RAJADHANI INSTITUTE OF ENGINEERING

AND TECHNOLOGY
NAGAROOR, ATTINGAL

MECHANICAL ENGINEERING
WORKSHOP MANUAL
 RAJADHANI INSTITUTE OF ENGINEERING AND
TECHNOLOGY
NAGAROOR, ATTINGAL

MECHANICAL ENGINEERING DEPARTMENT

MECHANICAL WORKSHOP/MANUAL
Semester I and II
(As per APJ Abdul Kalam Technological University)

Name: - …………………………………………………………………………………..…………

Branch: - ………………………………………………Semester:-………………………..…….

Roll No: - ………………………………………...… Year:-……………………………………

University Register No……………………………………………………………………..

Certified that that this is the bonafied record of work done

By………………………………………………………… in the…………………………………………………….

H.O.D WORKSHOP SUPDT

Internal examiner External Examiner.

 INTRODUCTION

Workshop is a place where raw materials are converted into useful products with the
utilization of men ,materials and machines(tools)

A person who wish to become an engineer in what ever discipline he wishes, must have
a basic knowledge about different aspects of manufacturing including theory and practical. The
curriculum introduced by the A.P.J. Abdul Kalm technological University aims to cover the theory
and practical’s of mechanical engineering work shop in a simple and scientific way. The work
shop practicals involves the study of various tools, manual methods of manufacturing processes
by using of hand tools and machine tools.

Engineer are expected to work under different management capacities and responsible
for production as a whole. An engineer should aware of excellence and must have thorough
knowledge safety precautions and “First Aid”.
This workshop also aims at creating an awareness about the possible accident’s in the
work place and about safety precautions to be taken to avoid the accidents.
 SAFETY IN WORKSHOP

Accident are unpleasant, unplanned and un controlled events take place in a work area
or anywhere. To avoid such events the following precautions should be observed by the people
involved in work shop.

General Safety precautions

 Wear tight clothes in workshops especially when using rotating machines.

 Keep the floor clean and tidy. The floor should be free from Oils and greases.(the slippery
floor is always dangerous).
 Wear goggles whenever there is danger o f flying matter.
 Do not run or play on the shop floor.
 Do not operate any machine or tool without permission of the staff in Charge.
 Do not operate any machine without knowing its mechanism.
 Never work on unguarded machine.
 Do not talk to others or disturb them while they are operating a Machine.
 Keep your body behind the cutting edge of sharp edged cutting tool’
 When you switch off a machine do not leave before it has stopped running.
 Store inflammable materials like kerosene, turpentine,etc away from the Shop .

 Never place sharp tools on the floor or at edges of work bench, keep them in proper place
marked for them.
 Be were of electrical hazards such as bare wires; poor earth return connuction,wet floor etc.
 of hanging hair, ties, clothing, scarves, or belts getting caught.
 Never enter the workshop without shoes.
 Do not use rings and watches while working.
 GENERAL

Study of some of the Mechanical engineering Workshop tools. Tools are generally
divided into two viz. Machine tools and Hand Tools. Machine requires energy to operate.

HAND TOOLS

They are used by hand, require only man power to operate

(a) Screw driver

It is a hand tool used for tightening (fixing)or loosening (removing)screws. It

consists of three parts. Blade, shank and handle. The shank usually round in cross section ,Is

made of carbon steel. On end of shank is flattened to form the blade which is hardened and

tempered, and the other side is provided with a handle. The flat end is used for tightening and

loosening the screws. Screw drivers are specified with their length of shank and width of blade.

Two type of screw drivers used , Philips screw driver and flat end screw driver.

(b). Allen key

Allen key is a steel rod having hexagonal cross section and one end is bend at

90 degrees. It is used for tightening and loosening Allen nuts having hexagonal holes on its

head.

(c). Spanners

Spanners are also used for tightening or loosening the various types of nuts

with bolts. It is a drop forged hand tool made of carbon steel or vanadium steel. Various shapes

and size of spanners are use some of them are:- Single ended spanner, double ended spanner,

adjustable(screw )spanner box spanner, ring spanner, pipe wrenches etc.

(d) Pliers

Pliers is a hand tool used for holding small objects and cutting small

diameter wires. Usually combination cutting plier is used. It is also used for removing small

broken screws, bearing locks, broken taps etc. Two type of pliers used are,

i) Long nose pliers ii) Combination pliers

 Study of components

(a) Bearings

In power (motion) transmission area, shaft of different types and sizes are used. All

shaft are supported by bearings for smooth running. Bearings are classified according the

characteristics, nature of applied load and speed of rotation. Bearings are mainly divided into)

Friction bearings and anti friction bearings.

(1) Friction bearings are:- Solid bearings, Bush bearing and Plummer block.
(2) Antifriction bearings are:- Ball bearings, Roller bearings, Taper pin bearings,
Needle bearings etc.

(b ) Seal

Seal is used to prevent the leakage of fluids between the mating surfaces of

components either in stationary or in motion. It should be strong enough to with stand

deformation and operational stresses. Usually they are made of processed rubber material.

Seals are used in turbines , blowers, pumps, motors and bearings.

(c) O Rings

An O-ring is used to block any potential leak of a fluid between two closely spaced

surfaces. It also prevents the lose of fluid .Usually they are installed in a machined groove in

one of surfaces to be sealed. O-rings are generally made of processed rubber materials. They

are commonly used in automobile industry.

(d) Circlips

Circlip is a type of lock as well a fastener, It consists of a semi flexible matel ring

with open ends and have small hole at the open ends to accommodate the nose of the nose
plier. Thees rings have great resisting capacity against rotational speed. They are made of

carbon spring steel.

(e) Keys:

Keys are used for preventing self rotation of shafts from bearings, gears and

pullys,by providing temporary fastening between them. They are metal pieces of different

forms. Such as Flate and saddle key , hollow saddle key, Giphead key, Woodruff key, Feather

key and Splins.

