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Hooghly Engineering and Technology College

Vivekananda Road, Pipulpati, P.O. & Dist. Hooghly

Department of Mechanical Engineering

Workshop Practice (ME 192/292) Course Details, Theory & Assignments
Session: 2012-13

Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292)

Hooghly Engineering & Technology College
Vivekananda Road, Pipulpati P.O & Dist. – Hooghly, Pin – 712103

Department of Mechanical Engineering
Name : Year : Class Roll No. : Lab Name Ist Semester : 1st/2nd Batch : 2012-2016

University Roll No : Workshop Practice Code ME 192/292

INDEX
Sl No. 01 02 03 04 05 06 07 08 09 10 Title of the Experiment / Job Date of Experiment Date of Submission Page No

Signature of the Faculty-in-Charge

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O & Dist. Pipulpati P. Pin – 712103 Department of Mechanical Engineering LAB REPORT Lab Name with Code : Workshop Practice Title of the Experiment / Job : Name : Year : Class Roll No. – Hooghly. : Date of Experiment : 1ST Semester : 1ST / 2ND Session : 2013-2017 University Roll No : Date of Submission : Signature of the Faculty-in-Charge 3 .Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292) Hooghly Engineering & Technology College Vivekananda Road.

Classification / Major grouping. Mould. FORMING / SHAPING FROM LIQUID TO SOLID. Other casting processes (for larger volume and quality). functional principles and applications. Drilling. Applications . . Forging.General classification and basis.Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292) Workshop Practice Code: ME192/292 Contacts: 1L+3P Credits: 3 SYLLABUS 1. Drawing and Coining. JOINING PROCESSES.t. Shearing. Pouring. Sand mould casting. Drawing. Requirements. -3L 5. Physical.t. REMOVAL (MACHINING) PROCESS. Turning.CASTING.Definition. -3L B. -3L 6. Principle. Boring.Bending. Major machining parameters (and responses). Relative Advantages and Applications.r. Feed and Depth of cut. Solidification. Chemical and Mechanical properties. ENGINEERING MATERIALS. Clearance and Cutting angles). Investment casting. Pattern.25% (3 days 9hrs) • Welding (gas. Rolling. DIFFERENT CONVENTIONAL MANUFACTURING PROCESSES MAINLY COVERING BASIC PRINCIPLES. Die casting. Centrifugal casting. Threading.1L 3.procedural steps and requirements. Tool geometry (Rake. Extrusion. SCHEDULE OF PRACTICAL CLASSES Suggested apportionment / weightage: • Machining (and fitting) 50% (6 days) 18 hrs • Casting (including pattern making molding and preparation) . Arc welding. Brazing and soldering. Welding (Permanent Joining). Major grouping and Examples. Socio-economic role.Speed. Definition. General principles. Machining requirements. arc and resistance) (2 days 6hrs) and Sheet Metal Working (1 day 3hr) 25% (3 days 9hrs) 4 . . DIFFERENT METHODS AND GENERAL APPLICATIONS. General classification w. Elementary machining operationsFacing. Shaping and Milling. Press tool work. Principle and purpose of machining. Gas welding. Centering. General classification or Types of casting. INTRODUCTION TO MANUFACTURING.1L 2.r. Extracting and Fettling. Melting.3L 4. w. Manufacturing by forming /shaping from solid (input) to solid (product). Cutting fluid application. Friction welding and Resistance welding. Machine tools.

6. 10. 3. 4. 7. Make a slot (6 mm) on one parallel plane of the MS rod generated earlier as per given drawing by performing milling operation on a milling machine Forming a cone as per given drawing by performing different sheet forming and soldering operations Make a wooden pattern as per given drawing by performing different pattern making operations Making a sand mould with the pattern developed earlier by performing sand mould making operations 2.Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292) Workshop Practice Code: ME 192/292 Contacts: 1L+3P Credits: 3 ASSIGNMENTS LIST 1. 5. 8. Manufacture a gauge from MS plate as per given drawing by performing different Fitting and Bench Work operations Join two thick (6mm) MS plates as per given drawing by performing VButt joint by MMA welding Join two thin (3mm) metal sheets as per given drawing by performing Lap joint by Oxy-Acetylene Welding Manufacture a component as per given drawing by performing different machining operations on an Engine Lathe Generate two parallel planes opposite to each other from a MS rod as per given drawing by performing shaping operation on shaping machine. Cast the aluminum block as per given drawing by using the sand mould prepared earlier by performing different sand mould casting operations 5 . 9.

