MANUAL

Prepared by Dr. Mike Munro

Modified by Dr. Michel Nganbe

MCG 4328 - Manufacturing

Laboratory

Laboratory work is an essential part of a mechanical engineering education; therefore,

MCG 4328 includes six laboratory experiment sessions covering processes in the fields of bulk
deformation, sheet forming, casting and machining. Since the experiments in MCG 4328 are
coordinated with the design project in MCG 4322, all students will work in the same groups as
MCG 4322 with only few justified exceptions. Obviously, each student should prepare in
advance. Laboratory reports will be submitted by groups. The location for each laboratory session
is given prior to each experiment. Available dates and times for the experiments will be
communicated and posted on virtual campus. You may choose the lab period that best suits your
schedule; a group that fails to choose a time period by the deadline will be assigned the
remaining available periods.

LABORATORY SAFETY AND FIRE PRECAUTIONS

Each student must conduct himself/herself in a manner that ensures the safety of all
individuals in the laboratory. Because of the nature of laboratory work, some moving parts are
unguarded. Avoid loose clothing such as loose coats, long shirt sleeves, ties and long, loose hair
that mat be caught and drawn into the machinery. Students must not handle any switches, valves
or other parts of the undergraduate laboratory equipment unless instructed by the demonstrator.
Students must not handle any research apparatus in the same area.

Any accident including chemical spills, however slight, must be reported immediately to
Dr. Nganbe, Mr. Perrins or the demonstrator

Smoking is not permitted in Colonel By Hall. Since flammable materials are kept in some
of the laboratories, this rule is of even greater importance during the undergraduate laboratory
periods. In the case of a fire, the student’s first duty is to leave the building through the nearest
safe exit and move away from the building so as not to interfere with the fire fighters. Students
should know the location of the nearest fire exits, fire alarms and fire extinguishers.
All assignments, laboratory reports and log books are to be submitted by the due date.

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 LABORATORY LOG BOOKS

Each student is required to keep a log book in order to provide a proper record of each
experiment. You may use your previous log books from other courses, but not your previous one
for the same course if you are repeating. The primary purpose of the log book is to record
data (expected values and experimental values) and sample calculations. The expected
values information must be written in the logbook or photocopies can be used if they are
securely attached to the logbook pages by glue (not stapled, not taped). Complete
calculations, discussion and conclusions will be given in the lab report.

Use of Log Books

Before the laboratory session:

-students are to read the text in this manual for the assigned experiments and prepare the
log books before attending the laboratory sessions.
-record expected values (for example, results from reference books, etc.) that are not
included in the laboratory manual.
At the beginning of the laboratory session, the demonstrator will initial all work
prepared before the laboratory session

During the laboratory session:

-record experimental data
-record sample calculations during the lab session. The sample calculations should
include one of each type required for a laboratory report. The purpose of these
calculations is to help verify that all the necessary information has been recorded
(including proper units) and to compare the results with the expected values that you
have obtained from reference texts. This gives you an opportunity during the lab period
to re-measure your values, if they are not similar to the expected values.
-record experimental procedures, special techniques, sources of experimental error and
demonstrator comments not included in the laboratory manual
At the end of the laboratory session, the demonstrator will initial all pages
completed during the laboratory session

After the laboratory session:

-complete the sample calculations, if necessary.

Grading of Log Book

Log books are to be submitted with the last lab report. They will be graded and will represent
20% of the total labs grad. Grading of the log books will be done as follows:

- Preparation (expected values; drawings, sketches; etc.) 6%

- Completeness and presentation (data for all labs; etc.) 6%
- Evaluation and discussion (drawings; sketches; calculations; evaluation; discussion; etc.) 8%

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 MCG 4328

Laboratory Experiment No. 1: Bulk Deformation Processes

Laboratory Experiment: True Stress-True Strain Curve for a Highly Deformable Steel
(Room D05)

Purpose: For forging, rolling, extrusion and drawing an accurate value of true stress is required
in order to calculate the capacity of the appropriate forming equipment. This is the
most critical aspect in bulk deformation processes. Therefore, this experiment will
illustrate the preparation of a true stress-true strain curve from a standard tensile test.

