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1 Assignment No: ME 192/292/01 Title: Manufacture a gauge from MS plate as per given drawing by performing different Fitting and Bench Work operations Aim: To obtain basic knowledge about different Fitting and Bench Work operations Raw Material: Mild steel Plate Raw Material Size: ………………………………… Tools required: 1. 12” Steel Rule.  2. 4” Parallel-Jaw Bench vice 3. 6” Odd leg caliper  4. 6’’ Try square 5. 6” Scriber 6. 6’’ Divider 7. 12’’ Hacksaw Frame 8. 12”- 18 TPI High Carbon Hacksaw Blade 9. 4’’ Prick punch 10. 4” Centre Punch 11. 250 gm Ball Peen Hammer 12. 12” Flat Ba stard File 13. 6” Smooth File  14. 6” Half round File 15. 6” Triangular File  16. 13mm Bench Drilling Machine with drilling vice 17. Ø9mm HSS Twist drill bit 18. M10 x 1.5 HSS tap set 19. Tap handle 20. 500 gm Ball Peen Hammer 21. Lettering and numbering Punch 22. Safety Goggles Procedure: 1. Check the size of raw material by using steel rule whether it is acceptable for performing the job as per drawing. 2. Hold the MS plate in the bench vice. 3. Make two adjacent sides of the MS plate right angle with the help of bastard file and try square so that the performing adjacent sides can act as datum reference lines for making measurement and marking lines. 4. Layout the flat surface by marking media chalk and water. 5. Marking is done as per drawing on the laid out surface of the metal plate using different marking instruments like steel rule, odd Leg caliper, try square, surface plate and scriber. 6. Punch the scribed lines for make the line permanent with the help of prick punch, centre punch and ball Peen Hammer. 7. Cut the work piece as per marking to bring the approximate size by removing extra metal with the help of Hacksaw and Bench vice. 8. Calculate the Tap size drill according to the internal thread (M10 x 1.5 mm). Here it is 8mm. 9. Hold proper drill bit into the drill chuck and the job in the drilling vice. Then centering of job to the proper position is performed by adjusting the table.

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1

Assignment No: ME 192/292/01

Title: Manufacture a gauge from MS plate as per given drawing byperforming different Fitting and Bench Work operations

Aim: To obtain basic knowledge about different Fitting and BenchWork operationsRaw Material: Mild steel PlateRaw Material Size: ………………………………… Tools required:

1. 12” Steel Rule. 2. 4” Parallel-Jaw Bench vice3. 6” Odd leg caliper 4. 6’’ Try square 5. 6” Scriber 6. 6’’ Divider 7. 12’’ Hacksaw Frame 8. 12”- 18 TPI High Carbon Hacksaw Blade

9. 4’’ Prick punch 10. 4” Centre Punch 11. 250 gm Ball Peen Hammer 12. 12” Flat Ba stard File13. 6” Smooth File 14. 6” Half round File15. 6” Triangular File 16. 13mm Bench Drilling Machine with drilling vice17. Ø9mm HSS Twist drill bit18. M10 x 1.5 HSS tap set 19. Tap handle20. 500 gm Ball Peen Hammer21. Lettering and numbering Punch 22. Safety Goggles

Procedure:1. Check the size of raw material by using steel rule whether it is acceptable for

performing the job as per drawing.2. Hold the MS plate in the bench vice.3. Make two adjacent sides of the MS plate right angle with the help of bastard file

and try square so that the performing adjacent sides can act as datum referencelines for making measurement and marking lines.

4. Layout the flat surface by marking media chalk and water.5. Marking is done as per drawing on the laid out surface of the metal plate using

different marking instruments like steel rule, odd Leg caliper, try square, surfaceplate and scriber.

6. Punch the scribed lines for make the line permanent with the help of prickpunch, centre punch and ball Peen Hammer.

7. Cut the work piece as per marking to bring the approximate size by removingextra metal with the help of Hacksaw and Bench vice.

8. Calculate the Tap size drill according to the internal thread (M10 x 1.5 mm). Hereit is 8mm.

9. Hold proper drill bit into the drill chuck and the job in the drilling vice. Then

centering of job to the proper position is performed by adjusting the table.

