Professional Documents
Culture Documents
Dhapakhel,Lalitpur
Submitted by:
Abishek Luitel (KANO79BCT004)
Submitted to:
Er. Prem Bahadur KC, Lecturer
Department of Mechanical Engineering
Kantipur Engineering College
Preface
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The bedrock of hands-on learning and practical skill development spans across
diverse fields like engineering, manufacturing, and craftsmanship, with workshop
technology serving as the cornerstone. This concise guide stands as a fundamental
resource, providing insights into the indispensable techniques, tools, and processes
employed in workshops worldwide.
In the industrial landscape, workshop technology and its application have gained
prominence in producing goods for the betterment of humanity. Proficiency in
manufacturing practices is imperative for engineers and technocrats to acquaint
themselves with contemporary manufacturing technologies. The essential goal is to
impart theoretical and practical knowledge of manufacturing processes and
workshop technology to all engineering students. Recognizing the universal needs
of engineering students and acknowledging their limited exposure to hand tools,
equipment, machines, and manufacturing setups, a foundational workshop
technology course remains integral for all engineering branches.
Acknowledgement
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I would also like to express my gratitude to Workshop Teacher Er. Prem Bahadur
K.C for providing consistent technical assistance and guidance throughout the
challenges encountered during the completion of the workshop lab. His expertise
has been instrumental in enhancing our understanding and proficiency in workshop
practices.
Lastly, I want to thank my friends for their collaborative efforts in initiating and
successfully completing the workshop lab. Their contribution has been invaluable,
creating a conducive environment for sharing information, acquiring skills, and
collectively enriching our technical capabilities. Together, we have not only
completed the lab requirements but have also cultivated a supportive network that
extends beyond the workshop, preparing us for diverse challenges in the
engineering industry.
Table of content
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Introduction 5
Objective 6
Background 7
Machine tools 16
Construction of Dustpan 20
Recommendation 32
Introduction
delves into the nuanced aspects of machine handling, including the identification
of machine parts and their respective functions. This knowledge proves invaluable
in navigating the complexities of modern machinery.
Objectives
Background
A workshop serves as an invaluable space for students to gain insight into the
intricacies of manufacturing and production processes. The Workshop Practice
course not only imparts competence in executing practical tasks within an
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engineering environment but also extends to cover diverse maintenance and repair
works. It becomes a focal point for students to familiarize themselves with various
tools utilized in workshops and learn their correct usage.
1. Hammers
a. Ball pen hammer
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b. Sledgehammer
A sledgehammer is a tool characterized by a large, flat, often metallic
head affixed to a long handle. The extended handle, paired with the hefty
head, enables the sledgehammer to accumulate momentum during a
swing, delivering a substantial force in comparison to hammers designed
for nail-driving tasks. Like a mallet, a sledgehammer possesses the
capability to distribute force over a broad area, setting it apart from other
hammer types that concentrate force within a relatively confined space.
This design makes the sledgehammer particularly effective for
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2. Scale
A scale ruler is a precision tool used for measuring lengths and transferring
measurements at a consistent ratio; two familiar types are an architect's scale
and an engineer's scale. In scientific and engineering contexts, any
instrument designed to measure linear distance and establish proportional
measurements is termed a scale. For drawing straight lines, a straight edge or
ruler is utilized. In everyday language, both tools are commonly referred to
as a ruler.
3. Snips
Snips, also referred to as shears, represent hand tools specifically designed
for cutting sheet metal and other resilient materials. These cutting tools
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4. Bench Vise
The prevalent form of this tool is the bench vise, typically affixed semi-
permanently to a workbench. This sturdy, weighty apparatus, often crafted
from cast iron, serves the purpose of securing items in place during various
tasks. Many tools in your collection will inevitably find application in
conjunction with a vise, as it efficiently stabilizes the workpiece, allowing
for precise and controlled work.
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.
5. Filling
Filing stands out as a crucial operation in the skill set of a metalworker.
Typically performed after treatment and often following chipping, filing
serves multiple purposes. It is essential for removing burrs from cuts,
cleaning the surface of the cuts, and refining the final shape of a workpiece.
