QIS College Of Engineering & Technology

Autonomous

ENGINEERING WORKSHOP
MANUAL

DEPARTMENT OF MECHANICAL
ENGINEERING

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 Department of Mechanical Engineering

Engineering Workshop Manual

Name: ______________________________________

Roll No : ______________________________________

Class : ______________________________________

Semester : ______________________________________

Year : ______________________________________

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 Department of Mechanical Engineering

Name of the Student :

Class :

Roll No : Academic year:

INDEX

Initial of
S.No Name of the exercise Conducted
Incharge
1.
2.
3.
4.
5.
6.
7.
8.
9.
10
11.
12.
13.
14.
15

LIST OF EXPERIMENTS

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CARPENTRY (Wood Working)
1. T-Lap Joint
2. Cross Lap Joint
3. Dovetail Joint
4. Mortise and Tenon Joint

FITTING
1. V Fit
2. Square Fit
3. Half Round Fit
4. Dovetail Fit

TIN SMITHY (Sheet Metal Working)

1. Taper Tray
2. Square Box without lid
3. Open Scoop
4. Funnel

HOUSE WIRING
1. Parallel / Series Connection of three bulbs
2. Stair Case wiring
3. Florescent Lamp Fitting
4. Measurement of Earth Resistance.

FOUNDRY TRADE
1. Demonstration and practice on Moulding tools and processes,
2. Preparation of Green Sand Moulds for Solid pattern
3. Preparation of Green Sand Moulds for Stepped pattern

WELDING SHOP
1. Demonstration and practice on Arc Welding and Gas welding.
2. Preparation of Lap joint
3. Preparation of Butt joint.

PLUMBING
1. Demonstration and practice of Plumbing tools,
2. Preparation of Pipe joints with coupling for same diameter and with reducer
for different diameters.

BASIC REPAIRS OF TWO-WHEELER VEHICLE –

1. Demonstration of working of two-wheeler vehicle and its repairs.

4
CARPENTRY

5
Try square Divider

Bar Cramp/ Sash Cramp

Marking and Mortise gauge

Auger
Divider
Claw hammer

Cross cut saw

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 CARPENTRY TOOLS
WORK HOLDING TOOLS
CARPENTRY VICE: - Carpenters bench vice is used to hold work piece for planning,
cutting and chiseling. The jaws of the vise are lined with hard wood faces.

Carpentry Vice
BAR-CRAMP: - It is made of steel base Tee-section, with malleable iron fittings and a
steel screw. It is used for holding wide works such as frames.

MARKING AND MEASURING GAUGE

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 on it, on the
stem is fitted a marking pin, made of steel.
TRY-SQUARE: - it is used for marking and testing the squareness of planed surfaces.
It consists a steel blade, fitted in a cast iron stock. It is also used for checking the
planed surfaces for flatness.
COMPASS AND DIVIDER: - Compass and divider are used for marking arcs and
circles on the planed surfaces of the wood.
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 thumbscrew.
PLANNING TOOLS
Planning is the operation used to produce flat surfaces on wood. A plane
is a hand tool used for the purpose. The cutting blade used in a plane is
fitted in a wooden or metallic block, at an angle.

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 Dovetail chisel

Firmer chisel

(a).G-Cramp (b). Its use

Hand Drill Mallet

8
JACK PLANE: - It is most commonly, used general purpose plane. It is
about 35cm long. The cutting blade should have a cutting edge of slight
curvature.

CUTTING TOOLS
CROSS-CUT or HAND SAW: - It is used to cut across the grains of the
stock.The teeth are so set that the saw kerf will be wider than the blade
thickness.This allows the blade to move freely in the cut, without
sticking.
TENON SAW: - It is used for cutting the stock either along or across the
grains. It is used for cutting tenons and in fine cabinet work,
CHISELS:-Chisels are used for cutting and shaping wood
accurately .Wood chisels are made in various blade widths, ranging from
3to 50mm.
FIRMER CHISEL: - The wood ‘firmer’ means ‘stronger’ and hence
firmer chisel is stronger then other chisels.
DOVE-TAIL CHISEL: - it has a blade with a beveled back, due to which
it can enter sharp corners for finishing.
MORTISE CHISEL: - It is used for cutting mortises and chipping inside
holes.
ADZE: - Adze is a side axe used to chap extra wood quickly by
carpenters. Adze with very long handle is used to plane long palm tree
barks in standing position.

MISCELLANEOUS TOOLS
Hand drill:-Carpenter’s brace is used to make relatively large size holes,
where as hand drill is used for drilling small holes. The drill bit is
clamped in the chuck at its end and is rotated by a handle attached to gear
and pinion arrangement.

