Mechanical Workshop Lab

ACKNOWLEDGEMENT

This is a representation of theoretical and practical knowledge gained during studying the course of
“Mechanical Workshop” in Pokhara University.

I am very thankful to workshop technology department(Civil & Rural Engineering Department) of Nepal
Engineering College for providing me the golden opportunity to prepare the report on mechanical
workshop which can be taken as a quick reference instead of dealing with the comprehensive books. It
will help the readers to know about the workshop tools used in manufacturing, fabrication or repair
jobs. It also emphasis on the description on machines in brief.

Similarly, I am indebted to the help and advice of our dedicated lectures and my helpful colleagues
who helped me to prepare this report in this format. The positive response received from all related
person to workshop and always supporting and helping friends are also the source of inspiration for
getting this report.

A very special thanks goes to Mr. Pradip Shrestha for his valuable guidance, care, expertise
and devotion of time in completion of this report in a short and sweet form.

I also thank all my classmates, seniors who directly and indirectly supported me in completion of
this report. A very special thanks goes to principal and vice principal of Nepal Engineering College too.

-Prashant Bhattarai

Mechanical Workshop

Introduction

Mechanical workshop is a place where machinery parts, equipments and tools for manufacturing, to do
fabrication and repair jobs are made. The fabrication may be of machines themselves or some erection
structures like trusses, parts of bridges, etc. ‘Workshop technology’ is intended to provide instruction
and practical experience in basic shop of machines and metal working operations for manufacturing of
machinery equipments.
 The heart of workshop is machines shop with metal cutting machine called ‘Machine Tools’ like
lathe machine, drill machine, shaping machines etc. And ‘Hand Tools’ like hacksaw, hammer, file etc as
well as joining machine like soldering and welding machines. Similarly it also has forming department
with forging, banding machine, heat department and so on.

Workshop is such a machine shop which provides human reliable, accurate and cheap equipment
which will help people to perform their respective machinery job fast and accurately with providence of
less effort as well as usual.

The product of workshop must be accurate and require more careful inspection than general
manufacturing so with regard to the future demands of workshop products there must be the
advancement in the technologies like automation; numerical control and specialization are going on in
the field of machines tools.

Objectives

The objectives of workshop are as follows;

1. To know the concept of making Hammer and Dustpan.

1. To have knowledge about the uses of different machines as well as their working procedure and
principle.

2. To know about the uses of metal and their alloys for manufacturing different tools in mechanical
workshop.

3. To get the appropriate knowledge of tools and equipments for definite working purpose.

4. To study layouts, measurements and further mechanical operations during working progress.

5. To get familiar with name of machines, tools and their working purpose like;

Cutting tools

Drill machine

Lathe machine etc.

6. To get theoretical and practical knowledge of sheet metal work, benchwork etc for manufacturing of
different tools.

List of Contents

1. Metal

-Ferrous Metal

-Non-Ferrous Metal

2. Mechanical Properties of Metal

3. Bench Work

-Introduction

-Tools Used in Benchwork

-Hammer

4. Sheet Metal Work

-Introduction

-Joints

-Some joints with description

-Tools Used in Sheet Metal Work

-DustPan

5. Drill Machine

6. Safety Measures

7. Conclusion
Metal

[A] Introduction:

Metals are generally solid in nature except Mercury (Hg). Metals have some general characteristics like
malleability, ductility, good conductor of heat and electricity, high melting & boiling point as well as high
density. On behalf of their massive utilizing properties, metals are widely used as raw materials in
workshop. Metals are used to make different tools and equipments for machines also to repair jobs.
Metals are repeatedly used for fabrication in the form of block or thin sheet.

Metals are subdivided into two types.

i. Ferrous Metal

ii. Non-Ferrous Metal

i. Ferrous Metal:

Ferrous metals are those metals which attract during magnetic action and also which can form a
homogeneous mass with iron during chemical combination to form an alloy. Some basic examples of
ferrous metal/alloys are:- Iron, Steel(Ordinary, Stainless, Manganese, Tungsten), Invar etc.

ii. Non Ferrous Metal:

Non Ferrous metals are those metals which don’t attract during magnetic action and also which
can’t form a homogeneous mass of alloy during chemical combination with iron. Besides iron and steel,
mechanical workshop uses other metals, so called Non-ferrous metals. Some basic examples of ferrous
metal/alloys are:-Gold, Silver, Copper, Zinc, Tin, Aluminum, Lead, Brass, Bronze, and German silver etc.

