F & f lab manual prepared by prashant mulge appa iet gulbarga

DEPARTMENT OF MECHANICAL ENGINEERING, APPA IET, KALABURAGI. 1
FOUNDRY AND FORGING LAB MANUAL 2016
APPAINSTITUTE OF ENGINEERING & TECHNOLOGY, KALABURAGI
DEPARTMENT OF MECHANICAL
ENGINEERING
FOUNDRY AND FORGING LAB MANUAL
FOUNDRY AND FORGING LAB MANUAL
2016-17
PREPARED BY
PRASHANT MULGE
Assistant Professor
Department of Mechanical Engineering
Appa IET, Kalaburagi 585103

Department of Mechanical Engineering
LABORATORY SAFETY PRECAUTIONS
1. Laboratory uniform, shoes & safety glasses are compulsory in the lab.
2. Do not touch anything with which you are not completely familiar. Carelessness may
not only break the valuable equipment in the lab but may also cause serious injury to
you and others in the lab.
3. Please follow instructions precisely as instructed by your supervisor. Do not start the
experiment unless your setup is verified & approved by your supervisor.
4. Do not leave the experiments unattended while in progress.
5. Do not crowd around the equipment‟s & run inside the laboratory.
6. During experiments material may fail and disperse, please wear safety glasses and
maintain a safe distance from the experiment.
7. If any part of the equipment fails while being used, report it immediately to your
supervisor. Never try to fix the problem yourself because you could further damage the
equipment and harm yourself and others in the lab.
8. Keep the work area clear of all materials except those needed for your work and
cleanup after your work.
‘Instructions to the Candidates’
1. Students should come with thorough preparation for the experiment to be conducted.
2. Students will not be permitted to attend the laboratory unless they bring the practical
record fully completed in all respects pertaining to the experiment conducted in the
previous class.
3. Experiment should be started only after the staff-in-charge has checked the experimental
setup.
4. All the calculations should be made in the observation book. Specimen calculations for
one set of readings have to be shown in the practical record.
5. Wherever graphs are to be drawn, A-4 size graphs only should be used and the same
should be firmly attached to the practical record.
6. Practical record should be neatly maintained.
7. They should obtain the signature of the staff-in-charge in the observation book after
completing each experiment.
8. Theory regarding each experiment should be written in the practical record before
procedure in your own words.

FOUNDRY AND FORGING LABORATORY 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

INDEX
Expt.
No.
Date NAME OF THE EXPERIMENT
Page
No.
Remarks
PART-A
01 Tensile test on Universal Sand Testing Machine
02 Compression test on Universal Sand Testing Machine
03 Shear test on Universal Sand Testing Machine
04 Mould hardness test
05 Clay content determination in Base Sand
06 Permeability test
PART- B
01 Use of foundry tools and other equipment’s
02 Mould preparation: a] with pattern b] without pattern
PART- C
01 Use of forging tools and other equipment’s
02
Forging practices
Job:1
Job:2
Job:3

PROPERTIES OF MOULDING SAND
Good moulding sand must possess the following properties. The properties
are determined by the amount of clay, moisture content and by the shape and size of the
silica grain in the sand.
PERMEABILITY:
It is the ability of sand to allow the gasses to escape from the mould.
COHESIVENESS OR STRENGTH:
This is the ability of sand particles to stick together. Insufficient strength may lead to a
collapse in the mould or its partial destruction during conveying turning over or closing.
ADHESIVENESS:
The sand particles must be capable of adhering to another body, i.e, they should cling to
the sides of the moulding boxes.
PLASTICITY:
It is the property to retain it shape when the pressure of the pattern is removed.
REFRACTORINESS:
The sand must be capable of withstanding the high temperature of the molten metal
without fusing.
BINDING:
Binder allows sand to flow to take up pattern shape.
CHEMICAL RESISTIVITY:
Moulding sand should not chemically react or combine with molten metal so that it can
be used again and again.
FLOWBILITY:
It is the ability of sand to take up the desired shape.

