Compressing Machine 1

MAHARAJA’S TECHNOLOGICAL INSTITUTE (MTI)
THRISSUR
WORKSHOP PRACTICE MANUAL

COURSE CODE-3027
Semester 3&4
DEPARTMENT OF
MECHANICAL ENGINEERING
Workshop Practice Manual (Sem-3&4)
PREFACE
This manual is prepared based on the curriculum prescribed for second

and third semester diploma in Mechanical engineering program for
polytechnics under Department of Technical Education, Kerala.
Mechanical Workshop is a place where students acquire knowledge in
operation of various processes involved in manufacturing and production. The
Workshop Practice course makes students competent in handling practical
work in engineering environment. This manual covers general information
about; safety, details of tools used in various workshop sections, exercises
with supportive figures etc.
After successful completion of this course, students will be able to
perform various exercises in machine tools based on given drawings and
specifications in respective sections viz. sheet metal and aluminium
fabrication, fitting, welding and machine shop.
We presume this manual will help and support students for
understanding the basics and essentiality of practical work in engineering
stream.
Workshop Superintendent,
Maharaja’s Technological Institute (MTI),
Thrissur
Maharaja’s Technological Institute (MTI), Thrissur 3|Page

TABLE OF CONTENTS
1. SAFETY PRECAUTIONS……………………………………………………….……..07
2. SHEET METAL & ALUMINIUM FABRICATION………………....….……..11
3. FITTING………………………………..…………………………………………………….41
4. WELDING…………………………………………………………………………………….71
5. MACHINE SHOP….…………………………………….………………………………105
APPENDIX-1 - COURSE SYLLABUS……………………..…………………….135
APPENDIX-2 - SAMPLE QUESTION PAPERS.…….……..……………….141

SAFETY PRECAUTIONS
PERSONAL SAFETY
 Wear tight clothes; beware of hanging hair, ties, clothing, scarves or belts
getting caught.
 Never enter the workshop without safety shoes.
 Do not use rings, watches etc. while working.
 Keep the workshop clean and tidy. The floor should be free from oil and
grease; the slippery floor is always dangerous.
 Wear goggles whenever there is danger of flying matter.
 Never attempt to measure the job in running.
 Always stand in respectful distance from moving and hanging parts.
 Practice cleanliness and orderliness in the shop.
 Do not run or play on the shop floor.
 Keep your body behind the sharp edges of cutting tools.
 Do not attempt to lift heavy articles without assistance.
 Never handle chips or shavings with bare hands; use special hooks,
brushes etc.
 Never place sharp tools on the floor or at the edges of the workbench;
keep them in proper place assigned for them.
 Be aware the cause of electrical hazards such as bare wires, poor earthing,
return connections, wet floors etc.
MACHINE SAFETY
 Never operate the machine unless you have been properly instructed.
 Never work on the machine having unguarded moving parts.
 Stop the machine immediately, if it produces any unusual sounds.
 Before starting an operation, always check whether the work and cutting
tools are secured fast.
 Never leave a machine when it is running.
 Never mount or remove the work, replace tools, clean or lubricate the
machine, or remove the swarf, while the machine is running.
 Do not run the machine in an incorrect speed.
 Do not talk or disturb others while they are operating a machine.

JOB SAFETY
 Use right tools for right job.
 Use metal strips to hold work pieces like Brass or Aluminum, to avoid
gripping marks on the finished surface.
 Put oil lightly on finished jobs to avoid rust.
 Tools with loose fitting or broken handles shall not be used.
 To save the time and material, frequent checking has to be made.
 Do not mix the precision measuring instruments with other tools and
equipments.
 Store inflammable materials like kerosene, turpentine etc. away from the
shop.
 Be aware of the details and location of fire fighting devices like fire buckets,
fire extinguishers etc. and first aid box in the workshop.

Workshop Practice Manual (Sem-3&4) - Sheet Metal
SHEET METAL
& ALUMINIUM FABRICATION
Semester 3&4
Maharaja’s Technological Institute (MTI), Thrissur 11 | P a g e

SHEET METAL
INTRODUCTION
Sheet metal has its own significance as a useful trade in engineering and
for our day to day requirements. It is generally the working of metals from
16 gauge down to 30 gauge, with simple tools and equipments.
In sheet metal work, the knowledge of geometry, mensuration and properties
of metal is most essential since nearly all pattern come from the development
of the surfaces of a number of geometrical models such as cylinder, prism,
cone and pyramid.
Sheet metal works include various cutting, forming and joining processes in
sheet metal. Common examples of sheet metal work are hoppers, canisters,
guards, covers, pipes, hoods, funnels, bends, boxes etc. Such articles are
found less expensive, lighter in weight and at many places they easily replace
the use of the castings or forgings.
METALS USED IN SHEET METAL WORK

The sheets used in sheet metal work are specified by standard gauge
numbers. It is a series of numbers known as standard wire gauge (SWG)
numbers. Each gauge designates a definite thickness; higher the SWG
number of a sheet, lesser will be its thickness. Lower the SWG number,
higher the thickness of sheet.
The term ‘sheet’ normally used to describe metal sheets with a maximum
thickness of 2 mm; above this, it is usual to use the term ‘plate’.
Metal sheets used in sheet metal works are:
BLACK IRON
Black Iron is the cheapest sheet metal and is uncoated. It corrodes rapidly.
GALVANIZED IRON
Zinc coated iron is known as galvanized iron or GI iron.
STAINLESS STEEL
This is an alloy of steel with nickel, chromium and traces of other metals, it
has good corrosive resistance.
COPPER
Copper is a non-ferrous metal and has corrosive resistance property.

SCRIBER
TRAMMEL POINTS
Prick Punch Centre Punch
PUNCHES
Maharaja’s Technological Institute (MTI), Thrissur 14 | Page

ALUMINIUM
Aluminium is a light weight and corrosion resistant metal. It cannot be
used in pure form.
TIN PLATE
Tin plate is iron sheet coated with Tin to prevent corrosion.
LEAD
Lead is very soft and heavy. It is used in highly corrosive acid tanks.
SHEET METAL HAND TOOLS
1. MEASURING TOOLS
a. STEEL RULE
It consists of a hardened steel strip having graduations etched in it. They
are usually 150mm or 300mm long, and is used to take linear measurements
to an accuracy of 0.5mm.
b. FOLDING RULE
This is useful in measuring and laying out larger works; the accuracy of
being 0.5mm. It can be folded in hinges.
c. CIRCUMFERENCE RULE
This is used to find out directly the circumference of a cylinder.
d. BEVEL PROTRACTOR
It is used for angular measurement. It consists of a semicircular steel disc
graduated in degrees from 0° to 180° and a bevel gauge pivoted centrally.
e. MICROMETER
Micrometer is a precision measuring instrument with an accuracy of
0.01mm. Thickness of sheets can be measured by this instrument.
f. VERNIER CALIPER
Vernier caliper is a precision measuring instrument which is used for
outside, inside and depth measurements. Its accuracy is 0.02mm.
g. STANDARD WIRE GAUGE
Both the thickness of the sheet metal and diameter of wires can be
checked by means of Standard Wire Gauge.
2. MARKING TOOLS
a. SCRIBER
This is the metal worker’s pencil with its one end sharply pointed and
hardened to scratch lines on sheet metal in laying out patterns.
Gauge Approx.
No. thickness
(in mm)
0 7.937
1 7.142
2 6.846
4 5.895
6 4.935
10 3.175
15 1.775
20 0.996
22 0.794
24 0.629
25 0.560
26 0.498
28 0.396
30 0.315
32 0.256
35 0.177
STANDARD WIRE GAUGE

b. DIVIDER
It consists of two pointed legs, and used for drawing circles or arcs or to
divide lines into equal parts.
c. PUNCHING TOOLS
-
SOLIND PUNCHES are used for making small holes or markings.
Different types of solid punches commonly used are:
 Prick punch - 40°
 Centre punch - 90°
- HOLLOW PUNCHES are also used to punch holes in thin sheet metal,
leather, plastic, cork etc.
- HAND LEVER PUNCH is used where a large number of holes to be
punched.
d. TRAMMEL POINTS
It consists of a bar with two movable heads. It is used to draw large
circles or arcs that are beyond the limit of the dividers.
e. STRAIGHT EDGE
This is a flat graduated steel bar with one longitudinal edge beveled. It is
useful for scribing long straight lines.
f. STEEL SQUARE
It is a L-shaped piece of hardened steel with marks graduated on the
edges for measuring. It is used for marking perpendicular lines to any base
line.
g. TRY SQUARE
Try square is used for marking in the perpendicular direction to any base
line. Main parts are stock and blade.
3. STRIKING TOOLS
i. BALL PEEN HAMMER
It is used for general purpose.
ii. SETTING HAMMER
It is used to set up seams, flaring the edge of the cylindrical job and to set
up the long channels etc.
iii. RIVETTING HAMMER
It is used to jump the rivet shanks and finish the rivet heads.
iv. CREASING HAMMER
It is used to finish the wired edges, make the corner of the sheets with the
help of creasing stake, stretch sheets etc.

MALLET
HATCHET STAKE HORSE STAKE

v. RAISING HAMMER
It is used for forming of a flat sheet of metal into a curved or hollow shape
such as saucer, bowl, tray or spoon.
vi. PLANISHING HAMMER
It is used to give smooth surface finish to the job. Soft nylon hammers are
also used to avoid damage to the metal sheet.
vii. MALLET
Mallets are soft hammers and are made of hard rubber, copper, brass,
lead, fiber or wood. It is used to strike a soft blow on the metal so that nicks
will not be made on the surface of the sheet. Types of mallets are; ordinary
wooded mallets, bossing mallets and end faked mallets.
4. SUPPORTING TOOLS
a. STAKES
They are the sheet metal worker’s anvil used for bending, seaming or
forming operations, using mallet or hammer. It consists of a shank and a
head or horn. The shanks are designed to fit into a hole in the bench.
1. HATCHET STAKE
It consists of a horizontal sharp straight edge and is used for making sharp
bends, folding the edges of the sheet metal, forming boxes and pans by
hand.
2. HALF MOON STAKE
It has a sharp edge in the form of an arc of a circle, beveled along one
side. It is used for circular folding and seaming.
3. FUNNEL STAKE
It is used for shaping and seaming of funnels and tapered articles. It is also
used to obtain a conical shape in sheet metals for various purposes.
4. CREASING STAKE
It has a square horn with grooved slots at one end and a tapered round
horn at the other end. These are used for wiring and heading and for conical
shaped pieces.
5. BEAK HORN STAKE (BICK IRON STAKE)
It has two horns, one is tapered and the other is rectangular shaped. It is
used as a general purpose anvil, for riveting, forming etc.

