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DEPARTMENT OF
MECHANICAL ENGINEERING
B SRINIVASULU
LLL
L
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PRODUCTION TECHNOLOGY LABORATORY
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PRODUCTION TECHNOLOGY
[SUBJECT CODE:-A40312]
LIST OF EXPERIMENTS
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Experiment-1:PATTERN DESIGN AND MAKING (CONNECTING ROD)
1.2 RESOURCES:
Name of the
S.NO Quantity
Equipment
1 Steel rule 1
2 Outside caliper 1
3 Mortise chisel 1
4 Inside chisel 1
5 Peering chisel 1
6 Firmer chisel 1
7 Outside chisel 1
8 Try square 1
9 Handsaw 1
10 Sandpapers 1
11 Teak wood 1
1.3 PRECAUTIONS:
a) Thetools arekept sharp to cut freelywithout burning andalso without much
pressure to cause chipping.Maintain proper turning angles.
b) Be alert to avoid accidents.
1.4. WORKPIECEDIAGRAM:
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1.5 ALLOWANCES:
A pattern is always larger in size when compared to normal casting,
because it carries certain allowances due to mechanical reasons and
metallurgical reasons for example, shrinkage allowance is the result of
metallurgical phenomenon whereas machining, draft, and other
allowances are provided on the patterns because of mechanical
reasons.
The various pattern allowances are:
(a) Shrinkage or contraction allowance.
(b) Machining or finishing allowance.
(c) Draft or taper allowance.
(d) Distortion or camber allowance.
(e) Shake or rapping allowance. Among them shrinkage and draft
allowances are important
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Solution:
Shrinkage Allowance :
Draft Allowance:
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Draft allowance is imparted on internal as well as external surfaces; of
course it is more on internal surfaces.
Taper on external surfaces = 10 to 25
mm/meter or 10 - 20. Taper on internal
surfaces = 40 to 65 mm/meter or 30 – 40.
After providing this taper .The procedure for preparing the pattern is
given below.
1.7 PROCEDURE:
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1.9 POST LAB QUESTIONS:
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Experiment-2: PREPARATION MOULD CAVITY USING SPLIT PATTERN
2.1 OBJECTIVE: To prepare a mould cavity for a stepped circular split pattern.
2.3 THEORY:
A pattern is a mold forming tool in the hands of foundry men.
A pattern is the model or the replica of the object to cast.
Except for the various allowances a pattern exactly resembles the
casting to be made.
A pattern may be defined as a model or form around which sand is
packed to give rise to a cavity known as mould cavity in which when
molten metal is poured, the result is CAST OBJECT.
Functions of a Pattern:
A pattern prepares a mold cavity for the purpose of making a casting.
A pattern may contain projections known as core prints if the casting
requires a core and need to be hallow.
Runner, gates and risers (used for introducing and feeding molten
metal to the mold cavity) may form the part of the pattern.
A pattern may help in establishing locating points on the mold and
therefore on the casting with a purpose to check the casting
dimensions.
Pattern establishes the parting line and parting surfaces in the mold.
Patterns properly made and having finished and smooth surfaces
reduce casting defects.
Properly constructed patterns minimize overall cost of the castings.
Pattern Making Tools:
The following tools are used for different purposes by a pattern maker.
(a) Measuring, Making and Layout Tools
(i) Steel rule (ii) Shrinkage rule
(ii) Caliper (iv) Divider
(v) Marking gauge (vi) Trammels
(vii) Try square (viii) T-bevel
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(ix) Combination square.
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of the lathe and the maximum distance between centers.
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2.5 PROCEDURE:
8. One half of the pattern is molded in the bottom box, the parting being cut an
incline as shown. The other half pattern is then placed in position and sand
poured and rammed to form the second parting with a slope down wards
from the upper flange of the pulley
9. The top box is next placed on the bottom box and properly located. Sand is
poured and rammed without damaging the false core.
10.The top box is gently removed; the upper half pattern is gently taken out
from the top box.
