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Topics including this report at a glance

1) Machine Maintenance 02-04

2) Fabrication Section 05-07

3) MT (heavy) Shop 08-11

4) MT (light) Shop 12-15

5) Plastic Technology 16-19

6) PCD; IED & IS 20-22

7) HT & PC 23-27

8) Mould & CNC Shop 28-31

9) Foundry Shop 32-34

10) Pattern Shop 35-39

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Machine Maintenance

Machine maintenance refers to keep the active machine running and at the same

time inactive machines are able to be in running mode.

Hand Tools: There are some tools which are needed for the maintenance.

Hammer

Pipe range

Slide range

Ring range

Screw driver

Cutting pliers

Wrench

Allen key

Flat file

Half file

Round file

Triangular file

Jewellery file

Nose pliers

Pliers

Machines:

Some machines that have to be maintained are given below:

Crank shaft grinding machine

Hand press machine

Hydraulic press machine

Radial drill machine

Column drill machine

Rolling machine

Bending machine

Shearing machine

Vertical lathe machine

Central lathe machine

Hydraulic planner machine

Mechanical planner machine

Horizontal boring machine

Horizontal shaper machine

Vertical shaper machine

Horizontal milling machine

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Rotary table

Surface grinding machine

Internal grinding machine

Thread grinding machine

Power saw machine

Bend saw machine

Small parts:

Small parts of these machines are given below.

Gear

Oil seal

Bearing

Surclip

Nut and bolt

LM bolt

Plane washer

Error:

There are two types of error

1. Mechanical error

2. Electrical error

Mechanical error:

If there is no particular lubricants in machines parts

For the leakage of oil seal during operations

Failure of bearing during operations

Bearing shapes can cause mechanical error too.

Break down of gear tooth

Erosion too gear shaft surface

Break down of surclip

For the jam of tailstock

For the jam of tool post

For the jam of compound rest

If the gears inside carriage is failed down during operation

Exhaustion of key

If carriage box automate does not work

Failure of lead screw half nut.

Electrical error:

Failure of main switch

If channel board does not work

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Failure of the machine switch

Failure of the water pump switch

Burn down of motor

Failure of motor bearing

Damage to the motor shaft key

If motor and machine pulley belts are loose down.

Gear:

Some gears which are introduced are given.

Bevel gear

Helical gear

Spiral gear

Spur gear

Rack gear

Sprocket gear

Worm wheel gear

Worm shaft gear

Types of bearing:

Ball bearing

Roller bearing

Taper roller bearing

Thrust bearing

Needle bearing

Bush bearing

Lubricants:

Mobile( use only for engines)

Hydraulic oil(use only for hydraulic machines)

Shell beta oil(use only for machines)

Uses: Cutting compound or coolant reduces the corrosion and keeps the job

cool down after machining work

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Fabrication section

Metal fabrication is the building of metal structures by cutting, bending, and

assembling processes. It is a value added process that involves the construction of

machines and structures from various raw materials. A fab shop will bid on a job,

usually based on the engineering drawings, and if awarded the contract will build the

product. Large fab shops will employ a multitude of value added processes in one

plant or facility including welding, cutting, forming and machining. These large fab

shops offer additional value to their customers by limiting the need for purchasing

personnel to locate multiple vendors for different services. Metal fabrication jobs

usually start with shop drawings including precise measurements then move to the

fabrication stage and finally to the installation of the final project. Fabrication shops

are employed by contractors, OEMs and VARs. Typical projects include loose parts,

structural frames for buildings and heavy equipment, and stairs and hand railings for

buildings.

The main operation of the fabrication shop is to assemble all the parts. In this shop

welding does a lot of joining. We saw,

TIG welding

Gas tungsten arc welding (GTAW), also known as tungsten inert gas (TIG) welding,

is an arc welding process that uses a non-consumable tungsten electrode to produce

the weld.

