INDEX

S.
DATE NAME OF THE EXPERIMENT MARKS SIGN
NO.

Taper turning & eccentric turning on circular parts

1.
using lathe machine
External, Internal thread cutting and Knurling on
2.
circular parts using lathe machine
Square head & hexagonal head shaping on circular
3.
parts using shaper machine
Contour milling operation on a work piece using a
4.
milling machine
5. Spur gear cutting in milling machine

6. Helical gear cutting in milling machine

7. Gear generation in gear hobbing machine

8. Gear generation in gear shaping machine

Machining a work piece using a surface grinding
9.
machine
Machining a work piece using a center type
10.
cylindrical grinding machine
11. Measurement of cutting force in milling process

12. Measurement of cutting force in turning process

13. The horizontal welding (Butt joint)

14. The vertical welding (T joint)

15. The overhead welding (Lap joint)

16. Solid pattern in green sand mould

17. Split patterns in green sand mould

18. Loose-piece patterns in green sand mould

19. Drilling and reaming

 SAFETY PRECAUTIONS

Proper safety measures are required to prevent any impending danger. Workshop
generally involves large number of machines and number of moving parts. This may cause
accidents and injuries if proper measures are not taken for safeguarding against them.

1. PERSONEL SAFETY:
• Wear tight dress
• Avoid long hair
• Always wear sheet tipped shoes
• Use goggles when grinding
• Always be alert to anticipate any impending danger.

2. MACHINE SAFETY:
• Never attempt to operate a machine without knowing how to operate it.
• Never pass through a running shaft, rod or open belts.
• Never stand before planner or shaper.
• Do not attempt to stop a machine by hand.
• Do not wear rings, watches, etc while operating a machine.

3. WORKSHOP SAFETY:
• Never joke or play near the machine.
• Don’t attempt to adjust or remove belt from a moving shaft.
• Avoid using unsafe tool and instruments.

SAFETY PRECAUTION WHILE WORKING ON LATHE

• We should apply oil moving parts before and after the machine is used.
• While mounting or dismounting the chuck we should keep a wooden plank on the
bed to avoid damage.
• Do not leave the chuck key on the chuck.
• Do not try to take measurements when machine is running.
• Do not shift the gear while the machine is running.
• Do not remove the chips by bear hands.
• Use always proper guards.
TAPER TURNING

ALL DIMENSIONS ARE IN “mm”

EX.NO: DATE:
TAPER TURNING & ECCENTRIC TURNING ON CIRCULAR PARTS USING
LATHE MACHINE
TAPER TURNING
Aim: To perform Taper Turning in Lathe according to the
given dimensions by Compound rest swiveling
method.
Tools Required: Single Point Cutting Tool, Vernier Caliper, etc.
Material Required: Mild Steel rod Ø25mm x 100mm

Sequence of Operations: 1. Marking 2. Facing 3. Turning

4. Taper turning
Formula:

tan =

Where, D = Major diameter in mm

d = Minor diameter in mm
l = Length of Taper in mm
Procedure:
Apply Chalk on the surfaces.
Mark the given dimensions on the work piece.
Fix the work piece in the Headstock spindle.
Fix the cutting tool in the tool post.
Feed the tool and reduce the job to the required length.
Feed the tool and do the facing operation.
Give depth of cut and do turning operation.
Swivel the compound rest to the required angle “ ”.
Give uniform feed by hand through compound rest.
Perform the Chamfering operation according to the given dimensions.
ECCENTRIC TURNING

ALL DIMENSIONS ARE IN ‘mm’

ECCENTRIC TURNING
Material Required: Mild Steel rod Ø32mm x 95mm
Sequence of Operations: 1. Marking 2. Facing 3. Turning
4. Eccentric setting 5. Eccentric turning
Procedure:
Apply Chalk on the surfaces.
Mark the given dimensions on the work piece.
Fix the work piece in the Four Jaw Chuck lathe Headstock spindle.
(This operation should be performed only in Four Jaw Chuck)
Fix the cutting tool in the tool post.
Feed the tool and reduce the job to the required length.
Feed the tool and do the facing operation.
Give depth of cut and do turning operation.
Feed the tool to perform Eccentric turning after setting to required conditions.
Perform the Chamfering operation according to the given dimensions.

