AGARTALA Name- PRADEEPTA SEN Roll No.- 21UBE010 Registration No.- 2113709 Semester- 1st Section- B Subject - WORKSHOP PRACTICE-1En. Be atonal inettute of Technology Agartala Net Nories= Pr ie See; B \ Poulso;- 24 UBE 040 een Sh ee TIN Chapter 1 FITTING SHOP .1INTRODUCTION ‘Mochi fo08 are eapsblo of promkelng work at fantt rate, but, Yoo. aro occalons when ‘Compononis ara. procestod at he bench, Somolimas, | bocames necessary to replace OF ripe f ly. This volves certain ‘fomponent which must be M accurately with anther ecmpnanton reason toa tan ting, The ary of machi Lon os au, a ns Fina it bbonch work, Tho accuracy of work dans depends upen tho axpeionc. ane “Th liye work’ roars tothe productlon of carpononts by hand. onthe barch where ws {iting deals which the assornly of mating parts, tivough removal of metal, to obtain the reqused Both the bench werk and fing requees the use of number of simple han! toals and corsiorable ‘manual efarts. The operations the above works consist of fling. chipping, scraping, sing drilieg, and tapping 1.2 HOLDING Toots 1.2.1 Bench vice ‘The bench vies ia work holcing devin: It fs the most commonly used vice jn afitig shop. The banc vies is sown in Figuto 1.1 niente) mates 2e j Figure 141: Bench Vico 7 11 fhe to the bench with bots and nuts The vice Body consists OF two main parts, ned jaw ‘and movable avi, When the vice handle Is tured In 9 clockwise direction, the sliding jaw work agains the fixed aw: Jaw plates are made of hardened! stet.Serrations onthe jaws ons © rip. Jaw caps made of soft matertal are used to protect finished surfaces, gripped in the vice. The sia ‘the vce i specified by the length ofthe jaws The wiee body Is made of cast Iron which is strong Compression, woak In tension and so fractures under shocks and therefore should never be *Name: Pradpopta s oes fr RoW NDi- 24 VBE DIO 1.2.2 Viblock Wenlock Is rectangular oF square block with a Vigoow on one or both sides oppenite to each Other. Tho angle of the “V: Is usually 90". V-tlock with a Glartip fs Used to hold cylindrical work securely uring thyout of measurement, for monsuring operations of for dilting for this the bar Is faced \ongitudinally in the V:Groove and tho serow of V-clamp is tightened This gry thes roe! bs ern wits Its xls paraliol to the axis of tho v-groove, negra Sanfee wearer Serer National institute of Technology Agartala 1.23.¢-Clamp TNs Is used to hold work against an angio plato or viblock ar any other surface, when gripping ts fequired its fixed jaw is shaped the English alphibot -C’ and tho movable jaw Is round Int shape and ‘rectly fitted to the threaded screw at the end The working principle of this clamp is the same as that Of the bench vice. \ Figure 1.2; V-blocs Figure 1.3; C-slamp Sketch and name parts Feqi- y-block,Nome: Praconpto Ser. € Sac.- 8 THROM ND i- 24 UBE0L0 aredra Srenen ea eT eee National Institute of Technology Agartala 11.3. MARKING AND MEASURING TOOLS 1.3.1 Surface plate e rk AR plate is machined 0 fine limits and Is used for testing fe oe ote ce It's also used for marking out smal box acs moro precious than the marking WE. hk Of the fished dopends upon whether iti designed for bench work in afiting shop OF fcr SEN Te Inspection room: the surface plate ts made of Cast iron, hardened Steel or Granite ot os shifting by length, width, height and grade. Handles are provided on two opposite sides, to cary from one place to another Figure 1.4: Surface piote Figure 1.5; Angie plate Sketch of Surtace piate Sketch of angle plate A { machPnoc Faces O. Fgroang(o- e Fiqi-sunhoce plote E qe i POE 1.3.2 Try square = 1118 measuring ind marking too! for 90° angle In practice, its used for checking the squareness of mary types of small works when extrome eg scr eae "he be of ‘ney square made of hardened steol and the stock of cast Iron or steel. The size of the Tr a ry square is spociied by the ‘SketchNOume:-Pradrepta Son 62c i= B EaROU NO:- 24 BE 0S sre rl er aetren National institute of Technology Agartala 1.3.3 Seriber {A Scribes is 2 slender steet tool. used to scribe or mark lines on metal work pieces. I's made of hardened and tempered High Carbon Stool The Tip of the sri is goneraly ground at 120 15° It (generally avalable In lengths, ranging from 125mm to 250mm. It has two pointed ends the bent end is {used fac marking fines where the straight end cannot reach, Figure 1.6: Try square Figure 1.7: Scriber ‘Sketch of Try Square and Scriber Rode ie @fock, Fig Piny Square— Names—Pracdeopte fon A So ne a on =P = i ss od is cred srt et TTT i ‘National institute of Technology Agartala 4,34 Odd ley ‘or Hermaphrodite or Jenny Caliper ve aso called Jonny Caliper oc Hermaptrodite, Tiss used for making porate lines trom 1 Jog pointed like. a dWvider ‘a finished edge and also for locating the center of round bars; It has on tho other log bant lke a callpr. Its speclicd by the length of the fog UP to the hinge point Sketch of Jenny Caltiper Sketch of Divider ary og auido Odd fog catlepen 1.3.5 Divider It bs basically similar to the calipers except that its logs are Kept straight and pointed at the: measuring edge. This is used for marking circles, arcs Faying out per setting lines, : rpendicular lines, by setting lines. It is made of case hardened mild steel or hardened and tempered low carbon steel. Its size is ified : i ft specified by Fig Serna. . Agjuehing rut Figure 1.8. Odd leg caliper and dividerNomet= Praceopta son 4ec;-B En-ROWNO 24 VBENIO si ' sede deen esa APTA Ss National institute of Technology Agartala s 13.6 Trammet Tramymal ts Used for caning fare cccles oF arcs 1.3.7 Punches These are used for making indontations on the scribed fnos. to mako therm wiibio clearly. These are made of gh carbon stect. A pureh i spacified by is length anv esamotor (say a8 190 125mm). I consists of a cylindrical knurled body, which Is platn for some longth at the top af it. At the other end, It [ground to.a point. The tapered point ofthe punch is harden over i Yongth of 20 10 20m Dot punch Is used to lightly indent along the layout lines, to locate center of holes and to provide a small center mark for divider pont, ee. for this purpose, the punch is round 10,9 conical polint having 60° Included angie Center punch is similar to the dot punch, except that it ground 10,8 conical paint having 90° Included angle. t's used tio mark the locaton of the holes to be drilled b- Centre punch Figure 1.9: Punches. ‘Sketch of Dot Punch ‘Sketch of Centre Punch . b-Contre punch,Nouns Pracleapta sor Sec B 9. e ‘ En—Rolino> DAVBE a 40 ara Sf era sree es National institute of Technology Agartala atte = 1.38 Calipers They ace indirect measuring tools used to measure cr transfor lingar dimensions. These arc used with the hlp of a steel Rule to check inside and outside measuremonts These are made of Case hardenect mild stea! or hardened and tempered low carbon steel, While using, but the fogs of the caliper are set against the surface of the,work, whether Inside oF outside and the distance between the legs & measurect with the help of a scale and the same can be tansferrad to another desiod place. These ave Specified by the length of th fog. in the case of outside caliper, the legs are bent inwards and in the case Of Inside caliper, the legs bat outwards. ees : (2-Dutside calipers b= Inside calipers Figure 1.10: Calipers, . ‘Sketch Outside spring Caliper Inside spring Caliper Outside Hinge Caliper Inside Hinge Caliper Kane | Pivot Yooh Spmii chen Nae oe ca Buaciora| Je erty coupon e eee | 2 Tyee Fr coker | collipen os ae Collipen j Filgs- coluipenssName Pradecpta sen Seci-B En- ROUND: 24 BEDID ere St ee ar National In tute of Technology Agartala 6 14 CUTTING TOOLS 1.1 Hack Saw fs a thio blade, The Hack Siw is used for cutting motal by hand. It consists of a frame, fone at eae Ary poten, ata binds peiie bythe must of Aosth for