Lab name:



(Backside of cover page)

Vision of the Institute

To impart quality technical education with a focus on Research and Innovation emphasising on Development of Sustainable and Inclusive Technology for the benefit of society.

Mission of the Institute

• To provide an environment that enhances creativity and Innovation in pursuit of Excellence.

• To nurture teamwork in order to transform individuals as responsible leaders and entrepreneurs.

• To train the students to the changing technical scenario and make them to understand the importance of Sustainable and Inclusive technologies.

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DAYANANDA SAGAR COLLEGE OF ENGINEERING

(An Autonomous Institution affiliated to Visvesvaraya Technological University, Belagavi)

DEPARTMENT OF MECHANICAL ENGINEERING, BENGALURU-560078

|VISION OF THE DEPARTMENT |

| |

|To impart quality technical education with a focus on Research and Innovation emphasizing on Development of Sustainable and Inclusive Technology for the|

|benefit of society. |

|MISSION OF THE DEPARTMENT |

|To provide a platform that imparts scientific knowledge and technical skills. |

|To train students to demonstrate their technical and managerial skills. |

|To engage students in professional activities through research, higher education and lifelong learning. |

|PROGRAMME EDUCATIONAL OBJECTIVES [PEOs] |

|PEO-1: Graduates shall acquire the knowledge and competency for career in and related to Mechanical engineering. |

|PEO-2: Graduates shall acquire the necessary skills to lead and manage professional teams. |

|PEO-3: Graduates shall demonstrate their Engineering Profession by addressing Scientific and Social challenges. |

|PEO-4: Graduates shall engage in Professional and Intellectual Development through Higher Education, Research and Lifelong learning in Engineering or |

|related fields. |

| |

|PROGRAMME SPECIFIC OUTCOMES [PSOs] |

|PSO-1: |

|PSO-2: |

| |

DAYANANDA SAGAR COLLEGE OF ENGINEERING

(An Autonomous Institution affiliated to Visvesvaraya Technological University, Belagavi)

DEPARTMENT OF MECHANICAL ENGINEERING, BENGALURU-560078

FOUNDRY AND FORGING LABORATORY (SYLLABUS)

III SEMESTER B. E (ME)

Sub. Code: IA Marks :

Hrs/Week : Exam Hrs :

Total Hrs: Exam Marks :

Course Objectives:

|1 |Illustrate the preparation of sand specimens |

|2 |Demonstrate the technique of mould making using the moulding tools |

|3 |Evaluate the properties of mould subjecting the specimen to mechanical testing |

|4 |Summarize the principles and methodology of carrying out the forging operation |

Syllabus:

PART – A

1. Testing of Moulding sand and Core sand Preparation of sand specimens and conduction of the following tests: 1 Compression, Shear and Tensile tests on Universal Sand Testing Machine. 2 Permeability test 3 Core hardness & Mould hardness tests. 4 Sieve Analysis to find Grain Fineness number of Base Sand 5 Clay content determination in Base Sand

PART – B

2. Foundry Practice Use of foundry tools and other equipments. Preparation of moulds using two moulding boxes using patterns or without Patterns. (Split pattern, Match plate pattern and Core boxes). Preparation of one casting (Aluminum or cast iron-Demonstration only)

PART – C

3. Forging Operations: Calculation of length of the raw material required to do the model. Preparing minimum three forged models involving upsetting, drawing and bending operations. Out of these three models, at least one model is to be prepared by using Power Hammer.

Course Outcomes:

|1 |Interpret results of sand testing for preparing sand mixture properties for mould making |

|2 |Develop skills for mould making using mould making tools |

|3 |Demonstrate open die forging skills through use of forging tools |

|4 |Analyze casting parameters which requires engineering knowledge , design, production and environment aspects |

DAYANANDA SAGAR COLLEGE OF ENGINEERING

(An Autonomous Institution affiliated to Visvesvaraya Technological University, Belagavi)

DEPARTMENT OF MECHANICAL ENGINEERING

FOUNDRY AND FORGING LABORATORY (MEL38)