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10. Switch on the drilling m achine and feed the Drill Bit manually to produce the Φ8mm hole. Apply cutting fluid during the drilling operation as per requirement.

11. Switch off the Drill Machine and remove the job from Drill Vice and Drill Bitfrom the drill chuck.

12. Then hold the drilled plate in the bench vice rigidly with the hole in the uprightposition. Then to produce the internal thread as per drawing tapping operationis performed by using Tap Set according to chronological order i.e. rougher tap,intermediate tap and lastly finisher tap by turning the tap two or three rotationin the forward direction followed by a half rotation in backward direction for

breaking and removal of chips by Tap Wrench until the entire length of the tapenter the hole. Pour oil during tapping as a lubricant.

13. Finally the job is brought to accurate size as per drawing with the help of BastardFile, Smooth File, Triangular file, Half round file and Try Square.

14. Check and note the final dimensions of the job to ascertain whether it is finishedaccording to drawing or not by using Steel Rule, Try square, and VernierCaliper. Also verify the right angles of all adjacent sides by Try Square.

15. Punch roll number and branch code on the job for proper identification with thehelp of numbering punch lettering punch and ball peen hammer.

Precautions:1. Never place sharp material such as scriber, punch etc on the floor.2. Always use safety goggles.3. Never perform any Hamming Operation on the Surface Plate

Scale: 1:1 All Dimensions are in mm

JOB DR WING

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6. Put the welding electrode into the electrode holder and fit the earthing clamp tothe welding table. Then switch on the welding machine and set the proper arclength by adjusting voltage / current.

7. Tack both ends of the metal plates at the sides to be joined to avoid distortionusing welding machine and electrode.

8. Welding is performed by maintaining proper arc speed and arc length (2-3 mm).9. Cool the job in natural air.10. Then hold the job on the anvil by using tong and after that de-slugging is done

by rapid striking of the job by the chipping hammer.11. Clean the job by wire brush.12. Test the joint by visual observation.13. Finish the job by using file and bench grinder.14. Punch roll number and branch code on the job for proper identification using

lettering punch, numbering punch and ball peen hammer.Precautions:

1. Always perform welding after wearing all the safety gears.2. Do not perform welding operation with bare eye. Always use welding shield.3. Do not touch the electrode or job with bare hand. Always use flat tong.4. Always wore safety goggles during the chipping operation.5.

Scale: 1:1 All Dimensions are in mm

JOB DR WING

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Assignment No: ME 192/292/03

Title: Join two thin (3mm) metal sheets as per given drawing byperforming Lap joint by Oxy-Acetylene Welding

Aim: To get basic knowledge about Oxy- Acetylene gas welding Raw material: Two nos. Mild Steel Sheets

Raw Material Size: ……………………………

Tools and Accessories:

1. 12” Steel rule 2. 6”Try Square 4. 6” Scriber 4. 4” Prick Punch 5. 4” Parallel -Jaw Bench vice 6. 12” Flat Bastard File7. 8” Bench Grinder 8. Oxygen and Acetylene Cylinders fitted with pressure regulators and pressure

gauges9. Hoses (Blue or Black for Oxygen and Maroon or Red for Acetylene)10. Welding Torch 11. Cylinder Valve Opening Key12. Tip Cleaner 13. Spark Lighter14. Nozzle (No. 13) of Welding Torch 15. C.C.M.S Welding Rod

16. Flat Tong17. Safety Guards (Apron, Gloves, Leg Guard, Welding Goggles, and Helmet)18. Safety Goggles 19. Welding Table20 Hose Protector and Flash Back Arrester 21. Anvil (25 kg/50 kg)22.Chipping Hammer 23. Wire Brush24. Numbering & Lettering Punch 25. 500 gm Ball Peen Hammer26.Metal Bucket 27. Emery Cloth (100)

Procedure:1. Check the size of raw material by using steel rule and try square.2. Clean the surface and edges of the sheets using flat bastard file, emery paper and

wire brush.3. Marking the metal sheets as per drawing using steel rule, try square and Scriber.

