subject: workshop semester: 1st ay: 2015-16

DEPARTMENT OF MECHANICAL ENGINEERING

Subject: Workshop

Semester: 1st AY: 2015-16

Workshop

Sr.

No

AIM Date Page

number

Sign.

1. To study about workshop realization.

2. Demonstrate the carpentry shop.

3. Demonstrate the fitting shop.

4. Demonstrate the smithy shop.

5. Hands on experiment of welding shop.

6. Hands on experiment of carpentry, fitting

and smithy shop.

7. Demonstrate the difference types of

machine tools.

8. Demonstrate the plumbing operation.

9. Demonstrate the electro plating operation.

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Experiment:-1

Aim: - To study about workshop realization.

Introduction

Manufacturing and workshop practices have become important in the industrial environment

to produce products for the service of mankind. Manufacturing is the backbone of any

industrialized nation. Manufacturing and technical staff in industry must know the various

manufacturing processes, materials being processed, tools and equipment’s for manufacturing

different components or products with optimal process plan using proper precautions and

specified safety rules to avoid accidents. Beside above, all kinds of the future engineers must

know the basic requirements of workshop activities in term of man, machine, material,

methods, money and other infrastructure facilities needed to be positioned properly for optimal

shop layouts or plant layout and other support services effectively adjusted or located in the

industry or plant within a well-planned manufacturing organization.

SCOPE OF Workshop STUDY

Today’s competitive manufacturing era of high industrial development and research, is being

called the age of mechanization, automation and computer integrated manufacturing. Due to

new researches in the manufacturing field, the advancement has come to this extent that every

different aspect of this technology has become a full-fledged fundamental and advanced study

in itself. This has led to introduction of optimized design and manufacturing of new products.

New developments in manufacturing areas are deciding to transfer more skill to the machines

for considerably reduction of manual labour. The scope of the subject of workshop technology

and manufacturing practices is an extremely wide as it specifies the need of greater care for

man, machine, material and other equipment’s involving higher initial investment by using

proper safety rule and precautions. The through and deep knowledge in the course of study of

this important subject is therefore becoming essential for all kinds of engineers to have sound

foundation in their profession. Therefore the course of study of this subject provides a good

theoretical background and a sound practical knowledge to the engineering students and

workshop staff.

Types of shop

Carpentry

Fitting

Smithy

Welding

Plumbing

Electroplating

Machine shop.




Question:-

1) According to you what is the significant of training workshop?

2) Which machines are available in machine shop?




Experiment:-2

Aim: - Demonstrate the carpentry shop.

INTRODUCTION

In carpentry workshop, wooden pieces of commercial sizes are given specific shape and size,

as per the requirements. The processes involved in carpentry shop are making layout, marking,

sowing, plaining, chiselling jointing etc. In this chapter we shall study about the raw material

and tools used in carpentry shop various raw material used that shop are wood, nut, screw, nut

and bolt and glue etc. The tools are classified as marking, cutting, planning, chiselling, striking

etc.

VARIOUS TYPES OF TIMBER AND PRACTICE BOARDS

Types of Wood –

Common wood are generally classified according to their degree of hardness of softness.

1. Hardwood- Hard wood has closed structure, heavy in weight, dark in colour and is difficult

to work on it, annual rings are not distinct and good tensile strength.

2. Soft Wood- Hard wood has less weight, less durable and is easy to work out. Soft wood

catches fire soon as compared to hardwood, annual rings are quite distinct.

3. Plywood: It consists of more than three layers. Middle layer is called care which is thick and

not of good quality. The top and bottom are called as face ply which is glued on the care at top

and bottom. The grains of adjacent layers are kept perpendicular to each other which prevents

plywood form war page.

CARPENTRY HAND TOOLS

1) Carpentry tools:

The efficiency of the workman depends upon the tools used in the workshop. Good quality

tools always makes the work easy. In the carpentry shop the tools are classified as under:

1) Measuring tools

2) Marking tools

3) Cutting tools

4) Planning tools

5) Striking tools




1) Measuring Tools

a. Four Fold box wood rule: It is generally 2 feet long and is folded from three

places. It is marked with inch and millimetre scale.

b. Steel rule: It is made up of stainless steel and is marked with scale.

c. Inch tape: It is made up of flexible thin steel strip. It is folded around a centre

pin attached with a small handle.

