UNIVERSITY OF GONDAR INSTITUTE OF TECHNOLOGY

MECHANICAL AND INDUSTRIAL ENGINEERING

Welding Lab Report of trash bag and sand casting

Name Id

Trash Bag

1. INTRODUCTION
1.1 TYPE OF ACTIVITIES PERFORMED
The basic type of activities performed in the production of trash bag are,

 Sheet Metal cutting

 Metal bending
 welding and
 grinding
1.2 DESCRIPTION OF EACH ACTIVITIES

1.2.1 SHEET METAL CUTTING

In this process of cutting, we have used a metal shearing machine. The objective of the
shearing machine is to cut the desired length of the metal sheet. And we have to determine the
position of the steel plate to ensure the maximum size of the remaining material, so that the
remaining material can be used.

1.2.2 METAL BENDING

Bending is a metal forming process in which a force is applied to a piece of sheet metal,
causing it to bend at an angle and form the desired shape. A bending operation causes
deformation along one axis, but a sequence of several different operations can be performed to
create a complex part. We have used for the bending process the CNC hydraulic press brake
with a high control precision, desired shape, and smooth appearance of the lamp pole.

1.2.3 WELDING
Welding is a fabrication process pressure or both forming a join as the parts cool.
Welding is usually used on metals and thermoplastics but can also be used on wood. We have
welded the metal sheet. The welder has a more responsibility in order to adjust the welding
position to ensure the straightness of the weld.
 1.2.4 GRINDING
A mechanical process using a rotating grinding wheel made from abrasive material containing
small particles of grit ranging from fine to coarse. We grind our pole after the weldment is over
to get a smooth and fine surface.

1.3 OBJECTIVE

1.3.1 MAIN OBJECTIVE

The main objective of this project is to manufacture a trash bag having a bottom area of 900cm2 ,
top area of 1600cm2 and 65cm height with standing height of 230cm.

1.3.2 SPECIFIC OBJECTIVE

The Specific objectives is to manufacture a trash bag with appropriate length for the purpose of
disposal of trash.
2. Required instrument/equipment’s

2.1Trash bag production

A. Hydraulic shearing machine

Shearing machine is driven by the hydraulic system to press the steel plate, and the left and
right oil cylinder to drive the blade up and down movement. The upper blade on the blade carrier
and the lower blade fixed on the blade holders adopt reasonable blade clearance. Shear force is
applied to the metal sheet of various thicknesses and separate the sheet according to the size of
the required fracture.

Shearing machine is widely used in all kinds of metal materials, to meet the various
demands for direct shearing. It is mainly applied in steel manufacturing, shipbuilding,
automobile, container manufacturing, and switch electrical appliances, machinery
manufacturing, light industry etc. .
  Main structure and its function
1. Shearing machine frame
- The frame is welded with steel plate, includes the left, right board, worktable, clamp
holder and fuel tank
2. Blade holder
- Fixed upper blade, connect with the hydraulic cylinder, do up and down straight
movement, pass shear force , achieve the cutting purpose
3. Shear blade
- The upper and lower shear blades made of high standard steel can suitable for
shearing steel from low carbon steel to stainless steel sheet.
4. Backguage mechanism
- The movement of shearing machine Backguage is driven by the motor, and driven the
running of Backguage stopper plate to realize cut-to- length cutting
5. Fuel tank
6. Clearance adjustment device

7. The front supporter

- Ensure that the shear plate is perpendicular to both sides
8. Finger protection plate
- Used to control the safe distance of the fingers
9. Hold down cylinder
- Prevent the moving of the plate during the cutting process
10. Electrical system
- Provide driving force for hydraulic shears, supply control power
11. Hydraulic system
- Controls the system pressure and hydraulic oil direction.
 B. Bending machine

Press brake is a kind of widely used bending machine, which has already achieved
hydraulic efficiency. Press break, as an important equipment for sheet metal processing, plays an
irreplaceable role. It plays a decisive role in product quality, processing efficiency and precision.
Usually, the press brake is the upper piston type press machine, which is composed of the frame,
sliding block, hydraulic system, front-loading rack, back gauge, mold, electrical system etc...
Vertical downward pressure is formed by two parallel working hydraulic cylinder to drive the die
on the bending beam to complete bending process.
The hydraulic control system, as the brain of the press brake, mainly controls the synchronous
operation of the bending process and the positioning of the hydraulic cylinder brake machine is
fully loaded.

Parts

1. Left upright
2. Left oil cylinder
3. Oil tank
4. Right hydraulic cylinder
5. Ram
6. Worktable

C. Welding equipment

Welding equipment are used to create a joint on a work piece. They include soldering irons, stick
welders, TIG welders, MIG welders, and gas welders as well as the torches, electrodes, filler
metals, solder, and other welding supplies that are used with them. Plasma-cutting and arc-
cutting equipment cut or gouge materials. Welding helmets, gloves, blankets, and other safety
equipment are designed to withstand hazardous glare, sparks, spatter, and heat generated during
welding to prevent injury to workers and avoid damage to equipment and surfaces. Welding
tables and accessories support the work piece to improve efficiency and accuracy during welding
tasks.

