Heritage Institute Of Technology

Department of Mechanical Engineering

LAB MANUAL

Sub: Workshop / Manufacturing Practices

(MECH-1051)
 SCHEME OF PARALLEL GROUP RUNNING

To be followed from session 2021-2022

For EVEN Semester

Faculty: 1 Faculty: 2
Scheme-I Scheme-II
Job Day Job
Pattern making 1 Fittings 1

Foundry and Casting 2 Fittings 2

Fittings 1 3 Pattern making

Fittings 2 4 Foundry and Casting

Lathe 1 5 MMA Welding

Lathe 2 6 Sheet Metal and Brazing

Shaper and Milling 7 Smithy

MMA Welding 8 Lathe 1

Sheet Metal and Brazing 9 Lathe 2

Smithy 10 Shaper and Milling

Plastic Moulding 11 Electrical and Electronics

Electrical and Electronics 12 Plastic Moulding

Viva-voce 13 Viva-voce
 HERITAGE INSTITUTE OF TECHNOLOGY
Department of Mechanical Engineering

Name of the jobs carried out during the semester

Sl. No. Shop Name Job No Job Title

Carpentry
1. MECH1051/01 Making a wooden pattern (dovetail joint)
Shop

Making a Aluminum Alloy casting of a given

2. Foundry Shop MECH1051/02
pattern
Making a Gauge from MS Plate
3. MECH1051/03A (50% student will make half part and half part will
be made by rest 50% student), 2 student in a group
Fitting Shop
Making a M8 stud and Nut by dye and taps
4. MECH1051/03B (50% student will make M8 stud and 50% student
will make Nut part), 2 student in a group
Making a Stepped pin.
Machine Shop Day 1 – Student will first make the stepped pin
5. MECH1051/04
- Lathe Day 2 – Student will make the thread at one end of
the stepped pin
Shaper and
6. Milling MECH1051/05 Making a Cuboid from a Cylindrical bar.
Machine
Sheet Metal Making a truncated cone by surface
7. MECH1051/06
Work development.
Welding Shop Make a double V butt joint
8. – Arc MECH1051/07 (50% student will make one side and other side will
Welding be made by rest 50% student)
Welding Shop
9. – Gas MECH1051/08 Join the truncated cone by gas welding
Welding
Making a square bolt head from a cylindrical
10. Smithy Shop MECH1051/09
bar.

