KL UNIVERSITY

DEPARTMENT OF BASIG ENGINEERING

SCIENCES-2
WORKSHOP MANUAL
LIST OF EXPERIMENTS

1. Carpentry
a. Lap tee joint
b. Mortise and Tenon joint
2. Fitting
a. Square Fit
b. “L” Fit
3. Tin-smithy
a. Rectangular Tray
b. Pipe “T” Joint

4. Basic Electrical
House Wiring
a. Stair case connection
b. Godown connection.
5.Trades for demonstration

a.Demo on grinding,milling and power hacksaw

b.demo on welding machine.
c.Demo on mimic panel board,(Double bedroom house wiring)
Instructions to the students

1. Enter the lab with proper dress- code ( khaki apron and shoes)

2. Maintain a 200 pages white long note book (Drawing&workshop)

3. Draw the figures of tools and equipments proportionately using pencil only
on the left side of the page.

4. Write the related theory part only on the right side of the page.

5. For every experiment, draw the related figure and write the individual
procedure in the observation book and take signature by the concerned
faculty. Write the date and Experiment number in the observation book.
And take signature of staff member on index page of lab manual.

6. Only after taking signature in the observation book, write the record. Marks
are allotted for your regularity. Performance of the students will be
assessed for every session of workshop being conducted.

7. The records should be written, up to date without delay. They should be

signed by the concerned faculty.

8. Medical kits provided in the First – Aid Box. The students can utilize the
available medicines if at all there is any necessity.
 Safety in Workshop

In order to achieve a safe working environment, knowing and practicing safety

is the necessary pre-requisite in all Workshop activities. Safe equipment
processes and operations are necessary to avoid any accidents in Workshop.
Safe working environment can be achieved by following the instructions given
below.

1.General& Hygiene:

• Present yourself neat and tidy inside the Workshop. No student will be
allowed to work without safety shoes.
• Always be alert inside the Workshop.
• Horseplay during work should be strictly avoided and it will be viewed
very seriously.
• Trim off your nails to reduce hand injury while working.
• No bangles, rings, watches etc should be worn when working in
Workshop.
• Students (especially girls) should ensure that their hairs are kept intact.
• The wash basin area should be kept clean and soaps after every hand
wash should be washed and kept for others use.
• The specified toilets should be used by the specified people.

2.Housekeeping:

• Ensure that the place around you is kept neat and tidy.
• See that there are no loose materials like tools, finished product, and
personal belongings lying on the shop floor.
• Oil, grease, lubricants, coolant, saw dust etc spilled on the floor is to be
completely cleaned before start and completion of the work.
• The walk ways inside the workshop should be kept free for easy
movement of persons using it.
• The best housekeeping ensures safe working environment.

3.Fire:

• Be vigilant about sparks and small fires in and around the Workshop.
• Inflammable materials like diesel, kerosene, petrol and chemicals
should be kept away from welding, smithy, grinding areas, etc.
• Avoid contact lenses when you are exposed directly to welding sparks
and chemical fumes.
• Familiarize yourself with the basic types of fire extinguishers and their
usage.
• In case of tire immediately evacuate yourself and assemble at the
“Emergency assembly point”
4.Electrical:

• Be careful about all electric connections and do not tamper with them.
• If you spot any loose wires or loose connections inform the authorities
immediately.
• Do not switch ‘on’ any electrical switches, unless you are asked to do
so.
• Sharp objects including tools should be avoided colliding with electrical
wires.
• Do not tamper with the chemical bath in the Electroplating section.

5. Care about others:

• Be aware that unsafe practices of a person also affect others directly /

indirectly. Hence proper care should be taken towards safety.
• Loose material should not be kept on the floor near machines or in
public areas like walkways, passages, entrance etc.
• While using tools in your work area ensure that you are keeping a safe
distance from others.
• Do not cramp between Machine tool areas.(blocking the way for
others.)
• Be co-operative and helpful to your fellow students.

6.Communication:

• Before starting any exercise, ensure that the procedures are

understood properly by you.
• Do not hesitate to ask for any doubt, In the procedure. (even if It is
silly.)
• Any untoward incident (major or minor) in the Workshop should be
immediately informed to the authorities.
• If you spot out any loose wires, loose objects, unsafe conditions and
your doubts about any unsafe area, should be reported to the
concerned immediately.
• If you are uncomfortable, unhealthy do not hesitate to inform the
authorities.
7.Personal protective equipments:
• Personal protective equipments commonly used in workshop are safety
shoes, coveralls, gloves, goggles, welding shield, fireman helmet,
leather apron, nose mask etc.
• Personal protective equipments are only the last protective items for an
accident, it is always better to have a sate working environment and
ensure zero accidents.
8. Handling. (Tools, Measuring Instruments & Machine tools):
• Material handling and handling of tools, measuring instruments and
machine tools play a vital role in the workshop safety.
 • Ensure that all the materials and tools are received from stores as per
the requisition slip and the same is returned to the stores after proper
cleaning.
• Use the carry box available for carrying the tools and materials and see
that you use only the walkways while carrying them.
9. Tools:
• Tools are generally precise and sharp in nature hence handled with
utmost care.
• Ensure that the tools are properly placed in the workplace.
• Never load the tool more than the required limits it may tend to break
leading to accidents.
• While working on bench, ensure that the work piece is held rigid on the
holding devices. (Vices etc.)
• Never try to use a tool without knowing how to use it.
• Use a tool for the specified operation it is meant for, ( eg. Do not use a
dot punch for scribing lines.)
• Avoid heavy hammer blows on the job while it is fixed in the vice. The
job may slip leading to an accident.
10 Measuring instrument:
• Ensure utmost care while handling measuring instruments which are
highly precise and costly.
• At any point of time measuring instruments should not be dropped
down and penalty will be imposed for such acts.
• Learn to differentiate high precision and low precision measurements
and use the appropriate tool. (Do not use a vernier caliper to measure
a job forged in smithy section.)
• Never use the measuring instrument while the machining is in
progress. (eg. Do not measure a revolving job in a Lathe.)
11 Machine tools:
• While working on Machine tools instructions of the concerned staff are
to adhered very strictly. Deviation of the above will lead to serious
accidents and damages.
• Ensure that the work piece is held rigidly in the work holding device,
(chuck, machine vice etc.)
• Ensure that the tool/cutter is held rigidly in the Machine tool.
• Do not shift any levers when the machine is in operation.
• While working in a Machine tool never exceed the limits of operation
due to curiosity, as this may lead to accident. (eg. Never give automatic
feed in a machine toot unless you are instructed to do so.)
• Never exceed the limits while giving depth of cuts. This may lead to
accident.
CARPENTRY
 Screw Handle

