Workshop practice

WORKSHOP PRACTICE
16ME103

LAB MANUAL
Student name: Vakalapudi Shashank
Regd no: 211FA19041

DEPARTMENT OF MECHANICAL ENGINEERING

VFSTR Deemed to be UNIVERSITY
2017-18

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CERTIFICATE

This is to certify that Vakalapudi Shashank being regd. no 211FA19041 Is a

student of I/IV B. Tech has completed ……………….. Experiments in WORKSHOP
PRACTICE during the academic 2017-2018.

Signature of Signature of lab

Head of the department in charge

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LIST OF EXPERIMENTS
E.No List of experiments

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Index
S.No Experiment Page. No Remarks

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CARPENTRY

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CARPENTRY
THEORY
Marking and measuring tools:

Accurate marking and measurement is very essential in carpentry work, to produce parts to exact
size.

Steel rule:

It is an important tool for linear measurement. It can also be used as a marking tool.

Steel tape:

It is used for large measurements, such as marking on board and checking the overall dimensions
of the work.

Marking gauge:

It is a tool used to mark lines parallel to the edge of a wooden piece. It consists of a square
wooden stem with a sliding wooden stock (Head) on it. On the stem is fitted with a marking pin,
made of steel. A mortise gauge consists of two pins. In this, it is possible to adjust the distance
between the pins, to draw two parallel lines on the stock.

Try square:

It is used for making and testing the squareness and straightness of planed surfaces. It consists of
a steel blade, fitted in a cast iron stock. It is also used for checking the planned surfaces of
flatness. Its size varies from 150 to 300mm, according to length of the blade; it is less accurate
when compared to the try square used in the fitting shop.

Compass and divider:

They are used for marking arcs and circles on the planed surfaces of the wood.

Scriber for Marking knife:

It is used for marking on timber. It is made of steel, having one end pointed and the other end
formed into a sharp cutting edge.

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Bevel:

It is used for laying-out and checking angles. The blade of the bevel is adjustable and may be
held in place by a thumb screw. After it is set to the desired angle, it can be use in much the same

way as a try square. A good way to set it to the required angle is to mark the angle on a surface
and then adjust the blade to fit the angle.

Cross-cut or Hand saw:

It is used to cut across the grains of the stock. The teeth are so set that the kerfs will be wider
than the blade thickness. This allows the blade to move freely in the cut, without sticking.

Rip saw:

It is used for cutting stock either along or across the grains. It is used for cutting tenons and in
fine cabinet work. However, it is used for small and thin cuts.

Chisels:

Chisels are used for cutting and shaping wood accurately. Wood chisels are made in various
blade widths, ranging from 3 to 50 mm. They are also made in different blade lengths. Most of
the wood chisels are made into tang type, having a steel shank which fits inside the handle.
These are made of forged steel or tool steel blades.

Firmer chisel:

The word ‘firmer’ means’ Stronger’ and hence firmer chisels are stronger than other chisels. It is
a general purpose chisel and is used either by hand pressure or by a mallet. The blade of a firmer
chisel is flat.

Dovetail chisel:

It has a blade with a beveled back, due to which it can enter a sharp corner for finishing, as in
dovetail joints.

Mortise chisel:

It is used for cutting mortises and chipping inside holes, etc. the cross-section of the mortise
chisel is proportioned to withstand heavy blows during mortising. Further, the cross section is
made stronger near the shank.

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T-LAP JOINT
Experiment no: Date:

AIM: To make a required t-lap joint from a given work piece of size 50x50x250 mm.

TOOLS REQUIRED: Carpenter’s vice, steel rule, jack plane, try square, marking gauge, 25
mm firmer chisel, cross cut saw, tenon saw, scriber and mallet.

MATERIAL REQUIRED: 50x50x250 mm wood-two pieces.

