EXPERIMENT 01
Objective:
To Prepare a Plastic
product using Injection Molding machine.
Equipment:
Injection molding
machine Setup.
Material Required:
High grade poly
ethylene
Injection Molding
An important industrial
method of producing articles of thermoplastics is Injection Molding. The
process is essentially as follows:
The moulding material is loaded into a hopper
from which it is transferred to a heating section by a feeding device, where
the temperature is raised to 1500C – 370 0C and pressure is built up. The
material melts and is forced by an injection ram at high pressure through a
nozzle and sprue into a closed mould which forms the part. The mould is in at
least two sections, so that it may be split in order to eject the finished
component. For the process to be competitive the mould must be fairly cool
(between ambient temperature and the softening point of the plastic) and
consequently the mould must be cooled by circulating water.
The single – screw pre-plasticizer is probably
the most successful design for injection moulding machines.The rotation of the
screw provides the plasticizing action by shearing and frictional effects and
the axial motion of the screw provides the filling action. Injection moulding
machines range in size from an injection capacity of 12,000 mm3 to 2.2 x 106
mm3 . The injection pressure may range from 100-150 MPa.
Procedure:
·
Pour the raw
material in the hopper.
·
Place the die in
such a way that its hole coin sides with the central axis of the cylinder.
·
Heat the
cylinder by pouring plastic pallets in it.
·
When the metal
is heated at 800C to 1000C it is converted into molten metal.
·
Press the lever
so that the softened plastic will enter into the die and gets the desired shape
of the mould.
·
Allow it to cool
for some time.
·
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.
EXPERIMENT 02
Objective:
To generate an arc
& create a weld bed.
Equipment:
Gloves, Safety Helmet,
250 amp welding machine, hammer, cleaner,etc
Material Required:
work piece, electrodes
etc
INTRODUCTION:
Welding is more than
dragging a welding rod across a piece of steel &gluing it to another one. The process begins with properly
fitting and securing the work piece., or metal to be welded together. For
thicker pieces you may want to grind a bevel so subsequent beads can be placed
in the groove to fill it completely with a solid weld. Here are the basic steps
for completing a simple weld.
Procedure:
· Strike the arc.
(This is the
process of creating an electric acr between the electrodes and the work piece.
If the electrode simply allows the current to pass directly into the grounded
work piece, there will not be enough heat produced to melt & fuse metal
to-gather).
·
Move the arc to create a bed.
(The bed is the metal from melting
electrodes flowing together with the molten metal from the base metal to fill
the space between the pieces being joined by welding).
·
Shape the weld bed.
(This is done by waving the arcback and
forth across the weld path either in a zig zag or in motion so the metal
spreads to the width that you want your finished weld bead to be).
·
Chip and brush the weld in between process.
(Each
time we compete the process ,or trip from one end to another of your weld we
need to remove the slag , or the melted electrode flux material from the
surface
of the weld bead so only clean molten metal will be filling the weld on the
subsequent process.
COMMENT:
During welding process the electrode should not touch the
surface of work piece . There sould be distance in between the metal and the
electrodes otherwise the metal will stick to the electrode and cause sparking
,that can cause harmful for the person who is welding or can damage the work
piece.
Safety Recommendations for ARC Welding:
The beginner in the
field of arc welding must go through and become familiar with these general
safety recommendations which are given as under.
1.
The body or the
frame of the welding machine shall be efficiently earthed. Pipe lines
containing gases or inflammable liquids or conduits carrying electrical
conductors shall not be used for a ground return circuit All earth connections
shall be mechanically strong and electrically adequate for the required
current.
2.
Welding arc in
addition to being very is a source of infra-red and ultra-violet light also;
consequently the operator must use either helmet or a hand-shield fitted with a
special filter glass to protect eyes.
3.
Excess
ultra-violet light can cause an effect similar to sunburn on the skin of the
welder .
4.
The welder’s
body and clothing are protected from radiation and burns caused by sparks and
flying globules of molten metal with the help of the following.
5.
Gloves protect the hands of a welder.
6.
Leather or
asbestos apron is very useful to protect welder’s clothes and his trunk and
thighs while seated he is doing welding.
7.
For overhead welding, some form of protection
for the head is required.
8.
Leather skull cap or peaked cap will do the
needful.
9.
Leather jackets
and 1ather leggings are also available as clothes for body protection.
10.
Welding
equipment shall be inspected periodically and maintained in safe working order
at all times.
11.
Arc welding
machines should be of suitable quality.
12.
All parts of
welding set shall be suitably enclosed and protected to meet the usual service
conditions.
