WORKSHOP LABORATORY MANUAL FOR R23 REGULATIONS7 : PACE INSTITUTE OF TECHNOLOGY & SCIENCES WORKSHOP LABORATORY LAB MANUAL Prepared By Mr. A. Sai Prasad, Assistant Professor Department of Mechanical Engineering PACE INSTITUTE OF TECHNOLOGY &SCIENCES (Autonomous) Vallur — 523272,Andhra PradeshDepartment of Mechanical Engineering Program: Bachelor of Technology (B. Tech) Vision & Mission of Institution VISION OF THE DEPARTMENT Our vision is to impart futuristic technical education transforming the students technically superior, ethically strong, self disciplined to serve the nation as a valuable resource. MISSION OF THE DEPARTMENT To inculcate quality education by implementing innovative teaching-learning methods and state-of- the-art facilities. To enrich the intellectual know-how, credibility and integrity of the students to necessitate industry. To recognize as scholarly and influential leaders in engineering education, and to develop human power with creativity, advanced technology and passion for the betterment of future nation. 1|PageDEPARTMENT OF MECHANICAL ENGINEERING Program Outcomes Engineering knowledge: Apply the knowledge of mathematics, science, engineering or _| fundamentals, and an engineering specialization to the solution of complex engineering problems. Problem analysis: Identify, formulate, review research literature, and analyze complex poz | engineering problems reaching substantiated conclusions using frst principles of mathematics, natural sciences, and engineering sciences. Design/development of solutions: Design solutions for complex engineeringproblems and design system components or processes that meet the specified needs with PO3 | appropriate consideration for the public health and safety, and the cultural, societal, and environmental considerations. ‘Conduct investigations of complex problems: Use research-based knowledge and og _ | search methods including design of experiments, analysis and interpretation of data, and synthesis of the information to provide valid conclusions, Modern tool usage: Create, select, and apply appropriate techniques, resources, and pos | modern engincering and IT tools including prediction and modeling to complex engineering activities with an understanding of the limitations, ‘The engineer and society: Apply reasoning informed by the contextual knowledge to pos | #8e8s societal, health, safety, legal and cultural issues and the consequent responsibilities relevant to the professional engineering practice. Environment and sustainability: Understand the impact of the professional po7 | engineering solutions in societal and environmental contexts, and demonstrate the knowledge of, and need for sustainable development. Ethics: Apply ethical principles and commit to professional ethies and responsibilities POS _| and norms of the engineering practice. Individual and team work: Function effectively as an individual, and as a member or PO9 | leader indiverse teams, and in multidisciplinary settings. ‘Communication: Communicate effectively on complex engineering activities with poio | the engineering community and with society at large, such as, being able to comprehend and write effective reports and design documentation, make effective presentations, and give and receive clear instructions. Project management and finance: Demonstrate knowledge and understanding of the pout | "gineering and management principles and apply these to one’s own work, as a ‘member and leader in a team, to manage projects and in multidisciplinary environments. Life-Long learning: Recognize the need for, and have the preparation and ability to por2 | engase in independent and life-long learning in the broadest context of technological change, 21 Page‘The Program Specific outcomes (PSO’s) listed below were developed specifically to meet the Program Educational Objectives (PEO’s). The focus of these PSO’s is consistent with the set of required PO’s identified in the NBA accreditation guidelines. ‘The Mechanical Engineering PSO’s require that graduates receiving a Bachelor of Technology in Mechanical Engineering degree ftom the following. DEPARTMENT OF MECHANICAL ENGINEERING Program: Bachelor of Technology (B. Tech) PROGRAM SPECIFIC OUTCOMES (PSO°s) PSOI | Promotes the technical Knowledge, skills and attitude for the requirement of industry and] society towards mechanical engineering. PSO2_ | Facilitates to plan, design, develops and tests an energy efficient manufacturing system for| required engineering applications. PSO3__ | Nurtures the students towards advanced design and analysis tools for mechanical system. 3|Page(CENTRAL ENGINEERING WORKSHOP TECHNOLOGY LAB SYLLABUS EXP NO. EXPERIMENT NAME {To prepare Half lap joint using wood piece (150 mm X 33mm X 33mm). {To make a mortise and tenon joint from the given reaper of size 50 x 35 x 250 mm. [To prepare Comer Briddle joint using wood pieces of size 50 x 35 x 250 mm [To prepare an Tapered Tray of required dimensions using the given sheet metal. [To prepare Conical Funnel of required dimensions 160 x 80mm size using the given sheet metal. [To make Elbow pipe using the given G.I. Sheet 160 x 80mm. [To do the brazing operation on given workpiece. e] al ofelalelole [To prepare V- fit of a given dimensions (46°46"4mm3) on MS. flat plate 9. [fo prepare dove tail it of a given dimensions (48*34*4mm) on MS. flat plate. 10. _ {fo prepare Semi Circular Fit of a given dimensions (48*34*4mm) on M.S. flat plate. 