Workshop Practical File

PRACTICAL FILE
B.Tech. First Semester

( WORKSHOP /MANUFACTURING PRACTICE)
[BTMP101-18]
Name :
Roll No. :
Branch :
BTMP101-18 Workshop/Manufacturing Practices

INDEX
S. No. Exercise Page No.
CARPENTRY SHOP
1. Flow Chart for Job Fabrication 4

2. Safety Precautions 5
3. To make a Mortise part of a Mortise & Tenon Joint (with 5
actual job snap)
4. To make a Tenon part of a Mortise & Tenon Joint 7
(with actual job snap)
FITTING SHOP

6. Safety Precautions 12
7. To make a job to controlled dimensions, involving different operations 13
like, Marking, Measuring, Punching, Hack Sawing, filing and Squaring
etc. (with actual job snap)
8. To make a job to controlled dimensions, involving different operations 13
like, Marking, Measuring, Punching, Hack Sawing, Filing, Drilling and
Tapping etc. (with actual job snap)
SHEET METAL SHOP

10. Introduction & Safety Precautions 16
11. To make different sheet metal joints 17
12. To make a Rectangular Tray(with actual job snap) 19
13. To Develop a cone of diameter 60 mm and slant height of 90 mm (with 22
actual job snap)
14. To develop a cylinder of diameter 50 mm and height 80 mm (with actual 24
job snap)
WELDING SHOP

16. To make a Butt joint by Manual Metal Arc Welding (with 27
actual job snap)
17. To make a “T’ joint by Manual Metal Arc Welding (with 30
actual job snap)
18. To join two metal sheets of 1.5 mm thickness through the Spot Welding 32
19. Making a permanent joint between Two Plates using gas welding process 34
MACHINE SHOP
20. To make a job, involving Facing, Plain turning, Step turning & 38
Chamfering etc.

21. To make a job, involving operations, Facing, Plain Turning, Step turning 40
Grooving, Taper turning, Knurling and Chamfering etc.
SIMTHY SHOP
22 Introduction 40
Job Snap 46
FOUNDARY SHOP
Introduction 47
Job Snap 54

Carpentry Shop: Flow Chart for Job Fabrication
Start
RAW MATERIAL
Deodar, Babool, Teak, With proper
Choose
Shisham, Mango, Kail, Permission as
Pine, Sal, Mahogany, Suitable R/M
per sketch.
Walnut. as per sketch.
Finish the job and

FINISHING TOOLS
control the dimensions.
Wooden Jackplane, Trying plane,
Iron Jackplane, Spoke, Shave,
Smoothing Plane, Hollow &
Round Plane.
If not correct
Mark the dimensions
CUTTING TOOLS and cut different
slots on job
Keyhole saw, Ripsaw, Crosscut
saw, Coping Saw, Panel saw,
Tenon Saw, Dovetail Saw,
Compass saw, Firmer chiesel,
Mostise Chiesel, Gauge Chiesel. Check the
dimensions.
MEASURING/ CHECKING
TOOLS: Try square, Bevel
Square, Steel scale. If correct,
then,
FINISHING AND
STRIKING TOOLS: Finish the pieces and
Wooden Jackplane, Jackplane, assemble for final
Spoke shave, Claw Hammer, assessment.
Ball Peen Hammer.
MARKING TOOLS
Pen, pencil, No Punch,
Marking gauge, Mortise Mark your Roll No on
gauge, divider, steel rule, try the job and submit it.
square.
Safety Precautions in Carpentry Shop End
1. Keep your eyes, mind on the job, and do not talk to any one while working.
2. Loose clothing should always be avoided.
3. Tools not in use should not be scattered on the table.

4. Do not keep any sharp tool in your pocket.
5. While using chisel, cutting should be in the direction always away from your body.
6. The tool being used should be well sharpened.

7. The saw blade should be properly set and sharpened. A dull tool requires excessive force.
8. The shop floor should be well cleaned, free from the scraps and wooden pieces carrying nails.
9. All safety guards on the machines should be in proper position and well secured.
10. Do not operate any machine without fully knowing its working and safety rules.
11. While working on a circular saw, avoid standing in line with the plane of the rotating blade. Always
keep your hand at distance from the blade.
12. Before starting cutting, allow the saw to attain the full speed.
13. While plaining, the work-piece should be free from knots, splits and nails.
14. Make certain that tool handles are surely attached to the tool before using them.
15. Hold driving tool correctly, so that they will not slip off the work surface.
Carpentry Exercise-I: To make a Mortise part of a Mortise & Tenon Joint.

Material Used: Soft wood piece of 242 x 42 x 36 mm.
Tools Required: Steel Rule, Try Square, Marking Gauge, Rip Saw, Tenon Saw, Metal jack plane, Smoothing
Plane, Firmer Chisel, Cross Peen or Claw Hammer etc.
Steps for job Making:
1. Grip the wooden piece in Carpentry Vice.

2. Plane one broad Surface of the wooden piece and check its trueness using a try square.
3. Then plane the adjacent narrow surface and check its trueness and squareness using a Try Square.
4. Likewise, Plane the remaining two surfaces and check the squareness of all the surfaces with their
adjacent surfaces.
5. Check for dimensions 40 & 30mm.

6. Cut the piece in two halves after marking a mid-way line. You will get two pieces A&B.
7. Mark one of the pieces as 'B' and do marking for Mortise as per the sketch.
8. Using Mortise Chisel & Mallet cut out Materialthroughout the depth.
9. Use firmer Chisel to maintain width of the Mortise.
10. Clean sides of the Mortise using Rasp file if required.
Job Specifications:
Measuring Instrument Required Dimensions(mm) Actual Dimensions (mm)
Used
Steel rule Length 120 mm 118 mm
Steel rule Width 30 mm 29 mm
Steel rule Height 40 mm 40 mm
Steel rule Mortise 40 x 10 mm 40 x 10 mm
Try Square Perpendicularity OK
Visual Over all finish Good
Actual Job Snap:
Lab Instructor (Sign.) Workshop Supdtt. (Sign.)
Carpentry Exercise-II: To make a Tenon part of a Mortise & Tenon Joint and assemble it with the
previously made Mortise.
Material Used: wooden piece 'A' of dimensions 120X40X30 mm.
Tools Required: Steel Rule, Try Square, Marking Gauge, Rip Saw, Tenon Saw, Metal jack plane, Smoothing
Plane, Firmer Chisel, Cross Peen or Claw Hammer etc.
1. Do marking on Piece 'A' for making a Tenon as per the sketch.

