RAJADHANI

INSTI
TUTEOFENGI
NEERI
NG
ANDTECHNOLOGY
NAGAROOR,
ATTI
NGAL

MECHANI
CALENGI
NEERI
NG
WORKSHOPMANUAL
 RAJADHANI
INSTI
TUTEOFENGI
NEERI
NG
AND
TECHNOLOGY
NAGAROOR,
ATTI
NGAL

MECHANI
CALENGI
NEERI
NGDEPARTMENT

MECHANI
CALWORKSHOP/
MANUAL
Semes
terI
andI
I

(
AsperAPJAbdul
Kal
amTechnol
ogi
cal
Uni
ver
sit
y)

Name:
-………………………………………………………………………………….
.
…………

Br
anch:
-………………………………………………Semest
er:
-……………………….
.
…….
 Rol
lNo:
-……………………………………….
.
.…Year
:-
……………………………………

Uni
ver
sit
yRegi
sterNo…………………………………………………………………….
.

Cer
ti
fi
edt
hatt
hatt
hisi
sthebonaf
iedr
ecor
dofwor
kdone

By
…………………………………………………………i
nthe…………………………………………………….

H.
O.D WORKSHOPSUPDT

I
nter
nal
exami
ner Ext
ernal
Exami
ner
.

I
NTRODUCTI
ON

Wor
kshopi
sapl
acewher
erawmat
eri
al
sar
econv
ert
edi
ntous
eful
product
swi
th
t
heut
il
i
zat
ionofmen,
mat
eri
al
sandmachi
nes
(tool
s)

Aper
sonwhowi
sht
obecomeanengi
neeri
nwhatev
erdi
sci
pl
inehewi
shes
,mus
t
hav
eabas
icknowl
edgeaboutdi
ff
erentas
pect
sofmanuf
act
uri
ngi
ncl
udi
ngt
heor
yand
pr
act
ical
.Thecur
ri
cul
um i
ntr
oducedbyt
heA.
P.
J.AbdulKal
mtechnol
ogi
calUni
ver
sit
y
ai
mst
ocov
ert
het
heor
yandpr
act
ical
’
sofmechani
cal
engi
neer
ingwor
kshopi
nas
impl
e
ands
cient
if
icway
.Thewor
kshoppr
act
ical
sinv
olv
est
hes
tudyofv
ari
oust
ool
s,manual
met
hodsofmanuf
act
uri
ngpr
oces
sesbyus
ingofhandt
ool
sandmachi
net
ool
s.

Engi
neerar
e expect
ed t
o wor
kunderdi
ff
erentmanagementcapaci
ti
esand
r
espons
ibl
eforpr
oduct
ionasawhol
e.Anengi
neers
houl
dawar
eofexcel
l
enceandmus
t
hav
ethor
oughknowl
edges
afet
ypr
ecaut
ionsand“
Fir
stAi
d”.
Thi
swor
kshopal
soai
msatcr
eat
inganawar
enes
saboutt
hepos
sibl
eacci
dent
’
s
i
nthewor
kpl
aceandabouts
afet
ypr
ecaut
ionst
obet
akent
oav
oidt
heacci
dent
s.
 SAFETYI
NWORKSHOP

Acci
dentar
eunpl
eas
ant
,unpl
annedanduncont
rol
l
edev
ent
stakepl
acei
nawor
k
ar
eaorany
wher
e.Toav
oids
uchev
ent
sthef
oll
owi
ngpr
ecaut
ionss
houl
dbeobs
erv
edby
t
hepeopl
einv
olv
edi
nwor
kshop.

Gener
alSaf
etypr
ecaut
ions

 Weart
ightcl
othesi
nwor
kshopses
peci
al
lywhenus
ingr
otat
ingmachi
nes
.

 Keepthefl
oorcl
eanandti
dy.
Thef
loors
houl
dbef
reef
romOi
l
sandgr
eas
es.
(
thes
li
pper
y
f
loori
salwaysdanger
ous
).

 Weargoggl
eswhenev
ert
her
eisdangeroff
lyi
ngmat
ter
.

 Donotr
unorpl
ayont
hes
hopf
loor
.

 Donotoper
ateanymachi
neort
ool
wit
houtper
mis
sionoft
hes
taf
finChar
ge.

 Donotoper
ateanymachi
newi
thoutknowi
ngi
tsmechani
sm.

 Nev
erwor
konunguar
dedmachi
ne.

 Donott
alkt
oot
her
sordi
stur
bthemwhi
l
etheyar
eoper
ati
ngaMachi
ne.

 Keepy
ourbodybehi
ndt
hecut
ti
ngedgeofs
har
pedgedcut
ti
ngt
ool
’

 Whenyouswi
tchof
famachinedonotleav
ebef or
eithasstoppedrunni
ng.
 St
orei
nfl
ammablemat
eri
al
slikeker
osene,t
urpent
ine,
etcawayfromtheShop.

 Nev
erpl
aces
har
ptool
sont
hef
loororatedgesofwor
kbench,
keept
hemi
npr
oper
pl
acemar
kedf
ort
hem.

 Bewer
eofel
ect
ri
cal
haz
ardss
uchasbar
ewi
res
;poorear
thr
etur
nconnuct
ion,
wetf
loor
et
c.

 ofhangi
nghai
r,
ti
es,
clot
hing,
scar
ves
,orbel
tsget
ti
ngcaught
.

 Nev
erent
ert
hewor
kshopwi
thouts
hoes
.

 Donotus
eri
ngsandwat
cheswhi
l
ewor
king.
 GENERAL

Studyofs
omeoft heMechani
cal
engi
neer
ingWorkshoptools.
Tool
sar
egeneral
ly
di
vi
dedintotwovi
z.Machinet
ool
sandHandTool
s .
Machi
ner equi
resener
gyt
ooperat
e.

HANDTOOLS

Theyar
eus
edbyhand,
requi
reonl
ymanpowert
ooper
ate

(
a)Scr
ewdr
iver

I
t i
s a hand t
ool us
ed f
or t
ight
eni
ng (
fi
xi
ng)
or l
oos
eni
ng

(
remov
ing)
scr
ews
.Itcons
ist
soft
hreepar
ts.
Blade,s
hankandhandl
e.Thes
hankus
ual
l
y

r
oundi
ncr
osss
ect
ion,
I
smadeofcar
bons
teel
.Onendofs
hanki
sfl
att
enedt
ofor
mthe

bl
adewhi
chi
shar
denedandt
emper
ed,
andt
heot
hers
idei
spr
ovi
dedwi
thahandl
e.The

f
latendi
sus
edf
ort
ight
eni
ngandl
oos
eni
ngt
hes
crews
.Scr
ewdr
iver
sar
especi
fi
edwi
th

t
hei
rlengt
hofs
hankandwi
dthofbl
ade.
Twot
ypeofs
crewdr
iver
sus
ed,
Phi
l
ipss
crew

dr
iverandf
latends
crewdr
iver
.

(
b).
All
enkey
Al
l
enkeyi
sas
teelr
odhav
inghexagonalcr
osss
ect
ionandoneendi
s

bendat90degr
ees
.Iti
sus
edf
ort
ight
eni
ngandl
oos
eni
ngAl
l
ennut
shav
inghexagonal

hol
esoni
tshead.

(
c).
Spanner
s

Spanner
sar
eal
sous
edf
ort
ight
eni
ngorl
oos
eni
ngt
hev
ari
oust
ypes

ofnut
swi
thbol
ts.
Iti
sadr
opf
orgedhandt
ool
madeofcar
bons
teel
orv
anadi
ums
teel
.

Var
iouss
hapesands
izeofs
panner
sar
eus
esomeoft
hemar
e:-Si
ngl
eendeds
panner
,

doubl
eendeds
panner
,adj
ust
abl
e(s
crew )
spannerboxs
panner
,ri
ngs
panner
,pi
pe

wr
encheset
c.

(
d)Pl
i
ers

Pl
i
ersi
sahandt
ool
usedf
orhol
di
ngs
mal
lobj
ect
sandcut
ti
ngs
mal
l
di
amet
erwi
res
.Us
ual
l
ycombi
nat
ioncut
ti
ngpl
i
eri
sus
ed.
Iti
sal
sous
edf
orr
emov
ing

s
mal
lbr
okens
crews
,bear
ingl
ocks
,br
okent
apset
c.Twot
ypeofpl
i
ersus
edar
e,

i
)Longnos
epl
i
ersi
i
)Combi
nat
ionpl
i
ers

St
udyofcomponent
s

(
a)Bear
ings

I
npower(
mot
ion)t
rans
mis
sionar
ea,
shaf
tofdi
ff
erentt
ypesands
izesar
e

us
ed.
All
shaf
tar
esuppor
tedbybear
ingsf
ors
moot
hrunni
ng.
Bear
ingsar
ecl
ass
ifi
ed

accor
dingt
hechar
act
eri
sti
cs,
nat
ureofappl
i
edl
oadands
peedofr
otat
ion.
Bear
ingsar
e

mai
nl
ydi
vi
dedi
nto)Fr
ict
ionbear
ingsandant
ifr
ict
ionbear
ings
.

(
1)Fri
cti
onbeari
ngsare:
-Solidbear
ings,Bushbeari
ngandPlummerbl
ock.
(
2)Anti
fr
ict
ionbear
ingsar
e:-Bal
lbeari
ngs,Roll
erbear
ings
,Taperpi
nbear
ings
,
Needl
ebearingsetc.

(
b)Seal

Seal
isus
edt
opr
eventt
hel
eakageoff
lui
dsbet
weent
hemat
ings
urf
aces

ofcomponent
sei
theri
nst
ati
onar
yori
nmot
ion.I
tshoul
dbes
trongenought
owi
th

s
tanddef
ormat
ionandoper
ati
onals
tres
ses
.Us
ual
l
ytheyar
emadeof pr
oces
sed

r
ubbermat
eri
al
.Seal
sar
eus
edi
ntur
bines,
blower
s,pumps
,mot
orsandbear
ings
.

(
c)ORi
ngs

AnO-
ri
ngi
sus
edt
obl
ockanypot
ent
iall
eakofaf
lui
dbet
weent
wocl
osel
y

s
paceds
urf
aces
.Ital
sopr
event
sthel
oseoff
lui
d.Us
ual
l
ytheyar
eins
tal
l
edi
na

machi
nedgr
oov
einoneofs
urf
acest
obes
eal
ed.O-
ri
ngsar
egener
all
ymadeof

pr
oces
sedr
ubbermat
eri
al
s.Theyar
ecommonl
yus
edi
naut
omobi
l
eindus
try
.
 (
d)Ci
rcl
i
ps

Ci
rcl
i
pisat
ypeofl
ockaswel
laf
ast
ener
,Itcons
ist
sofas
emi
flexi
bl
emat
el

r
ingwi
thopenendsandhav
esmal
lhol
eatt
heopenendst
oaccommodat
ethenos
eof

t
henos
epl
i
er.
Theesr
ingshav
egr
eatr
esi
sti
ngcapaci
tyagai
nstr
otat
ional
speed.
They

ar
emadeofcar
bons
pri
ngs
teel
.

