GITM (Gurgaon Institute of Technology & Management) 2 km from Bilaspur Chowk on Bilaspur-Tauru road in Gurgaon is the best engineering college and Lead of “Gurgaon Group of Institutions”. It is also one of the best B-school.

Gurgaon Group of Institutions has engineering colleges as:

●       Gurgaon Institute of Technology & Management

●       Gurgaon college of Engineering

●       GITM institute of Technology

●       Gurgaon college of Engineering for women

All the colleges are approved by AICTE and affiliated to MDU, Rohtak.

We have all the branches in these colleges.

I SC Malhotra 69, the eldest and oldest faculty in GITM since 2005 assure the best teaching to the emerging engineering students in our colleges.

Workshop Manual

GURGAON INSTITUTE OF TECHNOLOGY
AND MANAGEMENT
Bilaspur -Tauru Road, Gurgaon




FIRST YEAR: BE
Session 2008-09





WORKSHOP
MANUAL






Name of Student…………………………………………

Branch……………………………………........................

Roll no…………………………………………………….






EXPERIMENT # 1

ME: 107-E

AIM: To study different types measuring tools used in metrology and determine least counts of vernier calipers, micrometers and vernier height gauges.

MATERIAL AND TOOLS REQUIRED:
• Work shop Manual
• Steel Rule
• Vernier caliper
• Micrometer
• Vernier micrometer & height gauge

OPERATIONS INVOLVED:
• Reading of chapter # 2(Bench Work & Fitting) of workshop manual.
• Visualizing different types of clamping, measuring and marking tools in fitting shop
• Understanding the function & method of using the tools and instruments e.g. vernier caliper etc.

PROCEDURE:
1. Vernier Caliper-
Vernier caliper is precision instrument used for measuring fraction of a millimeter. It has two jaws. One jaw is fixed having a rectangular graduated scale in mm & inch, which is called main scale. The other jaw is movable having another graduated scale, which slides along the main scale and called venier scale. The minimum dimension which can be measured is called Least Count of a particular Vernier Caliper, which is the difference of one division of main scale and one division of vernier scale.
Least count calculation of the vernier scale:
In vernier caliper, which we used-
50 division of vernier scale are equal & coincide with 49 division of main scale and one division of main scale is 1 mm.
Therefore one div of vernier scale is = 49/ 50 mm.
So LC = 1 msd - 1vsd = (1 – 49/ 50) mm = 1/ 50 mm= 0.02 mm.
2. Micrometer:
The U type frame of micrometer is made of cast steel. Its anvil is of HCS and spindle is made of MCS.
Least Count = Pitch of Lead screw/ no of div on thimble (vernier scale on cap)
= 0.5 mm/ 50 = 0.01 mm




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3. Vernier Micrometer:
To measure more precise dimension with accuracy, a vernier micrometer is used. It consists of a third scale around the hub and provided 10 parallel lines on thimble.
Least Count:
One vsd =1/10x9/ 1000 cm=9/ 10,000 cm
LC=1msd-1vsd= 1/1000-9/10,000 cm= 1/10,000 cm=1/ 1000 mm=0.001 mm.

4. Vernier Height Gauge:
It is used for measuring the height of the parts, scribing the lines at height or for marking purposes. It consists of a vertical bar mounted on a heavy base. A sliding head with pointer is carried on the vertical bar. The bar and head are graduated. It is always used by placing it on the surface plate. The base is of cast iron and beam is of SS. The least count is generally 0.02 mm or 0.001”.

OBSERVATIONS: We have observed that the work can be done with a great accuracy in the work shops with these precise instruments.

RESULT: What we have measured is as follows:

Final reading:
:
1.On vernier caliper




2. On micrometer




3. On height gauge




SAFETY PRECAUTIONS:
• Before using the precise instruments, one should know the method of using as well as the function of each part.
• The error of the instrument must be calculated and noted.
• The error must be added in the final reading.
• The instruments must be kept carefully in their respective boxes.


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EXPERIMENT # 2

ME: 107-E

AIM: To study different types of machine tools (lathe, shaper, planer, milling and drilling machines)

INTRODUCTION:
A machine, which performs an operation of material removal with tools to produce desired shape and size of the work piece, is known as Machine Tool. The various types of machine tools commonly used in a workshop are:
1. Lathe Machine
2. Shaper Machine
3. Planer Machine
4. Milling Machine
5. Drilling Machine

1. LATHE MACHINE
The lathe probably one of the earliest machine tools, is one of the most versatile and widely used machine tool, so also known has mother machine tool.

Types of Lathe
• Speed Lathe
• Engine or Centre Lathe
• Bench Lathe
• Tool Room Lathe
• Automatic Lathe
• Special Purpose Lathe

Principal Parts of Lathe
a) Bed: -
It is the base or foundation of the lathe. It is heavy rugged and single piece casting made to support the working parts of the lathe.
b) Head Stock: -
The head stock is permanently fastened on the inner ways at the left side of the bed.
c) Tail Stock:-
It is situated at the right hand end of the bed is mounted on the inner guide ways.
d) Carriage:-
The carriage controls and supports the cutting tool. It has five major parts-
• Saddle- It is an H-shaped casting mounted on the top of the lathe ways so it slides along the ways between the headstock and tailstock.



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• Cross slide- It is mounted on the saddle. It supports the compound rest.
• Compound rest- It is mounted on the top of the cross-slide and is used to support the cutting tool. It can be swiveled to any angle for taper turning operations.
• Tool post- It is mounted above the compound rest. It clamps the cutting tool or cutting tool holder in a desired position.
• Apron- It is fastened to the saddle and contains the feeding mechanism. The apron hand wheel can be turned by hand to move the carriage along the bed of the lathe.

Lathe Accessories
The devices, which are used, for holding and supporting the work and the tool on the lathe are called the lathe accessories. The various lathe accessories are as follow:
Chucks:
These are used for holding and rotating the work-piece in head stock of a lathe.
• Three jaw universal chuck- This chuck is self centering and called scroll chuck. It is used to hold round and hexagonal work because centering is not needed.
• Four jaw chuck- It has four reversible jaws, each of which may be independently adjusted to accommodate the work, so It is used for prismatic parts (i.e. square, round or irregular shape)
Centres
The lathe centre is a hardened steel device with a taper shank on one end and sixty degree point on the other end. The taper shank fits in the headstock and tailstock.
Drive plate (catch plate)
It is plain disc of cast iron or steel, which is bored out and threaded so that it can be attached to a spindle nose.
Face Plate
It is similar to the drive plate except that it is larger in diameter. It has open and T-slots and can be used to clamp the work of complicated shape and size.
Lathe dog or carrier
It is attached to the work-piece to be turned between the centres or placed on mandrel. These are straight tail type or bent tail type.
Mandrel
It is hardened and tempered steel shaft, which is used to hold the hollow work-piece for machining the external surfaces.
Rests
When a very long job is to be turned between centres, the work is supported at some intermediate points between the centres to avoid sagging o the job due to its own weight.




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Cutting Tool Materials
• Carbon Steels
• Medium alloy steels
• High speed steels
• Satellites
• Cemented carbides
• Ceramics
• Diamonds
• Abrasives aluminium oxide

Lathe Tools
The tool used in a lathe for general purpose work are single point cutting tools in turning, facing, chamfering, threading, etc. But multipoint cutting point tool are used in drilling, knurling, etc. The tool depending upon the nature of operation done by the tool, are classified as follow:
• Turning tool
• Facing tool
• Chamfering tool
• Form or profile too
• Parting or necking tool
• External threading tool
• Internal threading tool
• Boring tool
• Knurling tool

Lathe operations:-
The most common operations which can be performed on a lathe are centering, facing, plain turning, step turning, taper turning, drilling, reaming, boring, under cutting, threading, and knurling.

Terms Used in Lathe Machine
• Cutting Speed
It is defined as the speed at which the metal is removed be the tool from the work-piece. It is usually expressed in m/minute.
• Feed
It is defined as the distance, which the tool advances (axially) for each revolution of work. It is usually expressed in mm.
• Depth of Cut
It is defined as the depth of penetration of the tool into the work-piece during machining. It is usually expressed in mm.
Feed Mechanism:
the movement of the tool relative to the work is termed as feed. Lathe tools way have three types of feed
• Longitudinal Feed-When tool moves parallel to the work towards or away from the headstock.

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• Cross Feed- When tool moves perpendicular to the work towards or away from the operator.
• Angular Feed-When the tool moves at an angle to the work. It is obtained by swiveling the compound slide.

SAFETY PRECAUTIONS:-
• Use hand powers only when putting on or removing chuck or face plate.
• Do not shift or change gears while lathe is running.
• Stand erect. This keeps the head away from the flying chips.
• Choose or adjust proper depth of cut.
• While working on a lathe, use goggles.

2. SHAPER MACHINE

INTRODUCTION:
It is a reciprocating type of machine tool in which the ram moves the cutting tool backward and forward in a straight line to generate the flat surface. The flat surface may be horizontal, inclined or vertical.

Principal parts of a shaper machine:
a) Base: -
It is a heavy and robust cast iron body which acts as a support for all other parts of the machine which are mounted over it.
b) Column (body):-
It is a box types iron body mounted upon the base. It acts as housing for the operating mechanism of the machine cross rail and ram.
c) Cross Rail:-
It is a heavy cast iron construction, attached to the column at its front on the vertical guide way.
d) Table:-
It is made of cast iron and used for holding the work piece. T slots are provided on its top and sides for securing the work on to it.
It then slides along the cross-rail to provide feed to the work-piece.