 CARPENTARY

Wood is an important material widely used in Engg. Field. It also known as timber, is
available in nature as trees. Wood, after cutting from trees, make available to undergo seasoning
(To reduce water contents and increase mechanical properties) is used for engineering purposes.
Carpentry is the process of converting wood in to articles like patterns, furniture, doors, windows,
and roofs etc.

Basic material used in Carpentry

Basic materials used in carpentry shop are timber and plywood. Auxiliary materials used
are nails, screws adhesives, paints, varnish etc.
Tools used in carpentry are:-
A. Measuring and marking tools :-
a) Steel rule
b) Four fold rule
c) Flexible measuring tape
d) Straight edge
e) Try Square
f) Bevel Square
g) Pencil
h) Scriber and marking knife
i) Marking gauge
j) Mortise gauge

B. CUTTING TOOLS
a) Hand Saw (Cross cut saw)

It is used to cut thick wooden pieces across the grain. These saws has about 3 to 4
teeth per cm and have a length of about 650 mm.
b) Tenon saw (Back saw):-

This saw is used for short straight cuts. It has a parallel blade of 25 to 40 cm length and 6 to
10 cm width. The number of teeth per cm ranges from 5 to 8. In order to avoid bending of blade it
is provided with a reinforcing strip at the top.

Chisels: - These are used for cutting wood to get different desired shapes. Different types of chisels
are:-
 1. Firmer chisel
They have flat blade of about 15 to 50 mm width and 125 mm length.
2. Bevel edged firmer chisel :
These Chisels are used for fine and delicate work as well as for cutting corners.

3. Mortise chisel

These are used for heavy and deep cut to remove a large quantity of wood. These
chisels have width of 15 mm and the blade thickness ranges from 6 to 15 mm.

4. Gouges: -
These are chisels with curved section. They are used to cut curved shapes of internal or
external type

C. STRIKING TOOLS

1. Mallet – It is a hard piece of wood of round or rectangular cross section, It is

provided with a wooden handle for stricking on the cutting tools.

2. Claw hammer – This hammer is made of cast steel having a striking head at on end
and a claw at the other end, which is used for pulling nails.

D. Planning Tools

1. Iron Jack plane- It is used to produce flat surfaces on wood, made of cast iron body. A
wooden knob in the front side, a wooden handle at the back side fixed on the sobe for
pushing with two hands

2. Wooden jack plane – Made of wood, A steel blade having knife edge is fixed at an angle
with the help of wooden wedge.

Holding Tools

1. Carpenters Bench Vice: - It is used for holding jobs while sawing or planning. It consists
of a jaw fixed on the table side and a movable jaw kept in position by means a screw and
handle.
2. C or G clamp :- It is used to clamp the work pieces on the work bench while sawing
chiseling etc.

E. Boring tools
Boring tools are ment for making holes in wood. They include, Auger, Gimlet, bradawl,
Ratchet brace, Tool bit and drills.
F. Miscellaneous tools
1. Rasp and files: - Is a rough file used to remove excess wood form the surface and
corners.

2. Sand paper: - This is a thick sand or glass powder coated paper. When the sand paper is
rubbed on the surface, a thin layer of wood is removed resulting smooth
surface.

3. Pincer: - This is a tool similar to pliers is used for buffing out screws and nails etc from
the wood.

4. Screw driver :- It is used to drive in and out screws.

Process in wood work

1. Marking and Measuring: - It is marking of the dimension on wood piece so that the excess
wood can be removed to obtain the required shape.

2. Sawing: - It is done after holding the wooden piece in a vice and sawing along or a cross the
grain by hand or machine.

3. Planning: - Is the process of making wood surface smooth by removal of a small layer of
wood from it, by using a jack plane.
4. Chiseling: - Chiseling is used to remove small stock to retain the desired shape.

5. Boring: - The process of production of round through hole or blind hole is called boring. They
are made by using drill bit, augers , gimlet etc….
 Ex No:- Date: / /
PLANING PRACTICE (Model)

Aim : To plane a wooden block using jack plane to obtain the required size and shape

1. Material required :-
Soft wood ( Size : 35x50x250 mm )
2. Tools required
a) Jack plane
b) Try square
c) Hand saw
d) Mortise gange
e) Steel rule
f) Firmer chisel
g) Mallet

Procedure :-

1. Clamp the job in carpentry vice

2. Plane two adjacent faces using jack plane. So that sides are at right angle.
3. Use try square to verify the squareness of the sides.
4. Use mortise gauge to mark the desired dimensions on the remaining two faces.
5. Planning or chiseling has to be done to the remaining two surfaces, up to the dimension
marked
6. Both ends are square marked and square cut be done with mallet and firmer chisel
7. Verify the dimensions by steel rule.

Result: - The required shape of job is this obtained by planning process using jack plane.
 SMITHY

Blacksmithy is a process in which metal is heated to a desired temperature to obtain sufficient

plasticity and shaped to the requirements by using smithy tools. The operation is carried out either
by hand or by power hammer. Process of heating is done in an open hearth furnace and shaping is
done by using hand tools. Smithy process has an advantage that there is no wastage metals. Forging
also enhances the mechanical properties, improve grain flow and increase s the strength and
toughness of the metal.

For blacksmith operations the metal should possess malleability. Carbon steel, Aluminium,
Copper, Magnesium etc. are forgeable metals. For forging operations mild steel is to be heated
above 750*C. Aluminum and magnesium above 300°C,and Copper above 600°C.

BLACKSMITHY TOOLS

Tools used in blacksmithy can be classified into following 5 categories.

1. Supporting tools

It provides necessary support during forging the metal stock.Importent supporting tools
are anvil and swage block.

2. Striking tools

Different type of hammers are used for hammering to obtain the required shape to the
heated metal. Sledge hammer ,ball pein hammer, crosspein hammer, set hammer etc are using.