6’’ Divider 7. 6” Odd leg caliper 4. 12” Steel Rule. 4” Parallel-Jaw Bench vice 3. Hold the MS plate in the bench vice. 2. Ø9mm HSS Twist drill bit 18. 3. 6” Half round File 15. 250 gm Ball Peen Hammer 12. M10 x 1. 12”. Make two adjacent sides of the MS plate right angle with the help of bastard file and try square so that the performing adjacent sides can act as datum reference lines for making measurement and marking lines. Layout the flat surface by marking media chalk and water. 6” Smooth File 14. 6” Scriber 6. 500 gm Ball Peen Hammer 21. Lettering and numbering Punch 22. 4’’ Prick punch 10. 2. 12” Flat Bastard File 13. Safety Goggles Procedure: 1. 12’’ Hacksaw Frame 8.Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292) Assignment No: Title: Aim: Raw Material: ME 192/292/01 Manufacture a gauge from MS plate as per given drawing by performing different Fitting and Bench Work operations To obtain basic knowledge about different Fitting and Bench Work operations Mild steel Plate Raw Material Size: ………………………………… Tools required: 1. .18 TPI High Carbon Hacksaw Blade 9. 6” Triangular File 16. 4” Centre Punch 11. 6 4.5 HSS tap set 19. Check the size of raw material by using steel rule whether it is acceptable for performing the job as per drawing. 6’’ Try square 5. 13mm Bench Drilling Machine with drilling vice 17. Tap handle 20.

Then to produce the internal thread as per drawing tapping operation is performed by using Tap Set according to chronological order i. intermediate tap and lastly finisher tap by turning the tap two or three rotation in the forward direction followed by a half rotation in backward direction for breaking and removal of chips by Tap Wrench until the entire length of the tap enter the hole. Precautions: 1. punch etc on the floor. 9. Cut the work piece as per marking to bring the approximate size by removing extra metal with the help of Hacksaw and Bench vice. Punch the scribed lines for make the line permanent with the help of prick punch. Try square. Hold proper drill bit into the drill chuck and the job in the drilling vice. and Vernier Caliper. Switch off the Drill Machine and remove the job from Drill Vice and Drill Bit from the drill chuck. Half round file and Try Square.e. Finally the job is brought to accurate size as per drawing with the help of Bastard File. 10. Marking is done as per drawing on the laid out surface of the metal plate using different marking instruments like steel rule. Then hold the drilled plate in the bench vice rigidly with the hole in the upright position. 7. odd Leg caliper. 14. Punch roll number and branch code on the job for proper identification with the help of numbering punch lettering punch and ball peen hammer. 11. Smooth File. Then centering of job to the proper position is performed by adjusting the table. 2. Switch on the drilling machine and feed the Drill Bit manually to produce the Φ8 mm hole. Always use safety goggles. Triangular file.Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292) 5. Pour oil during tapping as a lubricant. Also verify the right angles of all adjacent sides by Try Square. Check and note the final dimensions of the job to ascertain whether it is finished according to drawing or not by using Steel Rule. 15. Apply cutting fluid during the drilling operation as per requirement. Never place sharp material such as scriber. 13. 12.5 mm). centre punch and ball Peen Hammer. 8. Here it is 8mm. try square. surface plate and scriber. 7 . 6. Calculate the Tap size drill according to the internal thread (M10 x 1. rougher tap.

Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292) Scale: 1:1 All Dimensions are in mm JOB DRAWING 8 .