I - CYCLE

1. INTRODUCTION TO FOUNDRY

2. PREPERATION OF SQUARE MOULD CAVITY

3. PREPERATION OF HEXAGONAL MOULD CAVITY USING TWO MOULD BOXES

4. MOULD PREPERATION USING SPLIT PATTERN

5. MOULD PREPERATION USING SOLID PATTERN

II - CYCLE

6. INTRODUCTION TO FORGING

7. TO OBTAIN A SQUARE BAR FROM ROUND ROD BY FORGING

8. TO OBTAIN A HEXAGONAL BAR FROM ROUND ROD BY FORGING

9.TO OBTAIN GIB HEAD KEY FROM A GIVEN ROUND ROD BY FORGING

III – CYCLE

10. SIEVE ANALYSIS OF BASE SAND

11. TO FIND THE AMOUNT OF CLAY

12. TO FIND THE COMPRESSION STRENGTH

13. TO FIND THE SHEAR STRENGTH

14. TO FIND THE EFFECT OF WATER AND CLAY

ON THE PERMEABILITY OF GREEN SAND

15. TO FIND THE PERCENTAGE OF MOISTURE IN

GREEN SAND

16. TO FIND THE TENSILE STRENGTH OF THE

CORE SAND

17. TO FIND THE BENDING STRENGTH OF THE

MOULDING SAND

18. TO FIND THE SAND MOULD HARDNESS

19. TO FIND THE CORE HARDNESS OF THE GIVEN CORE

DAYANANDA SAGAR COLLEGE OF ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

BENGALURU – 560078

Experiment No:________ Date:____________

Introduction to Foundry

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Introduction to Foundry:

Foundry is a manufacturing process where metal casting is produced. A shaped cavity is formed in the sand bounded by cope and drag boxes. Molten metal is poured in to the cavity through the spruce. After solidification, sand and metal are separated to get the solid mass of metal which is called casting. Cavity corresponding to the component shape is called as the mould. Mould is made out of refractory sand grains is called sand mould.

Moulding Sand Preparation

The constituents used for foundry sand preparation is

Silica sand or Base sand 70 – 80%

Binder (Clay or Bentonite) 6 – 8 %

Additive (coke Powder) 4 %

Moisture (Water) 6 – 8 %

This sand is called green sand.

Dry Sand: Sand prepared without moisture.

Facing Sand: Sand used around the pattern.

Parting Sand: to avoid sticking of mould boxes, the dry silica sand is sprinkled between two boxes is called parting sand.

Baking Sand: After taking castings from the sand, the sand left on the floor is called baking sand. It is also called floor sand.

Core Sand: Sands used to prepare core, this contains high percentage of silica sand

Oil Sand: silica sand prepared by using oil binder

Molasses sand: sand prepared by using molasses as binders, used to prepare intricate shape moulds.

FOUNDRY TOOLS:

Showel: It is used in mixing and conditioning of the sand by hand, and to transferring it to the flask.

Hand Riddle: It consists of wooden frame fitted with a screen of standard wire mesh at the bottom. It is used for hand riddling of sand to remove foreign materials from the sand.

Peen Ramer: It as a wedge shape in its bottom and it is used in packing of sand in pockets and corners for uniformity.

Round Rammer: It is used after the peen rammer and it is used to strike the sand rigidly

Strike-off Bar: It is flat bar made of wood or iron. It is used to Strike-off excess sand from the top of mould box after ramming to provide a level surface.

Vent Wire: It is thin steel wire carrying pointed edge at one end and wooden handle at the other end or bend. After ramming and strike of excess sand it is used to make small holes called vents in the sand which help in escaping of a gases and steam during casting.

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Trowel: Trowel is used for finishing flat surfaces and joints in a mould. It is made of different shapes like square, heart etc.

Slicks: They are used for repairing and finishing of mould edges after removing the pattern from the mould and used to cut gates for flow of liquid metal in the mould.

Lifter and Cleaner: They are used to cut the mould to remove loose sand from the mould cavity.

Draw Spike: It has loop at its end, used to draw pattern and shake the pattern in the mould

Swab: It is a fibre brush used to moisten the mould around the pattern before removing the pattern from the mould.

Sprue pin: It is taper rod of wood which is embedded in the sand mould and later with drawn to produce a hole called runner or raiser hole through which molten metal is poured in to the mould.

Gaggers: They are bend pieces of wire, which are used for reinforcing downward projection of sand mass in the cope.

Bellow: It is used to blow out the loose sands from the mould cavity.

Mould Boxes or flask: These boxes used in sand moulding, may be made of wood or cast iron or mild steel .The lower box is called drag or upper box is called cope. If three boxes are used, intermediate box is called cheek.

Laddle: They are used to receive the molten metal from the melting furnace, and are used to pour the molten metal in to the mould.

Crucible:

They are made of refractory materials like silicon carbide or graphite. They are used in melting metals and alloys.

