LABManualMECH2113 2157

Heritage Institute Of Technology
Department of Mechanical Engineering
LAB MANUAL
Sub: Workshop Practice II

(MECH-2113/2157)
HERITAGE INSTITUTE OF TECHNOLOGY
Chowbaga Road, Anandapur, P.O.-East Kolkata Township,
Kolkata 700107
REPORT
ON
Workshop Practices II
JOB NO ______________________ __________________SHOP
JOB TITLE ___________________________________________
DATE(S)OF WORK __________________________________________
DATE OF SUBMISSION __________________________________________
PREPARED BY
NAME ____________________________________________
DEPARTMENT ____________________________________________
GROUP ________________ ROLL NO. _________________
EVALUATED BY
Signature of Faculty/Examiner _________________________________________

SYLLABUS
Course Name: WORKSHOP PRACTICE II

Course Code: MECH 2113/2157
Contact hrs L T P Total Credit Points
per week: 0 0 3 3 1.5
Course Outcomes:
At the end of the course, a student will be able to
Understand various manufacturing processes that are used in a typical

CO 1 workshop, be aware of various safety precautions that needs to be observed
while working.
Understand the mechanics of material removal in a lathe machine, Identify

various metal cutting operations that are possible in lathe, Select speed, feed and
CO 2
depth of cut depending on the material to be processed, List and Sequence
various operations and Manufacture and Inspect a Job from a given drawing.
Define the key parameters of spur gear, be Conversant with the cutting of spur
CO 3 gear in a milling machine, Calculate the blank diameter of a spur gear given its
module and no of teeth, Manufacture and Inspect the spur gear.
Differentiate between the TIG and MIG welding, Select TIG and MIG welding
CO 4 parameters, Operate the TIG and MIG welding machines, Perform a simple job
and Assess its defects.
Understand and Explain various allowances given to a product drawing ,

Prepare and Inspect a wooden pattern from given a product drawing,
CO 5
Demonstrate the purpose and use of core in a mould , Cast a component and
Inspect the component for any casting defects .
Differentiate between hot working and cold working of metals, Prepare a sheet
metal component and a forged component from a given drawing, Calculate the
CO 6
blank size of sheet metal from a manufacturing drawing, Appreciate the various
safety measures needs to be taken while forging.
Sr. No. Job. No. Job Description CO
1. MECH 2157/01 To prepare a Job involving various operations involving 1,2

Lathe machine.
2. MECH 2157/02 To cut a spur gear in Milling machine. 1,3
3. MECH 2157/03 To cut a key way in a shaft and spur gear( manufactured 1,2,3
in Job no MECH 2157/02), prepare key and assemble
onto the shaft.
4. MECH 2157/04 To prepare a wooden pattern as per drawing given. 1,5
5. MECH 2157/05 To prepare a sand mould using the pattern manufactured 1,5
in Job No. MECH 2157/04 and cast the same.
6. MECH 2157/06 To prepare a sheet metal fabricated component as per 1,6
given drawing.
7. MECH 2157/07 To prepare a chisel from a hexagonal bar. 1,6
8. MECH 2157/08 To prepare a sheet metal fabricated component using TIG, 1,4
MIG and SPOT Welding.
Reference books:
1. “Elements of Workshop Technology” Vol 1 &2, Hajra Choudhury, Media Promoters &
Publishers Pvt. Ltd.
2. “A course in Workshop Technology” Vol 1 & 2, B. S. Raghuwanshi, Dhanpat Rai & Co.
3. Workshop Technology (Vol- I and II) – Chapman, Viva Books Privet Limited.
4. Workshop Technology – R.S Khurmi, J.K Gupta , S Chand & Company Ltd.
5. Manufacturing Technology Vol – I and II – P. N Rao, Tata McGrawHill House.
Name of the jobs carried out during the semester
Shop
Sl. No. Job No Job Title
Name
To prepare a sample as per the Drg. No.
1. MECH/2113/2157/1 MECH 2113/2157/1 using various
operations in Lathe.
Machine To cut a spur gear in a horizontal Milling

2. Shop MECH/2113/2157/2
Machine with the help of Form tool cutter.
3. MECH/2113/2157/3 To Assemble a spur gear onto a shaft.
Carpentry To prepare a wooden pattern of pipe with

4. MECH/2113/2157/4
Shop flange.
To prepare a sand mould using the wooden

Foundry
5. MECH/2113/2157/5 pattern of a flanged pipe and make an AL
Shop
casting.
Sheet To prepare an Air Conditioning duct from

6. Metal MECH/2113/2157/6 GI sheet as per Drg. No. MECH
Shop 2113/2157/06.
Welding Joining of two mild steel plates by TIG & MIG

7. MECH/2113/2157/7
Shop welding process.
To prepare a chisel from a Hexagonal MS

Smithy
8. MECH/2113/2157/8 Bar as per Drg. No. MECH 2113/08 by
Shop
forging operation.
Paper Name: Workshop Practice II Paper Code: MECH 2113/2157
Lesson Plan
Contact
Day Job No Job Title Hours
Remarks
To prepare a sample as per the 6 hours

Drg. No. MECH 2113/2157/1
1 MECH/2113/2157/1
using various operations in
Lathe.
3 hours
To cut a spur gear in a
horizontal Milling Machine
2 MECH/2113/2157/2
with the help of Form tool
cutter.
3 hours
To Assemble a spur gear onto a
3 MECH/2113/2157/3
shaft.
3 hours
To prepare a wooden pattern of
4 MECH/2113/2157/4
pipe with flange.
3 hours
To prepare a sand mould using
5 MECH/2113/2157/5 the wooden pattern of a flanged
pipe and make an AL casting.
3 hours
To prepare an Air Conditioning
6 MECH/2113/2157/6 duct from GI sheet as per Drg.
No. MECH 2113/2157/06.
3 hours
Joining of two mild steel plates
7 MECH/2113/2157/7 by TIG & MIG welding
process.
3 hours
To prepare a chisel from a
Hexagonal MS Bar as per Drg.
8 MECH/2113/2157/8
No. MECH 2113/08 by forging
operation.
DEPARTMENT OF MECHNICAL ENGINEERING
WORKSHOP / MANUFACTURING PRACTICES (MECH 2113/2157)
WORK INSTRUCTION SHEET
MACHINE SHOP
LATHE
Introduction: In a machine shop, metals are cut to shape on different machine tools. A lathe is used to cut
and shape the metal by revolving the work against a cutting tool. The work is clamped either in a chuck,
fitted on to the lathe spindle or in‐between the centers. The cutting tool is fixed in a tool post, mounted on a
movable carriage that is positioned on the lathe bed. The cutting tool can be fed on to the work, either
lengthwise or cross‐wise. While turning, the chuck rotates in counter‐clockwise direction, when viewed
from the tail stock end.
Tools used:
Specification
Types of Tool Name of Tools Materials of
Size
Construction
Centre Lathe ( Head Largest work diameter that can

stock, Tail stock, be swung over the lathe bed.
Carriage, Saddle, Cross Shape of bed ways and horse
A. Machine Tool Slide, Compound rest, power of the driving motor. Cast Iron Body,
Tool post, Tool holder, Distance between head stock
Lead Screw, Feed Rod, and tail stock center.
Centre’s) Length of the bed.
Three Jaw Chuck
Four Jaw Chuck
Face Plate
B. Holding Tools
Lathe dogs and driving
Steady rest and follower
rest
Carbon steel or tool steel
or high speed steel (18-
C. Cutting Tool Single point cutting tool 4-1 HSS) or Carbide
tipped tools fixed in tool
holders
Inside Caliper
Outside Caliper
D. Measuring
Vernier Caliper
Tool
Micrometer
Steel Rule
Cutting parameters
I. Cutting Speed: It is defined as the speed at which the material is removed and is specified in meters per
minute. Ti depends upon the work piece material, feed, depth of cut, type of operation and so many other
cutting conditions. It is calculated from the relation,
Spindle speed (RPM) = cutting speed x 1000 / (πD) Where D is the work piece diameter in mm.
II. Feed Rate: It is the distance traversed by the tool along the bed, during one revolution of the work. Its value
depends upon the depth of cut and surface finish of the work desired.
III. Depth of Cut: It is the movement of the tip of the cutting tool, from the surface of the work piece and
perpendicular to the lathe axis. Its value depends upon the nature of operation like rough turning or finish
turning.
Cutting tool geometry
A single point cutting tool used on lathe may be considered as a simple wedge.
Figure 1: Common turning tools
Tool geometry
LATHE OPERATIONS
I. Turning: Cylindrical shapes, both external and internal, are produced by turning operation. Turning
is the process in which the material is removed by a traversing cutting tool, from the surface of a
rotating work piece. The operation used for machining internal surfaces is often called the boring
operation in which a hole previously drilled is enlarged.
For turning long work, first it should be faced and center drilled at one end and then supported by
means of the tail‐stock centre.
II. Taper Turning: A taper is defined as the uniform change in the diameter of a work piece, measured
along its length. It is expressed as a ratio of the difference in diameters to the length. It is also
expressed in degrees of half the included (taper) angle.
Taper turning refers to the production of a conical surface, on the work piece on a lathe.
Short steep tapers may be cut on a lathe by swiveling the compound rest to the required angle. Here,
the cutting tool is fed by means of the compound slide feed handle. The work piece is rotated in a
chuck or face plate or between centers.
III. Facing: Facing is a machining operation, performed to make the end surface of the work piece, flat
and perpendicular to the axis of rotation. For this, the work piece may be held in a chuck and rotated
about the lathe axis. A facing tool is fed perpendicular to the axis of the lathe. The tool is slightly
inclined towards the end of the work piece.
IV. Boring: Boring is enlarging a hole and is used when correct size drill is not available. However, it
should be noted that boring cannot make a hole.
V. Drilling: Holes that are axially located in cylindrical parts are produced by drilling operation, using
a twist drill. For this, the work piece is rotated in a chuck or face plate. The tail stock spindle has a
standard taper. The drill bit is fitted into the tail stock spindle directly or through drill chuck. The tail
stock is then moved over the bed and clamped on it near the work. When the job rotates, the drill bit
is fed into the work by turning the tail stock hand wheel.
VI. Knurling: It is the process of embossing a diamond shaped regular pattern on the surface of a work
piece using a special knurling tool. This tool consists of a set of hardened steel rollers in a holder
with the teeth cut on their surface in a definite pattern. The tool is held rigidly on the tool post and
the rollers are pressed against the revolving work piece to squeeze the metal against the multiple
cutting edges. The purpose of knurling is to provide an effective gripping surface on a work piece to
prevent it from slipping when operated by hand.
VII. Threading: Threading is nothing but cutting helical groove on a work piece. Threads may be cut
either on the internal or external cylindrical surfaces. A specially shaped cutting tool, known as
thread cutting tool, is used for this purpose. Thread cutting in a lathe is performed by traversing the
cutting tool at a definite rate, in proportion to the rate at which the work revolves.
VIII. Chamfering: It is the operation of beveling the extreme end of a work piece. Chamfer is provided
for better look, to enable nut to pass freely on threaded work piece, to remove burrs and protect the
end of the work piece from being damaged.
Operations of Lathe
JOB NO. MECH 2113/2157/01
Name of the Job: To prepare a sample as per the Drg. No. MECH 2113/2157/1 using various operations in
Lathe
Aim : To 1. study anatomy of a standard Lathe.
2. specify a Lathe.
3. describe various operations done in a Lathe.
4. understand types of Cutting tool(single point cutting tool , Multi-point cutting tool) and
describe tool geometry.
5. specify cutting speed , feed and depth of cut.
6. prepare a component as per Drg. No. MECH 2113/2157/1.
7. make an inspection report after making the component.
8. discuss various safety norms that needs to be observed .
Drawing of the job:
(All dimensions are in mm)

