FITTING (SPANER)

Aim: To Make a Spanner from the given mild steel blank.

Material: One mild steel plate of size 210x50x5mm

Tools required: Flat file, round file, drill, hacksaw, dot punch, centerpunch,
vernier caliper, scriber and hammer.
Sequence of operations: -
1) Blank cutting
2) Marking with template
3) Dot punching
4) Chain Drilling
5) Slot cutting and finishing
6) Profile finishing

Theory:

Bench work and fitting has its own important in engineering work. Measurement plays a
vital role in manufacturing, assembly and design of new components. Even after
machining, finishing by hand to exact accuracy is necessary which is called bench work
and fitting. In fitting all operations are done by hand. Fitting is essential where parts to
be assembled. Alignment of machine parts, bearing, engine, slide, values and other
similar works require fitting operation.
Material : Mild steel flat of size 210x50x5mm

Procedure:

a) Hold the job in a bench vice.

b) Perform filling operation on all sides and check that the adjacent sides are at
right angles using try square.
c) Maintain the dimension of the job 209x49x4.5mm after filling.

d) Mark the job using a template.

e) Mark the positions for holes
f) Drill the holes dia 20 and dia 18
g) Mark the area of material to be removed from as per drawing using Chisel,
and hammer.

h) Slot the taper profile at one end and maintain the size as per drawing.
Repeat the procedure for the taper profile at the other side.
i) Smoothen the remaining Profile on the pieces using a file.
 j) Slot the round corner using a form tool.
k) Deburr the corners for smoothness.
l) Check the various dimensions of spanner using mesuring instruments.
.

Result: A perfect “Spanner” is obtained as shown in fig.

Precautions:

a. Job should be held tight in vice while doing operations such as filling and cutting.
b. Pressure should be applied while filing and cutting during forward stroke.
c. Cutting should be done a accurately as per lines drawn after marking.
d. Holes are to be located and drilled accurately.
Aim: To Prepare a Cross lap joint according to the dimension as shown in fig.

Theory:
Wood is available in nature in form of a tree. Wood after cutting from tree and
seasoning treatment (to reduce the moisture content in wood) is called timber.
The timber is widely used for engineering and building purpose. Carpentry is the
process of components such as pattern for casting, furniture, roofs, partitions,
door and windows. Carpentry tools are used for carpentry process. Carpentry
process includes.
1. Cutting
2. Planning
3. Joining so as to produce a finished product

Material : Soft wood block( Kail) of size 150x45x35mm

Tools required:

a. Jack plane
b. Try square
c. Vice carpentry
d. Marking gauge
e. Firmer chisel
 f. Steel rule
g. Rip saw
h. Fill or sander
i. Mortise chisel

Procedure:

A. Hold the job securely in carpentry.

B. Plane the job to the dimension 150x42x35mm using jack plane.
C. Cut the job in two pieces of equal length using rip saw mark them ‘A’ and ‘B’.
D. Mark requires dimensions on pieces ‘A’ and ‘B’ to identify the material which is to
be removed. Use marking gauge and steel rule for marking.
E. Remove the unwanted material using a rip saw and cutting chisel.
F. Smoothen the remaining surface using file or sand paper.
G. Assemble Both pieces to make the joint.

Result: The cross-lap joint of required dimension is obtained.

Precautions:
1. Job should be held securely in carpentry vice so that job doesn’t move while
planing.
2. Check the squareness of side while planing .
3. Marking should be done properly and accurately.
4. Cutting and removal of material should be done accurately.
5. Surface to be smoothen before securing in lap joint.
Aim: To Prepare a Dovetail joint according to the given dimension as shown in fig.

Theory:
Wood is available in nature in form of a tree. Wood after cutting from tree and
seasoning treatment (to reduce the moisture content in wood) is called timber.
The timber is widely used fir engineering and building purpose. Carpentry is the
process of components such as pattern for casting, furniture, roofs, partitions,
door and windows. Carpentry tools are used for carpentry process. Carpentry
process includes
4. Cutting
5. Shaping
6. Joining so as to produce a finished product
7. Job
8. Soft wood block of size 150x45x35mm

Material: Soft wood block (Kail) of size 150x45x35mm

Tools required:
a. Jack plane
b. Try square
c. Vice carpentry
d. Marking gauge
e. Firmer chisel
f. Steel rule
g. Rip saw
h. Fill or sander
i. Mortise chisel

Procedure:

a. Hold the job securely in carpentry.

b. Plane the job to the dimension 150x42x32mm using jack plane.
c. Cut the job in two pieces of equal length using rip saw mark them ‘A’ and ‘B’.
d. Mark the require dimensions on pieces ‘A’ and ‘B’ to identify the material which is
to be removed. Use marking gauge and steel rule for marking.
e. Remove the unwanted material using a rip saw and cutting chisel.
f. Smoothen the remaining surface using file or sand paper.
g. Make the joint.

