Workshop Mannual

ABESIT WORKSHOP PRACTICE LAB (BWS151/BWS251) B.
TECH I YEAR
EXPERIMENT NO - 1
Layout, Safety Measures and Engineering Materials
OBJECTIVE: To study layout, safety measures and different engineering materials (mild
steel, medium carbon steel, high carbon steel and cast iron etc) used in workshop.
Layout: Plant layout is such a systematic and efficient functional arrangement of various
departments, machines, tools, equipment and other supports services of an industrial
organization that will facilitate the smooth processing of the product in the most effective,
efficient and economical manner in the minimum possible time.
Workshop: A building or a part of a building or a place where things are manufactured or

repaired.
Manufacturing: Manufacturing processes are broadly classified into four categories; (i)
Casting processes, (ii) Forming processes, (iii) Fabrication processes, and (iv) Material
removal processes. In all these processes, components are produced with the help of either
machines or manual effort. To performed these processes to manufacture a component,
workshop is divided into different shops according to the operations performed on the
components.
1. Fitting Shop - Working on components with hand tools and instruments, mostly on
work benches is generally referred to as 'Fitting Work'. The hand operations in fitting
shop include marking, filing, sawing, scraping, drilling, tapping, grinding etc., using
hand tools or power operated portable tools. The term "bench work" generally denotes
the production of a part by hand on the bench.
2. Carpentry Shop - Carpentry may be defined as the process of making wooden
components. It deals with the specific work of carpenter like making different types of
joints to form a finished product.
3. Machine shop - A place where hand tools and power-driven tools are used for making,
finishing, or repairing machines or machine parts. Machine tool is a non-portable power
operated device in which the energy is utilized to produce jobs of desired shape and
size and surface finish by removing excess material. The oldest machine tool used in
machine shop is a lathe machine.
DEPARTMENT OF MECHANICAL ENGINEERING 1

ABESIT WORKSHOP PRACTICE LAB (BWS151/BWS251) B. TECH I YEAR
4. Welding Shop - Welding is a process of joining similar metals by application of heat

with or without application of pressure and addition of filler material. Welding is
extensively used in fabrication work in which metal plates, steel sections, casting of
ferrous materials are joined together. It is also used for repairing broken, worn out and
defective metal part.
5. Foundry Shop - Foundry practice deals with the process of making castings in moulds,
formed in either sand or some other material. The process involves the operations of
pattern making, sand preparation, moulding, melting of metals, pouring in moulds,
cooling, shake-out, heat treatment, finishing, and inspection.
6. Black Smithy Shop - A smithy is a place where blacksmiths do their work, heating,
and shaping metal, especially to make tools. Smithy or Forging is the oldest shaping
process used for producing small articles for which accuracy in size is not so important.
The parts are shaped by heating them in an open fire or hearth by the blacksmith and
shaping them through applying compressive forces using a hammer.
7. Sheet Metal Shop – Sheet metal work is generally regarded as the working of metal
sheet from 0.3 to 1.6 mm with hand tools and simple machines into various forms by
cutting, forming and joining.
Safety Measures:
Remember that “accidents do not occur, they are caused”. With this in mind, strictly
follow the general safety rules given below and safe practices indicated in brief under
each section.
1. Safety first, work next.

2. Know your job and follow instructions.
3. Avoid wearing clothing that might catch, moving or rotating parts. Long sleeves
of shirts, long hair, neck tie and jewellery are definite hazards in the shop.
4. Wear safety shoes. Do not wear canvas shoes; they give no resistance to hard
objects dropped on the feet.
5. Keep the area around machine or work clean.
6. Keep away from revolving work.
7. Be sure that all guards are in place.
8. One person only should operate the machine controls.

9. Use tools correctly and do not use them if they are not in proper working
condition.
10. Wear safety goggles when working in areas, where sparks or chips of metal are
flying.
11. Get to know who in-charge of first aid is and where boxes are placed and where
the first aid can be found in case of emergency.
Engineering Materials: Engineering materials are mainly classified into two categories.
a) Ferrous materials are those which have the iron as their main constituent, such as pig
iron, cast iron, wrought iron and steels.
b) Non-ferrous materials are those which have a metal other than iron as their main
constituent, such as copper, aluminium, brass, bronze, tin, silver zinc, invar etc.
Ferrous Materials: Main Types of Iron are
1. Pig iron
2. Wrought iron
3. Cast iron
4. Steel
A. Plain carbon steels
i. Low Carbon steels
ii. Medium Carbon steels
iii. High Carbon steels
B. Alloy steels
i. High speed steel
ii. Stainless steel
Pig Iron: The basic principal raw material for all ferrous materials is pig iron which is obtained
by smelting iron ore, coke and limestone in the blast furnace.
Wrought Iron: Wrought iron is the assumed approximately as purest iron which possesses at
least 99.5% iron. It is said as a mechanical mixture of very pure iron and a silicate slag.
Cast Iron: Cast iron is basically an alloy of iron and carbon and is obtained by re-melting pig
iron with coke, limestone and steel scrap in a furnace. The carbon content in cast iron varies