Welding Table 12. 3. 4. try square odd leg caliper and Scriber. emery paper and wire brush. 4’’ Prick punch 7. 12” Steel Rule. Flat Tong 13. 2. Chipping hammer 16. Electrode (Ø 3. 8” Bench Grinder 19. Edge preparation is performed as per drawing (beveling of edges) using flat bastard file. Mild Steel Plates Raw Material Size: …………………………… Machine: AC Welding Machine Specification of the Machine: …………………………………… Tools and Accessories: 1. Lettering and numbering punch 21. Clean the surface and edges of the plates using flat bastard file. Leg guard. Anvil (25 kg / 50 kg) 17.Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292) Assignment No: Title: Aim: Raw material: ME 192/292/02 Join two thick (6mm) MS plates as per given drawing by performing V-Butt joint by MMA welding To acquire basic knowledge about MMA welding Two nos. 2.15 mm x 450 mm) 11. 12” Flat Bastard File 6. Marking the metal plates as per drawing using steel rule. Electrode holder 10. 500 gm ball peen hammer 22. 6” Scriber 8. Check the size of raw material by using steel rule and try square. Emery Cloth (100) Procedure: 1. Safety Gears ( Apron. Earthing clamp 9. 9 . and Helmet) 14. Welding shield 15. Safety Goggles 20. 4” Parallel-Jaw Bench vice 3. 6’’ Try square 5. 6” Odd leg caliper 4. Wire Brush 18. Gloves. bench vice and bench grinder.

7. Always use welding shield. Scale: 1:1 All Dimensions are in mm JOB DRAWING 10 . Do not touch the electrode or job with bare hand. Always use flat tong. Set the metal plates on the welding table (face to face making a root-gap of 1-2 mm) with proper support. numbering punch and ball peen hammer. 9. Welding is performed by maintaining proper arc speed and arc length (2-3 mm). Precautions: 1. Punch roll number and branch code on the job for proper identification using lettering punch. 4. 2. Clean the job by wire brush. Test the joint by visual observation. Finish the job by using file and bench grinder. Tack both ends of the metal plates at the sides to be joined to avoid distortion using welding machine and electrode. Always perform welding after wearing all the safety gears. Always wore safety goggles during the chipping operation. Do not perform welding operation with bare eye. 10. 12. 14. 13. Then switch on the welding machine and set the proper arc length by adjusting voltage / current. Put the welding electrode into the electrode holder and fit the earthing clamp to the welding table.Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292) 5. Cool the job in natural air. 11. Then hold the job on the anvil by using tong and after that de-slugging is done by rapid striking of the job by the chipping hammer. 6. 8. 3.

Emery Cloth (100) Procedure: 1. Anvil (25 kg/50 kg) 22. Spark Lighter 14. 4. Hoses (Blue or Black for Oxygen and Maroon or Red for Acetylene) 10. 3. . 2. Gloves.Acetylene gas welding Two nos. Hose Protector and Flash Back Arrester 21. Tip Cleaner 13. 4” Prick Punch 4” Parallel-Jaw Bench vice 6. Numbering & Lettering Punch 25. Punching Roll No. try square and Scriber.M. and Helmet) 18. Clean the surface and edges of the sheets using flat bastard file. and Branch Code in any piece of metal by using Punch and Hammer. Check the size of raw material by using steel rule and try square. Cylinder Valve Opening Key 12. 11 1.C. Marking the metal sheets as per drawing using steel rule. Flat Tong 17. 5. 13) of Welding Torch 15. 3. Welding Torch 11. 12” Flat Bastard File 8” Bench Grinder Oxygen and Acetylene Cylinders fitted with pressure regulators and pressure gauges 9. emery paper and wire brush. 8. Welding Table 20. Edge preparation is performed as per drawing using flat bastard file. Nozzle (No.S Welding Rod 16. 6”Try Square 6” Scriber 4. Safety Goggles 19. Safety Guards (Apron.Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292) Assignment No: Title: Aim: Raw material: ME 192/292/03 Join two thin (3mm) metal sheets as per given drawing by performing Lap joint by Oxy-Acetylene Welding To get basic knowledge about Oxy. Leg Guard. Chipping Hammer 23. 7. Wire Brush 24. Mild Steel Sheets Raw Material Size: …………………………… Tools and Accessories: 12” Steel rule 2. Welding Goggles. 500 gm Ball Peen Hammer 26. Metal Bucket 27. bench vice emery cloth. C. 5.