These fundamental filing techniques play a pivotal role in achieving
precision and a polished finish in metalworking processes.
a. Cross Filing
This technique, known as straight forward filing, entails pushing the file
across the edge of the material. Widely utilized for finishing, shaping, or
sharpening, it stands as the most employed filing method.
b. Draw Filing
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Draw filing is a rapid material removal technique where the user holds the
file handle in the left hand and the file tip in the right hand. In this method,
material is efficiently removed by exerting downward force with the file
onto the material while simultaneously pulling the file towards the user. This
technique is effective for swift and efficient material removal in
metalworking processes.
c. Lathe Filing
Lathe filing is a specialized technique employed to smooth and shape
cylindrical pieces of material, such as wooden chair legs. In this process, the
workpiece is securely mounted in a lathe, a machine that rotates the material
when activated. To achieve optimal filing consistency, the lathe is set to spin
at a faster-than-usual speed. This method ensures precise shaping and
surface smoothing for cylindrical objects, enhancing the efficiency and
precision of the filing process.
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6. Punches
Punches serve a versatile role in various applications, primarily driving
fasteners like nails and dowels, creating holes, or forming indentations on a
workpiece. Additionally, decorative punches offer the ability to craft patterns
or even imprint images, adding aesthetic elements to the finished product.
The diverse functionalities of punches make them indispensable tools in
woodworking, metalworking, and decorative crafts, allowing for precision
and creativity in material manipulation.
7. Scissors
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Scissors are manual shearing tools with a pair of blades hinged to slide
against each other when the handles (bows) opposite to the pivot are closed.
These versatile tools find application in cutting various thin materials such
as paper, cardboard, metal foil, cloth, rope, and wire. The design and size of
scissors can vary significantly, and a diverse range of specialized scissors
and shears cater to specific purposes, highlighting their adaptability in
different cutting tasks.
8. Hacksaw
A hacksaw is a fine-toothed saw primarily designed for cutting metal, with its
wood-cutting counterpart commonly known as a bow saw. Hacksaws typically
take the form of hand saws, featuring a C-shaped walking frame that holds a
tensioned blade. These hand saws often come with a pistol grip handle,
incorporating pins for attaching a narrow, disposable blade. The frames are
adjustable to accommodate blades of varying sizes, and a screw or another
mechanism is utilized to apply tension to the thin blade during use.
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9. Anvil
An anvil is a metalworking tool characterized by a substantial block of
metal, featuring a flattened top surface where other objects are struck. The
massiveness of anvils is intentional, as it enhances their inertia. This
increased inertia ensures a more efficient transfer of energy from striking
tools to the workpiece, making anvils crucial for various metalworking
processes where precise and forceful shaping is required.
Machine Tools:
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1. Lathe Machine
A lathe is a versatile machine tool that revolves a workpiece around an axis
of rotation, facilitating a range of operations such as cutting, sanding,
knurling, drilling, deformation, facing, and turning. Utilizing various tools
applied to the workpiece, lathes create objects with symmetry about their
rotational axis.
Lathes find application in diverse fields such as woodturning, metalworking,
metal spinning, thermal spraying, parts reclamation, and glass working.
They are instrumental in shaping pottery, with the Potter's wheel being a
well-known application. Equipped metalworking lathes can produce solids
of revolution, plane surfaces, screws, threads, or helices. Ornamental lathes
take it a step further, creating three-dimensional solids with intricate
complexity. The adaptability of lathes makes them essential tools in a variety
of manufacturing and crafting processes.
2. Drilling Machine
A drilling machine is specifically engineered to cut accurate cylindrical holes in
various materials. The market offers a diverse range of drilling machines, spanning
from handheld drills to multi-head turret drilling machines. Each type comes with
its unique set of advantages, disadvantages, and ideal-use cases. The versatility in
design and functionality allows users to select the drilling machine that best suits
their specific requirements, making these tools indispensable in a wide array of
applications and industries.
3. Milling Machine
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Milling machines are versatile machining tools used in the process of removing
material from a workpiece by feeding it against a rotary cutter. These machines are
crucial in the manufacturing industry for creating a wide range of precision
components and parts. There are mainly two types of milling machines, they are
given below:
Construction of Dustpan:
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Objective:
The primary goal of this project is to acquaint individuals with various operations
involved in sheet metal work, including marking and layout, bending, cutting,
folding, and assembling, utilizing a variety of tools. The project specifically
focuses on these operations in the context of constructing a dustpan, providing
hands-on experience in the comprehensive process of creating a functional and
well-crafted sheet metal product.