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Trammel. WarringtonHammer

Types of Screw drivers

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SCREW DRIVER: - The screw driver of a carpenter is different from the
other common types. It has a thick blade and long handle to apply greater
pressure.
MALLET:-It is used to drive the chisel, when considerable force is to be
applied.
WOOD-RASP FILE:-It is a finishing tool used to make the wood surface
smooth, remove sharp edges and finishing fillets.
CLAW HAMMER: It has a striking flat face at one end and the claw at the
other. The face is used to drive nails into wood and for other striking
purposes.
PINCER: - It is made of steel with a hinged joint and is used for pulling
out small nails from wood.

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12
 CARPENTRY - EXCERSISE- No: 1

T-LAP JOINT

AIM: To make a T-lap joint from the given reaper of size

45 X 30 x 130 mm -2No.

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

SEQUENCE OF OPERATION:
1. The reaper is firmly clamped in the carpenter’s vice and any two
adjacent faces are checked for sureness with the try-square.
2. Marking gauge is set and lines are drawn at 30mm and 45mm, to
mark the thickness and width of the model respectively.
3. The excess material is first chiseled out with firmer chisel and then
planned to correct size.
4. The mating dimensions of the parts X and Y are then marked using
scale and marking gauge.
5. 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
separated by cross-cutting, using the tenon saw.
6. The ends of both the parts are chiseled to the exact lengths.
7. The parts are fitted to obtain a slightly tight joint.

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

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CARPENTRY - EXCERSISE- No: 2
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 DOVE TAIL-LAP JOINT

AIM: To make a Dove Tail -lap joint from the given reaper of size 45 X
30 x 130 mm - 2No.

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

SEQUENCE OF OPERATION:
1. The reaper is firmly clamped in the carpenter’s vice and any two
adjacent faces are checked for sureness with the try-square.
2. Marking gauge is set and lines are drawn at 30mm and 45mm, to
mark the thickness and width of the model respectively.
3. The excess material is first chiseled out with firmer chisel and then
planned to correct size.
4. The mating dimensions of the parts X and Y are then marked using
scale and marking gauge.
5. 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
separated by cross-cutting, using the tenon saw.
6. The ends of both the parts are chiseled to the exact lengths.
7. The parts are fitted to obtain a slightly tight joint.

RESULT:

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16
 CARPENTRY - EXCERSISE- No: 3

CORNER BRIDLE JOINT

AIM: To make a corner bridle joint from the given reaper of size 45 X 30
x 130 mm - 2No.

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

SEQUENCE OF OPERATION:
8. The reaper is firmly clamped in the carpenter’s vice and any two
adjacent faces are checked for sureness with the try-square.
9. Marking gauge is set and lines are drawn at 30mm and 45mm, to
mark the thickness and width of the model respectively.
10.The excess material is first chiseled out with firmer chisel and then
planned to correct size.
11.The mating dimensions of the parts X and Y are then marked using
scale and marking gauge.
12.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
separated by cross-cutting, using the tenon saw.
13.The ends of both the parts are chiseled to the exact lengths.
14.The parts are fitted to obtain a slightly tight joint.

RESULT:

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FITTING

PRACTICE

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 FITTING TOOLS

HOLDING TOOLS
BENCH VICE: - The bench vice is a work-holding device. It is fixed to
the bench with bolts and nuts. The size of the vice is specified by the
length of the jaws. The vice body is made of cast iron which is strong in
compression.
V-BLOCK WITH CLAMP: - The v-block is a rectangular or square block
with a v-groove on one or both sides, opposite sides to each other. The
angle of the ‘V’is usually 900 .V-block with a clamp is used to hold
cylindrical work.
C-CLAMP:-This is used to hold work against an angle plate or v-block or
any other surface when gripping is required. The working principle of this
clamp is same as that of the bench vice.
MARKING AND MEASURING TOOLS
SURFACE PLATE:-The surface is machined to fine limits and is used for
testing flatness of the work piece. The surface plate is made of cast iron,
hardened steel or granite stone. It is specified by length ‘width’ and
‘height’ grade.
MARKING TABLE: - A marking table is a heavily build cast iron table
used for layout work on all sizes of jobs.
ANGLE PLATE:-The angle plate is made of cast iron. It has two surfaces
machined at right angles to each other. Plates and components are marked
out, may be held against the upright of the angle, to facilitate the marking.
Slots are provided on the angle plate to clamp the work in position.
UNIVERSAL SCRIBING BLOCK:-This is used for scribing lines for
layout work and checking parallel surfaces.