FUNNEL STAKE CREASING STAKE
CONDUCTOR STAKE COPPER SMITH STAKE

6. COPPER-SMITH STAKE
It has a rounded edge on one side of the head and a sharp rectangular
edge on the other.
7. CONDUCTOR STAKE
It is having two cylindrical horns of different diameter.
8. HORSE STAKE
It is double ended holder for small stakes, one of which is cranked
downwards for clearance purpose and has square/round holes at both ends.
b. FOLDING BARS
It is used for bending and folding straight sheet metal held between its
bars and clamped to the vice. The folding line coincides with the top of the
folding bars.
c. GROOVER
It is used for closing and locking of seams (joints) in sheet metal work. The
end of the tool is recessed to fit over the lock, making the grooved seam.
d. RIVET SET OR RIVET HEADER
This is a hardened steel tool with a hollow in one end. It is used to shape
the end of a rivet into a round, smooth end.
5. HOLDING TOOLS
a. BENCH VICE
It is made of cast iron or cast steel and is used to hold the work for filing,
sawing, threading and other hand operations. The size of the vice is stated by
the width of the jaws. It consists of fixed and movable jaws with jaw plates, a
lead screw with handle and a base.
b. PLIERS
It is used to hold work pieces like wires, small work sheets etc.
6. CUTTING TOOLS
a. SNIPS or HAND SHEAR
A snip, also called a hand shear is used like a scissors to cut thin, soft
metals. It should be used only to cut 20 gauge or thinner metal.
These commonly used snipes are: Straight snips and Bend snips.
b. FILES
A file is a hardened piece of high grade steel with slanting rows of teeth. It
is used to cut, smooth, or fit metal parts.

GROOVER RIVET SET
STRAIGHT SNIPS
BEND SNIPS

c. CHISELS
Chisels are generally used in sheet metal work for cutting sheets, rivets,
bolts and chipping operations.
7. SOLDERING IRON
Soldering iron also called soldering coppers. This is used for soldering work
pieces. It consists of a forged piece of copper joined to an iron rod with a
wooden handle.
8. SHEET METAL OPERATIONS

a. SHEARING
Shearing is a general name for most sheet metal cutting but in a specific
sense designates a cut in a straight line across a strip, sheet or bar. Shearing
action has three basic stages: plastic deformation, fracture and shear. Basic
shearing operations are:
1. CUTTING OFF
This means severing a piece from a strip with a cut along a single line.
2. PARTING
Parting signifies that scrap is removed between the two pieces to part
them.
3. BLANKING
This means cutting a whole piece from sheet metal just enough scrap is
left all around the opening.
4. PUNCHING
Punching is the operation of producing circular holes on a sheet metal by a
punch and die.
5. PIERCING
Piercing is the process of producing holes of any desired shape like square,
triangle, rectangle etc.
6. NOTCHING
Notching is a process of removing metal to the desired shape from the
edge of a sheet.
7. SLITTING
When shearing is conducted lengthwise between rotary blades, the
process is referred to as slitting.

CUTTING-OFF
scrap work
blank
scrap
(work)
PIERCING BLANKING PUNCHING
PARTING NOTCHING SLITTING
LANCING NIBBLING TRIMMING
SHEET METAL OPERATIONS

8. LANCING
This makes a cut part way across a strip.
9. NIBBING
Nibbing is an operation of cutting any shape from sheet metal on a nibbing
machine without special tools.
10. TRIMMING
Trimming is the operation of cutting away flash from a piece of excess
metal in a flange.
b. BENDING
Bending of sheet metal is the process of applying forces to localized areas,
beyond the elastic limit, such as in bending a piece of metal into a right
angle. Bending incorporates angle bending, roll bending, roll forming and
seaming.
c. DRAWING
Drawing is the operation of producing thin-walled hollow or vessel shaped
parts from sheet metal. These are two types; deep drawing and box drawing.
d. SQUEEZING
It is a quick and widely used way of forming ductile metal. The squeezing
operations are sizing, coining, hobbing, ironing, riveting etc.
e. RIVETTING
It is a process of joining permanently two pieces of sheet metal with rivets.
Riveting is largely used in manufacture of steel structures, boilers, pressure
vessels, rail wagons and coaches, furnace bodies, steel bridges etc.
9. HEMS AND SEAMS

a. HEM
Hem is an edge or border made by folding. It stiffens the sheet of metal
and does away with sharp edge. Hems are three types; single hem, double
hem and wired edge.
b. SEAM
A seam is a joint made by fastening two edges together. Seams are lap
seam, grooved seam, single seam, double seam, dovetail seam and burred
bottom seam.

SINGLE HEM DOUBLE HEM WIRED HEM
SINGLE SEAM DOUBLE SEAM GROOVED SEAM
HEMS AND SEAMS

10. SHEET METAL MACHINES

When a large number of jobs are made, particularly in heavier types of
sheets, and operations like shearing, punching, bending etc. is difficult, time
consuming and uneconomical. To cope with this problem, both hand and
power operated machines have been developed. Smaller machines are
usually referred as ‘bench machine’ while the others as ‘floor machine’ which
are particularly useful in mass production of identical parts.
Commonly used machines are as follows:
a. SHEARING MACHINE
Used to cut or shear metal sheets in many ways.
b. BAR FOLDER
Used for bending and folding the edges of the metal sheets to form the
joint at the seam.
c. BURRING MACHINE
Used to make a burr of the edges of the bottom for a can and on the end
of a cylinder.
d. TURNING MACHINE
Similar to burring machine, but produces a rounded edge for wiring
operations, bodies of cylinders and for double seaming.
e. WIRING MACHINE
Used to perform wiring operation strengthen the edges.
f. SETTING DOWN MACHINE
After the burr has been made on a burring machine, the seams are closed
or set down on a setting down machine.
g. FORMING MACHINE
Used for various forming operations, eg. forming stove pipes, cans etc.
h. BRAKE
A brake is a machine used for bending and folding the sheet metal.

Blade
Stock
TRY SQUARE

ALUMINIUM FABRICATION
INTRODUCTION
Aluminum fabrication is an important part of a great number of modern
industries, especially transportation, manufacturing and marine industries.
Aluminum fabrication takes part of the metal fabrication industry which is in
charge of building metal structures by means of bending, cutting, and
assembling. Replacing heavier metals with aluminum has proved as an
effective way to achieve considerable weight reductions. Hence aluminum
fabrication has become an ideal solution for meeting specific manufacturing
needs when it comes to product performance, flexibility, design and cost
savings.
HAND TOOLS
a) MARKING AND MEASURING TOOLS
Commonly used marking and measuring tools in aluminium fabrication
work are; steel rule, measuring tape, try square, bevel square, scriber,
pencil, wing compass, spring dividers, punches, trammels etc.
b) CUTTING TOOLS
Commonly used cutting tools are; hack saw, files (flat, square, round,
needle), flat chisel, straight snips etc.
c) STRIKING TOOLS
Commonly used striking tools are; ball peen hammer, mallet, nylon
hammer etc.
d) MISCELLANEOUS TOOLS
Other important tools used in aluminium fabrication are hand drill, screw
driver, plum bob, spirit level etc.
1. HACK SAW
Hack saw is one of the main tool used in aluminium fabrication industry for
cutting rods, angles, pipes and extrusion in to desired length. It consists of a
metal frame which may be solid or adjustable.
2. PORTABLE ELECTRIC HAND DRILL
The portable hand drill is used for easy and quick drilling operation. It
consists of an electric motor, a trigger switch and drill chuck. Holes up to
6mm dia can be easily drilled with an electric hand drill.

3. SCREW DRIVER
The screw drivers are used for driving the screws into the object or for
unscrewing them. These are available in various sizes and shapes.
4. PLUM BOB
It is used for checking vertical levels of articles at the time of fixing.
5. SPIRIT LEVEL
A spirit level consists of an air bubble current glass tube protected by a
wooden or metal frame. It is used for checking horizontal level of the objects.
COMMON EXTRUSIONS USED IN ALUMINIUM FABRICATION

1. FIXED GLASS FRAMES
Commonly used types are; 2x1 single side, 2x1 plane, 2x1 double side, 1
½ x1 plane, 2½ x1½ plane, 2 ½ x1 ½ single side, 2x2 square (plane)
glassing plate, glassing clips and beadings.
2. SIT OUT AND HAND RAILS
Commonly used are; 4” closed book, 4” open book, 3 ½ “ open book, 2 ½
and 3’ pipes, C-channels, 1 ½ flat, 1” square, 1” oval, 1” pipe, grill etc.
3. DOORS
a. FLAT DOOR
Commonly used are; door vertical, door top, door bottom, door divider,
handle, clip, door closer, lock, pivot, bolt & nut, edge beading etc.
b. SLIDING DOORS
Commonly used are; ‘E; channel or double channel, runner, striker etc.
c. SUPER SLIDING DOOR
They are; two rack, sliding plane, sliding lock, ‘U’ bending, PVC bush and
sleeve, lock etc.
4. CEILING
Commonly used types are; ‘T’ section, ‘I’ angle, four way clip etc.
*******

Exercise No.1
Date:
DUST PAN
160
30 100 30
R15
530
146
185
150
30
55 150 55 6 30 6
170
150
100
150
30
5
12
15
Scale 1:1
All dimensions are in mm

Exercise No.1 Date:
DUST PAN
AIM
To make a dust pan as per the given dimensions.
MATERIALS REQUIRED
GI sheet (26 SWG) – size 185x170mm (for pan)
GI sheet (26 SWG) – size 176x42mm (for handle)
GI wire (dia 3mm) – 360 mm length
Aluminium Rivet (dia 3mm) – 2 nos (flat headed)
TOOLS REQUIRED
Steel rule, Scriber, Try square, Flat file, Mallet, Straight snips, Stakes, Ball
peen hammer, Punch, Rivet set etc.
OPERATIONS TO BE CARRIED OUT

Measuring, marking, cutting, leveling, filing, folding, wiring, riveting,
checking and finishing.
PROCEDURE
- Mark and size the given work piece as per required dimensions with the
help of steel rule, try square, scriber, snips and file.
- Fold the edges in to required shape to form the pan shape using mallet,
bench vice and stakes.
- Lock the folded edges of the pan using mallet to form final shape.
- Cut and bend the wire required for handle wiring as per drawing.
- Fold the edges of handle and lock the wire into it.
- Place handle on the pan and mark positions of rivet holes.
- Make rivet holes using punch and place the rivets to hold handle and
pan together.
- Complete the riveting process using rivet set and hammer.
- Check and finish the work.

Exercise No.2
Date:
TAPER TRAY
150
10
36
100
70
36
10
10 36 120 36 10
10
0
0
15
36
0
12
70
Scale 1:1
Exercise No.2 Date:
TAPER TRAY
AIM
To make a taper tray as per the given dimensions.
MATERIALS REQUIRED
GI sheet (26 SWG) – size 214x164mm
TOOLS REQUIRED
peen hammer etc.

Measuring, marking, cutting, leveling, filing, folding, wiring, checking and
finishing.
PROCEDURE
- Mark and size the given work piece as per required dimensions with the
help of steel rule, try square, scriber, snips and file.
- Fold the edges in to required shape to form the tray shape using
mallet, bench vice and stakes.
- Lock the folded edges of the tray using mallet to form final shape.
- Cut and bend the wire required for wiring as per drawing.
- Fold the top edges of tray and lock the wire into it.
- Complete the wiring process using mallet and supporting stakes.

Exercise No.
Date:
RECTANGULAR TRAY
795
10
100
5
5 160 230 160 230 5 5
(TRAY BODY)
5 5 230 5 5
5 5
160
180
250
(TRAY BOTTOM)
16
0
0
23
100
5
KNOCKED-UP JOINT
Scale: NTS
Exercise No. Date:
RECTANGULAR TRAY
AIM
To make a rectangular tray as per the given dimensions.
MATERIALS REQUIRED
GI sheet (26 SWG) – size 795x115mm (for body)
GI sheet (26 SWG) – size 250x180mm (for bottom)
TOOLS REQUIRED
peen hammer etc.

