workshop complete practical

8/20/2019 Workshop Complete Practical

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Work shop

EXPERIMENT 01

FACING AND PLAIN TURNING

PERFORMANCE/OBJECTIVES

• To obtain required diameter of a cylindrical work piece with the given

length

EQUIPMENTS AND TOOLS

• Lathe machine, Mild steel bar, right hand cutting tool, box key or tool

post key, chuck key, steel rule and outside calipers or vernier calipers.

THEORY

acing is the operations of !nishing the ends of work to make

ends "at, smooth and to required length. #ough turning operation is used

where excessive stock is to be removed and surface !nish is not critical. or

such an operation deep cuts with coarse feed are used. $uring rough

machining, maximum metal is removed and very little oversi%e dimension is

left for !nishing operation.

PROCEDURE

&. The given work piece is held in the '()awchuck of the lathe machineand tightened !rmly with chuck key.

*. #ight hand single point cutting tool is taken tightened !rmly with thehelp of box key in the tool post.

'. Machine is switched on and the tool post is swiveled and the cuttingpoint is ad)usted such that it positioned approximately for facingoperation then the tool is fed into the work piece and the tool post isgiven the transverse movement by rotating the hand wheel of the

cross slide.+. With this facing is completed and the tool post is swiveled and cutting

point is made parallel to the axis of work piece.. $epth of cut is given by cross slide to the tool post and the side hand

wheel is rotated to give the longitudinal movement for the tool postand )ob is turned to the required length and diameter.

-. fter completion of the )ob it is inspected for the dimensions obtainedwith the help of steel rule and outside caliper or vernier caliper.

rslan /han 0age &

Name ______________________________ ID______________ Date ________________

Signature of the Lab Teacher _______________________ Remarks ________________


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Length

$i am

et er

Work shop

PRECAUTIONS

&. Work piece should be held !rmly.*. 1n rough turning operation do not over feed the tool, as it may damage

the cutting point of the tool.

'. 2xercise over hung of tool should be avoided as it results in chatterand causes rough machined surface.

+. 1t is important to ensure that during facing operation the cutting isperformed from center point to the outer diameter of the work piece.

EXPERIMENT RESULTS

• The )ob is thus made according to the given dimensions.

• $imensions before facing and plain turning

Length 3333333333333333 $iameter 3333333333333333 • $imensions after facing and plain turning

Length 3333333333333333 $iameter 3333333333333333

rslan /han 0age *


3/26

Work shop

EXPERIMENT 02

STEP TURNINGPERFORMANCE/OBJECTIVES

• To obtain required diameters 4steps5 on a cylindrical work piece with

the given lengths.




THEORY

6tep turning is the operation of creating various cylindrical cross

sections on a metal blank. #ough turning operation is used where excessive

stock is to be removed and surface !nish is not critical. or such an operation

deep cuts with coarse feed are used. $uring rough machining maximum

metal is removed and very little oversi%e dimension is left for !nishing

operation.

PROCEDURE


*. #ight hand single point cutting tool is taken tightened !rmly with thehelp of box key in the tool post.

'. $epth of cut is given by cross slide to the tool post and the side handwheel is rotated to give the longitudinal movement for the tool postand )ob is turned to the required length and diameters according to thesketch shown in !gure.

+. fter making !rst step, the tool post is given vertical forward

movement and again the side hand wheel is rotated to give thelongitudinal movement for the tool post and )ob is turned to therequired length and diameters. 6o the second step is formed

. Then 'rd step is made in the same manner.-. fter completion of the )ob it is inspected for the dimensions obtained

with the help of steel rule and outside caliper or vernier caliper.

PRECAUTIONS

rslan /han 0age '

Name ______________________________ ID______________ Date ________________



4/26

L& L* L'

$& $* $'

Work shop


the cutting point of the tool.'. 2xercise over hung of tool should be avoided as it results in chatter

and causes rough machined surface.