3. HOLDING TOOLS

These tools are used to hold the heated metal for forging operation. These tools are made of mild
steel. Flat tongs, square bit tongs, round bit tongs and pick-up tongs are common tongs.

4. Cutting tools

Cutting tools are used for cutting and necking metals as per the requirement. Hot and cold
chisels are used as cutting tools. The included angle of the cutting edge of cold chisel is 60° and hot
chisel is 30°.

5. Finishing and shaping tools tools

These tools are used to give the desired shapes and forms to the metal stock. Important
tools are as follows.

a) Swage- Used to reduce the measurements and finishing the work. They are made of high
carbon steel having two parts called top and bottom swage, carry necessary groves to suit the
size of work.

b) Fullers:- Used to make neck by reducing the cross –section of a job. Tools are made of high
carbon steel in different sizes. They are used in pairs of top and bottom fullers
c) Flatters:- Used for leveling and finishing a flat surface after foging operation.They are made of
carbon steel.
d) Punch :- It is used for making holes in the heated work piece.
e) Drift :- Used for making holes to a particular shape and size which is already made by punch.

BLACKSMITHY OPERATIONS

1.Up setting

It is the process of increasing the thickness of a metal piece with corresponding

reduction in the length by applying the end pressure.

2. Drawing down

It is a process to reduced the thickness corresponding increasing the length. The force is
applied in direction of the axis.

3.Setting down

It is the process of local thinning down of the work piece by hammering.

4. Punching and drifting

A process of making holes in a desired shape by the use of punch and drift.

5.Bending

A process of brining metal rod to a required angle and shape. It is done by at the edge of the anvil
face or over the anvil horn or by inserting the end in the hole and bending the bar with tongs.

6.Forge welding

An operation performed by hammering together the end of two heated metal pieces to
join them.Wrought iron and mild steel can be easily forge weld.

7. Cutting off

It is a forging operation in which a metal stock is cut off into two or more pieces by using chisel.

7. Fullering

It is a forging operation in which metal of the work piece is spared along its length
by hammering and using fullers as tools.

Applications

a. Forging is used for fabricating agricultural tools ,bolts and nuts, keys, tongs, springs, links etc.

b. Forging is used wherever components are required to have high strength and great resistance
to impact and fatigue loads.

HEAT TREATMENT

Heat treatment is the process of heating a metal to a desired temperature, without

melting and then cooling it to obtain certain changes in the characteristics of the metal.Heet
treatment improves the properties of the metal, such as:-

Machinablity

Change of grain size.

Mechanical properties

Magnetical and electrical properties

Increase resistance to wear heat and corrosion.

To produce hard surface.

HEAT TREATMENT PROCES FOR IRON

Cooling method
Process Heating temperature Socking time
By quenching in water
Hardening 820 ° c 30 min
or oil
Up to 700 c in furnace,
then up to room
Annealing 820 °c 35 min
temperature in silica
sand or ash
In air up to room
Normalising 820 °c 30 min
temperature
Quench in the
Tempering 400 ° c 30 min
quenching bath
Ex No- Date :- / /

FORGING A SQUARE ROD ( Model )

Aim:-- To make a square rod from a round rod as per dimension

Materials required

MS rod x 18 x 100 mm long

Tools requires;

1.Smithy

forge 2. Anvil

3.Tongs

4.Hammer

5.Steel rule

Operations carried out;

1. Lighting of forge

2.Hammering

3.Measuring

4.Cooling

Procedure

1.Light up forge and make proper fire.

2.Insert the job into the fire at proper place and heated to red hot.

3.Take out the job with tongs and put it on the anvil within no time.

4. Hammer the red hot area for getting required shape.

5.The process of heating and hammering is repeated to get the job in required shape
and dimensions.

6.Job is dipped into water for getting hardness.

Result :- The normal rod is converted into square rod as per dimensions.

Precautions
1. The job is heated to red hot to obtain plasticity. But the job will not allow to melt.

2. Wear protective apron and gloves to prevent accidents..

3. Always use proper tongs and hold it tightly.

 FOUNDRY
INTRODUCTION

A place where moulding, casting and their related works are carried out is known as foundry

shop. Moulding is the process of making of activity (mould) of the object, which we want to

produce, usually in large quantities, with the help of moulding sand, and patterns (which are the

triplica of the products.) Casting is the process of pouring the molten metal in to the mould,

allowing them to solidify and take it out from the moulding sand. Related works includes felling

(removing the unwanted portion, cleaning etc.), testing and inspection.

FOUNDRY TOOLS AND EQUIPMENTS

The foundry tools and equipment’s are divided in to 6 parts.

1. Hand Tools, 2. Moulding Box, 3. Moulding Machine,4. Melting equipment
5. Pouring, Shake out and finishing equipment, 6. Inspection and testing equipments

FOUNDRY HAND TOOLS

1. Bellow :- Bellow is used to blow loose particles of sand from the pattern and mould
Cavity.
2. Brush: - A brush is used to sweep away the dust from pattern.

3. Lifter: - Lifter is made of thin sections of steel and is used to clean and finish the bottom
and side of the sand mould cavity.
4. Gaggers : - Gaggers are the piece of wires or rods bent at one or both ends. They are used
to reinforce sand in the top part of the moulding box and support hanging bodies of sand.

5. Slick: - A slick is small double ended tool having a flat on one end and a spoon on the
other. It is used for finishing the mould cavity.

6. Rammer: - Rammer is made up of wood or metal in the shape of round flat and conical. It
is used for ramming the sand in Bench moulding.

7. Riddle: - It is a wooden square or round frame fitted with wire mesh at the bottom. It is
used for cleaning the moulding sand by removing unwanted materials such as nails, wood, plastic
etc...
 8. Sprue pin / riser rod :- It is a tapered wooden peg used for making pouring sprue or rises
hole in a mould.
9. Sprue cutter: - It is a tube of steel which is forced in to the rammed cope to cut the sprue
cavity.

