PATTERN SHOP
AIM: TO STUDY ABOUT PATTERN SHOP
OBJECTIVES: 1) To study about different types of Timbers use for pattern making
2) To study safety during pattern shop
COMMON SAFETY IN PATTERN SHOP
There are some general safety precautions to be taken care of while working in carpentry
Shop. Some of which are discussed as under.
1) Before starting any wood working machine, it should be ensured that all the safety
Guards are in proper places and secured well.
2) While working on a circular saw, one should not stand in a line with the plane of the
rotating blade and always keep your fingers always away from the reach of Blade.
3) One should not use defective or damaged carpentry tools while carrying out
carpentry Work.
4) Nails, screws should be properly kept in a box for proper house keeping.
5) Sufficient safety precautions are to be taken for preventing fire in the carpentry
Shop.
6) No carpentry tools should be thrown for saving time in handling.
TYPES OF COMMON TIMBERS
1Shisham 5 Mango 9 Babul
2 Sal 6 Mahogony 10 Fire wood
3Teak wood 7 kail 11 Walnut
4Deodar 8Chid 12 Haldu
Difference between Hard Wood and SoftWood
SR Hard wood Soft wood
No
1 It is dark in colour Its color is light
2 It is heavy in weight. It is light in weight
3 Hard woods are harder and denser Soft woods are comparatively lighter
4 It has less resin content Few softwoods are resinous
5 It does not split quickly It gets splitted quickly
6 It is difficult to work It is easy to work.
7 It’s annual rings are close and often Its annual rings are well spaced and quit
indistinct distinct
8 It is slow growing. It is fast growing.
9 It has good tensile and shear It has good tensile resistance but is weak
resistance. across the fibers.
10 It does not catch fire very soon It catches fire very soon.
OUTCOMES: Students will be able to understand fundamental of different types of wood
uses in pattern shop
WELDING SHOP
AIM: TO STUDY ABOUT WELDING SHOP
OBJECTIVES: 1) To understand fundamental of welding process
2) To understand layout of welding shop
3) To understand safety and its equipments
INTRODUCTION AND LAYOUT OF WELDING SHOP
LAYOUT OF WELDING SHOP
PRACTICAL-1
STUDY OF ARC WELDING SET UP OF POLYTECHNIC WORKSHOP
1 CIRCUIT DIAGRAM OF ARC WELDING:
EQUIPMENT USED IN ARC WELDING:
SR. NAME OF ONLINE FUNCTION SPECIFICATIONS
NO EQUIPMENTS
1 TRANSFORMER Transfer available power into AC-50 volts,100 amps. with
(STEP DOWN) required high amperage and 440/415 supply voltage, oil
low voltage combination cooled
2 WELDING CABLE Circulate current from main to -----------------
work station
3 EARTHING Provide earthing to the work ------------------
CLAMPS station
4 ELECTRODE Clamp on electrode and ------------------
HOLDER conducting an electric current
to it
5 ELECTRODE Produce arc and provide filler IS-E31743
metal to weld 3.15 dia x 350 mm length
ACCESSORIES:
1 Chipping hammer Used from removing slag from finished welds -------
2 Wire brush Used for cleaning the work weld and also cleaning --------
the edges prior to welding in tight places
3 Chisel Used for removing sputtered metal and chipping back ---------
defects from weld
SAFETY EQUIPMENTS:
1 Welding goggles or Used to protect operator's eyes from larger proportion ----------
welding screens of visible light, injurious infra-red & ultraviolet rays
2 Leather gloves, Used to protect operator's body from electric arc and ----------
apron & gun shoes hot metal -
3. Brief Procedure of Arc welding:
3.1 Setting Parameters:
Flux Electrode. length : 3.15 mm diameter * 350 mm
Current : 100 amps
Voltage : 50 volts
Plate Thickness : 5 mm
Gap at weld junction (G) : 2 mm
Electrode material : M.S Flux coated
3.2 Operating Procedure:
➢ Set all the welding parameters as indicated in 3.1.
➢ Prepare the edges of the work piece.
➢ Properly place the work piece on table as per G mentioned.
➢ Wear all the safety equipment like goggles or welding screen, leather gloves, aprons
and gun shoes.