11, _ {fo prepare Semi Circular Fit of a given dimensions (48*34*4mm) on M.S. flat plate. 12, _ [fo Repair bicycle tyre puncture and change of two-wheeler tyre. 13, To make a circuit for two bulbs controlled by one-way switch in Parallel and Series Connection, 14, __ | To make a circuit for one bulb controlled two switches. 15, [fo make a circuit for Go down lighting, 16,__ [fo make a circuit for tube light connection, 17. _ [fo give connection for Three Phase Motor. 18, __ [lo do the process of soldering of by using Flux. 19, [fo Prepare a pipe line connection to the wash basin. 20, [To prepare a lap joint using arc welding process 21, _ {To prepare a butt joint using arc welding process. 22, [To adjustment of brake and clutch as per specification. 23, [To prepare a mould cavity for a casting of Solid pattern by using two patterns. alPageATTAINMENT OF PROGRAM OUTCOMES (P0’s) & PROGRAM SPECIFIC OUTCOMES (PSO’s) Exp No. Program outcomes Program specific ‘outcomes 1. [To prepare Half lap joint usin; jwood piece (150 mm X 33mm 33mm), POI, PO2 PSO1, PSO2 [To make a mortise and tenor jioint from the given reaper o hize 50 x 35 x 250 mm. POI, PO2, POS PSO2 [To prepare Corner Briddle join lusing wood pieces of size 50 [35 x 250 mm PO4, POS, POS PSO1, PSO2 [To prepare an Tapered Tray 0} fequired dimensions using 1 lziven sheet metal. PO2, PO3, POS PSO1, PSO2 [To prepare Conical Funnel o! kequired dimensions 160 [80mm size using the given sheet Imetal. POI, POS PSO! [To make Elbow pipe using the [eiven G.I. Sheet 160 x 80mm, POI, PO4, POS, POY PSO1, PSO2 [To do the brazing operation on given workpiece. POI, POS PSO2 [To prepare V- fit of a given {limensions (46*46*4mm3) on IMSS. flat plate. POI, PO4 PSO1, PSO2 [To prepare dove tail fit of riven dimensions (48*34*4mm) n M.S. flat plate, POI, PO3 PSO2 10. [To prepare Semi Circular Fit of lk given dimension: (48*34*4mm) on M.S. flat late. POI, POS, PO6, PO8 Pso2 i. [To prepare Semi Circular Fit of lk given ——_ dimension: (48*34*4mm) on M.S. flat late. POI, PO2 PSO1, PSO2 [To Repair bicycle tyre puncture land change of two-wheeler tyre. POI, PO2, POS, PSO2 [To make a circuit for two bulbs controlled by one-way switch it [Parallel and Series Connection. PO4, POS, POS PSO1, PSO2 14. To make a circuit for one bull controlled two switches PO2, PO3, POS PSO1, PSO2 5|PageJo make a circuit for Go down) 7 POI, POS PSO! - lighting. ae POI, PO2 PSOI, PSO2 [To give connection for Thred POI, PO2, POS PSO2 17. Phase Motor. [To do the process of soldering 0 PO4, POS, POS PSO1, PSO2 18. by using Flux. To Prepare a pil 19. : a PO2, PO3, POS PSO1, PSO2 ‘onnection to the wash basin. 3p, [Fo repaFe a ap joint using are POI, POS PSOr hwelding process 31, [Fo prepare a butt joint using are for cae Soe hwelding process, ap, [Fo prepare @ butt joint using are POI, PO2, POS PSO2 ” Iwelding process. 33, [FO adjustment of brake a PO4, POS, POS PSO1, PSO2 * clutch as per specification. [To prepare a mould cavity for a 24, PO2, PO3, POS PSO1, PSO2 sting of Solid pattern by usin, lwo patterns. 6|PageMANDATORY INSTRUCTIONS Students should report to the labs concerned as per the timetable. Record should be updated from time to time and the previous experiment must be signed by the faculty in charge concerned before attending the lab, . Students who turn up late to the labs will in no case be permitted to perform the experiment scheduled for the day. After completion of the experiment, certification of the staff in-charge concerned inthe observation book is necessary. Students should bring a notebook of about 100 pages and should enter the readings/observations/results into the notebook while performing the experiment. ‘The record of observations along with the detailed experimental procedure of the experiment performed in the immediate previous session should be submitted and certified by the staff ‘member in-charge. 7. Not more than FIVE students in a group are permitted to perform the experiment on a set up. 7|Page The group-wise division made in the beginning should be adhered to, and no mix up of student among different groups will be permitted later. The components required pertaining to the experiment should be collected from Lab- in- charge after duly filling in the requisition form, ). When the experiment is completed, students should disconnect the setup made by them, and. should return all the components/instruments taken for the purpose. . Any damage of the equipment or burnout of components will be viewed seriously either by putting penalty or by dismissing the total group of students from the lab for the semester/year. . Students should be present in the labs for the total scheduled duration, . Students are expected to prepare thoroughly to perform the experiment before coming to Laboratory. . Procedure sheets/data sheets provided to the student groups should be maintained neatly and. are to be returned after the experiment. . DRESS CODE: a. Boys- Formal dress with tuck in and shoes. b. Girls - Formal dress (salwarkameez). ¢. Apron in blue color for both boys and girls. 4d. Wearing of jeans is strictly prohibitedCONTENTS S.No. Description 24.___| Vision & Mission of department 25. _| Program Outcomes (PO"s) 26. _| Program Specific Outcomes (PSO"s) 27.___| Syllabus ‘Attainment of program outcomes (PO's) & program specificoutcomes (PSO"s) 28, 29, | Mandatory Instructions 30___| Contents 31.__ [To prepare Half lap joint using wood piece (150 mm X 33mm X 33mm). 