Result: The Dovetail joint of required dimension id obtained.

Precautions:
1. Job should be held securely in carpentry vice so that job doesn’t more while
planing.
2. Check the squareness of side while planing .
3. Marking should be done properly and accurately.
4. Cutting and removal of material should be done accurately.
5. Surface to be smoothen before securing in lap joint.
Aim: To Make a Single V- butt joint by using arc welding.

Theory:

Electric arc welding process in which heat is generated by an arc it uses AC and DC
power source for striking the arc between the electrode and the work piece. Electron
moves from positive to Negative terminal in the form of spark and electrode energy is
converted into heat energy. There by facilitating welding. Two third heats are generated
at positive terminal and are third at negative terminal. The heat meets both metal and
filler material so that welding can take place.

Material: Two mild steel pieces of dimension 65 x 50 x 5 mm.

Tools and equipment’s:

a. AC arc welding M/C set

b. Welding electrode
c. Face shield
d. Hand gloves
e. File
 f. Chipping hammer
g. Welding table
h. Bench vice
i. Wire brush
j. Apron
k. Tong

Procedure

a. Clean the surface of the metal pieces using a file and maintain dimension as per
drawing.
b. Prepare the edges of pieces for single “V” groove by filling.
c. Prepare the edges to be welded touching each other on a welding table.
d. Fix an electrode into the electrode holder of the machine. The clamp of the
machine is grounded to the welding table.
e. Switched on the machine and position the electrode on the single ‘V’ groove.
f. Start the welding process by arc between the electrode and the interface (single
V-groove) of the metal pieces.
g. Switched off the machine after completing the welding.
h. Lift the completed job with a tong and keep in safe place for cooling.
i. Remove the slag or spatter using chipping hammer and wire brush.

Result: The required single ‘ V ‘ butt of metal pieces is obtained.

Precautions:

1. Use welding eyes shield and goggles while performing welding operation.
2. Wear lather apron and gloves.
3. Move the electrode gradually ensuring filling of the joint.
4. Do not touch the metal pieces unless cooling has be done.
Aim: To Prepare the Mould by split pattern with horizontal core using natural moulding
sand.

Theory:

Foundry is a manufacturing process to produce parts of desired shape and sizes.

Foundry is a process of metal casting in which metal is melted into liquid state. (II)
Poured into molds and (III) Solidified to obtain desired shape and sizes. A pattern is
used in casting. It is replica or model of desired casting. A pattern is embedded in a
suitable moulding material (generally sand) to produce a cavity in the molding material
(generally sand) to produce a cavity in the moulding material on the removal of the
pattern which is called mould. The cavity when filled with molten metal produces the
desired casting on the solidification of the casting on the solidification of the poured
molten metal.

Objective: At the end of this exercise you shall be able to

 Select the split pattern and flask

 Prepare a drag
 Prepare a core
 Provide gating system
 With drawn the pattern from the mould cavity
Tools and equipments:

 Rammer * Trowel
 Vent wire * Cleaner
 Draw spike * leveler
 Gate cutter * Swab
 Dust bag * Hand billons
 Shovels * Runner & riser pins
 Sprit level * Smoothers
 Cope and Drag
 Moulding board

Equipment /machine

 split pattern
 Set of moulding box

Materials

1. Natural moulding sand

2. Parting sand
3. Prepare and baked straight core
4. Facing material
5. Silica sand
6. Bentonite
7. Graphite powder
8. Coal Dust
9. Molasse
10. River sand

