Production Technology Lab Department of Mechanical Engineering

RAGHU ENGINEERING COLLEGE

Dakamarri (v), Bheemunipatnam (M)
Visakhapatnam Dist, Andhra Pradesh, PIN-531162
Approved by AICTE, New Delhi, and Affiliated to JNTU Kakinada (AP)
Accredited by NAAC with “A” Grade and NBA accredited

LABORATORY MANUAL
For

PRODUCTION TECHNOLOGY LAB

DEPARTMENT OF

MECHANICAL ENGINEERING

Lab In-charge HOD

1|Page
Production Technology Lab Department of Mechanical Engineering

VISION & MISSION

VISION & MISSION OF THE INSTITUTE

Vision
Envisioning to be a world class technical institution by synergizing quality education with ethical
values.

Mission

M1 To enlist the services of expert faculty

M2 To encourage training and research in cutting-edge technologies.
M3 To develop and strengthen strategic links with the industry.
M4 To kindle the zeal among the students and promote their quest for academic
excellence.
M5 To encourage extra-curricular activities along with good communication skills.

VISION AND MISSION OF THE DEPARTMENT

Vision
To become a global knowledge hub, striving continuously in pursuit of excellence in the field of
Mechanical Engineering education, Entrepreneurship and Innovation.

Mission

M1 To impart total quality education through effective hi-tech teaching-learning techniques

and department-industries collaboration.

M2 To develop linkages and interaction with industry, R & D organizations and educational
institutions for excellence in research and consultancy practices.

M3 To achieve National / International standards to contribute to the Government's "Make in

India" industrial policy through innovation and research.

2|Page
Production Technology Lab Department of Mechanical Engineering

PEO’S, PO’s&PSO’s of the Department

Program Educational Objective
PEO I
Developing capability to comprehend the fundamentals of Mechanical Engineering for
application to engineering problems in the field of design, manufacture, research and
mould themselves as successful engineers.
To produce skilled and competent graduates capable of facing the challenges of real
PEO II life, engineering practices and command over various aspects of Mechanical
Engineering Education.

PEO Upgrade themselves personally and professionally in taking up state of the art
III technological challenges, pursuing leadership roles and employability while believing
on the ethical values.

Program Out Comes

PO DESCRIPTION
PO1 Engineering knowledge: Apply the knowledge of mathematics,
science, engineering fundamentals, and an engineering specialization
to the solution of complex engineering problems.
PO2 Problem analysis: Identify, formulate, review research literature,
and analyze complex engineering problems reaching substantiated
conclusions using first principles of mathematics, natural sciences,
and engineering sciences.
PO3 Design/development of solutions: Design solutions for complex
engineering problems and design system components or processes
that meet the specified needs with appropriate consideration for the
public health and safety, and the cultural, societal, and
environmental considerations.
PO4 Conduct investigations of complex problems: Use research-
based knowledge and research methods including design of
experiments, analysis and interpretation of data, and synthesis of the
information to provide valid conclusions.
PO5 Modern tool usage: Create, select, and apply appropriate
techniques, resources, and modern engineering and IT tools including
prediction and modeling to complex engineering activities with an
understanding of the limitations.

PO6 The engineer and society: Apply reasoning informed by the

contextual knowledge to assess societal, health, safety, legal and
cultural issues and the consequent responsibilities relevant to the
professional engineering practice.
PO7 Environment and sustainability: Understand the impact of the
professional engineering solutions in societal and environmental
contexts, and demonstrate the knowledge of, and need for
sustainable development.

3|Page
Production Technology Lab Department of Mechanical Engineering

PO DESCRIPTION
PO8 Ethics: Apply ethical principles and commit to professional ethics and
responsibilities and norms of the engineering practice.
PO9 Individual and team work: Function effectively as an individual,
and as a member or leader in diverse teams, and in multidisciplinary
settings.
PO1 Communication: Communicate effectively on complex engineering
0 activities with the engineering community and with society at large,
such as, being able to comprehend and write effective reports and
design documentation, make effective presentations, and give and
receive clear instructions.
PO1 Project management and finance: Demonstrate knowledge and
1 understanding of the engineering and management principles and
apply these to one’s own work, as a member and leader in a team, to
manage projects and in multidisciplinary environments.
PO1 Life-long learning: Recognize the need for, and have the
2 preparation and ability to engage in independent and life-long
learning in the broadest context of technological change.

Program Specific Outcomes (PSOs)

Graduates will be able to explore the technical knowledge and able to
design a system, product, or process to meet desired needs within
PSO: 01
realistic constraints such as economic, environmental, social, political,
ethical, health and safety, manufacturability, and sustainability.

Graduates will be able to work comfortably with various machines,

manufacturing and processing equipment, and also can use proficiently
PSO: 02
various CAD/CAM/CIE software such as Auto Cad, Catia, Pro E, Ansys,
Nastran simulation tools like Matlab etc..

4|Page
Production Technology Lab Department of Mechanical Engineering

5|Page
 Production Technology Lab Department of Mechanical Engineering

Course Objective:

To impart hands-on practical exposure to manufacturing processes and

equipment.

Course Outcomes:
17ME3L40.1: To gain practical knowledge on metal casting.

17ME3L40.2: To become familiar with various welding methods.

17ME3L40.3: To gain practical knowledge on metal forming and powder

metallurgy.

17ME3L40.4: To become familiar with processing of plastics.