EXPERIMENT 03
Objective:
To create different
types of welds.
Equipment:
Mild steel electrode and electrode holder,
Ground clamp, Face shield , Apron,
Chipping hammer, 250 amp welding machine
INTRODUCTION:
Lap weld joint:
Single-Lap Joint
This joint, made by
overlapping the edges of the plate, is not recommended for most work. The
single lap has very little resistance to bending. It can be used satisfactorily
for joining two cylinders that fit inside one another.
Double-Lap
Joint
This is
stronger than the single-lap joint but has the disadvantage that it requires
twice as much welding.
Butt weld joint:
Single-Vee Butt Weld
It is used for plates up to 15.8 mm thick. The
angle of the vee depends upon the technique being used, the plates being spaced
approximately 3.2 mm.
Double-Vee Butt Weld
It is used for plates
over 13 mm thick when the welding can be performed on both sides of the plate.
The top v-angle is either 60° or 80°, while the bottom angle is 80°, depending
on the technique being used.
Etc
LAP JOINT
Procedure:
·
The given M.S
pieces are thoroughly cleaned of rust and scale.
·
The two pieces
are positioned on the welding table such that, the two pieces overlapped one
over the other as shown in drawing.
·
The electrode is
fitted in the electrode holder and the welding current is ser to be a proper
value.
·
The ground clamp
is fastened to the welding table.
·
Wearing the
apron and using the face shield, the arc is struck and the work pieces are
tackwelded at both the ends and at the centre of the joint.
·
The alignment of
the lap joint is checked and the tack-welded pieces are required.
·
The scale
formation on the welds is removed by using the chipping hammer.
·
Filling is done
to remove any spanner around the weld.
BUTT JOINT
Procedure:
·
The given M.S
pieces are thoroughly cleaned of rust and scale.
·
One edge of each
piece is believed, to an angle of 300 , leaving nearly ¼ th of the flat
thickness, at one end.
·
The two pieces
are positioned on the welding table such that, they are separated slightly for
better penetration of the weld.
·
The electrode is
fitted in the electrode holder and the welding current is ser to be a proper
value.
·
The ground clamp
is fastened to the welding table.
·
Wearing the
apron and using the face shield, the arc is struck and holding the two pieces
together; first run of the weld is done to fill the root gap.
·
Second run of
the weld is done with proper weaving and with uniform movement. During the
process of welding, the electrode is kept at 150 to 250 from vertical and in
the direction of welding.
·
The scale
formation on the welds is removed by using the chipping hammer.
·
Filling is done
to remove any spanner around the weld.
EXPERIMENT 04
OBJECTIVE:
To
perform the fine surface Grinding operation on a given work piece.
TOOLS AND EQUIPMENT:
Surface
grinding machine, steel rule.
MATERIAL REQUIRED:
M.S
Flat ( 60x45x5)mm3
SEQUENCE OF OPERATION:
·
Mark the require
dimensions on the work piece.
·
Hold the work
piece in the magnetic chuck.
·
Adjust the
grinding wheel on to the work piece.
·
Start the
machine and perform grinding operation.
·
Reduce the
required thickness on the work piece by grinding operation. Perform fine
finishing
operation on the work piece.
PRECAUTIONS:
1.
Do not wear loose clothes.
2.
While measuring the work piece dimensions, stop the grinding machine.
3.
Ensure the optimum feed and depth of cut and must be maintained during the
operation
accident may occur.
4.
Do not start a machine of which operation is not known. Damage to the machine
as
well
as accident may occur.
5.
Before starting the work chuck whether all levers are in proper position.
RESULT:
Work
piece has been machined according to given measurement.
EXPERIMENT 05
OBJECTIVE:
To perform the Step cutting operation on shaper
TOOLS AND
EQUIPMENT:
Shaper
machine tool, Planing tool, Key way cutting tool, Vernier caliper.
PROCEDURE:
1. Hold the work piece in a vice or holding device.
2. Set the planing tool in the tool head with
minimum overhang. Raise the table up to
required position.
3. Adjust the length and position of the stroke.
4. Adjust the cutting speed and feed.
5. Perform planning operation on the work piece.
6. Mark the dimensions on the work piece.
PRECAUTIONS:
1. Do not wear loose clothes
2. While measuring the work piece dimensions, stop
the machine
3. Ensure the optimum speed, feed and depth of cut
during the machine operation.
4. Do not start the machine, of which operation is
not known damage to the machine as
well as accident may occur.
5. Before starting the work, check whether all
levers are in proper position.