Electrical and
11. MECH1051/10 Speed control of a DC Motor
Electronics
Plastic
moulding or
12. MECH1051/11 Prepare a job as per given drawing
Injection
Moulding
 SYLLABUS
Subject: Workshop / Manufacturing Practices Subject Code: MECH1051
Contact: 1L Credit: 3
Class
Contents Topics need to be covered in the THEORY classes
No
1. Introduction Introduction to workshop - various shops in a typical workshop - Carpentry,
to Workshop Fitting, Foundry, Sheet Metal Shop, Welding and Brazing Shop, Machine Shop ,
and Safety Forging & Smithy - Safety precautions to be followed in a workshop.
precautions Manufacturing Process – classification of manufacturing processes
Introduction to Carpentry – Timber - Market forms of converted Timber e.g.
2. Carpentry log, balk, plank, batten, beam -Types of Wood - Hard Wood-Soft Wood-
Seasoning of wood-Natural seasoning-Artificial seasoning, Carpentry joints.
Introduction to casting and moulding –
 Pattern – Importance of pattern – pattern material – Types of pattern –
Pattern Allowances –
Foundry and
3. Metal Casting  Mould making – Constituents of moulding sand – Types of moulding
sand - Preparation of sand (silica, clay, moisture, and miscellaneous
items and their functions) - Properties of a good sand mould.
 Melting of metals in muffle furnaces – Pouring of molten metal in
cavity – Solidification – removal of casting.
 Casting defects-different types of casting defects.
 Introduction to Fittings – Importance of fittings – Fitting operations
(job holding, filing, measuring, marking, sawing, chipping, drilling,
Fitting reaming)
Operations  Thread - Thread nomenclature, Different types of standard threads –
4. and Power metric thread, BSW, BSP, TPI.
Tools  Tapping – Tap drill size calculation, Dieing, Twist drill and its
nomenclature.
 Power tools – details about upright drilling machine.
5. Machine shop 1. Discuss the following components of a Lathe especially the
following components : (a) Head Stock (b) Tail Stock (c) Carriage
(d) Cross slide (e) Tool post (f)Lead Screw (g) compound rest (h)
Bed
2. Lathe machine specification (a) Height of dead centres from the
bed. (b) Distance between two dead centres (c) No of spindle
speed available (d) Horse Power of Motor(e) Height of bed from
its base.(f) Type of chuck
3. Describe with the help of a diagram various operations that may
be performed in a standard Lathe Machine.(a) Straight Turning
(b) Taper Turning (c) Facing (c) Chamfering.(d) Knurling (e)
Grooving (f) Thread cutting (g) Eccentric Turning
6. Machine shop Thread cutting operation in Lathe- basic principle- Different standard threads-
different mechanisms and components associated in thread cutting by Lathe-
thread cutting tool
7. Machine shop Description and working principle of a milling machine-Specification of Milling
machine-Types of Milling-Up Milling-Down Milling (differences between
them)- Types of milling machine-Vertical Milling Machine-Horizontal Milling
Machine.
Description of a Shaping machine- working principle -Quick return mechanism
and ratio -Feed Mechanism-purpose of shaping machine
8. Welding Welding – Weldability - Types of Welding – MMAW– Electrode - Functions of
Flux - Equipment for MMAW - Different types of welding joints - AC Welding
 - DC Welding - Safety precautions in Welding Shop.
9. Gas welding Introduction to Gas welding – Chemistry of Oxy-acetylene gas welding – Oxy-
and Acetylene ratio control by regulators - Welding torch - Different types of
Sheet metal Flames in Gas Welding and Gas Cutting - Neutral Flame – Oxidizing Flame –
Carburizing Flame - Brazing
Specification of sheet metal - SWG vs. mm - HR sheet - CR sheet - GI Sheet -
Stainless Steel Sheet - Aluminum sheets - Tin Plates.
10. Injection Introduction to Injection Moulding –Advantages and limitations - Applications
moulding – Working principle – Procedure of injection moulding
11. Introduction – Basics of electrical & electronics (Electricity, Voltage, Current,
AC, DC, Current, Resistance, Capacitance, Inductance) – Conductor –
Electrical and Semiconductor – Insulator – Electrical & Electronics Components (Power
Electronics source, resistor, Capacitor, Inductor, Diode, Transistor, Switch, Rectifiers) –
Electrical machines (Transformer, Motor) – Tools (Pliers, Wire cutter, Wire
stripper, Tester, Multi-meter, Solder iron).
12. CNC
Machining Introduction to CNC machining – working principle – benefits.
and Additive Introduction to Additive manufacturing – working principle – Benefits
Manufacturing
13. Introduction – Smithy and Forging - Fuels used – Forging materials – Forging
Smithy Temperatures – Forging operations (Upsetting, Drawing out or Drawing down,
Cutting, Bending, Punching and Drifting, Setting down and finishing) -
14. Written Examination

Recommended books:-
1. Elements of Workshop Technology (Vol- I and II) - Hajra Choudhury, Media Promoter &
Publishers Privet Limited.
2. Workshop Technology (Vol- I and II) – Chapman, Viva Books Privet Limited.
3. Workshop Technology – R.S Khurmi, J.K Gupta , S Chand & Company Ltd
4. Manufacturing Technology Vol – I and II – P. N Rao, Tata McGrawHill House
 HERITAGE INSTITUTE OF TECHNOLOGY
Department of Mechanical Engineering
Subject: Workshop / Manufacturing Practices Subject Code: MECH1051
Contact: 4P Credit: 3