Introduction:
Sheet metal plays a pivotal role in workshop activities, encompassing crucial
mechanical operations such as marking, layout, and cutting. Marking involves the
precise scribing of lines on a metal surface to outline the profile of the finished
component. Layout, on the other hand, entails the development of patterns—a flat
outline representing the stretched-out form of the intended product.
Furthermore, sheet metal work often includes processes like bending and rolling.
This project involves transforming a fine square metal sheet into a dustpan.
Through this undertaking, participants gain practical experience in various sheet
metal operations, honing their skills in shaping and fabricating a functional
product.
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Materials:
1. Rectangular G.I. sheet
2. Rivets
3. Punches
Punches play a crucial role in metalworking processes, serving various
functions such as providing a starting point for scribing circles, marking
locations for hole drilling, and indicating positions in bench work.
4. Try Square
A Try square is a compact and lightweight square tool with a hardened steel
blade that lacks graduation markings. It serves the purpose of checking the
perpendicularity or squareness of various small workpieces when precision
and accuracy are paramount. This tool is particularly useful in
woodworking, metalworking, and other trades where ensuring right angles is
critical for the quality and integrity of the final product. The absence of
graduations on the blade allows for clear and unobstructed reference when
verifying the perpendicular alignment of components.
2. Mallets
A mallet is a tool designed for applying force to another object, typically
crafted from rubber or wood. It is smaller than a maul or beetle and typically
features a relatively large head. Mallets are versatile instruments used in
various applications, providing controlled impact without causing damage.
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Brief Procedure:
a. Figured out the drawing and its sizes.
b. Made a piece of steel flat and even using a rubber mallet.
c. Marked the sheet with a scriber, pencil, and steel ruler, matching the
drawing's dimensions.
d. Trimmed away unnecessary parts using a notching tool and hand shear.
e. Folded the sheet along marked lines with a hemming machine vice, bringing
in a hammer for tricky spots.
f. Shaped folded sections with a softheaded hammer.
g. Drilled holes for holders in specific spots on the pan and the handle.
h. Completed the assembly by hammering soft nails into the holes, joining
handles and pan.
i. Added a final touch by punching in the roll number.
j. Submitted the finished pan.
Safety Measures:
i) Apron Always wore appropriate personal protective equipment, including
protective aprons, safety goggles, gloves, etc.
ii) Ensured proper training and education on safe handling and operations of
tools and equipment by lab teachers.
iii) Regularly check and maintain tools and equipment to ensure they're in good
working order.
iv) Keep your workspace neat and organized.
v) Be mindful of hand movements to avoid accidental slips into cutting tools or
blades.
vi) Exercise caution when using tin snips or cutting tools to prevent unnecessary
cuts.
vii) Work in an adequately spaced and ventilated area for safety.
viii) Return portable tools to their designated storage after each use.
ix) Execute marking, cutting, and folding tasks with care to prevent disorder and
errors.
x) Aim for uniformity and smoothness in crafting edges.
xi) Select the appropriate hammer for the specific task at hand.
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Conclusion:
Upon completing the project, a series of regular operations were concluded on the
sheet metal in a secure manner. This hands-on experience has fostered familiarity
and instilled a wealth of knowledge through the execution of various operations in
sheet metal works.
Introduction:
In the realm of technical education, practical expertise is as vital as theoretical
knowledge. Bench work serves as the foundational and imperative facet, involving
essential operations with an assortment of tools including hand tools, measuring
tools, and layout tools. This project is dedicated to the creation of a bottle opener
from a flat mild steel bar, employing a diverse set of hand tools along with some
machine tools.
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3. Hacksaw
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This specialized hand tool is crafted for the precise cutting of metals.
Comprising a metal frame with clips at its ends to securely hold cutting
blades, it is tailored for effective and controlled metal cutting tasks.
4. Bench Vise
Designed for secure workpiece clamping, this tool is affixed to the bench
base using bolts for stability. The jaws of the tool feature light serration and
hardening, guaranteeing a strong and reliable grip on the work material.