10. Swab: - It is a small brush having long hemp fibres and it used for cleaning the sand
around the edge before the pattern is removed.
11. Trowels: - A trowel is a metal blade fitted with wooden handle with various shapes is
used for finishing and repairing mould cavities and flat surface of mould.

12. Showel :- It is used for mixing and transferring the moulding sand from one place to
another place.

13. Vent wire: - It is used for making vent holes to permit easy escape of steam and gases
generated during pouring of the molten metal.
14. Strike off bar: - It is piece of metal or wood used to strike off excess sand from the mould
after ramming to provide a level surface.

15. Draw spike: - Draw spike is a tapered steel rod at one end sharp point is used to rap and
draw pattern from the mould.

4. MOULDING BOX

The sand moulds are prepared in a specially constructed boxes called Flasks, which
are open at top and bottom. They consist of two or more parts. The lower part is called drag, the
upper part is called cope. If the flask is made in three or more parts the intermediate parts are called
cheeks.

These boxes / Flasks can be made of either wood or metals. All the parts are
individually equipped with suitable clamping during pouring. Common type of moulding boxes in
foundry are
Box flask, Snap flask, Wooden moulding box.

5. MELTING EQUIPEMENT

Furnaces suitable for melting some important metals are given below
1. Cast iron :- Cupola furnace, Electric furnace, rotary furnace
2. Steel: - Open hearth, Electric and besmear furnaces
3. Non- Ferrous metals :- Crucible furnace, Rotary furnace, Electric furnace
Moulding Sands:-
Sand is widely used mould material for casting ferrous and non ferrous metals.
Classification of moulding sand according to specify uses.

a. Green sand, b. Dry sand, c. Loam Sand, d. Facing sand e.

Backing or floor sand f. System sand, g. Parting sand, h. Core sand (Oil sand )
Main constituents of moulding sand are silica sand, Binders, Additives, water.

Core and Core Making: A core is essentially a body of material which forms the contour of a casting
that is not moulded with a pattern. Cores are mainly used to form internal cavities or holes in
casting.
Ex No. Date:- / /

STEPPED PULLEY /ROUND DISC (MODELS FOR PRACTICE)

Aim: - To make a green sand mould of given stepped pulley /Round Disc

Tools requires: - Flat rammer, conical rammer, trowel, strike off bar, vent wire, sprue cutter riser
swab, lifter, slick, brush, draw spike, Riddle and Bellow

Material required:-
Box flask, green sand, pattern, parting sand and water.

Procedure :-
1. Placed the given pattern in middle of drag box and fill the green sand laid over it
2. Rammed sand with conical rammer up to top of the drag Box
3. Rammed sand with flat rammer for levelling up to top bottom of drag box
4. Levelled sand with strike of bar and finish with trowels
5. Make the vent hole with vent wire for removing bowl gases from sand when casting
6. The drag box turned upside and applying parting sand
7. The cope box placed above the drag box and runner, riser placed in correct position

8. Fill the green sound to the cope box and rammed with conical rammer up to the cope
box
9. Rammed the green sand with flat rammer
10. Levelled with strike off bar and finish with trowels and make vent hole with vent wire
11. Remove the cope box and make gate way with slick runner hole to pattern

12. Remove the given pattern and remove the unwanted sands with bellow if need.

Results: - The Green sand mould of stepped pulley / Rod Disc is obtained.
 SHEET METAL

Introduction: - Many articles of day to day use are made from metal sheets, like pipes elbow
boxes, funnels, gaurds, hoppers, decorative articles and house hold utensils. In sheet metal work

knowledge of projective geometry, especially development of surfaces and properties and uses of
each metal to most essential. Usually metal plates of thickness less than 5 mm are considered as
sheet metal. The sheets are specified in thickness by standard wire (sheet) gauge numbers. The
thickness of sheets vary inversely as their gauge numbers.
Most commonly used sheets in sheet metal work are black iron, galvanised iron, copper,
aluminum, stainless steel and Tin sheets etc........

TOOLS AND EQUIPMENTS

The Hand tools used in sheet metal works are as follows:-
1. Steel Rule, 2. Folding Rule, 3. Flexible tape, 4. Straight edge wing compasses,
5. Trammel, 6. Dividers, 7. Flat chisels, 8. Scribing tools, 9. Bevel protractor,
10. Steel square (L square), 11. Scratch awl
12. Hammers like setting hammer, riveting hammer, creasing hammer, raising hammer
planishing hammer, soft hammer, PVC hammer, Mallet etc.
13. Snips, 14. Hand lever shear, 15. Punches,
16. Stakes, 17. Folding bar 18. Groover

Important tools :-

Snips: - A Snip is also called a hand shear, it is used like a pair of scissors to cut thin soft metal sheets
up to 20 swg. Two type of snips namely straight snips and bend snips are used. Straight snips have
straight blades used for cutting along the straight lines. Bend snips, have curved blades, used for
cutting curves and trimming curved edges.

Hand lever shear: - These are used to cut sheets which cannot be cut with hand shears. It consists
of a fixed lower blade and movable upper blade, on which a lever handle is fixed to operate for
cutting.
Punches: - Different types of punches are used in sheet metal work. They are prick punch, center
punch solid punch and hollow punch. Prick punch is used to make small marks on lay out lines, while
center punches are used to enlarge the prick punch marks. A solid punch is used to make small holes
on sheet metal. Hollow punches are hollow in cross section and are used for making holes on sheet
metal, leather and plastic.