Class Name of
Topics that need to be covered in the PRACTICAL classes
No Shop
Introduction to workshop - Safety precautions to be followed in a workshop.
Manufacturing Process – classification of manufacturing processesCarpentry Tools
- Marking Tools - Cutting Tools - Planning Tools - Boring Tools - Striking Tools -
Carpentry
1 Holding & Miscellaneous Tools - Carpentry Processes (marking, sawing,
Shop
planning, Chiseling, boring, grooving etc. ) - Safety precautions in Carpentry
Shop.
Job Title: Making a wooden pattern (dovetail joint).
Introduction to moulding – Pattern –General procedure for making a good sand
mould - Different tools used for preparation of a mould - Explanation of various
Casting and terms ( Cope and Drag Box, Runner, Riser, Gating and its utility, Parting sand,
2 Foundry Vent holes). placing of sprue – gate cutting – melting of metals in muffle furnaces
shop – Pouring of molten metal in cavity – Solidification – removal of casting –
Checking of casting defects – finishing
Job Title:Making a Alluminium alloy casting of a given pattern
Introduction to fittings,Fitting operations (Marking, Drilling, Reaming, Thread
Cutting, Holding tools (Vices, V-block, C-clamp etc) – Marking and Measuring
tools (Surface plate, Try square, Scriber, Calipers, Divider, Punch etc) – Cutting
Fitting Shop
3 tools (Hacksaw, Chisel, Twist drill, Tap and Tap wrenches, Dye and Dye-holders
-I
etc) – Finishing Tools (Reamers, Files – Rough; Bastard, Second cut, Half round,
Triangular etc).
Job Title:Making a gauge from MS plate
Fitting Operations – Marking – Drilling – Tapping(Rougher-Intermediate-Finisher
Fitting Shop taps)-Sawing-Dieing-Internal Thread-External Thread-.Safety precautions in
4
- II Fitting Shop.
Job Title:Making a M8 stud and Nut by dye and taps
Sheet metal working Tools – Micrometer-Chisels-Punches-Hammers – Mallets-
Hand Shear or Snips-Various sheet metal forming operations – Shearing –
Marking – Punching-Drilling-Bending – Drawing – Brazing- Safety precautions in
Sheet Metal
5 Sheet Metal Working Shop.Introduction to Gas welding, - Different types of
Work and
Flames in Gas Welding, Neutral Flame – Oxidizing Flame –Carburizing Flame –
Brazing.
Job Title:Making a truncated cone by Surface Development
Welding-Weldability-Types of Welding-MMAW-Gas Welding-Electrode –
Welding Functions of Flux-Equipment for MMAW- Different types of welding joints-AC
6 Shop – Arc Welding-DC Welding- Various types of welding joints-Butt joint-Fillet Joint-
Welding Safety precautions in Welding Shop.
Job Title:Making a double V-Butt joint
 1. Demonstration of all the components of Lathe.
2. Power Transmission mechanism: Motor- Belt drive- Gear Train-
Spindle Speed. Explain how speed may be changed. Explanation of
Cutting Speed calculation.
3. Keep components ready to explain various operations that are done in
lathe.
4. Explain how to calculate the cutting speed, once the rpm is fixed for the
spindle- how the cutting speed varies with the variation of job diameter-
how the surface roughness varies with feed rate- how by looking at chip
size and shape one can conclude the type of material that are cut – explain
Machine the process of Job centering and Tool centering – and the effects if they
7
Shop – are not done properly- (you may show defective pieces to explain).
Lathe 5. Explain the function of directional switch of the spindle – why the
rotation of the spindle should be in the anti-clockwise direction (while
looking towards the spindle) – what if the rotation is clockwise- explain.
6. Explain how to decide the depth of cut and what is the material removal
rate and the process time- why focus should be given to reduce the
process time.
7. Explain the Safety procedures that needs to be followed while working in
Lathe, especially girls should be told to do up their hair while working.
8. Job centering and tool centering

Job Title:Making a stepped pin

Thread cutting operation in Lathe- basic principle- Different standard threads-
Machine different mechanisms and components associated in thread cutting by Lathe-thread
Shop – cutting tool- change gear calculation. (if possible)
8
Lathe
Job Title:Making a stepped pin. (Continued)

Description of a milling machine-components of machine-power and motion

Machine
transmission process in milling machine- up milling-Down milling.
Shop –
Description of a Shaping machine-Base –Column-Saddle-Clapper box-power and
9 Shaper and
motion transmission process in shaping machine-Feed Mechanism-Table-Rotation
Milling
of table-Adjustment of stroke length and changing the position of stroke.
Machine
Job Title:Making a Cuboid from a cylindrical bar.
Introduction – Smithy and Forging , Principle tools (Smith’s forge or hearth,
Smithy Anvil, Hammer, Smithy hammer, Sledge hammer, Swage, Swage block, Tongs,
10
Shop Chisels, Punches, Flatters, Set hammer, Fullers etc).
Job Title:Making a square bolt head from a cylindrical bar.
Introduction – Basics of electrical & electronics (Electricity, Voltage, Current, AC,
DC, Current, Resistance, Capacitance, Inductance) – Conductor –Semiconductor –
Electrical Insulator – Electrical & Electronics Components (Power source, resistor,
12 and Capacitor, Inductor, Diode, Transistor, Switch, Rectifiers) – Electrical machines
Electronics (Transformer, Motor) – Tools (Pliers, Wire cutter, Wire stripper, Tester, Multi-
meter, Solder iron).
Job Title:Speed control of a DC Motor
Introduction to Injection Moulding –Advantages and limitations - Applications –
Plastic
13 Working principle – Procedure of injection moulding
Moulding
Job Title: Making a job as per given drawing.

14 Evaluation Viva-voce
 HERITAGE INSTITUTE OF TECHNOLOGY
Chowbaga Road, Anandapur, P.O.-East Kolkata Township,
Kolkata 700107

REPORT
ON

Workshop / Manufacturing Practices

JOB NO ______________________ __________________SHOP

JOB TITLE ___________________________________________

DATE(S)OF WORK __________________________________________

DATE OF SUBMISSION __________________________________________

PREPARED BY

NAME ____________________________________________

DEPARTMENT ____________________________________________

GROUP ________________ ROLL NO. _________________

EVALUATED BY

Signature of Faculty/Examiner _________________________________________

 HERITAGE INSTITUTE OF TECHNOLOGY
Department of Mechanical Engineering
Subject: Workshop / Manufacturing Practices Subject Code: MECH1051
Note:The report must be submitted in A4 Size paper on both sides with cover page, page no,
border line & roll no on each page in a channel file.