SEQUENCE OF OPERATIONS: 1. Measuring & cutting 2. Planning 3. Marking

4. Chiseling 5.finishing 6. Inspection

Procedure:

1. The given work piece is checked to ensure its correct size.

2. The work piece is firmly clamped in the Carpenter’s vice and any two adjacent faces are
planned by the jack plane and the two faces are checked for squareness with the try
square.
3. Marking gauge is set and lines are drawn at 50 and 50 mm, to mark the thickness and
width of the model respectively.
4. The excess material is first chiseled out with firmer chisel and then planed to correct size.
5. The mating dimensions of the parts X AND Y are then marked using scale and marking
gauge.
6. Using the cross-cut saw, the portions to be removed are cut in both the pieces, followed
by chiseling and also the parts X and Y are then marked using cross-cutting, using the
tenon saw.
7. The ends of both the parts are chiseled to the exact lengths.
8. A fine finishing is given to the parts, if required so that proper fitting is obtained.
9. The parts are fitted to obtain a slightly tight joint.

SAFETY PRECAUTIONS:

1. Tools that are not being used should always be kept at their proper places.
2. Make sure that hands are not in front of sharp edged tools while using them.
3. Sharp tools are not only to be used. A dull tool requires excessive pressure, causing the
tool to slip.
4. Never chisel towards any part of the body.

RESULT: The T-Lap joint is thus made by following the above sequence of operations.

SIGNATURE OF STAFF

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MORTISE AND TENON JOINT

Experiment no: Date:

AIM: To make Mortise and Tenon joint.

APPARATUS AND TOOLS:

Carpenter’s vice, Steel rule, Jack plane, Try-square, Marking gauge, 25mm Firmer chisel, 6mm
Mortise chisel, Cross-cut saw, Tenon-saw joint and Mallet.

MATERIAL REQUIRED: 50X50X250mm Wood –Two pieces.

SEQUENCE OF OPERATIONS: Cutting, Planning, Marking, Chiseling, Pairing and finishing.

PROCEDURE:

1. The given wood piece is checked to ensure its correct size.

2. The wood piece firmly clamped in the carpenter’s vice and one of its faces was planned
by the jack plane and checked for straightness.
3. The adjacent face is then planned and the faces are checked for squareness with the
try-square.
4. Marking is set and lines are drawn at 50 and 50mm, to mark the thickness and width of
the model respectively.
5. The excess material is first chiseled out with firmer chisel and then planned to correct
size.
6. The mating dimensions of the parts X and Y are then marked by a marking gauge.
7. Using the cross-cut saw, the portions to be removed in the party are cut, followed by
chiseling.
8. The material to be removed in part x is removed by using mortise and firmer chisel.
9. The parts x and y are separated by cross-cutting with the tenon saw.

SAFETY PRECAUTIONS:

1. Tools that are not being used should always be kept at their proper places.
2. Make sure that hands are not in front of sharp edged tools while using them.
3. Sharp tools are not only to be used. A dull tool requires excessive pressure, causing the
tool to slip.
4. Never chisel towards any part of the body.

RESULT: The mortise and tenon joint is thus made by following the above, sequence of
operations

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SIGNATURE OF STAFF

FITTING

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FITTING
THEORY
1. Holding tools:
Bench vice:

The bench vice is a work-holding device.. It is the most commonly used vice in a fitting shop. It
is fixed to each bench with bolts and nuts. The vice body consists of two main parts, fixed jaw
forces the work against the fixed jaw. The greater the pressure applied to the handle, tighter is the
work held. Jaws are made of hardened steel. Serrations on the jaws ensure a good grip. Jaw caps
made of soft material are used to protect finished surfaces, gripped in the vice.

The vice body is made of cast iron which is strong in compression, weak in tension and so
fractured under shocks and therefore should never be hammered.

V-block with clamp:

The v-block is a rectangular or square block with a v-groove on one or both sides, opposite to
each other. The angle of the B' is 90o. V-Block with a clamp is used to hold cylindrical work
securely, during layout of measurements, for measuring operation or for drilling.