STAKES – Stakes are the sheet metal workers anvil used for bending seaming or forming using a
hammer on mallet sheet. They are used as a supporting tool as well as forming tools. They are made
in different shapes and sizes to suit the types of operations. A stake consist of a shank and head or
horn. The shanks are designed to fit in to a hole in the bench plate.
The most commonly used stakes are:-
1. Hatchet stake, 2. Half-moon stake, 3. Funnel stake, 4. Beak horn stake (Bick iron)
5. Creasing stake, 6. Planishing stake, 7. Horse head stake

GROOVER (Seam set) – A groover is used for closing and locking of seams in sheet metal work.
The sheet metal operations are classified into measuring and marking

Cleaning
Laying out
Cutting off and Shearing

Trammel (Beam compass) :- A trammel consists of rigid beam carrying two movable heads or frames
with steel points that can be fixed in the desired positions by means of thumb screws. It is used for laying
out larger arcs, circles and various other geometrical shapes like an ellipse etc...........

Standard wire guage (SWG) - Wire gauge have stots with which the thickness of the sheet metal or
diameters of wire are measured. Each slot is numbered. The sheet metal or wire has the same
number as the slot in which it fits. The numbers are called gauge numbers. Wire gauges are made
of stain less steel usually 5mm thickness.

Sheet metal joints

1. Hem :- Is an edge or border made by folding
2. Seams :- It is a joint made by fastening two edges together
Types of hem
1. Single hem, 2. Double hem, 3. Wired edge
Types of seam
1. Lap seam, 2. Grooved seams, 3. Single Seams, 4. Double Seam,
5. Dove tail seam, 6. Burred bottom seam
Riveted Joint :- Riveting is a processor of joining two pieces of sheet metal by using rivets
permanently. Types of riveted joints are:-

1. Single riveted lap joint. 2. Double rivet lap joint, 3. Zig Zag lap joint,
4. Single strap butt joint 5. Double strap butt joint
 Rectangular Tray (Model)
Ex: No.
Date. / /

Aim :- To make a rectangular tray of give in dimensions with sheet metal

Material required: - 150x130 mm 26 SWG.G.I sheet, rivets.

Tools required: - Steel rule try square scriber, divider straight snips steel strip, Bench vice Mallet
of soft hammer.

Procedure : -
1. Check the G.I sheet for overall length and width using a steel rule.

2. Mark out the development of the body of the tray, using steel rule, try square divider
and Scriber.
3. Cut out the development, and remove the unwanted sheet, by using straight strips.

4. Make single hen on the outer edges of the height portion to give strength at thredge by
a Folding using bench vice and mallet.
5. Do all the folding and bending process to form the tray.

6. Bend the projected portion of the width side on length side and make it firm with
revetted Joint.

Results :- A rectangular tray of given dimension is obtained.

 WELDING
Welding is a permanent metal joining process by heating two or more metal pieces and joining
them together with or without pressure and addition of filler material. Welding process is
employed in most of the modern fabrication works and industries such as ; a ) structural work in
bridges and buildings b ) manufacturing of automobiles c ) Air Craft industry d ) Ship building
industry e ) Oil industry f ) Repairing of mild steel,Cast iron, and other ferrous and non ferrous
metals etc…. Welding includes several type of metal joining, by several methods. Most commonly
used welding are arc and gas welding.

Arc Welding

Electric arc Welding is a process in which heat is generated by an electric arc. Both AC & DC
current can be used for welding. While welding electrons move from positive to negative terminal
in the form of spark and electric energy in converted into heat energy, thereby facilitating
welding. Two third heat generated at positive terminal and one third at negative terminal. Heat
melts both the metal and filler material so that welding can take place.

EQUIPMENTS AND TOOLS

1. AC or DC Machine

A step down transformer is used in AC machine. Supply voltage from 220 to 440 volts
may be stepped down to 50 to 90 volts. The DC power source consists of (1) Power transformer
(2) Current regulator ( 3 ) a wave rectifier to convert the AC to DC supply.

2. Electrodes

The filler used in an arc welding is called electrodes. The electrodes are made of
metallic wire which is uniformly coated with flux. The flux forms a gas shield to protect the weld
metal from oxygen and nitrogen in atmosphere.

3. Electrode holder

It is a holding device to hold the electrode. It is connected to the end of welding

cable, it conducts the power source. The jaws of the holder is insulated to avoid electric
shock.

4. Ground Clamp

It is a clamp used to ground the cable coming from the power source to the work piece.

5. Cable and Connectors.

Cables are used to conduct electricity from the power source to the electrode holder and
the work piece. It is made up of copper or aluminium and highly insulated by rubber cover.
Connectors are used to connecting the ends of the lead to the transformer.
6. Chipping hammer

It is a striking tool used removed the slag from the welded portion.

7. Wire brush.

It is made of stiff steel wire used to clean the small particles of slag.

8. Face Shield

It is used to protect eyes and face of a welder from the ultraviolet and infrared
radiation of arc welding. The shield can be either helmet type or hand hold type.

9. Protective clothing

Hand gloves are used to protect the hands of a welder and apron ( made of cloth or
leather ) protects the body from heat and spark.

Gas Welding

Gas welding is a fusion type of process in which the joint is made with the application of
heat. The heat is generated by the combustion of a fuel gas. The fuel gas widely used acetylene
gas. When the gas mixed with oxygen , acetylene gas burns to produce high temperature of the
range of 3100 C .

The flame of acetylene and oxygen melts and fuses together the edges of the parts to be
welded. The addition of extra metals for the joint is done by using a filler rod during welding.

Oxy-acetylene welding equipment

The basic equipment used in gas welding consist of

1. Oxygen gas cylinder . ( Painted black )

2. Acetylene gas cylinder ( Painted Maroon )

3. Hose .

4. Welding torch

5.Welding torch

Gas welding accessories

The accessories includes Goggles , Welding glouses , Jacket and boot , spark lighter , fire
extinguisher, etc.
Ex No. Date : - / /
SINGLE ‘’ V ‘’ BUTT JOINT

Aim:-
To make a single “” V “” but joint by arc welding methods

Material required:-

Two nos of mild steel pieces of 75x30x5 mm

Tools required:-

1. Arc welding machine, 2. Bench vice 3. Welding table 4. Steel rule 5. Flat File 6. Welding
electrode , 7. Face Shield, 8. Hand gloves , 9. Chipping hammer , 10. Wire brush 11.
Tongs

Procedure

1. Prepare the metal pieces so as to obtain a ‘’ V ‘’ groove when they are placed side by side. ( use
file and grinding )

2.Set the metal pieces on the welding table with edges prepared touching each other, using
clamp.

