EXPERIMENT No.

01
Object: Design of pattern for a desired casting (containing hole).
Material required: Soft wood.
Theory:
Pattern is a form used to produce a mould cavity in molding sand or any other suitable
Material.

Type of pattern
1. solid or single piece pattern : a solid pattern is made in one piece without any joints. These
are generally used for simple shapes and low quantity production. Solid pattern are generally
made of wood and are inexpensive.
2. Split pattern: Many pattern cannot be made of a single piece because of the difficulty in
molding to eliminate the difficulty the pattern are made split, half rest in lower part of the
mould and half in upper part.
3. Gated pattern: These are used in production work where many casting are required. Patterns
are made of metal to give them strengths and to eliminate any warping tendency. The gates or
runners for the molten metal are foundry by connecting part between the individual patterns.

4. Loose Piece Pattern: It consists of loose piece, which are necessary to facilitate with
drawing it from the mould.
5. Match Plate Pattern: These provide a substantial mounting for pattern. It consists of a flat
metal or wooden plate to which the pattern and gate are permanently fastened. These are
generally used for small casting with higher dimensional accuracy and mass production.

6. Sweep Pattern: These are used where the shape to be molded can be formed by the rotation
of a curved line element about an axis. This type of pattern is generally suitable for very large
casting such as bells for ornamental purpose.

7. Skeleton Pattern: These consist of a simple wood frame outlining the shape of the casting.
This type of pattern is used for large casting, required in small numbers.

8. Follow Board Pattern: These are used for those casting where there are some portions
which are structurally weak and if not supported properly are likely to break under the force of
ramming. Thus the bottom board is modified as a Follow board to closely fit the contour of the
weak pattern and provide support to it during ramming of the drag.

9. Segmental Pattern: These are also known as part patterns. This type of pattern revolve
about a centre and after ramming one section, it moves to another section to complete the mould,
such type of pattern are used for making large circular diction casting e.g rings , wheel rims and
gears.
10. Cope and Drag Pattern: It is a type of split pattern. The pattern is made up of two halves,
which are mounted on different plates. The cope and drag parts of the mould are made separately.

Pattern material:
The common pattern materials are wood, plastics, plaster of Paris, wax and polystyrene

1. Wood: wood is the most common material used for pattern making because of the following
advantages:
i) it is cheap and easily available.
ii) Can be easily shaped.
iii) Light in weight.
iv) Good surface finish can be obtained by planning and sanding.
v) Can be perverse for long time by applying varnish.
However it has certain disadvantages:
i) Due to low resistance to sand.
ii) It is affected by moisture which results in warping or splitting.
iii) Strength is low and gats damaged on rough usage.
The usual varieties of wood commonly used for making pattern are PINE, TEAK.
MAHOGANY, DEODER and KAIL.

2. Metal: Metal patterns are used for mass production of casting and for closer dimensional
accuracy. They have much longer life than wooden pattern. Thy have following advantages:
i) Strong and durable
ii) Have good surface finish.
iii) Do not deform on storage.
iv) Difficult to repair
v) Have a tendency to get rusted.

Though many materials such as Cost iron, brass etc. are used as pattern material but aluminum
and white metal are the most communally used. These are light can be easily worked are
corrosion resistant.

3. Plastics: These are gradually gaining favour as pattern materials because of their low weight,
high strength. High resistance to wear, smooth surface, durability and lower cost. The plastics
used as pattern materials are THERMO-SETTING RESINS. Phenolic resin and foam plastic
have the desired properties of a Pattern material.

4. Plaster of Paris: Gypsum cement known as Plaster of Paris, is used for making pattern
material since it can be easily cast into intricate shapes. It has a high compressive strength and its
expansion can be easily controlled. It is used in making small pattern. Since this type of cement
expends on being solidified hence it can neutralize the shrinkage of casting during solidification.
5. wax: Patterns made from wax have a high degree of surface finish and close dimensional
tolerances. After being molded, the wax pattern is not taken out of the mould but the mould is
inverted and heated to remove the wax in molten form. Commonly used waxes are Carnauba
wax, Shellac wax, Bees wax & Ceresin wax.

6. Polystyrene: Polystyrene or Expanded Thermo Cole is a special type of pattern material

since it changes to Gaseous state on heating. Polystyrene pattern are of disposable type and are
used for single casting, like a prototype. It is easy to make a pattern from Polystyrene since it is
soft. The pattern is not taken out of the mould to create the cavity. When the molten metal is
poured into the mould the polystyrene changes to gaseous state, Leaving negligible residue and
the space occupied by the pattern is filled by the metal.