conti Fave a nurmbot of tooth ranging from 5 to 18 por cetimator (em re algae Hacksaw blades aro cassied (Al had and i) obo typo. ho nil arc! bhades ore re NSS hardenod and tempered throughout to raisin thok cutng edges fonger, Tow a Mat Pe hard metals. Those blades ara har and brite and can break easly by ttlng nl Forcing thom i Te ‘work wile sawing Fesbio blades aro mado of SS. ow alloy ste ut only tha fealh rm ME ‘and the rast of the biadk is stand fexiio, These aro suitable for te bay Unkle persons Aijudoba tone Figure 1.1% Hacksaw frame with blade Thé teeth of the hacksaw blade are staggored, as shown in figure and known as » ‘set of teeth These make siots wider than the biade thickness, proventing the biade from jamming. om Figure 1.14: Sat of tooth Toothiorm skate Show ant Tooth face ‘and direction of stroke only) £4 + £ot ob eothyNounei— Prraceepta Son Saci-8 En-ROLL NO‘ 2.4°V BEOLO prt Treg te rey rer saree ce National Institute of Technology Agartala 142 Chisels Chisels aro used for removing surplus metal oF for culling thin shoots: These tools are made fom 0.9% 10 110% carbon steel of octagonal or hexagonal section. Chisols aro annoaiod. hardored ant empored 10 procuce a tough shank and hard cutting odge Aanoating reHoves the Intarnal strosses. ina Imdtal. The cutting anglo of the chisel for gaara! purpose is about 60" ——————D =) Figure 1.15; Flat chisel 1.4.3 Twist Drill Twist cris aro used for making holes. These are made of High speed stool. Both straight and {taper shank twist drills are used. The parallal shank twist dit can be held in an ordinary se = contoring rll check. The tapper shank twist dri fits into a corresponding tapered: bore provided in the driting machine spindle Figure 7.16: Twist oils cArokgrt shank Flutes Shah and name pats 6 songrw y ons o : anon ahr oe Mang @hanK—4 jlutte Lenatn H— 2d Ung W Ovendwl 22) we =tebioe 7g sigicintet dnilsNome -Pradoepto Bo 6ac:-B En-Role NOH 2.40 BEDIO f “ era re ra aor a a ‘y x National Institute of Technology Agartala: 1.44 Tops and Tap wrenches ‘htap is. hardened and steo! tool, used for cutting Internal theead In a dil holo, Hand Taps are Usually supplied In sets of throe in cach diameter and throad size, Each sot consists of @ tappar tap, Jntermectate tap ana plug oy bottoming tap. Taps are made of high cartoon stool or high speod sto 24, Teper o tir st Second or intermediate Bottoning orptug Fix Too wranch Figure 1.17: Taps and tap wrench ‘Sketch of Hand tap Taper ar First tap Second or intermediate tap, od Ee 2 paigs-Tapen on €543- Secondon Finettap stnton mediate 4ap Bottoming or plug tap é Tap wrench 0. vaaee Frr00 fon Fae eotfent pee tte on plugto ‘ fQ2- Top wnench-Namer Prades pta Sen See B Pr-ROLL Noy 24 BED ‘ ee stray er srr, National Institute of Technology Agartala Bs ‘Dies aro the cutting tools ese for making oxtornal thraad, Dios are mada olthor sot or spit type. Thay aire fed in a die stock for hokding anxt adjusting tho alo. gap. They ana made of Steet or HighNaing:— Prractecpta Boh Sec p En-Rolt WO O447BED40 a i sre etd se, seg Natlonalinsthute of Technology Agartaia Ball Pen hammer ae rean aera Foor ards fore Fig i Atralghd Foor tHommen ~ Foes puaiike Offset Double ended box spanner face ) fig i-optet double .. 00) n 2nded_ bot Rigi cn0%6 P homme spannerNomt- Prodecpto. Ben Soc:-B Em- ROUND: 25 UB EOIO areata hen rere serra National institute of Technology Agartala Beveive 1 Fitting shop ‘AlN To make a squace from a MS (Mild Steel) round bar All meesians aroin mm Wy ee ae | 1 I : 2 MATERIAL REUIRED:- Nid Sic! Round bar (01,16 x SS U9) TOOLS REUIRED;- 1 RowghFie 6 Centrepanch 2 Smooth File 7. Bal Poon Hammer 3 Try Squace 8. Odd leg caliper 4 Scriber 9 Table Vico 5,Outsidecalliper 10. Steel Rul PROCEDURE. 1. First find the centor inthe round bar with the help of ced iogealipee, 2.-Mter finding the center we mark by hitting tho center punch 3 Thon wo take tho alameter of the round bar as the agonal of the Square. Then we mack the four ines af the square : Then we attach them.s round bar in the table vice tightly and start to fle it with rough fat fle 8: Mier the certain interval of time we use the try square to know whethee Its coming good or not 8 ter the compeliation offing with rough flat fite and the jo is almost complete we use the smooth fat file to make it more smooth and exact. SAFETY PRECAUTION: 7) Wehave to use the ful engin of the'raugh fat fe, otherwise it can break by the heat generated when, ‘ing, 5 2 One paper is used around the Job so that it does not deformed by the hat while the works going 3. The-bar shouldbe attachod properly withthe table vce 41” THIS handjob Soe should take care of handing the hand tools, otherwise Injuries may hap 21Nouns Pradcepta Sen- Lht --B En- RoMNO:- 941 BED10 4. (sName:-Prodecrta son Gee i-B Em ROLL 95 VBEDIO Te 0. 8 2 tii $C imegorets poe TO MhaKo cL SAuany 4yrorn M5 Material: Lrsound barr rege tira ear enn ‘National Institute of Technology Agartala 2A mmong and asm diomoton- [ SIN. ‘Sequence of Operations Took Used 4 Toko angund ban Chonkpiece)s MS sound ban ond fix ft inthe Bonchvieo | of dia+6mm) ae pe ue eG + Benehviee woe BR mm Len ob-the |, Wilony wankpzcy dont ee | Caen With « elp of ahanksan |? HOEK San’. 2 | Aig the cut out pleco of * Roneh viec. hound -ban of Length warn |+ Roetonguian | £nthe Benehviec vertically 4lat 4idon . andAhon by the help ob: _tOuN etng i fied pene who-thon Ahe-t0 p anc. |* Ty squoure. ¥ oes pontfon eb-tne mound q Aan 2's §Rat on notby waling Thy swan As | Skoteh ploce Coun bon) * chalk pbeeo. Wonkpicce (nou "Odd. ethan ta Afters Anak Meth si oe 7 Aho halp ofa, ode Lo oh va ; aknoady +. Sok We Qmm wads PY steel nulen, dirvan foun aentcthc Oyen One ae. a nen 6acteng Por roads tie conkire. of-the Wound sunfaces Bbgek wie nck DnNome prodeopta Sey Soe.-B En-RoLusa:- 21 UBEOIO tte. are refs aera Serer nae National Inatitute of Technology Agartala fing pactee mode TOMOKO. Square tn aprteen inate MEL ieougeund bon Te eae Se ey mumiong and 46mm dfameten [SiNo, ——fequenee of Operations m: [Again the Wonkpeoce & | Baneh vite: Sean Encthe benee vice |* Centra puneh- vorticaly:neth dhe Walp |+ pay poan Cho centre punch. wmMank) — Aammen- arade on Ano. fntance.cting| Point he weth a Baw pach hammers 6 vergttcat £21 cL + Chalk plete. ahee Beontal tne te anawr|, Gere Oe ¥ [through Ane opplychg chai Thy sqanes an n¥ agaen applychg chatt tang atgentton or do 2 Tay’ square « ne te ene el Fe | connect Ahe_end pois * Scnifben- thos ional ie “Thy squane . Ahehelp of a scntben and Wy Ce pouane a6 @ |Make emallsmal holes | + Beneh vireo hougheue tne. cOrcun=— |« contive punch: te sates ted | pagan ' , { { Poon iy fs on Abad ene SEO. ON Prty perch vi qr againcthe rank place # ffxed|* Beneh vito’ vente Vethe. bench vere ,| » ofr, tne foanerpane")“siaeyanene” Snomthe. nownd bor wtng ry vy Alok . Thy square» lied sAbon gf nd: choc Ok yeauan. aan feet zAHEETMETAL SHOP ~ ee SS ome: Tnadeopae Bon En-pottno:- DATTBEDSO —parionattnstiute of Technology Agertala j FIEG.S Marking and measuting tools, Cutting Toots '* Straight snip They have straight jaws and used for straight lina cutting. Ref fig.6.10 7% Ganeed snip «They have eyrved blades for making circutar cuts. Ref fig.6.102 BENE Ly. Figi- Cunved_cnfp Bat a ae ert ae a aeAR = & ae ¥ Narnes-Prodagpta bon *S eouno +24 VBEDLO ee a, oy Nationat insthute of Technology Agartala 86 Striking Tools Mallet - It is wooden-headed hammer of round or rectangular cross section. The striking, face {s made Mat to the work. A mallet is usod to give light blows to the Sheet metal in bending and finishing, Ref fig.11comet Madoopta sorv ee aie Oo UBEDIO resin aretftnda rear er National institute of Technology Agartala EAD tee ce Nozze Fe fi — Révet gun ‘Mechanical Saidering tron o > Z Zz 4 . A ae Pgs Machanttal soldonitg tron Biectri Soldering kon £92 Elocthife 4 Sotdening Tn, 10)Nome:—Pradoapto Ber Sets ELECIRODES a PEAT REGULATOR ff Dia p KiTeE = t SS \WATER LINE Ps 3 a WATER SUPPLY pUrevETCH a “a Sea Be Fi i-spot holding wachine <= 66 Merits ae Pt , High strenath © Good dimensional accuracy and surface finish Relatively low cost 67 Demerits i gt a + Wrinkling and tearing are typical mits to drawing operation ‘+ Different techniques can be used to overcome these limitations © Drawbeads © artical projections and matching grooves nthe die and blank hole ponte nTns May Be Used toreach final denensions ba ee adKN wnt Pra dcop to Sow Soc-s En-Rotk no 9417 BENLO ™ Sheet Metal Shop : J oi (OB NO. 01 (EPP AIM > To make a single seam joint (Galvanised iron sheet) * =o) All Dimensions are in mm ; Migertols Required » GI Sheet (60x20mm) 02 ttos. Toals Roulred:- _ 1. Steet rule © 2. pollpeentiammen © 9) 3. Centre Poneh 4 Serfben 5. Mallet hammen 6 Snip \ot4 :Woune —Fradeepxa, Sew Boers EN-ROUND! 