Mapping of COs vs. POs:

Course Program Outcomes & Program Specific Outcomes

Outcomes PO PO PO PO PO PO PO PO PO PO1 PO1 PO1 PSO
1 2 3 4 5 6 7 8 9 0 1 2 1 PSO2
17ME3L40.
3 2 3 - - 3 1 - 3 3 3 3 1 3
1
17ME3L40.
3 2 3 - - 3 1 - 3 3 3 3 1 3
2
17ME3L40.
3 2 3 - - 3 1 - 3 3 3 3 1 3
3
17ME3L40.
3 2 3 - - 3 1 - 3 3 3 3 1 3
4
average 3 2 3 - - 3 1 - 3 3 3 3 1 3

6|Page
Production Technology Lab Department of Mechanical Engineering

CERTIFICATE

Branch: Mechanical Engineering

Class and Semester: II YEAR – I SEMESTER

Prepared By Verified By
Name : BVS ARUN KUMAR Name:
Designation: Asso. Professor Designation:
Date: 10-09-2019 Date:
IQAC verification by

Name:

Designation:

Date:
Approval of (HoD)

Name:

Signature:

Date:

7|Page
Production Technology Lab Department of Mechanical Engineering

CONTENTS
Lab Objective 4

University Syllabus 5

List of Experiments 6

Experiment No. 1: MAKING OF SINGLE PIECE PATTERN 7

Experiment No. 2: MAKING OF SPLIT PIECE PATTERN 9

Experiment No. 3: SINGLE PIECE MOULDING 12

Experiment No. 4: MOLD MAKING BY USING SPLIT PIECE PATTERN 15

Experiment No 5: PERMEABILITY TEST OF THE MOLDING SAND 17

Experiment No 6: SPOT WELDING 20

Experiment No 7: ARC WELDING – LAP JOINT 23

Experiment No 8: ARC WELDING – SINGLE V-BUTT JOINT 25

Experiment No 9: ARC-WELDING – ROD BUTT JOINT 28

Experiment No 10: BENDING PROCESS 30

Experiment No 11: BLANKING 34

Experiment No 12: PIERCING 36

Experiment No 13: INJECTION MOULDING 38

Experiment No 14: BLOW MOULDING 40

Experiment No 15: SOLDERING 42

8|Page
Production Technology Lab Department of Mechanical Engineering

University Syllabus:

JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY KAKINADA

II Year B. Tech. Mechanical Engineering – II Sem. Subject code:RT22037

Credits:2
PRODUCTION TECHNOLOGY LAB SYLLABUS

Minimum of 12 exercises need to be performed

I. METAL CASTING LAB

1. Pattern Design and making – for one casting drawing

2. Sand properties testing – Exercise – for strengths, and permeability – 1
3. Molding Melting and Casting – 1 Exercise

II. WELDING LAB:

1. Arc Welding Lap & Butt Joint – 2 Exercises

2. Spot Welding – 1 Exercise
3. TIG Welding – 1 Exercise
4. Plasma welding and Brazing – 2 Exercises (Water Plasma Device)

III.MECHANICAL PRESS WORKING:

1. Blanking & Piercing operation and study of simple, compound and progressive press tool.
2. Hydraulic Press: Deep drawing and extrusion operation.
3. Bending and other operation

IV. PROCESSING OF PLASTICS

1. Injection Moulding
2. Blow Moulding

EVALUATION PROCEDURE Internal Marks:

Internal Assessment : 25 Marks Day To Day Evaluation=10 Marks

University Exam : 50 Marks Records=5 Marks
Total : 75 Marks Internal Test = 10 Marks
Total =25 Marks

9|Page
Production Technology Lab Department of Mechanical Engineering

LIST OF EXPERIMENTS
List of Experiments

I.METAL CASTING LAB

1. Making of single piece pattern

2. Making of split piece pattern
3. Single piece molding
4. Split piece molding
5. Permeability test of the molding sand

II.WELDING LAB:

1. Spot welding
2. Arc welding – lap joint
3. Arc welding – single V-butt joint
4. Rod butt joint

III. MECHANICAL PRESS WORKING:

1. Pipe bending
2. Blanking
3. Piercing

IV. PROCESSING OF PLASTICS

1. Blow molding
2. Injection molding

10 | P a g e
Production Technology Lab Department of Mechanical Engineering

EXPERIMENT NO. 1 DATE:

MAKING OF SINGLE PIECE PATTERN

Aim: To make single piece pattern.
Material Required: Kamba wood of 80×50×50 mm.
Tools Required: Steel rule, Divider, Calipers, Firmer chisel, Mortise chisel, Metal Jack plane,
Bench vice, Emery paper.

Fig.1: Single piece pattern

Theory:
1. A pattern is a mold forming tool in the hands of foundry men.
2. A pattern is the model or the replica of the object to cast.
3. Except for various allowances a pattern exactly resembles the casting to be made.

11 | P a g e
Production Technology Lab Department of Mechanical Engineering

4. A pattern may be defined as model or form around which sand is packed to give rise to a
cavity known as mould cavity in which molten metal is poured, the result is cast object.

Pattern Making Procedure:

1. The given Kamba wood piece is taken and the required dimensions of the pattern are
marked on the faces of the wooden piece.
2. The given wooden specimen is fixed to the bench vice and the cutting operations are
done with the help of required cutting tools.
3. After the extra material is removed, the specimen rough surfaces are polished with the
help of emery paper.
Precautions:
1. The work piece should be held rigidly in the bench vice while performing cutting
operations.
2. Pattern should have good surface finish, because finish of the casting depends on the
finish of the pattern.
Result: Hence the single piece pattern with the required dimensions is made.