32, _ [fo make a mortise and tenon joint from the given reaper of size 50 x 35 x 250 mm. 33. [fo prepare Comer Briddle joint using wood pieces of size 50 x 35 x 250 mm 34.__ [fo prepare an Tapered Tray of required dimensions using the given sheet metal. 35. __ {fo prepare Conical Funnel of required dimensions 160 x 80mm size using the given sheet metal] 36. To make Elbow pipe using the given G.I. Sheet 160 x 80mm. 37.__ Todo the brazing operation on given workpiece. 38. [To prepare V- fit of a given dimensions (46°46"4mm3) on MSS. flat plate. 39. [To prepare dove tail fit of a given dimensions (48*34*4mm) on M.S. flat plate. ns (48°34*4mm) on MS. flat plate. 40, {To prepare Semi Circular Fit of a given dimen: 4], __ [To prepare Semi Circular Fit of a given dimensions (48*34*4mm) on M.S. flat plate. 42, __ {fo Repair bicycle tyre puncture and change of two-wheeler tyre. 43, __ To make a circuit for two bulbs controlled by one-way switch in Parallel and Series Connection. 44, | To make a circuit for one bulb controlled two switches. 5, {To make a circuit for Go down lighting. 46,_ To make a circuit for tube light connection, 47, _ [To give connection for Three Phase Motor. 48,_ [To do the process of soldering of by using Flux. 49, _ [lo Prepare a pipe line connection to the wash basin. 50, _ [To prepare a lap joint using are welding process 51, [Fo prepare a butt joint using arc welding process, 52, _ [Fo adjustment of brake and clutch as per specification. '53, [To prepare a mould cavity for a casting of Solid pattern by using two patterns. B|PageCARPENTRYINTRODUCTION: Carpentry may be defined as the process of making wooden components. It deals with the building work, furniture, cabinet making etc., proportion of joints in one of the important operations in all wood works, It deals with making joints for a variety of application via door frames, window frames, wardrobes, cupboards, stairs etc., In this chapter tools and works associated with joinery are present. Carpentry Material - Timber:- ‘Timber is basic material used for any class of carpentry. The term timber is applied to the wood obtained from well grown trees, The trees are cut; saw into various sizes to suit the required purpose. ‘Common varieties of Indian Timber:- Indian timber most commonly used for various carpentry works are as follows: Babul, Deodar, ‘Mahogany, Mango sol, Sissy, Teak and rosewood. Marking and Measuring Tools: Steel rule | ® ‘Try square Marking gauge Steel Rule:- It is a strip of steel with graduation on the edges and is used for measuring and setting out dimensions. 10| Page eee‘Try Square:- ‘Try square is used for making and testing of right angles and for testing flatness of surface. Marking gauge:- Itis a tool which has one projected marking pin and is used to mark accurate times parallel to the true edge of a wooden piece. Holding Tools:- Carpenter's vice C- damp Carpenter's viee:- Iti used for holding the work for planning, sawing and chiseling. The whole vice is made of iron and steel. It has two jaws one of which is fixed to the side of the table while the other is movable. C- Clamp:- Itis holding the work piece on the bench to carry different operations. Bench — Stop:- Itis simply a block of work projecting above the top surface of the bench, This is used to prevent the wood from moving forward when being planned. Cutting tools:- ‘Wooden jack plane Cross cut saw L = Kgs IN Tenon Saw Cross cut teeth 11|Page eeeFirmer chisel Dovetail chisel Mortise chisel Adze C= Wooden rasp file Pincer Wooden mallet Wooden Jack Plane:- It consists of wooden body in which blade is set at angle of as to the body or sole. The cutting blade used is made of high carbon steel and is very similar to a wheel. Jack plane is a general purpose plane and is used to produce flat and smooth surface on wood. Hand (or) Cross Cut Saw:- It is used to cut across the grains of the stock (or) thick wood. The teeth are set alternatively to the right and left to the blade and its purpose is to make the cut wider than the thickness of the blade. This allows the blade to move freely in the cut, without sticking near the teeth are set at 25 mm apart. Rip Saw: Itis used for cutting the stock along the grain. The cutting edge of this saw makes a steeper angle i.e., about where as that hand (or) across cut saw makes an angle 45° with the surface of stock. Tenon Saw (or) Back Saw: This saw is mostly used for across cutting when a finer and more accurate finish is required. The teeth are sharped in the form of an equilateral triangle and generally have 13 teeth for 52 mm length, 12|PageFirmer Chisel (or) Straight Edge Chisel:- tis a general purpose chisel and is ised for cutting and sharping wood accurately. The width of the blade varies from 15 to 50 mm. is used to chop extra wood quickly by carpenters. Adze with very long handle is used to plane long palm tree barks in standing position and also used as a hammer. Miscellaneous Tools: Pincers:- tis made of steel with a thinned joint and is used for pulling out small nails from wood. (Claw hammer:- It is a dual purpose hammer. It has a hammer face; which is used to drive in nails and claw at the other interior surface. Sharp cutting teeth are provided on its surface. Sharp cutting teeth are provided on its surface. This file is exclusively used in woodwork. Wood Joints:- There are many kinds of joints used to connect wood stock. Each joint has a definite use and