Experiment No: __________ Date: ____________

Preparation of Square Mould Cavity

Aim:

Prepare Square Cavity using single moulding box

Tools required:

Mould Box, Showel, Peen Ramer, Round Rammer, strike-off bar, cleaner, Square trowel, Steel scale

Operations:

Ramming, Cutting and Finishing operations

Procedure:

➢ Prepare the sand and transfer the sand to working place using showel.

➢ Take drag and keep it on the moulding table. Fill it with green sand and ram with Peen Rammer and again fill the sand and ram with round rammer.

➢ Remove excess sand from strike off bar

➢ Spray parting sand and finish the surface with trowel

➢ Mark the square on the surface using scale and vent wire.

➢ Cut the required cavity using lifter and remove the loose sand from the cavity.

➢ Cut the gate and pouring basin.

➢ Square mould cavity is kept ready for pouring.

Diagram

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SQUARE CAVITY

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Results:

Skill for preparation of square cavity mould will be acquired.

Applications:

Used in Foundry for manufacture of casting

Remarks :

Signature of Staff Incharge with date

Experiment No: __________ Date: ____________

Preparation of hexagonal mould cavity using two mould boxes

Aim:

Cutting a hexagonal cavity using two mould boxes.

Tools required:

moulding flask, hand rammer, trowel, leveller, strike off bar, cleaner,

vent rod, scale, divider

Operations:

Ramming, Cutting and Finishing operations

Procedure:

➢ Keep the drag on the table and fill it with moulding sand. First ram the sand with flat head rammer, put more sand and rammed with round head rammer. Remove the excess sand and finish the top surface of the mould using leveller and trowels.

➢ Sprinkle sand on the top of the finished drag mould. Draw circle of required diameter on the top surface of the mould and inside the circle draw the hexagon to the required dimension.

➢ Now keep the open box on top of the drag box and keep the wooden sprue and riser at appropriate location on the drag and fill the cope box with the moulding sand and finish the cope box in the same manner as that of the drag box.

➢ Lift the cope box and keep it inverted position on the table. Now using the sand lifter remove the sand from the mould to get the desired shape that is round finish of the mould after outing the gate in this position.

Diagram

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CASTING

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Results:

Skill for preparation of hexagonal cavity mould will be acquired.

Applications:

Used in Foundry for manufacture of casting

Remarks :

Signature of Staff Incharge with date

Experiment No: __________ Date: ____________

Mould Preparation using Split Pattren

Aim:

To prepare a mold using split Pattern

Tools required:

Shovel, moulding box, hand rammer, strike off bar, trowel, lifter, sprue pin, split pattern.

Operations:

Ramming, Cutting and Finishing operations

Procedure:

➢ Prepare the moulding sand by separating the foreign materials by riddle.

➢ Transfer the green sand to the working place

➢ Keep the drag on the table and place the lower part of the split pattern at the centre of the drag. Fill it with green sand and ram the sand with round head rammer and remove excess sand using strike off bar and finish the top surface using trowel.

➢ Spray parting sand on the top of the drag and fix the other half split pattern to the drag.

➢ Put the cope, riser and runner and fill up the sand and ram with hand rammer. Remove excess sand, make vent hole to remove air.

➢ Separate the mould boxes and remove the pattern by using vent wire, cut the cavity using cleaner. Prepare pouring basin gate

➢ Assemble cope and drag which is kept ready for pouring.

Diagram:

[pic]

Results:

Skill for preparation of mould cavity using split mould pattern will be acquired.

Applications:

Used in Foundry for manufacture of casting

Remarks :

Signature of Staff Incharge with date

Experiment No: __________ Date: ____________

Mould preparation using Solid Pattern

Aim:

To prepare a mould using solid pattern (Pelton Cup).

Tools required:

Shovel, moulding box, hand rammer, strike off bar, trowel, lifter, sprue pin, pelton cup pattern.

Operations:

Filling up the sand, ramming the sand, leveling the sand, marking, cutting, finishing.

Procedure:

➢ Keep the drag box on the table and place the given pattern (pelton cup) in the drag. Fill up sand and ram it properly.

➢ Using straight leveller, sand is levelled.

➢ Tilt the drag box and sprinkle parting sand.

➢ Place the other half of the pelton cup and place the runner and riser. Fill the sand in cope and ram it properly.

➢ Remove the runner and riser. Prepare vent holes.

➢ Remove the cope and place it on the table and ram it to obtain the pattern (pelton cup).

➢ Cut the ingate in the drag. Assemble the two mould boxes which is ready to pour the molten metal.

Diagram:

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PELTON CUP CASTING

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Results:

Skill for preparation of mould cavity using solid mould pattern will be acquired.