C-Clamp:

The jaw is round in shape and directly fitted to the threaded screw at the end. This is used to hold
work against the angle plate or V-Block or any other surface, when gripping is required. Its fixed
jaw is shaped like English alphabet, “c” and the movable

2. Marking and Measuring Tools:

Surface plate:

The surface plate is machined to find limits and is used for testing the flatness of the workpiece.
It is also used for marking out small works and is more precise than the marking table.

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Angle plate:The angle plate is made of cast iron. It has two surfaces, machined at right angle to
each other

3.Finishing tools:

Files: filing is one of the methods for removing small amounts of material from the surface of a
metal part. A file is a hardened steel tool, having cutting edges or teeth on its surfaces. On the
faces, the teeth are usually diagonal to the edge.

Types of files:

Files are classified according to their shape, cutting teeth and pitch or grade of teeth. Table gives
different types of files and their description and uses.

Type of file, description and use:

Type of file Description and use

Hand file Rectangular in section, tapered in thickness in
width.
Flat file Rectangular in section and tapered for 1/3 rd
length in width and thickness.
Square file Square in section and tapered for 1/3rd length
on all faces.
Triangle file Equilateral triangular in section and tapered
for1/3rd length on all faces. All the faces have
double cut teeth. Used for filing internal
corners.
Half round file It has one flat face, connected by a curved face
and tapered for 1/3rd length. The flat face has
double cut teeth and the curved face, single cut.
Used for filing concave surfaces and internal
corners
Round file Circular cross-section and tapered for 1/3rd
length. Used for filing for corners, grooves,
narrow slots, etc., in intricate work.
Swiss or needle file It is normally 150mm long, with cut teeth.
Used for filing corners, groves, narrow slots,
etc., in intricate work.
Filen card: It is a metal brush, used for cleaning the files, to free them from filings, clogged in
between teeth.

Center punch:

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This is similar to dot punch, except that it is ground to a conical point having 90o included angle.
It is used to mark the location of the holes to be drilled.

Calipers:

They are indirect measuring tools used to measure or transfer linear dimensions. These are used
with the help of a steel rule to check inside and outside measurements. While using, both the legs
of the caliper are set against the surface of the work, whether outside or inside and the distance
between the legs is measured with the help of a scale and the same can be transformed to desired
place.

Vernier Calipers:

These are used for measurement outside as well as inside dimensions accurately. It may also be
used as a depth gauge. It has two jaws.

Least count of vernier= one main scale division-one vernier scale division=0.05mm

Least count may be defined as the minimum dimension which can be measured by the device.

Vernier Height Gauge:

The vernier height gauge, clamped with a scriber. It is used for layout work. An off-set scriber is
used when it is required to make measurements from the surface, on which the gauge is standing.
The accuracy and working principle of this gauge are the same as those of the vernier caliper.

Vernier depth gauge:

It is used for precision measurement of blind holes, slots, grooves, etc. Principle of working is
the same as that of the vernier caliper.

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‘V’ SHAPE FITTING

Experiment no: Date:

AIM: To make ‘v’ shape fitting from the given two M.S. pieces.

APPARATUS AND TOOLS REQUIRED :

Bench vise, Steel rule, Try square, ball peen hammer, Scriber, Dot punch, Set of files, Surface
plate, jenny caliper, Hack saw with blade.

MATERIAL REQUIRED:

M.S Flat, 50x50x6mm two pieces.

SEQUENCE OF OPERATIONS:

1. Cutting 2. Filing 3. Marking & cutting 4. Assembling 5. Checking/inspection

PROCEDURE:

1. The dimensions are checked with the steel rule after removing burrs.
2. The pieces are clamped one after the other and the outer mating edges are filed and
checked for their flatness, with the help of the try square.
3. The side edges of the two pieces are filed such that they are at right angles to each other
and widths are exactly 48mm and apply the wet chalk on two pieces.
4. The given dimensions of the square fitting are marked, by using the jenny caliper, steel
rule and surface plate. Dots are punched above the scribed lines by dot punch.
5. Using the hacksaw, the unwanted portions are removed.
6. Using the flat chisel, the unwanted material from the work piece is removed.
7. The cut edges are filed by the half-round file.
8. The corners of the stepped surfaces are filed by using a square or triangular file to get the
sharp corner.
9. The pieces are fitted together and the mating is checked for the correctness of the fit, any
defects noticed are rectified by filing with a smooth file.