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20
TRY-SQUARE: - It is a measuring and marking tool for 90 0 angle, it is
used for checking the squareness of many types of small works. The
blade of the try-square is made of hardened steel and the beam of cast
iron or steel.
SCRIBE: - A scriber is a slender steel rod used to scribe or mark lines on
metal work pieces.
ODD-LEG CALIPER:-This is also called ‘Jenny Caliper’. This is used for
marking parallel lines from a finished edge and also for locating the
centre of round bars.
DIVIDER: - This is used for marking circles, arcs, laying out
perpendicular lines, bisecting lines. It is made of case hardened mild steel
or hardened and tempered low carbon steel.
PUNCHES: - These are used for marking indentations on the scribed
lines, to make them visible clearly. These are made of high carbon steel.
DOT PUNCH:-this is used to locate centre of holes and to provide a small
centre mark for divider point, etc.for this purpose, the punch is ground to
conical point having 600 inclined angle.
CENTRE PUNCH:-This is similar to the dot punch except that it is
ground to a conical point having 900 included angle. It is used to mark the
location of the centre where holes are to be drilled.
DRIFT PUNCH:-A drift punch is long tapered tool used to align holes in
two or more pieces of material that are to be joined together, so that holes
or rivets can be easily placed in the holes.
LETTER PUNCH:-It has square body with a tapered end. At this end, a
projection, corresponding to the replies of the letter to be marked is made.
The letters used are A to Z.

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22
NUMBER PUNCH:-It is similar to letter punch to construction but has
numbers are at its end. The numbers used are from 0to8.punches are
made of tool steel, hardened and tempered.
CUTTING TOOLS
HACKSAW:-the hacksaw is used for cutting metal by hand. It consists of
a frame which holds a thin blade, firmly in position. The number of teeth
per 25mm of the blade length or teeth per inch (TPI) is selected on the
basis of the work material.
FIXING HACKSAW BLADE:-Body action applies pressure on forward
stroke and relief on return. Blade must be fitted to cut on forward stroke.
CHISELS:-Chisels are used for removing surplus material or for cutting
thin sheets. The cutting angle of the chisel for general purpose is 600.
A flat chisel is a common chisel used for removing chipping and cutting
off thin sheet-metal.
A cape chisel is narrow shaped tool, it is used mostly for the clipping
grooves and keyways.
FINISHING TOOLS
FILES:-Filing is one of the method of removing small amounts of
material from the surfaces of a metal part. On the faces the teeth are
usually diagonal to the edge. One end of the file is shaped to fit into a
wooden handle.
HAND FILE:-Rectangular in section and tapered in thickness but parallel
in width. The faces Cary double cut teeth and one of the edges single cut.
The other edge, known as safe edge, does not have any teeth, hence this
file is known as safe edge file.
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FLAT FILE:-It is rectangular in section and tapered for 1/3 length in
width and thickness towards the point.

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25
SQUARE FILE:-It is square in section and carry double cut teeth on all
the four faces. It is tapered for 1/3 of its length towards the point. Square
files are used for filing corners and slots.
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THREE SQUARE FILE:-It is of equilateral triangular in section and
tapers towards the tip. These files are used to file angular hole and
recesses.
ROUND FILE:-It is tapered for 1/3 length with double cut on large coarse
grades, used for filing out round, elliptical and curved openings.
HALF ROUND FILE:-The half round file has one flat and one curved
side. The flat side is double cut and the curved side is single cut. This is
an extremely useful double purpose file for flat surfaces and for curved
surfaces.
SWISS or NEEDLE FILES:- 150mm long with double cut teeth .Used for
filing corners,grooves,narrow slots etc.

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Date Ex. No: 1

STRAIGHT FITTING ALL DIMENSIONS ARE IN

mm

MATERIAL: M.S

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 STRAIGHT FITTING

AIM: To make a straight fitting from the given M.S piece.

RAW MATERIAL: Work piece of M.S of dimension 50 x 45 x 6 mm

TOOLS REQUIRED: Bench Vice, Steel Rule, Dot Punch, Set of Files,
Surface Plate, Universal Scribing Block and Hacksaw with blade.

SEQUENCE OF OPERATION:

1. The burrs in the pieces are and the dimensions are checked with
the steel rule to 48 x 42 x 6 mm.
2. Using a steel rule mark the centre line and use dot punch and
dots are punched along the line and cut by hacksaw and separate
it into two pieces of sizes 48 x 20 x 6 mm.
3. 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.
4. Chalk is then applied on the surfaces of two pieces.
5. The given dimension of the straight fitting are marked, by using
steel rule and surface plate.
6. Using the dot punch, dots are punched along the above scribed
lines.
7. Using the hacksaw, the unwanted portions are removed.
8. The cut edges are filed by flat file.
9. The corners of the stepped surfaces are filed by using a square
or triangular file to get the sharp corners.

