LABORATORY MANUAL

MEC 355
Manufacturing Technology II

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TABLE OF CONTENTS

S. No.

Title of the Experiment

Page No.

Moisture testing of the sand using speedy moisture tester.

To prepare the mould and make the Aluminium sand casting

Surface finish analysis using different types of moulding sands.

Graph plotting of variation in hardness at different zones of job after

welding with TIG and MIG welding.
Manufacturing of a gear on milling machine and Inspection of PCD,
tooth profile and run out of PCD in respect of bore.
Manufacturing and analyzing a flat surface on surface grinding and
shaper machine.
Manufacturing and analyzing a flat surface on surface grinding and
shaper machine.
To Prepare Spur Gear using Milling machine using different indexing
methods

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6
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Foundry Shop
1.

Experiment: 1

Moisture testing of the sand using speedy moisture tester

Machine/Equipment used:Speedy Moisture testing apparatus
Material required:Calcium Carbide
2. Learning Objectives:
1) To practice how to check the moisture percentage of the prepared sand to control the
manufacturing process & reduce the casting defects due to variation of moisture.
3. Outlines of the Procedure:
1) Take a batch of prepared green sand.
2) Weigh it with standard weighing scale of the apparatus.
3) Add the measured quantity as per the apparatus.
4) Shake the mixture by making a tight fitting of the apparatus lid & get the reading of
the moisture.
4. Required results
1. Analysis of the variation in the moisture percentage in green sand process.
2. Analyzing casting defects produced due to that variation.

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5. Cautions:
1. Wear apron, shoes and tight fitted clothes.
2. Be careful and attentive while working on this job.
3. Use proper tools for each operation.
4. Dont keep any sharp tool in your pocket.
5. Tools being used should be well sharpened.
6. Always use gloves when doing casting
7. Make sure the lid of the moisture teller to be opened slowly & carefully.

6. Learning outcomes: to be written by the students in 50-70 words.

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1. Experiment: 2
To prepare the mould and make the Aluminium sand casting
Machines/Equipments/tools to be used:
Tilting pit furnace, Aluminium, Moulding box, shovel, hand rammer, strike off bar, vent wire,
trowel, lifter, sprue and flow off pin swab, hand riddle
Material Required
Moulding sand, silica sand, bentonite, dextrine, soap stone powder, Aluminium scrap 10 kg.
2. Learning Objectives
To study the sand casting process to produce complex shaped parts with the low tooling and
equipment cost. Scrap can be recycled. ii)
3. Outline of the Procedure:
1. Place a pattern in sand to create a mold.
2. Incorporate a gating system.
3. Remove the pattern.
4. Fill the mold cavity with molten metal.
5. Allow the metal to cool.
6. Break away the sand mold and remove the casting.
4. Scope of results expected:
1. Analysis of the process of aluminium sand casting.
2. Preparing sand mould and hence casting.
3. Investigate the casting defects and suggest the remedial measures.

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5. Cautions:
1. Wear apron, shoes and tight fitted clothes.
2. Be careful and attentive while working on this job.
3. Use proper tools for each operation.
4. Dont keep any sharp tool in your pocket.
5. Tools being used should be well sharpened.
6. Runner and riser should be placed at the right place.
7. Sand should be mixed properly.
8. Always use gloves while doing casting.
6. Learning outcomes: to be written by the students in 50-70 words.

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1. Experiment: 3
Surface finish analysis using different types of moulding sands.
Material required: Green sand, Mollasis Sand, Co2 Binder sand, bentonite powder,
Sodium silicate and Co2 Gas, Silica and ordinary river sand.
Tools required: Shovels, Trowels, Hand sieve riddle, Sprue pipe, Sprue cutter, Gaggers,
Heart and Square shape lifters, Rammers, Vents, Swabs, Draw skew, Roller, Strike of
bar.
2. Learning Objectives: To know the variations of different sand during the molding.
3. Outline of the Procedure:
1) First of all we take three types of molding sand green sand, Mollasis sand & Co2 binder sand
in prepared conditions with silica as well as ordinary river sand and will prepare the moulds for
the same.
2) Then we pour the molten metal in the moulds and after decoring will check the surface finish
of the castings produced from different mould and compares them.

