iii FOLLOWING ARE SOME OF THE SAFETY PRECAUTIONS YOU NEED TO TAKE CARE OF IN THE WORKSHOP, PRECAUTIONS * Always wear lab coat while working in the lab + Wear gloves while handling the metal sheets and sharp tools. «+ Use appropriate tools as told by lab staff. « After usage, submit the tools back in the lab. « Getfullknowledge before operatingany machine or using any tool * Files must have well fitted handles. See that work piece is perfectly clamped or fixed in the vice. * Never use hammers with loose heads. Never tilt the hacksaw blade while sawing. brill the holes centralizing on pop marks, give gradual feed. Do not use a spanner asa hammer. Do not use a steel rule asa screw driver. Use the coolant at the time of hack-sawing and drilling. keep the work place neat and clean after work. Incase of emergency immediately call the attendant.6 3 LN 5 3 a g 3 g = a ¢ 3 S 5 3 2 8 a 2 = ws $ eI = fg = 5 TL taLAYOUT DETAILS ‘e M1-Drill Machine No. 1 /® M2- Drill Machine No.2 _° M3-Power Hacksaw Machine e M4-Double End Pedestal Grinder e M5-Arber Press © M6-Surface Grinding Machine © M7-Air Compressor ° M8-Pneumatic Press ° M9-Pneumatic Metal Shearing M\C e M10-Bending Machine e 11-Sheet shearing machine T1-Metal sheet surface plate table 1 © T2- Metal sheet surface plate table 2 © T3- Metal sheet surface plate table 3 ¢ Working Table 4SS M1-Drill Press Machine No. 1 ‘The most widely used process of material-removing or cutting process in which the tool uses a drill bit to cut a hole of circular cross-section in solid materials. 75% of all metal cutting material removed comes from the drilling operation. Specifications Thismachine basically for makingholesbutitisalso used in various processes other than drillinge.g,,itisusedin counter boring, tapping, spot facing, reaming, grinding, lapping, bottomingand trepanning. Working Theholeisgeneratedbythe rotatingedgeofacuttingtool whichexertslarge forceonworkclamponthetable.Asthemachine exerts vertical pressure onwork clamptodrillholeitiscalled drill press. Holes may be produced bytwist drill or flat drill or by boring with one or more single point tools or cutters mounted ina bar or head.speedinlight jobs. They are capable of rotating drills of diameter from 1.5 to 15.5mm. A large number of spindle speeds and feeds can accessiblefor varioustypesof work. Theyare presented in different sizesandwithdrilling capacityrangeableto75mmdiameterdrills. M3-Power Hacksaw Machine / ; itis used to cut across materials like metal and bone. It provides a vise for — ing the work and means for reciprocating a U-shaped frame on which is as a straight steel hacksaw blade that cuts when moving in one hb direction only. Each blade of the power hacksaw is composed of 14 to 24 teet per inch of the blade.Working it has the same function as the saw machines is used to cut metal in the machine shop, drawing a blade containing cutting teeth through the the power hacksaw uses a reciprocating (back and forth) work piece. The saw machine is faster and easier than hand cutting action similar to the one used in a hand hacksaw M4-Double End Pedestal Grinder It works on the same principle as the grinder that is mounted on a pedestal, which may be bolted to the floor or may sit on rubber feet. They are commonly used to hand grind various cutting tools and perform other rough grinding. Working They are used to sharpen high-speed steel cutting tools used on the lathes and milling machines, deburr, or used to remove surface imperfections and to work extremely hard materials. The grinding wheels are held betweentwo flanged disks, M5-Acrobe Press {tis a small hand-operated press. It is typically used to perform smaller jobs, such as staking, riveting, installing, configuring and removing bearings and other press fit work. It can be mounted on a work bench. Working It is a compact machine with different parts working together to produce a press. The components of the arbor press include the ram, a recoil spring, a lever arm, an arm stop, the press caul, and the arbor base, When using an arbor press, the item to be pressed is placed on the base and the lever arm is pulled down.M6-Surface Grinding Machine It is the conventional finish machining Process used for producing a good surface finish on the components. It is one of the widely accepted finishing operations because of its material removal capacity in a very small size of chips ranging from 0.25 to 0.5 mm The abrasive particles present on the surface of a grinding wheel will be acting as a single point cutting tools for removing the material from the work piece.M7-Air Compressor An air compressor is a pneumatic device that converts power (using an electric motor, diesel or gasoline engine, etc.) into potential energy stored in pressurized air Working Air compressors work by forcing air into a container and pressurizing it. Then, the air is forced through an opening in the tank, where pressure builds up. The compressed air can be used as energy as it's releasedM8-Pneumatic Press machine us Frame See eere cylinder to generate a compressive force. pneumatic press with various Briers orem main components of the FE aimoniy lise Taachine trols fee an Presses are one of the most ress brake i typically narrow and ustry for the forming of different materials Recents Jong so that large pieces of sheet metal can Working aan aes sheet metal by lowering esssiprake Unt paar die, The metal may