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 10.The pieces (X and Y) are fitted together and then mating is
checked for the correctness of the fit. Any defects noticed, are
rectified by filing with a smooth file.

PRECATUTIONS: Care is taken to see that the marking dots are not
crossed, which is indicated by the half of the punch dots left on the
pieces.

RESULT:

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Date Ex. No: 1

V-FITTING ALL DIMENSIONS ARE IN mm

MATERIAL: M.S

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 V-FITTING

AIM: To make a V-fitting from the given M.S piece.

RAW MATERIAL: Work piece of M.S of dimension 50 x 45 x 6 mm

TOOLS REQUIRED: Bench Vice, Steel Rule, Dot Punch, Set of Files,
Surface Plate, Universal Scribing Block and Hacksaw with blade.

SEQUENCE OF OPERATION:

1. The burrs in the pieces are and the dimensions are checked with the
steel rule to 48 x 42 x 6 mm.
2. Using a steel rule mark the centre line and use dot punch and dots
are punched along the line and cut by hacksaw and separate it into
two pieces of sizes 48 x 20 x 6 mm.
3. 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.
4. Chalk is then applied on the surfaces of two pieces.
5. The given dimension of the straight fitting are marked, by using
steel rule and surface plate.
6. Using the dot punch, dots are punched along the above scribed
lines.
7. Using the hacksaw, the unwanted portions are removed.
8. The cut edges are filed by flat file.
9. The corners of the stepped surfaces are filed by using a square or
triangular file to get the sharp corners.

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 10.The pieces (X and Y) are fitted together and then mating is
checked for the correctness of the fit. Any defects noticed, are
rectified by filing with a smooth file.

PRECATUTIONS: Care is taken to see that the marking dots are not
crossed, which is indicated by the half of the punch dots left on the
pieces.

RESULT:

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Date Ex. No: 3

INCLINED - FITTING ALL DIMENSIONS ARE IN

mm

MATERIAL: M.S

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 PRECATUTIONS: Care is taken to see that the marking dots are not
crossed, which is indicated by the half of the punch dots left on the
pieces.
RESULT:

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ELECTRICAL

WIRING

PRACTICE

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Date Ex. No: 1

ONE LIGHT CONTROLLED BY ONE SWITCH

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 ONE LIGHT CONTROLLED BY ONE SWITCH

AIM: To give connections to one light controlled by one switch.

TOOLS REQUIRED: Wooden wiring board, one way switch, lamp

holder with casing box, connector screw driver, 14/36wires, wire clips,
nails, Tester, Insulator remover and 60Watts bulb.

SEQUENCE OF OPERATION:
1. The outline of the wiring diagram is marked on the wooden wiring
board.
2. Clips are nailed to the board, following wiring diagram.
3. Wires are stretched and clamped with the clips.
4. Round blocks (2 No.s) are screwed onto the board, as per the
diagram.
5. Wires are connected to the holders and switch, which are then
screwed onto the round blocks.
6. Bulbs are fitted to the holders.
7. The wiring connections are then tested, by giving power supply.

RESULT:

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 Date Ex. No: 2

TWO LIGHTS CONTROLLED BY ONE SWITCH IN

SERIES

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 TWO LIGHTS CONTROLLED BY ONE SWITCH IN SERIES

AIM: To give connection to two lights controlled by one switch in series.

TOOLS REQUIRED: Wooden wiring board, one way switch, lamp

holder with casing box, connector screw driver, 14/36wires, wire clips,
nails, Tester, Insulator remover and 60Watts bulb.

SEQUENCE OF OPERATION:
1. The outline of the wiring diagram is marked on the wooden wiring
board.
2. Clips are nailed to the board, following wiring diagram.
3. Wires are stretched and clamped with the clips.
4. Round blocks (2 No.s) are screwed onto the board, as per the
diagram.
5. Wires are connected to the holders and switch, which are then
screwed onto the round blocks.
6. Bulbs are fitted to the holders.
7. The wiring connections are then tested, by giving power supply.

RESULT:

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 Date Ex. No: 3

ONE LIGHT CONTROLLED BY 2 TWO-WAY SWITCHES

(STAIR CASE CONNECTION)

41
 ONE LIGHT CONTROLLED BY 2 TWO-WAY SWITCHES
(STAIR CASE CONNECTION)

AIM: To give connections to one light controlled by 2 two-way switches.

