CHAROTAR INSTITUTE OF TECHNOLOGY-CHANGA

Department of Mechanical Engineering

Metal Forming and Fabrication Technique (M-505)

INDEX
Date
No.
Sr. of Sign of
Date Title of Marks
No. Assess Faculty
Pages
ment
Overview of Metal Forming and
1
Fabrication Technique
2 Joining Methods
3 Weld joint design as per I.S. code.
4 Gas welding and Gas cutting processes
5 Arc Welding Processes
6 Resistances Welding Processes
7 Weld Defects and Dye Penetrant (DP) test
8 Basic concepts of Metal Forming
9 Press and Press Working operations.
10 Drawing Operation
11 Forging operation
Rolling operation Using three roller
12
bending machine.
Bending operation using Hydraulic Pipe
13
bender
14 Extrusion Process

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 CHAROTAR INSTITUTE OF TECHNOLOGY-CHANGA
Department of Mechanical Engineering

Metal Forming and Fabrication Technique (M-505) Date:

PRACTICAL NO. 1
OVERVIEW OF METAL FORMING AND FABRICATION
TECHNIQUE

AIM: - Overview of Metal Forming and Fabrication Technique

OBJECTIVES: -

 Student should be able to define the terminology “Metal Forming and

Fabrication Technique”.
 Student should able to specify all the welding equipments available in the
CITC – welding shop.


THEORY:-

REVIEW QUESTIONS: -

1. What is the meaning of Fabrication Technology?

2.
3. List down the welding and forming facilities available in the CITC workshop.
Write their detailed specifications.

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 CHAROTAR INSTITUTE OF TECHNOLOGY-CHANGA
Department of Mechanical Engineering

Marks obtained: Signature of faculty: Date:

Metal Forming and Fabrication Technique (M-601) Date:

PRACTICAL NO. 2
JOINING METHODS AND WELD JOINT DESIGN AS PER
I.S. CODE

AIM: - Introduction to various joining methods.

OBJECTIVES: -

 Student should be able to classify various joining methods.

 Student should able to compare permanent joints and temporary joints.
 Student should able to classify welding in detail.
 Student should be able to comprehend welding symbols, basic symbols and
supplementary symbols as per AWS

REVIEW QUESTIONS: -

1. Classify joining methods with the help of a classification tree.

2. List the advantages and disadvantages of a permanent joint over a temporary
joint.
3. Classify welding in detail using classification tree.

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 CHAROTAR INSTITUTE OF TECHNOLOGY-CHANGA
Department of Mechanical Engineering

4. Compare brazing and soldering processes.

5. What do you mean by Weld Design?
6. Draw and describe weld location symbol.
7. Sketch and name the following symbols in tubular form.
a. Welding symbols
b. Basic symbols
c. Supplementary symbols
8. Describe in brief about welding positions as per ASME Section IX.

Marks obtained: Signature of faculty: Date:

Metal Forming and Fabrication Technique (M-601) Date:

PRACTICAL NO. 4
GAS WELDING AND GAS CUTTING PROCESSES

AIM: - Introduction to gas welding and gas cutting.

OBJECTIVES: -

 Student should be able to know the principle of gas welding.

 Student should able to know the gas welding setup, the major equipments and
consumable used.
 Student should able to identify various gas welding flames and their
applications.
 Students should understand the safety of different types of welding processes
before the performance of the practical.

REVIEW QUESTIONS: -

1. Explain briefly: Gas Flame and the reaction.

2. Explain various types of flames obtained, in gas welding. State their specific
applications.

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 CHAROTAR INSTITUTE OF TECHNOLOGY-CHANGA
Department of Mechanical Engineering

3. Differentiate between gas welding and gas cutting processes.

4. Oxidizing flame makes a roaring should. Why?
5. State the functions of flux used in Gas welding process.

Marks obtained: Signature of faculty: Date:

Metal Forming and Fabrication Technique (M-601) Date:

PRACTICAL NO. 5
ARC WELDING PROCESSES

AIM: - Introduction to various arc welding processes. To prepare various joints

using MMAW, TIG and MIG processes.

OBJECTIVES: -

 Student should know the principle of all arc welding processes.

 Student should understand different types and functions of coatings on any
arc-welding electrode.
 Student should know the effects of various welding parameters on the weld
bed.
 Student should be able to decide upon the welding process for a given welding
problem.