➢ Start welding machine.
➢ Make a contact between electrode and work piece and then lift it by 2 mm. Thus arc
will be produced.
➢ As welding proceeds. the electrode will consume itself so the gap between electrode
and work piece will increase. Try to maintain the arc gap constant by feeding
electrode in down ward direction also.
➢ After completion of welding, hold the work piece with tongs and place it on a
separate table for natural cooling.
➢ After some time with the help of chipping hammer remove the slag from finished
weld.
➢ Clean the weld and work piece with the help of wire brush.
PRACTICAL-2
STUDY OF SAFETY MEASURES IN WELDING SHOP
1. SAFETY EQUIPMENT USED IN WELDING:
SR Equipment Function
No
1 Welding goggles Used to protect operator's eyes from larger proportion of
or welding screen visible light, injurious infra-red and ultraviolet rays
2 Leather Gloves Used to protect operator's hands from electric arc and hot
metal.
3 Apron Used to protect operator's body from heat, electric arc and
hot metal
4 Gun metal shoes Used to protect operator's legs from heat, electric arc and
hot metal
2. TIPS OF SAFETY DURING WELDING:
(Ref-M/s. Sun Arc Welding Rod Mfg. Co., Udhana)
➢ Always weld in dry area.
➢ Ventilate properly.
➢ Avoid breathing welding fumes.
➢ Wear protective clothing
➢ Do not weld with wet gloves and wet shoes.
➢ Avoid looking at arc with naked eyes
➢ Use properly insulated holders.
➢ Protect eyes while chipping slag.
➢ Earth welding machine correctly. Check loose cable connections.
➢ Avoid excessive welding current.
➢ Do not weld on or near containers holding combustible material.
➢ Follow proper welding procedure
❖ IS SYSTEM FOR PRESENTATION OF WELDS:
Representation of weld as per IS 813
OUTCOMES: Students will be able to understand fundamental of welding
process with its tools and application and safety aspects.
FOUNDRY SHOP
AIM: TO STUDY ABOUT MOULDING PROCESS FOR MANUFACTURING OF CASTING
OBJECTIVES: 1) To study of equipment uses in foundry shop
2) Step wise preparation of sand mold, importance of gating systems
3) Overview regarding furnaces, cupola for preparation of liquid metals use
for manufacturing casting product
1. FUNCTION OF MOULDING TOOLS:
1. Shovel: - It consists of an iron pan fitted with a wooden handle. It is used in mixing and
conditioning the foundry sand by hand & transferring it to the flask.
2. Hand Riddle:- It consists of a wooden frame fitted with a screen of standard wire mesh
at its bottom. It is used for hand riddling of sand to remove foreign material from it.
3. Rammer:- Rammers are used for striking the sand mass in the moulding box to pack it
uniformly around the pattern. The common forms of rammers used in hand ramming are:
(a.) Peen Rammer: It has a wedge-shaped construction formed at bottom of a metallic rod.
It is common hand tool used in packing sand in pockets & corners.
(b.) Hand Rammer: It is smaller than peen rammer with a wedge shape (peen) at one end
& a cylindrical shape (butt) at the other. It is mainly used in bench moulding.
4. Strike of bar:- It is flat bar made of wood or iron, to strike off the excess sand from the top of a
box after ramming. Its one edge is made beveled and the surface perfectly smooth and plane.
5. Vent Wire: It is thin steel rod or wire carrying a pointed edge at one end and a wooden
handle or a bent loop at the other. After ramming & striking off the excess sand, it is used
to make small holes called vents, in the sand mould to allow the exit of gases & steam
during casting.
6. Trowel:- It is used for finishing flat surfaces and joints in at mould. They are made of iron
& are provided with a wooden handle.
7. Slick: - It is used for repairing and finishing the mould surfaces and edges after the
pattern has been withdrawn. Commonly used slicks are heart and leaf spoon and bead, and
heart and spoon shaped.
8. Lifter or Cleaner: - It is also a finishing tool & used for repairing and finishing & removing
loose sand from the sand mould after withdrawal of pattern.
9. Draw Spike: - It is tapered steel rod having a loop or ring at its one end & a sharp point
at other. It is used to rap and draw patterns from the mould.
