Department of Mechanical Engineering

Amrita School of Engineering

Coimbatore

23MEE182 MANUFACTURING PRACTICE-B LAB MANUAL

FOR INTERNAL CIRCULATION ONLY

DEPARTMENT OF MECHANICAL ENGINEERING

Jan – 2024

Complied by

Dr. A. Sumesh

Course Plan – JANUARY 2024

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 1.Course Details

Name of the Course MANUFACTURING PRACTICE -B

Course Code 23MEE182
Course Type LAB
Course Credit 0-0-3-1
Name of the mentor and Associated
Dr. A SUMESH
faculty members)

2.Course outcomes

At the end of the course, the student will be able to:

Knowledge
level
S.No. Course Outcomes
[Bloom’s
Taxonomy]
CO01 Practice safety procedures in a shop floor environment. Understand
Select appropriate tools and methods for basic manufacturing
CO02 Understand
processes.
Build simple geometries using an additive manufacturing
CO03 Apply
process.

CO04 Perform basic metal joining using welding and soldering. Apply

Design, simulate, and testing of simple pneumatic and electro-

CO05 Apply
pneumatic circuits for automation application
Understand the functioning of automotive systems and realize
CO06 the importance of recent developments in automotive Understand
technologies.

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3.Mapping of Course Outcomes with Programme Outcomes

Program Outcomes (Pos)

COs
PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11 PO12
CO 3 1 1 1 1 2
01
CO
02 2 3 2 2 3
CO
03 2 2 1 3 1 1 2 1 3
CO
04 2 3 2 2 1 3
CO
05 3 2 2 3 2 1 3
CO
06 3 2 2 3 3 1 3

4. Lab Schedule

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5. Lecture Plan

Type of
Lecture Week Course Mode of Assessment
Topic Instructional
No. No outcome delivery mode
material
1 1 General Lab safety

Write a ASCII code for CO01,

Lab
2 2 representing the Cube of side CO02, exercise
Lab Manual
1 unit in STL format CO03
Record:10
Marks,
Additive Manufacturing CO01, Model -10
Lab
3 3 Exercise-slicing & inputting CO02, exercise Marks
into FDM CO03

Demonstration of Machine Lab

4 4 Demo
Lab Manual
tools
5 5 Evaluation 1

Demonstrating a pneumatic Lab

6 6 CO05 exercise
Lab Manual
circuit for clamping purpose

Record:10
Hands on practice a pneumatic Marks
Lab Simulation -
7 7 circuit for the movement of CO05 exercise
Lab Manual
Robotic arm 10 Marks

Demonstration of systems in CO01, Lab

8 8 Lab Manual
cut section vehicle CO02 Demo

9 9 Evaluation 2
Introducing the practical
application of various tools
and measuring equipment
CO01, Lab
10 10 used for basic manufacturing exercise
Lab Manual
CO02
processes. Understanding the
Record:10
sketching and dimensioning of Marks,
a real component. Model -10
Marks
CO01,
Manual arc welding practice Lab
11 11 CO02, exercise
Lab Manual
for making Butt joints
CO04
Manual arc welding practice CO01, Lab
12 12 Lab Manual
for making Lap joints CO02 exercise
13 13 Evaluation 3
14,15 14,15 Missed Lab

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6. Evaluation Pattern

Group Labs CA End evaluation

Additive Lab safety -Lab staff

manufacturing (Y/N) Model -Lab staff
G1 (10) Model -Lab staff 1 (10)
Viva -Faculty 1 (10)

Machine shop
All lab
Lab safety -Lab staff
Record -
Automation (Y/N) On screen Model -Lab staff 2 (10)
TA (10
G2 evaluation -Lab Viva –Faculty 2 (10)
for every
staff (10)
Cycle)
Automobile
Product/ Lab safety -Lab staff
(Y/N)
G3 soldering* Model -Lab staff (10) Model -Lab staff 3 (10)
Viva –TA (10)

Welding

7. Evaluation pattern

Component Weightage Remarks

Continuous Assessment (60%)

Additive manufacturing & Machine shop 20% Weightage 20

Automation lab & Automobile workshop 20% Weightage 20

Welding & Product/ soldering* 20 % Weightage 20

End Semester Evaluation (40 %)

8.Rubrics used for Evaluation.