11.The top box is replaced on the drag and the entire mould is turned upside
down. The bottom box, which now is at the top, is gently lifted and the
remaining half of the pattern is withdrawn.
12.The bottom box is replaced and the mould id inverted. The spruces are
removed, pouring basin is cut and the mould is finished after piercing holes
(vents).
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2.6 PRECAUTIONS:
3. Make sure that the axis of drill coincides with the axis of work.
Optimum machining conditions should be maintained.
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EXPERIMENT-
3PREPARATIONOFMOULDCAVITYUSINGSINGLEPIECEPATTERN
3.2 RESOURCES:
Name of the
S.NO Equipment Quantity
1 Moulding sand 10 Kg
Facing sand, Baking
2 sand 1 kg
3 Parting sand ½ kg
4 Pattern 1
5 Cope box 1
6 Drug box 1
7 Bottom board 1
8 Sprue, Riser 1
9 Chaplets 1
10 Gate cutter 1
11 Trowel 1
12 Vent rod 1
13 Sleek 1
14 Bellow 1
3.3 PRECAUTIONS:
3.4 PROCEDURE :
1. First a bottom board is placed either on the moulding platform or the floor
making surface ever.
2. The drag-moulding flask is kept upside down on the bottom board along with
the drag part of the platform at the center of the flask on the board
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4. The top box is gently removed; the upper half pattern is gently taken out
from the top box.
5. The top box is replaced on the drag and the entire mould is turned upside
down. The bottom box, which now is at the top, is gently lifted and the
remaining half of the pattern is withdrawn.
6. The bottom box is replaced and the mould is inverted. The sprues are
removed, pouring basin is cut and the mould is finished after piercing holes
(vents).
3.5 DIAGRAM :
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EXPERIMENT-4 MELTING AND CASTING PRACTICE
4.1 OBJECTIVE :To observe the meltingof Aluminum alloy to preparethe casting
for a connecting rod
4.2 RESOURCES :
Name of
S.NO the Quantity
Equipment
Electric
1 1
furnace
2 Metal 1 kg
Graphite of Dia 1 „ x height
3 Crucible
1.5‟‟
4 Ladle to sir 1
4.3 PRECAUTIONS:
1. The furnace crucible should be clean and red hot for charging
4.4 PROCEDURE:
MeltingProcedureForAluminumAlloys:-
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4. 3H2O+2Al→Al2O3+6H
5. Hydrogen absorbed byliquid metal causes serious porosityin
castingduringsolidification. Degassingshould be done in the temperature
4.5 CASTINGDEFECTSDUETOIMPROPERMELTING:
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6. Sandfusion,metalpenetration,roughsurface Excessivepouringtempof liquid
causes damage to the castingsurfacebyattackingmould surface.
7. Sanderosionsandinclusions Uncontrolled high pouringrate from ladle into
mould leads to erosion ofmould/core
4.6 DIAGRAM :
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EXPERIMENT -5 PREPARATIONOFBUTTJOINTUSINGARCWELDING
5.2 RESOURCES :
5.3.PRECAUTIONS:
1. Wearapron,shoes,nosemask,glovesandtight
fittedclothes.Becarefulandattentivewhile workingonweldingjob.
2. Duringweldingdon‟tseetheweldinglightragedirectlywithoutthe gagglefaceshield.
3. Donotcoolthe Weldingpieceinwater.
4. Donotkeepelectrodeholder ontheweldingmachine.
5. Noinflammable materialshouldbe presentinweldingshop.
5.4 PROCEDURE:
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5. Thebeadsarepolished, etched with two percentnatal solution and studied
under themicroscopewhose magnification factors 10X forthe heat effected
zone.
6. Bygrippingthe beads b/w the jaws Tensiletestingmachine and load is applied
until the work piece breaks and the readings is to be noted.
7. Thesameprocedure is repeated fortheremaininghalfwhich is weldedbyreverse
polarityand theresults areto becompared.
5.5 DIAGRAM:
5.6.RESULTS :
prepared V butt Joint for given MS work pieces by using arc welding
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1. What are the basic requirements of welding?