Applications:

Used in Foundry for manufacture of casting

Remarks :

Signature of Staff Incharge with date:

Introduction to Forging (Smithy)

A blacksmith’s work involves heating of metal stock to a desire temperature (above recrystalisation temperature), enable it acquire sufficient plasticity, followed by operations like hammering, bending, Pressing etc. to give desire shape. This work is known as Forging.

The above operations either carried out by hand hammering or by power hammering or by forging machine.

Smithy is the term used for process when it is done by means of hand tools.

Power hammers are used in large quantity of production

Advantages of Forging:

Forging refines structure of metal

It renders metal stronger by setting the direction of the grains.

It saves material, Labor and time of production as compare to other production process.

Forging furnace:

LPG Fired Furnace: LPG fired furnace used for forging/ hand smithy consists of a refractory lined furnace. The furnace has a hinged door which can be opened for loading the raw material pieces. It is equipped with a burner in which LPG is supplied & it burns inside the refractory lined chamber. A thermocouple inserted in the chamber which is connected to a temperature indicator with temperature controller and temperature display unit for precise temperature measurement. Temperature can be set to a desired level( 850-880c) for forging. The furnace is having gas sensors to detect gas supply. The safety of operator is taken care of.

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Forging tools:

Smiths Forge or Hearth: It has a robust steel structure consisting four leg supports, iron bottom known as hearth. A hood /Chimney at the top and tuyers openings in to the hearth either from the rear or from the bottom. The hearth carries the coal which is used for heating the metal by combustion of coal. The hearth is lined with fire bricks withstand high temperature. Air under pressure is supplied by the blower is suitably placed near the hearth. This blower can either be hand operated or power driven . Metal pipes are used to connect the tuyers and blower. Chimney is provided at the top to enable easy escape of smoke and fumes.

Anvil:

It is equipment used as a support to the job. It is generally made of mild steel provided with hardened top, about 22 – 25 mm thick. The horn or beak is used in bending the metal or forming curved shapes. It carries square hole to accommodate this square shank of the bottom part of various hand tools like swages,fullers. It is called hard die hole. the circular hole provided near the hard die hole is known as pritchel hole.

Swage Block:

It is a block of cast steel carrying a number of slots of different shapes and sizes and through holes from its top to bottom. This is used as a support in punching holes and forming different shapes.

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FULLERS SWAGES

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FLATTER

Swages:

They are made of High carbon steel. Their working faces carry circular groups to suit the size of the work. Top swage carries a handle and bottom swage has a square to be fitted in to the hardy hole during forging operation.

Sledge hammer:

Hammer is a principal striking tool made of forge steel.

Classification of hammers is largely according to the size and weight of the hammers is used in forging. All the hammers are mainly divided in to four parts; namely Peen, eye, cheeks and face. The face is hardened and polished

Sludge hammers are comparatively 3 – 4 times heavier than the hand hammer. They are available in varying sizes and weights from 3 kg – 8 kg. They are employed when heavy blows are needed in forging.

Tongs:

They are used to hold the job in position and turning over during forging. They are made of mild steel. Tongs are usually made in two pieces, riveted und together to form a hinge.

Tongs are usually name after the inside shapes of the jaws. Flat Tongs are used for gripping small flat pieces. Round hollow tongs are used for holding round work.

Hollow tongs with square jaws are used to hold square or hexagonal work.

Chisels:

Chisels are used to cut metals in hot or cold state. Those which are used for cutting the metal in hot state are termed as hot chisels and others used for cutting in cold state are known as cold chisels.

Punches: punches are tapered tools made in various shapes and sizes. They are used for producing holes in red hot jobs.

Drifts: Drifts is a large sized punch used to expand the hole to the desired shape and size, after the punching is over.

Fullers:

These tools are made of high carbon steels in different sizes to suit the various types of jobs. They are usually used in pairs, consisting of top and bottom fuller. Their working edges are normally rounded. They are employed for making necks by reducing the cross section of job and also in drawing out.

Flatters:

They are also known as smoothers. They are made of high carbon steel and consist of a square body fitted with handle and flat square bottom. They are used for leveling and finishing a flat surface after drawing out or any other forging operations.

Experiment No: __________ Date: ____________

To obtain a Square Bar from Round Rod by Forging

Aim:

To obtain a square bar from round rod by forging

Tools required:

Anvil, sledge rammer, round & square tong, swage, flatter, steel scale.

Operations:

Heating(using LPG fired furnace), hammering, drawing

Precautions:

Hold the tong outside the anvil while hammering.

Take care about hammer slipping from handle.