from 2% to 6.67% but practically it is in between 2% to 4.5% only. It also contains small
amounts of silicon, manganese, phosphorus and sulphur in form of impurities elements.
Steel: Steel is an alloy of iron and carbon with carbon content maximum up to 2%.
A. Plane Carbon Steel: Plain carbon steel is an alloy of iron and carbon. It is different
from cast iron as regards the percentage of carbon. It contains carbon from 0.05 to 2%
whereas cast iron possesses carbon from 2 to 6.67%. Depending upon the carbon
content, a plain carbon steels can be divided to the following types:
I. Low carbon or mild steel — 0.05% to 0.3% carbon
II. Medium carbon steel — 0.3% to 0.8% carbon
III. High carbon steel — 0.8% to 1.5% carbon
B. Alloy Steel: For improving the properties of ordinary steel, certain alloying elements
are added in it. The main purpose of alloying element in steel is to improve its
mechanical properties.
I. High Speed Steel: High speed steels (HSS) are most commonly operated as
cutting tools at much higher Speed. It contains 18% tungsten, 4% chromium
and 1 % vanadium, 0.8% carbon and remaining iron.
II. Stainless Steel: Stainless steel contains chromium together with nickel as
alloying element. Stainless steel surface is responsible for corrosion resistance.
Minimum chromium content of 12% is required for the film’s formation, and
18% is sufficient to resist the most severe atmospheric corrosive conditions. A
steel containing 18% chromium and 8% nickel is widely used and is
commonly referred to as 18/8 steel.

EXPERIMENT NO - 2
Vernier Caliper & Micrometre
OBJECTIVE: To determine the least count of Vernier Caliper and Micrometre (Screw
Gauge) and take different reading over given metallic pieces using these instruments.
Vernier Caliper: Vernier instruments used an additional scale, called the Vernier scale, which
can slide along the main scale. This arrangement enables a friction of main scale division to be
determined with a fixed accuracy depending upon the nature of scale. For illustration, consider
a main scale where in the graduations are in cm and that each cm is divided in to ten equal
parts. The reading taken by such a scale would be accurate within ±1 mm. Let a sliding Vernier
scale, having 50 equal divisions.
Since fifty-divisions of a Vernier scale coincide with forty-nine divisions of the main scale,
50 Vernier Scale Divisions = 49 Main Scale Divisions = 49 𝑚𝑚
1 Vernier Scale Divisions = 𝑚𝑚 = 0.98 𝑚𝑚
Least Count = 1 Main Scale Division - 1 Vernier Scale Division
Least Count = 1𝑚𝑚 − 0.98 𝑚𝑚
Least Count = 0.02𝑚𝑚
The difference between one main scale division and one Vernier division is called the least
count of the Vernier. This represents the smallest length that can be measured accurately by
using the Vernier.
Vernier Principle: Vernier principle is used in Vernier caliper, which are designed both for
internal and external measurements. The unit consists of a rectangular steel bar with a main
scale made integral with the fix jaw. A sliding jaw carries the Vernier scale, slide along the
main scale and can be fixed at any position by the locking screws.
Generally, when the two jaws touch each other, the zero of the Vernier scale considers with
zero of the main scale. If it not so, here is zero error which must be accounted for.