Drg No. MECH 2113/2157/01
Raw Materials: Mild steel bar.

Raw material size: Mild steel bar of 35mm diameter and 120 mm length.
Tools Required: Lathe machine, Mild steel bar, right hand cutting tool, box key or tool post key, chuck
key, steel rule, Vernier caliper, outside calipers.
Sequence of operation:
(i) MS bar of 25 mm dia and about 110 mm long is taken
(ii) Workpiece is securely held in chuck ( either in self centering chuck or in 4 jaw chuck)
(iii) Tool is held securely in tool post and centering is done .
(iv) Suitable spindle speed is chosen .
(v) Now the facing is done for the face 1.
(vi) Then the turning is done in steps and the diameter of the job is reduced to 20 mm.
(vii) Now the job is taken out from the chuck and the machined portion of the job is held in the
chuck and the second facing operation on the other side is done. Then turning operation is
done to reduce the diameter to 20 mm.
(viii) Now the knurling operation is done upto a length of 35 mm from the tail stock end.
(ix) Next the knurled portion is held at the chuck and the step down turning (Ø=16mm) is done
for a length of 20 mm.
(x) Now the turning is done from right hand side towards left for a length of 30mm and the
diameter is reduced to 14 mm.
(xi) Now the taper angle is calculated and the compound rest is swivelled to the calculated angle
and the taper turning is done.
(xii) Next the undercutting is done to 12 mm dia for a length of 10 mm.
(xiii) Thread cutting is done for a length of 20 mm.
(xiv) Job is taken out from the machine and an inpection report is made to ascertain the accuracy
of the part manufactured.
Questions:
1. Discuss the following components of a Lathe especially the following components : (a) Head Stock
(b) Tail Stock (c) Carriage (d) Cross slide (e) Tool post (f)Lead Screw (g) compound rest (h) Bed
2. Lathe specification (a) Height of dead centres from the bed. (b) Distance between two dead centres
(c) No of spindle speed available (d) Horse Power of Motor(e) Height of bed from its base.(f) Type
of chuck.
3. Describe with the help of a diagram various operations that may be performed in a standard
Lathe.(a) Straight Turning (b) Taper Turning (c) Facing (c) Chamfering.(d) Knurling (e) Grooving (f)
Thread cutting (g) Eccentric Turning
4. Define single point cutting tool geometry.

5. Define cutting speed , feed,and depth of cut.
6. Write the common safety measures that needs to be followed while machining.
INSPECTION REPORT
Name of the Part : Threaded Spindle Drawing No : MECH 2113/2157/01
Qty Produced: 1x Quantity Checked : 1 x
Inspected By: Checked By:
Sr. Drawing Measured Remarks Sr. Drawing Measured Remarks

No. Dimension Dimension No. Dimension Dimension
1. 8.
2. 9.
3. 10.
4. 11.
5.
6.
7.
WORKSHOP / MANUFACTURING PRACTICES (MECH1051)
MILLING
Milling is a metal removal process (machining) in which material is removed from work piece in the form of chips
by the application of a rotary cutting tool, called milling cutter (multipoint cutting tool), having multiple nos. of
cutting teeth on its periphery. With this process we can make different types of configuration on work piece.
Generally, the milling cutter is given cutting motion while the work piece is given feed. Depending upon the
direction of feed and cutting motion we can classify milling into two types.
1. Up milling (Conventional milling) in which cutting tip and the work piece moves in opposite direction to
each other.
2. Down milling (Climb milling) in which cutting tip and the work piece moves in the same direction (seems
like cutter is climbing on work piece.)
Milling machine:
Milling machine is a machine tool where milling is done.
A knee type horizontal arbor milling machine is shown in figure below. The parts of milling machine are as follow:
1. Milling arbor to hold the milling cutter.
2. Arbor support
3. Overarm
4. Machine table on which the job and job holding devices are mounted to provide feed.
5. Saddle
6. Power drive with speed and feed gear box to provide power and motions to tool and work.
7. Knee which moves up and down.
8. Column with base which is main structural body.
HORIZONTAL ARBOUR MILLING MACHINE
VERTICAL MILLING MACHINE
JOB NO. MECH 2113/2157/02
Name of the Job: To cut a spur gear in a horizontal Milling Machine with the help of Form tool cutter
Aim : To
1. study anatomy of a standard Horizontal Milling Machine
2. specify a standard horizontal milling machine
3. describe various operations done in a Standard Horizontal Milling Machine
4. understand types of Cutting tool(single point cutting tool , Multi-point cutting tool) and
describe tool geometry
5. specify cutting speed , feed and depth of cut
6. Cut a spur gear from the blank given
Drawing:
Raw Materials: Gear blank of mild steel
Tools Required: Steel rule, Vernier caliper, Outside caliper.
Machine tool used: Horizontal milling machine
Cutting tool used: Milling Cutter (HSS)

Components of (a) Horizontal milling machine and (b) Vertical milling machine
Produced parts by a Milling Machine
Up Milling (Conventional Milling) and Down Milling (Climb Milling)

Face Milling
Straddle Milling and Form Milling
Gear Cutting
Thread Milling
Milling Cutter
Cutting speed, feed and depth of cut:

Gear Cutting Procedure
The gear blank is mounted on a mandrel which is supported between the center of the dividing head and
one more center at the other end, as shown in fig. At a time one tooth space is cut by the milling cutter,
and a dividing head is used to index the job to the next required tooth space. The cutter is chosen
according to the module (or DP) and number of teeth of the gear to be cut. This cutter is mounted on the
milling arbor. Before the gear can be cut, it is necessary to have the cutter centred accurately relative to
the gear holding mandrel. One way is to adjust the machine table vertically and horizontally until one
corner of the cutter just touches the mandrel on one side. Both the dials (of the table and the knee) are then
set to zero. The table is then adjusted for the cutter to just touch on the other side of the mandrel with
vertical dial showing zero. The reading of the horizontal feed screw is read. This reading divided by two
gives the central position of the mandrel relative to the cutter. When the table is set centrally in this
manner it should be locked in that position. The table is then fed vertically so that the blank just touches
the cutter. The vertical dial is then set to zero. This is required to give the depth of cut on the job. With
these settings the machine can be started and traversed along the axis of the job to cut the tooth over the
whole width of the gear. Depth is increased slowly until it reaches the full depth of the tooth. With the
depth setting the backlash of the gear can be controlled suitably. After one tooth space is cut, the blank is
indexed through 1/z revolution by means of the dividing head, and the process is repeated until all the
teeth are cut.
Spur Gear Terminology

Calculation
Recommended series of module (mm):
Choice-I 1 1.25 1.5 2 2.5 3 4

Preferred 5 6 8 10 12 16 20
Choice-II 1.125 1.375 1.75 2.25 2.75 3.5

4.5
Preferred 5.5 7 9 11 14 18
Z = No. of teeth = 23
m = module = 2 mm
Blank Diameter = (Z + 2) m
= (23 + 2) 2 =
50 mm
Tooth Depth = 2.25 m
= 2.25 * 2 =
4.5 mm
Indexing Calculation = 40 / Z = 40 / 23 = 1 17/23
Spur Gear
Addendum (ha)=(m) Dedendum (hf)=(1.25m)
Clearance (c)=(0.25m) Working depth (hk)=(2m)
Whole dept (h)=(2.25m) Tooth thickness (s)=(1.5708m)
PROCEDURE:
Calculate the gear tooth proportions.

Blank diameter =(Z+2)m
Tooth depth = 2.25 m
= 1.5708m where,
Tooth width
Z=Number of teeth required

m= module Indexing calculation
Index crank movement= 40/Z
JOB NO. MECH 2113/2157/03
Name of the Job: To Assemble a spur gear onto a shaft.
Aim: To
1. make a key way slot in the spur gear with special cutting tool in shaping machine.
2. turn a shaft with proper tolerance.
3. make a keyway in a milling machine.
4. prepare a suitable key for assembly.
5. assemble gear onto the shaft.
Drawing:
Spur Gear Shaft Key
Assembled view of the spur gear into a shaft

Assembled front view of the spur gear into a shaft
Sequence of Operation:
1. Measure the inside diameter of the spur gear.