3. Fix a welding electrode into the electrode holder. The earth clamp is fix on the welding table or
work

4. Switch on the machine and bring the electrode to the metal piece.

5. Start the welding process by initiating arc between the electrode and the ‘’V ‘’ groove on work
piece.

6. Carryout the welding throughout the length.

7. Remove the slag form welded portion and check.

8. Repeat the welding process if needed.

9. Switch of the machine after completing the welding.

10. Lift the jointed work piece with a tong and drop it into water for cooling.

11. Remove the slag using chipping hammer and wire brush.

RESULT: The required butt joint of metal piece is obtained.

PRECAUTIONS

Use face shield while welding . Wear leather gloves and apron . Do not touch the metal
piece unless cooling has been done.
 FITTING AND ASEMBLING

Introduction :- Fitting is one of the most important operation in production Engineering. An operator
who does the fitting job is called fitter. Although majority of works can be finished to a fairly good
degree of accuracy, they still require the hand operations to be done on them to finish them to the
desired accuracy. A fitter’s work is unavoidable when different parts are to be assembled in position
after they have been finished. The term fitting refers to the hand work such as sawing, filing, tapping
etc...., necessary after machine work for assembling parts together. Fitting
may or may not be carried out on a bench vice.
Generally three types of fitting are there:-
1. Machine fitting 2. Bench fitting 3. Pipe fitting

FITTING TOOLS
The hand tools used in fitting work are classified in to the following groups.

1. Measuring and Marking tools 2. Cutting tools 3. Holding tools

4. Striking tools 5. Inspection tools 6.Miscellaneous tools

1. Measuring and marking tools

1. Steel Rule 2. Try square and bevel square 3. Sine Bar
4. Combination square 5. Bevel gauge 6. Universal gauge 7. Bevel protractor
8. Vernier Bevel protractor 9. Vernier calliper 10. Vernier depth gauge
11. Micrometer 12. Vernier height gauge 13. Slip gauge 14. Angle gauge
15. Dial gauge (Dial Test indicator) 16. Feeler gauge 17. Radius gauge
18. Screw pitch gauge. 19. Thread gauge 20. Standard wire gauge 21. Scriber and
marking knife
2. CUTTING TOOLS

CHISSELS: - Different type of cold chisels are used by fitters for chipping and cutting off operations.
Chipping is an operation of removing excess metals by using chisel and Hammer. Chisels are made
from high carbon steel or chrome vanadium steel. The cutting edge is hardened and tempered. The
types of chisels , are flat chisel half round nose chisel, Diamond point chisel, side chisel etc
Files: - A File is a hardened piece of high grade steel with slanting rows of teeth and is used for
removing excess material to smooth or fit metal parts. Files are generally forged out of high carbon
steel or tungsten steel followed by cutting of teeth, hardening and tempering.

File specification: - Files are specified according to their size, cut of teeth, grade and shape or cross
section such as:-

Flat file, Hand file, Square file, Pillar file, Round file, Triangular file, Half round file, knife
edge file and needle file.

Scrapers: - Scraping is employed for removing the high spot from machined surfaces for obtaining
fine surface finish on the work. The tool used for scraping is scraper.

Hack saws: - The hacksaw is used to cut metals of different sections. It is also used to cut slots and
contours. The main parts of the hacksaw are the frame, blade and the handle. Two different types of
hacksaw frames are used. Fixed frame and adjustable frame.

Drills: - A drill is cutting tool used for creating circular holes for various purpose. It is made of high
speed steel or high carbon steel. Two types of drills are straight shank and taper shank drill.

Reamers: - A reamers is a multi-pointed cutting tool used for enlarging and finishing the previously
drilled holes to correct size.

Hand Taps and Tap wrenches: - Hand taps are used for internal threading of components. They are
made from high carbon steel or high speed steel hardened and ground. Tap wrench are used to hold
and drive the hand taps correctly in to the hole to be threaded. Taps are used in set of three.

Dies and Die stock: - Hand operated threading dies are used to cut external threads on cylindrical
work pieces such as bolts and studs. A die is made of high quality tool steel. The tools for holding
and turning the threading dies called die stock.

3. Holding tools

Vice is the most common tool for holding the work. They are available in different types for
different type of work. They include bench vice, leg vice, pipe vice, Hand vice, Pin vice tool makers
vice, V-block and U-clamp.
Bench vice :- A bench vice is the most common device, made of cast iron/ cast steel and is used to
hold the work for filling, sawing, threading and other hand operations. The size of the vice is stated
by the width of the jaws. It consists of a movable jaw and a fixed jaw.

4. STRIKING TOOLS
1. Ball pein hammer 2. Straight pein hammer
3. Cross pein hammer 4. Sledge hammer
Hammers are specified to it shape of pein and weight

5. INSPECTION TOOLS :- The various instruments are used for checking the job in fitting shop
They are steel rule, micrometer, Vernier caliper, straight edge, bevel protractor, height gauge, drill
gauge, sine bar, slip gauge, screw pitch gauge feeler gauge, spirit level. Dial test indicator etc.