6. 11. Maintain a safe distance from the burning flame. 9. Test the joint by visual observation. The Torch and Filler Rod are moved backwards along the line to be welded. 10. 17. 7. Open the O2 Cylinder and move the O2 regulator to flow gases through the hose and use Tip cleaner to clean the carbon particle and asses from hose and Tip and then close it. After welding first close the C2H2 gas and then O2. Always transfer gas cylinders from one place to other with the help of welding trolley. if there is any leakage take preventive measure like tightening and using Teflon Tape in the position of threaded area and close it. 12. Clean the job by wire brush. 14. 19. Do not touch the job with bare hand. 15. Cool the job in the natural air. Cool the welding nozzle by dipping it in the water contained in the metal bucket intermittently to avoid back fire. Set the flame as per requirement by adjusting the acetylene and oxygen valves of the welding torch. 3. 12 . Always wore safety goggles during the cleaning operation. Release the internal gases of both the hoses by opening both the valves of blow pipe. Punch roll number and branch code on the job for proper identification using lettering punch. 13. Precautions: 1. numbering punch and ball peen hammer. Then ignite the flame by spark lighter. Always use flat tong. 20. Welding is performed by the proper flame and also maintains required welding speed.Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292) 6. Open both the Gas Cylinders slowly one by one (chronological order) with gas opening key to check internal pressure of the cylinders and then set proper welding pressure by moving the regulator cap up to the required level. 8. 7. Before welding check the leakage test of Gas Welding set up with soap water and brush. 4. Finish the job by using file and bench grinder. 18. Tack both ends of the metal sheets at the sides to be joined to avoid distortion. Never lay down the acetylene cylinder. Then hold the job on the anvil by using tong and after that de-slugging is done by rapid striking of the job by the chipping hammer. 8. 5. Always perform welding after wearing all the safety gears. 2. Close the cylinder tightly with cylinder key. Set the metal sheets on the welding table by overlapping one edge of one sheet over the surface of the other sheet at proper place as per drawing with proper support. 16.

Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292) Scale: 1:1 All Dimensions are in mm JOB DRAWING 13 .

12”Vernier Caliper 5. Centre the job with the help of Adjustable Marking Gauge by slowly rotating the chuck manually. 14 7. Hold the job firmly inside the jaws of the Chuck by tightening the jaw’s screw with the Chuck key.p. Tool Holder Key 9. Hand Gloves 15. Marker Pen Procedure: 1. Turning Tool 12. sharpness of the cutting edges etc. Place the tool holder inside the Tool Post and centre the tool with respect to dead centre by using metal seams and finally fix the position by tightening the bolts of Tool Post with the tool post wrench.m. Check the size of Raw Material by using Steel Rule and Outside Caliper. Tool Post Wrench 10. 4. 3. 6. 3 or 4 Jaw Independent/Universal Chuck 2.). Chuck Key 3. Tool Holder 8. 6”Outside Caliper 6.Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292) Assignment No: Title: Aim: Raw material: ME 192/292/04 Manufacture a component as per given drawing by performing different machining operations on an Engine Lathe To gain knowledge about operation of Engine Lathe and also about different machining operations of Engine lathe Mild Steel Rod Raw Material Size: …………………………… Machine: Engine Lathe Specification of Machine: ……………………………… Tools and Accessories: 1. feed and depth of cut for different operations required. 6”Flat Smooth File 13. 2. 5. 12”Adjustable Marking Gauge 7.) Fix the Cutting Tool inside the tool way of the Tool Holder firmly by tightening screw with the help of Tool holder key. Check the nomenclature of the tool (tool angles. Emery Cloth (100) 14. Calculate the cutting speed (r. Facing Tool 11. 12” Steel Rule 4. .