(
e)Key
s:

Key
sar
eus
edf
orpr
event
ings
elfr
otat
ionofs
haf
tsf
rom bear
ings
,gear
s

andpul
l
ys,
bypr
ovi
di
ngt
empor
aryf
ast
eni
ngbet
weent
hem.
Theyar
emet
alpi
ecesof

di
ff
erentf
orms
.SuchasFl
ateands
addl
ekey,hol
l
ow s
addl
ekey
,Gi
pheadkey
,

Woodr
uffkey
,Feat
herkeyandSpl
i
ns.
 CARPENTARY

Woodi
sani
mpor
tantmat
eri
alwi
del
yus
edi
nEngg.
Fiel
d.I
tal
soknownast
imber
,
i
sav
ail
abl
einnat
ureast
rees
.Wood,af
tercut
ti
ngf
rom t
rees
,makeav
ail
abl
etounder
go
s
eas
oni
ng(
Tor
educewat
ercont
ent
sandi
ncr
eas
emechani
calpr
oper
ti
es)i
sus
edf
or
engi
neer
ing pur
pos
es.Car
pent
ryi
sthepr
oces
sofconv
ert
ing wood i
nto ar
ti
cl
esl
i
ke
pat
ter
ns,
fur
nit
ure,
door
s,wi
ndows
,andr
oof
set
c.

Bas
icmat
eri
alus
edi
nCar
pent
ry

Bas
icmat
eri
al
sus
edi
ncar
pent
rys
hopar
eti
mberandpl
ywood.
Auxi
l
iar
ymat
eri
al
s
us
edar
enai
l
s,s
crewsadhes
ives
,pai
nts
,var
nis
het
c.

Tool
sus
edi
ncar
pent
ryar
e:-

A. Meas
uri
ngandmar
kingt
ool
s:-

a)St
eel
rul
e

b)Fourf
oldr
ule

c)Fl
exi
bl
emeas
uri
ngt
ape

d)St
rai
ghtedge

e)Tr
ySquar
e

f
)Bev
elSquar
e

g)Penci
l

h)Scr
iberandmar
kingkni
fe

i
) Mar
kinggauge

j
) Mor
ti
segauge

B.CUTTI
NGTOOLS

a)HandSaw(
Cros
scuts
aw)

I
ti
sus
edt
ocutt
hickwoodenpi
ecesacr
osst
hegr
ain.
Thes
esawshasabout
3t
o4t
eet
hpercmandhav
eal
engt
hofabout650mm.
b)Tenons
aw(
Backs
aw)
:
-
 Thi
ssawi
sus
edf
ors
hor
tst
rai
ghtcut
s.I
thasapar
all
elbl
adeof25t
o40cml
engt
h
and6t
o10cm wi
dth.Thenumberoft
eet
hpercm r
angesf
rom 5t
o8.I
nor
dert
oav
oid
bendi
ngofbl
adei
ti
spr
ovi
dedwi
thar
einf
orci
ngs
tri
patt
het
op.

Chi
sel
s:-Thesear
eusedf
orcut
ti
ngwoodt
ogetdi
ff
erentdes
ireds
hapes
.Di
ff
erentt
ypesof
chi
sel
s
are:
-
1.Fir
merchi
sel

Theyhav
eflatbl
adeofabout1
5to50mmwi
dthand1
25mml
engt
h.
2.Bev
eledgedf
ir
merchisel
:

Thes
eChi
sel
sar
eus
edf
orf
ineanddel
i
cat
ewor
kaswel
lasf
orcut
ti
ngcor
ner
s.

3.Mor
ti
sechi
sel

Thes
ear
eus
edf
orheav
yanddeepcutt
oremov
eal
argequant
it
yofwood.
Thes
echi
sel
shav
ewi
dthof1
5mmandt
hebl
adet
hicknes
srangesf
rom6t
o15
mm.

4.Gouges
:-

Thes
ear
echi
sel
swi
thcur
veds
ect
ion.
Theyar
eus
edt
ocutcur
veds
hapesofi
nter
nal
or

ext
ernal
type

C.STRI
KINGTOOLS

1
. Mal
l
et–I
tisahar
dpi
eceofwoodofr
oundorr
ect
angul
arcr
osss
ect
ion,
Iti
s
pr
ovi
dedwi
thawoodenhandl
efors
tri
cki
ngont
hecut
ti
ngt
ool
s.

2.Cl
awhammer–Thi
shammeri
smadeofcas
tst
eel
hav
ingas
tri
ki
ngheadaton
endandacl
awatt
heot
herend,
whi
chi
sus
edf
orpul
l
ingnai
l
s.

D.Pl
anni
ngTool
s

1
.Ir
onJackpl
ane-I
tisus
edt
opr
oducef
lats
urf
acesonwood,madeofcas
tir
on
body
.Awoodenknobi
nthef
ronts
ide,
awoodenhandl
eatt
hebacks
idef
ixedon
t
hes
obef
orpus
hingwi
tht
wohands
 2.Woodenj
ackpl
ane–Madeofwood,
Ast
eel
bladehav
ingkni
feedgei
sfi
xedatan
angl
ewi
tht
hehel
pofwoodenwedge.

Hol
di
ngTool
s

1
. Car
pent
ersBenchVi
ce:-I
tisus
edf
orhol
di
ngj
obswhi
l
esawi
ngorpl
anni
ng.I
t
cons
ist
sofaj
aw f
ixedont
het
abl
esi
deandamov
abl
ejaw kepti
npos
iti
onby
meansas
crewandhandl
e.
2.C orG cl
amp:
-Iti
sus
edt
ocl
ampt
hewor
kpi
ecesont
hewor
kbenchwhi
l
e
s
awi
ngchi
sel
i
nget
c.

E. Bor
ingt
ool
s

Bor
ingt
ool
sar
ementf
ormaki
nghol
esi
nwood.
Theyi
ncl
ude,
Auger
,Gi
mlet
,br
adawl
,

Rat
chetbr
ace,
Tool
bitanddr
il
l
s.

F. Mis
cel
l
aneoustool
s
1
. Raspandfi
l
es:-Isaroughf
il
eus
edt
oremov
eexces
swoodf
ormt
hes
urf
aceand
cor
ners.

2.Sandpaper
:-Thi
sisat
hicks
andorgl
asspowdercoat
edpaper
.Whent
hes
and
paperi
s
r
ubbedont
hes
urf
ace,at
hinl
ayerofwoodi
sremov
edr
esul
ti
ng
s
moot
h
s
urf
ace.

3.Pi
ncer
:-Thi
sisat
ool
simi
l
art
opl
i
ersi
sus
edf
orbuf
fi
ngouts
crewsandnai
l
set
c
f
rom
t
hewood.

4.Scr
ewdr
iver:
-Iti
sus
edt
odr
ivei
nandouts
crews
.

Pr
oces
sinwoodwor
k

1
. Mar
kingandMeas
uri
ng:-I
tismar
kingoft
hedi
mens
iononwoodpi
eces
othatt
he
exces
swoodcanber
emov
edt
oobt
aint
her
equi
reds
hape.

2.Sawi
ng:-I
tisdoneaf
terhol
di
ngt
hewoodenpi
ecei
nav
iceands
awi
ngal
ongora
cr
osst
hegr
ainbyhandormachi
ne.

3.Pl
anni
ng:
-Ist
hepr
oces
sofmaki
ngwoods
urf
aces
moot
hbyr
emov
alofas
mal
ll
ayer
ofwoodf
romi
t,
byus
ingaj
ackpl
ane.
 4.Chi
sel
i
ng:
-Chi
sel
i
ngi
sus
edt
oremov
esmal
lst
ockt
oret
aint
hedes
ireds
hape.

5.Bor
ing:-Thepr
oces
sofpr
oduct
ionofr
oundt
hroughhol
eorbl
i
ndhol
eiscal
l
ed
bor
ing.
Theyar
emadebyus
ingdr
il
lbi
t,auger
s,gi
mletet
c….

ExNo:
- Dat
e: / /
PLANI
NGPRACTI
CE(
Model
)

Ai
m:Topl
aneawoodenbl
ockus
ingj
ackpl
anet
oobt
aint
her
equi
reds
izeands
hape

1
.Mat
eri
alr
equi
red:
-

Sof
twood(Si
ze:
35x50x250mm)

2.Tool
srequi
red

a)Jackpl
ane

b)Tr
ysquar
e

c)Hands
aw
 d)Mor
ti
segange

e)St
eel
rul
e

f
)Fi
rmerchi
sel

g)Mal
l
et

Pr
ocedur
e:-

1
. Cl
ampt
hej
obi
ncar
pent
ryv
ice

2.Pl
anet
woadj
acentf
acesus
ingj
ackpl
ane.
Sot
hats
idesar
eatr
ightangl
e.

3.Us
etr
ysquar
etov
eri
fyt
hes
quar
enes
soft
hes
ides
.

4.Us
emor
ti
segauget
omar
kthedes
ireddi
mens
ionsont
her
emai
ni
ngt
wof
aces
.

5.Pl
anni
ng orchi
sel
i
ng hast
o bedonet
other
emai
ni
ng t
wo s
urf
aces
,up t
othe
di
mensi
onmarked

6.Bot
hendsar
esquar
emar
kedands
quar
ecutbedonewi
thmal
l
etandf
ir
merchi
sel

7.Ver
if
ythedi
mens
ionsbys
teel
rul
e.

Res
ult
:-Ther
equi
reds
hapeofj
obi
sthi
sobt
ainedbypl
anni
ngpr
oces
sus
ingj
ackpl
ane.
 SMI
THY

Blacks mit
hyisaproces si
nwhi chmet ali
sheatedtoades i
redtemperaturetoobt ai
nsuffi
ci
ent
plasti
cityandshapedt ot herequir
ement sbyus i
ngs mithytool
s.Theoper ati
oni scarri
edout
ei
t herbyhandorbypowerhammer .Processofheati
ngi sdoneinanopenhear thfur
naceand
shapingi sdonebyus i
nghandt ools.Smithyproces shasanadv antaget hatthereisno
was tagemet al
s.Forgingalsoenhancest hemechani calpropert
ies
,impr ovegr ai
nflow and
i
ncr easest hest
rengthandt oughnes softhemetal
.

Forbl
acksmi
th oper
ati
onsthe met alshoul
d possessmal l
eabi
li
ty.Carbon s
teel,
Al
umi
nium,Copper
,Magnesi
um etc.
areforgeablemetal
s.Forfor
gingoperati
onsmil
ds teel
i
stobeheatedabove750*C.Alumi
num andmagnes ium abov
e300° C,andCopperabov e
600°
C.

BLACKSMI
THYTOOLS

Tool
sus
edi
nbl
acks
mit
hycanbecl
ass
ifi
edi
ntof
oll
owi
ng5cat
egor
ies
.

