International Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering Course Title: Workshop Practice LAB e ME-112L None Credit Hours: 02 Course Object This course is imperative for the Engineering undergrads to accrue their knowledge domain and to develop their understanding regarding different Workshop stations/Facilities as well as to develop their hands-on experience on various tools and machines with ensuring safety measures. The course focuses and targets to enhance their cognitive and psychomotor skills. At the end of this course, students will be able and understand to use workshop facility in their Engineering Projects. Course Learning Outcomes (CLOs) Al the end of course, student will: Daal 0 | CLOs Statements Level | PLO | Domain | Copy basic operations on different machines/tools P3 [04 __| Psychomotor — Az [08 _ | Affective Follow safely rules while performing different experiments, ‘Learn how to work as a (am member or ag a (eam leader while doing 09 | Psychomotor workshop-projects and performing, combine tasks,International Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering LIST OF EXPERIMENTS Introduction to workshop Lab, Safety rules 1 to study Vernier caliper and micro meter. OTH TENNIS HHT ALYY (AKO (ALYY | Celie} 2 3 in Workshop and To study different tools used single open-end wrench spann in fitting shop and to construct a ner in fitting shop. spanner in fitting shop. To continue the construction of a single open. nd wrench To study different tools in wo ¢ifferent joints of woods (a) Lap joint (b)Dado joint (c) wood block joint (d) miter joint, sodshop and to construct To study different tools used ii Butt joints in welding shop th in welding shop and to perform rough sheet metal are welding. To perform (a) Tee joint (b) comer welding shop through sheet metal arc welding Joints (c) Lap joint in To study different tools used i mold for Casting in foundry shop and to make To cast 4 pattem in foundry shop (Open end Mold) 10 iW i2 To study different tools in ele and parallel circuit, clric shop and to make a series To study various parts of Lath ueving (b) facing operations o ‘machine and to perform (ay on Lath machine. © perform (a) taper turning (b) threa knurting (e) C To perform di off operations on Lath machine, ing, boring, operations and int vg (c) chumfering (ayInternational Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering Student Learning Outcome: Students who pass the course will gain the knowledge about Workshop equipment’s. (ol ifo}s STs ORT "Rubrics Marks during Lab 7 Viva Voce Exam 20 7 7 v | Final Exam 40 a v v Total Marks Distributions 100 333 333 333 } Total Marks - 100International Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering SAFETY IN THE WORKSHOP AW hand and machine tools ean be dangerous if used improperly or carelessly. Working safety is one of the first things a student should learn because the safe way is usually the corteet and most efficient way. A person leaming to operate machine tools must first Team the safety regulations and precautions for each tool or machine. Far too many accidents are caused by careless work habits. It is easier and much more sensible to develop safe work habits then to suffer the consequences of an accident Accidents don’t just happen; they are caused. The cause of an accident can usually be traced to carelessness on someone's part. Accidents can be avoided, and a person learning the machine tool trade must first develop safe work habits. A Safe Worker Should 1. Be neat, tidy, and safely dressed for the job. 2. Develop a responsibility for personal safety and the safety of fellow workers. 3. Think safely and work safely at all times. Safety in the Shop Safety in the shop may be divided into two broad categories J. Those practices which will prevent injury to workers 2. Those practices which will prevent damage to machine and equipment. Too often damaged equipment results in personal injuries Jn considering these categories, we must consider personal grooming, proper e), safe work practices and fire prevention. housekeeping (including machine maintena Personal Grows ny The following rules should be observed when working in machine shop. 1. Always wear approved safely glasses in any area of the machine shop. 2. Never wear loose clothing when operating any machine, Always roll up your y should be made of hard, smooth material sleeves or wear half sleeves, ClotInternational Islamic University, Islamabad Ete (Uy Faculty of Engineering and Technology wa 9 Department of Mechanical Engineering & that will not catch easily in the machine, Loose fitting sweaters would not be worn far this reason, Remove wrist watches, rings, and bracelets; these can be caught in the machine, causing painful and offen serious injury. 4. Never wear gloves when operating a machine. Long hair must be protected by a hair net or approved protective shop cap. & Canvas shoes o open-toed shoes must never be wor in a machine shop because they offer no protection (o the feet against chips or filling objects Housekeeping ‘The operator should remember that good housekeeping will never interfere with safety or efficiency; therefore, the following points should be observed 1. Always stop the machine before you attempt to clean it, 2. Always keep the machine and hand tools clean, Oily surfaces can be dangerous Metal chips left on the table surface may interfere with the safe clamping of a work piece. 3. Oily surfaces should be cleaned with a cloth. Do not keep tools and materials on the machine table- use a bench near the machine, Keep the floor free from oil and grease. 6. Always use br ish and not a cloth to remove any chips. Sweep up the metal chips on the floor frequently. They become embedded in the soles of the shoes and can cause dangerous slippage if'a person ws floor. alks on concrete Safe Wark Practice 1, Do not operate any machine before understanding ils mechanisin and knowing how to stop it quickly. Knowing how (o stop a muchine quickly can prevent a serious injury, Before operating any machine, be sure that the safety devices are present,International Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering 1 Always disconnect the power and lock it off at the switch box when making Place a sign on the machine noting that itis out of order. repairs fo any machi 4. Abways be sure that the culting tool and the work piece are properly mounted before starting the machine. Keep hands away from moving parts. It is dangerous practice to stop the macl by hand, 6. Always stop a machine before measuring, cleaning or making adjustments. It is dangerous to do any type of work around moving parts of machine. 7. Never have more than one person operate a machine at the same time. 8. Get first aid immediately for any injury, no matter how small. Report the injury and be sure that the smallest cut is treated (o prevent the chance of serious infection 9. Before you handle any work piece, remove all burrs and sharp edges with a file. 10. Do not attempt to lift heavy or old-shaped objects which are difficult to handle on your own. 11. Be sure the work is clamped securely in the vise or to a machine table. 12, Whenever work is clamped, be sure the bolts are placed closer to the work piece than (o the clamping blocks. 13. Never start a machine until you are sure that the cutting tool and machine parts will clear the work piece. Pire Prevention 1. Always dispose off oily rags in proper metal containers. Be sure of the proper procedure before lighting a gas furnace. her in the shop. Know the location and the operation of every fire extingt Know the location of the nearest fire exit from the building, Know the location of the nearest fire-alarm box and its operating procedure. 6. When using a welding or hy, bo sure ( direct the sparks away from any combustible material, siting |International Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering WORKSHOP RULES AND REGULATIONS Students Guidance for the Rules Regarding Labs The students are advised to note the following rules regarding the workshops. The safety rules in the workshops must be strictly observed. Must come to the workshop on time.. Must actively participate in performing the experiments, and should also take an active role in writing a group report. The report must be submitted by a team leader selected for each report. General Rules The workshop timetable must be strictly followed. Be punctual for your workshop session. Experiment must be completed within the given time. Respect the workshop and its other users. Noise must be kept to a minimum level, Workspace must be kept clean and tidy at all time. Handle all apparatus with care. All students are liable for any damage to equipment due to their own negligence. All apparatuses and tools must be retumed to their original place after use. Students are strictly prohibited from taking out any items from the ‘workshop, Please consult the workshop supervisor if you are not sure on how to Operate the workshop equipment. Report immediately to the workshop supervisor if any injury occurred. Report immediatoly to the workshop supervisor any damages to equipment. Please check tho workshop notice board regularly for any update and announcement, Foods, drinks and smoking are nol allowed. All bags must bo left al tho indicated placo.International Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering VERNIER CALIPER - MANUAL VERSION be used (0 measure internal and The Vernier Caliper is a precision instrument that extemal distances extremely accurately. The example shown below is a manual caliper. Measurements are interpreted {rom the scale by the user. This is more difficult than using a digital Vernier Caliper which has an LCD digital display on which the reading appears. The manual version has both an imperial and metric scale. Manually operated Vernier Calipers can still be bought and remain popular because they mn the digital version. Also, the digital version requires a small are much cheaper th n does not need any power source. battery whereas the manual vei INTERNAL r Lockie Sas Loca \ Ar __- IMPERIAL SCALE \pe re 0 “> METRIC SCALE DEPTH MEASURING BLADE EXTERNAL JAWS: Mow To Read A Measurement From The Seales