The specimen or work piece is placed between the jaws and the position of the movable jaw is
so adjusted that the work piece just held. The length of the work piece is then evaluated in the
manner given below;
(i) Read the position of the Vernier zero mark on the main scale reading to the
nearest division on the low side.
(ii) Look along the Vernier for a coincidence between graduations on the Vernier
and the main scale. This number multiplied by the Vernier least count give the
fraction to be added to the main scale reading.
The jaws projecting from the upper part are used to measure the internal diameter of a tube etc.
The rectangular rod R carried by the movable jaw serves to measure the depth of vessel.
Micrometer: Vernier calipers can measure accurately up to 1/100 of an mm. For greater
accuracy, which is essential in the measurement of small size such as the diameter of a wire,
thickness of a metal plate etc. we use a micrometer screw gauge. Micrometer screws designed
according to the screw and the nut principle where calibrated screw thread and a circular scale
division are used.
The semi- circular frame carries affixed anvil at one extremity and a cylindrical barrel at the
other end. A fine accurately cut screw of uniform pitch is machined on a spindle. The spindle
passes through the barrel and its left-hand side constitutes the movable anvil. A sleeve fits on
the screw and carries on its inner edge (called thimble). A thimble or circular scale division
divided into desired number of divisions. The spindle with its screw and the thimble is in one
piece and sleeve forms the nut. The thimble scale serves to measure the friction of its circular

rotation. The number of complete rotations is read on the main (or pitch) scale, which is
graduated in mm on the nut parallel to axis of the screw.
The work piece is just held between the two anvils without undue pressure. This is
accomplished by having a ratchet drive to turn the thimble.
Least count: The least count of the screw refers to the distance through which the screw moves
forward or backward when the head (thimble) is rotated through one division on the thimble
(circular) scale.
(𝑃𝑖𝑡𝑐ℎ 𝑜𝑓 𝑡ℎ𝑒 𝑆𝑐𝑟𝑒𝑤)

𝐿𝑒𝑎𝑠𝑡 𝐶𝑜𝑢𝑛𝑡 =
(𝑁𝑜. 𝑜𝑓 𝐷𝑖𝑣𝑖𝑠𝑖𝑜𝑛 𝑜𝑛 𝑡ℎ𝑒 𝐶𝑖𝑟𝑐𝑢𝑙𝑎𝑟 𝑆𝑐𝑎𝑙𝑒)
If the pitch of the screw is 0.5 mm, and the circular scale has 50-division mark on it, then.
Least Count = 0.5/50= 0.01mm= 0.001cm
In measuring the dimension of a work piece, the main scale up to the beveled edge of the
thimble and the no. of divisions of the thimble scale to the axial line on the barrel are observed.
The addition of two readings gives the required result.

EXPERIMENT NO - 3
Fitting Tools
OBJECTIVE- To study and use of different types of tools, equipment, devices & machines
used in fitting and welding shop.
Tools Used:
Holding Tools:
1. Bench Vice: The bench vice is a work holding device. It is fixed to the bench with bolts
and nuts. The vice body consists of two main parts, fixed jaw and movable jaw. When
the vice handle is turned in a clockwise direction, the sliding jaw forces the work against
the fixed jaw. The vice body is made of cast iron which is strong in compression.
Bence Vice
Marking and Measuring Tools:
1. Steel Rule: It is flat in shape and calibrated up to half mm. Its length specifies it.
Generally available in length of 6”, 12”, 24” and 1 meter.
2. 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. The size of the Try square is specified by the length of the blade.
3. Scriber: A Scriber is a slender steel tool, used to scribe or mark lines on metal work
pieces. It is made of hardened and tempered High Carbon Steel. The Tip of the scriber

is generally ground at 120 to 150. It has two pointed ends the bent end is used for
marking lines where the straight end cannot real.
Try Square Scriber

4. Calipers: They are indirect measuring tools used to measure or transfer linear
dimensions. These are used with the help of a steel Rule to check inside and outside
measurements. These are made of Case-hardened mild steel or hardened and tempered
low carbon steel. While using, the legs of the caliper are set against the surface of the
work, whether inside or outside and the distance between the legs is measured with the
help of a scale.
5. Odd Leg Caliper: This is also called ‘Jenny Caliper’. This is used for marking parallel
liners from a finished edge and also for locating the centre of round bars. It has one leg
pointed like a divider and the other leg bent like a caliper. It is specified by the length
of the leg up to the hinge point.
6. Divider: It is basically similar to the calipers except that its legs are kept straight and
pointed at the measuring edge. This is used for marking circles, arcs laying out

perpendicular lines, by setting lines. It is made of case-hardened mild steel or hardened

and tempered low carbon steel. Its size is specified by the length of the leg.
Odd Leg Caliper Divider

7. Punches: These are used for making indentations on the scribed lines, to make them
visible clearly. These are made of high carbon steel. The tapered point of the punch is
hardened over a length of 20 to 30mm.
a) Dot Punch is used to lightly indent along the layout lines, to locate centre of holes
and to provide a small centre mark for divider point. For this purpose, the punch is
ground to a conical point having 60° included angle.
b) Centre Punch is similar to the dot punch, except that it is ground to a conical point
having 90° included angle. It is used to mark the location of the holes to be drilled.
Dot and Centre Punch