Classifications of Shaper
• According to the ram driving machine
a) Crank shaper
b) Geared shaper
c) Hydraulic shaper
• According to the position and travel of ram
a) Horizontal shaper
b) Vertical shaper
c) Travelling head shaper



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• According to the direction of cutting stroke
a) Push cut shaper
b) Draw cut shaper
• According to the design of the table
a) Standard or plane shaper
b) Universal shaper

Specifications of a shaper
• Maximum length of stroke
• Maximum horizontal travel of a table
• Maximum vertical travel of table
• Size of the table i.e. length, width and depth of the table.
• Maximum vertical travel of tool slide
• Power of the drive motor in H.P
• Maximum no. of strokes per minute
• Type of quick return mechanism
• Floor space required
• Weight

SAFETY PRECAUTIONS
1. After setting the stroke length and position, see that the adjusting nuts are light.
2. Use goggles while working
3. Never remove chips while ram is in motion
4. All ways maintain the parallel clean
5. Remove all the tools from the table after use

3. PLANER MACHINE

INTRODUCTION:
Planer is used to produce plane and flat surfaces by a single point cutting tool, when the work piece is very large in size. It is similar to shaper but its size is very large, so used for producing flat surfaces on much larger work than a shaper. The major difference between shaper and planer is that in a planer, the tool remains stationary and the work reciprocates whereas in the shaper, the work remains stationary and the tool reciprocates.

Types Of Planers
• Standard or double housing planer
• Open side planer.
• Pit planer.
• Edge or plate planer.
• Divided table planer.
• Among all the above types of planers, the standard or double housing planer is
Commonly used.


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Principal Parts of a planer
• Bed
• Table
• Housing or columns
• Cross rail
• Tool heads

Size and specifications of a planer
• Width of the table in mm.
• Maximum distance of the table to the cross rail in metres.
• Maximum stroke of the table in mm.
In addition to the above planer size, the following particulars are necessary to specify the planer.
• Length of bed
• Length of table
• Type of drive
• Power of the motor
• Number of speed and feed

Work holding devices
The following work holding devices are used
• Vices
• Clamps
• T-Bolts
• Stops
• Stop blocks
• Planer jacks
• V- Blocks etc.

Operation Performed on Planer
• Machining horizontal flat surfaces
• Machining vertical flat surfaces
• Machining angular surfaces, including dovetails
• Machining different types of slots and grooves
• Machining curved surfaces
• Machining along contours

SAFETY PRECAUTIONS
1. After the work is fastened, check that it clears the cross rails.
2. Ensure that the work holding devices are in proper place and properly clamped.
3. Keep planer idle while adjusting length of bed stroke and speed of machine to suit work.
4. Don’t reach over a moving job and never ride the bed or platen.
5. Don't leave any tool between the ways.
.
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4. MILLING MACHINE

INTRODUCTION:
Milling Machine is a machine tool in which metal is removed by means of a revolving cutter with many teeth, each tooth having a cutting edge which removes the metal from the work-piece.

Principal parts of a milling machine
• Base
It is the foundation of the machine upon which all other parts are mounted. It is generally made of grey cast iron to absorb shock and vibration. Some time it also serves as a reservoir for cutting fluid.
• Column
It is the main supporting frame mounted vertically on one side of the base. The motor and other driving mechanisms are contained in it. Its supports and guides the knee in its vertical travel. It carries the jack for elevating the knee.
• Knee
The knee projects from the column ands slides up and down on its face. It supports the saddle and table. It is partially supported by the elevating screw which adjusts its height. It carries the table feed mechanism and controls to feed in longitudinal, cross vertical and rotation etc. by hand power o machine power.
• Saddle
The saddle supports and carries the table and is adjustable transversely on ways on top of the knee. It is provided with graduation for exact movement and can be operated by hand or power.
•Table
The table rests on ways on the saddle and travels longitudinally in a horizontal plane. It supports the work pieces, fixtures etc.
• Over arm
The over-arm is mounted on and guided by the top of the column. It is adjusted in and out by hand to the position of maximum support for the arbor and then clamped.
• Spindle
The spindle is mounted on the upper part of the column. It receives power form the motor through belts, gears clutches etc .and can be rotated at different speeds by the step cone pulley drive or by gearing arrangement and transmits it to arbor or sub-arbor.
• Arbor
The arbor is the extension of the spindle on which all the various cutters are mounted. It is tapered at one end to fit the spindle nose and has two slots to fit the nose keys for locating and driving it.





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Milling Operations: -
• Plain or slag milling
• Face Milling
• Angular or Bevel Milling
• Form Milling
• End Milling
• Milling T- Slots
• Milling key ways, Grooves, slots etc.
• Gear Milling Operation
• Side Milling

SAFETY PRECAUTIONS
1. Make sure that the cutter and arbor are secure.
2. See that the cutter and arbor support clear the work
3. Use the cutters that are correctly ground and in good condition.
4. Check speed and feeds these should be proper.
5. Never reach over a revolving cutter.

5. DRILLING MACHINE

INTRODUCTION:
Drilling machine is a machine tool designed for drilling holes in metallic and nonmetallic materials. The cutting tool is a multipoint cutting tool, known as drill.

Principal Parts of the drilling Machine
• Head
Head contains the electric motor, v-pulleys and belt which transmit rotary motion to the drill spindle at a number of speeds.
• Spindle
Spindle is made up of alloy steel. It rotates as well as moves up and down in a sleeve.
• Drill chuck
It is held at the end of the dill spindle and in turn it holds the dill bit.
• Adjustable Table
It is supported on the column of the drilling machine and can be moved vertically and horizontally. It also carries slots for bolts clamping.
• Base
It supports the column which, in turns supports the table, head etc.
• Column
It is a vertical round or box section, which rests on the base and supports the head and the table.






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Types of drilling machines
• Portable drilling machine
• Bench types drilling machine
• Sensitive drilling machine
• Up right drilling machine
• Radial drilling machine
• Multiple spindle drilling machine
• Deep hole drilling machine
• Gang drilling machine
• Automatic drilling machine

Specifications of a drilling machine
• Drilling capacity
• Transverse of spindle
• Working surfaces of table
• Range of spindle speeds
• Range of power feed per revolution
• Distance between spindle and column
• Motor speed
• Motor power etc.

Drilling Operations:-
• Drilling
• Boring
• Reaming
• Tapping
• Counter Boring
• Spot Facing
• Counter Sinking

SAFETY PRECAUTIONS
1. Always use a correct size drill.
2. Select a proper drill material to suit the hardness of the work material.
3. Always maintain the cutting speed with in the permissible range.
4. Don’t wear loose clothing.
5. Always use protective eye shields








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EXPERIMENT # 3
ME: 107-E

AIM: To prepare a job on lathe machine involving facing, outside turning, taper turning, step turning, and radius making and parting -off.

MATERIAL AND TOOLS REQUIRED:
• Engineering drawing of the job
• Lathe Machine
• A cylindrical metal piece
• Single point turning tool
• Parting tool
• Steel rule
• Vernier caliper
• Flat file(smooth) ˝
• Spanners
• Emery paper

OPERATIONS INVOLVED:
• Marking
• Facing
• Turning
• Filing
• Finishing
• Parting-off

PROCEDURE:
• A piece of work from cylindrical rod is taken and held in head stock chuck.
• Aligned properly the work-piece in to the chuck.
• Tool is held in tool post tightly.
• Tool is brought near the projected surface of work for facing and 1mm cut is fed.
• Tool is taken back near the outer surface of job and 0.5 mm cut is fed, longitudinally from faced surface to head stock for parallel turning up to the length as per drawing.
• Repeated the same operation for second cut of 0.5 mm and got the required diameter.
• Now under-cut tool is held in the tool post and 1.0 mm cut is provided. Subsequently another cut of 0.5 mm is given to get desired diameter (no-feed ).
• Reversed the job in head stock chuck and same procedure is adopted for facing & parallel turning.
• Now step turning is done by feeding cuts of 0.5 mm until required diameter is obtained as per drawing.
• For taper turning 0.5 mm cuts are given as per taper turning calculation.

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Taper angle (Ø) = tan¯ ( D – d) / 2 L
Where D= Bigger diameter, d= Smaller diameter, L= Axial length of taper portion.

After completing the turning, the turned surfaces are ground nicely by emery paper and the completed job is removed from the chuck.

OBSERVATIONS: We have measured the finished job and found the dimensions are accurate and were within the permissible limit.

RESULT: The job was checked by the workshop instructor and found o.k.

SAFETY PRECAUTIONS IN MACHINE SHOP:
• Before switching ‘ON” power, tailstock, tool holder and job are properly clamped,
• Work is not to be measured or tool is not to be felt, while lathe is running.
• Gears are not to be changed or shifted, while lathe is running.
• We should stand straight, to protect from flying chips.
• To clean the chips, brush is used.
• We use apron and goggles, while working on machine.





















ALL DIMENSIONS ARE IN mm

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EXPERIMENT # 4

ME: 107-E

AIM: To study different types of fitting tools and marking tools used in fitting practice.

