Course Name : Fabrication Technology & Erection Engineering

Course Code : FE
Semester : Fourth
Subject Title : Fabrication Process
Subject Code : 9232

Teaching & Examination Scheme

Teaching Scheme Examination Scheme

PAPER
TH TU PR TH TEST PR OR TW TOTAL
HRS
04 -- 02 03 80 20 -- -- 25@ 125

RATIONALE - This subject will help the students to know the basic requirements of
fabrication & the order in which a component is prepared for fabrication.

OBJECTIVES:

The student will be able to:

• Know basic fabrication processes.

• Identify & select various marking, measuring, holding, striking/ cutting
tools in sheet metal shops.
• To know the machines used for straightening & cutting in sheet metal
works.
• GRAPHICAL STRUCTURE OF THE SUBJECT FUNDAMENTALS OF
FABRICATION PROCESS

Problems Alternative marking & measuring eg. Templates, Heat treatment

methods & distortion control.

Procedures Marking as per drawing Straightening & cutting as per

requirements drawing requirements
.

Principles Tools in measurement works. Application of forces & thermal

effects. Machines & tools in
cutting works.

Concepts Linear, angular, datum Manual, machine & thermal

measurements. straightening.
Geometric shapes. Cutting processes.

Facts Standards in measurements, straightening & shearing of sheet metals.

Chapter Description Marks Hours.
MEASUREMENT
Theory

Introduction 06 02
• Precision & Accuracy
• Sources of error
• Repeatability
• Calibration
• Sensitivity & Readability
• Classification of measurements

Standard measurement 06 02
• Introduction to standards
• Line standard
• End standard
• Angular standard
10 12
Linear Measurement
• Engineer’s rule
• Steel rule & tape
1 • Possible error with eye measurement
• Slip gauges-grades, selection of slip gauges
for required dimension, slip gauge
accessories, care and use of slip gauges.
• Vernier caliper
• Vernier height gauge
• Vernier depth gauge
• Micro meter
• Filler gauge, radius gauge, screw pitch gauge

Angular measurement 06 06
• Protractors-engineer’s protractor, vernier
protractor, universal bevel protractor
• Sine bar, Sine centre
• Angle gauges

Datum measurement
• Vertical datum-plumb line 06 06
• Horizontal datum-spirit level
• Alignment testing-use of tensioned wire,
alignment telescope, surveyor’s level
Chapter Description Marks Hours
Geometric Shape
• Straightness testing-straight edge method,
sprit level method
• Flatness testing-comparison with flat circles,
use of spirit level
• Squareness testing, engineer’s square, block 10 08
square
• Roundness measurement

Templates
• The need of templates
• Materials used for templates 04 06
• Information given on templates
• Use of templates
• Templates as means of checking
• Protection and storage of templates and tools
• Basic methods of laying out templates for
roof truss.
• Comparison of methods of direct marking and
use of templates

STRAIGHTENING METHODS
Theory: -

Mechanical Straightening:
• Manual
• Machine Straightening
II 06 05
Thermal Methods
• Hot Shrinking
• Use of heat strips
• Use of heat triangles
• Principle of hot straightening for structural
sections
CUTTING PROCESSES

Straight shearing machines
Theory :-
Basic Principles of shearing
• Shearing angle
III
• Rake angle of blades
• Clearance between cutting edges
• Actuation of moving machines (brief
description)
Straight Cutting Machines
 • Bench shearing machine 10 09
• Treadle guillotine machine
• Power guillotining machine
• Setting the guillotine
• Operation on guillotine
• Safety precaution during operation

ROTARY SHEARING MACHINE
Theory: -
Types of rotary shearing
• Parallel shaft machine
IV • Incline shaft machine 06 02
• Advantages of rotary shearing machine
• Shearing essential features

OTHER SHEARING MACHINES

Theory: -

V Nibblers (Portable) 10 06

Cropping & Notching Machine

Total 80 64

Practice: -
• Study of marking procedures

Tools used in marking

Marking methods for large size plates

Method of marking out bolt holes for flanges

Marking out a bracket from a datum surface

Procedure for marking out instrument panel

Use of chalk line for marking long straight line.

Marking of holes in angle sections, channel sections, ‘T’ sections, columns
and beams
• Study of templates

Templates for setting out sheet metal fabrications

Templates for copper plates

Box templates

Steel templates (ordinary and bushed)
Skill to be developed:

Intellectual skills

1. Ability to read job drawings.

2. Ability to estimate, identify & select proper material & tools.

Motor skills

1. Ability to prepare & use templates.

2. Ability to set tools, work piece, and machines for desired operations.

3. Ability to complete job as per job drawing in allotted time.

4. Ability to inspect the job for confirming desired dimensions and shape.

5. Ability to acquire hands-on experience

• IMPLEMENTATION STRATEGIES:

The subject matter will be taught as per the teaching scheme for Theory and practical.
The identified list of practical may be conducted along with Theory session. The subject
teacher will prepare and provide learning material/handout for supplementing/
complementing classroom instructions.

• REFERENCES:

Publisher
Year of
Author Title Edition &
Publication
Address
Kadam Manish J Metrology & Quality - - Everest Pub.
Control House
Hume K.J. Practical Metrology - - ELBS
Sharp G.H. Macdonald
& company
R.K.Jain Metrology - - Khanna
Publications
Kenyon W. Pitman Basic welding and Ist 1979 Pitman Pub.
fabrication Ltd.
F.J. M. Smith/ Basic fabrication and Ist 1975 Longman
Longman welding Engg Craft
Studies.