Equipment: Instron screw or servo-hydraulic testing machine

Low carbon (1018 or 1020) annealed steel tensile specimen
Instron materials testing software or LabView data acquistion unit
Digital caliper

References: Text book-chap. 2 and MCG 4328 course notes

Procedure:
1. Measure the appropriate dimensions of the tensile specimen.

2. The lab demonstrator will conduct the tensile test.

3. Crosshead displacement and matching load data will be available in a text file. Please bring a
flash/USB card to record your data.

4. Prepare an engineering stress-engineering strain curve for your test using the load versus
elongation data from the experimental test.

5. Determine estimates of the true stress-true strain behaviour of the material:

(a) - Calculate K (strength constant) and n (strain hardening exponent) at ultimate tensile
strength.
- Calculate the actual true strain at failure from measurements of the specimen
- Plot the true stress-true strain curve for your tensile test (Figure A) using the
relationship:

σT = KεnT

(b) - Correct the curve (see Figure 2.5 of your Kalpakjian text book) by applying the stress
correction factor shown in Figure 1. Also plot this curve in Figure A.

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 (c)- Calculate K and n using a log-log plot of the true stress and true strain values using the
engineering stress and strain values between the yield point and the ultimate tensile
strength. (Do not plot a true stress-true strain curve). Correct the true stress values (see
Figure 2.5 of your Kalpakjian text book) by applying the stress correction factor shown in
Figure 1:

(d) Using the corrected true stress values and true strain values from (c) determine revised
values for K and n (again use the log-log plotting method). Plot the corrected curve from
(b) and the curve from this step (i.e. using the revised K and n values) in Figure B.

(e) Calculate the actual true stress at failure based on actual load and cross-sectional area at
failure. Compare the predicted true stresses from methods (b) ‘corrected’ (Figure A) and
(d) ‘revised’ (Figure B) with the actual true stress at failure. Which method is more
accurate? Why?

(f) Compare the true stress-true strain curve from the more accurate method of (e) with the
engineering stress-engineering strain curve from step 4. (Figure C).

(g) Compare the values for K and n for the more accurate method of (e) with reference
values (from text/hand books; standards, etc…).

Laboratory Report
-one report is to be submitted per group
-for this laboratory experiment report the experimental results, experimental calculations,
discussion of results and conclusions.

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 MCG 4328

Laboratory Experiment No. 2a and 2b: Sheet Forming Processes

Laboratory Experiment 2a: Deep Drawing and 2b: Stretch Forming

Purpose: Sheet forming processes include bending, rolling, stretch forming and deep drawing.
Lab. 2a will illustrate the deep drawing of a circular cup. Deep drawing is particularly
sensitive to grain orientation as found in cold-rolled thin sheet. For this reason, the
normal anisotropy of the steel sheet material will be determined. Lab 2b will illustrate
the stretch forming of a thin plate. Both processes are often found in complex sheet
formed parts (automotive fenders, oil pans, air filters, etc.)..

Equipment:
Tensile testing equipment
Low carbon annealed steel tensile specimens cut from cold-rolled sheet (0̊, 45̊ and 90̊
to roll direction of sheet).
0̊ 45̊ 90̊
______ ______ ______

Low carbon annealed steel circular blanks (with etched 2.54 mm. dia. circles.)
Deep drawing/stretch forming apparatus
Digital caliper, digital micrometer

References: Kalpakjian text book - Chapter 16 and MCG 4328 course notes

Procedure:
Lab 2a: DEEP DRAWING LAB
Tensile Testing (Room D05)
1. Measure a single width and thickness at the centre of the gauge sections of the three steel
tensile specimens using the digital micrometer. Mark the location of the measurements.
2. Determine the required extension of gauge section to achieve elongations of 20% (in the gauge
sections of 125 mm length)
3. The demonstrator will test the three specimens according to your instructions in 2.
4. Determine the three normal anisotropy values and the average anisotropy. Since the cross-
section of the strained specimens is curved, take care in measuring the thickness (all
measurements should be at the previously marked location). Based on the average normal
anisotropy value obtained, what type of steel was used for the specimens? Hint: see Tables in
Kalpakjian text book - Chapter 16. Why is this type of steel used for sheet forming operations?
5. Determine the limiting draw ratio for this material.