12 | P a g e
Production Technology Lab Department of Mechanical Engineering

EXPERIMENT NO. 2 DATE:

MAKING OF SPLIT PIECE PATTERN

Aim: To make split piece pattern.
Material Required: Kamba wood of 80×50×50 mm.
Tools Required: Wood turning lathe, Calipers, Spanner, Chuck spanner, Single point cutting
tool, and emery paper.

Fig.2: Split piece pattern

Theory:
1. A pattern is a mold forming tool in the hands of foundry men.
2. A pattern is the model or the replica of the object to cast.
3. Except for various allowances a pattern exactly resembles the casting to be made.
4. A pattern may be defined as model or form around which sand is packed to give rise to a
cavity known as mould cavity in which molten metal is poured, the result is cast object.

13 | P a g e
Production Technology Lab Department of Mechanical Engineering

Fig.3:split piece pattern

Pattern Making Procedure:
1. The given work piece is fixed between live centre and dead centre of wood working
lathe.
2. Adjust the machine to run the job to a required cutting speed.
3. The cutting tool is placed in a proper position to cut the work piece.
4. Give the depth of cut and feed to the cutting tool.
5. Plain turning operation is performed until the diameter of the work piece reduces to
required dimension.
4. Step turning operation is performed according to the given dimensions.
5. Frequently check the dimensions using caliper.
6. The work piece rough surfaces are polished with the help of emery paper.
Precautions:
1. The work piece should be held rigidly between the two centers before operating the
machine.
2. Make sure that the axis of drill coincides with the axis of work.

14 | P a g e
Production Technology Lab Department of Mechanical Engineering

3. Optimum machining conditions are should be maintained.

4. Pattern should have good surface finish, because finish of the casting depends on the
finish of the pattern.
Result: Hence the split piece pattern with the required dimensions is made.

15 | P a g e
Production Technology Lab Department of Mechanical Engineering

EXPERIMENT NO. 3 DATE:

SINGLE PIECE MOULDING

Aim: To make mould of a single piece pattern.
Material Required: Molding sand, Parting sand and Facing sand.
Tools Required: Pattern, Shovel, Sieve, Trowel, Rammer, Sprue pin, Strike off bar, Lifter, Gate
cutter, Runner, Riser, Vent rod, Draw spike and Molding boxes.

Fig.4 Casting mould

Sequence of Operations:
Sand Preparation, Placing the pattern on the molding board, Ramming of drag, Placing runner
and riser, Ramming of cope, Removal of runner, riser, pattern and Gate cutting.
Theory
Casting process does not impose any restriction for type of metal or alloy while as forging process
cannot use brutal material. This process provides the greatest ease in design in terms of size, shape and

16 | P a g e
Production Technology Lab Department of Mechanical Engineering

product quality. This process is economically suitable for both small quality job production as well as
mass production. casting which are made of gray cast iron are used in manhole covers, sanitary fittings
water pipes, die blocks, brake drums, cast steels are used in gears, shafts, vessel, liner of ball mills,
furnace parts etc..,
A mold is a cavity, which is formed with the help of pattern in a suitable mold material. A core is used to
produce recess in casting. The main purpose of mold is to receive molten metal.

Molding Procedure:
1. First a bottom board is placed either on the molding platform or on the floor, making the
surface even.
2. The drag flask is kept upside down on the bottom board along with the drag part of the
pattern at the centre of the flask on the board.
3. Dry facing sand is sprinkled over the board and pattern to provide a non-sticky layer.
4. Freshly prepared molding sand of requisite quality is now poured in to the drag and on the
pattern and uniformly rammed.
5. After the ramming is over, the excess sand in the flask is completely scraped using a flat bar
to the level of the flask edges.
6. Now with a vent wire with a pointed end, vent holes are made in the drag to the full depth of
the flask as well as to the pattern to facilitate the removal of gases during casting
solidification. This completes the preparation of the drag.
7. Now finished drag flask is rolled over to the bottom board exposing the pattern.
8. Using a slick, the edges of sand around the pattern is repaired and cope box is placed over the
drag box, aligning it with the help of dowel pins.
9. The riser pin is then located on the surface of the surface of the pattern.
10. The sprue pin is placed at about 50 to 60 mm from the pattern.
11. Dry parting sand is sprinkled all over the drag surface and on the pattern.
12. Steps 4 to 6 are repeated.
13. The sprue and riser are removed carefully withdrawn from the flask.
14. Cope is kept a side and the pattern is removed using draw pins.
15. Gate is prepared using gate cutter.
16. The cope is placed back on the drag taking care of the alignment of the two by means of the
pins.

17 | P a g e
Production Technology Lab Department of Mechanical Engineering

17. The mould is ready for pouring molten metal.

Precautions:
1. There should be enough clearance between the pattern and the walls of the flask.
2. The ramming of sand should be done properly so as not to compact it too hard, which
makes the escape of gases difficult.
3. Pattern should have good surface finish because finish of the casting depends on the
finish of the pattern.
Result: The sand mold for a single piece pattern is thus made, which is ready for pouring the
molten metal.