2. Turn a shaft with tolerance - 0.2 mm.
3. Cut a key way onto the shaft by end milling cutter.
4. Cut a keyway in the spur gear.
5. Prepare a suitable rectangular key in surface grinding machine.
6. Fix the spur gear onto the shaft.
7. Place the key in the right location and drive the key with hammer.
8. Check the rigidity of the assembly.
Questions:
1. (A) Discuss the following components of a Standard Horizontal Milling Machine especially the
following components : (a) Base (b) Column (c) Knee (d) Table (e) Spindle (f) Arbor.
2. Standard Horizontal Milling Machine specification (a) Table size Table length x width (b)
Maximum travel of longitudinal, cross and vertical travel of the bed (c) Motor power (d) Speed
selection range (e) Milling machine attachments.
3. Describe with the help of a diagram various operations that may be performed in a Standard
Horizontal Milling Machine.(a) Plain Milling (b) Face Milling (c) Side Milling (c) Straddle
Milling (d) Form Miliing (e) Gear Cutting (f) Thread Milling.
Foundry
Introduction: Foundry is a shop where metal casting is done. It involves two processes, first one is
moulding and then casting. In moulding a mould is made with the help of a pattern which resembles the
job. Molten metal is poured and then solidifies to give the product.
PATTERN
A pattern is a model or the replica of the object (to be casted). It is embedded in molding sand and
suitable ramming of molding sand around the pattern is made. The pattern is then withdrawn for
generating cavity (known as mold) in molding sand.
Common pattern materials
The common materials used for making patterns are wood, metal, plastic, plaster, wax or Mercury.
Types of pattern
The types of the pattern and the description of each are given as under.
1. One piece or solid pattern 2. Two piece or split pattern
3. Cope and drag pattern 4. Three-piece or multi- piece pattern
5. Loose piece pattern 6. Match plate pattern
7. Follow board pattern 8. Gated pattern
9. Sweep pattern 10. Skeleton pattern
11. Segmental or part pattern
1. Single-piece or solid pattern: Solid pattern is made of single piece without joints, partings lines
or loose pieces. It is the simplest form of the pattern. Typical single piece pattern is shown in Fig.
10.1.
2. Two-piece or split pattern: When solid pattern is difficult for withdrawal from the mold cavity,
then solid pattern is split in two parts. Split pattern is made in two pieces which are joined at the
parting line by means of dowel pins. The splitting at the parting line is done to facilitate the
withdrawal of the pattern. A typical example is shown in Fig. 10.2
Fig 10.1 Single Piece Pattern Fig 10.2 Two Piece Pattern
Pattern allowances
Draft or Taper Allowance
By draft is meant the taper provided by the pattern maker on all vertical surfaces of the pattern so that it
can be removed from the sand without tearing away the sides of the sand mold and without excessive
rapping by the molder shows a pattern having no draft allowance being removed from the pattern. In this
case, till the pattern is completely lifted out, its sides will remain in contact with the walls of the mold,
thus tending to break it is an illustration of a pattern having proper draft allowance. Here, the moment the
pattern lifting commences, all of its surfaces are well away from the sand surface. Thus the pattern can be
removed without damaging the mold cavity.
Pattern having Draft on Vertical Edges
Draft allowance varies with the complexity of the sand job. But in general inner details of the
pattern require higher draft than outer surfaces. The amount of draft depends upon the length of
the vertical side of the pattern to be extracted; the intricacy of the pattern; the method of
molding; and pattern material.
Draft Allowances of Various Metals

Machining or Finish Allowance
The finish and accuracy achieved in sand casting are generally poor and therefore when the
casting is functionally required to be of good surface finish or dimensionally accurate, it is
generally achieved by subsequent machining. Machining or finish allowances are therefore
added in the pattern dimension. The amount of machining allowance to be provided for is
affected by the method of molding and casting used viz. hand molding or machine molding, sand
casting or metal mold casting. The amount of machining allowance is also affected by the size
and shape of the casting; the casting orientation; the metal; and the degree of accuracy and finish
required.
Machining Allowances of Various Metals
Distortion or Camber Allowance
Sometimes castings get distorted, during solidification, due to their typical shape. For example, if
the casting has the form of the letter U, V, T, or L etc. it will tend to contract at the closed end
causing the vertical legs to look slightly inclined. This can be prevented by making the legs of
the U, V, T, or L shaped pattern converge slightly (inward) so that the casting after distortion
will have its sides vertical.
The distortion in casting may occur due to internal stresses. These internal stresses are caused on
account of unequal cooling of different section of the casting and hindered contraction. Measure
taken to prevent the distortion in casting include:
i. Modification of casting design

ii. Providing sufficient machining allowance to cover the distortion affect
iii. Providing suitable allowance on the pattern, called camber or distortion allowance
(inverse reflection)
Distortions in Casting
Rapping Allowance
Before the withdrawal from the sand mold, the pattern is rapped all around the vertical faces to
enlarge the mold cavity slightly, which facilitate its removal. Since it enlarges the final casting
made, it is desirable that the original pattern dimension should be reduced to account for this
increase. There is no sure way of quantifying this allowance, since it is highly dependent on the
foundry personnel practice involved. It is a negative allowance and is to be applied only to those
dimensions that are parallel to the parting plane.
Tools/equipments used
Specification
Types of Tools Name of Tools
Size Material of Construction
Cast Iron Frame
Jaw Width / Wide – 7’’ / 150mm
Carpenter’s Vice Plated Steel Screw and Slide
Opening – 6’’ / 130mm
A. Holding bar
Tools Ductile iron, hardened steel
C-Clamp Opening capacity and load capacity cup point set screw and
locknut
12” (Maximum measureable length)
Steel Rule Stainless steel
Least Count
B. Measuring
Maximum measureable length
Tool Steel Tape Cold rolled steel strip
Least Count
Try Square 6” (Length of the blade) HCS/ stainless steel
Marking Gauge Length of the stem Wood
C. Marking
Mortise Gauge length of the stem wood
Tool
Compass and Divider maximum diameter that can be drawn High carbon steel
Jack Plane [Metal
D. Planning
Jack Plane / Wooden Length and blade width Tool steel / Wood
Tool
Jack Plane]
Length of the blade and teeth per unit
Rip Saw Tool steel
E. Cutting Tool length
Firmer Chisel Blade width and length HCS / tool steel
Mortise Chisel Blade width and length HCS / tool steel
Maximum shank diameter of the of
Carpenters Brace
the spindle
F. Boring Tool
Auger Bit
Gimlet Diameter of shank high carbon steel
Wooden Mallet wood
G. Striking
Claw Hammer weight Forged high carbon steel
Tool
Ball Peen Hammer 200 gm (Weight) Forged high carbon steel
Screw Driver Type and length Tool steel
H.
Miscellaneous Wood Rasp File Length HCS / Tool steel
Pincer length forged steel
CASTING:
Casting is very ancient but fundamental manufacturing process and is able to manufacture
different types of product solid or hollow. For hollow products usually a core is used.
Application of cast products includes home wares, engine parts of automobiles, parts of
machines etc. Generally cast products need further machining operations because of several
defects due to casting. By adjusting the several parameters and the process of casting these
defects can be minimized or eliminated.
Some of these casting defects are

1. Blow hole
2. Porosity
3. Cold shut
4. Misrun
5. Mould shift
6. Drop
7. Fusion
8. Buckle
9. Cut or wash
Core and Core Prints
Castings are often required to have holes, recesses, etc. of various sizes and shapes. These
impressions can be obtained by using cores. So where coring is required, provision should be
made to support the core inside the mold cavity. Core prints are used to serve this purpose. The
core print is an added projection on the pattern and it forms a seat in the mold on which the sand
core rests during pouring of the mold. The core print must be of adequate size and shape so that
it can support the weight of the core during the casting operation. Depending upon the
requirement a core can be placed horizontal, vertical and can be hanged inside the mold cavity. A
typical job, its pattern and the mold cavity with core and core print is shown.
A Typical Job, its Pattern and the Mold Cavity
Molding sand
The general sources of receiving molding sands are the beds of sea, rivers, lakes, granular
elements of rocks, and deserts.
Molding sands may be of two types namely natural or synthetic. Natural molding sands contain
sufficient binder. Whereas synthetic molding sands are prepared artificially using basic sand
molding constituents (silica sand in 88-92%, binder 6-12%, water or moisture content 3-6%) and
other additives in proper proportion by weight with perfect mixing and mulling in suitable
equipments.
Binder
In general, the binders can be either inorganic or organic substance. The inorganic group
includes clay sodium silicate and port land cement etc. In foundry shop, the clay acts as binder
which may be Kaolonite, Ball Clay, Fire Clay, Limonite, Fuller’s earth and Bentonite. Binders
included in the organic group are dextrin, molasses, cereal binders, linseed oil and resins like
phenol formaldehyde, urea formaldehyde etc. Organic binders are mostly used for core making.
Among all the above binders, the bentonite variety of clay is the most common. However, this
clay alone cannot develop bonds among sand grins without the presence of moisture in molding
sand and core sand.
Additives
Additives are the materials generally added to the molding and core sand mixture to develop
some special property in the sand. Some common used additives for enhancing the properties of
molding and core sands are discussed as under.
1. Coal dust: Coal dust is added mainly for producing a reducing atmosphere during
casting.
2. Corn flour: It belongs to the starch family of carbohydrates and is used to increase the
collapsibility of the molding and core sand
3. Dextrin: Dextrin belongs to starch family of carbohydrates that behaves also in a manner
similar to that of the corn flour. It increases dry strength of the molds.
4. Sea coal: Sea coal is the fine powdered bituminous coal which positions its place among
the pores of the silica sand grains in molding sand and core sand
5. Wood flour: This is a fibrous material mixed with a granular material like sand; its
relatively long thin fibers prevent the sand grains from making contact with one another.
6. Silica flour: It is called as pulverized silica and it can be easily added up to 3% which
increases the hot strength and finish on the surfaces of the molds and cores
Kinds of moulding sand
Molding sands can also be classified according to their use into number of varieties which are
described below.
1. Green sand: Green sand is also known as tempered or natural sand which is a just
prepared mixture of silica sand with 18 to 30 percent clay, having moisture content from
6 to 8%. The clay and water furnish the bond for green sand. It is fine, soft, light, and
porous.
2. Dry sand: Green sand that has been dried or baked in suitable oven after the making
mold and cores, is called dry sand. It possesses more strength, rigidity and thermal
stability.
3. Loam sand: Loam is mixture of sand and clay with water to a thin plastic paste. Loam
sand possesses high clay as much as 30-50% and 18% water.
4. Facing sand: Facing sand is just prepared and forms the face of the mould. It is directly
next to the surface of the pattern and it comes into contact molten metal when the mould
is poured. Initial coating around the pattern and hence for mold surface is given by this
sand. This sand is subjected severest conditions and must possess, therefore, high
strength refractoriness.
5. Backing sand: Backing sand or floor sand is used to back up the facing sand and is used
to fill the whole volume of the molding flask.
6. Parting sand: Parting sand without binder and moisture is used to keep the green sand
not to stick to the pattern and also to allow the sand on the parting surface the cope and
drag to separate without clinging
7. Core sand: Core sand is used for making cores and it is sometimes also known as oil
sand. This is highly rich silica sand mixed with oil binders such as core oil which
composed of linseed oil, resin, light mineral oil and other bind materials.
PROPERTIES OF MOULDING SAND
The basic properties required in molding sand and core sand are described as under.
1. Refractoriness: Refractoriness is defined as the ability of molding sand to withstand