MODEL CALCULATION

Result:
The work piece is machined to the required dimensions by performing the TAPER
TURNING operation.
EXTERNAL THREAD CUTTING

ALL DIMENSIONS ARE IN “mm”

EX.NO : DATE:
EXTERNAL, INTERNAL THREAD CUTTING AND KNURLING ON CIRCULAR
PARTS USING LATHE MACHINE

Aim: To perform External, Internal Thread Cutting and

Knurling in Lathe according to the given dimensions.
Tools Required: Single Point Cutting Tool, V tool, Vernier Caliper,
etc.
Material Required: Mild Steel rod Ø25mm x 100mm
Sequence of Operations: 1. Marking 2. Facing 3. Turning
4. Thread Cutting
Formula: Core diameter d = Major diameter – (2 x depth)
Depth = 0.6495 x pitch
Procedure:
Apply Chalk on the surfaces.
Mark the given dimensions on the work piece.
Fix the work piece in the Headstock spindle.
Machine to required dimensions.
Set the change gear.
Fix the Thread cutting tool in the tool post.
Adjust speed for threading.
Engage half nut to any one number on the thread chaser.
Depth of cut is given through cross slide.
After the tool has produced a helical groove to the required length withdraw the tool
and disengage half nut.
Move the carriage to the starting position and engage half nut.
Repeat till required depth of thread is obtained.
Perform the Chamfering operation according to the given dimensions.
INTERNAL THREAD CUTTING

ALL DIMENSIONS ARE IN “mm”

INTERNAL THREAD CUTTING
Tools Required: Single Point Cutting Tool, Vernier Caliper, Tap set,
Drill Bit, etc.
Material Required: Mild Steel rod Ø25mm x 100mm
Sequence of Operations: 1. Marking 2. Facing 3.Turning
4. Thread cutting using taps.
Formula: Tap drill diameter d = Thread dia (D) – (2 x depth)
Depth = 0.6495 x pitch
Procedure:
Apply Chalk on the surfaces.
Mark the given dimensions on the work piece.
Fix the work piece in the Headstock spindle.
Fix the cutting tool in the tool post.
Feed the tool and reduce the job to the required length.
Fix the drill bit in tailstock.
Give depth of cut and produce a hole for required dimensions.
By using taps make internal thread according to the given dimensions.
Perform the Chamfering operation according to the given dimensions.
KNURLING

ALL DIMENSIONS ARE IN “mm”

KNURLING
Tools Required: Single Point Cutting Tool, Vernier Caliper, Grooving
and Knurling tool, etc.
Material Required: Mild Steel rod Ø25mm x 100mm
Sequence of Operations: 1. Marking 2. Facing 3.Turning
4. Knurling
Procedure:
Apply Chalk on the surfaces.
Mark the given dimensions on the work piece.
Fix the work piece in the Headstock spindle.
Fix the cutting tool in the tool post.
Feed the tool and reduce the job to the required length.
Fix the Grooving tool and carry out Grooving operation to the given dimensions.
Then Fix the Knurling tool and carry out Knurling operation.
Perform the Chamfering operation according to the given dimensions.

Result:
The work piece is machined to the required dimensions by performing the External
Internal and knurling operations were done Successfully
SQUARE HEAD

ALL DIMENSIONS ARE IN “mm”

EX.NO DATE:

SQUARE HEAD & HEXAGONAL HEAD SHAPING ON CIRCULAR PARTS

USING SHAPER MACHINE

Aim: To generate a square and hexogen from rounded on

the given work piece in a shaping machine and
milling machine
Tools Required: Punching machine, steel rule, hammer, shaper tool
and milling cutter, try square.
Material Required: Mild Steel rod Ø25mm x 100mm
Sequence of Operations: 1. Marking 2. Punching 3.Shaping

Procedure:
1. The job was checked to the given dimensions.

