College Of Engineering Chengannur

ME 110 Mechanical Engineering

Workshop

Workshop Manual
 General Safety
Precautions:
Objectives

1. Dress safely for the workshop.

2. Behave safely in the workshop.
3. Safe use of tools and machinery
3. Recognize the importance of keeping the workshop clean and tidy.
Introduction to workshop safety
A workshop is where you learn to use tools and machines to make things; It can be a
dangerous place, so you must learn the safety rules for the workshop. The safety rules
tell you how to dress appropriately and how to behave whilst working with tools that
may cause harm.

Personal safety:
Proper clothing , Proper eye protection. Remove tie and jewelry. Cut or secure long
hair Proper shoes

Use of tools
You will learn to use many tools and machines in the workshop. Always ask for
your teacher’s advice before using a machine for the first time. You must listen to
the teacher when he tells you how to use them safely.

Worksop cleanlines
It is very important to keep the workshop clean and tidy. This will help save
time and prevent accidents. When you have finished using tools, they must be
put away and kept in the proper place. Do not leave tools lying around the
benches or workshop; accidents may occur.
 EXPERIMENT NO 1
SAFETY INSTRUCTIONS

1: Be sure that all machine’s have effective and properly working guards that are always in
place where machine’s are operating.
2: Replace guards immediately after any repair.
3: Don’t attempt to oil, clean, adjust or repair any machine while it is running, stop the machine
and lock the power switch in the off position.
4: Even after the power is off, don’t leave the machine until it has stopped running. Someone
else may notice that it is still in motion and be injured.
5. Do not leave tools or work on the table of a machine even if the machine is not running.
Tools or work may fall off and cause a toe or foot injury.
6: Don’t operate any machine unless authorized, to do so by the instructor or under his
supervision
7: Don’t try to stop the machine with your hand or body.
8: Always see that work and cutting tools on any machine are clamped securely before starting.
9: Keep the floor clean of metal chips or curls and waste pieces, put them in container provided
for such things.
10: When working with another worker only one should operate machine or switches.
11: Don’t lean against any machine.
12: Concentrate on the work and don’t talk unnecessary while operating machine.
13: Don’t talk to others when they are operating a machine.
14; Get first aid immediately for any injury.
15: Be sure you have sufficient light to see clearly.
16: Always wear safety glasses, or face shields designed for the type of the work operating any
machine
17: Wear safety shoes if heavy work is being done.
18: Wear clothing suited for the job, wear shoes with thick soles.
19: Don’t wear rings, watches, bracelets or other jewelery that could get could get caught in
moving machinery.
20: Don’t wear neck ties or loose turn clothing of any kind.
21: Wear shirts or uppers with sleeves cut off or rolled above the elbows.
22: Always remove , gloves before turning on or operating a machine. If material is rough and
sharp then gloves must be work place or handle material with machine turned off.
23: Keeping floor free of oil, grease or any other liquid. Clean up spilled liquid immediately
24: Aisles should be clear, at all time to avoid tripping of other accident.
25: Store materials in such a way that they cannot become tripping hazards.
26: Use the proper tool for the job. Check tools before use to ensure that they are safe to use.
27: Place tools always away from work when not in use.
28: Always keep separate boxes for waste and scrap material
29: Use a brush to remove chips – never with your hands, fingers, or rags. Chips are extremely
sharp and can easily cause cuts and injuries.
30: Do not use compressed air to clean your clothes or yourself.
31: When using compressed air, always point the air outlet down and away from yourself and
other persons.
32: Stop work 10 minutes prior to the time you need to leave the shop. This will provide ample
time to clean and replace tools to respective places
33: Always inspect the machines, tools , work piece visually for any abnormalities and conduct
periodical maintenances for the long life of machines.
34: Listen to the machine(s) – if something does not sound right, shut it down. Often if the
machine sounds abnormal to you, it probably is not operating properly. Inform the shop
supervisor if you believe the machine to be operating abnormally..
35. De burr sharp edges of freshly cut stock. This includes the piece of stock that goes back in
the stock rack. Eliminating burred edges minimizes the chances for personal injury and marring
of precision machine surfaces.
 EXPERIMENT NO 2
STUDY OF TOOLS

CARPENTRY
1. INTRODUCTION
The term carpentry is used with any class of work with wood. It is the art and trade of cutting,
working, and joining timber using hand tools. A carpenter is a skilled craftsman who performs
carpentry-a wide range of wood working that includes constructing buildings, furniture, and
other objects out of wood.

2. MATERIALS USED IN CARPENTARY.

Basic materials used in carpentry shop are timber and plywood. Timber is a term used to
describe wood, either standing or that has been proposed for use-from the time trees are
fallen, to its end product as a material suitable for industrial use.

3.HOLDING TOOLS
3.1 C or G clamp.
The C-clamp or G-cramp is a type of clamp device used to hold a wood workpiece. Typicaly
made of steel or cast iron, though smaller clamps inay be made of pot metal. They are composed
of a C - shaped frame and a machine threaded screw which is tightened to produce the clamping
action.
3.2 Carpenter's vice
These vices are made from robust castings and are designed with generous jaw rea which gives
even clamping on the whole depth of the work piece. Long life is assured with replaceable nut
corrosion resistant screw and handle. The square body seating enables easy fitting to work
bench and large diameter slide bars run in accurately machined guide holes to provide a smooth
parallel movement. Vice body and sliding jaw have provision for attaching wooden liners to
protect the vice, work piece and working tools.