high temperatures without breaking down or fusing thus facilitating to get sound casting.
It is a highly important characteristic of molding sands. Refractoriness can only be
increased to a limited extent
2. Permeability: It is also termed as porosity of the molding sand in order to allow the
escape of any air, gases or moisture present or generated in the mould when the molten
metal is poured into it. All these gaseous generated during pouring and solidification
process must escape otherwise the casting becomes defective
3. Cohesiveness: It is property of molding sand by virtue which the sand grain particles
interact and attract each other within the molding sand
4. Green strength: The green sand after water has been mixed into it, must have sufficient
strength and toughness to permit the making and handling of the mould. For this, the sand
grains must be adhesive, i.e. thev must be capable of attaching themselves to another
body
5. Dry strength: As soon as the molten metal is poured into the mould, the moisture in the
sand layer adjacent to the hot metal gets evaporated and this dry sand layer must have
sufficient strength to its shape in order to avoid erosion of mould wall during the flow of
molten metal
6. Flowability or plasticity: It is the ability of the sand to get compacted and behave like a
fluid. It will flow uniformly to all portions of pattern when rammed and distribute the
ramming pressure evenly all around in all directions
7. Adhesiveness: It is property of molding sand to get stick or adhere with foreign material
such sticking of molding sand with inner wall of molding box
8. Collapsibility: After the molten metal in the mould gets solidified, the sand mould must
be collapsible so that free contraction of the metal occurs and this would naturally avoid
the tearing or cracking of the contracting metal.
Tools/equipments used
1. Flask 6. Rammer 13. Slick

a. Cope 7. Sprue pin 14. Trowel
b. Drag 8. Riser pin 15. Muffle furnace
2. Pattern 9. Vent rod 16. Ladle
3. Moulding board 10. Draw spike 17. Chaplet
4. Shovel 11. Gate cutter 18. Chill
5. Hand riddle 12. Lifter 19. Tong
Moulding Flask Hand Riddle
Rammer Trowl
Shovel
Sprue pin Lifter Slick

Blower Vent rod
Gate cutter Draw Spike Riser pin
Muffle furnace Ladle

Job No: MECH 2113/2157/04
Name of the Job: To prepare a wooden pattern of pipe with flange.

Aim: To
1. Study about Pattern.
2. Consider factors for selection of Pattern material.
3. Describe various types of Pattern materials.
4. State advantages and limitations of Wooden Patterns.
5. Discuss different types of Patterns.
6. Understand different types of Pattern Allowances.
7. Understand the use of core.
8. Prepare the pattern as per Drg. No. MECH 2113/2157/4.
9. Prepare an Inspection report.
10. Discuss various safety norms that need to be observed.
Job Diagram:
10 Deg. draft both sides PATTERN
Line of Split
Φ 80 mm ± 0.3
Φ 50 mm ± 0.3
Φ 30 mm ± 0.3 Φ 30 mm ± 0.3
5 mm ± 0.2
20 mm ± 0.5 70 mm ± 0.5 20 mm ± 0.5
110 mm ± 0.5
Flanged Pipe
Drg. No. MECH 2113/2157/04
Raw Material: Wood
Tools Required: Wood working lathe, Rip saw, rasp file, scale, outside calliper
1. Marking and parting off required length, with necessary cutting allowance.
2. Planning all surfaces for parallelism.
3. Hold the job in a four jaw chuck of a wood working lathe.
4. Perform the job centering.
5. Perform the tool centering.
6. Turn the workpiece according to the dimensions in the lathe.
7. Use rasp file to make the surface smoother.
8. Finish the work using emery paper.
Precautions:
1. The workpiece should be held in the vice while performing cutting operation.
2. The workpiece should be held rigidly in the chuck of lathe.
3. Optimum machining conditions should be maintained.
Job No: MECH 2113/2157/05
Name of the Job: To prepare a sand mould using the wooden pattern of a flanged pipe and make
an AL casting.
Aim: To
1. Study about preparation of sand. (Sand, Bentonite, moisture, molasses, clay)
2. List various properties of a good sand mould (Permeability, Grain Fineness
Number, Green shear strength, Mould hardness)
3. List the names of various tools used in Foundry shop.
4. List the various foundry terminologies.( Cope box, Drag box , Sprue pin , Riser ,
vent holes etc)
5. Study mould making procedure and prepare the mould.
6. Prepare the core and make it dry.
7. Cast the flanged pipe.
8. Inspect for visual casting defects, if any.
9. Discuss various safety norms that need to be observed.
Job Diagram:
10 Deg. draft both sides
Φ 80 mm
Φ 50 mm
Φ 40 mm
5 mm
70 mm
Drg. No. MECH 2113/2157/5
Tools Required: Pattern, Moulding Flask, Moulding Board, Rammer, Sprue Pin, Riser Pin,
Shovel, Hand Riddle, Draw Spike, Vent Rod, Gate Cutter, Lifter, Slick,
Trowel, Muffle Furnace, Ladle, Tong, Aluminium chips.
Sequence of operations:
1. Sand preparation
2. Placing the mould flask(drag) on the moulding board/ moulding platform
3. Placing the split pattern at the centre of the moulding flask
4. Ramming the drag
5. Placing the pattern at the centre of the moulding flask (Cope box)
6. Placing runner and riser
7. Ramming the cope
8. Removal of the pattern, runner, riser
9. Gate cutting
Procedure: Mould Making

1. First a bottom board is placed either on the molding platform or on the floor, making the
surface even.
2. The drag molding flask is kept upside down on the bottom board along with the drag part
of the pattern at the centre of the flask on the board.
3. Dry facing sand is sprinkled over the board and pattern to provide a non-sticky layer.
4. Freshly prepared molding sand of requisite quality is now poured into the drag and on the
split-pattern to a thickness of 30 to 50 mm.
5. Rest of the drag flask is completely filled with the backup sand and uniformly rammed to
compact the sand.
6. After the ramming is over, the excess sand in the flask is completely scraped using a flat
bar to the level of the flask edges.
7. Now with a vent wire which is a wire of 1 to 2 mm diameter with a pointed end, vent
holes are in the drag to the full depth of the flask as well as to the pattern to facilitate the
removal of gases during casting solidification. This completes the preparation of the drag.
8. Now finished drag flask is rolled over to the bottom board exposing the pattern.
9. Using a slick, the edges of sand around the pattern is repaired and cope half of the pattern
is placed over the drag pattern, aligning it with the help of dowel pins
10. The cope flask on the top of the drag is located aligning again with the help of the pins of
the drag box.
11. Dry parting sand is sprinkled all over the drag surface and on the pattern
12. Sprue of the gating system for making the sprue passage is located at a small distance of
about 50 mm from the pattern. The sprue base, runners and ingates are also located as
shown risers are also placed. Freshly prepared facing sand is poured around the pattern.
13. The moulding sand is then poured in the cope box. The sand is adequately rammed,
excess sand is scraped and vent holes are made all over in the cope as in the drag.
14. The sprue and the riser are carefully withdrawn from the flask
15. Later the pouring basin is cut near the top of the sprue.
16. The cope is separated from the drag any loose sand on the cope and drag interface is
blown off with the help of the bellows.
17. Now the cope and the drag pattern halves are withdrawn by using the draw spikes and
rapping the pattern all around to slightly enlarge the mould cavity so that the walls are not
spoiled by the withdrawing pattern.
18. The runners and gates are to be removed or to be cut in the mould carefully without
spoiling the mould.
19. Any excess or loose sand is applied in the runners and mould cavity is blown away using
the bellows.
20. Now the facing paste is applied all over the mould cavity and the runners which would
give the finished casting a good surface finish.
21. A dry sand core is prepared using a core box. After suitable baking, it is placed in the
mould cavity.
The cope is placed back on the drag taking care of the alignment of the two by means of the
pins.
Questions:
1. What if vent holes are not provided in a mould?
2. What is the function of core?
3. What is the function of a riser?
4. What is the relation between degree of ramming and Permeability?
WORKSHOP PRACTICE II (MECH 2113/2157)
LAB MANUAL
SHEET METAL SHOP