SAFETY PRECAUTIONS:

1. Keep the tools clean, free from dirt, oil and greases.

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2. Keep the tools sharp and in good condition. avoid holding the point portion of the tool.
Don't hold the piece in hand while cutting.
3. When sawing in a vice, make sure that work is held tight. A loose vice is dangerous.
4. Cut a small groove with a corner of the file, where a saw cut is to be started.
5. Apply force on the forward stroke only and relive the force on return stroke.

RESULT:

The required square fitting is thus obtained, by performing all the operations.

HALF ROUND FITTING

Experiment no: Date:

AIM: To make a half-round fitting from the given two mild steel pieces.

APPARATUS AND TOOLS REQUIRED:

Bench vise, Steel rule, Try square, ball-peen hammer, spring divider, Dot and center punches, set
of files, surface plate, jenny caliper and hack saw with blade.

MATERIAL REQUIRED:

M.S. FLAT 50x50x6mm(02 pieces).

SEQUENCE OF OPERATIONS:

1. Measuring 2. Cutting 3. Filing 4. Marking 5. Sawing 6.Fitting and Finishing

Procedure:

1. The burrs in the pieces are removed and the dimensions are checked with a steel rule.
2. The outer mating edges are filed, by rigidly fixing bench wise. The flatness of the edges
is also checked by the try-square.
3. The edges of the two pieces are filed such that they are at right angles to the edges 1,1
and the widths 48mm each.
4. Chalk is then applied on the surfaces of the two pieces.
5. The given half rounds(semi-circles) are marked on the two pieces, by using a jenny
caliper and spring divider.
6. Using the dot punch, dots are punched along the above scribed lines.
7. Using the hack saw the unwanted portions are removed to the extent possible.
8. The cut edges are filed by using square and Half-round files.
9. The pieces are fitted two together and the mating is checked for the correctness of the fit.

SAFETY PRECAUTIONS:

1. Keep the tools clean, free of dirt, oil and grease.

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2. Keep the tools sharp and in a good condition. Hold the pointed tool away from the body
to avoid injury. Fix the job firmly in the bench-wise.
3. Cut a small grove with a corner of the file, where a saw-cut is to be started. The groove
permits the accurate positioning of the saw and avoids the slipping of the teeth.
4. Apply force on the forward stroke only and relieve force on return stroke.

RESULT: The required half round fitting is thus obtained, by the following the stages described
above.

SIGNATURE OF STAFF

HOUSE WIRING

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HOUSE WIRING
THEORY
Introduction:

Power is supplied to domestic installations through the face and a neutral; forming a single face
A.C. 230 V, two wire systems to give 440V. Figure shows the power Tapping for domestic and
industrial purposes. The neutral is earthed at the distribution substation of the supply.

As a safe practice all single-phase devices such as switches, fuses etc., are connected to live
conductors. All electrical conductors and cables are colour coded and must be correctly
connected up. Electrical wiring is defined as a system of electric conductors, components and
apparatus for conveying electric power from the source to point of fuse. The wiring system must
be designed to provide a constant voltage 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 etc.,

WIRES AND WIRE SIZES:

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A wire is defined as a bare or insulated conductor consisting of one or several stands. 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 the 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 (cab tyre sheathed/tough rubber sheathed wiring).
3. Wooden casing and capping wiring.
4. Lead sheathed wiring.
5. Conduit wiring.
6. PVC casing and capping.