INTRODUCTION
The bench work and fitting plays an important role in engineering. Although in today ‘s industries most of the work is done by automatic machines, which produce the jobs with good accuracy, but still it (job) requires some hand operations, called fitting operations. The person working in the fitting shop is called fitter.
The work carried out by hand at the bench is called bench work and fitting is the assembling of parts and sometime removing the metal for assembling. It may or may not be carried out at bench.

FITTING TOOLS
• Clamping tool
• Measuring & marking tool
• Cutting tool
• Striking tool
• Drilling tool
• Threading tool
• Miscellaneous tool

Clamping Tools-The vice is the most common tool used for clamping or holding work. Following are the various types of vices used for different purposes.
• Bench Vice- It is firmly fixed to the bench with the help of nuts and bolts. It consists of a cast iron body & cast iron jaws. One jaw is fixed to the body and the second slides on a square threaded spindle screw with the help of a handle. The vice can be specified on width of the jaw plate and the size of the job, which can be held in the vice.
• Hand Vice
• Pin Vice
• Pipe Vice
• V Block with U clamp

Measuring & marking Tools
• Try Square-It is used for checking square ness of two surfaces, marking the right angles and measuring the straightness of surfaces.
• Surface Plate- It is made of cast iron or graphite and used for testing the flatness, trueness of the surface. It is also used for scribing on the work for marking.

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• Angle Plate- It is made of cast iron in different sizes and has two plain surfaces at right angles.
• Bevel Protractor- It is made of steel and the dial can be rotated around the centre.
• Combination Set-It is multipurpose instrument that can be used as a protector, a level, a centre square and a try square.
• Center Square
• Scriber and Surface Gauge
• Universal Marking Surface Gauge
• Punches- Punches are made of HCS of HSS and used for marking purpose. The dot punches are used for marking dotted lines and centre punch is used to mark the centre before whole drilling.
• Steel Rule
• Vernier Caliper
• Micrometer
• Dial Indicator- It is used for checking the run-out or joviality of the job
• Dividers
• Calipers (outside, inside, spring hermaphrodite, jenny or odd leg caliper)
• Gauges (depth, feeler, radius, thread, wire, vernier height gauge)
Method of marking
• Surface to be marked is coated with paste, chalk or red lead.
• Work (job) is held in holding device e.g. surface plate, V block, angle plate etc.
• Lines are scribed by surface gauge or vernier height gauge.
• The centre on the end of round bar can be located by using odd leg caliper, surface gauge etc.
• Circles and arcs on flat surfaces are marked by divider.
• After scribing work is over, indentations of the markings on the surface are made by punch and hammer.

Cutting Tools-These are used to remove the material from the work piece, which is described below:
•Hacksaw-It consists of a frame made of mild steel. The blade (HCS or HSS) is placed inside the frame and is tightened by fly nut. These are of two types (Fixed and adjustable frame)
•Files-These are multipoint cutting tools and used for removing the material by rubbing on the metal. Files are available in number of sizes, shapes, cuts & grade of coarseness
-Sizes- The length of the files varies from 4 to 14 inches.
-Shapes- The various shapes/ cross-section of files available are flat, triangular, square, round, half round, knife edge, needle etc
-Cuts-Types of cut are single, double and rasp-cut.
-Grade of coarseness- Rough (20 tpi), Bastard (30 tpi), Second cut (40 tpi), smooth file (50 tpi), Dead smooth (100 tpi)


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•Chisels-These are made of HCS and used for chipping away the material from the work piece. Commonly used are flat, cross cut, half round and diamond point.

Striking Tools
Hammers are the only tools for striking in work shops. A hammer consists of a heavy iron body with a wooden handle. The types of hammers generally used are ball Pean, straight Pean and cross Pean in fitting shop.

Drilling Tools
The operations of making round holes in metal pieces are know as drilling. It is done with the help of drilling machine and drills. The operations carried out in drilling are as bellow:
• The job is marked with center punch as center at the hole to be drill
• Job is held properly in the vice.
• Drill is fitted in the chuck.
• With the help of hand lever spindle is lowered such that drill point is exactly over the center marked.
• Motor is now started to rotate the drill and is gently pressed in to the job to produce the desired hole.
For finishing of the drilled holes a reamer is used and counter-sunk holes are made by c’ sunk tool.

Threading Tools- For screwing fastening e.g. nuts & bolts, threads are cut on the surface of the work piece. For making external threads like bolt, we use die as tool with die stock and for internal threads like nuts we use taps as tool. The die and tap can be used up to the limit size. Beyond that we make threads on the lathe machine with threading tool.

Miscellaneous Tools
• Pliers
• Screw driver
• Spanner
• Wrench
• Allen key










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EXPERIMENT # 5

ME: 107-E

AIM: To prepare layout on a metal sheet by making and prepare rectangular tray, pipe-shaped components e.g. funnel.

SHEET METAL WORK

INTRODUCTION
Sheet metal work has its own significance in the engineering work. Many products, which fulfill the household needs, decoration work and various engineering articles are produced from sheet metal. Common examples of sheet metal work are hoopers, canisters, guards, covers, pipes, hoods, funnels, bends, boxes etc. Such articles are found less expensive, lighter in weight and in some cases sheet metal products replace the use of castings or forgings.
.
SHEET METAL TOOLS

1. Rules
• Steel rule-The steel rule (30 cm long) is particularly useful in measuring and laying out small work.
• Folding rule-Folding rule (2 m long) is useful in measuring large work. It can be folded into shorter length pieces.
• Steel tape-It is also used for measuring large work. It is coiled in a small size box.
2. Steel-Square- IT is an L-shaped piece of hardened steel with graduation marks on the edges for measuring. The narrow arm of the square is called the tongue and the wide part is known as body.
3. Straight Edge- IT is a flat bar of steel with a beveled edge. This bar comes in a variety of lengths ranging from 1 metre to 3 metre. It is useful for drawing long lines.
4. Vernier caliper- This is used for measuring the dimensions in fractions. For further detail refer experiment # 1.
5. Micrometer- It is also used for measuring the thickness of metal sheets. For further detail refer experiment # 1.
6. Swinging Blade Protractor- The swinging blade protractor is used in sheet metal work for marking and measuring of angles. It is made of steel.
7. Dividers- The dividers are made with each leg tapered to a needle point. The dividers are of two types. Spring divider and wing divider. The legs of the spring divider are adjusted by turning the knurled nut. The leg adjustment on the wing divider is made by the screw of the wing and the knurled nut on the end of the wing. It is used for drawing circle, arc on sheet metal, transferring the dimensions, or dividing the distances into equal parts.

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8. Trammel Points-The trammel points also called a beam compass consists of two straight, removable legs tapered to needle points and attached to separate heads. These heads slide on the beam and are locked at that place by thumb screws. A special clamp for a pencil can be attached to one of the points. It is used to draw large arcs and circles that are beyond the limit of dividers.
9. Scribers- It is used to scribe or mark line on a metal surface for a variety of purposes. It is a metal worker’s pencil.
10. Punches-Punches are used in sheet metal work for marking and locating centers in a more permanent manner. Various types of punches are:
• Prick punch- It is used to make small marks on layout lines. Point angle is 30º
It is used for punching small holes in thin metal sheets.
• Center punch- It is used to mark the centre of holes to be drilled. Point angle is 90º
• Hollow Punch- It is used for punching holes in the sheets. Inner and outer faces of the punch meet at an angle of 40º
• Hand lever punch- It is used for making holes with punch & die, when a large number of holes to be punched by hand pressure.
11. Chisels-In sheet metal work, cold chisels are used. These are used for cutting thick sheets, rivets, bolts and chipping operations.
12. Snip- It is called hand shear and similar to scissors. It is used to cut thin & soft metal (not more-thicker than 20 gauge). These are straight and curved.
13. Hammers- Hammers are used for forming shapes by hollowing, raising, stretching or throwing off. Various types of hammers are:
• Ball peen hammers- It has a round, slightly curved face and a round head. It is used for general purposes.
• Riveting hammer- It has a square, slightly curved face and used for riveting.
• Setting hammer- It has a square, flat face and a tapered peen with beveled end. Flat face is used for flattening seams, while peen end is used for peening operations.
• Raising hammer- It has oblong flat face with corners slightly rounded off. It is used for raising operations to form saucer, bowl, tray or spoon.
14. Mallets-The mallet may be made from fibre or wood. It is used to strike a soft and light blow in the metal.
15. Pliers- These are used for holding, cutting and bending work. Different types of pliers are available in the market.
16. Stakes- These are the sheet metal anvils used for bending, seaming and forming by using a hammer or mallet. The following are the types of stakes.
• Blow horn stake
• Beak horn stake
• Hollow mandrel stake
• Solid mandrel stake
• Bevel edge stake
• Double seaming stake


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17. Stake Holder- It is used in sheet metal shop and is a rectangular bench plate to accommodate the stakes.
18. Hand Groover- These are also called seam set and is used for grooving a seam by-hand
19. Rivet Set- It is used in riveting operation.
20. Soldering Iron- These are used to join two pieces of thin metal by using solders (alloy of tin & lead).
21. Folding Bars- These are used for bending and folding straight metal pieces.
22. Wire Gauge- This is used to check the diameter of wire or thickness of sheets.

