ENGINEERING WORKSHOP LAB MANUAL

B. Tech – I YEAR

Department of Mechanical Engineering

 CONTENT

S. No TOPIC Page No.

1. Preface 3

2. Acknowledgement 4

3. General Instructions 5

4. Safety Precautions 5

5. Institute Vision and Mission 7

6. Department Vision Mission, Programme Educational Objectives 7

7. Programme Outcomes 8

EXPERIMENTS:
8.
Introduction to workshop technology
1. CARPENTRY
2. FITTING
3. HOUSE WIRING
4. TINSMITHY
5. BLACKSMITHY
6. WELDING
7. FOUNDRY
TRADES FOR DEMONSTRATION & EXPOSURE:
1. PLUMBING
2. MACHINE SHOP
3. METAL CUTTING (WATER PLASMA), POWER
TOOLS IN CONSTRUCTION AND
4. WOOD WORKING
 INDEX
[Link] NAME OF THE EXPERIMENT PAGE DATE SIGN
NO.
 PREFACE
This book entitled “Engineering Workshop Lab” is intended for the use of First [Link] (all
branches) students of Marri Laxman Reddy Institute of Technology and Management,
Dundigal, Hyderabad. The main objective of the Engineering Workshop Lab Manual is to furnish
the conceptual understanding of the basic principles of instruments involved in engineering
applications, before the students carry out laboratory experiments. This book lays foundation of
certain basic concepts and skills that can be repeatedly employed by the students in their future
endeavors. The main aim of this book is to develop the habit of scientific reasoning and providing
answers to all the doubts that arise during the course of conducting experiments. The book was
written as per the new syllabus prescribed by the JNTUH University in a simple language. These
experiments will help the students to expertise in the analysis and reporting the instruments
quality for different applications. Hence we hope this book serve for better understanding by the
student community with all details of experiments.

By,
N RAVITEJA,
Assistant Professor,
Department of Mechanical engineering
 ACKNOWLEDGEMENT
I express my sincere thanks to Mr.U. SUDHAKAR sir, Head of the Department of Mechanical
Engineering, Marri Laxman Reddy Institute of technology & Management, for his concern towards
me and gave me opportunity to prepare Engineering Workshop laboratory manual.

I am deeply indebted and gratefully acknowledge the constant support and valuable patronage of Dr.
R. KOTAIH sir, Director, Marri Laxman Reddy Institute of technology & Management. I am
unboundedly grateful to him for timely corrections and scholarly guidance.

I express my hearty thanks to Dr. K. VENKATESWARA REDDY sir, Principal, Marri Laxman
Reddy Institute of technology & Management, for giving me this wonderful opportunity for preparing
the EWS laboratory manual.
At last, but not the least I would like to thanks the entire Department faculties those who had inspired
and helped me to achieve my goal.

By,
N RAVITEJA,
Assistant Professor,
Department of Mechanical engineering.
 GENERAL INSTRUCTIONS

 The objective of the laboratory is learning. The experiments are designed to illustrate

phenomena in different areas of Workshop and to expose you to uses of instruments. Conduct

the job with interest and an attitude of learning.

 You need to come well prepared for the job.

 Work quietly and carefully (the whole purpose of experimentation is to make reliable

measurements!) and equally share the work with your partners.

 All presentations of job and diagram should be neatly and carefully done.

 Diagrams should be neatly drawn with pencil. Always display units.

 Come equipped with scales, pencils etc

 Do not fiddle idly with apparatus. Handle instruments with care. Report any breakage to the

Instructor. Return all the equipment you have signed out for the purpose of your experiment.

SAFETY PRECAUTIONS

General Guidelines

a. Conduct yourself in a responsible manner at all times in the laboratory.

b. Be familiar with your lab experiment before you come to the lab. Follow all written
and verbal instructions carefully. If you do not understand a direction or part of a
procedure, ask the lecturer/instructor/technician before proceeding.
c. No student may work in the laboratory alone. The lab instructor/lecturer grant
exceptions on a case by case basis.
d. When first entering a laboratory, do not touch any equipment or other materials in the
laboratory area until you are instructed to do so.
e. Do not eat, drink beverages or chew gum in the laboratory. Do not use laboratory
glassware as containers for food or beverages.
f. Smoking is strictly not allowed in any indoor area.
g. No music allowed in the laboratory. Radio (including walkman) and other
entertainment devices are not permitted.
h. No cellular phone is allowed in this laboratory.
 Clothing
1. Safety goggles and safety jacket must be worn whenever you work in lab.
2. Gloves should be worn whenever you use chemicals that cause skin irritations or
need to handle hot equipment.
3. Mask should be worn every time you prepare the chemicals.
4. Safety shoes and hard hat should be worn at all times while in the laboratory.
5. Contact lenses should not be worn in the laboratory unless you have permission
from your instructor.
6. Dress properly during a laboratory activity.
7. Long hair, dangling jewellery and loose or baggy clothing are a hazard in the
laboratory. Long hair must be tied back and dangling jewellery and loose or baggy
clothing must be secured.
8. Sandal, open-toed shoes, high heels or shoes with holes in the sols will not be worn
in the lab.
9. Shorts and skirts are not permitted.
 INSTITUTION VISION AND MISSION
VISION

To establish as an ideal academic institution in the service of the nation, the world and the
humanity by graduating talented engineers to be ethically strong, globally competent by
conducting high quality research, developing breakthrough technologies, and disseminating and
preserving technical knowledge.

OUR MISSION

To fulfill the promised vision through the following strategic characteristics and aspirations:

 Contemporary and rigorous educational experiences that develop the engineers and
managers.
 An atmosphere that facilitates personal commitment to the educational success of students
in an environment that values diversity and community.
 Undergraduate programs that integrate global awareness, communication skills and team
building.
 Education and training that prepares students for interdisciplinary engineering research
and advanced problem-solving abilities.

DEPARTMENT VISSION, MISSION, PROGRAMME EDUCATIONAL

OBJECTIVES AND SPECIFIC OUTCOMES

Vision Statement:
“The H&S Department strives for immense success in the field of education, research and
development by nurturing the budding minds of young engineers inventing sets of new designs
and new products which may be envisaged as the modalities to bring about a green future for
humanity”

Mission Statement:
i) Equipping the students with manifold technical knowledge to make them efficient and
independent thinkers and designers in national and international arena.
ii) Encouraging students and faculties to be creative and to develop analytical abilities and
efficiency in applying theories into practice, to develop and disseminate new knowledge.
iii) Pursuing collaborative work in research and development organizations, industrial enterprises,
Research and academic institutions of national and international, to introduce new knowledge and
 methods in engineering teaching and research in order to orient young minds towards industrial
development.

Course Objectives:
1. To Study of different hand operated power tools, uses and their demonstration.
2. To gain a good basic working knowledge required for the production of various engineering
products.
3. To provide hands on experience about use of different engineering materials, tools, equipments
and processes those are common in the engineering field.
4. To develop a right attitude, team working, precision and safety at work place.
5. It explains the construction, function, use and application of different working tools,
equipment and machines.
6. To study commonly used carpentry joints.
7. To have practical exposure to various welding and joining processes.
8. Identify and use marking out tools, hand tools, measuring equipment and to work to prescribed
tolerances.

Programme Outcomes: At the end of the course, the student will be able to:

1. Study and practice on machine tools and their operations

2. Practice on manufacturing of components using workshop trades including pluming, fitting,
carpentry, foundry, house wiring and welding.
3. Identify and apply suitable tools for different trades of Engineering processes including drilling,
material removing, measuring, chiseling.
4. Apply basic electrical engineering knowledge for house wiring practice.
 INTRODUCTION

Workshop practice imparts basic knowledge of various tools and their uses in
different sections of manufacturing such as Fitting, Tin Smithy, House Wiring, Carpentry
etc. It is true that engineers are not going to become carpenters or blacksmiths or skilled
workers on the shop floor, but by exposing themselves to all working trades, they get a bird
eye view of the basic practical activities associated with all sections of manufacturing. It
helps them, when they occupy managerial positions, in understanding the activities and
practical difficulties, so that they can take appropriate decisions.

Even when large amount of mechanical equipment is available for producing or

repairing parts, there are still some elements of work which have to be performed by
manual methods. However, it must be borne in mind that all workshops and work areas are
places of some risk. A healthy regard for rules and respect for all equipment being used
reduces the risk of an accident considerably.
Finally, the engineers must also be familiar with the first aid practices. In case
some minor injuries in the form of cuts, burns, fractures, fainting, electric shock etc occur
in the shop floor, they should know how to give first aid to the victims.
 1. CARPENTRY
INTRODUCTION:

Carpentry deals with the processing of wood to obtain desired shapes and sizes. The process
dealing with the technique of making wooden pattern is called pattern making.
Wood obtained from tree is the chief product of forest. It has been universally
acceptable as raw material for manufacturing wooden products or appliances. From the pre-
historic times, wood has been utilized an important source of getting heat by firing it. It has
been utilized as major construction material for making shelter for the basic need of human
being. As the civilization advanced, it gained tremendous importance as special material for
boatbuilding, for piling to support docks and railroad tracks. But in modern times, with the
advance of wood chemistry, the uses of wood have recognized its importance in
manufacturing cheap useful products used in day today life such as paper, furniture, textiles,
plastics and hundreds of chemicals and extractives. The wooden products as plywood have
superseded in some products in comparison metallic and ceramic materials. Compressed
wood has also replaced some metals for gears and die casts. In war-time, in Europe, wood has
been used as a source of wood gas for propelling automobiles. Similarly clothing has-been
made from wood cotton and wood wool. The useful work on wood is being generally carried
out in a most common shop known as carpentry shop. The work performed in carpentry
shops comprises of cutting, shaping and fastening wood and other materials together to
produce the products of woods. Therefore, carpentry shop deals with the timber, various
types of tools and the art of joinery. In wood, there are two types of cells namely radiating
outward from the center of wood cross-section and running parallel to the length of wood.
Trees are generally classified into exogenous and endogenous types according to manner of
growth.

CLASSIFICATION OF CARPENTRY TOOLS:

1. Marking and Measuring Tools

2. Cutting and planning tools
3. Drilling and boring tools
4. Striking tools
5. Holding tools
1. MARKING AND MEASURING TOOLS:
Steel rule, marking knife, Steel tape, marking gauge, Folding rule, Mortise gauge, Try square,
Wing compass, Bevel square, Divider, Meter square, Trammel.

fig:Steel Rule

fig:Steel Tape

Fig: Mortise gauge

fig:Marking Knife
 Fig:Try Square

[Link] Square

2. CUTTING AND PLANNING TOOLS:

i) SAWS: Cross cut saw (Hand saw), Rip saw, Tenon saw.
ii) CHISELS: Firmer chisel, Dovetail chisel, Mortise chisel, outside chisel, inside chisel.
iii) PLANNING TOOLS: Wooden jack plane, metal jack plane, Smooth plane.
 Fig:Saws

Fig:types of chisels
3. DRILLING AND BORING TOOLS:

Gimlet, Ratchet brace, Hand Drill, Auger

4. STRIKING TOOLS:

Wooden hammer, Claw hammer, Mallet, Straight peen hammer

5. HOLDING TOOLS:

Bench vice, Sash cramp, G-Cramp, C-Cramp

 [Link] bench

Fig.C-Clamp
6. MISCELLANEOUS TOOLS:

Screw driver, Wood rasp file, Pincer

Fig:scew driver

fig:Wood rasp file

1. MARKING AND MEASURING TOOLS:

Marking is one of the most important features of wood work and success of completing job
accurately depends on accuracy of marking and measuring.
STEEL RULE: Used for making and measuring linear dimensions. It is specified by its
length.

STEEL TAPE: The steel tape is used for measuring longer dimensions. They are available
in different sizes, ranging from 0.6 to 2.5 m. It is flexible can be coiled and presses in a case.
FOLDING RULE: Four-fold box wood rule is made of four pieces of each of 15 cm length.
They are hinged in such a way that they can be folded. It is adapted to carpentry up to 60 cm
length.
TRY SQUARE: The try square is used for testing flatness of surface marking parallel lines
and also for marking and testing of right angles. It has a steel blade fitted at right angles in
wooden or cast iron stock. It is available in various sizes ranging from 100 to 300 mm.
BEVEL SQUARE: It is used for marking and testing of any angle between 0 degrees to 180
degrees. It has a slotted blade and stock. The blade can be fixed at any position by means of a
screw.
MARKING KNIFE: All dimensional lines marked with pencil are cut with marking knife. It
has a chisel edge and sharp point at other end. It is made of steel and generally used with a try
square.
MARKING GAUGE: The marking gauge is commonly used when absolute accuracy is
required. It has a stem with a sharp pin at one end. It is used to cut line along the grains and
parallel to an [Link] distance can be adjusted by sliding the stock (head) on a stem. This
can be achieved by thumbscrew.
MORTISE GAUGE: It has two sharp pins, one is fixed to the stem and other to a brass
slide, which can be secured at any position by a screw. It is used to cut two parallel lines in a
single stroke. It is particularly adopted for marking in Mortise and Tenon joints.
Divider: It consists of two pointed legs, the points are hardened and tempered to prevent
wear. It is used for transferring the sizes and scribing curves is circles on wooden surface.
TRAMMEL: It is used for drawing very large circles and arcs which are beyond the scope of
a compass. It consists of a wooden beam on which the two pins are located and distance
between them can be adjusted by means of thumb screws.
2. CUTTING AND PLANNING TOOLS:
Cutting tools are used for cutting timber to approximate size, cutting excess wood to obtain
desired shape and accuracy. Planning tools are intended to make smooth and a accurate
surface.
CROSS CUT SAW: It is used for cutting the wood across the grains. (Hand saw) Its teeth
are pointed. The pitch of the teeth is about 2.5 to 3.0 mm and the blade length is about 600
mm. its teeth have less ‘set’ than the rip saw.
RIPSAW: It is used for cutting the wood along the grains. Its teeth have chisel edge the pitch
of the teeth is about 5 to 8 mm and the length of the blade is about 700 mm. The process of
cutting the wood along the grains is called ripping. Because of high flexibility of the blade
and a smaller number of cutting points per cm. (i.e., high pitch) it is not suitable for cutting
across the grains.
TENON SAW: Tenon saw or back saw is used for cutting small work. It is mostly adapted
in joint work. It has a brass or steel back which strengthens the blade, but it restricts the depth
of cut. Its fine theeth (6 to 8 teeth/cm) and stiff back permits the smooth, accurate cutting for
marking joints. The saw is available in different length ranging from 250 to 400 mm.