Arc welding:

Arc welding is a type of welding that uses a welding power supply to create

an electric arc between an electrode and the base material to melt the metals at the

welding point. They can use either direct (DC) or alternating (AC) current, and

consumable or non-consumable electrodes.

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Spot welding

Resistance spot welding (RSW) is a process in which contacting metal surfaces are

joined by the heat obtained from resistance to electric current. Work-pieces are held

together under pressure exerted by electrodes. Typically the sheets are in the 0.5 to

3 mm (0.020 to 0.118 in) thickness range. The process uses two shaped copper

alloy electrodes to concentrate welding current into a small "spot" and to

simultaneously clamp the sheets together. Forcing a large current through the spot

will melt the metal and form the weld.

In this shop some hand tools are also used such as:

Hammer File Wrench Slide Wrench Ring Wrench Flat Screw drivers Star Screw drivers Pliers Cutting Pliers Nose Pliers Allen Key Flat File Half Flat File Round File Triangular File

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FIG: Fabrication section

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Machine TOOL (Heavy) shop

Heavy machine shop is equipped with manual lathes, conventional drilling

machines, boring mills, honing equipment, hydraulic torqueing machines and a

variety of support equipment and portable line boring equipment.

Lathe Machine:

In a lathe machine, material is removed from a work piece by rotating it when a

cutting tool is moved longitudinally with a depth of cut. Lathe machines are widely

used to work on cylindrical work pieces.

Various operations can be done using lathe. Among them turning, facing, boring,

parting, drilling, reaming, knurling, threading, chamfering etc.

Principle units of lathe:

1.bed 9.carriage

2.motor drive 10.cross slide

3.feed gear box 11.tool post

4.head stock 12.collum

5.tail stock 13.table

6.spindle 14.swivel plate

7.lead screw 15.top slide

8.feed rod 16.switch box

Boring:

Boring is internal turning. Boring can use single point cutting tools to produce internal

cylinder or conical surfaces.

Name of the Machines:

1. Horizontal Boring Machine:

It is the more powerful machine in the heavy machine shop. A horizontal boring

machine or horizontal boring mill is a machine tool which bores holes in a horizontal

direction. There are three main types — table, planer and floor. The table type is the

most common and, as it is the most versatile, it is also known as the universal type.

Operation: Facing, drilling, boring, internal flat cutting, gear cutting etc.

Job: All size gear box, engine head, pump machine, bearing housing, bevel gear,

spur gear etc.

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2. Vertical Lathe & Boring Machine:

At vertical boring machine table can be set in desire angle. Or can be used for jig

boring with the help of dividing head.

Operation: Turning, facing, boring, radius cutting by hand.

Job: Gear box.

3. Jig Boring Machine:

Jig boring machine like a Moore, the spindle is always square to the table and there

is no knee movement.

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Planer:

A planer is a type of metalworking machine tool that uses linear relative motion

between the work piece and a single-point cutting tool to machine a linear tool path.

Its cut is analogous to that of a lathe, except that it is (archetypally) linear instead of

helical.

In this machine shop there are two types of planer machine. They are

1. Hydraulic Planer Machine:

Operation: Surface finish, side cutting, slot cutting, grinding.

Job: Spur gear, bevel gear, v-block etc.

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2. Mechanical Planer Machine:

Its operation is just like hydraulic planer machine. But in this machine there is no

gear in the lever, so no thread cutting in this machine.

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Machine tool (Light) Shop

Light machine shop is mainly equipped with various types of lathe and milling

machines. In light machine shop, small jobs and machine parts are machined.

Machines in light machine shop are:

1) Shaper machines :

There are two kinds of shaper machines.

Vertical and

Horizontal

a) Vertical Shaper Machine:

Vertical shaper machine situated vertically. Here job moves clockwise, table is fixed.

Mainly used for finishing.

b) Horizontal Shaper Machine: Here job is fixed and ram moving to and fro

motion.