2) Marking Tools

a. Pencil: Lead pencil is generally used for marking purposes.

b. Scriber: Scriber has a sharp conical edge used to mark on even hard surfaces.

The front edge is hardened so as to resist wear and tear. It is made up of

carbon steel.

c. Marking gauge: It is used to draw parallel lines. The movable portion of the

gauge is adjusted to suitable position and is tightened on to stem.

d. Try square: It is used to draw parallel lives at right angles, parallel or to

check the trueness of planed surfaces. It is made up of a steel blade with

heavy base.

e. Bevel square: It consists of wooden handle fitted with an adjustable handle

blade. The blade can be rotated by 180º w.r.t. handle. It is used for marking

various angles.

f. Compass/Dividers: These are used for dividing equal number of parts and

for drawing arcs and circles. It consists of two legs with a spring on the top

of the legs. A screw is also attached at the centre of the legs for adjustment.

3) Cutting Tools: There are two types cutting tools in carpentry shop.

(a) Saw

(b) Chisel

a) Saw: A saw is a multi-tooth tool made up of thin sheet attached with a wooden handle.

Its teeth are ground and sharpened to achieve smooth cutting.

Different types of saw are:

Rip Saw: It is hand saw from 30 cm to 75 cm long, containing one to one and half

teeth per cm. It should not be called a hand saw but a rip saw only.




Tenon saw: It derives its name from the tenon form of joint It is a thin saw ranging

from 20 cm to 40 cm in length, and is supported by back of wrough iron or brass;

hence it is also called a back saw. It contains about 4 teeth at a cam.

Coping Saw: It is used for cutting quick or sharp curves either internal or external.

Compass Saw: It is a short narrow saw, tapering towards the point, used for cutting

sweeps and large interior curves by hand sometimes termed as a table saw.

Keyhole or Pad saw: It is used for cutting thick internal curves where it is

impossible to use other saws.

Cross-cut saw: It is a saw provided with two handles, one at each end used for

cutting heavy timber across the grains.

Bow saw: It consists of a wooden frame, a bar, a string, lever and two handles. It is

used to produce curved surfaces with quick turns. The blade is tightened with the

help of string and lever.

b) Chisel:

There are three types of chisels commonly used in carpentry shop:

Firmer Chisels: It is a general chisel used to finish inside grooves. It has various

sizes of cutting edge depending upon the work to be done. Width varies from 5 mm

to 35 mm.

Mortise Chisel: It is used to make mortises. Mortise chisel is used for heavy cuts.

The blade thickness varies from 5 mm to 12 mm.

Gauge Chisel: It is used to finish curved holes. Gauge chisels are of two types i.e.

inside and outside.




4) Planning Tools

Planning tools are used for smoothening purposes. Preparing proper sizes and for forming

curved wooden strips. Many types of planes are used in carpentry shop

(a) Trying plane: Trying plane is 18” long and used for general purpose planning of wood. It

is applied after jack plane.

(b) Jack plane: Jack plane is 10”-14” long. Heavy and is used for rough cutting.

(c) Smoothing plane: Smoothing plane is used for finishing work. It is small in size generally

9” long.

(d) Rebate plane: Rebate planes are used for preparing household goods are furniture plough

plane is used for making grooves.

5) Striking Tools:

Striking tools are used to force the nails or chisels into the wood. Main striking tools are as

under:

(i) Cross Peen Hammer: It has a cast steel body and a wooden handle. Body has two parts

face and pean. In cross pean hammer, the pean is in the form of a narrow, round edge ridge

placed at right angle to the axis of the handle.




(ii) Claw Hammer: It is used for striking as well as for pulling the nails from the wood. The

material of the wood is cast steel, one end is made striking and the second is claw face.

(iii) Mallet: It is used to strike the chisels which have wooden handles. It is made up of a hard

wood and is round or rectangular in shape.