TOOLS REQUIRED: Wooden wiring board, one way switch, lamp

holder with casing box, connector screw driver, 14/36wires, wire clips,
nails, Tester, Insulator remover and 60Watts bulb.

SEQUENCE OF OPERATION:
1. The outline of the wiring diagram is marked on the wooden wiring
board.
2. Clips are nailed to the board, following wiring diagram.
3. Wires are stretched and clamped with the clips.
4. Round blocks (2 No.s) are screwed onto the board, as per the
diagram.
5. Wires are connected to the holders and switch, which are then
screwed onto the round blocks.
6. Bulbs are fitted to the holders.
7. The wiring connections are then tested, by giving power supply.

RESULT:

42
Date Ex. No: 4

CALLING BELL CONTROLLED BY ONE SWITCH

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 CALLING BELL CONTROLLED BY ONE SWITCH

AIM: To give connections to calling bell controlled by one switch.

TOOLS REQUIRED: Wooden wiring board, one way switch, lamp

holder with casing box, connector screw driver, 14/36wires, wire clips,
nails, Tester, Insulator remover and 60Watts bulb.

SEQUENCE OF OPERATION:
1. The outline of the wiring diagram is marked on the wooden wiring
board.
2. Clips are nailed to the board, following wiring diagram.
3. Wires are stretched and clamped with the clips.
4. Round blocks (2 No.s) are screwed onto the board, as per the
diagram.
5. Wires are connected to the holders and switch, which are then
screwed onto the round blocks.
6. Bulbs are fitted to the holders.
7. The wiring connections are then tested, by giving power supply.

RESULT:

44
BLACK
SMITHY

45
46
 Introduction to Black smithy

Practically all metals, which are not used in cast form are reduced to some
standard shapes for subsequent processing.
Manufacturing companies producing metals supply metals in form of ingots
which are obtained by casting liquid metal into a square cross section.
Slab (500-1800 mm wide and 50-300 mm thick)
Billets (40 to 150 sq mm)
Blooms (150 to 400 sq mm)
Sometimes continuous casting methods are also used to cast the liquid metal into
slabs, billets or blooms.
These shapes are further processed through hot rolling, forging or extrusion, to
produce materials in standard form such as plates, sheets, rods, tubes and
structural sections.
Primary Metal Forming Processes
Rolling
Forging
Extrusion
Tube and wire drawing
and Deep drawing
Although Punching and Blanking operations are not metal forming processes
however these will be covered due to similarity with deep drawing process.
Rolling
Rolling is the most extensively used metal forming process and its share is
roughly 90%
The material to be rolled is drawn by means of friction into the two revolving roll
gap
The compressive forces applied by the rolls reduce the thickness of the material or
changes its cross sectional area
The geometry of the product depend on the contour of the roll gap
Roll materials are cast iron, cast steel and forged steel because of high strength
and wear resistance requirements
Hot rolls are generally rough so that they can bite the work, and cold rolls are
ground and polished for good finish

47
48
Forging
• Forging is perhaps oldest metal working process and was known even during
prehistoric days when metallic tools were made by heating and hammering.
• Forging is basically involves plastic deformation of material between two dies
to achieve desired configuration. Depending upon complexity of the part
forging is carried out as open die forging and closed die forging.
• In open die forging, the metal is compressed by repeated blows by a
mechanical hammer and shape is manipulated manually.
• In closed die forging, the desired configuration is obtained by squeezing the
workpiece between two shaped and closed dies.
• On squeezing the die cavity gets completely filled and excess material comes
out around the periphery of the die as flash which is later trimmed.
• Press forging and drop forging are two popular methods in closed die forging.
• In press forging the metal is squeezed slowly by a hydraulic or mechanical
press and component is produced in a single closing of die, hence the
dimensional accuracy is much better than drop forging.
• Both open and closed die forging processes are carried out in hot as well as in
cold state.
• In forging favorable grain orientation of metal is obtained
Extrusion
• It is a relatively new process and its commercial exploitation started early in
the nineteenth century with the extrusion of lead pipes. Extrusion of steels
became possible only after 1930 when extrusion chambers could be designed
to withstand high temperature and pressure.
• In extrusion, the material is compressed in a chamber and the deformed
material is forced to flow through the die. The die opening corresponds to the
cross section of the required product.
• It is basically a hot working process, however, for softer materials cold
extrusion is also performed.
 In direct extrusion metal flows in the same direction as that of the ram.
Because of the relative motion between the heated billet and the chamber
walls, friction is severe and is reduced by using molten glass as a lubricant in
case of steels at higher temperatures. At lower temperatures, oil with graphite
powder is used for lubrication.
49


50
  In indirect extrusion process metal flows in the opposite direction of the ram.
It is more efficient since it reduces friction losses considerably. The process,
however, is not used extensively because it restricts the length of the extruded
component.