Measuring, marking, cutting, leveling, filing, folding, wiring, checking and
finishing.
PROCEDURE
- Mark and size the given work piece as per required dimensions with
the help of steel rule, try square, scriber, snips and file.
- Fold the edges in to required shape to form the tray shape using
mallet, bench vice and stakes.
- Fold the edges of tray and join both ends by paned down and knocked
up joint.
- Size the bottom part and mark folding lines.
- Place the tray body on bottom plate markings and lock them together
by knocked up joint.
- Cut and bend the wire required for wiring as per drawing.
- Fold the top edges of tray and lock the wire into it.
- Complete the wiring process using mallet and supporting stakes.

Exercise No.3
Date:
ALUMINIUM FABRICATION - CORNER JOINT
RECTANGULAR SECTION
25x38 mm
L-SECTION (CLEAT)
150
19x19mm (2 Nos.)
150
Scale 1:1

Exercise No.3 Date:
ALUMINIUM FABRICATION - CORNER JOINT
AIM
To make a corner joint (straight edge joint) by aluminium fabrication
MATERIALS REQUIRED
Aluminium rectangular section (size 25x38mm) – 300mm (length)
Aluminium L-section (size 19x19mm) –60mm (length)
Counter sunk head screw – 8 Nos. (Size 3mm)
TOOLS REQUIRED
Steel rule, Scriber, Try square, Hack saw, Flat file, Drilling machine, Drill
bit, Screw driver etc.

Measuring, marking, cutting, filing, drilling, screwing and finishing.
PROCEDURE
- Mark and cut the given aluminium rectangular section of 25x38mm in
to 150mm length (2 nos).
- Mark 45° angles at one end of each section and cut them out to form a
90° corner joint.
- Level the 45° cut out edges using flat file and check the angle to make
90°
- Cut 19mm L angle section for cleat in required dimensions (2 nos).
- Drill 4 nos of holes on the aluminium section (25x38mm) for fixing
cleats (2 on each side).
- Place the cleat on the drilled section and mark the holes on them.
- Drill holes on the cleats to match with the holes in aluminium section.
- Fix the cleats on the aluminuim section as shown using screw and
screw driver.
- Tighten the screw, check the 90° angle and finish the work.

Workshop Practice Manual (Sem-3&4) – Fitting
FITTING
Semester 3&4

FITTING
INTRODUCTION
The term ‘Bench work’ denotes the production of an article by hand on the
bench. Whereas ‘Fitting’ is the assembling of parts together and removing
metals to secure the necessary fit, by keeping accurate dimension and may
or may not be carried out at the bench. These two types of work require the
use of a large number of hand tools and other devices or equipment that
involve a number of operations for accomplishing the work to the desired
shape and size. Some of the commonly used tools are discussed as under.
1. MEASURING & MARKING TOOLS

a) DIVIDERS
Dividers are very useful instruments employed in marking work. Their
principal use is in measuring distance between two points or parallel lines on
a flat surface, dividing a given length in a definite ratio, drawing circles and
arcs and transferring dimensions from scales to objects.
b) CALIPERS
A caliper is used to transfer and compare a dimension from one object to
another or from a part to scale or micrometer where the measurement
cannot be made directly. The commonly used calipers are given below.
c) HERMAPHRODITE OR JENNY CALIPER
This is sometimes called odd – leg caliper. It has one pointed leg like a
divider and one bent leg as shown in figure. The caliper is extremely useful
for scribing lines parallel to the edge of the work and for finding the center of
a cylindrical work. A steel rule is a necessary adjunct.
d) ANGLE PLATE
The angle plate which is made of grey cast iron has two plane surfaces at
right angles to each other. This is used in conjunction with the surface plate
for supporting work in the perpendicular position. It has various slots in it to
enable the work to be held firmly by bolts and clamps.

SURFACE PLATE
V-BLOCK

e) SURFACE PLATE
The surface plate as shown in figure is used for testing the flatness of work
itself and is also used for marking - out work. This is used for small pieces of
work while the marking – out table is used for larger jobs. Surface plates are
made of grey cast iron and of solid design or with ribs. They should be well
and reflection-free illuminated and rest horizontally on firm support, the
working height being about 800 mm from the floor. The marking-out surface
must be protected from rust and dirt and wiped clean and smeared with
grease or oil after use.
f) VERNIER HEIGHT GAUGE
A Vernier height gauge consists of a heavy base, a graduated beam, a
sliding head with Vernier sliding jaws holding the scriber and a fine
adjustment clamp. It is similar to large Vernier calipers in construction,
except that it consists of a heavy base which allows the gauge to stand
upright instead of a fixed jaw in a Vernier. The movable jaw of Vernier height
gauge consists of a projection or extension which is leveled to sharp edge for
scribing lines at any required height.
g) V – BLOCK
The V-block is a block of steel with v-shaped grooves. Round shaped work
pieces which are to be marked or drilled are placed on v – supports. In this
way they are firmly supported in a horizontal position and cannot rotate
easily. V-Blocks of the following sizes are found to be most useful: length
from 50 to 250 mm width and height from 50 to 100 mm. For long cylindrical
work, several blocks of the same size are used as set.
2. CUTTING TOOLS
a. FILES
It is used for removing excess material to smoothen or fit metal parts.
They are generally forged out of high carbon steel or tungsten steel, followed
by cutting of teeth, hardening and tempering etc.
CLASSIFICATION OF FILES
i. CUT OF FILES
The files are divided into two groups as per cut of the teeth, ie., Single cut
and Double cut. On single cut files, the teeth are cut parallel to each other

TYPES OF FILES

running across the faces and at an angle of 60 to the center line of the file.
These types of files are frequently termed as flats and are used for very hard
metals. In double cut files, there are two sets of teeth. The first set is similar
to those of single cut files. The second set of teeth is cut diagonally across
the first set of teeth at an angle of 80 to the center line of the file. It is used
for general work.
ii. SHAPE OF FILES
The shape of file is its general outline and cross-section. Files are made in
hundreds of shapes. Figure show the most commonly used shapes.
a. Flat file: This is tapered in width and thickness, and one of the most
commonly used files for general work. They are always double – cut on
the faces and single – cut on the edges.
b. Hand file: This is parallel in width, and tapered in thickness. A hand file
is used for finishing flat surfaces. It has one edge (i.e., it is uncut) and
therefore, is useful where the flat file cannot be used. They are always
double – cut.
c. Square file: This is square in cross section, double – cut, and tapered
towards the point. This is used for filing square corners, enlarging
square or rectangular openings as splines and keyways.
d. Pillar file: pillar files are double – cut, narrow and of rectangular
section. It has one safe edge, and is used for narrow work, such as
keyways, slots and grooves.
e. Round files: they are round in cross – section and usually tapered,
when they are termed rat – tailed. When parallel they are described as
parallel round. Round files are used for filing curved surfaces and
enlarging round holes and forming fillets. They may be single – cut or
double – cut.
f. Triangular files: the square or triangular file is tapered, double – cut,
and the shape is that of an equilateral triangle. They are used for
rectangular cuts and filing corners less than 90.
g. Half round file: This is tapered double – cut and its cross section is not
a half circle but only about one-third of a circle. This file is used for
round cuts and filing curved surfaces.

DRILL NOMENCLATURE
HACK SAW

h. Knife edge file: this is shaped like a knife, tapered in width and
thickness and double – cut. They are used filing narrow slots, notches,
and grooves.
iii. SPECIAL TYPE FILES
There are number of file in less common use. They are all used for
special purposes and not in general use. They are wording file, needle file,
riffler etc.
A wording file is a thin flat file having fine cut teeth, about 100 mm long.
This is widely employed for all kinds of fine work.
A needle file is made in sizes from 100 to 200 mm, of various shapes and
cuts. They are extremely delicate and are used for fine work.
Rifflers are curved upwards at the ends into an arc. They are used to reach
the bottom of a sinking and for filing the insides of castings.
b. HACKSAW
It is used to cut metals of different sections. It is also used to cut slots and
contours. It consists a frame, blade and handle. There are two types of
hacksaw frames.
(a) Solid frame
(b) Adjustable frame
The blade is fixed with its teeth facing forward so that it cuts material in the
forward stroke. The frame is made of mild steel whereas the blade is made of
high carbon steel.
c. CHISELS
Chisels are used for cutting and chipping away pieces of metal and are
made of carbon steel usually rectangular, hexagonal or octagonal cross
section. They are forged to shape, roughly ground, and then hardened and
tempered. Afterward the edge is ground sharp to the correct cutting angle,
care being taken not to overheat the steel and draw the temper. The cutting
angle given to the chisel is determined mainly by the nature of the metal to
chip. It varies between 35 and 70°, the less acute angles being for the harder
and tougher metals.


1. FLAT CHISEL
The flat chisel as shown in figure is the most common of all the chisels
used in engineering. It is the chisel which is used for most of the general
chipping operations. It may be used for removing surplus metal from surfaces
of the jobs.
2. CROSSCUT CHISEL
The cross-cut chisel figure or cape chisel as it is sometimes called, is used
for cutting grooves in large surfaces previous to using the flat chisel, and is
also used in cutting key ways in wheels and shafts. The cutting edge is
slightly wider than the supporting metal to provide clearance.
3. HALF ROUND CHISEL
A half – round chisel is shown in figure and of particularly useful for
cutting oil-ways or grooves in bearing, bosses and pulleys, etc. they are also
used for setting-over pilot holes.
4. DIAMOND POINT CHISEL
The diamond-point chisel as shown in figure is used for cutting vee
grooves, cleaning corners and squaring small holes. The chisel is drawn to a
square section. The end is ground off at an angle producing the diamond
shape.
5. SIDE CHISEL
A side chisel is shown in figure. This is particularly useful in chipping and
removing the surplus metal in cotter ways and slots, which may have to be
cut by hand after having been drilled. The shank of this chisel is bent out a
little sideway and then vertically down again.
3. STRIKING TOOLS
a. BALL PEEN HAMMER
It is a striking tool suitable for forming rivet head and weighs from 0.5 to
1.5 kg. it is used for striking punches while marking.
b. STRAIGHT PEEN HAMMER
It is used to spread metal at right angle to the line of striking and for using
in corners and slot & weighs from 0.5 to 1.5 kg.
c. CROSS PEEN HAMMER
It is used to spread metal in the line of striking and weigh from 0.5 to 5 kg.
It is also used for striking small work piece.


d. SLEDGE HAMMER
It is a striking tool which is comparatively larger in size and heavier in
weight and weight of it range from 3 to 8 kg. It is used for striking flat
surface.
4. HOLDING DEVICES
a. BENCH VICE
It is made of cast iron or cast steel and it is used to hold work for filing
sawing, threading and other hand operation. It consists of a fixed jaws and
movable jaws. The size of the vice is specified by the width of the jaws and
maximum opening between the jaws.
b. LEG VICE
It is used by black smith but it is also suitable for heavy hammering,
chipping and cutting in fitters work.
c. HAND VICE
It is used for holding screws, rivets, keys and other similar object which are
too small to be conveniently held in the bench vice. The vice is held in one
hand and the required operation is performed by other hand.
d. PIN VICE
It is used for holding small diameter works, such as wire and pins. The
work is gripped between the jaws of the chuck by rotating the handle.
e. TOOL MAKERS VICE
It is particularly useful for holding small work which require filing or drilling
and for such work as laying out small jobs on the surface plate. It is made of
mild steel.
5. SPECIAL TOOLS
a) REAMER
Reaming is an operation of correcting the dimension of holes which is
produced by drilling or other machining process. Hand reaming is done when
exactness is required. Lubrication may be used while reaming is performed
and reamer is turned only in the clockwise direction even when removing it
from the hole.
A reamer is used for finishing a drilled hole to an accurate size and to
produce a good surface finish. It is made of HSS. There are three types of
reamers:

TAP AND DIE

1. Hand reamer
2. Machine reamer
3. Expanding reamer
b) TAP AND TAP WRENCHES
Tapping is an operation of cutting inside threads, after the hole has been
drilled with the tap drill.
Tapping has three steps; first work is clamped in a vice with the hole in the
upright position. A rougher (taper tap) is used in the next step. Second tap
(plug tap) is used the second stage. For finishing the operation, bottoming
tap is used. For perfection, appropriate lubricants can be used while cutting.
The figure explains the tapping operation.
A tap is hardened steel tool used for cutting internal threads in a drilled hole.
Hand taps are available in sets containing three taps. Taper tap, Second tap,
and plug or bottom tap.
TAP DRILL SIZE
The tap drill size may be derived from the following formula:
D = T – 2d
Where,
D = Diameter of the tap drill size.
T = Diameter of tap or bolt to be used
D = Depth of thread
c) DIE
Cutting external threads on a round rod or bolt with a die and stock is called
dieing or external thread cutting.
Dies are cutting tools used for making external threads. They are made of
tool steel or high carbon steel.
There are mainly two types of dies in common use:
1. Solid die
2. Adjustable die
SOLID DIE
It is one of which has fixed dimension and cannot be adjusted for larger or
smaller diameter.