#Ferrous Metals#

1. IRON:

Iron is the main metal of ferrous group metals. Symbol of iron is ‘Fe’ which is derived from Latin
word Ferrum. Extraction of iron from its ores (Hematite, Magnetite, Siderite, Limonite and pyrite
groups) if done following the steps provided below;

i. Crushing and Concentration: Iron ore is crushed in fine powder form and concentration is done by;

Gravity Separation Method (i.e.; Washing by water is carried out) .

Magnetic Separation Method (i.e.; passing through magnetic conveyer belt)

ii. Calcination: Volatile impurities like Carbon, Sulphur, and Phosphorous etc are removed from
concentrated iron ore by heating with limited air.

iii. Smelting: The ore is then mixed with Limestone and Carbon (Coke) and then heated in Blast furnace
to obtain molten form. During which slag is formed in the middle of blast furnace, which is then
removed

Thus finally, the iron obtained from blast furnace is impure iron, called Pig Iron or Cast Iron.

# Types of Iron:

1.1. Pig Iron:

It is the impurest form of iron and also not shaped(i.e.; Molten State). It is used as cast iron or converted
into wrought iron or steel. It is the primary form of Iron.

1.2. Cast Iron:

It is also the impurest form of iron but casted into definite shapes as per use and requirement. The
carbon content in cast iron is greater than or equals to 2.5% to 4.5%. It is used to make pipes, building
railway tracks etc. It is brittle in nature.

1.3. Wrought Iron:

It is most pure form of iron. The carbon content in wrought iron is greater than or equals to 0.1% to
0.2%. It is used to make crane hooks, chain slings etc.

2. STEEL:

Steel is any alloy of iron containing chiefly carbon <maximum 2%>, other metals being added for
specific superpose. Steel are made from pig iron. Here pig iron is charged in converter where impurities
like sulphur and phosphorous are largely burnt off and carbon connected are controlled and other
metals are added as per requirement. Steel has multi-ferrous use so much that capita consumption of
steel forms one of the development criteria of country. Steel is cast as steel cast in very limited amount,
most of any rolled in rolling mills into verities of section. Iron and carbon give various crystal structure of
steel. The quality of steel is very dependent upon the amount of carbon. Higher the carbon, hardest and
strongest steel comes on the other hand. Hardness can led to brittleness. However, hardness can even
be controlled by heat treatment to steel.

Thus, on the basis of carbon connected, the steel is categorized as;

i. Low Carbon Steel <Mild Steel>:

Ø Contains less than 0.2% carbon.

Ø Soft in nature.
Ø Used for pressing sheets for automobiles and incase where brittleness is to be avoided and good
wearing is not required like clamps, washers, bottles etc.

ii. Medium Carbon Steel:

Ø Contains carbon between 0.2% to 0.6%.

Ø Medium in hardness.

Ø Used where very high hardness is not required such as for structural steel, axles etc.

iii. High Carbon Steel:

Ø Carbon content is between 0.6% to 1.3%

Ø Used where hardness is required.

Ø Raw material for the workshop and also called as tool steel.

iv. High Speed Steel:

Steel in which metals such as tungsten, cobalt are added to minimize or avoid the loss of hardness
due heat produced due to high speed of machines are called High speed steel, also called alloy steel. It
also minimizes the expansion at high temperature.

v. Special Steel:

Ø Chromium + Steel = Stainless Steel

Ø Nickel + Cobalt + Steel = Powerful Magnets

Ø Silicon + Steel = To avoid magnetic loss

Electrical Machines

#Non - Ferrous Metals#

1. Gold: Used to plate glass plates of sophisticated building to conserve heat of the sun.
2. Silver: It is the best conductor of heat and electricity. It is used in plating in small amount but is
consumed mainly in making photographic film.

3. Copper: It is best conductor of electricity and is used to from some alloys of copper.

Zinc + Copper = Brass

Tin + Nickel + Aluminum + Copper = Bronze

4. Zinc: It is used to prevent rust <Galvanize> in iron sheets and also electric cells. It is cheaper than
copper. Added in high proportion, it makes brass less ductile and harder to roll. Zinc is added upto 5% to
make coin. The alloy is called Gliding metals.