1
.Suppor
ti
ngt
ool
s

I
tpr
ovi
desneces
sar
ysuppor
tdur
ingf
orgi
ngt
hemet
als
tock.
I
mpor
tents
uppor
ti
ng
t
ool
sar
eanvi
lands
wagebl
ock.

2.
Str
iki
ngt
ool
s

Dif
fer
entt
ypeofhammer
sareusedforhammeri
ngtoobt
aint
her
equi
redshapet
o
theheatedmetal
.Sl
edgehammer,
bal
lpei
nhammer ,
cross
pei
nhammer,
sethammeretc
areusi
ng.

3.
HOLDI
NGTOOLS

Thesetool
sareusedtohol
dtheheat
edmet al
forfor
gingoperat
ion.Thes
etoolsar
emadeof
mil
dsteel
.Fl
attongs
,squar
ebitt
ongs
,roundbitt
ongsandpick-uptongsarecommontongs
.

4.
Cut
ti
ngt
ool
s

Cutt
ingtool
sareusedforcut
ti
ngandnecki
ngmetal
sasperther
equir
ement.
Hotand
col
dchis
elsareusedascutt
ingtool
s.Thei
ncl
udedangl
eofthecut
ti
ngedgeofcol
dchi
seli
s
60°andhotchisel
is30°
.

5.
Fini
shi
ngands
hapi
ngt
ool
stool
s

Theset
ool
sar
eusedt
ogi
vet
hedes
ireds
hapesandf
ormst
othemet
als
tock.
I
mpor
tantt
ool
sar
easfol
l
ows
.

a)Swage-Usedt
oreducet
hemeasur
ementsandfi
ni
shi
ngthework.
Theyaremadeofhigh
carbonst
eel
havi
ngtwopar
tscal
l
edtopandbott
oms wage,
car
ryneces
sarygr
ovest
os uit
t
hes
izeofwor
k.

b)Ful
l
ers
:-Usedtomakeneckbyreduci
ngthecr
oss–sect
ionofaj
ob.Tool
sar
emade
ofhi
ghcarbonst
eeli
ndi
ff
erents
izes.
Theyareus
edinpair
softopandbott
omful
l
ers
c)
Flat
ter
s:-Us
edf
orl
evel
i
ngandf
ini
shi
ngaf
lats
urf
aceaf
terf
ogi
ngoper
ati
on.
Theyar
e
madeofcar
bons
teel
.
d)Punch:-I
tisusedf
ormaki
nghol
esi
ntheheatedworkpi
ece.
e)Dri
ft:-Usedformaki
ngholest
oapar t
icul
arshapeandsi
zewhi
chi
sal
readymadeby
punch.

BLACKSMI
THYOPERATI
ONS

1
.Ups
ett
ing

Iti
sthepr
ocessofi
ncr
easingt
hethi
cknessofamet
alpi
ecewi
thcor
res
pondi
ng
r
educt
ioni
nthel
engt
hbyapplyi
ngtheendpress
ure.

2.
Drawi
ngdown

Iti
saproces
storeducedthet
hicknes
scor
res
pondi
ngi
ncr
eas
ingt
hel
engt
h.The
f
orcei
sappl
i
edindir
ect
ionoftheaxi
s.

3.
Set
ti
ngdown

I
ti
sthepr
oces
sofl
ocal
thi
nni
ngdownoft
hewor
kpi
ecebyhammer
ing.

4.
Punchi
nganddr
if
ti
ng

Apr
oces
sofmaki
nghol
esi
nades
ireds
hapebyt
heus
eofpunchanddr
if
t.

5.
Bendi
ng

Apr ocessofbr
ini
ngmetalrodtoar
equir
edangl
eands
hape.I
ti
sdonebyattheedgeofthe
anvilf
aceorovertheanv
ilhor
norbyins
erti
ngt
heendi
nthehol
eandbendi
ngthebarwit
h
tongs.

6.
For
gewel
di
ng

Anoper
ati
onperf
ormedbyhammer
ingt
oget
hert
heendoft
woheat
edmet
al
pi
ecestoj
oi
nthem.Wr
oughti
ronandmi
lds
teel
canbeeasi
l
yfor
gewel
d.

7.
Cut
ti
ngof
f

I
tisaf
orgi
ngoper
ati
oni
nwhi
chamet
als
tocki
scutof
fint
otwoormor
epi
ecesbyus
ing
chi
sel
.
7.
Ful
l
eri
ng

I
ti
safor
gingoperat
ioninwhichmetal
ofthewor
kpi
ecei
sspar
edal
ongi
ts
l
engt
hbyhammer i
ngandus i
ngful
l
ersastool
s.

Appl
i
cat
ions

a.
Forgi
ngi
sus
edf
orf
abr
icat
ingagr
icul
tur
alt
ool
s,bol
tsandnut
s,key
s,t
ongs
,spr
ings
,li
nks
etc.

b.Forgingi
susedwher evercomponent
sar
erequi
redt
ohav
ehi
ghs
trengt
handgr
eat
resi
stancet
oimpactandfati
gueloads
.

HEATTREATMENT

Heattr
eat
menti
sthepr ocessofheat
ingametalt
oades ir
edtemper
atur
e,
wi
thoutmel
ti
ngandt
hencooli
ngittoobtai
ncert
ainchangesinthechar
act
eri
sti
csoft
he
metal
.
Heett
reat
mentimpr
ovesthepr oper
ti
esofthemetal
,suchas:
-

Machi
nabl
i
ty

Changeofgr
ains
ize.

Mechani
cal
proper
ti
es

Magnet
ical
andel
ect
ri
cal
proper
ti
es

I
ncr
eas
eres
ist
ancet
owearheatandcor
ros
ion.

Topr
oducehar
dsur
face.

HEATTREATMENTPROCESFORI
RON

Cool
i
ngmet
hod
Pr
ocess Heat
ingt
emper
atur
e Socki
ngt
ime
Byquenchi ngin
wat er
Har
deni
ng 820°c 30mi
n
oroil
Upt o700ci n
furnace,
thenupt oroom
Anneal
i
ng 820°
c 35mi
n
t
emper atureinsili
ca
sandorash
Inairupt or oom
Nor
mal
i
sing 820°
c 30mi
n
temper ature
Quenchi nt he
Temper
ing 400°c 30mi
n
quenchingbat h
ExNo- Dat
e:- / /

FORGI
NGASQUAREROD(Model
)

Ai
m:-
-Tomakeas
quar
erodf
romar
oundr
odasperdi
mens
ion

Mat
eri
al
srequi
red

MSr
odx1
8x1
00mml
ong

Tool
srequi
res
;

1
.Smi
thy

f
orge2.
Anv
il

3.
Tongs

4.
Hammer

5.
Steel
rul
e

Oper
ati
onscar
ri
edout
;

1
.Li
ght
ingoff
orge

2.
Hammer
ing

3.
Meas
uri
ng

4.
Cool
i
ng

Pr
ocedur
e

1
.Li
ghtupf
orgeandmakepr
operf
ir
e.

2.
I
nser
tthej
obi
ntot
hef
ir
eatpr
operpl
aceandheat
edt
ored

hot
.3.
Takeoutt
hej
obwi
tht
ongsandputi
tont
heanv
ilwi
thi
n

not
ime.
4.Hammert
her
edhotar
eaf
orget
ti
ngr
equi
reds
hape.

5.Thepr
oces
sofheat
ingandhammer
ingi
srepeat
edt
ogett
hej
obi
nrequi
red
shapeanddi
mensi
ons.

6.
Jobi
sdi
ppedi
ntowat
erf
orget
ti
nghar
dnes
s.

Res
ult:
-Thenor
mal
rodi
sconv
ert
edi
ntos
quar
erodasperdi
mens
ions
.

Pr
ecaut
ions
1
.Thejobi
sheat
edt
oredhott
oobt
ainpl
ast
ici
ty.
Butt
hej
obwi
l
lnotal
l
owt
omel
t.
2.
Wearpr
otect
iv
eapr
onandgl
ovest
opr
eventacci
dent
s.
.

3.
Alway
sus
epr
opert
ongsandhol
ditt
ight
ly.
 FOUNDRY
I
NTRODUCTI
ON

Apl
acewher
emoul
di
ng,
cas
tingandt
hei
rrel
atedwor
ksar
ecar
ri
edouti
sknownas
f
oundr
y

s
hop.
Moul
di
ngi
sthepr
oces
sofmaki
ngofact
iv
it
y(moul
d)oft
heobj
ect
,whi
chwewantt
o

produce,
usual
l
yinl
argequant
it
ies
,wi
tht
hehel
pofmoul
di
ngs
and,
andpat
ter
ns(
whi
char
e
the

t
ri
pl
icaoft
hepr
oduct
s.
)Cas
tingi
sthepr
oces
sofpour
ing t
hemol
tenmet
ali
ntot
hemoul
d,

all
owingt
hemt
osol
i
dif
yandt
akei
toutf
romt
hemoul
di
ngs
and.
Rel
atedwor
ksi
ncl
udes
fel
li
ng

(
remov
ingt
heunwant
edpor
ti
on,
cleani
nget
c.)
,tes
tingandi
nspect
ion.

FOUNDRYTOOLSANDEQUI
PMENTS

Thefoundr
ytool
sandequipment
’
saredi
vi
dedi
nto6parts.
1
. HandTools,2.Mouldi
ngBox,3.Moul
di
ngMachi
ne,
4.Melt
ingequipment
5 Pour
ing,
Shakeoutandfi
ni
shi
ngequi
pment
,6.I
nspect
ionandtest
ing
. equi
pments

FOUNDRYHANDTOOLS

1
.Bel
l
ow:
-Bel
l
owi
sus
edt
obl
owl
oos
epar
ti
cl
esofs
andf
romt
hepat
ter
nandmoul
d

Cav
it
y.
2.Br
ush:
-Abr
ushi
sus
edt
osweepawayt
hedus
tfr
ompat
ter
n.

3.Li
ft
er:
-Li
ft
eri
smadeoft
hins
ect
ionsofs
teeland i
sus
edt
ocl
eanandf
ini
sht
he
bott
omands i
deofthesandmouldcavi
ty.
4.
Gaggers:-Gagger
sarethepieceofwi
resorr
odsbentatoneorbothends.
They
areusedtorei
nfor
cesandinthetoppartoft
hemouldi
ngboxandsupporthangi
ngbodi
es
ofsand.

5.
Sli
ck:
-As
li
cki
ssmal
ldoubl
eendedt
ool
hav
ingaf
latononeendandas
poonon
t
heot
her
.I
ti
sus
edf
orf
ini
shi
ngt
hemoul
dcav
it
y.

6.Rammer
:-Rammeri
smadeupofwoodormet
ali
nthes
hapeofr
oundf
latand
coni
cal
.I
ti
sus
edf
orr
ammi
ngt
hes
andi
nBenchmoul
di
ng.