2. Hold the piece in the Carpentry Vice.
3. Using Tenon Saw cut away unwanted material from the piece 'A' to get Tenon.
4. Clean the Sawn faces of the Tenon using a Rasp File and Sand paper.
5. Try assembling Tenon with the Mortise.
6. Smoothen the surfaces of Mortise and Tenon using Rasp file as required.
7. Make final assembly as per the sketch.
8. Note that the joint should be close fitting.
9. Over tight assembly may rip apart the Mortise.
Job Specifications:

Measuring Ins[trument Required Dimensions (mm) Actual Dimensions (mm)
Used
Steel rule Tenon 40 x 10 mm 39 x 10 mm
Try Square Perpendicularity OK
Visual Type of fit Satisfactory
Actual Job Snap:
START
Mark the dimensions as per cutting

with specified mark on the material
Cut the required profile With proper

from the given raw material permission
NO
Check the dimensions of the Profile if OK Correct it
YES
Check the straightness of the job using

Try Square and use file if necessary
Again check the dimensions of the

Fitting Shop: Flow Chart for Job Fabrication
SAFETY PRECAUTIONS IN FITTING SHOP
• One should not put neck tie while doing work.
• One should not wear watch or ring while doing work.
• Always fold the sleeves of your shirt above your elbows.
• Never try to stop the running machine with your hand.
• Always wear tight clothes while doing work.
• Be careful about your safety.
• Spanner, wrench should always be clean and without any oil on it.
• Files should never be used without a purpose handle.  Clean the file with file card.
• Never use hammer on the file
• Never use try square on the hammer.
• Never use scale in case of screw divider.
• Minimum part of the job should be kept outside on the bench for filling operation.
• Always use a coolant while cutting a job with hacksaw.
• While drilling never hold the job in hand, clamp it on the table.
• Reduce the feed on drill on completion of job.
• Never forget to make out the key from drill chuck.
• Always keep the coolant while drilling.
• Do not keep tools, cutters and spanners on the machine table.

Fitting Exercise-I: To make a job to controlled dimensions, involving different operations like, Marking,
Measuring, Punching, Hack Sawing, filing and Squaring etc.
Tools and equipment used: Hacksaw, Files, Vernier Caliper, Try Square, Dot Punch, Height gauge etc.
Material required: Mild Steel flat 52x50x6 mm.
Procedure:
1. Cut a piece of required Dimensions from a flat.

2. Hold it in vice and file two adjacent sides. Check that these two sides are at right angle.
3. Mark overall dimensions, using a height gauge, taking two side at right angle as reference.
4. Use prick punch to firm up the marking lines.
5. File all the four sides to required dimensions and check squareness of the sides.
6. File the job from both the faces and check its trueness with the help of a surface plate.
7. Finally finish file the job using a smooth file.
8. De burr all the sharp corners.
Job Specifications:
Measuring Instrument Used Required Dimensions (mm) Actual Dimensions
(mm)
Vernier caliper Length 48 mm 48 mm
Vernier caliper Width 48 mm 48 mm
Vernier caliper Thickness 6 mm 6 mm
Vernier caliper Flatness of the sides Satisfactory
Try Square Perpendicularity of the sides Satisfactory
Actual Job Snap:

Fitting Exercise-II: To make a job to controlled dimensions, involving different operations like, Marking,
Measuring, Punching, Hack Sawing, Filing, Drilling and Tapping etc.
Tools and Equipment used:
File, Hand hacksaw, Bench Vice, Twist Drill, Try Square, Drilling Machine, Surface Plate, Angle
Plate, Vernier Caliper, Vernier Height Gauge, Round File, Half Round file, Dot Punch, Triangular
File & Hammer.
Material Required : Mild Steel flat 50*50*6 mm

Procedure:
1. Check the tools and equipments required to ensure that tools are in good working condition. Do
marking on the MS Flat using scale. Draw the line with the help of Hacksaw.
2. Hold the job in the bench vice.
3. Do filling on the job piece with proper method of filing and make adjacent side at a right angle.
4. Do marking for inclined cutting, square cutting and tapped hole using height gauge.
5. Do drilling operation with the bench drilling machine of 8 mm.
6. Do tapping operation with the tap (3/8’’) and tap handle.
7. Do finishing operation with smooth file.
Job Specifications:
Measuring Instrument Used Required Dimensions (mm) Actual Dimensions (mm)
Vernier caliper Length 48 mm 47 mm
Vernier caliper Width 48 mm 47 mm
Vernier caliper Thickness 6 mm 6 mm
Vernier caliper Dimn. 15 x 15 mm 15 x 15 mm
Vernier caliper Dimn. 10 x10 mm 10 x 10 mm
Visual Tapping Quality Good

Actual job Snap:

START
Sheet Metal Shop: Flow Chart for Job Fabrication
Markthedimensions as per
cuttingwith specifiedtools
on sheet
Cut the requiredthe profilefrom

the sheet & smoothen it. With proper
permissio
n
Checkdimensions
of profile.
If OK
NO
Correct it.
NO
YES YES
Bend it as per instructed. Perform

soldering.
Again check dimensions of final

product.
Write checked dimensions on

your notebook.
Punch your Roll No & submit

it.
STOP
Sheet metal shop is a place where metallic sheets of thickness 8/10 SWG(4.064mm/3.416mm) and thinner
(foils and leaves of gold and silver) are used for producing decoration work, household and engineering
goods (refrigerator bodies, coolers, containers, tumbler, hoppers, funnels, bends, guards, hoods, pipes, covers
etc.). With sheet metal hand tools, by cutting, forming into space and joining operation through other
methods are either uneconomical or complicated. Articles thus formed are less expensive and lighter in
weight. Sheet metal replaces the use of casting and forgings in many applications. Sheet metal is generally

implies to cool or hot rolled (generally malleable and ductile in nature). Generally thickness up to ¼” is rolled
hot while lesser thickness can be cold or hot rolled.
Objective: To understand the various sheet metal operations, tools and concept of development of various
surfaces in sheet metal shop.
Safety and Precautions:

1. Check the raw material that it should be free from all type of sharp edges.
2. Check the cutting tools whether they are sharp or not.
3. After cutting of profile straighten the edges with the help of hammer and then use them.
4. While working with chisels, don’t hold small work in your hand.
5. Wear snug fitting clothing; avoid wristwatches, rings, bracelets and neckties etc.
6. If any sharp has left after cutting then remove it with the help of snip.
7. Be continues while using acids as soldering flux.
8. Don’t cut metal heavier than the capacity of shears/snips.
9. The breathing of fumes coming from soldering flux should be avoided, as they are harmful for the
health.
10. Working place should be well ventilated.
11. During hammering operation hold the job properly.
12. Extra allowance must be provided in sheets while cutting so that the finished product is of correct size.
Sheet Metal Exercise-I- To make different sheet metal joints
Raw Material: G.I. sheet of 28 SWG.
Tools Required- Flat Steel plate, Hand Shears, Steel Rule, Steel Square, Scriber, Mallet, Soft Face Hammer,
Try square, and Stakes.
Different Sheet Metal Joints:
According to the requirements many different types of joints are used in sheet metal work.
Hem Joint is wired edge, cup and angular enables the edges to join the pieces along them.
Seam joint is a very commonly used one and most widely used methods for joining light- and mediumgauge
sheet metal. It consists of two folded edges that are locked together with a hand groover.
Locked Seam Joint:
Seam joint is locked so as to ensure a positive grip and also to make the joint flush with the surface.
Alap joint is very frequently used and can be prepared by means of soldering or riveting.A lap joint involves
placing one piece of sheet metal over another, "lapping" it. Lap joints are among the strongest joints
available.
Wired Edge Joint is often specified in the plans, Objects, such as ice-cube trays, funnels, garbage pails, and
other articles, formed from sheet metal are fabricated with wire edges to strengthen and stiffen the jobs and
to eliminate sharp edges. The formula for a wired edge is 1½ x diameter of wire minus 1 or 2 metal
thickness approximately.
.

Diagram – I & II
Job Specifications:
Measured By Required Parameter Actual Parameter
Try Square/ Straight Edge Alignment of the Joint Correct/ Incorrect
Steel Scale Size of the Hem Correct/ Incorrect
Manual Tightness of the Joint Correct/ Incorrect
Manual Locking of the Joint Correct/ Incorrect
Manual Riveting Correct/ Incorrect
Manual Wired Edge Correct/ Incorrect

Actual Job Snap:
Sheet Metal Exercise-II: To make a Rectangular Tray

Raw Material: G.I. sheet of 28 SWG.
Tools Required- Flat Steel plate, Hand Shears, Steel Rule, Steel Square, Scriber, Mallet, Soft Face Hammer,
Try square, and Stakes.
1. Mark and cut piece of size 244 mm x 183 mm from the given G.I. sheet.
2. Place it on the flat surface and straighten with the help of the mallet, and soft face hammer (if
required).
3. The layout of the required tray is given in figure III. Mark it on the straightened piece and
check all the dimensions properly.
4. Cut away the unwanted material from the metal piece to obtain the final figure, as shown in
layout fig.III
5. Again straighten the piece and check it dimensions, make necessary corrections, if needed.
6. Using suitable stake and soft face hammer/mallet, bend the surface P, Q, R, S along the lines
12,3-4,2-3 and 1-4 , to make them perpendicular to horizontal base of the tray.
7. In the same way, bend the four triangular surfaces along the vertical edges of surface R and S.

8. Check the squareness of the entire four bent surface, with reference to the rectangular base of
the tray, by means of a try square.
9. Finally bend the smaller rectangular surface K, L, M and N at 180o outwards for edge folding.
10. This, in addition to providing reinforcement and rigidity to the tray, will also avoid the sharp
edges making handling safe.
Job Specifications:
Steel rule Edge Folding 6 mm 6 mm
Try Square Perpendicularity Correct
Visual Sharp Edge, dents Removed
Visual Over all Finish Very Good
Safety Precautions:
1. Avoid feeling the cut portion by hand while cutting with snip.
2. Do not let sheet metal slip through your hands. Most cuts from sheet metal results from allowing it to
slide through the hands.

3. Use snips only for metal that can be cut by force applied by hand.
4. Hand snips should never be used to cut wires. Such practice ruins the cutting edges of the blades
Actual Job Snap:

Sheet Metal Exercise-III: To Develop a cone of diameter 60 mm and slant height of 90 mm.
APPARATUS TOOLS REQUIRED:

Snips, scale, divider, nylon, hammer, anvil, protector.
MATERIAL REQUIRED: G.I. Sheet
PROCEDURE:
1. Draw top view and front view of cone as shown in figure and divide top view in 12 equal parts and
project the same as front view.
2. Calculate Ф according to given formula: - Ф = r/Rx360
Where r = radius of circle, R = slant height
3. Now on the sheet from any suitable print draw slant height and with the help of divider, draw an angle
of 120 and divide area into 12 equal parts.
4. Again on the arc, draw 12 equal divisions as done on base circle.
5. Cut the profile with the help of snip
6. Now with the help of anvil and nylon hammer complete shape of the cone.
7. Engrave your roll no. On job with the help of punch and hammer.
SAFETY PRECAUTIONS:
1. Avoid feeling the cut portion by hand while cutting with snip.
2. Do not let sheet metal slip through your hands. Most cuts from sheet metal results from allowing it to
slide through the hands.
3. Use snips only for metal that can be cut by force applied by hand.
4. Hand snips should never be used to cut wires. Such practice ruins the cutting edges of the blades.
RESULT: The cone is thus made, from the given sheet metal.