txampleill: ‘The external measurement (diameter) of a round seetion piece of steel is per, metric seale. measured using, a Vernier Caliper, shows that there are 13 whole the first number is 13. J. ‘The main metric scale is read first and thi divisions before the 0 on the hundredths scale, Therefore, cule is then read, Only one division on the main metric it, whilst others do 2. ‘The ‘hundredths of seale lines up with a division on the hundredths seale below hot. In the example below, the 21st division on the bundredihs seale lines up exacly with a division onthe metric scale aboveInternational Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering 3. This 21 is multiplied by 0.02 giving 0,42 as the answer, 4. The 13 and the 0.42 are added together to give the final measurement of 13.42mm {the diameter of the picce of round section steel), EXAMPLE 41 13421%0,02 2) (1340.42 13.42mm (final answer) 41 13 +41x002 13 +002 {| __13 82mm (fina! answer) a Oe ee ee Ht pl Hatt iii settee ied ales HUNOREDTHS OF mm EXAMPLE #2 19 32 | 19 + 32x0.02 Sa een , on oe 19 + 0.64 atealolali ly yal say una u 19.64mm (final answer) MAIN METRIC SCALE, HUNDREDIHS of mimTe i ic Uni International Islamic University, I: go ©) Faculty of Engineering and Tect SS Department of Mechanical Engit VERNIER CALIPER EXERCISE QUESTION 1: ANSWER, 3a in . G Sa _ sealieysfunateseT nti ihe gale MAIN METRIC SCALE HUNDREDTHS of mm QUESTION 2: ANSWER: 4 102003 5 6 7 Jyootyad usta A sythunptihy ea 1 eT ioe MAIN METRIC SCALE HUNDREDTHS of mm QUESTION 3: mal HUNDREDTHS OF mun i MAIN METRIC SCALEInternational Islamic University, tslamabay Faculty of Engineering and Technology Department of Mechanical Engineering DIGITAL VERNIER CALIPER that can be used to measure internal and nple shown below is a digital Vernier the Vernier Caliper is a precision instr icly. ‘The e Caliper asthe distances are read from LCD display. The most important parts have been labeled. Earlier versions of this type of measuring instrument had to be read by He and there was a need for very good eyesight in order to extremely aceura extemal distances looking carefully at the imperial or metric s ‘ead the small sliding scale, The digital version requires a small battery, “r 10 use as the measurement is clearly displayed and Digital Vernier calipers are also. by pressing the incl/mm bution the distance can be read ay metric or imperial. ERNE BGRRICANCH LOCKING 7 SANS / >) BUTTON SCREW ~l\ LOD OISPLAY _— scaLe ri Ty tit idtstttiiiiite DEPTH MEASURING BLADE EXTERNAL IKUG The display is turned on with the on/alT button, ‘The extemal jaws should then be brought ‘eeether until they touch and the zero button Hhould be pressed. ‘The Vemiier Caliper can then be used to men , be used t measure distances, Always wo through this procedure when tuming on the ‘splay for the first time,International Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering Measuring Paternal Distances the bcouglt together, The locking screw is tightened so that the jaws do not move apart. The atenal ty be measured és placed between the extemal jaws and they are carefully ughial display’ can then be read, The distance can be read by in metric and imperial by ppeessing the inch mn button. Measuring Internal Distances The example below shows a Vernier Calipers being used to measure the internal diameter of a piece of copper tube. The internal jaws are adjusted carefully until they touch the internal ‘sides’. The locking screw is tightened so that an accurate measurement can be made even if the jaws are ‘knocked” against the sides as the jaws are removed from the hole. The measurement is shown on the LCD display.Ww gouty International islamic University, Islamabag Fe © Faculty of Engineering and Technolog, Wt ss Department of Mechanical Engineering Measuring Depths Measuring the depth of a hole can be very difficult, However, using a Vernier Caliper makes this task easy. The base of the Vernier Caliper rests on the top of the hole and the depth measuring blade is adjusted until it touches the bottom of the hole. The locking screw is tightened and the measurement can be read on the LCD display.“ ( 1 International Islamic University, Islamabad (CO) Faculty of Engineering and Technology S Se y Department of Mech; ‘anical Engineering MICROMETER the micrometer is @ precision measuring instrument, used by engineers. Each revolution wf the Gichet moves the spindle face 0.5mm towards the anvil fa face. The object to be messured is placed between the envil face and the spindle face, The rachet is tured stockwise until the object is trapped" betwe (hese two surfaces and the rachet makes a “ehching® noise. This means that the measurement can be read. rachet cannot be tightened anymore and the (ILL SRIRDLEC SIINDELE WOUK SLEEMETIIMBEIBLE RACKET FROTE FACE ) usr | Example Measure Readings Using the first example seen below: J. Read the seale on the sleeve, ‘The example clearly shows12 nm divisions. 2. Still reading, the scale on the sleeve, a further % mm (0.5) measurement can be seen on the bottom hall of the scale, ‘The jeasturement now reads 12.Smm., 3. Finally, the thimble seule shows 16 full divisions (these are hundredths of a mim) the final measurement is 12.5mm 4 O.1omm= 12.66International Islamic University, Islamabad & 7D) "Faculty of Engineering and Technology Department of Mechanical Engineering SLEEVE READS FULL mm = 17.00 SLEEVE READS %mm = 050 THIMBLE READS = 016 TOTAL MEASUREMENT = 12 66mm SLEEVE READS FULL mm= 16.00 SLEEVE READS % min THIMBLE READS TOTAL MEASUREMENT 0.355 16 355mmInternational Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering / DEPTH GAUGE MICROMETER The depth gauge micrometer is a precision measuring instrument, used by engineers to sneesure depths. Each revolution of the rachet moves the spindle face 0.5mm towards the bemoan of the blind hole, The diagram below shows how the depth gauge is used. The et is turned clockwise until the spindle face touches the bottom of the blind hole. ‘The scales are read in exactly the same way as the scales of a normal micrometer (see previous information sheets). j+— SLEEVE SPINDLE © SPINDLE FACEMICROMETER EXERCISE ANSWER. ANSWER. ANSWER:international Islamic University, 'slamapay Foren Faculty of Engineering and Technology & (yy) Department of Mechanical Engineering GNC) 8 S45 We & BENCH VISE cd for holding or clamping a work piece to allow Vise isa nechanical serew apparatus ; destolens work to be performed on it with tools such as sawing, chipping, filing, polishing, drilling, reaming, and tapping operations. Vises usually have one fixed jaw and another parallel jaw which is moved towards or away from the fixed jaw by the screw, HARDENED STEEL Vises are mounted close to the edge of the bench. They permit long work to be held in vertical position. Vises may be made of cast iron or cast steel. Vise size is determined by the width of the jaws. Kinds of vise 1. Hand vises (hand-held). 2. Machine vises - drill vises (lie fat on a drill press bed). Vises of the same general form are used also on milling machines and grinding machines. 3. Compound slide vises are more complex machine vises. They allow speed and precision in the placement of the work. 4, Off-center vises, 5. Angle vises, 6. Sine vi which use solving triangles and gauge blocks to set up a highly accurate angle, 7. Rotary vises, 8. Die makers! vises. 9. ‘Table vises, 10, Pun vises (for holding thin, long cylindrical objects by one end).International Islamic University, Islamabad Faculty of Engineering and Technology Pepartment of Mechanical Engineering HAMMERS The name hammer has also b used for devices that are designed to deliver blows, {tis # Sel meant to deliver an impact to an object. The most common uses are for driving pails Ging parts, and breaking up objects. Hammers are often designed for a specific purpose, and widely in their shape and structure, Usual features are a handle and a ead, with most of the weight in the head. Many different types of hammers are used by the machinist. The most common being the ball-peen hammer. The larger striking surface is called the face, and the smaller rounded end is called the peen. Sofi-faced hammers have heads made of plastic, copper, or lead. These heads are fastened to a steel body and can be replaced when worm. Soft-faced hammers are used in sssembling or dismantling parts so the finished surface of the work will not be marred. PEEN ction with ham ‘Tools used in con| ier for spiting wood. 1. Wood splitting wedye - hit with a hu Chisel Punch Anvil'nternational Islamic University, Faculty of Engineering and Te Department of Mechanical En, Islamabad chnology gineering CE RE AND DOT PUNCH the center punch is made from mild steel with the point hardened and tempered so that it Sustands impact with the material it is marking. Itis normally used to mark the center ofa hole to be drilled cither by hand or on the drilling machine, CENTRE — DOT PUNCH =~ PUNCH The dot punch is a lighter and thinner version of the center punch and is used basically for the same job. However, it is more accurately as the dot produced is smaller. ir e a ris used to fsoth the center and dot punches are used in the same way. A ball pin hammer tap the head of the punch and this deliv fc i cl yu a enough force to the point of the punch to p smaJ} indentation into the surface of the material,International Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering % TRY-SQUARE he engincers ay-square is composed of two parts, the stock and the blade, They are usually made foo bright mild steel with the blade being hardened and tem, ipered so that it resists damage, It js ‘ally used during engineering / metalworking projects Je the example seen below, the iry-squa ae is used (0 test that a 90 degree tee OF the steel. Although a bure exists on the edge of the steel, | it fits into the stot and does not affect the way the try-square ix used angle exists across the A TRY-SQUARE,International Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering a7 Faculty of Mechanical Engineering ME 112 Lab Workshop Practice Experiment # 02 FITTING SHOP TOOLS AND ACCESSORIESInternational Islamic University, ee Faculty of Engineering and Technology Department of