7.
Riddl
e:-I
ti
sawoodens
quar
eorr
oundf
ramef
it
tedwi
thwi
remes
hatt
hebot
tom.
It
i
sus
edf
orcl
eani
ngt
hemoul
di
ngs
andbyr
emov
ingunwant
edmat
eri
al
ssuchasnai
l
s,wood,
pl
ast
icet
c..
.

8.
Spr
uepi
n/r
iserr
od:
-Iti
sat
aper
edwoodenpegus
edf
ormaki
ngpour
ings
prueor
r
iseshol
einamoul
d.
9.
Spr
uecut
ter
:-I
tisat
ubeofs
teel
whi
chi
sfor
cedi
ntot
her
ammedcopet
ocutt
he
s
pruecav
it
y.

1
0.Swab:-I
tisas
mal
lbr
ushhav
ingl
onghempf
ibr
esandi
tus
edf
orcl
eani
ngt
he
s
andar
oundt
heedgebef
oret
hepat
ter
nisr
emov
ed.
1
1.Tr
owel
s:-At
rowel
isamet
albl
adef
it
tedwi
thwoodenhandl
ewi
thv
ari
ouss
hapes
i
sus
edf
orf
ini
shi
ngandr
epai
ri
ngmoul
dcav
it
iesandf
lats
urf
aceofmoul
d.

1
2.Showel
:-I
tisus
edf
ormi
xi
ngandt
rans
fer
ri
ngt
hemoul
di
ngs
andf
romonepl
ace
t
oanot
herpl
ace.

1
3.Ventwi
re:
-Iti
sus
edf
ormaki
ngv
enthol
est
oper
miteas
yes
capeofs
team and
gas
esgener
ateddur
ingpour
ingoft
hemol
tenmet
al.
1
4.St
ri
keof
fbar
:-I
tispi
eceofmet
alorwoodus
edt
ost
ri
keof
fexces
ssandf
rom
t
hemoul
daf
terr
ammi
ngt
opr
ovi
deal
evel
sur
face.

1
5.Dr
aws
pike:
-Dr
aws
pikei
sat
aper
eds
teel
rodatoneends
har
ppoi
nti
sus
edt
o
r
apanddr
awpat
ter
nfr
omt
hemoul
d.

4.
MOULDI
NGBOX

Thes
andmoul
dsar
epr
epar
edi
nas
peci
al
lycons
truct
edboxescal
l
edFl
asks
,
whi
char
eopenatt
opandbot
tom.Theycons
istoft
woormor
epar
ts.Thel
owerpar
tis
cal
l
eddr
ag,t
heupperpar
tiscal
l
edcope.I
fthef
las
kismadei
nthr
eeormor
epar
tst
he
i
nter
medi
atepar
tsar
ecal
l
edcheeks
.

Thes
eboxes/Fl
askscanbemadeofei
therwoodormet
als
.Al
lthepar
tsar
e
i
ndi
vi
dual
l
yequi
ppedwi
ths
uit
abl
ecl
ampi
ngdur
ingpour
ing.Commont
ypeofmoul
di
ng
boxesi
nfoundr
yar
e
Boxf
las
k,Snapf
las
k,Woodenmoul
di
ngbox.

5.
MELTI
NGEQUI
PEMENT

Fur
nacess
uit
abl
eformel
ti
ngs
omei
mpor
tantmet
alsar
egi
venbel
ow

1
. Cas
tir
on:
-Cupol
afur
nace,
Elect
ri
cfur
nace,
rot
aryf
urnace

2.St
eel
:-Openhear
th,
Elect
ri
candbes
mearf
urnaces

3.Non-Fer
rousmet
als:
-Cr
uci
bl
efur
nace,
Rot
aryf
urnace,
Elect
ri
cfur
nace

Moul
di
ngSands
:-

Sandi
swi
del
yus
edmoul
dmat
eri
alf
orcas
tingf
err
ousandnonf
err
ousmet
als
.

Cl
assi
fi
cat
ionof
moul
di
ng s
andaccor
dingt
ospeci
fyus
es.

b.Dry c.Loam e
a.Greens
and, sand, Sand, d.
Faci
ngs
and .
Backi
ngorfl
oor f
.Syst
em g.
Part
ingsand,
sand s
and, h. Cor
esand(
Oil
sand)

Mai
ncons
tit
uent
sofmoul
di
ngs
andar
esi
l
icas
and,
Binder
s,Addi
ti
ves
,wat
er.

Cor
eandCor
eMaki
ng:
Acor
eises
sent
ial
l
yabodyofmat
eri
alwhi
chf
ormst
hecont
ourofa
cas
tingt
hati
snotmoul
dedwi
thapat
ter
n.Cor
esar
emai
nl
yus
edt
ofor
mint
ernal
cav
it
iesor
hol
esi
ncas
ting.
ExNo. Dat
e:- / /

STEPPEDPULLEY/
ROUNDDI
SC(
MODELSFORPRACTI
CE)

Ai
m:-Tomakeagr
eens
andmoul
dofgi
vens
teppedpul
l
ey/
RoundDi
sc
Tool
srequi
res
:-Fl
atr
ammer
,coni
cal
rammer
,tr
owel
,st
ri
keof
fbar
,ventwi
re,
spr
uecut
ter
r
isers
wab,
li
ft
er,
sli
ck,
brus
h,dr
aws
pike,
Riddl
eandBel
l
ow

Mat
eri
alr
equi
red:
-

Boxf
las
k,gr
eens
and,
pat
ter
n,par
ti
ngs
andandwat
er.

Pr
ocedur
e:-

1
. Pl
acedt
hegi
venpat
ter
ninmi
ddl
eofdr
agboxandf
il
lt
hegr
eens
andl
ai
dov
eri
t

2.Rammeds
andwi
thconi
cal
rammerupt
otopoft
hedr
agBox

3.Rammeds
andwi
thf
latr
ammerf
orl
evel
l
ingupt
otopbot
tomofdr
agbox

4.Lev
ell
eds
andwi
ths
tri
keofbarandf
ini
shwi
tht
rowel
s

5.Maket hev
enthol
ewi
thv
entwi
ref
orr
emov
ingbowlgas
es f
rom s
andwhen
cas
ting

6.Thedr
agboxt
urnedups
ideandappl
yi
ngpar
ti
ngs
and

7.Thecopeboxpl
acedabov
ethedr
agboxandr
unner
,ri
serpl
acedi
ncor
rect
pos
iti
on

8.Fi
l
lthegr
eens
oundt
othecopeboxandr
ammedwi
thconi
calr
ammerupt
othe
copebox

9.Rammedt
hegr
eens
andwi
thf
latr
ammer

1
0.Level
l
edwi
ths
tri
keof
fbarandf
ini
shwi
tht
rowel
sandmakev
enthol
ewi
thv
ent
wir
e

1
1.Remov
ethecopeboxandmakegat
ewaywi
ths
li
ckr
unnerhol
etopat
ter
n

1
2.Remov
ethegi
venpat
ter
nandr
emov
etheunwant
eds
andswi
thbel
l
owi
fneed.

Res
ult
s:-TheGr
eens
andmoul
dofs
teppedpul
l
ey/RodDi
sci
sobt
ained.
 SHEETMETAL

I
ntr
oduct
ion:
-Manyar
ti
cl
esofdayt
odayus
ear
emadef
rommet
als
heet
s,l
i
kepi
pesel
bow

boxes,
funnel
s,gaur
ds,
hopper
s,decor
ati
vear
ti
cl
esandhous
ehol
dut
ens
il
s.I
nsheetmet
al
work

knowl
edgeofpr
oject
iv
egeomet
ry,es
peci
al
lydev
elopmentofs
urf
acesandpr
oper
ti
esand
us
esofeachmet
alt
omos
tes
sent
ial
.Us
ual
l
ymet
alpl
atesoft
hicknes
sles
sthan5mm ar
e
cons
ider
edass
heetmet
al.Thes
heet
sar
especi
fi
edi
nthi
cknes
sbys
tandar
dwi
re(
sheet
)
gaugenumber
s.Thet
hicknes
sofs
heet
svar
yinv
ers
elyast
hei
rgaugenumber
s.

Mostcommonl
yus
eds
heet
sins
heetmet
alwor
kar
ebl
acki
ron,
gal
vani
sedi
ron,
copper
,

al
umi
num,
stai
nl
esss
teel
andTi
nsheet
set
c..
.
..
.
..

TOOLSANDEQUI
PMENTS
TheHandt oolsusedinsheetmetalworksareasf ol
l
ows :
-
2.Foldi
ng
1.
Steel Rule, Rule, 3.Flexi
bletape,4. Str
aightedgewingcompas ses,
5.Trammel , 7.Fl
atchisel
s,8.Scribi
ng
6. Div
iders
, t ool
s, 9.Bevel
protr
actor,
1
0 St eelsquare(
L
. s quare), 11.Scratchawl
1
2 Hammer sli
kes et
ti
nghammer ,ri
vet
inghammer ,creasi
nghammer ,rai
sing
. hammer
pl
ani
shi
nghammer
,sof
thammer,
PVChammer,Mall
etetc.
1
3 1
. Snips, 4. Handlev
ershear
, 1
5.Punches
,
1
6
. Stakes, 17. Fol
di
ngbar1
8.Groover

I
mpor
tantt
ool
s:-
Sni
ps:-ASni
pisal
socal
l
edahands
hear
,iti
sus
edl
i
keapai
rofs
cis
sor
stocutt
hins
oft
met
als
heet
supt
o20s
wg.Twot
ypeofs
nipsnamel
yst
rai
ghts
nipsandbends
nipsar
e
us
ed.
Str
aights
nipshav
est
rai
ghtbl
adesus
edf
orcut
ti
ngal
ongt
hes
trai
ghtl
i
nes
.Bends
nips
,
hav
ecur
vedbl
ades
,us
edf
orcut
ti
ngcur
vesandt
ri
mmi
ngcur
vededges
.

Handl
evers
hear
:-Thes
ear
eus
edt
ocuts
heet
swhi
chcannotbecutwi
thhands
hear
s.I
t
cons
ist
sofaf
ixedl
owerbl
adeandmov
abl
eupperbl
ade,
onwhi
chal
everhandl
eisf
ixedt
o
oper
atef
orcut
ti
ng.
Punches
:-Di
ff
erentt
ypesofpunchesar
eus
edi
nsheetmet
alwor
k.Theyar
epr
ickpunch,
cent
erpunchs
oli
dpunchandhol
l
owpunch.
Pri
ckpunchi
sus
edt
omakes
mal
lmar
ksonl
ay
outl
i
nes
,whi
l
ecent
erpunchesar
eus
edt
oenl
arget
hepr
ickpunchmar
ks.
Asol
i
dpunchi
s
us
edt
omakes
mal
lhol
esons
heetmet
al.Hol
l
owpunchesar
ehol
l
owi
ncr
osss
ect
ionand
ar
eus
edf
ormaki
nghol
esons
heetmet
al,
leat
herandpl
ast
ic.