Procedure

a. Select the split pattern

 b. Select the set of Molding box(cope and drag)
c. Place the pattern over the molding board
d. Sprinkle the parting sand, place the molding flask over the board
e. Apply the facing sand around the pattern surface, ram it by hand
f. Fill the backing sand layer by layer ram it with help of peen wedge rammer
g. Add backing sand above the flask level, press it, ram it by flat rammer
h. Strick off extra molding sand from the top surface of the flask with strick off
bar
i. Sprinkle parting sand over the drag parting surface
j. Roll over the drag and keep sand bed sleek it, sprinkle parting material
k. Place the cope over the rammed drag with guide pin
l. Locate runner & riser pin
m. Sprinkle the facing sand ram it by hand
n. Fill the backing sand and ram it by peg rammer, finished ram with help of flat
rammer
o. Provide vent in the cope
p. Strike off the excess moulding send and sprinkle parting sand
q. Remove the runner and riser pegs and cut the pouring basin
r. Roll over the cope on the moulding board
s. Rap and with drawn the both of the cope and drag pattern
t. Clean the mould cavity and apply the mould coating
u. Set the straight pipe core in the mould
v. Remove extra sand with hand bellows
w. Place the cope pattern over the drag pattern align using dowel pin
x. Sprinkle parting sand around cope pattern
y. Close the drag and cope mould and clamp it keep the weight over the flask
z. The mould is ready for pouring

Result: The mould cavity is ready for the given split pattern

Precautions:-
 Proper ramming of the moulding sand must be done in done in drag and cope to
insure cohesiveness
 Parting sand must be sprinkle and spread at all parting surface so that no
unnecessary sticking of moulding send take palce.
 Lifting and rolling over of the drag and cope have to be performed gently and
carefully without any jerk.
Aim: : To make S-hook from a given round rod, by hand forging operation.

Theory: Black smithy involves heating of a metal stock to a designed temperature

which enabled the metal stock to a acquire sufficient plasticity so that the metal stock
can be subject to hammering, bending in order to obtain desired shape out of the metal
stock.

Tools required: Electric furnace, Anvil, ball-peen hammers, Flatters, Swage block,
Half round tongs, Pick-up tongs, Cold chisel.

Material Required :- MS Rod 8mm.

Sequence of operations:

1. One end of the bar is heated to red hot condition in the furnace for the required
length.
2. Using the pick-up tongs; the rod is taken from the forge, and holding it with the half
round tongs, the heated end is forged into a tapered pointed end.
3. The length of the rod requires for S-hook is estimated and the excess portion is cut-
off, using a cold chisel.
4. One half of the rod towards the pointed end is heated in the forge to red hot condition
and then bent into circular shape as shown.
5. The other end of the rod is then heated and forged into a tapered pointed end.
6. The straight portion of the rod is finally heated and bent into circular shape as
required.
7. Using the flatter, the S-hook made as above, is kept on the anvil
and flattened so that, the shape of the hook is proper.
NOTE: In-between the above stage, the bar is heated in the furnance, to facilitate
forging operations.
Result:
The S-hook is thus made from the given round rod; by following the stages mentioned
above.
Precautions:
1. Hold the job carefully while heating and hammering
2. Job must be held parallel to the face of the anvil.
3. Wear steel-toed shoes.
4. Wear face shield when hammering the hot metal
5. Use correct size and type of tongs to fit the work.
Aim: To Prepare a Plastic component using a Hand Injection Moulding machine.

Theory:

Injection moulding is a method to obtain molded product by injection plastic materials

molten by heat into a mold, and then cooling and solidifying them. The method is
suitable for the mass production of product with complicated shapes and takes a large
part in the area of plastic processing.

Machine used: Hand injection moulding machine.

Material: PVC

Procedure:

1. Put the heater on.

2. Purge the machine in with suitable material.
 3. Clamp the mould in position using spacer plates.
4. Inject the material into the mould using rack and pinion.
5. Allow cooling time.
6. Eject the component out.

Result: A prefect plastic component is obtained.

Precautions:

a. At the time of operation ensure hand gloves and shoes were worn.
b. Die should be held tightly in vice while doing injection moulding operation.
c. Switch off the machine after completing the process.

Practical exercise record sheet:

1. Machine used and make

2. Shot capacity
3. Mould used
4. Material used
5. Temperature
6. Quality of product
7. Total cycle time
8. Safety observed
9. Identify the defect
Aim

Aim:-To perform facing, turning, step turning, taper turning, drilling, chamfering, thread
cutting operations on a cylindrical work piece by lathe machine and obtain dimension as
shown.

Tools & Equipment

Lathe machine, single point cutting tool , box key or tool post key, chuck key, steel rule,

vernier calipers, drill, scriber, knurling tool and thread cutting tool.

Theory

The principle of lathe is that the metal cutting is carried out by creating relative motion
between the workpiece and the tool in which the work piece is rotated and the tool is
made parallel to the axis of the rotation of the workpiece. A lathe provides a variety of
rotating speeds and a means to manually and automatically move the cutting tool into
the workpiece to remove the excess material.