18 | P a g e
Production Technology Lab Department of Mechanical Engineering

Experiment No. 4 Date:

Mold Making By Using Split Piece Pattern

Aim
To prepare a sand mold by using a split piece pattern.
Objective
i. Choose a design which will produce an effective mold and a strong useful casting.
ii. List the different types of molds used for sand casting.
iii. Enumerate the advantages and limitations of each type of sand mold.
iv. Demonstrate the methods of producing sand molds for each of these patterns: flat parting line,
cylindrical pattern, pattern with a core insert, and expendable pattern.
v. Identify the procedures for producing runners and gates.
Material Required
Coarse sand (75%), Bentonite (10%), Water (5%), coal dust (10%)
Molding Accessories
 Box Flask
 Triangular Snap Flask
 Shovel
 Riddle
 Trowels
 Slicks
 Lifters
 Draw Spikes
 Rammer
 Swab
 Row hide Mallet
 Gate Cutter
 Clamps
THEORY:
Casting process does not impose any restriction for type of metal or alloy while as forging process
cannot use brutal material. This process provides the greatest ease in design in terms of size, shape and

19 | P a g e
Production Technology Lab Department of Mechanical Engineering

product quality. This process is economically suitable for both small quality job production as well as
mass production. casting which are made of gray cast iron are used in manhole covers, sanitary fittings
water pipes, die blocks, brake drums, cast steels are used in gears, shafts, vessel, liner of ball mills,
furnace parts etc..,
A mold is a cavity, which is formed with the help of pattern in a suitable mold material. A core is used to
produce recess in casting. The main purpose of mold is to receive molten metal.

Fig 5: Split piece moulding

Procedure
i. Firstly sand is conditioned by removing lumps and by mixing water
ii. The flak is laid and parting sand is spread over the flask
iii. The split piece pattern is placed and the molding sand is spread to form a layer
iv. The ramming is done and process is repeated until the molding sand comes up to the flask
v. Then the flask is inverted and another piece of pattern is attacked with the help of dowel pins.
vi. The parting sand is spread and riser and runner are kept.
vii. The molding sand is placed and ramming is done until the sand comes up to the flask
viii. The pattern is taken out with help of pins and gate is cut using lifter

Result
A mold is made using split piece pattern.

20 | P a g e
Production Technology Lab Department of Mechanical Engineering

EXPERIMENT NO. 5 DATE:

PERMEABILITY TEST OF THE MOLDING SAND

Aim: To determine the permeability of the given molding sand sample.
Apparatus: Sand Specimen Rammer, Sand, Permeability Tester, Electronic weighing scale,
stripper, Stop watch, Measuring jar, Specimen tube, Specimen tube cup.

Fig.6:Permeability test
Theory:
1. Molten metal always contain certain amount of dissolved gases, which are evolved when the
metal starts freezing.
2. When molten metal comes in contact with moist sand, generates steam or water vapour.
3. Gases and water vapour are released in the mould cavity by the molten metal and sand. If
theydo not find opportunity to escape completely through the mould, they will get entrapped and

21 | P a g e
Production Technology Lab Department of Mechanical Engineering

form gas holes or pores in the casting. The sand must therefore besufficiently porous to allow the
gases and water vapour to escape out. This property of sand is referred to as permeability.
4. Permeability is one of the most important properties affecting the characteristic of moulds
which depends upon the grain size, grain shape, grain distribution, binder content,moisture level
and degree of compactness.
5. Permeability is a physical property of the physical sand mixture, which allows gasesto pass
through it easily.
6. The AFS (American Foundry Men Society) definition of permeability is “The number
obtained by passing 2000cc of air through a standard specimen under a pressure of 10
gm/cm2 for a given time in minutes”.
7. The permeability number PN can be found out by the equation.
V .H
P N=
P. A.T
Where
V = Volume of air passing through the specimen, 2000cc
H = Height of the specimen = 5.08cm (standard value)
P = Pressure as read from the manometer in gm/cm2
A = Area of the specimen = πd2/4, here d = 5.08 cm (standard value)
T= Time in minutes for 2000cc of air passed through the sand specimen.

Sand Rammer:

Fig.7 Sand rammer

22 | P a g e
Production Technology Lab Department of Mechanical Engineering

Experimental Setup Details:

Permeability meter has a cylindrical water tank in which an air tank is floating. By properly
opening the valve, air from the air tank can be made to flow through the sand specimen and a
back pressure is setup. The pressure of this air is obtained with the water manometer. The meter
also contains the chart, which directly gives the PN depending on pressure.
Procedure:
1. Take weighed proportions of sand dry mix them together for 3 minutes. Then add required
proportions of water and wet mix for another 2 minutes, to get a homogeneous and mixture.
Take the total weight of the mixture between 150-200 grams. The correct weight has to be
determined by trial and error method.
2. Fill the sand mixture into the specimen tube and ram thrice using sand rammer. Use the
tolerance limit provided at the top end of the rammer for checking the specimen size. If the
top end of the rammer is within the tolerance limit, the correct specimen is obtained. If it lies
below the limit, increase the weight of sand mixture and prepare a new specimen. The
specimen conforming to within limits represent the standard specimen required.
3. After preparing the standard specimen of diameter 5.08 cm and height 5.08 cm.
5. Place the standard specimen along with the tube in the inverted position on the rubber seal or
on the mercury cup (specimen in the top position in the manometer reading).
6. Operate the valve and start the stop watch simultaneously. When the zero mark on the inverted
jar just touches the top of water tank, note down the manometer reading.
7. Note down the time required to pass 2000cc of air through the specimen. Calculate the
permeability number by using the formula given.
Direct Scale Reading:
The permeability can also be determined by making use of the graduated marker provided near
the manometer.

Result: Hence the required permeability test of the given moulding sand is completed.

23 | P a g e
Production Technology Lab Department of Mechanical Engineering

EXPERIMENT NO. 6 DATE:

SPOT WELDING
Aim: To Weld the given sheet metal pieces with the help of spot-welding.
Equipment and Material Required: Spot welding machine (440 V, single phase, 50 cycles
fuse rating 15 amps,), GI Sheets.
Tools Required: Wire brush, hand gloves.
Description: Fig shows Spot welding set up. It is a solid state welding process, in which the
work pieces to be welded are forced together by apply a compressive load. Current is passed
through the contact area.