5. Tin: Tin itself is a rust proof metal. Tin takes high polish and is suitable for packing edible stuffs. It is
highly fusible and furnace base metal for solder. Tin bronze makes densely packed casting. Around 10%
tin is used for valves and pumps with addition of some zinc, we get gun metal which is used to make
canon barrels.

6. Aluminum: It is used more wisely because of lightness, softness making it easier to work and good
color. It is the useful material in aircraft industries. It is used extensively for elastic bare conductor.

7. Lead: It is soft and resistance to common acids. It is used in printing as well as to a certain extent in
chemical industries but extensively in lead acid batteries

8. Nickel: It is used in making a number of non ferrous alloys. It is very lustrous and highly rust-
resistance. Similarly to chromium and used in chemical industries because it is corrosion resistant was
used in replace silver coins because it had silvery cooler with zinc added. It is also called German Silver.

Mechanical Properties of Metal

The mechanical properties of a metal are determined by observing the deformation that a test piece of
this metal undergoes under different kinds of loadings.

The Load per Unit Area is called stress (F). F = P / A

The Stress may be;

· Tensile : When the load stretches and tends to elongate it.

· Compressive: When the load stretches and tends to shorten it.

· Shear: When it tends to shear it.

· Torsion: When twisting is done.

Tensile and compressive stresses act right angles to the area being considered whereas shear acts in
same plane as the area. Units used are tons /sqinch; kg/mm2; N/mm2. To measure deformation, the
term strain is used; it is the ratio of change in length to the original length.

Strain (σ) = Change in length <▲l> / Original length <L>

Tensile or Compressive stress produce strain of the opposite kind in perpendicular directions. Within
elastic limit, the ratio of the lateral strain to longitudinal strain is constant for metal and is called
Poisson’s ratio<m>.

The important parameters relating to metals properties are determined by using various tests. The
tensile test is the most convenient of them. The Graph of tensile stress to strain takes the following
form. (For Mild Steel)
Here from Graph; We have noticed:

Ø Proportional Limit: It is the point at which the straight line relationship between stress and strain
ends.

Ø Elastic Limit: It is the maximum stress to which the test of the piece is subjected and still returns to its
original length upon release of the load.

Ø Yield Point: It is the point where a sudden increase in stress i.e.; When the metal begins to flow.

Ø Ultimate Strength: It is the maximum stress value and is also called tensile strength.

Now also the modulus of elasticity (E) is calculated and is the ratio of stress to strain. Where E is called
Young’s Modulus of Elasticity.

All the above parameters enable as to compare various metals in respect of important properties. These
properties are as follows;

· Elasticity:- This property which is exhibited in the low stress region upto elastic limit is important as
care has to be taken to ensure that structure are stressed well within elastic region.

· Plasticity:- When the working stress exceeds the elastic limit, it is said to be in the plastic region.
Flow of the material takes place here as during coining or hammering. It is increased by heating.

· Ductility:- Ductility is that property of metal which allows it to be drawn out by tension to a smaller
section as in making thin wire. Ductile extension, the metal exhibits a certain degree of elasticity
together with considerable plasticity. Brittleness is lack of dutility.

· Malleability:- When a metal can be beaten or rolled, it is said to be malleable. Malleability is similar
to ductility.
· Hardness:- It is defined as resistance towards the penetration under pressure, or to scratching by a
sharp point or to abrasion and is of greatest importance in workshop. There are three main methods of
testing it;

i. Brinell Ball Hardness Test

ii. Vicker’s diamond pyramid test

iii. Rock well hardness test

Bench Work

[A] Introduction:

The place where assembling and fitting process takes place is known as “Bench”. Human needs hand
hits for every aspect of work. Hand tools are the basis for every operation. Infact, No work is completed
without bench operation and no workshop is complete without bench for working with hand tools.

[B] Tools used in Bench Work Operation:

a. Bench Vice

A bench vice is the device for holding the work piece where most hand processes to be carried out. The
body of the vice is made of cast iron while the two clamping jaws are made up of hardened tool steel.
Some bench vice has a swivel base, which can set the work pieces at any angle to the table. One of the
jaws of vice is fixed and other movable, threaded in and out by a screw and leveled. They are of three
types;

Ø Wood working

Ø Engineers

Ø Others

# Cares of Vice:

· Light hammering can be done on and only on the Anvil of the vice.