SAND TESTING EXPERIMENTS
Periodic test are necessary to determine the essential qualities of foundry sand.
The most important tests to be conducted for any foundry sand are as follows.
1. Compression, shear and tensile strength test on universal sand testing machine.
Purpose:
i) Moulding sand must have good strength otherwise it may lead to collapse of mould.
ii) It must be retained when the molten metal enters the mould (bond
strength)
iii) To retain its shape when the patter is removed and movement of the mould.
2. Permeability test.
It is the property of moulding sand which allows gases to pass through easily in the
mould.
3. Core and mould hardness test.
The hardness test is useful to find out the moulds surface uniformly.
4. Sieve analysis to find the grain fineness number of base sand.
To find the average grain fineness number for the selection of fine, medium, and course
sand.
5. Clay content determination in base sand.
It is to find the % of the clay content in the base sand.

EXPERIMENT NO. 01
DETERMINATION OF TENSILE STRENGTH OF THE
GIVEN SAND SPECIEMEN
Aim: To determine the tensile strength of the given sand sample.
Materials Used: Given sand sample
Apparatus: UTM, Sand rammer with sand rammer standard specimen box and tensile test
attachments, etc.
Theory:
During casting the core is placed inside the mould and the molten metal is poured in
to the cavity. As the molten metal begins to cool, it begins to contract on the inner radius as
well as the outer radius. Due to the contraction of the inner radius the core sand will be pulled
outwards causing a tensile load around the core. Hence knowledge of tensile strength of core
sand is important.
Procedure:
1. Prepare a standard sand specimen with the help of sand rammer and standard
specimen box.
2. Insert the tensile test attachments in respective position to apparatus.
3. Place the specimen between tensile test attachments.
4. Apply load gradually on the specimen by rotating the hand wheel of machine in
clockwise direction, till specimen is fractured.
5. Note down the corresponding reading on the strength scale of the pressure gauge.
6. Repeat the above procedure for two more times.
7. The average of these reading shows respective tensile strength of given sand
specimen.

Observation Table:
Sl.No. Pressure gauge
reading(gm/cm2
)
Multiplying factor
Average tensile
strength((gm/cm2
)
01 10
02 10
03 10
Calculation: Average tensile strength of given sand sample =
Result: Tensile strength of the given sand sample is =………..gm/cm2

EXPERIMENT NO.02
DETERMINATION OF COMPRESSION STRENGTH OF
THE GIVEN SAND SPECIEMEN
Aim: To find the green compression strength of the sand sample.
Apparatus: UTM, Sand rammer with sand rammer standard specimen box and compression
pads, etc.
Theory:
The compacting limits of the material is called compression strength, it is opposite to
tensile strength. Periodic tests are necessary to check the quality of foundry sand and
compression strength test is one among them. Compression test determines the bonding or
adhesiveness power of various bonding material in green sand. The green compressive
strength of foundry sand is the maximum compression strength a mixture is capable of
developing when it is in moist condition.
Procedure:
1. Prepare a standard sand specimen of diameter 50mm and height 50mm with the help
of sand rammer and standard specimen box.
2. Insert the compression pads in respective position to apparatus.
3. Place the specimen between the pads such that the, plain surface of the specimen
touches against the pads.
4. Apply load gradually on the specimen by rotating the hand wheel in a clockwise
direction till specimen is fractured.
5. When the specimen is fractured, the needle of the pressure gauge returns to its
original position while the red pointer of the pressure gauge remains at the maximum
reading.
6. Note down the corresponding reading on the compression strength scale of the
pressure gauge.
7. Repeat the above procedure for two more times and take its corresponding readings.

8. The average of these three reading shows respective compression strength of given
sand sample.
Observation Table:
reading(gm/cm2
)
Multiplying factor
Average compression
strength((gm/cm2
)
01 100
02 100
03 100
Calculation: Average compression strength of given sand sample =
Result: Tensile compression of the given sand sample is =………..gm/cm2

EXPERIMENT NO. 03
DETERMINATION OF SHEAR STRENGTH OF THE
GIVEN SAND SPECIEMEN
Aim: To find the green shear strength of the sand sample.
Apparatus: UTM, Sand rammer with sand rammer standard specimen box and Shear test
attachments, etc.
Theory:
Shear strength is the ability of sand particles to resist the shear stress and to stick
together. Insufficient shear strength may lead to the collapsing of sand in the mould or its
partial destruction during handling. The mould and core may also be damaged during flow of
molten metal in the mould cavity. The moulding sand must possess sufficient strength to
permit the mould to be formed to the desired shape and to retain the shape even after the hot
metal is poured into the mould cavity. In shearing, the rupture occurs parallel to the axis of
the specimen.
Procedure:
1. Prepare a standard sand specimen of diameter 50mm and of height 50mm with the
help of sand rammer.
2. Insert the shear test attachment in respective position to apparatus.
3. Place the specimen between shear pads, such that the plain surface of the specimen
touches against the pads.
4. Apply load gradually on the specimen by rotating the hand wheel of machine in
clockwise direction till specimen is fractured.
5. When the specimen is fractured, the needle of the pressure gauge returns to its
original position while the red pointer of the pressure gauge remains at the maximum
reading.
6. Note down the corresponding reading on the shear strength scale of the pressure
gauge.
7. Repeat the above procedure for two more times and take its corresponding readings.
8. The average of these three reading shows respective shear strength of given sand
sample.