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2) Lathe:

a) Center lathe machine: The center lathe machine is used to turn and cut

metal. Some common operations are turning, boring, facing, knurling, taper turning

etc.

b) Coppying lathe machine : This machine can copy design and can produce

the exact replica of the given sample.

3) Milling :

a) Vertical milling machine:

Here the table has vertical, longitudinal, and transverse movement and the spindle

has vertical movement.

Operations: Boring, Facing, Drilling, Key cutting, slot cutting etc.

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b) Horizontal milling machine :

In this machine, longitudinal travel of the table is fixed at right angles to the spindle.

Gear Hobbing machine 3) :

It’s a special type of milling machine, which is used for gear cutting, cutting splines

and sprockets.The teeth or splines are progressively cut into the workpiece by a

series of cuts made by a cutting tool called hob.

Operations : Spur gear, Worm gear and Helical gears are being cut.

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4) Grinding section :

Grinding is needed for a smooth surface finish of the metal.

a) Cutter grinding machine :

it is used to grind the edge of cutting tools, hence sharpen the tool for the next use.

b) Surface grinding machine: It is used to smooth the surface of any flat

surface of the metal job.

c) Cylindrical grinding machine: It is external grinding, commonly used to grind

the outer diameter of a piece of work often for the purpose to reduce the diameter.

d) Internal grinding machine: It is used to grind the internal surface, i.e. the

bore surface of a hollow work piece.

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Plastic technology

Plastic pipe extruder:

The extruder can turn solid plastic into a uniform melt through the heating, pressure

and shear. The mold includes mixing master batch and the other addictives, blending

resin and smash in the production process. The pressure must be large enough to

viscous polymer extrusion. Extrusion machine complete the above pattern through

the barrel with a spiral track and a screw.

Raw material: Poly propylene

Use: To make any kind of pipe shaped plastic accessories.

Injection Molding Machine:

Generally injection molding machine includes,

Injection device

Clamping device

Hydraulic system

Electrical control system

Capacity: maximum 100kg weighted product.

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Plastic wastage crusher:

There are four blades. Two are fixed and two can rotate.

Cutting edges of the cutters are face to face.

Clearance 0.3

It works on hydraulic system. After cutting the plastic in the cutter they fall down on

the net below the cutter and they have to be cut until they get to pass the net and

here a roller is used.

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Blow molding:

Hopper: Contains raw material.

Barrel: A chamber where raw material is heated.

Mold: To get the shape of the mold according to the purpose and here uses water

chiller to cold the mold at 0-5 c.

Use: To make bottle shaped plastic material.

Vacuum forming machine:

Raw Material:

PVC sheet

Poly carbonate (PC) sheet

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Vacuum forming is usually restricted to forming plastic parts that are rather sallow

in depth. Thin sheets are formed into rigid cavities. Thick sheets are formed into

permanent object. Relatively deep parts can be formed if the formable sheet is

pneumatically stretched.

Use: It is one type of packaging used in medicine company.

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PCD, IED & IS

Production Control Division

Production planning is the planning of production and manufacturing processes in a

company or industry. It utilizes the resource allocation of activities of

employees, materials and production capacity, in order to serve different customers.

Different types of production methods, such as single item manufacturing, batch

production, mass production, continuous production etc. have their own type of

production planning. Production planning can be combined with production control

into production planning and control, or it can be combined and or integrated

into enterprise resource planning.

Production planning is used in companies in several different industries, including

agriculture, industry, amusement industry, etc.

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Industrial Engineering Division

Industrial engineering is a branch of engineering which deals with the optimization of

complex processes or systems. Industrial engineers work to eliminate waste of time,

money, materials, man-hours, machine time, energy and other resources that do not

generate value. According to the Institute of Industrial Engineers, they figure out how

to do things better. They engineer processes and systems that improve quality and

productivity.