4. Punching Roll No. and Branch Code in any piece of metal by using Punch andHammer.

5. Edge preparation is performed as per drawing using flat bastard file, bench viceemery cloth.

6. Set the metal sheets on the welding table by overlapping one edge of one sheetover the surface of the other sheet at proper place as per drawing with propersupport.

7. Open the O 2 Cylinder and move the O 2 regulator to flow gases through the hoseand use Tip cleaner to clean the carbon particle and asses from hose and Tip and

then close it.

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8. Open both the Gas Cylinders slowly one by one (chronological order) with gasopening key to check internal pressure of the cylinders and then set properwelding pressure by moving the regulator cap up to the required level.

9. Then ignite the flame by spark lighter. Set the flame as per requirement byadjusting the acetylene and oxygen valves of the welding torch.

10. Tack both ends of the metal sheets at the sides to be joined to avoid distortion.11. Welding is performed by the proper flame and also maintains required welding

speed. The Torch and Filler Rod are moved backwards along the line to bewelded.

12. After welding first close the C 2H 2 gas and then O 2.13. Close the cylinder tightly with cylinder key.14. Release the internal gases of both the hoses by opening both the valves of blow

pipe.

15. Cool the job in the natural air.16. Then hold the job on the anvil by using tong and after that de-slugging is done

by rapid striking of the job by the chipping hammer.17. Clean the job by wire brush.18. Test the joint by visual observation.19. Finish the job by using file and bench grinder.20. Punch roll number and branch code on the job for proper identification using

lettering punch, numbering punch and ball peen hammer.Precautions:

1. Before welding check the leakage test of Gas Welding set up with soap waterand brush, if there is any leakage take preventive measure like tightening andusing Teflon Tape in the position of threaded area and close it.

2. Always perform welding after wearing all the safety gears.3. Do not touch the job with bare hand. Always use flat tong.4. Always wore safety goggles during the cleaning operation.5. Maintain a safe distance from the burning flame.6. Cool the welding nozzle by dipping it in the water contained in the metal bucket

intermittently to avoid back fire.

7. Always transfer gas cylinders from one place to other with the help of weldingtrolley and never lay down the acetylene cylinder.

Scale: 1:1 All Dimensions are in mm

JOB DR WING

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7

Assignment No: ME 192/292/04

Title: Manufacture a component as per given drawing by performingdifferent machining operations on an Engine Lathe

Aim: To gain knowledge about operation of Engine Lathe and alsoabout different machining operations of Engine lathe Raw material: Mild Steel RodRaw Material Size: ……………………………Machine: Engine LatheSpecification of Machine: ……………………………… Tools and Accessories:

1. 3 or 4 Jaw Independent/Universal Chuck 2. Chuck Key3.12” Steel Rule 4. 12”Vernier Caliper

5.

6”Outs ide Caliper 6. 12”Adjustable Marking Gauge7.Tool Holder 8. Tool Holder Key9.Tool Post Wrench 10. Facing Tool11. Turning Tool 12. 6”Flat Smooth File 13. Emery Cloth (100) 14. Hand Gloves15. Marker Pen

Procedure:1. Check the size of Raw Material by using Steel Rule and Outside Caliper.2. Hold the job firmly inside the jaws of the Chuck by tightening the jaw’s screw

with the Chuck key.3. Centre the job with the help of Adjustable Marking Gauge by slowly rotating the

chuck manually.4. Check the nomenclature of the tool (tool angles, sharpness of the cutting edges

etc.)5. Fix the Cutting Tool inside the tool way of the Tool Holder firmly by tightening

screw with the help of Tool holder key.6. Place the tool holder inside the Tool Post and centre the tool with respect to dead

centre by using metal seams and finally fix the position by tightening the bolts ofTool Post with the tool post wrench.

7. Calculate the cutting speed (r.p.m.), feed and depth of cut for differentoperations required.

8. Switch on the Machine and making a flat surface at the end of the job,perform facing operation by advancing the facing tool perpendicular to the axisof rotation of the job (cross feed).

9. Reduce the diameter of the job up to requisite length as per drawing byperforming rough turning followed by finish turning by advancing the turningtool along the axis of rotation of the job (longitudinal feed).