Mechanical Engineering 2% FITTING SHOP ‘here are various types of tools used in fitting shop. 1. Bench vise and its types Hacksaw File (tool) and its types Scriber Chisel Other tools and accessories Paha Bench vise: A vise or vice is a mechanical screw apparatus used for holding or clamping a work piece to allow work to be performed on it with —tools such as saws, planes, drills, mills, screwdrivers , sandpaper, etc. Vises usually have one fixed jaw and another, parallel, jaw which is moved towards or away from the fixed jaw by the screw. Types of Bench vise: Without qualification, "vise" usually refers to a bench vise with flat, parallel jaws, attached 19 @ workbench. There are two main types: a woodworking vise and engineer's vise. The woodworker's bench vise main characteristic is its integration into the bench. Hacksaw: #hacksawis a fine-tooth saw with a blade under tension in a frame, used for cutting materials such as metal or plastics. Hand-held hacksaws consist of a metal arch vétn @ handle, usually a pistol grip, with pins for attaching a narrow disposable blade. A Screw oF other mechanism is used to pul the thin blade under tension. The blade can be mounted vith the teeth facing toward or away from the handle, resulting in cutting action £0 either the push or pull stroke. On the push stroke, the arch will flex slightly, decreasing the tension on tho blade. Fig. hacksawFaculty of eng) Department of Mechanical Engineering 29 A file is a Mmetahvorking and woodworking tool Used to cut fine amounts Sk Piece I most commonly rofors to tho hand 001 style, which take: @ steel bar with a caso hardoned surlaco and a series of sharp, parallel ter have a Parow, pointed tang at ono ond to which a handle can be fitted, % the form of eth. Most files come in a wide varioly of materials, sizes, shapes, cuts, and tooth configurations, The orss-section of a file can bo lat, round, hall-round, triangular, square, knife edge or * & more specialized shape. Thero is NO unitary international standard for file enclature; however, there are many Senerally accepted names for certain kinds of files, The cut of the file refers to how fine ils teeth are. They are defined as (from roughest to ‘crming diamond. In Swiss-paltern files the teeth are. cut at @ shallower angle, and are sraded by number, with a number 1 file being coarser than a number 2, etc. Some of the common shapes and their uses: * Mill files are the'most common shape; they are rectangular in cross section and taper Slightly in both width and thickness from tang lo end. They are all single-cut * Hand files are parallel in width and tapered in thickness: they are used for general * Half round ring files taper in width and thickness, coming to a point, and are narrower ‘han a standard half round. Used for filing inside of rings. * Checkering files are parallel in width and gently tapered in thickness. They have teeth cat in a precise grid pattern, and aro usod for doing checkering work, 2s on gunstocks. * Knife files aro tapored in width and thickness, but the knife edge has the same thickness the whole length, with tho knife edge having an arc to il. Used for slotting or wedging operations. * Square files aro gradually tapored and cut on all four sides. Used for a wide variety of things. * Three squaro files, also callod trlangular fllos, havo a triangular cross-section, which usually gradually tapers. Some filos tapor all the way to a point (especially small ones)International Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering 30 Three square files aro used for many cuts, such as cutting angles less than 90 degrees. Round files, also called rat-tail files, are gradually tapered and are used for many tasks that require a round lool, such as enlarging round holes or cutting a scalloped edge. Round parallel files are similar to round files, except that they do not taper. Shaped like a toothed cylinder. Seriber: Aseriberis ahand tool used in metalworking to mark lines on work pieces, prior fomachining. The process of using a scriber is called scribing and is just part of the process of marking out. It is used instead of pencils or ink lines, because the marks are Ferd to see, easily erased, and inaccurate due to their wide mark; scribe lines are thin and semi-permanent. On non-coated work pieces marking blue is commonly used to increase the contrast of the mark lines. They are a rod with a tip made of cast steel that has been hardened and tempered. The gent is sharpened to an angle of 30 or 40 degrees. Some scribers have a point at both £095. Itis used by drawing the point over the surface of the work piece to leave a shallow scratch on its surface. Fig. scribors{nternational Islamic University, Islamabad Faculty of Engineering and Technology Department of mechanical Engineering @ hard material such as Wood, stone, or metal, The handle and blade of s chisel are made of metal or wood with a sharp edge in it, A gouge, one typeof _— chisel, is used, particularly 2 woodworking, woodturning and sculpture, to carve small Pieces from the material, Gouges are most often used in creating concave surfaces. A gouge typically has a ‘U'. shaped cross-section. Fig. chisels Caliper: / caliper is a device used to measure the distance between two opposing sides of an object. The tips of tho caliper are adjusted to fit across the points to be measured, the caliper is then removed and tho distance road by Measuring between the tips with a measuring tool, such as a rulor.International Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering 22 Types: Fhe inside calipers are used to measure the internal size of an object. * The upper caliper in the image requires manual adjustment prior to fitting, fine setting ot this callper type is performed by tapping the caliper legs lightly on a handy surface unt! they will almost pass over the object. A light push against the resistance of the Central Pivot screw then spreads the legs to the correct dimension and provides the nauited. consistent feel thal ensures a repeatable measurement. * The lower caliper in the image has an adjusting screw that permits it to be carefully @djusted without removal of the tool from the work piece, @g Outside caliper; Cy and repeatability. They are especially useful when measurin, er y i : exer Very latge distances, consider it the calipers are used to measure a large diameter ona 4 Vetnier caliper does not have the depth capacity to straddle this large diameter vile at the same time reach the outermost points of the pipe's diameter.International Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering 33 Fig. external calipers Divider caliper: In the metalworking field divider calipers are used in the Process of marking out suitable work pieces. The points are sharpened so thal they act as Scribers, one leg can then be placed in the dimple created by a center or prick punch and the other leg pivoted so that it scribes a line on the work piece’s surface, thus forming an arc or circle. A divider caliper is also used to measure a distance between two points on a map. The ‘wo caliper’s ends are brought (o the two points whose distance is being measured. The caliper’s opening is then either measured on a separate ruler and then converted to the actual distance, or it is measured directly on a scale drawn on the map. Fig. divider caliper Odd leg caliper: Odd leg calipers, Hermaphrodile calipers, Mick Jagger calipers or Oddleg jennys, are generally used to scribe a line a set distance from the edge of a workpiece. The bent leg is used to run along the workpleco odgo while the scriber makes its mark at a predetermined distance, this ensuros a lino parallol to the edgo.International Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering 34 in the diagram at left, the uppermost caliper has a slight shoulder in the bent leg allowing it to ston the edge moro securely; the lower caliper lacks this feature but has a renewable scviber that can be adjusted for wear, as well as being replaced when excessively worn. Vernier caliper: - Outside jaws: used {o measure external diameter or width of an object - Inside Jaws: used fo measure Internal diameter of an object . Depth probe: uscd to measure dopths of an object or a hole - Main scale: scalo markod every mm . Main scale: scale marked In Inchos and fractions - Vernier scale gives interpolated moasuroments to 0.1 mm or belter N@oReono - Vernier scale gives Interpolated measurements in fractions of an inch‘ternational Islamic University, Islamabad Faculty of Engineering and Technology Pepartment of Mechanical Engineering 35 & Retainer: used to block movablo part to allow the easy transferring of a measurement The Vernier, dial, and digit high accura These jal calipers give a direct reading of the distance Measured to They are functionally identical, with different ways of reading the result, calipers comprise a calibrated scale with a fixed jaw, and another jaw, with a that slides along the scale. The distance between the jaws is then read in different for the three types, mplest method is to read the position of the pointer directly is between two markings, the user can mentally interpolate to improve the sion of the reading. This would be a simple calibrated caliper; but the addition of a Sr scale allows, more accurate interpolation, and is the universal practice; this is the Vemier caliper. ly on the scale. When the g Sr. dial, and digital calipers can measure internal dimensions (using the uppermost in the picture al right), external dimensions using the pictured lower jaws, and in cases depth by the use of a probe that is allached to the movable head and slides ‘ong the centre of the body. This probe is slender and can gel into deep grooves that may prove difficult for other measuring tools. any The Vernier scales may include metric measurements on the lower part of the scale ¢ inch measurements on the upper, or vice versa, in countries that use inches. Vernier iers commonly used in industry provide a precision to 0.01 mm (10 micrometers), or one thousandth of an inch. Dial caliper: Instead of using a Vernier mechanism, which requires some practice to use, the dial caliper reads the final fraction of a millimeter or inch on a simple