Cutting Tools:
1. Hack Saw: The Hack Saw is used for cutting metal by hand. It consists of a frame,
which holds a thin blade, firmly in position. Hacksaw blade is specified by the number

of teeth per centimetre. Hacksaw blades have a number of teeth ranging from 5 to 15
per centimetre (cm). Blades having lesser number of teeth per cm are used for cutting
soft materials like aluminium, brass and bronze. Blades having larger number of teeth
per centimetre are used for cutting hard materials like steel and cast Iron.
Hacksaw Frame with Blade

2. Files: Filing is one of the methods of removing small amounts of material from the
surface of a metal part. A file is hardened steel too, having small parallel rows of cutting
edges or teeth on its surfaces. One end of the file is shaped to fit into a wooden handle.
The hand file is parallel in width and tapering slightly in thickness, towards the tip. It
is provided with double cut teeth.
Parts of a Hand File

Miscellaneous Tools:
1. Ball - Peen Hammer: Ball‐ Peen Hammers are named, depending upon their shape and
material and specified by their weight. A ball peen hammer has a flat face which is used
for general work and a ball end, particularly used for riveting.

Ball Peen Hammer Cross Peen Hammer Straight Peen Hammer
2. Cross - Peen Hammer: It is similar to ball peen hammer, except the shape of the
peen. This is used for chipping, riveting, bending and stretching metals and hammering
inside the curves and shoulders.
3. Straight‐Peen Hammer: This is similar to cross peen hammer, but its peen is in‐line
with the hammer handle. It is used for swaging, riveting in restricted places and
stretching metals.

EXPERIMENT NO - 4
Fitting Shop
OBJECTIVE- To Prepare a V -Shape Male Female Work piece which contains: Measuring,
Marking, Filing, Sawing.
Material Required: Mild steel flat piece of size 50 mm x 30 mm x 5 mm.
Tools Required: - Bench vice, steel rule, try-square, ball-peen hammer, dot punch, scriber,
files, hacksaw with blade.
Note:
1. All dimensions are in mm.

2. Remove the crossed symbol portion.

Sequence of Operations:
1. The dimensions of the given pieces are checked with the steel rule.
2. The pieces are clamped one after the other in a bench vice and the outer mating edges are
filed using files.
3. The pieces are checked for their flatness with the help of the try -square.
4. The side edges of the two pieces are filed such that, they are at right angle to each other, and
the required dimensions are obtained.
5. Chalk is then applied on the surface of the two pieces.
6. The given dimensions of the V-fitting are marked, by using steel rule, scriber and surface
plate.
7. Using dot punch, dots are punched along the above scribed lines.
8. Using the hacksaw, the unwanted portions are removed.
9. Using the flat chisel, the unwanted material is removed.
10. The corners of the stepped surfaces are filed by using a square or triangular file to get the
sharp corners.
11. The pieces (X and Y) are fitted together and the matting is checked for the correctness of
the fit. Any defects noticed are rectified by filing with a smooth file.
Precautions:
1. Care should be taken while marking.
2. Care should be taken while hack sawing.
3. Use cleaning brush while removing chips.
Result: The required V - fitting is thus obtained.

EXPERIMENT NO - 5
Woods and Carpentry
OBJECTIVE- Study of Carpentry Tools, Equipment, Woods and different joints.
Introduction: Carpentry may be defined as the process of making wooden components. It

starts from a raw form of wood and ends with finished products. Preparation of joints is one of
the important operations in all woodworks.
Timber:
Timber is the name given to the wood obtained from well grown trees. The trees are cut, sawn
into various sizes to suit building purposes.
Classification of Timber: Wood suitable for construction and other engineering purposes is
called timber. Woods in general are divided into two broad categories: Soft woods and Hard
woods.
Soft woods are obtained from conifers, kair, deodar, chir, walnut and seemal. Woods obtained
from teak, sal, oak, shisham, beach, ash mango, neem and babul are known as hard wood, but
it is highly durable.
Seasoning of Wood
A newly felled tree contains considerable moisture content. If this is not removed, the timber
is likely to wrap, shrink, crack or decay. Seasoning is the art of extracting the moisture content
under controlled conditions, at a uniform rate, from all the parts of the timber. Only seasoned
wood should be used for all carpentry works. Seasoning makes the wood resilient and lighter.
Further, it ensures that the wood will not distort after it is made into an object.
Tools Used:
Marking and Measuring Tools:
1. Marking Gauge: It is a tool used to mark lines parallel to the edge of a wooden piece.
It consists of a square wooden stem with a sliding wooden stock (head) on it. On the
stem is fitted a marking pin, made of steel. The stock is set at any desired distance from