Vernier caliper: - A Vernier caliper is a precision measuring instrument is used to measure up to

accuracy of 0.02 mm in metric system. It consists of a beam carrying the main scale, inside measuring
jaw, outside measuring jaw, depth gauge bar, vernier slide, vernier scale and a thump screw. The
thump screw help to set the vernier slide in any position on the main scale. A vernier caliper with an
accuracy of 0.02mm in this 50 divisions of the vernier scale occupy 49 divisions (49 mm) of the main
scale. Therefore the least count of the vernier scale:-
L.C =1MSD = 1 VSD
= 1 mm = 49/50 mm
= 1/50 mm = 0.02 mm

Micrometer:-
A micro meter is precision instrument used to measure a job with in an accuracy of 0.01 mm.
They are available in various ranges like 0-25 mm, 25 to 50, 50 to 75 mm, etc.... main parts are frame,
anvil, spindle, parallel thimble, Ratchet stop, locking screws. The pitch of the micro meter is 0.5 mm
ie, in one rotation of the thimble the spindle advances by 0.5 mm. The barrel is graduated in
millimeters from 0-25 mm. The thimble is graduated in into 50 divisions and marked 0-5-10-
......50 in clock wise directions
Movement of one division of thimble = 0.50x1/50mm
ie, least count =0.01mm

6.MICELLANEOUS TOOLS ;
Various types of tools are - spanners, screw drivers, pliers, crowbar, alenkeys etc….
 MODEL – I
FILING PRACTICE
Aim : - Cutting and filing of a Rectangular Piece

Material Required :- MS Fiat 51x25x6m

Tools Required :- Bench vice, Steel rule, Try square, Scriber, Hacksaw, Fiat file (Rough and
Smooth Vernier height gauge and vernier caliper ,punch and hammer
Job sequence:-
1. Measure the size of given job.
2. Making as per the dimensions with the help of try square, steel rule and scriber.
3. Hold the work piece on bench vice properly.
4. Cut the job by Hacksaw.
5. File one side and true the surface level.
6. Filing one corner by file and check with try square.
7. Check the length of width respectively by marking with help of vernier height gauge, punch
and hammer
8. Finish the job by filing as per the given dimensions.
9. Remove the burs and finish the job.
Safety point:- 1. Use correct size of tools only 2. Set the job in vice properly 3.
Hack saw blade fix correctly and avoid over tight 4. Sharped ended tools on used for marking
5. Clean the vice and machine after finishing the job 6. Keep tools in proper place.

Result : - Work finished as per the given dimensions are obtained

 DIS ASSEMBLING AND RE- ASEMBLING TAIL STOCK OF A LATHE.
JOB SEQUENCE AND SKILL SEQUENCE

1. MATERIALS REQUIRED - A TAIL STOCK OF LATHE MACHINE

Preparation: -
a. Select proper place and clean
b. Select the required tools wooden block, screw driver, spanner set, allen key set, hammer,
Punch, oil can, grease, smooth file, emery paper and cotton waste
2. before the exercises
a. Check the tail stock body if there is any crack or brake.
b. Remove the locking clamp from bed. c. Taken out the tail stock from machine.
3. Doing the Exercise
a. Clean the body and remove lock nut of tail stock spindle handle
b. Remove the handle
c. Remove the spindle lock liver
d. Remove the spindle from body
e. Remove spindle and micro coller and key
f. Remove spindle and check the spindle bore
g. Remove the offset screws
h. Remove the body top and bottom parts separately
4. after the Exercises:-
1. Remove rust and dust from all parts.
2. Clean and oiling the parts and apply grease.
3. Re set body parts one by one.
4. Check and make clear all parts are assembled.
5. Place the tail stock in lathe bed.
6. Lock the tail stock in correct locking position.
7. Check the spindle movement.
8. Oiling through the oil holes.
9. Replace all the tools in proper places.
5. Safety measures:-
1. Place the Tail stock in wooden flank.
2. Use correct size of spanners.
3. Avoid over tight and over load.
4. Clean the work places using brushes.
6. Result
Dis assembling and Re- assembling of Tail stock is completed
 CYLINDER PISTON ASSEMBLY
JOB AND SKILL SEQUENCE: -
Aim :- To dismantle and assemble the given cylinder piston assembly unit.
Materials required : -
1. A piston cylinder assembly unit of a two stroke petrol engine.
2. A tray3. Diesel 4. Cleaning brush 5. Cotton waste 6. Lubricating oil
Tools required : -
1. Box spanner set 2. Screw driver 3. Claw hammer 4. Circlip remover
5. Ring Expander 6. Ring compressor

PARTS

1. Piston
2. Gudgen pin
3. Circlip
4. Small end of connecting rod
5. Bush bearing
6. Connecting rod
7. Journal bearing
8. Cap

Study of the assembly

The piston and cylinder assembly is the most important portion in an petrol or diesel engine.
Piston moves up and down inside a cylinder while fuel burning and converts the heat energy into
mechanical energy with the help of a crank shaft.

Works to be carried out

Dismantling, Cleaning, Fault finding and rectification, Assembling, Oiling, and Checking

Dismantling procedure:
1. Remove the nut and bolt from the big end of connecting rod.
2. Remove the cap and journal bearing.
3. Disconnect the big end from crank shaft.
4. Take out the piston with connecting rod.
5. Remove the piston rings.
6. Remove the circlip.
7. Dismantle the Gudgen pin.
8. Dismantle the piston and connecting rod
9. Remove the bush bearing from the small end of connecting rod.
Cleaning: -
Clean all parts with a brush in diesel. Put all cleaned parts in a convenient place or tray. Check all
parts and find any damage or fault. Rectify the defects.

Re assembly: - Follow all the dismantling procedure in require action is the last step of dismantling
is the first step of assembly.

Checking
Rotate the crank shaft and make sure that the piston assembly is moving smoothly inside the
cylinder.

Result:-
The piston cylinder unit dismantling and assembling is completed.
 STUDY OF MACHINES
1. DRILLING MACHINE

Introduction:-

The drilling machine is one of the most important machine tool in a general
workshop. It is primarly designed to originate a hole. It can perform a number of similar operations.
It is the oldest form of drilling mechanism is developed in 1200 BC, called bow drills.
In drilling machine the hole is generated by the rotating edge of a cutting tool
Known as drill. It exerts large force on the work clamped on the table

Study of drilling machine.