REVIEW QUESTIONS: -

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 CHAROTAR INSTITUTE OF TECHNOLOGY-CHANGA
Department of Mechanical Engineering

1. Explain arc-welding principle with neat sketch. List the common tools
required for arc welding.
2. Explain MMAW, MIG and TIG process of welding with neat sketch.
3. Compare MIG & TIG welding processes with respect to their principle,
operation and applications.
4. What is HAZ? Explain in detail with neat sketch.
5. What do you mean by straight polarity and reverse polarity in an arc welding
process? How will you make a selection between straight and reverse
polarities for a given welding problem?
6. What is OCV? Describe in brief about the power sources used in arc welding
processes.
7. Explain electrode classifications as per AWS and I.S.
8. Discuss the physical and metallurgical changes that take place during fusion
welding and briefly explain how these adverse effects are controlled.
9. Explain the following electrode classification.
a. E 7018 (as per AWS)

Marks obtained: Signature of faculty: Date:

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 CHAROTAR INSTITUTE OF TECHNOLOGY-CHANGA
Department of Mechanical Engineering

Metal Forming and Fabrication Technique (M-601) Date:

PRACTICAL NO. 6
RESISTANCES WELDING PROCESSES

AIM: - Introduction to various resistances welding processes and prepares lap joint
using spot welding process.

OBJECTIVES: -

 Student should understand the principle of resistance welding process.

 Student should understand the welding cycle & different time phases involved.
 Student should tell about the equipment used in various resistance welding
processes.
 Student should understand various welding parameters of resistance welding
process.
 Student should know different resistance welding processes and their
applications.

REVIEW QUESTIONS: -

1. State the principle of resistance welding. Also, explain the welding cycle of
spot welding process with sketch.
2. Explain resistance welding power source.
3. List various resistance welding processes. What are the main factors to be
considered in resistance welding?
4. Write short notes on: -
a. Spot welding
b. Projection welding
c. Seam welding
d. Upset welding
e. Precision welding

Marks obtained: Signature of faculty: Date:

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 CHAROTAR INSTITUTE OF TECHNOLOGY-CHANGA
Department of Mechanical Engineering

Metal Forming and Fabrication Technique (M-601) Date:

PRACTICAL NO. 7
WELD DEFECTS AND D.P TESTING

AIM: - To study of weld defects and carry out Dye Penetrant (DP) test on welded joint.

OBJECTIVES: -

 Students should know the types of welding defects, and its remedies.
 Students should know types of testing methods available, its principle and
working.
 How to test weld?
 To carry out Dye Penetrant (DP) test.

REVIEW QUESTIONS: -

1. List the common welding defects. Explain briefly with neat sketch, the causes
and its remedies of the defects.
2. Explain the term: Gas Entrapment, Cold Crack, Arc Blow
3. List the common testing method available to test weld.
4. Explain the X-Ray test.
5. Compare Ultrasonic testing of weld with Magnetic Particle Test with neat
sketch.
6. Explain complete procedure of Dye Penetrant Test.

Marks obtained: Signature of faculty: Date:

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 CHAROTAR INSTITUTE OF TECHNOLOGY-CHANGA
Department of Mechanical Engineering

Metal Forming and Fabrication Technique (M-601) Date:

PRACTICAL NO. 8
PRESS AND PRESS WORKING OPERATIONS.

AIM: - To study various press working operations.

OBJECTIVES: -

 To know set up of press working. (tools)

 To know various processes.
 To know effect of clearance.
 To know fundamental of shearing action.
 To know various press working operations.
 To know difference between punching, piercing & blanking.
 To know different types of processes used.

REVIEW QUESTIONS: -

1. List out different types of die used in sheet metal working.

2. Enlist various press working processes.
3. Explain the effect of shear on cutting.
4. Explain the principle of sheet metal shearing.
5. How clearance controls shearing process.
6. State & explain different dies used in press working with neat sketch.
7. Differentiate between punching, piercing & blanking.

Marks obtained: Signature of faculty: Date:

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CHAROTAR INSTITUTE OF TECHNOLOGY-CHANGA
Department of Mechanical Engineering

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 CHAROTAR INSTITUTE OF TECHNOLOGY-CHANGA
Department of Mechanical Engineering

Metal Forming and Fabrication Technique (M-601) Date:

PRACTICAL NO. 9
DRAWING OPERATION

AIM: - To carry out drawing operation on press.

OBJECTIVES: -

 To know principle of deep drawing operation.

 To know set up of drawing operation.
 To know various drawing operation.
 To know drawing ratio.
 To calculate drawing force.
 To know rod wire & tube drawing.

REVIEW QUESTIONS: -

1. What is drawing?
2. State & explain different drawing process & with sketch.
3. What is drawing radius & how blank size & force needed out?
4. Explain rod, tube & wire drawing with neat sketch.
5. Find out the actual dimensions and relations between die, punch and material
of component, which you are, performing in the laboratory. Also draw the
actual figure of the component and write the machine specification you use.