Impact Extrusion
 Impact Extrusion is similar to indirect extrusion. Here the punch descends
rapidly on to the blank which gets indirectly extruded on to the punch and to
give a tubular section. The length of the tube formed is controlled by the
amount of metal in the slug or by the blank thickness. Collapsible tubes for
pastes are extruded by this method.
Wire Drawing
• Large quantities of wires, rods, tubes and other sections are produced by
drawing process which is basically a cold working process. In this process the
material is pulled through a die in order to reduce it to the desired shape and
size.
• In a typical wire drawing operation, once end of the wire is reduced and
passed through the opening of the die, gripped and pulled to reduce its
diameter.
• By successive drawing operation through dies of reducing diameter the wire
can be reduced to a very small diameter.
• Annealing before each drawing operation permits large area reduction.
• Tungsten Carbide dies are used to for drawing hard wires, and diamond dies is
the choice for fine wires.
Tube Drawing
• Tube drawing is also similar to wire drawing, except that a mandrel of
appropriate diameter is required to form the internal hole.
• Here two arrangements are shown in figure (a) with a floating plug and (b)
with a moving mandrel
• The process reduces the diameter and thickness of the tube

Deep Drawing
• This operation is extensively used to for making cylindrical shaped parts such
as cups, shells, etc from sheet metal.
51
As the blank is drawn into the die cavity compressive stress is set up around the
flange and it tends to wrinkle or buckle the flange.

Defects in Drawing
(a) Wrinkling in the flange or (b) in the wall (c) tearing, (d) Earing, (e) surface
scratches

Punching and Blanking

 Punching and blanking operations are not metal forming operations but are
discussed together with metal forming because of their similarity with deep
drawing operation.
 Objective of punching and blanking is to remove material from the sheet metal
by causing rupture, the punch and die corners are not provided with the any
radius.
Tool steel is the most common material for tool and die. Carbides are also used when
high production is needed.

52
 ROUND TO SQUARE

ALL DIMENSIONS ARE IN mm

53
 ROUND ROD TO SQUARE ROD

Aim:
To make a 130mm length and 8mm side square rod.

Material supplied:
M.S. Round rod of diameter 10mm and length to be calculated (refer
calculation).

Tools required:
1. Blacksmith furnace 2. Tongs 3. Anvil
4. Swage block 5. Sledge hammer 6. Flatters
Sequence of operations:
1. Heating 2. Hammering 3. Flattering
4. Squareness checking 5. Cooling
Working steps:
1. The given material is held in a furnace and heated to red hot temperature
(12000 C).
2. After the material attains the required hot condition in the furnace, it is
held by means of tongs and placed on anvil.

54
 3. By using a sledge hammer required force is applied on the material so that
the round rod is deformed into square rod and length is increased due to
the reduction in diameter.
4. The force applied should be uniform on the material to form a square
shape throughout the rod with a fine finish.
5. The operation is continued until the required square shape size is obtained.
6. The workpiece is held using tongs and cooled.
Result:

Note: Square rod is used where the load bearing applications involved. Other
industrial elements such as levers, cotters etc., are made using square rod.

S - HOOK

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 S - HOOK

Aim:

56
 To make a S-Hook.

Material supplied:
M.S. Round rod of diameter 10mm and length 150mm to be calculated (refer
calculation).

Tools required:
1. Blacksmith furnace 2. Tongs 3. Anvil
4. Swage block 5. Sledge hammer
Sequence of operations:
1.Heating 2. Hammering 3.Shaping 4. Cooling
Working steps:
7. The given material is held in a furnace and heated to red hot temperature
(12000 C).
8. After the material attains the required hot condition in the furnace, it is
held by means of tongs and placed on anvil.
9. By using a sledge hammer required force is applied on the material so that
the round rod is deformed into curved rod and length is increased due to
the reduction in diameter.
10. The force applied should be uniform on the material to form a s-shape
throughout the rod with a fine finish.
11. The operation is continued until the required s-shape size is obtained.
12. The workpiece is held using tongs and cooled.
Result:
Thus the required 130x8mm square rod is obtained from the round rod.

Note: S-hook is used where the load bearing applications involved. Other
industrial elements such as crane hooks etc., are made using round rod.