Steel Rule

Blade Body C- Clamp

Stock Testing for Testing for
Straightness Squareness

Try Square Blade

Wedge
Back Iron

Solo

Wooden Jack Plane

Marking Guage

Cross cut hand saw

Trigger for quick opening

Carpernter’s vice Tenon or back saw

 CARPENTRY

Introduction:
Carpentry may be defined as the process of making wooden components. It deals
with the building work, furniture, cabinet making etc. Jointly, i.e., Preparation of joints is
one of the important operations in all wood works. It deals with making joints for a variety
of applications viz, door frames, window frames, wardrobes, cupboards, stairs etc. In this
chapter tools and works associated with joinery are presented.
Carpentry Material – Timber:
Timber is the basic material used for any class of carpentry work. The term timber is
applied to the wood obtained from; well-grown trees. The trees are cut, sawn into
various sizes to suit the required purpose.

Common Varieties of Indian Timber:

Indian timbers most commonly used for various carpentry words are as follows: Babul,
Deodar, Mahogany, Mango, Sal, Sissy and teak.
Carpentry Tools:
In carpentry large numbers of hand tools are used for processing the wood. Here, the
details of tools that are being used in our workshop only are presented.

Marking and Measuring Tools:

Steel Rule: It is strip of steel with graduations on its edges and is used for measuring
andsetting out dimensions.
Try Square: Try squares are used for marking and testing of right angles and for
testingflatness of surface.
Marking Gauge: It is a tool which has one projected marking pin and is used to
markaccurate lines parallel to the true edge of a wooden piece.
Holding Tools:
Carpenter’s Vice: It is used for holding the work for planning, sawing and chiseling.
Thewhole vice is made of iron and steel. It has two jaws one of which is fixed to the side
of the table while the other is movable.
C-Clamp: It is used for holding the work projecting above the top surface of the Bench.
This is used to prevent the wood from moving forward when being planned.
Bench Stop: It is simply a block of wood projecting above the top surface of the bench.
Thisis used to prevent the wood from moving forward when being planed.
Firmer chisel Mortise chisel

Adze wood rasp file

Pincer Claw hammer

Wood joints
Cutting Tools:
Wooden Jack Plane: It consists of wooden body in which blade is set at an angle of
45degrees to the body or sole. The cutting blade used is made of high carbon steel and
is very similar to a chisel. Jack Plane is a general purpose plane and is used to produce
flat and smooth surfaces on wood.

Hand or Cross-cut Saw: It is used to cut across the grains of the stock or thick wood.
Theteeth are set alternately to the right and left of the blade, and its purpose is to make
the cut wider than the thickness of the blade. This allows the blade to move freely in the
cut, without sticking. Her teeth are set at 2.5 mm apart.

Tenon Saw or Back Saw :This saw is mostly used for cross cutting when a finer and
moreaccurate finish is required. The teeth are shaped in the form of an equilateral
triangle and generally have 13 teeth for 25 mm length.

Firmer Chisel or Straight Edge Chisel :It is a general-purpose chisel and is used
forcutting and shaping wood accurately. The width of the blade varies from 1.5 to 50
mm.
Adze: Adze is a side axe used to chop extra wood quickly by carpenters. Adze with
verylong handle is used to plane long palm tree barks in standing position and also used
as a hammer.
Miscellaneous Tools:
Pincer: It is made of steel with a hinged joint and is used for pulling out small nails from wood.

Claw Hammer :It is a dual-purpose hammer. It has a hammer face, which is used to
drive innails and claw at the other end for pulling out mails from the wood.
Wood Rasp File: It is a finishing tool used to make the wood surface smooth, remove
thesharp edges and other interior surfaces. Sharp cutting teeth are provided on its surface.
This file is exclusively used in woodwork.
Wood Joints :
There are many kinds of joints used to connect wood stock. Each joint has a definite use
and required marking, cutting and joining together. The strength of the joint depends on
the amount of contact area. If a particular joint does not have much contact area, then it
must be reinforced with nails, screws or dowels.
Lap Joint: Also called halving joint. The aim of this joint is to secure the corners
andintersections of the framing and at the same time in the same plane. They may be
usefully employed in many types of framing where strength and appearance are of
secondary consideration.
Mortise and Tenon Joint: This family of joints is a large one and does probably the
woodworker use the commonest. It consists of a rectangular peg (tenon) fitting into a
rectangular hole (mortise).

Briddle Joint: These are the reverse of mortise and tenon joints in form and are often
calledthe open mortise tenon. These joints are used where the members are of square
or near-square or near-square section and thus unsuitable for making a mortise and
tenon joint of good proportions.
Instructions

1. When you are using your thumb as a guide for cross cutting and ripping,
raise it sufficiently high.

2. Planing should be done along grains only.

3. Push the chisel away from you while chiseling.

4. Always use marking gauge (or) a mortise gauge for drawing lines.

5. Check the squareness of planned surfaces with try square.

6. Use wooden mallets for driving chisel.

7. Do not test sharpness of the edge of the cutting tools on your hand.

8. Do not keep your hands In front of the sharp edged tools while they are in use.

9. Only un wanted material should be removed.

Safety Precautions :

General :Make sure that your hands are not in front of sharp edged tools while you are
usingthem.
Saws :Be careful when you are using your thumb as a guide in cross cutting.
Chisels :
1. Never chisel towards any part of the body.
2. Test the sharpness of the cutting edge on wood or paper, not on your hand.
Exercise:

1. Lap Tee Joint

2. Mortise & Tenon Joint

Fig:1
Fig:2
 LAP TEE JOINT
Experiment No: Date:
Learning Objectives :

• To learn about different types of woods used in day - to - day life.

• Different tools used in carpentry.
• Application of different types of wood.
• Different wood cutting operations.

Aim: To prepare a Lap Tee Joint as per dimensions given in sketch.