WIRING METHODS:

1. Series circuit
2. Parallel circuit

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

LINE TESTER: Used for testing the current.

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

BALL-PEEN HAMMERS: Used for fitting nails in the walls or wooden words.

SYMBOLS:

- One way switch

- Two way switch

- Bulb

- Earth

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TYPES OF WIRES:

1. Vulcanized Indian rubber insulated cables (BIR).

2. Tough rubber sheathed in cables (TRS).
3. Cab type sheathed cables (CTS).
4. Weather proof cables.

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ONE LAMP CONTROL BY ONE SWITCH

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Experiment no: date:

AIM: To arrange a setting of one lamp controlled by one switch and checking of circuits by
connecting in parallel and in series.

REQUIRED TOOLS:

Cutting pliers, tester, clips, nails PVC round blocks, battle holder, one way switch, bulb.

PROCEDURE:

1. Wire pieces are taken and insulation is removed at the ends by using wire strippers.
2. A phase wire is connected to one point switch s1 and s2.
3. The lower points of switches s1 s2 are connected to one point of bulb holder and one point of
plug socket respectively.
4. Two neutral wires are taken and one is connected to the remaining point of the bulb holder.
5. The other is connected to the remaining points of the plug socket.
6. After checking the proper circuit connections the power supply is given.
7. Now the bulb is ready to glow bright and the plug socket is also ready with control.

PRECAUTIONS:

1. Check the circuit once again to avoid any short circuit before giving the connection.
2. Phase wire should be connected to the switch to prevent shock when not in use.
3. Do not touch the wires at joints and conductor after giving the supply to circuit.

RESULT: Connecting the circuit of one lamp control by one way switch and checked
successfully.

SIGNATURE OF STAFF

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ONE LAMP CONTROLLED BY TWO WAY SWITCH

Experiment no: date:

AIM: To arrange a setting of one lamp controlled by a two way switch and then checking these
circuits by connecting in parallel and in series.

REQUIRED TOOLS:

Cutting pliers, Tester, Screw drivers, Hammer.

MATERIALS REQUIRED:

C.T.S Wire, Wooden rappel, clips, Nails, PVC Round blocks, Batten holders, Two way
switches-2, Lamps.

PROCEDURE:

1. A phase wire is taken and its one end is connected to the middle point of the two – way
switch, S1.
2. While the other end is connected to the phase point of the main supply.
3. Another phase wire (second wire) is taken and used for connecting the lower points of the two
switchesS1; S2.
4. The third phase wire piece is taken and is connected between the middle point of S2 and one
of the points o f the bulb holder.
5. A neutral wire piece is taken and its one end is connected to the remaining points of bulb
holders, while the other end is connected to the main supply.
6. Now the glowing of the bulb is controlled by two way switches.

PRECAUTIONS:

1. Check the circuit once again to avoid some short circuit before giving connection of
power.
2. Phase wire should be connected by switch to prevent shock when not in the job.
3. Test the pass of current and give the connection to pass over the current.

RESULT:

Setting of one lamp controlled by two way switches was done and checked successfully.

SIGNATURE OF STAFF

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TINSMITHY

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TINSMITHY
THEORY
INTRODUCTION:

Many engineering and household 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 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 rule, try square, wire gauge, scriber,
ball-peen hammer, cross-peen hammer, nylon mallet, snips, divider, stakes, cutting plier and
soldering iron.

WIRE GAUGE:

The thickness of the sheet is referred to in numbers known as standard wire gauge (SWG). The
gaps in the circumference of 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 and setting 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 have straight blades and are used for cutting along straight lines and for
trimming edges.

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Curved snips have a curved blade and are used for cutting circles and irregular shapes.

DIVIDER: It is used for transferring the sizes and scribing curves or circles.

BALL-PEEN HAMMER: It has a cylindrical, slightly curved face and ball head. It is a general
purpose hammer used mostly for riveting in sheet metal work.

CUTTING PLIERS: Used for holding, cutting and bending works.