Procedure:

➢ Switch on the LPG fired furnace and set the forging temperature to 800-8500C.

➢ Keep the given work piece in the hearth and heat it to red hot condition.

➢ Flatten the opposite face with the help of flatter by placing it on the anvil

➢ Obtain the required model and then dip it in water for quick cooling.

➢ The required model is thus obtained.

Diagram:

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ROUND MILD STEEL

*length can vary from 70-75mm/ diameter can vary from 18-20mm

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*length can vary from 90-105mm

Calculation of raw material length in forging

1. To find the length of raw material required for forging to square

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Let

a=side of the finished square

i.e a=15mm

h=length of the finished square

i.e h=105mm

Volume of the finished square=a2 x h

=152 x 105 = 23625mm3

Volume of the raw material [MS round dia=20mm] = [pic]

Assuming no scaling losses

Volume of the finished square = volume of the raw material

a2 x h = π r2 l (Taking r = 10mm)

l= a2 x h / π r2

l= 152 x 105 / 3.142 x 102

l=75mm

Length of raw material will vary depending on raw material diameter/ radius

Results:

Skill for getting square bar by forging is acquired.

Applications:

Used in industry for making simple components by forging.

Remarks :

Signature of Staff Incharge with date:

Experiment No: __________ Date: ____________

To obtain a Hexagonal Bar from Round Rod by Forging

Aim:

To obtain a hexagonal bar from round rod by forging

Tools required:

Anvil, sledge rammer, round tong, swage, flatter, steel scale.

Operations:

Heating(using LPG fired furnace), hammering, drawing

Precautions:

Hold the tong outside the anvil while hammering.

Take care about hammer slipping from handle.

Procedure:

➢ Switch on the LPG fired furnace and set the forging temperature to 800-8500C.

➢ Keep the given work piece in the hearth and heat it to red hot condition.

➢ Flatten the opposite face with the help of flatter by placing it on the anvil

➢ Obtain the required model and then dip it in water for quick cooling.

➢ The required model is thus obtained.

Diagram:

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ROUND MILD STEEL

*length can vary from 70-75mm/ diameter can vary from 18-20mm

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HEXAGONAL BAR

*the length can vary from 90-110 mm

Calculations:

To find the length of raw material required for forging to hexagon

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Consider the right angle triangle

Area of triangle= ½ x base x height

By Pythagoras theorem : a2=h2 + (a/2)2

h2=3 x a2/4

h= (3)1/2 x a /2

Therefore area of triangle= ½ x a x (3)1/2 x a /2

= (3)1/2 x a2 / 4

This is for one side but hexagon consists of 6 sides i.e 6 x (3)1/2 x a2 / 4

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Let a= side of the finished hexagon = 10mm

h= length of the finished hexagon = 90 mm

Volume of the finished hexagon = 6 x (3)1/2 x a2 / 4 x h

= 23382 mm3

Volume of the raw material [ MS round dia=20mm]= [pic]

Assuming no scaling losses

Volume of the finished hexagon = volume of the raw material

23382= π r2 l (Taking r = 10mm)

Therefore l = 23382 /π r2

l = 75 mm

Length of raw material will vary depending on raw material diameter/ radius.

Results:

Skill for getting hexagonal bar by forging is acquired

Applications:

Used in industry for making simple components by forging.

Remarks :

Signature of Staff Incharge with date:

Experiment No: __________ Date: ____________

To obtain Gib Head Key from a given Round Rod by Forging

Aim:

To obtain a Gib head key from round rod by forging

Tools required:

Anvil, sledge hammer, flat tong, chipping tool, flatter, steel scale.

Operations:

Heating(using LPG fired furnace), neck forming, hammering, drawing

Precautions:

Hold the tong outside the anvil while hammering.

Take care about hammer slipping from handle.

Procedure:

➢ Switch on the LPG fired furnace and set the forging temperature to 800-8500C.

➢ Keep the given work piece in the hearth and heat it to red hot condition.

➢ Flatten the all face with the help of flatter as per drawng by placing it on the anvil.

➢ Finish sides as per dimensions.

➢ Obtain the required model and then dip it in water for quick cooling.

Diagram:

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ROUND MILD STEEL

*length can vary from 70-75mm/ diameter can vary from 18-20mm

[pic]

*length can vary from 95-100mm.other dimensions are approximate

Results:

Skill for getting Gib head key from round by forging is acquired

Applications:

Used in industry for making simple components by forging.

Remarks :

Signature of Staff Incharge with date:

SAND TESTING

Importance of sand test:

Important property of mould sand is that it should produce a sound casting. To achieve this, sand should posses following desired properties.