Precautions:
1. Use of uniform thickness in pattern, where possible.
2. When uniform cross-section cannot be maintained, then changes in cross-section must be
gradual.
3. Large unsupported area tent to warp, so they should be avoided.
4. A minimum wall thickness must be maintained to avoid voids and non fill areas
5. All the dimensions should be taken carefully.
6. Proper pattern allowances should be made while designing.

EXPERIMENT No. 2
Object : Making of Green Sand Mould for a Single Piece Pattern.
Material required : Green Sand, Parting sand, facing sand.
Tool used : Cope & Drag, Rammer, sprue pin, swab, trowels, shovels, vent wire, strike off bar,
gate cutter.

Theory :
1. Place the flat surface of solid pattern on the molding board. Keep the drag section of the
molding box over it. Sprinkle parting sand on the pattern so that the pattern may not stick to the
molding sand and be withdrawn easily.
2. Fill layer of facing sand over and around the pattern, now fill the drag with layer of green sand
compacting each later with a rammer, scrap-off the excess from the top of the drag with a strike
off bar, ensure correct mould hardness with too hard ramming, the escapement of gases & steam
become difficult, with too soft ramming the mould may break in handling
3. Produce sufficient vent hole on the mould with a vent wire so that when the molten metal is
poured the gases & steam generated may escape.
4. Thus the drag part of molding is completed and now turns it over. Sprinkle sufficient amount
of parting sand over the mould surface and the pattern, to prevent the sand of drag sticking with
the sand of cope.
5. Set the cope over the drag and assemble them with locking pins. Now place the two sprue pins
at suitable place sprue and riser.
6. Now proceed as for molding in drag first applying parting sand, then filling the cope with
facing sand and finally with green sand, rammed it above the molding box level, then with help
of mallet compact it, scrap-off the excess sand with strike off bar, then smoothen the surface with
help of a planer. Now produce vent hole with the help of vent wire.
7. Once the cope is ready, remove sprue pins from it, cut a funnel shaped opening at the top of
sprue to form pouring basin.
8. Lift the cope and place it on the board with the parting line upward.

9. Now with the help swab moisten the out line of the pattern that will make its withdrawal easy,
makes light rapping on the pattern. Then with the help of draw spike and mallet withdraw the
pattern from the mould, left the required cavity in the drag part of the mould.
10. Now with the help of gate cutter, slick and lifter cut the gate in the drag portion of the mould
from the cavity to the surface.

Precautions :
1. Vent holes must be sufficiently away from the pattern in the mould.
2. The sprue pin should be placed sufficiently away from the pattern in the mould.
3. Sufficient parting sand should be used to avoid undesired sticking of pattern pieces of cope
with drag.
4. Mould hardness should be adequate.

EXPERIMENT No. 06
Object : Study of Hand Forging processes
Material Required: Mild steel material
Tool Used: Anvil, Hammer (Cross peen, Ball peen, Straight peen ), Tongs, Furnaces ( For Hot
forging operation ).

Theory:
Forging:Forging is the working of metal by localized compressive forces exerted by manual or power
hammer, presses or special forging machines.
Forging processes are among the most impotent manufacturing technique since forged are used
in the manufacturing of small tools. Rail road equipment, aero planes part and in many other
small industries.

Types of forging processes1.

2.
3.
4.
5.
6.

Smith Forging
Drop Forging
Press Forging
Upset Forging
Roll Forging
Swaging

1. SMITH FORGING
Smith forging is the simplest of all the forging processes. It is also called smiting or hand forging
or hammer forging. The shop in which this work is carried out is known as Smiting shop.
Smiting is used to handle relatively small jobs only such as can be heated in an open fire or
hearth. The heated job is held with a tong and is supported over an anvil. The required shape is
obtained by hammering with hand hammers. In modern practice. Mechanical hammers are also
used for this purpose.
This process is mainly used for the repair and manufacturing of AGRICULTURAL EQUIPMENT,
and similar type of small jobs made out of M.S. or similar type of ductile material. Accuracy of
the job is dependent on the skill of the operator.
This process is simple and flexible. The set-up cost is very less, but the process is very slow and
the resulting shape depends entirely on the operator.

2. DROP FORGING:
Drop forging uses rapid blows of a power hammer to forge the material inside closed dies. It is
so named because the hammer drops over work, generally due to gravity. Since closed dies are
used for forging. The part made more accurate and uniform and rate of Production is high. Some
common example of Drop Forged components is connecting rod, Crank shaft, gears, hand tools.