10. Draw screws and rapping plate: - Draw screws are straight mild steel rods with a loop
or ring at one end & a wood or machine screw at other They are used along with rapping
plate for rapping & without pattern from the sand, rapping plate is provided with several
holes for either wood screw type or machine type draw rods.
11. Smoothers and corner slicks: - They are also finishing tools used for repairing &
finishing flat & round surfaces, round or square corners & edges.
12. Mallet: - It is a wooden hammer used for driving draw spike into the pattern & then rapping it.
13. Swab: - It is a hemp fiber brush used for moistening the edges of sand mould which are
in contact with the pattern surface before withdrawing pattern. It is used for coating liquid
backing on the mould faces in dry sand moulds.
14. Sprue pin: - It is tapered rod of wood or iron which is embedded in sand & later
withdrawn to produce a hole called runner through which the molten metal is poured into
the mould.
15. Sprue cutter: - It is also used for the same purpose as a sprue pin but cutter is used to
produce hole after ramming the mould. It is a tapered hollow tube which is inserted in
sand to produce the hole.
16. Gate cutter: - It is shaped piece of sheet metal to cut the feeding gate to connect the
runner hole with the mould cavity.
17. Soft brush:- It is a soft fiber brush used for sweeping away the mould sand from the
mould surface & pattern.
18. Gaggers: - Bent pieces of wires & rods which are used for reinforcing the downward
projecting sand mass in the cope are known as gaggers.
19. Clamps, cotters & wedges: - They are made of steel & are used for clamping the
moulding box firmly together during pouring.
20. Nails and wire pieces:- They are used to reinforce thin projections of sand in the mould
or cores made in two halves.
21. Bellow:- It is used to blow away the loose or unwanted sand from the surface of the mould.
2. TERMS RELATED TO SAND MOULDING
Various terms related to sand moulding are:
1. Cope:-The upper moulding flask is called the cope.
2. Drag:-The lower moulding flask is called the drag.
3. Runner:-Runner is passage through which molten metal is poured.
4. Gate:-It is the small passage connecting the runner to the mould cavity.
5. Parting Line:-It is the line along which the sand surfaces of the drag & cope meet each other.
6. Riser:-Riser is the passage through which the molten metal rises up after filling the
mould cavity. It is ensured that the mould has been completely filled It also helps the
escape of gases out of the mould.
3. SAND MOULDING PROCEDURE:
The procedure for making a mould in either green or dry sand is as follows:
1. First of all a suitable flask is selected large enough to accommodate the pattern & also allow
some space around it for ramming of sand.
2. The drag part is placed upside down on the moulding board.
3. The pattern is placed on the board inside the flask in such a position that space is left for gate cutting.
4. If in two parts, the lower part of pattern is placed in the drag.
5. If facing sand is used, it is placed all along the pattern surface to suitable depth (say 25 mm).
6. The drag is then filled with ordinary moulding sand & rammed properly.
7. The excess sand is cut-off to bring it in level with the edges of the flask.
8. A small amount of dry loose sand is sprinkled over the top surface & drag turned upside down
along with the bottom board placed over it after venting.
9. The cope is then placed over the drag & the top part of the pattern (if in two parts) assembled
in position.
10. Dry, loose, parting sand is then sprinkled over the entire surface of the drag & pattern.
11. Runner & riser are put in positions & supported vertically by tucking a small amount of
moulding sand around them.
12. The facing sand if used is again put around the pattern surface to the usual depth.
13. Gaggers if used then placed in position & the cope filled with ordinary moulding sand & rammed.
14. Excess sand is then cut-off, runner pins removed, venting performed, pouring basin formed &
dry sand sprinkled on the top surface.
15. A bottom board is placed over the cope and the latter rolled over.
16. The pattern parts are then removed from both the drag & cope.
17. Repairs, if any, are made & gates cut.
18. Dressing is then applied.
19. If it is a dry sand mould. It is baked.
20. The dry sand cores, if any are located in position and mould closed for pouring.
OUTCOMES:
Students will be able to understand fundamental of foundry and different kind of foundry Tools,
preparation of the mold, gating system.
SMITHY AND FORGING SHOP
PRACTICAL-1
AIM: INTRODUCTION TO FORGING
OBJECTIVES: 1) To study about forging operations.