247 EOL ) At firet mark the sheet withneqyinedimeniunament Then cubthe G1 Sheet with the help of: ) then bend the chest with the halpot nanualsheat bending machine. } Then over tap to form the ingle seam, ) Finally stage Seam ts formed. i, Precaution: . Fag ad Adways wear proper dross and shous ina workshop, _.») Bofore operating a machine, It should be cldaned and olted If necessary. Me) The heowg work should not be ite! by hand, 8) Ship should be used. carelully, nage ey aceNote Peadeop ba Serv £oc'-B Fn-RoUunoi- A VBENLO rege echt ses TTA oy National lostxe of Technology Agartals Mig prcicemedet TOM AK a gfrato epam ioenk Material Calvaniesact me eee Fon Sehoot: 4 Gakvantsod inon shook 46 tokorv and Ano peaes ee om eoodn SO mm. #s bein ' WE tho Ake of ruler y 20mm tonoty £ “moors Ahen W pf merené wank, Pala wing a setiken mom one ent of bot Ana pieces honizont aly Plocod: Boththe pieces ane bent useing moto shootbendon id 20mm. manks Jorn ioe hom by Che fnto. othen piece, in 0" dashte ay ‘ead Meet Boom soit & ¢ batvahy. padednors + Stniben + sheolauler "Motol sheet hendenSS TT Noumtas Paadecp+a ser B eM-PROULNO— QT BELO Aohory Precaudions (ay ti ALUOLYS hoctha proper dinoe Bm a Wonk shop: [ Novon conten Ento Workshop without AN ons 5 Before openatin amy machine ,amnake Aue% C Lt dogsmot couse. aw miuny ' 2 nah AEbA- any hoowy Work oy yourr mand ‘) BM ghowld. pe usec caurrahuliy«Names Proadacp to San Sec-B En-Rowmor TVCEOIO = Sheet Metal-Shop fe" JOB NO.02 ene To make a Single Rivet Lap joint. “ orem = Mids % ie om, a, Materiats Required :- 1) G | Sheet (80x 50 mm) 2 Nos. 2) Aluminum Rivets 3 Nos, s Is Revired= Ay.-Steel rule 2. Ball peen Hammer 3. Contre Punch 4 Serlber 5, Mallet hammer 6. Snip 7. Hand drilling Machine lures -_-g) ALdirst we have to cut two similar sheet of length 80 x 50mm. bh Then the distance of 10. mm isrrarkedon two plateAgo MRO NO 2 VBEDLO @) Then mark points of 20mm dictance cms wim Ine fe choot: « @ Thon mark the point with help contro punch, aftor that drilled the pointed place, ‘ @ “hendivide 10mm into parts of S mua « 4) Thon rivets are used to join two plated with the help of hammor, afety Precaution: a) Always wear proper dress and shoos ina workshop, _ b) Before operating a machine, it should be cleaned and oiled If necessary. an The heavy work should not be lifted by hand. © d) Snip should be used carefully, -None i Pradecpto. 807 eer En-ROUNO- 24 WBE 010 sede eb a TP poe oy National attute of Technology Agata lo Rivet Lap ion Flin proctcemoaet TO Moke O- Gil Matera GT shoot ono ALuinintur Rivet sue (80% Ha) MM + etee\qulon docos 0} éimélare dimen zi is One. iy ouk}2, |* Scniben bo lant + corte pureh nom one connen of bo-th-they , oe 40 rim ts mayekoo ie pect ey Scnsbor and staal | “munen: Tle "H tondoridLtng . machine. tomm £6 dévéde a exto edo k Parats + + Aleunindlue Thon Mank spoints ako Jap of 20mm afstoner on Ce Bing dn shoots WANG Contre punely On Bowl pean hammen: nae {hes etnin2c points ang Hand ainéMing machine+ Atuminfum nerot & Monta ok nese ee pointe is toth it ih A perp a Aly, use Revol oie Soave mec mo névet:None% Prodaapta dar eee Peo NOE IL BEDO Zokely Preeaublonis ) Always Hoory O pwopen dnass Eg workshop (6) ever enters 2nto tho Henk. shop wethout «hoes (© Beton. opersatsing anu amoachena, Le ghoutd too choornack and oftede £h nacess any « (aly Never 18kt-on Ahoowy machtne [+o ol cinackty. ©) ~vee shanp Aools canepulty »Name — fradeopta Sev £2t-B em ROUHOH 217 BEDIO oe arc entre meery STAT Se, Natlona institute of Technology Agartala Chapter 2 CARPENTRY 2.1 INTRODUCTION Carpentry may be defined as tha process. of making wooden components, |t starts from a marketable form of wood and ends with finished products, 116 doals with the building work, furniture cabinet making. Ete. joinery, Le. preparation of joints ‘5 ane of the Important. operations In all vinod- ‘works it deals with the specific work of carpenter like making different types Of joints 10 form a finish product 2.2 TIMBER Timber fs the name given to the wood obtained from well grown trees. The trees are aut, sawn Into various sizes to sult building purposes, ‘The word, ‘grain’ 3¢ appllod to wood, refers to the appearance or pattern of the wood on the Cut surfaces. The grain of the wood is.a fibrous structure and to make it strong, the timber must be so ‘et, that the grains run parallel to the length 22.1 Timber sizes Timber sold in the markot is In various si20s and shapes. The following are the common shapes and sizes a Log The trunk of the tree which is fre from branches. b. Balk ——_- The log, sawn to have roughly square cross section. & Post = timber piece, round or square incross section, having its diameter or side from 778 to 300mm, d. Plank -Asawn timber ploce, with more than 275 mi in width, $0 to 150 mm in thickness and 2.5 to 6 5 meters in length @ Board § = A sawn timber piece, below 175 mm in width and 30 to 50 mm in thickness. F Reapers - Sawn timber pieces of assorted and non-standard sizes, which do not canfirm 10 the above shapes and sizes 222 Classification of Timber ‘Wood suitable for construction and other engineering purposes is called timber Woods in (general are divided nto’ two broad categories: Soft woods and Hard woods Soft woods are obtained from conifers, kai, deodar, chir, walnut and seemal. Woods obtained from teak, sal, oak, shisha, beach, ash mango, neem and babul are known as hard wood, but it & highly durable ‘Another classification of woods is based on the namie of the trees lke teak, babul, shisham, ‘neem, kai, chir, etc 2.23 Seasoning of Wood ‘Annewly felled tree contains considerable moisturo: content. If this is hot removed, the timber Is likely to wrap, shrink, crack or decay, Seasoning is the art of extracting the moisture content under onirolled concitions, at 2 uniform rate, from all the pacts of the timber. Only seasoned wood should be Used for al carpentry warks. Seasoning makes the wood resent and lighter: Further, It ensures that the Wood will not Gistort after itis made inte an object 224 Characteristics of Good Timber x seuneny em ‘must re ‘the following characteristics a ‘minimum moisture content, |e, the ti The grains of wood should be straight and long, Sn 2 Ds Ho eed, 'G It must retain its straightness after seasoning, dt should produce near metalic sound on hammering. @. It should be froe from knots or cracks. By)Nome Preadoopta Serv L00'-B Seen dr Res rede reife or National institute of Technology Agartala FF Wshould be of uniform color, troughout the part of the wood! 19. should respond well fo tho ishing and polishing ofsorations Fh Diuing driving the nails and screw, Mt should not spilt casly 2.3 MARKING AND MEASURING TOOLS ‘Accurate marting and measurement 's vory essential In carpantry work. 10 produce ports ‘enact size. To transfer dimensions ofto the werk: the following are the marking and measuring tools that aro