Do not touch the cutting tools and chips during the operation. Mark the Roll No. Switch on the Machine and making a flat surface at the end of the job. out Side Caliper. Do not use too much depth and feed in the time of cutting operation. 13. Produce the required Chamfer at the end of the job by performing Chamfering operation. 16. Hold the job into chuck tightly. 18. and Branch Code on the job with the Marker Pen for proper identification. Switch off the Machine and take out the job from the chuck by loosening the jaw’s screw. 20. Clean the Machine properly with Brush and Cotton Thread. 15. 5. Do not put your hands and finger inside the movable parts. Fit the opposite end of the job into chuck in a similar manner as described in 2-3. 19. Scale: 1:1 All Dimensions are in mm JOB DRAWING 15 . Produce the required Chamfer at the end of the job by performing Chamfering operation. Take out the job from the chuck by loosening the jaw’s screw. Vernier Caliper and record the deviation. 4. 12. 9. Make the end of the job flat by performing facing operation. Do not wear loose garments. 11.Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292) 8. 2. Precautions: 1. 3. 14. 17. 10. Check and note the final dimensions of the job whether it is finished according to drawing or not using steel rule. perform facing operation by advancing the facing tool perpendicular to the axis of rotation of the job (cross feed). Reduce diameters up to requisite length at different position by performing step turning operation. Finish the job for getting better surface finish by using smooth file and fine emery cloth. Reduce the diameter of the job up to requisite length as per drawing by performing rough turning followed by finish turning by advancing the turning tool along the axis of rotation of the job (longitudinal feed).

Double Ended Spanner 16. 12” Vernier Caliper . Out Side Caliper and Vernier Caliper. Mild steel rod. Scriber 11. Mark the job as per drawing keeping it on the Surface Plate using Steel Rule. 2. 12” Vernier Height Gauge 5. V block 6. 6” Try Square 7. Make the marking permanent by Prick Punch and Ball peen Hammer. 6” Out Side Caliper 8. Hand Gloves Procedure: 1. 16 2. Fix the cutting tool into the tool holder with the help of tool key and after that hold the tool holder into the tool head of the Clapper Box rigidly. 250 gm Ball Peen Hammer 10. 6. 500 gm Ball Peen Hammer 19. 12” Steel Rule 3. Try square. Single Point Shaping Tool 14. sharpness of the cutting edges etc. Vernier Height Gauge and Scriber. Check the size of raw material by using Steel Rule. 2’x 2’ Surface plate 4. Check nomenclature of the cutting tool (tool angles. 4. Lettering & Numbering Punch 18.Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292) Assignment No: Title: ME 192/292/05 Generate two parallel planes opposite to each other from a MS rod as per given drawing by performing shaping operation on shaping machine. Machine Vice & Vice Handle 12. Adjustable Spanner 17. Fix the job rigidly on the Machine Vice of the Shaping Machine and level it by spirit level. 3.). 4” Prick Punch 9. Tool Holder & Tool Key 13. Aim: Raw material: Raw Material Size: …………………………… mm Machine: Plain horizontal Cone Pulley Type Shaping Machine Specification of the Machine: ……………………………… Tools and Accessories: 1. 5. To acquire knowledge about the operation of Shaping machine. Spirit Level 15.

4. After generation of one plane. Precautions: 1. Check and note the final dimensions of the job whether it is finished according to drawing or not using Try Square and Vernier Caliper. generate the other one by following the same operations mentioned above (4-11). Adjust the length of stroke and position of ram with the help of ram control lever according to job length. 13. 12. Adjust the depth of cut by moving down the feed screw of the tool slide. numbering punch and ball peen hammer. 2.Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292) 7. Always use hand gloves. 15. 11. Punch roll number and branch code on the job for proper identification using lettering punch. 8. 10. Scale: 1:1 All Dimensions are in mm JOB DRAWING 17 . Do not put your hands and finger inside the movable parts. Align the job with respect to the table by moving the table horizontally and vertically. 9. Repeat the above operations (9-10) until required depth is achieved as per marking. 3. 14. Switch on the machine and enter the feed to the job under the reciprocating cutting tool by moving the table manually/automatically and complete the cut. Hold the job into Vice tightly. Do not wear loose garments. After competition of the machining as per drawing switch off the machine and remove the job from machine vice.