2) To understand different types of tools use in forging shop
FORGING: - It refers to the production of those parts which must be heated in
closed furnace. The portion of work in which forging is done is termed the
forged and work mainly performed by means of heavy hemmers, forging
machines presses.
Forging processes are among the most important techniques since forged are
used in small tools, rail-road equipments, automobiles and trucks, aero plane
industries as well as in small industries.
ADVANTAGES OF FORGING:
1. It refines the structure of the metal.
2. It renders the metal stronger by setting the direction the grains.
3. It affects considerable saving in time, labour and material as compared to the
production of similar items by cutting from a solid and then shaping it.
4. Since the production of articles with reasonable degree of dimensional
accuracy is possible the machining operation can be avoided in most of the cases.
This also results in a considerable saving of time and labour.
PRACTICAL-2
AIM: TO STUDY FORGING OPERATIONS, INSPECTION METHODS AND DEFECTS.
FORGING OPERATIONS: For giving desired shapes to the products, the
following processes are used in smithy shop. A combination of two or more of
these is generally required.
I) UPSETTING II) BENDING
III) DRAWING OUT IV) PUNCHING AND DRIFTING
V) CUTTING VI) SETTING DOWN AND FINISHING.
I UPSETTING:
Upsetting or Heading is the process through which the cross-section of a metal
piece is increased with a corresponding reduction in its length. The particular
part in the bar shape, where increase in the cross-section is desired to heat till
acquires a fully plastic state. The hot portion of the bar is then kept on the anvil
face and the bar hammered at the top. A round bar being unsettled is shown in
fig.
II DRAWING OUT
This process is exactly a reverse process to that of upsetting. The pre- determined
length of the bar is heated to the plastic state. The bar of rectangular or square
cross-section is laid flat on the anvil face and hammer by cross peen hammer. If
the heavier reduction in dimensions is required the bar is drawn out between a
set of top and bottom fullers and required blows given by means of sledge
hammer.
III BENDING:
Bending bars, flats and other similar stock material is usually done in a smithy
shop. This can do to produce different shapes such as angles, ovals and circle
etc. Any desired angles or curvatures can be made through this operation. For
making right angles bend that particular portion of the stock, which is carried
out or the edge of anvil. Curved shapes of bends are formed on the horn of
anvil. Fig. shows a round bar being bent.
FORGING DEFECTS: The defects are generally noticed in forging due to one or
more of the following Reasons:
I) Due to defective original metal.
II) Improper heating of components for forging.
III) Faulty die design.
IV) Forging operation not carried out properly.
V) Faulty forging design.
PRACTICAL-3
AIM: To study about smith forging JOB as given in practical.
Making a job like shape S from a round bar.
a) Overall size of job is as shown in the diagram.
b) Stock size-M.S. Round bar 10 mm diameter & 150 mm long.
TOOLS USED:
1) Anvil
2) Hammer
3) Flat Tong
4) Steel foot rule
OPERATIONS: -
1) Heat the half length of the bar stock & draw out to bend by hammering.
2) Repeat the same operation for remaining half of the bar length.
3) Form “S” shape by heating and hammering the round bar half and half in
two operations.
OUTCOMES: Students will be able to understand fundamental of forging
process with its application
TIN SMITHY
AIM: TO STUDY ABOUT TIN SMITHY SHOP
OBJECTIVES: 1) To understand the fundamental of sheet metal operations
2) To understand the different metals used in Tin smithy shop
SHEET METAL OPERATIONS: A large number of operations are to be carried out in sheet metal work.
Some are done by hand, some by using machines and some can be performed either manually or
by using machines. The operations are the following: Laying out
1. Cutting and Shearing 5. Piercing and 8. Bending
2. Hand forming 6. Blanking 9. Drawing
3. Nibbling 7. Edge forming and 10. Soldering
4. Circle cutting Wiring
1. LAYING OUT: Laying out means the operation of scribing the development of the surface of the
component on the sheet/sheet blank, together with the added allowances for overlapping,
bending, hammering, etc., which when cut out of the blank and folded and joined will give the
required component. Such a layout when made on the sheet is called a pattern and the process
as pattern layout. If, however, the jobs to be made are small and in large number it is better to
use a template for repetitive marking of the development and then cutting it along the marked
contours. The templates size will obviously include the required allowances.