NYLON MALLET: It is used for bending and folding work.

STAKES: Stakes are made of steel and forged in a variety of shapes and sizes. These are used as
supporting tools and to form, seam, bend or rivet sheet metal objects.

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SQUARE TRAY
Experiment no: date:

AIM: To prepare a square tray of given dimensions.

TOOLS REQUIRED:

Snips, Bench shear, Stakes, Nylon tipped hammer, Scriber, Drawing sheets, Scissors.

RAW MATERIAL:

Galvanized Iron sheet (28 gauge).

PROCEDURE:

1. Cut the G.I. Sheet from the big sheet with one inch more, both in width and length, than
the required dimensions by using straight snips.
2. Draw the development of the given model on a drawing sheet, according to given
dimensions, which acts as a template for the actual job or model.
3. Cut-off the template from the drawing sheet and keep it on the G.I. Sheet.
4. Now mark with the scriber on the G.I. sheet to represent the replica of the template.
5. Cut the G.I. Sheet by using straight snips to get the required piece for preparing the given
job.
6. Bend it to the required shape by using a nylon tipped hammer on a beak horn stake.
7. Join the ends by seaming and get the required square tray

PRECAUTIONS:

1. Sharp tools are only to be use. A dull tool requires excessive pressure, causing G.I. sheet
may bend and irregular cuts.
2. Test the sharpness of the cutting edge on paper, but not on hand.
3. Make sure that hands are not in front of sharp edged tools while using them.

RESULT:

Prepared a square try of required dimensions.

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SIGNATURE OF STAFF

TRUNCATED CYLINDER
Experiment no: Date:

AIM: To prepare a truncated cylinder of the given dimensions.

TOOLS REQUIRED:

Snips, Bench shear, Stakes, Nylon tipped hammer, Scriber, Scissors.

RAW MATERIAL:

Galvanized Iron sheet (28 sheet)

PROCEDURE:

1. Cut the G.I. Sheet is one inch more, both in width and length, than the required
dimensions by using straight strips.
2. Draw the development of the given model on a drawing sheet, according to the given
dimensions, which acts as a template for the actual job or model.
3. Cut-off the template from the drawing sheet and keep it on G.I. Sheet.
4. Now mark with the scriber on the G.I. Sheet to represent the replica of the template.
5. Cut the G.I. sheet by using a curved snip to get the required shape for preparing the given
job.
6. Roll it to the required shape by using a nylon tipped hammer/mallet on a round stake.
7. Join the ends by streaming and get the required truncated cylinder.
PRECAUTIONS:

1. Sharp tools are only to be use. A dull tool requires excessive pressure, causing G.I. sheet
may bend and irregular cuts.
2. Test the sharpness of the cutting edge on paper, but not on hand.
3. Make sure that hands are not in front of sharp edged tools while using them.

RESULT:

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Prepared a Truncated cylinder of required dimensions.

SIGNATURE OF STAFF

BLACK SMITHY

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BLACK SMITHY
THEORY
Black smithy or hand forging is an ancient method in which heating of a raw material till it
acquires sufficient plasticity (red hot condition) followed by hand forging operations like
bending, hammering, pressing etc.,

ADVANTAGES OF FORGING:

1. Strength and toughness is high.

2. Strength to weight ratio is high.
3. Internal defects in the metal are eliminated.

FORGE OR HEARTH:

A smith’s forge or hearth is used to heat the metal to be shaped. Hearths are used for heating
small jobs to be forged by hand. Gas, oil or coal firing may be used for the purpose. The required
air for the fire is supplied under pressure, by a blower through the tuyere in the heart. The
blowers may either be hand operated or power driven. In the latter case, the amount of air supply
is controlled by valves near the forge. The following are the temperatures of various metals.

S.No Metal Forging temperature, (in oc) range

1. Mild steel 750-1300
2. Wrought iron 900-1300
3. Medium carbon steel 750-1250
4. High carbon and alloy steel 800-1150

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Heating metal to the proper temperature is important. Insufficient temperature also results in cold
working defects like strain hardening and cracking.