2. What is ARC welding. Explain in detail.
3. Explain the classification of welding processes.
4. What are the different types of welded joints?
5. Write about design of welded joints.
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6.1 OBJECTIVE : To prepare a LAP joint for given MS sheets by using arc welding
6.2 RESOURCES :
Name of the
S.NO Equipment Quantity
1 Scale 1
2 Scriber 1
3 Hand hack saw 1
4 Flat file 1
5 Swing scale protector 1
6 Welding machine 1
7 gloves, 1
8 Shield 1
9 Wire brush 1
10 Chipping hammer 1
11 Welding rod 1
6.3 PRECAUTIONS :
1. Wearapron,shoes,nosemask,glovesandtight
fittedclothes.Becarefulandattentivewhile workingonweldingjob.
2. Duringweldingdon‟tseetheweldinglightragedirectlywithoutthe gagglefaceshield.
3. Donotcoolthe Weldingpieceinwater.
4. Donotkeepelectrodeholder ontheweldingmachine.
5. Noinflammable materialshouldbe presentinweldingshop.
6.4 PROCEDURE :
1. Two pieces are cut to size and surfaces to be welded are cleaned properly.
2. Electrode is held in electrode holder and earth clamp is clamped to be work
piece.
3. The pieces are positioned overlapping each other for lap joint and tack weld
is done at two end points.
4. 2-3 mm spark gap is maintained and welding is done smoothly.
5. Slag is removed using chipping hammer and weld is cleaned using wire
brush.
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6.5 DIAGRAM:
6.6 RESULT:
EXPERIMENT-7 PREPARATIONOFLAPJOINTUSINGSPOTWELDING
7.1 OBJECTIVE:To prepare a lap Joint on the given work pieces using spot welding
equipment.
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7.2 RESOURCES :
Name of the
S.NO Equipment Quantity
1 Spot welding machine 1
2 GI Sheet of 75 x 50 mm 2
7.3 PRECAUTIONS :
7.4 THEORY:
In resistance welding (RW) a low voltage (typically IV) and very high current
(typically 15,000 A) is passed through the joint for a very short time
(typically 0.25 s).This high amperage heats the joint, due to the contact
resistance of the joint and melts it.The pressure on the joint is continuously
maintained and the metal fuses together underthis pressure. The heat
generated in resistance welding can be expressed as
H = k i2 R t
Where H = the total heat generated in the work, J
i = electric current, A
t = time for which the electric current is passing through the joint, s
r = the resistance of the joint, ohms
and
k = a constant to account for the heat losses from the welded joint.
The resistance of the joint, R is a complex factor to know because it is
composed of
i. The resistance of the electrodes,
ii. The contact resistance between the electrode and the work piece,
iii. The contact resistance between the two work piece plates,
iv. The resistance of the work piece plates.
The amount of heat released is directly proportional to the resistance. It is
likely to be released at all of the above-mentioned points, but the only place
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where a largeamount of heat is to be generated to have an effective fusion is
at the interface betweenthe two work piece plates. Therefore, the rest of the
component resistances should be made as small as possible, since the heat
released at those places would not aid in thewelding.
Because of the squaring in the above, equation, the current, i needs to be
precisely controlled for any proper joint. The main requirement of the process
is the low voltageand high current power supply. This is obtained by means
of a step down transformerwith a provision to have different tappings on the
primary side, as required for differentmaterials. The secondary windings are
connected to the electrodes which are made ofcopper to reduce their
electrical resistance. The time of the electric supply needs to be
closely controlled so that the heat released is just enough to melt the joint
and the subsequent fusion takes place due to the force (forge welding) on
the joint. The forcerequired can be provided either mechanically,
hydraulically or pneumatically. Toprecisely control the time, sophisticated
electronic timers are available.
The critical variable in a resistance welding process is the contact resistance
between the two work piece plates and their resistances themselves. The
contact resistance is affected by the surface finish on the plates, since the
rougher surfaceshave higher contact resistance. The contact resistance also
will be affected by thecleanliness of the surface. Oxides or other
contaminants if present should be removedbefore attempting resistance
welding.