2. CUTTING AND SHEARING: Although the objective in both these operations is the same i.e. to
separate a sheet piece into two along a remarked fine or contour. The word cutting is normally
used when the sheet metals is cuts by means is cut beam of a chisel and a hammer manually.
The term shearing stands for cutting of sheet metal by two parallel cutting edges moving in
opposite direction. This can be done either manually by using hand shears or snips or by means
of machines called shears. The operation is then known as machine shearing or mechanical
shearing.
3. HAND FORMING: The term metal forming stands for shaping and or bending of sheet metal in
three dimensions in order to give the desired shape and size of the final product. For this the
metal is either required to be stretched or shrunk in all directions or may need a combination of
both. Best example of this operation can be seen if one observes the traditional metal workers
manufacturing cooking utensils of brass out of blanks by hand hammering and shaping them into
different shapes and sizes without any joint. For producing hollow shapes through band forming
the centre of the metal has to be thinned or the edges have to be thickened the former will
involve sinking and hollowing work while the later will my raining of edges. Both hammers and
mallets of different shapes are used in this operation acceding whether the metals has to be
stretched, needing a solid blow formed(needing as blow a mallet or a soft hammer) or
sunk(requiring a floating blow).
4. NIBBLING: Nibbling process of continuous cutting along a contour, which may be a straight line
or an irregular profile. The machines used in this operation are known as Nibblers, which are
portable shearing machines. These machines can be either electrically operated or
pneumatically.
5. CIRCLE CUTTING: It is the operation of cutting circular blanks or curved contours with the help
of a circle cutting machines. it is also a continues cutting operation.
6. PIERCING AND BLANKING: Piercing basically a hole punching operation while blanking is an
operation of cutting out a blank, in both the cases blanks will be produced but in the former
case obtaining a blank is not objective. It is the hole of a desired size which is the objectives and
the blank produced may or may not be used further. In the latter operation the production of a
blank of the desired size is the main objective which is a useful part for further processing.
7. EDGE FORMING AND WIRING: The edges of sheet metal products are formed (or folded) to
ensure safety of hands while handling these products and to provide stiffness to the products in
order that they will retain their shapes during handling, i.e., will not get buckled or compressed by
simple hand or finger pressure during handling When still stringer edges are needed they are
reinforced by inserting a metal wire or rod and then forming the edge by curling the edge of metal
around it. This not only increases stiffness of the joint but also improves its appearance.
8. BENDING: Sheet metal is required to be bent at different angles and curvatures to shape it into
the required form. The bending operation involves stretching of metal on the outer surface and
compressing it on the inner surface along a neutral line which remains unchanged in length. Sheet
metal can be bent by hammering over a base by hand or by means of bending or rolling machines.
9. DRAWING: Thin walled hollow shapes are produced in sheet metal through the drawing
operation. The operation is carried out with the help of a die and a punch on a suitable press if the
drawn length of the component is less than its width or diameter it is called box drawing or
shallow drawing. When the length is more than the width the operation is known as deep
drawing.
10. SOLDERING: It is very common method of joining sheet metal parts. It involves spreading of a
low melting point alloy (solder) in molten condition between the surfaces or edges to be joined
and allowing into solidify there.
METALS USED IN SHEET METAL WORK: A fairly large variety of metals are used in sheet metal
work in the form of sheet plates. The specifications of metal sheets are given in terms of their
gauge number and length and width The gauge numbers correspond to definite thickness of the
These numbers can be known by using a Standard Wire Gauge. The thicknesses sheets vary
inversely as their gauge number. The higher the gauges number the smaller the thickness and
vice-versa.
1. Black iron 4. Aluminum sheets 7. Brass
2. Galvanized iron 5. Tin plates 8. Lead
3. Copper sheets 6. Stainless steel 9. Zinc
Note: Write down two lines about given listed metals. e.g aluminum:- it is light in weight and offer
very high resistance to corrosion and abrasion so it is used in manufacture of aeroplane bodies,
kitchenware and domestic appliances.
OUTCOMES: Students will be able to understand fundamental of sheet metal process with its
application aspects.