DEVELOPMENT OF CONE
Actual Job Snap:

Sheet Metal Exercise-IV: -To develop a cylinder of diameter 50 mm and height 80 mm
TOOLS REQUIRED: Sheet scale, scriber, straight snip, anvil, nylon hammer, lever shearing machine,
round stake.
PROCEDURE: -
1. Calculate the surface of development of cylinder i.e. equal to circumference 157mm.
2. From the raw material cut a rectangular portion of length 157mm and breadth 80mm.
3. From one side of rectangle, clamp on the stake and start hammering on shape of cylindrical shape with
the open ends.
4. Solder the open ends of the job
5. Engrave your roll number with the help of punch.
Circumference of cylinder = πd
=3.14 x 50
= 157mm (APPROX.)
157mm
80mm
FIRST STAGE
80mm 80mm
Soldering
50mm
50mm
SECOND STAGE FINAL STAGE

DEVELOPMENT OF CYLINDER
Actual Job Snap:

Welding Shop: Flow Chart for Job Fabrication
Start
Choose the raw

materials as per sketch
Mark the following

edge smooth or V-
groove
Check air gap
Put the work piece on

the table, and start
welding
In order to start welding

scratch the filler metal on
theBTMP101-18 Workshop/Manufacturing Practices
table
Welding Exercise-I: To make a Butt joint by Manual Metal Arc Welding.

Equipment and Tools used: Arc welding set, electrodes, Bench vice, Steel Rule, Try square, Flat Bastard
file 12", Chipping hammer, Anvil, flat Tongs, Steel wire Brush, Face Shield, Number punch set.
Material Used: Mild steel flat of size 80x32x5 mm and MS electrode size 3.15m.

1. Cut metalpieces(02 nos.) of dimensions80x32 x 5 mm fromMild SteelFlat using Lever
Shearing Machine.
2. Straighten the cut pieces using hammer.
3. File ends of the work pieces to make them at right angle to the length. Check with a Try square.
4. Put piecesalongsidelengthand Tack weld at bothends,so thatpiecesdo not shift under
welding stresses.
5. Keep Root Gap of about 2mm.
6. Place the job on the Work Table and lock the job at both ends by welding.
7. Weld the job in the centre of the pieces to make a Butt joint.
8. Remove the Slag using Chipping Hammer.
9. Clean the job with the help of a steel wire brush.
10. Punch your UID on the job using punch set and a hammer.
Butt Joint
All dimention in mm
Job Specifications:
Steel rule Length 80 x 80 mm 80 x 80 mm
Steel rule Width 32 x 32 mm 32 x 32 mm
Steel rule Thickness 5 mm 5 mm
Visual Bead Shape & Straightness Satisfactory
Visual Spatter Not much
Precautions
1. Edge preparation should be done very carefully.

2. Before welding ensure that the surfaces are extremely clean
3. While welding always use face shield or goggles.
Actual Job Snap:
Welding Exercise-II: To make a “T’ joint by Manual Metal Arc Welding.

Equipment and Tools used: Arc welding set, electrodes, Bench vice, Steel Rule, Try square, Flat Bastard
file 12", Chipping hammer, Anvil, flat Tongs, Steel wire Brush, Face Shield, Number punch set.
Material Used: Butt joint weldment from practical no.-11& MS flat 32x5 mm and MS electrode size 3.15
mm.
1. Take your job of Butt joint.

2. Clean and file welding from one face of the weldment.
3. Take 80 mm long piece from MS Flat 32x5 mm.
4. File ends of the piece of flat to make them perpendicular to the length using Try Square.
5. Tack weld 80 mm long piece in middle of the weldment at ends.
6. Check for perpendicularity and weld alternatively from both sides.
7. Remove the slag with the help of chipping hammer.
8. Clean the job with the help of steel wire brush.
9. Punch roll no. on the job with number punch set and a hammer.
‘T’ Joint
All Dimensions are in mm
Job specifications:
Observations
Try Square Squareness of ends to sides Correct
Visual Bead Shape & Straightness Good
Visual Spatter Not much

Actual Job Snap:
Welding Exercise-III: To join two metal sheets of 1.5 mm thickness through the Spot Welding.
Apparatus
Two metal sheets of thickness 1.5 mm and length 100 mm, sand paper, spot welding machine.
Procedure
1. Initially cut two mild steel sheets of length 100 mm each.
2. Clean using a hammer and chisel.
3. Rub face surface of the sheets with a sand paper.
4. Then the welding parameters are to be calculated according to the thickness of the sheet.
5. Thereafter the two sheets are made to overlap up to correct length and finally the overlap region is
placed between the electrodes.
6. As the electrodes are being pressed with the help of paddle the circuit gets, the completed and a
nugget is ground due to heat offered due to resistance between the sheets.

Principle of Arc: An arc is generated between two conductors of electricity, cathode and anode (considering
direct current, DC), when they are touched to establish the flow of current and then separated by a small
distance. An arc is a sustained electric discharge through the ionized gas column called plasma between the
two electrodes. Electrons liberated from the cathode move towards the anode and are accelerated in their
movement. When they strike the anode at high velocity, large amount of heat is generated. In order to
produce the arc the potential difference between the two electrodes should be sufficient to allow them to
move across the air gap. The larger air gap requires higher potential differences. If the air gap becomes too
large for the voltage the arc may be extinguished.
Straight and Reverse Polarity: When more heat is required at the work piece side for welding thicker sheets
or for the work materials which have high thermal conductivity such as aluminum and copper the work is
made as anode liberating the large heat near it. This is termed as straight polarity or DCEN. This gives rise to
higher penetration required in thick work pieces. However for the thinner materials where less heat is
required in the weld zone the polarity is reversed making the work negative. This is termed as reversed
polarity or DCEP. In reverse polarity the penetration is small.
Selection of Electrodes: The electrodes for welding operation should be selected properly depending on the
requirements of the welding. The main points to be considered are
1. The composition of the base metal which determines the electrode composition.
2. The tensile strength of the required joint.
3. The thickness of the base metal. For thinner metals the current setting should be lower.
4. The required metal deposition rate.
5. The type of the arc welding equipment used.
6. The weld position (flat, horizontal, vertical, overhead.) A flat position can accommodate large size
electrode.
The electrodes are marked with six digits numeral associated by a prefix, and suffix. The meaning of
these and various values it can take is shown in the figure.
Precautions
(a) Welding parameters play an important parameter in deciding the quality of weld, so must be calculated
properly.
(b) The paddle faces at the sheet must be properly cleaned with the help of sand paper.
(c) The paddle must be kept pressed until whole of nugget formation takes place.
Result
The mild steel sheets have been perfectly joined by the Spot Welding process.
Actual Job Snap:

Welding Exercise IV: Making a permanent joint between Two Plates using gas welding process.
Objective of the Exercise: To study the welding procedure & also familiars with gas welding tools &
equipments.
Theory: Oxy-fuel welding is a process that use fuel gases and oxygen to weld and cut metals, respectively.
French engineers Edmond Fouché and Charles Picard became the first to develop oxygen-acetylene welding
in 1903. Pure oxygen, instead of air (20% oxygen/80% nitrogen), is used to increase the flame temperature to
allow localized melting of the workpiece material (e.g. steel) in a room environment. A common propane/air
flame burns at about 3,630 °F (2,000 °C), a propane/oxygen flame burns at about 4,530 °F (2,500 °C), and an
acetylene/oxygen flame burns at about 6,330 °F (3,500 °C).
In oxy-fuel welding, a welding torch is used to weld metals. Welding metal results when two pieces are
heated to a temperature that produces a shared pool of molten metal. The molten pool is generally supplied
with additional metal called filler. Filler material depends upon the metals to be welded.
Apparatus: The apparatus used in gas welding consists basically of an oxygen source and a fuel gas source
(usually cylinders), two pressure regulators and two flexible hoses (one of each for each cylinder), and a
torch. This sort of torch can also be used for soldering and brazing. The cylinders are often carried in a
special wheeled trolley.
The role of Oxygen: Oxygen is not the fuel. It is what chemically combines with the fuel to produce the heat
for welding. This is called 'oxidation', but the more specific and more commonly used term in this context is
'combustion'. In the case of hydrogen, the product of combustion is simply water. For the other hydrocarbon
fuels, water and carbon dioxide are produced. The heat is released because the molecules of the products of
combustion have a lower energy state than the molecules of the fuel and oxygen. In oxy-fuel cutting,
oxidation of the metal being cut (typically iron) produces nearly all of the heat required to "burn" through the
workpiece.
Types of Flames:
1. Neutral Flame (Acetylene oxygen in equal proportions)
2. Oxidising Flame (Excess of oxygen)
3. Reducing Flame (Excess of acetylene)
Neutral Flame: A neutral flame is produced when approximately equal volumes of oxygen and acetylene are
mixed in the welding torch and burnt at the torch tip. (More accurately the oxygen-to-acetylene ratio is 1.1 to
1). The temperature of the neutral flame is of the order of about 5900ºF (3260ºC). The flame has a nicely
defined inner cone* which is light blue in colour. It is surrounded by an outer flame envelope, produced by
the combination of oxygen in the air and superheated carbon monoxide and hydrogen gases from the inner
cone. The neutral flame is commonly used for the welding of: (i) Mild steel (ii) Stainless steel (iii) Cast Iron
(iv) Copper (v) Aluminium.
Oxidising Flame: If, after the neutral flame has been established, the supply of oxygen is further increased,
the result will be an oxidising flame. An oxidising flame can be recognized by the small white cone which is
shorter, much bluer in colour and more pointed than that of the neutral flame. A slightly oxidising flame is
helpful when welding most (i) Copper base metals (ii) Zinc base metals.
Reducing Flame: If the volume of oxygen supplied to the neutral flame is reduced, the resulting flame will
be a carburising or reducing flame, i.e. rich in acetylene. A reducing flame can be recognized by acetylene
feather which exists between the inner cone and the outer envelope. The outer flame envelope is longer than
that of the neutral flame and is usually much bright in colour.

Welding: The flame is applied to the base metal and held until a small puddle of molten metal is formed. The
puddle is moved along the path where the weld bead is desired. Usually, more metal is added to the puddle as
it is moved along by means of dipping metal from a welding rod or filler rod into 24 the molten metal puddle.
The metal puddle will travel towards where the metal is the hottest. This is accomplished through torch
manipulation by the welder.
Figure 3 Gas welded joint
Precautions: Oxyacetylene welding/cutting is not difficult, but there are a good number of subtle safety
points that should be learned such as: More than 1/7 the capacity of the cylinder should not be used per hour.
This causes the acetone inside the acetylene cylinder to come out of the cylinder and contaminate the hose
and possibly the torch. Acetylene is dangerous above 15 psi pressure. It is unstable and explosively
decomposes. Proper ventilation when welding will help to avoid large chemical exposure.
Actual Job Snap:


Machining Exercise-I: To make a job, involving Facing, Plain turning, Step turning & Chamfering etc.
Equipment & tools required: Center Lathe, Turning Tool, Grooving Tool, Steel Rule & Vernier Caliper etc
Material Used: Mild Steel bar Ø 25 x 125 mm.
1. Hold the bar in 3jaw chuck in a way that at least 20 mm of bar stock is projected outside the
chuck.
2. Do facing of both the ends of bar and maintain dimn.120 mm.
3. Hold the turning tool in Tool post so that it projects out of the tool post about 25mm. The
cutting edge of the tool should coincide with the center of work piece.
4. Hold the job in a 3 jaw chuck, about 45 mm of the job projecting out. The Ø22mm is obtained
first taking one or more rough cuts then finally a finishing cut of not more than 0.50 mm depth
is taken.
5. Similarly turn Ø18 mm to a length of 30 mm from the free end.
6. Chamfer the free end.
7. Remove job from the Chuck and hold from Ø 18 mm resting against Ø 22 mm shoulder.
8. Reduce and finish Ø 25 mm to Ø 21 mm up to length 78 mm from end by plain turning.
9. Turn Ø18 mm up to length 30 mm as explained above.
10. Do Chamfering on the free end at the same setting.
11. De burr all over and remove job from the Chuck.
Tolerance ± 0.5 mm on lengths