requires marking cutting and joining together. The strength of the joint depend on the amount of contact area, If a particular joint does not have much contact area, then it must be reinforced with nails screws (or) dowels Lap joi Itis also called halving joint. The aim of this joint is to secure the corners and intersections of the framing where strength and appearance are of secondary cor Mortise and Tenon Joint This is a large one and does probably the wood worker use the consi family of joints rectangular fitting into a rectangular hole. Riddle Joint:- ‘These are the reverse of mortise and tenon in form and are often called the open mortise and tenon joints are used where the members are of square of square section and thus suitable for making a mortise and tenon joint of good proportions. Safe Practices:- General:- Make a sure that your hands are not in front of sharp edged tools while you are using them, Saws:- 13|Page eeeBe careful when you are using your thumbs as a guide in cross cutting. Chisels: > Never chisel towards any part of the body. > Test the sharpness of the cutting edge on wood (or) paper, not on your hand. 14|Page eeeExp No: Date: HALF LAP JOINT : = To prepare Half lap joint using wood piece (150 mm X 33mm X 33mm). Material required: - Wood pieces ‘Tools required: - 1. Carpentry bench vice 2. Wooden mallet 3. Chisels Flat chisel, dove tail 4. Wooden rasp file 5. Cross cut saw 6. C-clamp 7. Metal jack plane 8. Scriber 9. Try square 10. Steel rule Procedure: - 1. The two given wooden pieces are fixed in a wise and planed with jack plane along the grains for getting true surfaces and are equal in size 150*40*30mm, ‘The sides are checked for perpendicularity with try sequence ‘The unwanted material is cut with the help of cross cut saw. ‘The unwanted material is removed on two pieces with a firmer chisel. yee DE ‘The two pieces are filed with the help of wooden rasp file in order to get smooth surface finish. 6. Two pieces are fixed together to form the required joint. Precautions: - 1. Only unwanted material should be taken while using chisels. Tools that are not being used should always be kept at their proper places. Use only sharp tools. A dull tool requires excessive pressure, causing the tool to slip. ‘Test the sharpness of the cutting edge on wood or paper, but not on your hand, wan Never chisel towards any part of the body. 15|Page eee40 4 49 T 1 1 4 T-LAP JOINT nm Result: - Faculty sign: - Date: - 16 [Page ALL DIMENTIONS ARE IN MM eeeExp No: Date: MORTISE AND TENON JOINT Aim: - To make a mortise and tenon joint from the given reaper of size 50 x 35 x 250 mm. Material required: - Wood pieces Tools Required: - 1. Jackplane 2. Catpentry vice 3. Try square 4. Marking gauge 5. Steel rule 6. Tenon saw 7. Rip saw 8. Firmer chisel 9. Mallet Procedure 1. The given reaper is checked to ensure its correct size. 2. The reaper is firmly clamped in the carpenter's vice and one of its faces are planed by the jack plane and checked for straightness. 3. The adjacent face is then planed and the faces are checked for squareness with the try-square. 4, Marking gauge is set and lines are drawn at 30 and 45 mm, to mark the thickness and width of the model respectively. ‘The excess material is first chiseled out with the firmer chisel and then planed to correct size. ‘The mating dimensions of the parts X and Yare then marked using the scale and marking gauge. Using the cross-cut saw, the portions to be removed in part Y (tenon) is cut, followed by chiseling. ema ‘The material to be removed in part X (mortise) is carried out by using the mortise and firmer chisels 9. The parts X and Yare separated by cross-cutting with the tenon saw 10. The ends of both the parts are chiseled to exact lengths 1. Finish chiseling is done wherever needed so that, the parts can be fitted to obtain a near tight joint 1. Only unwanted material should be taken while using chisel Tools that are not being used should always be kept at their proper places. Use only sharp tools. A dull tool requires excessive pressure, causing the tool to slip. ‘Test the sharpness of the cutting edge on wood or paper, but not on your hand. yeep . Never chisel towards any part of the body. al Pase eee40 40 75, 45 a x , t T | 4] 1 ! s | ! | | a b Result: - Faculty sign:- Date:- Exp No: Date: 48 [Page eeeCORNER BRIDDLE JOINT im: - To prepare Comer Briddle joint using wood pieces of size 50 x 35 x 250 mm-2 Nos. Material required: - Wood pieces Tools required:- 1. Carpentry bench vice 2. Wooden mallet 3. Chisels Flat chisel, dove tail . Wooden rasp file Cross cut saw 4. 5 6. C-clamp 7. Metal jack plane 8, Scriber 9. Try square 10. Steel rule Procedure: - 1. The given reaper is checked for dimensions ‘They are planed with jack plane and checked for straightness. ‘The two surfaces are checked for squareness with a try square, Marking gauge is set and lines are marked at 30 and 45 mm to mark the Thickness and width of the model respectively. ‘The excess material is first chiseled with firmer and then planned to correct size. 6. The mating dimensions of the parts X and Y are then marked using steel rule and marking gauge. 7. Using the crosscut saw, the portions to be removed are cut in both the pieces, followed by chiseling 8, The ends of both the parts are chiseled to the exact lengths. 9. The fine finishing is given to the parts, if required so that, proper fitting is obtained. 