3) PLANNING TOOLS:

Planning tools are for reducing to its final and for smoothing the [Link] jack plane:
It consists of a wooden body or stock in which blade or cutter is fastened at an angle of 450 to
the sole. The plane iron (blade or cutter) and the cap iron (back iron) are assembled and
assembly is inserted in the mouth of plane along with the wedge. The back iron supports the
cutting edge and also breaks the shaving so that they curl away from the blade. The blade can
be set for taking deeper or shallower cuts. The length of the jack plane is about 350 to 425
mm. the blade is made of high carbon steel and has a width of 50 to 75 mm. its cutting edge
id tempered and ground to an angle of 25 to 300 and it is slightly curved (convex).

METAL JACK PLANE: Its body is made of gray cast iron, and is provided with a wooden
handle at the back and a wooden knob at the front for holding with both the hands. A fine
screw is used for adjusting the depth of cut i.e. the thickness of shaving removed, and a lever
is used for lateral adjustment of the blade. It is very durable and gives better finish.

CHISELS: Chisels are used for cutting excess wood in shaping and joint making.
FIRMER CHISEL: The firmer chisel is capable of doing heavy work and is used for joining
and shaping the wood, with or without mallet. The chisel blade is made of rectangular section
with beveled edge, length of the blade is about 125 mm and the width of the edge varies from
3 to 50 mm.
Dovetail chisel: It is similar to firmer chisel but sides are beveled so that it can cut sharp
corners. It is used for cutting sockets where the angles is less than a right-angle.
Mortise chisel: These chisels are robust, and can withstand heavy blows. It has a thick stock
and narrow cutting edge. It is used for cutting mortises, and its width is ground to exact size
of mortise to be cut.
4) STRIKING TOOLS:

Striking tools are used to drive in nails and to operate chisels.

Wooden Hammer: It is mostly used for bench work and light work. It is made of cast steel
with tempered face and peen. The wooden handle fits in the eye and steel wedge is driven
into from a rigid joint.
Claw hammer: It is a dual-purpose hammer. It has a hammer face which is used to drive in
nails, and claw at other end for pulling out nails from the wood. It is designated by its weigh
and it varies from 375 to 675 grams.
Mallet: It is used for operating the chisels and gauges. It is made of hard wood and is
provided with handle. The striking faces are made flat, and may be round or rectangular in
cross-section.
5) DRILLING TOOLS:

These tools are used for drilling and marking holes in wooden jobs.
Gimlet: It is hand operated tool used for making small holes for screw. It has a spiral flutes
with screw like point.
Hand drill: It is used for drilling small holes. A straight shank drill is used with this tool. It is
small, light in weight. The bit is clamped in the chuck at its end.
Auger: It is used for producing long deep holes. It is a steel bar with an eye at the top in
which a handle is fitted. The bottom end s provided with a screw point.
6) WORK HOLDING TOOLS:

The vice and cramp are used to hold work while some operations are carried out.

CARPENTRY BENCH VICE: It is made of gray cast iron or steel, and it has two jaws one
of which is fixed to the side of a bench and the other is movable. The faces of jaws are lined
with hard wood to prevent damage of work surface. It is used for holding the work for
planning sawing and chiseling on the bench.
G or C – CLAMP:
7) MISCELLANEOUS TOOLS:
SCREW DRIVER: These are used for driving the screws on wood or unscrewing them from
wood. The size is specified by length of the blade.
PINCER: It is used for pulling out the nails and is more efficient the claw hammer.
WOODRASP FILE AND RASPS:

Files and Rasps are of used for maintaining other wood working tools and equipment. They are
made of hardened tool steel which is tempered and they should never be dropped as they are
very brittle to break. They are of various types depending upon their size, shape, cuts and degree
of their coarseness.

DRILLING MACHINE:
In drilling machine the drill is rotated and fed along its axis of rotation in the stationary
workpiece. Different parts of a drilling machine are discussed below:
(i) The head containing electric motor, V-pulleys and V-belt which transmit rotary
motion to the drill spindle at a number of speeds.
(ii) Spindle is made up of alloy steel. It rotates as well as moves up and down in a
sleeve. A pinion engages a rack fixed onto the sleeve to provide vertical up and
down motion of the spindle and hence the drill so that the same can be fed into
the work piece or withdrawn from it while drilling. Spindle speed or the drill
speed is changed with the help of V-belt and V-step-pulleys. Larger drilling
machines are having gear boxes for the said purpose.
(iii) Drill chuck is held at the end of the drill spindle and in turn it holds the drill bit.
(iv) Adjustable work piece table is supported on the column of the drilling machine.
It can be moved both vertically and horizontally. Tables are generally having
slots so that the vise or the work piece can be securely held on it.
(v) Base table is a heavy casting and it supports the drill press structure. The base
supports the column, which in turn, supports the table, head etc.
(vi) Column is a vertical round or box section which rests on the base and supports
the head and the table. The round column may have rack teeth cut on it so that
the table can be raised or lowered depending upon the workpiece requirements.
This machine consists of following parts
1. Base
2. Pillar
3. Main drive
4. Drill spindle
5. Feed handle
6. Work table
EX. NO: 1.1 HALF LAP JOINT DATE:
AIM: To prepare half lap joint as per dimensions.

MATERIAL REQUIRED:
wood 50 mm x 25 mm x 300 mm.

TOOLS REQUIRED:
1. Carpenters vice (6”)
2. Steel rule (12”)
3. Marking gauge (6”)
4. Metal jack plane (45 mm)
5. Firmer chisel (30 mm)
6. Mallet (1 kg)
7. Wood rasp file (100 mm)
8. Try square (9”)
9. Cross cut saw (300 mm)
SEQUENCEING OPERATIONS:

1. Initial measuring
2. Rough planning
3. Smooth planning
4. Marking
5. Cutting
6. Hammering
7. Chiseling
8. Filing
9. Final Finishing
WORKING PROCEDURE:
1. The given wood is checked for dimensions.
2. One side is planed with metal jackplane and checked for trueness by try square.
3. The four sides are also planned.
4. The excess material is cut by cross cut saw.
5. Now the portions for lapping are marked.
6. After sawing remove the waste material by firmer chisel.
7. It the material is still remained in 2 or 3 mm, and then removes by filing with wood
rasp file.
SAFETY PRECAUTIONS:
1. Do not keep the tools at the edge of the workbench.
2. Do not keep the plane horizontal in idle mode.
3. Care must be taken while sawing operation.

RESULT:

FIG: HALF LAP JOINT

 VIVA QUESTIONS
1. What is the importance of workshop?

2. Name the common carpentry tools?

3. What is the use for firmer chisel?

4. What is the use of metal jack plane?

5. What is the use of Rasp file?

6. Name the carpentry process?

7. What are the uses of wood?

8. What is the use of the bench vice?

9. What are the striking tools?

10. Define Carpentry?

11. What is Timber?

12. Name the type of timbers and give examples?

13. What are the types of rules used for measuring?

14. What is the use of Try-square?

15. What are the types of gauges used in carpentry?

16. What is the use of calipers?

17. What is the need of spirit level?

18. What is the chisel Material and types used in carpentry?

19. What are the types of carpentry joints?

20. What is the need of Bench vice?

EX. NO: 1.2 DOVETAIL LAP JOINT DATE:

AIM: To prepare Dovetail lap joint as per dimensions.

MATERIAL REQUIRED:

Wood 50 mm x 50 mm x 300 mm.

TOOLS REQUIRED:
1. Carpenters vice
2. Steel rule
3. Marking gauge
4. Metal-jack plane
5. Firmer chisel
6. Mallet
7. Wood rasp file
8. Try square
9. Cross cut saw
SEQUENCEING OPERATIONS:
1. Initial measuring
2. Edge Preparation
3. Rough planning
4. Smooth planning
5. Marking
6. Cutting
7. Hammering
8. Chiseling
9. Filing
10. Final Finishing
WORKING PROCEDURE:
1. The given wood is checked for dimensions.
2. One side is planed with metal jackplane and checked for trueness by try
square
3. The four sides are also planned.
4. The excess material is cut by cross cut saw.
5. Now the portions for lapping are marked.
6. After sawing remove the waste material by firmer chisel.
7. It the material is still remained in 2 or 3 mm, then remove by filing with woo rasp file.
SAFETY PRECAUTIONS:
1. Do not keep the tools at the edge of the workbench.
2. Do not keep the plane horizontal in idle mode.
3. Care must be taken while sawing operation.

RESULT:

FIG: DOVETAIL LAP JOINT

 VIVA QUESTIONS
1. What is the importance of workshop?

2. Name the common carpentry tools?

3. What is the use for firmer chisel?

4. What is the use of metal jack plane?

5. What is the use of Rasp file?

6. Name the carpentry process?

7. What are the uses of wood?

8. What is the use of the bench vice?

9. What are the striking tools?

10. Define Carpentry?

11. What is Timber?

12. Name the type of timbers and give examples?

13. What are the types of rules used for measuring?

14. What is the use of Try-square?

15. What are the types of gauges used in carpentry?

16. What is the use of calipers?

17. What is the need of spirit level?

18. What is the chisel Material and types used in carpentry?

19. What are the types of carpentry joints?

20. What is the need of Bench vice?

 [Link]
INTRODUCTION:

Machine tools are capable of producing work a faster rate, but there are occasions when
components are processed at the bench. The term bench work refers to the production of
components by hand on the bench, whereas fitting deals with the assembly of matting parts,
through removal of metal to obtain the required fit. Both the bench work and fitting operations
consists of filling, chipping, sawing, drilling, tapping etc.

CLASSIFICATION OF TOOLS:

The tools commonly used in fitting may be classified as

1. Work holding tools

2. Cutting tools
3. Striking tools
4. Marking and checking tools

[Link] HOLDING TOOLS:

Bench vice b)Hand vice c)Pipe vice d)Pin vice e)Tool makers vice f)Leg-vice g)C- clamp

BENCH VICE:The bench vice is a work-holding device. It has two jaws one of which is fixed to
the bench and other slides with aid of square screw and a box nut arrangement. The outer end of
screw carries a handle. The jaws are made with hardened steel and body is cast iron or cast steel.
The working faces of jaws are serrated to give additional grip for holding. File is a cutting tool. A
file is hardened steel is a hardened steel tool, having slant parallel rows of cutting edges or teeth
on its surface on the faces. The one end of the file is shaped to fit into wooden handle. The hand
file is parallel in width double cut teeth on the faces, single cut on the one edge and no teeth on
the other edge, which is known as “safe edge”.

Fig:Bench Vice
 TYPES OF FILES
Files are classified according to their shape, cutting teeth and pitch grades of teeth.
Hand file -------------- It is used for filing a surface, at a right angle to an already finished surface.
Flat file -------------------- Used for general filing
Square file------------ Used for slots and key ways.

Triangular file ----------- Used for sharp corners

Half round file----- Used for filing concave surfaces and internal corners.

Round file-------- Used for deep hole filing

CUTTING TOOLS

HACK SAW:

1. Solid frame

2. Adjustable frame

The hack saw is used for cutting metal by hand. It consists of a frame. This holds a thin
blade, firmly in position. Hack saw blades have a number of teeth ranging 5 to 15 per
cm.. The teeth of Hack saw blade are staggered or bended alternatively are known as a set of
teeth. These make slots wider than the blade thickness, preventing the blade from jamming.
Hack saw blades are classified as

1. All hard files

2. Flexible type

Fig:Hack Saw

DRILLS:
Drills are cutting tools used for making holes. These are usually made of high speed steel tools.
Drills are two cutting edges and two helical grooves. The flute (grooves) admits coolants and
allows the chips in The shank of twist drill may either straight or taper.
REAMER:
A reamer is used to finishing a drilled hole to accurate size and to produce a good surface
finishing. It is made of HSS. They are two types of reamers.
1. Hand Reamer
[Link] reamers

CHISELS:
Chisel are used for removing extra material from the surface and cutting the [Link] tools are
made up of from 0.9% to 1.0% carbon steel of octagonal or hexagonal. The cutting angle for the
chisel for general purpose is about 60 degree. The recommended angles for cutting different
materials at cold [Link]-35 degrees Mild steel- 55 degrees Copper and brass- 40-50
degrees Cast iron 60 degrees cast steel 70 [Link] chisels are specified by width of the
cutting edge. The most common used chisels are.

1. Flat chisel
2. Half round Chisel
3. Side chisel
4. Diamond point chisel
5. Cross cut chisel

SCRAPPERS: Scrapers are used for producing finished surface. It removes the surface
irregularities at selected spots on a surface hardened. The scrapers are made of tool steel. The
cutting edge is but not usually tempered. The most commonly used scrapers are.