SHEET METAL OPERATIONS
The following are the various sheet metal operations:
Measuring and Marking
Cleaning
Laying out
Cutting and shearing
Bending
Stretch Forming
Deep Drawing
Riveting
Soldering
Hollowing or Blocking
Sinking
Raising
Planishing

• Measuring and Marking
Marking straight lines
Marking circles and arcs
Marking irregular curves
Marking indentation marks
Transferring a pattern
• Cleaning
Sometimes the blank surfaces need proper cleaning before being processed. For leaning pickling process is used. In this process sheets, are immersed in a hot bath of part dilute sulphuric acid and 20 parts water after allowing sufficient time for pickling the tanks are thoroughly washed in a stream of water and then allowed to dry.
• Laying out
While doing the marking of development of the surface of component on the sheet certain material for various allowance are added. Such a layout when made on the sheet is called laying out process.


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Cutting and shearing
-Cutting off
This means severing a piece from a strip with a cut along a single line.
-Parting
Parting signifies that scrap is removed between the pieces to part them
-Blanking
This means cutting a whole piece from sheet matel. Around this piece there is enough scrap left all around this piece. This piece with is cut from the sheet metal is our objective. The sizes of the blank is our requirement and the remaining sheet is scrap
-Punching
Punching is the operation of producing circular holes on a sheet metal by a punch and die. The material punched out is removed as waste and the sheet. Which is having holes is our objective or requirement.
-Piercing
Piercing is similar to punching, circular holes are produced in a sheet where as in piercing holes other than circular are produced in a sheet. The sheet which is having the holes of desired shape is our requirement.
-Slitting
When shearing is conducted between rotary blades, the process is referred to as slitting. It cuts the sheets, which are having larger width than required.
-Nibbling
Nibbling or nibbling is a process of continuous cutting along a contour, which may be a straight line or an irregular profile. The machines used in this operation are known as nibblers, which are portable type shearing machines.
-Trimming
Trimming is the operation of cutting away excess metal in a flange or flash from a piece when holes are produced in a manually, first circular blank is cut with a chisel and hammer. Then fine shape (accurate size) is trimmed with the help of a shear or snip. This operation i.e. cutting snip is called trimming
-Lancing
This makes a cut part way across a strip. So this operation leaves a tab with out removing any material. Sometimes lancing operation means that cut is produced along three sides and the cutting part is bent towards the forth side so in this way opening is created in a box.
-Notching
This is a process of removing metal to the desired shape from the side or edge of a sheet or strip. Some times notching operation is also performed to prevent overlapping of metal where the corners come together. So openings are created at the corners. A very good example is covering a book with a paper. Now suppose paper is sheet metal and the various cutting operations are performed to remove the sheet openings (square notch etc.) that operation is known as notching


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Types of notches are:
Straight notch and Square notch,

The following are some common and important operations performed in sheet metal work.
• Bending
• Stretch forming
• Riveting
• Soldering

Sheet metal joints
• Single hem
• Double hem
• Wired edge
• Seams

Sheet Metal Machines
• Shearing machine
• Folding machine
• Bending machine
• Wiring machine
• Turning machine
• Burring machine
• Double seaming machine





















-21-
EXPERIMENT # 5

ME: 107-E

AIM: To prepare layout on a metal sheet by making and prepare rectangular tray, pipe shaped component e.g. funnel.

MATERIAL AND TOOLS REQUIRED:
• Drawing of the job
• Drawing sheet & drawing instruments
• GI sheet as per drawing spec & size
• Steel rule & scriber
• Try square
• Divider & odd-leg caliper
• Bench vice & stake
• Snips & pliers
• Mallet & hammer
• Soldering iron, solder and flux
• Emery paper

OPERATION INVOLVED
• Pencil drawing of layout (development of surface) for tray and funnel on drawing sheet.
• Cleaning of the GI sheet Supplied
• Measuring & marking
• Cutting and shearing
• Bending
• Stretch forming-conical shape of funnel
• Matching the joint
• Hemming/ seaming
• Soldering
• Finishing

PROCEDURE:
• Drawn development drawing on drawing sheet for the tray and funnel.
• Added bending and joining allowance on seams.
• Marked the layout on the GI sheet, being development drawing as template with the help of steel rule and scriber.
• Marked the lines of bending and bent as required to get the shape of the object.


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• Straightened and cleaned the portion to be joined.
• For tray the joint was soldered.
• For funnel the hem joints were performed with the help of mallet & stakes.

OBSERVATIONS: We understood the importance of sheet metal working that it is less expensive, lighter in weight, and in some cases sheet metal products replace the use of forging & casting. It is widely used in automobile industries e.g. vehicle’s body parts.

RESULT: The job was checked by the workshop instructor and found o.k.

SAFETY PRECAUTION:
• All instructions supplied by the manufacture should be strictly followed.
• Used safety shoes, hand gloves, apron & arm sleeves and goggles if, required.
• The development of surface must be drawn after understanding it thoroughly.
• Joining allowances must be given to get the accurate size of the job.
• Snips are to be used & kept carefully.
• Bending of the sheet should be done after being confirmed, otherwise sheet will be spoiled.
• Soldering iron should be properly heated and should not be touched when hot.
• The surface to be soldered must be cleaned and free from oil & dirt.
• There should be perfect capillary action, while soldering.

















ALL DIMENSIONS ARE IN mm

-23-
EXPERIMENT # 6

ME: 107-E

AIM: To prepare joints for welding suitable for butt and lap welding.

WELDINGA FABRICATION PROCESS

INTRODUCTION
Welding is a process of joining two similar or dissimilar metals by fusion, with or without the application of pressure, with or without use of filler metal. Fusion of the metals takes place by means of heat. Heat is obtained by electric arc, electrical resistance, chemical reaction, gases, friction or radiant energy.

Welding processes can also be divided into the following two groups

Forge or pressure welding (Plastic Welding): In forge or pressure welding, the work pieces are heated to plastic state and then the work pieces are joined together by applying external pressure on them.


























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Fusion or non- pressure welding: In this welding, the material at the joint is heated to a molten state and then allowed to solidify.




























Commonly welded base metals:
Metals can be classified as:
1 .Ferrous
2. Non-Ferrous

Ferrous materials contain iron and these are the most important metals/ alloys in the metallurgical and mechanical industries because of their extensive use.
Ferrous materials which can be used in welding application are:
• Wrought Iron
• Cast Iron
• Alloy Steel
• Stainless Steel
• Carbon Steel (low, medium & high carbon steel)


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Non ferrous materials are those that are not iron based. N.F. materials, which can be used in welding applications, are:
• Aluminium and its alloys
• Copper and its alloys
• Magnesium and its alloys
• Nickel and its alloys
• Zinc and its alloys etc
Advantages of welding
• A good weld is as strong as the base metal.
• A large no. of metals/alloys can be joined by welding.
• Repair by welding is very easy.
• Welding can be easily mechanized.
• Portable welding equipment is available.
• General welding equipment is not very costly.
• Total joining cost is less in case of welding joints.
Disadvantages of welding
• Welding produces the harmful radiation fumes and spatter.
• A skilled welder is required.
• Welding heat produces metallurgical changes.
• Cost of equipments is high.
• Edge preparation is required before welding.
• More safety devices are required.
• Jigs and fixtures are required to hold the parts to be welded.

Applications of welding
• Automobile construction
• Railroad equipment & Ships
• Aircraft construction
• Building construction
• Bridges construction
• Pressure vessels
• Storage tanks
• Piping and pipe lines
• Fabrication of jigs, fixtures and machine tools
• Repair of broken and damaged parts
• House hold furniture
• Material handling equipment

Types of welding joints
• Lap joint
• Butt joint
• Corner joint
• Edge joint
• T- Joint

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Edge Preparation:
In order to obtain sound welded joint, edge preparation is very essential. It consists of beveling the edges .After that cleaning of faces is done. Square, single V, double V, single U, double U are the common types of edge preparation.
Welding Position
• Flat position
• Horizontal position
• Vertical position
• Over Head position
• Inclined position
Gas Welding:
Gas welding also called an oxy- fuel gas welding, derives the heat from the combustion of a fuel gas such as acetylene in combination with oxygen. The process is a fusion welding process wherein joint is completely melted to obtain the fusion.
Gas Welding Equipments
• Oxygen gas cylinder
• Acetylene gas cylinder
• Oxygen and Acetylene pressure regulators
• Welding torch or blow pipe
• Trolleys for the transportation of oxygen and acetylene cylinders
• Set of keys and spanners
• Filler rods and fluxes
• Gas lighter
• Protective clothing for welder (e.g. Asbestos apron, gloves, goggles etc.)
Flames
• Neutral flame
• Oxidizing flame
• Reducing flame
Arc welding
Arc welding is a group of welding processes wherein heating is produced with an electric arc, mostly without the application of pressure and with or without the use of filler metal, depending upon the base plate thickness.
Arc welding equipment
The most commonly used equipments for arc welding are:
• A.C. or D.C. power supply source.
(D.C. welding is mostly used for heavy work and at sites where electricity is not available.)
• Electrode holder
• Electrode
• Cable & Cable connectors
• Cable lug


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Chipping hammer
• Farthing clamps
• Wire brush & Tong
• Welding screen (Helmet screen & Hand screen)
• Safety goggles
• Hand gloves
• Aprons, Arm sleeves etc
.
ELECTRODES
The electrodes are used for providing heat input in arc welding .Electrodes can be classified on the following basis:
• Consumable electrodes
• Non- consumable electrodes
• Coated electrodes
• Bare electrodes

RESISTANCE WELDING
Resistance welding is a group of welding processes in which welding heat is obtained from resistance of the work to the flow of electric current and by the application of pressure. No filler metal or flux is added.