be bent several rm has been achieved. a punch onto sheet metal that times by @ matic cylinder rod. When doubleacting cylinder dueto pressure & ovided at end ofthe pneu! The shearing tool is pr compressed airissupply bythe DCV'. é force created bycompressed air causes Shearingactionofthe sheet metals.strips& force rengblades.Theshest meal cating workswiththehelpof Hsredoubleactnecyinde re connectedtothe movingcutting tool. Itisusedto cutthesmallsizeofsheet metal. The machineis portable insize,SO easilyM10-Bending Machine Aroll bending machine uses roller to bend a metal. The roller of bending machine can be two rollers, three rollers, or four rollers. The common product of roll bending machine is tube bending, plate bending and a coil. M11: Sheet bending machine A machine for bending and straightening metal sheets and strips. Specifications Its purpose is to assemble a bend on a work piece. It is stable in structure and simple in operation. It is really the device necessary for construction of ventilation duct. Sturdy construction. High operational fluency. Impeccable performance.Steel And Its Types Steel is classified by its composition: iron is fused with carbon and any number of other elements to achieve a specific end, The four main types are: Types * Carbon steel © Stainless steel * Alloy steel © Tool steel Carbon Steel All steel contains carbon, but carbon steel is unique for a notable absence of other elements in its makeup. Though it only contains 2% carbon or less by weight, its elemental nature makes carbon steel a strong, durable material that is ideal for numerous uses. Carbon steel is sometimes confused with cast iron, though it must contain less than 2% carbon. Cast iron contains 2% to 3.5% carbon, giving it a rough texture and more brittle nature. Even though carbon steel is composed of alloyed metals, it doesn’t have alloy classification because of the lack of other alloying ‘elements in its composition. This simplicity contributes to carbon steel’s popularity — it accounts for about 90% of all steel production.FABRICATION AND FITTING Fabrication Fabrication is the process used to manufacture steelwork components that will, when assembled and joined, form a complete frame or structure. Function Itis a value-added process involving the creation of machines, parts, and structures from various raw materials. Typically, a fabrication shop bids ona job, usually based on engineering drawings, and if awarded the contract, builds the product. Fitting The term Fitting is related to the assembly of parts, after bringing the dimension or shape to the required size or form, in order to secure the necessary fit. Function Fitting Shop involves a large number of hand operations to finish the work to desired shape, size and accuracy. The various operations performed are marking, chipping, sawing, filing, scraping, drilling, tap (Internal threading) and die (External threading). MOVABLE JAW {HOLE FOR SECURING TO BENCH.° PROCESSES Filling Marking Punching Drilling Taping Reamming Sawing Die TOOLS Try square scale File © Single cut file © Double cut bastard file Scrubber and paint Centre punch & ball pin hammer Drilling machine Reamer Taps o Taper Tap o Plug Tap o Bottom Tap Hacksaw Die & Die stock1)Filling Filling is a material removing process in manufacturing. Itis functionally versatile but mostly used in deburring operations. Filing operations can be used on wide range materials, Filling helps to achieve working function by removing some excess material and making the surface smooth Right hand Work File Left handAE. SS yes Cross filling Draw filling she work piece is tightly clamped in the vice with surface to be filled is kept sojizontal ile is held in the position of work piece the hand of file is right hand, and wit hand is on the other end pressing it downward and foreword horizontally ehrough its full length. Foghtinand Wark Fs Lettihenad Draw filling tis used to remove marks and scratches left by cross filling and used to produces smooth and flat surface on workpiece. File is moved on workpiece widthwise file.00h single cut file pouble cut bastard file single cut file aving teeth so fine as to make an almost smooth surface. Saw sharpening t to deliver a smooth finish. They are suited to sharpening wre a finer, sharper edge oF 1e, used primarily file bi jlesare usually single cu igv blades and dressing tool edges, especially whe smoother surface finish is desired. The Chainsaw file is one exampl for sharpening chainsaws. Double cut bastard file tong and has oth bastard 0 inc! , ouble cut file remove stock: TREY Itis also called flat bastard 3 refers toh et roy weave ave" coinsand double cut. TEE ihe same file sl pgp work are made of hardened te yer used f pr ne rough surface, so they are —ao —SSS = 2)sarking syorking is done on work piece at top right mm away from top and second 8mm away from previous and 16mm away from top. They are lines of 20 mm long, At pattom left side marking done at 20mm by 20mm. Also, at right left side matkit fe done at 20mm by 20mm " ns oan 7s Cong) a Y Sim _—___20mm__ —_ aa 20mm fools Try square scale Scale iii, Scrubber and paint Try square scale Atry square or try-square i 30° angles on pieces of wood. Tho of square, the try square is consi Working, The square in the name refers to the 90° is a woodworking tool used for marking and checking ugh woodworkers use many different types dered one of