WORK SHOP PRATICE ME/MT/CH/RE 1962 SKILL DEVELOPMENT

A H VITHANAGE 100560P CHEMICAL AND PROCESS ENGINEERING

Practical 1 : Machining of Thread and Taper

Machining processes used in the practical are as follows 1. Facing 2. Drilling 3. Taper Turning 4. Threading

Practical 2 : Welding Shielded Metal Arc Welding (SMAW)

Shielded Metal Arc Welding uses a consumable electrode coated in flux (flux potash, charcoal, coke, borax, lime, lead sulfide and etc) to lay the weld. Electric current from the welding power supply, is used to form an electric arc between the electrode and the metal to be joined. As the weld is laid, the flux coating of the electrode vaporizes and then becomes a layer of slag, which protects the weld area from atmosphere. Because of the simplicity of both its process and equipment, shielded metal arc welding is one of the most popular of various welding processes. Although there are new welding methods being developed, shield metal arc welding continues to be used extensively in the construction of steel structures and in industrial fabrication. This welding

process is used primarily to weld iron and steels, but aluminium, nickel and copper alloys can also be welded with this method.

Purposes of the coating of the electrode used in shielded metal arc welding Gives off gases as it decomposes to prevent weld contamination Introduces deoxidizers to purify the weld Causes weld-protecting slag to form Improves the arc stability Provides alloying elements to improve the weld quality

Oxy-Fuel Gas Welding

Oxygen-acetylene welding was developed by two French engineers in 1903. In oxy-fuel gas welding fuel gases and oxygen is used to weld metals. Apart from welding this method can also be used to cut metals too. Pure oxygen is used to increase the flame temperature to allow localized melting of the material (e. g. steel) in a room environment. A common propane/air flame burns at about 3,630 F (2,000 C), a propane/oxygen flame burns at about 4,530 F(2,500 C), and an acetylene/oxygen flame burns at about 6,330 F (3,500 C). In oxy-fuel welding, a welding torch is used to weld metals. Welding happens when the two pieces of metals are heated to a temperature that produces a shared pool of molten metal. The molten pool is generally supplied with additional metal called filler. Filler material depends upon the metals to be welded.

Resistance Spot Welding

Resistance spot welding is a process in which contacting metal surfaces are joined by the heat obtained from resistance to electric current flow. Work-pieces are held together under pressure exerted by electrodes. Normally the sheets are in the 0.5 to 3 mm (0.020 to 0.12 in) thickness range. The process uses two shaped copper alloy electrodes to concentrate welding current into a small "spot" and to simultaneously clamp the sheets together. Forcing a large current through the spot will melt the metal and form the weld. As the huge energy is delivered to the spot in a very short time, welding occurs without excessive heating to the rest of the sheet. It is used in a wide range of industries but notably for the assembly of sheet steel vehicle bodies where more than 100 million welds are made per day in Europe alone. High quality welds can also be made in stainless steels, nickel alloys, aluminium alloys and titanium for aerospace application.

Practical 3 : Sheet Metal Forming

 Industrial applications of sheet metal 1. In Airplane wings 2. For vehicle bodies 3. For conductor pipes and gutters 4. Used in the making of air conditioners to provide the self-contained unit for the refrigeration system 5. For tables and storage units 6. Manufacturing of toys

Practical 4 : Wood Work