Property of moulding sand:

1. Refractoriness: it is that property of moulding sand which enables it to withstand high temperature of molten metal without fusing.

2. Permeability: It is that property of sand which allows the gases and steam to escape through, heater.

3. Flowabilty: It is that property of sand due to which it flows during ramming to all portions of the moulding flask, packs properly around the pattern to acquire the desired shape

4. Adhesiveness: It is that property of sand due to which capable of adhering to surface of the other materials

5. Cohesiveness: It is that property of sand due to which its rammed particles bind together firmly show that when the pattern is withdrawn from the mould ,with out damaging the mould surfaces and edges.

6. Collapsibility: It is that property of sand due to which sand mould automatically collapses after solidification of castings.

7. Other Requirements:

7.1 It should be cheap and easily available

7.2 It should be reusable

7.3 It’s coefficient of expansion should be low.

7.4 It should not stick the surface of the castings.

Sand test:

Various sand tests are conducted on moulding sands to as certain its working qualities. The Sand tests helps in controlling the sand properties during mould preparation.

Experiment No: __________ Date: ____________

Sieve Analysis of Base Sand

Aim:

To find the distribution of sand grains, using a set of sieves and to find average grain fineness number (G.F.N).

Materials required:

Base sand/Silica sand

Apparatus Used:

Weighing Balance (Digital), Stop watch, sieve set, motor run sieve shaker.

Procedure:

1. Take 50/100 gm of dry sand and place it in the top sieve of series of sieves and tightened the lid and clamp it tightly

2. Switch on the sieve shaker and start the stopwatch. After shaking the sand for 15 min stop the sieve shaker.

3. The sand particles retained in each sieve are collected separately and weighed. These weights are entered in the tabular column.

4. The percentage of weight retained in each sieve is calculated and entered in the tabular column ((A).

5. Multiply this weight by multiplication factor (B) of each sieve and find the total of the product ((AB).

1. Find the average grain fineness number using the formula

G.F.N= (A.B/(A=

Where,

(AB= Sum of he percentage sand retained in the sieves and corresponding multiplier

(A=Sum of the percentage of the sand retained in the sieves.

2. Plot graph of cumulative percentage of sand retain (X-Axis) V/S Sieve No (Y-Axis).

Diagram:

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SEIVE SHAKER SETUP

Tabular Column:

|Sl.No |Sieve No |Sieve Size in |Weight of sand |Percentage of sand |Multiplier |Product AXB |Cumulative |

| | |Micron |retained in gm |retained |‘B’ | |percentage of sand|

| | | | |‘A’ | | |retained |

|1 |16 |850 | | |10 | | |

|2 |22 |600 | | |20 | | |

|3 |30 |425 | | |30 | | |

|4 |44 |300 | | |40 | | |

|5 |60 |210 | | |50 | | |

|6 |100 |150 | | |70 | | |

|7 |160 |100 | | |100 | | |

|8 |200 |75 | | |140 | | |

|9 |300 |53 | | |200 | | |

|10 |PAN |PAN | | |300 | | |

| |∑A = |∑AB = |

Results:

The average grain fineness number (G.F.N) =

Applications:

GFN is used in foundry for preparing moulding sand.

Remarks :

Signature of Staff Incharge with date:

Experiment No: __________ Date: ____________

To find the Amount of Clay

Aim:

To determine the amount of CLAY in the given base sand (Silica sand).

Apparatus/Components required:

A Clay washer measuring jar, Mechanical stirrer, siphon tube, weighing balancening sand from the jar to a PAN.

Procedure :

1. The sample under test (dry silica sand containing clay) is dried and then 50 gm (W1) is poured into the jar.

2. 475 cc of distilled water and 25 cc of standard sodium hydroxide solution is poured into the jar.

3. The jar is covered with mechanical stirrer and rotate the stirrer at about 60 rpm for about one minute.

4. Lift the stirrer and water to the jar so that the height from the bottom of the jar is 150mm with water. Again stir for about one minute at slow speed.

5. Lift the stirrer allowed the mixture to settle for about five minutes so that silica particle settled in the bottom and clay particles float on top of water.

6. Siphon the water about 125mm from the top.

7. Repeat the steps 4,5 and 6 about 3 to 4 times to remove all the clay particles from the sand.

8. Take out the remaining sand

Observations & Calculation

Initial Weight of sand (W1)= 50gm

Amount of NaoH taken= 25 cc

Amount of distilled water = 475 cc

Final weight of sand = W2 gm

Percentage of clay = W1-W2/W1*100

Diagram:

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CLAY CONTENT APPARATUS

Results:

The percentage of clay in the given sand =

Applications:

The clay content in the sand is used for preparing moulding sands.