the essential tools for wood angle. eSyr SrereceCeeRCReRTareaE TT ——— A OO aaa spy + banda sale jeisdefined as the ratio of the length of any object on a model (blueprint) to z cual length of the same object in the real world, Scrubber and paint Tiese are used for the marking on workpiece.104 JO. : adaidyJom e uo diy ayy jo uoissasduu}/uo}yeq¥9PU! ue Bul ae 10y e Bupjew ‘sjamop pue seu se yons s1dUaISeJ BAP 0} PAS” St ee qpuncsnuey yawweyuldyed yound aqua) Joo] _—_——>| wwoe fron Cause ‘Buypund auop aney am os Nise? anowad Wed Buje) ‘BdaIdy1OM e UO di} ay} Jo UOISsaIdLUI/UO}JeyUBPU! UE uw Jo ‘ajoy & Bupjew ‘sjamop pue sileu se yons ssauaysey anyip 0 pasn He soypued sarqoundt aABall pin hammer | Apin hi i A | ae hammer se very lightweight hammer which is used for very fine work. ommon| ing i panel pins and tacks, ly used for knocking in small very small nails, 4)Drilling it is simplest stationary (clamped in position and drill rotates to mak: ig in which drill bit is used It is commonly used machine and accurate used in production shop. The workpiece is held hole). It used to remove unwanted material or cutting ectimate 75 percentage of all metal cutting remove comes from drill machine. Tool © Drill Machine Types Sensitive Drilling Machine Upright drilling machine Radial Drilling Machine ii. iti,Sensitive Drill Machine 160 still dill machine make for drilling tiny holes at a high speed in light jobs. They are able of rotating drills of diameter from 1.5 to 15.5mm. Hong, feed Depin.. adjustment ees ae) work table @UNGRAMRITKUMAR Upright Drill Machine tis used for various types of work. It is available in different sizes with drilling capacity range 75mm diameter drill, Bevelgeardrivetospindle spindle Overhead shaft Backstay Countershaftcone pulley Fastand loose pulley Table elevating handleviii. Footpaddle ix. Base x. Rackoncolumn xi, Tableelevating clamp handle xii, Table clamp xii, Table xiv. Column xv. Hand wheel for quickhandfeed xvi. Handwheelforsensitivehandfeed Upright drilling machine Radial Drilling Machine Radial Drilling Machine is used to drill medium to large and heavy drill in work pieced It is mostly used when the component size is large in height.Motor for elevating screw Motor for spindle Dri heaa ( oxgf ] Feed hana weet Spindle Den Column, Radial Drilling Machine Function The hole is generated by rotating edge of a cutting tool known as drill which exerts large force on work clamped on the table. As the machine exerts vertical pressure to originate a hole it is called “drill Machine”. Holes may be produces by drilling with twist drill, flat drill etc. or by boring with one or more single point tools or cutters mounted in a bar or head. Reaming can also be done which is finishing process. It may be applied to drill or bored holes to give a better finish. mia 36mr US Zomm 20mm5)ta i} ng dove by using taper, plug, bottom tap to make threads in hole that drilled | thread, a hole is first drilled same as the size of n internal hole. Next, th xt the second tap is used and at the internal thread in the hole. 1 pachine. To create 2! ue. itis called a tapping size yale then we removed it, ne used. These taps cuta screw it .e taper tap is used to screwed into the end plug tap is yooL eo Taps i, Plug tap Bottom/second tap Taper tap Taper Plug Bottoming Taper tap itis first used taping threading of hole. It has to taped 8 to 10 treads. It is shaped so that this tap helps to start the thread. It is required higher cutting forces than other taps. ESplug ta per tap. Itis ike taper tap. The difference is that we have fewer a ally the first 3 to 5 threads so we get taping of thread sooner. Itis not pissed after (0 ofthem Us goay to start as taper t@P so gottom tap iris used after plug tap and used to cut thread in hole that already partially formed by plug tap. It has tapped only a thread of count of 4-2, This threading will ensure maximum usage of hole at the bottom of thread. It is use to finish tap. 6)Reamming Reaming is a cutting process that involves the use of a rotary cutting tool to cr that they can use to start the thread. ate smooth interior walls in an existing hole in a workpiece. TOOL «Reamer Reamer itis type of rotary cutting too! used in metal work. They are making to enlarge the vine ofa previously formed hole by a very small amount but also smooth the hole formed by drill machine. It moves clockwise to enlarge the hole and then counter clockwise so that fine small particles of metal remove from hole. It moves clockwise and then counter clockwise pattern until whole hole smooth.8mm t 16m = Y Reaming —_ (45mm) Tapping ¥ Sle 1 S Udinm 20mm 20mm 7)Sawing Sawing is used to separate work parts into two or more pieces, or to cut off an unwanted section of a part. * ole [= ‘ wal Reaming ——_ ™ ¥ sa 20mm nm Bun 20mm 20mm Tool e Hacksaw8)Die is a proc s used ft ner on work pie jor very smooth cutting. ess which is used to form or cut a male thread on the outside of rods or for cutting purpose. It is C-shaped tool with blade in it ww at 90 degrees if we want to make cutting through ce. It has relatively large teeth per inch (TPI) through p hacksal -_— oejoo! 4 Die And Diestock pie And D stock pye stocks also known as die holders. It is usage for fitting and shape the cie when tatting is done. Its use to cut thread onto bolt. Before using of die first cetermine fumber of threads per inch (TPI). It formed outer thread on bolt. ~