Types of Resistance welding
• Spot welding
• Seam welding
• Projection welding
• Resistance butt welding
• Flash butt welding
• Percussion welding

















-28-
EXPERIMENT # 6

ME: 107-E

AIM: To prepare joints for welding suitable for butt and lap welding.

MATERIAL AND TOOLS REQUIRED:
• Mild steel pieces -3 Nos.
• Welding transformer
• Electrode & electrode holder
• Arc-welding booth
• Chipping hammer
• Wire brush
• Welding Screen
• Hand gloves
• Apron
• Arm sleeves
• Safety shoes
• Welding goggles

OPERATION INVOLVED
• Cutting to size from MS flat
• Edge preparation
• Tacking of work pieces
• Welding run
• Removing of the slag
• Finishing of weld-bead
• Inspection & Testing

PROCEDURE
• Cut the pieces to size 80 x 50 x 5 mm from MS flat by power hacksaw.
• All the 3 pieces were cleaned after the edge preparation.
• Chose the electrode as 3.15mm & put into the holder.
• Switched on the transformer & set the current from 90-120A.
• Set the work pieces into flat position for butt joint and tacked.
• Set the work pieces into flat position for lap joint and tacked.
• Stroked the electrode on the earth piece.
• Welded the butt-joint by using correct arc and angle as told by instructor.
• Welded the lap-joint by using correct arc and angle as told by instructor.


-29-
• Another run was done on other side of the work piece.
• After completing the four runs two each side, the job was lifted by tong and kept on the working table and let it to be cooled.
• Now chipping is done by chipping hammer and cleaned the weld by wire brush.
• Finished the joints by filing if required.

OBSERVATIONS: We understood that welding is a permanent fastening, by which two metal pieces are joined together and give us a strong joint as good as the base metal.

RESULT: The job was checked by the workshop instructor and found o.k.

SAFETY PRECAUTION IN WELDING:
•All instructions supplied by the manufacture should be strictly followed.
•Power supply source should be isolated from the main supply
•Before starting welding, ensure that the welding equipment is properly earthed.
•Electrode holder should be soundly connected to the welding lead.
•Used welding screen during welding.
•Used safety shoes, hand gloves, apron & arm sleeves.
•We used safety goggles during chipping of slag.
•Welding should be carried out in clean, dry & well ventilated place/ location.
•Never repair unless qualified to do so.

















ALL DIMENSIONS ARE IN mm

-30-
EXPERIMENT # 8

ME: 107-E

AIM: To study various types of carpentry tools and prepare simple types of at least two wooden joints.

INTRODUCTION
Carpentry and joinery are common terms related with the work of wood. Carpentry is related with the works of roofs, floors, partitions etc, while joinery is related with the making of doors, windows, cupboards etc for a building.
The timber is the material used for carpentry and joinery work. It is wood obtained from exogenous trees by cutting these trees after their full growth.
Wood is available in the nature in the form of trees. Useful part of the tree is cut and is converted into timber. Trunk is the most useful part of the tree.

ADVANTAGES OF TIMBER
• Easy to work and low cost
• Easily available and good strength.
• It is non conductor of heat.
• Sound proof in nature.
• Very suitable for doors, window and furniture work.

CLASSIFICATION OF TREES
Trees are classified into following two classes:
• Exogenous Trees
• Endogenous Trees

TYPES OF WOOD
Timber is divided into two main classes:
1. Soft wood. 2. Hardwood.

1. Soft wood- This belongs to narrow leave’s trees and they are:
• Light in weight and light in colour.
• Fibres are generally coarse but straight.
• Colour of the sapwood is not different than heart wood.
• Examples are deodar, pine, chir, kail, etc.

2. Hard wood- This belongs to bored leave’s trees and they are:
• Dark in colour and Comparatively heavy.
• Having more strength than soft wood.
• Fibres are fine grained, compact and found very straight.
• These are equally strong both along and across the fibres.
• Examples are teak, shisham, sal, mango, neam, mahogany.

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SEASONING OF TIMBER
The process of removing moisture from the freshly cut trees are known as seasoning. If this excess or unwanted moisture is not dried, it creates lot of problems like shrinkage, warping, twisting etc.

Seasoning Methods
• Natural or Air Seasoning
• Water Seasoning
• Kiln Seasoning

ADHESIVES USED IN CARPENTRY
The adhesives are used in wood work for joining the wood pieces together. For this purpose glue is widely used. Various types of glue are:
• Animal Glue
• Resin Glue
• Vegetable Glue
• Blood Albumen Glue
• Contact Cement

AUXILIARY MATERIALS USED IN CARPENTRY
• Nails
• Screws
• Bolts and Nuts
• Dowels

CARPENTRY TOOLS
The efficiency of the workman depends upon the tools used in the workshop. Good quality tools always mark the work easy. In the carpentry shop the tools are classified as under.
• Measuring tools
• Marking tools
• Cutting tools
• Planing tools
• Drilling tools
• Holding tools
• Striking tools
• Sharpening tools
MEASURING TOOLS:
a) Four Fold box wood rule:
It is generally 2 feet long and is folded from 3 (three) places. It is marked with inch and milli-metre scale.
b) Steel Rule:
It made up of stainless steel and is marked with centimeter scale and inch scale.

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c) Measuring Tape:
It is made up of a flexible thin steel strip. It is flowed around a center pin attached with a small handle. It is graduated
MARKING TOOLS
a) Pencil:
Lead pencil is generally used for marking purposes.
b) Scriber:;
It has a sharp conical edge used to mark on even hard surfaces. The front edge is hardened to reduce the wear and tear. It is made up carbon steel.
c) Marking Gauge:
It is used to scribe the line parallel to and at a desired distance from a finished face or edge. Stock is movable portion and can be adjusted any position on the stem with the help of thumb screw.
c) Mortise Gauge:
It is used to draw two parallel lines its working is a similar to marking gauge except it has two sharp edges. One pin is fixed while other is moveable.
d) Try Square:
It is used to draw lines at right angle, parallel or to check the trueness of planed surface. It made up steel blade with heavy base.
e) Compass:
These are used for dividing equal number of parts and for drawing arcs and circles. It consists of two legs with a spring on the legs; a screw is also attached at the center of legs for adjustment.
CUTTING TOOLS:
Saw and chisel are used as cutting tools in carpentry shop
Saw:
A saw is a multi tooth tool up of thin steel attached with a wooden handle. Its teeth are ground and sharpened to achieve smooth cutting. Different types of saw are:
• Rip Saw:
• Tenon Saw:
• Copping Saw:
• Compass Saw:
• Key Hole Saw:
• Bow Saw:
• Cross Cut Saw:
Rip Saw:
It is hand saw from 30 cm. to 75 cm long. The width of blade is about 120 mm to 150 mm near the handle and 60 mm to 70 mm at the toe.
Setting of Saw teeth:
The teeth of saw bend in opposite direction alternatively. This is done to generate the clearance for the movement of blade.

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Chisel:
It is flat thick piece of tool steel, whose one edge is grounded to from a cutting edge and the other is provided with a wooden handle.

There are three type of chisel commonly used in the carpentry shop:
a) Firmer Chisel:
It is a medium duty tool used for general work. It carries wide blade. Width of the blade varies from 5 mm to 35 mm.
b) Dovetail Chisel:
It has long carbon steel blade with a beveled back, so that it can enter in the sharp corners to finish them. It is generally required in dovetail joints.
c) Mortise chisel:
It is used for taking heavy and deep cuts, so more material removals are possible by this chisel. The blade thickness various from 5 mm to 12 mm.
d) Gouge chisel:
It is used to finish the curved holes. Gouge chisel are of two types- inside and outside.
PLANING TOOLS:
Planes:
Planes are used to maintain the job smooth and of proper size. Sometimes grooves can also be prepared. Commonly used planes are:
a) Wooden Jack Plane:
The main cutting part known as blade or iron cutter is fitted in the stock such that it remains at an angle of 45º with the sole(The bottom portion of the stock).
b) Iron Jack Plane:
It gives better surface finish and are more durable than wooden jack plane. Its use is similar to wooden jack plane.
c) Trying Plane:
It is nothing but a longer wooden jack plane. It is applied after the jack plane to produce a true flat surface.
d) Smoothing Plane:
It is used for smoothing the wooden surface after jack plane and trying plane. It has no handle.
e) Special Planes:
A large number of special planes are used depending upon the job, for example rebate plane, plough plane, router plane, spoke sheave etc.
f) Rasp Cut File:
It is finishing tool used to make the wooden surface smooth, remove sharp edge, finishing fillet and other interior surfaces. Sharp cutting teeth are proved on its surface for this purpose and can be used for woodwork only.





-34-
DRILLING AND BORING TOOLS
The drilling and boring tools are used to produce the holes in a job. Commonly used drilling and boring tools are:
a) Hand Drill:
Hand drill consists of a spindle, drill chuck, handle and two bevel gears. Bevel gears are fitted on the body. Drill is held in chuck and rotation to spindle is given through gears with the help of a crank. In its operation, handle is pressed downwards with one hand and the crank handle is rotated by other hand. Due to this bit rotates which is gripped in the jaws of the chuck and the hole is drilled.
b) Gimlet Drill:
Gimlet drill is a very simple type of drilling tool. It consists of two parts. One is gimlet and second is handle. Gimlet is made up long twisted bar. It has a screw type starting edge. While drilling, it is rotated and pressed on to wooden work piece with the help of the handle.

