish between direct and indirect extrusion.

Q2. Why is friction a factor in determining the ram force in direct extrusion but not a factor in
indirect extrusion?

59
 NED University of Engineering & Technology
Department of Mechanical Engineering

Course Code & Title: ME-220 Manufacturing Processes-I

Software Use Rubric (P3)

Extent of Achievement
Skill Sets
0 1 2 3 4
Identification and usage Does not use Rarely uses software Occasionally Often uses Uses software
of correct software software menus at menus correctly. uses software software menus menus correctly and
menus all. menus correctly. correctly. effectively.
Skills to use basic options Not able to use Uses basic options Uses basic Uses basic Exhibits all basic
any basic with detailed options with options without options effectively.
options. supervision. some guidance. guidance .
Skills to use Not able to use Uses Uses Uses Exhibits all
advanced/associated any advanced/associated advanced/associa advanced/associa advanced/associated
features advanced/associ features with ted features with ted features features effectively.
ated features. detailed supervision. some guidance. without guidance
Performing the assigned Can not use the Uses the software Uses the Uses the software Uses the software
task using software software for with below-average software with with above- with proficient
assigned task expertise average average expertise
expertise expertise
Extraction of required Does not extract Rarely extract Occasionally Often extract Effectively extract
output from software requried output requried output from extract requried requried output requried output
at all. software. output from from software. from software.
software.

Laboratory Session No. _____________ Date: ______________________

Weighted CLO (Psychomotor Score)

Remarks

Instructor’s Signature with Date:

60