STAKES–St
akesar
ethes
heetmet
alwor
ker
sanv
ilus
edf
orbendi
ngs
eami
ngorf
ormi
ng
us
ingahammeronmal
l
ets
heet
.Theyar
eus
edasas
uppor
ti
ngt
ool
aswel
lasf
ormi
ngt
ool
s.
Theyar
emadei
ndi
ff
erents
hapesands
izest
osui
tthet
ypesofoper
ati
ons
.As
takecons
ist
ofas
hankandheadorhor
n.Thes
hanksar
edes
ignedt
ofi
ti
ntoahol
eint
hebenchpl
ate.

Themos
tcommonl
yus
eds
takesar
e:-

1 Hatchet 2.
Half-
moonstake, Funnel
stake,
4.Beakhor
nst
ake(
Bick
.s t
ake, 3. i
ron)
5 Creasi
ng 6.Pl
ani
shi
ng
.s t
ake, st
ake, 7.Horseheadstake

GROOVER(
Seams
et)–Agr
oov
eri
sus
edf
orcl
osi
ngandl
ocki
ngofs
eamsi
nsheetmet
al
wor
k.Thes
heetmet
aloper
ati
onsar
ecl
ass
ifi
edi
ntomeas
uri
ngandmar
king

Cl
eani
ng
Lay
ing
out

Cut
ti
ngof
fandShear
ing

Tr
ammel(
Beam compas
s):
-At
rammelcons
ist
sofr
igi
dbeam car
ryi
ngt
womov
abl
eheadsor
f
rameswi
ths
teel
poi
ntst
hatcanbef
ixedi
nthedes
iredpos
iti
onsbymeansoft
humbs
crews
.It
i
sus
edf
orl
ayi
ngoutl
argerar
cs,ci
rcl
esandv
ari
ousot
hergeomet
ri
cals
hapesl
i
keanel
l
ips
e
et
c..
.
..
.
..
.
..

St
andar
dwi
reguage(
SWG)-Wi
regaugehav
est
otswi
thwhi
cht
het
hicknes
soft
hes
heet
met
alordi
amet
ersofwi
rear
emeas
ured.Eachs
loti
snumber
ed.Thes
heetmet
alorwi
re
hast
hes
amenumberast
hes
loti
nwhi
chi
tfi
ts.Thenumber
sar
ecal
l
edgaugenumber
s.
Wi
regaugesar
emadeofs
tai
nles
sst
eel
usual
l
y5mmt
hicknes
s.

Sheetmet
alj
oi
nts

1
. Hem:
-Isanedgeorbor
dermadebyf
oldi
ng

2.Seams:
-Iti
saj
oi
ntmadebyf
ast
eni
ngt
woedgest
oget
her

Ty
pesofhem

1
.Si
ngl
ehem, 2.
Doubl
ehem, 3.
Wir
ededge

Ty
pesofs
eam

1
.Laps
eam, 2.
Groov
eds
eams
, 3.
Singl
eSeams
,4.
Doubl
eSeam,

5.
Dov
etai
lseam, 6.
Bur
redbot
toms
eam

Ri
vet
edJoi
nt:
-Ri
vet
ingi
sapr
oces
sorofj
oi
ni
ngt
wopi
ecesofs
heetmet
albyus
ingr
ivet
s
per
manent
ly.
Typesofr
ivet
edj
oi
ntsar
e:-

Si
ngl
eri
vet
edl
ap
1
.joi
nt. 2. Doubl
eri
vetl
apjoi
nt, 3.
ZigZagl
apj
oi
nt,
Doubl
est
rapbut
t
4. Si
ngl
est
rapbut
tjoi
nt 5. j
oi
nt
 Rect
angul
arTr
ay(
Model
)

Ex:
No.

Dat
e. / /

Ai
m:-Tomakear
ect
angul
art
rayofgi
vei
ndi
mens
ionswi
ths
heetmet
al

Mat
eri
alr
equi
red:
-150x1
30mm26SWG.
G.I
sheet
,ri
vet
s.

Tool
srequi
red:
-St
eel
rul
etr
ysquar
escr
iber
,di
vi
ders
trai
ghts
nipss
teel
str
ip,
Benchv
ice
Mall
et

ofs
ofthammer
.

Pr
ocedur
e:-

1
.Checkt
heG.
Isheetf
orov
eral
ll
engt
handwi
dthus
ingas
teel
rul
e.

2.
Mar
koutt
hedev
elopmentoft
hebodyoft
het
ray
,us
ings
teelr
ule,t
rys
quar
e
di
vi
derandScr
iber
.

3.
Cutoutt
hedev
elopment
,andr
emov
etheunwant
eds
heet
,byus
ings
trai
ghts
tri
ps.

4.
Makes
ingl
ehenont
heout
eredgesoft
hehei
ghtpor
ti
ont
ogi
ves
trengt
hat
t
hredgebyaFol
di
ngus
ingbenchv
iceandmal
l
et.

5.
Doal
lt
hef
oldi
ngandbendi
ngpr
oces
stof
ormt
het
ray
.

6.
Bendt
hepr
oject
edpor
ti
onoft
hewi
dths
ideonl
engt
hsi
deandmakei
tfi
rm wi
th
r
evet
tedJoi
nt.

Res
ult
s:-Ar
ect
angul
art
rayofgi
vendi
mens
ioni
sobt
ained.
 WELDI
NG
Weldingisaper manentmet alj
oiningprocessbyheat i
ngtwoormor emet alpiecesand
j
oini
ngt hem t
oget herwi t
horwi t
houtpr ess
ur eandaddi tionoffil
lermaterial
.Wel di
ng
pr
oces sisemployedinmos tofthemoder nfabricat
ionwor ksandindustri
ess uchas;a)
st
ructuralwor
ki nbr i
dgesandbui l
dingsb)manuf acturi
ngofaut omobil
esc)Ai rCr aft
i
ndustryd)Shipbui l
dingindustr
ye)Oi li
ndustryf)Repai r
ingofmi l
ds t
eel,
Cas tiron,and
ot
herf err
ousandnonf err
ousmet al
set c….Weldingincl
udess ever
altypeofmet aljoi
ning,
byseveralmet
hods .Mos tcommonlyus edweldingarear candgaswel di
ng.

Ar
cWel
di
ng

Elect
ricarcWeldingi saprocessi
nwhi chheati sgeneratedbyanel ectr
icar
c.BothAC
&DCcur rentcanbeus edforweldi
ng.Whil
ewel dingelectr
onsmov efrompos i
ti
veto
negativeterminal
inthef ormofsparkandel ectr
icener gyinconv ert
edintoheatenergy,
therebyfacil
i
tati
ngwel ding.Twothi
rdheatgener atedatpos it
iv
et er
minalandonethirdat
negativeterminal
.Heatmel tsbotht
hemet al andf i
ll
ermaterialsothatweldi
ngcantake
place.

EQUI
PMENTSANDTOOLS

1
.ACorDCMachi
ne

Astepdowntr
ans
formeri
sus
edinACmachi
ne.
Suppl
yvolt
agefr
om220t o440
v
oltsmaybest
eppeddownto50to90vol
ts.
TheDCpowers
ourcecons
ist
sof(
1)Power
t
ransf
ormer

(
2)Cur
rentr
egul
ator(3)awav
erect
if
iert
oconv
ertt
heACt
oDCs
uppl
y.

2.
Elect
rodes

Thefi
l
lerusedi
nanarcweldingi
scall
edelectr
odes.
Theel
ect
rodesaremade
ofmetall
icwi
rewhichi
suni
for
mlycoatedwi
thfl
ux.Thefl
uxfor
msagasshi
eldt
oprot
ect
theweldmetalfr
omoxygenandni
trogeni
natmosphere.

3.
Elect
rodehol
der

Iti
saholdi
ngdevi
cet
ohol
dtheel
ect
rode.I
ti
sconnectedtotheendofweldi
ng
cabl
e,i
tconduct
sthepowers
our
ce.Thej
awsofthehol
deri
sinsul
atedtoavoi
del
ectr
ic
shock.

4.
GroundCl
amp

I
ti
saclampus
edt
ogr
oundt
hecabl
ecomi
ngf
romt
hepowers
our
cet
othewor
k
pi
ece.

5.
Cabl
eandConnect
ors
.

Cabl
esar
eus
edt
oconductel
ect
ri
ci
tyf
romt
hepowers
our
cet
otheel
ect
rode
holderandtheworkpi
ece.I
tismadeupofcopperoral
umi
niumandhighl
yins
ulat
edby
rubbercover.
Connect
orsareusedtoconnect
ingt
heendsofthel
eadtothetr
ansfor
mer
.

6.
Chi
ppi
nghammer

I
ti
sas
tri
ki
ngt
ool
usedr
emov
edt
hes
lagf
romt
hewel
dedpor
ti
on.

7.
Wir
ebr
ush.

I
ti
smadeofs
tif
fst
eel
wir
eus
edt
ocl
eant
hes
mal
lpar
ti
cl
esofs
lag.

8.
FaceShi
el
d

Iti
sus
edt
oprot
ecteyesandf
aceofawelderf
romtheult
ravi
ol
etandi
nfr
ared
r
adi
ati
onofar
cwel
di
ng.Thes
hiel
dcanbeeit
herhel
mettypeorhandhol
dtype.

9.
Prot
ect
iv
ecl
othi
ng

Handglov
esareusedt
oprot
ectt
hehandsofawelderandapr
on(madeof
cl
othorl
eat
her)prot
ect
sthebodyf
romheatands
park.

GasWel
di
ng

Gaswel di
ngi saf usi
ontypeofpr ocessinwhicht hej
ointismadewi t
ht he
appli
cat
ionofheat.Theheatisgener
atedbyt hecombust
ionofafuelgas.
Thefuelgas
widel
yus edacety
lenegas .Whenthegasmi xedwithoxygen,acet
ylenegasburnsto
producehight
emper at
ureofther
angeof3100C.

Thefl
ameofacet
yl
eneandoxygenmelt
sandfus
estoget
hert
heedgesoft
hepar
tst
o
bewel
ded.
Theaddi
ti
onofext
rametal
sfort
hejoi
nti
sdonebyusi
ngafi
l
lerr
odduri
ng
wel
di
ng.