2. The square was scribed in the outer circle of diameter of 50mm and punching was
done.

3. The job was attached in the vice of a shaper

4. The job was checked for perpendicular dimension.

5. Then the square from round was obtained in the shaper

6. Fit the helical cutter on the arbor and the specimen between the centers of the
dividing head and the tail center (if milling)

7. Calculate the necessary depth of cut and then mill the Four faces of the hexagonal
head in succession.

8. The work piece was removed and burns are removed with accuracy was checked.

.
HEXAGONAL HEAD

ALL DIMENSIONS ARE IN “mm”

HEXAGONAL HEAD SHAPING

Tools Required: Punching machine, steel rule, hammer, shaper tool

and milling cutter, try square.
Material Required: Mild Steel rod Ø25mm x 100mm
Sequence of Operations: 1. Marking 2. Punching 3.Shaping

Procedure:
1. The job was checked to the given dimensions.

2. The square was scribed in the outer circle of diameter of 50mm and punching was
done.

3. The job was attached in the vice of a shaper.

4. The job was checked for perpendicular dimension.

5. Then the square from round was obtained in the shaper.

6. Fit the helical cutter on the arbor and the specimen between the centers of the
dividing head and the tail center (if milling).

7. Calculate the necessary depth of cut and then mill the six faces of the hexagonal
head in succession.

8. The work piece was removed and burns are removed with accuracy was checked.

RESULT:
Thus, the Square and hexagonal head from round was performed on the given
dimension in a shaper and milling machine with the required dimensions were done
successfully
EX.NO: DATE:

CONTOUR MILLING OPERATION ON A WORK PIECE

USING A MILLING MACHINE
AIM:

To perform contour milling operation on the given work piece using a milling

machine.

MATERIALS REQUIRED:

Square aluminum plate-100x80x10

TOOLS REQUIRED:

1. Vertical Milling machine

2. Contour milling cutter

3. Outside Caliper

4. Steel Rule

5. Vernier Caliper

80

100

FIG - 2.1 GIVEN WORK PIECE

 80

100

FIG – 2.2 FINISHED WORK PIECE

PROCEDURE:

1. The given work piece is fixed in a table.

2. The form milling cutters are used for contoured milling.
3. The machine is switched on to revolve the cutter at the selected speed.
4. By giving cross feed and longitudinal feed to the work table, the contour operations
are done respectively. The profile of the cutter coincides with that of the work piece.
5. After the work piece is milled as per the given drawing machine is switched off.
6. The work piece is removed from the work table and all the dimensions are measured
and checked.

RESULT:

The contour milling operation was done on the given work piece as per the given
drawing.
EX.NO: DATE:

SPUR GEAR CUTTING IN MILLING MACHINE

AIM :

To cut spur gear in the given workpiece using Milling machine.

TOOLS / EQUIPMENT REQUIRED:

1. Milling machine,
2. Vernier caliper,
3. Mandrel.
4. Milling Cutter

PROCEDURE :

1. The dividing head and the tail stock are bolted on the machine table. Their axis must
be set parallel to the machine table.

2. The gear blank is held between the dividing head and tailstock using a mandrel. The
mandrel is connected with the spindle of dividing head by a carrier and catch plate.
3. The cutter is mounted on the arbor. The cutter is centred accurately with the gear
blank.
4. Set the speed and feed for machining.

5. For giving depth of cut, the table is raised till the periphery of the gear blank just
touches the cutter.

6. The micrometer dial of vertical feed screw is set to zero in this position.

7. Then the table is raised further to give the required depth of cut.

8. The machine is started and feed is given to the table to cut the first groove of the
blank.

9. After the cut, the table is brought back to the starting position.

10. Then the gear blank is indexed for the next tooth space.

11. This is continued till all the gear teeth are cut.
DIAGRAM :

Fig – 3.1 SPUR GEAR GENERATION

RESULT:
Thus, the given workpiece is cut into spur gear using Milling machine.
EX.NO: DATE:

HELICAL GEAR CUTTING IN MILLING MACHINE

AIM :

To cut Helical gear in the given workpiece using Milling machine.