the marking point and fixed in position by a screw. It must be ensured that the marking
pin projects through the stem, about 3 mm and the end are sharp enough to make a very
fine line. A mortise gauge consists of two pins. In this, it is possible to adjust the
distance between the pins, to draw two parallel lines on the stock.
Marking gauge Mortise gauge

Holding Tools:
1. Carpenter's Vice: It is used as a work holding device in a carpenter shop. It’s one jaw
is fixed to the side of the table while the other is movable by means of a screw and a
handle. The Carpenter's vice jaws are lined with hard wooden' faces.
Carpentry Vice
Planing Tools: Planing is the operation used to produce flat surfaces on wood. A plane is a
hand tool used for this purpose. The blade of a plane is fitted in a wooden or metallic block, at
an angle.
1. Jack Plane: It is the most commonly used general purpose plane. It is about 35 cm
long. The cutting iron (blade) should have a cutting edge of slight curvature. It is used
for quick removal of material on rough work and is also used in oblique planning.

2. Smoothing Plane: It is used for finishing work and hence, the blade should have a
straight cutting edge. It is about 20 to 25 cm long. Being short, it can follow even the
slight depressions in the stock, better than the jack plane. It is used after using the jack
plane.
Planing Tools
Cutting Tools:
1. Saws: A saw is used to cut wood into pieces. There are different types of saws, designed
to suit different purposes. A saw is specified by the length of its toothed edge.
I. Cross-Cut Saw 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.
II. Rip Saw: It is used for cutting the stock along the grains. The cutting edge of this
saw makes a steeper angle, i.e., about 60° whereas that of crosscut saw makes an
angle of 45° with the surface of the stock.
III. 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. However, it is used for small and
thin cuts. The blade of this saw is very thin and so it is stiffened with a thick back
steel strip. Hence, this is sometimes called as back-saw. In this, the teeth are shaped
like those of cross-cut saw.

IV. Compass Saw: It has a narrow, longer and stronger tapering blade, which is used
for heavy works. It is mostly used in radius cutting. The blade of this saw is fitted
with an open type wooden handle.
2. Chisels: Chisels are used for cutting and shaping wood accurately. Wood chisels are
made in various blade widths, ranging from 3 to 50 mm. They are also made in different
blade lengths.
I. Firmer Chisel: The word 'firmer' means 'stronger' and hence firmer chisel is
stronger than other chisels. It is a general-purpose chisel and is used either by hand
pressure or by a mallet. The blade of a firmer chisel is flat, as shown in figure.
II. Dovetail Chisel: It has a blade with a beveled back, as shown in Figure, due to
which it can enter sharp comers for finishing, as in dovetail joints.
III. Mortise Chisel: It is used for cutting mortises and chipping inside holes, etc. The
cross-section of the mortise chisel is proportioned to withstand heavy blows during
mortising. Further, the cross-section is made stronger near the shank.
Chisels

Mallet: A mallet is a tool used for imparting force on another object, often made of wood, and
usually has a relatively large head.
Mallet

EXPERIMENT NO - 6
Carpentry Shop
OBJECTIVE- To make a Mortise & Tenon joint as per given drawing.
Material Required: Two wooden pieces (130 mm x 30 mm x 20 mm) of soft wood.
Tools/ Equipment Required: Steel scale, Try square, Marking gauge, Tenon saw, carpentry
bench vice, Iron jack/smooth plane, Firmer chisel and mallet etc.
Operations Involved:
1. Measuring & Marking

2. Planning
3. Sawing
4. Mortise & Tenon joint making practice.
1. The given reaper is checked to ensure its correct size.

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

Precautions:
1. Care should be taken while marking.

2. Work piece should be well tight in vice in proper position.
3. Care should be taken while cutting the wooden piece with chisel.
Result: The Mortise and Tenon joint is thus made by following the above sequence of
operations.
Note: All dimensions are in mm.