1. TIG and MIG Welders

The most common welder used in basic projects by homeowners and hobbyists is the
stick welder. Also known as the shielded-metal arc welder, most people prefer it due to
how easy it is to buy and the lack of a special environment needed to use it. But the
electrodes in a stick welder require frequent replacement compared with other forms of
welding. These include the gas tungsten arc machines, TIG and gas metal arc welder,
known as MIG welders. You will also need some sort of gas feed with this type of
welder.
2. Charged Electrode
An electrode is the tip of the tool that passes the current from the welder to the material
being welded, making it so hot it becomes liquid. In the cases of the stick and MIG
welders, the type of metal and the heat to melt it drives the type of electrode tip needed.
But in a TIG welder, the electrode tip is made of non-consumable tungsten, and does not
require replacement.
3. Wire and Electrode Feeds
some welds require a feed to strengthen the joint due to the geometry or weakness of the
weld. Stick welding uses the electrode to feed; MIG welding often uses a wire feed. In
addition, TIG welding likewise uses a feed due to its non-consumable nature.
4. Other Tools
Most welders also use an angle grinder to help smooth out joints, wire brushes, to clean
metal surfaces or abrade them before welding, a chipping slag hammer, C-clamps, ball
peen hammer, electrode tip cleaners, flint strikers, needle nose and linesmen cutting
pliers. Other tools to have on hand: cold chisels, flat-head and Phillips screwdrivers,
round and flat files, levels and squares.
5. Safety Equipment
Due to the temperature and elements involved, welding is highly dangerous and can be
lethal if handled incorrectly. Before you touch a welding setup, wear a welding helmet
that protects your eyes, earplugs, solid boots to protect your feet from sparks or slag,
 welding gloves to protect your hands and leathers to cover the rest of your body. Do not
weld without these, as you will likely get hurt.

D. Grinder

A grinding machine, often shortened to grinder, is one of power tools or machine tools
used for grinding; it is a type of machining using an abrasive wheel as the cutting tool. Each
grain of abrasive on the wheel's surface cuts a small chip from the work piece via shear
deformation.

Grinding is used to finish work pieces that must show high surface quality (e.g., low
surface roughness) and high accuracy of shape and dimension. As the accuracy in dimensions in
grinding is of the order of 0.000025 mm, in most applications it tends to be a finishing operation
and removes comparatively little metal, about 0.25 to 0.50 mm depth. However, there are some
roughing applications in which grinding removes high volumes of metal quite rapidly. Thus,
grinding is a diverse field.
3. PROCEDURE
TRASH BAG PROCEDURE

1. METAL PLATE CUTTING

The plate which needs to be cut with the running of the walking device. When pressing the
material, place the plate horizontally according to the required size and the tapered plate can be
cut.

Before cutting first we adjust the slope of the slitter and the required cutting size. Then we
determine the position of the sheet metal. After the size is adjusted it is completed by a strip
cutting machine and automatic cutting machine by pressing the foot pedal, we cut the sheet
metal.

For our project we have cut

 Two sheet metal having top and bottom length of 80 and 60cm respectively with a height of
60cm.
 Supporting pole of 230cm
 And a cover of 25cm radius
2. BEND FORMING
After we have finished cutting our sheet metal in the proper length and diameter the next step
will be bending the metal. For the bending process we use CNC hydraulic press brake. The
quality of the bend directly affects the quality of the light pole. Before the bending check the
length, width and straightness of the sheet. If the straightness meets the requirements, we correct
it.

 Bending the single sheet plate into two equal part

 Bending the shredded supporting pole. ( we shred the supporting pole in order to bend it
by using cutting grinder).

3. WELDING
The next step or procedure of our electrical pole is that of welding the sheet metal. The process
of joining metal to metal with the help of an electric arc is called arc welding. In this welding
process, the arc is used to create intense heat and this heat is used to join the metals together.

 First we turn on the AC or DC source

 Adjusted to the proper welding voltage and
 Displaying the ground in the proper position.
 The arc is brought in between two metal pieces and due to the heat generated,
 The metals melt and when it cools a strong welded joint is formed.
This process is carried out by giving a high safety protection. Since the welding process have
cause eye hazard. The two separated part of the pole is collided together by welding. Processes
are

 First we weld the two sheet metal

 Then we weld the shredded supporting pole after bending for strength and rigidity by
using filler material
 We weld the top cover

 After we weld the trash bag with the supporting pole

4. GRINDING
Grinding is used to finish work pieces that must show high surface quality (e.g., low surface
roughness) and high accuracy of shape and dimension. As the accuracy in dimensions in
grinding is of the order of 0.000025 mm, in most applications it tends to be a finishing operation
and removes comparatively little metal, about 0.25 to 0.50 mm depth.