TOOLS AND EQUIPMENTS REQUIRED:

1. Horizontal Milling machine

2. Vernier caliper
3. Mandrel
4. Milling Cutter
5. Bevel Protractor

HELICAL GEAR MILLING:

1. Helical parts most commonly cut on the milling machine include helical gears,
spiral flute milling cutters, twist drills. and helical cam grooves.
2. When milling a helix. a universal index head is used to rotate the workpiece at the
proper rate of speed while the piece is fed against the cutter.
3. A train of gears between the table feed screw and the index head serves to rotate the
workpiece the required amount for a given longitudinal movement of the table.
4. Milling helical parts requires the use of special formed milling cutters and double-
angle milling cutters.

DIAGRAM:

Fig – 4.1 TOOL FEED IN HELICAL MILLING

PROCEDURE:

1. Milling cutter is mounted on a horizontal arbor.

2. Indexing is done to cut each tooth.
3. Indexing is the process of dividing the periphery of the workpiece into any number
of equal divisions.
4. Gear blank is done for indexing the workpiece.
5. It is also used for rotating workpiece at a ratio to the table feed rate to produce
helical grooves on gears.
6. In helical gear milling, only direct and simple indexing can be used .
7. Change gears for helical milling.
8. The workpiece is held in a dividing head parallel to the milling table.
9. The teeth was cut using a brown and Sharpe type gear cutter held on an horizontal
arbor to confirm the cutter directly above the workpiece.
10. Doing this means the cutter is directly above the workpiece.
11. But if the milling table is at right angles to the horizontal arbor the cutter is going to
make cuts along the axis of the workpiece.
12. Clearly for a helical gear the cut needs to be made at an angle.
13. The way to do this is the make the table capable of swivelling round to the required
angle.
14. Usually this would be done using some sort of power feed.
15. A universal milling machine is one with a table that swivels.
16. A purely horizontal machine can only cut helical gears if it has a table that swivels.
17. Suppose the dividing head is to the left. The cutter is to the right of the workpiece.
The dividing head is set to zero. The sector arms are set to the number of spaces that
represents one tooth (or rather the gap between two teeth).
18. The cutter is set to the depth required.
19. The table moves to the right. This can be done by hand or by means of a motor. As
the table moves right it will rotate the workpiece.
20. After the cutter has cleared the workpiece and cut one gap, the milling table is
lowered so the cut will not touch the workpiece when the table is rewound back.
21. Once the cutter is to the right of the workpiece the table can be raised.
22. The workpiece is rotated to the cutting position of the next “tooth” by moving the
pin on the dividing head through the spaces as defined by the sector arms.
23. Then the sector arms are rotated. Then the next cut can start.

RESULT:

Thus the given workpiece is cut into Helical Gear using Milling machine.
EX.NO: DATE:

GEAR GENERATION IN GEAR HOBBING MACHINE

AIM:
To cut Spur Gear using a Gear Hobbing machine.

MATERIALS REQUIRED:
Cast iron blank - φ 86 X 25 X 20 mm

TOOLS REQUIRED:
1. Gear Hobbing machine
2. Gear Hob
3. Gear tooth vernier
4. Spanner set

Fig – 6.1 GIVEN WORKPIECE

 Fig – 6.2 FINISHED WORK PIECE

PROCEDURE:

1. The given work piece is held firmly on the spindle of the gear hobbing machine.
2. The Hob is set at an angle to the hob helix angle for cutting spur gear.
3. The change gears are set for the desired speed of work piece and Hob and feed of
the Hob.
4. The machine is switched on.
5. The work piece and Hob are allowed to rotate at the desired speed.
6. The hob or work piece is given full depth of cut equals to the tooth depth.
7. The cutter is given feed for the full width of the work.
8. After machining all gear teeth on the blank the machine is switched off.
9. The gear teeth are checked using a gear tooth vernier.

RESULT:

Thus the given workpiece is cut into spur gear using Gear Hobbing machine.
EX.NO: DATE:

GEAR GENERATION IN GEAR SHAPING MACHINE

AIM:
To generate gear using gear shaping machine.