Material Required: Teak wood 300mm X 45mm X 35mm
Tools Required:
1. Steel rule 300mm
2. Handsaw 300mm
3. Wooden jack plane 450mm
4. Try square 200mm
5. Marking gauge 200mm
6. C-Clamp 200mm
7. Firmer chisel 150mm
8. Adze 150mm
Sequence of Operations:
1. Marking 2. Planning 3. Cutting 4. Setting
Procedure:
1. Select a teak wood material and mark the size as per drawing with the help of
marking tools like steel rule, marking gauge, try square.
2. Planning of sides with the help of wooden jackplane to maintain the required
dimensions.
3. Fix the work piece in carpentry vice and cut into two equal pieces of size
150mm X 30mm with the help of handsaw.
4. Mark the two work pieces for male cutting and groove cutting as per dimensions.
5. Fix the work pieces one by one on the bench with the help of ‘C’ Clamp and a
groove is made as shown in drawing with the help of chisels and adze.
6. The two work pieces are fitted to make Lap Tee Joint as per drawing.
Precautions :
1. We should be careful while marking and planning
2. Special care is required while cutting the groove with firmer chisel so that the
dimension is not exceeded.
Result: Lap Tee Joint is prepared as per given dimensions
 Mortise and Tenon Joint
Experiment No: Date:
Learning Objectives :

• To learn about different types of woods used in day - to - day life.

• Different tools used in carpentry.
• Application of different types of wood.
• Different wood cutting operations.

Aim: To prepare a Mortise and TenonJoint as per dimensions given in sketch.

Material Required: Teak wood 300mm X 45mm X 35mm
Tools Required:

1. Steel rule 300mm

2. Marking gauge 200mm
3. Try square 200mm
4. Wooden jack plane 450mm
5. Hand saw 300mm
6. Firmer chisel 150mm
7. Mortise chisel 150mm
8. C-clamp 200mm
9. Adze 150mm

Sequence of Operations:
1. Marking 2. Planning 3. Cutting 4. setting

Procedure:
1. Select a teak wood material and mark the size as per drawing with the help of
marking tools like steel rule, marking gauge, try square.
2. Planning of sides with the help of wooden jackplane to maintain the required
dimensions.
3. Fix the work piece in carpentry vice and cut into two equal pieces of size 150mm X
30mm with the help of handsaw.
4. Mark the two work pieces for male cutting and groove cutting as per dimensions.
5. Fix the work pieces one by one on the bench with the help of ‘C’ Clamp and a groove
is made as shown in drawing with the help of chisels and adze.
6. The two work pieces are fitted to make Lap Tee Joint as per drawing.
Precautions :
1. We should be careful while marking and planning
2. Special care is required while cutting the groove with firmer chisel so that the
dimension is not exceeded.
Result: Mortise and TenonJoint is prepared as per given dimensions
VIVA QUESTIONS :

1. What are the various types of wood material used in carpentry?

2. What is the sequence of operations in carpentry?
3. Classify the tools used in carpentry.
4. Name some measuring tools.
5. Name some marking tools.
6. Name some cutting tools.
7. Name some finishing tools.
8. Name some work holding devices.
9. What is the use of mortise gauge?
10. What is the use of wooden jackplane?
11. What are various types of saws?
12. What are various types of chisels?
13. What is the difference between saw and chisels?
14. What is the use of try square?
15. What is the use of C-Clamp?
16. Differentiate between bench vice and C-clamp
17. What is the use of adze?
18. What are the various types of joints
19. Which joint is more strongest.. justify your answer
20. What is the difference between marking gauge and mortise gauge
21. What is the use of claw hammer
22. Why saw setting is required
23. What are the safety precaution should be taken in carpentry
24. Why butt joint is not performed in carpentry
25. Identify the parts of wood jackplane
26. Define carpentry
27. What is the use of pincer
28. Which chisel is convenient for making
29. What is the max. length you can measure with steel rule
30. Identify the given joint.
FITTING
 BENCH VICE HACK SAW

Try square Square file

Triangular file Scriber

Odd legs calipers Divider

Dot punch Center punch

INTRODUCTION
Fitting is the process of assembling parts of get the necessary fit. Some operations do not
require
the use of machines. e.g. filing. stamping, chipping and sawing operations.
The shop where these operations are carried out is called the fitting shop. An operator
who
does the fitting work is called fitter. There arc various groups of fitters such as bench fitter.
assemble
fitter and erection fitter, etc. To perform fitting operation, various tools are needed.
FITTING TOOLS
The tools used in the fitting shop are classified as follows:
I . Marking and measuring tools
2. Work holding tools
3. Striking tools
4. Cutting tools
5. Finishing tools
6. Other tools
Marking and Measuring Tools
A work that has to be marked and measured are carried out by the following tools. Some
of the marking and measuring tools and their uses are discussed below.
Steel rule: It is a linear measuring tool usually available at lengths of 150 mm and 300 mm
graduated both in millimetres and inches .It is made up of tempered rust-free steel or
stainless steel. The least count of a steel rule is 1 mm.
callipers: Callipers are used for measuring curved surfaces. There are two types of
calipers.namely inside callipers and outside callipers.
An inside callipers are used to measure the outer diameter of pipe. An outsidecallipers are
used to measure the inner diameter of a pipe.
Vernier callipers: Vernier callipers are made of steel having graduations both on the bar
and on the sliding jaw They are used for measuring the inside, outside diameters and
depth of a workpiece. The least count of verniercallipers is 0.02 mm.

Vernier height gauge: It is made of steel having an upright steel bar fixed to a steel base.
A movable jaw is fitted with an upright bar with the help of the screw. It is used to mark the
work to the required size of machining and also to check the height of the work. The least
count of a vernier height gauge is 0.02 mm.

Scribers: Scribers made of carbon steel and have a sharp-pointed edge .They are used to
scribe the workpiece.

Dividers: Dividers are used for dividing, and marking length equally. They have both
points sharpened like needle points. The dividing length may be adjusted by a thumb
screw provided on the dividers.

Try square: A try square is used for marking and testing right angles. It consists of a steel
blade riveted at a right angle to the edge of the machined stock. The blade length varies
from 150 to 300 mm.
Dot punch: It has conical points with an angle 600 . It is used to make dots along a

marked line on the workpiece.

centre punch: The point of the punch is made to 90°. It is used to mark a drill point on the
work for setting the drill bit for drilling operation

Surface plate: A surface plate is made of grey cast iron. It is used for testing the flatness
of a workpiece. It also supports a vernier height gauge. and a surface gauge while
measuring.