EXPERIMENT RESULTS


• $imensions before facing and plain turningLength 3333333333333333 $iameter 3333333333333333

•

$imensions after facing and plain turningLength L&33333333333L*33333333333L'33333333333 $iameter $&33333333333$*33333333333$'3333333333

rslan /han 0age +


5/26

Work shop

EXPERIMENT 03

Boring Opr!"ionPERFORMANCE/OBJECTIVES

• To obtain required internal diameters on a cylindrical work piece

4hollow5.




THEORY

$rilling and boring are two methods of machining used in

manufacturing. 7oth methods are used for creating or enlarging a circular

hole in the material. $rilling is the process of perforating a solid material

surface using a drill bit to create a cavity.

7oring is the process of enlarging a hole that is already in the material8

it may be a hole made by drilling or in the casting. 7oring concerns the

internal diameter and the surface of the hole rather than the depth of thehole.

PROCEDURE


*. 6uitable cutting tool is taken tightened !rmly with the help of box keyin the tool post.

'. Machine is switched on and the tool post is swiveled and the cuttingpoint is ad)usted

+. then the tool is fed into the work piece and the tool post is given theoutward transverse movement by rotating the hand wheel of the crossslide.

. 1t is performed until the required internal diameter is achieved-. fter completion of the )ob it is inspected for the dimensions obtained

with the help of steel rule and outside caliper or vernier caliper.

PRECAUTIONS

rslan /han 0age

Name ______________________________ ID______________ Date ________________



6/26

1nternal $iameter

1nternal $iameter

Work shop


the cutting point of the tool.'. 2xercise over hung of tool should be avoided as it results in chatter

and causes rough machined surface.


EXPERIMENT RESULTS


• $imensions before facing and plain turning

$iameter 3333333333333333 •

$imensions after facing and plain turning

$iameter 3333333333333333

rslan /han 0age -


7/26

Work shop

EXPERIMENT 04

S#$!r Fi%%ingPERFORMANCE/OBJECTIVES

• To !le the given Mild 6teel piece in to a required square shape.


• 7ench vice, set of iles, 6teel rule, Try(square, 9ernier caliper, 9ernier

height gauge, 7all(peen hammer, 6criber, $ot punch, 6urface plate,

ngle plate and nvil.

THEORY

iling is a material removal process in manufacturing. 6imilar,

depending on use, to both sawing and grinding in e:ect, it is functionally

versatile, but used mostly for !nishing operations. iling operations can be

used on a wide range of materials as a !nishing operation. iling helps

achieve work piece function by removing some excess material. 6andpaper

may be used as a !ling tool for other materials, such as glass.

PROCEDURE

&. The dimensions of the given piece are checked with the steel rule.*. The )ob is !xed rigidly in a bench vice and the two ad)acent sides are

!led, using the rough "at !le !rst and then the smooth "at !le suchthat, the two sides are at right angle.

'. The right angle of the two ad)acent sides is checked with the try(square.

+. ;halk is then applied on the surface of the work piece.. The given dimensions are marked by scribing two lines, with reference

to the above two datum sides by using 9ernier height gauge, ngle

plate and 6urface plate.-.


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Width

L en gt h

Width

L en gt h

Work shop

*. The work must be a little under the height of the elbow or on +? to ++inches as of the "oor.

'. @rasp the lever of the !le by the right hand and hold the palm againstthe end of the handle by the thumb on crest.

+.


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Work shop

EXPERIMENT 05

Fi%%ing !n& Grin&ingPERFORMANCE/OBJECTIVES

• To !le the given Mild 6teel piece in to a required triangular shape.


• @rinding machine 7ench vice, set of iles, 6teel rule, Try(square,

9ernier caliper, 9ernier height gauge, 7all(peen hammer, 6criber, $ot

punch, 6urface plate, ngle plate and nvil.