TOOLS REQUIRED:
1. Cast Iron workpiece
2. Gear shaper with attachment
3. Vernier Caliper
4. Spanner set
5. Bevel Protractor

GEAR SHAPER:

1. A gear shaper is a machine tool for cutting the teeth of internal or external gears.
2. The name shaper relates to the fact that the cutter engages the part on the forward
stroke and pulls away from the part on the return stroke, just like the clapper box on
a planer shaper.
3. The cutting tool is also gear shaped having the same pitch as the gear to be cut.
4. However number of cutting teeth must be less than that of the gear to be cut for
internal gears.
5. For external gears the number of teeth on the cutter is limited only by the size of the
shaping machine.
6. For larger gears the blank is sometimes gashed to the rough shape to make shaping
easier.

The principal motions involved in rotary gear shaper cutting are as following:

1. Cutting Motion: The downward linear motion of the cutter spindle together with
the cutter .
2. Return Stroke: The upward linear travel of the spindle and cutter to withdraw the
latter to its starting position.
3. Indexing Motion: Slow speed continuous rotation of the cutter spindle and work
spindle to provide circular feed, the two speeds being regulated through the change
gears .
4. Completion of Cutting Operation: The indexing and reciprocating motions
continue until the required number of teeth to the required depth are cut all along the
periphery of the gear blank
PROCEDURE:
1. Attach the shaper cutter to the gear shaping machine.
2. Perform gear cutting in vertical direction from the upper to the down section and
back to the upper section (non-cutting) in reciprocal motion.
3. As cutting cannot be performed at the returning motion, cutting is not as efficient as
hobbing with continuous processing.
4. Remove the workpiece from the attachment after the gear generation operation is
performed.

Fig – 7.1 SPUR GEAR GENERATION USING GEAR SHAPER

RESULT:
Thus, the Gear generation is done on the given work-piece using Gear shaper.
EX.NO: DATE:

MACHINING A WORK PIECE USING A SURFACE GRINDING MACHINE

AIM:

To grind the given workpiece using a surface grinding machine.

MATERIALS REQUIRED:

Mild steel Flat - 80 X 50 X 10 mm

TOOLS REQUIRED:

1. Surface grinding machine

2. Vernier Caliper

Fig -9.1 GIVEN WORKPIECE

 Fig -9.2 FINISHED WORKPIECE

PROCEDURE:

1. The given work piece is held firmly on a magnetic chuck of a surface grinder.
2. The machine is started and the grinding wheel is allowed to revolve at a selected
speed.
3. After giving a depth of cut, the work piece is made to reciprocate under the grinding
wheel.
4. The table is fed axially between passes to produce a fine flat surface.
5. The process is repeated for grinding another side until the desired dimension is
achieved.
6. The dimensions are checked for its given dimensions using a Vernier caliper.

RESULT:
Thus the Grinding operation is performed on the given workpiece.
EX.NO: DATE:

MACHINING A WORK PIECE USING A CENTRE TYPE

CYLINDRICAL GRINDING MACHINE
AIM:
To grind a work piece using a cylindrical grinding machine.

MATERIALS REQUIRED:
Mild steel polished round rod - φ 25 x 150 mm
TOOLS REQUIRED:
1. Centre type cylindrical grinder
2. Vernier Caliper
3. Spanners

Fig – 10.1 GIVEN WORKPIECE

PROCEDURE:

1. The given work piece is held between centers.

2. The machine is switched on and the grinding wheel is allowed to revolve at a
selected speed.
3. By giving longitudinal and cross feeds the work piece is ground for the required
dimensions.
4. The work piece is removed from the machine and is checked for the given
dimensions.
 Fig – 10.2 FINISHED WORK PIECE

RESULT:

Thus the grinding operation is performed on the given workpiece using cylindrical
Grinding machine.
EX.NO: DATE:

MEASUREMENT OF CUTTING FORCE IN MILLING PROCESS

AIM:
To measure cutting force in Milling machine using Milling Tool Dynamometer.