1. Flat scraper
2. Triangular scraper
3. Half round scraper.

STRIKING TOOLS:
Hand hammers are striking tools. They are made of medium carbon steel. The various types of
hand hammers in common use are ball peen hammer, cross peen hammer, and straight peen
hammer.

MARKING TOOLS: Marking is a process of layout of sizes on work piece. The following
tools are used in marking out operations.
1. Scriber
2. Dividers
3. Jenny calipers
4. Scribing book
5. Angle plate
6. V-block
7. Punch
8. Try square
9. Surface plate.
SCRIBERS: A scriber is slender tool used to scribe or marking lines on metal work piece.

TAP AND TAP WRENCHES: A Tap is hardened steel tool. Used for cutting internal threads in
a drilled hole. Hand taps are available in sets containing three taps. Taper tap, second tap and plug
or bottom tap.

PUNCH:
Punch is made of tool steel. The various types of punches prick punch, center punch, number
punch and letter punch.

PRICK PUNCH: It is also called as dot punch. Used for marking small dots along the layout
lines.
CENTER PUNCH: This is similar to dot punch, except that is point grounded to an angle 90 o. It
is used for mark the location of holes to be drilled
V-BLOCK:
v-blocks are made of cast iron or hardened steel. They are provided with grooves on the top and
bottom, and rectangle slots on two sides for location of
clamps.

TRY SQUARE: It is used for checking the squareness of small works. The size of try square is
specified by the length of the blade.

SURFACE PLATE: It is used for provide true surface support to the work during marking is
made of cast iron, hardened steel or granite it is specified by length x width x height x grade.
DIVIDER: This is used for making circles, arcs, laying out perpendicular lines, bisecting lines
etc

CLENNY CALIPER:

This is also called as odd leg or hermaphrodite caliper used for marking parallel lines from a
finished edge and also for locating the center of round bars.

SCRIBING BLOCK: It is also known as universal scribing block. This used for scribing lines
for layout work and checking parallel surfaces.
ANGLE PLANE: The angle plate is made of cast iron or hardened steel. They are provided with
v-grooves on the top and bottom, and rectangle slots on two sides for location of clamps

VERNIER HEIGHT GUAGE: It is clamped with scriber it is used when it is required to take
measurements from the surface on which the guage is standing. The accuracy and working
principles of this guage are the same as those of the vernier caliper

Fig: VERNIER HEIGHT GUAGE

OUTSIDE MICROMETER: It is used for measuring external dimensions accurately of 0.01mm

INSIDE MICROMETER: This is used to measure inside dimensions accuracy of 0.01 mm. It
consists of measuring unit, a number of interchangeable extension rods, and a handle.
MEASURING AND CHECKING INSTRUMENT:

Measuring tools may be classified:

1 LINEAR MEASURING INSTRUMENTS

(a) Steel rule (b) caliper (c) depth gauge (d) vernier caliper
(e) Micro meter (f) gauge block (g) dial indicator or dial gauge
2 ANGULAR MEASURING INSTRUMENTS
(a) Bevel protractor (b) Combination set (c) Sine bar
3 SURFACE MEASURING INSTRUMENTS
(a) Spirit level (b) straight edge
STEEL RULE: It is a strip of steel with graduation on its edges

CALIPERS: Used for transferring the dimensions both external and internal. They are made
either with firm joint or spring caliper.

OUTSIDE CALIPER: Used for measuring outside dimensions of cylindrical shapes.

INSIDE CALIPER: Used for measure the diameter of holes and width of key ways.

VERNIER CALIPER: They are used for measuring outside as well as inside dimensions
accurately. It may be also used as depth guage. Least count = one main scale division – one
vernier scale division

COMBINATION SET: It consist of a rule, square head, center head, and a protractor. This
may be used for making mitres(45o) for locating the centre on the end of the round bar.

GUAGES:
Gauges are inspection tools used in production work to control the size and shape of the
components.

PEELER GUAGES: These are thin steel blades hardened and grounded to various sizes.
These are used to check the clearance between the two mating parts. The blade thickness
varies from 0.03 to 1.0mm and the length of the blade is about 100mm.

SCREW PITCH GUAGE: It is used to check the pitch of the screw. The pitch of the
screw is directly on the gauge.

WIRE GUAGE: The wire gauge is used to check the diameter of wire from 0.1mm to
10mm

PLATE GUAGE: Plate gauge (standard wire gauge) is used to measure thickness. Each slot is
represented by number (SWG NUMBER), as the number increases the thickness decreases. The
most common gauge used in sheet metal has 21 slots with gauge numbers ranging from 4 to 24

RADIUS AND FILLET GUAGE: These are used to check the radii of curvature of convex and
concave surfaces.
EX. NO:2.1 L-FIT DATE:

AIM: To prepare a L-fit.

MATERIAL REQUIRED: MS FLAT of 50 mm X 50 mm X 5 mm.

TOOLS REQUIRED:

1).150 mm Try square

2).250 gm Ball peen hammers

3) Dot punch

4) Centre punch

5) scriber

6) 15cm Steel rule

7) Odd leg Caliper

8) Vernier height Gauge

9) Chisel

12) 250mm Rough and Smooth square files

13) 6mm rough and Shank square files

14) 3mm Straight Shank Drill Bit.

15) Half round file

16) Divider.

PROCEDURE:

1. The given material is checked for (48X48X2) dimensions.

2. One edge of the given MS Flat is filed to straightness with rough and smooth files and check
with try square for flatness.
3. An Adjacent edge is also filed such that it is a square to the first one and checked with try
square. Wet chalk is applied on one side of the flat and dried for marking.
4. Marking is done in accordance with the dimensions using vernier height gauge
5. Using dot punch, dots are made along the marking lines.
6. The excess material is cut with hacksaw and then filed to correct size. Care taken to see that
the marking dots are not crossed.
7. Finish the mating surfaces with rough file followed by smooth file.
8. Prepare the counterpart in similar way.
9. File the other surfaces also and remove burns and rust.

PRECAUTIONS:

Never remove chips with hand, use always a brush to remove chips.

Working tools should not be kept at the edge of the table.

While sawing, secure the work rigidly.

RESULTS:
 VIVA QUESTIONS

1. What is meant by fitting?

2. What is the use of vice and give the various types of vice?
3. State the different types of hammers used in fitting work.
4. What is the use of V- block?
5. What are the materials used for files?
6. What are the methods of filing?
7. What is the composition of high speed steel?
8. What is meant by peening or swaging?
9. What are the different types of punches?
10. What is a wrench?
11. What is the material used for making hacksaw blades?
12. When should a blade with 32 teeth per inch be used?
13. What are the causes of breaking of hacksaw blades?
14. How to specify a vice?
15. What are the types of wrenches?
16. What is a torque wrench?
17. Name the material lout of which the vice is made.
18. Name the different types of drills used in fitting shop?
19. How can a tap drill step be determined?
20. What is the length of available steel rule?
21. What is the material used in making taps?
22. What is the use of tap?

23. Name the files which are classified based on longitudinal

shape and cross section.
EX. NO:2.2 V- FITTING DATE:

AIM: To prepare a V- FITTING.

MATERIAL REQUIRED: MS FLAT of 80 mm X 40 mm X 5 mm.

Tools required:

1).150 mm Try square 2).250 gm Ball peen hammers 3) Dot punch

4) Centre punch 5) scriber 6) 15cm Steel rule 7) Odd leg Calliper

8) vernier height Gauge 9) Chisel 12)250mm Rough and Smooth square files

13) 6mm rough and Shank square files 14) 3mm Straight Shank Drill Bit.

15) Half round file 16) Divider.

PROCEDURE:

1. The given material is checked for (40X40X5) dimensions.

2. One edge of the given MS Flat is filed to straightness with rough and smooth files and check
with try square for flatness.

3. An Adjacent edge is also filed such that it is a square to the first one and checked with try
square.

4. Wet chalk is applied on one side of the flat and dried for marking.

5. Marking is done in accordance with the dimensions using vernier height gauge

6. Using dot punch, dots are made along the marking lines.

7. The excess material is cut with hacksaw and then filed to correct size. Care taken to see that the
marking dots are not crossed.

8. Finish the mating surfaces with rough file followed by smooth file.

9. Prepare the counterpart in similar way.

10. File the other surfaces also and remove burns and rust.
Precautions:

1. Never remove chips with hand, use always a brush to remove chips.

2. Working tools should not be kept at the edge of the table.

3. While sawing, secure the work rigidly.

RESULTS:
 VIVA QUESTIONS

1. What is the mechanical meaning of fitting?

2. What is The Use of Try Square?
3. What Is The Name Of Vice Used In Fitting Shop?
4. Name the different files?
5. Which tools are used in fitting shop?
6. What is the use of center punch?
7. Write any five advantages of wood over the other materials?
8. What is bench vice made up of?
9. Should the hardness of work piece be same as that of the file?
[Link] is a file?
11. What is meant by fitting?
12. What is the use of vice and give the various types of vice?
[Link] the different types of hammers used in fitting work.
[Link] is the use of V- block?
[Link] are the materials used for files?
[Link] are the methods of filing?
[Link] is the composition of high speed steel?
[Link] is meant by peening or swaging?
[Link] are the different types of punches?
[Link] is a wrench?
[Link] is the material used for making hacksaw blades?
EX. NO:2.3 HALF ROUND FITTING DATE:

Aim: To make a half round fitting from the given two M.S pieces.
Material: Two MS FLAT of size 50x50x5mm
Tools required:
150mm try-square, 250gm ball-peen hammer, dot punch, scriber, chisel,
300mm hacksaw frame, 18TPI hacksaw blade, 250mm rough and smooth
hand files, 6mm rough and smooth square files, Bench vice and steel rule.

Sequence of operations:
1. The burs in given materials are removed and the dimensions are checked for
50x50x5mm with steel rule.
2. The pieces are clamped one after the other and outer mating edges are
filed and checked for their flatness, with the help of try-square.
3. The side edges of the two pieces are filed such that, they at right angles to
each other and widths are exactly 48mm.
4. Wet chalk is applied on surfaces of the two pieces.
5. The given dimensions of the Stepped fitting are marked, by using jenny
caliper, steel rule scriber, and the surface plate.
6. The portion to be removed is then marked.
7. Using dot punch, dots are punched along the above scribed lines.
8. Using the hacksaw, the unwanted portions are removed.
9. Now the potions are filed and burrs are removed by filing on the surfaces of
fitted job.
Note: The centers of the half rounds are marked by a centre punch. However,after
marking the centre of the half round in the piece Y, the edges of it is further filed,
till half of the punch dot is left.

Precautions:
1. Never remove chips with hand use a wire brush.
2. Working tool should not be kept at the edge of table.
3. While sawing secure work rigidity.
Result:.
 VIVA QUESTIONS

1. What is the mechanical meaning of fitting?

2. What is The Use of Try Square?
3. What Is The Name Of Vice Used In Fitting Shop?
4. Name the different files?
5. Which tools are used in fitting shop?
6. What is the use of center punch?
7. Write any five advantages of wood over the other materials?
8. What is bench vice made up of?
9. Should the hardness of work piece be same as that of the file?
[Link] is a file?
11. What is meant by fitting?
12. What is the use of vice and give the various types of vice?
[Link] the different types of hammers used in fitting work.
[Link] is the use of V- block?
[Link] are the materials used for files?
[Link] are the methods of filing?
[Link] is the composition of high speed steel?
[Link] is meant by peening or swaging?
[Link] are the different types of punches?
[Link] is a wrench?
[Link] is the material used for making hacksaw blades?
 [Link] SMITHY

INTRODUCTION:

The metal plank having less than 2 mm thickness is called sheet metal. Sheet metal work
deals with the production of components in wide variety of shapes and sizes from sheet metal,
with aid of tools or machines metals used in sheet metal work variety of metal shop. The
characteristics and uses of some of the important metals used in sheet metal work are
described below:

Galvanized iron: It is a sheet of soft steel, which is coated with zinc. Zinc resists corrosion
and improves the appearance of metal. Galvanized iron is one of the least expensive metals
and is used for making pans, buckets, ducts, gutters, tanks, boxes, etc.

Black iron: It is uncoated sheet of metal with bluish-black appearance. It corrodes rapidly
and is not used extensively due to difficulties of soldering. The black iron sheets are used for
the parts that are to be painted.

Tin plate: Tin plate is an iron or steel coated with pure tin. It has very bright silver
appearance and is used for food containers, cans and pans.

Stainless steel: It is an alloy steel possessing corrosion resistance. General type stainless steel
contains 18 percent chromium and 8 percent nickel. This steel is commonly known as 18-8
stainless steel. These are available in various sizes and thickness. It is widely used for food
containers and dairy equipment.

Copper: It has reddish color and possesses good malleability, ductility and resistance to
atmospheric corrosion.

Aluminium: Sheet aluminium is never pure aluminium and it is always allowed with small
quantities of copper silicon, magnesium and iron.

TOOLS AND EQUIPMENT:

Some of the tools used in fitting are also used in sheet metal work. Certain additional
tools used by sheet metal worker are described below:
Snips: Hand shears or snips are used to cut sheet metal. Although there are many types, the
sheet metal workers generally use straight snips and curved snips.

Straight snips: Straight snips have straight blades and are used for cutting along the straight
lines and for trimming edges.

Curved snips: Curved snips has a curved blade and are used for cutting circles and irregular
shapes.

Bench shears: Bench shear is used for cutting thicker sheets. It is the lower fixed blade firmly
secured by bracket at the bottom. The movable blade is pivoted at the rear end; the hand
operating lever is attached to the front end of movable blade in a link mechanism.