3. PRESS FORGING:
Press Forging employed a slow squeezing action of presses to deform the metal as compared to
rapid blows of a hammer. The process is more efficient and accurate than drop forging. It can be
used for making large parts such as Car Bodies of other automobile and machines out of Sheet
Metal.

4. UPSET FORGING:
Upsetting is the operation of increasing Cross-Sectional area of the work piece while reducing
length. Upsetting force is applied length wise on the hot work.
Forging of the rings and rod types with all kinds of heads and shoulders, such as nuts, bolts etc.
are the examples of the parts made by this process.

6. ROLL FORGING :
Roll forging is used to draw out sections of bar stock reducing the diameter of thickness and
increasing the length. Tapering operation can also be done. While Plain Rolling is used for
Producing uniform cross-section, roll forging is used for obtaining length of varying section.
Grooved half rolls are used for roll forging.
Levers, leaf springs axles, etc. are main parts made by roll forging.

7. SWAGING :
In Swaging, the cross-section of the changed to a limited length by partially confining it inside a
swage blocks or die. The work is inserted into the desired length by applying repeated blows by
hammer.
Example To close out and form the open end of a cylinder.

EXPERIMENT No. 7
Object: Press work experiment such as blanking / piercing. Washer making
Material required: Mild steel sheet.
Tool used: Power Press.
Theory:
Press Working Press working is also known as sheet metal working or sheet metal forming.
Sheet metal forming consists of many complementary processes that are used to form sheet metal
parts. One or more of these processes is used in which a flat sheet of ductile metal is taken, and
deformation forces applied to alter the shape of the sheet. Before deciding on the processes, one
should determine whether a particular sheet metal can be formed into the desired shape without
failure. Compared to casting and forging, sheet metal parts offer the advantages of light weight
and versatile shape.
The Basic mechanisms of a all sheet-forming processes are Stretching and Bending.

Advantages of Sheet Metal Forming

It is a Mass production process.

Production rate are rapid. Forming speed can run as a high as 300 ft/min for some shapes
are average 50 to 100 ft/min for most applications.
The low labour cost and the saving in material cost provides very low cost production if
quantities are large enough to pay off the initial tooling and equipment charges.

Disadvantages of Sheet-Metal forming

Generally, Production requirements in excess of 100,000 ft/year are necessary before the
process becomes economical.
Set-up times are lengthy due to the large number of tooling elements that are interrelated.

PRESSES
Presses shape work piece without cutting away material. That is, without making chips. A Press
consists of A Frame supporting a stationary bed, A Ram, A Power source, and A Mechanism
that moves the Ram in line with or at Right angles to the bed. The ram is guided in the frame of
the machine to give a definite path of motion. Presses are equipped with dies and punches

designed for such operation as Forming and Shearing. They are capable of rapid production
because the operation time is the time needed for only one stroke of the ram. There are three
methods of working sheet metal in Presses.
(i)
Shearing It is a sheet metal cutting operation along a straight line between two
cutting edges. Shearing is used to cut large sheets into smaller sections for subsequent
press working operation.
(ii) Deep-Drawing It is characterized by the production of a parallel- wall cup from a
flat blank of sheet metal.
(iii) Bending It is the straining of material, usually that sheet or strip metal, by moving it
around a straight axis lying in the neutral plane. Metal flow takes place within the plastic
range of the metal, so that the bent part retains a permanent set after removal of the
applied stress.

Classification of Presses:Presses are classified according to the following Characteristics:

(1)
(2)

Source of Power
(i)
Hand Press or Fly Press.
(ii)
Power Press.
Type and design of Frames (i) Inclined Press (ii) Gap Press
(iii) Straight Side Press. (iv) Arch Press
(v) Horn Press

(3)

According to action
(i) Single action

(ii) Double action

(iii) Triple action

(4)

Mechanism used for applying power to Ram.

(i) Crank

(ii) Eccentric

(iii) Cam

(iv) Toggle

(v) Knuckle

(vi) Rack and Pinion

(vii) Hydraulic.

(5)

Number of Drive Gears(i) Single

(ii) Twin drive

(iii) Quadruple drive.

(6) Methods of Power Transmission from Motor to Crankshaft(i) Direct
(ii) Non-geared.
(7)

Based on Tonnage(i) Mechanical Press

(1)

(ii) Hydraulic Press.

SOURCE OF POWER:

(i) Hand Press or Fly Press: This type of press is made of cast iron frame and is hand
operated. The construction consist of a screw which carries a wheel fitted with a handle at one
end and a ram which slides in the guide fitted at the other end of the screw. Further the ram
carries the punch at its bottom. Thus as the ram moves, the punch also moves providing the
required thrust on the sheet metal.