TOOLS REQUIRED:

1. Milling Tool Dynamometer

2. Dividing head
3. 7/8” Arbor

PROCEDURE:

1. This is a simple and easy to understand set up to study the behavior of cutting forces
during milling operation in three directions.
2. With this unit we can evaluate cutting forces for varying cutting depth, speed and
feed.
3. The unit works on standard method of Octagonal ring with strain gauges.
4. It is in two parts one mechanical set up consisting a set of octagonal rings
sandwiched between two M.S. plates with strain gauges fixed on it.
5. This set of octagonal rings transmits the relevant data to the force indicator during
milling operation.
6. Milling tool dynamometer is a Rigid in construction, Compact Unit, Easy in
handling and Assessment of cutting forces by giving due consideration to various
parameters like depth of cut, material, speed and feed.
7. It has Digital force indicators to measure three forces simultaneously.

SCPOE OF EXPERIMENTATION :

1. To measure force values in three directions.

2. To study the change in these forces by varying speed cut and feed.

UTILITY REQUIRED :
• Necessary Milling Machine with automatic feed arrangement and tooling and 230
Volts, Single phase, 50 Hz stabilized power supply.

TECHNICAL DETAILS :
1. Mechanical sensing unit with set of octagonal rings and strain gauges.
2. Three channel Digital Force Indicator with balancing potentiometers and
polycarbonate front plate.
3. Range of force measurement in coordinate direction – 0 to 500 Kg.
4. Overall size of mechanical unit – 300 x 300 mm
 Fig – 12.1 Milling Tool Dynamometer

RESULT:

Thus the cutting force is measured using Milling Tool Dynamometer.

EX.NO: DATE:

MEASUREMENT OF CUTTING FORCE IN TURNING PROCESS

AIM:
To measure cutting force in Turning operation using Lathe Tool Dynamometer.

TOOLS REQUIRED:

1. Lathe tool Dynamometer

2. Sensor
3. Single Point cutting tool

PROCEDURE:

1. Lathe Tool Dynamometer is a cutting force measuring instrument used to measure

the cutting forces coming on the tool tip on the Lathe Machine.
2. The sensor is designed in such a way that it can be rigidly mounted on the tool post,
and the cutting tool can be fixed to the sensor directly.
3. This feature will help to measure the forces accurately without lose of the force.
4. The sensor is made of single element with three different wheat stones strain gauge
bridge.
5. Provision is made to fix 1/2" size Tool bit at the front side of the sensor.
6. The tool tip of the tool bit can be grind to any angle required.
Forces in X - Y - Z directions will be shown individually & simultaneously in three
Digital Indicators Supplied.
 TECHNICAL DETAILS:
CAPACITY : X,Y,Z – Force 500Kg
EXCITATION : 10V DC
LINEARITY : 2%
ACCURACY : 2%
CROSS-SENSITIVITY : 5%
MAX. OVER LOAD : 150 %

LATHE TOOL DYNAMOMETER

RESULT:

Thus, the cutting force is measured using Lathe Tool Dynamometer.

34
35
EX.NO: DATE:
THE HORIZONTAL WELDING
(BUTT JOINT)
AIM:

To arc weld two metal piece of mild steel to get the Horizontal Welding.

TOOLS REQUIRED:
1. Electrode
2. Welding transformer
3. Gloves
4. Tong
5. Chipping hammer
6. Wire brush
7. Welding shield
8. Electrode holder

PROCEDURE:
1. The mild steel plates to be joined are first cleaned. Using the wire brush to remove dust &
rust.
2. The edges and surface to be welded using the wire brush to remove dust and rust. The edge
and surface to be welded are then filled or ground to get the required dimension.
3. Now the metal plates to be welded are placed in proper position on a cathode plate (that is a
metal plate).
4. The welding electrode is held using an electrode holder and tack welds at two places are
made such that the position of the plates do not change while welding (The planes should be
at 90° to each other).
5. Now the electrode is made to touch the metal plates and then electrodes is separated to leave
a small gap. (3 to 4 mm) between its tips and the metal plates. This initiates an arc. Once the
arc is initiated, the electrode is moved along the length of the metal pieces. For completing
the welding process on one side.
6. Using tongs, the metal plates welded on one side is over turned. Welding is now carried out
on this side also in the previously explained manner.
7. After welding, the plates are allowed to cool for some time. Using a chipping hammer, oxides
are removed to complete the exercise.