The thematic scope of the Division of Industrial Engineering and Logistics covers the

design and management of the supply chain, namely production and logistic systems

to generate goods and services, as well as the necessary techniques for solving

efficiently its derived problems. The Division undertakes research activities on these

topics and transfer of the research results. This is done through consulting and

elaboration of studies, models and software.

Fields of activity

Supply chain design

Capacity planning

Aggregate planning

Design and task assignment of assembly and production lines

Activity programming

Working time management

Task assignment to employees taking into account learning and forgetting effects

Urban logistics

Port logistics

Reverse logistics

Green logistics

Simulation of production and logistic systems

Generator assignment and electrification of isolated areas

Quantitative techniques

Lean management

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Inspection Section

An inspection is, most generally, an organized examination or formal evaluation

exercise. In engineering activities inspection involves the measurements, tests,

and gauges applied to certain characteristics in regard to an object or activity. The

results are usually compared to specified requirements and standards for

determining whether the item or activity is in line with these targets, often with

a Standard Inspection Procedure in place to ensure consistent checking. Inspections

are usually non-destructive.

Inspections may be a visual inspection or involve sensing technologies such

as ultrasonic testing, accomplished with a direct physical presence or remotely such

as a remote visual inspection, and manually or automatically such as an automated

optical inspection.

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HEAT TREATMENT

Heat treatment is the controlled heating and cooling of metals to alter their physical

and mechanical properties without changing the product shape. Heat treatment is

sometimes done inadvertently due to manufacturing processes that either heat or

cool the metal such as welding or forming.

Heat treatment involves the use in heating or chilling, normally to extreme

temperature, to achieve a desired temperature such as hardening or softening of a

material. Heat treatment techniques include

Annealing

Case hardening

Precipitation strengthening

Tempering

Normalizing &

Quenching

In this process, various furnaces are used:

1. Semi muffle gas furnace:

Carburizing temp:950 to 1000 degree Celsius

Hardening temp:750 to 800 degree Celsius

Annealing temp: 600 to 650 degree Celsius.

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2. Sol bath furnace:

Hardening temp: 1000 degree Celsius.

3. Electric super furnace:

This furnace is used for precision making. Hardening temp is 850 to 1300

degree Celsius.

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Other instrument used in this section:

Tempering machine(temp:150 to 550 degree celsius)

Arban press machine

Job quenching tank(for cooling the job by water,oil,air)

Hardness tester machine

Grinding machine &

Tool box.

Carburizing compound:

Coal (58%)

Mineral coalter (25%)

Sodium carbonate (2%)

Barium arbonate (15%)&

Blackstrap molasses.

Carburizing compound is arranged layer by layer with job and placed in the furnace.

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Protective coating

An industrial coating is a paint or coating defined by its protective, rather than its

aesthetic properties, although it can provide both.

The most common use of industrial coatings is for corrosion control of steel

structures such as offshore platforms, bridges and underground pipelines. Other

functions include intumescent coatings for fire resistance. The most common

polymers used in industrial coatings are polyurethane, epoxy and moisture-cure

urethane. Another highly common polymer used in industrial coating is

a fluoropolymer. There are many types of industrial coatings including inorganic zinc,

phosphate, and Xylan and PVD coatings.

A typical coating system may include a primer, an intermediate coat, and a top coat.

The 4 main stages of a three coat system is given below:

Abrasive Blasting: This roughens and cleans the surface and prepares the

surfaces for Primer.

Primer: This wets the substrate, creating a base for the Intermediate coat. These

primers can consist of Inorganic Zinc Silicate, Epoxy Zinc or even general Epoxy

Polyamide

Intermediate: Provides system thickness build, and prevents permeability.

Intermediates can consist of general Epoxy Polyamide, amongst others.

Top coat: Provides Chemical Resistance and adds aesthetic value to the

surface.