10. The parts are fitted to obtain a slightly tight joint Precauti 1. Only unwanted material should be taken while using chisels. ‘Tools that are not being used should always be kept at their proper place: Use only sharp tools. A dull tool requires excessive pressure, causing the tool to slip. Test the sharpness of the cutting edge on wood or paper, but not on your hand. yeep Never chisel towards any part of the body. 19|Page eeeLoLlio 10 |+—s0—+| Result: - Faculty sign:- Date:- 2|Page eeeVIVA QUESTIONS & ANSWERS 1) What is seasoning? Ans: - It is the process of removing moisture from wood. 2) Name the different processes of seasoning? ‘Ans:-Air seasoning, kiln seasoning, and water seasoning. 3) Classify the tools used in carpentry shop? Ans: - Holding, marking, measuring, cutting, sawing, planning, drilling and boring tool. 4) Name any two types of hammers used in carpentry shop? Ans:- Claw hammer, mallet 5) What is Ans:-To make mortises. mortise chisel? 6) What is the function of a rebate plane? Ans:-To make recesses. 7) Name any three wood working machines. Ans:-Lathe, circular saw, planner. 8) Write any five advantages of wood over the other materials, Ans ight in weight, good strength, good appearance, easy to work, easily available. 9) What is carpenter's vice? Ans:- It is used to hold work pieces. 10) What is the pitch of saw? Ans:-It is the distance between two teeth 21|Page eeeTIN SMITHYTIN SMITHY INTRODUCTION: Many engineering and house hold articles such as boxes, cans, funnels, ducts etc. are made from a flat sheet of metal; the 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 from the required shape of the article. Allowance should be given in the drawing stage for folding and bending. This allowance depends upon the radius of the bend and the thickness of the sheet metal. Sheet Metal Materials:~ ‘A variety of metals are used in a sheet metal shop such as Galvanized Iron, Black Iron, Tin Stainless Steel, Copper and Aluminum. Hand Tool ‘The common hand tools used in sheet metal work are Steel rule, Try square, Wire gauge, Scriber, Ball peen hammer, Cross peen hammer, Nylon Mallet, Snips Divider, Stakes, Cutting plier and Soldering Iron. Here, the details of tools that are being equipped by our workshop purchase only are purposed. Wire gauge Straight snip Curved snip ‘Straight Bent end, Divider Cutting pliers Scriber 23|Page eeeae Ball peen hammer —_Cross peen hammer Straight peen hammer Stakes Sheet metal joints Wire Gauge:- ‘The thickness of sheet 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. Steel Rule:- It is a strip of steel with graduations on its edges. It is used for measuring and setting out dimensions. Seriber: A scriber is a slender steel tool, used to scribe or mark lines on sheet metal. Snips: Hand shears or snips are used to cut sheet metal. Straight snips are having straight blades and are used or cutting along straight lines and for trimming edges. Curved Snips have a curved blade and are used for cutting circles and irregular shapes. Divider: Itis used for transferring the sizes and scribin 1g curves are circles. Bench vice:- Itis generally used for holding and bending the work piece. 2|Page eeeHammers:- Lightweight hammers and mallets are used in sheet metal work. Ball peen Hammer has a cylindrical, slightly curved face and a ball head. It is general purpose hammer used mostly for reverting in sheet metal work Cross Peen Hammer has a tapered peen end and is perpendicular to the handle. Because of thi reach awkward comets, Straight Peen Hammer has the peen end similar to the cross peen, but it is positioned parallel to the handle which can be used conveniently for certain operations of folding, Cutting Pliers: - Used for holding, cutting and bending works. Nylon Mallet:- Nylon Mallet is used for bending and folding work. Itis light in weight, covers more area and to not damage the surface area. Stakes:- Stakes are made of steel and forged tool and to form, seam bend or rivet sheet metal objects. Sheet Metal Joints:- a variety of shapes and sizes. These are used as supporting Various types of joints are used in sheet metal work, to suit the varying requirements. Some commonly used sheet metal joints and folded edges are shown in figure. These are self — secured joints, formed by jointing together two pieces of sheet metal and using the metal itself to from the joint. Sheet metal Lay out:- ‘The shapes of most articles made with sheet metal are in few geometrical forms. All these forms are made from flat sheet; therefore the first requirement is developing the lines, which forms the pattern ‘The development or stretch out of a job is called pattern and developing lines which forms a pattem is layout. It may be drawn on paper first and then transferred in the sheet or it may layout directly on sheet metal. When a pattern is made repeatedly, itis generally made of metal and referred to as template. Safety precautions:: 1. Use hand leather gloves while handling heavy sheets 2. Avoid feeling the cut portion by hand while cutting 3. Do not let sheet metal slip through your hands. Most cuts from sheet metal result from allowing it to slide through the hands. 4. Use snips only for metal that can be cut by force applied by hand, 5. Hand snips should never be used to cut wire. Such practice ruins the cutting edges of the blades. 25|Page eeeExp No: Aim: - To prepare an Tapered Tray of required dimension: Date: TAPERED TRAY ing the given sheet metal. Material required: - Galvanized Iron (Gl) sheet. Tools req iL 4. 