Oxy
-acet
ylenewel
di
ngequi
pment

Thebas
icequi
pmentus
edi
ngaswel
di
ngcons
istof

1
.Oxy
gengascy
li
nder.
(Pai
ntedbl
ack)
2.
Acet
ylenegascy
li
nder(Pai
ntedMar
oon)

3.
Hos
e.

4.
Wel
di
ngt
orch

5.
Wel
di
ngt
orch

Gaswel
di
ngacces
sor
ies

Theaccessor
iesi
ncl
udesGoggl
es,
Weldi
nggl
ous
es,Jacketandboot,
spar
k
l
ight
er,f
ir
eexti
nguis
her,
etc.
ExNo. Dat
e:- / /
SI
NGLE‘’
V‘’
BUTTJOINT

Ai
m:-
Tomakeas
ingl
e“”V“
”butj
oi
ntbyar
cwel
di
ngmet
hods

Mat
eri
alr
equi
red:
-

Twonosofmi
l
dst
eel
piecesof75x30x5mm

Tool
srequi
red:
-

1
. Ar
cwel di
ngmachine,
2. Benchvi
ce3.Wel
di
ngtabl
e4.St
eel
rul
e5.Fl
atFi
l
e6.
Weldi
ngelectr
ode,7.FaceShiel
d,8.
Handgl
oves,9.
Chi
ppi
nghammer,1
0.Wi
re
br
ush11.Tongs

Pr
ocedur
e

1.
Preparet
hemetalpi
ecess
oast
oobt
aina‘
’V‘
’gr
oov
ewhent
heyar
epl
aceds
idebys
ide.
(usefi
l
eandgri
nding)

2.
Sett
hemetal
piecesont
hewel
di
ngt
abl
ewi
thedgespr
epar
edt
ouchi
ngeachot
her
,
us
ingcl
amp.

3.Fi
xaweldi
ngel
ect
rodei
ntot
heel
ect
rodehol
der
.Theear
thcl
ampi
sfi
xont
hewel
di
ng
tabl
eorwor
k

4.
Swi
tchont
hemachi
neandbr
ingt
heel
ect
rodet
othemet
alpi
ece.

5.
Startthewel
di
ngpr
oces
sbyi
ni
ti
ati
ngar
cbet
weent
heel
ect
rodeandt
he‘
’
V‘’
groov
eon
workpiece.

6.
Car
ryoutt
hewel
di
ngt
hroughoutt
hel
engt
h.

7.
Remov
ethes
lagf
ormwel
dedpor
ti
onandcheck.

8.
Repeatt
hewel
di
ngpr
oces
sifneeded.

9.
Swi
tchoft
hemachi
neaf
tercompl
eti
ngt
hewel
di
ng.
1
0.Li
ftt
hej
oi
ntedwor
kpi
ecewi
that
onganddr
opi
ti
ntowat
erf
orcool
i
ng.

1
1.Remov
ethes
lagus
ingchi
ppi
nghammerandwi
rebr
ush.

RESULT:Ther
equi
redbut
tjoi
ntofmet
alpi
ecei
sobt
ained.

PRECAUTI
ONS

Usefaceshi
el
dwhil
ewel
ding.
Wearleat
hergl
ovesandapr
on.
Donott
oucht
hemet
al
pi
eceunl
esscool
i
nghasbeendone.
 FI
TTI
NGANDASEMBLI
NG

I
ntr
oduct
ion:
-Fi
tt
ingi
soneoft
hemos
timpor
tantoper
ati
oni
npr
oduct
ionEngi
neer
ing.An
oper
atorwhodoest
hef
it
ti
ngj
obi
scal
l
edf
it
ter
.Al
thoughmaj
ori
tyofwor
kscanbef
ini
shed
t
oaf
air
lygooddegr
eeofaccur
acy
,theys
til
lrequi
ret
hehandoper
ati
onst
obedoneon
t
hem t
ofi
ni
sht
hem t
othedes
iredaccur
acy
.Af
it
ter
’swor
kisunav
oidabl
ewhendi
ff
erent
par
tsar
etobeas
sembl
edi
npos
iti
onaf
tert
heyhav
ebeenf
ini
shed.
Thet
ermf
it
ti
ngr
efer
sto
t
hehandwor
ksuchass
awi
ng,f
il
i
ng,t
appi
nget
c..
.
.,neces
sar
yaf
termachi
newor
kfor
as
sembl
i
ngpar
tst
oget
her
.Fi
tt
ing

mayormaynotbecar
ri
edoutonabenchv
ice.

Gener
all
ythr
eet
ypesoff
it
ti
ngar
ether
e:-

1
.Machi
nef
it
ti
ng 2.
Benchf
it
ti
ng 3.
Pipef
it
ti
ng

FI
TTI
NGTOOLS

Thehandt
ool
sus
edi
nfi
tt
ingwor
kar
ecl
ass
ifi
edi
ntot
hef
oll
owi
nggr
oups
.

Meas ur
ingandMar
king
1. tool
s 2.
Cutti
ngtools 3.
Hol
di
ngt
ool
s
Stri
ki
ng 5.
Inspecti
on
4. tool
s tool
s 6.
Mis
cel
l
aneoust
ool
s

1
.Meas
uri
ngandmar ki
ng
t
ool
s
1 2.Trysquareandbev el 3.Si
ne
.Steel Rule squar e Bar
4Combi nat
ions quare 5.Bevel 6.Univ
ersal
.gauge gauge 7.Bevelpr
otr
act
or
8VernierBev el Ver nier Verni
.protractor 9. call
iper 1 0. er depthgauge
1
1 Mi cromet er12.Verni
erheight 13 Sli
p 4
1. gauge . gauge . Angl egauge
1
5 Di al (Di
alTestindi
cat
or )16.Feeler
. gauge gauge 1 7. Radiusgauge
1
8 1 Thr ead 20 St andar
dwi regauge21.Scr
iber
. Scr ewpi tchgauge. 9. gauge . and

mar
kingkni
fe

2.
CUTTI
NGTOOLS

CHI
SSELS:-Di
ff
erentt
ypeofcol
dchi
sel
sar
eus
edbyf
it
ter
sforchi
ppi
ngandcut
ti
ngof
f
oper
ati
ons
.Chi
ppi
ng i
san oper
ati
on ofr
emov
ing exces
smet
alsbyus
ing chi
seland
Hammer
.Chi
sel
sar
emadef
rom hi
ghcar
bons
teelorchr
omev
anadi
um s
teel
.Thecut
ti
ng
edgei
shar
denedandt
emper
ed.
Thet
ypesofchi
sel
s,ar
efl
atchi
sel
hal
froundnos
echi
sel
,
Di
amondpoi
ntchi
sel
,si
dechi
sel
etc
Fi
l
es:
-AFi
l
eisahar
denedpi
eceofhi
ghgr
ades
teel
wit
hsl
ant
ingr
owsoft
eet
handi
sus
ed
f
orr
emov
ingexces
smat
eri
alt
osmoot
horf
itmet
alpar
ts.Fi
l
esar
egener
all
yfor
gedoutof
hi
ghcar
bons
teel
ort
ungs
tens
teel
fol
l
owedbycut
ti
ngoft
eet
h,har
deni
ngandt
emper
ing.

Fi
lespeci
fi
cat
ion:
-Fil
esares
peci
fi
edaccor
dingt
othei
rsi
ze,
cutoft
eet
h,gr
adeands
hape
orcr
osssecti
onsuchas:
-

Fl
atf
il
e,Handfi
l
e,Squar
efi
l
e,Pi
l
larf
il
e,Roundf
il
e,Tr
iangul
arf
il
e,Hal
froundf
il
e,kni
fe
edgef
il
eandneedlef
il
e.

Scr
apers:-Scr
apingi
semploy
edforremovi
ngthehi
ghspotfr
om machinedsur
facesf
or
obt
aini
ngfi
nesurf
acef
ini
shont
hework.Thet
ool
usedfors
crapi
ngi
sscraper.

Hacks
aws
:-Thehacks
awi
sus
edt
ocutmet
alsofdi
ff
erents
ect
ions
.Iti
sal
sous
edt
ocut
s
lot
sandcont
our
s.Themai
npar
tsoft
hehacks
awar
ethef
rame,
bladeandt
hehandl
e.Two
di
ff
erentt
ypesofhacks
awf
ramesar
eus
ed.
Fixedf
rameandadj
ust
abl
efr
ame.

Dri
l
ls:
-Adri
l
liscut
ti
ngtool
us edf
orcreat
ingci
rcul
arhol
esforvar
iouspurpos
e.I
tismadeof
hi
ghspeedst
eelorhi
ghcarbonsteel
.Twotypesofdri
l
lsar
es t
rai
ghtshankandt
apershank
dr
il
l
.

Reamer
s:-Areamer
sisamul t
i-
point
edcut
ti
ngt
oolus
edf
orenl
argi
ngandf
ini
shi
ngt
he
pr
evi
ousl
ydr
il
l
edhol
estocor
rectsi
ze.

HandTapsandTapwr
enches
:-Handt
apsar
eus
edf
ori
nter
nalt
hreadi
ngofcomponent
s.
Theyar
emadef
rom hi
ghcar
bons
teelorhi
ghs
peeds
teelhar
denedandgr
ound.Tap
wr
enchar
eus
edt
ohol
danddr
ivet
hehandt
apscor
rect
lyi
ntot
hehol
etobet
hreaded.
Taps
ar
eus
edi
nsetoft
hree.

Di
esandDi
est
ock:-Handoper
atedt
hreadi
ngdi
esar
eus
edt
ocutext
ernalt
hreadson
cy
li
ndr
ical
wor
kpi
ecess
uchasbol
tsands
tuds
.Adi
eismadeofhi
ghqual
i
tyt
ool
steel
.The
t
ool
sforhol
di
ngandt
urni
ngt
het
hreadi
ngdi
escal
l
eddi
est
ock.
 3.Hol
di
ngt
ool
s

Vi
cei
sthemos
tcommont
oolf
orhol
di
ngt
hewor
k.Theyar
eav
ail
abl
eindi
ff
erent
t
ypesf
ordi
ff
erentt
ypeofwor
k.Theyi
ncl
udebenchv
ice,
legv
ice,
pipev
ice,Handv
ice,
Pin
v
icet
ool
maker
svi
ce,
V-bl
ockandU-
clamp.

Benchv
ice:
-Abenchv
icei
sthemos
tcommondev
ice,madeofcas
tir
on/cas
tst
eel
andi
s
us
edt
ohol
dthewor
kforf
il
l
ing,
sawi
ng,
thr
eadi
ngandot
herhandoper
ati
ons
.Thes
izeoft
he
v
icei
sst
atedbyt
hewi
dthoft
hej
aws
.Itcons
ist
sofamov
abl
ejawandaf
ixedj
aw.

4.
STRI
KINGTOOLS
Str
aightpei
n
1
. Bal
lpei
nhammer 2. hammer
3. Cr
osspei
nhammer 4. Sl
edgehammer

Hammer
sar
especi
fi
edt
oits
hapeofpei
nandwei
ght

5.I
NSPECTI
ONTOOLS:
-Thev
ari
ousi
nst
rument
sar
eus
edf
orchecki
ngt
hej
obi
nfi
tt
ing
s
hopTheyar
est
eel
rul
e,mi
cromet
er,
Ver
niercal
i
per
,st
rai
ghtedge,
bev
elpr
otr
act
or,
hei
ght
gauge,
dri
l
lgauge,
sinebar
,sl
i
pgauge,
scr
ewpi
tchgaugef
eel
ergauge,
spi
ri
tlev
el.
Dial
tes
t
i
ndi
cat
oret
c.