Scope of the results expected:

To analysis the surface finish due to verity of the moulding processes using different sands.

5. Cautions:
1. Wear apron, shoes and tight fitted clothes.
2. Be careful and attentive while working on this job.
3. Use proper tools for each operation.
4. Dont keep any sharp tool in your pocket.
5. Tools being used should be well sharpened.
6. Runner and riser should be placed at the right place.
7. Sand should be mixed properly.
8. Always use goggles while doing castings.
9. Proper moisture content should be maintained.
10. Follow the operative instructions clearly.
6. Learning outcomes: to be written by the students in 50-70 words.

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Welding Shop
1. Experiment: 4
Graph plotting of variation in hardness at different zones of job after welding with TIG and MIG
welding.
Equipment required: MIG and TIG welding machines, Hardness tester.
Material required: M.S flat
2. Learning Objectives: The objective of this work is to identify the part of a weld joint
that exhibited irradiated weld joint tensile specimen and investigate the mechanisms
occurring by analyzing the corresponding microstructure.
3. Procedure
1) First of all we will take the mild steel pieces and weld the mild steel pieces with the TIG and
MIG welding.
2) The various effects will be read out with welding in the different zones.
3) Then take the readings at different zones.
4) Then again check the regions after the welding. There are various HAZ after welding with
TIG and MIG we check the hardness at various regions.
5) Then plot the variations of hardness at different zones.
4. Scope of the results to be reported:
To understand the working of various operations by TIG and MIG and analyze the hardness at
various levels.
5. Cautions:
1) Always wear shoes while performing the practical.
2) Do not wear bangles, bracelets, rings, chains, and even neck tie.
3) Turn off all equipment when not in use.
4) Do not drape cables over your body.
6. Learning outcomes: to be written by the students in 50-70 words.

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Machine Shop
1. Experiment: 5
Manufacturing of a gear on milling machine and Inspection of PCD, tooth profile and run out of
PCD in respect of bore.
Equipment required:
Vernier Calliper, Steel scale, outside callipers, inside callipers, Lathe machine equipped with
different tools, Mandrels and milling cutters etc.
Material required: Raw material of specific dimension
2. Learning Objectives:
A) To learn indexing method,
B) To learn Bore , Turning procedures.
3. Outline of the Procedure:
A) Take a blank of the required dimension, turn it for the outer dimensions and make a bore in it
to be fitted on the mandrel using lathe machines.
B) Then fixing the piece on the mandrel of the indexing head on the milling machine c) Adjust
the indexing head for the required profile of the gear.
4. Scope of the result expected:
The tooth profile and PCD should be accurate. Indexing method help in the generation of
different gears which are used in almost all the industrial applications.
5. Cautions:
1. Always wear shoes while performing the practical
2. Do not wear bangles, bracelets, rings, chains and even neck tie.
3. Always wear lab coat (white).
4. Always wear safety goggles.

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5. Do not wear loose clothes while working on machine.

6.Do not even try to touch anything unknown.
7. Do not let anybody to stand on the left side of the operator.
8. Do not lean on to the machine.
9. Follow the operative instructions given strictly.
10. Check the alignment of the bed of the machine.
6).Learning outcomes: to be written by the students in 50-70 words.