dial. In this instrument, a small, precise gear rack drives a pointer on a circular dial, allowing direct reading without the need to read a Vernier scale. Typically, the pointer rotates once every inch, tenth of an inch, or 1 millimeter, This measurement must be added to the ‘coarse whole inches or cntimotors read from the slide. The dial is usually arranged to be rotatable beneath the pointer, allowing for “differential” measurements (the measuring of the difference in size between two objects, or the setting of the dial using a master hae and subsequently being able to read directly the plus-or-minus variance in size of subsequent objects relative to the master object).? a International Islamic University, Islamabad Faculty of Engincering and Technology Department of Mechanical Engineering 36 © of a dial calipor can usually bo locked at a setting using a small lever or screw; NWS simple go/no-go checks of part sizes. Fig. dial caliper Digital caliper: & refinement now popular is the replacement of the analog dial with an electronic digital cisplay on which the reading is displayed as a single value. Increasingly, digital calipers offer @ serial dala output to allow them (o be interfaced with a dedicated recorder or 2 personal computer. The digital interface significantly decreases the time to make and record a series of measurements, and it also improves the reliability of the records. Like Gial calipers, the slide of a digital caliper can usually be locked using a lever or thumb- screw. Micrometer caliper: A caliper using a calibrated screw for measurement, rather than a slide, is called 2 micrometer caliper or, more often, simply a micrometer. ‘Try Square: A try square or try squaro is a woodworking or a motal working toolused for marking and Measuring a pioce of wood. The square refers to the tool's primary use of measuring the aeoxacy Of aright angle (00 degroos); to try a surface is to check its straightness or correspondence to an adjoining surface, ‘Try square’ is somotimos Incorroctly spallod ‘th Square’, Its etymology though is from “Wo/ng', In the sanso of tasting, rathor than the prefix ‘rie meaning three.International Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering 37 Faculty of Mechanical Engineering ME 112 Lab Workshop Practice Experiment # 3 Experiments Related To Wood ShopWwW » International Islamic University, Islamabad Wa : () ) Faculty of Engineering and Technology pe Department of Mechanical Engineering & LY Faculty of Mechanical Engineering ME 1142 Lab Workshop Practice Timber, Its Defects & Its Preservation MethodsInternational Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering 39 DEFINITION OF TIMBER SSEIION OF TIMBER Wood suitable for building of othor the t PROPERTIES Timber or wood, as building material, possesses a number of valuable properties such as - * Low heat conductivity, * _ Amenability (0 mechanical working, * Small bulk density, and * Relatively high strength, etc, DRAWBACKS Timber has its own drawbacks such as: * Susceptibility to decay and inflammable . Fluctuations in Properties due to changes in moisture content, . Variations in strength in length and across fibers, etc. * These shortcomings require careful consideration while making use of it USES OF TIMBER Timber is mainly used for following categories of works: * His used for construction purposes including building Construction, house posts, beams, rafters, bridges, piles, poles and railway sleepers ete. * tis used for furniture and cabinet making, * Itis used for light packing cases, * Mis also used for heavy packing cases such as machinery and similar stores. [tis used for manufacturing agricultural implements and tool handles 7 {tis used for making tumory articles and toys ete, * His used for manufacturing venoors and plywood,ternational Islamic University, ilar Faculty of Engineering and Techno! sy Department of Mechanical Engineering DEFECTS IN TIMBER DEI ‘Some major defects in wood are 1. Knots. 2. Checking 3. Shakes 4. Wood worm 5. White ant 4. KNOTS A knot is a particular type of imperfection in a piece of timber, which reduces its strength, but which may be exploited for artistic effect. {nthe tree a knot is eithor the base of a side branch or a dormant bud. * During the development of a tree, the lower limbs often die, but may remain allachod for a time, sometimes years. Subsequent layers of growth of the attaching stom are no longer intimately joined with the dead limb, but are grown around it * Hence, dead branches produco knots which are not attached, and likely to drop out aftor tho (ree has been sawn into boards, 40CE Se International Istamic University, \slamabad Faculty of Engineering and Technology Department of Mechanical Engineering 41 2. CHECKING Che cking Is the appearance of cracks oF splits in wood as the wood dries out ever time, 3. SHAKE ‘Shake is the separation of the rings in a piece of wood that occurs as itdries. The wood can also ‘peel off around the tings, similar to the layers of an onion.University, Islamabad SS & International Islamic (Uy) Faculty of Engineering and Technology Wes Department of Mechanical Engineering is 42 Faia’ 4 WOOD WORM Noadworm is the commonly used term for a number of wood boring insects that lay eggs in timber and whose larvae bore through the wood leaving a network of small tunnels, damaging and weakening the structure. * Woodworm is the infestation of a wooden item by the wood-eating larvae/grubs of one of many species of beetle. Infestation refers to the state of being invaded or overrun by pests or parasites. 5. WHITE ANT Also known as termite is considered to be the biggest enemy of wood.Strong digestive system helps them to eat wood, hence causing the failure of its internal structure in no time.'nternational Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering PRESERVATION OF TIMBER Timber has to be protectod from the attack Of Insects, e.g. white ants etc., and from ‘femal decay duo to dry and wot rots. Perfect Seasoning is the most effective Sees Of preservation, Timber should be so used that either itis wholly dry and well 43 However, when these conditions cannot be obtained then Preservatives have to be soplied for preservation. Timber should be well seasoned hefore the application of Breservatives as otherwise the preservatives would block the pores of timber thereby SSusing its decay due to the entrapped moisture. Direct contact with lime mortar Should be avoided while using preservative with masonry. METHODS OF PRESERVATION OF TIMBER mets OF PRESERVATION OF TIMBER Following are some of the common methods of preservation adopted Charting Tarring Painting Creosoting Wolman salt Ascu treatment Fire proofing of timber NOAPFwONa 1. Charring Lower ends of the posts that ara to bo embadidod in ground are generally charred with a view to prevent dry rot and attack of worms. Itis done by quenching the ends of posts in water after they are charred on wood fire to a depth of 1.5 cm.International Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering 44 2. Tarring in coating with tar or tar mixed with pitch. Embedded portions of timber q w frames, battens and beams built in wall are ase of those portions of structural members © posts, ends af door and windo\ iy tarred, Tarting is not done in ¢ are open to view, because of unsightly black color. 3. Painting paint when applied to limber acts not only as a good preservative but also it enhances the appearance of the surface so treated. Only well seasoned timber should be painted as otherwise the moisture entrapped in the limber, because of the closing of timber bores by paint, would cause decay. Paints however, protect seasoned timber against moisture thereby prolonging its life, e.g. soligum paints have excellent preservative properties and protect timber against the attack of white ants. 4. Creosoting Creosote oil is a dark brown thick oily liquid. Thoroughly seasoned timber dried for 24 hrs before its treatment is placed in an airtight chamber. After the air has been exhausted from this chamber, the creosote oil is then pumped in at a pressure of 9 kg/ cmat a temperature of 50 degree centigrade long as the timber is not fully saturated with oil. The oil preserves the timber from rot and from the attacks of white ant Uses + Itis used in case of railway sleepers, piles and transmission poles. Limitations * Undesirable colour and smell, inability to take paint well and the tendency to stain plaster limit its use. 5. Wolman Salt This salt consists of creosote and sodium fluoride and is soluble in water. It is ‘odourlass and leavos no stain on wood. After troatmont, timber could be painted or varnished. Thoso salts dostroy many kinds of fungl that cause timber to rot. This renders the timbor oxtromoly firo resistant too, Treatment of timber with zine chloride, sodium fluoride, magnesium, silico fluoride or copper sulphate renders the timber immune from the attacks of fungi. The timber so treated is capable of being painted on drying.International Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering 45, 6. Ascu Treatmont Ascu is availabla in the form of powder and Is made up of three chemicals mixed in the ratios given below : + {part by weight of hydrated arsenic pentaoxide (As2 Os.2H2 O) + 3 parts by weight of blue vitriol (CuSOx . 5H2 O) «4 parts by weight of potassium dichromate (Kz Cr2O7 . 2H20) ix parts of this powder are mixed with 100 parts by weight of water. Ascu solution can be applied or sprayed in two coats. To ar ieve better results, timber may be soaked in the solution and impregnated will under pressure. The timber should be allowed to dry for three to six weeks. This wwatment renders timber immune fo the ‘attacks of white ant, Ascu treated timber may be painted, varnished, polished or waxed. The solution is odourless. 