ANVIL:

It provides the necessary support during forging by resisting the heavy blows rendered to the job.
It is also useful for operations such as blending, swaging, etc, its body is generally made of cast
steel, wrought iron or mild steel, with a hardened top layer of about 20 to 25mm thick. The beak
or horn is used for blending metal to a round shape.

CROSS-PEEN HAMMER:

A cross peen hammer is a hammer used by blacksmiths to complete metal work. The

wedge-shaped end of the hammer allows you to make the metal fuller when used with heat. The
main functions of a cross peen hammer is forging and riveting.

STRAIGHT-PEEN HAMMER:

Mainly used for shaping metal, the peen can be at right angles to the handle or parallel with it.

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ROUND ROD
Experiment no: date:

AIM: To make a round rod from a given square rod by using hand forging operation.

APPARATUS & TOOLS REQUIRED:

Smith's forge, Anvil, 500gm and 1000gm ball peen hammers, flatter, Round bit tongs and
pick-up tongs.

MATERIALS REQUIRED:

Mild steel square rod 10x150mm.

SEQUENCE OF OPERATIONS:

1. Sizing
2. Heating
3. Swaging
4. Inspection

PROCEDURE:

1. One-half the round is heated to red hot condition in the smith’s forge, keeping it for 15 to
20 minutes.
2. Holding the rod with round bit tongs, the rod is placed between half round top and
bottom. Swages which are kept over the anvil, the surface of the rod is hammered such
that two flat faces are converted into round shape.
3. The rod is rotated and hammered while placed in swags such that a round shape is formed
over half of the length of the rod.
4. Following the above stages the remaining length of rod is forged into required shape.
5. The flat faces of the square shape are corrected to do the forging operations.

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 Workshop practice

NOTE: In between the rod is heated in the furnace, to do the forging operations.

SAFETY PRECAUTIONS:

1. Hold the hot work down wards close to the ground, while transferring the piece from
hearth to anvil to minimize the danger of burns, resulting in collision with the others.
2. Use the correct size and type of tongs to fit the work. These should fit the work securely
to prevent its bouncing out of control by repeated hammer blows.
3. Wear gloves while handling hot metal.
4. Ensure the hammer is fitted with tight and wedged handles.

RESULT: The round rod thus is made from the given square rod.

SIGNATURE OF STAFF

BRACKET
Experiment no:

AIM: To make a bracket from a given square rod.

APPARATUS TOOLS REQUIRED:

Smith's forge, Anvil, 500gm and 1kg ball-peen hammers, flatter square bit-tongs and pick up
tongs.

MATERIAL REQUIRED:

M.S. Square rod 10x10x150mm

SEQUENCE OF OPERATIONS:

1. Sizing 2. Heating 3. Blending 4. Inspection

PROCEDURE:

1. The half of the given M.S. the rod is heated to red hot condition in the smith’s forge,
keeping it there for 15 to 20 minutes.
2. The length of the rod is bent as per required shape and then placed on the anvil face.
3. The rod is then hammered such that the hook shape is formed over half of the length of
the rod.
4. Following the above stages the remaining length of the rod is straight.
5. The flat faces of the bracket formed are corrected, if required, using the flatter.

NOTE: In between the rod is heated in the furnace, to do the forging operations.

SAFETY PRECAUTIONS:

Vignan’s university 40
 Workshop practice

1. Hold the hot work down wards close to the ground, while transferring the piece from
hearth to anvil to minimize the danger of burns, resulting in collision with the others.
2. Use the correct size and type of tongs to fit the work. These should fit the work securely
to prevent its bouncing out of control by repeated hammer blows.
3. Wear gloves while handling hot metal.
4. Ensure the hammers are fitted with tight and wedged handles.

RESULT:

The bracket thus is made from the given square rod.

SIGNATURE OF STAFF

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