RESULT
Stepped block has been produces on Shaping machine.
EXPERIMENT 06
OBJECTIVE:
To perform drilling, reaming and tapping operations
on the given M.S Flat work-piece.
Apparatus:
1. Drilling Machine with standard accessories
2. Work piece
Material:
Mild Steel
round rod of diameter 20 mm.
INTRODUCTION:
The drilling machine is one of the most important
machine tools in a workshop. As regards its importance it is second only to the
lathe. The hole is generated by the rotating edge of a cutting tool known as
the drill, which exerts large force on the work clamped on the table. As the
machine tool exerts vertical pressure to originate a hole it is loosely called
a “drill press”.
Procedure:
1. The given work piece is first fitted to get
required length, breadth and thickness wet chalk
is applied on four sides and with the scriber lines
are drawn to get centre hole at required
location.
2. The centres are punched with a Punch and hammer.
3. The work piece is fixed firmly in the vice of the
Drilling Machine
4. 3/8” drill bit is fixed firmly in the chuck and
drilling is performed giving uniform depths.
5. The drill bit is removed from the drill chuck and
is replaced by a reamer.
6. The reaming operation is performed on the hole
which has been previously drilled.
7. The work is removed from the vice for performing
tapping operation.
8. The job is fixed firmly in a bench vice.
9. Tap is fixed in the tap handle and pressure
applied on the taps to obtain internal thread.
Precautions:
While performing reaming and tapping operations
lubricant should be used to
minimize friction.
Result:
Drilling and
Tapping operations are performed on the given work piece as per given
dimensions.
EXPERIMENT 07
OBJECTIVE:
To
perform a sheet metal cutting operation using Power Press.
APPARATUS:
Power
Press, Sheet Metal.
THEORY:
A
power press is a very useful machine used in mass production mainly from cold
working of ductile materials such as mild steel. Normally a power press has a
rotating flywheel which acts like a storehouse of energy and is used to operate
the ram which provides the necessary impact to the work-piece.
Power
press is a machine that houses the stamping tool (tooling) and carrying them
around to the kinematics indicated by the user (process set-up). The knowledge
of press used for the stamping operation .
PROCEDURE:
A
sheet formed part is usually obtained through a number of operations:
·
Gravity fall
·
Holding
·
Forming
·
Trimming
·
Spring back
GRAVITY
FALL
The blank adapt to the blank holder shape.
HOLDING
The die pushes the blank holder & squeezes the blank.
Holding controls the shape of the blank & the
contact between the blank & punch.
FORMING
The die goes down until it squeezes blank onto the
punch.
The forming operation can be divided into 2 parts:
·
First the volume
of the part is created
·
The geometry
details are formed.
SPRING
BACK
Plastics deformation leaves some stresses locked
through metal thickness. After the extraction from the tool these stress are
released originating a different shape than that of the tool. Spring back
before trimming is something important for the design of tool and robots of the
press. Spring after trimming may change the shape of the part to the point that
is impossible to assemble.
EXPERIMENT 08
OBJECTIVE:
To do Facing, Straight Turning, & Taper Turning on
job using Lathe Machine.
APPARATUS:
Single point cutting tool, Mild Steel Rod, Steel
Rule, Vernier Caliper, Lathe Machine.
INTRODUCTION:
The lathe is an ancient tool. The earliest evidence
of a lathe dates back to Ancient Egypt around 1300 BC. There is also tenuous
evidence for its existence at a Mycenaean Greek site, dating back as far as the
13th or 14th century BC.
A lathe is a machine tool that rotates a workpiece
about an axis of rotation to perform various operations such as cutting,
sanding, knurling, drilling, deformation, facing, and turning, with tools that
are applied to the workpiece to create an object with symmetry about that axis.
PROCEDURE:
FACING OPERATION
1. It
is done for getting fine finish (good surface finish) on the face of the job.
2. Facing
tool is set at an angle to the work piece.
3. The
tool is fed from the center of work piece towards the outer surface against the
rotating work piece.
4. Depth
of cut is low for the facing operation.
TURNING OPERATION
·
It is done for reducing the diameter of the work
piece.
·
A cutting tool with 70° setting angle is used
for roughing operation.
·
More feed is given for rough turning while less
feed is given for finishing.
·
Work piece is held in chuck and tool is set to
center height of the work piece.
TAPER TURNING
·
It is different
from the turning operation.
·
• Taper is
defined as uniform change in the diameter of a work piece measured
·
along its
length.
Where,
·
D – large
Diameter
·
d – Small diameter
·
l – Length of taper
·
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