DIAL GAUGE
BENCH DRILLING MACHINE

ADJUSTABLE DIE
It can be set to cut larger or smaller diameter.
d) STOCK
The tool for holding and turning the threading die is called a die stock.
e) DRILLS
Drills are cutting tools used for making holes. These are naturally made of
high speed steel tools. Drills have two cutting edges and two helical grooves
(flutes). The flutes admit coolants and also allow the chips to escape during
the drilling. Its cutting angle (lips) is grounded to 118˚. The shank of twist
drill may be either straight or taper.
6. DRILLING MACHINE
The drilling machine or drill press is one of the most common and useful
machine employed in industry for producing forming and finishing holes in a
work piece. The unit essentially consists of: - A spindle which turns the tool
(called drill) which can be advanced in the work piece either automatically or
by hand. - A work table which holds the work piece rigidly in position.
Working principle:
The rotating edge of the drill exerts a large force on the work piece and the
hole is generated. The removal of metal in a drilling operation is by shearing
and extrusion. The machine has only a hand feed mechanism for feeding the
tool into the work piece. This enables the operator to feel how the drill is
cutting and accordingly he can control the down feed pressure. Sensitive drill
presses are manufactured in bench or floor models, i.e., the base of machine
may be mounted on a bench or floor.
7. GAUGES
Gauges are inspection tools used in production work to control the size and
shape of the components.
a) DIAL GAUGE
Dial gauges or dial indicators are used to true and align machine tools,
fixtures and work, to test and inspect the size and trueness of a finished work
to an accuracy of 0.01mm. They are also used in conjunction with other
measuring instruments example, inside calipers, depth gauges etc to
measure inside and outside dimensions errors in parallelism, flatness etc.

FEELER GAUGE
SCREW PITCH GAUGE
RADIUS AND FILLET GAUGE

b) FEELER GAUGE
These are thin steel blades hardened and grounded to various sizes. These
are used to check the clearance between two mating parts. The blade
thickness varies from 0.03mm – 1.0mm and the length of the blade is about
100mm.
c) SCREW PITCH GAUGE
It is used to check the pitch of the screw. They consist of a number of flat
blades which are cut out to a given pitch and pivoted in a holder. Each blade
is stamped with the pitch or number of threads per inch and the holder bears
an identifying number designating the thread it is indented for.
d) RADIUS AND FILLET GAUGE
These are used to check the radii of curvature of convex and concave
surfaces. In the gauge, its measuring range is punched.

Exercise No: 1 Date:
T - JOINT
16
All dimesnsions are in mm
Scale 1:1

T - JOINT
AIM
To make a T – joint with MS flat piece as per given sketch.
MATERIALS REQUIRED
MS flat plate of size 70 x 50 x 6 mm.
TOOLS REQUIRED
Flat file, hacksaw frame with blade, try square, steel rule, scriber, surface
plate, V-block, vernier height gauge, ball peen hammer, center punch, drilling
machine with drill bit, chisel and square file.

Measuring, marking, cutting, filing, drilling, chiseling, checking and finishing.
PROCEDURE
- Hold the MS flat work piece in the bench vice and file one of its edges.
- Check the flatness of that edge using try square. File the adjacent side to
get perpendicular edge.
- Apply a thin layer of chalk paste on one face of the work piece.
- Mark the dimensions as per figure.
- Punch dots on marked lines.
- Cut the work piece along punch mark using hack saw.
- Remove the unwanted portion by cutting, drilling, chiseling and filing.
- Properly file and make the male and female part as per the given sketch.
Check the dimensions, fit and finish the work

V - JOINT
Scale 1:1

V - JOINT
AIM
To make a V – joint with MS flat piece as per given sketch.
MATERIALS REQUIRED
TOOLS REQUIRED
plate, V-block, vernier height gauge, ball peen hammer, center punch,
triangular file.

Measuring, marking, cutting, filing, checking and finishing.
PROCEDURE
- Remove the unwanted portion by cutting and filing.
Check the dimensions, fit and finish the work

DOVE TAIL JOINT
Scale 1:1

DOVE TAIL JOINT
AIM
To make a Dove tail joint using MS flat as per given sketch
MATERIALS REQUIRED
MS flat flat of size 72 x 50 x 6 mm.
TOOLS REQUIRED
Steel rule, try square, flat file, hacksaw frame with blade, bench vice, punch,
hammer, drilling machine and drill bit, vernier height gauge & scriber

Measuring, marking, cutting, filing, drilling, chiseling, checking and finishing.
PROCEDURE
- Hold the MS flat work piece in the bench vice and file one of its edge.
- Remove the unwanted portion by cutting, drilling and filing.
- Check the dimensions, fit and finish the work

THREAD CUTTING PRACTICE
Scale: NTS

THREAD CUTTING PRACTICE
AIM
To make internal and external threads on given MS flat and rod as per given
sketch.
MATERIALS EQUIRED
MS rod of size diameter 12mm and length 40mm.
TOOLS REQUIRED
plate, V-block, vernier height gauge, ball peen hammer, center punch, round
file, tap and die set, reamer, drilling machine with drill bit.

Measuring, marking, cutting, chalk applying, filing, drilling, tapping, dieing,
checking & finishing.
PROCEDURE
INTERNAL THREAD CUTTING (TAPPING)
- Punch dots on marked lines to get the V-joint fit.
- Remove the unwanted portion by cutting, drilling, chiseling and filing.
- Mark centre point of the hole as per the figure.
- Hold the work piece in the drilling machine vice and drill 9.5mm hole.
- Ream the hole to correct the diameter of the hole to 10mm.
- Tap the internal thread using taper tap, intermediate tap and finishing tap
(bottoming tap).


- Check the pitch of the thread using screw pitch gauge

EXTERNAL THREAD CUTTING (DIEING)
- Cut the given MD rod of diameter 12mm to a length of 40mm.
- File one end of the rod to square shape as in the figure.
- Hold the square head in bench vice and make external thread using die
with the size 12mm.
- Cut the thread up to a length 25mm.
- Check the thread profile using screw pitch gauge.

Workshop Practice Manual (Sem-3&4) - Welding
WELDING
Semester 3&4

WELDING SAFETY PRECAUTIONS
To prevent injury to personnel, extreme caution should be exercised when

using any types of welding equipment. Injury can twill from fire, explosions,
electric shock, or harmful agents. Both the general and specific safety
precautions listed below must be strictly observed by workers, who weld or
cut metals,
 Do not permit unauthorized persons to use welding or cutting,
equipment.
 Do not weld in a building with wooden floors, unless the floor', are
protected from hot metal by means of fire, resistant fabric, and, or
other fireproof material. Be sure that hot sparks or hot metal will not
fall on the operator or on any welding equipment components.
 Remove all flammable material, such as cotton, oil, gasoline, etc from
the vicinity of welding.
 Before welding or cutting, warn those in close proximity who are not
protected to wear proper clothing or goggles.
 Remove any assembled parts from the component being welded that
may become warped or otherwise damaged by the welding process.
 Do not leave hot rejected electrode stubs, steel scrap, or tools on the
floor or around the welding equipment. Accidents and/or fires may
occur.
 Keep a suitable fire extinguisher nearby at all times. Ensure the fire
extinguisher is in operable condition.

WELDING
Electric Welding Process Gas Welding Process Other Welding Processes
Oxy- Oxy- Oxy- Oxy- Air-

acetylene hydrogen coal liquefied acetylene
gas gas gas gas gas
welding welding welding welding welding
Electric Induction Laser Electron Electric Thermit Forge Plastic Friction Ultrasonic Explosive Cold
Maharaja’s Technological Institute (MTI), Thrissur

Arc Welding welding Beam Resistance Welding Welding welding welding welding welding Pressure
Welding welding welding welding
Spot Seam Butt Flash Projection

Welding Welding welding Butt welding
welding
Metallic Carbon MIG TIG Atomic CO Flux Submerged Electro Plasma

Arc Arc welding welding Hydrogen Gas Cored Arc Slag Arc
welding welding Arc Arc Arc welding welding welding
welding welding welding
74 | Page
WELDING
INTRODUCTION
Welding is a process of joining similar or dissimilar metal pieces. Welding is
metal joining method in which the joining edges are heated and fused
together to form a permanent bond. Riveting, assembling with bolt, seaming,
soldering and brazing all result in temporary joints. Welding is the only
method to join metals permanently. It is the strongest joints and type of
metal any thickness can be joined. Welding joints cannot b separated like
soldering and brazing because it is made homogeneous by heating and fusing
the joining edges together. Even though there is draw back in welding joints
because of the twisting due to shrinkage of joints while the solidification of
molten material in the joints. Welding is superior to other metal joining
methods because it.
- It is a permanent pressure tight joint.
- Occupies less space
- Gives more economy of material
- Has less weight
- Withstands high temperature and pressure equal to joint material
- Can be done quickly
- Gives no color change to joints
Welding methods are classified in to:
1. Fusion method without pressure/with pressure
2. Non fusion method
FUSION WELDING WITHOUT PRESSURE
A method of welding in which similar and dissimilar metals are jointed
together by melting and fusing their joining edges with or without the
addition of filler metal but without the application of any kind of pressure os
known as fusion welding. The joint made is permanent.
PRESSURE WELDING
This is a method of welding in which similar metals are joined together by
heating them to plastic or partially molten state and then joined by pressure
or hammering without the use of filler metal. This is fusion method joining
with pressure. The joint is made permanent. Heat source may be black
smiths forge (forge welding) or electric resistance (resistance welding) or
friction.