THEORY

@rinding is an abrasive machining process that uses a grinding wheel

as the cutting tool. wide variety of machines are used for grindingB

&. CandDcranked knifeDsharpening stones 4grindstones5*. Candheld power tools such as angle grinders and die grinders'. 9arious kinds of expensive industrial machine tools called

grinding machines+. 7ench grinders often found in residential garages and basements

PROCEDURE

&. The dimensions of the given piece are checked with the steel rule.*. The )ob is grinded through grinded so that the material can be

removed'. The )ob is grind diagonally to achieve a triangular shape+. Then )ob is !xed rigidly in a bench vice and the two ad)acent sides are

!led, using the rough "at !le !rst and then the smooth "at !le suchthat, the two sides are at right angle.

. The right angle of the two ad)acent sides is checked with the try(square.

-. ;halk is then applied on the surface of the work piece.=. The given dimensions are marked by scribing two lines, with reference

to the above two datum sides by using 9ernier height gauge, ngleplate and 6urface plate.

A.


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Length

C ei gh t

Width

Length

Width

Work shop

E. The two sides are then !led, by !tting the )ob in the bench vice8followed by checking the "atness of the surfaces.

PRECAUTIONS

&. $on>t use !le with no handle.*. The work must be a little under the height of the elbow or on +? to ++inches as of the "oor.

'. @rasp the lever of the !le by the right hand and hold the palm againstthe end of the handle by the thumb on crest.

+. or heavy !lling, put the palm of the left hand on the tip of the !le withthe !ngers pressing beside the underside.

. Wear goggles and other safety gadgets.

EXPERIMENT RESULTS


• $imensions before !ling operation

Length 3333333333333333 Width 3333333333333333 Ceight 3333333333333333

• $imensions after !ling operation

Length 3333333333333333 Width 3333333333333333 Ceight 3333333333333333

rslan /han 0age &?

C

e i g h t


11/26

Work shop

EXPERIMENT 06

Cornr Join"PERFORMANCE/OBJECTIVES

• To make a corner )oint, using the given mild steel pieces by arc welding


rc welding machine, Mild steel electrodes, 2lectrode holder, @round clamp,

Metallic work Table, 7ench vice, #ough "at !le, Try square, 6teel rule, Wire

brush, hammer, ;hisel and @rinding machine.

THEORY

Welding is the process of )oining similar metals by the application of heat,

with or without application of pressure or !ller metal, in such a way that the

)oint is equivalent in composition and characteristics of the metals )oined. 1n

the beginning, welding was mainly used for repairing all kinds of worn or

damaged parts. Fow, it is extensively used in manufacturing industry,

construction industry 4construction of ships, tanks, locomotives and

automobiles5 and maintenance work, replacing riveting and bolting, to a

greater extent.

The various welding processes areB

&. 2lectric arc welding,*. @as welding'. Thermal welding+. 2lectrical #esistance welding and. riction welding

rslan /han 0age &&

Name ______________________________ ID______________ Date ________________



12/26

Work shop

PROCEDURE

&. Take the two mild steel pieces of given dimensions and clean thesurfaces thoroughly from rust, dust particles, oil and grease.

*. #emove the sharp corners and burrs by !ling or grinding and prepare

the work pieces.'. The work pieces are positioned on the welding table such that, the L

shape is formed.+. The electrode is !tted in to the electrode holder and the welding

current is set to a proper value.. The ground clamp is fastened to the welding table.-. Wearing the apron, hand gloves, using the face shield and holding the

pieces the arc is struck and the work pieces are tack(welded at boththe ends.

=. The alignment of the corner )oint is checkedA. Welding is then carried out throughout the length.

E. #emove the slag, spatters and clean the )oint.

PRECAUTIONS

&. lways wear the safety hand gloves, apron and leather shoes.*. $o not weld around combustible or in"ammable materials, where

sparks may cause a !re.'. *. Fever weld containers, which have been used for storing gasoline,

oil or similar materials, without !rst having them thoroughly cleaned.+. '. ;heck the welding machine to make sure that it is properly

grounded and that all leads properly insulated.