Observation Table:
reading(gm/cm2
)
Multiplying factor
Average shear
strength((gm/cm2
)
01 100
02 100
03 100
Calculation: Average shear strength of given sand sample =
Result: Tensile shear of the given sand sample is =………..gm/cm2

EXPERIMENT NO. 04
DETERMINATION OF CLAY CONTENT IN GIVEN SAND
SAMPLE
Aim: To determine the percentage of clay present in the give sand sample.
Materials Used: 50grams moisture free or dry sand, Sodium Hydroxide(NAOH) and water.
Apparatus: Sand washer(mechanical stirrer), Measuring jar, Electronic weighing machine,
Oven, siphon tube, etc.
Theory:
Clay can be those particles having less than 20 microns size. Moulding sand contains
2 to 50 percent clay. When mixed with water it imparts, binding strength and plasticity. Clay
consists of two ingredients (a) Fine silt (b) true clay. Fine silt has no binding power where as
true clay imparts the necessary boundary strength to the moulding sand; thereby the mould
does not lose its shape after ramming. Clay is the main constituent in a moulding sand and
mixture other than sand grains. Clay imparts binding action to the sand and hence the
strength. Clay is of mineral origin available in plenty on earth. It is made of alumina silicate.
The types of clay are (a) montmorillonite (b) kaolinite (c) illite. The first type is generally
referred to as Bentonite. Clay is the main constituent in a moulding sand mixture other than
sand grain. Clay help impart binding action to the sand and hence strength to the sand.
Procedure:
1. Given sand sample under test is dried and cooled.
2. It is then taken in a glass jar in a weighed amount of 50grams.
3. To this add 475cc of water and 25cc of 3% NAOH standard solution.
4. Glass jar along with the content is placed in clay washer apparatus for 5 minutes.
5. Remove the glass jar from the apparatus and is allowed to settle for some time.
6. Using siphon tube Siphon out water leaving 25mm in the bottom of the jar .add water
again up to 150 mm and allow it to settle down for 5 minutes.
7. Repeat the same procedure for three to four times until the water becomes clear in the
wash bottle.
8. Remove the remaining sand grains from the bottle in to the drying pan and dry the
sample at 105 to 1100
C in a oven.

9. After drying the sand accurately weigh the sand and fine the percentage of clay using
the calculation.
Observation table:
Sl.No. Weight of sand before
washing (A)
Weight of sand after
washing (B)
%clay =
01
Calculation:
% of clay =
% of clay =
% of clay =……….
Result: Clay content in the given 50grams sand sample is………%

EXPERIMENT NO. 05
DETERMINATION OF PERMIABILITY NUMBER OF A
GIVEN SAND SAMPLE
Aim: To determine the green permeability number of the given sample of sand.
Materials: 100grams of moisture content sand sample.
Apparatus: Sand rammer & accessories, beam balance, stop watch, permeability meter.
Theory:
Molten metals always contain certain amount of dissolved gases, which are evolved
when the metal starts freezing. When molten metal comes in contact with moist sand,
generates steam or water vapour. Gases and water vapour are released in the mould cavity by
the molten metal and sand. If they do not find opportunity to escape completely through the
mould, they will get entrapped and form gas holes or pores in the casting. The sand must
therefore be sufficiently porous to allow the gases and water vapour to escape out. This
property of sand is referred to as permeability. Permeability is one of the most important
properties affecting the characteristics of moulds which depend upon the grain size, grain
shape, grain distribution, binder content, moisture level and degree of compactness.
Procedure:
1. Prepare a standard sand specimen 50mm diameter and 50mm height with the help of
sand rammer and specimen tube.
2. Place the permeability testing apparatus on a platform then fill the water in water tank
of tester at approximate measured quantity of 200ml and also fill the water into the
manometer.
3. Screw the proper orifice with washer or rubber sealing boss of the tester.
4. Put the valve lever to “D” position on and lift the bell tank.
5. Put the valve lever to “O” position for adjusting the height and fixed amount of air
volume in bell tank.
6. Put the valve lever “O” to “P” position for release of air at constant pressure from air
tank through the sand specimen.