RESULT:

Thus the two mild steel plates are welded to get the Horizontal Welding.

36
37
EX.NO: DATE:

THE VERTICAL WELDING

(T JOINT)
AIM:

To arc weld two metal piece of mild steel to get the Vertical Welding.

TOOLS REQUIRED:
1. Electrode
2. Welding transformer
3. Gloves
4. Tong
5. Chipping hammer
6. Wire brush
7. Welding shield
8. Electrode holder

PROCEDURE:

1. The mild steel plates to be welded are first cleaned. Using the wire brush to remove dust &
rust. The edges and then filed or ground to get the required dimension.
2. Now the metal plates to be welded are placed in proper position on a cathode plate (that is a
metal plate).
3. The welding electrode is held using an electrode holder and tack welds at two places are
made such that the positions of the plates do not change while welding.
4. Now the electrode is made to touch the metal plates and then electrodes is separated to leave
a small gap. (3 to 4 mm) between its (electrode) tips and the metal plates. This initiates an
arc. Once the arc is initiated, the electrode is moved along the length of the metal pieces. For
completing the welding process on one side.
5. Using tongs, the metal plates welded on one side is over turned. Welding is now carried out
on this side also in the previously explained manner.
6. After welding, the plates are allowed to cool for some time. Using a chipping hammer, oxides
are removed to complete the exercise.

RESULT:
Thus the two mild steel plates are welded to get the Vertical Welding.

38
39
EX.NO: DATE:

THE OVERHEAD WELDING

(LAP JOINT)
AIM:

To arc weld two metal piece of mild steel to get the Overhead Welding.

TOOLS REQUIRED:

1. Electrode
2. Welding transformer
3. Gloves
4. Tong
5. Chipping hammer
6. Wire brush
7. Welding shield
8. Electrode holder

PROCEDURE:

1. The mild steel plates to be joined are first cleaned.

2. The edge and surface to be welded are then filled or ground to get the required dimension.
3. Now the metal plates to be welded are placed in position on metal plate.
4. The welding electrode is held using an electrode holder and tack welds at two places are
made such that the position of the plates does not change while welding.
5. Now the electrode is made to touch the metal plates and then electrodes is separated to leave
a small gap. (3 to 4 mm) between its tips and the metal plates.
6. This initiates an arc.
7. Once the arc is initiated, the electrode is moved along the length of the metal pieces. For
completing the welding process on one side.
8. Using tongs, the metal plates welded on one side is over turned. Welding is now carried out
on the other side.
9. After welding, the plates are allowed to cool for some time. Using a chipping hammer, oxides
are removed to complete the exercise.

RESULT:
Thus the two mild steel plates are welded to get the Overhead Welding.

40
GIVEN PATTERN (FIG: 1)

FINISHED MOULD (FIG: 2)

41
EX.NO: DATE:
SOLID PATTERN IN GREEN SAND MOULD
AIM:
To make a green sand mould using a given pattern.

MATERIALS REQUIRED:
1. Pattern
2. Moulding sand
3. Parting sand.

TOOLS REQUIRED:
1. Moulding boxes 6.Sprue pin
2. Moulding board 7. Riser pin
3. Shovel 8. Strike off bar
4. Trowel 9. Draw spike
5. Rammers 10. Vent rod

PROCEDURE:
1. The given pattern is placed on the moulding board.
2. Parting sand is applied over the pattern and the moulding board.
3. The drag is placed on the moulding board such that the pattern is at the center of the drag box.
4. The prepared moulding sand is filled and evenly rammed in the drag box.
5. Excess sand is removed using strike off bar.
6. The drag box is turned upside down.
7. The cope box is placed on the drag box.
8. The sprue pin and riser pin are kept at the respective positions.
9. The parting sand is applied at the parting plane
10. The green sand is filled and rammed in the cope box.
11. Vent holes are made in the cope box.
12. Sprue and riser pins are removed from the cope box.
13. The cope box is kept aside and the pattern is removed using draw spike.
14. The cope box is placed over the drag box.