Marks obtained: Signature of faculty: Date:

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 CHAROTAR INSTITUTE OF TECHNOLOGY-CHANGA
Department of Mechanical Engineering

Metal Forming and Fabrication Technique (M-601) Date:

PRACTICAL NO. 10
FORGING OPERATION

AIM: - Study of forging operation and generating square headed bolt using
different forging operation.

OBJECTIVES: -

 Definition of Forging.
 Material behavior of different metals during forging.
 Classification of forging process & operation.
 Old & new forging equipments.
 To know the forging defects & to rectify.

REVIEW QUESTIONS: -

1. What is forging in general?

2. What are the ferrous & non-ferrous forging materials? Write down them with
different Indian standards.
3. How different material behave with increase in temperature.
4. Write down all the forging processes & machines with brief description &
examples.
5. What is automation forging?
6. What is the biggest capacity of forging press in the world & where are they?
7. Specify forging defects & its remedies.

Marks obtained: Signature of faculty: Date:

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 CHAROTAR INSTITUTE OF TECHNOLOGY-CHANGA
Department of Mechanical Engineering

Metal Forming and Fabrication Technique (M-601) Date:

PRACTICAL NO. 11
ROLLING OPERATION AND THREE-ROLL BENDING
MACHINE

AIM: - Study of rolling operation. Rolling of sheet and prepare cylinder using three-
roll bending machine.

OBJECTIVES: -

 To understand between bending & rolling of shell, plate & section.

 To know the metallurgical charges during rolling operations continuous &
non-continuous.
 To know about different rolling processes & its classifications.
 Metal rolling mills, types & principles.
 Rolling load analysis.
 Rolling variables & its design criteria.
 Defects in rolled products, inspection & remedies.

REVIEW QUESTIONS: -

1. Write down different rolling processes & their classification with brief
description of each.
2. What are the temperature ranges for different metals & alloys for non-ferrous
& ferrous metals rolling operation?
3. Explain the principle of metal rolling mills.
4. Give formula for rolling load calculations & its application.
5. Which are the rolling variables to keep under control for best product output?
6. Write down the defects in rolled products.
7. Describe your practical in lab.

Marks obtained: Signature of faculty: Date:

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 CHAROTAR INSTITUTE OF TECHNOLOGY-CHANGA
Department of Mechanical Engineering

Metal Forming and Fabrication Technique (M-601) Date:

PRACTICAL NO. 12
BENDING OPERATION AND HYDRAULIC PIPE BENDER

AIM: - Study of bending operation. Pipe bending practice using hydraulic pipe
bending machine, vertical and horizontal conduit pipe bender

OBJECTIVES: -

 To know principle of bending.

 To know bending process
 To know nomenclature in bending.
 To know effect of bending alone & across the grain.

REVIEW QUESTIONS: -

1. Explain the principle of bending.

2. How pipe bending can be done?
3. Sketch the figure of bending.
4. Which one is desirable, bending across the grain or along the grain? Why?

Marks obtained: Signature of faculty: Date:

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 CHAROTAR INSTITUTE OF TECHNOLOGY-CHANGA
Department of Mechanical Engineering

Metal Forming and Fabrication Technique (M-601) Date:

PRACTICAL NO. 13
EXTRUSION PROCESS

AIM: - Study of Extrusion Process.

OBJECTIVES: -

 To know principle of Extrusion Operation.

 To know types of Extrusion process.
 To know the practical Application of Extrusion process.
 To know how to manufacture tube and pipe?

REVIEW QUESTIONS: -

1. Define the principle of Extrusion Process.

2. Draw neat sketch of direct and indirect process.
3. Explain the complete procedure of manufacturing of tube and pipe.

Marks obtained: Signature of faculty: Date:

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 CHAROTAR INSTITUTE OF TECHNOLOGY-CHANGA
Department of Mechanical Engineering

Metal Forming and Fabrication Technique (M-601) Date:

PRACTICAL NO. 14
METAL FORMING

AIM: - To study the basic concepts of metal forming.

OBJECTIVES: -

 Classification of basic forming processes.

 Metal working criteria.
 Selection & advantages of hot & cold working.
 Stress-strain concern in metalworking.
 Initial metallurgical structure & after metal working-metallurgical structure.
 Metal working with reference to hydrostatic pressure.
 Workability & residual stresses.

REVIEW QUESTIONS: -

1. Write down the different forging processes with advantages & disadvantages.
2. How temperature effects in different materials during formation process.
Explain with example.
3. Differentiate hot & cold working as mass production.
4. Equate stress & strain at different stages of metal forging.
5. What you understand about residual stresses.

Marks obtained: Signature of faculty: Date:

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CHAROTAR INSTITUTE OF TECHNOLOGY-CHANGA
Department of Mechanical Engineering

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