Question:-

1. Explain the joint of two dissimilar intricate shapes by the using of

various carpentry tools?




Experiment:-3

Aim: - Demonstrate the fitting shop.

Fitting Shop

Introduction

In Fitting shop unwanted material is removed with the help of hand tools. It is done for mating,

repair and manufacturing purposes. Commonly used tools in fitting shops are hacksaw, files,

chisels, etc.

Classification of Metals

Metals are classified into two categories:

1. Ferrous Metals

In ferrous metals the percentage of iron is very high. Some other materials like carbon, sulphur,

nickel, etc. are also mixed into ferrous metals to change the properties. They are magnetic in

nature. Some ferrous metals are discussed as under.

i) Steel:- Steel is a mixture of iron and carbon.

Low Carbon Steel – Carbon content 0.08 to 0.25%.

Medium Carbon Steel - Carbon content 0.25 to 0.55%.

High Carbon Steel - Carbon content 0.55 to 0.8%.

Tool Steel - Carbon content 0.8 to 1.5%.

ii) Alloy Steel :- Alloy steel is made by combining some percentage of additional elements

like nickel, phosphorous, silicon, chromium, molybdenum in the plain carbon steel to give

strength, hardness, resistance to corrosion properties.

iii) Cast Iron: - Iron containing carbon more than 2% is known as cast iron. It is hard and

brittle material, used in machine beds, heavy parts of machines.

iv) Wrought Iron – It is almost pure iron containing 99.9% of iron. It is ductile and soft.

v) High speed Steels – The composition of high speed steel is 18% tungsten, 4% chromium,

1% vanadium and 0.7% carbon, used for making cutting tools.

vi) Spring Steel – It contains 0.5 to 0.6% carbon, used for making springs.




2. Non Ferrous Metals

The metals which contain no quantity of iron are known as nonferrous metals, copper,

aluminum, brass, bronze, tin ,lead are common nonferrous metals.

i). Copper: Reddish brown color, soft, ductile, high electrical and thermal conductivity.

ii). Brass: Alloy of copper and zinc, soft and ductile.

iii). Bronze: Alloy of tin and copper, wear resistance material.

iv). Aluminum: Soft metal, white in color, light in weight, good electrical conductivity.

v). Gun metal: Alloy of copper, tin and zinc, used in making casting.

Tools:-

1. Clamping Tools:

Clamping tools are used for holding the job firmly during various fitting operations.

i) Bench vice: It is a common tool for holding the jobs. It consists of cast iron body and iron

jaws .The jaws are opened up to required length, job is placed in the jaws and is fully

tightened with handle.

ii). Leg vice: It is stronger than bench vice and used for heavy work.

iii). Hand vice: It is used to grip very small objects.

iv) Pin vice: Pin vice is used to hold wire or small diameter rods.

v) Pipe vice: It is used to hold pipes. It grips the pipe at four places and is fixed on bench or

can be grouted.

2. Measuring and Marking Tools

i). Try Square: It is used for checking square ness of two surfaces. It consists of a blade

made up of steel which is attached to base at 90°.

ii). Bevel Protector: It consists of a steel dial divided into 360° divisions.

iii). Combination Set – Multipurpose instrument can be used as a protector, a level, a meter,

a centre square and a Try square.

iv). Centre Square – It is used to find the centre of the round jobs.




v). Scriber and Surface Gauge – It is used for marking of lines parallel to a surface.Scriber

mounted on a vertical bar is called surface gauge.

vi). Dot Punch – It is used for marking dotted lines. Angle of punching end is 60°.

vii). Centre Punch – It is like a dot punch used to mark the centre of hole before drilling.

Angle of punch end is 90°.

viii). Surface Plate – Surface plate is used for testing the flatness, trueness of surfaces, its

upper face is planed to form a very smooth surface.

ix). Angle Plate – It consists of cast iron in which two ribs of metal are standing at right

angle to each other, used for holding and supporting the jobs.

x). ‘V’ Block – It is used for supporting as well as marking of round jobs.

xi). Steel Rules – It is made up of stainless steel and marked in inches or millimeters,

available in various sizes ½ ft to 3 ft.

xii). Vernier Caliper – It is a precision instrument used for measuring lengths and diameters.