The guideline rubrics will be

Individual lab evaluations done for 30 marks and will be converted to 20 marks to enter into excel
1. Record submission: Good (9-10 marks) – Diagrams are neatly drawn & procedures were
detailed; Medium (7-8 marks) - Diagrams are ordinary & procedures were not detailed without any
error. Low (5-6 marks) - Diagrams and procedures are ordinary & with errors. Less than 5 Marks for
very late submission.
2. Models / Circuit simulation: Good – 10-9 Marks (Model / Circuit adequately met its criteria),
Average –8-7 Marks, Poor –6-5 Marks.
3. viva: Good (9-10 marks); Medium (7-8 marks); Low (5-6 marks); Poor (4-3 marks) Very
poor
(less than 3)
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 9. Text Book / Reference Book
1. Lab Manual circulated during the laboratory session.
2. Workshop Technology, W.A.J. Chapman. Part-1& PART-2
3. Elements of Workshop Technology – S.K and A.K. Hajra Choudhury

10.Details of the Mentor and Associated faculty member handling the course

a) Details of the Mentor

S.No Name of the Faculty Staff Code Section Signature

member

1 DR. A SUMESH 30082161 --------

b) Details of Associated faculty member

23MEE182 Manufacturing Practice B - Even Semester 2024-25

Sl. Additive + Automation

Batch Slot Welding
No. Lathe &Spl Machines +Automobiule
+Product
1 CSE G Monday 2-4 Mr.A.S. Prakash Dr.R. Saravanan Dr. Sudheer Reddy
2 CSE D Monday 8-10 Dr.K. Balaji Dr.M. Govindaraju Mr. K Muralitharan
3 Mech.B Tuesday 2-4 Dr.P.G. Saleeshya Dr.J. GokulaChandran Mr. Rameshkumar
4 Civil Tuesday 5-7 Mr.M. Pushparajan Dr.N. Tamilarasan Mr. Gokul V
5 CSE C Tuesday 8-10 Mr.A.S. Prakash Dr.R. Saravanan Dr Raghunath
6 CSE H Wednesday 2-4 Mr.A. Srinivaas Dr.S. Karthick Mr. Madhu Kottical
7 CSE A Wednesday 8- Dr.P.G. Saleeshya Dr N Tamilarasan Dr Raghunath
10
8 CSE F Thursday 2-4 Mr.C. Lakshmikanthan Dr.S. Karthick Mr. Madhu Kottical
9 Aerospace Thursday 5-7 Dr. Vaira Vignesh Dr.N. Tamilarasan Mr Rameshkumar
10 CSE E Thursday 8-10 Dr.P.G.Saleeshya Dr.M.Govindaraju Mr. B Nandakumar
11 Mech.A Friday 2-4 Dr.K.Balaji Ms.Sivaselvi Mr. Gokul V
12 Chemical Friday 5-7 Mr.A.S.Prakash Dr.Ajith Ramesh Mr. K Muralitharan
13 CSE B Friday 8-10 Mr.A.S. Prakash Dr.Ajith Ramesh Dr. Sudheer Reddy

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 c) Details of Supporting staff member