roquieed ina carpentry shop, 2.3.1 Steet rule and Steel tape Stoo! rule fsa simple measuring instrument consisting OF a long, thin motal strip with a mackoe! scale of unit divisions. It Is an inipartant ool for linear measurement, Stool tape Is used for large ‘Measurements. such as marking on boards and checking the overall dimensions of the work. TOP lees 2 3 6 $ $6 7 8 8 WH 1 O Figure 2.1: Steel rute anaStoa! tape 23.2 Marking gauge It isa tool used to mark lines parallel to the edge of a wooden piece. It consists of 2 square ‘wooden stem with a sliding wooden stack (head) on it. On the stem |s fitted @ marking pin, made of Stee), The stock Issel at any desired distance from the marking point and fixed in position by a screw. It ‘must be ensured that the marking pin projects through the stem, about 3 mm and the end are sharp ‘enough to make a very fine line. A mortise gauge consists of two pins. In this, itis possible to adjust the distance botween the pins, to draw two parallel lines on the stock.Name Pradgopta sow Focre farrottmo- 21 BE0!10 neta arate rrearr serene National institute of Technology Agartala Figure 2.6: Carpontors view Figure 2,7: C-clamp 242 Clamp Figure 27 shows a C-clamip, which i used for holding small Works ‘Sketch Clamp Handle oe Scnew _ fad nv Bo. Triagen fon quick, It opentig S a C—Clamp bs Canpentens vice 2.43 Bar cramp Figure 28 shows a bar cramp. I's made of steel bar of T-section, with malleable Iron fittings anda steel screw. Its used for holding wide works such as: frames or tops. Figure 2.8: bar cramp uame Pradeepta sow BeceB En-Rolwno— 2V BELO aye Sher ives National Insitute of Technology Skotch meh avers CAP moa ick ton Q. Wood Jack Plane encothing Hone Blade wedge e- smoothing plane 36,Name Pradeepta sen Soc+B Emy-Rottmoi—24V E04 i, rede dhenftreht meant server National Institule of Technology Agartala 2A CUTTING TOOLS 2.6.1 Saws Mnf nee 10 cul wood Ino plocos. There are effort ypos Of AWA. doslgnee to st iroront purposes. A saw Is spied by the longth af Is toothed edge 2.6.1.1 Crosscut or hand saw Teg used to cut actos ‘wider than tha blade thicknos, 241.2 Rip sn Lis unbd for cuttlg the stock along the prains, Tho citing edge of this saw makos a steoper angie Le, about 6 whereas that of erosscu kw makas an argo of 45 with te sucace of hn stork the grains of tho stock, The teoth aco s0 set that the sm ery il bo This alloys the blade to movo frooly in the cut, without sticking 2.6.1.3 Tenon saw its used for cutting the stock elther along or acroxs tho grains. Its used for cutting tenores and Infine cabinet work, However, Its used for small and thin cuts. The blade ofthis savy ts very thin and so itis sttrened with a thick back stec! strip. Honeo, this is somotimes called as back-saw. In th, the teeth Aare shapod tke those of crosscut $20 2.6.1.4 Compass saw - Tthas.a narrow, longer an stronger tapering blade, which is used for heavy works (Fig. 1.13). It Is mestly used in rads cutting, The blade of this saw Is fitted with an open type wooden handle a4 es EN ASA Blade Handie “onan saw INN) ‘cman a0 ten ‘Gompass sow ‘Cross cut saw teeth Rip Saw teeth _ “ie a» Cnoss cut sateen be Rip Sl Aaa, ”: Narnes Prados pta Son BOteB Ey Round 247 GE 010 : is redraft tears oereee 2 i! ‘National Institute of Technology Agartala ae Sketch Firmer Chisel 1) a: Firion chisel bs Dovetail chisal Mortise Chisel ee) €Mentiee chisel ds Sockot-chigel Outside ground Chisel Sa Ds) @ Outstde qround chise Inside Ground chisel SE Setnsdde Ghound chésol 9| Nromet- Prodeopta Sov Agt-B Eneolno:- Bry BEDLO 7 Daas, ayer pete winery sprragy Say? National institute of Technology Agartala 2.7 ORILLING AND BORING TOOLS 27.) Carpenters brace it 1s Usod for rotating auger bits, twist cris, fe) 1a produce holes if wood! In some designs braces: are mado with ratchet device. With this, holes may be mado in a cOrrer whore complete ‘evolvton of the handla cannot be hide. The stzo OF a brace Fs BoterMircd by is sw 2.7.2 Auger bit IU the most common tool used for making holes In wood. Quring dling, the lead screw of the bit gues into the wood. necessltating only moderate pressure on the brace The helical utes cn the surface carry the chips to the Butor surfoce 27.3 Hand dei Crpentor’s brace (used to, maka: telatvely lange size holes: whereas hand dil ts used tor tiling small holes. A straight shank dil Is used with the tool It small, ight in wokght: and may be Corweriontly used than the brace. The dil bit Is clamped in the chuck at Its end and is rotated by 3 handle attached to gest and pinion aecangement 2.7.4 Gimlet It has citing exges tice a twist nil it fs used for driling large alameeter holes with the hand pressure, - fe & ‘ee = ee Accae Hang ant Gimiet Figure 2.13: Driling tools Sketch + Carpenters Brace Gimiet a0 As Carpenten’ braceName Pradeepta Sem AeerB tn ROUNO- 2VBEOAO F aregrey thehfteh) viverra servers ‘National institute of Technology Agartala Be ‘Sketch Wood Working lathe Wood Wonk piece. ; Dead cutterName: Pradeepka Sav SCLIB En-Rolnd 24VBED10 Pes rede Shel eer error og ational tte of Teohnology Agntle irc Saw Fgi-Cinculare Saw a5Novia! Phacoeptasev ACO En-ROlnd!- 24 VB E040 ren sents ener sen National institute of Technology Agartala ‘Band Saw AdjustableNomme:-Pradcopta ene 401-8 en—Potlno— 24 VBENO negra teh frat ree area ___Nallonal Insthute of Technology Agartala “Brorek 7 Lap joint Aim To mako 9 Tap joint as shown In Figure 2.19, from the given reaper of sizo 60 x 35 x 250 mm. Tools required Carpontor’s vice, steol rule, jack plano, tryeaquare, marking gauge, 25 mim firmer chisel, cross-cut saw ‘tomon saw, seribor and matte Sequence of operations 1. The given reaper is chocked to ensure its correct size 2. The reaper is firmly clamped in the carpenter's vice and any two adjacent faces are: planed ty the jack plane and the two faces are chacked for squaroness with tho try square J. Marking gauge is sot and lines aro drawn at 30 and 45 mm. to mark the thickness and width of the model respectively 4, The excess matoral i fist chiseled out with firmer chisel and then planed to correct siz. 5. The mating cimensions of the parts X and Yare then marked using scale and marking gauge Using the cross-cut saw, the portions to be removed are cut in:both the piecos, followed by chiseling and also the parts X and ¥ are separated by cross-cutting, using the tenon saw 7) The ends of both the parts are chiseled to tho exact lengths, 8 Aine finshing is given to the parts, required so that, proper fiting is obtained, 9, Tho parts are fitted to obtain a slightly tight joint. Result The T-Lap joint is thus made by following the above sequence of operations. £5 6 6 Figure: ¢- £1; T= tap joint 49Somei— Pradoopta Sew Sorr8 En-roumor 230 BEOIO k Ab “e An “ Ay len ab * Fi'gi- B14) igi Cb) PAr Bb) {So6eu-B Pr—Roltno- 247 BEOIO oo anedrn Shen then serra fag ren To mar, \ fecal motte at ectinojogs Aoartate practice rede oa TH reg ert hue WOON. IOC I T-Lap josie Se -THO WOO den HLOCKS af dimerwfony (42. An 490 mn) z Qn LH A & RAKIM) [Sine | —___Seuenee ot Operations | Woolshed | 4e | A uoodon Stock ct- , |* Boneh vtec suitabe. dimenrtor- #5 |. on eaig ffoad Ento a benedwice- : THo nectonguian places |* Ca0ee cue Oh climanclbr (t2x45x00 | mam\ond (44 5x 4px 30m) Aree being cutout Hey the help of tenon som ov Chose cut SOM * =} 2+ | lotus eae Sinck oO X and ¥ seepor- THe of alinerncon U2hx ABKedMm) and- | Ciiny 4B yx 20mm) | By skool nulan , Perneél See and ‘Ary square manks | Rene On ay Admm Menom, 208 conned ee mang Ke ahdetneteh a tine oh chow), Tq tans Socio (toh xAr min) and we WAM mM en -tWe cwoss, S2.ttfow (42h x20mm),0v [ block X [figrBta)) A> |The % bhOCK £5 AGath Heracll « 3 Bn beneh vite. ant tho wy eS wing san 40mm portion aw °. non cach comnar «beth Nome: Pradgopto son 5 50Somas—Pu adoo pra Sow Ae Colkmo~ a4 BENLO ares cree era