5, 6 1, 8, 9, juired:- Steel rule Seriber Mallet Divider Straight snip Curved snip Nylon hammer Base plate ). Funnel stake...... ete. Sequence of operations:- iL, 2, 3 4. 5, 6. Marking . Cutting . Notching, Folding edges Bending Seam making Procedure:- 1. The size of the given sheet is checked with the steel rule. yee Precautio mns:- ‘The layout of the scoop is marked on the given sheet. ‘The layout of the scoop is cut by using the straight snip. ‘The corners of the scoop are hemmed. ‘The edges of the scoop can be riveted or soldered to ensure stability of the joints. 1. Dimensions should be marked with more careful attention, 2. Cutting should be done carefully along the marked lines. Otherwise the metal sheet might bend giving wrong shape. 3. Care is to be taken in avoiding wastage of sheet metal. 4. Proper pressure is to be applied with mallet. 26|Page eee5. Care should be taken while using the nylon mallet and straight snip. 6. Bending and finishing should be done properly, neatly and straight so that safe edges can be obtained. SS ed = LAA EAA 4 ub - eG nn wentoa materiat Result: - Faculty sign:- Date:- 27|Page (0 aretntsonsomerExp No: Date: Aim: Material require Tools required:- Sequence of operations:- Procedure:- os Precautions:- 1 28|Page - To prepare Conical Funnel of required dimensions 160 x 80mm size using the given sheet metal. 2. 3, 4. 5, 6 Z 8 9, CONICAL FUNNEL |: - Galvanized Iron (GI) sheet. 1. Steel rule Seriber Mallet Divider 5. Straight snip . Curved snip Nylon hammer Base plate Funnel stake...... ete. 1. Marking 2. Cutting 3. Notching 4, Folding edges 5. Bending 2 Seam making The size of the given sheet is checked with the steel rule, The layout of the scoop is marked on the given sheet. The layout of the scoop is cut by using the straight snip. ‘The comers of the scoop are hemmed, ‘The edges of the scoop can be riveted or soldered to ensure stability of the joints, ‘The angle subtended by the are of the sector is calculated from the relation, 0 = 360° xradius of the base circle of the cone / slant height. Dimensions should be marked with more careful attention. Cutting should be done carefully along the marked lines. Otherwise the metal sheet might bend giving wrong shape. Care is to be taken in avoiding wastage of sheet metal. eee4. Proper pressure is to be applied with mallet. Care should be taken while using the nylon mallet and straight snip. Bending and finishing should be done properly, neatly and straight so that safe edges can be obtained. 15 0 -360% 2360% pb TTD one b Development Funnel b Development Faculty sign:- Date: 29|Page eeeExp No: ELBOW PIPE Aim: - To make Elbow pipe using the given G.l. Sheet 160 x 80mm, Material required: - Galvanized Iron (Gl) sheet. ‘Tools required: - iL Sequence iL, 2, 3 4. 5, 6. Steel rule Seriber Mallet Divider Straight snip Curved snip Nylon hammer Base plate Funnel stake... .. ete. of operations: - Marking . Cutting . Notching, Folding edges Bending Seam making Procedure: - Daye ED Precautio 1, Dimensions should be marked with more careful attention, 2. Cutting should be done carefully along the marked lines. Otherwise the metal sheet might bend Clean the given sheet with cotton waste. ‘The size of the given sheet is checked with the steel rule, Flatten the surface of the given sheet with wooden mallet. Check the G.I. Sheet for dimensions and remove extra material, if any. ‘Mark all the measuring lines on the given sheet with scriber. Cut the given sheet with straight snips as required Fold the given sheet by using stakes and ball peen hammer to the required shape. giving wrong shape. 30|Page Date: eeeCare is to be taken in avoiding wastage of sheet metal, Proper pressure is to be applied with mallet. Care should be taken while using the nylon mallet and straight snip. Bending and fi obtained. ae ishing should be done properly, neatly and straight so that safe edges can be Result Faculty sign:- Date:- 31|Page eeeExp No: Date: BRAZING Aim: - To do the brazing operation on given workpiece. Brazing: Brazing is defined as the technique of joining two similar or dis-similar ‘materials, by addition of special filler metal. Brazing is also called as hard soldering and it results in a stronger joint than soldering. It can withstand temperatures up to 800°C and higher pressures. The filler metal, ic. solder used in brazing is known as spelter, a non- ferrous metal or alloy. The following are the stages involved in brazing: 1) Make a tight-fitting joint. Where necessary, file a groove along the joint for the solder to run into, 2) Clean the surface of the joint, free from oil, drt, grease, rust, etc. 3) Apply flux with a brush 4) Preheat the area until the flux dries out. Then, heat the joint until it is bright red. 5) Apply the solder when it begins to melt; move the torch along the joint for the solder to flow evenly. 6) Clean, file and smoothen the joint Advantages: 1. Produce leak-proof joints, which are superior to soldered joints. 2. Produce corrosion resistant joints. 3. Brazing can be performed on similar or di Disadvantages: 1, Large areas cannot be brazed easily due to the possibility of lack of uniform, heating of internal surfaces. Joints have poor strength compared to welded joints, Require tightly mating parts. Brazing fluxes may produce toxic fumes. It cannot be performed on hardened steel. imilar metals. yey Precautions: Avoid the inhalation of fumes produced because of fluorides and fluorine ‘compounds that are present in brazing fuses, particularly those used with silver, magnesium and aluminum silicon brazing filler metals. Result; Faculty sign:- Date: 32|Page eeeFITTINGFITTING INTRODUCTION:- Manufacturing process is broadly classified in to four types. 