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7.5 PROCEDURE:
1. Switch on the machine and set the current in the machine to 2 Ampere
2. Set the timer to two seconds
3. Over lap the two metal pieces to the requires size and place them between
the two electrodes.
4. Apply pressure by foot on the lever such that two electrodes come into
contact if the over lapped metals.
5. After 2 seconds remove the pressure on the lever slowly.
6. Now the joint is ready for use.
7. Repeat the same procedure at various amperes
8. Test the strength of the joints using universal testing machine.
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7.6 DIAGRAM:
7.7 RESULT :prepared a lap Joint on the given work pieces using spot welding
equipment
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EXPERIMENT-8 PREPARATION OF BUTT WELDING USING TUNGSTEN
INERT GAS (TIG) WELDING
8.3 THEORY:
Argon and helium are completely inert and therefore they provide completely inert
atmosphere around the puddle, when used at sufficient pressure. Any
contaminations in these gases would decrease the weld quality.Argon is normally
preferred over helium because of a number of specific advantages. It requires a
lower arc voltage, allows for easier arc starting and provides a smooth arc action. A
longer arc can be maintained with argon, since arc voltage does not vary
appreciably with arc length.
Tungsten inert gas (TIG) welding is as inert gas shielded arc welding process using
non consumable electrode. The electrode may also contain 1 to 2% thoria mixed
along with core tungsten or tungsten with 0.15 to 0.4% zirconia. The pure tungsten
electrodes are less expensive but will carry less current. The thoriated tungsten
electrodes carry high currents and are more desirable because they can strike and
maintain stable arc with relative ease. The zirconia added tungsten electrodes are
better than pure tungsten but inferior to thoriated tungsten electrodes.
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A typical TIG welding setup is shown in fig.
It consists of a welding torch at the centre of which is the tungsten electrode. The
inert gas is supplied to the welding zone through the annular path surrounding the
tungsten electrode to effectively displace the atmosphere around the weld puddle.
The TIG welding process can be used for the joining of a
number of materials though the most common ones are aluminium, magnesium
and stainless steel.
The power sources used are always the constant current type. Both DC and AC
power supplies can be used for TIG welding. When DC is used, the electrode can be
negative (DCEN) or positive (DCEP). With DCEP is normally used for welding thin
metals where as fro deeper penetration welds DCEN is used. An Ac arc welding is
likely to give rise to a higher penetration than that of DCEP.
8.4 PROCEDURE:
Prepare the edges of the work pieces to be joined to the required V shape.
Place the work pieces on the work table in the required position.
Touch the electrode to the work, so that current flow will be established and
then separated by a small distance and the arc will be generated.
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First tack weld is done on the work pieces.
Move the electrode slowly along the length of the joint with the filler rod, so
that the filler metal will be deposited in the joint.Repeat the operation for the
second pass, so that required amount of filler metal will be deposited on the
work pieces.
8.5 PRECAUTIONS:
1. Never look at the arc with the naked eye. Always use a shield while
welding.
2. Always wear the safety hand gloves, apron and leather shoes.
8.6 RESULT:Prepared a V – Butt Joint Using TIG Welding for given MS sheets
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EXPERIMENT-9 PREPARATION OF BUTT WELDING USING PLASMA
WELDING
9.2 RESOURCES :
Name of the
S.NO Equipment Quantity
1 Scale 1
2 Scriber 1
3 Hand hack saw 1
4 Flat file 1
5 Swing scale protector 1
6 Welding machine 1
7 gloves, 1
8 Shield 1
9 Wire brush 1
10 Chipping hammer 1
11 Weld rod 1
9.3.PRECAUTIONS:
9.4 PROCEDURE:
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3. Connections to be given such that electrode- and work .Welding is to be done
carefully for the half-length of the plates.
4. The work piece is to be cut into two halves by hacksaw.
5. The beadsare polished, etched with two percentnatal solution and studied
under themicroscope whose magnification factors 10X forthe heat effected
zone.