EXPERIMENT NO - 7
Lathe Machine
OBJECTIVE- Demonstration of working, construction and accessories for Lathe machine.
Introduction: Lathe Machine is most widely used machine tool for different operations like
turning, facing, threading, knurling etc. In this machine the work metal is fixed between two
canters (one is live & other called dead center) and revolves in anticlockwise direction. A
stationary tool is feeded closer to the revolving job and metal removes in the form of chips.
Main Parts of Lathe Machine
Bed: It is heavy structure made up of casted iron in single piece or in two or more than two
pieces also. It usually works as supporting and guiding base for carriage, headstock and
tailstock. On the top of bed, v-grooved structure is provided for proper movement of carriage
and tailstock.
Head stock: It is a hollow rectangular casted structure mounted over bed and works as housing
for chuck and shafts on the basis of driving mechanism used for driving shaft.

Tail stock: It is a casted structure mounted at other end of bed. It provides housing for dead
centre. Tail stock can slide over V- shaped guide way provided over bed surface.
Carriage: It is a casted structure providing housing for cross slide and tool post. It is situated
between tail stock and head stock on the V- Shaped guide ways provided on the bed. It can
slide over bed in left and right position.
Compound rest: It is mounted on the cross slide with the help of a swivel plate by which it
can rotate in horizontal plane. It provides housing for tool post.
Tool post: - It is mounted over compound rest and provides housing for tool. All types of tool
post may rotate at 360o angle. It is a mild steel machined structure as designed for holding tool
bit. These are made in various designs. Some of them are designed for single tool holding
capacity and some are designed for holding multi-tools at a single time.
Leg: These are supporting structure and provide support for bed or we say whole body of lathe
machine. These are made of cast iron.
Chuck: It is used for holding/gripping work piece. It is mounted at one end of spindle.
According to construction and application, these may be divided in to flowing types.
 Three jaw chuck: It is also known as self-centering chuck because it contains three
jaws, which operate simultaneously while operating any pinion. But its use is limited
because it requires uniform surface of work from where it is to be gripped.
 Four jaw chuck: It contains four jaws, every jaw moves independently to any jaw
containing non- uniform surface which can also be centered in this chuck, so generally
this chuck is most popular.
Cutting Tools:
 Single point cutting tools: These cutting tools contain only one cutting edge/point. For
example, turning, parting & grooving tools for lathe machine, shaper tools and planer
tools etc.
 Multipoint cutting tools: These cutting tools contain more than one cutting
edge/points. For example, drill bit, broach and milling cutters etc.

EXPERIMENT NO - 8
Machine Shop
OBJECTIVE- To make a workpiece on Lathe Machine by performing operations like -

Facing, Plane Turning, Taper Turning, Knurling etc.
Material Required: Mild Steel bar.
Tools/ Equipment Required: Lathe Machine, Chuck key, tool post key, tool bit, surface
gauge, Vernier caliper etc.
Operations Involved:
1. Centering
2. Facing
3. Turning
4. Taper turning
5. Knurling
6. Grooving
1. Hold the mild steel bar properly in chuck of lathe machine.

2. Check the position of job, it should be in center of chuck, check with the help of surface
gauge.
3. Check all the levers, they should be in unengaged position before starting the machine.
4. After switching on the machine see visually the approximate center of job. It should not
revolve in elliptical position.
5. Switch off the machine and mount the tool bit in the tool post in proper position. It
should be well tightened and tip of tool bit should coincide with the center of job.
6. Tilt the position of tool post in such a manner that the tip of tool bit come about 30-40”
with the job.
7. Then by feeding with the help of cross-slide feeding wheel till the tip of tool bit reach
at center of job. This process of metal removing is known as facing.

8. Now change the position of job in chuck and tilt the compound rest at desired angle and
feed the tool with help of compound rest wheel till get the desired dimensions.
9. After taper turning engage back gear and reduce the speed of spindle and replace the
taper turning tool bit with knurling tool bit and do knurling same applying feed as in
plain turning applied.
10. After knurling, turn the position of job in chuck.
11. After knurling, tilt back the tool post to its previous position and reducing diameter for
a short length, called groove and process making called grooving.
Precautions:
1. Care should be taken while holding the workpiece.

2. Workpiece should be well tight in chuck in proper position.
3. Care should be taken while cutting the workpiece with cutting tool.
Result: The required workpiece is thus made by following the above sequence of operations.