ARC WELDING PROCESS
TYPES OF WELDED JOINTS

NON FUSION WELDING

This is a method of welding in which similar or dissimilar metals are joined
together without melting the edges of the base meal by using a low melting
point filler rod but without the application of pressure.
Eg: soldering, brazing and bronze welding.
ARC WELDING
PRINCIPLE
Electric arc is formed when both the terminals of an electric circuit are
brought together and then separated by a small gap. When high current
passes through an air gap from one conductor to another, it produces very
intense and concentrated heat in the form of a spark. The temperature of this
spark (or arc) is approximately 3600°C, which can melt and fuse the metal
very quickly to produce a homogeneous weld.
ARC LENGTH
It is the straight distance between the electrode tip and the job surface when
the arc is formed. There are three types of arc lengths,
1. Medium and normal
2. Long
3. Short
1. Medium or Normal Arc
The correct act length or normal arc length is approximately equal to the
diameter of the core wire of the electrode. It is used to weld mild steel using
a medium coated electrode.
2 .Long Arc
If the distance between the tip of the electrode and the base metal is more
than the diameter of the core wire it is called a long arc. It is used in plug
and slot welding, for restarting the arc and while withdrawing the electrode at
the end of a bead after filling the crater. Generally long arc is to be avoided
as it will give a defective weld.
3. Short Arc
If the distance between the tip of the electrode and the base metal is less
than the diameter of the core wire, it is called a short arc. It s used for root
runs to get good root penetration for positional welding and while using a
heavy coated electrode, low hydrogen, iron, power and deep penetration
electrode.

WELDING POSITIONS

POLARITY IN ARC WELDING

Polarity indicates the direction of current flow in the welding circuit. Direct
current always flows from, the positive (higher potential) terminal to the
negative (lower potential) terminal, as per the conventional theory. Negative
terminal to positive terminal, as per electronic theory. In the latest machines
a polarity switch is used to change the polarity.
In AC, we cannot utilize the polarity as the power source changes its poles
frequently.
In DC welding, 2/3rd of the heat is liberated from the positive end and 1/3rd
from the negative end. To have this advantage of unegual heat distribution in
the electrode end base metal, the polarity is an important factor of successful
welding.
TYPES OF POLARITY
Straight polarity: In straight polarity, the electrode is connected to the
negative and the work to the positive terminal of the power source.
Reverse Polarity: In reverse polarity the electrode is connected to the positive
and the work to the negative terminal of the power source.
ELECTRODE SIZES
The electrode size refers to the diameter of its core wire. Each electrode has
a certain current range. The welding current increases with the electrode
sizes.
Electrode Sizes:-
1.6mm, 2.0mm, 2.5mm, 3.15mm, 4.0mm, 5.0mm, 6.0mm, 6.3mm, 8.0mm,
10.mm. the electrodes are manufactured in two different lengths, 350mm or
450mm.
TYPES OF ELECTRODE
Electric arc welding electrodes are of three general types. They are carbon
electrodes, bare electrodes, flux coated electrodes.
ARC WELDING MACHINES
In arc welding process, the sources of het is electricity (high ampere-low
voltage). The required electrical energy for welding is obtained from an arc
welding machine, a power source.

WELDING TRANSFORMER
LAYOUT OF ARC WELDING EQUIPMENT

The equipment is used to,

- Provide AC or DC welding supply for arc welding.
- Change the high voltage of the main supply to low voltage and
heavy current supply (AC or DC) suitable for arc welding.
- Establish a relationship between arc voltage and welding current.
- Control and adjust the required welding current during arc welding.
- Weld with all gauges of electrode.
- Weld with all gauges of electrode.
- Weld thin and thick plates, both ferrous and non ferrous metals.
Basically, power sources are:

1. Alternate current welding machine
2. Direct current welding machine
DC MACHINES: 1. Motor generator set

2. Engine generator set
3. Rectifier set
AC MACHINES: 1. Transformer set
AC WELDING TRANSFORMER
This is a type if AC welding machine which converts AC main supply into AC
welding supply. AC main supply has high voltage-low ampere. AC welding
supply has high ampere-low voltage. It is a step down transformer, which:
- Reduces the main supply voltage (220v or 440v) to welding supply
open circuit voltage (ocv) between 40 and 100 volts.
- Increases the main supply low current to the required high output
welding current in hundreds of amperes.
The main AC supply (220-440v) is connected to the primary winding which
produces a magnetic line of force in the iron core. The magnetic lines of force
affect the secondary winding and induce high ampere-low voltage welding
supply in it. This action is called the principle of mutual induction.


DC WELDING GENERATOR
DC welding generator are used to,
- Generate DC welding supply with the help of AC main supply
- Generate welding supply where electricity (main supply) is not
available, with the help of engine driven sets.
- Get relative advantages of polarity, heat distribution between the
electrode and the base metal and welding non ferrous metals.
COMPARISON BETWEEN AC AND DC ARC WELDING
AC ARC WELDING DC ARC WELDING
1. The AC welding transformer has no 1. The DC welding generator has
moving parts and is simpler. rotating parts and is more
complicated.
2. The transformer costs less and its 2. The generator cost more and its
maintenance cost is low maintenance cost is high
3. Since the distribution of heat is 3. Heat distribution is different in two
equal, therefore there is no need for poles by changing the polarity, all
changing. Hence only ferrous metals types of metals can be welded by DC
are usually welded by AC
4. All types if electrodes cannot be 4. All types of electrodes bare or
used in AC arc welding, because the coated can be used in DC arc
current constantly reverses with welding, because the polarity can be
every cycle. Only coated electrodes changed to suit the electrode.
can be used.
5. The problem of arc blow does not 5. In DC the arc blow is severe and
arise as it is very easy to control. cannot be controlled easily.
6. The arc is never stable 6. The arc is more stable.
7. It can be used only when AC 7. In the absence of AC main supply,
supply from the main is available. an engine driven DC generator set
can be used.
8. AC is more dangerous. 8. DC is comparatively less
dangerous.


WELDING DEFETCS
Always a defective welded joint will have the following bad effects:
- The effective thickness of the base metal is reduced
- The strength of the weld is reduced
- The joint will break, when loaded, causing accident.
- The effective throat thickness is reduced.
- The properties of base metal will change
- More electrodes are required which will also increase the cost of
welding
- Waste of labour and materials
- The weld appearance will be poor
Weld defects may be considered under two heads. External defects

and internal defects.
EXTERNAL DEFECTS INTERNAL DEFECTS
1. Under cut 1. Cracks
2. Cracks 2. Blow hole and porosity
3. Blow hole and porosity 3. Slag inclusions
4. Slag inclusions 4. Lack of fusion
5. Edge of plate melted off 5. Lack of root penetration
6. Excessive convexity 6. Internal stresses
7. Excessive concavity
8. Overlap
9. Mismatch
10. Uneven/irregular bead appearance
11. Spatters

GAS TUNGSTEN ARC WELDING
GAS METAL ARC WELDING

GAS TUNGSTEN ARC WELDING (TIG)

The gas tungsten arc welding process fused melts by heating them between a
non consumable tungsten electrode and work piece. The heat necessary for
fusion is provided by an arcing electric current between the tungsten
electrode and the base metal. The tungsten electrode and the weld zone are
shielded from the atmosphere by an inert has, such as argon or helium. Filler
metal may be or may not be used, this process is also called TIG (Tungsten
Inert Gas) welding. This welding is used for stainless steel, aluminium,
titanium and many other non ferrous metals. Tig welding process produces
sound weld because there is very little smoke, fumes or sparks.
Advantages:
- Highly suitable for joining reactive metals like stainless steel,
aluminium, magnesium etc.
- More economical use of filler wire and higher welding speed
- It is always clean and without any oxidation
- It produces high quality weld in non ferrous metals
- The arc and weld pool are clearly visible to the welder
GAS METAL ARC WELDING (MIG)
Gas metal arc welding is a gas shielded metal arc welding process which uses
the high hear of an electric arc between a continuously fed, consumable
electrode wire and the material to be welded. In this process the wire is fed
continuously from a reel through a gun to constant surface which imparts a
current upon the wire. A fixed relationship exists between the rate of wire
burn off and the welding current. The current ranges from 100 to 400A
depending upon the diameter of wire and the speed of melting of the wire
may be upto 5m/min. In this welding, the welding area is flooded with a gas
(an inert gas) which will not combine with the metal. The rate of flow of this
gas is sufficient to keep oxygen of the air away from the hot metal suface
while welding is being done. Carbon dioxide (CO2), Argon helium mixtures,
argon-oxygen mixtures are used as inert gases for this welding.

SPOT WELDING

Advantages:
- No flux required
- High welding speed
- Increased corrosion resistance
- Easily automated welding
- Welds all metals including aluminium and stainless steel
- High economy
SPOT WELDING
This type of resistance welding machine is most commonly used for
resistance welding. The material to be joined is placed between two
electrodes. Pressure is applied after a quick shot of electricity is sent from
one electrode through the job to the other electrode. Spot welding is made in
three steps. The first step is when the parts to be joined are clamped
between the electrodes. In the second step a high current is allowed to pass
through the clamped members and is raised to the welding temperature. The
third step sees the current being cut off and high pressure being applied to
the joint and the joint completed.
The pressure may be developed by afoot lever or by air pressure or by
hydraulic cylinders. This may be used to weld steel and other metal parts up
to a total thickness of 12 mm. A special copper alloy material has been
developed for use as electrodes. It can be used for steel, aluminium, copper,
stainless steel, galvanized metals etc.
GAS WELDING
Gas welding is a process o joining similar metal by a gas flame with the
application of pressure and with or without use of filler metal. Oxy-acetylene
flame and oxy-hydrogen flame are generally used in this process.
EQUIPMENTS AND ACCESSORIES FOR GAS WELDING
1. Cylinders
2. Regulators
3. Low pressure gas generator
4. Hose pipes
5. Hose clips
6. Hose protector


7. Blow pipe
a). high pressure blow pipe
b). low pressure blow pipe
8. Gas cutting torch and railing
9. Spanners
10. Cylinder key
11. Welding goggles and helmet
12. Spark lighter
13. Protective clothings
14. Tongs
15. Tip cleaner
16. Chipping hammer
17. Carbon steel wire brush
In a gas welding the direction of travel and the tilt of the torch and the
welding rod have appreciable effects on the speed and quality of welding.
Three typical procedures that may be employed are,
1. Leftward or forward
2. Rightward or backward
3. Vertical
The temperature of the oxy-acetylene flame in its hottest region is about
3200°C.
The functions of a pressure regulator are, to reduce the cylinder pressure to
the required working pressure and also to produce a steady flow of gas
regardless of the pressure variations at the source.
REGULATOR PRESSURE FOR GAS WELDING
The pressure required for gas welding depends on the thickness of the plates
to be welded. For plates of thickness of about 1 to 25mm, the regulator
pressure in oxygen and acetylene varies from 0.15 to 0.75kg/cm2 (15 to
70kN/m2) and for plate thickness over 25mm, the pressure of each gas is
about 0.98 kg/cm2 (98 kN/m2).
The cutting torch differs from the regular welding blowpipe in most cases; it
has an addition lever for the control of cutting oxygen used to cut the metal.