7. Fire Proofing of Timber Timber cannot be made completely fireproof, however, by treating a8 below it can be made fire resistant to a sufficient extent. Soaking timber in ammoniin sulphate, cmmonium chloride, ammonia phosphate, sodium arsenate, zinc chloride etc. or spraying on timber, a solution of sodium silicate, potassium silicate or ammonia phosphate etc. imparts fire resisting properties. ‘Abel's methods of fire proofing timber is painting the surface first with a dilute solution of sodium silicate (Naz SiOs) then vith a cream like paste of slaked fal time and in the end with a concentrated solution of silicate of soda.International Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering 46 Faculty of Mechanical En ME 112 Lab Workshop Practice gineering Types of Wood JointsInternational tslamic University, islamabad Faculty of Engineering and Technology Department of Mechanical Engineering a7 WOOD JOINTS Looking at wooden (urnlture or discussing your needs with a qualified joiner, it is usefut to have some Idea of the basics of wood joinery. Wood joinery is probably the mast ba! oncept in woodworking. If there was no simple way to join two pieces of wood together ina secure way, the only option would be to carve it from a solid piece of wood: both expensive and very time consuming. Sut the skilled joiner has a wide range of joint types available, each with a specific purpose and dependent on the job in hand. Most used types of wood joints are: Butt Joint 2. Mitered Butt Joint 3. 4, 5. Half- Lap Joint . Mortise and Tension Joint . Dovetailed Joint iF R 2% Bs SE sont DOWELED BUTT volt 0a0 RASBET uP i CRS I an ue HORTISE AN MITER VAT TONGUE AND GROOVE DOWEIAL JORTISE AND TENDOI én :International Islamic University, Cee Faculty of Engineering and Technology Department of Mechanical Engineering 4B. 1) Butt Joint a Simplest of all is the butt Joint. This is simply one piece of wood et into another, normally ata right angle, or square to the other board. It is fastened using ti mechanical fastoners. This type of joint is often used in wall framing on construction sites or othar simple bits of joinery. As with any wood joint, an accurate cul when preaanng the two pieces is critical. The joint itself is secured by strong wood glue and, especially with hardwoods, by woodscrews. 2) Mitered Butt Joint A slightly more sophisticated version of this joint is the mitered butt, often seen in Siting boards. Here the (wo boards are joined at an angle, giving the advantage of peens-grain on view once the joint is made, but itis less strong than the simpler butt joint. 3) Half-Lap Joint Another simple, but very useful, joint is the half-lap. Each Piece of the join, normally ‘of the same thickness, has half of the wood removed, Using this Style, the two Boards can be fastened together with adding any thickness to the Piece. Most joiners wriluse this technique for ight-angled joints, particularly in furniture such as desks 4nd cupboards, where the extra strength is required, 4) Mortise and Tension joint the thre ing of joints, Dovetail joints can be very difficul to create, even for the experienced athock go cauGlalling jigs have made this much easier in rooont times. This is, ‘without doubl tho most sophisticated and aosthotically pleasing join, ua {rough dovetail ls the most common dovetail Joint used in drawer construction, @ eck fide te wooden drousor or chest of drawors and you will see one variation but not the one Jovolail, Hall-blind dovotalls, whare tho sides of the tails are visible mah nds, are used whon tho sldas of the drawor must connect directly with the face. Dovetails on dra 3 hidden whan fs closed "8 Should only bo visibla when the drawer ie opened, but \International Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering Faculty of Mechanical Engineering ME 1) lab Workshop Practice Experiment #5 Experiments Related To Welding ShopInternational Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering 50 Faculty of Mechanical Engineering ME 112 Lab Workshop Practice Electric Arc WeldingInternational Islamic University, faculty of Engineering and Te ‘epartment of Mechanical En; Islamabad chnology gineering 1 Introduction Are welding is a type of wolding thal uses a welding power supply to create an electn: are belween an electrode and the base material to melt the metals at the »g point, They can use either direct (DC) or altemating (AC) current, and ° able or non-consumable electrodes. The welding region is usually protected ‘ome type of shielding gas, vapor, or slag. Arc welding processes may be manual, semi-automatic, or fully automated. we! Welding methods There are two types of welding methods. 4. Consumable electrode methods 2. Non- Consumable electrode methods 4. Consumable electrode methods One of the most common types of arc welding is shielded metal arc welding (SMAW). which is also known as manual metal arc welding (MMAW) or stick welding. An electric current is used to strike an arc between the base material and a consumable electrode rod or stick. The electrode rod is made of a material that is compatible with the base material being welded and is covered with a flux that gives 24 vapors that serve as a shielding gas and providing a layer of slag, both of which cA the weld area from atmospheric contamination. The electrode core itself acts 39 filler material, making separate filler unnecessary. The process is very versatile, uiring little operator training and inexpensive equipment. However, weld times are ‘other slow, since the consumable electrodes must be frequently replaced and because stag, the residue from the flux, must be chipped away after welding. 2. Non-consumable electrode methods Gas tungsten are welding (GTAW), or lungsten/inert-gas (TIG) welding, 's a manual : welding process thal uses a non-consumable olactrode made of tungsten, ote o temi-inert gas mixture, and a separate filler material Espocally wsetul for weld 3 thin materials, this mothod Is characterizod by a stable are and high aul an but It requires significant oporator skill and can only be accomplished a fe : oe speeds. It can be used on nearly all weldable metals, though it is mosInternational Islamic University, slamabad Faculty of Engineering and Technology Department of Mechanical Engineering 52 { stainless steel and light motals. ICs alton used whan quallly wolds aro oxtremely PoHLant, such as In bicyclo, alicraft and naval applications. Power supplies To supply the electrical energy necossary for arc welding processes, a number of different power supplies can bo used. The most common classitication is constant Current power supplies and constant voltage power supplies. In arc welding, the voltage is directly related (o the length of the arc, and the current is related to the amount of heat input. Constant current power supplies are most often used for manual welding processes Such as gas tungsten arc welding and shielded motal are walding, because they maintain a relatively constant current even as the vollago varies, This is important because in manual welding, it can be difficult to hold the electrode perlectly steady, and as a result, the arc length and thus voltage tend to fluctuate. Constant voltage power supplies hold the vollage constant and vary the current, and 38 @ result, are most often used for automated welding processes such as gas metal are welding, flux cored arc welding, and submerged arc welding, In these processes, arc length is kept constant, since any fluctuation in the distance between the wire and the base material is quickly rectified by a larga chango in current, For example, if ine wire and the base material got too closo, the current will rapidly increase, which in tum causes the heat to increase and the tip of the wire to melt, roturning it to its original separation distance. Safety issues Welding can bo a dangerous and unhoal however, with the uso of now tachnolo: death associated with wolding can bo thy practice without the proper precautions; ay and proper protection the risks of injury or qoally reducod.International Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering 53 + Heat and sparks 2use many common welding procedures involve an open electric arc or flame, sk of bums from heal and sparks is significant. To prevent them, welders wear ve clothing in the form of heavy leather gloves and protective long sleeve sokets to avoid exposure to extreme heal, flames, and sparks. 2 + Eye damage = to the brightness of the weld area leads to a condition called arc eye in évch ultraviolet light causes inflammation of the cornea and can burn the retinas of es. Welding goggles and helmets with dark face plates - much darker than se in sunglasses or oxy-fuel goggles - are worn to prevent this exposure. w + Inhaled matter ers are also often exposed to dangerous gases and particulate matter. Processes like flux-cored arc welding and shielded metal arc welding produce smoke niaining particles of various types of oxides. The size of the particles in question to influence the toxicity of the fumes, with smaller particles presenting a ater danger.International Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering Faculty of Mechanical Engineering ME 112 Lab Workshop Practice Experiment #7 Introduction to Foundry ShopInternational Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering 55 INTRODUCTION + Casting (process) ity. molt the metal, pour into a mold by gravity or other force and + ADVANTAGES ~ Complex geometries - external and internal ~~ Can be net-shaped or near net-shaped ~ Can produce very large parts ~ Any metals ~ Can be mass-produced ~ Size variety — big and small + DISADVANTAGES ~ Limitation in mechanical properties, porosity, ~ Dimensional accuracy, surface finish ~ Safety Hazard ~ Environmental problems OVERVIEW + A Foundry is a casting factory which equipped for making molds, melting and handling molten metal, performing the casting process, and cleaning the finished casting. — Foundry men are workers. + Open Molds ~ Simple parts * Closed Molds — Complex parts. — A passageway - the gating system leading into the cavity + Two categories -Expandable or permanent molds. TWO MAIN CATEGORIES 1. Expendable mold processes ~A mold after processmust be destroyed in order to remove casting = Mold materials: sand, plaster and similar materials + binders ~ More intricate geometries 2. Pormanont mold processes ~ A mold can be used many times to produce many castings fol: made of motal and, loss commonly, a ceramic refractory material ~ Part shapes are limilod . ~ Permanent mold procossos are more aconomic in high production operations.; j International Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering 56 BASIC FEATURES OF MOLDS + Sand Casting Molds: ~ Mol, cope (upper half) &drag (bottom half) ~ Flash - containment ~ Parting lino ~ Pattern ~ the mold cavity ~ The gating system — pouring cup, (down)sprue, runner | oo. ~ Riser ~ a source of liquid metal to compensate for shrinkage during solidification Sand Casting Open riser Vent Pouring. basin (cup) — Flask I— sand Parting SAND CASTING a : hc videly used casting process, pene ranging in size from small to very large - ction quantities from one to millions * Sand mold in used, * Patterns and Cores ~ Solid, Split, Match-plate and ci « b: ‘Ope-and-drag P. ante ~ achieve the Internal surface of tho eet “Molds ~ Sand with a mixture of water and bondini cl lay ~ Typical mix: 90% sand, 3% water, and 7% clay O enhance strength and/or permeability,International Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering 37 MoLDs + Sand ~ Refractory for high temperature + Size and shape of sand ~ Smalt yrain size: better surface finish ~ Large grain size: to allow escape of gases during pouring ~ teregutar grain shapes: strengthen molds due to interlocking but to reduce pemeability + Types ~ Green-sand molds - mixture of sand, clay, and water; “Green” means mold contains moisture at time of pouring ~ Dy-sand mold - organic binders rather than clay and mold is baked to improve strength ~ Skin-dried mold - drying mold cavity surface of a green-sand mold to a depth of 10 to 25 mm, using torches or heating lamps STEPS IN SAND CASTING The cavity in the sand mold is formed by packing sand around a pattern, separating the mold into two halves — The mold must also contain gating and riser system — For internal cavity, a core must be included in mold — Anew sand mold must be made for each part 1. Pour molten metal into sand mold 2. Allow metal to solidity 3, Break up the mold to remove casting 4, Clean and inspect casting 5. Heat treatment of casting is sometimes required to improve metallurgical Properties Fabricate Fabricate Core Boxes Patten =e cnt Material ~ vga : Faas Sa prec ]_, | PE Sand —>| “sand ~[| Mold Raw Casting inspection + Zz Nu t : Fished Cr MeInternational Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering $8 TYPES OF PATTERNS USED IN SAND CASTING (a) Solid pattern (2) Split pattem (s) Mateh-plate pattern (2) Cope and drag pattern - Plser pattem / — Cope pattern —Panem yp Piato (Bs Ga TEAS @ © © CASTING DEFECTSsg acu of Engineering and Technology SS 2 ‘partment of Mechanical Engineering YL Mistuns 59 Cold shut Shrinkage Cavity Microporosity [a Metal Peneration METALS FOR CASTING + Ferrous casting alloys: cast iron ~ Gray Cast Iron, Nodular iron, White Cast Iron, Malleable Iron, Alloy cast iron + Ferrous casting alloys: Stools ; — Melting temperature is higher that casting alloys. Thus they are more reactive. — Less Fluidity = Higher strength, Tougher = Isotropy and woldable + Nonferrous casting alloys ~ Aluminum, Magnesium, Coppor, Tin-based, Zinc, Nickel and Titanium Alloys.International Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering 60 Faculty of Mechanical En: ME 412 Lab Workshop Practice gineering Experiment # 09 Introduction to Electric Shop (DC Electrical Circuits)scoring anu HeCIMOIORy Mechanical Engineering Department of 61 The current in a circuit is DIRECTLY proporth 2 ECTL jonal ( re sucert| prof al {o the applied voltage and proportional to the circuit resistance, Ohm's law may be expressed as an equation: I=VIR As stated iy Ohm's law, current is inversely proportional to resistance. This means, as the resistance ina circuit increases, the current decreases proportionately. SERIES CIRCUIT ‘A SERIES CIRCUIT is defined as a circuil that contains only ONE PATH for current ow. Lane asic cinculT SERIES CIRCUIT Resistance in a Series Circuit: Referring to figure, the current in a series circuit must flow through each lamp to criica| pal ii dded resistance. In a series Arical path in the circuit. Each additional lamp offers a THE oe a AL CIRCUIT RESISTANCE (RT) IS EQUAL TO THE SUM OF INDIVIDUAL « RESISTANCES, RTERIFRZ+ R34... RN s t might be NOTE: Tho subscript n donotos any number of adiditional resistances that mg! in the equation.amic University, Islamabad ering and Technology Engineering International Isl Faculty of Engine Department of Mechanical CI i ts Current ina Serles Clreul se there is only one path for current ir tovough each component of the circuit. T ‘only te cutrant through one of the compo na series circuit, the same current must flow ‘0 determine the current in a series circuit, nents need be known. The fact that the same current flows through each component of a series circuit can be verified by inserting meters into the circuil al various points, as shown in figure. If this were done, each meter would be found to indicate the same value of current. ITs Voltage in a Series Circuit: The voltage dropped across the resistor in a circuit consisting of a single resistor and 2 vollage . source is the total voltage across the circuit and is equal to the applied voltage. The total voltage across a series circuil that consists of more than one resistor is also €qual to the applied voltage, bul consists of the sum of the individual resistor voltage drops. In any series circuit, the SUM of the resistor voltage drops must equal the source vollago, VT=V14+V2+V3+...Vn PARALLEL DC CIRCUITS: A PARALLEL CIRCUIT is dofined us ano having MORE THAN ONE CURRENT PATH connected to a common voltage source. Parallel circuits, therefore, must comlain wo or more rasistancos which are not connected in series. An example of a basic parallel circuit is shown in figure.SNE. Mternational Islamic University, istamabad Wit ( » ; 5 MM nylneer| ie ing and Technolo, ne Department of Mechanteal tnginvarmg 63 Se 4 ur PANEL . po Paina Start at the voltage source (Fp) and trace countorelockwiso around the circuit. Two Sooypetey and enpatate path, Gan ho Identified In which current can flow, One path is faced from the sous, fhreugh fopistance R41, and back to the source. The other path fs frony the source, through rosistance F2, and back to the source. Voltage In a Parallel Clreult: ‘You have soon thal the source vollage In a sories circuit divides proportionately gerose each rosibtor In the circuit, INA PARALLEL CIRCUIT, THE SAME VOLTAGE 15 PRESENT IN EACH BRANCH (A branch Is a section of a circuit that has a completo path for cunront,) tn figure 3-37 thia voltage Is equal to the applied voltage (€5), This can bo eypreniod In equation form as ES © ER1 = ER2 Curront In a Parallol Chreult; Thora 8 6 binglo path for curront in a sorios clrcult. Tho amount of current is deteemninod by thi tolal rasiotanco of tho eiroult and the applied voltage. In a parallel dares! tho source current divides among the available paths. ESe ERI + ER2 Resistance ina Parallol Clroult: Tho total rosistance of» parallol clrcull {o, omalier than any of (he individual resistors, total ues as was irtance of paral circuit Je not tho aur of tho Individual rasisioy Vel" ao eee coring real, Tho total rjotance of rosistors in parallel Ks also refered See QUITAL HTL AEGIGTANGL (Req), Tho forme total resistance and equivalen resistance re ased Infarehangonbly. Rog = URI + RZ¥e International Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering 64 ‘circuit is an accidental path of low resistance which passes an abnormally Mount of current. A short circuit exists whenever the resistance of a circuit or tance of a part of a circuil drops in value to almost Zero ohms. A short often SSSUrS as a result of improper wiring or broken insulation,a International Islamic University, Faculty of Engineering and Te Department of Mechanical En Islamabad chnology gineering 65 i ineering Ity of Mechanical Engine Facaty Ot ME 12 Lab_ Workshop Practice Switch, and Its Typesamic University, Islamabad ineering and Technology ering International Isl Faculty of Engh Department of Mechanical Engine SWITCH a switch is an electrical component that can break ta electrical engineering, diverting it from one conductor to an electrical circuil, interrupting the current or another. ‘The most familiar form of switch is a manually operated electromechanical device with one or more sets of electrical contacts, which are connected to external circuits. Each set of contacts can be in one of two states: either "closed" meaning the contacts are touching and electricity can flow between them, or “open”, meaning the contacts are separated and the switch is non-conducting. A switch may be directly manipulated by a human as a control signal to a system, such as a computer keyboard button, or to control power flow in a circuit, such as a light switch. Automatically operated switches can be used to control the motions of machines, for example, to indicate thal a garage door has reached its full open position or that a machine tool is in a position to accept another workpiece. BASIC SWITCH SYMBOLS The switch symbols below shows SPST, SPDT, DPST and DPDT. S| ee ee ° oe SPST SPDT DPST ‘DPDT SPST Single Pole, Single Throw. An on-off switch allows current to flow only when it is in the closed (on) position. SPDT Single Pole, Double Throw. A 2-way changeover switch directs the flow of current to ono of two roulas according to its position. Some SPOT switches have a antral off position and are doscribod as ‘on-off-on', DPST Double Polo, Singlo Throw. A dual on-off switch which is often used to switch mains electricity because it can Isolate both the live and neutral connections. DPDT Double Pole, Double Throw. This switch can be wired up as a reversing switch for a motor. Some DPDT switches have a central off position.International Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering 67 ‘There are two typos of switches based on control. 