ier ‘National Institute of Technology Agartala fitiog practea model TO MAK. o.T—lap sown Materia: HDOdON. b LOCK» ‘SiNO. Sequence of Operailons Tools Uied fermen chtsol fs both "Pohmory ¢ Ploceck overrtho. mace Gnd ler enecl ts hétoc 4y honmen veny |* tammen SMOOHLY to gio a LEO ae} re ae SOU | Aw) acta Ponts ane Femovad abt, Jf mtr Beny mserttvel He | moog the Gop thy Pant |*Faamern chisat buthg éhmar, chése shang. trorrmerr and" thon File Lew ety ee o filen Uethg atirysuam,’ len the flatness Pe chocked. |* Thy square The X block #6 yoady « iE Frg:- B(b)] 6 Uedg staal ular perch * skal aulon Ohd “ty square monk aerate ore An mn. onthe cross sachon. otha mamkdtha tx 4% mm) and 4mm oy “Tay squarre CHORE to ctidyy (18% xa.9me Taig:- tt ay] + lYolock % Sexo again iV| + Conch ‘e VN" C2 Chytee onde Saw Me cut 4hmm ond Aw mv * Saw MOanKs Wurpeckivaly S"THOHOOAON bioeks of diriensfons CoH KAM SOMM) and 18x45 ——, *30rmm)Wamo:- Pradoopto Bov £0ers Tm-eouno- 24-VBEDSO Sojety Procautions:— ® tools thatane net boing us bj wocl- ehould aluays be Kopt od-inedy Preopen ploces d e a (WH) Make sune-tn ak Yours Hands ane not fn Snont o sharp edged Aools whtde yours 2 eu ham: v (1D Donot we asaw cnractalte> cubstanens a Don't Wee mallet stostriko nails 2 . Don't Uso saw weth £0082 han dieredraft seaet sere Natlonal institute of Technology Agartala Exercise 2 Dovetail lap joint ‘Aim To make a dovetall lap joint as shown in Figure 2:20, froe the given reaper of size 60x 38 250mm, Tools required : Carpenter's vice, stoe!ruto, Jock plane, try-square, marking gaixe, 25 mmm firmer chisel, cross-cut saw, Jonon saw, scriber and mallet. Sequence of operations 4. The gen reaper ischocked to ensure its correct size 2. The reaper is firmly clamped in the carpenter's vice and any two adjacont faces. are planed by the jack plane and the two faces are checked for squareness with the try square. 3. Marking gauge & set and lines are drawn at 30 anc145.mm, to mark the thickness and width of the model respectively 4. Tho.exooss material s first ebiselod out with firmer chisel and then planed to correct sire. 5. Tho mating dmonsions of tho parts X and Yare then marked using scale and marking gauge. ‘6. Using the cross-cut saw, the portions to be removed are cut in both the pieces. fllowed by chiseling ‘and aio the parts X and Yare separated by cross cutting, using tho tenon sav 7. The ends of both the parts are chiseled to exact lengths 8. Aine Tinishing is given to the parts, f requérod so that, proper iting Is obtained. 9 The parts are fitted to obtain a slightly tight joint Result The dovetall lap joint is thus made by following the above sequence of operations. 6 Figure C- £2: Dovetail lap joint 1Nomet- Paacgopta 62 Ear tine - DSUBEDIO A0—a a ee =, Feqe- Dove-toit Lap inenteSrONe- Prodecp to. Aen ROAD EnvoumenENd !— 9408E010 National ir rregre thentehy sears, serrraea institute of Technology Agartala ‘ei Ue CO soft ST HO Wooden LOCKS Of climonsfon Sequence of Operations s(4onx4bysorm compa kab am) Take o wooden Hore 40 sirooth Ou-the. eos, Une Wood Plamen: Wet “ho hot 6 onefl and “id sQLOe mark oon 4 co of “thot ow K pi2ee" + A0od plarhen * PonekL “Trey oa Usthg ponen/ efirculors cans) Cut the work pleee ceenne— m 4o-te Mank Made oni Aton Ck |the_worsk Peco of suet ab! SBasritons aomova the extno_pants: » Chinon 2aM' 3. Toke that wonKpecee » monk otine rr ae ee Ano meddle OF 5 ey ond. abyitte £t coup » Then ceeonatng, to thak moro wetn-ne nel of powan ZOM* AS O WALES TNO oven ovecoknacd Cromnesy » XY) fi E *Ppongh 2aW) HMOCKS Of DOLL atrrensiing |ee Procaopte sav Eroltqnane! NOr LIU BEOIO aedr thenitre teary aera National Institute of Technology Agartala Fating practice model: “TC) dovotatl Lap sore mere (oan btNck a tiaiatbu Ui BYABY 20mm % tae £50 x Abx 300 ‘SiN, [___Sequenee af Operations [Tool ec al’ ie make-the onda ofboth *Bonehveeo he, bkOCKS wore 2VZN» vein ame mp gt Be wood naspdtle. | Vo. eS Mn pe tihen 4h xing arom. Biv jooneh viens 5 | Ad Piaot-blOck X és token, |* Poni an y aubtorte etna Ce O gmandod onstwey |* Hack 4aW- seth hetpot penckt ond |e poe mer chisel | Stool euulore »Thon-cutsthe | + Wood vasphile TER ten wetW Chisel yornove. eal a hoc! thon ushha Pelores MaKe | the sunpod even: é: son ake aha JotoaleY « axooiauien ash One a te mi ety | ees of steal euler and * Hack 2ow) ent eat the erat Fone wet Wock £0. | peace the block Y oven Alock X ahd Os aviewut Bovotodl Lap loent Ss Obtoentd«Nama:- Pradeopto. Bary 422 B T-Rouno- 24-V BEDIO Sooty Praccudtions:— tools thatane not boing usec should aluays be Kapt ot efh Propen places « CO Make stime-that yours hands anenot fn Sronk of- shamp adaod. tools white you drs 2 uachg them « ("donot we asan mnMetallic subatahers () Don't wemallee +ogemntke nase VW) sont use sow with 0082 handleProdoopto. serv at OB nto 24-V BED Eovapttonentros 24 Chapter 7 SMITHY SHOP. TAlntroduction: Forging 's the process of shaping metals by impact or very high pressure. The metal in this process is Squeezed to altain the desired shape and this requires the matal 10 be in plastic state. This plastic state 6 plasticity is brought about either by healing or increasing tho stress level beyond elastic limit ‘When the metal is heated to plastic temperature and shaped, It is called hot forging. ‘When the metal is deformed and shaped at room temperature. raising the stress lovel bayone elastic limit th process i called cold forging, Forging as a manufocturing process Is Intended to produce gomponents of high strength of wrought iron, steel, aluminum’ loys, brasses etc It fhust bo remembered that, all metas can not be forged. For example, brittle metals like Cast Iron can not be forged. Components such as connecting ‘od, crankshaft, leaf spring etc, are all forged Hand forging and Machine forging: Hand forging 6 done by blacksmith in-a séction of workshop called Smithy. Heating of metal 's dene in an open fire or hearth and hand tools: are employed for forging. Job works of smaller size are handled fn.the smithy section, Machine forging |s done in a section catled Forge. where closed fumaces aro Used for heating the jobs and power hammers. or presses are used for shaping thom, 7.2 Tools and equipments used in Smithy: 1. Hearth: In Torging process the hearth is used for heating the job, Coal, coke or charcoal is usee as fuel to heat the Job. A blower provides. blast of air to produce rapid combustion, 108 eNome Prodeapta sen 40e 3-8 Emmoliment 10-247 BEOIO coda Arend veer serra National institute of Tochnology Agartala ‘Sketch ‘Swage Block Holog Fagi- swage Block, Anvil Chipping Block Face Polite. Square Tong 20 ys saan ce Hallow Ton“nome ns peer Serv ae cored NOI“ VIVRE 040 sain ms Bea 3 oe National instttute of Technology Agartala Pucker latter Top Fuitarwanas— Pradeepta serv ALLt-B oe ae Eola ant no%— 2) VBEDID Sinn tiny ney eran oa \ National Institute of Technology Agartala - Fip—teae fs ste aNome *—Foodorpia sey RECID Envouencné NO 2x UBEOIO Har TTT National institute of Technology Agartala AIM := To mako a square from 3 MS (Mild Steal) round bar, xerchsa 7 SMITHY SHOP. lL 125 - +} ‘All Dimesions are inom (MATERIAL REQUIRED: MS Round bar (Oia. 16 x 100mm) TOOLS REUIRED:- 1. Flatter with wire handle ‘Double face sledge hammer Square Tongue Ball pen harmo Hearth Anvil Stool Rule Poker ‘PROCEDURE: J Atfiest take a MS. Round bar of 100 mm length and diameter of 16mm, Fld the one end ofthe workpiece withthe Relp of round tong and other end ofthe workplace pt into ‘tho open hearth furnace & Mer few minutes when the tmporature wil rise 800-1200, the work plece wil be red hot A Nove, place this workpiece on thasurface of the Anuland strike the heated end portion with theholp of ball poen hammer. 