Angle plate: An angle plate is made of grey cast iron. It has two plane surfaces at right
angles to each other. It is used in conjunction with the surface plate for supporting the
workpiece in a perpendicular position.

Striking Tools or Hammers

Hammers are made of high carbon steel. They are used for striking nails, rivets, punches,
chisels, etc. A hammer consists of a head, peen, striking face and a handle. According to
the shape and weight of hammers, they are classified into the following types.

Ball peen hammer: One side of the ball peen hammer is flat and the other side is
spherical in shape. It is used for rounding off rivets, making ground and concave
indentations and also for flattering surfaces.

Cross peen hammer: It has a flat face on one end and a peen at right angles to the
handle. The flat face is for striking and the cross peen is used for making grooves on
workpieces.

Straight peen hammer: One head is flat and the other end has an edge parallel to the
handle. It is used for making grooves and straight indentations on workpieces.
Flat chisel Sledge hammer

Ball peen hammer Cross peen hammer

Straight peen hammer Surface plate

Height gauge Angle plate

Sledge hammer: A sledge hammer is a heavy hammer, mostly used in smithy shops and
used by stone breakers.

Soft face hammer: It is made of soft metals like copper, aluminium or lead. This hammer
is used for hammering finished jobs.

Claw hammer: It has a cut in the centre and named claw. It has a bend with a sharp
curve. The claw helps to pull out nails from walls and wooden pieces.

Mallet: A mallet is a wooden hammer. it is used in for driving a workpiece to give a tight fit.
It is also used in sheet metal works for bending thin sheets.

Types of chisels The following are types of chisels,

Cold chisel: It is a commonly used chisel in a fitting shop. it is used for cutting cold metals.
The cutting edge is slightly curved shape and its cutting angle is 600. The width of the
cutting edge varies from 20 to 25 mm and its length varies from 100 to 400 mm.

Cape chisel or cross cut chisel: A cape chisel has a long tapered cutting point. It is used
for cutting narrow grooves, key-ways, slots and channels. The length of the chisel varies
from 100 to 400 mm and Its width depends on the proportional length.

Round nose chisel: This type of chisel is used for cutting grooves in pulleys and in
shafts. The cutting edge is semicircular. The length of the chisel is about 150—250 mm
and the width is around 6—16 mm

Diamond point chisel: It is squared and bevelled to make a diamond shape cutting edge.
It is used for cutting cast iron pipes, cutting grooves and square corners edges.

Hacksaw A hacksaw is a hand tool used by the fitter for cutting operations. It has two
parts, namely a frame and a blade. One end f the frame is fixed type and the oilier is an
adjustable type. Between the frame grooves the blade is locked.
Hacksaw blade: A hacksaw blade is a cutting tool having a number of teeth set in proper
order. It has two holes at its ends for fixing it with the frame. The hacksaw blade is made
of high carbon steel. low tungsten alloy and is used for cutting mild steel, brass, copper,
aluminium, soft alloys, plastics. etc.

Setting of teeth: The teeth of blades are set a particular way so that the saw cut becomes
wider than the thickness of the blade to avoid jamming of the blade. The teeth are set to
give clearance for the blade to move forwards, backwards and also to avoid noise when
cutting. The blades are available in various shape, size and quality.

Type of blade according to size:

I. Coarse blade: 14 teeth per inch (for soft metal)

2. Medium blade: 22 teeth per inch (for medium hard metal)

3. Fine blade: 35 teeth per inch (for hard metal).

Type of blade according to hardening:

1. Fully hardened blades

2. Flexible blades

3. High speed steel blades

Finishing Tools

Finishing tools are used to remove burrs and clean the outer surface of the workpiece. The
best example for finishing tools are Files and abrasive paper.

Other Tools

Ball peen hammer

. Hammers are named, depending on their shape and material and specified by their
weight.

. Hammers are used for striking punches, cold chisels to make letters and figures on the
surface of the workpiece .

. It is also used for forging hot metal, riveting, bending, straightening and stretching. etc.

FILES

A file is a widely used finishing tool in a fitting shop. Files are made of hardened steel
having parallel rows of teeth throughout their surface.

Parts of a file: Figure shows different parts of a file.

Tang: It is a pointed part fixed on a wooden handle.

Point.- It is the opposite edge to the tang.

Heel: It is the face of the file that comes next to the tang.

Classification of Files

Files are classified according to the following factors.

Shape and cross section view

Figure classified according to their shape and cross section:

1. Flat file 2. Square file 3. Round file 4. Half round file 5. Triangular file 6. Knife edge file
Flat file: The teeth of the file is double cut and is used for rough filing works. It is
rectangular in cross section.

Dead smooth cut file: A dead smooth cut file has 40—45 teeth per centimetre. It removes
less material and gives best polish surface.

Table shows the classification of files based on grades of teeth.

FITTING PROCESS

There are several fitting operations performed on a workpiece to get required size, shape
and fit. The following operations are performed in a fitting shop.

1. Measuring and marking 2. Sawing 3. Filing 4.Scraping 5. Chipping 6.Drilling

7.Reaming 8. Tapping

Measuring and Marking

Measuring is the first step and then marking is done in fitting work. Marking is done by
using a scriber or by surface gauge. The surface of the workpiece to be marked is coated
with chalk and the measurement is taken from the centre line or from a filed (finished)
edge. The workpiece is held on the surface plate or V’ block or angle plate for marking.
Sawing
Sawing is the process of cutting different metal pieces to the desired shape and size by
using a hacksaw.
In sawing operation:
• The handle of hacksaw should be in the right hand.
• The teeth of the hacksaw blade should be in the direction of the cut and
away from the handle.
• The blade should be held straight and correctly tensioned.
• Little downward pressure is needed in a forward stroke and there is no
pressure needed during a reverse stroke.

Filing

Filing is the process of removing a small amount of metal by using a file. The method of
filing depends upon the following:

I. The type of surface to be filed.

2. The type of surface texture needed.

3. The amount of material that is to be removed.

Filing methods

The following are the types of filing methods:

Longitudinal filing: Using this method the workpiece is finished to the required size in a
longitudinal direction. The file is moved parallel the longer side of the work. This is the
most commonly used filing method.

Transverse filing: The stroke of the file is at right angles to the longer side of work. Using
this process the material is brought close to the final finishing state.

Diagonal filing: The stroke applied on the workpiece is at an angle of 450

• The diagonal filing process is used to reduce heavy material from the workpiece.
• The teeth of the hacksaw blade should he in the direction of the cut and away from the
handle.