Introduction: Sheet metal work has its own significance in the engineering work. Many products, which fulfill the
household needs, decoration work and various engineering articles, are produced from sheet metals. Common
examples of sheet metal work are hoopers, canisters, guards, covers, pipes, hoods, funnels, bends, boxes etc. Such
articles are found less expensive, lighter in weight and in some cases sheet metal products replace the use of castings
or forgings.
Types of sheet metals:
MS Sheet
CR Sheet
HR Sheet
(CRCA)
DD (Deep EDD (Extra

O (Ordinary) D (Drawing)
Drawing) Deep Drawing)
Metals used in sheet metal work:
A metal plate of thickness less than 4 mm is considered as sheet. The size of the sheet is specified by its
length, width and thickness in mm. In British system, the thickness of sheet is specified by a number called
Standard Wire Gauge (SWG). The commonly used gauge numbers and the equivalent thickness in mm are
given below
SWG
16 17 18 19 20 22 24 27 30
(No.)
Thickness
1.62 1.42 1.22 1.02 0.91 0.71 0.56 0.42 0.37

(mm)
The following metals are generally used in sheet metal work:
1. Black Iron Sheet

It is the cheapest among ail. It has a bluish-black appearance and is uncoated sheet. Being uncoated,
it corrodes rapidly. It is prepared by rolling to the desired thickness, then annealed by pleasing in a
furnace and then set aside to cool gradually. The use of this metal is limited to articles that are to be
painted or enameled such as stovepipes, tanks, pans etc.
2. Galvanized Iron
It is soft steel coated with molten zinc. This coating resist rust, improves appearances, improves
solderability, and improves water resistance. It is popularly known as G.I. sheets. Articles such as
pans, buckets, furnaces, cabinet etc. are made from Gl sheets.
3. Stainless Steel
It is an alloy of steel with nickel, chromium and traces of other metals. It has good corrosive
resistance. The cost of stainless steel is very high but tougher than Gl sheets. It is used in
kitchenware, food handling equipment, chemical plants etc.
4. Copper
It is a reddish colored metal and is extremely malleable and ductile. Copper sheets have good
corrosion resistance as well as good appearances but costs are high as compared to Gl and stainless
steel. Because of high thermal conductivity, it is used for the radiator of automobiles, domestic
heating appliances etc.
5. Aluminium
Aluminium cannot be used in its pure form, but is used in alloy form. Common additions are
copper, silicon, manganese and iron. It has many qualities like high ratio of strength to weight,
corrosion resistant qualities, and ease in fabrication and whitish in color. It is used in manufacturing
of a number of products such as refrigerator trays, household appliances, lighting fixtures, window
work, construction of airplanes and in many electrical and transportation industries.
6. Tin Plates
It is an iron sheet coated with the tin to protect it against rust. This metal has a very bright silvery
appearance and is used principally in making food containers, cans and pans.
7. Lead
It is a very soft, malleable, low melting point and possesses high resistance to acid corrosion. It is
having low mechanical strength so it is used to provide lining to the highly corrosive acid tanks. It
is also used in radiation shielding.
Tools used:
Specification
Types of Tools Name of Tools Material of
Size
Construction
Body: steel cast,
Width:
A. Holding Handle:
Bench Vice Maximum opening
Tools mild steel, Jaw plates:
between the jaws:
cast steel
12” (Maximum measureable
Steel Rule length) Stainless steel
Least Count
Maximum measureable length
Steel Tape Cold rolled steel strip
B. Measuring Least Count
Tool
Try Square 6” (Length of the blade) HCS / Stainless Steel
Vernier Caliper
Micrometer
Sheet Metal Gauge
Length: 150 to 300 mm
Scriber Hardened steel
Diameter: 3 to 5 mm.
Maximum length between
C. Marking Compass and
legs/maximum diameter that can High carbon steel
Tool Divider
be drawn
Punches Length – 3’’ / 4’’
Trammel
Hand Shear or Snip
D. Cutting Tool
Shearing Machine
Setting Hammer
Wooden Mallet Diameter: 5 cm wood
E. Striking Tool Plain steel (0.6%
Riveting Hammer 0.11 kg to .91 kg
carbon)
Raising Hammer
Rivet Set Tool steel
Hand Grooves
F.
Miscellaneous Forged piece: copper
Soldering Iron Rod: Iron
Handle: Wood
Figure1.1: Bench vice Figure2.1: Steel Rule and Steel Tape
Figure2.2: Try-square Figure 2.3: Vernier Caliper
Figure 2.4: Micrometer Figure 2.5: Sheet Metal Gauge / Wire Gauge
Figure 3.1: Scriber Figure 3.2: Divider Figure 3.3: Compass
Figure 3.4: Trammel Figure 3.5: Punches
Figure 4.1: Snip or Hand Shear Figure 4.2: Shearing Machine

Figure 5.1: Different Types of Striking Tool
Figure 6.1: Hand Grooves
Figure 6.3: Soldering Iron
Sheet metal joints:
The line of joint on a sheet metal pieces is called seam. The most common types of seams are as follows:
1. Lap seam: This is the simplest seam used in sheet metal work (Figure (a)). This consists of one edge
lapping over the other and joint is made by soldering or riveting.
2. Grooved seam: A grooved seam is made by hooking two-folded edges together and then off setting
them as shown in Figure 5.8(b). This joint is self-locking and stronger to some extent than lap seam.
3. Single seam: This seam is used to join a bottom portion to a vertical body as shown in Figure (c).
The bottom edge is hooked over the bent edge of the vertical body. This method of joint can be used
for square, rectangular or round containers.
4. Double seam: This seam is similar lo single scam with the difference that the formed edge is bent
upwards against the body as shown in Figure (d).
5. Dove-tail seam: This seam is used to connect a cylindrical piece to a flat as shown in Figure (e). The
edge of the cylindrical part to be joined is slit at short distance and is bent so that alternate pieces
come inside and outside of the joint. Permanent joint is obtained by soldering or riveting.
6. Flanged (burred) bottom seam: This seam is used to fasten the bottom of a container to its body.
The flange of a cylindrical job is often called a burr. The joint consists of a narrow flange which may
be joined to inside or outside of the vessel as shown in figure (f).
Edge Forming
For sheet metal objects strength is given to the edge and the sharpness is eliminated by folding the edge. The
common types of folding used in sheet metal work are as follows:
1. Single hem 2. Double hem 3. Wired edge

Figure shows the three types of edge folding. A wired edge consists of an edge wrapped around a steel wire
for better strength.
Joining Methods:
The fabrication of engineering systems frequently needs joining of simple components and parts. Three
types of joining methods namely mechanical joining (nuts & bolts, clamps, rivets), adhesive joining (epoxy
resins, fevicol), welding (welding, brazing and soldering) are commonly used for manufacturing variety of
engineering product/component.
Resistance Spot Welding:
In resistance welding (RW) a low voltage (typically IV) and very high current (typically 15,000 A) is passed
through the joint for a very short time (typically 0.25 s). This high amperage heats the joint, due to the
contact resistance of the joint and melts it. The pressure on the joint is continuously maintained and the
metal fuses together under this pressure. The heat generated in resistance welding can be expressed as
H = k l2 R t
Where H = the total heat generated in the work, J

l = electric current, A
t = time for which the electric current is passing through the joint, s r = the resistance of the joint,
ohms
and k = a constant to account for the heat losses from the welded joint.
The resistance of the joint, R is a complex factor to know because it is composed of
1. The resistance of the electrodes
2. The contact resistance between the electrode and the work piece
3. The contact resistance between the two work piece plates
4. The resistance of the work piece plates
The amount of heat released is directly proportional to the resistance. It is likely to be released at all of the
above-mentioned points, but the only place where a large amount of heat is to be generated to have an
effective fusion is at the interface between the two work piece plates. Therefore, the rest of the component
resistances should be made as small as possible, since the heat released at those places would not aid in the
welding.
Because of the squaring in the above, equation, the current, i needs to be precisely controlled for any proper
joint. The main requirement of the process is the low voltage and high current power supply. This is
obtained by means of a step down transformer with a provision to have different tappings on the primary
side, as required for different materials. The secondary windings are connected to the electrodes which are
made of copper to reduce their electrical resistance. The time of the electric supply needs to be closely
controlled so that the heat released is just enough to melt the joint and the subsequent fusion takes place due
to the force (forge welding) on the joint. The force required can be provided either mechanically,
hydraulically or pneumatically. To precisely control the time, sophisticated electronic timers are available.
The critical variable in a resistance welding process is the contact resistance between the two work piece
plates and their resistances themselves. The contact resistance is affected by the surface finish on the plates,
since the rougher surfaces have higher contact resistance. The contact resistance also will be affected by the
cleanliness of the surface. Oxides or other contaminants if present should be removed before attempting
resistance welding.
Procedure:
1. The two pieces to be joined by spot welding are placed between the two electrodes in the required
position.
2. Set the timer for which the current flows through the electrodes with reference to the thickness of the
plates
3. Press the foot lever, so that the movable electrode moves towards the fixed electrode.
4. This causes to develop a pressure of about 200-1000 Kg / cm2 on the sheets.
5. A low voltage and very high current is passed through the joint for a very short time. The duration of
the current flow is for about 2 sec (This high amperage heats the joint, due to contact resistance at
the joint and melts it).
6. Then the metal under electrodes pressure is squeezed and welded
7. Pressure is then released and the process is repeated until the job is completed.
JOB NO: MECH 2113/2157/06
Name of the Job: To prepare an Air Conditioning duct from GI sheet as per Drg. No. MECH
2113/2157/06.
Aim: To
1. Study different types of sheet metal.
2. Specify sheet metal (MS Sheet)
3. Describe various operations in sheet metal work
3.1. Shearing,
3.2. Deburring,
3.3. Marking,
3.4. Punching,
3.5. Bending / Folding,
4. Describe various sheet working tools,
5. Prepare an Air Conditioning duct as per Drg. No. MECH 2113/06.
6. Prepare an Inspection report.
7. Discuss general safety rules in sheet metal working shop.
Drawing of the job:
Air Conditioning Duct
Drg. No. MECH 2113/2157/06
Raw Materials: Galvanized Iron Sheet of required dimension (1 mm thick).