7. When the pressure is released, reading is attained on manometer and can be read on
vertical scale.
8. At the same time put the valve lever to “P” position start the stop watch, when air tank
is reached to 200ml marked line, stop the watch and note down the corresponding
time in minutes.
Observation table:
Sl.No. Orifice size (mm) Manometer reading
(gm/cm2
)
Permeability Number
(AFS)
01 1.5
02 1.5
03 1.5
Calculation:
The permeability number is calculated from the below formula:
Permeability number Pn =
Where;
V = Volume of air in cm3
passes through the specimen = 2000cc
H = Height of the specimen = 50mm
P = Applied pressure by manometer in gm/cm2
A = Cross sectional area of the specimen
T = Time taken by 2000cc of air passes through the sand sample.
1] Cross sectional area of the specimen = A=
A= = 19.63 gm/cm2
2] Permeability number Pn = = ……..
Result: Permeability number (AFS) of given sand sample is ……….AFS

EXPERIMENT NO. 06
MOULD HARDNESS
Aim: determination of mould hardness
Apparatus required: mould hardness tester with ball indenter, electronic ball sand rammer
with specimen tube etc.
Procedure:
1. Prepare the mould sand specimen like soft,hard,meadium and very hard and help of
rammer and mould box
2. Place the mould tester tip vertically on the surface
3. Gently press the instrument on the mould surface until the bottom ring contact the
mould surface throughout periphery
4. The depth of penetration of tip indicates the mould hardness directly
5. Repeat the same procedure over the different rammed specimen and note the
corresponding reading.
Observation table
Sl.no Ramming type Compact energy by
ramming machine
in Kg-m
Hardness no
(HBR)
1 Soft
2 Medium
3 Hard
4 Very hard
Result: The mould hardness of given sand specimen =……………

EXPERIMENT NO. 07
SIEVE ANALYSIS
Aim: Determination of Grain Fineness Number of given Sand.
Materials: 100grams moisture free, clay free dry sand .
Apparatus: standard Sieve shaker machine set of sieve, sand washer, oven and electronic
balance etc.
Theory:
The determination of the proportions of particles within certain size ranges in a
granular material by separation on sieves of different size openings is called sieve
analysis.During sieving the sample is subjected to horizontal or vertical movement in
accordance with the chosen method. This causes a relative movement between the particles
and the sieve; depending on their size the individual particles either pass through the sieve
mesh or are retained on the sieve surface. The likelihood of a particle passing through the
sieve mesh is determined by the ratio of the particle size to the sieve openings, the orientation
of the particle and the number of encounters between the particle and the mesh openings.
Procedure:
1. The given sand sample under test after washing out of clay dried at 1050
C to 1100
C
and cooled.
2. It taken into a upper sieve plate in a weight of 100grams.
3. Standard sieve set along with the content is placed in sieve shaker, apparatus to
vibrate or shake for 10 to 15 minutes.
4. The sand remaining balance in individual sieve and pan is weighed on percentage
bases.
5. Each weight quantity is multiplied by constant, value of each sieve term multiplied
stated as in standard.
6. The fineness number is calculated by using below equation.
AFS=
L=
7. The average grain size of sand is calculated by
DL=
8. The shape of the sand visual observed by using magnified glass.

Observation and constant factor table
Sl.No. Sieve opening
number in micron
Weight in
gram of
sand
retained on
sieve
% of sand
retained on
sieve
Multiplying
constant
factor
Total
product
A B C D E F=D X E
GFN=
Result = GFN of given sample is ……..