RESULT:
The green sand mould cavity is prepared as shown in fig (2) by using the given pattern as
shown in fig (1).

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GIVEN PATTERN (FIG: 1)

FINISHED MOULD (FIG: 2)

43
EX.NO: DATE:
SPLIT PATTERNS IN GREEN SAND MOULD
AIM:
To make a green sand mould using a given pattern.

MATERIALS REQUIRED:
1. Pattern
2. Moulding sand
3. Parting sand.

TOOLS REQUIRED:
1. Moulding boxes 6.Sprue pin
2. Moulding board 7. Riser pin
3. Shovel 8. Strike off bar
4. Trowel 9. Draw spike
5. Rammers 10. Vent rod

PROCEDURE:
1. The given pattern is placed on the moulding board.
2. Parting sand is applied over the pattern and the moulding board.
3. The drag is placed on the moulding board such that the pattern is at the center of the drag box.
4. The prepared moulding sand is filled and evenly rammed in the drag box.
5. Excess sand is removed using strike off bar.
6. The drag box is turned upside down.
7. The cope box is placed on the drag box.
8. The sprue pin and riser pin are kept at the respective positions.
9. The parting sand is applied at the parting plane
10. The green sand is filled and rammed in the cope box.
11. Vent holes are made in the cope box.
12. Sprue and riser pins are removed from the cope box.
13. The cope box is kept aside and the pattern is removed using draw spike.
14. The cope box is placed over the drag box.

RESULT:
The green sand mould cavity is prepared as shown in fig (2) by using the given pattern as
shown in fig (1).

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LOOSE-PIECE PATTERN

45
EX.NO: DATE:
LOOSE-PIECE PATTERNS IN GREEN SAND MOULD
AIM:
To prepare green sand mould for the given loose-piece pattern.

MATERIALS REQUIRED:
1. Pattern
2. Moulding sand
3. Parting sand.

TOOLS REQUIRED:
1. Moulding boxes 6.Sprue pin
2. Moulding board 7. Riser pin
3. Shovel 8. Strike off bar
4. Trowel 9. Draw spike
5. Rammers 10. Vent rod

PROCEDURE:
1. The mould box, pattern, tools, and the table /floor are cleaned.
2. The drag is filled with green sand after positioning lower part of the pattern on the table.
3. The green sand is rammed carefully and the excess sand is struck off.
4. Till the drag upside down and sprinkle river sand on top of it.
5. The cope is positioned on the top of the drag and upper part of the pattern is positioned
carefully.
6. Position the sprue pin and riser pin, then the fill cope with sand ramming is done and the
excess sand is struck off.
7. Remove the sprue pin and the riser pin carefully
8. Apply water on the edges of the pattern and remove them carefully using the draw spike, and
then finish the cavity.
9. Vent holes are made using vent wire.
10. A funnel – shaped opening and gate is made to pour the molten metal.

RESULT:
Thus, the mould cavity of the given loose piece pattern is obtained.

46
MARKING AND PUNCHING DRILLING AND REAMING

47
EX.NO: DATE:

DRILLING AND REAMING

AIM
To drill and Ream the given work piece as per the required dimensions.

MATERIALS REQUIRED
Mild steel plate of size 50x50x6mm.

TOOLS REQUIRED
1. Bench vice
2. Machine vice
3. Steel rule
4. Try square
5. Surface plate
6. Dot punch
7. Vernier height gauge
8. Scriber
9. Drill bit
10. File
11. Reaming bit
12. Drilling machine

PROCEDURE
1. The dimensions of the given work piece are checked.
2. The chalk is applied throughout the surface of the work piece
3. Marking is done on the work piece by using scriber, dot punch and hammer with the help of
Vernier height gauge, steel rule measurement is taken.
4. The adjacent sides of the work piece are filed and then the punched work piece is clamped in
the vice.
5. The required size of hole is made on the work piece by using drilling machine.
6. During the drilling operation, the coolant is applied to avoid the heat and to reduce wear.
7. Then the drilled holes are reamed by using Reaming tool.

RESULT
Thus, the drilling and Reaming operation is done for the required size.

48
ADDITIONAL EXPERIMENTS

49