Stakes: Stakes are made of steel and forged in a variety of shapes and sizes. Its working face is
machined and polished to facilitate various operations such as bending, seaming or forming.
The following types of stakes are most generally used:

Double seaming: These stakes has two horns and it is used to make double seam for vessels.

Blow horn: These stakes has two horn tapering horns and it is used to form or seam funnels.

Break horn: These stakes has a square tapered horn on one side and a round tapered horn on
opposite side. It is used for shaping round and square surfaces, bending edges and making
corners.

Conductor stake: These stakes has two cylindrical horns having different diameters. It is used
for forming pipes and cylindrical pieces.

Funnel stake: It is used for forming conical shapes and for making wire rings.

Hatchet stake: It has a horizontal sharp straight edge and can be used for making straight,
sharp bends and for folding and bending edges.
Hand hammers and mallets: The sheet metal worker uses a wide variety of hammers and
mallets for forming shapes by different operation. The most commonly used hammers are as
follows:

Straight-peen hammer: It has a peen end similar to its bottom size round shape and its top
side is straight point. Square, slightly curved face and its peen is tapered. It is used for
riveting.

Cross-peen hammer: It has a square, flat face and it is tapered on one side. It is used for
setting down the edges for making a double seam.

Mallet: Mallet is generally made of wood or plastic. It is used whenever slight blows are
required. Wooden mallets do not damage the surface.
Wire Gauge: The thickness of sheet metal is preferred in numbers known as the standard wire
gauge (SWG). The gaps in the circumference of the gauge are used to check the gauge number
as shown below.

Sheet metal joints: Various types of joints are used in sheet metal work to suit the varying
requirements. Some commonly used sheet metal joints and folded edges are shown below.
These are self secured joints, formed by joining together two pieces of sheet metal and using
the metal itself to form the joint.

FIG: MECHANICAL SHEARING PRESS

TINSMITHY TOOLS
[Link].1 ROUND TIN DATE:

AIM: To prepare a ROUND TIN from the sheet metal as per given dimensions.

MATERIALS REQUIRED: Gl Sheet of size 110 mm X 70 mm.

TOOLS REQUIRED: 1. Scriber [Link] snip 3. Beak horn

stake

4. Hatchet stake [Link] rule 12” [Link]

PROCEDURE:

1. In order to obtain correct size and shape of the article, prepare a template.
2. The template is drawn directly on the sheet metal.
3. The sheet is cut with the help of snip and the notching operation is carried out to obtain the
desired shape.
4. The sheet metal is bent along the marked lines by striking with a mallet on proper stake.
5. The edge of the sheet metal is folded to strengthen the edge and to eliminate the sharp edges.
6. Finally seaming operation is completed to obtain the rectangular tray.

EXPERIMENT DIAGRAM:

PRECAUTIONS:

1. Never carry tools in pockets.

2. Do not try to hold sheet with bare hands.
3. Remove scrap metal to avoid injuries.

RESULTS:
FIG:ROUND TIN
 VIVA VOCE

1. Define sheet metal work?

2. What are the applications of sheet metal working?
3. What is the principle behind the sheet metal layout?
4. How do you identify the thickness of metal sheet?
5. What will be the result of the sheet thickness when increasing the
gauge number?
6. What are the metals used in sheet metal work?
7. Name the striking tools used in sheet metal work?
8. Name the five tools and equipments which are used for cutting
sheet metal?
9. What is a snip?
10. What are the types of snips?
11. Define punching operation?
12. Define nibbling operation in sheet metal work?
13. How will you design the diameter of rivet for sheet metal work?
14. Name the various sheet metal operations?
15. What is hem?
16. What are the functions of hem?
17. What is seam?
18. Double seam is .................. than single seam
19. What are the different types of seam?
 [Link].2 REACTANGULAR TRAY DATE:

AIM: To prepare Rectangular Tray from the sheet metal as per given dimensions.

MATERIALS REQUIRED: Two Gl sheets

TOOLS REQUIRED: 1. Scriber 2. Straight snip 3. Curved snip

4. Beak horn stake 5. Hatchet stake 6. Steel rule 12”

7. Mallet 8. Soldering iron

EXPERIMENT DIAGRAM:

PROCEDURE:

1. The size of the given sheet is checked with steel rule.

2. Mark the measurement and make the development surface sketch diagram.
3. The layout of the tray is marked on given sheet.
4. The layout of the tray is cut by using the straight snips.
5. The sheet is bent to the required shape using stakes and mallet.
6. Now the bent edges are made to overlap each other and stuck with a mallet to get
the required joint.
7. The joint is soldered.

PRECAUTIONS:

1. Never carry tools in pockets.

2. Do not try to hold sheet with bare hands.

3. Remove scrap metal to avoid injuries.

RESULTS:
 VIVA QUESTIONS

1. Define sheet metal work?

2. What are the applications of sheet metal working?
3. What is the principle behind the sheet metal layout?
4. How do you identify the thickness of metal sheet?
5. What will be the result of the sheet thickness when increasing the gauge
number?
6. What are the metals used in sheet metal work?
7. Name the striking tools used in sheet metal work?
8. Name the five tools and equipments which are used for cutting sheet
metal?
9. What is a snip?
10. What are the types of snips?
[Link] punching operation?
12. Define nibbling operation in sheet metal work?
13. How will you design the diameter of rivet for sheet metal work?
[Link] the various sheet metal operations?
15. What is hem?
16. What are the functions of hem?
[Link] is seam?
18. Double seam is ................... than single seam
19. What are the different types of seam?
 [Link].3 CONE DATE:

Aim: To make a cone as per the given dimensions.

Tools required: 300mm steel rule, try square, divider, scriber, straight snip,
mallet, ball peen hammer and hatchet stake.
Sequence of operation:
1. The size of given sheet is checked with the steel rule.
2. The layout of the cone is drawn in the sheet and cut as shown in the
development.
3. The allowance for folding and bending is added to the development.
4. The waste metal is cut away by using the straight and bent snips.
5. The development of the cone is folded by using the funnel stake, after
forming the single hemmed joint.

Note: The angle subtended by the arc of the sector is calculated from the
relation,

θ 360 x Radius of thebasecircleof thecone

Slant Height

67
 Precautions:
1. Do not try to hold the sheets with bare hands.
2. Be sure that the fingers are away from the shearing bend.
3. Markings should be done carefully.
4. Cutting should be done carefully to avoid cross cutting.
Result:
 VIVA VOCE

1. Define sheet metal work?

2. What are the applications of sheet metal working?
3. What is the principle behind the sheet metal layout?
4. How do you identify the thickness of metal sheet?
5. What will be the result of the sheet thickness when increasing the gauge
number?
6. What are the metals used in sheet metal work?
7. Name the striking tools used in sheet metal work?
8. Name the five tools and equipments which are used for cutting sheet
metal?
9. What is a snip?
10. What are the types of snips?
[Link] punching operation?
12. Define nibbling operation in sheet metal work?
13. How will you design the diameter of rivet for sheet metal work?
[Link] the various sheet metal operations?
15. What is hem?
16. What are the functions of hem?
[Link] is seam?
18. Double seam is ................... than single seam
19. What are the different types of seam?
 [Link] WIRING

INTRODUCTION:

Electrical wiring is defined as a system of electrical conductor, components and apparatus, for
conveying electric power from the source to the point of use.
Electrical power is supplied to domestic installation through a phase and a neutral
forming a single phase A.C. 230V, two wire system. For industrial establishment, power is
supplied through 3-phase wire system to give 440v. The figure below shows the power tapping for
domestic and industrial purpose. The neutral is earthed at the distribution sub-station of the supply.

ELEMENTS OF HOUSE WIRING:

1. Fuses and circuit breakers:

These are devices designed to provide protection to a circuit against excess current.

[Link] Switch:
This is a device that makes and breaks or changes the course of electric circuit.

3. Plug:
It is a device carrying two or three metallic contacts in the form of pins, intended for engaging
with corresponding socket contacts and arranged for attachment to appliances such as radio,
T.V., Fan etc.

[Link] out let:

It is a device carrying two or three contact designed for engagement with corresponding plug
pins and arranged for connection to fixed wiring.
[Link] Holder:
Lamp Holder is designed to hold lamps and connect there in the circuit.

6. Main Switch:
This is a switch intended to connect or cut off the supply of the electricity to the whole of
insulation. It contains one or more fuses.

PARTS OF A LAMP AND LAMP HOLDER

MAIN SWITCH
COMMON HOUSE WIRING CONNECTIONS:

One lamp controlled by a one-way switch:

Figures show the wiring diagram for a lamp controlled by a one-way switch. This is the
normal connection one comes across in house wiring.

Two lamps connected in series or parallel by a one-way switch:

Two lamps may be connected by one-way switch in parallel for bright glow or in series
for dull glow.

One lamp controlled by 2 two-way switches:

It is sometimes desirable to control a lamp from two different places. One may come across
this situation with staircase, long corridors or hall containing two entrances etc.
Combination Piler: It is made of steel and its size is given according to fix length. It has a cutter
for cutting the wires.

Electrician knife: It is the tool used for removing the insulation from the wires. It has two folding
blades, one for removing the insulation and the other for clearing the wires.

Test Lamp: A test holder with a lamp is called a test lamp. It is used for testing the supply.

Pocker: It is long sharp tool used for making pilot holes in wood before fixing and tightening of
wood screws.

Rawl plug tool and bit: It has two parts namely the tool bit and tool holder. The tool bit is made of
carbon steel and the tool holder is made of mild steel. It is used for making holes in brick and
concrete walls or ceilings. Its size depends upon the number, as the number increases; the thickness
of the bit as well as the plug also increases.

Ball peen Hammer: There are different types of hammers used for different purposes. The
purpose of ball peen hammer is generally used in electrical trades. The size of hammer is usually
indicated by its weight.

Electric soldering Iron: It is used for soldering wires to commutator segments and small joints
with solder. It consists of pointed oval copper bit fixed to an iron rod which is heated by an electric
element only.
EX. NO:4.1 TWO LAMPS CONNECTED IN SERIES BY ONE SWITCH.
DATE:

AIM: To prepare a wiring to control two lamps connected in series by one switch. (SERIES CONNECTION)

TOOLS REQUIRED:
1. Screw driver,
2. Connector,
3. Tester,
4. Lamp holders,
5. One way switch, wires,
6. Wire clips,
7. Bulbs,
8. Wire cutter,
9. Nose plier,
10. Cutting plier,
11. Ball peen hammer

SEQUENCE OF OPERATIONS:

1. The outline of the wiring diagram is marked on the wooden wiring board.
2. Clips are nailed to the board, following the wire diagram.
3. Wires are stretched and clamped with the clips.
4. Wires are connected to the holder and the switch as shown in the above diagram,
Which are then screwed on the board.
5. Bulbs are fitted to the holders.
6. The wiring connections are tested by giving power supply.
PRECAUTIONS:

1. Never remove a plug from an outlet by pulling the cord. Always pull by the plug.
2. Whenever there is power failure, put off the power supply to all equipment in order to
prevent Spontaneous recovery.
3. Put on mains only ascertaining completion of correct wiring.
RESULT:
 VIVA QUESTIONS

1. For domestic use, power is supplied through a…………and a………….forming a single

phase A.C, two wire system.

2. For industrial establishments, power is supplied through ............... phase……wire system,

3. Electric switch………..and… ....... the electric circuit.

4. A plug engages with corresponding… ........................ contacts.

5. Main switch I only to cut-off the supply of electricity (T/F)

6. A lamp filament is made of……………………..

7. A multi-core conductor consists of several cores… ............. from each other.

8. Wire sizes are specified by the diameters /length of the wire.

9. The wire specification 14/36 indicates………….stands of ............. SWG.

10. In series circuit, when one device breaks down; the remaining devices operate.(T/F)

11. In parallel circuit, if one device breaks down; the other devices continue to operate.(T/F)

12. Regulator is used for controlling the… ...........................of a fan.

13. While using a table fan, always use two/three core flexible wire for connection.

14. Universal fans operate both on AC and DC

15. If the bulb on the handle of an automatic electric iron glows, it means that the iron is
cool/hot.

16. The intensity of the glow of an indicator lamp is a measure of voltage/ current level.
EX. NO:4.2 TWO LAMPS CONNECTED IN PARALLEL BY ONE SWITCH

DATE:
AIM: To prepare a wiring to control two lamps connected in parallel by one switch. ( PARALLEL
CONNECTION)

TOOLS REQUIRED:

1. Screw driver
2. Connector
3. Tester
4. Lamp holders
5. One way switch
6. Wires
7. Wire clips
8. Nails
9. Bulbs
10. Wire cutter
11. Nose pliers
12. Cutting pliers
13. Ball peen hammer.

SEQUENCE OF OPERATIONS:

1. The outline of the wiring diagram is marked on the wooden wiring board.
2. Clips are nailed to the board, following the wiring diagram.
3. Wires are stretched and clamped with clips.
4. Wires are connected to the holder and the switch as shown in above diagram,
which are then screwed on the board.
5. Bulbs are fitted to the holders.
6. The wiring connections are tested by giving power supply.
SAFETY PRECAUTIONS:

1. Never remove a plug from an outlet by pulling the cord. Always pull the plug.
[Link] there is power failure, put off power supply to all equipment in order to prevent
spontaneous recovery.
[Link] on mains only after ascertaining completion of correct wiring.