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1. Experiment: 6
Manufacturing and analyzing a flat surface on surface grinding and shaper machine.
Equipment required:
Vernier Calliper, Steel scale, Outside callipers, Inside callipers, Surface grinding machine &
Shaping machine equipped with different tools, cutters etc.
Material required: Raw material of specific dimensions (Rectangular in shape)
2. Learning Objectives:
To find out difference in the roughness of surfaces generated on Grinding & Shaper machine
3. Outline of Procedure:
1. Fixing the blank on the clamping device of the shaping machine and performing operations
accordingly to flatten the all surfaces of the rectangular blank by changing the feed and speed of
the machine for different sides for the reference.
2. Fixing the blank on the clamping device of the lathe machine and performing operations
accordingly to flatten the all surfaces of the rectangular blank by changing the feed and speed of
the machine for different sides for the reference. Afterwards fixing that particular piece to the
surface grinding machine for the further operations to make it in the comparable state.
4.

Scope of the result expected:

This will help the student in find out use of proper machining process to be used for different industrial
applications.

5.

Cautions:

1. Always wear shoes while performing the practical

2. Do not wear bangles, bracelets, rings, chains and even neck tie.
3. Always wear lab coat (white).
4. Always wear safety goggles.
5. Do not wear loose clothes while working on machine.

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6. Do not even try to touch anything unknown

7. Do not let any body to stand on the left side of the operator.
8. Do not lean on to the machine.
9. Follow the operative instructions given strictly.
10. Make sure not to make contact of the grinding wheel with a sudden impact.
11. Make sure the feed of the grinding wheel should be in microns only.
12. Tighten the tools on the shaping machine properly.
6. Learning outcomes: to be written by the students in 50-70 words.

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1. Experiment: 7
To prepare a job as per sketch using Capstan and Turret Lathe Machine.
Equipment Required:
Scriber, engineering steel scale, vernier Calliper, Marking Chalk, Power hacksaw, Bench
grinder, Capstan and Turret Lathe Machines, Cutting Tool bit, Hammer, Marking gauge.
Material Required:
Raw material of specific dimensions (Rectangular in shape)

2. Learning Objectives:
To practice & learn how to perform different operations in machine shop using Capstan and Turret Lathe
machine like
Facing, Turning, Step Turning, Grooving, Centre making and Chamfering.

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3. Outline of the Procedure:

a) Fix the specimen in the chuck / Collet of the machine.
b) Perform the different operations as per the sketch of job required.

4. Scope of results to be reported:

To get different experience from the conventional machining and experiencing the production machines.

5. Precautions:
1. Always wear shoes while performing the practical.
2. Do not wear bangles, bracelets, rings, chains, and even neck tie.
3. Always wear Lab coat (white).
4. Always wear safety goggles.
5. Do not wear loose clothes while working on machines.
6. Do not even try to touch anything unknown.
7. Do not let anybody to stand on the left side of the operator.
8. Do not lean on to the machines.
9. Follow the operative instructions given strictly.

6. Learning outcomes: to be written by the students in 50-70 words.

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1. Experiment: 8
To Prepare Spur Gear using Milling machine using different indexing methods
Equipment Required:
Scriber, Engineering steel scale, Vernier calliper, Marking chalk, Milling Machine, Milling
cutters, Cutting oil, Hammer, mandrills, Marking gauge.
Material Required: Mild steel bar or as per availability in lab.
2. Learning objectives:
To practice spur gear manufacturing on milling machine with indexing.
3. Procedure:
Hold the work piece on the mandrill of the milling machine
Starting operation by setting the indexing for the particular teethes in the rotation as per sketch to
maintain the dimensional accuracy.
4. Required Results:
1. Reading practice and preparation of job as per sketch with detail dimensions.
2. Recognition and practice for the usage of the equipments and tools .
3. Operations performed and their significance.
4. Conclusions if Any
5. Cautions:
1 .Always wear shoes while performing the practical
2. Do not wear bangles, bracelets, rings, chains and even neck tie.
3. Always wear lab coat (white).
4. Always wear safety goggles.
5. Do not wear loose clothes while working on machine.
6. Do not even try to touch anything unknown.
7. Do not let anybody to stand on the left side of the operator.
6. Learning outcomes: to be written by the students in 50-70 words.

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