10. Produce the required Chamfer at the end of the job by performing Chamfering

operation.11. Take out the job from the chuck by loosening the jaw’s screw.

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12. Fit the opposite end of the job into chuck in a similar manner as described in 2-3.13. Make the end of the job flat by performing facing operation.14. Reduce diameters up to requisite length at different position by performing step

turning operation.15. Produce the required Chamfer at the end of the job by performing Chamfering

operation.16. Finish the job for getting better surface finish by using smooth file and fine

emery cloth.17. Switch off the Machine and take out the job from the chuck by loosening the

jaw’s screw. 18. Check and note the final dimensions of the job whether it is finished according to

drawing or not using steel rule, out Side Caliper, Vernier Caliper and record thedeviation.

19. Mark the Roll No. and Branch Code on the job with the Marker Pen for properidentification.

20. Clean the Machine properly with Brush and Cotton Thread.Precautions:1. Do not put your hands and finger inside the movable parts.2. Do not wear loose garments.3. Hold the job into chuck tightly.4. Do not touch the cutting tools and chips during the operation.5. Do not use too much depth and feed in the time of cutting operation.

Scale: 1:1 All Dimensions are in mm

JOB DR WING

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Workshop Practice (ME 191/ 292)

9

Assignment No: ME 192/292/05

Title: Finish two opposite sides of a MS block as per given drawing byperforming shaping operation on a shaping machine.

Aim: To acquire knowledge about the operation of Shaping machineand also shaping operation of shaping machine.

Raw material: Mild steel blockRaw Material Size: …………………………… mmMachine: Plain horizontal Cone Pulley Type Shaping MachineSpecification of Machine: ……………………………… Tools and Accessories:

1. 12” Steel Rule 2. 12” Vernier Caliper 3. 2’x 2’ Surface plate 4. 12” Vernier Height Gauge 5. 6” Try Square 6. 6” Out Side Caliper 7. 4” Prick Punch 8. 250 gm Ball Peen Hammer9. Scriber 10. Machine Vice & Vice11. Handle 12. Tool Holder & Tool Key13. Single Point Shaping Tool 14. Spirit Level15. Double Ended Spanner 16. Adjustable Spanner17. Lettering & Numbering Punch 18. 500 gm Ball Peen Hammer

19. Hand Gloves 20. Hand Gloves

Procedure:1. Check the size of raw material by using Steel Rule, Out Side Caliper and

Vernier Caliper.2. Mark the job as per drawing keeping it on the Surface Plate using Steel Rule,

Try square, Vernier Height Gauge and Scriber.3. Make the marking permanent by Prick Punch and Ball peen Hammer.4. Fix the job rigidly on the Machine Vice of the Shaping Machine and level it by

spirit level.5. Check nomenclature of the cutting tool (tool angles, sharpness of the cutting

edges etc.).6. Fix the cutting tool into the tool holder with the help of tool key and after that

hold the tool holder into the tool head of the Clapper Box rigidly.

7. Adjust the length of stroke and position of ram with the help of ram controllever according to job length.

8. Align the job with respect to the table by moving the table horizontally andvertically.

9. Adjust the depth of cut by moving down the feed screw of the tool slide.

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10. Switch on the machine and enter the feed to the job under the reciprocatingcutting tool by moving the table manually/automatically and complete the cut.

11. Repeat the above operations (9-10) until required depth is achieved as permarking.

12. After completion of one side, finish the other side by following the sameoperations.

13. After competition of the machining as per drawing switch off the machine andremove the job from machine vice.

14. Check and note the final dimensions of the job whether it is finished accordingto drawing or not using Try Square and Vernier Caliper.

15. Punch roll number and branch code on the job for proper identification usinglettering punch, numbering punch and ball peen hammer.