Carpenter's vice

4. STRIKING TOOLS
4.1. Mallet
A mallet is a type of hammer, and is manufactured in different designs according to their
intended use. Wooden mallet, usually used in carpentry to knock wooden pieces together, or to
drive dowels or chisels. A wooden mallet will not deform the striking end of a metal tool, as
most metal hammers would, but it also reduces the force available to drive the cutting edge of
a chisel.
 mallet

4.2. Claw hammer

Claw hammer is used by carpenters and other trades. mainly to nail or to remove nails from
wood. It has one flat face for hammering nails into wood, with the second having two claws,
or a single claw with a vee shaped slot in it. The hammer claw is placed over a partially inserted
nail, which fits into the vec slot. The outer face of the claw is often curved; the handle of the
hammer is used as a lever to roll' the head along this curved face and pull the nail out of the
wood.

Claw hammer
5. PLANING TOOLS
5.1. Wooden jack plane
A jack plane is the general-purpose bench plane, used for general smoothing of the edges and
sizing of wood. Jack planes are about 15 inches long, and the blade usually has a moderately
curved edge. In preparing stock, the jack plane is used after the scrub plane and before the
smooth plane. The name is related to the saying "jack of all trades".Jack planes performs both
the work of smooth planes and trying planes.A Jackplane has a measuring screw which makes
the blade go in or out of its body so it can make the workpiece straighter.

Wooden jack planes

5.2. Metal Jack plane
This has a cast iron body whose sole is finely machined. A wooden knob and a handle are fitted
at the front and rear end of the body. This is used for better finish of the work.

Metal jack plane

6. CUTTING TOOLS
6.1. Chisels
A chisel is a tool with a cutting edge on its end, for carving and/or cutting a hard material such
as wood, stone, or metal. The handle and blade of some types of chisels are made in one piece.
In use, the chisel is forced into the material to cut the material. The driving force may be
manually applied or applied using a mallet or hammer.
6.1.1. Firmer or straight edge chisel
This is used by carpenters generally for cutting recess of mortises, chamfers and for edge
trimming. Its width varies from 5 to 40mm and is applied with hand pressure or mallet flows.
Its cutting edge is flat and ground at an angle 10° to 20⁰.

Firmer or straight edge chisel

6.1.2. Mortise chisel
This is directly employed to cut through mortise or blind mortise under heavy malleting. Width
of these chisel is tapered to the cutting edge from one side. The thickness varies from 5 to 20
mm.
6.2. Saws
6.2.1. Hand saw or Cross cut saw
Hand saws are used to cut pieces of wood into different shapes. This is usually done in order
to join the pieces together and create a wooden object. They usually operate by having a series
of sharp points of some substance that is harder than the wood being cut. These points are
called teeth.

Hand saw
6.2.2.Tenon saw
Tenon saw, or often just backsaw a midsized backsaw used to cut tenons or in a mitre box. The
saw derives its name from its use in the cutting of tenons for mortise and tenon joinery. Tenon
saws are commonly available with rip-filed teeth for rip cutting and cross-cut for cutting across
the grain. Teeth are relatively fine, with 13 teeth per inch being a common size.

Tenon saw
7. Measuring and marking tools
7.1.Marking gauge
A marking gauge is used in woodworking and metalworking to mark out lines for cutting or
other operations. In metalworking they can be known as a scratch gauge. The purpose of these
gauges is to scribe a line parallel to a reference edge or surface. The gauge consists of a beam,
a headstock and a marking implement - either a pin, knife, pen or wheel. The headstock slides
along the beam and is locked in place via one of a variety of methods, such as a locking screw,
cam lever or wedge. The marking implement is fixed to one end of the beam.

Marking gauge

7.2. Try square

A try square is a tool used for marking and measuring a piece of wood. The Square refers to
the primary use of the tool: measuring the accuracy of a right angle (90 degrees). A piece of
wood that is rectangular, flat, and has all edges (faces, sides, and ends) 90 degrees is called
four square. A board is often milled four square in preparation for using it in building furniture.
A traditional try square has a broad blade made of steel or brass that is riveted to a wooden
handle. The inside of the wooden handle typically has a steel or brass strip fixed to it that is
precisely 90 degrees to the blade.
 Try square
7.3. Ratchet brace
The main parts of ratchet brace are Head, handle, ratchet and chuck. The handle is shaped as a
crank. The drill bit is securely held by the chuck saw. This is mainly used for drilling holes up
to 8 mm diameter on any wood for fixing thick nails or bolts. During penetration the handle
turns with the chuck and the handle slips due to ratchet in the reverse direction.

Ratchet brace
8. MISCELLANEOUS TOOLS
8.1. Screw driver
A screwdriver is a device designed to insert and tighten, or to loosen and remove, screws. The
screwdriver comprises a head or tip which engages with a screw, a mechanism to apply torque
by rotating the tip, and some way to position and support the screwdriver:) A typical hand
screwdriver comprises an approximately cylindrical handle of a size and shape to be held by a
human hand, and an axial shaft fixed to the handle, the tip of which is shaped to fit a particular
type of screw. The handle and shaft allow the screwdriver to be positioned and supported and,
when rotated manually, to apply torque.

Screw driver
8.2. Rasp file
A rasp file is a half round file used for smoothening especially the curved surfaces of wood by
filing. It is a body with sharp projected teeth like pyramid which remove excess material.

Rasp file