List of Supporting staff

Sl.
Additive +Lathe Automation Welding
No Batch Slot
&Spl Machines +Automobile +Product
.
1 CSE G Monday 2-4 Mr.R.Vijayakumar Mr. Sai Abijith Mr. R.
Senthilkumar
Mr.
2 CSE D Monday 8-10 Mr. Sai Abijith Mr.K.Sundararaman Mr.D.Vijayakuma
r
3 Mech.B Tuesday 2-4 Mr.R.Vijayakumar Mr.A.Ragu Mr. C.
Chandramohan
4 Civil Tuesday 5-7 Mr. Sai Abijith Mr.K.Sundararaman Mr. S. Kannapiran
5 CSE C Tuesday 8-10 Mr.R.Vijayakumar Mr.K.Sundararaman Mr.
Mr.D.Vijayakuma
r
6 CSE H Wednesday 2- Mr.R.Vijayakumar Mr.A.Ragu Mr. R.
4 Senthilkumar
7 CSE A Mr.D.Vijayakuma
Wednesday 8- Mr.R.Vijayakumar Mr.A.Ragu
r
10
8 CSE F Thursday 2-4 Mr.Mohanprasad Mr.K.Sundararaman Mr. R.
Senthilkumar
9 Aerospace Thursday 5-7 Mr.Mohanprasad Mr. Sai Abijith Mr.D.
Vijayakumar
10 CSE E Thursday 8-10 Mr.R.Vijayakumar Mr.A.Ragu Mr. S. Kannapiran
11 Mech.A Friday 2-4 Mr.Mohanprasad Mr.K.Sundararaman Mr. R.
Senthilkumar
12 Chemical Friday 5-7 Mr.A.Ragu Mr. Sai Abijith Mr.D.Vijayakumar
13 CSE B Friday 8-10 Mr. Sai Abijith Mr.A.Ragu Mr. T. Meganathan

*******************

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 Contents
Exp. Name of the Experiments Page No.
No.
GENERAL SHOP-SAFETY INSTRUCTIONS 9
ADDITIVE MANUFACTURING 11
Objective 12
1 Generate the ASCII STL Code Representation of a Unit Cube with 1-
14
Unit Side Length
2 3D Printing using Fused Deposition Modelling 18
BASIC MACHINE TOOLS AND MACHINING PROCESS 21
Introduction 22
Lathe 22
Drilling Machine 24
Milling Machine 25
Grinding Machine 26
CNC Milling Machine 27
AUTOMATION LAB 28
Introduction to fluid power and pneumatic Automation & Study of
29
pneumatic system
1 Design and simulation of pneumatic system using clamping purpose 36
2 Design and simulation of pneumatic system using double-acting cylinder 38
AUTOMOBILE ENGINEERING LAB 41
Introduction 42
Study of working principle of the automobile components 43
PRODUCT WORKSHOP 50
Measuring instruments 51
Tools 54
Procedure for the conduct of experiments 56
1 Study of single cylinder diesel engine 57
2 Study of single cylinder petrol engine 65
WELDING 72
Introduction 73
Types 73
Arc Welding 74
Welding Symbols 79
1 Square Butt Joint Weld 80
2 Lap Joint Weld 82

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 GENERAL SHOP-SAFETY INSTRUCTIONS

All tools can be dangerous if used improperly, so learning and following safety rules is essential. Most
accidents happen because procedures are not followed, so develop safe work habits to avoid them.
Safety practices may vary depending on the tool or process, so always study and follow the specific
precautions.

Appropriate Attire for Skin Wear long sleeves, pants, and safety gear like gloves during welding
Protection: to protect your skin

Foot Safety with Sturdy Closed- Wear sturdy, closed-toe safety shoes to avoid injuries from falling
Toe Shoes: objects or sharp metal chips

Eye Protection: Always use safety glasses or goggles to shield your eyes from flying
debris or harmful radiation

Hazardous Noise Protection: Use earmuffs or earplugs to prevent hearing loss in noisy
environments.

Electrical Safety: Disconnect power before repairs. Ensure proper grounding and
insulation during welding.

Ensuring Proper Grounding and Insulation of Wires and Preventing

Electrical Safety in Welding:
Electrical Hazards for a Safe Working Environment

Tool Selection for Task Efficiency Use the right tools for the job to ensure efficiency and safety
and Accident Reduction:

Avoiding Damaged or Never use broken tools as they can cause injuries or affect work
Malfunctioning Tools: quality.

Proper Storage for Organized and Store tools properly and clean up spills to maintain a safe and tidy
Hazard-Free Workspace: workspace.

Preventing Accidental Falls and Keep tools away from edges to prevent them from falling and causing
Injuries: injuries.

Stay alert, follow safety rules, and be aware of your surroundings to

Vigilant Safety Awareness:
avoid accidents.

Avoiding Jewellery and Remove jewelry to prevent it from getting caught in machines.
Accessories for Safety:

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Guidance from Instructors for Ask for guidance when unsure and never use a machine until fully
Uncertain Procedures: trained.