· Don’t direct impact the Vice body by hammer.

· To avoid over clamping, the handle of the vice should be tightened by hand only.
b. Steel/ Stainless Steel Scale

Steel scale is a flat surface of hot rolled steel consisting pig iron <Ferrous/ Ferric> oxides, Hematite,
Magnetite.

c. Hacksaw
 Hacksaw is a fine-tooth hand saw with a blade held under tension in a frame, used for cutting materials
such as metals or plastics. A hand-held hacksaw consists of a metal frame with a handle, usually a pistol
grip, with pins for attaching a narrow disposable blade. A screw or the other mechanism is used to put
the thin blade under tension. The blade can be mounted with the teeth facing towards or away from the
handle, resulting in cutting action on either the push or pull stroke. On the push stroke, the arch will flex
slightly, decreasing the tension on the blade, obtain resulting in an increased tendency of the blade to
buckle and crack.

# Safety and Cares of Hacksaw:

· Avoid much pressure while push or pull action.

· Work piece must be hold firmly.

· The cutting action is carried on the forward action only. So tne blade must be mounted with its
teeth pointing forward.

· Suitable tension should be applied on the blade to avoid breakage or loosen.

· Change the blade if some teeth are broken.

· Avoid rapid and erratic strokes of cut.

d. File

Files are the most important hand tools used for the removal of materials. They are made of hardened
High Carbon Steel with soft ‘tang’ to which a handle can be fixed. Files are categorized as follows;

Ø Length:- Measure from the shoulder to tip.

Ø No. of Cuts:- Single or Double.

In single cuts file, the teeth are parallel and single set are made at 600 from horizontal whereas in
double cut two sets of teeth are present where another set at teeth are at 500 to the 600 teeth.

Ø Grade <No of teeth per inch>

File with:

21 Teeth / Inch ――› Bastard

26 Teeth / Inch ――› Second cut

40 Teeth / Inch ――› Smooth

72 Teeth / Inch ――› Dead Smooth

Ø Shape of file:-

o Hand file:- Common file used for roughing and finishing. It is a rectangular in section and parallel in
width. It has double cut teeth on two faces and single cut on one edge and one save edge.

o Flat file:- It is similar to hand file. Rectangular in section, tapered slightly in width and thickness
towards the tip. It has double cut teeth on two faces and single cut on two sides.

o Square file: It is used to file at corners and double cut.

o Half round file: The section is chord of a circle with its tapers towards the tip. It is used for forming
radii, groves, etc. And flat side is used for finishing flat surface.

o Round file: This is of round section tapering towards end and used for enlarging holes, producing
internal round corners. Usually, double cut in large and single cut in smaller size.

o Tri-Square file: Also, Known as triangular file, with tapered tip, double cut on the both faces and used
for filing corners or angles less than 900.

o Needle file: Needle files are a set of small files with their shapes similar to the large ones.

# Cares of File:

· Hold workpiece slightly.

· The tang of the file must invariably be inside the handle before beginning to file.

· Don’t use too much pressure.

· Make long stokes, apply pressure while working away and no pressure while returning.
e. Vernier Callipeer

Vernier Callipeer is a hand measuring tool used to measure internal, external ratio as well as length and
also the depth of the hole.

f. Tri-Square

Tri-Square is made of hardened tool steel. It is used for checking the straightness, perpendicularity and
the squareness of workpiece. It can also be used for making perpendicular lines into a workpiece.

g. Radius Gauge

A radius gauge is also known as a fillet gauge. It is a tool used to measure the radius of any object.
Radius gauge require a bright light behind the object to be measured. The gauge is placed against the
edge to be checked and any light leakage through the blade and edge indicates a mismatch that requires
correction.

h. Centre Punch

A centre punch is a hard metal rod with a shaped tip at one end and a blunt butt end at the other. It is
usually struck by a hammer. Most wood workers prefer to use a ball pen hammer for using punches.
Punches are used to drive objects, such as nails, to form an impression of the tip on a workpiece.
Decorative punches may also be used to create pattern or image.

i. Drill

A drill is a tool fitted with a cutting tool attachment or driving tool attachment, usually a drill bit or drive
bit used for boring holes in various materials or fastening various materials using fasteners.
j. Tap / Die/ Stock:

v Tap: Taps are used to cut internal screws, threads. It is made of hardened High carbon steel or high
speed steel. The ends of the shank are square to fit a wrench. Usually taps are provided in set of three.