. +. Fever look at the arc with the naked eye. The arc can burn youreyes severely. lways use a face

EXPERIMENT RESULTS

• The )ob is thus made according to the given shape and dimension

rslan /han 0age &*


13/26

Work shop

EXPERIMENT 07

Do$'% L!p (oin"


• To make a double lap )oint, using the given mild steel pieces and by arc

welding.


rc welding machine, Mild steel electrodes, 2lectrode holder, @round clamp,

Metallic work Table, 7ench vice, #ough "at !le, Try square, 6teel rule, Wirebrush, hammer, ;hisel and @rinding machine.

THEORY

Welding is the process of )oining similar metals by the application of heat,

with or without application of pressure or !ller metal, in such a way that the

)oint is equivalent in composition and characteristics of the metals )oined. 1n

the beginning, welding was mainly used for repairing all kinds of worn or

damaged parts. Fow, it is extensively used in manufacturing industry,

construction industry 4construction of ships, tanks, locomotives andautomobiles5 and maintenance work, replacing riveting and bolting, to a

greater extent.

The various welding processes areB

&. 2lectric arc welding,*. @as welding'. Thermal welding+. 2lectrical #esistance welding and. riction welding

rslan /han 0age &'

Name ______________________________ ID______________ Date ________________



14/26

Work shop

PROCEDURE

&. Take the two mild steel pieces of given dimensions and clean thesurfaces thoroughly from rust, dust particles, oil and grease.

*. #emove the sharp corners and burrs by !ling or grinding andprepare the work pieces.

'. The work pieces are positioned on the welding table, to form a lap )oint with the required over lapping.

+. The electrode is !tted in to the electrode holder and the weldingcurrent is set to a proper value.

. The ground clamp is fastened to the welding table.-. Wearing the apron, hand gloves, using the face shield and holding

the pieces the arc is struck and the work pieces are welded at boththe ends.

=. The alignment of the lap )oint is checked and the tack(weldedpieces are reset, if required.

A. Welding is then carried out throughout the length of the lap )oint, on

both the sides.E. #emove the slag, spatters and clean the )oint.

PRECAUTIONS

&. lways wear the safety hand gloves, apron and leather shoes.*. $o not weld around combustible or in"ammable materials, where

sparks may cause a !re.'. Fever weld containers, which have been used for storing gasoline,

oil or similar materials, without !rst having them thoroughlycleaned.

+. ;heck the welding machine to make sure that it is properlygrounded and that all leads properly insulated.

. Fever look at the arc with the naked eye. The arc can burn youreyes severely. lways use a face

EXPERIMENT RESULTS

rslan /han 0age &+


15/26

Work shop

• The )ob is thus made according to the given shape and dimension

EXPERIMENT 08

T)L!p Join"


• To make a T(lap )oint as shown in igure.


;arpenterGs vice, steel rule, )ack plane, try(square, marking gauge, * mm

!rmer chisel, cross(cut saw, tenon saw, scriber and mallet.

THEORY

;arpentry may be de!ned as the process of making wooden components. 1t

starts from a marketable form of wood and ends with !nished products. 1t-

deals with the building work, furniture, cabinet making. 2tc. )oinery, i.e.,

preparation of )oints is one of the important operations in all woodworks. 1t

deals with the speci!c work of carpenter like making di:erent types of )oints

to form a !nished product.

PROCEDURE

&. The given reaper is checked to ensure its correct si%e.*. The reaper is !rmly clamped in the carpenterGs vice and any two

ad)acent faces are planned by the )ack plane and the two faces arechecked for squareness with the try square.

rslan /han 0age &

Name ______________________________ ID______________ Date ________________



16/26

Work shop

'. Marking gauge is set and lines are drawn at '? and + mm, to markthe thickness and width of the model respectively.