PART-B
EXPERIMENT NO. 01
TOOLS USED IN FOUNDRY
1. Shovel: A shovel is used for mixing and tempering moulding sand and for moving the
sand from the pile to flask.
2. Sprue pin: A sprue pin is a tapered peg pushed through the cope up to the joint of the
mould. As the peg is withdrawn, it removes the sand, leaving an opening for the
metal. This opening is called the sprue, through which the molten metal is poured.
3. Vent rod: A vent rod or wire is used to make a series of holes to permit gases to
escape while the molten metal is poured into the mould.
4. Gate cutter: It is a small piece of the plate, which serves as a tool for cutting gates
and runners in the mould.
5. Rammer: A hand rammer is a wooden tool for packing or ramming the sand into the
mould. One end is called peen and the other is butt. Peen is wedge or cone shaped and
the butt is cylindrical. Pneumatic rammers also available for machine moulding.
6. Slick: It is a small double-ended tool having a flat on one end and spoon on the other
end. This tool is made in variety of shapes; the most common shape is oval shaped. It
is used for repairing and finishing of mould cavities.
7. Strike of Bar: It is a piece of wood or metal with bottom surface straight and plane. It
is used to stickle or strike off excess sand from the mould after ramming to provide a
levelled surface.
8. Clamps: Clamps are used for holding together the cope and drag of the complete
mould to prevent the cope from floating or rising when the metal is introduced into
the mould.
9. Draw spike: The draw spike is a pointed steel rod, with a loop at one end, It is used
to rap and draw patterns from the sand.
10. Spirit level: The spirit level is used to check the flatness, straightness and taperedness
of mould.
11. Moulding Box: Sand moulds are generally prepared in specially constructed boxes
known as flasks, which give rigidity and strength.

EXPERIMENT NO. 02
MOULD PREPARATION
A] With pattern
Aim: To prepare a mould cavity in a sand mould using given pattern.
Tools required: pattern, base, strike bar, lifters, mould box, etc.
Material required: Moulding sand, etc.
Procedure:
1. Take sand from the pit with the help of shovel.
2. Crush the sand with the help of ramming tool until the sand becomes very fine and
uniform particle size.
3. Add water in the crushed sand and mix it proper such that the sand particle should
adhere to each other.
4. Then take a base plate and mould box, place the mould box on the base and put the
pattern at the centre of the mould box and add wood powder on the pattern so that the
pattern should not adhere with the sand and add sand in the mould box.
5. Put the sand uniform throughout the mould box and ram it with the help of ramming
tools.
6. After this remove the mould box from the base plate and reverse the mould box.
7. After reversing the mould box the patterns comes on the surface of the mould box
then with the help of pattern lifter remove the pattern from the mould box.
8. Now in the mould box the replica of pattern is formed.

B] Without pattern
Aim: To prepare a mould cavity in a sand mould.
Tools required: Base, strike bar, lifters, mould box, etc.
Material required: Moulding sand, etc.
Procedure:
1. Take sand from the pit with the help of shovel.
2. Crush the sand with the help of ramming tool until the sand becomes very fine and
uniform particle size.
3. Add water in the crushed sand and mix it proper such that the sand particle should
adhere to each other.
4. Then take a base plate and mould box, place the mould box on the base and add sand
in the mould box.
5. Put the sand uniform throughout the mould box and ram it with the help of ramming
tools.
6. After this as per the given dimension cut the sand using steel rule and with cutter.
7. Now in the mould box the given shape of the mould cavity is formed.

PART-C
EXPERIMENT NO. 01
TOOLS USED IN FORGING
Tools used in manual and machine forging. Forging tools are used for moving, clamping,
supporting, and measuring forging stock during forging and stamping operations. Hand
forging is performed on an anvil. A hammer man delivers the blows with a sledgehammer.
The blacksmith manipulates the forged piece, holding it with tongs and using a hand hammer,
which is also used for light blows, to indicate to the hammer man where to strike a blow.
Punches are used for making holes, chisels are used for cutting material into pieces, and
swages are used during the finishing of forged pieces.