2. Try Square
This tool features a blade inserted into a slot in the stock, both parts riveted
together at a 90° angle. Its applications include assessing the plainness,
straightness, and perpendicularity of edges, as well as facilitating the
drawing of perpendicular lines.
3. Vernier Caliper
Comprising a stationary main scale and a mobile vernier scale, this tool is
employed for precise measurements of both inside and outside dimensions,
as well as depth measurements of the workpiece.
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Marking Tools:
1. Scriber
A pointed steel tool, the scriber is employed for etching lines onto metal
surfaces with precision. Its bent end serves the purpose of scratching lines in
areas where the straight end may not easily reach.
2. Center Punch
Crafted from a sharply pointed steel rod, the center punch is utilized for
creating deep marks that aid in centering and establishing layout lines with
precision.
3. Divider
This tool comprises a pair of steel legs, adjusted by a screw, and held
together by a circular spring at one end. Its purpose extends to measuring
distances between points, as well as scribing circles and arcs on the
workpiece.
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Material:
A flat mild steel bar is provided with dimensions specified as M.S. (6x25x125).
Brief Procedure:
a) Drawing Understanding the drawing and its measurements, the necessary
tools were gathered for the project. The workpiece, a flat mild steel bar with
dimensions (6x25x125), was clamped in a bench vice and filed on all sides
to remove rust. The surface with dimensions (125x25 mm (about 0.98 in) ²)
was then made smooth and plane using a file.
b) The adjacent edge with dimensions (125x5 mm (about 0.2 in) ²) was filed to
be plane and perpendicular to the previously smoothed surface, verified
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frequently with a try square. Following this, the edge with dimensions (25x5
mm (about 0.2 in) ²) was also made plane and perpendicular to the reference
sides.
c) Using the plane and perpendicular reference sides as a base, markings were
scribed on the other sides with the required dimensions from the given
drawing. Steel ruler, scriber, and divider were used for precision. The centers
and layout lines were emphasized by hammering through the center punch.
d) The unwanted edges were removed using a hacksaw and filed for a smooth
finish. Holes were drilled according to the drawing at the punch markings,
utilizing a drilling machine with specified drill bits. Remaining unnecessary
portions were removed with a hacksaw, and necessary curves were achieved
using both rough and needle files of required shapes.
e) A semi-circular shape at the lower end was obtained through cutting and
filing processes. The rough face of the workpiece was carefully filed to
achieve a plane face with a thickness of 4 mm (about 0.16 in), using a
vernier caliper for accuracy.
f) The top end was filed in an inclined position from both sides to achieve a tip
with a thickness of 1 mm (about 0.04 in), as shown in the drawing. Finally,
all dimensions received a finishing touch using different needle files, and a
roll number was punched between two holes.
g) To prevent rusting, the bottle opener was lubricated and then submitted at
the workshop lab.
Safety Measures:
i) Utilize proper personal protective equipment, including aprons, safety
goggles, and gloves.
ii) Operate machinery under proper supervision and with adequate experience.
iii) Prioritize the protection of primary organs such as eyes, ears, and hands.
iv) Avoid wearing baggy clothes that could be easily caught by machines while
using different tools and machinery.
v) Handle sharp-edged tools with care to prevent injuries.
vi) Ensure that all machine tools are switched off after use.
vii) Refrain from playing with tools and making jokes about them.
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Conclusion
Consequently, through a sequence of operations, the flat mild steel bar was
transformed into a well-crafted and shiny bottle opener. The project primarily
emphasized filing work, which proved to be time-consuming and demanding. It is
suggested to focus more on machine works future projects and minimize reliance
on filing. Nevertheless, the completion of this project enhanced our familiarity
with fundamental operations involving various hand, measuring, layout, and
machine tools, along with an understanding of the safety protocols essential in the
workshop.
Recommendation
For those reading this workshop lab practices, the main advice is to really
understand and adopt the principles and techniques explained here. It's not just
about learning in theory; the real value comes from putting this knowledge into
practice. I recommend that readers get involved in workshop projects, applying
what they've learned to develop a strong grasp of hands-on skills.
The project was a resounding success, achieving its primary objective with
precision and thoroughness. Guided by our knowledgeable teacher, we not only
acquainted ourselves with fundamental workshop operations but also became adept
at handling various tools. This collaborative effort provided us with valuable
insights into the dynamics of teamwork.