4” Prick Punch 6. Spirit Level 11. 12” Vernier Height Gauge 10. Try square. Check the sharpness of the Milling Cutter. Fix the job rigidly on the Machine Vice of the Milling Machine and level it by spirit level. 6. 250 gm Ball Peen Hammer 7. 2. Make the marking permanent by Prick Punch and Ball peen Hammer. Mark the job as per drawing keeping it on the Surface Plate using Steel Rule. Adjustable Spanner 14.…………………………… mm Machine: Column and Knee type Universal Milling Machine Specification of the Machine: ……………………………… Tools and Accessories: 1. Double Ended Spanner 13.Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292) Assignment No: Title: ME 192/292/06 Make a slot (6 mm) on one parallel plane of the MS rod generated earlier as per given drawing by performing milling operation on a milling machine To acquire knowledge about the operation of Milling machine and also production of slots by milling machine Mild steel rod Aim: Raw material: Raw Material Size: . 6” Try Square 4. 500 gm Ball Peen Hammer 17. 2’x 2’ Surface plate 9. 6” Out Side Caliper 5. 4. Insert the Milling Cutter into the arbor & fix it by tightening the nut. Check the size of raw material by using Steel Rule. 3. Out Side Caliper and Vernier Caliper. Place the job below the cutter and place it appropriate position by adjusting the table by rotating cross feed handle and longitudinal feed wheel.25”X1” Plain Side Milling Cutter 15. 5. Lettering & Numbering Punch 16. 12” Vernier Caliper 3. 12” Steel Rule 2. 3. Hand Gloves Procedure: 1. 7. Scriber 8.. 18 .5”X0. Vernier Height Gauge and Scriber. Machine Vice & Vice Handle 12.

switch off the Machine and remove the job from the Milling Vice. Do not put your hands and finger inside the movable parts. Scale: 1:1 All Dimensions are in mm JOB DRAWING 19 . Hold the job into Vice tightly. 3. After completion of the milling operation. numbering punch and ball peen hammer. Switch on the Machine and coolant Pump and give required feed to the job under the rotating cutter by moving the table manually /automatically and complete the cut. 9. 11.Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292) Set the desired depth of cut by adjusting the knee by rotating the knee elevating handle. Precautions: 8. Punch roll number and branch code on the job for proper identification using lettering punch. Check and note the final dimensions of the job whether it is finished according to drawing or not using Try Square and Vernier Caliper. Do not wear loose garments. 2. 10. 13. 1. 12. Repeat the above operations (8-9) until the required depth is achieved.

Develop the pattern of the cone) on the GI sheet. by Steel Rule. 6”Scriber 3. Marker Pen 6. Fold edges of the sheared sheet and then bend the sheet according to the development of surface with the help of funnel stake and ball point hammer. Flux (ZnCl2) Procedure: 1. 7. Flatten the GI Sheet by Mallet Check the Dimensions of GI Sheet by steel rule.220-230V Soldering Iron 3. 6”Pliers 9. Solder 7. 6”Divider 8. 240W. 5 mt. 8. G. solder and requisite amount of flax. 25 mm Outside Micrometer 6. Sheet Raw Material Size: …………mm X……………… mm X…… SWG Tools and Accessories: 1. 18”Straight Snip 10. 6”Try Square 7. Clean the job properly. Ball Peen Hammer 2. Try Square. Divider. 6. 12”Steel Rule 5. Mallet 2. and Scriber. 5. 2. Extension Cord 4. 4” Parallel-Jaw Bench vice 4. . Check the final Dimension of the Funnel whether it is finished according to 20 3. Solder the joint of the cone by using soldering iron. Also measure the thickness by outside micrometer and find out the corresponding Standard Wire Gauge number (SWG) from standard table.Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292) Assignment No: Title: Aim: Raw material: ME 192/292/07 Forming a cone as per given drawing by performing different sheet forming and soldering operations To acquire essential knowledge about Sheet metal working and soldering. Join (Double Seam) the folded edges of the funnel. 250 gm. providing allowances for bending and forming. Cutting the GI Sheet as per developed surface (laid out pattern) by shearing with the help of snip. 9.I. Hand Gloves 5. 4. Funnel Stake 1.

Do not handle the cut pieces with bare hand. Precautions: 1.Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292) drawing using Steel Rule and record the deviation. Always use hand gloves Do not forget to straighten the sheet metal pieces (Laid out pattern) after shearing. 10. 2. Scale: 1:1 All Dimensions are in mm JOB DRAWING 21 . Mark Roll Number on the job with the help of Marker Pen for proper identification.