5 ‘Afr striking, the clcuar end periion of the workpiece wil bo ‘elipticl shape and then again strike It With thehelp of ball pen hammer by ‘rotating it at 90” anglo to form a square shape. £, When one ond ofthe workpiece wil be the shape of a square. use fatter and double fac sledge hammer oghe shape of the other end ofthe workpiece 38 a square of four face 7 Asa finished jab, length ofthe the square wil be 125 mim and with ll be1amm each sds 5. Thus the jot Ibe the square shape of proper measurement. 1. The fire shoul be lightened inthe hearth very carefully 3 Dear touch ary metal part unless you know that is temperatures orl 4 Nevor handle the tongs and hammer loose while working A Nevar wear sky cloths in forging shop while work §. Hammering should notibe dane inlay mood usName pradeepta sen- 03-8 Enaollanntnro'- DIVeEO10 All dirmencions ors Bh. romNomes— Poadorpt a Serv Aee-B enroimnk wo 9 VEDI aed thine meena aerrten 3 National institute of Technology Agartala 4 ee To Make o silt 2 from OMS hound ban ema MS (Meld sto2l) wound bar = (Dh 46x 400 mmf) cm _Sexqenc oF Operators Toni Used ] + AMS houndbon of |+ Stolnuler cae and 46 oe ie * Hack saw i cut * 100 Vieo onfathar rn a ave ween Abe help 0f- Hoek saw and nulen: a ee Wonk pizee “Round tong mas eles ou | woodesv Hovacoo cpa port feroes Fopan haanth seen chiar patanse| Pee 3|Abtonfen minutes, | gona | Jaiponabi Round tong fs rogeod upto 1100, Ko. the, dren tol At pier Nite Fipd round, ond A: | place Ahe- hoctad pee! + AnyEl overr-the ounvel and het * Batkpeeh- a nit bowl paziv ommen+ 116womet- Poader pt sen, Apet-B Ear 0llanent Noi- 24 UBE 010 ea tieifia dere-orrcn spi, oy Nationa Institute of Technology Agartala Peng tia tose Ko 0 squian a. broom MS found ban Mate FAS CHAT oe ie amine ea oe ‘SINo, Sequence of Operations: | Tools Used Ll & | Afton Wetting . Ane. * BOM paon eulon endpontsoy | hammen wel be ebtfprtcat and- thon 09 cfr, WEEE WEth the badl pzen- hommen 20 qéve © hapa of square _| Wikrmate ty. | 8 Uiiag qiaaton andy “Plate |Wuble stodge free *Double face | homens toee shape | sted: ee Se ee endothe | harmen 20 ab ASQuONYe oun a ace + % 7 Fenty, a squares | barzt obtofned of- BEC Oia alae Wictth 19mm Lach ety 107Nome ¢— Prodoe pra sary ReCEB Ennctimont 103 4VREDIO Sourety Prive cueLorvs 4+ Tho £Gne shouto be Lg heenacl Bhthe Ahocueth, varaty ean offily 2+ Do nok touch any moral part: tuners You kno) that ° tS tomponoture fs Noremar- + Nevers handke the-ongs and Amman (ooaa_ WhRLL wOrnKEng « * Wever Wao AEIRY ctoths in fonging zhop while. vorskcing - Be Naamen'tng shoulc mokee done in hory mood: myNoune*—Pradmpta serv Ave t-B WeN!— aeedran efron) been ere OSE 040 National institute of Technology Agartala Torche? SMITHY SHOP ‘NIM = To-mako a Hoxngan from a Ms (Mild Steel) Round bar L rs 4 ‘| Dimensions are in mem MATERIAL REQUIRED:« MS Round bar (Dia 16x 100mm Lg) ‘TOOLS REUIRED:. ‘1 Flatter with wire handle 2 Double face sledge hammer 3. Square Tongue 4 Bali peen hammers, Hearth SAnvil 7. Stool Rule 8, Poker PROCEDURE;- 3) Abfirst take 4.M1S. Round bar of 100 mm length and diameter of 16mm. 2. Hold the one end of the workpiece with the help of round tang and ther end of the work piece put into the open hearth furnace 3 Aftor few minutes when the tmperature will riso 800°C - 1200°C, the work plece will be red hot 4 Now place this workplace on the surface of the Anvil and strike tho. ‘heated end portion with the ball peen hammer, 5 Alle striking the crear end portion ot the workpiece wl ba eiptical shape and then strike it again and ‘spin with the ball peen hammer rotating it at 60° anglo gracualy to form hexagon shape. When one end of the workpiece wll be the shape of a hexagon, use flatter and double tace sledge hhammner to give the shape ofthe other and of the workplece as shhexagon of six faco 7 As afiished job length of the the square wal ba 125 mm and OBmam willbe each sido 4 Thus the job willbe the hexagon shape of propes measuremant PRECAUTION: 1. The fre should bo lightened in the hearth very carefully : 2. Doral touch any metal part unless you know that its temperature is normal, 3 roe tongs and hammer loose white: + wear siky cloths in forging shop while working, 5. Hammering shoud not be done in Lary mood, 7Names Pradeepta sory Avti-B Envoltmonto.-14 UREN =-63 ALL dimonetong ane thimmeNamet— Practoopta Serv ALLB Enoolument wor 21 BE 04D aredre Sheitey very yer i atonal intule of Technology Agartala tim pacers: TO OL KD QL rorkag or {roma MG round ban waco MS CMMPld qtatl) Round bar (rkotermm soommtq-) ‘SINo, Sequence of Operations —__ | Toots Used 4: (Plnea tho Ma nound-ban “Leg vero | | inane Leqviee panawely « errohmulon | 0 bodnthe sans Ob |. tack caw Then, mowsk 400mm oe the help | of hlon Oven it Gnd cute PE astth the helpof hack san | & ee Fins : ‘ *Round:tong WER of- reoun Ang cond ines LE By | Open hearth the_-opon, Ncsttly, funnaes ninco, Asters ntefon of; woodorv coo tntt: , Hodge Upto 400M 000 + Aficn becoming had= * Round tong AoE» takenudthe motor + Pavel { and place “Hover, amt ond atinfke & ee weth the bout paan Nournnacre 5 1gName +— Pradoopto Serv £OC4-B Eeroumnerlt NO-2IVBEDID Rr ok aed aheaitva ther sertraan Nae National Instue of Technology Agartala ane rum moeanaa TOMAKE hexagon from aM hound ban . waren MGC Met oboe) Lound boar He (pf bmim % 4100 mm Lg) cee epee nen | TTS 4: |Atton striking, the | “Ball penn canewan end pontéory ¢hommen witl ba elongatec-and than stafke =f agaky and 09 on uxtig wou pean “Aanumnen ana +o form hexagon: Be \Vcthg Flatter and-coubel » Platter 7 face Madge MAMMEN) « royr1e Kaeo 2 Anike-tne Other ends) srodgo ¥ 0f-the Honk plece also | harntnen +0 2 MEXOQon ab shape of ex faces: MS Hogagonar-ban Of Length. 49% rate Wd “sfdeok emnv ' 2ath cs obtained 6Nowe ¢— Pradeopta sory HEEB Ennolument 103- VV BEDIO | Sauety Prove autfons S 4+ Tho fine shoutd be {lghtenacl fintne hooey vary eanalplly ‘As tomponotune fs Moramar- | 2+ Do nok touch any motto pant tuners You Know) that: | | 3: Nevers handle tnetongs and hoummar oose Whee working « 4: sever Woon 2éiky cloths th fonging shop while working - Be Homers ing shoul mokbe done en hary mood:Names Prodgop ta s ary ALO.“ Em wOULMENENO—PAVCEOIO e National Institute of Technology Agartala Chapter 3 WELDING 3.1 mTRODUCTION Welding is tho: process of Joining similar metals by the application of heat, with or wathcut application of pressure or filer metal, in such a way that tho joint is equivalent in composition and Characteristics of the motals joined, n the beginning, welding was mainly used for rapaiing ail Kins of Worn or damaged parts. Now, |I is extensively usod in manufacturing Industry, construction industry (construction of ships, tanks, locomotives and automobiles) and maintenance work, replacing riveting and bolting. toa greater extent The various wolding procosses are 1. Electric are weiaing, 2. Gas woiding 3. Thermal welding 4 Hloctrical Resistance welding and 5. Friction welding Howover, only electric arc welding process ts discussed inthe subject point of view. 3.2 ELECTRIC ARC WELDING ‘Arc welding Is the welding process. in which heat is generated by an electric arc struck between an electrode and tho work ploce. Electric arc Is luminous electrical discharge between two electrodes through ionized gas. ELECTRODE LEAD Figure 3.1: Arc welding set up ‘Any arc welding method is based on an electric circuit consisting of the following parts: ‘a. Power supply (AC or OC) b. Woiding electrode Work plece: Welding leads (electric cabtes)'connecting the electrode and work piece ta the power supply. Electric arc. between the electrode and work plece closes the electric crcult: The are temperature may reach 10000°F (550°C), which Is sufficient for fusion the werk plece edges and Joining them When a long joint is required the are Is moved along the jot line The front edge of the weld ‘poo! molts the welded surfaces when the rear edge of tho weld pool solidifies forming the joint