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 TIN
SMITHY

58
 TIN SMITHY
INTRODUCTION

Tin smithy deals with making of metal boxes, cans, funnels and ducts from
flat sheet metal. In this, the development is drawn on the sheet metal and it is cut
and folded to form the required shape of the object. For successful working in this
trade, one should have a thorough knowledge of development of surfaces.
Many engineering and house hold articles such as boxes, cans, funnels,
ducts etc., are made from a flat sheet of metals. These 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. The edge of the
articles are then secured through welding, brazing, soldering, riveting etc.,
SHEET METAL JOINTS:
Various types of joints are used in sheet metal work to suit the varying
requirement. These are self-secured joints, formed by joining together two
pieces of sheets metal and using the metal itself to form the joints. These
joints are to be used on sheets of less than 1.6mm thickness.
Riveting:-
Rivets are used to fasten two of more sheets of metal together. It is the
common practice to use the rivets of the same material as that of the sheets
having fastened.
Sheet metal screws:-
These are used in sheet metal work to join and install duct work for
ventilation air conditioning etc. These screws are also known as self-tapping
screws since they cut their own threads.
Soldering:-
Soldering is one method of joining two pieces of metal with an alloy that
melts at a lower temperature than the metals to be joined for a good job. The
metals to be joined must be free from dirt, grease and oxide. Solder is made
of tin and lead in equal proportions. It comes either in the form of wire and
bar.
Soldering iron:-
Soldering requires a source of heating. A common method of transmitting
heat of the metal surfaces is by using a soldering iron.
TOOLS AND EQUIPMENT
Some of the tools used in fitting are also used in sheet metal work. Certain
additional tools used by sheet metal workers are described below.
Bench Shear
Sheet metal may be cut by shearing action. Fig 5.1 shows a bench shear. In
this the force is applied through a compound lever, making it possible to cut sheet
metal up to 4 mm thick. It can shear a mild steel rod up to 10 mm diameter.

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 Fig: Bench Shear

In this type of hand cutting machine, the sheet is cut by shearing action. The force is
applied through compound lever. The machine is able to cut the sheet metal upto 2 mm
thick.

Hand Tools
The common hand tools used in sheet metal work are steel rule, usually of
60cm length, wire gauge, dot punch, trammel, scriber, ball peen hammer, cross
peen hammer, mallet, snips and soldering iron.
Trammel
Sheet metal lay out requires marking of arcs and circles. This may be done
by using the trammel, as shown. The length of the beam decides the maximum size
of the arc that can be scribed.

Stake
Stakes are made of steel and are available in a variety of shapes and
sizes. Its working face is machined and polished to facilitate various
operations as bending, seaming or forming. The various types of stakes are
shown in fig.
Funnel Stake
It is used for forming conical shapes and for making wire rings. The below figure
shows the line diagram of funnel stake:
Half Moon Stake
It is used for folding edges of cylindrical shaped articles. The half moon stake is
shown in figure below:

Beak Horn Stake

It is used for shaping round, square surfaces, bending edges, and making
corners. The beak horn stake is shown in figure below:

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 Snip
Hand shears or snips are used to cut sheet metal. Although there are many
types, the sheet metal worker generally uses straight snip and curved snip. Straight snips
have straight blades and are used for cutting along the straight line and for trimming
edges. Curved snip have a curved blade and are used for cutting circles and
irregular shapes.

Snips are hand shears, varying in length from 200mm to 600mm, 200mm to
250mm
being the lengths commonly used. Figure shows straight and curved snip or
bentsnip is for trimming along in side curves.

Types of Snips:

Straight snip

It has a straight blade and is used for cutting along straight lines and for trimming the
edges. The straight snip and its usage is shown in figure below:

Fig: Straight Snip

Bent or Curved Snip

It is having curved blade and is used for cutting circles and irregular shapes. It is also
used for trimming the cylindrical edges. The curved snip and its usage is shown in figure
below:

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 Fig: Bent or Curved Snip

Double Snip

Double shears are used for cutting thin cylinders, stove pipes and for cutting holes and
light gauge metals. The double cut snip is shown in figure below:

Fig: Double Snip

Trammels:-
Sheet metals layouts require marking of arcs and circles. This may be done
by using the trammels. The length of the beam decides the maximum size of
the arc that can be scribed.

Hand tools:-
The common hand tools used in sheet metals
work are steel rule, usually of 60 cm length,
Vise gauge, dot punch, scriber, trammels, ball peen hammer, and straight peen
hammer, cross peen hammer, mallets, snips and soldering iron
Hammers:-
Ball peen hammer has a cylindrical slightly curved face and a ball head
straight peen and similar to the cross peen, but it is positioned paralleled to
the handle which can be used conveniently for certain operations of folding.