So after the welding process have completed we carried out the grinding process.To get the fine
surface finishing.

5. FILLING THE SHREDDED POLE We fill the shredded pole with stucco with appropriate amount
of fluid for increasing hardness and for faster drying of the stucco.

This figure shows stucco filled in the shredded supporting pole.

4. RESULT and CONCLUSION
4.1 RESULT

We manufactured a trash bag having a bottom area of 900cm2, top area of 1600cm2 and 65cm
height with standing or supporting height of 230cm.

4.2 CONCLUSION
The manufacture of the trash bag with the given dimension ensures the clean disposal of trash
with standing the weight of the trash. The trash bag has good strength and have appropriate
height.
5. Recommendation

We recommend that we fill the shredded supporting pole, we should apply a good amount of the
poison used for hardening and for faster drying of stucco unless it will not dry faster and when
shredding the pole we should be accurate and give the same amount of space between them in
order to have good bend quality and to have the same cut length.
 SAND CASTING

1. INTRODUCTION
Casting is a manufacturing process by which a molten material such as metal or plastic is
introduced into a mold, allowed to solidify within the mold, and then ejected or broken out to
make a fabricated part.
Casting is used for making parts of complex shape that would be difficult or uneconomical to
make by other methods, such as cutting from solid material.
Casting maybe used to form hot, liquid metals or melt-able plastics (called thermoplastics), or
various materials that cold set after mixing of components such as certain plastic resins such as
epoxy, water setting materials
Substitution is always a factor in deciding whether other techniques should be used instead of
casting.
Sand casting is a metal forming process in which a mold is first formed from a three dimensional
pattern of sand, and molten metal is poured into the mold cavity for solidification. The sand shell
is subsequently removed after the metal component cooled and formed. Certain sand casting
components require a secondary machining process after casting. Sand casting can process a
wide range of metals and alloys, including iron, special alloy steel, titanium alloy, and others.
Sand casting is a cost effective and efficient technology, which is generally flexible with regards
to size and change of geometry design. Secondary machining is usually needed to improve
product accuracy.

Fundamentals of Casting
Basic factors involved in the casting process:
- Mold cavity
- Melting process
- Pouring technique
- Solidification process
- Part removal process
- Post processing
Casting Terms
 Pattern
 Flask
 Cope
 Drag
 Core
 Core Box
 Core Print
 Mold Cavity
  Riser
 Gating System
 Pouring Cup
 Sprue Runner
 Gate
 Parting Line
 Draft

Sand casting is simply melting the metal and pouring it into a preformed cavity, called mold,
allowing the metal to solidify and then breaking up the mold to remove casting. In sand casting
expandable molds are used. So for each casting operation we have to form a new mold.
1.1 TYPES OF ACTIVITY PERFORMED

 Prepare the mold cavity

 Melt the metal

 Pour it into a mold

 Let it freeze

1.2 OBJECTIVE
1.3.1 MAIN OBJECTIVE
The main objective of this report is to study to know how to use sand casting manufacturing
process for making useful casserole.
1.3.2 SPECIFIC OBJECTIVE
1. Drag portion of pattern is placed in flask
 the pattern on a flat board and a casting box called a ‘drag’ being placed over it.

2. Drag is packed with sand

 Special casting sand will soon be packed around the pattern.
 To ensure the easy removal of pattern from the sand, parting powder is sprinkled
over and around it. (parting powder is similar to talcum powder).
 It stops the casting sand sticking to the pattern and pulling away with it when the
pattern is finally removed from the sand.
 Casting sand is then shaken through a sieve.
 Only fine particles fall around the pattern. This is called facing sand and it must
be fine so that detail on the pattern shows up on the final casting.
3. Packing of sand with ram
 The drag is then packed with more castings and. It is a good idea to sieve
all the sand being placed above the pattern and then ram it down firmly
using a ramming tool.

The tool has two ends,

 Cylindrical (used for general packing down of the sand)
 Pointed (Used for packing sand close up to the pattern).

4. Leveling
 When the drag is packed fully it is leveled off (called ‘stickled off’)
using a straight steel bar.

5. Turn Over Drag

 The entire drag and its contents are then turned over so that the base of
the pattern can be seen.

6. Fixing and positioning Locating Pin

 A top box called a ‘cope’ is then placed on top of the drag and locating
pins are put in position so that the casting boxes cannot move
sideways.