• The blade should I held straight and correctly tensioned.

Little downward pressure is needed in a forward stroke and there is no pressure needed
during a reverse stroke.
 SQUARE FIT

Experiment No: Date:

Aim:To prepare a square fit as per the given dimensions

Materials required: M.S. plates 50mm X 50mm X 4mm 2 no’s

Tools required ;
1. Steel rule 300mm
2. Scriber 200mm
3. Try square 200mm
4. Dot punch 100mm
5. Flat file 300mm
6. Hack saw 300mm
7. Square file 300mm
8. Chisel 200mm

Procedure:
1. Take M.S plates, mark the dimensions as per the diagram by using steel rule and
scriber on chalk applied surface
2. Filing the edges to remove excess material and burrs.
3. Punch dots along the marked lines with dot punch.
4. Cut the unwanted material with the help of hacksaw and chisel.
5. Filing cutting edges with square file to get surface finish of the edges.
Precautions:
1. Cut the material along marked lines towards removing side
2. Hold hacksaw proper position to cut the material
3. Remove burrs properly by filing.
4. Do not test sharpness of cutting tools on your body
5. Hold the work piece firmly in bench vice while cutting.
Result :
Required square fit is prepared as per the given dimensions.
 “L “ FIT

Experiment No: Date:

Aim:To prepare a “L” fit as per the given dimensions

Materials required: M.S. plates 30mm X 30mm X 4mm 2 no’s

Tools required ;
1. Steel rule 300mm
2. Scriber 200mm
3. Try square 200mm
4. Dot punch 100mm
5. Flat file 300mm
6. Hack saw 300mm
7. Triangular file 300mm
8. Chisel 200mm

Procedure:
1. Take M.S plates, mark the dimensions as per the diagram by using
steel rule and scriber on chalk applied surface
2. Filing the edges to remove excess material and burrs.
3. Punch dots along the marked lines with dot punch.
4. Cut the unwanted material with the help of hacksaw and chisel.
5. Filing cutting edges with square file to get surface finish of the edges.
Precautions:
1. Cut the material along marked lines towards removing side
2. Hold hacksaw proper position to cut the material
3. Remove burrs properly by filing.
4. Do not test sharpness of cutting tools on your body
5. Hold the work piece firmly in bench vice while cutting.
Result :
Required square fit is prepared as per the given dimensions.
TIN SMITHY
 Bench vice Standard Wire Gauge(SWG)

Try Square Scriber

Divider Odd legs calipers

Ball peen Hammer Cross peen Hammer

 Straight Peen Hammer Straight snip

Curved snip Anvil

Nose plier Cutting plier

Nylon mallet Rubber mallet

Wooden mallet steel rule

 Forming stakes

Sheet metal joints

 TIN SMITHY
Introduction :

Many engineering and house articles such as boxes, cans, funnels, ducts
etc. are made from a flat sheet of metal. The process being known as tin smithy.
For this the development of the article is first drawn on the sheet metal, then cut
and folded, to form the required shape of the article.
Allowance should be given in the drawing stage for folding and bending. This
allowance depends upon the radius of the bend and thickness of the sheet metal.

Sheet Metal Materials :

A variety of metals are used in a sheet metal shop such as galvanized Iron,
black, Iron, tin, Stainless Steel, copper and Aluminium.

Hand Tools :

The common hand tools used in sheet metal work are steel, try square, Wire
gauge,
Scriber, Ball peen hammer, Nylon Mallet, Snips Divider, Stakes, Cutting plier and
Soldering
Iron. Here, the details of tools that are being equipped by our workshop purpose
only are presented.
Wire Gauge: The thickness of sheet is referred in numbers known as standard wire
gauge(SWG). The gaps in the circumference of the gauge are used to check the gauge
number.

Steel Rule : It is a strip of steel with graduations on its edges. It is used for
measuring andsetting out dimensions.
Scriber :A scriber is a slender steel tool, used to scribe or mark lines on sheet
metal.

Snips :Hand shears or snips are used to cut sheet metal.

Straight Snips : These are having straight blades and are used for cutting along
straightlines and for trimming edges.

Curved Snips : These are having curved blades and are used for cutting circles
andirregular shapes.
Divider :It consists of two pointed legs. The points are hardened and tempered
toprevent wear. It is used for transferring the sizes and scribing curves or circles.

Bench vice :It is generally used for holding and bending the work piece.

Hammers :Light weight hammers and mallets are used in sheet metal work.

Ball Peen Hammer : It has a cylindrical, slightly curved face and a ball head. It is a
generalpurpose hammer used mostly for riveting in sheet metal work.

Cross Peen Hammer : It has a tapered peen end and is perpendicular to the
handle. Becauseof this, it can reach awkward corners.

Straight Peen Hammer : It has the peen end similar to the cross peen, but it is
positionedparallel to the handle which can be used conveniently for certain
operations of folding.

Cutting Plier :Used for holding, cutting and bending works.

Nylon Mallet : It is used for bending and folding work. It is light in weight, covers
more areaand do not damage the surface area.

Stakes :Stakes are made of steel and forged in a variety of shapes and sizes.
These areused as supporting tool and to form, seam, bend or rivet sheet metal
objects.
Anvil :Anvil provides the necessary support during hammering. It is also useful for
operations such as bending. Its body is generally made of mild steel and a strip of
high carbon steel about 20 mm thick is welded on top to provide hard face.

Sheet Metal Joints :

 Various types of joints are used in sheet metal work, to suit the varying
requirement. Some commonly used sheet metal joints and folded edges are shown
in the figure. These are self-secured joints, formed by joining together two pieces of
GI sheet metal and using the metal itself to form the joint.

Sheet Metal Layout:

The shapes of most articles made with sheet metal are in few geometrical
forms. All these forms are made from flat sheet; therefore the first requirement is
developing the lines, which forms the pattern. The development or stretch out of a
job is called pattern and developing lines which forms a pattern is layout. It may be
drawn on paper first and then transferred in the sheet or it may layout directly on
sheet metal. When a pattern is made repeatedly, it is generally made of metal and
referred to as a template.