HOLDING TOOL
The holding tool are used to hold the work so that it can be worked easily and efficiently. The various devices used are:
a) Working Bench:
It is a table, which is made of sal or sea-sour wood. Size of table is 6’3’. Two of four carpentry vices are fixed at the four corners of the table. This table acts as a base for all the carpentry or wood working operations.
b) Clamping Vice:
One jaw of the clamping vice is fixed to the table while the other is kept movable by means of a screw and a handle. The whole vice is made of iron and steel. Vice is made up cast steel and jaws are lined with hard wood.
c) C-Clamp:
C-clamp is simple type of clamping device. It is generally used to past one wood on the other or for alignment purposes.
STRIKING TOOLS
Striking tools are used to force the nails or chisels into the wood. Main striking tools are as under.
a) Cross Pean Hammer:
It has a cast steel body and wooden handle. Body has two parts face and pean. In cross pean hammer the pean is in the form of a narrow-round edge ridge placed at right angle to the axis of the handle.
b) Claw Hammer:
It is used for striking as well as for pulling the nails form the wood. The material of the wood is the case steel. One end is made striking and the second is claw face. Its weight varies from 0.25 kg to 0.75 kg.
c) Mallet:
It is used to strike the chisels witch have wooden handle. It is made up of a hard wood and is round or rectangular in shape

-35-

SHARPENING TOOL

Water Stone:
It is a rectangular piece of stone generally kept in a wooden base. It is used to re-sharpen the chisels, bits, plane blades and other tools.

CARPENTRY PROCESSES
1. Marking
2. Sawing
3. Planing
4. Boring
5. Grooving
6. Chiseling
7. Rebating
8. Molding

WOOD WORKING JOINTS
Lengthening Joints
Widening Joints
Framing Joints
Box Joints
Circular Joints

WOOD WORKING MACHINE
Wood Working Lathe
Circular Saw
Band Saw
Thickness Planer
















-36-
EXPERIMENT # 8
ME: 107-E

AIM: To prepare simple types of at least two wooden joints (T-shaped lap & cross lap)

MATERIAL AND TOOLS REQUIRED:
• Engineering drawing of the job
• Rectangular Wooden Piece (12”x2”x1”) -2nos.
• Metal Jack planner
• Files
• Try Square
• Steel Rule
• Pencil
• Chisel
• Rip-Saw ˝
• Hammers etc.

OPERATIONS INVOLVED:
• Marking
• Cutting
• Planing
• Chiseling
• Filing & fitting of pieces
• Finishing

PROCEDURE:
• A 12˝×2˝×1˝ wooden piece was taken and was held in vice for surfacing.
• Made all the surface plain at the right angle-faces with each other the help of try square & metal jack planer.
• It was then cut in to two pieces of size 6”x2”x1” by rip-saw.
• Marked the cut pieces for cutting as per drawing given.
• Chiseled the marked portion as per size and quantity required.
• Finished the one piece by filing.
• Similarly the second piece was prepared as per drawing by repeating the above operations.
• Both the pieces are joined by using hammers for completing the lap joint.

The above procedure is repeated to make the other job of cross-lap joint.



-37-
OBSERVATIONS: We have done joinery work, which is generally performed in doors, windows and cupboards etc

RESULT: The joint is temporary and needs an adhesive application for making it permanent.

SAFETY PRECAUTIONS IN CARPENTRY SHOP:
• Tool should be placed on the working bench properly.
• Blunt tools should not used.
• Never stand in front of the blade while working with a rip saw.
• Machine/ Tools should not be used without any proper knowledge.
• Cutting should be done at full speed of saw.



























ALL DIMENSIONS ARE IN mm

-38-
EXPERIMENT # 11

ME: 107-E


AIM: To prepare horizontal surface/ vertical surface/ curved surface/ slot or V-grooves on a shaper/ planer.

MATERIAL AND TOOLS REQUIRED:
• Engineering drawing of the job
• Shaper Machine with vice
• A cubical metallic block
• Shaper tool
• Steel rule
• Vernier caliper
• Outside caliper
• Flat file(smooth) ˝
• Spanners
• Emery paper
• Brush

OPERATIONS INVOLVED:
• Marking
• Setting of machine as per job
• Slotting/ grooving
• Facing
• Filing
• Finishing

PROCEDURE:
• A block of C.I. (60x60x60) mm was taken and cleaned with cloth.
•The cutting portion of the slot is marked in fitting shop and punched.
• The block is held in vice such that its top surface is horizontal.
•Stroke travel was set as per job’s cutting length.
• Tool is held in tool post tightly.
•The tool is brought near to the vertical surface at the top of the job and cut is set (2mm) by lifting-up the table by 2mm.
•After setting the job, tool and cut at right spot, machine is switched on.
•The tool cut the length of the job in forward stroke and backward stroke was idle.
•In subsequent stroke cross feed of 1mm is given to cut widthwise till we got the width of the slot.



-39-
Now table is lifted by 2mm and same procedure was adopted until tool reached at the starting point.
•The same to and fro movement of the tool in same plane is repeated until we reach near to depth marked.
•For finishing the slot we filed all the three faces (2 vertical & 1 horizontal).
•The slot’s dimensions were checked, whether more machining is needed or not.

OBSERVATIONS: We have measured the finished job and found the dimensions are accurate and were within the permissible limit.

RESULT: The job was checked by the workshop instructor and found o.k.

SAFETY PRECAUTIONS:
• Be sure, ram, tool, work, table support, clamping screws and vice are properly secured in position and that the tool head and tool clear the work before starting the shaper.
• Always maintain the parallel clean.
• Place a metal shield over the tool to catch the chips.
• Always select a proper tool, proper tool material, proper tool angles, proper speed and feed.
• After setting the stroke length and position, see that the adjusting nuts are tight.
• Check up all the controls of the machines before starting the operation.
• Never remove chips while ram is in motion.


















ALL DIMENSIONS ARE IN mm

-40-
EXPERIMENT # 12

ME: 107-E


AIM: To prepare a job involving side and face milling on a milling machine.

MATERIAL AND TOOLS REQUIRED:
• Engineering drawing of the job
• Milling Machine with vice
• A cubical metallic block
• Milling cutter
• Steel rule
• Vernier caliper
• Outside caliper
• Flat file(smooth)
• Spanners
• Emery paper
• Brush

OPERATIONS INVOLVED:
• Marking
• Setting of machine as per job
• Side milling
• Facing
• Filing
• Finishing

PROCEDURE:
• A block of C.I. (70x70x70) mm was taken and cleaned with cloth.
• The block is held in vice such that its top surface is horizontal.
• The tool is held in arbor and checked that it is revolving perfectly.
• The tool is brought near to the vertical surface at the top of the job and cut is set (2mm) by lifting-up the table by 2mm.
• After setting the job, tool and cut at right spot, machine is switched on.
• The feed was given to the table manually after completion of every cut until the face is totally machined.
• This operation is repeated until we get the required dimension of the job and now one face is machined.
• The job is now turned 90° and same operation is done to machine upper surface (face) of the job.
• All the 6 faces are machined to get a cubical block of 60x60x60mm.
• For finishing of all the faces, filing operation was performed and job is complete


-41-
OBSERVATIONS: We have measured the finished job and found the dimensions are accurate and were within the permissible limit.

RESULT: The job was checked by the workshop instructor and found o.k.

SAFETY PRECAUTIONS:
• Make sure that the cutter and arbor are secured.
• See that the cutter and arbor support clear the work.
• Use cutters that are correctly ground and in good condition.
• Don’t try to tighten or to take off arbor nut by applying power to machine.
• When using cutters in a vertical milling machine, don’t take an excessively heavy cut or feed.
• Never reach over a revolving cutter.
• Check speed and feeds and to be kept proper.





























ALL DIMENSIONS ARE IN mm

-42-
EXPERIMENT # 13

ME: 107-E
AIM: To prepare a job in fitting shop as per drawing.

MATERIAL AND TOOLS REQUIRED:
• Drawing of the job
• MS flat 50x50x8 mm
• Steel rule & scriber
• Try square
• Hacksaw 12”
• Bench vice & flat rough file12”
• Chalk & brush
• Surface plate & V block
• Center punch, dot punch & hammers
• Drilling machine & machine vice
• Drill 8.5 mm, counter sunk tool
• Vernier caliper & Vernier height gauge
• Tap M10x1.5 with handle
• Number & Letter punch
• Coolant & lubricant

OPERATION INVOLVED
• Checking &marking of dimensions as per drawing
• Sawing
• Filing
• Coating
• Marking
• Punching
• Drilling
• Counter sunking
• Finishing & measuring
• Tapping
• Stamping

PROCEDURE
• The work piece is clamped in bench vice after marking.
• The work piece was made to size by hacksaw as per drawing’s dimensions.
• The filing operation was done by flat rough file

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• Checked the perpendicularity by try-square.
• Finished all the vertical surfaces smooth, accurate and perpendicular.
• The square surface (50x50mm) was coated with chalk & put on the surface plate for marking of the centres of the holes by the centre-punch.
• The work piece placed & clamped in the vice of drilling machine.
• The top (punched) surface was placed in the vice such that it is perpendicular to the drill axis.
• The drill point is kept just over the center marks and the feed is given to the drill by pressing the handle in anti-clockwise and coolant is used while drilling.
• The drilling operation is repeated for getting the required size of the hole.
• The counter-sunk tool is used for getting c’ sunk hole to the size.
• The another hole is drilled to size (D-2h) for tapping.
• The tap-set of 10mm is taken and tapped as required. The tapping operation is repeated to get the required depth of the thread by different taps of the set.
• After getting the holes drilled and tapped, the work-piece is taken from the vice and finished by final filing with smooth file.
• When the job is finished and checked, it is punched with roll no by number & letter punch.