+. The excess material is !rst chiseled out with !rmer chisel and thenplaned to correct si%e.

. The mating dimensions of the parts H and Iare then marked using

scale and marking gauge-.


17/26

Work shop

rslan /han 0age &=


18/26

Work shop

EXPERIMENT 09

Do-"!i% %!p (oin"PERFORMANCE/OBJECTIVES

• To make a dovetail lap )oint as shown in igure.




THEORY


starts from a marketable form of wood and ends with !nished products. 1t





PROCEDURE

&. The given reaper is checked to ensure its correct si%e.*. The reaper is !rmly clamped in the carpenterGs vice and any two

ad)acent faces are planed by the )ack plane and the two faces are

checked for squareness with the try square.'. Marking gauge is set and lines are drawn at '? anc&+ mm, to mark

the thickness and width of the model respectively.+. The excess material is !rst chiseled out with !rmer chisel and then

planed to correct si%e.. The mating dimensions of the parts H and Iare then marked using

scale and marking gauge.-.


19/26

Work shop

PRECAUTIONS

-. Tools that are not being used should always be kept at their properplaces.

=. Make sure that your hands are not in front of sharp edged tools while

you are using them.A.


20/26

Work shop

rslan /han 0age *?


21/26

Work shop

EXPERIMENT 10

Mor"i0 !n& Tnon (oin"PERFORMANCE/OBJECTIVES

• To make a mortise and tenon )oint as shown in igure.




THEORY


starts from a marketable form of wood and ends with !nished products. 1t-





PROCEDURE

&&. The given reaper is checked to ensure its correct si%e.&*. The reaper is !rmly clamped in the carpenterGs vice and one of

its faces are planed by the )ack plane and checked for straightness.&'. The ad)acent face is then planed and the faces are checked for

squareness with the try(square.&+. Marking gauge is set and lines are drawn at '? and + mm, to

mark the thickness and width of the model respectively.&. The excess material is !rst chiseled out with the !rmer chisel and

then planed to correct si%e.&-. The mating dimensions of the parts H and Iare then marked

using the scale and marking gauge.&=.


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Work shop

*&. inish chiseling is done wherever needed so that, the parts canbe !tted to obtain a near tight )oint.

PRECAUTIONS

&. Tools that are not being used should always be kept at their properplaces.*. Make sure that your hands are not in front of sharp edged tools while

you are using them.'.


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Work shop

EXPERIMENT 11

S"!ir1!0 2iringPERFORMANCE/OBJECTIVES

• To study staircase wiring.


• 'J** 6W@ wires, lamp holders, two way switch, +?w bulb ' 09; casing,

strips and pliers.

THEORY

1t is that wiring which makes use of * switches to operate bulb at the

beginning of the stair lights and the bulb gives o: by pushing the button in

the end. Kne of the terminals of the bulb is connected to the main line whose

power line is connected to middle slot of twoDway switch. #emaining !rst of

there slots is connected in parallel as in crossed node. PROCEDURE

1. Plan the wiring and casing according to the circuit diagram.

. !ith the hel" of "lier and stri""ers are the ends of wire of re#uired length.

$. %onnect the wire carr&ing the current to the central "in of the two'wa& switch.(. %onnect the remaining ends ) and * to the corres"onding other two wa&s switch.

+. %onnect the center "in wire of second two'wa& switch to the lam".

,. %onnect the second "oint to the neutral for com"leting the circuit.-. se P/% case wiring to co0er e"ose wiring.

2. Switch 3N and 344 the two switches alternati0el& to the bulb.

PRECAUTIONS

&. Tools should be used carefully.*. itting should be tightly !tted.

'. ;onnection should be tight.+. Wire should be on the conduit, power gripped properly.

EXPERIMENT RESULTS

• We understood the staircase wiring.

rslan /han 0age *'

Name ______________________________ ID______________ Date ________________



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Work shop

rslan /han 0age *+


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workshop complete practical

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