Insturctions :

1. Draw the development of object to be prepared with true dimensions only.

2. Use curved snip for trimming along inside curves.
3. Always provide folding (Hem) for top edges of the object to avoid sharp
edges and to stiffen the sheet.
4. Ground properly the exposed metal parts of electrically heated soldering
iron.
5. For good soldering the metals to be joined must free from dirt, grease and
oxide.
6. Do not pull (or) peel the cut portion by hand while cutting with snip.
7. Do not bend the sheet with hand, always use nylon mallet with proper
support.

SafetryPrecautions :

1. Use hand leather gloves while handling heavy sheets.

2. Avoid feeling the cut portion by hand while cutting with snip.
3. Do not let sheet metal slip through the hands.
4. Never carry tools in pockets.

Exercise:

1. Rectangular Tray
2. Pipe TEE Joint
 RECTANGULAR TRAY
Experiment No. Date :
Learning objectives:
➢ To learn about different types of sheet metal operations.
➢ To learn about different tools used in sheet metal operations.
➢ To understand applications of sheet metal working process in day- to – day
life

Aim :To prepare a Rectangular tray as per dimensions given in the sketch.

Materials Required :118 mm x 88mm size Galvanized Iron sheet.

Tools Required :
1. Steel rule 300 mm
2. Scriber 150 mm
3. Try square 200 mm
4. Straight snip 200 mm
5. Curved snip 200 mm
6. Ball peen hammer 750 grams
7. Nylon mallet 450 grams
8. Cutting plier 200 mm
9. Rectangular stake 70mm x 40 mm x 20mm

Sequence of Operations:
1. Marking 2. Cutting 3. Folding 4.Bending 5. Finishing
Procedure:
1. Take a galvanized iron sheet flatten it properly by light blows using nylon mallet.
2. From the drawing of the Rectangular tray (fig1) obtain the necessary
dimensions, by the development of surface, of the sheet to be cut.
3. Do the marking on the sheet of metal using the scriber and scale as per dimensions
obtained providing allowance for bending at the edges.
4. Cut of the sheets using snips.
5. Using nylon mallet and cutting plier join the two edges of the sheet.
6. Finish the work by using rectangular stake.
Precautions:
1. Should pay attention while marking.
2. Bending and finishing should be done neatly and straight.
3. Cutting should be done carefully along the marked lines, and while cutting care
should be taken to cut it at the further end. Otherwise the metal sheet might bend
giving wrong shape.
Result: Required Rectangular Tray is obtained.
 Development of pipe “T” joint

Development of pipe “T” joint

PIPE “T” JOINT

Experiment No. Date :

Learning objectives:
➢ To learn about different types of sheet metal operations.
➢ To learn about different tools used in sheet metal operations.
➢ To understand applications of sheet metal working process in day- to – day life

Aim :To prepare a pipe “T” joint as per dimensions given in the sketch.
Materials Required :170 mm x 100mm size Galvanized Iron sheets 2 no’s.

Tools Required :
1. Steel rule 300 mm
2. Scriber 150 mm
3. Try square 200 mm
4. Straight snip 200 mm
5. Curved snip 200 mm
6. Ball peen hammer 750 grams
7. Nylon mallet 450 grams
8. Cutting plier 200 mm
9. Cylindrical stake Ø50 mm

Sequence of Operations:
1. Marking 2. Cutting 3. Folding 4.Bending 5. Finishing
Procedure:
1. Take a galvanized iron sheet flatten it properly by light blows using nylon mallet.
2. From the drawing of the pipe “T” joint (fig2) obtain the necessary
dimensions, by the development of surface, of the sheet to be
cut.
3. Do the marking on the sheet metal using the scriber and scale as per dimensions
Obtained, providing allowance for bending at the edges.
4. Cut of the sheets using snips.
5. Using nylon mallet and cutting plier join the two edges of the sheet.
6. Select the cylindrical stake and roll it to obtain cylindrical shape.
7. Join two pieces to obtain pipe “T” joint by soldering.
Precautions:
1. Should pay attention while marking.
2. Bending and finishing should be done neatly and straight.
3. Cutting should be done carefully along the marked lines, and while cutting care
should be taken to cut it at the further end. Otherwise the metal sheet might bend
giving wrong shape.
Result: Required Pipe “T” joint is obtained.

VIVA QUESTIONS

1. What is the raw material used in Tin smithy for doing experiments
2. Classify the tools used in Tin smithy
3. Name some measuring tools
4. Name some marking tools
5. Name some cutting tools
6. Name some finishing tools
7. What is the use of Nylon mallet
8. What is the purpose of given tool
9. Differentiate between mallet and Hammer
10. Differentiate between straight snip and curved snip
11. What is the purpose of snip
12. What is the use of anvil
13. What is the purpose of Stake
14. What is the use of scriber
15. What is use of cutting plier
16. What is the supporting tool used to obtain the final shape of the Model
17. What type of development is applied for Plain Pipe
18. What type of development is applied for Rectangular tray
19. What type of development is applied for Funnel
20. What is the full form of SWG
21. Tell some precautions should be taken in Tin Smithy Trade
22. What are the various types of hammer
23. What do you mean by Galvanization
24. Draw any sheet metal joint symbols
25. Name different parts of anvil
26. What is the difference between cross peen hammer and straight peen hammer
27. What are the different types of metal sheets available
28. What is the use of divider
29. What is the sequence of operations in Tim Smithy
30. How did you join metal sheets
ELECTRICAL
 Godown wiring

Stair case wiring Series lamp wiring

Flouroscent lamp wiring

Incandescent lamp
Compact Flouroscent lamp Light emitting diode

Single ended box spanner Single ended spanner

Double ended spanner Adjustable wrench

 Offset double ended box spanner Allen wrench

Standard Wire gauge Nose Plier

Cutting plier Line tester

Double fold knife Insulated Screwdriver

 HOUSE WIRING

Introduction:

Power is supplied to the domestic installations through, the phase and a neutral,

forming a single phase A.C. 230V, two wire system. For industrial establishments, power is

supplied through three-phase four-wire system to give 440V. Figure shows the power

tapping for domestic and industrial purposes. The neutral is earthed at the sub-station of the

supply.

As a safe practice all single-phase devices such as switches, fuses etc., are

connected to the live conductor. All electrical conductors and cables are colored coded and

must be correctly connected up. Electrical wiring is defined as a system of electrical

conductors, components and apparatus for conveying electrical power from the source to

the point of use. The wiring system must be designed to provide a constant voltage to the

load.