Procedure

1. The given work piece is held in the 3‐jawchuck of the lathe machine and tightened
firmly with chuck key.
2. Right hand single point cutting tool is taken tightened firmly with the help of box key in
the tool post.

3. Machine is switched on and the tool post is swiveled and the cutting point is adjusted
such that it positioned approximately for facing operation then the tool is fed into the
work piece and the tool post is given the transverse movement by rotating the hand
wheel of the cross slide.

4. With this facing is completed and the tool post is swiveled and cutting point is made
parallel to the axis of work piece.

5. Depth of cut is given by cross slide to the tool post and the side hand wheel is rotated
to give the Longitudinal movement for the tool post and job is turned to the required
length and diameter.

6. Start the turning operation to obtain the different step on the round bar as per sketch.

7. Set the compound slide to the required taper angle as per sketch and move the tool
for turning using cross slide.

8. Set the cross slide to about 45 degree and give a small feed in longitudinal direction
move the tool using cross slide to chamfer the end.

9. Fix the drill in tail stock and moves the drill towards the work piece for drilling
operation.

9. Thread cutting is performed as per sketch

10. After completion of the job it is inspected for the dimensions obtained with the help
of

vernier caliper.

Precautions

1. Work piece should be held firmly.

2. In rough turning operation do not over feed the tool, as it may damage the cutting
point of the tool.

3. Exercise over hung of tool should be avoided as it results in chatter and causes
rough machined surface

.4. It is important to ensure that during facing operation the cutting is performed from
center point to the outer diameter of the work piece.

Result :-The job is thus made according to the given dimensions.

 SCREW DRIVER
Aim: To make a screw driver from the given specifications.
Material: mildsteel and wood
Machine required : lathe and carpentary lathe
Tools required: carpentary tools and single point cutting tool.
Parts:- wooden handle , steel rod

Job sequence : handle.

 1) Check the raw material size
2) Hold the job between centre and turn to dia 40mm and length 115 mm.
3) Form undercut as per drawing using a form tool
4) Turn the taper as per the drawing and maintain its sizes.
5) Drill the hole depth in the handle as per drawing
6) With the help indexing head make groove on the periphery for gripping.
7) Check the size of the job size with a vernier caliper.
MODEL CALCULATIONS

The amount by which the compound rest has to be swivel is estimated using the
taper
angle. Taper angle is calculated as follows.
Taper angle (α) = tan-1(D-d)/2L
Where,
D = Diameter of bigger end, mm
d = Diameter of smaller end, mm
L = Length of taper, mm

Job sequence : rod

1) Check the raw material size
2) Hold the job between centre and turn to dia 10mm and length 220 mm.
3) Check the dia size of the job e with a vernier caliper.
4) Grid the taper tip of rod as per dimensions.
Precautions:

• Before starting the spindle by power, lathe spindle should be revolved by one
revolution by hand to make it sure that no fouling is there.
• Tool should be properly ground, fixed at correct height and properly secured, and
work also be firmly secured.
• Chips should not be allowed to wind around a revolving job and cleared as often
as
Possible.
• No attempt should be made to clean the revolving job with cotton waste.
• On hearing unusual noise, machine should be stopped.
Result: The required SCREW DRIVER is thus made by following the above
sequences of operations.

PEN STAND
Aim: To make a Pen stand from the given specifications.
Material: wood
Machine required : nil
Tools required:
1.Marking tools
2. Measuring tools
3. Holding tools
4. Cutting tools
5. Planning tools
6. Boring tools
7. Striking tools
8. Miscellaneous tools
Parts:- main body , support
Procedure
1. The given work piece is firmly clamped in the carpentry vice and any two
adjacent surfaces are planed to get right angles using the jack plane.
2. Using the try square, the right angles of planned faces are checked.
3. Now the other two surfaces are planned to get smooth surface.
4. now cut the shoulder of the main body as per drawing by using the rip saw.
5. Using the steel rule and marking gauge, marking is done on the top face of the
body for drilling holes.
6. Using the jack plane, the other two faces of work piece is planned to the
required size.
8. The finished two pieces are assembled to getter to form the pen stand.
9. Finally, the finished job is checked for required size and shape using the steel
rule and try square.

Result

Result: The required PEN STAND is thus made by following the above sequences
of operations.

TACK HAMMER
Aim: To make a Tag Hammer from the given specifications.
Material: Mild steel, wood (handle)
Machine required : lathe machine, Drill Machine
Tools required: Vernier calipers, steel rule, spanner, chuck spanner, and H.S.S.
single point cutting tool, die and tap.