In BITAC, there are five types of coatings

Hard chrome plating (1 hour working time)

Nickel plating (10 hour working time)

Copper plating (2-3 days working time)

Zinc plating (1 hour working time) &

Bright chrome plating

Tools used for protective coating:

Polishing machine

Hard chrome plating tank

Chemical filter machine

Rectifier machine

Hot water tank

Nickel plating tank

Copper plating tank &

Bright chrome plating tank.

All protective coating procedures are same. So, here nickel plating with bright

chrome plating is described.

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A flow chart is given below:

Job Finishing Polishing

Chalk powder

Binding one head of

the job by copper

wire

To clean the job by

using calcium

carbonate

Wash out by water

The job will be binding by

the wire in the middle

position of the nickel

chemical tank

Anode will be fitted

both side of the job

Supply the current

through the rectifier

Keep it for 10-12

minutes

Increase or decrease

the voltage

according to the job

Off the current

supply after 10-12

minutes

Take of job & wash

out by hot water

Wiping the job by

dry cloths

Polishing the job for

brightness

To remove radish color,

bright chrome plating is

used for 2-3 minutes

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Moulding & CNC Machine

MOULDING:

Pantrograph milling machine:

A pantograph is a mechanical linkage connected in a manner based on

parallelograms so that the movement of one pen, in tracing an image, produces

identical movements in a second pen. If a line drawing is traced by the first point, an

identical, enlarged, or miniaturized copy will be drawn by a pen fixed to the other.

Using the same principle, different kinds of pantographs are used for other forms of

duplication in areas such as sculpture, minting, engraving and milling

FIG: Pantograph milling machine

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Uses of pantograph

Drafting

The original use of the pantograph was for copying and scaling and line

drawings. Modern versions are sold as toys.

sculpture and minting

Acoustic cylinder duplication

Medal

Monograms, seals

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Computerised numerical controlled Machine (CNC)

Milling is the machining process of using rotary cutters to remove material from a

work piece advancing in a direction at an angle with the axis of the tool. It covers a

wide variety of different operations and machines, on scales from small individual

parts to large, heavy-duty gang milling operations. It is one of the most commonly

used processes in industry and machine shops today for machining parts to precise

sizes and shapes

CNC wire cut EDM

The tool electrode in wire EDM is simply a wire. In wire electrical discharge

machining (WEDM), also known as wire-cut EDM and wire cutting, a thin single-

strand metal wire, usually brass

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FIG: CNC wire cut EDM

Die sink EDM

The wire-cut process uses water as its dielectric fluid, controlling its resistivity and

other electrical properties with filters and deionizer units. The water flushes the cut

debris away from the cutting zone. Flushing is an important factor in determining the

maximum feed rate for a given material thickness. Along with tighter tolerances, multi

axis EDM wire-cutting machining centres have added features such as multi heads

for cutting two parts at the same time, controls for preventing wire breakage,

automatic self-threading features in case of wire breakage, and programmable

machining strategies to optimize the operation.

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FOUNDRY

List of furnaces of foundry in BITAC:

1. Cupolas

2. Tilt furnace

3. Pit furnace

4. Electric furnace

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Cupolas

Parts: Air door, slug gate, metal gate, charging door,

Mainly used for Cast iron. The mixture of iron, coke, lime and a little alloying element

are used as charge.

Crucible Furnace

Crucible furnace is also known as pit furnace. Crucible is mainly a pot which is kept

inside the furnace with metal inside it and by using gas as fuel desirous amount of

heat is produced to melt the metal.

Tilt Furnace

Mainly a type of crucible furnace which has a benefit of tilting the crucible so that

molten metal can easily take out from the furnace

Electrical Furnace

The main benefit of an electric furnace is here we can produce exact degree of

temperature that is needed in foundry. So, perfect temperature for the work can be

produced. The main difference with other furnace is there have a coil around the pot

where metal is kept. That coil passes the electricity through it and heated the pot to

its required temperature.