Skill: - Drilling machines are widely used for all engineering work shop construction sites.

Tool
Main Job holding Main Operation and
Types Tools Used holding
Parts system remarks
methods
Bench type Base, Mainly used Drills are Machine 1..............................
Sensitive Table straight - holding in vice
type Column shank drill , & drill Bench vice 2................................
Pillar type Spindle - Taper - shank check, or Clamps
drills (made
Radial type head direct in Bolt and 3..................................
of HSS,
Colum type Motor spindle nuts
Cutting angle
Portable type handle 118 degree) bore of Angle plate 4...................................
Tap, Reamer. the Jigs etc
etc.. machine 5...................................
with help
of sleeves 6...................................
 2. LATHE

Introductions:-

The lathe is the oldest and most common machine used for turning operation. The present
form of Lathe developed initially by HENRY MAUDSLAY in 1800, for screw cutting.
The main function of a lathe is to remove metal from a piece of work to give it require shape
and size. The work in holding and rotating by lathe and the cutting tool is fixed in the tool post.
There are several type of lathes in design, size and use. The most widely used type is Engine
lathe or centre lathe.

Study of Lathe

Skill: - This machine tool is mainly used in general purpose and production workshops.

Tool
Job holding Main Operation and
Types Main Parts Used Tools holding
system Remarks
method
Centre Leg, Turing Tool Tools Mainly job
1..............................
lathe, Bed, (RH&LH) holding in held by 3 jaw
Bench lathe Head Stock, various size the Tool chuck, 2................................
Special Carriage, and shape) post of the 4 Jaw chuck
lathe Cross slide, solid tools, lathe by the .mandrels, 3..................................
CNC Lathe Compound tipped tool, help of face plate,
4................................
(general rest, lead holder with spanners carries and
5................................
purpose screw and tool bits) and shims . with help of
cone pulley Tail Stock Threading rests. 6................................
and all tool,
general grooving 7................................
types ) tool,
8................................
Baring Tool ,
9................................
Knurling tool
etc.
10..............................
(It is made
HSS bit.)
 2. SHAPING MACHINE

Shaper is a reciprocating type of machine tool intended primarly to produce flat surfaces.
These surfaces may be horizontal,vertical or inclined. In general the shaper can produse any
surface composed of straight line elements. The modern shaper was developed in 1836 by JAMES
NASMYTH, an English man.

The work piece in hold on the shaper bed by machine vice and the cutting tool is fixed
on the shaper ram. The ram is reciprocating member in the machine which remove the metal from
piece with the help of a cutting tool.
Study of shaping Machine

Types Main Parts Used tools Tool holding Job holding Main operation and
methods system Remarks
Crank shaper, Base, Mainly used Single point Machine 1..............................
Geared Column, for various Tools hold in Vice, Angle
2................................
shaper, Cross nail, shape of the part of plate, ‘V’
3..................................
Hydraulic Saddle, grinded HSS clapper Block,
type, Table, tool block of the Shaper- 4...................................
Drawcuttype Ram, machine. index
5...................................
etc. Tool head. centre.
6....................................

Skill : Commonly shaping work are carried in the production engineering work shops.
 3. MILLING MACHINE

Introduction:-

A milling machine tool can perform several operations of wide variety. It is used to produce
complex shapes in work material. It can produce flale as well as internal or external curved surfaces.
A multi tooth rotating cutter, when the work piece is feeded against it.
Study of Milling Machine :-
Types Main Parts Used tools Tool holding Job holding Main
methods system operation
and
Remarks.
(a) Plain, Base, ) Multi tooth Hold in the Jobs are
Knee, milling arbour with hold in the
Horizontal Saddle, cutter made help of table by
Table, of HSS arbour machine
Vertical Arbor, Over support and vice, clamp,
arm, Knee (It is spacers. nut and bolt
Omniversal elevating specified by chuck with
screw, Cross the shape, mandrel.
Universal - feed screw bore size
types Telescopic and use)
driving
shaft
(Indexing
mechanism)

Skill :- Mainly used in production centre with accurate jobs done by this machine tool
 5. GRINDING MACHINE

Introduction:-
Grinding is a metal cutting operation performed by means of a rotating
abrasive wheel grinding is used as a finishing operation.
Grinding wheel is made up for carborandom on other hardened alloy
materials.
The wheel is rotated with the help of an electric motor. The is to be ground is hold by hand on with
work holding devices, against the rotating wheel.

Study of Grinding Machine

Types Main Parts Used Tools Tool Job holding Main operation and
holding system Remarks
method
A. Bench Base, table (Grinding Abrasive Jobs are A)1.............................
Wheel head, wheel is act grinding fixed table 2.............................
B. Portable Saddle, as a multi wheels are part of the B) 1.............................
Feed handle, point cutting hold in machine or 2..............................
C. Surface Wheel tool made of machine chuck. C) 1.............................
spindle, abrasive wheel Different 2.............................
D. Cylindrical motor. metals spindles type of job D) 1..............................
(Aluminium holding 2.............................
E. Centre less oxide or methods E) 1...............................
Silicon are used 2...............................
F. Tool and carbide ) clamps, nut F) 1..............................
cutter grinder and bolt, 2.............................
magnetic
table etc.

Skill :- Grinding machines are used for remove metal with good surface finish in all engineering works.
 MACHINE SHOP

Model Questions :-

1. Give three main features of headstock of a centre lathe?

2. Lathe beds are made of ...............................
3. Dead centre is fix on ................................... part this tail stock
4. What is difference between 4 Jaw chuck and 3 Jaw Chuck
5. Give three types of cutting tool materials used in Lathe work.

6. Lubricants is a substance, Which reduces friction between machine parts. What are the 3
group of lubricants?
7. Give two examples multipoint cutting tool?
8. Difference between shaping and milling?
9. Grinding external surface which types of machine tool is suitable.
10. What are the use of drilling machines in engineering workshop?