Minimum dimension that can be expressed on vernier caliper is known as least count which

is usually 0.001 or 0.02 mm.

xiii). Micrometer – It is used for measuring diameters or thickness of any Job. The

graduation on micrometers is available in inches as well as in millimeters.

xiv). Dial Indicator – A round gauge in which a pointer moves over a graduated scale.The

movement is magnified through links. It is used to check the run out or ovality of Jobs.

xv). Dividers – Dividers have two legs having sharp feet. It is used for marking arcs, dividing

a line or transferring the dimensions.

xvi). Calipers: it is generally used to measure the inside or outside diameters. There are four

types of callipers.

(a) Outside calipers

(b) Inside calipers

(c) Spring calipers

(d) Odd leg calipers

Bench Working Processes

1. Marking – Measurement is performed on the job by measuring instrument and marking is

done by scriber.

2. Chipping – Material is removed with the help of chisels.

3. Sawing – This operation is required to cut the metal in different sizes and shapes by

hacksaw.




4. Filing – This operation is performed with the help of files, pressure should be exerted in

the forward stroke and backward stroke is ideal.

5. Scrapping – This is done for reducing more accurate finish that obtained by filing.

6. Drilling – This is done to produce holes with the help of drills. It is done on a drilling

machine and job is held in a machine vice. Drill is fixed on the drilling machine,

7. Tapping – This is done to cutting the internal threads with the help of tap and tap holder.

8. Dieing – This is done to cut the external threads by the help of die and die holder.

Question:-

1. Enlist the different types of fitting operation like checking, marking, punching

cutting, filing etc by the using various fitting tools.




Experiment:-4

Aim: - Demonstrate the smithy shop.

Introduction:

Forging is the process of shaping metals by impact or very high pressure. The metal in this

process is squeezed to attain the desired shape and this requires the metal to be in plastic

state. This plastic state or plasticity is brought about either by heating or increasing the stress

level beyond elastic limit.

When the metal is heated to plastic temperature and shaped, it is called hot forging. When the

metal is deformed and shaped at room temperature raising the stress level beyond elastic

limit, the process is called cold forging.

Forging as a manufacturing process is intended to produce components of high strength of

wrought iron, steel, aluminum alloys, brasses etc. It must be remembered that, all metals

cannot be forged. For example, brittle metals like Cast Iron cannot be forged. Components

such as connecting rod, crankshaft, leaf spring etc. are all forged.

Tools and equipment’s used in Smithy:

Hearth: In forging process the hearth is used for heating the job. Coal, coke or charcoal is used as fuel

to heat the job. A blower provides blast of air to produce rapid combustion.

Anvil: The anvil is an important tool used in smithy. It is used for supporting the job while it is struck

with hammer. The body of the

anvil is made of mild steel. The

beak is soft like the anvil body and

its shape makes it useful for

bending round section to different

diameters.

In the top of the anvil, is a square

and a round hole. The square hole

known as hardie hole is used for

square shank shaping tools like

bottom fullers, swages and hardie.

The round hole is used for

admitting the ends of the punches

or drifts. The hole is also used for bending round bars of different curvatures. The anvil is




placed either on a wooden block or on cast iron stand such that the top face is about 600 mm

to 700 mm from the floor.

Hammers:

The hammers commonly used in forging are of the two types (a) Hand hammer, (b) Sledge

hammer. Hand hammers are classified as Ball peen, Cross peen and straight peen hammers

depending on the shape of the peen. The sledge hammers are used by smith’s helper. The

mass of sledge hammer varies from 5 to 8 kg.

Tongs:

The blacksmith requires suitable tongs to handle the work while forging. These are made of

mild steel. The various types of tongs commonly used for holding job are as follows:

a) Closed mouth tong: A closed mouth tong is used for holding thin sections

b) Open mouth tong: An open mouth tong is suitable for holding heavier stock.

c) Round hollow tong: A round hollow tong is used for holding round, hexagonal and

octagonal section.

d) Square hollow tong: A square hollow tong is used for holding square, hexagonal and

octagonal section.