Wire

Gauge

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 The thickness of sheet metal is referred in numbers known as Standard Wire
Gauge (SWG). The gaps in the circumference of the gauge are used to check the gauge
number as shown in Fig. Some of the standard wire gauge numbers with corresponding
thickness are as follows:

S. No. SWG No Thickness mm

1 10 3.20
2 12 2.60
3 14 2.30
4 16 1.60
5 20 1.00
6 22 0.70
7 24 0.65
8 26 0.45
9 30 0.30
Sheet Metal Screws
Sheet metal screws are used in sheet metal work to join and install duct
work for ventilation, air conditioning, etc. These screws are also known as self-tapping
screws since they cut their own threads. Sharp and blunt pointed screws are used
generally to join light material. The hole size should be equal to the root diameter
of the screw.
Try Square
It is measuring and marking tool for 900 angle .In practice, it is used for checking the
squareness of many types of small works when extreme accuracy is not required .The
blade of the Try square is made of hardened steel and the stock of cast Iron or steel.
The size of the Try square is specified by the length of the blade.

Fig: Try Square

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Compass and Divider

Compass and divider, are used for marking arcs and circles on the planed
surfaces of the GI sheet.

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 RECTANGULAR TRAY
AIM: To make a rectangular tray, using the given sheet metal
APPARATUS & TOOLS REQUIRED
300 mm steel rule, try-square, divider, scriber, straight snip, mallet, ball
peen hammer and hatchet stake.
MATERIAL REQUIRED : G.I. (Galvanized Iron)

SHEET SEQUENCE OF OPERATIONS

1. CUTTING
2. BENDING
3. INSPECTION
PROCEDURE:
1. The size of the given sheet is checked with the steel rule.
2. The layout of the tray is marked on the given sheet by using scriber.
3. The layout of the tray is cut by using the straight snip
4. The four sides of the tray are bent to 90°, as shown in Figure
5. The allowances on edges are folded to get the required joints on the four
sides of the tray.
SAFETY PRECAUTIONS:
1. Avoid feeling the cut portion by hand while cutting with snip.
2. Do not let sheet metal slip through your hands. Most cuts from
sheet metal results from allowing it to slide through the hands.
3. Use snips only for metal that can be cut by force applied by hand.
4. Hand snips should never be used to cut wires. Such practice ruins
the cutting edges of the blades.
RESULT: The rectangular tray is thus made, from the given sheet metal.

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 CONE SHAPE

AIM: To make a cone using the given sheet metal

APPARATUS TOOLS REQUIRED:

300 mm steel rule, divider, protractor, scriber, straight and bent snips,
protractor, mallet and funnel stake.

MATERIAL REQUIRED : G.I.

SHEET PROCEDURE:
1. The size of the given sheet is checked with a steel rule.
2. The development of the cone is marked on the given sheet by using
scriber.
3. The angle subtended by the arc of the sector is
calculated from the relation, θ = 360o x
radius of the base circle of the cone / slant
height.
4. The allowance for folding and bending is added to the development
5. The waste metal is cut-away by using the straight and bent snips.
6. The development of the cone is folded by using the funnel stake,
after forming the single hemmed joint.

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SAFETY PRECAUTIONS:
1. Avoid feeling the cut portion by hand while cutting with snip.
2. Do not let sheet metal slip through your hands. Most cuts from
sheet metal results from allowing it to slide through the hands.
3. Use snips only for metal that can be cut by force applied by hand.
4. Hand snips should never be used to cut wires. Such practice ruins
the cutting edges of the blades.

RESULT: The cone is thus made, from the given sheet metal.

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 OPEN SCOOP

AIM: To make a open scoop from the given sheet metal.

MATERIAL : 30 gauge galvanized iron (GI) sheet 110 x 120mm

TOOLS REQUIRED:

1. Steel rule
2. Mallet
3. Scriber
4. Divider
5. Protractor
6. Straight snip

SEQUENCE OF OPERATIONS:

1. Checking
2. Leveling
3. Marking
4. Cutting
5. Bending
6. Seaming

PROCEDURE:

1. The size of the given sheet is checked with the steel rule.
2. The layout of the scoop is marked on the given sheet.
3. The layout of the scoop is cut by using the straight snip.
4. The corners of the scoop are hemmed.
5. The corners of the scoop can be riveted or soldered to
ensure stability of the joints.
PRECAUTIONS:

1. Mark the dimensions correctly

2. Cutting of the sheet should be done carefully.
3. Clean the chips with brush.
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RESULT:

69