OBSERVATIONS: We understood that fitting operations are very precise and accuracy & correctness plays very important role in assembling the parts of a job.

RESULT: The job was checked by the workshop instructor and found o.k. The tapped hole was checked by screwing on a screw in the hole.

SAFETY PRECAUTION:
• All instructions supplied by the manufacture should be strictly followed.
• Always move the hacksaw in perfect straight and horizontal direction.
• Work should be held firmly in the vice.
• Too much pressure should not be applied.
• Entire length of the blade should be used.
• Files should be stored in wooden racks.
• Files should never be used without handle or with loose handle.
• Files/ tools should not be allowed to rust.
• Wire brush should be used to clean the files.
• New file should be used of copper, brass and then on WI or MS.
• File should never be used as hammer.
• Too much feed should not be given to the drills.



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• Lubricants are to be used as and when needed.
• Oil-ness should be cleaned before using the files etc.
• Used safety shoes, hand gloves, apron & arm sleeves and goggles if, required.
• Coolant must be used in drilling and not to be drilled whole length at a stretch. • In blind holes chips should be removed intermittently.


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Dear students....For any welding question,
first write defnition of welding and then
write the type of welding of the question asked for:
write of principle of that welding and draw the figure of the said welding and describe the process/ procedure of that welding as explained in the class.
Under fusion or non-pressure welding we would discuss about gas welding.

GAS WELDING:It is type of fusion welding,wherein joint is completely melted to obtain the fusion.The fuel gases are Acetylene, Propylene, Propane, Hydrogen and Natural gas.
PRINCIPLE OF GAS WELDING:When Acelytene is mixed with Oxygen in correct proportion in the welding torch and ignited.The temprature of flame is about 3100 C. The filler rod is used to build up the seam for strength.Make the figure of oxy-Acelytene Welding(refer web site).
TYPES OF FLAMES:
1.Neutral Flame: Oxy to Acetylene ratio 1.1:1, Flame temprature is 3200 C,Inner cone is light blue and outer enevelope is dark blue in colour.It will not oxidize or carburize the metal. USES: MS, SS, Copper, CI and Aluminium.
2.Oxidizing Flame: Supply of oxygen is increased.Inner cone is more pointed and outer enevelope is much shorter. Flame temprature is about 6300 F. It is harmful to steels. USES: copper and copper alloys.
3.Carburizing or Reducing Flame: Volume of oxygen is reduced, rich in Acetylene. Acetylene feather exists in inner and outer enevelope.Flame temprature is 5500 F. Metals tend to absorb carbon are not to be welded. USES: Welding of Lead anf surface Hardening, welding of high carbon steels with low alloy steel rods.

Introduction to Manufacturing Processes (WORKSHOP TECHNOLOGY)

Introduction to Manufacturing Processes (WORKSHOP TECHNOLOGY)
Everyday we use so many items like furniture, clothing, telephone, cars, airplanes, railways, TVs', household items, food items etc and these item are directly or indirectly depend upon Manufacturing Process.
Manufacturing Process is a branch of Mechanical Engineering. in all branches, manufacturing is virtually most important activity because it involves conversion of raw material to final product.




Instructor: S.C.Malhotra
Telephone: 09313937977
e-mail id: sucham6@yahoo.com, scmalhotra6@gmail.com

Classes



Text Books: Workshop Technology (Manufacturing Processes) by S.K.GARG & VIRENDER NARULA
Ref Books: As per syllabus, preferably foreign authors

Consulting hours: Mondays & Thursdays
From

Contents:

This course is one of the subjects of mechanical engineering, which are taught to each and every engineering student in 1st year (refer manual of Workshop-Practice). The course consists of the topics to be covered include manufacturing methods, practices and processes for producing a job with the help of machines, tools & tackles(introduction, industrial safety, foundry, forming and welding).

Tutorials NA

In the tutorial I will review background material (re-cap), present additional examples, and you can work in groups on your homework/ question bank. This is also intended as an informal opportunity to discuss things in more depth.

Exams

There will be....... mid term exam of ….. hrs during the term. The exams will be closed book and closed notes unless otherwise specified.
Mid term exam accounts for ……marks. There will no final exam.

Assignments

There will be four assignments to be submitted on the date and time mentioned. Unless the circumstances are extraordinary late submissions will not be accepted.

Tests

There will be a total of two tests of ….. hour duration. During the test hour, students should give written/ oral responses. Tests accounts for ….. internal marks.

Attendance

It is necessary that students attend all classes. To discourage students from missing classes and thereby end up having poor academic performance, the following measure is taken:
 
Attendance As explained in the class.


Manufacturing Processes:
Objective of Industrial Safety
Prevention……………loss of human…………..production………educate workers
Their morale…………tension…………..Relation between management & worker
Accident:

Accident is a mishap, which causes injury to the persons, damages to machines, tools and equipment. An injury may result temporary or permanent disablement to the employees/ workers or even death.

Types of accidents
1. Near accident…………………… no damage or injury
2. Trivial…………………………….. very less damage
3. Minor accident…………………...damage & injury more than trivial
4. Serious/ major accident…………heavy damage & a lot of injury
5. Fatal ………………………………very heavy damage & even loss of life


Causes of accident:
Causes of accidents may be classified as follows:
Mechanical, Working environment, Human

Sources of accidents:
1. Mechanical
Use of old, poor maintained or unsafe equipment
Use of unguarded or improper guarded machines and equipment
Unsafe design & construction of building, structure and processes
Improper layout and material handling system
Lack of safety devices
2. Working environment
Improper temperature, humidity and fatigue to the worker
Inadequate illumination, presence of dust, fumes and smoke
Improper floor, height of working rooms noise level and ventilation
Poor housekeeping, plant layout, blocked entry & exit passages
3. Human
Operating machines without (knowledge, authority and safety devices)
Working of unsafe speed and equipment
Working for long duration and improper use of tools
Failure of protective devices
Working with worries, ignorance, carelessness, in day dreaming & excitement

Effect of accident:
1. On owner
a) Direct cost of accident
- due to compensation paid to the injured employee
- due to money paid for treatment
- money value of damaged equipment, tools and materials
b) Indirect cost of accident
- cost of lost time of injured person and other employees
- cost of lost time by supervisor, engineers and managers
- cost by delay in production and lowered production by substitute worker
2. On worker/ employee
- family loses the earner and compensation never equals the earnings
- affects the morale of the employees
- workers get temporary and permanent disability
3. On society
- cost of accident is included in product & society has to bear more prices - some employees do not come under compensation act and need for help
by society is much greater.
- loss of production hours causes lower production and cost will go up, if
demand is more than production.


Method of safety:
The common methods of safety are as follows:
- by proper working conditions and workplace layout
- by proper construction in every area
- by proper material handling system
- by position and using different guards(fixed, trip, interlock, automatic etc)
Note: refer book for further details on page # 21 to 23. remember Factories Act 1948 regarding safety.


Engineering Materials
There is wide range of materials used in engineering applications in almost all areas of technological advancement.
Engineering materials may be classified as follows:
i) Metals ii) Non-metals
i) Metals are further divided into two categories:
Ferrous metals- contain iron as main constituent e.g. cast iron, wrought iron, steel and alloys.
Non ferrous metals-do not contain iron as the main constituent e.g. copper, aluminium, lead, zinc and alloys (bronze, brass, duralumin etc).
ii) Non-metals are leather, rubber and asbestos.
Leather is used for belt drives, packing, washer etc. It is very flexible and with stand wear under suitable conditions.
Rubber is used for packing, belt drives and electric insulators.
Asbestos is used for roofs of temporary sheds and in heat insulation for steam pipes & steam boilers because of its being poor conductor of heat.
There are much more other engineering materials as follows:
1. Metal and alloys
2. Ceramic materials
3. Organic polymers
4 Composites
5. Semiconductors

Note: refer book at page # 61 to 63 for details of other materials. Also recollects general terms such as:
Stress, Tensile stress, Compressive stress, Shear stress, Strain, Tensile strain, Compressive strain, Hook’s law, Modulus of Elasticity, Modulus of Rigidity, Bulk modulus, Linear & Lateral strain and Poisson’s ratio.