Remarks :

Signature of Staff Incharge with date:

Experiment No: __________ Date: ____________

To find the Compression Strength

Aim:

To determine the compression strength of the given green sand containing different amount of clay and water

Apparatus/Components required:

Weighing Balance, Measuring Jar ,A.F.S sand rammer, Specimen tube, Universal sand tester, compression shackles.

Procedure:

The experiment may be conducted in two ways.

a) Vary clay content in sand and keep water content constant

b) Vary water content in sand and keep clay content constant

Weighed quantities of sand, clay& water mixed thoroughly for 3 min, this sand mixture is transferred to the specimen tube and rammed thrice in standard A.F.S. sand rammer so as to obtain a correct size of specimen ( 50 mm length and 50 mm diameter) remove the specimen from the tube using strippers post. Place the specimen between compression shackles of the universal sand tester. Rotate the hand wheel for applying the load on the specimen. After breaking the specimen note down the reading from the dial gauge of the universal sand tester. This gives the compression strength of the sand mix. Repeat the above procedure for specimens containing various percentage of clay and water.

Diagram

[pic]

UNIVERSAL SAND TESTER

[pic]

SAND RAMMER

[pic]

COMPRESSION TEST

Graph to be plotted/ Nature of Graph

1. Compression strength Vs Percentage of clay content when moisture is constant

2. Compression Strength Vs Percentage of moisture when the clay content constant

Tabular Column:

|Sl.No |Sand |Moisture |Clay |Compression Strength |

| | | | |( gm / cm2 ) |

| |% of Weight |Weight in |% of weight |Weight in |% of weight |Weight in | |

| | |grams | |grams | |grams | |

| | | | | | | | |

| | | | | | | | |

| | | | | | | | |

| | | | | | | | |

Results:

The compression strength of given sand =

Applications:

The value of compression strength of sand mixture is useful in preparing sand green moulds.

Remarks :

Signature of Staff Incharge with date:

Experiment No: __________ Date: ____________

To find the Shear Strength

Aim:

To determine the shear strength of the given green sand containing different amount of clay and moisture.

Apparatus/Components required:

Weighing Balance, Measuring Jar, A.F.S sand rammer, Specimen tube, Universal sand tester, shear shackles

Procedure :

The experiment may be conducted in two ways.

a. Vary clay content in sand and keep water content constant

b. Vary water content in sand and keep clay content constant

Weighed quantities of sand, clay& water mixed thoroughly for 3 min, this sand mixture is transferred to the specimen tube and rammed thrice in standard A.F.S. sand rammer so as to obtain a correct size of specimen ( 50 mm length and 50 mm diameter) remove the specimen from the tube using strippers post. Place the specimen between shear shackles of the universal sand tester. Rotate the hand wheel for applying the load on the specimen. After breaking the specimen note down the reading from the dial gauge of the universal sand tester. This gives the shear strength of the sand mix. Repeat the above procedure for specimens containing various percentage of clay and water.

Diagram:

[pic]

SHEAR TEST

Graph to be plotted/Nature of Graph

Shear strength Vs Percentage of clay content when moisture is constant

Shear Strength Vs Percentage of moisture when the clay content constant

Tabular Column:

|Sl.No |Sand |Moisture |Clay |Shear Strength |

| | | | |( gm / cm2 ) |

| |% of Weight |Weight in |% of weight |Weight in |% of weight |Weight in | |

| | |grams | |grams | |grams | |

| | | | | | | | |

| | | | | | | | |

| | | | | | | | |

| | | | | | | | |

| | | | | | | | |

| | | | | | | | |

Results:

The shear strength of given sand =

Applications:

The value of shear strength of sand mixture is useful in preparing sand green moulds.

Remarks :

Signature of Staff Incharge with date:

Experiment No: __________ Date: ____________

To find the effect of water and clay on the permeability of green sand

Aim:

To determine the effect of water and clay on the permeability of green sand

Apparatus required:

Weighing balance, A.F.S sand rammer, Specimen Tube, permeability tester, stop watch.

Procedure:

The experiment may be conducted in two ways.