RESULTS:
 Viva questions
1. what is meaning of electrical wiring?
2. what is an electric conductor?
3. What are the tools are required in house wiring ?
4. What is difference between one way switch and two way switch ?
5. What is earthing?
6. Electric switch………..and the electric circuit.
7.A plug engages with corresponding ............................ contacts.
[Link] switch I only to cut-off the supply of electricity (T/F)
9.A lamp filament is made of……………………..
10.A multi-core conductor consists of several cores ................. from each other.
11. Wire sizes are specified by the diameters /length of the wire.
12. The wire specification 14/36 indicates…………. stands of ............. SWG.
13. In series circuit, when one device breaks down; the remaining devices
operate. (T/F)
14. How much household supply in India?
15. what are units of current, electromotive force, resistance and
power?[Link] is the relation among Volt, ohm and Amperes?
EX. NO:4.3 ONE LAMP CONTROLLED BY TWO 2-WAY
SWITCHES
DATE:
AIM: To prepare a wiring to control one lamp controlled by two 2-way switch.
TOOLS REQUIRED:
1. Screw driver
2. Connector
3. Tester
4. Lamp holders
5. One way switch
6. Wires, wire clips
7. Nails
8. Pocker
9. Bulbs
10. Wire cutter
11. Nose plier
12. Cutting plier
13. Ball peen hammer
SEQUENCE OF OPERATIONS:

1. The outline of the wiring diagram is marked on the wooden wiring board.

2. Clips are nailed to the board, following the wiring diagram.

3. Wires are stretched and clamped with clips.
4. Wires are connected to the holder and the switch as shown in above diagram,
which are then screwed on the board.
5. Bulbs are fitted to the holders.
6. The wiring connections are tested by giving power supply.
PRECAUTIONS:
1. Never remove a plug from an outlet by pulling the cord. Always pull the plug.
2. Whenever there is power failure, put off power supply to all equipment in order to prevent
spontaneous recovery.
3. Put on mains only after ascertaining completion of correct wiring.
RESULTS:
 Viva questions
[Link] is meaning of electrical wiring?
[Link] is an electric conductor?
3. What are the tools are required in house wiring ?
4. What is difference between one way switch and two way switch ?
5. What is earthing?
[Link] switch………..and ............the electric circuit.
7.A plug engages with corresponding ............................ contacts.
[Link] switch I only to cut-off the supply of electricity (T/F)
9.A lamp filament is made of……………………..
10.A multi-core conductor consists of several cores ................. from each other.
11. Wire sizes are specified by the diameters /length of the wire.
12. The wire specification 14/36 indicates………….stands of .............. SWG.
13. In series circuit, when one device breaks down; the remaining devices
operate.(T/F)
14. How much household supply in India?
15. what are units of current,electromotive force,resistance and power?
[Link] is the relation among Volt,ohm and Amperes?
 5. WELDING PROCESSES
Solid materials need to be joined together in order that they may be fabricated into useful shapes
for various applications such as industrial, commercial, domestic, art ware and other uses.
Depending on the material and the application, different joining processes are adopted such as,
mechanical (bolts, rivets etc.), chemical (adhesive) or thermal (welding, brazing or soldering).
Thermal processes are extensively used for joining of most common engineering materials,
namely, metals. This exercise is designed to demonstrate specifically: gas welding, arc welding,
resistance welding, brazing.

WELDING PROCESSES

Welding is a process in which two materials, usually metals, and is permanently joined
together by coalescence, resulting from temperature, pressure, and metallurgical conditions.
The particular combination of temperature and pressure can range from high temperature with
no pressure to high pressure with any increase in temperature. Thus, welding can be achieved
under a wide variety of conditions and numerous welding processes have been developed and
are routinely used in manufacturing.

To obtain coalescence between two metals following requirements need to be met:-

(1) Perfectly smooth, flat or matching surfaces.
(2) Clean surfaces, free from oxides, absorbed gases, grease and other contaminants.
(3) Metals with no internal impurities.
These are difficult conditions to obtain. Surface roughness is overcome by pressure or by
melting two surfaces so that fusion occurs. Contaminants are removed by mechanical or
chemical cleaning prior to welding or by causing sufficient metal flow along the interface so
that they are removed away from the weld zone friction welding is a solid state welding
technique. In many processes the contaminants are removed by fluxing agents.

The production of quality welds requires

(1) A satisfactory heat and/or pressure source,
(2) A means of protecting or cleaning the metal, and
(3) Caution to avoid, or compensate for, harmful metallurgical effects.

ARC WELDING

In this process a joint is established by fusing the material near the region of joint by means of
an electric arc struck between the material to be joined and an electrode. A high current low
voltage electric power supply generates an arc of intense heat reaching a temperature of
approximately 3800oC. The electrode held externally may act as a filler rod or it is fed
independently of the electrode. Due to higher levels of heat input, joints in thicker materials
can be obtained by the arc welding process. It is extensively used in a variety of structural
applications.

There are so many types of the basic arc welding process such as shielded metal arc welding
(SMAW), gas metal arc welding (GMAW), gas tungsten arc welding (GTAW), submerged arc
welding
RESISTANCE SPOT WELDING
The tips of two opposing solid cylindrical electrodes touch a lap joint of two sheet metals,
and resistance heating produces a spot weld. In order to obtain a strong bond in the weld
nugget, pressure is applied until the current is turned off. Accurate control and timing of
the electric current and of the pressure are essential in resistance welding.
The strength of the bond depends on surface roughness and on the cleanness of the
mating surface. Oil, paint, and thick oxide layers should, therefore, be removed before
welding. The presence of uniform, thin layers of oxide and of other contaminants is not
critical.
The weld nugget is generally 6 to 10 mm in diameter. The surface of the weld spot has a
slightly discolored indentation. Currents range from 3000 A to 40000 A: the level depends
on the materials being welded and on their thicknesses.

PROCESS CAPABILITIES:
Spot welding is the simplest and the most commonly used resistance-welding process.
Welding may be performed by means of single or multiple pairs of electrodes, and the
required pressure is supplied through mechanical or pneumatic means. Rocker-arm type
spot-welding machines are normally used for smaller parts; press type machines are
used for larger work pieces. The shape and surface condition of the electrode tip
and the accessibility of the site are important factors in spot welding.

Spot welding is widely used for fabricating sheet metal parts. Examples range from
the attaching of handles to stainless-steel cookware to the spot welding of mufflers.

[Link] Of Arc Welding

 Fig:Basic elements of arc welding

1) Switch box.
2) Secondary terminals
3) Welding machine.
4) Current reading scale.
5) Current regulating hand wheel.
6) Leather apron.
7) Asbestos hand gloves.
8) Protective glasses strap
9) Electrode holder.
10) Hand shield
11) Channel for cable protection.
12) Welding cable.
13) Chipping hammer.
14) Wire brush.
15) Earth clamp.
16) Welding table (metallic).
17) Job.
[Link].1 BUTT JOINT WITH ARC WELDING
DATE:
Aim: - To prepare a butt joint with mild steel strip using Arc Welding

Equipment and materials: -

Welding unit, consumable mild steel Electrodes, mild steel flats. Wire brush, Tongs, Chipping
hammer etc.
Procedure: -
1. Clean the mild steel flats to be joined by wire brush
2. Arrange the flat pieces properly providing the gap for full penetration for butt joint
(gap ½ thicknesses of flats).
3. Practice striking of arc, speed and arc length control.
4. Set the welding current, voltage according to the type of metal to be joined.
5. Strike the arc and make tacks at the both ends to hold the metal pieces together during
the welding process
6. Lay beads along the joint maintaining proper speed and arc length (Speed 100-150
mm/min).
7. Clean the welded zone and submit.

Result:
 VIVA QUESTIONS
1. Which is the welding process you have carried out in workshop?

2. What is Welding?
3. Name the types of welding?

4. Name the welding tools used in workshop?

5. Which outer cover is on the welding rod?

6. Name some of the arc welded joints?

7. What is the difference between electrode and filler rod?

8. What is arc welding?

9. What distance should be maintained between the work and electrode?

10. What is the arc temperature?

11. What is the function of coating in coated electrodes in metal arc welding?

12. What is the output range of voltage and current on the metal arc welding?

13. What will happen if the arc length is reduced while welding?
[Link].2 BUTT JOINT WITH ARC WELDING
DATE:
Aim: To make a double lap joint, using the given mild steel pieces and by
arcwelding

Material used: Two mild steel pieces of 100X40X6 mm

Tools and equipment used:

1. Arc welding machine,
2. Mild steel electrodes,
3. Electrode holder,
4. Ground clamp,
[Link] nose Tong,
6. Face shield,
7. Apron,
[Link] gloves,
9. Metallic work
Table,
[Link] vice,
11. Rough flat file,
12. Try square,
13. Steel rule,
[Link] brush,
15. Ball peenhammer,
16. Chipping hammer

Operations to be carried out:

1. Cleaning the work pieces
2. Tack welding
3. Full welding
4. Cooling
5. Chipping
6. Finishing
 Fig:Lap Joint

Procedure
1. Take the two mild steel pieces of given dimensions and clean the surfaces
thoroughly from rust, dust particles, oil and grease.
2. Remove the sharp corners and burrs by filing or grinding and prepare the work
pieces.
3. The work pieces are positioned on the welding table, to form a lap joint with the
required over lapping
4. The electrode is fitted in to the electrode holder and the welding current is set to a
proper value.
5. The ground clamp is fastened to the welding table.
6. Wearing the apron, hand gloves, using the face shield and holding the over
lapped pieces the arc is struck and the work pieces are tack‐welded at the ends of
both the sides
7. The alignment of the lap joint is checked and the tack‐welded pieces are reset, if
required.
8. Welding is then carried out throughout the length of the lap joint, on both the
sides.
9. Remove the slag, spatters and clean the joint.

Precautions:
1. Use goggles, gloves in order to protect the human body.
2. Maintain the constant arc length.

Result:
 VIVA QUESTIONS

1. Which is the welding process you have carried out in workshop?

2. What is Welding?

3. Name the types of welding?

4. Name the welding tools used in workshop?

5. Which outer cover is on the welding rod?

6. Name some of the arc welded joints?

7. What is the difference between electrode and filler rod?

8. What is arc welding?

9. What distance should be maintained between the work and electrode?

10. What is the arc temperature?

11. What is the function of coating in coated electrodes in metal arc welding?

12. What is the output range of voltage and current on the metal arc welding?

13. What will happen if the arc length is reduced while welding?
 6. BLACKSMITHY
Black smithy or Forging is an oldest shaping process used for the producing small
articles for which accuracy in size is not so important. The parts are shaped by
heating them in an open fire or hearth by the blacksmith and shaping them through
applying compressive forces using hammer.
Thus, forging is defined as the plastic deformation of metals at elevated
temperatures into a predetermined size or shape using compressive forces exerted
through some means of hand hammers, small power hammers, die, press or
upsetting machine. It consists essentially of changing or altering the shape and
section of metal by hammering at a temperature of about 980°C, at which the metal
is entirely plastic and can be easily deformed or shaped under pressure. The shop in
which the various forging operations are carried out is known as the smithy or
smith’s shop.
Hand forging process is also known as black-smithy work which is commonly
employed for production of small articles using hammers on heated jobs. It is a
manual controlled process even though some machinery such as power hammers
can also be sometimes used. Black-smithy is, therefore, a process by which metal
may be heated and shaped to its requirements by the use of blacksmith tools either
by hand or power hammer.
Forging by machine involves the use of forging dies and is generally employed for
mass-production of accurate articles. In drop forging, closed impression dies are
used and there is drastic flow of metal in the dies due to repeated blow or impact
which compels the plastic metal to conform to the shape of the dies.

APPLICATIONS OF FORGING:
Almost all metals and alloys can be forged. The low and medium carbon steels are
readily hot forged without difficulty, but the high-carbon and alloy steels are more
difficult to forge and require greater care. Forging is generally carried out on carbon
alloy steels, wrought iron, copper-base alloys, aluminum alloys, and magnesium
alloys. Stainless steels, nickel-based super alloys, and titanium are forged especially
for aerospace uses.

FORGEABILITY:
The ease with which forging is done is called forgeability. The forgeability of a
material can also be defined as the capacity of a material to undergo deformation
under compression without rupture. Forgeability increases with temperature up to a
point at which a second phase, e.g., from ferrite to austenite in steel, appears or if
grain growth becomes excessive.
 COMMON HAND FORGING TOOLS:
For carrying out forging operations manually, certain common hand forging tools
are employed. These are also called blacksmith’s tools, for a blacksmith is one
who works on the forging of metals in their hot state. The main hand forging tools
are as under.
Tongs: The tongs are generally used for holding work while doing a forging
operation

Straight-lip fluted tongs are commonly used for holding square, circular and
hexagonal bar stock.

Rivet or ring tongs are widely used for holding bolts, rivets and other work of
circular section.

Flat tongs are used for mainly for holding work of rectangular section.

Gad tongs are used for holding general pick-up work, either straight or tapered.

Swage
Swage is used for forging work which has to be reduced or finished to round,
square or hexagonal form. It is made with half grooves of dimensions to suit the
work being reduced. It consists of two parts, the top part having a handle and the
bottom part having a square shank which fits in the hardie hole on the anvil face.
Fuller
Fuller is used in forging shop for necking down a forgeable job. It is made in top
and bottom tools as in the case of swages. Fuller is made in various shapes and
sizes according to needs, the size denoting the width of the fuller edge
Punch
Punch is used in forging shop for making holes in metal part when it is at forging
heat.