Precautions:

1. Do not put your hands and finger inside the movable parts.

2. Do not wear loose garments.

3. Hold the job into Vice tightly.

4. Always use hand gloves.

Scale: 1:1 All Dimensions are in mm

JOB DR WING

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11

Assignment No: ME 192/292/06

Title: Make a slot (6 mm) on a MS block as per given drawing byperforming milling operation on a milling machine

Aim: To acquire knowledge about the operation of Milling machineand also production of slots by milling machine

Raw material: Mild steel block

Raw Material Size: .. …………………………… mm

Machine: Column and Knee type Universal Milling Machine

Specification of Machine: ………………………………

Tools and Accessories:

1. 12” Steel Rule 2. 12” Vernier Caliper 3. 6” Try Square 4. 6” Out Side Caliper 5. 4” Prick Punch 6. 250 gm Ball Peen Hammer7. Scriber8. 2’x 2’ Surface plate 9. 12” Vernier Height Gauge

10. Spirit Level11. Machine Vice & Vice Handle12. Double Ended Spanner13. Adjustable Spanner14. 3.5”X0.25”X1” Plain Side Milling Cutter15. Lettering & Numbering Punch16. 500 gm Ball Peen Hammer17. Hand Gloves

Procedure:

1. Check the size of raw material by using Steel Rule, Out Side Caliper andVernier Caliper.

2. Mark the job as per drawing keeping it on the Surface Plate using Steel Rule,Try square, Vernier Height Gauge and Scriber.

3. Make the marking permanent by Prick Punch and Ball peen Hammer.4. Fix the job rigidly on the Machine Vice of the Milling Machine and level it by

spirit level.5. Check the sharpness of the Milling Cutter.6. Insert the Milling Cutter into the arbor & fix it by tightening the nut.

7. Place the job below the cutter and place it appropriate position by adjustingthe table by rotating cross feed handle and longitudinal feed wheel.

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8. Set the desired depth of cut by adjusting the knee by rotating the kneeelevating handle.

9. Switch on the Machine and coolant Pump and give required feed to the jobunder the rotating cutter by moving the table manually /automatically andcomplete the cut.

10. Repeat the above operations until required depth is achieved.11. After completion of the milling operation, switch off the Machine and remove

the job from the Milling Vice.12. Check and note the final dimensions of the job whether it is finished according

to drawing or not using Try Square and Vernier Caliper.13. Punch roll number and branch code on the job for proper identification using

lettering punch, numbering punch and ball peen hammer.Precautions:

1. Do not put your hands and finger inside the movable parts.2. Do not wear loose garments.3. Hold the job into Vice tightly.4. Always use hand gloves.

Scale: 1:1 All Dimensions are in mm

JOB DR WING

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Assignment No: ME 192/292/07

Title: Forming a cone as per given drawing by performing differentsheet forming and soldering operations

Aim: To acquire essential knowledge about Sheet metal working andsoldering.

Raw material: G.I. Sheet

Raw Material Size: …………mm X……………… mm X…… SWG

Tools and Accessories:

1. Mallet

2. 6”Scriber 3. 4” Parallel -Jaw Bench vice4. 12”Steel Rule 5. 25 mm Outside Micrometer6. 6”Try Square 7. 6”Divider 8. 6”Plier s9. 18”Straight Snip

10. Funnel Stake1. 250 gm. Ball Peen Hammer2. 240W,220-230V Soldering Iron3. 5 mt. Extension Cord4. Hand Gloves5. Marker Pen6. Solder7. Flux (ZnCl 2)

Procedure :

1. Flatten the GI Sheet by Mallet2. Check the Dimensions of GI Sheet by steel rule. Also measure the thickness by

outside micrometer and find out the corresponding Standard Wire Gaugenumber (SWG) from standard table.

3. Develop the pattern of the cone) on the GI sheet, providing allowances for bending and forming, by Steel Rule, Try Square, Divider, and Scriber.

4. Cutting the GI Sheet as per developed surface (laid out pattern) by shearing with

the help of snip.5. Fold edges of the sheared sheet and then bend the sheet according to the

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development of surface with the help of funnel stake and ball point hammer.6. Join (Double Seam) the folded edges of the funnel.7. Solder the joint of the cone by using soldering iron, solder and requisite amount

of flax.8. Clean the job properly.9. Check the final Dimension of the Funnel whether it is finished according to

drawing using Steel Rule and record the deviation.10. Mark Roll Number on the job with the help of Marker Pen for proper

identification.