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Cup Forming (Room E010)
6. Compare the limiting draw ratio with the draw ratio of the deep drawing apparatus.
7. With the assistance of the demonstrator, perform the deep drawing test
8. Section the cup. Remove burrs with a file. Measure using the caliper the thickness variation at
bottom, wall and flange of the cup and comment on these values as compared to the original
sheet thickness.
9. Comment on other features of the deep drawn cup (for example, evidence of wrinkling,
evidence of directionality in the material, formation of ears, etc.)

Lab. 2b: STRETCH FORMING

Stretch Forming of Disk (Room E010)

1. The demonstrator will install the hemispherical ball at the end of the punch. Spread a small
amount of oil on the bottom (non-etched surface) of the blank. Place the etched blank in the die
with the etched pattern facing up.
2. Deform the steel blank with the hemispherical ball until a tear appears in the steel blank.
3. Using the clear plastic measuring tape (supplied) determine the major and minor engineering
strains at one or, if possible, both ends of the tear. Compare your results with the Forming-limit
Diagrams (FLD) in the Kalpakjian text book - Chapter 16.
4. Select an ellipse close to the tear (but not connected to the tear) and measure the major and
minor engineering strains. Compare this result with the FLD in the Kalpakjian text book -
Chapter 16.
5. Measure the major and minor diameters for at least 10 ellipses/circles across a diameter of the
formed blank. Based on the areas of an ellipse and circle and assuming constant material volume,
predict the thickness distribution across the diameter.
6. Section the cup along the selected diameter. Remove the burrs with a file. Measure the actual
thickness variation across the diameter of the formed blank using the digital caliper and compare
with the predicted values.

Laboratory Report
-Only one report is to be submitted for both lab 2a and lab 2b
-for this laboratory experiment report the experimental results, experimental calculations,
discussion of results and conclusions.

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 MCG 4328
Laboratory Experiment No. 3a and 3b: Casting

Purpose: The main purpose is to design and experimentally evaluate the casting set-up for a part
that is similar in shape to one of the parts that will be used in your group’s CAD/CAM project. It
is not required that the part be a scaled version of your final CAD/CAM design. It should though
have all the features of your design. A second purpose is to evaluate the use of the ‘lost foam’
casting process for prototype designs.
NOTE: THE MAXIMUM VOLUME OF THE STYROFOAM PATTERN CANNOT
EXCEED 300 CM3. (INCLUDING POURING CUP, SPRUE, RUNNER AND RISER).
THE MAXIMUM LENGTH OF THE PART (INCLUDING SPRUE, RUNNER AND
RISER) IS 200 MM.

Equipment and supplies:

Styrofoam in the following cross-sections:
- 10 mm x 75 mm, 15 mm x 75 mm and 20 mm x 75 mm
- 20, 30 and 40 mm dia.
Styrofoam pouring cups
Utility knife, coping saw, sandpaper and masking tape
Ceramic coating (water based, air dry)
Thermoplastic glue gun
Dry sand and flask
Aluminum alloy @ approx. 750̊C
Digital caliper

Procedure:
Lab. 3a: FIRST CASTING LAB
1. Prepare a report in your log book giving a drawing (sketch is acceptable) showing the casting
set-up (including part orientation, location of sprue, runner and riser, if required) for the part
that you plan to cast. Indicate the solidification times on the drawing (sketch) for the
standard sections that you have selected. Because priority is given to allowing styrofoam gases
to escape, some of the corrective measures discussed in the Casting Design Procedure
section in lecture notes cannot be applied during the casting lab experiment. Therefore, you
should indicate on the drawing the major visible and hidden defects that you expect to