Chisels
Chisels are used for cutting metals and for nicking prior to breaking. They may be
hot or cold depending on whether the metal to be cut is hot or cold. A hot chisel
generally used in forging shop.
The main difference between the two is in the edge. The edge of a cold chisel is
hardened and tempered with an angle of about 60°, whilst the edge of a hot chisel
is 30° and the hardening is not necessary. The edge is made slightly rounded for
better cutting action.
Hand hammers
There are two major kinds of hammers are used in hand forging:
a. The hand hammer used by the smith himself and
b. The sledge hammer used by the striker.
 Hand hammers may further be classified as
(a) ball peen hammer, (b) straight peen hammer, and (c) cross peen
hammer.
 Sledge hammers may further be classified
as
(a) Double Face Hammer, (b) Straight Peen
Hammer, And
(c) Cross Peen Hammer.
Hammer heads are made of cast steel and, their ends are hardened and tempered.
The striking face is made slightly convex. The weight of a hand hammer varies
from about 0.5 to 2 kg whereas the weight of a sledge hammer varies from 4 to 10
kg

Anvil
An anvil is a most commonly tool used in forging [Link] acts as a support for
blacksmith’s work during hammering. The body of the anvil is made of mild steel
with a tool steel face welded on the body, but the beak or horn used for bending
curves is not steel faced. The round hole in the anvil called pritchel hole is
generally used for bending rods of small diameter, and as a die for hot punching
operations. The square or hardie hole is used for holding square shanks of various
fittings. Anvils in forging shop may vary up to about 100 to 150 kg and they
should always stand with the top face about 0.75 mt. from the floor. This height
may be attained by resting the anvil on a wooden or cast iron base in the forging
shop.

Swage block
Swage block generally used in forging [Link] is mainly used for heading,
bending, squaring, sizing, and forming operations on forging jobs. It is 0.25 mt. or
even more wide. It may be used either flat or edgewise in its stand.

FORGING OPERATIONS:

The following are the basic operations that may be performed by hand forging:
1. Drawing-down:
Drawing is the process of stretching the stock while reducing its cross-
section locally. Forging the tapered end of a cold is an example of drawing
operation.
2. Upsetting:
It is a process of increasing the area of cross-section of a metal piece
locally, with a corresponding reduction in length. In this, only the portion to be
upset is heated to forging temperature and the work is then struck at the end with a
hammer. Hammering is done by the smith (student) himself, if the job is small, or
by his helper, in case of big jobs, when heavy blows are required with a sledge
hammer.
3. Fullering:
Fullers are used for necking down a piece of work, the reduction often
serving as the starting point for drawing. Fullers are made of high carbon steel in
two parts, called the top and bottom fullers. The bottom tool fits in the hardie hole
of the anvil. Fuller size denotes the width of the fuller edge.
4. Flattering:
Flatters are the tools that are made with a perfectly flat face of about 7.5 cm
square. These are used for finishing flat surfaces. A flatter of small size is known
as set-hammer and is used for finishing near corners and in confined spaces.
5. Swaging:
Swages like fullers are also made of high carbon steel and are made in two parts
called the top and swages. These are used to reduce and finish to round, square or
hexagonal forms. For this, the swages are made with half grooves of dimensions
to suit the work.

6. Bending:
Bending of bars, flats, etc., is done to produce different types of bent shapes
such as angles, ovals, circles etc. Sharp bends as well as round bends may be
made on the anvil, by choosing the appropriate place on it for the purpose.
7. Twisting:
It is also one form of bending. Sometimes, it is done to increase the rigidity
of the work piece. Small piece may be twisted by heating and clamping a pair of
tongs on each end of the section to be twisted and applying a turning moment.
Larger pieces may be clamped in a leg vice and twisted with a pair of tongs or a
monkey wrench. However, for uniform twist, it must be noted that the complete
twisting operation must be performed in one heating.
8. Cutting (Hot and Cold Chisels):
Chisels are used to cut metals, either in hot or cold state. The cold chisel is
similar to fitter’s chisel, except that it is longer and has a handle. A hot chisel is
used for cutting hot metal and its cutting edge is long and slender when compared
to cold chisel. These chisels are made of tool steel, hardened and tempered.
9. Iron-Carbon Alloy:
If the carbon is less than 2% in the iron-carbon alloy, it is known as
steel. Again, based on the carbon content, it is called mild steel, medium
carbon steel and high carbon steel. The heat treatment to be given to these
steels and their applications are shown in table below.

Carbon Hardening Tempering Applications.

% temp. 0C temp. 0C

0.1 800-840 250-300 Chains, rivets, soft wire, sheet

0.25 800-840 250-300 Tube, rod, strip
Mild Steel
0.5 800-840 250-300 Girders
Saws, hammers, smith’s and
0.6 800-840 250-300 general
purpose tools
Cold chisels, smith’s tools shear
blades,
0.75 760-800 250-300
table cutlery
Taps, dies, punches, hot shearing
0.9 760-800 250-300 blades
Medium Drills, reamers, cutters,
Carbon blanking and
steel 1.0 760-800 250-300
slotting tools, large turning tool
Small cutters, lathe and
engraving tools,
1.2 720-760 250-300 files drills
Extra hard, planning, turning and
High slotting
Carbon 1.35 720-760 250-300
tools, dies and mandrels
1.5 720-760 250-300 Razor blades

NOTE: The forging produced either by hand forging or machine forging should be
heat treated.
The following are the purposes of heat treatment:
i. To remove internal stresses set-up during forging and cooling.
ii. To normalize the internal structure of the metal.
iii. To improve machinability.
iv. To improve mechanical properties, strength and hardness.

Fig:anvil

FIG:TYPES OF TONGS
[Link].1 J -SHAPE DATE:

Aim: To make a J-shape from a given round rod, by following hand forging operation

Tools required:
Smith’s forge, Anvil, 500gm and I kg ball-peen hammers, Flatters, Swage block, Half round
tongs, Pick-up tongs, Cold chisel.

SEQUENCE OF OPERATIONS:
1. One end of the bar is heated to red hot condition in the smith’s forge for the required
length.

2. Using the pick-up tongs; the rod is taken from the forge, and holding it with the half
round tongs, the heated end is forged into a tapered pointed end.

3. The length of the rod requires for J shape is estimated and the excess portion is cut-
off, using a cold chisel.

4. One half of the rod towards the pointed end is heated in the forge to red hot
condition and then bent into circular shape as shown.

5. The other end of the rod is then heated and forged into a tapered pointed end.

6. The straight portion of the rod is finally heated and bent into circular shape as
required.

7. Using the flatter, the J shape made as above, is kept on the anvil and flattened so
that, the shape of the J is proper.

NOTE: In-between the above stage, the bar is heated in the smith’s forge, to facilitate forging
operations.

Precautions:
1. Hold the job carefully while heating and hammering

2. Job must be held parallel to the face of the anvil.

3. Wear steel-toed shoes.

4. Wear face shield when hammering the hot metal

5. Use correct size and type of tongs to fit the work.

Result:
 VIVA QUESTIONS
Q.1 Name the types of furnace?

Q.2 Name the tools used in smithy shop?

Q.3 Why furnace is used in our workshop?

Q.4 Which type of furnace is used in our workshop?

Q.5 What is use of anvil & swage block?

[Link].6.2 S-HOOK DATE:
Aim: To make an S-hook from a given round rod, by following hand forging operation

Tools required:
Smith’s forge, Anvil, 500gm and I kg ball-peen hammers, Flatters, Swage block, Half
round tongs, Pick-up tongs, Cold chisel.

SEQUENCE OF OPERATIONS:
1. One end of the bar is heated to red hot condition in the smith’s forge for the
required length.

2. Using the pick-up tongs; the rod is taken from the forge, and holding it with
the half round tongs, the heated end is forged into a tapered pointed end.

3. The length of the rod requires for S-hook is estimated and the excess portion
is cut-off, using a cold chisel.

4. One half of the rod towards the pointed end is heated in the forge to red hot
condition and then bent into circular shape as shown.

5. The other end of the rod is then heated and forged into a tapered pointed end.

6. The straight portion of the rod is finally heated and bent into circular shape as
required.

7. Using the flatter, the S-hook made as above, is kept on the anvil and flattened
so that, the shape of the hook is proper.

NOTE: In-between the above stage, the bar is heated in the smith’s forge, to facilitate
forging operations.

Precautions:
6. Hold the job carefully while heating and hammering

7. Job must be held parallel to the face of the anvil.

8. Wear steel-toed shoes.

9. Wear face shield when hammering the hot metal

10. Use correct size and type of tongs to fit the work.

Result:
 VIVA QUESTIONS
Q.1 Name the types of furnace?
Q.2 Name the tools used in smithy shop?
Q.3 Why furnace is used in our workshop?
Q.4 Which type of furnace is used in our workshop?
Q.5 What is use of anvil & swage block?
 7. FOUNDRY
PATTERN:
A pattern is a model or the replica of the object (to be casted). It is embedded in molding sand
and suitable ramming of molding sand around the pattern is made. The pattern is then
withdrawn for generating cavity (known as mold) in molding sand.
COMMON PATTERN MATERIALS:
The common materials used for making patterns are wood, metal, plastic, plaster, wax or
Mercury.
TYPES OF PATTERNS:
The types of the pattern and the description of each are given as under.
1. One piece or solid pattern
2. Two piece or split pattern
3. Cope and drag pattern
4. Three-piece or multi- piece pattern
5. Loose piece pattern
6. Match plate pattern
7. Follow board pattern
8. Gated pattern
9. Sweep pattern
10. Skeleton pattern
11. Segmental or part pattern

1. Single-Piece Or Solid Pattern:

Solid pattern is made of single piece without joints, partings lines or loose pieces. It is the
simplest form of the pattern. Typical single piece pattern is shown in Fig. 10.1.
2. Two-piece or split pattern: When solid pattern is difficult for withdrawal from the mold
cavity, then solid pattern is split in two parts. Split pattern is made in two pieces which are
joined at the parting line by means of dowel pins. The splitting at the parting line is done to
facilitate the withdrawal of the pattern. A typical example is shown in Fig.

MOLDING SAND

 The general sources of receiving molding sands are the beds of sea, rivers, lakes,
granular elements of rocks, and deserts.
 Molding sands may be of two types namely natural or synthetic. Natural molding
sands contain sufficient binder. Whereas synthetic molding sands are prepared
artificially using basic sand molding constituents (silica sand in 88-92%, binder 6-
12%, water or moisture content 3-6%) and other additives in proper proportion by
weight with perfect mixing and mulling in suitable equipments.
BINDER
 In general, the binders can be either inorganic or organic substance. The inorganic
group includes clay sodium silicate and port land cement etc. In foundry shop, the
clay acts as binder which may be Kaolonite, Ball Clay, Fire Clay, Limonite,
Fuller’s earth and Bentonite. Binders included in the organic group are dextrin,
molasses, cereal binders, linseed oil and resins like phenol formaldehyde, urea
formaldehyde etc. Organic binders are mostly used for core making.
 Among all the above binders, the bentonite variety of clay is the most common.
However, this clay alone cannot develop bonds among sand grins without the
presence of moisture in molding sand and core sand.
ADDITIVES
Additives are the materials generally added to the molding and core sand mixture to
develop some special property in the sand. Some common used additives for enhancing
the properties of molding and core sands are discussed as under.

 Coal dust: Coal dust is added mainly for producing a reducing atmosphere during casting.
 Corn flour: It belongs to the starch family of carbohydrates and is used to
increase the collapsibility of the molding and core sand
 Dextrin: Dextrin belongs to starch family of carbohydrates that behaves also in a
manner similar to that of the corn flour. It increases dry strength of the molds.
 Sea coal: Sea coal is the fine powdered bituminous coal which positions its place
among the pores of the silica sand grains in molding sand and core sand
 Wood flour: This is a fibrous material mixed with a granular material like sand;
its relatively long thin fibers prevent the sand grains from making contact with
one another.
 Silica flour: It is called as pulverized silica and it can be easily added up to 3%
which increases the hot strength and finish on the surfaces of the molds and cores