Precautions:

1. Do not handle the cut pieces with bare hand. Always use hand gloves 2. Do not forget to straighten the sheet metal pieces (Laid out pattern) after

shearing.

Scale: 1:1 All Dimensions are in mm

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JOB DR WING

Assignment No: ME 192/292/08

Title: Make a wooden pattern by performing different pattern makingoperation.

Aim: To obtain basic knowledge about pattern making.

Raw material: Gamari Wood

Raw Material Size: …………………………… mm

Machine: Belt and Disc Sander

Specification of Machine: Size: HP: RPM:

Tools and Accessories:1. 2’ Four Fold wooden Rule / 12” Steel Rule2. 9” Carpentry Vice3. 12” Iron Jack Plane4. 6” Try square 5. Marking Gauge6. Pencil7. 18” Cross -cut Hand Saw8. 12” Tenon Saw

9. 1” Firmer Chisel10. Mallet11. Sand Paper12. Marker Pen

Procedure:

1. Check the initial dimensions of the wooden piece by four fold wooden rule /steelrule.

2. Hold the wooden piece in the carpentry vice and all the surfaces excepting twoends are planned as per drawing and are also right angled to each other by using jack plane, steel rule and try square.

3. Marking is done on the plane surface according to drawing with the markinggauge, steel rule, pencil and try square.

4. Sawing and chiseling wooden piece according to the drawing using Cross-cutHand Saw, Tenon Saw, Firmer Chisel and Mallet.

5. Using belt sander machine finish the tapered portions.6. Final finishing and polishing of the job is done by using sand paper.7. Check the accuracy of final dimensions as per drawing

8. Mark roll number for proper identification using marker pen.

Precaution:

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Assignment No: ME 192/292/09

Title: Making a sand mould with the pattern developed earlier byperforming sand mould making operations.

Aim: To gather knowledge regarding different mould making tools, gating system design, core making and green sandmoulding

Raw Materials: The pattern developed earlier as per drawing, Green Sand,Bentonite Powder, Coal Dust, Yellow Dextrin, Facing Sand,Parting Sand, French chalk and Water.

Tools and Accessories:

1. Riddle2. Shovel3. Moulding Board4. Moulding Flask (Cope and Drag parts)5. Rammer6. Strike off Bar7. Bellow8. Sprue Pin9. Riser Pin

10. Vent Rod11. Draw Spike12. Gate Cutter13. Lifter14. Slick15. Trowels16. Cleaning Brush17. Water Mug

Procedure:1. Green sand for moulding is prepared by mixing Silica sand with 8-12% bentonite

and 2-3% water. To improve bonding strength, 5-6% coal dust and 2-3% yellowdextrin are added as additives. All mixing is done with the help of shovel.

2. Then the prepared green sand is screened by Riddle fitted with coarse andmedium mesh size wire mesh in order to remove the impurities. During thisprocess to avoid dryness of the green sand suitable amount of water is added.

3. Drag part of the moulding flask is placed on the moulding board. The half portionof the given Split Pattern is placed at a convenient position within the mouldingflask keeping space around all the sides. Facing sand is sprinkled over the boardand pattern. Then the box is filled with the prepared green sand by using shovel.

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4. During filling the green sand is rammed properly with the Rammer to facilitatethe adherence of the sand to the surfaces of the box.

5. Upper surface of the drag box is smoothened and leveled with the edges of thedrag box by removing excess sand by using the Strike- off Bar.

6. Then by using a Vent Rod, small holes are created in the rammed sand forproviding paths for removal of gases.

7. Then another moulding board is placed on the drag box and the box is turnupside down with bottom board.

8. Then the upper board is removed and the upper surface is cleaned by removingloose sand particles by blowing air by using Bellow

9. Then parting sand is sprinkled over the cleaned upper surface.10. Then the other half portion of the Pattern is placed on the first half portion of the

Pattern already fitted in the drag box.11. Then the Cope part of the moulding flask is placed properly on the drag part.