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 occur. The explanations for these possible defects will be given in the lab report. Submit one
logbook per group by Friday before the lab by 2:00 PM. The casting set-up will be
reviewed and returned on the lab day. The purpose of the review is to correct any obvious
errors in the set-up.
Hints:
- try to orient the part vertically so the styrofoam gases can escape during the pouring of the
molten aluminum.
- the sprue is often connected directly to the component without the use of a runner.
- avoid long, horizontal passageways
- all passageways should be at least 1.5 cm. in diameter or width in order to permit the styrofoam
gases to escape
- you may shorten the height of the pouring cup to obtain a large bottom diameter.
- You may use vents to allow gases from the burning styrofoam to escape
- sand the molded styrofoam surfaces for better adhesion of the ceramic coating

2. Fabricate the pattern using the styrofoam materials provided. Join the pieces of styrofoam
together using the thermoplastic glue gun. It may be possible to produce your styrofoam
pattern by CAM. Any surface defects in the styrofoam will be reproduced in the final part.
3. Measure using the caliper a dimension of the styrofoam pattern that can be used to determine
the % linear shrinkage.
4. Coat the pattern with the ceramic coating and allow to air dry (the workshop staff may do this
for you).

Lab. 3b: SECOND AND THIRD CASTING LAB

5. Place the ceramic-coated styrofoam pattern in the flask and fill with dry sand. (E010)
6. Cast using molten aluminum @ approx. 750 ̊C. One member of the group will do the actual
casting. It is imperative that all members of the group follow the instructions of the
demonstrator when in the casting area. (E012)

7. Recover the cast after solidification is complete.

8. Determine the % linear shrinkage. Compare with published value(s)
9. Mark the casting for saw cuts through regions where hidden defects might occur
10. The casting will be sectioned by the machine shop staff using a bandsaw. (E012)
11. Inspect the sectioned casting for hidden defects.

Laboratory Report
-one report is to be submitted per group (Only one report for all 3 casting lab sessions)
The report consists of:
-the actual casting set-up used. (Also correct your log books, if necessary). If there were no
modifications to your original report, then simply photocopy the pages from the log book.
Discuss major defects under the following topics:
a) major hidden and visible defects that you expected to occur but that did not occur. Why do you
think these expected defects did not occur?
b) major hidden and visible defects that did occur. Give details of what you would do if you were

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to cast the part a second time to prevent these major defect(s) from occurring.
c) other major defects that you could cause to occur. Explain how you would cause these major
defects to occur.

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 MCG 4328

Laboratory Practice No. 4: Machining (Room E010 and E012)

Purpose:
The main purpose of this laboratory is to give you some practical experience in
machining. You will either machine the teeth of a spur gear on a milling machine or machine a
V-shaped or ACME thread on a lathe. You will gain some appreciation and “feeling” for
machining operations.

Equipment and Supplies:

Gear blank (annealed low carbon leaded steel)
Threading rod blanks (aluminum)
Gear form cutter (14.5̊ pressure angle, diametral pitch of 16)
Dividing head with three jaw chuck or horizontal collet index (milling machine
operation)
60̊ and ACME tool bits (lathe operation)

Procedure:

1. Report to the machine shop at the assigned time.

2. You will have up to 20 minutes to machine your part.
3. You may keep your machined part.

NOTE: IT IS MANDATORY THAT YOU:

1. WEAR A FULL FACE MASK OR GOGGLES WHILE MACHINING
2. OBEY THE INSTRUCTIONS OF THE MACHINIST
3. DO NOT WEAR LOOSE CLOTHING; COVER LONG HAIR!
4. DO NOT TOUCH ANY OTHER OBJECTS IN THE SHOPS

Laboratory Report
- one report is to be submitted per group
- for this laboratory, discuss the impact of machining parameters such as cutting tool, cutting
speed and lubricant. Discuss potential heat evolution, tool life, chip form and flow, and any other
observations you may make during the lab.

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