6. By gripping the beads b/w the jaws Tensiletesting machine and load is
applied until the work piece breaks and the readings is to be noted.
7. The same procedure is repeated for theremaining half which is welded by
reverse polarity and the results are to be compared.
9.5 DIAGRAM:
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9.6.RESULTS :
Prepared Joints for welding suitable for butt- welding by using Plasma welding
equipment.
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EXPERIMENT-10 PREPARATION OF BUTT JOINT USING
OXY-ACETYLENE BRAZING PROCESS
10.2 RESOURCES :
Name of the
S.NO Equipment Quantity
1 Oxy-acetylene torch 1
2 filler rod 1
GI sheets
3 150x150x1mm 1
4 Wire brush 1
5 Hand gloves 1
6 Chipping hammer 1
7 Spark lighter 1
10.3 PRECAUTIONS:
1. As the filler metal fills the joint bycapillaryaction, give onlyneeded clearance.
2. Seethat the joints are extremelyclean.
10.4 DESCRIPTION:
2. Brazingisametal-
joiningprocesswherebyafillermetalisheatedabovemeltingpointanddistributed
betweentwoormoreclose-
fittingpartsbycapillaryaction.Thefillermetalisbroughtslightlyaboveits
melting(liquidus)temperaturewhileprotectedbyasuitableatmosphere,usuallyafl
ux.Itthenflowsover
thebasemetal(knownaswetting)andisthencooledtojointheworkpiecestogether.I
tissimilartosoldering,except the temperatures used to melt the filler metal
arehigher.
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10.5 DIAGRAM:
10.6 PRCEDURE:
10.7 RESULTS:Two sheets are joined using oxy-acetylene brazing process brazing
process
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EXPERIMENTS-11HYDRAULICPRESSWORKS-ROD BENDING
11.2 RESOURCES:
Name of the
s.no Equipment Quantity
1 Hydraulic Press 1
2 MS rod 1
11.3. PRECAUTIONS:
11.4 THEORY:
BENDING:
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Advantages of hydraulic presses are
11.5 PROCEDURE:
11.6 RESULT:
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11.7 POST LAB QUESTIONS:
1. what is blanking
2. what is piercing
3. what is a compound tool
12.1 OBJECTIVE: To determine drawing force and blank holding force for
producing a symmetrical cup of circular cross section using a Draw Tool and
Perform Drawing Operation on hydraulic press.
DRAWING:
Drawing operation is the process of forming a flat piece of material into a hollow
shape by means of a punch which causes the blank to flow into the die cavity. The
depth of draw may be shallow, moderate or deep. If the depth of the formed cup is
up to half of its diameter, the process is called “Shallow drawing”. If the depth of
the formed cup exceeds the diameter it is termed as "Deep drawing". Parts of
various geometries and sizes are made by drawing operation, two extreme
examples being bottle caps and automobile panels.
As the drawing progress i.e. as the punch forces the blank into die cavity, the blank
diameter decreases and causes the blank to become thicker at its outer portions.
This is due to the circumferential compressive stress to which the material element
in the outer portions is subjected. If this stress becomes excessive the outer
portions of the blank will have the tendency to buckle or wrinkle. To avoid this, a
pressure pad or blank holder is provided. The holding down of pressure is obtained
by means of springs, rubber pad, compressed air cylinder or the auxiliary ram on a
double action press.
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The portion of the blank between the die wall and punch is subjected to nearly
purely tension and tends to stretch and becomes thinner. The portion of the formed
cup which wraps around the punch radius is under tension in the presence of
bending. This part becomes the thinnest portion of the cup. This action is termed as
'necking' and in the presence of unsatisfactory drawing operation, is usually the
first place to fracture. The outer portions of the blank under the blank holder
become thicker during the operation. When these portions are drawn into the die
cavity, 'ironing' of this section will occur if the clearance between the punch die is
not enough to accommodate this increased thickness of the work piece. This ironing
is useful if uniform thickness of the product is desired after the drawing operation.
Drawing Force:
The drawing force depends on the cup material, its dimensions and the
configuration. The drawing force can empirically be calculated using the following
equation for cylindrical shells.