Transformers, motor genérators and rectifiers’ sots are used as arc welding machines. These: Machines supply high electric currents at low voltage and an electrode is used to produce the nacessary arc, The clectrode serves as the filler rod and the arc melts the surface so that, the metals to be joined arc actually fined together, Sizes of welding machines are rated according to their approximate amperage Capacity at 60%. duty cycle, such as ¥50,200,250,300;400,500 and 600 amperes. This amperage fs the Fated current output at the working terminal isee ee ee NS : NOC Prorcloopte 2arv ALCY-B n Em lment 0% 91BF04 O is area et et Sree National Inatitute of Technology Agartala ae 2.3 WELDING TOOLS 3.3.1 Electrode holder The electrode holder is connected 10 the ond of the waidng cable and holds the electrode. it should bo light. strong and casy to handle. and should not become hot while in operation. Figure shows ‘on type of aleetrada holder The Jaws of the holder are Inculatod, offering protection from etek shock =— Figure 3.3: Electrode holder Figure 3.4: Ground clamp 33.2 Ground damp if connected fo tho end of the ground cabo and is clamped to the wark or welding table 10 ‘Complete tho olecirc circuit. t shouldbe strong and durable and give alow resistance connection. sheik ray epihg_ entinudecl coversing 0 Peg & Electrode! : Sinilingend connie Gone and fer qnépping | See Ey aloctnode holaen’ FeQe- Hecinode Holden Ground Ctamp FEQ'— Grounct thampNome‘ Pyadez eta son é00r-8 AERoe 0 eqrvourment Noi- 24 VGEO4 Fa emane sae srr q Mational Institute of Technology Agartala Figure 3.11: Wolding positions 214.1 Flat postion welding in thes postion, tho welding fs porfrmed fram tho upper sd ofthe jot, and the face of the wld |s approximately horizontal Flat wolding is the. preferred term) however, the same pesition sometinies called down hand, 316.2 Horizontal position welding In this postion, welding performed on the upperside Of an approximately orizontal suctace ‘and against an approimately vertical surface 3163 Vertical postion welding inthis postion, the anis oF the weld Is approximately vertical as shown in igure 1.6.4 Overhead postion welding inthis welding postion, the molding i performed freen the underside of a oint 37 ADVANTAGES & DISADVANTAGES OF ARG WELDING Advantages. 4) Welding procoss ts simple 2: Equipront is portable and the Gost fairy tow 3. All the engineering metats can be welded because of the avalabiity of a wick variety oF electradtes Disadvantages 4. Mechanized welding s not posible because of limited longth of the electrode 2, Number of eaetrodes may have to be used while welding long joins, 3. Adefoct (slag inclusion or insufficient penetration) may occur atthe plac where welding Is restarted swt a frosh electrode. Techniques of Gas Welding ‘Skelehes showng the filler rod and blow torch positions Lot ward welding welding toneh © oY Fxg— a i a Name +— Prod te ptor 82n- Atee-B Enmtumont ot yy BE40 aredra shea em Serre a ‘National institute of Technology Agartala Lf) VA FiQe apices : FPg- Butt torn Corner of V joint ‘Tjoint ( / Fig!- T=$0ine Feige con pen JoinNant Prodeepta sary Ares B ENadlmont NO 947 BED O Ment oh yea ston ope Nallonal institute of Technology Agartala ‘Spot Welding Machine Uppen hon Pocksrs anny fiesNoumes- Ales-B Praottment Nos- Poaderpta Sen | & ‘ i vet rredrer renfdh sear. yer © re: National institute of Technology Agartala ‘Arc Welding Setup EUcvods Anion Gionund sornth cue *% Euctnode tad FEq2-hac wong 2etup 3.8 SAFE PRACTICE Adways wold ina well ventilated place: Furnes given off from welding are unpleasant and in some ‘eases may be Injurlous, particularly from galvanized or zinc coated ports 1. Do not weld around combustible or inflammable materi\s. where sparks may couse a fre 2, Never wold containers. which have boon used for storing gasoline, oll or similar materials, without first having ther thoroughly cleaned. Check the welding machine to make sure that it Is property grounded and that all leads property 3 ulate ’ Never look at the arc with the naked eye. The arc can burn your eyes severely, Aways use a face Shield while weicing Prevent welding cables from coming in contact with hot meta, water. Ol or grease. Avoid dragging the cables around sharp eons * {6 Erauro propor insulation of the cables and chock for openings. 7. Alyuays wear the safety hand gloves, apron and feather shoes. Always turn off the machine whan leaving the work. Apply eye drops aftor welding Is aver forthe day, to relieve the strain on the eyes. 10. While welding, stand on dry fooling and Keep the body instaated from the elactrode, anyother eRe esea non ectewe ace bia gplo'y 5NOmes~ Pradgepta sen 4004-8 Enavllamnt Nor-94°V BEDIO areira Shen rear Serres National Institute of Technology Agartala Exel 2 Double -tap joint Aim To make a double lp joint using the given mild stool ploces ard by arc welding Material uso 5 Two mild steel places of 100X40X mm. Tools and equipment used 'N¢ welding machine. Mild steel eloctrades, Electrode holder. Ground elarmp, flat nose Tong, Face shield, ‘Apron, Hand gloves, Matallle work Table, Ranch vies, Rough fat fle, Try square, Stoel rule, Wire brush, gh i ‘hammer, Chipping hammer. Chisel and Grinding machine. r Figure 3.13: Double lap joint ‘Operations to be caried out Cleaning the work pieces tack welding full welding cooing chipping finishing Procedure 11 Tike the two mil tee! ploces of given ckmensiors and clean the sutaces thoroughly from rust, dust parties, oil and grease 2. Remove the sharp coriors and burrs by fling 6 grincing and propare the work pieces 3. The work ploees are positioned on the welding table, to form lap joint with the required over apping. ‘The electtode (sitet nto the electrode older and the welding current is et to proper value ‘The ground clamp isfestoned to the welding table. Wearing the apron, hand gloves, using the faee shield and holding tho over lapped pioees the arcs siruek and the work pleces aro tack-welded at the ends of both the sides The aligamient of te lap joint is checked and the tackwelded pieces ae reset W required. ‘Welding i tein carried out throughout the length ofthe lap aint, on both the sides. 9 Remove the slag, spattors and clean the joint, Result The double lap joint thus made, using the too's and equipment as mentioned above,ae Noumes—Pradee pta son- 400°-B Fmrolment nor 14°UBE0I0Narmet Prada pta Sen aec 4B Exaoltmment 0-24 VBEO10 aid hed oe aor o. National nate of Technolo Agartala Filing practice made: “] © 17 rok gdouble £0 rofne, wathg mila aael Materia “THO M$ ( and arc sxe: ADO KAO 6 MM_LOK¢ es toting [ SINo. ‘Sequence of Operations | Tools Used | 4+ | inet iy wo hove-to @lean- The | + Avec walding | Aunioror of born-tha mild) machere ef20| ee «Thon memove |. Bid vtool Fax anp Conshens by | dactvodes . Gpoundelamp | 2a ae 0802 Ory "Poot mose4on: onic alstng ey dale otra fadhuat fase CLAP soit HE he acquis at Apron oainges ae m=)" Yond qloves aloetrandd. Eo held wEin the |+ Honk LOtgte, help of oldore and woldéng |, Benehvé curate ett too proper | | Rugh Bint bl p es foste-| Ty 0uat 2 ace “He Weld} Ae |e sAcol vuln 4+ | woo apron Mand qLvess | Waire bushy jaca. and notdthe |, ae eoces andton oO Peary real won-thany | urumer Fray cine geen Hest chtpp 2a mea ofboth 2faes |arneners qd He fo checkeo and * ee Agr fo ches eee ee = mMachene+ 6. leans canntecdouton of Jap soent pr i oOxre NS te Eo ve-the, sauNoune.