KINDS OF MOULDING SAND

Molding sands can also be classified according to their use into number of varieties which
are described below.
1. Green sand: Green sand is also known as tempered or natural sand which is a just
prepared mixture of silica sand with 18 to 30 percent clay, having moisture content
from 6 to 8%. The clay and water furnish the bond for green sand. It is fine, soft,
light, and porous.
2. Dry sand: Green sand that has been dried or baked in suitable oven after the making
mold and cores, is called dry sand. It possesses more strength, rigidity and thermal
stability.
3. Loam sand: Loam is mixture of sand and clay with water to a thin plastic paste.
Loam sand possesses high clay as much as 30-50% and 18% water.
4. Facing sand: Facing sand is just prepared and forms the face of the mould. It is
directly next to the surface of the pattern and it comes into contact molten metal when
the mould is poured. Initial coating around the pattern and hence for mold surface is
given by this sand. This sand is subjected severest conditions and must possess,
therefore, high strength refractoriness.
5. Backing sand: Backing sand or floor sand is used to back up the facing sand and is
used to fill the whole volume of the molding flask.
6. Parting sand: Parting sand without binder and moisture is used to keep the green
sand not to stick to the pattern and also to allow the sand on the parting surface the
cope and drag to separate without clinging
7. Core sand: Core sand is used for making cores and it is sometimes also known as oil
sand. This is highly rich silica sand mixed with oil binders such as core oil which
composed of linseed oil, resin, light mineral oil and other bind materials.
PROPERTIES OF MOULDING SAND
The basic properties required in molding sand and core sand are described as under.
1. Refractoriness: Refractoriness is defined as the ability of molding sand to withstand
high temperatures without breaking down or fusing thus facilitating to get sound
casting. It is a highly important characteristic of molding sands. Refractoriness can
only be increased to a limited extent
2. Permeability: It is also termed as porosity of the molding sand in order to allow the
escape of any air, gases or moisture present or generated in the mould when the
molten metal is poured into it. All these gaseous generated during pouring and
€ solidification process must escape otherwise the casting becomes defective
3. Cohesiveness: It is property of molding sand by virtue which the sand grain particles
interact and attract each other within the molding sand.
4. Green strength: The green sand after water has been mixed into it, must have
sufficient strength and toughness to permit the making and handling of the mould. For
this, the sand grains must be adhesive, i.e. thev must be capable of attaching
themselves to another body
5. Dry strength: As soon as the molten metal is poured into the mould, the moisture in
the sand layer adjacent to the hot metal gets evaporated and this dry sand layer must
have sufficient strength to its shape in order to avoid erosion of mould wall during the
flow of molten metal
6. Flowability or plasticity: It is the ability of the sand to get compacted and behave
like a fluid. It will flow uniformly to all portions of pattern when rammed and
distribute the ramming pressure evenly all around in all directions
7. Adhesiveness: It is property of molding sand to get stick or adhere with foreign
material such sticking of molding sand with inner wall of molding box
8. Collapsibility: After the molten metal in the mould gets solidified, the sand mould
must be collapsible so that free contraction of the metal occurs and this would
naturally avoid the tearing or cracking of the contracting metal.
HAND TOOLS USED IN FOUNDRY SHOP
Hand riddle: It consists of a screen of standard circular wire mesh
equipped with circular wooden frame. It is generally used for
cleaning the sand for removing foreign material such as nails, shot
metal, splinters of wood etc. from it. Even power operated riddles are
available for riddling large volume of sand.
Shovel: It consists of a steel pan fitted with a long wooden handle. It
is used in mixing, tempering and conditioning the foundry sand by
hand. It is also used for moving and transforming the molding sand to
the container and molding box or flask.
 Fig. Rammers Fig. Sprue Pin

Rammers: Rammers are shown in Fig. These are required for striking the molding sand mass in
the molding box to pack or compact it uniformly all around the pattern.
Sprue pin: It is a tapered rod of wood or iron which is placed or pushed in cope to join mold
cavity while the molding sand in the cope is being rammed.
Trowels: These are used for finishing flat surfaces and comers inside a mould. Common shapes
of trowels are shown as under. They are made of iron with a wooden handle.
Lifter: A lifter is a finishing tool used for repairing the mould and finishing the mould sand.
Lifter is also
used for removing loose sand from mould.
Strike off bar: It is a flat bar, made of wood or iron to strike off the excess sand from the top of
a box after ramming.
Its one edge made beveled and the surface perfectly smooth and plane.
Vent wire: It is a 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 and striking off the excess sand it is used to make
small holes, called vents, in the sand mould to allow the exit of gases and steam during casting.
Slicks: They are also recognized as small double ended mold finishing tool which are generally
used for repairing and finishing the mold surfaces and their edges after withdrawal of the pattern

Swab: Swab is shown in Fig. It is a small hemp fiber brush used for moistening the edges of
sand mould, which are in contact with the pattern surface before withdrawing the pattern. It is
used for sweeping away the molding sand from the mold surface and pattern.
Gate cutter: Gate cutter is a small shaped piece of sheet metal commonly used to cut runners
and feeding gates for connecting sprue hole with the mold cavity.
Bellows: Bellows gun is shown in Fig. It is hand operated leather made device equipped with
compressed air jet to blow or pump air when operated. It is used to blow away the loose or
unwanted sand from the surfaces of mold cavities.
Draw spike: Draw spike is a tapered steel rod having a loop or ring at its one end and a sharp
point at the other. It may have screw threads on the end to engage metal pattern for it
withdrawal from the mold.
Sprue Pin: It is a tapered wooden pin, used to make a hole in the cope through which the
molten metal is poured into the mould.

MOULDING BOX:
Moulding box is also called moulding flask. It is frame or box of wood or metal. It is made of
two parts cope and drag as shown in figure.
[Link].1 MOULD FOR A SOLID DATE:
Aim: To prepare a sand mold, using the given single piece pattern.
Raw material required: Moulding sand, Parting sand, facing sand, baking sand,
single piece solid pattern, bottom board, moulding boxes etc.
Tools Required:
1. Molding board
2. Drag and cope boxes
3. Molding sand
4. Parting sand
5. Rammer
6. Strike-off bar
7. Bellows
8. Riser and sprue pins
9. Gate cutter
10. Vent rod
11. Draw spike
12. Wire Brush
Sequence of operations:
1. Sand preparation
2. Placing the mould flask(drag) on the moulding board/ moulding platform
3. Placing the pattern at the centre of the moulding flask
4. Ramming the drag
5. Placing runner and riser
6. Ramming the cope
7. Removal of the pattern, runner, riser
8. Gate cutting

Procedure: Mould Making

1. First a bottom board is placed either on the molding platform or on the floor,
making the surface even.
2. The drag molding flask is kept upside down on the bottom board along with the
drag part of the pattern at the centre of the flask on the board.
3. Dry facing sand is sprinkled over the board and pattern to provide a non-sticky layer.
4. Freshly prepared molding sand of requisite quality is now poured into the drag
and on the pattern to a thickness of 30 to 50 mm.
5. Rest of the drag flask is completely filled with the backup sand and uniformly
rammed to compact the sand.
6. After the ramming is over, the excess sand in the flask is completely scraped using
a flat bar to the level of the flask edges.
7. Now with a vent wire which is a wire of 1 to 2 mm diameter with a pointed end,
vent holes are in the drag to the full depth of the flask as well as to the pattern to
facilitate the removal of gases during casting solidification. This completes the
preparation of the drag.
8. Now finished drag flask is rolled over to the bottom board exposing the pattern.
9. Using a slick, the edges of sand around the pattern is repaired
10. The cope flask on the top of the drag is located aligning again with the help of the
pins of the drag box.
11. Sprue of the gating system for making the sprue passage is located at a small
distance of about 50 mm from the pattern. The sprue base, runners and in-gates
are also located as shown risers are also placed. Freshly prepared facing sand is
poured around the pattern.
12. The moulding sand is then poured in the cope box. The sand is adequately
rammed, excess sand is scraped and vent holes are made all over in the cope as in
the drag.
13. The sprue and the riser are carefully withdrawn from the flask
14. Later the pouring basin is cut near the top of the sprue.
15. The cope is separated from the drag any loose sand on the cope and drag
interface is blown off with the help of the bellows.
16. Now the cope and the drag pattern halves are withdrawn by using the draw spikes
and rapping the pattern all around to slightly enlarge the mould cavity so that the
walls are not spoiled by the withdrawing pattern.
17. The runners and gates are to be removed or to be cut in the mould carefully
without spoiling the mould.
18. Any excess or loose sand is applied in the runners and mould cavity is blown
away using the bellows.
19. Now the facing paste is applied all over the mould cavity and the runners
which would give the finished casting a good surface finish.
20. A dry sand core is prepared using a core box. After suitable baking, it is
placed in the mould cavity.
21. The cope is placed back on the drag taking care of the alignment of the two by means of
the pins.
22. The mould is ready for pouring molten metal. The liquid metal is allowed to cool and
become solid which is the casting desired.
Result:
[Link].2 MOULD FOR A SPLIT PATTERN DATE:
Aim: To prepare a sand mold, using the given Split-piece pattern.

Raw Material required: Moulding sand, Parting sand, facing sand, baking sand, pattern, bottom
board,
moulding boxes.
Tools Required:
1. Molding board
2. Drag and cope boxes
3. Molding sand
4. Parting sand
5. Rammer
6. Strike-off bar
7. Bellows
8. Riser and sprue pins
9. Gate cutter
10. Vent rod
11. Draw spike
12. Wire Brush

Sequence of operations:

1. Sand preparation
2. Placing the mould flask(drag) on the moulding board/ moulding platform
3. Placing the split pattern at the centre of the moulding flask
4. Ramming the drag
5. Placing the pattern at the centre of the moulding flask (Cope box)
6. Placing runner and riser
7. Ramming the cope
8. Removal of the pattern, runner, riser
9. Gate cutting

Procedure: Mould Making

1. First a bottom board is placed either on the molding platform or on the floor, making the
surface even.
2. The drag molding flask is kept upside down on the bottom board along with the drag
part of the pattern at the centre of the flask on the board.
3. Dry facing sand is sprinkled over the board and pattern to provide a non-sticky layer.
4. Freshly prepared molding sand of requisite quality is now poured into the drag and on
the split-pattern to a thickness of 30 to 50 mm.
5. Rest of the drag flask is completely filled with the backup sand and uniformly
rammed to compact the sand.
6. After the ramming is over, the excess sand in the flask is completely scraped using
a flat bar to the level of the flask edges.
7. Now with a vent wire which is a wire of 1 to 2 mm diameter with a pointed end,
vent holes are in the drag to the full depth of the flask as well as to the pattern to
facilitate the removal of gases during casting solidification. This completes the
preparation of the drag.
8. Now finished drag flask is rolled over to the bottom board exposing the pattern.
9. Using a slick, the edges of sand around the pattern is repaired and cope half of the
pattern is placed over the drag pattern, aligning it with the help of dowel pins
10. The cope flask on the top of the drag is located aligning again with the help of the
pins of the drag box.
11. Dry parting sand is sprinkled all over the drag surface and on the pattern
12. Sprue of the gating system for making the sprue passage is located at a small distance
of about 50 mm from the pattern. The sprue base, runners and ingates are also located
as shown risers are also placed. Freshly prepared facing sand is poured around the
pattern.
13. The moulding sand is then poured in the cope box. The sand is adequately
rammed, excess sand is scraped and vent holes are made all over in the cope as in
the drag.
14. The sprue and the riser are carefully withdrawn from the flask
15. Later the pouring basin is cut near the top of the sprue.
16. The cope is separated from the drag any loose sand on the cope and drag interface
is blown off with the help of the bellows.
17. Now the cope and the drag pattern halves are withdrawn by using the draw spikes
and rapping the pattern all around to slightly enlarge the mould cavity so that the
walls are not spoiled by the withdrawing pattern.
18. The runners and gates are to be removed or to be cut in the mould carefully
without spoiling the mould.
19. Any excess or loose sand is applied in the runners and mould cavity is blown away using the
bellows.
20. Now the facing paste is applied all over the mould cavity and the runners
which would give the finished casting a good surface finish.
21. A dry sand core is prepared using a core box. After suitable baking, it is placed in the mould
cavity.
22. The cope is placed back on the drag taking care of the alignment of the two by means of the
pins.

[Link] mould is ready for pouring molten metal. The liquid metal is allowed to cool
and become solid which is the casting desired.
Result:
SPLIT PATTERN.

Step :1 Place Drag part of the pattern on mould board and filled with mould sand

Step -2: Turn drag box upside down and Place cope box over drag box
Step -3: place cope part of the pattern ,riser, Sprue, runner in position and filled with
mould sand.
Step-4: Finally the Mould cavity is produced by removing the pattern .
 VIVA QUESTIONS
1. List the tools and equipment used in foundry.

2. List the Hand tools used in Foundry.

3. What is the function of Hand riddle?

4. What is a Rammer?

5. What is the use of Vent wire in foundry?

6. What is a Mallet?

7. What is a Swab?
8. What are Goggers?

9. What is the use of Bellow?

10. Mention the use of Trowels?

11. What are Slicks?

12. Which is the commonly used Slick?

13. List the containers used in foundry.

 [Link]
Introduction
Plumbing refers to installation of pipelines, water tanks and other pipe fittings to distribute water
in a building.
Best practices
1. Loose clothing should be avoided.
2. Wear shoes while working in the shop.
3. Tools should be placed in their respective places after proper cleaning.
4. Always use the right tool for the job.
5. Keep the cutting tools separate from the measuring tools.
6. Sharp edges of the cutting tools should be covered when they are not in use.