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D = blank diameter, mm
P = drawing force, N
t = thickness of the blank material, mm
s = yield strength of the metal, Mpa
C = constant to cover friction and bending. Its value is between
0.6 and 0.7
The blank holding pressure required depends on the wrinkling tendency of the cup,
which is difficult to determine and hence it is obtained more by trail and error. The
maximum limit is generally one-third of the drawing force
2
Drawing
. Force = N
3
Blank
. Holding Force = N
12.5 PROCEDURE
1. Drawing Operation:
2. Fix the punch to the ram of the press.
3. Fix the die on the bed of the machine using clamps, bolts and nuts.
4. Calculate the required blank size and place the same between the punch and
die block.
5. Apply the hydraulic pressure on the punch through ram so that the punch
slowly descends on the blank and forces it take the cup shape formed by the
end of the punch, by the it reaches the bottom of the die.
6. When the cup reaches the counter bored portion of the die, the top edge of
the cup formed around the punch expands slightly due to spring back.
7. Observe the reading of the pressure gauge which directly gives the force
required to perform th operation.
8. Calculate the drawing force required, to perform the operation using above
relations.
9. Compare the two readings
10.Then move the punch in the return direction so that the cup will be
11.stripped by counter bored portion.
12.6 PRECAUTIONS:
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c. The load should be applied uniformly on the bar.
d. The bar should be held properly on the die block.
2
Drawing
. Force = N
Blank
. Holding Force = N
13.2 RESOURCES:
Name of the
s.no Equipment Quantity
1 Fly wheel Press 1
2 Al sheet 1
13.3. PRECAUTIONS:
13.4 THEORY:
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Press operation: The sheet metal operations done on a press may be grouped
into two categories, cutting operations and forming operations.
In cutting operations, the work piece is stressed beyond its ultimate strength.
The stresses caused in the metal by the applied forces will be shearing stresses.
In forming operations, the stresses are below the ultimate strength of the metal.
In this operation, there is no cutting of the metal but only the contour of the work
piece is changed to get the desired product. The cutting operations include:
blanking, punching, notching, perforating, trimming, shaving, slitting and lancing
etc.The forming operations include: bending, drawing, redrawing and squeezing.
The stresses induced in the metal during bending and drawing operations are
tensile and compressive and during the squeezing operations these are
compressive.
Blanking: Blanking is the operation of cutting a flat plate from sheet metal. The
article punched out is called the „blank‟ and is the required product of the
operation. The hole and metal left behind is discarded as waste. It is usually the
first step of series of operations.
Trimming: This operation consists of cutting unwanted excess material from the
periphery of a previously formed component.
Shaving: The edges of a blanked part are generally rough, uneven and un
square. Accurate dimensions of the part are obtained by removing a thin strip of
metal along the edges.
Bending: In this operation, the material in the form of flat sheet or strip is
uniformly strained around a linear axis which lies in the neutral plane and
perpendicular to the lengthwise direction of the sheet metal.
Drawing: This is a process of a forming a flat work piece into a hollow shape by
means of a punch which causes the blank to flow into a die cavity.
13.5 DIAGRAM:
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13.6 PROCEDURE:
13.7 RESULT:
2. what is a advance
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EXPERIMENT-14 PROCESSING OF PLASTICS-INJECTION MOULDING
14.1 OBJECTIVE: To make an air tight bottle cap by using injection moulding.
14.3 THEORY:
Plastics:
Polymers can be divided into three broad divisions: plastics, fibers and
elastomers (polymers of high elasticity, for example, rubber). Synthetic
resins are usually referred to as plastics. Plastics derive their name from the
fact that in a certain phase of their manufacture they are present in a plastic
stage (that is acquire plasticity), which makes it possible to impart any
desired shape to the product. Plastics fall into a category known chemically
as high polymers.
Plastics are classified on the broad basis of whether heat causes them to
set( thermosetting) or causes them to soften and melt(thermoplastic).