Theory:
In this welding at low voltage, very high current is passed through the joint for a very short time
(25 see). This high amperage heats the Joining due to the contact resistance at the joint. The
pressure on the joint is continuously maintained and the metals weld together, under this
pressure. The heat generated in the resistance welding can be expressed as H=kI 2 Rt
Where H = The total heat generated in the work, J
I = Electric current, A
T = Time for which the electric current is passing through the joint (seconds)
R = Resistance of the joint, Ω
K = A Constant to account for the heat losses from the welded joint.
24 | P a g e
Production Technology Lab Department of Mechanical Engineering

The main requirement of the process is the low voltage and high current power supply.
This is obtained, by means of a step down transformer with a provision to have different tapings
on the primary side, as required depending on the thickness and the properties of work pieces to
be weld .The secondary windings are connected to the electrodes which are made up of copper,
which have less resistance.
The time of electric supply needs to be closely controlled so that the heat released is just
enough to make the joint and subsequence fusion take place to the force on the joint. The force
required can be provided either mechanically, by hydraulically and pneumatically. To precisely
control the time, sophisticated electronic times are available. Spot welding machine consists of
two Electrodes out of which one is fixed. The other electrode is fixed to rocker arm for
transmitting mechanical force from a pneumatic cylinder. A resistance welding consists of
sequence of events that take place.
The squeeze time is the time required for the electrodes to align and clamp the two pieces
together under them and provide necessary electrical contact. The weld time is the time of the
current flow through work pieces till they are heated to the melting temperature of the work
pieces to be welded

Fig.9:Spot welding workpiece

25 | P a g e
Production Technology Lab Department of Mechanical Engineering

Procedure:
1. Place the sheets between two electrodes, such that the electrode should tough the sheet at
the required spot.
2. As the lower electrode arm is stationary, bring the upper electrode in to contact with the
sheet by means of spring – loaded foot pedal.
3. By completing the circuit resistance, spot welding will be carried out.
Precautions:
1. Proper care should be taken during welding.
2. Ensure the overlap the sheet to be proper.
Result: Hence the required joint using spot welding process is prepared.

26 | P a g e
Production Technology Lab Department of Mechanical Engineering

EXPERIMENT NO. 7 DATE:

ARC WELDING -LAP JOINT

Aim: To make a lap joint using arc welding on the given work pieces.
Material Required: Mild steel plate of size 100×50×5 mm – 2 Nos
Equipment Required: Arc welding machine.
Hand Tools Required: Power supply (AC or DC), Welding torch, Electrodes, Tongs, Chipping
hammer, Wire brush, Gloves, Apron, Face shield, Safety goggles and Files.
Sequence of Operations: Edge preparation (Removal of rust, scale etc.), Tacking, Welding,
Cooling, Chipping, Cleaning.

Fig.10:Lap joint
Theory
Joining two or more metals to make a single part is termed as a fabrication process. Among all
fabrication process welding is a metallurgical fusion process. The application of welding is now so wide
spread that there is no metal industry or branch of engineering where welding is not used in one form or
the other. Welding is widely used in aircrafts and ship bodies, building trusses welded machine frames,
sheet metal parts, automobiles, dies &food plant equipment etc.., Arc welding is one of most widely
used welding process mainly because of high production rates that can be achieved economically

27 | P a g e
Production Technology Lab Department of Mechanical Engineering

Electric arc welding process makes use of heat produced by the electric arc to fusion weld metallic
process. This is one of the most widely used welding process mainly because of the ease of use and high
production rate. An arc is generated between two conductors of electricity. Cathode and anode when
they are touched to establish the flow of current and then separated by a small distance. When
electrode is connected with negative pole of DC welding plant, it is called straight polarity.
Procedure:
1. First of all, the work pieces must be thoroughly cleaned to remove rust, scale and other
foreign material.
2. Now the work pieces are placed on the table in such a way that two work pieces are
overlapped one over another as shown in Fig.
3. Appropriate power supply should be given to the electrode and the work pieces.
4. Now the welding current output may be adjusted.
5. When current is passed, arc is produced between electrode and the workpieces.
6. First tack at both ends of the lap joint as shown in Fig.
7. Then the welding is carried out throughout the length of the work piece.
8. As soon as the welding process is finished switch off the current supply.
9. Then allow the work piece to cool, after that slags are removed by chipping process with
the help of chipping hammer.
10. Finally by using wire brush, welded portions (weldment) are cleaned.
Precautions:
1. The process is maintained at a current of 90-130 amperes.
2. Parallel passes are a must.
3. The electrode must be at 2-3 mm from work piece.
4. During the process the electrode is held at 60o to 70o to the horizontal.
5. Keeping the cloths safely the welding operation should be done.
Result: Thus the desired lap joint is obtained using arc welding.

28 | P a g e
Production Technology Lab Department of Mechanical Engineering

EXPERIMENT NO. 8 DATE:

ARC WELDING – SINGLE V-BUTT JOINT

Aim: To make a lap joint using arc welding on the given work pieces.
Material Required: Mild steel plate of size 100×50×5 mm – 2 Nos
Equipment Required: Arc welding machine.
Hand Tools Required: Power supply (AC or DC),Welding torch, Electrodes, Tongs, Chipping
hammer, Wire brush, Gloves, Apron, Face shield, Safety goggles and Files.
Sequence of Operations: Edge preparation (Removal of rust, scale etc.), Tacking, Welding,
Cooling, Chipping, Cleaning.