EXPERIMENT NO - 9
Arc Welding Shop
OBJECTIVE- Study of tools, equipment & machine used in arc welding & to make a butt
joint using arc welding.
Material Required: Mild Steel flat piece (30 x 50 x 5 mm)-2 Nos.
Tools/ Equipment Required: A.C. arc welding machine, face shield, Electrodes, chipping
hammer, wire brush and bench vice etc.
Welding: Welding is the process of joining similar metals by the application of heat, with or
without application of pressure or filler metal, in such a way that the joint is equivalent in
composition and characteristics of the metals joined.
Electric Arc Welding: Arc welding is the metal joining process, in which the joint is produced
by heating the workpiece with an electric arc generated between an electrode and the work piece.
The electric energy is converted into heat, which attains a temperature of around 5500oC. The
electrode itself melt and supplies the necessary filler material.
Tools and Equipment Used:
1. A.C. welding machine: These are simple in construction containing a step-down

transformer set oil/air cooled, which supplies different current values as per
requirement.
2. Electrode: Electrode may be defined as a filler metal rod used to fill up the gap between
the joints during welding procedure. Generally, these are in wire shape and made up of
different metals as per requirement. It works to transport current from electro holder to
work metal, which causes for arc development.
3. Electrode holder: It is used for electrode holding. It consists of two jaws. One jaw is
fixed type and another jaw is movable which is operated by a screw or spring connected
arm mounted over insulated handle.
4. Welding cable: -It is generally made up of many thin copper wires collected together
and wrapped in a suitable insulating material. It is specified by cross section of cable
and current carrying capacity of electrode.

5. Hand shield / face shield: This is used for protection of face and eyes from the spatter,
ultraviolet and infrared rays during welding process. It is made up of fiber sheet and
black glass is fitted to look at weld.
6. Chipping hammer: These are hammers having pointed or sharp striking face and used
for removing slag and spatter.

7. Wire brush: Wire brush is used for removing slag and unwanted materials from metal
surface in fine way than chipping hammer.
8. Hand gloves: These are used to protect the hands from electric shocks and hot spatters.
1. File one edge of both pieces as shown in figure to make V-groove. This process of edge
filing to make V-groove is known as edge preparation.
2. Place the work piece on the table for doing welding by applying any welding method.
3. Remove slag by chipping with the help of chipping hammer.
4. Remove fine layer of slag by using wire brush.
Precautions:
1. Check all the connections before starting the welding.

2. Use suitable current and voltage values for welding.
3. Use suitable hand gloves and face shield during welding operation.
4. Avoid stacking electrode at job in arc welding.


EXPERIMENT NO - 10
Gas Welding Shop
OBJECTIVE- Study of tools and equipment used in gas welding & to make a lap joint using
oxy-acetylene gas welding.
Material Required: Mild Steel flat piece (30 x 30 x 3 mm)-2 Nos.
Tools/ Equipment Required: Oxygen gas, Acetylene gas, filler rod, welding torch, welding
table, goggles, wire brush, bench vice and file etc.
Gas Welding: Gas welding is a joining process that melts and joins the metals by heating them
with a flame caused by a reaction of fuel gas and oxygen. The flux may be used to deoxidize
and cleanse the weld metal. The flux melts, solidify and forms a slag on the resultant weld
material.
Tools and Equipment Used:
1. Welding Torch: Welding torch or blow pipe may be defined as the equipment designed
for mixing oxygen and combustible gas (acetylene) in required proportion and injecting
for combustion and making flame.
2. Hosepipe: It is used for supplying gases from pressure regulator to welding torch.
3. Pressure Regulator: It is pressure-controlling device used for supply of desired
pressure of gas to hosepipe connected with welding torch. It is mounted directly over
gas cylinders.
4. Welding Torch Lighter: It is an instrument, which produces spark used for lightening
welding torch.
Oxygen Acetylene Flame: It is produced by combustion of gases and therefore based on air-
fuel mixture, different temperatures are achieved. A flame can be adjusted for different
temperature range. There are 3 types of flames produced in oxy-acetylene gas welding.
1. Neutral Flame (Temperature 3100oC): It is achieved when acetylene and oxygen are
used in equal quantity. It consists only two parts of flame; one is inner cone and outer
envelope. It is most widely used in gas welding. It produces around 3100oC
temperature.

2. Carburizing Flame (Temperature 2900oC): This can be achieved by increasing

acetylene gas quantity in neutral flame. It produces around 2900oC temperature.
3. Oxidizing Flame (Temperature 3300oC): It can be achieved by increasing percentage
of oxygen in natural flame. It is used only with brass welding. It produces around
3300oC temperature.