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Thermosetting Plastics: These plastics undergo a number of chemical
changes onheating and cure to infusible and practically insoluble articles.
The chemical change is not reversible. Thermosetting plastics do not soften
on reheating and cannot be reworked. They rather become harder due to
completion of any left over polymerization reaction. Eventually at high
temperatures, the useful properties of the plastics get destroyed. This is
called degradation. The commonest thermosetting plastics are: alkyds,
epoxides, melamines, polyesters, phenolics and ureas.
Injection Moulding:
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14.4 PROCEDURE:
1. The pellet form of plastic is introduced into the container through hopper.
2. The plastic pellet enters into the container. The container is heated
with the coil, which is wounded around it.
3. The plastic of powder form is converted into molten stage at a
temperature of 800C.
4. The die is placed exactly below the nozzle of the container.
5. The melted plastic is injected into the die with the help of lever arm
and it is allowed to solidify say for about one minute.
6. Then retract the lever arm slightly and open the mould.
7. Then eject the mould piece of the required shape from the die.
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14.5 PRECAUTIONS:
14.6 RESULT: Air tight bottle cap is prepared by using injection moulding.
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EXPERIMENT-15 PROCESSING OF PLASTICS- BLOW MOULDING
15.3 THEORY:
Working Principle: The process is applied to only thermo plastics, which are used
for producing hollow objects such as bottle, and flow table objects by applying air
pressure to the sheet material when it is in heated and in soft pliable condition.
Blow moulding can be accomplished in two manners; one is direct blow moulding
and other indirect blow moulding. In the former case, a measured amount of
material in the form of tube is either injected or extruded in a split cavity die. The
split mould is closed around the tube, sealing off the lower end. The air under
pressure is blown into the tube, which causes the tube to expand to the walls of
cavity. In the latter case, a uniformly softened sheet material by heat is clamped at
the edges between the die and cover, which causes the sheet to attain a
hemispherical shape or the configuration of mould whatever it may be parts
48
obtained by indirect blow moulding have excellent appearance but they are more
costly as only to percent of the sheet stock is utilized and also there is a tendency
for excessive thinning of sheet at the deepest point.
Experimental Diagram
Operating instructions:
1. Install the machine on a leveled strong flooring near the compressor (within 2
meters). For letter rigidity foundation bolt is recommended & anti vibration rubber
mounting can be used.
2. The machine must be placed in a position where all parts are accessible readily.
3. Check for loose any loose electrical connection with the help of certified
electrician and with the electrical circuit enclosed.
4. Fill the lubricator with SAE 20 grade oil to the level indicated. The lubrication has
been set to allow one drop of oil for every 5 strokes of air cylinder (oil) drop is
factory set, no need to adjust)
5. Connect the air filter to the compressor by rubber/nylon hose (Min inside dia
10mm), pressure with standing capacity 20kg/cm2.
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6.Set the pressure switch in the compressor as per the compressor manual to
switch on 7 kg/cm2 pressure & switch off at 10kg/cm2 (NOTE: The air pressure
should not exceed 10cm2)
7. Set the air pressure in machine by adjusting the injection & release regulator
(18).
9.Operate the hand lever valve and check for smooth functioning of plunger.
10.Set the blow pressure in regulator and operate the hand lever valve to check
flow of air throw blow nozzle.
13.Check the incoming voltage (230VAC, 50Hz) Now the machine is ready for
operation.
PROCEDURE:
1. Set the die in position. Adjust the guide rod nuts to suit die height. Align the
tapered face of the die for sealing the parison while blowing also checks for the face
opening and closing of the die.
3. Set the injection, release and blow pressure by rotating (clockwise) the regulator
knob to suit the requirement of moulding the container.
4. Feed correct quantity & quality of plastic material and switch on the power
supply.
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6. Set the required timings controller to control the bottom heater.
9. Extrude the parison (Tubular form) to the required length and close the two die
halves. Release the injection cylinder.
10. Operate the hand lever valve and blow the air so that the parison to form the
shape of the container as designed in the die.
12.Open the die & take the product out of the die.
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