· Taper Tap:- It is tapered off for a length of 8 to 10 threads and is a first tap to be used in a hole to
start the thread formed.

· Second Tap:- It is tapered off for a length of 4 to 5 threads to facilitate picking cut by the tapered
tap.

· Plug Tap:- This is fully threaded throughout its length and is cut bottoming tap. This tap to cut the
bottom of the blind hole.

# Precaution and Operation in Tapping:

§ The size of the hole is important and the correct drill size should be determined from the handbook,
standard table in the workshop or the recommendation on the shank of the tap.

§ Use taper first ensuring that it is kept square with top surface of work.

§ Always use correct size of wrench for the tap.

§ Lubricant oil should be used while cutting.

§ Use both hand to hold the wrench to maintain even torque.

§ About every half turn, reverse action slightly to break the sward and clear the threads.

§ Don’t force when tap reaches to the bottom of hole, It may break.

v Die: Dies are used for cutting external threads on round bars or tubes. It is made up of hardened high
carbon steel or high speed steel.

· Split Die / Bottom Die:- Split die is held in place in the “Stock”. The split permits a small amount of
adjustment in the size of the die by adjusting the screws in the stock. Since split dies cut their thread,
complete in one cut, the die thread are tapered and back off for one third of their length.

· Die Nuts:- Die Nuts are not capable of any adjustment. They are not usually employed for cutting
threads form bar, but for rectifying damage to existing threads. They are formed to hexagonal shape for
use with a spanner externally.

# Precaution and Operation of Die:

§ The diameter of blank rod must not be larger than the outside diameter of threads to be cut.

§ Lubricant oil should be used while cutting.

§ About every half turn, reverse frequently to clear off chips and thread oil be clear.

§ Ensure that die set is perpendicular to than rod.

k. Scriber: A scriber is used for scratching lines into the workpiece. It is made up od hardened tools steel.

l. Number Punch: It is used for punching numbers in the workpiece. It is a set of punch for 0 to 9
numbers.

m. Hammer: A hammer is a tool meant to deliver any impact to any object. The most common uses for
hammers are to drive nails, fit parts, forge metal and break apart objects. Hammers are often designed
for a specific purpose and vary in their shape and structure. Different types are hammers are as follows;

v Ball Pen Hammer:- Those hammer which contain ball on its one part of the head and the flat surface
on another side. Mainly used in the work with rivet.

v Claw Hammer:- Those hammer which contain a claw on one side used for taking out nails and rivets
sixed on the certain surface.

v Cross Peen Hammer:- Hammer with the pin used for the works when the acting surface area is small.

v Wood Hammer: Hammer made up of wood, commonly used for the sheet working.

v Club Hammer:- Hammer used for the heavy work like in works related with heavy metal.

# Procedure of making hammer:

§ First of all a metal block of given dimension was taken and it was filed till the surface of the metal
block is equal on all of its sides and is straight which was tested with tri-square and steel scale. For this,
first one of the side of block is filed and tested with steel scale if it is straight by the help of light
penetration.

§ Then other sides were tested using the tri-square after filing. Then, the surface was marked according
to the given measurement and then cut the metal block according to the measurement.

§ Then the cut surface was again filed to make it smooth and straight.
§ Then the centre punch was used to punch for driving the drill and then the hole was drilled through
the block using drill machine.

§ Then, the metal rod was taken and external threading was done in it along with the internal threading
in the hole of the metal block.

§ Both the rod and metal block were joined together to form a hammer.

Thus, hammer was preferred.

Sheet Metal Work

[A] Introduction:

Sheet metal work indicates surface development. It is a work performance over provided over sheet of
metal. Sheet metals are either black or galvanized. It is the formed by an industrial process into thin, flat
piece. It can be cut and bent into variety of shapes. Countless objects can be constructed with sheet
metal. The thickness is defined most commonly by the British Standard Wire<B.S.W.> gauge number.
According to it they can be cut by different tools.

B.S.W. No.