CUTTING TORCH

Usually different tip sizes are provided for cutting metals of different
thickness.
Pieces of wires or rods of standard diameter and length used as filler metal in
the joint during gas welding process are called filler rods or welding rods. The
size of the filler rod is determined from the diameter as 1.0, 1.2, 1.6, 2.0,
2.5, 3.15, 4.0, 5.0 and 6.3mm. length of filler rod 500mm or 1000mm.
Oxygen cylinders painted in black colour. Oxygen cylinders can store gas to a
capacity of 7 m3 with the pressure ranging between 120 to 150 kg/cm2.
Oxygen has cylinder valves are right hand threaded. Acetylene cylinders are
painted in maroon colour. The normal storing capacity of storing acetylene in
dissolved state us 6 m3 with the pressure ranging between 15-16 kg/cm2.
Acetylene gas cylinder valves are right hand threaded.
Blowpipes are used to control and mix the oxygen and acetylene gases to the
required proportion. The size of the nozzle varies according to the thickness
of the plates to be welded.
TYPES OF FLAME
There are three types if flame producing in the oxy-acetylene process.
NEUTRAL FLAME
Oxygen and acetylene are mixed in equal proportion in the blowpipe. It is
used to weld most of the common metals ie. Mild steel, cast iron stainless
steel, copper and aluminium.
OXIDISING FLAME
It contains an excess of oxygen over acetylene as the gases come out of the
nozzle. It is used for welding of brass and for brazing of ferrous metals.
CARBURISING FLAME
It receives an excess of acetylene over the oxygen from the blowpipe. It is
used for welding of aluminum.
OXY-ACETYLENE CUTTING PROCEDURE
Fix a suitable size cutting nozzle in the cutting blow pipe. Ignite the torch in
same way as was done in the case of the welding pipe. Set the neutral flame
for preheating. To start the cut, hold the cutting nozzle at angle 90° with the
plate surface, and the inner cone of the heating flame 3mm above the metal.

TONGS
EARTHING CLAMP
CHIPPING HAMMER
WIRE BRUSH

Preheat the metal to bright red before pressing the cutting oxygen lever. If
the cut is proceeding correctly, a shower of sparks will be seen to fall from
the underside of the plate. Move the torch steadily on the punched line. If the
edge of the cut appears to be too ragged, the torch is being moved too
slowly. For a bevel cut, hold the cutting torch at the desired angle and
proceed as is done in making a straight line cut. At the end of the cut, release
the cutting oxygen lever and close the control valves of the oxygen and
acetylene. Clean the cut and inspect.
TOOLS
1. CHIPPING HAMMER
A special type of hammer having one end sharpened and the other end
flattened. It is used for chipping the slag after welding and it is made with
mild steel or high carbon steel.
2. EARTHING CLAMP OR GROUND CLAMP
The ground clamp that complete the circuit between the electrode and the
welding machine is generally fastened to the metal being welded either with a
clamp, a bolt or some other means depending on the size of the metal
3. WIRE BRUSH
The wire brush, which removes small particles of slag , is generally made
of stiff steel wire embedded in wood.
4. ELECTRODE HOLDER
It is fitted at the end of the electrode cable. It should be light in weight and
well insulated the holder should have sufficient current carrying capacity.
5. CABLES AND CABLE CONNECTORS
Cables or leads are intended to carry the electric energy from welding
machine to work. The cables are flexible and well insulated .The cables are
generally made up of copper or aluminum wire. Welding cables are connected
by mechanical connectors soldering, welding or brazing . The mechanical
connectors are the connection leads that are probably most used because
they can be more easily assembled and dismantled .
6. CABLE LUGS
Cable lugs are used for connecting the cables to the welding machine. One
of the cables fastened to the cable lug by means of soldering or pressing

FACE SHIELD HAND GLOVES
ELECTRODE HOLDER CABLE LUG

7. FACE SHIELD
Face shield must be used to protect the operators face and eyes from flying
particles of spatters and burning action of the ultraviolet and infra red rays
given off by the arc. There are two types of lences used in the protective
shield known as colour lenses and cover glass. The colour lens is designed to
absorb the infra red rays and ultraviolet rays. Cover glasses are used in front
of the colour lens to prevent weld spatters from making or clouding the
colour lens chemically treated non spatters cover glasses to provide the best
protection.
8. HAND GLOVES
Hand gloves are used to protect the hands from the ultra violet and infra
red radiations as well as the heat that is given off by the arc column. Hand
gloves also protect the hand from minor burns during the chipping
operations. The gloves should be worn at all times during the welding
process.
9. APRONS
Aprons are two types, asbestos apron and lead limed leather aprons. Apron
is also protective clothing used to prevent the hot metal and harmful hot rays
attack on the body.
10. SAFETY GOGGLES
Goggles made of plastic frame and plane protective glasses are used while
chipping, so that any particles of slag may not strike on the eyes.
*****

Exercise No.1
Date:
SINGLE V-BUTT JOINT IN DOWN HAND POSITION
6
37
37 100
BEVELLING
4
2 3
ROOT GAP ROOT FACE
Scale 1:1

Exercise No.1 Date:

SINGLE ‘V’ BUTT JOINT IN DOWN HAND POSITION
AIM
To make a single ‘V’ butt joint in D.H.P. by electric arc welding.
MATERIALS REQUIRED
MS flat 102 x 40 x 6 mm - 2 No.
MS Electrode – ∅3.15mm x 350 mm – 2 No.
TOOLS AND EQUIPMENTS REQUIRED

Steel rule, Try square, scriber, hacksaw, bench vice, flat file, face shield,
apron, gloves, tongs, chipping hammer, wire brush, flat chisel and ball peen
hammer, welding machine and accessories.

Measuring, marking, cutting, holding, filing, beveling, setting, tacking,
welding, chipping and cleaning.
PROCEDURE
- Prepare the MS flat in required dimensions
- Bevel the edges for single V groove
- Set the pieces with root gap on the welding table as per figure
- Switch ON the welding machine and set the current 130 Amps for 10
SWG electrode
- Tack at two ends of the joint
- Weld through the V groove in down hand position with proper arc
length and speed
- Hold the work piece with tongs and chip out the slag and spatters
- Clean the weld bead with wire brush and subject to visual inspection
RESULT
Single V butt joint is obtained

Exercise No.2
Date:
FILLET ‘T’ JOINT IN HORIZONTAL POSITION
37
0
10
37
Scale 1:1

Exercise No.2 Date:
FILLET ‘T’ JOINT IN HORIZONTAL POSITION
AIM
To make a fillet ‘T’ joint in horizontal position by arc welding method
MATERIALS REQUIRED
MS flat 102 x 40 x 6 mm - 2 No.

PROCEDURE
- Set the pieces for fillet ‘T’ joint as per figure
SWG electrode
- Tack at the two ends of the joint
- Weld through the ‘T’ joint in horizontal position
- Hold the work piece with tongs and chip out the slag and spatters
- Joint subject to visual inspection
RESULT
Obtained fillet ‘T’ joint

Exercise No.3
Date:
FILLET ‘T’ JOINT IN VERTICAL POSITION
6
37
37
100
Scale 1:1

Exercise No.3 Date:

FILLET ‘T’ JOINT IN VERTICAL POSITION
AIM
To make a fillet ‘T’ joint in vertical position by electric arc welding
MATERIALS REQUIRED
MS flat 102 x 40 x 6 mm - 2 No.

PROCEDURE
- Set the pieces for fillet ‘T’ joint as per figure
SWG electrode
- Tack at the two ends of the joint
- Weld through the ‘T’ joint in vertical position
- Hold the work piece with flat tongs and chip out the slag and spatters
- Clean the job by wire brush and subject to visual inspection
RESULT
Obtained fillet ‘T’ joint in vertical position

Workshop Practice Manual (Sem-3&4)- Machine Shop
MACHINE SHOP
Semester 3&4

LATHE MACHINE

MACHINESHOP
INTRODUCTION
The machine shop is the production centre where the machining processes
consists of turning, cutting, shaping, drilling etc. can be done and the end
product of the industry can be the basic components of the products of other
industries like the machine industry, the aircraft industry, the car industry or
others.
A machine tool is a machine for making articles of a given shape, size and
accuracy according to the drawing by removing metal from the work piece.
The machine tools typically include lathes, milling machines, shaper, planing
machines, drill presses or grinding machines, many controlled with CNC.
INTRODUCTION TO LATHE
A lathe is a tool that rotates the work piece about an axis of rotation to
perform various operations such as cutting, facing, turning, knurling, drilling,
deformation, and with tools that are applied to the work piece to create an
object with symmetry about that axis.
The origin of modern lathe can be traced back to the time when the Industrial
Revolution took place. During that golden period, a number of mechanisms
were introduced to lathe. These mechanisms enabled humans to operate
lathe semi-automatically. Power generated from steam engines were used to
drive lathes. Nowadays, the machines receive its power from an individual
electric motor integral with the machines.
PRINCIPAL LATHE PARTS
LATHE BED
The lathe bed forms the base of the machine and all other parts are fitted
on it. The headstock and the tailstock are located at either end of the bed and
the carriage rests over the bed and slides on it. Lathe bed is made up of cast
iron alloyed with nickel and chromium.
HEAD STOCK
The headstock is normally mounted rigidly to the bed and holds all the
mechanisms that provide mechanical means of rotating the work at multiple
speeds. The spindle, carrying the work revolves on heavy duty bearings in
the headstock.

ORDINARY CENTRE TIPPED CENTRE
BALL CENTRE INSERT TYPE CENTRE
FRICTIONLESS CENTRE PIPE CENTRE
HALF CENTRE
LATHE CENTRES

LATHE SPINDLE
It is a hollow part, made of carbon or nickel chrome steel and perfectly
aligned with the lathe axis. The end of the headstock spindle is usually
machined, so that it can carry a faceplate, chuck, drive plate, internal or
external collets or even special attachments designed for particular jobs.
TAIL STOCK
The unit is arranged to slide along the bed and can be locked to it at any
convenient point. It supports the other end of the work or holds a tool for
performing operations like drilling, reaming, tapping etc.
CARRIAGE
The whole assembly of saddle, cross slide, compound slide or compound
rest, tool post, and apron is known as the Carriage. It serves to support,
move and control the cutting tool.
FEED MECHANISM
The movement of the tool relative to the work is termed as Feed. The feed
mechanism has different units, such as End of bed gearing, Feed gear box,
Feed road and Lead screw, Apron mechanism etc, through which motion is
transmitted from the head stock spindle to the carriage.
THREAD CUTTING MECHANISM
The rotation of the lead screw is used to transverse the tool along the work
to produce screw thread. A pair of half nuts or the half nut mechanism makes
the carriage to engage or disengage with the lead screw. Closing the half
nuts causes the carriage to move a fixed distance for each revolution of the
spindle.
WORK HOLDING DEVICES/ ACCESSORIES & ATTACHMENTS
LATHE CENTRES
Holding the work between the two centres- live centre and dead centre is a
common method in Lathe machine. They are made of very hard materials to
resist deflection and wear. The angle of the centre is usually 60° and the
shanks are machined to the Morse or Metric standard tapers.
Ordinary centre, tipped centre, ball centre, frictionless centre, half centre,
insert type centre and pipe centre are the different types of lathe centres.

CATCH PLATE LATHE CARRIERS
FOUR JAW CHUCK
THREE JAW CHUCK

CARRIERS AND CATCH PLATES

Carriers (driving dogs) and Catch plates are used together to drive a work
piece when it is held between two centres. The catch plates screwed to the
head stock spindle and the carriers attached to the end of work piece impart
positive drive to the work piece.
CHUCKS
A chuck is one of the most important devices for holding and rotating a
piece of work in a lathe. Work pieces of short length and large diameter or
irregular shape can be mounted rigidly in a chuck. The different types of
chucks are:
- Four jaw independent chuck - Three jaw universal chuck,
- Combination chuck - Hydraulic operated chuck
- Magnetic chuck - Collets chuck
- Drill chuck
Four jaw chuck has four jaws which may be made to slide within the slots
provided in the body of the chuck for gripping different sizes of work piece.
Each jaw may be moved independently by rotating the screw which meshes
with the teeth cut on the underside of the jaw.
In a three jaw universal chuck all the jaws may be made to slide
simultaneously by an equal amount by rotating any one of the three pinions
which meshes with the teeth cut on the scroll disc.
FACE PLATES
A face plate consists of a circular disc bored out and threaded to fit the
nose of the lathe spindle. It has plain or ‘T’ slots for holding work by bolts
and clamps. Face plates are used for holding thin or irregular work pieces
which cannot be conveniently held between centers or by chuck.
ANGLE PLATES
This is a cast iron plate having two faces machined at right angles to each
other. Holes and slots are provided on both faces for clamping purposes.
Angle plates are used in conjunction with a face plate in lathe machine.