Mold Sand Mixture:

sand 90%

sodium silicate gel 7%

saw dust 1.5%

coal dust 1.5%

Coal dust is mainly used for cleaning purpose. In nonferrous alloys coal dust is

avoided as in creates blow hole inside the mold during casting.

Mold coat r used inside the cavity of mold.

Partisan sand is used in between cope and drag parts.

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FIG: process of foundry

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PATTERN

A pattern is a shaped form of wood or metal around which sand is packed in the

mold. When the pattern is removed the resulting cavity is the exact shape of the

object to be cast.

The pattern must be designed to be easily removed without damage to the mold. It

must be accurately dimensioned and durable enough for the use intended. Either

one time use or production runs.

Pattern materials:

Wood - common material because it is easy to work, but it warps

Metal - more expensive to make, but lasts much longer

Plastic - compromise between wood and metal

Types of Pattern

One Piece/Solid Pattern. Used for simple shape low quantity

production. Made of wood and these are expensive.

Split Patterns. Two piece patterns made such that each part forms a

portion of cavity for casting.

Match-plate pattern. Two piece constructed by securing each half on

the opposite sides of a single plate.

Cope & Drag Pattern. Two piece constructed by securing each half on

the cope and Drag

For making a pattern, we need various tools. They are given bellow;

Steel tape

Steel roll

Cut pencil

Eraser

Scriber

Tri-square

Hand jaw

Hand planer

Scissor

Divider

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Inset and outset calipers

Wooden file

Steel and wooden clamp

Spoke shape

In pattern shop we saw many machines for making pattern. They are described

below;

Wood jigsaw machine:

A jigsaw power tool is a jigsaw made up of an electric motor and a reciprocating

saw blade. A jigsaw with a bevel function on the sole plate allows cutting angles of

typically up to 45 degrees relative to the normal vertical stroke for cutting miter joints.

In the past, what are now usually called scroll saws were often referred to as jig saw.

A power jigsaw may also be referred to, by some manufacturers, as a "bayonet saw"

or sabre saw

Wood turning lathe:

Woodturning is a form of woodworking that is used to create wooden objects on

a lathe. Woodturning differs from most other forms of woodworking in that

the wood is moving while a stationary tool is used to cut and shape it. Many intricate

shapes and designs can be made by turning wood. There are two distinct methods

of turning wood: spindle turning and bowl or faceplate turning. Their key difference is

in the orientation of the wood grain, relative to the axis of the lathe.

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Band saw machine

A band saw is a power tool which uses a blade consisting of a continuous band

of metal with teeth along one edge to cut various work pieces. The band usually

rides on two wheels rotating in the same plane, although some band saws may have

three or four wheels. Band sawing produces uniform cutting action as a result of an

evenly distributed tooth load. Band saws are used for woodworking, metalworking, or

for cutting a variety of other materials. They are particularly useful for cutting

irregular or curved shapes, but can make straight cuts. The minimum radius of a

curve that can be cut on a particular saw is determined by the width of the band and

its kerf.

Wood jointer machine

A jointer is a woodworking machine used to produce a flat surface along a board's

length. The jointer derives its name from its primary function of producing flat edges

on boards prior to joining them edge-to-edge to produce wider boards. The use of

this term probably arises from the name of a type of hand plane, the jointer plane,

which is also used primarily for this purpose

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Mortiser machine

A mortiser or morticer is a specialized woodworking machine used to cut square or

rectangular holes in a piece oflumber(timber), such as a mortise in a mortise and

tenon joint.

Bobbin sander machine

This is also known as inside finishing machine. The inside portion of the pattern have

to be finished for making the best quality mold to get the accurate job we want to

produce.

Design Considerations of a Pattern

Shrinkage allowance. Pattern must be slightly larger, generally 2%,

exact amount depend upon the material being used.

Draft. Friction, horizontal movement during removal may damage the

mold.

Machining allowance. Depends on the casting process and mold

material.

Core Allowance. If a core is used, it must compensate shrinkage.

Distortion Allowance. Irregular shape

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