1. Costing process Forming process Fabrication ae YL Material removal process In all this process components are produced with the help of either machines (or) manual effort. The attention of a filter is required at various stages of manufactures starting from making to assembling and testing the finishing goods. Working on components with hand books and instruments mostly on work benches is referred to as “Fitting work”. The hand operation in fitting shop, include marking, fitting, sawing, scrapping, drilling, tapping, grinding, etc., us 1g hand tools (or) power operator tools measured and inspection of components and maintenance of equipment of components and equipments is also considered as important work. Marking and Measuring Tools: (nahin Surface plate Universal scribing block Outside caliper Divider 34|Page eeec—a><° -O— Dot punch Centre punch Surface Plate:- ‘The surface plate is used for testing the flatness of the work piece and other inspection purpose. It is also used for marking on small works. It is more precise flatness from than the marking table, Surface plates are the plates made of CI (or) hardened steel ground and scrapped to the required precision. Now day's surface plates made of special granite stone and manufacture in wide range of precision rates colors and sizes. It is specified by length X width X height X grade. Ex:- 600*100* grade A has a flatness up to 0.005 mm two surfaces machines at right angle to each other plates and components which are to be marked be held against the upright face of angle flat to facilitate the marking (or) Inspection. Universal Seribing Block:- This is used for scribing lines for carry out work and checking parallel surfaced. Add By Caliper: This is called “Jenny Caliper”. This is used for marking parallel lines from finished edges and also for locating the center of round basis. They are specified by the height of the leg up to point. Ex: 100 mm, 30 mm ete., Dividers: This is used for marking circles ares. They lay out perpendicular lines by section lines ete., size range from 100 mm to 30 mm. Dot Punch:- It is used to locate centre holes and to provide a small centre mark for divides point etc., for this purpose the punch is ground to conical point having go include angle. Centre punch:- This used to locate center of holes and similar to dot except it is ground to a conical point having, 900 include angle include center punch ic., facilities easy weight. A ball peen hammer has a flat face which is used foe reverting they weight from 220 gm to 1.5kg. ‘The hammer consists of a hardened and tempered steel hand varying in mass from 0.1 kg to about kg firmly fires on a touch wooden handle. 35|Page eeeFinishing Tools: —=T I Round file =i») Half round file ‘Try square Flat Itis rectangular in section and tapered for ¥2 length in which and thickness towards. The point the paces carry double cut teeth and the edges carrying the cut then it is a general purpose file. Square File: It is a square in section of carry double cut them on all the four faces it is tapered for 1/3 of its Jength towards the point square files are used for filing corner and stores. It is also used to cut ray ways and stores. Try Squai The try square is used for checking is not easy locations of the drill tip and centre ac Drift Punch:- rately. Drift punch is along tapered tool used to a lighter holes in two (or) more pieces of material that are to be rained together that holes can be easily place in the holes. Number Pundl It similar to lather punch in construction but has numbers at its end, The numbers used are from Oto 8 punches are made of tool steel hardened and tapered. Cutting Tools: Hack saw frame Hack ~ Saw Frame:- ‘The Hack — Saw frame is used for cutting metal by hand. It consists of frame which holds blades 36|Page eeefamily in position on the blade has a no. of cutting teeth per 25 mm of the blade length is selected on the basis of the work material and thickness being out The teeth of the back blade are staggered as shown in fig. which is known as a set of teeth. They make the stores wider than the blade thickness, parenting the blade joining, Ball Peen Hammer:- Hammers are used depending on those shape and material and specified by their required size of the try square is specified by the length of the blade, Seriber:- ‘The scriber is slender steel and used to scribe for marking lines on metal work pieces. ‘Triangular Fi tis equilateral triangle is section and tapers towards the tip, the faces are double cut and the edges sharp this files are used to file angular hole and racers sharpening wood square. Round File:- It is tapered 1/3 length with double cut on large course grade of filling 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, it is not semicircle but only about 1/3 of circles regard second file for surface grades used in an extremely useful double purpose file for surface and for surface and for curved surfaces which are two large for the rare end to be used. 37|Page eeeExp No: Date: Y-EITTING Aim: - To prepare V- fit of a given dimensions (46%46*4mm3) on M.S. flat plate Material required: - Mild Steel (MS) flat plate Tools required:~ 1, Bench Vice Seribing Block Angle Plate Hack - Saw Frame, Seriber Try Square Dot Punch Center Punch Ser awepn Ball Peen Hammer 10. Steel Rule 11. Smooth Flat File. Sequence of Operations:~ 1. Sawing Marking 2. 