PLAIN MANDREL
STEP MANDREL
COLLAR MANDREL
CONE MANDREL
SCREWED MANDREL GANG MANDREL
EXPANSION MANDREL
FACE PLATE ANGLE PLATE

MANDRELS
A Mandrel is a device for holding and rotating a hollow piece of work that
has been previously drilled or bored. The work revolves with the mandrel
which is mounted between two centers. To avoid distortion and wear it is
made of high carbon steel. Different types of mandrels are employed
according to specific requirements.
PLAIN MANDREL
This type of mandrel is most commonly used in shops and finds wide
application where a large number of identical pieces having standard sizes
holes are required to be mounted on it.
STEP MANDREL
A step mandrel having steps of different diameters may be employed to
drive different work pieces having different sizes of holes without replacing
the mandrel each time.
COLLAR MANDREL
A collar mandrel is used for turning work pieces having holes of larger
diameter.
SCREWED MANDREL
Work pieces having internal threads are turned using screwed mandrel.
CONE MANDREL
This type of mandrel is suitable for holding work pieces having different
holes diameters.
GANG MANDREL
Gang mandrel is used to turn a set of hollow work pieces together.
EXPANSION MANDREL
This mandrel is used to grip work pieces having different hole diameters
within a limit.
RESTS
A Rest supports a long slender work piece, which is turned between
centers, at some intermediate point to prevent bending of the work piece due
to its own weight and vibrations set up due to the cutting force that acts on
it. The two types of rests used in an engine lathe are the steady rest and the
follower rest.

CHUCK KEY
SURFACE GAUGE
RADIUS AND FILLET GAUGE TOOL POST KEY
STEADY REST FOLLOWER REST

STEADY REST
Steady rest is clamped at any desired position of lathe bed. It consists of a
cast iron base, frame, three jaws and a hinge. The hinge facilitates setting
and removal of work pieces without disturbing the position of the steady rest.
FOLLOWER RESTS
A follower rest consists of a ‘C’ like casting having two adjustable jaws
which support the work piece. The rest is bolted to the back end of the
carriage and moves with it. The follower rest is used where the entire length
of the work piece is required to be turned without disturbing the setting.
CUTTING TOOLS
For general purpose work, the tool used in a lathe is a single point tool; but
for special operations multipoint tools may be used.
The commonly used single point tool in lathe machine is high carbon steel
or high speed steel tool bit which is either inserted in a forged carbon steel
tool holder or directly fitted in a tool post with the use of metal shims. The
cutting edges are ground to the shape to provide necessary tool angles.
IMPORTANT HAND TOOLS
SURFACE GAUGE
This is a most versatile instrument used in non-precision measurements. It
is generally used with surface plate for layout work and inspection. It can also
be usefully employed in setting up work or tools on the lathe machine. It
consists of a rigid base, a universal clamp, spindle and a scriber.
CHUCK KEY
Chuck key is used to hold an object with radial symmetry, especially a
cylinder in a lathe chuck. Often the jaws of chuck will be tightened or
loosened with the help of a chuck key, which is a wrench-like tool made for
the purpose.
TOOL POST KEY
The tool post key is a tool for tightening or loosening the cutting tool in a
lathe tool post. It has one end a square socket with the handle.
RADIUS AND FILLET GAUGE
Fillet or Radius Gauge is an external and internal radius on each leaf
permits both concave and convex surfaces to be measured. Radius and fillet
gauges are available as small steel inserts joined with a mounted design.

VERNIER CALIPER
DIGITAL VERNIER CALIPER
OUTSIDE MICROMETER

MEASURING INSTRUMENTS
VERNIER CALIPER
A vernier caliper is used to precisely measure linear dimensions. It can be
used for three types of measurements, outside distance, inside distance such
as the width of a groove or the diameter of a large hole, and depth, such as
the depth of a hole or the height of a step. The resolution or least count of
vernier calipers is usually 0.001 in, whereas the resolution of metric calipers
is 0.02mm.
MICROMETER
The micrometer is a precision measuring instrument, primarily used to
measure dimensions to an accuracy of 0.01mm. Each revolution of the
ratchet moves the spindle face 0.5mm towards the anvil face. The object to
be measured is placed between the anvil face and the spindle face. The
ratchet is turned clockwise until the object is ‘trapped’ between these two
surfaces and the ratchet makes a ‘clicking’ noise. This means that the ratchet
cannot be tightened anymore and the measurement can be read. There,
mainly three types of micrometers are used; Outside micrometer is used for
taking external measurements while the Inside micrometer is for internal
measurements. The depth micrometer is used for measuring depth of holes.
DIGITAL CALIPER
The Digital Caliper is a precision instrument that can be used to measure
internal and external distances extremely accurately; measurements are read
from a LCD display. Earlier versions of this type of measuring instrument had
to be read by looking carefully at the imperial or metric scale and there was a
need for very good eyesight in order to read the small sliding scale. The
digital version requires a small battery whereas the manual version does not
need any power source. Digital calipers are easier to use as the measurement
is clearly displayed and also, by pressing the inch/mm button the distance
can be read as metric or imperial.

SHAPER

SHAPER
The shaper is a reciprocating type of machine tool intended primarily to
produce flat surfaces. These surfaces may be horizontal, vertical, or inclined.
Modern shapers can generate contoured surface.
SHAPING MACHINE PARTS
BASE
It is made of cast iron and may be rigidly bolted to the floor of the shop. It
is so designed that it can take up the entire load of the machine and the
cutting forces.
COLUMN
The column is a box like casting mounted upon the base. It encloses the
ram driving mechanism. Accurate guide ways are machined both on the top
and front of the column to accommodate the ram and the cross rail
respectively.
CROSSRAIL
The cross rail is mounted on the front vertical guide ways of the column. It
has two parallel guide ways on its top. The cross rail with the table may be
raised or lowered to accommodate different sizes of jobs.
SADDLE
The saddle is mounted on the crossrail which holds the table firmly on its
top.
TABLE
The table which is bolted to the saddle receives crosswise and vertical
movements from the saddle and crossrail. It is a box like casting having T-
slots both on the top and sides for clamping the work.
RAM
The ram is the reciprocating member of the shaper. It slides on the
dovetail guide ways on the top of the column.
TOOLHEAD
The tool head has a swivel base which is held on a circular seat on the ram.
Tool head holds the tool rigidly, provides vertical and angular feed movement
of the tool and allows the tool to have an automatic relief during its return
stroke.

CUTTING TOOL NOMENCLATURE

WORK HOLDING DEVICES

MACHINE VISES
A vise is a quick method of holding and locating relatively small and regular
shaped work pieces. It consists of a base, fixed and movable jaws and a
screw. A machine vise may be classified as plain vise, swivel vise and
universal vise.
PARALLELS
Parallels are square or rectangular bars of steels or cast iron, hardened and
ground with opposite sides parallel. Parallels are used to raise and seat the
work pieces above the jaws.
HOLD DOWNS
The hold down is a hardened wedge shaped at an angle of 5°. Hold downs
or grippers are used for holding thin pieces of work in a shaper vise.
CLAMPING
When the work piece is too large to be held in a vise it must be fastened
directly on the shaper table. The different methods of clamping work are:
- T-Bolts and clamps - Stop pins
- Stop pins and toe dogs - Strip and stop pins
V-BLOCK
For holding round rods V-Blocks are used. Work may be supported on two
V-Blocks at its two ends and is clamped to the table by T-bolts and clamps.
DRILLING MACHINE
The drilling machine is an important machine tool in a workshop. Although it
is primarily designed to originate holes, it can perform a number of similar
operations. In a drilling machine holes may be drilled quickly and at a low
cost. The hole is generated by the rotating edge of a cutting edge known as
the drill which exerts large force on the work clamped on the table. So it is
loosely called a Drill press. Drilling machines made in many different types
and sizes are:
Portable drilling machines, Sensitive drilling machines,
Upright drilling machines, Radial drilling machines,
Multiple spindle drilling machines, Gang drilling machines,
Automatic drilling machine & Deep hole drilling machines etc.

RADIAL DRILLING MACHINE

DRILLING MACHINE PARTS

BASE
The base is a large rectangular casting on which vertical column is
mounted. The top of the base is accurately machined and has T-slots on it so
that large work pieces and work holding devices may be set up and bolted to
it.
COLUMN
The column is a cylindrical casting vertically mounted on the base of the
machine which supports all other parts of the machine except the table in
radial drilling machine.
RADIAL ARM
The radial arm that is mounted on the column extends horizontally over the
base. It is a massive casting with machined guide ways on which the drill
head may be made to slide.
TABLE
The table is a box type casting mounted on the base of radial drilling
machine and is provided with T-slots for clamping the work directly on its
face.
DRILL HEAD
The drill head is mounted on the radial arm and houses the driving and
feeding mechanism for the spindle.
SPINDLE, QUILL AND DRILL HEAD ASSEMBLY
The spindle is a vertical shaft which holds the drill. It receives its motion
from the top shaft through bevel gears. The lower end of the spindle is
provided with Morse taper hole for accommodating taper shank drill.
SPINDLE DRIVE AND FEED MECHANISM
For driving the spindle, a constant speed motor is mounted at the extreme
end of the radial arm. In some machines, a vertical motor is fitted directly on
the drill head and through gear box multiple speed and the feed of the
spindle can be obtained.
*****

Ex. No. 1
Date:
FACING AND PLAIN TURNING
80

Scale- 1:1

Ex.No.1 Date:
FACING AND PLAIN TURNING
AIM:
To practice the facing and plain turning operations on lathe machine
MATERIALS REQUIRED:
MS Round rod (diameter 25mm and length 130mm)
TOOLS REQUIRED:
Steel rule, odd leg caliper, vernier caliper, surface gauge, chuck key,
mallet, tool post key, facing tool etc.
OPERATIONS TO BE CARRIED OUT:
Measuring, marking, work setting, tool setting, facing, plain turning,
PROCEDURE:
- Check the given work piece if it is suitable for the work.
- Set the work piece in the lathe chuck with the help of chuck key and
surface gauge.
- Fix the cutting tool in the tool post at the centre height using tool post
key.
- Cut the end face of the work piece by feeding the cross slide across the
lathe axis.
- Mark the length for plain turning with the use of steel rule and odd leg
caliper.
- Turn the work piece while feeding the tool against it parallel to lathe
axis.
- Then, check the work using vernier caliper and finish it.