1) Single way Or One way Switch 2) Two Way Switeh 4) SINGLE WAY OR ONE-WAY SWITCH Taig is the most basic circuit, by which we can control a lamp by single way switch. [x ‘one way’ switch is typically considered a ‘single pole’ switch with essentially one contact for the connection of an electrical circuit. A single pole switch is typical used when a device (light switch, fan, receptacle) only needs to be controlled fram one location. One-way SwitchInternational Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering 68 2) TWO-WAY SWITCH Three-way switches are called thal because they have three connections, a common and two lines. Apparently in British electrical circles, i's known as a two-way switch. A ‘three way switch’ is used when a device needs to be controlled from more than one (I.E. the top and bottom of a stairway, at both ends of a hallway) A three way switch allows for a device to be controlled independently from two locations, regardless of the position of the other switch. POWER SWITCH 1 SWITCH 2Intemational Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering Ity of Mechanical Engineering Facy oie 112 Lab | Workshop Practice Experiment # 10 Experiments Related To Machine ShopInternational Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering 70 Faculty of Mechanical Engineering ME 112 Lab Workshop Practice Introduction to Lathe Machinea International Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering n i Lathe Machine Fstorically, tho tatho Is tho forerunner of all machine tools. The first application of the latho principle was probably the potter's wheel. The machine rotates a mass of Slay to be formed into a cylinder shape. The modern lathe operates on the same basic concepts. {se metalworking lathos the work piece in held and rotated on its axis while the cutting tecls are held rigidly in a too! holder that is mounted on a movable platform called the carriage. The tool is moved in and oul by means of hand cranks and back and forth either by hand cranking or under power from the lathe. The result is that material can be removed from the work piece under very precise control to produce shapes that are truly precision made. Dimensional accuracies of one-one thousandth of an inch (.001") are typical. Because of the inherent rotational nature of a lathe, the vast majority of the work produced on it is basically cylindrical in form. In spite of this, the lathe is an extremely versatile machine capable of producing a surprising variety of objects. Lathe Remember. Only one person operates the machineInternational Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering 2 Parts of Lathe Apron Front part of the carriage assembly on which the carriage hand wheel is mounted Sed Main supporting casting running the length of the lathe Carriage Assembly that moves the {ool post and cutting tool along the ways. Carriage Hand whee! A wheel with a handle used to move the carriage by hand by means of a rack and pinion drive : Chuck A clamping device for holding work in the lathe or for holding drills in the taistock. Self-Centering Chucks are ideal for gripping cylindrical or concentric work Secause all jaws work in unison and automatically center the piece. Independent shucks are suited for gripping irregularly shaped work pieces or for eccentric operations because jaws work independently. Adjustable chucks operate like a self- centering chuck but are used where extreme accuracy is required 2 Jaw Self-Centering 3 Jaw Self-Centering 4 Jaw Independent 6 Jaw IndependentInternational Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering 73 Movable platform on which the tool post is mounted; can be set at an angle to the work piece, Also known as the compound slide and compound rest. pound Hand wheel A wheel with a handle used to move the compound slide in and out. Also known as the compound feed. j@ Platform that moves perpendicular to the lathe axis under control of the hand wheel ie Hand wheel A wheel with a handle used to move the cross-slide in and Also Known as the cross feed. Half nut A nut formed from two halves which clamp around the lead screw under ‘ontrol of the half nut lever to move the carriage under power driven from the lead screw. Half nut Lever Lever to engage the carriage with the lead screw to move the carriage under power Headstock The main casting mounted on the left end of the bed, in which the spindle is mounted. Houses the spindle speed change gears. Lead screw Precision screw that runs the length of the bed. Used to drive the carriage under power for turning and thread cutting operations. Smaller lead screws are used within the cross-slide and compound to move those parts by precise amounts. Saddle A casting, shaped like an "H” when viewed from above, which rides along the ways. Along with the apron, itis one of the two main components that make up the carriage. Spindle Main rotating shaft on which the chuck or other work holding device is mounted. It is mounted in precision bearings and passes through the headstock Tailstock Cast iron assembly thal can slide along the ways and be locked.in place. ‘Used to hold long work in place or to mount a drill chuck for drilling into the end of the work. Tailetock Hand wheel A wheel with a handle used to move the {allstock ram in and out of the tailstock casting. Tailstock Ram A piston-type shafl that can be moved in and out of the tailstock by turning the tailstock hand wheel. . Joo! post /\ holding dovico mounted on the compound into which the cutting tool is damped Ways Procision ground surfaces along the top of the bed on which the saddle rides. The ways aro procisoly allgnod with tho cantortine of the lathe.International Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering ‘Compound Feed | Mandvueet Swing over bed ‘The diameter of the largest workpiece that can be rotated on the spindle without hinting the bed. This is the first of the two numbers used to describe the size of a metal lathe. In the case of the 9x20 lathe it is 9". Distance between centers ‘The longest piece of work that can be held between a center in the headstock and a canter in the lailstock. This is the second of the two numbers used to describe the lathe size, In case of 9x20 lathe it is 20". Spindle Through hole A dimension indicating the minimum diameter of the hole that_passes through the spindle. A workpiece with a diameter smaller than this can Pass through the spindlo {o facilitate working on long pieces of work.6) International Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering 75 Lathe Safety Guidelines Don't touch cutler or chips while machine is running. In setting up the too! holder place it to the left side of the compound slide to prevent the compound slide from running into the chuck or spindle attachment. , Always clamp the tool bit as short as possible in the tool holder to prevent it from breaking or chattering. Don't cut work completely through when turning between centers. Stop the machine before taking measurements. ‘Always make sure that the too! bits sharp and has the proper clearance.international Islamic Unlversity, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering Loy A 76 Faculty of Mechanical Engineering ME 112 Lab Workshop Practice Operations Performed on Lathe MachineEe Internation al Islamic Universi ersity, Ista Faculty of Engineering and Te cee ae ‘chnology Partment of Mechanical Engineering 7 7 How to Operate 1) Secure part in chuck or collet ae ‘stall appropriate cutter, make lhe proper position in the tool a " sure they are at the pr i Change gears with machine off, including feed changes Make sure machine is running in the correct direction for cutter. After operation, return tools and clean machine. \f problem arises, shut machine OFF and ask someone for Help. Three Important Elements In order to get an efficient process and beautiful surface at the lathe machining, itis important to adjust a rotating speed. A beginner of a lathe must operate with low rotating speed, small depth of cut and low sending speed (feed). Rotating Speed: It expresses with the number of rotations (rpm) of the chuck of @ lathe. When the rotating speed is high, processing speed becomes quick, and a processing surface is finely finished. However, since a litle operation mistakes may Iead to the serious accident, it is better to set low rotating speed at the first stage. Cutting Depth: the cutting depth of the tool affects to the processing speed and the roughness of surface. When the cutting depth is big, the processing speed Becomes quick, but the surface temperature becomes high, and it has rough surface. Moreover, a life of byte also becomes short. If you do not know a suitable cutting depth, it is better to set a small value. Sending Speed (feed): the sending speed of the tool also affects the processing speed and the roughness of surface. Feed i is actually the advancement of tool towards the workpiece in a single revolution of workpiece. When the sending speed is high, the processing speed bocomes quick. When the sending speed is !ow. the surtace is finished boaullfully, There are "manual sending” which tums and operates 2 handle, and “aulomatic handling’ which advances a byle automatically. A beginner must use the manual sonding, Bacauso sorlous accidents may be caused, such 38 touching the rotating chuck around tho byte in automatic sending.International Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering Operations Related to Lathe Facing: The tool is fed radially into the rotating work on one end to create a flat surface on the end. . Taper Turning: Instead of feeding the tool parallel to the axis of rotation of the work, the tool is fed at an angle, thus creating a tapered cylinder or conical shape. 3. Contour Turning: Instead of feeding the tool along a straight line parallel to axis of rotation as in turning, the tool follows a contour that is other than ‘Straight, thus creating a contoured from in the turned part. 4. Form Turning: In this operation, sometimes called forming, the tool has a shape that is imparted to the by plunging the tool radially into the work. 5. Chamfering: The cutting edge of the (ool is used to cut an angle of the comer of the cylinder, forming what is called a “chamfer”. 6. Cutoff: The too! is fed radially into the rotating work at some location along its length to cut off the end of the part. This operation is sometimes referred to as. parting. 