Parts:- Body, Head and Wooden Handle

SEQUENCE OF OPERATIONS:
 Centering
 Facing
 Plain turning
 Chamfering
 Step turning
  Grooving
 Taper turning
 Threading
 Drilling
 Assembly

Procedure for (Tack Hammer body)

1. The work piece is fixed in a 3-jaw chuck with sufficient overhang.
2. Adjust the machine to run the job to a required cutting speed.
3. Fix the cutting tool in the tool post and centering operation is performed so
that the axis of the job coincides with the lathe axis.
4. Give the feed and depth of cut to the cutting tool
5. Facing operation is performed from the center of the job towards outwards
or from the circumference towards the center and perform drilling as per
drawing.
6. Plain turning operation is performed until the diameter of the work piece
reduces to 26 mm
 7. Check the dimensions by using vernier calipers.
8. Then grooving is done on the 10 mm diameter surface as per drawing.
9. Reverse the work piece in the chuck and facing operation is performed to
reduce the length of work piece to the required dimensions.
10.Again Plain turning operation is performed until the diameter of the work
piece reduced to 10mm.
11.Swivel the compound slide to the required angle and taper turning
operation by rotating the compound slide wheel. The angle can be measured
by using the formula
The amount by which the compound rest has to be swivel is estimated using the
taper
angle. Taper angle is calculated as follows.
Taper angle (α) = tan-1(D-d)/2L
Where,
D = Diameter of bigger end, mm
d = Diameter of smaller end, mm
L = Length of taper, mm
Procedure for (Head)
 SEQUENCE OF OPERATIONS:
 Centering
 Facing
 Plain turning
 Drilling & tapping
 Chamfering

Procedure for (Tip for Head)

1. The work piece is fixed in a 3-jaw chuck with sufficient overhang.
2. Adjust the machine to run the job to a required cutting speed.
 3. Fix the cutting tool in the tool post and centering operation is performed so
that the axis of the job coincides with the lathe axis.
4. Give the feed and depth of cut to the cutting tool
5. Facing operation is performed from the center of the job towards outwards
or from the circumference towards the center .
6. Plain turning operation is performed until the diameter of the work piece
reduces to 26 mm up to length 20mm
7. Check the dimensions by using vernier calipers.
8. Chamfering operation is performed on the edges of dia 26 mm.
9. Drilling and tapping operation is performed on the bake face of the head as
per drawing.
PRECAUTIONS
1) Before starting the spindle by power, lathe spindle should be revolved by one
revolution by hand to make it sure that no fouling is there.
2) Tool should be properly ground, fixed at correct height and properly secured,
and work also be firmly secured.
3) Chips should not be allowed to wind around a revolving job and cleared as often
as
possible.
4) Before operating threading operation, V-tool should be properly ground to the
required helix angle.
5) Apply cutting fluids to the tool and work piece property.
6) No attempt should be made to clean the revolving job with cotton waste.
7) On hearing unusual noise, machine should be stopped.
Result: The required TACK HAMMER is thus made by following the above
sequences of operations
 SHEET METAL
AIM: - To make a rectangular tray.
Tools and materials used: Steel rule, Scriber, Divider, Mallet, Stakes, Try square,
snip straight (Tin cutter) Bench shear, file flat smooth, Nylon hammer, Tin sheet
piece.
Materials used: - Galvanized iron sheet 28 SWG.
Drawing: - See Diagrams
Procedure:
1. For developing the surfaces (lying out) draw plan, front view and end view of
the
required open rectangular box as shown is diagram.
2. Extend all the lines and cut these lines according to the height of the tray (i.e. 30
mm).
3. Addition strips of stocks are given along the edges for single hem allowance (6
mm).
4. All the four corner triangles are cut as shown in diagram for joint making.
5. Perform the operation of cuttings, shearing edges, hand forming, edge forming,
joint making and bending in to rectangular tray by using above mentioned sheet
metal tools by.
I. Square folding along 12, 23, 34, 41 lines.
II. Square folding of 15, 26, 37, 48, 2-10, 3-11, 19, 4-12,
III. Square fold for Hem 56, 78, 10, 11, 9-12.
6. File the sharp edges with a smooth flat file.
Safety Precautions:
1) Take precautions while working on sharp edges of sheets to avoid injury.
2) Appropriate cutting tools and machines must be used fro cutting tin sheets.
3) Avoid using blunt cutting tools.
4) Extra allowance must be provided in the sheets while cutting so that finished
product is of correct size and finish. Black portion is to be bend (hem). Hatched
portion is to be cut out. All Dimensions are in mm.