Plumbing Tools
Plumbing tools are many. The following tools are commonly used to install 25mm size pipelines.
PVC (Poly Vinyl Chloride) pipes and GI (Galvanized Iron) pipes are commonly used in
plumbing.
Pipe wrenchA pipe wrench is used to hold and rotate the pipes to tight them. It consists of a fixed
jaw, a movable jaw with adjusting screw.
Pipe vice A pipe vice in used to hold the pipe during cutting, making threads at the ends of the
pipe, fitting of couplings, etc. It also consists of a fixed jaw, a movable jaw and a screw with
handle for adjustment.
Pipe Fittings
A PVC pipe connection uses fitting like elbow, bend, coupling, tee reducer, etc. Fitting like
couplings, elbow, bend, union, nipple, tee reducer, plug, cap, flange, etc. with V-threads are
commonly used in GI pipe connections.
Valves and Taps
A gate valve or globe valve is commonly used in the main pipeline to control/regulate the floe of
water through it. Valves are usually made of cast iron or brass.
A domestic tap is commonly used to collect or tap water at desired points in the pipelines. Taps
are made of brass, steel or plastic.
Flow Control Angle Valve
Flow control angle valve is used along with the applications to regulate the flow of water. The
outlet of the valve and the control knob are at 90 degrees which is convenient to operate it.
Hacksaw
A hacksaw is used to cut pipes. It has a frame where the blade is tightened by means of a wing
nut.
Screw Drivers
Screw drivers are used to tighten screws in the appliances. Screw drivers of various sizes are used.
Hammers
Ball peen hammer is commonly used in plumbing work where greater power is required in
striking.
Measuring Tape
Measuring tape is used to measure the length of the pipe and also to mark the locations of the
fittings, valves and appliances.
 Fig: 1 pipe wrench

Fig: 2 pipe vice

Fig: 3 PVC pipe fittings

 Fig : 4 GI Pipe fittings

Fig: 5 CI Pipe fitting

Fig: 5 valves and tap

 [Link] SHOP
INTRODUCTION
In a machine shop, metals are cut to shape on different machine tools. A lathe is used to cut and
shape the metal by revolving the work against a cutting tool. The work is clamped either in a
chuck,fitted on to the lathe spindle or in‐between the centers. The cutting tool is fixed in a tool
post, mountedon a movable carriage that is positioned on the lathe bed. The cutting tool can be
fed on to the work,either lengthwise or cross‐wise. While turning, the chuck rotates in
counter‐clockwise direction, whenviewed from the tail stock end.
principal parts of a Lathe
Figure.1 shows a center lathe, indicating the main parts. The name is due to the fact that work
pieces are held by the centers.
Bed
It is an essential part of a lathe, which must be strong and rigid. It carries all parts of the machine
and resists the cutting forces. The carriage and the tail stock move along the guide ways provided
on the bed. It is usually made of cast iron.
Head stock
It contains either a cone pulley or gearings to provide the necessary range of speeds and feeds. It
contains the main spindle, to which the work is held and rotated.
Tail stock
It is used to support the right hand end of a long work piece. It may be clamped in any position
along the lathe bed. The tail stock spindle has an internal Morse taper to receive the dead center
thatsupports the work. Drills, reamers, taps may also be fitted into the spindle, for performing
operationssuch as drilling, reaming and tapping.
Carriage or Saddle
It is used to control the movement of the cutting tool. The carriage assembly consists of the
longitudinal slide, cross slide and the compound slide and apron. The cross slide moves across the
lengthof the bed and perpendicular to the axis of the spindle. This movement is used for facing
and to providethe necessary depth of cut while turning. The apron, which is bolted to the saddle,
is on the front of thelathe and contains the longitudinal and cross slide controls.

Fig :1 Parts of a center Lathe

Fig :2 three jaw and four jaw chuck

Fig:3 face plate

 Fig :4 lathe dog and driving plate

Fig: 5 calipers(outside and inside)

Compound Rest
It supports the tool post. By swiveling the compound rest on the cross slide, short tapers may be
turned to any desired angles.
Tool Post
The tool post, holds the tool holder or the tool, which may be adjusted to any working position.
Lead Screw
It is a long threaded shaft, located in front of the carriage, running from the head‐stock to the tail
stock. It is geared to the spindle and controls the movement of the tool, either for automatic
feeding or for cutting threads.
Centers
There are two centers known as dead center and live center. The dead center is positioned in the
tail stock spindle and the live center, in the head‐stock spindle. While turning between centers,
thedead center does not revolve with the work while the live center revolves with the work.

WORK‐HOLDING DEVICES
1. Three jaw chuck
It is a work holding device having three jaws (self‐centering) which will close or open with
respect to the chuck center or the spindle center, as shown in figure. It is used for holding regular
objects like round bars, hexagonal rods, etc.
Face plate
It is a plate of large diameter, used for turning operations. Certain types of work that cannot be
held in chucks are held on the face plate with the help of various accessories.
Lathe dogs and driving plate
These are used to drive a work piece that is held between centers. These are provided with an
opening to receive and clamp the work piece and dog tail, the tail of the dog is carried by the pin
provided in the driving plate for driving the work piece.

MEASURING INSTRUMENTS
1. Outside And Inside Calipers:
Firm joint or spring calipers are used for transfer of dimensions with the help of a steel rule.
2. Venire Calipers
Venire caliper is a versatile instrument with which both outside and inside measurements may be
made accurately. These instruments may have provision for depth measurement also.
3. Micrometers
Outside and inside micrometers are used for measuring components where greater accuracy is
required.

CUTTING PARAMETERS
1. Cutting speed
It is defined as the speed at which the material is removed and is specified in meters per minute. It
depends upon the work piece material, feed, depth of cut, type of operation and so many other
cutting conditions. It is calculated from the relation,
Spindle speed (RPM) = cutting speed x 1000 / (πD)
Where D is the work piece diameter in mm.
2. Feed
It is the distance traversed by the tool along the bed, during one revolution of the work. Its value
depends upon the depth of cut and surface finish of the work desired.

3. Depth of Cut
It is the movement of the tip of the cutting tool, from the surface of the work piece and
perpendicular to the lathe axis. Its value depends upon the nature of operation like rough turning
or finish turning.
TOOL MATERIALS
General purpose hand cutting tools are usually made from carbon steel or tool steel. The single
point lathe cutting tools are made of high-speed steel (HSS). the main alloying elements in 18‐4‐1
HSS tools are 18 percent tungsten, 4 percent chromium and 1 percent vanadium.5 to 10 percent
cobalt is also added to improve the heat resisting properties of the tool. Carbide tipped tools fixed
in tool holders, are mostly used in production shops.
 LATHE OPERATIONS
1. TURNING
Cylindrical shapes, both external and internal, are produced by turning operation. Turning is the
process in which the material is removed by a traversing cutting tool, from the surface of a
rotating workpiece. The operation used for machining internal surfaces is often called the boring
operation in which a hole previously drilled is [Link] turning long work, first it should be
faced and center drilled at one end and then supported by means of the tail‐stock centre.
2. BORING
Boring is enlarging a hole and is used when correct size drill is not available. However, it should
be noted that boring cannot make a hole.
3. FACING
Facing is a machining operation, performed to make the end surface of the work piece, flat and
perpendicular to the axis of rotation. For this, the work piece may be held in a chuck and rotated
about the lathe axis. A facing tool is fed perpendicular to the axis of the lathe. The tool is slightly
inclined towards the end of the work piece.
4. TAPER TURNING
A taper is defined as the uniform change in the diameter of a work piece, measured along its
length. It is expressed as a ratio of the difference in diameters to the length. It is also expressed in
degrees of half the included (taper) [Link] turning refers to the production of a conical
surface, on the work piece on a [Link] steep tapers may be cut on a lathe by swiveling the
compound rest to the required angle. Here,the cutting tool is fed by means of the compound slide
feed handle. The work piece is rotated in a chuckor face plate or between centers.
5. DRILLING
Holes that are axially located in cylindrical parts are produced by drilling operation, using a twist
drill. For this, the work piece is rotated in a chuck or face plate. The tail stock spindle has a
standard taper. The drill bit is fitted into the tail stock spindle directly or through drill chuck. The
tail stock is then moved over the bed and clamped on it near the work. When the job rotates, the
drill bit is fed into the work by turning the tail stock hand wheel.
6. KNURLING
It is the process of embossing a diamond shaped regular pattern on the surface of a work piece
using a special knurling tool. This tool consists of a set of hardened steel rollers in a holder with
the teeth cut on their surface in a definite pattern. The tool is held rigidly on the tool post and the
rollers are pressed against the revolving work piece to squeeze the metal against the multiple
cutting edges. The purpose of knurling is to provide an effective gripping surface on a work piece
to prevent it from slipping when operated by hand.

7. CHAMFERING
It is the operation of beveling the extreme end of a work piece. Chamfer is provided for better
look, to enable nut to pass freely on threaded work piece, to remove burrs and protect the end of
the work piece from being damaged.
8. THREADING
Threading is nothing but cutting helical groove on a work piece. Threads may be cut either on the
internal or external cylindrical surfaces. A specially shaped cutting tool, known as thread cutting
tool, is used for this purpose. Thread cutting in a lathe is performed by traversing the cutting tool
at a definite rate, in proportion to the rate at which the work revolves.
Fig: 6 operations on lathe
 [Link] FOR DEMONSTRATION
METAL CUTTING
(WATER PLASMA)

Introduction:
Plasma may be defined as the charged particle which are close together so that, each
particle influences many charged particles, rather than interactive with nearby particles.
Plasma is typically an ionized gas and it is considered to be distinct state of matter, because of
its unique properties.
Water Plasma:
It is a multi-functional, portable and hand-held device. It is a technological
breakthrough in the area of metal cutting, welding, soldering, tempering, spraying etc. as
maximum efficiency is achieved when plasma technique is used. Usage of water plasma tool
for welding in gas mode is similar to the regular gas welding process. The difference is that
electric power and water are used instead of gas tanks to produce a high temperature jet flame.
Plasma cutting:
It is a process that is used to cut steel and other metals of different thicknesses (or
sometimes other materials) using a plasma torch. In this process, an inert gas (in some units,
compressed air) is blown at high speed out of a nozzle; at the same time an electrical arc is
formed through that gas from the nozzle to the surface being cut, turning some of that gas to
plasma. The plasma is sufficiently hot to melt the metal being cut and moves sufficiently fast
to blow molten metal away from the cut. Plasma cutters use a number of methods to start the
arc. In some units, the arc is created by putting the torch in contact with the work piece. Some
cutters use a high voltage, high frequency circuit to start the arc. This method has a number of
disadvantages, including risk of electrocution, difficulty of repair, spark gap maintenance, and
the large amount of radio frequency emissions.
 CROSS-SECTION OF A PLASMA TORCH HEAD

The Electrode: The primary function of the electrode is to provide power to the
plasma arc. Electrode wear is detected by examining the insert and measuring pit depth.
Excessive electrode wear reduces cut quality and can result in damage to the plasma torch.
Premature electrode wear is most often caused by a few common culprits, the most common
being mismatched torch parts. Other contributors may include incorrect gas flow settings,
gas leaks, moisture build-up and impurities in the plasma gas.

The Nozzle: The nozzle limits the plasma arc to a specific diameter through a
perfectly round hole in it’s’ tip. It constricts the plasma gas, increasing it’s’ velocity. The
most common cause of nozzle damage is, once again, mismatched torch parts. The
electrode and nozzle should be changed as a set to keep cut quality astatine it’s very
highest.

The Shield: The shield surrounds the consumable stack, protecting the parts from
damage. It contains an identical, perfectly round hole as the Nozzle. The most common
trouble associated with the shield is damage to the main orifice due to being plugged or
clogged by dross or spatter.

The Swirl Ring: The swirl ring creates and controls the swirling action of the gas as it
flows around the electrode and nozzle. When inspected and
cleaned regularly, the swirl rings will outlive many electrode and nozzle changes. A
choked swirl ring will hamper gas flow, decrease cut quality and shorten electrode and
nozzle life.

Principle of operation:
The torch is activated by pressing the knob already filled with working fluid. When the
knob is pressed, movable cathode module slides forward and touches the nozzle anode; and
completes the anode cathode short circuit. After releasing the knob, the cathode module
moves back by means of the return spring and an electric arc between the cathode tip and
nozzle-anode.

PLASMA TORCH
Working of Plasma Cutter:
Plasma cutters work by sending an electric arc through a gas that is passing through a
constricted opening. The gas can be shop air, nitrogen, argon, oxygen etc. This elevates the
temperature of the gas to the point that it enters a 4th state of matter. We all are familiar with
the first three: i.e., solid, liquid, and gas. Scientists call this additional state plasma. As the
metal being cut is part of the circuit, the electrical conductivity of the plasma causes the arc to
transfer to the work.

The restricted opening (nozzle) causes the gas passing through it to squeeze by at a
high speed, like air passing through a venturi in a carburetor. This high speed gas cuts
through the molten metal. The gas is also directed around the perimeter of the cutting area to
shield the cut.

PLASMA CUTTING
Advantages:
3. Plasma tool is cost effective, portable and less power consumption.
4. Does not require lightening as the flame produces effective
illumination.
5. The device can be operated continuously.
 [Link] TOOLS

Introduction:

A power tool is a tool powered by an electric motor, an internal combustion engine, a

steam engine, compressed air, direct burning of fuels and propellants, or even natural power
sources like wind or moving water. Power tools are classified as either stationary or portable,
where portable means handheld. They are used in industry, in construction, and around the
house for driving, drilling, cutting, shaping, sanding, grinding, polishing, painting, and
heating.

Stationary power tools for metalworking are usually called machine tools. The term
machine tool is not usually applied to stationary power tools for woodworking, although such
usage is occasionally heard, and in some cases, such as drill presses and bench grinders,
exactly the same tool is used for both woodworking and metalworking. Stationary power
tools are prized not only for their speed, but for their accuracy. A table saw not only cuts
faster than a hand saw, but the cuts are smoother, straighter and more square than even the
most skilled man can do with a hand saw. Lathes produce truly round objects that cannot be
made in any other way.

Common power tools include the drill, various types of saws, the router, the electric
sander, and the lathe. The term power tool is also used in a more general sense, meaning a
technique for greatly simplifying a complex or difficult task. Some safety tips are mentioned
below:

1. Never operate any power equipment unless you are completely familiar with its
controls and features.
2. Inspect all portable power tools before using them. See that they are clean and in
good condition.
3. Make sure there is plenty of light in the work area. Never work with power tools
in dark areas where you cannot see clearly.

4. Before connecting a power tool to a power source, be sure the

tool switch is in the “OFF” position.
Some examples of Portable Power Tools:

HAND DRILL POWER CUTTER

BLOWER CIRCULAR SAW

DISC GRINDER ROTARY HAMMER

 JIG SAW MARBLE CUTTER

ORBIT SANDER SAND POLISHER

SCREW DRIVER CHAIN SAW

 ENGINEERING WORKSHOP – I [Link]

Some examples of Stationary Power Tools:

POWER HACK SAW

VERTICAL BAND SAW

CIRCULAR SAW

MARRI LAXMAN REDDY INSTITUTE OF TECHNOLOGY & MANAGEMENT, DUNDIGAL, HYDERABAD