7. Threading: A pointed tool is fed linedrly across the outside surface of the rotating workpart is the direction parallel to the axis of rotation at a large effective feed rate, thus creating threads in the cylinder. %. Boring: A single-point tool is fed linearly, parallel to the axis of rotation, on the inside diameter of an existing hole in the part. &. Drilling: Drilling can be performed on a lathe by feeding the drilt into the rotating work along ils axis. 10.Knurling: This is not a machining operation because it does not involve cutting of the material. Instead, it is a metal forming operation used to produce a regular cross-hatched pattern in the work surface. It is also sometimes called as material addition process. 11. Reaming: Roaming Is used to slightly enlargo a hole, to provide a better tolerance on its diametor, and to Improve its surface finish. vIntern: teen Islamic University, tstamabad Gane Engineering and Technology went of Mechanical Engineering Faculty of Mechanical Engineering ME 112 Lab Workshop Practice Experiment # 14 Oxy Acetylene Gas WeldingInternational Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering 80 Oxy-Acetylene Weldin: Oxy-Acetylene (OA) wolding Is one of the many types of. It is extremely versatile, and with enough skill and practice you can use this type of welding for virtually any metal, tn fact, the oxy-acolylene flame burns al 6000 | 1F, and is the only gas flame that ‘s hot enough to melt all commercial metals. Oxy-acetylene welding is simple in et - No pieces of metal are brought together, and the touching edges are ed by the flame. Advantages of Oxy-Acetylene Welding: + Is easy to leam. * The equipment is cheaper than most other types of welding rigs (e.g. TIG welding) + The equipment is more portable than most other types of welding rigs (e.g. TIG welding) + OA equipment can also be used to "flame-cut” large pieces of material, Disadvantages of Oxy-Acetylene Welding: + OA weld lines are much rougher in appearance than other kinds of welds, and require more finishing if neatness is required. + OA welds have large heat affected zones (areas around the weld line that have had their mechanical properties adversely affected by the welding process) Preparation: 1) _ Assemble all of the materials needed to make the weld. This includes parts, OA equipment, fixturing, tools, safety mask, gloves, and filler rod. 2) Clean the parts to be welded to remove any oil, rust, or other contaminants. Use a wire brush if needed to remove any rust. 3) Assemble and fixture the parts in place - the parts need to be stable for a good weld line, 4) Select the nozzle you plan to use for welding. Nozzles come in a variety of sizes, from 000 (for a very small flame - typically used for thin materials) to uguards of 3 (for a large flame - needed for thick materials). Larger nozzles produce larger flames and, in general, are more appropriate for thicker material. Chooting the right size nozzle becomes easier with more experience. Ask a TA oF rake Gore: test welds to determine if you are using the right size nozzle. 5) Clean the nozzle. Carbon deposits can build up on the nozzles which interfere with flare quality and cause backfiring, The cleaning tool has a wide flat blade (with a file-ike surface) which is usod (0 clean carbon deposits on the exterior of the nozzle, Uso il to serapo any deposits from tho flat face of the tip. Use the wire-like files to clean tho Inlorlor of tho nozzle, Pick the largest wire which will fit inside the nozzle and the scrapo tho edges of the hole to remove any carbon buildup 6) Attach the nozzle to the gas feod line by hand. Don't over-torque - the nozzle and hose fitting are both made of brass which doesn't stand up well to abuse. A snug, finger tight itis the sufficient.i Har Islamic University, Facity of Engineering and Te epartment of Mechanical Eni Islamabad chnology gineering a1 7) Check the pressure to at feast 50 pst in tho mee and acetylene tanks, There should be completely 0 . The oxygen tank ili pletely empty. I needed, ask a TA to change bottles. Note: The axygen used iy OA welding in NOT f J for human consumpli could bo unhealthy if aken in large wanes eamane coniemnane ot Lighting the flame t) Open the main valve on the acetylene tank ~1/2 turn. This charges the pressure regulator at the top of the tank. Open the pressure regulator valve on the acetylene tank (turn clockwise to open) and adjust the pressure in the acetylene line to 5 psi, DO NOT pressurize the acetylene over 15 psi - it will explode. 3) Open the acetylene pin valve on the handle of the welding tool, letting acetylene escape. Tweak the pressure regulator valve until the regulator pressure is constant at 5 psi. Close the acetylene pin valve. 4) Open the main valve on the oxygen tank. Turn the valve until it is fully open (until it stops turning). 5) Open the pressure regulator valve on the oxygen tank (turn clockwise to open) and adjust the pressure in the oxygen line to 10 psi. 6) Open the oxygen pin valve on the handle of the welding tool, letting oxygen escape. Tweak the pressure regulator valve until the regulator pressure Is constant at 10 psi. Close the oxygen pin valv 7) Slightly open the acetylene valve (~1/8), u escaping. a) Make sure there is no person or anything flammable in the path of the nozzle. Use the striker to ignite the acetylene. The flame should be yellow and will give off a lot of soot. you can just barely hear acetylene Adjusting the flame 4) Open the acetylene valve further and watch the flame near the nozzle tip. Add more acetylene until the flame is just about to separate {rom the tip. (The flame Val separate from the tip of the nozzle if you add too much acetylene.) If so, Yeduce the flow until the flame realtaches to the tip, and then open the valve again to the near-separation point. 2) etightly open the oxygen pin valve. Ifthe flame goes out, tum off the gases and try again. DO NOT try and ignite the flame with both oxygen and acetylene pin valves opon, As tho oxygen is added the flame will turn bluish in color. 4) "the blus flamo will bo divided Into 3 different color regions - a long yellowish tip, 8 blue middlo section, and a whilish-blue intense inner section. There are three types of flames as doscribed bolow: . Noval = This typo of flama ts tho one you will use most often in the shop. Itis called *noutral” because it has no chomical effect upon the metal during welding, {his achieved by mixing equal parts oxygen and acetylene and is witnessed in theInternational Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering 2 tame by acting tho oxygon flow until tho middlo blue section and inner whitish- blue parts morgo into a single ragion. Reducing tluno = If thoro ls oxcoss acotyleno, the whilish-blue flame will be larger than tho bluo flame. This flame contains white hot-carbon particles, which may be dissolved during welding. This *reducing’ flame will remove oxygen from tron oxides in stecl, ; Oxidizing flame - If there is excess oxygen, the whitish-blue flame will be smaller than the blue flame. This flame burns hotter. A slightly oxidizing flame is used in brazing, and a more strongly oxidizing flame is used in welding certain brasses and bronzes. Welding Procedure 1) _ Puton a dark face shield to protect your eyes from the light of the flame. Make sure you have on long sleeves and all natural fibers. You can wear a leather welding jacket and/or gloves if it makes you feel more comfortable. 2} Apply the flame to the parts to begin heating. Use the region of the flame near the tip of the bluish inner region. 3) __The metal will begin to glow. Continue heating both parts being welded until a small pool of welded metal appears near the edge of each of the parts. You must get molten pools on BOTH parts simultaneously to create the weld. They may Fequire adding more heat to one side than the other, and takes some practice. 4) _ After the molten pools have formed on both sides of the weld, use the flame to gently stir the two pools together to form the weld. This also takes a little practice. 5) After the two pools have joined, slowly move the flame along the weld line, lengthening the pool using metal from both parts. A gentle, circular, swirling motion will help mix the molten metal from both sides as the puddle is lengthened. This process is highly dependent on the materials and part geometries being welded. Practice, practice, practice to get better control. Welding sample parts is a good idea. 6) Continue this process until the entire weld line is complete. 7) _ Once you're done, turn off the flame. Close the oxygen pin valve first, and then the acetylene valve. Note: Welded parts can remain hot for a LONG time. Backfiring Innproper operation of the torch may cause the flame to go out with a loud snap or op. This is called backfire. It is caused by one of a few things. The first thing to do is turn the gas in the torch off, check all the connections and try relighting the torch. Backfiring can be causod by touching the tip agains! your work piece, overheating the tip, operating tho torch at other than racommended gas pressures, by a loose tip or head or by dirt on tho Goal, Shutting Down and Cleaning Up When you're completely finishod wolding and are ready to quit for the day, you need to clean up ; : 1) With the flame extinguished and the pin valves closed, close the main valve on the oxygen tank. It should be firmly seated at the bottom,) ov §) International Islamic University, Islamabad Faculty of Engineering and Technology Department of Mechanical Engineering 83 Open the oxygen pin valve to bleed off all of the oxygen in the regulator and feed close the pin valve once the feed line pressure has gone to zero. Fully back oul the oxygen regulator valve so there is no pressure in the line. DO NOT close the valve, as this will pressurize the line once the tank is open, again. tthe case of the acetylene, if itis pressurized over 15 psi, it may explode! If you are not sure about doing this properly, find a TA to help you. Repeat steps 1 through 3 for the acetylene line. Retum all of the tools to their proper storage places and coil the feed lines Seng the handle on the gas cylinder cart. Note: Do not remere the nozzle from feed line, The feed lines should always have a nozzle attached to prevent gental damage to the threads used to attach the nozzle. Don't forget to ask for a shop job!