Tools Required: Steel rule, Flat File, Scriber, Try-square, Snips, Dot Punch and Mallet, Hand Shear, Shear
Machine, Rolling Machine, Resistance spot welding
1. The size of the given sheet is checked with steel rule.
2. Mark the measurement and make the development surface sketch diagram.
3. The layout of the Air-conditioner duct is marked on the given sheet.
4. The layout of the Air-conditioner duct is cut by using the straight snips.
5. The sheet is bent to the required shape using stakes and mallet.
6. Now the bent edges are made to overlap each other and stuck with a mallet to get the required joint.
7. Join both the ends by resistance spot welding.
Precautions:
1. Mark the dimensions carefully.

2. Care should be taken while cutting with snip.
3. Care should be taken while bending.
4. Join the the sheets carefully with the resistance spot welding machine.
Result:
The air conditioning duct is successfully made.
Questions:
1. What is resistance welding?

2. Describe the working principle of Spot Welding Process with a schematic diagram.
3. Which material is generally used for electrode in resistance spot welding?
4. Is it possible to weld to join nonconductive material by resistance spot welding process?
5. Write down the Process parameters of Spot welding.
WORKSHOP PRACTICE II (MECH 2113/2157)
LAB MANUAL
ARC WELDING
Welding is defined as a joining process that produces coalescence of materials by heating them to the
welding temperature, with or without the application of pressure or by the application of pressure alone, and
with or without the use of filler metal. Welding is employed in various applications such as construction of
Ships, buildings, bridges fabrication.
Manual metal arc welding and gas welding are the two types of welding in which heat sources are electric
arc and combustion of gases respectively. Welding can joint different types of materials in different
orientation.
Manual metal arc welding:

In metal arc welding a metal rod is used as one electrode (consumable) while the work being melted is used
as another electrode. The arc is formed between the work and the electrode. Temperature around 3600o
centigrade is generated. Molten metal is deposited in the joint and coalesces to form the joint.
Electric arc welding is “a welding process where in coalescence is produced by heating with an arc or arcs,
with or without the application of pressure and with or without the use of filler metals”. Electric arc welding
is quite versatile and able to weld under many conditions. High quality welds are produced. Metal is
deposited rapidly and it is competitive cost wise for many situations.
Electric arc welding is the most extensively used method of joining components of metallic parts, the source
of heat being an electric arc. An electric arc is a continuous stream of electrons flowing through some sort of
medium between two conductors of an electric circuit and accompanied by intense heat generation and
radiation. An electric arc for welding is obtained in the following ways:
1. Between a consumable electrode (which also supplies filler metal) and the work piece.
2. Between a non consumable electrode (carbon, graphite or tungsten etc.) and the work piece.
3. Between two non-consumable electrodes.
The most common electric arc welding method is the one in which the arc is struck between an
electrode and the work. This is called as ‘Direct arc’. The arc struck between two non consumable
electrodes adjacent to the parts being welded is called as “Independent or Indirect arc”. The metal is heated
by the indirect action (by radiation) of the arc. Due to this, the thermal efficiency of the method is poor.
To strike an arc, the electrode is brought in contact with the work at the point where the welding is to be
started, after connecting the work to the welding circuit. After a light contact, the electrode is immediately
withdrawn to a distance of from 2 to 4 mm from the work. Only a comparatively low potential difference is
required between the electrode and the work to strike an arc. From 40 to 45 V is usually sufficient for D.C.
and from 50 to 60 V for A.C. This voltage available at the output terminals of a welding set, before the arc
is struck, is known as open circuit voltage (OCV). The voltage falls after the arc is established this is
normally less than half the OCV. A stable arc can be maintained between a metal electrode and the work
metal with a voltage of 15 to 30 V while from 30 to 35V is needed to strike an arc between non consumable
electrode and the work.
The stable arc required for high quality welding can be achieved with an arc length equal to 0.6 to 0.8 of the
electrode diameter. The arc length is defined as the distance between the end of the electrode and the surface
of the molten metal on the work. When the electrode first makes contact with the job, a large short circuit
current flows. When the electrode later is immediately withdrawn, the current continues to flow in the form
of spark across the air gap so formed. Due to this, the air gap gets ionized, that is, splits into electrons and
positive ions. The lighter electrons flow from cathode to anode and the heavier positive ions flow from
anode to cathode. Thus, the air gap becomes conducting and current is able to flow across the gap in the
form of an arc.
When the lighter, high-velocity electrons strike the anode at great velocity, intense heat is generated at the
anode. Heat generated at the cathode is much less, because of the low velocity of impinging positive ions.
Thermal and luminous energy is not uniformly evolved in the welding arc. About 43 percent of the total
amount of heat is evolved on the anode and about 36 percent on the cathode. The remaining 21 per cent is
evolved by the arc.
The temperature of an electric arc depends upon the type of electrodes between which it is struck. It is about
32000C on the cathode and about 39000C on the anode for carbon electrodes and 24000C and 26000C
respectively for metal electrodes. The temperature may reach 6000 0 to 70000C in the centre of the arc. Only
from 60 to 70% of the heat is utilized an arc welding to heat up and melt the metal. The remaining 30 to
40% is dissipated into the surroundings.
Welding Joint Design:
Since welding joins metals, design for welding is chiefly concerned with joints i.e. when to use a joint, how
to weld it, where to place it, what to do and what not to do. Selection and preparation of weld joint is an
important step in the fabrication of a weldment. Selection of correct joint design is very essential if welded
members are to perform within the load service, corrosive atmosphere and safety requirements. Not only
must the product have sufficient strength to perform well under the load conditions expected but it must be
pleasing in appearance also. Proper joint design is a vital part of a welding procedure because it helps to:
1) Control distortion
2) Minimizes residual stresses
3) Facilitates good workmanship Achieve proper weld strength Reduce welding costs
4) Result in greater reliability.
The weld joint design should be such that the welds can be tested non-destructively for necessary quality
control, especially if the welds are in pressurized or contaminates and inaccessible areas. The consideration
in joint includes safety, service, quality and cost.
Types of Welding Joints:
While designing for welding it appears both logical and fundamental to first consider the various forms of
weld joints. A joint indicates the position where two or more members of a structure meet and are to be
joined by welding.
Classifications:
* Butt Joint * Edge Joint
* Tee Joint * Corner Joint
* Lap Joint
Selection of Welding Joint:
The selection of a suitable joint for a particular type of weldment depends upon the following factors:
1) Base plate thickness
2) Geometry of structure
3) Magnitude of loading
4) Type of loading, i.e. tension, shear, impact, bending etc.
5) Rate of loading (sudden or gradually applied).
The load or stress applied on a weldment may be static or dynamic. A static load places the least strain on a
weld. The most severe load is stress under dynamic or changing conditions.
1. Cost of joint preparation
2. Number of passes
3. Electrode consumption
4. Chances and magnitude of distortion
5. Ease of welding
Tungsten Inert Gas Welding (TIG Welding)
The Endeavour of welder is always to obtain a joint which is as strong as the base metal and at the same
time, the joint is as homogeneous as possible. To this end, the complete exclusion of oxygen and other gases
which interfere with the weld pool to the detriment of weld quality is very essential. In manual metal arc
welding, the use of stick electrodes does this job to some extent but not fully. In inert gas shielded arc
welding processes, a high pressure inert gas flowing around the electrode while welding would physically
displace all the atmospheric gases around the weld metal to fully protect it.
The shielding gases most commonly used are argon, helium, carbon dioxide and mixtures of them. Argon
and helium are completely inert and therefore they provide completely inert atmosphere around the puddle,
when used at sufficient pressure. Any contaminations in these gases would decrease the weld quality.
Argon is normally preferred over helium because of a number of specific advantages. It requires a lower arc
voltage, allows for easier arc starting and provides a smooth arc action. A longer arc can be maintained with
argon, since arc voltage does not vary appreciably with arc length.
It is more economical in operation. Argon is particularly useful for welding thin sheets and for out of
position welding.
The main advantage of Helium is that it can with stand the higher arc voltages. As a result it is used in the
welding where higher heat input is required, such as for thick sheets or for higher thermal conductivity
materials such as copper or aluminium. Carbon dioxide is the most economical of all the shielding gases.
Both argon and helium can be used with AC as well as DC welding power sources. However, carbon
dioxide is normally used with only DC with electrode positive.
Tungsten inert gas (TIG) welding is as inert gas shielded arc welding process using non consumable
electrode. The electrode may also contain 1 to 2% thoria mixed along with core tungsten or tungsten with
0.15 to 0.4% zirconia. The pure tungsten electrodes are less expensive but will carry less current. The
thoriated tungsten electrodes carry high currents and are more desirable because they can strike and
maintain stable arc with relative ease. The zirconia added tungsten electrodes are better than pure tungsten
but inferior to thoriated tungsten electrodes.
A typical TIG welding setup is shown in fig.
It consists of a welding torch at the centre of which is the tungsten electrode. The inert gas is supplied to the
welding zone through the annular path surrounding the tungsten electrode to effectively displace the
atmosphere around the weld puddle. The TIG welding process can be used for the joining of a number of
materials though the most common ones are aluminium, magnesium and stainless steel.
The power sources used are always the constant current type. Both DC and AC power supplies can be used
for TIG welding. When DC is used, the electrode can be negative (DCEN) or positive (DCEP). With DCEP
is normally used for welding thin metals where as fro deeper penetration welds DCEN is used. An Ac arc
welding is likely to give rise to a higher penetration than that of DCEP.
Metal Inert Gas (MIG Welding)
This process is based on the principle of developing weld by melting faying surfaces of the base metal using
heat produced by a welding arc established between base metal and a consumable electrode. Welding arc
and weld pool are well protected by a jet of shielding inactive gas coming out of the nozzle and forming a
shroud around the arc and weld. MIG weld is not considered as clean as TIG weld. Difference in cleanliness
of the weld produced by MIG and TIG welding is primarily attributed to the variation in effectiveness of
shielding gas to protect the weld pool in case of above two processes. Effectiveness of shielding in two
processes is mainly determined by two characteristics of the welding arc namely stability of the welding arc
and length of arc besides other welding related parameters such as type of shielding gas, flow rate of
shielding gas, distance between nozzle and work-price. The MIG arc is relatively longer and less stable than
TIG arc. Difference in stability of two welding arcs is primarily due to the fact that in MIG arc is established
between base metal and consumable electrode (which is consumed continuously during welding) while TIG
welding arc is established between base metal and non-consumable tungsten electrode. Consumption of the
electrode during welding slightly decreases the stability of the arc. Therefore, shielding of the weld pool in
MIGW is not as effective as in TIGW.
Metal inert gas process is similar to TIG welding except that it uses the automatically fed consumable
electrode therefore it offers high deposition rate and so it suits for good quality weld joints required for
industrial fabrication. Consumable electrode is fed automatically while torch is controlled either manual or
automatically. Therefore, this process is found more suitable for welding of comparatively thicker plates of
reactive metals (Al, Mg, Stainless steel). The quality of weld joints of these metals otherwise is adversely
affected by atmospheric gases at high temperature.
Fig. 17.1 Schematic of GMAW process showing important elements A) Welding spool, B) Shielding gas
cylinder, C) welding torch, D) base plate, E) welding power source, and F) consumable electrode.
Like TIG welding, shielding gases such as Ar, He, CO2 and their mixtures are used for protecting the
welding pool from the atmospheric gases.
JOB NO: MECH2113/2157/07
Name of the Job: Joining of two mild steel plates by TIG & MIG welding process.
Aim: To
1. Describe TIG and MIG welding.
2. Differentiate TIG and MIG welding.
3. Select TIG and MIG welding parameters.
4. Prepare a V-Butt joint using TIG & MIG welding.
5. Understand, visualize and practice of joining two metal pieces by Metal Inert Gas arc welding process.
6. Inspect the weld quality by visual inspection.
V-Butt joint
Raw Materials: Mild steel plate, 6 mm thick.
Raw Material Size: 50 mm x 60 mm x 6 mm (thick).
Arc welding equipments:
For TIG Welding For MIG Welding
 Welding transformer  Welding transformer