Fig.11 Single V butt joint

29 | P a g e
Production Technology Lab Department of Mechanical Engineering

Theory
Joining two or more metals to make a single part is termed as a fabrication process. Among all
fabrication process welding is a metallurgical fusion process. The application of welding is now so wide
spread that there is no metal industry or branch of engineering where welding is not used in one form or
the other. Welding is widely used in aircrafts and ship bodies, building trusses welded machine frames,
sheet metal parts, automobiles, dies &food plant equipment etc.., Arc welding is one of most widely
used welding process mainly because of high production rates that can be achieved economically
Electric arc welding process makes use of heat produced by the electric arc to fusion weld metallic
process. This is one of the most widely used welding process mainly because of the ease of use and high
production rate. An arc is generated between two conductors of electricity. Cathode and anode when
they are touched to establish the flow of current and then separated by a small distance. When
electrode is connected with negative pole of DC welding plant, it is called straight polarity.
Procedure:
1. First of all, the work pieces must be thoroughly cleaned to remove rust, scale and other
foreign material.
2. Prepared the edges of the work pieces on grinding machine to be joined to the required V
shape.
3. Then the given work pieces are places on the table in such a way that two work pieces are
brought close to each other so that it forms a V-shape when the plates butt each other.
4. Appropriate power supply should be given to the electrode and the work pieces.
5. Now the welding current output may be adjusted.
6. When current is passed, arc is produced between electrode and the work pieces.
7. First tack at both ends of the butt joint as shown in Fig.
8. Then the welding is carried out throughout the length of the work piece.
9. As soon as the welding process is finished switch off the current supply.
10. Then allow the work piece to cool, after that slags are removed by chipping process with
the help of chipping hammer.
11. Finally by using wire brush, welded portions (weldment) are cleaned.
Precautions:
1. The process is maintained at a current of 90-130 amperes.
2. Parallel passes are a must.

30 | P a g e
Production Technology Lab Department of Mechanical Engineering

3. The electrode must be at 2-3 mm from work piece.

4. During the process the electrode is held at 60o to 70o to the horizontal.
5. Keeping the cloths safely the welding operation should be done.
Result: Hence the required single V-butt joint is prepared.

31 | P a g e
Production Technology Lab Department of Mechanical Engineering

EXPERIMENT NO. 9 DATE:

ARC-WELDING ROD BUTT JOINT

Aim: To make a rod butt joint using arc welding on the given work pieces.
Material Required: Mild steel rods of size 100×50×5 mm – 2 Nos
Equipment Required: Arc welding machine.
Hand Tools Required: Power supply (AC or DC),Welding torch, Electrodes, Tongs, Chipping
hammer, Wire brush, Gloves, Apron, Face shield, Safety goggles and Files.
Sequence of operations: Edge preparation (Removal of rust, scale etc.), Tacking, Welding,
Cooling, Chipping, Cleaning.

Fig.12 Rod butt joint

Theory
Joining two or more metals to make a single part is termed as a fabrication process. Among all
fabrication process welding is a metallurgical fusion process. The application of welding is now so wide
spread that there is no metal industry or branch of engineering where welding is not used in one form or
the other. Welding is widely used in aircrafts and ship bodies, building trusses welded machine frames,
sheet metal parts, automobiles, dies &food plant equipment etc.., Arc welding is one of most widely
used welding process mainly because of high production rates that can be achieved economically

32 | P a g e
Production Technology Lab Department of Mechanical Engineering

Electric arc welding process makes use of heat produced by the electric arc to fusion weld metallic
process. This is one of the most widely used welding process mainly because of the ease of use and high
production rate. An arc is generated between two conductors of electricity. Cathode and anode when
they are touched to establish the flow of current and then separated by a small distance. When
electrode is connected with negative pole of DC welding plant, it is called straight polarity.
Procedure:
1. First of all, the work pieces must be thoroughly cleaned to remove rust, scale and other
foreign material.
2. Prepared one of the edges of the rods on grinding machine to be joined to the required
bevel shape.
3. Then the given work pieces are places on the table in such a way that two work pieces are
brought close to each other so that it forms a bevel-shape when the rods butt each other.
4. Appropriate power supply should be given to the electrode and the work pieces.
5. Now the welding current output may be adjusted.
6. When current is passed, arc is produced between electrode and the work pieces.
7. Then the welding is carried out around bevel shape of the rods.
8. As soon as the welding process is finished switch off the current supply.
9. Then allow the work piece to cool, after that slags are removed by chipping process with
the help of chipping hammer.
Precautions:
1. The process is maintained at a current of 90-130 amperes.
2. Parallel passes are a must.
3. The electrode must be at 2-3 mm from work piece.
4. During the process the electrode is held at 60o to 70o to the horizontal.
5. Keeping the cloths safely the welding operation should be done.
Result: Thus the desired rod butt joint is obtained using arc welding.

33 | P a g e
Production Technology Lab Department of Mechanical Engineering

EXPERIMENT NO: 10 DATE:

BENDING PROCESS

Aim:To study and analyze the significant effect of spring back on bending and other sheet metal
forming process and to know how to determine the spring back factors for materials.