CARPENTRY SHOP
1. What are the differences between Hard Wood & Soft Wood?
2. Write and describe two methods of seasoning of wood.
3. Write three advantages of seasoning of wood.
4. Name a cutting, planning, striking, boring, holding, marking tool and draw the diagram of each
one in relation to carpentry shop.
5. Name different processes that are involved in a typical carpentry job and the tools used for those
operations.
6. Explain the terms Log, Batten, Plank, and Beam.
7. Write the specification/s and application/s of the following tools in association with carpentry.
i. Try Square v. Mortise Gauge
ii. Jack Plane vi. Rip Saw
iii. Vice vii. Bench Vice
iv. Marking Gauge

FITTING SHOP
1. Name five important operations that are performed in fitting shop and tools used to perform those
operations.
2. Draw the following tools used in a fitting shop with a neat sketch and write the specifications.
i. Bench Vice v. Half Round File
ii. Flat Chisel vi. Ball Peen Hammer
iii. Adjustable frame Hack Saw vii. Outside Spring Caliper
iv. Flat File
3. How do you calculate the drill size for doing internal thread in a job piece?
4. Why are three taps used for doing an internal thread by hand?
5. Name the tool used for making an external thread by hand and explain how to make an external
thread by hand using that tool?
6. Draw a typical thread profile and show major diameter, minor diameter, pitch diameter, depth of
thread, angle of thread, crest and root.
7. What do the abbreviations mean- BSW, BSP,TPI stand for in relation to a thread?

FOUNDRY SHOP
1. Describe the following tools that are used in foundry shop .What purpose are they used for?
i. Trowel v. Strike off bar
ii. Lifter vi. Vent rod
iii. Rammer vii. Draw spike
iv. viii. Cope and Drag box.
2. Why is sand used for preparing a mould?
3. What are the ingredients that are mixed with sand in order to make a good mould and why are
they used?
4. Describe the following terms in relation to a mould
i. Runner iii. Vent holes
ii. Riser iv. Gate
5. Draw typical green mould sand and label the following:
i. Cope Box iv. Riser
ii. Drag Box v. Parting Line
iii. Runner
SHEET METAL SHOP
1. What is the full name of SWG,HR sheet, CRCA sheet, GI sheet?
2. Name various sheet metal forming processes and the tools used to perform each of those
processes.
3. Name few sheet metal working processes and the tools used for each of those processes.
4. Draw the following tools used in Sheet metal work
i. Hand Shears iii. Prick Punch
ii. Round Mallet
iv. Bench Vice v. Sheet Metal Gauge

WELDING SHOP
1. What is Weldability?
2. Describe MMAW & Gas Welding.
3. Describe three types of flames in Gas welding with sketch.
4. What is the basic equipment that constitutes an Arc welding system?
5. Why is step down transformer used in Arc welding process?
6. What are the functions of flux used in electrodes?
7. Describe different types of welding joints
8. What are the safety precautions that need to be observed in welding shop?
MACHINE SHOP
LATHE
1. How is a lathe specified? Describe principal components of a centre lathe.
2. Describe the following operations with schematic diagram –Turning-Taper turning-Facing-Grooving-
Chamfering-Thread Cutting.
3. Explain Cutting speed, Feed & Depth of cut in relation to turning operation in lathe.
MILLING
1. How is a Milling machine specified?
2. What are the differences between UP milling and DOWN milling?
3. What are the operations can be done in a milling machine?
SHAPING MACHINE
1. Draw and explain a quick return mechanism in a shaping machine.
2. Explain the function of clapper box in shaper.
3. How is the stroke length and position of stroke in a shaping machine adjusted?
4. Describe automated table feed mechanism in a shaper.

SMITHY SHOP
1. What is meant by black smithy?
2. What is hot working and cold working?
3. Define the following terms: Upsetting and Down setting, Fullering, Smith die forging, Impression due
forging etc.
4. Explain the tools used in the smithy shop with net sketch.

ELECTRICAL AND ELECTRONICS

1. Define the following terms - Potential difference, Current, Resistance, Inductance, Capacitance, Diode,
Transformer, Rectifiers.
2. Draw and explain the circuit of a full wave bridge rectifier.
3. What is step up and step down transformer.

PLASTIC MOULDING
1. What are the types of injection techniques?
2. What is the working principle of Injection moulding?
3. Draw a net sketch and mark the important parts of an Injection moulding machine?