Tolerance ± 0.1 mm on diameters
Job Specifications:
Vernier Caliper Ø 18, 18 mm
Vernier Caliper Ø 22 mm
Vernier Caliper Length 120 mm

Actual snap of Job:

Machining Exercise-II: To make a job, involving operations, Facing, Plain Turning, Step turning Grooving,
Taper turning, Knurling and Chamfering etc.
Equipment & Tool Required: Center Lathe, Turning Tool, Grooving Tool, Steel Rule and Vernier Calliper
etc.
Material Used: Job made in previous practical in machine Shop.
1. Hold the job from Ø 21mm and about 60mm length projected outside the chuck.
2. Turn Ø 22 to Ø 21 and turn a groove of 8mm width and Ø 17 using a parting tool.
3. Do diamond knurling on Ø 21.
5. Remove job from the chuck and hold from Ø 18resting against the step Ø 22.
6. Turn Ø 21 mm to Ø 19 mm throughout length.
7. Find the half taper angle using the relation Tan θ = D-d/2L= 19-16/2x40=.0375, θ = 2.15°
8. Set the Compound slide at the calculated angle.
9. Turn taper slowly till a regular taper connecting Ø 16 to Ø 19 mm is achieved.
11. Deburr all over.
12. Remove job from the chuck and inspect.
Ø 16
All Dime nsions are in mm
30 40 8
12 30 Tolerance ± 0.5 mm on lengths
Tolerance ± 0.1 mm on diameters
Job Specifications:

Actual Snap of Job :

BLACKSMITHY
INTRODUCTION
Blacksmithy or hand forging is an ancient trade. It consists of heating a metal stock
till it acquires sufficient plasticity, followed by hand forging involving hammering bending pressing etc., till
the desired shape is attained.Hand forging is the term used when the process is carried out by hand tools. If
power operated machines are used for the process, it is known as machine forging. Hooks, links, lifting
tackles and agricultural implements are some of the items that are produced by machine forging. The
following are the advantages of forging:
1. Strength and toughness is high.

2. Strength to weight ratio is high.
3. Internal defects are eliminated.
4. Forged parts need less or no machining.
TOOLS AND EQUIPMENTS

FORGE OR HEARTH: A smith's forge or hearth is used to heat the metal to be shaped.
Hearths are used for heating small jobs to be forged by hand. Gas, oil or coal firing may be used for the
purpose. The required air for the fire is supplied under pressure by a blower through the pipe into the
hearth. The blowers may either be hand operated or power driven.
Metal Forging temperature,

°C
Mild steel 750-1300
Wrought iron 700-1300
Medium carbon steel 750-1850
High carbon and alloy steel 800-1150
ANVIL: It is a supporting tool used in smithy shop. It is useful for operations such as bending,
swaging, etc. Its body is generally made of cast steel, wrought iron or mild steel, with a hardened top
layer.
The beak or horn is used for bending metal to round shape of different radii. The portion between the beak
and face is called chipping block, which is used as a base for cutting operations, using hot chisels. The
square hardy hole is used to hold square shank tools like swages and fullers. A round hole is also provided
near the hardy hole, which is used for bending round rods and as a die for hot punching operation.
Anvils are made in sizes weighing from 85 kg to 850 kg. An anvil weighing about 75 kg is
suitable for general purpose.
SWAGE BLOCK: It is also a supporting tool used in a forge shop. It has a number of slots of
different shapes and sizes along its four side faces and through holes of different shapes and sizes,
running from its top to bottom faces. This is used as a support while forming (swaging) different
shapes, bending and in punching holes. It is generally made of cast iron or steel.
LEG VICE: It is a heavy duty vice, fixed to the work bench at one end of a leg set in a concrete base.
It is mainly used for light forging and bending work.
HAMMERS: Hammers of different types and weights are used in smithy. The ball-peen hammer
used for light forging works. The sledge hammer which is used for heavy work.
TONGS: It is a holding device .Figure shows the most commonly used shapes in a smithy
shop they are made of mild steel. A flat tongs I used for holding works in rectangular section, round tongs
used for holding round rod, Square tongs is used for holding square rod.

FORGING OPERATIONS
The following are the basic operations that may be performed by hand forging:
DRAWING-DOWN: Drawing is the process of stretching the stock while
reducing its cross-section locally. Forging the tapered end of a cold chisel is an
example of drawing operation.
UPSETTING: It is a process of increasing the area of cross-section of a
metal piece, with corresponding reduction in length. In this, only the portion to be
upset is heated to forging temperature and the work is then struck at the end with a
hammer

FULLERING: Fullers are used for necking down a piece of work. Fullers are
made of high carbon steel in two parts, called the top and bottom fullers.
FLATTENING: Flatters are the tools that are made with a perfectly flat face.
These are used for finishing flat surfaces. A flatter of small size is known as
sethammer and is used for finishing near corners and in confined spaces.
FLATTENER
SWAGING: Swages, like fullers are also made of high carbon steel and are
made in two parts called the top and bottom swages. These are used to reduce and
finish to round, square or hexagonal forms.
BENDING: Bending of bars, flats, etc., is done to produce different types

of bent shapes such as angles, ovals, circles, etc. Sharp bends as well as round bends may
be made on the anvil.
TWISTING: It is also one form of bending. Sometimes, it is done to
increase the rigidity of the work piece. Small pieces may be twisted by heating and
clamping a pair of tongs on each end of the section to be twisted and applying a
turning moment.
CUTTING (HOT AND COLD CHISELS): Chisels are used to cut metals,
either in hot or cold state. The cold chisel is similar to fitter's chisel, except that it is
longer and has a handle. A hot chisel is used for cutting hot metals and its cutting
edge is long and slender. Chisels are made of tool steel, hardened and tempered.
SAFE PRACTICES
1. Hold the hot work downwards close to the ground, while transferring from the hearth to
anvil, to minimize danger of burns; resulting from accidental collisions with others.
2. Use correct size and type of tongs to fit the work.
3. Care should be taken in the use of the hammer.

4 Wear face shield when hammering hot metal.
5 Wear gloves when handling hot metal. 6 Wear proper safety
shoes.
7. Ensure that hammers are fitted with tight and wedged handles.