—Pradoopta sanv 42c%-Pp, EM OUIENEND:~ O4-VBEDIO Baheiy Proeauttons ( do not viatd onound eombusthidle on Lnbtommobie- Motonials 5 Where sparks May COU O bert « © Seven 200k othe ane, Wethethe. maka oye The oe. ean iten youn-eyce S20 ‘ Gid Serer inslatfon- Of tho-ecudes and check, a A lh ace W) Abmays Aun off the machine whan 120. bug ne Wore kK «Nornes Pradgepta Sev 200 es Enroumant no VIUBEOSO rede Aenfeeh: ee seeer ‘National institute of Technology Agartala Chapter 4 MACHINE SHOP | 4. ntRopucrion Iva machine shop, motals are cut to shape on different machine (sols. A athe fs usod to cut and shape the metal by fevoling the work against a cuting tool. Tho work Is ckumped oither ina chuck fitted orto the lathe spindle or in-between the centors The cutting too! Is fixed in a tool post, mounted (on a mavate carriage that is positioned on the lathe bad. The cuttirg Yoo! can be fed on to tho wor either lengthwise or crosswise. While turning, the chuck rolatos in coxnitr-clockwrse cretion, when Wiewod from the tal stock end, 4.2 PRINCIPAL PARTS OF A LATHE Figure 4.1 shows. a canter lathe, indicating tho main parts: The naive fs due to the fact that work pleces are held by the conters, Flue 41: Parts ofa ener lathe 4.21 Bed Ls an essential part of a lathe, which must be strong and rigid, i carries all parts of the: machine. and resists the cutting forces. The carrlage and the tall stock move along the gude ways provided on the best. tis usualy macte of cast iron. 4.22 Head stock It contains ether a cone pulley or gearings to provide the naessiry range of speeds andl feeds. tt contains the main spine, to wich the work Is held and rotatea 4.23 Tail stock : Its used to support the right hand end of long work piece. It may be clamped in any position along the lathe bed. The tall stock spindle has an internat ‘Morse taper 10 receive the dead center that 5 the work Drs, reamers, taps may abo. be fet! Into the spindle, for performing operations such as driling, rearing and tapping 4.244 Carriage or Sade . It's used to control the movemegt of tho eutling tool. The cariago assembly consists of the Jonijtinal slide, cross silo and the compound side and apron. The cross sla moves across the length Othe bod and perpendicular to the axis of the spindle. This movement is used for facing and to provide the necessary depth of cut while turring, The apron, which s bolted to the saddle, i on the frant of the lathe and contains the longitucinal and crass side controls 425 Compound Rest it supports the toot post, By swiveling the compound rest on the cross side, short tapors may be turned ta any desired angles 1”Nome Pradaepta sary Ets ourmonk Hoy DIV SOO ‘National institute of Technology Agartala 426 To0! Post The a0! post, holds the tool holder othe tool, which may. bo adjusted to any warking position 42.7 Lead Screw (18 along threaded shaft, located in front of the carlage, running from the head-stock to the tall stock: 111s geared to the spindie and controls the movement of tho Loo, ther for automatic feeding OF for cutting threads, 428 Centers There are two centers known as dead contor and live canter. The dead center js positioned in the fall stock spindte and the live center, it the hoad-stack spindle. While turning between centers, tha (dead centr o's not revolve with the work while the ive center revalves with the work Sketch Figure of Headstock) eronge whois Hige-pants of, O-contis \atne 4,3 WORK-HOLDING DEVICES 43.1 Three jaw chuck IW1s a work holding device having three Jaws (scl-centering) which wil clase or open. with ‘espect to the chuck center or the spinele conter, as shown in figure It used for holding requir ‘objects ke round bars, hexagonal rots. etc, OG & Ot Figure 42: Three jaw chuck Figure 4.3: Four jaw chuck 8Roum’ + Pra.cuepta Sav Anes-B ee AO DN UBEOIO oredr Renfree area sree National institute of Technology Agartala 43.3 Face plate Iisa plate of large clameter, used for (urning operations. Certain typos of work that cannit tbe hold in chucks are held on the face plato with tho help of various accessories, Figure 44: Face plac figure 45: Lathe dog and diving plate ‘A3.4 Lathe dogs and driving plalo These are ured to dive work pleco that Iseld between cantors. These ave provided wath an opening t0 receive: und clamp the werk lowe and cop tal, the tll of tha dog Is carriod by the pin Provide In the diving plat fos ering the work piece Sketch These Jaw Chuck 16 Figs- Wren TOW Chuck.ome tProdoipta sory FROIB Envollanant MO> LIVBEOIO - aren te seen sore Exorcio 1 Facing and plain turning Aim To obtain required diameter of a cylindrical work place with the given longin¢ Fig4. 11), Tools & Equipment athe machine. Mid steel bar, right hand Culting too, box Key Gr 100! post Hay, chuck key, stool ul uti calipers or verior calipers * = 028510.2 | _—— 10.02 Fite ME Pisin Thrning ferns the operations of finishing the ends of work to make ends flat, smooth and to required length Rough turning operation is used where excessive stock is to.bo femoved and surface finish isnot critical For such a operation deep cuts with coarse feed are usod. During rough machining, maximum metal is removed and very litle oversize dimersion is left for finishing operation, Procedure 1. The givon work piece is held in the 3-jaerchuck of the Iathe:machine and tightened firmly with chuck fe 2. hha sige pont cating 0s taken intend fry the hep of box Key a te oo 4, i's bcd ot hs ot post Is skiveled and the cutting point is adjusted such that i Positioned approximately for facing operation then the tools fed into the work plece and the tool post is given the transyerso. movoment by rotating the hand whoo! of the cross side 44. With this facing Is completed and the tool post is swiveled ‘and cutting point made parallel to the axis of work piece " 5, Depth. of cutis given by cross slide to the tool post and the side hand wheo! is rotated to give the longitudinal movement forthe tool post and job is turncd to the required length and diameter 6, After completion of the job i s inspected for tha cimansions obtained with the help of stool rule ‘nd outside caliper or verner caliper Precautions ‘Werk ploce should be held Fem. Lh tig serge 3 td Lo ny drat citing pa of he to 2S ool should be avoided as it results in chatter and causes rough machined surface 4116s important to ensure that during facing operation the culting is performed from center point to the out dare of he work pet ihe m Result The job is thus made sccording.to the dhe dimensionsNOUNL'— Pradoopta sen- 403-8 te Ensoumoent NOt-24 7BED410400 1-8 Enaoumert NO- 9 Prodmpta sory sUBENO arregre Sener etree ST National institute of Technology Agartala Fill pastce model: Tp odtagn required dfiumetcn of acytincntear- Material: te ld gt oat frdintcar bi foe binag x saontn igs SIN Secparen of Opsuiions | Toasted ] the WoNnK pforo takon £6 "Lathe mochénz fold fn-the 3 taw chuck of-| setup Ovhe machine eal sous Chuck po | £igitoned with lake . 2 | Inthe too 2 posts might hand| * Tool po st | Angie pont cuttingtoolts |» Regie Anand ai ob ached and” beimiy | ng Polit +fghtoned Weth-tre bore” | cutting tool- Koy. BS | 10 smooth out-the cn0ss + lagna machine Aottfonal aren Of ronk PLS) getup: tool fs Kept at onan Teoeés obnot ation of An? ueth & of WOnKpecee> is yfver fe ety Low formant § of cross 4ecttonal ain2a. 4+ | gocondly twordtng openoro £6 anne diantiesine a Of-tHhe_worakpEc tes tqaoot & epttas nielyn comieto-the Wonk pire Zhe hol “chuck Key + Dor Key - ‘and fed. anand Ae contre bel out th&s stp s thepore REESE Sory De tieaark NOs DIV BEDLO @ National institute of Technolagy Agartala Fitiog pact mode: TO OAL nequtrod dParnetars Of o te Lindnicok of Meld stool ae Ree ' k pease Blore x 430 sm (q+ ‘SiNo. [Sequence of Operations: —__| Feats Used 1 Gasp} nototonof-wonks | *Lokhe- machen | prot. thon the chuck 6 = Actup LO Wed -+0 wotoke, anov | the eet te £5 gear area set arenes arr | O-FORHOn A fod Parstlys | Snead ee wane ofthe 21840 ba vadicocl on: andthe gnaaiay San ee fod £3 nt tun ghio le eee a i Safer) pro eouefons — Bee iS gan eye motection— Pn ditty, re Bone: © sbolo & Gd eee Hate wives eanc On VOtO: faq Honk, ao Kear” hort stoove anfste » WD) yraven ws, tage erg Cot bas Fhioyeus tna yack. W)| AvoPd neachtr Apiunihg chugs the