Elements of House wiring:

1. Fuses and circuit breakers

2. Electrical switch

3. Plug

4. Socket outlet

5. Lamp holder

6. Ceiling Rose

7. Main switch

8. Incandescent light
Wires and wire sizes:

A wire is defined as a bare or insulated conductor consisting of one or several

strands.

An insulated wire consists of a conductor (Silver/Copper/Aluminium) with insulating

material made of vulcanized Indian Rubber (VIR) or Poly Vinyl Chloride (PVC).

Wire sizes are specified by the diameter of the wire, using a standard wire
gauge
(SWG), which also gives an idea of the current carrying capacity. The specification

consists of both the number of strands and diameter of each wire in it. For Example,

the specification 3/18 PVC consists of 3 strands of 18 gauge each.

Various systems of wiring:

1. Cleat wiring

2. C.T.S. / T.R.S.Wiring (Cap tyer sheathed/ Tough rubber sheathed

wiring)

3. Wooden casing & capping wiring

4. Lead sheathed wiring

5. Conduit wiring

6. PVC casing & capping

Wiring methods:

1. Series circuit

2. Parallel circuit

Fundamentals of Electricity:

Electricity: Electricity is a form of energy, which cannot be seen. But can be felt and

effectslike magnetic effect, Heating effect and Chemical effect.

Voltage: It is a pressure which makes the electricity to flow. The unit of measure is

Volt. Thesymbol used is ‘V’. The instrument used to measure is Voltmeter.

Current: The free flow of electrons is called as current. The unit to measure current is
‘Ampere’.

The symbol is ‘A’. The instrument used to measure the current is Ammeter.
Resistance: It is opposition to current. The unit of resistance is ‘Ohm’. The symbol of
ohm isΩ. The resistance is measured by Ohmmeter.

Wattage (Power): It is the rate of energy consumption,

The following are the formulae for calculation.

Voltage V or E = W / I = IR

Current I = E / R = W / E

Resistance R = E2 / W = E / I

Wattage W = I2R = EI = E2 / R

House Wiring Tools:

Combination Pliers :Used for holding, twisting or cutting of wires.

Side cutting Plier: Used for Cutting at narrow places or ordinary places for
removing
insulation.

Round Nose Plier or Flat Nose Plier: Used for holding, twisting or joining the wire at
narrow

places.

Firmer Chisel: Used for chipping, scrapping and grooving the wood.
Cold chisel: Used for chipping, Boring and channeling in walls.

Tenon saw or back Saw: Used for cutting wooden boards, Block casting etc.

Hack saw: Used for cutting conduit GI pipes or mild steel.

Mallet: Used as a hammer and made of wood

Double Blade Electric knife: It has two blades, one for removing insulation of wires

andanother for cleaning the wires

Soldering Iron: Used to solder small joint terminals

Poker: Used for making pilot holes for fixing wood screws.

Line Tester: Used for testing the current.

Royal Plug Tool: It is made of steel and is used for making holes in the stone wall

or concretewall for fibre made Royal plugs.

Screw driver: Used for loosening, tightening and to keep the screws in position.

Ball Peen Hammer: Used for fitting nails in the walls or wooden boards.

Instructions :

1. When closing the electric switch, always grasp the switch by the insulated
handle.

2. Do not run too many electrical items from one point.

3. Use fuses and circuit breakers of proper capacity, so as to interrupt the

current before it becomes dangerous.

4. Disconnect the units to be repaired free from power supply and make sure
that they might not be energized while the repair work continue

5. Do not pour water to put-off fires in electric wires and electric equipment. You
will be subjected to electric shock or you will be electrocuted. Use sand to
put-off fires in electric items.

6. Whenever there is power failure, put-off the power supply to all equipment, in
order to prevent spontaneous recovery.

7. Never remove a plug from an outlet by pulling cord. Always pull by holding the
plug.

8. While testing always keep one hand in your packet. If the hands are in contact
with a circuit, current will flow across your body and is more dangerous.

9. Electricity has no respect for ignorance. Do not apply voltage or turn-on any
device until it has been properly checked.

10. Check earth connection before switching on portable equipment.

Safety Precautions :
1. First we should be insulated
2. Care should be taken while fixing the fuse
3. All the switches should be off before power supply.
4. When power is on, the terminal wires should not be touched
EXPERIMENT-2
Aim: To control one lamp from to different places(Stair Case Wiring).
Learning Objectives:
➢ Estimate the required material to control one lamp from two different places
➢ Practice connection of lamp with two way switch
➢ Control one lamp from two difffernt places
Tools Required:

S.No Name of the Tool Accounting Unit Size Qty

1 Combinatin Plier No’s 200mm 1

2 Neon Tester No’s 500 Volts 1

3 Heavy Duty Screw Driver No’s 300 mm 1

4 Ball Peen Hammer No’s 500 gr 1

5 Wooden Mallet No’s 500gr 1

6 Pocker No’s 200 mm 1

7 Firmer Chisel No’s 20 mm 1

Hack Saw with 24 Teeth per

8 No’s 300 mm 1
Inch

9 Power Drilling Machine No’s 350 Watt , 240Volts 1

10 Drill Bits No’s 3 mm, 6mm 1Each

11 Steel Measuring Tape No’s 5m 1

12 Round Rasp Cut File No’s 200 mm 1

13 Flat Rasp Cut File No’s 200 mm 1

14 Connector Screw Driver No’s 200mm 1

15 Electrcian’s Knife No’s 100mm 1

Materials Required:
S.No Name of the Material Accounting Unit Size Qty

1 PVC Conduit No’s 1"Dia, 1.5mmthick 2 Length

2 PVC Junction Box,1W No’s 1"Dia, 1.5mmthick 1

3 PVC Junction Box,3W No’s 1"Dia, 1.5mmthick 2

4 PVC ShortL – Bend No’s 1"Dia, 1.5mmthick 1

5 PVC Gang Box,1W No’s 100mmx 75mm 2

6 Two Way Switch No’s 6A, 240V 2

7 Straight Batten Holder No’s 6A, 240V 1

8 Ceiling Plate No’s 90 mm, 1.5 mm 1

9 Base Saddles No’s 25mm 20

10 Wooden Screws No’s 5, 12 mm 25

11 Wooden Screws No’s 6, 25 mm 20

12 PVC Insulated Copper Wire మీటర్స్ 1.5Sq.mm 10 m

13 PVC Insulated Tape No’s 1”Wide 1m

14 Lamp No’s 100W, 240V 1

15 Flexible Spring No’s 5m 1

Procedure:
1. Take installation plan and mark the positions of lamp holder, switches, cable run and
auxiliary accessories.
2. Cut the PVC Conduit in to required length as per the installation plan.
3. Install pvc conduit using base saddles and screws.
 4. Remove top covers of pvc junction boxes & gang boxes and install it as per the
installation plan.
5. Fix two way switches on the to covers of gang boxes.
6. Install lamp holders and switches as per the installation plan.
7. Take circuit diagram.
8. Run the cable and make connections to various accessories as per circuit diagram.
9. Close the top covers of all junction boxes and gang boxes.
10. Insert lamp in the lamp holder.
11. Switch ON supply to the circuit, and by operating switches as per the operation table,
lamp is controlled.
12. After Controlling, Switch OFF Supply to the circuit.