Ex. No. 2
Date:
STEP AND TAPER TURNING
10 15 30 15 10

Scale- 1:1

Ex.No.2 Date:
STEP AND TAPER TURNING
AIM:
To practice the step and taper turning operations on lathe machine.
MATERIALS REQUIRED:
Previous exercise, no.1 (MS rod-diameter 23mm and length 130mm)
TOOLS REQUIRED:
mallet, tool post key, double end spanner, turning tool, square nose tool etc.
Measuring, marking, work setting, tool setting, step turning, taper turning,
PROCEDURE:
- Measure and check the given work piece whether it is suitable as per
drawing.
surface gauge.
key.
- Mark the lengths for step turning with the use of steel rule and odd leg
caliper.
- Turn the work piece as per the drawing.
- Square the edges using square nose tool.
- Calculate the half taper angle using the formulae:
Tan α= D-d/2l
then, α= tan^-1 (D-d/2l)
where, D= Major diameter,
d= Minor diameter,
l= Length of taper.
- Swivel the compound slide at a desired taper angle by loosening and
tightening of the base screw.
- Set the turning tool perpendicular to the lathe axis and do the taper
turning by feeding the compound slide.
- Then, check the work using vernier caliper and finish it.

Ex. No. 3
Date:
SHAPING PLAIN SURFACES
e
trok
gS
ttin
Cu
Depth of Cut
Fe
ed

Scale- 1:1

Ex.No.3 Date:
SHAPING PLAIN SURFACES
AIM:
To practice planing operations on shaping machine
MATERIALS REQUIRED:
CI square block (55mm×55mm)
TOOLS REQUIRED:
Steel rule, vernier caliper, parallels, mallet, tool post key, shaping tool with
holder, machine handle etc.
Measuring, marking, work setting, tool setting, planning, checking and
finishing.
PROCEDURE:
- Set the work piece in the shaper vise with the use of parallels, mallet
etc.
- Fix the cutting tool in the tool head vertically.
- Set the speed of the machine, stroke length and stroke position etc.
- Set the depth of cut; manage the hand feed.
- Cut the top face of the work piece by feeding at the end of return
strokes.
- Then, measure and check the work and finish it.

Ex. No. 4
Date:
MARKING AND DRILLING HOLES
Counter Sinking, 5x5
50
50
50

Scale- 1:1

Ex.No.4 Date:
MARKING AND DRILLING HOLES
AIM:
To practice marking and drilling on radial drilling machine.
MATERIALS REQUIRED:
Cast Iron- square block (55mm×55mm)
TOOLS REQUIRED:
Steel rule, vernier height gauge, centre punch, ball peen hammer, surface
gauge, taper shank twist drill bit, sleeves, drift, machine handle etc.
Measuring, marking, work setting, tool setting, drilling, counter sinking,
PROCEDURE:
- Mark the centre point with the help of vernier height gauge, punch and
hammer.
- Set the work piece in the machine vise with the use of wooden packing,
surface gauge etc.
- Fix the drill bit into the spindle; make the arrangements to the radial
arm and drill head.
- Set the speed of the machine; locate the point of the drill at the
punched mark.
- Then, drill the through hole; manage the hand feed; no coolant should
be used for cast iron.
- Counter sink the end faces of the hole using counter sunk bit.
- Then, check the work and finish it.

Ex. No. 5
Date:
FORM TURNING
10 15 19 15 21

Scale- 1:1

Ex.No.5 Date:
FORM TURNING
AIM:
To practice form turning as per drawing.
MATERIALS REQUIRED:
Previous exercise, no.2 (Mild Steel rod)
TOOLS REQUIRED:
mallet, tool post key, V-nose tool, radius and fillet gauge etc.
Checking, marking, work setting, tool setting, turning, form turning,
measuring and finishing.
PROCEDURE:
- Check the given work piece whether it is suitable for the work.
surface gauge.
key.
- Mark the dimensions as per drawing.
- Cut the blank prior to form turning.
- Then, turn ball and radius forms onto the work piece.
- Check the work using radius and fillet gauge and finish it.

APPENDIX-1
COURSE SYLLABUS

COURSE TITLE : WORK SHOP PRACTICE-III
COURSE CODE : 3027
COURSE CATEGORY :B
PERIODS/ WEEK :6
PERIODS/ SEMESTER : 90
CREDIT :3
TIME SCHEDULE
MODULE TOPIC PERIODS

1 Machine Shop. 24
2 Fitting 24
3 Sheet metal , Aluminum fabrication. 22
4 Welding 20
TOTAL 90
Course Distribution:
Course Total periods per semester
Module Name of Module Outcome
Instructional Test Total
no.
1 Theory :
1 Machine Shop. 2 3 24
3 Practical :21
Theory :
2 Fitting 4 3 24
Practical :21
Theory :
Sheet metal , Aluminum
3 5 3 22
fabrication.
Practical :21
Theory :
4 Welding 6 3 20
Practical :21
Total periods per semester 90
Remarks based on feedback from students, faculty, industry (revision 2010)
GENERAL INFORMATION:
*Class is divided into 2 batches (Batch I and Batch II). For Batch I –it is M/c. Shop and Fitting shop and for
Batch II- it is Sheet metal, Aluminum fabrication And welding. This syllabus should be continued for
Semester IV also by interchanging the batch of students.
COURSE OUTCOME :
Sl.No. Sub Student will be able to

1 Work on Lathes.
1 2 Work on shaper machine.
3 Work on drilling machine.
4 Understand the fitting practice and use of gauges.
2 5 Work in sheet metal shop and aluminum fabrication
6 Work on welding machine.
CONTENT DETAILS
MODULE I MACHINE SHOP
Understand the safety precautions

1.1.0 Lathe work
1.1.1 Familiarization with lathes- principal parts, work holding device, measuring
instruments, accessories & attachments
1.1.2 Plain turning to the given accuracy - Practice with Precision measuring devices - use of
digital vernier and Micrometer
1.1.3 Taper turning
1.1.4 Form turning (ball and curve)
1.1.5 Combination of above operations (taper, ball and curve)
1.2.0 Work on shaper
1.2.1 Familiarize with the parts, accessories and attachments.
1.2.2 Simple operations on Shaper (Planning)
1.2.3 Shaping of a rectangular block
1.2.4 Shaping a ‘V’ in a rectangular block
1.3.0 Work on drilling machine
1.3.1 Familiarization of drilling machine parts
1.3.2 Marking and drilling holes
1.3.3 Boring and counter boring
1.3.4 Reaming
1.3.5 Combination works
MODULE II FITTING PRACTICE
2.1 Study of measuring gauges-dial gauges, feeler gauges, thread gauges

2.2 Working from a given blue print exercises involving marking filing, drilling, reaming and
tapping to an accuracy of 0.02mm (T- joint, V-joint, Single dovetail joint)
MODULE III SHEET METAL & ALUMINIUM FABRICATION
3.1 Understand safety precautions.

3.2 Familiarization of sheet metal tools – scribers, dividers, trammel points, set square, punches –
prick punches, centre punches – hand Grover, rivet, chisels, hammers, riveting hammers, ball
peen hammers – mallet, snip shears, pliers, hand seamers (tongs) files, stakes. Measuring
instruments in sheet metal - folding rule, common rule, steel circumference rule, vernier
calipers, micrometer, combination set, Thickness gauges – Plate gauge.
MODULE IV WELDING
4.1 Safety precautions

4.2 Study of various tools and equipments used in the welding shop for both arc welding and gas
welding (review)
4.3.0 Practice work
4.3.1. D.C. arc welding (review of practice)
4.3.2. A.C. arc welding (review of practice)
4.3.3. Gas welding (review of practice)
4.3.4. Horizontal, flat, vertical and over head welding
4.3.5. Edge preparation of welded joint such as V, double V.
4.3.6. Pipe welding – linear and round
4.3.7. Flame cutting
GENERAL INFORMATION:
*Class is divided into 2 batches (Batch I and Batch II). For Batch I –it is M/c. Shop and Fitting shop and
for Batch II- it is Sheet metal, Aluminum fabrication and welding
This syllabus should be continued for Semester IV also by interchanging the batch of students.
TEXT BOOKS
1. Mechanical Workshop Practice by K. C. John (PHI Learning Private Limited)

2. Mechanical Workshop & Laboratory Manual by K. C. John
REFERENCE
1. Workshop Technology Vol. I by S K Hajra Choudhary

2. Workshop Technology Vol. II by S K Hajra Choudhary
APPENDIX-2
SAMPLE QUESTION PAPERS

MAHARAJA'S TECHNOLOGICAL INSTITUTE, THRISSUR

WORKSHOP PRACTICE PRACTICAL EXAMINATION
SEMESTER S3-S4 REGULAR/SUPPLYMENTARY
REVISION : 2015 COURSE CODE : 3027
MONTH&YEAR: SECTION:SHEET METAL
AIM: To make a 'TAPER TRAY' as per below drawing.
162
10
38
110
80
38
10
10 38 132 38 10
11
0
2
16
32
2
13
80

Scale 1:1


MONTH&YEAR: SECTION:FITTING
AIM: To make a 'DOVE TAIL JOINT' as per below drawing.

Scale 1:1



MONTH&YEAR: SECTION:WELDING
AIM: To make a 'SINGLE V BUTT JOINT' in down hand

position as per below drawing.
6
37
37 100
BEVELLING
4
2 3
ROOT GAP ROOT FACE

Scale 1:1



MONTH&YEAR: SECTION:MACHINE SHOP
AIM: To perform a 'BALL & STEP TURNING' as per below drawing.
10 14 19 14 23

Scale 1:1

Compressing Machine 1

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MAHARAJA’S TECHNOLOGICAL INSTITUTE (MTI)

WORKSHOP PRACTICE MANUAL

This manual is prepared based on the curriculum prescribed for second

Maharaja’s Technological Institute (MTI), Thrissur 3|Page

2. SHEET METAL & ALUMINIUM FABRICATION………………....….……..11

APPENDIX-1 - COURSE SYLLABUS……………………..…………………….135

APPENDIX-2 - SAMPLE QUESTION PAPERS.…….……..……………….141

Maharaja’s Technological Institute (MTI), Thrissur 5|Page

Maharaja’s Technological Institute (MTI), Thrissur 7|Page

Maharaja’s Technological Institute (MTI), Thrissur 9|Page

WORKSHOP PRACTICE MANUAL

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METALS USED IN SHEET METAL WORK

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Prick Punch Centre Punch

Maharaja’s Technological Institute (MTI), Thrissur 14 | Page

SHEET METAL HAND TOOLS

STANDARD WIRE GAUGE

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Maharaja’s Technological Institute (MTI), Thrissur 17 | P a g e

HATCHET STAKE HORSE STAKE

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FUNNEL STAKE CREASING STAKE

CONDUCTOR STAKE COPPER SMITH STAKE

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GROOVER RIVET SET

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8. SHEET METAL OPERATIONS

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PIERCING BLANKING PUNCHING

PARTING NOTCHING SLITTING

LANCING NIBBLING TRIMMING

SHEET METAL OPERATIONS

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9. HEMS AND SEAMS

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SINGLE HEM DOUBLE HEM WIRED HEM

SINGLE SEAM DOUBLE SEAM GROOVED SEAM

HEMS AND SEAMS

Maharaja’s Technological Institute (MTI), Thrissur 26 | Page

10. SHEET METAL MACHINES

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Maharaja’s Technological Institute (MTI), Thrissur 28 | Page

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COMMON EXTRUSIONS USED IN ALUMINIUM FABRICATION

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Exercise No.1 Date:

OPERATIONS TO BE CARRIED OUT

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Exercise No.2 Date:

OPERATIONS TO BE CARRIED OUT

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5 160 230 160 230 5 5

Exercise No. Date:

OPERATIONS TO BE CARRIED OUT

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ALUMINIUM FABRICATION - CORNER JOINT

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Exercise No.3 Date:

ALUMINIUM FABRICATION - CORNER JOINT