 Argon Gas Cylinder  CO2 Gas Cylinder
 Tungsten electrode (Non Consumable electrode)  Filler Wire (Mild Steel)
 Filler Rod  Electrode holder
 Electrode holder  Cable
 Cable  Cable Connector
 Cable Connector  Earth clamps
 Earth clamps  Chipping hammer
 Chipping hammer  Face shield- Std. Size
 Face shield- Std. Size  Hand gloves- Std. Size
 Hand gloves- Std. Size
TIG Welding-
1. Edge preparation:
To obtain sound welds, good edge preparation is a prerequisite. This involves suitably beveling the
edges, and carefully cleaning the faces to be welded from dust, sand, oil and grease. For 6 mm
thick plate single-V edge preparation is done.
2. Place the work pieces on the work table in the required position. Set the current of the machine to
100 A.
3. Fix the tungsten electrode to the electrode holder.
4. Required size of the nozzle is selected and it is fixed to the torch
5. Adjust the inert gas flow rate to the required rate.
6. Select the filler rod (same as base metals) of required diameter.
7. Touch the electrode to the work, so that current flow will be established and then separated by a
small distance and the arc will be generated.
8. First tack weld is done on the work pieces.
9. Move the electrode slowly along the length of the joint with the filler rod, so that the filler metal
will be deposited in the joint.
10. Repeat the operation for the second pass, so that required amount of filler metal will be deposited
on the work pieces.
MIG Welding-
1. Edge preparation:
To obtain sound welds, good edge preparation is a prerequisite. This involves suitably beveling the
edges, and carefully cleaning the faces to be welded from dust, sand, oil and grease. For 6 mm
thick plate single-V edge preparation is done.
2. Check the machine to ensure it is working properly.
3. Check the wires are moving properly or not.
4. Check all gas and electric connections.
5. Switch on power.
6. Set all the gas and current parameters.
7. Prepare the edges of the work pieces with file.
8. Start the arc by touching the wire with the work piece and then maintain the gap by 2mm to
maintain the arc.
9. Perform joining operation.
10. Inspection the joint after cooling.
Precautions:
1. Never look at the arc with the naked eye. Always use a shield while welding.
2. Always wear the safety hand gloves, apron and leather shoes.
3. Ensure proper insulation of the cables and check for openings.
4. Select the parameters of the machine properly based on the metals to be welded.
5. Set these parameters properly before performing the operation.
6. Inflammable and combustible materials are removed from the vicinity of welding operations.
Testing and quality control: Welding quality is visually inspected after chipping the top surface of the
weld.
Questions:
1. What does TIG stand for?