Open Hearth: A open hearth is a type of hearth used for heating metals, or the workplace
(smithy) where such a hearth is located. The forge is used by the smith to heat a piece of
metal to a temperature where it becomes easier to shape by forging, or to the point where
work hardening no longer occurs. The metal (known as the "work piece") is transported to
and from the forge using tongs, which are also used to hold the work piece on the smithy's
anvil while the smith works it with a hammer.
Anvil: A blacksmith uses this tool to support the job which is being hammered by him,
probably during the process of hand forging. The body of an anvil is made up of mild steel
and the top surface which needs to be tough and rugged is made up of a high carbon steel
welded section. The protruding “beak” shaped portion becomes useful for operations that
involve bending. The anvil also incorporates a square cross-sectional hole for accommodating
shanks of other different tools.
Hammers: Primarily a blacksmith may prefer two types of hammers for the operations of
hand forging, the smith’s hand hammer and the sledge hammer. The first kind of hammer is
used by the smith for directing the hammering area, while the sledge hammer is used by his
assistant or the striker for wielding the particular job work.
Chisels: A blacksmith’s chisel is completely different from the usual fitter’s chisel, rather it’s
a specialized device used for nicking a particular job (metal) so that it may be broken off
easily and cleanly. These chisels can be either “hot” or “cold” type depending upon the metal
it’s being used to cut which may be hot or cold. While cutting a cold metal, the chisel is set
and worked at an angle of 60 degrees and at 30 degrees if the metal is hot. Chisels are
generally used in conjunction with a bottom tool also called Hardie, which is a square shaped
shank capable of fitting into the square hole of an anvil.
Fullers: These are often used at the beginning of a nicking down process of a metal and the
reduction process. A fuller is held at the point of the metal which is to be reduced over a
hardie by the smith and wielded by the striker. Fullers come with different edge sizes
depending upon the need of the blacksmith’s operations
Swages: These devices are used for shaping and reducing metal jobs into hexagonal or round
forms. Swages are made with semi-grooves of dimensions suiting the particular reduction
work. They may be in separate top/bottom halves, connected through spring steel strip so that
the blacksmith can use it without external assistance.

Swage Block: These are square blocks made of cast iron and may consists a multiple range of
slots of different size and shapes over one of its square surfaces suiting all types of swaging
work. The sides have channeled grooves also favoring swage operations. Usually a swage
block is fitted at a preferable height over a stand while doing the operations
Flatters: These are small iron tools having a square flat surface bottom (3 in. square)
specifically designed for providing flat finishes to a metal job.
Punches and Drifts: These are large tapered punch like devices also called drifts used for
punching or opening holes over softer iron jobs made by heating it.
Tongs: As the name refers to these devices are used for holding and clipping iron metal jobs.
They may come in three different forms namely, Flat nose, Pick-up, and Hollow depending
upon the type of operation.
Blacksmith’s Forge: It is a kind of furnace used by blacksmiths for heating metal jobs while
forging. It’s main parts consists of:
Hood: Which forms the outer cover of the furnace,
Chimney: For discharging the fumes and smokes generated,
Tuyere: From where the fire blast is injected,
Blast Producer: Which produces the required air thrust for creating the fire blasts (usually
fired by motors),And also a few auxiliary parts like Rake: which removes slag, Slice: For
collecting coal over the fire, Poker: For poking and optimizing fire strengths
Basic forging operations employed in giving required shape to the work piece are described
below:
(i)Upsetting:
It is the process of increasing the cross-section at expense of the length of the work piece.
(ii)Drawing down:
It is the reverse of upsetting process. In this process length in increased and the cross-
sectional area is reduced.
(iii)Cutting:
This operation is done by means of hot chisels and consists of removing extra, metal from the
job before finishing it.
(iv)Bending:
Bending of bars, flats and other such material is often done by a blacksmith. For making a
bend, first the portion at the bend location is heated and jumped (upset) on the outward

surface. This provides extra material so that after bending, the cross-section at the bend does
not reduce due to elongation.
(v)Punching and drifting:
Punching means an operation in which a punch is forced through the work piece to produce a
rough hole. The job is heated, kept on the anvil and a punch of suitable size is forced to about
half the depth of the job by hammering. The job is then turned upside down and punch is
forced in from the other side, this time through and through. Punching is usually followed by
drifting i.e., forcing a drift in the punched hole through and through. This produces at better
hole as regards its size and finish.
vi)Forging with Power Hammers:
The use of hand forging is restricted to small forgings only. When a large forging is required,
comparatively light blows from a hand hammer or a sledgehammer wielded by the striker
will not be sufficient to cause significant plastic flow of the material. It is therefore necessary
to use more powerful hammers. Various kinds of power hammers powered by electricity,
steam and compressed air (i.e., pneumatic) have been used for forging.