Properties of Engineering Materials: It is a factor which influences quantitatively & qualitatively the stimuli and constraints of a given material.
Following are the general properties of a material:
Physical properties
Chemical properties
Mechanical properties
Magnetic properties
Electrical properties
Optical properties
Thermal properties

Mechanical Properties:
Mechanical property of materials is defined as a behavior of the material under action of external forces.
Some important mechanical properties of materials are:
Strength-ability of material to sustain load without distortion (withstand all types of stresses without failure)
Stiffness-ability of material to resist deformation. Higher the value of E (young’s modulus) is more stiffer. Steel is stiffer than aluminium.
Elasticity-by virtue of this property a material deformation disappears on removal of the load, means it regains its original shape.
Plasticity-ability to undergo some degree of permanent deformation without rupture of failure. It is after the elasticity and important in forming & extrusion and many other hot & cold working processes.
Ductility-ability to withstand elongation under tension i.e. enables to draw wires without rupture e.g. gold, silver, platinum, steel, nickel, copper, zinc, aluminium etc.
Malleability-ability of metal to withstand deformation under compression without rupture, which enables to be hammered or rolled into the sheets. e.g. gold, silver, copper, platinum, tin, nickel, aluminium, zinc, lead etc.
Toughness-It is related to impact strength i.e. resistance to shock loading e.g. if load is applied suddenly on a piece of MS and then on a piece of glass, the mild steel will absorb more energy than glass before failure. It means steel is more tougher than glass.
Brittleness-Lack of ductility is brittleness. It is the property of breaking without much permanent deformation. These are glass, cast iron etc.
Resilience-property of material to absorb energy elastically. On removal of load, the energy stored is given off exactly in spring. It is important in manufacturing springs and shock-absorbers.
Hardness-It is defined as resistance of material to penetration. Hard materials resist wear and scratches. These are used for cutting tools. Diamond is most natural hard material.
Fatigue-When subjected to fluctuating or repeated load. It is to determine its behavior when subjected to thousands or even millions of cyclic load applications. Bridges, components of high speed aero and turbine engines are failed because of fatigue.
Creep-It is the slow plastic deformation of metal under constant stresses usually at high temperature. Metals generally exhibits creep at high temperatures. Plastic and rubbers are very high temperature sensitive to creep.
Machinability, formability, cast ability and weld ability are self explainatory properties. Students are advised to go through the book for further detail.


SHEET METAL WORK
INTRODUCTION
Sheet metal work has its own significance in the engineering work. Many products, which fulfill the household needs, decoration work and various engineering articles, are produced from sheet metal. Common examples of sheet metal work are hoopers, canisters, guards, covers, pipes, hoods, funnels, bends, boxes etc. Such articles are found less expensive, lighter in weight and in some cases sheet metal products replace the use of castings or forgings.
.
SHEET METAL TOOLS
1. Rules
• Steel rule-The steel rule (30 cm long) is particularly useful in measuring and laying out small work.
• Folding rule-Folding rule (2 m long) is useful in measuring large work. It can be folded into shorter length pieces.
• Steel tape-It is also used for measuring large work. It is coiled in a small size box.
2. Steel-Square- IT is an L-shaped piece of hardened steel with graduation marks on the edges for measuring. The narrow arm of the square is called the tongue and the wide part is known as body.
3. Straight Edge- IT is a flat bar of steel with a beveled edge. This bar comes in a variety of lengths ranging from 1 metre to 3 metre. It is useful for drawing long lines.
4. Vernier caliper- This is used for measuring the dimensions in fractions. For further detail refer experiment # 1.
5. Micrometer- It is also used for measuring the thickness of metal sheets. For further detail refer experiment # 1.
6. Swinging Blade Protractor- The swinging blade protractor is used in sheet metal work for marking and measuring of angles. It is made of steel.
7. Dividers- The dividers are made with each leg tapered to a needle point. The dividers are of two types. Spring divider and wing divider. The legs of the spring divider are adjusted by turning the knurled nut. The leg adjustment on the wing divider is made by the screw of the wing and the knurled nut on the end of the wing. It is used for drawing circle, arc on sheet metal, transferring the dimensions, or dividing the distances into equal parts.
8. Trammel Points-The trammel points also called a beam compass consists of two straight, removable legs tapered to needle points and attached to separate heads. These heads slide on the beam and are locked at that place by thumb screws. A special clamp for a pencil can be attached to one of the points. It is used to draw large arcs and circles that are beyond the limit of dividers.
9. Scribers- It is used to scribe or mark line on a metal surface for a variety of purposes. It is a metal worker’s pencil.
10. Punches-Punches are used in sheet metal work for marking and locating centers in a more permanent manner. Various types of punches are:
• Prick punch- It is used to make small marks on layout lines. Point angle is 30º
It is used for punching small holes in thin metal sheets.
• Center punch- It is used to mark the centre of holes to be drilled. Point angle is 90º
• Hollow Punch- It is used for punching holes in the sheets. Inner and outer faces of the punch meet at an angle of 40º
• Hand lever punch- It is used for making holes with punch & die, when a large number of holes to be punched by hand pressure.
11. Chisels-In sheet metal work, cold chisels are used. These are used for cutting thick sheets, rivets, bolts and chipping operations.
12. Snip- It is called hand shear and similar to scissors. It is used to cut thin & soft metal (not more-thicker than 20 gauges). These are straight and curved.
13. Hammers- Hammers are used for forming shapes by hollowing, raising, stretching or throwing off. Various types of hammers are:
• Ball peen hammers- It has a round, slightly curved face and a round head. It is used for general purposes.
• Riveting hammer- It has a square, slightly curved face and used for riveting.
• Setting hammer- It has a square, flat face and a tapered peen with beveled end. Flat face is used for flattening seams, while peen end is used for peening operations.
• Raising hammer- It has oblong flat face with corners slightly rounded off. It is used for raising operations to form saucer, bowl, tray or spoon.
14. Mallets-The mallet may be made from fibre or wood. It is used to strike a soft and light blow in the metal.
15. Pliers- These are used for holding, cutting and bending work. Different types of pliers are available in the market.
16. Stakes- These are the sheet metal anvils used for bending, seaming and forming by using a hammer or mallet. The following are the types of stakes.
• Blow horn stake
• Beak horn stake
• Hollow mandrel stake
• Solid mandrel stake
• Bevel edge stake
• Double seaming stake
17. Stake Holder- It is used in sheet metal shop and is a rectangular bench plate to accommodate the stakes.
18. Hand Groover- These are also called seam set and is used for grooving a seam by-hand
19. Rivet Set- It is used in riveting operation.
20. Soldering Iron- These are used to join two pieces of thin metal by using solders (alloy of tin & lead).
21. Folding Bars- These are used for bending and folding straight metal pieces.
22. Wire Gauge- This is used to check the diameter of wire or thickness of sheets.

SHEET METAL OPERATIONS
The following are the various sheet metal operations:
Measuring and Marking
Cleaning
Laying out
Cutting and shearing
Bending
Stretch Forming
Deep Drawing
Riveting
Soldering
Hollowing or Blocking
Sinking
Raising
Planishing
• Measuring and Marking
Marking straight lines
Marking circles and arcs
Marking irregular curves
Marking indentation marks
Transferring a pattern
• Cleaning
Sometimes the blank surfaces need proper cleaning before being processed. For leaning pickling process is used. In this process sheets, are immersed in a hot bath of part dilute sulphuric acid and 20 parts water after allowing sufficient time for pickling the tanks are thoroughly washed in a stream of water and then allowed to dry.
• Laying out
While doing the marking of development of the surface of component on the sheet certain material for various allowance are added. Such a layout when made on the sheet is called laying out process.
• Cutting and shearing
-Cutting off
This means severing a piece from a strip with a cut along a single line.
-Parting
Parting signifies that scrap is removed between the pieces to part them
-Blanking
This means cutting a whole piece from sheet matel. Around this piece there is enough scrap left all around this piece. This piece with is cut from the sheet metal is our objective. The sizes of the blank is our requirement and the remaining sheet is scrap
-Punching
Punching is the operation of producing circular holes on a sheet metal by a punch and die. The material punched out is removed as waste and the sheet. Which is having holes is our objective or requirement.
-Piercing
Piercing is similar to punching, circular holes are produced in a sheet where as in piercing holes other than circular are produced in a sheet. The sheet which is having the holes of desired shape is our requirement.
-Slitting
When shearing is conducted between rotary blades, the process is referred to as slitting. It cuts the sheets, which are having larger width than required.
-Nibbling
Nibbling or nibbling is a process of continuous cutting along a contour, which may be a straight line or an irregular profile. The machines used in this operation are known as nibblers, which are portable type shearing machines.
-Trimming
Trimming is the operation of cutting away excess metal in a flange or flash from a piece when holes are produced in a manually, first circular blank is cut with a chisel and hammer. Then fine shape (accurate size) is trimmed with the help of a shear or snip. This operation i.e. cutting snip is called trimming
-Lancing
This makes a cut part way across a strip. So this operation leaves a tab with out removing any material. Sometimes lancing operation means that cut is produced along three sides and the cutting part is bent towards the forth side so in this way opening is created in a box.
-Notching
This is a process of removing metal to the desired shape from the side or edge of a sheet or strip. Some times notching operation is also performed to prevent overlapping of metal where the corners come together. So openings are created at the corners. A very good example is covering a book with a paper. Now suppose paper is sheet metal and the various cutting operations are performed to remove the sheet openings (square notch etc.) that operation is known as notching
Types of notches are:
Straight notch and Square notch,

The following are some common and important operations performed in sheet metal work.
• Bending
• Stretch forming
• Riveting
• Soldering

Sheet metal joints
• Single hem
• Double hem
• Wired edge
• Seams

Sheet Metal Machines
• Shearing machine
• Folding machine
• Bending machine
• Wiring machine
• Turning machine
• Burring machine
• Double seaming machine