2. Describe the working principle of Tungsten Inert Gas (TIG) Welding Process.
3. Write down the name of the equipment’s used in TIG welding with a suitable sketch.
4. Mention the gases used in TIG welding?
5. Write down the Process parameters of TIG welding.
6. Write down the advantages and limitations of TIG welding.
7. What does MIG stand for?
8. Describe the working principle of MIG Welding Process.
9. Write down the name of the equipment’s used in MIG welding with a suitable sketch.
10. Mention the gases used in MIG welding?
11. Write down the Process parameters of MIG welding.
12. Write down the advantages and limitations of MIG welding?
13. What is the difference between TIG & MIG welding?
SMITHY SHOP
Introduction:
Black smithy or Forging is an oldest shaping
process used for the 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
hammer.
Thus forging is defined as the plastic deformation of metals at elevated temperatures into a
predetermined size or shape using compressive forces exerted through some means of hand hammers,
small power hammers, die, press or upsetting machine. It consists essentially of changing or altering
the shape and section of metal by hammering at a temperature of about 980°C, at which the metal is
entirely plastic and can be easily deformed or shaped under pressure. The shop in which the various
forging operations are carried out is known as the smithy or smith’s shop.
Hand forging process is also known as black-smithy work which is commonly employed for
production of small articles using hammers on heated jobs. It is a manual controlled process even
though some machinery such as power hammers can also be sometimes used. Black-smithy is,
therefore, a process by which metal may be heated and shaped to its requirements by the use of
blacksmith tools either by hand or power hammer.
Forging by machine involves the use of forging dies and is generally employed for mass-
production of accurate articles. In drop forging, closed impression dies are used and there is drastic
flow of metal in the dies due to repeated blow or impact which compels the plastic metal to conform to
the shape of the dies.
Applications of forging
Almost all metals and alloys can be forged. The low and medium carbon steels are readily hot forged
without difficulty, but the high-carbon and alloy steels are more difficult to forge and require greater
care. Forging is generally carried out on carbon alloy steels, wrought iron, copper-base alloys,
aluminum alloys, and magnesium alloys. Stainless steels, nickel-based super alloys, and titanium are
forged especially for aerospace uses.
Forgeability
The ease with which forging is done is called forgeability. The forgeability of a material can also be
defined as the capacity of a material to undergo deformation under compression without rupture.
Forgeability increases with temperature up to a point at which a second phase, e.g., from ferrite to
austenite in steel, appears or if grain growth becomes excessive.
Forging tools
For carrying out forging operations manually, certain
common hand forging tools are employed. These are also
called blacksmith’s tools, for a blacksmith is one who
works on the forging of metals in their hot state. The main
hand forging tools are as under.
Tongs
The tongs are generally used for holding
work while doing a forging operation.
Various kinds of tongs are shown in Figure.
a) Straight-lip fluted tongs are commonly used for holding square, circular and hexagonal bar
stock.
b) Rivet or ring tongs are widely used for holding bolts, rivets and other work of circular section.
c) Flat tongs are used for mainly for holding work of rectangular section.
d) Gad tongs are used for holding general pick-up work, either straight or tapered.
Flatter
Flatter is shown in Fig. 14.7. It is commonly used in forging shop to give smoothness and
accuracy to articles which have already been shaped by fullers and swages.
Swage
Swage is used for forging work which has to be reduced or finished to round, square or
hexagonal form. It is made with half grooves of dimensions to suit the work being reduced.
It consists of two parts, the top part having a handle and the bottom part having a square
shank which fits in the hardie hole on the anvil face.
Fuller
Fuller is used in forging shop for necking down a forgeable job. It is made
in top and bottom tools as in the case of swages. Fuller is made in various
shapes and sizes according to needs, the size denoting the width of the
fuller edge
Punch
Punch is used in forging shop for making holes in metal part when it is at forging heat.
Rivet header
Rivet header (Fig. 14.7) is used in forging shop for producing rivets heads on parts.
Chisels
Chisels are used for cutting metals and for nicking prior to
breaking. They may be hot or cold depending on whether the metal
to be cut is hot or cold. A hot chisel generally used in forging shop
is shown in Fig. 14.7. The main difference between the two is in
the edge. The edge of a cold chisel is hardened and tempered with
an angle of about 60°, whilst the edge of a hot chisel is 30° and the
hardening is not necessary. The edge is made slightly rounded for
better cutting action.
Hand hammers
There are two major kinds of hammers are used in hand forging:
a. The hand hammer used by the smith himself and
b. The sledge hammer used by the striker.
Hand hammers may further be classified as (a) ball peen hammer, (b) straight peen hammer,
and (c) cross peen hammer.
Sledge hammers may further be classified as (a) Double face hammer, (b) straight peen
hammer, and (c) cross peen hammer.
Hammer heads are made of cast steel and, their ends are hardened and tempered. The
striking face is made slightly convex. The weight of a hand hammer varies from about 0.5
to 2 kg whereas the weight of a sledge hammer varies from 4 to 10 kg
Set hammer
A set hammer generally used in forging shop is shown in Fig. 14.9. It is used for finishing
corners in shouldered work where the flatter would be inconvenient. It is also used for
drawing out the gorging job.
Anvil
An anvil is a most commonly tool used in forging shop which is shown in. It acts as a
support for blacksmith’s work during hammering. The body of the anvil is made of mild
steel with a tool steel face welded on the body, but the beak or horn used for bending curves
is not steel faced. The round hole in the anvil called pritchel hole is generally used for
bending rods of small diameter, and as a die for hot punching operations. The square or
hardie hole is used for holding square shanks of various fittings. Anvils in forging shop may
vary up to about 100 to 150 kg and they should always stand with the top face a bout 0.75
mt. from the floor. This height may be attained by resting the anvil on a wooden or cast iron
base in the forging shop.
Swage block
Swage block generally used in forging shop is shown in figure. It is mainly used for
heading, bending, squaring, sizing, and forming operations on forging jobs. It is 0.25 mt. or
even more wide. It may be used either flat or edgewise in its stand.
Forging operations:
The following are the basic operations that may be performed by hand forging:
1. Drawing-down:
Drawing is the process of stretching the stock while reducing its cross-section
locally. Forging the tapered end of a cold is an example of drawing operation.
2. Upsetting:
It is a process of increasing the area of cross-section of a metal piece locally, with a
corresponding reduction in length. In this, only the portion to be upset is heated to forging
temperature and the work is then struck at the end with a hammer. Hammering is done by the smith
(student) himself, if the job is small, or by his helper, in case of big jobs, when heavy blows are
required with a sledge hammer.
3. Fullering:
Fullers are used for necking down a piece of work, the reduction often serving as the starting
point for drawing. Fullers are made of high carbon steel in two parts, called the top and bottom
fullers. The bottom tool fits in the hardie hole of the anvil. Fuller size denotes the width of the fuller
edge.
4. Flattering:
Flatters are the tools that are made with a perfectly flat face of about 7.5 cm square. These
are used for finishing flat surfaces. A flatter of small size is known as set-hammer and is used for
finishing near corners and in confined spaces.
5. Swaging:
Swages like fullers are also made of high carbon steel and are made in two parts called the top and
swages. These are used to reduce and finish to round, square or hexagonal forms. For this, the
swages are made with half grooves of dimensions to suit the work.
6. Bending:
Bending of bars, flats, etc., is done to produce different types of bent shapes such as angles,
ovals, circles etc. Sharp bends as well as round bends may be made on the anvil, by choosing the
appropriate place on it for the purpose.
7. Twisting:
It is also one form of bending. Sometimes, it is done to increase the rigidity of the work
piece. Small piece may be twisted by heating and clamping a pair of tongs on each end of the
section to be twisted and applying a turning moment. Larger pieces may be clamped in a leg vice
and twisted with a pair of tongs or a monkey wrench. However, for uniform twist, it must be noted
that the complete twisting operation must be performed in one heating.
8. Cutting (Hot and Cold Chisels):
Chisels are used to cut metals, either in hot or cold state. The cold chisel is similar to fitter’s
chisel, except that it is longer and has a handle. A hot chisel is used for cutting hot metal and its
cutting edge is long and slender when compared to cold chisel. These chisels are made of tool steel,
hardened and tempered.
9. Iron-Carbon Alloy:
If the carbon is less than 2% in the iron-carbon alloy, it is known as steel. Again, based on
the carbon content, it is called mild steel, medium carbon steel and high carbon steel. The heat
treatment to be given to these steels and their applications are shown in table below.
Carbon Hardening Tempering Applications.
% temp. 0C temp. 0C
0.1 800-840 250-300 Chains, rivets, soft wire, sheet
0.25 800-840 250-300 Tube, rod, strip
Mild Steel
0.5 800-840 250-300 Girders
0.6 800-840 250-300 Saws, hammers, smith’s and general
purpose tools
Cold chisels, smith’s tools shear
0.75 760-800 250-300 blades, table cutlery
0.9 760-800 250-300 Taps, dies, punches, hot shearing
Medium blades Drills, reamers, cutters,
Carbon 1.0 760-800 250-300 blanking and slotting tools, large
steel turning tool
Small cutters, lathe and engraving
tools,
1.2 720-760 250-300 files drills
Extra hard, planning, turning and
High Carbon 1.35 720-760 250-300
slotting
tools, dies and mandrels
1.5 720-760 250-300 Razor blades
NOTE: The forging produced either by hand forging or machine forging should be heat treated.
The following are the purposes of heat treatment:
i. To remove internal stresses set-up during forging and cooling.

ii. To normalize the internal structure of the metal.
iii. To improve machinability.
iv. To improve mechanical properties, strength and hardness.
Job No: MECH 2113/2157/08
Name of Job: To prepare a chisel from a Hexagonal MS Bar as per Drg. No. MECH 2113/08 by
forging operation
Aim: To
1. Define Forging operation and discuss the advantages of Forging operation

2. Describe the applications of Forging operation
3. Describe various Forging operations
4. Prepare a chisel from a Hexagonal MS Bar as per Drg. No. MECH 2113/08
Raw Materials: Wrought Iron, Low and Medium carbon steel, Low alloy steels, Alluminium,
Magnesium, Copper alloy.
Tools Required: Anvil, Smith’s Forge or Hearth, Hammer, Swage block, Tong, Fullers.
Drawing of the Job:
Drg. No. MECH 2113/08
Sequence of Operations:
1. Take the raw material from stock i.e., hexagonal MS bar.
2. Handle specimen with round tong and heat in furnace upto the part appears as red cherry color
code.
3. The required piece heated upto it gets the recrystalization temperature.
4. Take it out from the furnace using a tong
5. Place it into the Anvil
6. Hammer at its one end for obtaining the chisel shape in one end.
7. Repeat the steps from 2 to 5 until the job is done.
8. The above mentioned all steps are done, after the specimen bent in required shape.
9. Cool the job in water and prepare an inspection report.
Result:
A chisel is formed from a Hexagonal MS bar.
Precautions:
1. Hold the job carefully while heating and hammering.
2. Job must be held parallel to the face of the anvil.
3. Wear steel-toed shoes.
4. Wear face shield when hammering the hot metal.
5. Use correct size and type of tongs to fit the work.

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Heritage Institute Of Technology

Department of Mechanical Engineering

Sub: Workshop Practice II

JOB NO ______________________ __________________SHOP

JOB TITLE ___________________________________________

DATE(S)OF WORK __________________________________________

DATE OF SUBMISSION __________________________________________

GROUP ________________ ROLL NO. _________________

Signature of Faculty/Examiner _________________________________________

Course Name: WORKSHOP PRACTICE II

At the end of the course, a student will be able to

Understand various manufacturing processes that are used in a typical

Understand the mechanics of material removal in a lathe machine, Identify

Understand and Explain various allowances given to a product drawing ,

1. MECH 2157/01 To prepare a Job involving various operations involving 1,2

Name of the jobs carried out during the semester

Machine To cut a spur gear in a horizontal Milling

3. MECH/2113/2157/3 To Assemble a spur gear onto a shaft.

Carpentry To prepare a wooden pattern of pipe with

To prepare a sand mould using the wooden

Sheet To prepare an Air Conditioning duct from

Welding Joining of two mild steel plates by TIG & MIG

To prepare a chisel from a Hexagonal MS

Paper Name: Workshop Practice II Paper Code: MECH 2113/2157

To prepare a sample as per the 6 hours

Centre Lathe ( Head Largest work diameter that can

Figure 1: Common turning tools

3. describe various operations done in a Lathe.

5. specify cutting speed , feed and depth of cut.

6. prepare a component as per Drg. No. MECH 2113/2157/1.

7. make an inspection report after making the component.

8. discuss various safety norms that needs to be observed .

Drawing of the job:

(All dimensions are in mm)

Raw Materials: Mild steel bar.

4. Define single point cutting tool geometry.

Name of the Part : Threaded Spindle Drawing No : MECH 2113/2157/01

Qty Produced: 1x Quantity Checked : 1 x

Inspected By: Checked By:

Sr. Drawing Measured Remarks Sr. Drawing Measured Remarks

Raw Materials: Gear blank of mild steel

Tools Required: Steel rule, Vernier caliper, Outside caliper.

Machine tool used: Horizontal milling machine

Cutting tool used: Milling Cutter (HSS)

Produced parts by a Milling Machine

Up Milling (Conventional Milling) and Down Milling (Climb Milling)

Straddle Milling and Form Milling

Cutting speed, feed and depth of cut:

Spur Gear Terminology

Recommended series of module (mm):

Choice-I 1 1.25 1.5 2 2.5 3 4

Choice-II 1.125 1.375 1.75 2.25 2.75 3.5

Tooth Depth = 2.25 m

Indexing Calculation = 40 / Z = 40 / 23 = 1 17/23

Addendum (ha)=(m) Dedendum (hf)=(1.25m)

Clearance (c)=(0.25m) Working depth (hk)=(2m)

Whole dept (h)=(2.25m) Tooth thickness (s)=(1.5708m)

Calculate the gear tooth proportions.

Z=Number of teeth required

JOB NO ____ SHOP

GROUP ROLL NO. _