Experiment No. 1
HEX ALLEN KEY 10A/F
Calculation of length of the raw material required to do the component
W= weight of the finished product
Hexagon = Volume x Density a= 6mm=0.6cm
= 2.6 x a
2
x L x ρ ρ = 7.2gm/cm
3
= 2.6 x 0.6
2
x 16 x 7.2 l=160mm=16cm
W = 107.8 gms
W = weight of the raw material MS round
Round = Volume x Density L =?
W = A x L x ρ d=12mm=1.2cm
107.8= ∏d
2
/4 x L x ρ ρ = 7.2gm/cm
3
L= 13.25cm w = 107.8
Add extra 10 % forging allowance =1.32
13.25+1.32
Total=14.57cm

Experiment No. 2
SQUARE SECTION NAIL
w1= square prism = volume x density L= 140mm=14cm
= L x b x h x ρ b= 12mm=1.2cm
= 14 x 1.2 x 1.2 x 7.8 h= 12mm=1.2cm
= 145.15gm ρ = 7.2gm/cm
3
w2=Square Pyramid = 1/3 x a
2
x h a=12mm=1.2cm
= 1/3 x 12
2
x 30 h= 30mm=3cm
= 10.36gm ρ = 7.2gm/cm
3
W=w1+w2 =145.15+10.36
=155.51gms

W = weight of the raw material MS round
Ll=?
Weight= Volume x Density d=16mm=1.6cm
155.15 = ∏d
2
/4 x L x ρ ρ = 7.2gm/cm
3
L=10.74cm
Add extra 10 % forging allowance =1.07 cm
=10.74 + 1.07
Total = 11.82 cm

Experiment No.3
T-BOLT (HEXAGONAL)
w1= Hexagon prism =2.6 x a
2
x l x ρ a=12mm=1.2cm
= 2.6 x 1.2
2
x 0.8 x 7.2 l=8mm=0.8cm
= 21.56gm ρ = 7.2gm/cm
3
w2= Round = ∏d
2
/4 x l x ρ d=12mm=1.2cm
= ∏ (1.2)
2
/4 x 5 x 7.2 l=50mm=5cm
= 40.71gm ρ = 7.2gm/cm
3
W=w1+w2 = 21.56+40.71
= 62.27gm
W = wt of the raw material MS Round d=12mm=1.2cm
62.27= ∏d
2
/4 x l x ρ l=?
L= 7.64 cm ρ = 7.2gm/cm
3
Add extra 10 % forging allowance = 0.76 cm
= 7.64 + 0.76
Total= 8.36 cm

FORGING PRACTICES
JOB: 1 CIRCULAR BAR TO SQUARE BAR.
Aim: To make circular bar to square bar.
Operation required: Heating, drawing, shaping and finishing.
Tools required: steel rule, anvil, double face sludge hammer, furnace, puller, open mouth
tong, pick up tong, open hearth furnace, rack, blower, etc.
Material required: ….. diameter and ……length.
Procedure:
1. Collect the required raw material of MS circular bar of diameter……..mm X
length….mm.
2. Bar is placed in open hearth furnace and heated it become red hot enough for
hammering.
3. Take it on anvil and hammering it to till it take the shape of square bar by using
sledge hammer and fullers.
4. Make finishing edge sharp by means of set hammer or flutters.
5. Put the work piece in the water to cool it.
6. Now the work piece is completed as per given specification drawing.
Diagram:

CALCULATION:

JOB: 2 SQUARE BAR TO EYE NAIL
Aim: To make eye nail
Tools required: steel rule, anvil, double face sludge hammer, furnace, puller, open mouth
tong, pick up tong, open hearth furnace, rack, blower, pocker, sweage &sprinkler.
Material required: ….. diameter and ……length. of MS circular bar.
Procedure:
1. Collect the required raw material of MS circular bar of diameter……..mm X
length….mm.
2. Bar is placed in open hearth furnace and heated it become red hot enough for
hammering.
3. Take it on anvil break or round stake and hammer it to adopt the shape of circle of
given dimension by using sledge hammer.
4. Again heat the work piece at specified location for sharp point.
5. Make finishing by means of swage.
6. Put the work piece in the water to cool it.
7. Now the work piece is completed as per given specification of drawing.
Diagram:

CALCULATION:

JOB: 3 UPSET FORGING
Upset forging increases the diameter of the work piece by compressing its length. Based on
number of pieces produced, this is the most widely used forging process. A few examples of
common parts produced using the upset forging process are engine valves, couplings, bolts,
screws, and other fasteners.
Upset forging is usually done in special high-speed machines called crank presses, but
upsetting can also be done in a vertical crank press or a hydraulic press. The machines are
usually set up to work in the horizontal plane, to facilitate the quick exchange of workpieces
from one station to the next. The initial work piece is usually wire or rod, but some machines
can accept bars up to 25 cm (9.8 in) in diameter and a capacity of over 1000 tons. The
standard upsetting machine employs split dies that contain multiple cavities. The dies open
enough to allow the work piece to move from one cavity to the next; the dies then close and
the heading tool, or ram, then moves longitudinally against the bar, upsetting it into the
cavity. If all of the cavities are utilized on every cycle, then a finished part will be produced
with every cycle, which makes this process advantageous for mass production.
These rules must be followed when designing parts to be upset forged:
 The length of unsupported metal that can be upset in one blow without injurious
buckling should be limited to three times the diameter of the bar.
 Lengths of stock greater than three times the diameter may be upset successfully,
provided that the diameter of the upset is not more than 1.5 times the diameter of the
stock.
 In an upset requiring stock length greater than three times the diameter of the stock,
and where the diameter of the cavity is not more than 1.5 times the diameter of the
stock, the length of unsupported metal beyond the face of the die must not exceed the
diameter of the bar.

VIVA QUESTIONS
1. Define casting? Name the different process.
2. What is the purpose of doing foundry?
3. What is core sand?
4. What are the properties of good moulding sand?
5. Name the different types of moulding boxes used?
6. What is moulding sand?
7. Name the various base sands & clays used in foundry practice?
8. What are the ingredients of foundry sand?
9. Why they call it as green sand though it looks like black sand?
10. Briefly explain how the preparation of mould cavities done.
11. What is a binder? give example
12. What is green sand?
13. Differentiate between the sand & clay used in foundry practice.
14. Define pattern & name the different types.
15. List the various pattern allowances?
16. What is clay? What are its properties?
17. What is permeability?
18. What is the name of the clay added to the foundry sand?
19. Why gates are provided?
20. What is the function of runner & riser? Which part will solidify first and why?
21. Define solidification.
22. What is the importance of GFN?
23. What is core and core print?
24. What is match plate pattern?
25. Name the various hand tools used in foundry practice?
26. What are the differences between green sand and dry sand?
27. What are the various gates provided for a mould?
28. How does the core sand differ from moulding sand?
29. Name the common metals used for producing casting?
30. What are the common defects seen in casting?
31. Name the furnaces used for melting?
32. Classify the various forging tools.

33. Name the different types of tongs.
34. Name the different hammers used for forging.
35. List the various forging operations.
36. What is the function of flatter?
37. What is the function of swages?
38. What is cold working & hot working of metals?
39. What is the significance of tensile and bending test of core sand?
40. What is a moulding machine? Name the different types of moulding machine.
41. What is cupola? What metals are melted in it?
42. Give example for ferrous and non ferrous metals.
43. Why vents are made in the mould?
44. What is an additive? Why it is used in foundry?
45. Name different additives used in practice.
46. What is shrinkage allowance and finishing allowance?
47. What is sprue?
48. What is riser?
49. What are the advantages & limitations of sand casting process?
50. What is ramming? Why it is required?
51. What is gating?
52. What is the difference between an open & a blind riser?
53. What is the difference between a pattern & casting?
54. What is the function of a muller?
55. What is the difference between smithy & forging?
56. What is the use of swage block?
57. What are the different operations performed in smithy & forging?
58. List the different defects in forging and casting.
59. List the different types of core making machines?
60. Name the material of anvil you are using.

EXPERIMENT: TENSILE STRENGTH TEST
Fig: 2 Tensile core box

Fig: 4 Tensile strength attachment
Fig:5 UNIVERSAL TESTING MACHINE
Fig:6 SAND RAMMER

EXPERIMENT: COMPRESSION STRENGTH TEST
Fig:2 SAND RAMMER
Fig:3 Standard compressive test
specimen
Height=50mm

EXPERIMENT: SHEAR STRENGTH TEST
Fig:2 SAND RAMMER
Fig:3 Standard shear test specimen
Height=50mm
Shear pads

EXPERIMENT: PERMEABILITY TEST
Fig:1 PERMEABILITY METER

EXPERIMENT:
CORE HARDNESS AND MOULD HARDNESS TEST

EXPERIMENT: SIEVE ANALYSIS
Fig: 1 SIEVE SHAKER

EXPERIMENT: CLAY CONTENT TEST
Fig: 1 CLAY WASHER

F & f lab manual prepared by prashant mulge appa iet gulbarga

F & f lab manual prepared by prashant mulge appa iet gulbarga

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