1. Check all the connections of oxy-acetylene gas cylinder. Clean surface of mild steel
flat piece surfaces.
2. Place carefully the M.S flat piece in proper position on the worktable.
3. Set properly the welding flame by adjusting the pressure of both gases. Start welding
flowing instructions of instructor.
4. The above same procedure may be adopted in making lap joint by changing the position
of the work piece.
Precautions:
1. Check all the connections before starting the welding.

2. Always adopt right tool and right procedure for every operation in welding shop.
3. Use suitable hand gloves and goggles during welding operation.
4. After welding, stop the supply of acetylene first and then stop the supply of oxygen.


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ABESIT WORKSHOP PRACTICE LAB (BWS151/BWS251) B.

Workshop: A building or a part of a building or a place where things are manufactured or

DEPARTMENT OF MECHANICAL ENGINEERING 1

4. Welding Shop - Welding is a process of joining similar metals by application of heat

1. Safety first, work next.

DEPARTMENT OF MECHANICAL ENGINEERING 2

Ferrous Materials: Main Types of Iron are

DEPARTMENT OF MECHANICAL ENGINEERING 3

DEPARTMENT OF MECHANICAL ENGINEERING 4

50 Vernier Scale Divisions = 49 Main Scale Divisions = 49 𝑚𝑚

1 Vernier Scale Divisions = 𝑚𝑚 = 0.98 𝑚𝑚

Least Count = 1 Main Scale Division - 1 Vernier Scale Division

Least Count = 1𝑚𝑚 − 0.98 𝑚𝑚

Least Count = 0.02𝑚𝑚

DEPARTMENT OF MECHANICAL ENGINEERING 1

DEPARTMENT OF MECHANICAL ENGINEERING 2

(𝑃𝑖𝑡𝑐ℎ 𝑜𝑓 𝑡ℎ𝑒 𝑆𝑐𝑟𝑒𝑤)

Least Count = 0.5/50= 0.01mm= 0.001cm

DEPARTMENT OF MECHANICAL ENGINEERING 3

DEPARTMENT OF MECHANICAL ENGINEERING 1

Try Square Scriber

DEPARTMENT OF MECHANICAL ENGINEERING 2

perpendicular lines, by setting lines. It is made of case-hardened mild steel or hardened

Odd Leg Caliper Divider

Dot and Centre Punch

DEPARTMENT OF MECHANICAL ENGINEERING 3

Hacksaw Frame with Blade

Parts of a Hand File

DEPARTMENT OF MECHANICAL ENGINEERING 4

Ball Peen Hammer Cross Peen Hammer Straight Peen Hammer

DEPARTMENT OF MECHANICAL ENGINEERING 5

Material Required: Mild steel flat piece of size 50 mm x 30 mm x 5 mm.

1. All dimensions are in mm.

DEPARTMENT OF MECHANICAL ENGINEERING 1

5. Chalk is then applied on the surface of the two pieces.

8. Using the hacksaw, the unwanted portions are removed.

9. Using the flat chisel, the unwanted material is removed.

1. Care should be taken while marking.

2. Care should be taken while hack sawing.

3. Use cleaning brush while removing chips.

Result: The required V - fitting is thus obtained.

DEPARTMENT OF MECHANICAL ENGINEERING 2

OBJECTIVE- Study of Carpentry Tools, Equipment, Woods and different joints.

Introduction: Carpentry may be defined as the process of making wooden components. It

Marking and Measuring Tools:

DEPARTMENT OF MECHANICAL ENGINEERING 1

Marking gauge Mortise gauge

DEPARTMENT OF MECHANICAL ENGINEERING 2

DEPARTMENT OF MECHANICAL ENGINEERING 3

DEPARTMENT OF MECHANICAL ENGINEERING 4

DEPARTMENT OF MECHANICAL ENGINEERING 5

OBJECTIVE- To make a Mortise & Tenon joint as per given drawing.

Material Required: Two wooden pieces (130 mm x 30 mm x 20 mm) of soft wood.

1. Measuring & Marking

1. The given reaper is checked to ensure its correct size.

DEPARTMENT OF MECHANICAL ENGINEERING 1

1. Care should be taken while marking.

Note: All dimensions are in mm.

DEPARTMENT OF MECHANICAL ENGINEERING 2

OBJECTIVE- Demonstration of working, construction and accessories for Lathe machine.

Main Parts of Lathe Machine

DEPARTMENT OF MECHANICAL ENGINEERING 1

DEPARTMENT OF MECHANICAL ENGINEERING 2