Selection and Use of Welding Use cables with the correct capacity to ensure safety and efficiency.
Cables:

Machine Shutdown and Safety Turn off machines when not in use to prevent accidents or
Protocol: unauthorized access.

Slag Removal and Workspace Use a chipping hammer to remove slag and keep the workspace clean
Safety: after welding.

Guarding of Revolving or Cover moving parts to prevent accidents and injuries.

Reciprocating Parts:

Proper Lighting Requirement: Always ensure adequate lighting for safe machine operation.

Do not lubricate machines while they are running to avoid injuries.

Lubrication Practice:

Use tools, not hands, to remove metal shavings to avoid cuts.

Handling Metal Chips and
Shavings:

Know the location of fire extinguishers and first aid boxes.

Fire Safety & First aid box:

Avoid playful behavior as it can lead to serious accidents.

Avoiding Horseplay:

Use safety nozzles with compressed air to avoid dangerous flying

Safe Use of Compressed Air:
debris.

Tool Placement and Clutter Keep tools organized and off machine tables to ensure safe working
Prevention: conditions.

Power Tool Usage Precautions: Keep power tools dry and remove keys or wrenches before use.

Securing Workpiece for Safety: Secure workpieces with clamps or a vise to prevent movement during
operation.

Sobriety and Drug-Free Operate machines only when sober and alert, and eat properly before
work.
Operation:

Proper Handling of Electrical Handle cords carefully to avoid damage and replace worn or broken
Cords: ones immediately.

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Department of Mechanical Engineering, Amrita School of Engineering,
Coimbatore

ADDITIVE MANUFACTURING LAB

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Objectives
• To build 3D prototype from CAD model using thermoplastic material
• To understand the technology of 3D printing process
• To generate G-codes through slicing software

Introduction

Additive Manufacturing (AM) represents a transformative approach to producing parts and

products, utilizing advanced layer-by-layer deposition techniques. This method has
revolutionized traditional manufacturing by offering unprecedented design flexibility, rapid
prototyping, and efficient material usage. Through this lab manual, students will gain a
comprehensive understanding of AM principles, classifications, standards, materials, and
processes. The objective is to equip learners with practical knowledge and skills essential for
harnessing the potential of additive manufacturing in real-world applications.

The manual outlines fundamental aspects of AM, including material types, ASTM
standards, and detailed procedural steps. Each section is designed to provide theoretical insights
alongside hands-on experience, fostering a balanced learning environment. By the end of this
course, students will be adept at applying additive manufacturing technologies in diverse
industrial scenarios.

Definition of Additive Manufacturing

Additive Manufacturing (AM), also known as 3D printing, is a process of creating objects

by sequentially adding material layer by layer. This technique contrasts with traditional
subtractive manufacturing methods, which involve cutting away material from a solid block to
achieve the desired shape. AM enables the production of complex geometries, customized
components, and rapid prototyping with reduced material wastage.

Key Features of Additive Manufacturing:

• Layer-by-layer construction.

• High design flexibility.

• Reduced lead times and material usage.

• Applications in industries like aerospace, healthcare, automotive, and consumer goods.

Additive Manufacturing technologies are classified based on the type of material and
process used:

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 Classification of Additive Manufacturing
Material-Based Classification Process-Based Classification (According to ASTM
F2792)
Polymers: Thermoplastics, thermosets, Vat Photopolymerization Examples:
elastomers.
Metals: Aluminum, titanium, steel, Stereolithography (SLA), Digital Light Processing
cobalt-chromium. (DLP).

Material Extrusion: Example: Fused Deposition

Modeling (FDM).

Ceramics: Alumina, zirconia. Powder Bed Fusion (PBF): Examples: Selective Laser
Sintering (SLS), Direct Metal Laser Sintering (DMLS).

Composites: Fiber-reinforced Binder Jetting:Example: Metal Binder Jetting.

polymers, metal matrix composites

Material Jetting: Example: PolyJet.

Directed Energy Deposition (DED): Examples: Laser

Engineering Net Shaping (LENS), Electron Beam
Additive Manufacturing (EBAM).