Requirement:
a. Different bending samples of Brass, Steel, Galvanized Iron and Aluminum are required.
b. Tubes - Dia 6mm
c. Steel Rule
d. Scriber
e. Snips
f. Blender
Equipment:
a. Bench Wise
b. Bending Dies

Theory:
Bending and bending dies:
Bending is the metal working process by which a straight length is transformed into a curved
length. It is very common forming process, for changing sheet and plate into channels, drums
and tanks etc.During the bending operation, the outer surface of the material is in tension and the
inside surface is in compression. The strain in the bent material increases with
decreasing the radius of curvature. The stretching of the bend causes the neutral axis to move
toward the inner surface. In most cases, the distance of the neutral axis from the inside of the
bend is 0.3 t to 0.5 t , where “t” is thickness of the part.

34 | P a g e
Production Technology Lab Department of Mechanical Engineering

Fig.13 Bending terms

Fig.14: Study of dies

Bending Methods:
The two bending methods commonly used are V-bending and edge bending.

1V–Bending:
In V–bending, a wedge shaped punch forces the metal sheet or strip into a wedge shaped die
cavity, shown in fig. The bend angle may be acute 90°, or obtuse. As the punch descends, the
contact forces at the die corner produce a sufficiently large bending moment at the punch corner
to cause the necessary deformation.

35 | P a g e
Production Technology Lab Department of Mechanical Engineering

2.Edge Bending:
In edge bending , a flat punch forces the stock against the vertical force of the die. The bend axis
is parallel to the edge of the die and the stock, is subjected. Minimum Bending Radius When
Bending Bars of Steel.

Fig.15 types of bending

Procedure:

1) Set the bending die on the pressing machine.

2) Set up the pressing machine for the test.
3) Select a sample test, and then measure its thickness (t).
4) Measure the die angle (αi) and die radius (Ri).
5) Perform the bending process by putting the flat sheet on the lower half of the bending die and
then press the sheet to the required bending shape by the upper half of the bending die.
6) Measure the final sheet angle (αf ) and radius (Rf) after bending.
7) Record all the measurements and observations.
8) Repeat the test for different sheet thicknesses and materials.

Precautions:

Working with sheet metal, especially after it’s been cut, can be dangerous. Each cut you make
exposes sharp edges and creates burrs that can slice a finger. That’s why it’s vital that you
take safety precautions. Wear safety gloves whenever possible, and always wear safety goggles
and work boots. Never run your hands, even when gloved, over a cut edge. Always file

36 | P a g e
Production Technology Lab Department of Mechanical Engineering

down burrs promptly. Keep your work surface free of scrap.

Metal waste also has hazardous edges. Handle metal sheets with care, especially if they are wet,
because moisture mixed with oil and dirt can slick the surface and make it hard to grasp. Finally,
make sure your hammers are solid and your shears are sharp.

Results:
Studied and analyzed the significant effect of spring back on bending and other sheet metal
forming process to determined the spring back factors.

37 | P a g e
Production Technology Lab Department of Mechanical Engineering

EXPERIMENT NO. 11 DATE:

BLANKING

AIM: To cut the blanked object from the given GI sheet.

APPARATUS: Hydraulic press and blanking die.

MATERIAL REQUIRED: GI sheet or MS plate.

THEORY:
BLANKING: It is the process in which the punch removes a portion of the material fromthe
stock which is a strip of sheet metal of the necessary thickness and width. Theremoved portion is
called a blank and is usually further processed to be of some use.

Fig.16 Blanking
PROCEDURE:

1. Take required size of material to place in closed die.

2. Clean the surface of the material.

3. Flatten the GI sheet to remove the UN even surface with wooden mallet.

4. Place the sheet in die and apply pressure with hydraulic press.

5. Release the pressure relief valve after cutting the blank.

38 | P a g e
Production Technology Lab Department of Mechanical Engineering

PRECAUTIONS:

1. Take care while operating hydraulic press.

2. Check Oil tank leakages before operating pressure leaver. 3. Stop applying pressure after
piercing operation is completed

RESULT:

39 | P a g e
Production Technology Lab Department of Mechanical Engineering

EXPERIMENT NO: 12 DATE:

PIERCING

AIM: To perform piercing operation on the given blanked object.

APPARATUS: Hydraulic press and piercing die.

MATERIAL REQUIRED:

GI sheet or MS Plate.

PIERCING: This is also called Punching. The piercing is making holes in a sheet. It is

identical to blanking except of the fact that the punched out portion coming out through the die

in piercing is scrap. Normally a blanking operation is will generally follow a piercing operation.

Fig.17 Piercing
PROCEDURE:

1. Take required size of material to place in closed die.

2. Clean the surface of the material.

3. Flatten the GI sheet to remove the un even surface with wooden mallet.

4. Place the sheet in die and apply pressure with hydraulic press.

5. Release the pressure relief valve after cutting the blank.

40 | P a g e
Production Technology Lab Department of Mechanical Engineering

PRECAUTIONS:

1. Take care while operating hydraulic press.

2. Check Oil tank leakages before operating pressure leaver.

3. Stop applying pressure after piercing operation is completed

RESULT:

41 | P a g e
Production Technology Lab Department of Mechanical Engineering

EXPERIMENT NO. 13 DATE:

INJECTION MOULDING
Aim: To make a component by Injection molding equipment.
Equipment and Material Required: Injection molding equipment, thermoplastic material and
dies.
Theory: Injection molding is usually employed for thermo plastic materials, which are soften by
heating and then re-harden during cooling. The molding material (thermoplastic) is fully
polymerized before pouring in to the mould, since undergo only a physical change during
Injection molding. In Injection molding the material is heated to the soften state and then the soft
material is injected in to the mould and then allowed to cool to harden, there by the desired
article is obtained. Heating unit temperatures usually ranges from 60°C to 80°C.The advantage
of injection molding is that mass production is possible, which offset the higher capital cost.