4
MODEL NO:1
SQUARE PRISM
Scale 1:1
All dimensions are in mm

4
MODEL NO:1
SQUARE PRISM
AIM: To make a square prism using the given cylindrical M.S rod.
MATERIALS REQUIRED:
Cylindrical M.S rod of dia 25 mm and length 100 mm, and coke for heating.
TOOLS REQUIRED:
1- Hammer,
2- Tongs,
3- Flattener,
4- Anvil,
5- Forge,
6- Brass rule.
LIST OF OPERATIONS:
1- Heating,
2- Hammering to square prism, 3- Jumping to reduce length .
PROCEDURE:
1- Copy the given drawing.

2- Collected the tools and material for the model.
3- Heat the given work piece in the hearth to red hot temperature.
4- Take the work piece from the hearth and keep it on the anvil in lengthwise and then
hammer. 5- Turned the work piece to 90 degree after flattening the opposite sides and
continued the heating & hammering to get exact shape of square prism.
6- To reduce the length of the prism to 122 mm, the jumping operation is performed by
keeping the square prism on the anvil in the vertical position.
7- Finally flattened the four faces of the prism using the flattener and finished the square
prism . 8- Then checked the dimensions using steel rule.
Actual Snap of Job

MODEL NO:2
4
HEXAGONAL BOLT
Scale 1:1
All dimensions are in mm

4
MODEL NO:2
HEXAGONAL BOLT
To make a hexagonal bolt using the given cylindrical M.S rod.

AIM:
MATERIALS REQUIRED:
Cylindrical M.S rod of dia 20 mm and length 100 mm, and coke for heating.
TOOLS REQUIRED:
1- Hammer
2- 2- Tongs,
3- Flattener,
4- Anvil,
5- Forge,
6- Brass rule.
LIST OF OPERATIONS:
1- Heating,
2- Jumping one end of the work piece to make bolt head, 3- Hammering
to form hexagonal head .
PROCEDURE:
1- Copy the given drawing.

2- Collected the tools and material for the model.
3- Heat the given work piece in the hearth to red hot temperature.
4- Take the heated work piece from the hearth for jumping operation on the heated end to form
the bolt head by hammering.
5- Repeated this operation to form the end of work piece to the required size of head. 6- Then
heated the head again and place the unheated end of the work piece in the pritchel hole of
the anvil and hammered it suddenly to form the cylindrical head of the bolt. 7- Again heated
the cylindrical head and keeping the end on the anvil and hammered it to form the
hexagonal head. This is repeated to form a regular hexagonal head of the bolt.
8- Finished the hexagonal headed bolt and checked the dimensions using brass rule.
Actual Snap of Job
4

5
FOUNDRY
INTRODUCTION
Foundry practice deals with the process of making castings in moulds

formed in either sand or 3me other material. The process involves the operations of
pattern making, sand preparation, moulding melting of metals, pouring in moulds,
cooling shake- out, fetling heat treatment, finishing and inspection. Moulding is the
process of making moulds.
Moulds are classified as temporary and permanent. Temporary moulds
are made of refractory and other binding materials and may be produced either through
hand moulding or machine moulding.
MOULDING SAND: Sand is the principal material used in a foundry.
The principal ingredients of moulding sands are: Silica sand, (ii) clay and (iii)
moisture. Clay imparts the necessary bonding strength to the moulding sand.
Moisture when added in correct proportion, provides the bonding action to the clay.
PROPERTIES OF MOULDING SAND: The essential requirement of a good
moulding sand is that it should produce sound castings which are free from defects. For
producing sound castings, molding sand or mold should possess the following
properties;
POROSITY OR PERMEABILITY: When molten metal is poured into a
mould, gases and steam will be formed. The sand mould should have sufficient porosity
to allow the gases and steam to pass through it. If they are not removed, casting defects
such as blow holes will be formed.
PLASTICITY: It is the property of the moulding sand by virtue of which, it
flows to all the comers around the pattern in the mold, when rammed. Only due to this
property, the molding sand gets the shape of the pattern in the mold.
COHESIVENESS: It is the property by which the sand particles stick to each
other. Coarsegrained sand particles give better cohesivene'ss than spherical grained sand
particles.
ADHESIVENESS: Sticking of the sand particles to another body is known as
adhesiveness. The moulding sand sticks to the sides of the cope and drag parts of the
moulding box.
PATTERNS: A pattern is the prototype of the desired casting, which when
packed in a suitable material, produces a cavity called the mould. This cavity when
filled with molten metal, produces the desired casting after solidification.
TYPES OF PATTERNS: Wood or metal patterns are used in foundry
practice. Single piece, split, loose piece, multi-piece and cored patterns are some of the
common types.
SINGLE PIECE PATTERN: It is the simplest of all the patterns. This has

5
a flat surface on the cope side. This makes possible a straight line parting on the joint
between the cope and drag of the mould. It is used for making simple castings.
SPLIT PATTERN: Split patterns are recommended for intricate castings,

where removal of the pattern from the mould is difficult. The two halves of the pattern are
put together by dowel pins.
LOOSE PIECE PATTERN: When a pattern cannot be withdrawn from
the mould due to its complexity, loose pieces are provided to facilitate this. The loose
parts or pieces are attached to the main body of the pattern with dowel pins. However,
only two moulding boxes are required for making a mould in this case.
CORE BOX: A core box is a pattern, made of either wood or metal, into
which sand is packed to form the core. Wood is commonly used for making a core box;
but metal boxes are used when cores are to be made in large numbers. Specially
prepared core sand is used in making cores.
PATTERN MATERIALS
The following are the materials that are widely used for making patterns:
1. Wood,
2. Metals and alloys,
3. Plastics,
4. Plasters and waxes.
TOOLS AND EQUIPMENT FOR HAND MOULDING
The tools and equipment used for sand moulding process are grouped as mentioned below:-
(a) Sand preparation tools and equipments.
(b) Moulding flask. (c) Moulders tools.
SAND PREPARATION TOOLS AND EQUIPMENTS
SHOVEL: It is used for mixing and tempering moulding sand and for
transferring the sand into the flask. It is made of broad steel blade with a wooden handle.