Sprue pin and Riser pin is placed at proper place for forming the sprue and riser.12. Then the cope box is also filled with green sand in a similar way like the drag box

(Step 3-6).13. Then Sprue and Riser Pin are removed carefully. Then a funnel shaped hole

(called pouring basin/cup) is made at the top of the Sprue hole.14. Then the cope is separated from the drag and any loose sand on the cope and drag

interface of the drag is blown off with the help of bellow.

15. Then the cope and drag pattern halves are withdrawn by using Draw Spike aftershaking properly.

16. Then the defective part, if any, of the mould is properly repaired with the help ofslick and lifter.

17. Then water is gently spread over the repaired portion and the portions adjacent tothe pattern of the mould carefully without damaging the mould

18. Then using Gate Cutter, gates and runners are cut in the drag part of the mould.19. Then any excess or loose sand in the runners and mould are lifted up by lifter and

then blown off by Bellow.

20. Then French chalk dust is spread all over the mould cavity and runners.21. Then the cope part is placed on the drag part taking care of the alignment of thetwo by means the pins.

Thus the sand mould for a pattern is made, which is ready for pouring the moltenmetal .

Precautions:

1. Ramming should be done properly to get the required rigidity of the sand mould. 2. Care should be taken during removal of pattern, sprue and riser pins so that any

portion of the mould is not damaged during removal.

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Hooghly Engineering & Technology CollegeDepartment of Mechanical Engineering

Workshop Practice (ME 191/ 292)

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Assignment No: ME 192/292/10

Title: Cast the aluminum block as per given drawing by using thesand mould prepared earlier by performing different sandmould casting operations

Aim: To obtain basic knowledge about sand casting

Raw Material: A luminium Ingots and Scraps

Consumable: Coverall 11 Flux

Machine: Electrically Heated Pit Furnace

Make: PSP Traders Capacity: 10 kg of aluminium meltingPower: 4.5 kW, 400V, 3ph, 50 Hz Max Temperature: 900°C

Tools and Accessories:

1. Crucible 2. Slotted steel spoon

3. Flat Tong 4. Refractory Bricks

5. 12” Hacksaw Frame fitted with 12”- 18 TPI High Carbon Hacksaw Blade

6. 8” Bench Grinder 7. 12”Vernier Caliper

8. 12”Steel Rule 9. Hand Gloves.10. Safety Goggles 11. Leather Apron

11. Numbering , Lettering punch

12. 500 gm Ball Peen Hammer.

Procedure:

1. Put required amount of Aluminum ingots and scraps inside of the Crucible.2. Cover the charge within the crucible with the requisite amount of coverall flux.

3.

Open the lid of the furnace and place the crucible into the furnace.4. Then close the furnace with its lid and switch on the furnace.5. Set the furnace temperature at 750 0C and set the furnace heating regulator at

100.6. Wait until the furnace temperature rise up to 750 0C and it is indicated

by a glowing yellow light.7. Then reset the furnace heating regulator at 80.8. Open the lid of the furnace and check the melting conditions of the charge and

extent the melting if required.

9.

When melting is complete then remove lid, scoop off slag, which is floating ontop, with a slotted steel spoon and turn off the furnace.10. Take out the crucible with the help of flat tong.

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Hooghly Engineering & Technology CollegeDepartment of Mechanical Engineering

Workshop Practice (ME 191/ 292)

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11. Then Pour the molten metal into the pouring basin and metal flow into themould cavity through gate via sprue and runners.

12. Pouring is continued till riser is filled up with molten metal.13. Wait for a considerable time of at least 1 hr for solidification of molten metal

within the mould cavity.14. Then crush the mould and taking out the casting.15. After that necessary fettling operation, that is removal of gates, riser and other

unnecessary projections by using hacksaw blade and cleaning of the surfaces bygrinding, is performed.

16. Checking of final dimensions by steel rule and vernier caliper according todrawing.

17. Punch roll number on the job for proper identification with the help ofnumbering and lettering punch.

Precautions:

1. Always use leather apron and hand gloves.2. During pouring keep mould on the refractory brick to prevent leaking.3. Always keep safe distance from the heat of the Furnace.4. During pouring handle molten metal carefully.

Scale: 1:1 All Dimensions are in mm

JOB DR WING