Fig.18 Injection moulding

42 | P a g e
Production Technology Lab Department of Mechanical Engineering

Fig.19 Injection molding process

Procedure:
1. Die is placed at proper position, under the nozzle hole, on the bed of the Injection
molding machine.
2. The molding material in the form of granules is fed through the hoper to the Cylinder
where it gets softened.
3. By electric means, heat the granules up to molten state.
4. After material reaches to molten state, move the plunger in to the heated chamber, which
advances against die cavity.
5. Molten material can pass though nozzle in to the mould cavity and then mould is allowed
to cool and hardened.
6. After hardening, the plunger to be returned backward.
7. Now mould is to be opened to eject the plastic particles.
Precautions:
1. Keep the heat unit temperature ranges from 60°C to 80°C.
2. Overheating should be avoided.
3. Sufficient time should be allowed for solidification of plastic grains.
4. Excessive pressure on the plunger should be avoided.
5. The die should be properly aligned.
Result: Hence the key chain is made using injection molding.

43 | P a g e
Production Technology Lab Department of Mechanical Engineering

EXPERIMENT NO: 14 DATE:

BLOW MOULDING

AIM: To inject the thermo plastic material into the mould for obtaining the desired article.

APPARATUS: Blow molding machine, die

MATERIAL: Thermo plastic pallets.

Fig.20 Blow moulding

PROCEDURE:

1. Pour the raw material in the tapered section.

2. Place the die in such a way that its hole coin sides with the central axis of the cylinder.

3. Heat the cylinder by pouring plastic pallets in it.

4. When the metal is heated at 2700c it is converted into molten metal.

5. Press the lever so that the softened plastic will enter into the die and gets the desired shape of

the mould.

6. Allow it to cool for some time.

44 | P a g e
Production Technology Lab Department of Mechanical Engineering

7. Open the die and eject the article.

PRECAUTIONS:

1. Align the opening of the die and an orifice of the cylinder carefully.

2. Use gloves while holding die.

RESULT:

45 | P a g e
Production Technology Lab Department of Mechanical Engineering

EXPERIMENT NO: 15 DATE:

SOLDERING

AIM: To perform soldering of two objects..

APPARATUS: Soldering gun or Soldering Iron,

MATERIAL: Flux, Tin/Lead solder

THEORY: Soldering accomplishes a strong bond between two pieces of metal by joining them
together. In this procedure, a material called solder, an alloy mixture of tin and lead, flows over
two pre-heated pieces of metal and holds them together. The process is similar to welding but
differs because when you weld you are fusing and melting two pieces together to make one.
When you solder you are essentially ‘gluing’ two parts together with molten metal. Most metals
with the exception of aluminum, white metal and porous cast iron can be soldered.

46 | P a g e
Production Technology Lab Department of Mechanical Engineering

PROCEDURE:

1. Prepare a work space. Lay down a mat or piece of cardboard that will catch any solder
that you drip.

2. Warm your soldering iron. If your soldering iron is electric, you’ll need to allow it to
warm up on its stand.

3. Secure the items you are soldering. It helps to have an extra hand while you are soldering.
We suggest using a vise or frame to secure your work.

4. Clean your soldering iron. Because soldering irons get so hot, they oxidize and become
dirty quickly. They key to reliable connections is clean components so make sure that
your soldering tip and parts you are joining are clean. To accomplish this, pass the tip of
your soldering iron on a wet sponge until it shines.

5. Apply flux. In soldering it often becomes necessary to use materials called fluxes to help
remove oxides and keep them absent while you solder. Flux needs to melt at a
temperature lower than solder so that it can do its job prior to the soldering action. There
are different methods to apply flux. The method you choose will be dependent on the
items you are soldering.

6. Tin your soldering iron. If you want to know everything there is to know about how to
use a soldering iron, you’ll need to know how to tin. Tinning is the process of coating a
soldering tip with a thin coat of solder. Melt a thin layer of solder on your iron’s tip. This
aids in heat transfer between the tip and the component you are soldering, and also gives
the solder a base from which to flow from. This process may need to be repeated as you
solder. You will only touch the tip of the soldering iron to the solder when you tin. Do
not touch the tip of the iron to the solder while you are actually soldering.

47 | P a g e
Production Technology Lab Department of Mechanical Engineering

7. Start soldering. Hold the soldering iron like you would a pen in the hand you write with
and the solder in the other.

8. Place the tip of the soldering iron tip. The tip needs to touch both the wire lead and the
surface so they achieve the same temperature.

9. Feed solder onto the joint after you have heated the area for two to three seconds. Touch
the solder to the side of the connection opposite the soldering iron. Then, let the solder
flow only until the connection is covered.

10. Remove the solder first. Then, remove the iron. Make sure the joint remains stationary
while it cools.

11. Evaluate. A smooth, shiny and volcano shaped joint is what you are looking for. If this
isn’t what you see, you’ll need to reheat and feed in more solder.

12. Remove leftover flux with a commercial flux cleaner.

PRECAUTIONS:

1. Keep the tip of the soldering iron away from your body and other materials, when not
using during the experiment. Do not touch the element or tip of the soldering iron. Its
temperature can be as high as 300-400°C.
2. Switch off the power supply when the soldering iron is not in use. Do not leave the power
turned on when unattended.
3. Do not inhale the fumes of the flux during the soldering activity. Keep your head to a side
while working. Work in a ventilated area.
4. Wash your hands after using solder. Solder contains lead which is a poisonous metal.

RESULT: Soldering experiment is performed.

48 | P a g e