Swages: The swages are used to get different sectional shapes like round, square and hexagon. The

bottom part having square shank fits into the hardy hole on the anvil. The top part having a

handle is held by the smith.

Swage block:

The swage block is generally made of cast iron and has round, square, rectangular and half

round grooves. In addition to this, it is provided with holes which are useful for holding bars

while bending and knocking up heads.

Forging operations:

1. Upsetting: It is the process of increasing the cross section of a job at the expense of its

length. It consists of heating that portion of the job increase in cross section is required and

hammering in an axial direction.

2. Drawing: It is the process of reducing the cross section of a bar and increasing its length.




3. Setting down: It is a process of local thinning down effected by the set hammer. The job is

first fullered down using fullers and then finished a flatter.

4. Punching: It is the process of producing holes by forcing a punch through the work.

5. Bending: It is an important operation in forging and is very frequently used.

6. Welding: Forge welding is different from other welding processes. In this process no filler

material is used. The welding is brought by bringing the two ends to be welded to the welding

temperature in a hearth and hammering them together.

7. Cutting: Cutting of tough jobs is facilitated by heating and cutting. Hot chisel is used for

the purpose.

Question

1. Write the sequence of operation to produce the forging component.




Experiment:-5

Aim: - Demonstrate the welding shop.

Introduction

Welding is metal joining process wherein localized coalescence is produced either by heating

the metal to a suitable temperature, with or without the use of filler metal, with or without

application of pressure. The filler material has similar composition and melting point

temperature as that of the base metal. It is used to fill gap between the joint surfaces.

Types of welding

The welding process is divided into two main sub divisions.

Plastic welding: - The pieces of metal to be joined are heated to the plastic state and then

forced together by external pressure without the addition of filler material.

Forge welding: - The work piece are placed in a forge or other appropriate furnace and heated

within the area to be joined to the plastic condition. Then parts are quickly superimposed and

worked into a complete union by hand or power hammering or by pressing together.

Resistance welding: - In resistance welding, a heavy electric current is passed through the

metals to be joined over limited area, causing them to be locally heated to plastic state and the

welding is completed by the application of pressure for the prescribed period of time.

Fusion welding: - In fusion welding, the metal parts to be joined are melted and then allowed

to solidify pressure is not applied and filler metals may be used for this type of welding.

Gas welding: - Gas welding is a process in which the required heat to melt the surfaces is

supplied by a high temperature flame obtained by a mixture of two gases. Usually the mixture

of oxygen and acetylene is used for welding purpose.

Electric Arc welding:-

Principle of operation




Electric arc welding is the process of joining two parts by melting their edges by an electric

arc with or without the application of pressure and with or without use of filler metals.

Thermit welding:-

Thermit welding is a fusion process in which weld is effected by pouring super-heated liquid

thermit steel, around the parts to be united with or without the application of pressure.

Welding Bead cleaning accessories

Chipping hammer: - A chipping hammer is chisel-shaped one and it is used to

remove the slag from the weld bead.

Wire Brush: - A wire brush made up of stiff steel wire, embedded in wood, removes

small particles of slag from the weld bead after the chipping hammer is used.

Hand Screen: - It is a protective device used in arc welding. A hand shield is held in

the hand of the welder and it is fitted with a suitable fitter lens.

Helmet: - It is used for shielding and protecting the face and neck of the welder and it

is fitted with a suitable fitter lens.

Tongs: - Tongs are used to handle the hot metal-welding job while cleaning; they are

also used to hold the metal for hammering.

Goggles: - Chipping goggle is used to protect the eyes while chipping the slag. They

are fitted while a plain glass to see the area to be cleaned.

Hand Gloves: - Hand gloves are used to protect the hands from electrical shock, arc

radiation and hot spatters.




Question:-

1) Enlist the variable of electric arc welding.

2) According to you how many types of join are possible through welding?



subject: workshop semester: 1st ay: 2015-16

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