Ver
niercal
i
per
:-AVer
niercal
i
peri
sapr
eci
si
onmeas
uri
ngi
nst
rumenti
sus
edt
omeas
ureup
t
oaccur
acyof0.
02mm i
nmet
ri
csy
stem.I
tcons
ist
sofabeam car
ryi
ngt
hemai
nscal
e,
i
nsi
demeas
uri
ngj
aw,out
sidemeas
uri
ngj
aw,dept
hgaugebar
,ver
niers
li
de,v
erni
ers
cal
e
andat
humps
crew.
Thet
humps
crewhel
ptos
ett
hev
erni
ers
li
dei
nanypos
iti
onont
hemai
n
s
cal
e.Av
erni
ercal
i
perwi
thanaccur
acyof0.
02mmi
nthi
s50di
vi
si
onsoft
hev
erni
ers
cal
e
occupy49di
vi
si
ons(
49mm)oft
hemai
nscal
e.Ther
efor
ethel
eas
tcountoft
hev
erni
er
s
cal
e:
-

L.
C=1
MSD=1VSD

=1mm =49/
50mm

=1
/50mm=0.
02mm

Mi
cromet
er:
-

Ami
cromet
eri
spr
eci
si
oni
nst
rumentus
edt
omeas
ureaj
obwi
thi
nanaccur
acyof
0.
01mm.Theyar
eav
ail
abl
einv
ari
ousr
angesl
i
ke0-
25mm,25t
o50,50t
o75mm,et
c..
.
.
mai
npar
tsar
efr
ame,
anv
il
,spi
ndl
e,par
all
elt
himbl
e,Rat
chets
top,
locki
ngs
crews
.Thepi
tch
oft
hemi
cromet
eri
s0.
5mm i
e,i
noner
otat
ionoft
het
himbl
ethes
pindl
eadv
ancesby0.
5
mm.
Thebar
rel
isgr
aduat
edi
nmi
l
li
met
ersf
rom0-
25mm.
Thet
himbl
eisgr
aduat
edi
nint
o50
di
vi
si
onsandmar
ked0-
5-1
0-

.
.
..
.
.50i
ncl
ockwi
sedi
rect
ions

Mov
ementofonedi
vi
si
onoft
himbl
e=0.
50x1
/50mm

i
e,l
eas
tcount
=0.
01mm

6.
MICELLANEOUSTOOLS;

Var
ioust
ypesoft
ool
sar
e-s
panner
s,s
crewdr
iver
s,pl
i
ers
,cr
owbar
,al
enkey
s
et
c….

MODEL–I

FI
LINGPRACTI
CE

Ai
m:-Cut
ti
ngandf
il
i
ngofaRect
angul
arPi
ece

Mat
eri
alRequi
red:
-MSFi
at51
x25x6m

Tool
sRequi
red:-Benchvi
ce,Steel
rul
e,Trys
quar
e,Scri
ber
,Hacks
aw,Fi
atf
il
e(Roughand
SmoothVer
nierhei
ghtgaugeandverni
ercal
i
per,
punchandhammer

Jobs
equence:
-

1
. Meas
uret
hes
izeofgi
venj
ob.

2.Maki
ngaspert
hedi
mens
ionswi
tht
hehel
poft
rys
quar
e,s
teel
rul
eands
cri
ber
.

3.Hol
dthewor
kpi
eceonbenchv
icepr
oper
ly.

4.Cutt
hej
obbyHacks
aw.

5.Fi
l
eones
ideandt
ruet
hes
urf
acel
evel
.

6.Fi
l
ingonecor
nerbyf
il
eandcheckwi
tht
rys
quar
e.

7.Checkthel
engt
hofwi
dthr
espect
iv
elybymar
kingwi
thhel
pofv
erni
erhei
ghtgauge,
punchandhammer

8.Fi
ni
sht
hej
obbyf
il
i
ngaspert
hegi
vendi
mens
ions
.
 9.Remov
ethebur
sandf
ini
sht
hej
ob.

1.
Usecorrects
izeoftool
s
Safetypoint
:- onl y 2.Sett
hejobinvi
ceproper
ly 3.
Hacks awbladefixcor
rect
lyandav oi
dover 4.Sharpedendedtool
sonusedfor
ti
ght mar
king
5.Cleantheviceandmachineafterfi
ni
shi
ng
thejob 6.
Keept
ool
sinpr
operpl
ace.

Res
ult:
-Wor
kfi
ni
shedaspert
hegi
vendi
mens
ionsar
eobt
ained
 DI
SASSEMBLI
NGANDRE-ASEMBLI
NGTAI
LSTOCKOFALATHE.

JOBSEQUENCEANDSKI
LLSEQUENCE

1
.MATERI
ALSREQUI
RED-ATAI
LSTOCKOFLATHEMACHI
NE

Pr
epar
ati
on:
-

a.Sel
ectpr
operpl
aceandcl
ean

b.Sel
ectt
her equi
redtool
swoodenbl
ock,scr
ew dri
ver
,spannerset
,al
lenkeys
et,
hammer
,Punch,oil
can,
greas
e,s
moot
hfi
le,
emerypaperandcott
onwast
e

2.bef
oret
heexer
cis
es

a.Checkt
het
ail
stockbodyi
fther
eisanycr
ackorbr
ake.

b.Remov
ethel
ocki
ngcl
ampf
rombed.c.
Takenoutt
het
ail
stockf
rommachi
ne.

3.
Doi
ngt
heExer
cis
e

a.Cl
eant
hebodyandr
emov
elocknutoft
ail
stocks
pindl
ehandl
e

b.Remov
ethehandl
e

c.Remov
ethes
pindl
elockl
i
ver

d.Remov
ethes
pindl
efr
ombody

e.Remov
espi
ndl
eandmi
crocol
l
erandkey

f
. Remov
espi
ndl
eandcheckt
hes
pindl
ebor
e

g.Remov
etheof
fsets
crews

h.Remov
ethebodyt
opandbot
tompar
tss
epar
atel
y

4.
aft
ert
heExer
cis
es:
-

1
. Remov
erus
tanddus
tfr
omal
lpar
ts.

2.Cl
eanandoi
l
ingt
hepar
tsandappl
ygr
eas
e.

3.Res
etbodypar
tsonebyone.

4.Checkandmakecl
earal
lpar
tsar
eas
sembl
ed.

5.Pl
acet
het
ail
stocki
nlat
hebed.

6.Lockt
het
ail
stocki
ncor
rectl
ocki
ngpos
iti
on.

7.Checkt
hes
pindl
emov
ement
.

8.Oi
l
ingt
hrought
heoi
lhol
es.
 9.Repl
aceal
lt
het
ool
sinpr
operpl
aces
.

5.
Saf
etymeas
ures
:-

1
. Pl
acet
heTai
lst
ocki
nwoodenf
lank.

2.Us
ecor
rects
izeofs
panner
s.

3.Av
oidov
ert
ightandov
erl
oad.

4.Cleant
hewor
kpl
acesus
ingbr
ushes
.
6.
Resul
t

Di
sas
sembl
i
ngandRe-as
sembl
i
ngofTai
lst
ocki
scompl
eted

CYLI
NDERPI
STONASSEMBLY

JOBANDSKI
LLSEQUENCE:
-

Ai
m:-Todi
smant
leandas
sembl
ethegi
vency
li
nderpi
stonas
sembl
yuni
t.

Mat
eri
al
srequi
red:
-

1. Api
stoncyl
i
nderas
semblyuni
tofat
wos
trokepetr
olengine.
4.
Cleani
ng 5.Cot
ton 6.Lubr
icat
ing
2. Atr
ay3.Di
esel br
ush waste oil
Tool
srequi
red:-
1.Boxspanner 3.Cl
aw 4.Ci
rcli
p
set 2.Scr
ewdr i
ver hammer remover
5.Ri
ng 6.Ri
ng
Expander compressor

PARTS

1
.Pi
ston

2.
Gudgenpi
n

3.
Cir
cli
p

4.
Smal
lendofconnect
ingr
od

5.
Bus
hbear
ing

6.
Connect
ingr
od

7.
Jour
nal
bear
ing

8.
Cap

St
udyoft
heas
sembl
y
 Thepi
stonandcy
li
nderas
sembl
yist
hemos
timpor
tantpor
ti
oni
nanpet
rol
ordi
esel
engi
ne.
Pis
tonmov
esupanddowni
nsi
deacy
li
nderwhi
l
efuel
bur
ningandconv
ert
stheheat
ener
gyi
ntomechani
cal
ener
gywi
tht
hehel
pofacr
anks
haf
t.

Wor
kst
obecar
ri
edout

Di
smant
li
ng,
Cleani
ng,
Faul
tfi
ndi
ngandr
ect
if
icat
ion,
Ass
embl
i
ng,
Oil
i
ng,
andChecki
ng

Di
smant
li
ngpr
ocedur
e:

1
. Remov
ethenutandbol
tfr
omt
hebi
gendofconnect
ingr
od.

2.Remov
ethecapandj
our
nal
bear
ing.

3.Di
sconnectt
hebi
gendf
romcr
anks
haf
t.

4.Takeoutt
hepi
stonwi
thconnect
ingr
od.

5.Remov
ethepi
stonr
ings
.

6.Removetheci
rcl
i
p.
7.Di
smantl
etheGudgenpi
n.

8.Di
smant
let
hepi
stonandconnect
ingr
od

9.Remov
ethebus
hbear
ingf
romt
hes
mal
lendofconnect
ingr
od.

Cl
eani
ng:
-

Cl
eanall
part
swithabrus
hindi
esel
.Putal
lcl
eanedpart
sinaconv
eni
entpl
aceort
ray
.
Checkal
lpar
tsandfi
ndanydamageorfaul
t.
Recti
fyt
hedefect
s.

Reassembl
y:-Fol
l
owallt
hedis
mantli
ngpr
ocedur
einr
equi
react
ioni
sthel
asts
tepof
di
smantl
i
ngisthef
ir
sts
tepofassembl
y.

Checki
ng

Rot
atethecranks
haf
tandmakes
uret
hatt
hepi
stonas
sembl
yismov
ings
moot
hly
i
nsi
det
hecyl
inder
.

Res
ult
:-

Thepi
stoncy
li
nderuni
tdi
smant
li
ngandas
sembl
i
ngi
scompl
eted.
STUDYOFMACHI
NES

1
.DRI
LLI
NGMACHI
NE
I
ntr
oduct
ion:
-

Thedril
li
ngmachi neisoneofthemostimportantmachinetoolinagener al
workshop.Iti
spr i
marl
ydes i
gnedtoor
igi
nateahol e.I
tcanperformanumberofs i
mil
ar
operat
ions.
I
tistheoldestformofdril
l
ingmechani
smi sdevelopedin1200BC, call
edbowdri
l
ls.
Indri
l
li
ngmachinetheholeisgeneratedbyther ot
atingedgeofacut
ti
ngt
ool
Knownasdr il
l.I
texert
slargefor
ceonthewor kclampedont hetabl e

St
udyofdr
il
l
ingmachi
ne.

Ski
l
l:-Dr
il
l
ingmachi
nesar
ewi
del
yus
edf
oral
lengi
neer
ingwor
kshopcons
truct
ions
ites
.