7. Check the accuracy of final dimensions as per drawing 8. Wood is a softer material so during handling the job during its operations care should be taken so that job surface is not damaged by different hand tools 22 . Mark roll number for proper identification using marker pen. Precaution: 1. 10. Marking is done on the plane surface according to drawing with the marking gauge. Firmer Chisel and Mallet. 2. pencil and try square. Sawing and chiseling wooden piece according to the drawing using Cross-cut Hand Saw. Using belt sander machine finish the tapered portions. steel rule. 4. 3. Check the initial dimensions of the wooden piece by four fold wooden rule /steel rule. 7. Final finishing and polishing of the job is done by using sand paper. 12. Hold the wooden piece in the carpentry vice and all the surfaces excepting two ends are planned as per drawing and are also right angled to each other by using jack plane. 5. 2. 9. 4. 6. 2’ Four Fold wooden Rule / 12” Steel Rule 9” Carpentry Vice 12” Iron Jack Plane 6” Try square Marking Gauge Pencil 18” Cross-cut Hand Saw 12” Tenon Saw 1” Firmer Chisel Mallet Sand Paper Marker Pen Procedure: 1. To obtain basic knowledge about pattern making. steel rule and try square. 11. 6. 5. Gamari Wood Raw Material Size: …………………………… mm Machine: Belt and Disc Sander HP: RPM: Specification of Machine: Size: Tools and Accessories: 1. 8. 3.Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292) Assignment No: Title: Aim: Raw material: ME 192/292/08 Make a wooden pattern by performing different pattern making operation. Tenon Saw.

5% Draft Allowance: 1° Scale: 1:1 All Dimensions are in mm JOB DRAWING 23 .Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292) Assuming: Shrinkage Allowance: 1.3% Machining Allowance: 2.

Sprue Pin 9. Facing Sand. Bellow 8. Moulding Flask (Cope and Drag parts) 5. Riddle 2. Upper surface of the drag box is smoothened and leveled with the edges of the 24 . 4. Drag part of the moulding flask is placed on the moulding board. Strike off Bar 7. French chalk and Water. Riser Pin 10. Cleaning Brush 17. The half portion of the given Split Pattern is placed at a convenient position within the moulding flask keeping space around all the sides. Then the box is filled with the prepared green sand by using shovel. Raw Materials: Tools and Accessories: 1. All mixing is done with the help of shovel. Lifter 14. 3. Facing sand is sprinkled over the board and pattern. Vent Rod 11. During this process to avoid dryness of the green sand suitable amount of water is added. Slick 15. To improve bonding strength. Gate Cutter 13. Water Mug Procedure: 1. 5-6% coal dust and 2-3% yellow dextrin are added as additives. 2. During filling the green sand is rammed properly with the Rammer to facilitate the adherence of the sand to the surfaces of the box. gating system design. Green sand for moulding is prepared by mixing Silica sand with 8-12% bentonite and 2-3% water. Yellow Dextrin. Rammer 6. To gather knowledge regarding different mould making tools. core making and green sand moulding The pattern developed earlier as per drawing. 5. Shovel 3. Parting Sand. Then the prepared green sand is screened by Riddle fitted with coarse and medium mesh size wire mesh in order to remove the impurities. Bentonite Powder.Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292) Assignment No: Title: Aim: ME 192/292/09 Making a sand mould with the pattern developed earlier by performing sand mould making operations. Trowels 16. Draw Spike 12. Moulding Board 4. Coal Dust. Green Sand.