3. Cutting 4. Fitting 5. Finishing Procedure:- 1. The world piece held firmly in the vice and all sides be filed with the help of flat rough file. 2. Ensure surface flatness and cheek the edges are at right angles using try square. 3. He surface of work is coated with a posted chalk and allowed to dry then the work is said with its coated surface on the face of the v — block kept on surface plate on the horizontal lines are first scribed using seribing block or surface gauge vertical lines and drawn by using the seriber. 4. Afier scribing work is over light indentations are made along the scribed lines where the part is to be removed with the help of dot punch and hammer. 5. Now cut the entire work piece into two half’s to make male & female parts with the help of hack saw and then remove the excess material 6. After cutting the edge of the male female parts to be filed with triangle file along the punched work to ensure that the job has gone under size. 38| Page eee7. Assemble the male & female parts to fit to get the exact fit. Precautions:- 5. Apply force only on the forward (cutting) stroke and relieve the force on the return stroke. Result: - Faculty sign:- Date:- 39|Page The given job is fit in bench vice correctly. Keep hands and tools wiped clean and free of dirt, oil and grease. Dry tools are safer to use than slippery tools Do not keep working tools at the edge of the table. Po springing, saw breakage and posses low noise. ion the work piece such that the cut fo be made is close to the vice. This practice prevents Do not hold the work piece in hand while cutting. = 15 46 eeeExp No: Date: DOVE TAIL FITTING Aim: - To prepare dove tail fit of a given dimensions (48*34*4mm) on M.S. flat plate. Material required: - Mild Steel (MS) flat plate. Tools required:~ 1. Bench vice Seribing block Angle plate Hack — saw frame Scriber, bustard 12 inch files Try square, Dot punch Center punch Ser awepn Ball peen hammer 10. Steel rule 11, Smooth flat file, Sequence of operations:- 1. Sawing 2. Marking 3. Cutting 4, Fitting 5. Finishing Procedure:- 1. The piece is cut down as per dimensions the piece is finished at two sides along length wire and bench wise and form a perfect dovetail with the help of try square level. 2. One surface of the dovetail piece is ruff with chalk piece after that with the help of universal seriber marking the given piece. On the ruffed surface mark our required dimensions as cutting lines and put the dots along the cutting lines with the help of dot punch. 3. The given piece is fit in a bench vice and cut the square piece with the help of hack saw frame along the dotted lines of own required shape. 4. After words the required dovetail fit is finished with the help of flat file to get good finish. ‘5. The final dovetail fit is made in required position Precautions:- 40 [Page eee1. The given job is fit in bench vice correctly. 2. Keep hands and tools wiped clean and free of dirt, oil and grease. Dry tools are safer to use than slippery tools 3. Do not keep working tools at the edge of the table. 4. Po springing, saw breakage and possess low noise. \n the work piece such that the cut to be made is close to the vice. This practice prevents 5. Apply force only on the forward (cutting) stroke and relieve the force on the return stroke. 6. Do not hold the work piece in hand while cutting Result: - Faculty sign:- Date:- M1 [Page eeeExp No: Date: ‘SEMI CIRCULAR FIT Aim: - To prepare Semi Circular Fit of a given dimensions (48*34*4mm) on M.S. flat plate. Material required: - Mild Steel (MS) flat plate. Tools required:~ 1. Bench vice Seribing block Angle plate Hack — saw frame Scriber, bustard 12 inch files Try square, Dot punch Center punch Ser awepn Ball peen hammer 10. Steel rule 11, Smooth flat file, Sequence of operations:- 1. Sawing 2. Marking 3. Cutting 4. Fitting 5. Finishing Procedure:- 1. The piece is cut down as per dimensions the piece is finished at two sides along length wire and bench wise and form a perfect Semicircular with the help of calipers and divider, try square level. 2. One surface of the Semi ‘ular piece is ruff with chalk piece after that with the help of universal seriber marking the given piece. On the ruffed surface mark our required dimensions as cutting lines and put the dots along the cutting lines with the help of dot punch. 3. The given piece is fit in a bench vice and cut the square piece with the help of hack saw frame along the dotted lines of own required shape. 4. After words the required semicircular fit is finished with the help of flat file to get good finish. 5. The final semicircular fit is made in required position. Precautions:- a2 [Page eee1. The given job is fit in bench vice correctly. 2. Keep hands and tools wiped clean and free of dirt, oil and grease. Dry tools are safer to use than slippery tools 3. Do not keep working tools at the edge of the table. 4. Position the work piece such that the cut to be made i springing, saw breakage and possess low noise. close to the vice. This practice prevents 5. Apply force only on the forward (cutting) stroke and relieve the force on the return stroke. 6. Do not hold the work piece in hand while cutting. Result: - Faculty sign:- Date:- 4 | Page (0 aretntsonsomer