Precautions:

1. While fixing saddes on pvc conduit in horizontal and vertical pojitions follow BIS
recommendations.
2. All connections must be neat and tight.
3. Check the cable continuity, and leave 15 cm extra cable for allowance.
4. Installation appearance shoud be neat and good.

Installation Plan:
Circuit Diagram:
Operation Table:

Switch - 1 Switch - 2 Lamp

OFF OFF OFF

ON OFF ON

OFF ON ON

ON ON OFF

EXPERIMENT-2
Aim: To practice Godown wiring
Learning Objectives:
➢ Estimate required material for godown wiring.
➢ Practice connection of one way & two way switches with lamps.

Tools Required:
S.No Name of the Tool Accounting Unit Size Qty

1 Combination Plier No’s 200mm 1

2 Neon Tester No’s 500 Volts 1

3 Screw Driver No’s 300 mm 1

4 Ball Peen Hammer No’s 500 gr 1

5 Wooden Mallet No’s 500 gr 1

6 Pocker No’s 200 mm 1

7 Firmer Chisel No’s 20 mm 1

 Hack Saw
8 No’s 300 mm 1
with 24 teeth per Inch

9 Power Drilling Machine No’s 350 Watts, 240Volts 1

10 Drill Bits No’s 3 mm, 6mm Each 1

11 Steel Measuring Tape No’s 5m 1

12 Round Rasp Cut File No’s 200 mm 1

13 Flat Rasp Cut File No’s 200 mm 1

14 Connector Screw Driver No’s 200mm 1

15 Electrician’s Knife No’s 100mm 1

Materials Required:

S.No Name of the Material Accounting Unit Size Qty

1 PVC Condiut No’s 1"Dia, 1.5mmthick 4 Lengths

2 PVC Junction Box, 1W No’s 1"Dia, 1.5mmthick 4

3 PVC Junction Box,3W No’s 1"Dia, 1.5mmthick 5

4 PVC Short L - Bend No’s 1"Dia, 1.5mmthick 1

5 PVC Gang Box,1W No’s 100 mmx 75 mm 4

6 One Way Switch No’s 6A, 240V 1

7 Two Way Switch No’s 6A, 240V 3

8 Straight Batten Holder No’s 6A, 240V 4

9 Ceiling Plate No’s 90 mm, 1.5 mm 4

10 Base saddles No’s 25mm 25

11 Wooden Screws No’s 5, 12 mm 25

 12 Wooden Screws No’s 6, 25 mm 30

13 PVC Insulated Copper Wire mts 1.5Sq.mm 30m

14 PVC Insulated Tape No’s 1”Wide 1

15 Lamp No’s 100W, 240V 4

16 Flexible Spring No’s 5m 1

Procedure:
1. Take installation plan and mark the positions of lamp holder, switches, cable run and
auxiliary accessories.
2. Cut the PVC Conduit in to required length as per the installation plan.
3. Install pvc conduit using base saddles and screws.
4. Remove top covers of pvc junction boxes & gang boxes and install it as per the
installation plan.
5. Fix two way switches on the to covers of gang boxes.
6. Install lamp holders and switches as per the installation plan.
7. Take circuit diagram.
8. Run the cable and make connections to various accessories as per circuit diagram.
9. Close the top covers of all junction boxes and gang boxes.
10. Insert lamp in the lamp holder.
11. Switch ON supply to the circuit, and by operating switches as per the operation table,
lamp is controlled.
12. After Controlling, Switch OFF Supply to the circuit.

Precautions:

1. While fixing saddes on pvc conduit in horizontal and vertical pojitions follow BIS
recommendations.
2. All connections must be neat and tight.
3. Check the cable continuity, and leave 15 cm extra cable for allowance.
4. Installation appearance shoud be neat and good.
Installlation Plan:
Circuit Diagram:

Operation Table:

Master Switch Switch - Switch - Switch - Lamp - Lamp - Lamp - Lamp -

(S1) 2 3 4 1 2 3 4

OFF OFF OFF OFF OFF OFF OFF OFF

ON OFF OFF OFF ON OFF OFF OFF

ON ON OFF OFF OFF ON OFF OFF

ON ON ON OFF OFF OFF ON OFF

ON ON ON ON OFF OFF OFF ON

VIVA QUESTIONS

1. Name the three fundamental terms related to Electricity

2. What is the relation between current, voltage and resistance.
3. State ohm’s law.
4. What are the units of current, voltage and resistance
5. Write the symbol of ohm.
6. Draw the circuit diagram of given connection
7. What is the value of voltage of single phase supply
8. What is the value of voltage of three phase supply
9. What is the unit of power
10. State the relation between HP and Watts
11. What do you mean by SPT and DPT
12. Why fluorescent lamp is white
13. What is the use of choke in fluorescent lamp connection
14. Once the fluorescent lamp glows, one item is not necessary in the circuit.
What is that ?and why?
15. What is the purpose of stair case connection
16. What is the purpose of godown connection
17. The electricity department gives the bill in units. What is meant by unit
18. What do you mean by KWH
19. In circuit diagram what is the significance of R,Y,B
20. What are the different color wires used in electric circuit
21. How will you represent SPT in circuit diagram
22. State the difference between single phase and three phases connection
23. What is the equivalent resistance When two resisters R1 and R2
connected in series
24. What is the equivalent resistance When two resisters R1 and R2 connected in
parallel
25. What is the disadvantage in series lamp connection
26. What type of connection is provided in domestic electric wiring
27. What are the various tools used in House wiring
28. State the function of given tool
29. What is the relation between power, voltage and current
30. What is meant by SWG