5
RIDDLE: Hand riddle consists of a square or circular wooden frame

fitted with a screen of standard wire mesh (No. 8) at its bottom. It is used for hand
riddling (sieving) of sand to remove coarse sand particles and other foreign material
from the foundry sand. It also produces required aeration to the sand. The spacing
between two consecutive wires in the sieve determine the fineness of the sand that can
be obtained through it.
MOULDING FLASK: It is a box, made of wood or metal, open at both ends. The
sand is rammed-in after placing the pattern in the moulding flask. Usually, it is made of
two parts. Cope is the top half of the mould, having guides for the aligning pins. Drag is
the bottom half of the flask, having aligning pins. Cheek is that part of the flask, which
comes in- between the cope and drag. Cheek is used when the pattern is a multi-piece
pattern.

5
RAMMER: It is used for packing or ramming the sand around the pattern.
One of its ends, called the peen end, is wedge shaped and is used for packing sand in
spaces, pockets and comers, in the early stages of ramming. The other end, called the
butt end, has a flat surface and is used for compacting the sand towards the end of
molding.
STRIKE EDGE OR STRIKE-OFF BAR: It is a piece of metal or
wood with straight edge. It is used to remove the excess sand from the mold after
ramming, to provide a level surface.
SPRUE (RUNNER) PIN: It is a tapered wooden pin, used to make a
hole in the cope through which the molten metal is poured into the mould.
RISER PIN: It is a straight wooden pin used to make a hole in the cope,
over the mould cavity for the molten metal to rise-in and feed the casting to compensate the
shrinkage that may take place during solidification.

48
TROWEL: It consists of a metal blade fitted into a wooden

handle. It is used to smoothen the surface of the mould. It may also be used
for repairing the damaged portion of the mould. Trowels are made in many
different styles and sizes, each one suitable for a particular job.
SPIKE OR DRAW PIN: It is a pointed steel rod with a
loop at the other end. It is used to remove the pattern from the mould. A
draw screw, with a threaded end, may also be used for the purpose.
SLICK: It is a small double ended tool having a flat on one end
and a spoon on the other. It is used for mending and finishing small surfaces
of the mould.
LIFTERS: Lifters are made of thin sections of steel of various
widths and lengths, with one end bent at right angles. These are used for
cleaning and finishing the bottom and sides of the deep and narrow pockets
of the mould.
GATE CUTTER: It is a semi-circular piece of tin sheet, used to
cut gates in the mould. Gates are meant for easy flow of molten metal into
the mould.
BELLOWS: It is a hand tool, used to blow air, to remove the
loose sand particles from the mould cavity.
VENT ROD: It is a thin rod used for making vents or holes in
the sand mould to allow the escape of mould gases generated during the
48
49
pouring of molten metal.
Actual Snap of Job:

49

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PRACTICAL FILE

B.Tech. First Semester

BTMP101-18 Workshop/Manufacturing Practices

1. Flow Chart for Job Fabrication 4

5. Flow Chart for Job Fabrication 11

9. Flow Chart for Job Fabrication 15

15. Flow Chart for Job Fabrication 26

BTMP101-18 Workshop/Manufacturing Practices

BTMP101-18 Workshop/Manufacturing Practices

Finish the job and

Safety Precautions in Carpentry Shop End

2. Loose clothing should always be avoided.

3. Tools not in use should not be scattered on the table.

BTMP101-18 Workshop/Manufacturing Practices

6. The tool being used should be well sharpened.

Carpentry Exercise-I: To make a Mortise part of a Mortise & Tenon Joint.

1. Grip the wooden piece in Carpentry Vice.

BTMP101-18 Workshop/Manufacturing Practices

Lab Instructor (Sign.) Workshop Supdtt. (Sign.)

1. Do marking on Piece 'A' for making a Tenon as per the sketch.

BTMP101-18 Workshop/Manufacturing Practices

Lab Instructor (Sign.) Workshop Supdtt. (Sign.)

Mark the dimensions as per cutting

Cut the required profile With proper

Check the straightness of the job using

Again check the dimensions of the

BTMP101-18 Workshop/Manufacturing Practices

BTMP101-18 Workshop/Manufacturing Practices

Material required: Mild Steel flat 52x50x6 mm.

1. Cut a piece of required Dimensions from a flat.

BTMP101-18 Workshop/Manufacturing Practices

Material Required : Mild Steel flat 50*50*6 mm

BTMP101-18 Workshop/Manufacturing Practices

Lab Instructor (Sign.) Workshop Supdtt. (Sign.)

BTMP101-18 Workshop/Manufacturing Practices

Cut the requiredthe profilefrom

Bend it as per instructed. Perform

Again check dimensions of final

Write checked dimensions on

Punch your Roll No & submit

BTMP101-18 Workshop/Manufacturing Practices

Safety and Precautions:

BTMP101-18 Workshop/Manufacturing Practices

BTMP101-18 Workshop/Manufacturing Practices

Lab Instructor (Sign.) Workshop Supdtt. (Sign.)

Sheet Metal Exercise-II: To make a Rectangular Tray

BTMP101-18 Workshop/Manufacturing Practices

BTMP101-18 Workshop/Manufacturing Practices

Actual Job Snap:

Lab Instructor (Sign.) Workshop Supdtt. (Sign.)

BTMP101-18 Workshop/Manufacturing Practices

APPARATUS TOOLS REQUIRED:

2. Calculate Ф according to given formula: - Ф = r/Rx360

Where r = radius of circle, R = slant height

4. Again on the arc, draw 12 equal divisions as done on base circle.

5. Cut the profile with the help of snip

BTMP101-18 Workshop/Manufacturing Practices

Lab Instructor (Sign.) Workshop Supdtt. (Sign.)

BTMP101-18 Workshop/Manufacturing Practices

BTMP101-18 Workshop/Manufacturing Practices

Lab Instructor (Sign.) Workshop Supdtt. (Sign.)

BTMP101-18 Workshop/Manufacturing Practices

Material Required : Mild Steel flat 50506 mm