(a). Vary clay content in sand and keep water content constant

(b). Vary water content in sand and keep clay content constant

Weighed quantities of sand, clay& water mixed thoroughly for 3 min, this sand mixture is transferred to the specimen tube and rammed thrice in standard A.F.S. sand rammer so as to obtain a correct size of specimen ( 50 mm length and 50 mm diameter). Place the specimen with the tube by inverting on the rubber pad of the permeability tester. Collect 2000 CC air in bell jar. By keeping valve in close position note down the monometer reading and pass the air through the specimen. Soon after air passing, start the stop clock and once again take the monometer reading. Note down the time to pass 2000 CC of air completely through the specimen and the air pressure. Substitute the values in the following formula and find the permeability.

Permeability No. PN = VH

PAT

V = Volume of the air passing through specimen = 2000 cc

H = Height of the specimen in cm = 5.08 cm

P = Pressure ( Final-Initial) reading from monometer in grams per square cm

A = Cross sectional Area of the specimen = Pd2/4

T = Time taken to pass 2000 CC of air through the specimen in minutes.

Compare the values with standard values graduated on the permeability meter.

Diagram:

[pic]

PERMEABILITY TESTER

Graph to be plotted/Nature of Graph

Plot the following Graphs

Permeability number v/s % of clay

Permeability number v/s moisture content

Tabular Column:

|Si. |Sand |Moisture |Clay |Pressure |Time |Permeability |

|No | | | |in gm / cm2 |T | |

| | | | | |in min | |

| |% |Weight in gms |% of |Wt in gms |% of |Wt in gms |

| | | |Wt | |Wt | |

| | | |Date: |Date: |Date: |Date: |

| | | |Viva |Record |

| | | |(05) |(10) |

|Name of the Faculty Incharge |(1) |

| | |

| |(2) |

| | |

| |(3) |

Note:

(1) Viva questions to be asked w.r.t the current experiment of the particular week.

(2) The above same page format is used for next set of experiments i.e. 5, 6,….expts.

(3) Separate sheets must be used for different batches.

DAYANANDA SAGAR COLLEGE OF ENGINEERING

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING, BENGALURU-560078

FINAL IA MARKS FORMAT

CONTROL SYSTEMS LABORATORY (10EEL68)

Year:

Semester /Section : Batch :

|SN |USN |Name Of The Student |Continual |IA Test Marks |Final Marks |Signature of |

| | | |Evaluation Marks |(10) |(25) |Student |

| | | |(15) | | | |

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FOUNDRY AND FORGING LABORATORY MANUAL

III Semester (MEL38)

DAYANANDA SAGAR COLLEGE OF ENGINEERING

Accredited by National Assessment & Accreditation Council (NAAC) with ’A’ Grade

(An Autonomous Institution affiliated to Visvesvaraya Technological University, Belagavi

&

ISO 9001:2008 Certified)

MECHANICAL ENGINEERING DEPARTMENT

SHAVIGE MALLESWARA HILLS , KUMARASWAMY LAYOUT

BENGALURU-560078

[pic]

FOUNDRY AND FORGING LABORATORY MANUAL

III Semester (MEL38)

DAYANANDA SAGAR COLLEGE OF ENGINEERING

(An Autonomous Institution affiliated to Visvesvaraya Technological University, Belagavi)

MECHANICAL ENGINEERING DEPARTMENT

SHAVIGE MALLESWARA HILLS

KUMARASWAMY LAYOUT

BENGALURU-560078

Name of the Student :

Semester /Section :

USN :

Batch :

Name of the Student :

Semester /Section :

USN :

Batch :

DO’s

➢ Wear prescribed uniform & shoes which is compulsory. Tie loose hair (for girls ) eith clip / band.

➢ Safety equipments like apron, gloves and hel[?] 234LMef / 0 òîêæØæÊ殪¦æ–ŠqSH–9h?»h?»CJ(OJQJaJ(h?»h?»OJQJ:h?»h?»B*CJOJQJ^J[?]aJfH[pic]phiiiqÊÿûûù1h?»h?»CJ(OJQJ^J[?]aJ(met must be worn while doing smithy / hand forging and operating LPG fired furnace.

➢ Use prescribed tools while doing models, as instructed by teaching staff and instructors.

➢ Observation book shall be used for recording lab work, calculations etc.

➢ Practical record book should be completed and get it valued every week by teaching staff to comply with CIE (continuous internal evaluations) format.

➢ Safety instructions as applicable must be followed.

➢

DONT’s

➢ The use of mobile/ any other personal electronic gadgets is prohibited in the laboratory.

➢ Wear loose clothing, leave loose hair for girls.

➢ Operate equipment without the consent of instructor.

➢ Play with tools which may have sharp edges.

➢ Absent from attending lab with valid reasons.

➢ Give excuses for not bring the record.

➢ Unsafe actions which may lead to accidents.

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➢

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