21. Then French chalk dust is spread all over the mould cavity and runners. Then Sprue and Riser Pin are removed carefully. of the mould is properly repaired with the help of slick and lifter. 7. Then using Gate Cutter. 11. 14. Then the defective part. Ramming should be done properly to get the required rigidity of the sand mould. sprue and riser pins so that any portion of the mould is not damaged during removal. 2.off Bar. 16. Then a funnel shaped hole (called pouring basin/cup) is made at the top of the Sprue hole. if any. Precautions: 1. Then the cope and drag pattern halves are withdrawn by using Draw Spike after shaking properly. 10. small holes are created in the rammed sand for providing paths for removal of gases. Sprue pin and Riser pin is placed at proper place for forming the sprue and riser. 8. Then another moulding board is placed on the drag box and the box is turn upside down with bottom board. Then parting sand is sprinkled over the cleaned upper surface. Care should be taken during removal of pattern. Then the Cope part of the moulding flask is placed properly on the drag part. Then the cope is separated from the drag and any loose sand on the cope and drag interface of the drag is blown off with the help of bellow. Then the upper board is removed and the upper surface is cleaned by removing loose sand particles by blowing air by using Bellow 9. gates and runners are cut in the drag part of the mould. Then by using a Vent Rod. 25 . 13. 15. 12. Thus the sand mould for a pattern is made.Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292) drag box by removing excess sand by using the Strike. which is ready for pouring the molten metal. 17. 20. 6. Then any excess or loose sand in the runners and mould are lifted up by lifter and then blown off by Bellow. Then the cope box is also filled with green sand in a similar way like the drag box (Step 3-6). Then water is gently spread over the repaired portion and the portions adjacent to the pattern of the mould carefully without damaging the mould 18. Then the other half portion of the Pattern is placed on the first half portion of the Pattern already fitted in the drag box. Then the cope part is placed on the drag part taking care of the alignment of the two by means the pins. 19.

10. which is floating on top. 400V. Hand Gloves. Pouring is continued till riser is filled up with molten metal.5 kW. 4. 8. 2. 8” Bench Grinder 7. with a slotted steel spoon and turn off the furnace. Crucible 2. 10. Put required amount of Aluminum ingots and scraps inside of the Crucible. Set the furnace temperature at 750 0C and set the furnace heating regulator at 100. 3ph. 12”Vernier Caliper 8. Cover the charge within the crucible with the requisite amount of coverall flux. 12” Hacksaw Frame fitted with 12”. When melting is complete then remove lid. 12. Wait for a considerable time of at least 1 hr for solidification of molten metal within the mould cavity. Open the lid of the furnace and place the crucible into the furnace. Procedure: 1. 12”Steel Rule 9. Take out the crucible with the help of flat tong. Lettering punch 12. 13. 6. Flat Tong 4.Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292) Assignment No: Title: ME 192/292/10 Cast the aluminum block as per given drawing by using the sand mould prepared earlier by performing different sand mould casting operations To obtain basic knowledge about sand casting Aluminium Ingots and Scraps Coverall 11 Flux Electrically Heated Pit Furnace Capacity: 10 kg of aluminium melting Max Temperature: 900°C Aim: Raw Material: Consumable: Machine: Make: PSP Traders Power: 4. 3.18 TPI High Carbon Hacksaw Blade 6. Refractory Bricks 5. Wait until the furnace temperature rise up to 750 0C and it is indicated by a glowing yellow light. 7. 5. Open the lid of the furnace and check the melting conditions of the charge and extent the melting if required. 26 . 50 Hz Tools and Accessories: 1. Then Pour the molten metal into the pouring basin and metal flow into the mould cavity through gate via sprue and runners. Then reset the furnace heating regulator at 80. 9. Numbering . Slotted steel spoon 3. 500 gm Ball Peen Hammer. scoop off slag. Then close the furnace with its lid and switch on the furnace. 14. Then crush the mould and taking out the casting. Safety Goggles 11. 11. Leather Apron 11.

Hooghly Engineering & Technology College Department of Mechanical Engineering Workshop Practice (ME 191/ 292) 15. During pouring keep mould on the refractory brick to prevent leaking. 16. 3. Always keep safe distance from the heat of the Furnace. riser and other unnecessary projections by using hacksaw blade and cleaning of the surfaces by grinding. is performed. Scale: 1:1 All Dimensions are in mm JOB DRAWING 27 . After that necessary fettling operation. 4. During pouring handle molten metal carefully. 2. Punch roll number on the job for proper identification with the help of numbering and lettering punch. Always use leather apron and hand gloves. 17. Precautions: 1. that is removal of gates. Checking of final dimensions by steel rule and vernier caliper according to drawing.