7. Insert Sprue and Risers

 Sprue pins are positioned. One usually on the back of the pattern and
the other to the side. These will eventually provide an entrance and
exit for the molten aluminum when it is poured into the sand.
 The sand is packed/ rammed in to the cope in the same way as the
drag. Parting powder is first applied, followed by facing sand.
 The sprue pins should be taller than the box and stand out from the
sand when it is leveled with a stickling bar.

8. Pack the cope with Sand

 Small depressions are dug into the sand at the top of the two sprue
pins. These are useful when the aluminum is poured.
 The depressions are called the pouring basin and feeder.
9. Gates and runners cut into mold
 The top box (the cope) is then removed and if all is well the cope with
the sand inside should lift off the drag (bottom box) without the sand
falling out. A small ‘gate’ is cut below the position of one of the sprue
pins.

10. Removal of Pattern

 The pattern is removed using a ‘spike’. The end of the spike can be
threaded and so it can be screwed into the soft wood pattern.
 Before removing the pattern, it is a good idea to gently tap the spike so
that it loosens the pattern from the sand. It can then be lifted away
from the casting box (drag)

11. Pouring of Molten Metal

The aluminum is poured with great care.

 The aluminum is poured down the hole left by the first sprue
pin (now called the ‘runner’).
 As it runs down the runner it flows through the ‘gate’ cut by
the trowel, into the cavity left by the pattern and up the riser
(the hole left by the second sprue pin).
 The casting should be left for sufficient time before removal
from the sand.

12. Final Casting

 When removed from the sand, the final casserole is achieved

2. REQUIRED INSTRUMENTS OR EQUIPMENTS

 Safety Shoes.
 A safety coat.
 Molding sand.
 Casting flask.
 Metal to be molten.
 Furnace.
 Ladle

3. EXPERIMENTAL PROCEDUERS
1. Prepare core sand
  Assemble the core box after applying some parting sand
 Fill the core box cavity with core sand and ram it
 Tap the mold on all sides to loosen the core from the box

2. Mold making
 Place the drag part of the pattern with parting surface down on ground
 Heap more molding sand in the drag and ram with rammer carefully
 Make vent holes
 Strike of the excess sand using strike bar
 Remove pattern carefully
3. Melting and Pouring
 Melt the aluminum metal in the furnace
 Pour the molten aluminum metal into the pouring ladle
 Allow sufficient time for the metal to solidify in the mold
 Break the mold carefully and remove the casting casserole
4.Discussion
There are several defects on our casting product that we are identified. The defects are porosity
and cavities. Porosity in a casting may be caused by dissolved gases, shrinkage or both. Due to
shrinkage, porous region can be developing in casting of the solidified metal. This happened
when the thin section in a casting solidify sooner than thicker regions, so the molten metal flows
into the thicker regions that have not yet solidified. The porous regions may develop at their
centers because of contraction as the surfaces of the thicker region begin to solidify first.
Porosity is detrimental to the ductility and strength of a casting and its surface finish, potentially
making the casting permeable, thus affecting the pressure tightness of a cast pressure vessel. The
factors that caused the porosity happened are:
 Melt temperature is too high
 Non-uniform cooling rate
 Sand has low permeability

Porosity of metal

For the cavities defect occurred in the form of shrinkage cavities. Due to internal area of the
casting was remained molten the shrinkage void occurred. Void occurs as the material solidifies
forming a shrinkage cavity when there is no sufficient amount of molten metal to feed the
shrinkage.

Shirinkage of cavity
There are several ways to prevent the defect in the casting. For the first defect which is
porosity it can be prevent by melt the metal with the suitable temperature, uniform the
 cooling rate and use the sand that has a good permeability. The other defect is cavities
that occurred caused by the shrinkage. The way to fix this problem is to add padding to
the area of the casting that is experiencing shrinkage. It promotes directional
solidification back to the molten sprue or riser. As this casting cool, there is still a molten
path open that will feed the liquid and solidification shrinkage, which give a part with
minimal shrinkage defects. Another method of reducing the shrinkage cavity is adding a
riser near to the shrinkage defect. Risers require additional metal for the casting process,
removal and additional finishing. All of which tend to increases the cost of the finished
casting.

5. Result and Conclusion:

From the experiment the following items are concluded as follows:
The product is casted successfully based on the proper techniques and methods which started
from the making of the mold using sand, the removal of the pattern, melting of the aluminum
metals and pouring it to the mold through the sprue and pouring cup. The finishing work should
be done to remove the gate and runner.
However, there are some defects that occurred on our product which are porosity and cavities.
But, there are some defects can be minimized or eliminated by proper design and preparation of
the mold, and pouring procedures. The examples of defects occur are blow, scar, blister, scab,
wash, Misrun, cold shut and etc.

6. Recommendation
We would like to recommend that it is better to use permeable and good collapsible sands to give
the casting good surface finish and better mechanical property. And also it would be better to
cast other metal types for better understanding of casting for us because we can easily identify
the properties of metals that are to be casted.