ASTM Standards for Additive Manufacturing

The ASTM International has developed standards to guide additive manufacturing

processes:

• ASTM F2792-12a: Standard Terminology for Additive Manufacturing Technologies.

• ASTM F2971: Standard Practice for Reporting Data for Test Specimens Prepared by
Additive Manufacturing.

• ASTM F2924: Standard Specification for Additive Manufacturing Titanium Alloys.

• ISO/ASTM 52900: Overview of Additive Manufacturing Processes.

Feedstock Materials:

1. Polymers: PLA, ABS, Nylon, PETG.

2. Metals: Titanium alloys, Aluminum alloys, Stainless steel.

3. Composites: Carbon fiber-reinforced materials.

4. Ceramics: Alumina, Silicon carbide.

5. Biomaterials: Hydroxyapatite, biodegradable polymers.

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 Ex. No.: 1
Generate the ASCII STL Code Representation of a Unit Cube with
Date: 1-Unit Side Length

AIM:
To understand and generate the ASCII STL (Stereolithography) representation of a 3D model for a
unit cube with a side length of 1 unit.

ITEMS REQUIRED:

• Computer with any text editor (Notepad, VS Code, etc.)

• 3D Modeling software (optional)
• STL viewer software (for visualization)

Procedure:

Step 1: Conceptualization and CAD Modeling

• Design the 3D model using Computer-Aided Design (CAD) software.

The given component to be modelled using the FBM in the software “FUSION”

• Ensure the design is optimized for additive manufacturing constraints.

Step 2: File Conversion and Transfer

• Convert the CAD model to a compatible format (e.g., STL or AMF)

• ASCII code to represent a CUBE of side 1 unit in STL format
• Write the coordinates of the corners of the cube

•
• Divide each square face in to triangles. Each face will have two triangles as shaded in figure

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•

Mark the normal to the surface of the triangle in such a way that no material present in the
direction of the normal

ASCII code for the shaded triangle is as below

Facet normal 1.0 0.0 0.0 (Normal to the shaded triangle is along the positive x direction)
Outer loop
Vertex 1.0 0.0 0.0 [Vertices to be sequenced in the counter-clockwise direction with
Vertex 1.0 1.0 1.0 respect to the facet normal]
Vertex 1.0 0.0 1.0
End loop
End facet
Repeat the same for all the remaining 11 triangles
Consolidated ASCII code for a cube is as below

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Save this code in STL format and upload in FUSION to get the tessellated CUBE

• Transfer the file to the 3D printer’s software.

Step 3: Pre-Processing

• Set process parameters such as layer thickness, build orientation, and support structures.

• Slice the 3D model into layers for printing.

Step 4: Printing

• The printer deposits or solidifies material layer by layer according to the sliced data.

• Monitor the printing process for consistency and accuracy.

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 Step 5: Post-Processing

• Remove the part from the build platform.

• Perform additional steps such as cleaning, curing, sintering, or surface finishing.

Step 6: Inspection and Testing

• Conduct dimensional checks and non-destructive testing to ensure part quality.

• Validate mechanical properties as required.

Result:

The ASCII STL representation of a unit cube was successfully created.

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 Ex. No.: 2
3D Printing using Fused Deposition Modelling
Date:

AIM:
To fabricate the prototype of given CAD model using 3D printing with fused deposition
modelling technique

ITEMS REQUIRED:
Equipment: 3D Printer, Personal Computer
Software: CURA
Tools & Materials: Wire cutter, PLA filament

PROCEDURE:
• Locate the given 3D CAD model (.STL format) in the PC
• Open the CURA slicing software and load the CAD model
• Orient and position the CAD model to have minimum supports and minimum build time
• Set the recommended values of build parameters such as layer height, fill density, support type,
build temperature and bed temperature.
• Animate and preview the different layers to check for any printing errors
• Save the G-code in the given SD card and eject the SD card safely from the PC
• Switch ‘ON’ the 3D printer and check the loaded PLA filament spool
• Go to ‘Print’ option in the main menu and select the generated ‘G-code’ file. Select ‘Confirm’
print option
• Wait for 100% completion of the job
• Remove the part carefully from the platform.

RESULT:
Thus, the prototype of given 3D CAD model is built using fused deposition modelling

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