Tool
Main Jobhol ding Mai
nOperati
onand
Ty
pes ToolsUs ed hol ding
Par
ts system r
emarks
met hods
Bencht ype Bas e, Mainl
yus ed Machine
Dr i
ll
sar e
Sens i
ti
ve Table str
aight- vi
ce 1
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
ty
pe Column shankdri
ll, holdingin
Benchv ice
& dril
l
Pi
ll
artype Spindl
e Clamps 2.
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
Taper- check,or
Radialty
pe -head Boltand
shankdri
lls direct in
Columt ype Mot or nuts 3.
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
(madeof spindle
Portabl
e handle HSS, Angleplate
bor e of
ty
pe Cutti
ng Ji
gset c 4.
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
the
angle118 machi ne
degree) 5.
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
withhel p
Tap,
of
Reamer. 6.
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
sleeves
et
c..
 2.
LATHE

I
ntr
oduct
ions
:-

Thel
athei
stheol
des
tandmos
tcommonmachi
neus
edf
ort
urni
ngoper
ati
on.
The
pr
esentf
ormofLat
hedev
elopedi
ni
ti
al
lybyHENRYMAUDSLAYi
n1800,
fors
crewcut
ti
ng.
Themai
nfunct
ionofal
athei
stor
emov
emet
alf
romapi
eceofwor
ktogi
vei
trequi
re
s
hape

ands
ize.
Thewor
kinhol
di
ngandr
otat
ingbyl
atheandt
hecut
ti
ngt
ool
isf
ixedi
nthet
ool
pos
t.

Ther
ear
esev
eral
typeofl
athesi
ndes
ign,
siz
eandus
e.Themos
twi
del
yus
edt
ypei
s
Engi
ne

l
atheorcent
rel
athe.

St
udyofLat
he

Ski
l
l:-Thi
smachi
net
ool
ismai
nl
yus
edi
ngener
alpur
pos
eandpr
oduct
ionwor
kshops
.

Tool
Used Jobholdi
ng Mai
nOperati
onand
Ty
pes Mai
nPar
ts hol
ding
Tool
s s
ystem Remar
ks
method
Cent
re Leg, Tur
ing Tool Tool
s Mai
nl
y j
ob
1
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
l
athe, Bed, (
RH&LH) hol
di
ng i
n hel
dby3j
aw
Bench HeadSt
ock, v
ari
ouss
ize t
he Tool chuck, 2.
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
l
athe Car
ri
age, and s
hape) pos
toft
he 4Jaw chuck
Speci
al Cr
osss
li
de, s
oli
d t
ool
s,l
athe by .
mandr
els
, 3.
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
l
athe Compound t
ipped t
ool
,thehel
pof f
ace pl
ate,
4.
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
CNCLat
he r
est
, l
ead hol
derwi
th s
panner
s car
ri
es and
5.
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
(
gener
al s
crew and t
ool
bit
s) ands
hims. wi
th hel
p of
pur
pos
e Tai
lSt
ock Thr
eadi
ng r
est
s. 6.
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
cone t
ool
,
pul
l
ey and gr
oov
ing 7.
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
al
lgener
al t
ool
,
8.
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
t
ypes) Bar
ingTool
9.
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
, Knur
li
ng
t
ool
etc.
1
0..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
(
Iti
s made
HSSbi
t.
)
 2.
SHAPI
NGMACHI
NE

Shaperi
sareci
procat
ingty
peofmachi netoolint
endedpr i
marl
ytoproducefl
at
surf
aces .
Thesesur
facesmaybehorizontal
,
vert
icalorincl
ined.
Ingener
alt
hes hapercan
produseanysurf
acecompos edofs
traightl
i
neelement s.Themodernshaperwas
developedin1
836byJAMESNASMYTH, anEngli
shman.

Theworkpieceinhol
dont heshaperbedbymachinev
iceandt
hecutt
ingt
ooli
s
f
ixedontheshaperr
am. Theramisrecipr
ocatingmemberint
hemachi
newhichr
emovethe
metal
frompiecewit
hthehelpofacutti
ngt ool
.
Studyofs hapingMachi
ne

Ty
pes Mai
nPar
ts Us
edt
ool
s Toolhol
di
ng Job holdi
ng Main operati
on and
methods sy
stem Remarks
Cr
ank Bas
e, Mai
nl
yus
ed Si
nglepoint Machi
ne 1.
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
.
s
haper
, Col
umn, f
or v
ari
ous Tool
s hol
d Vi
ce,Angl
e
2.
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
Gear
ed Cr
ossnai
l
, s
hape of i
nthe par
t pl
ate, ‘
V’
3.
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
s
haper
, Saddl
e, gr
inded of cl
apper Bl
ock,
Hy
draul
i
c Tabl
e, HSSt
ool bl
ockoft
he Shaper
- 4.
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
t
ype, Ram, machi
ne. i
ndex
5.
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
Dr
awcut
type Tool
head. cent
re.
6.
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
.
et
c.

Ski
l
l:Commonl
yshapi
ngwor
kar
ecar
ri
edi
nthepr
oduct
ionengi
neer
ingwor
kshops
.
 3.
MILLI
NGMACHI
NE

I
ntr
oduct
ion:
-

Ami
l
li
ngmachi
net
oolcanper
for
msev
eraloper
ati
onsofwi
dev
ari
ety
.Iti
sus
edt
o
pr
oducecompl
exs
hapesi
nwor
kmat
eri
al
.I
tcanpr
oducef
lal
easwel
lasi
nter
nal
orext
ernal
cur
veds
urf
aces
.Amul
ti
toot
hrot
ati
ngcut
ter
,whent
hewor
kpi
ecei
sfeededagai
nsti
t.

St
udyofMi
l
li
ngMachi
ne:
-

Tool Jo holdi
n
Ty
pes Mai
nPar
ts Us
edt
ool
s hol
ding b g Main
methods sy
stem oper
ati
on
and
Remarks.
)
Bas Mul Hold Jo
(
a)Pl
ai
n, e, t
i t
oot
h i
n t
he bs are
Kne arbo wi t hol i
n
e, mil
l
ing ur h d the
cut
ter tab
Hor
izont
al Saddl
e, made help of l
e by
Tab arbo
l
e, ofHSS ur machine
Arb Ov e suppor
t vic cl am
Ver
ti
cal or, r and e, p,
ar
m Kne spac
, e (
It i
s ers. nutandbol t
ch
speci
fi
ed uc
Omni
ver
sal elev at
ing by k with
scr ew, shap
Cr os s the e, mandr
el.
fee s cre bo
Uni
ver
sal- d w re siz
e
t
ypes Tel escopic anduse)
driving
sha
ft
(I
ndexi ng
mechani s
m
)

Ski
l
l:-Mai
nl
yus
edi
npr
oduct
ioncent
rewi
thaccur
atej
obsdonebyt
hismachi
net
ool
 5.
GRI
NDI
NGMACHI
NE

I
ntr
oduct
ion:
-

Gr
indi
ngi
samet
alcut
ti
ngoper
ati
onper
for
medbymeansofar
otat
ing
abr
asi
vewheel
gri
ndi
ngi
sus
edasaf
ini
shi
ngoper
ati
on.
Gr
indi
ngwheel
ismadeupf
orcar
bor
andomonot
herhar
denedal
l
oy
mat
eri
al
s.

Thewheel
isr
otat
edwi
tht
hehel
pofanel
ect
ri
cmot
or.
Thei
stobegr
oundi
shol
dbyhandon
wit
h

wor
khol
di
ngdev
ices
,agai
nstt
her
otat
ingwheel
.

St
udyofGr
indi
ngMachi
ne

Ty
pes Mai
nPar
ts UsedTool s Tool Job Main operation and
holding holding Remarks
met hod system
A.Bench Base,
tabl
e ( Gri
nding Abras iv
e Jobs ar e A)1
..
.
..
.
..
.
..
..
.
..
.
..
.
..
.
..
..
..
Wheelhead, wheel isact gri
ndi ng fi
xedt able 2.
..
..
.
..
.
..
.
..
.
..
..
.
..
.
..
..
.
.
B.Port
abl
e Saddl e, as a mul t
i wheel s partoft he B)1.
.
..
..
.
..
.
..
.
..
.
..
..
.
..
.
..
..
.
Feed point arehol din machi ne 2.
..
..
.
..
.
..
.
..
.
..
..
.
..
.
..
..
.
..
C.Surf
ace handl
e, cutti
ngt ool machi ne or chuck. C)1 .
..
.
..
.
..
.
..
.
..
..
.
..
.
..
.
..
..
.
Wheel made of wheel Diff
er ent 2.
..
..
.
..
.
..
.
..
.
..
..
.
..
.
..
..
.
.
D.Cyli
ndr
ical spi
ndl
e, abras i
ve spi
ndl es typeofj ob D)1.
..
.
..
.
..
.
..
.
..
..
.
..
.
..
.
..
..
.
.
motor
. met al
s holding 2.
..
..
.
..
.
..
.
..
.
..
..
.
..
.
..
..
.
.
E. Cent r
e (Al
umi ni
um met hods E)1 .
.
..
.
..
..
.
..
.
..
.
..
.
..
..
.
..
..
.
..
l
ess oxi
de or are us ed 2.
..
..
.
..
.
..
.
..
.
..
..
.
..
.
..
..
.
..
.
Sil
i
con clamps , F)1.
.
..
.
..
.
..
..
.
..
.
..
.
..
.
..
..
..
.
.
F.Tooland carbide) nut and 2. .
..
.
..
.
..
..
.
..
.
..
.
..
.
..
..
..
.
cutt
er bolt,
gri
nder magnet i
c
tableet c.

Ski
l
l :
-Gri
ndi
ngmachi
nesar
eus
edf
orr
emov
emet
alwi
thgoods
urf
acef
ini
shi
nal
lengi
neer
ing
works.
 MACHI
NESHOP

Model
Ques
tions:
-

1
.Gi
vet
hreemai
nfeat
uresofheads
tockofacent
rel
athe?

2.
Lat
hebedsar
emadeof.
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..

3.
Deadcent
rei
sfi
xon.
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.
..
.par
tthi
stai
lst
ock

4.
Whati
sdi
ff
erencebet
ween4Jawchuckand3JawChuck

5.
Giv
ethr
eet
ypesofcut
ti
ngt
ool
mat
eri
al
sus
edi
nLat
hewor
k.

6.
Lubr
icant
sisas
ubs
tance,Whi
chr
educesf
ri
cti
onbet
weenmachi
nepar
ts.Whatar
e
t
he3gr
oupofl
ubr
icant
s?

7.
Giv
etwoexampl
esmul
ti
poi
ntcut
ti
ngt
ool
?

8.
Dif
fer
encebet
weens
hapi
ngandmi
l
li
ng?

9.
Gri
ndi
ngext
ernal
sur
facewhi
cht
ypesofmachi
net
ool
iss
uit
abl
e.

1
0.Whatar
etheus
eofdr
il
l
ingmachi
nesi
nengi
neer
ingwor
kshop?