(ii) Power Press: In a power press the ram is moved by a crank and a connecting rod. The
punch is connected to the ram, while die is attached to the bolster plate. The machine is driven by
means of a belt and pulley arrangement. A flywheel and a clutch store and control the flow of
energy. This energy is supplied continuously at a relatively constant rate to the ram.

(2) Type and design of Frame:(i) Inclined Press: An inclinable open back press with a gap frame is shown in fig. this press
can tilted backward to permit the parts and scrap to slide off the back side. Parts slide by gravity
into a box. Most presses of this type are adjustable and very from vertical to a steep angle
position. Inclinable presses are often used in the production of small part involving bending,
punching, blanking and similar operations.

(ii) Gap Press: - Gap or C-frame Presses are named because of the open arrangement of the
press frame. Gap presses provides excellent clearance around the dies and permit the press to be
used for long or wide parts. Stamping operations are performed on Gap Press.

(iii) Straight-side Press: - These are stronger since the heavy loads are taken in a vertical
direction by the massive side frame, and there is little tendency for the punch and die affected by
the strain. These presses are available for capacities in excess of 1250 tons (11 MN).
Straight side presses are manufactured with various means of supplying power and different
methods of operation. For smaller presses single crank or eccentric is usually employed but as

the size of press increases additional cranks are needed to distribute the load on the slide
uniformly. The slide is guided by one, two or four guides or points of suspension.

Experiment No.05
Objective:
1. To understand the basic bending operation
2. To study the effects of material properties (ductility, types, strength) on the bend
radius, springback and bending force
Equipment:
1. Tooling dies with 0 bend radius, (1.5*thickness) bend radius and (3*thickness) bend
radius
2. Arbor press
3. Work pieces
a. Half Hardened C26000 brass: 1/8 and 1/16 thicknesses
b. Precipitation hardened 6061 Al alloy: 1/8 and 1/16 thicknesses
c. Mild Steel 1018 1/8 and 1/16 thicknesses
4. Protractor
5. Calipers/Micrometer
Procedure:
1. Insert the 0 bend radius die into the arbor press.
2. Insert the work piece into the holder.
3. Pull down the handle on the press firmly.
4. Check for material failure (cracking at the bend). Measure the bend
radius. Record results on data sheet provided.
5. Repeat steps 1-4 for each type of material.
6. Repeat steps 1-5 for each bend radius
Lab Deliverables:
1. Prepare a report detailing the lab activity, observations, results and difficulties
faced (follow the lab report instructions).
2. Plot the following function for the different materials (R vs t)
R = Minimum bend
radius t = Material
thickness
%A = Tensile reduction
in area %E= %
ofelongation at break
The area of the graph above and to the left of this line is supposed to result in ductile
bending without failure. The area below and to the right represents processing
conditions that will result in material cracking. Plot the experimental values used in lab

on this graph. Do these values make sense? What is the effect of ductility on minimum
bend radius?
3. What is the effect of ductility on spring back? Is there a consistent trend?
Does this relationship make sense? Which material would permit better
bend tolerances?
4. Calculate the bending force for each case. Compare the bending forces required for
hardened brass vs. annealed brass for different thicknesses and die opening.
5. Tabulate the springback vs. thickness for the different materials and explain the trend
based on their youngs modulus.
Table 1: Elastic properties of the given materials
Material

Poissons
ratio

Youngs
modulus
(GPa)

% Elongation at
break

TS (MPa)

Ys
(MPa)

425 (half hardened)

C26000
Brass

0.375

110

23

525 (hardened)

360

325 (annealed)
Al 6061
Alloy

0.330

69

12

310

276

1018 Steel

0.290

205

15

440

370

Experiment No.9
Objective:- Press work experiment such as blanking/piercing, washer, making etc.
Equipment:- 1. 22 X 26 sheet of 20 gage low carbon cold rolled steel
2. Power Shear
3. Hand Shear
4. Sheet-metal Scissors (hand operated)
5. Press Break Press
6. Finger Break Press
7. Spot-Welder
8. Lay-out equipment

Procedure:- 1. Read and understand the assembly part print provided.

2. Develop a process plan for manufacturing the part.
3.Design and develop a flat blank lay-out for the product See Attachment 16 for sheet metal
formulas.
4.Lay-out the flat blank on the raw material
5. Make the required cuts to the sheet metal
6. Make the required bends to the cut sheet metal
7. Spot weld the folded joints
8. Inspect your part to the print dimensions
9. Conclude your findings / experiences