10-12-14

16-18-19

20-22-24

Cut by
Hand lever shear

Guillotine Press

Sniper or Hand Shear

[B] Joints:

Joints are the mechanical equipments for joining two or more components together. It helps in
assembly of different components of machine or any equipment in workshop to make it a single useful
form. It is of two types.

i. Temporary Joints: It can be obtained without breaking it. Some of the joints are like nut and bolts.

ii. Permanent Joints: Joining in which breaking has to be resolved in order to open joints is known as
permanent joining. Some of the permanent joints are rivet, welded, soldered joints etc.

[C]. Some of the joints with description:

i. Nut and Bolts: It is temporary joint since it can be obtained breaking. The term “Pitch”{The distance
between two consecutive threads and equal distance travelled when the thread makes one complete
rotation for common single start threads where the heeler start. However the common term for
distance lead which is;

Lead = Pitch × No. of Starts.

ii. Riveting: It is done to permanently join together two or more components parts by means of fasters
called rivets. The rivets are made up of wrought iron with head on only one end ready, called set head.
The holes are drilled or punched on the components which are to be jointed with rivets where set head
id rested on the dolly. Then the closing head at the other end is formed by pressure along by hammer.
Blows through the snap over the rivet end with the help of rivet gun and the process is called riveting.

iii. Soldered joints: Soldered joints are permanent joints which are always liquid tight with the heating of
solder{made of Tin and Lead with some cadmium and bismuth}.

iv. Welded Joint: Welded joints are also permanent joint which may be formed by gas or electricity. In
Gas welding, Acetylene is produced in generator by interaction if calcium carbide and water at low
pressure and oxygen in another cylinder. Both are mixed in oxygen torch after the spark has been start.

In electric welding, AC is used with bare or collected electrodes into the joints in order to coat at
the joint to form a protective layer which can point the further oxidation.
Some of the types of welded joints are as follows;

v Butt Joint

v Lap Joint

v Corner Joint

v Tee Joint

[D] Tools used in Sheet Metal work:

i. Working Sheet:

Sheet metals are either block or galvanized. Their thickness is defined most commonly by British
Standard wire gauges{B.S.W.}. Various steps are applied for surface development of the given sheets
and to have its final look/ design.

ii. Measurement tools:

Various measuring scales are required to measure the length of the surface of given sheet. The general
measuring tools are scale, tri-square, various calipers etc. It is important to know least count of each
scale before performing measurement.

iii. Markers:

The working piece is to be marked well before cutting as per the provided design, various marking
device are pencil, centre punch, coloring material etc.

iv. Bench Vice: A bench vice is used for holding a sheet while folding it to a desired length while shaping.

v. Mallet hammer: It is a plastic hammer used to make the flat surface of sheet smooth and straight. It is
also used while folding the sheet or during the use of centre punch to punch a point to drive a drill.

vi. Centre Punch: It is used to punch a spot to drive a drill to make a hole.

vii. Snip:

It looks like a scissor which contains pair of blade and handle which move around the pivot. It is a hand
tool for cutting the sheet metal into desired shape. It is also called as shears.
vii. Rivet Gun:

Rivet gun is used for riveting the rivet at the joint to join the two or more component. The holes are
drilled or punched on the line of intersection of the rivets. The set hand is rested on the dolly then the
closing heat at the other end is formed by pressure or hammer flows through the snap over the rivet
end.

viii. Drill Machine/ Hand drill:

Hand drill is a hand tool for drilling in a sheet metal. It consists of a drill bit fixed with a handle which is
rotated with the help of both the hands so that even torque is applied and results in the formation of
hole.

Dust Pan

A dust pan is a cleaning utensil, commonly used in combination with broom or brush. The dustpan may
appear to be a type of flat scoop. It is obtained hand held for home use but industrial and commercial
enterprises often use a hinged variety on the end of a stick to prevent the user from constantly stopping
to use it. This improved dustpan design was patented by African American inventor, Lioyd Ray on August
9, 1817. A variant on the dustpan is the silent butler, hand held, lidded dustpan.

Procedure of making dustpan

Tin sheet having rectangular shape of dimension 200mm×200mm was taken and cleared up and made
flat and smooth by the mallet hammer. Then the layout was drawn according to the required dimension
as the given figure with the help of steel scale and scriber. Unwanted parts of sheet were cut off by the
snip and 6mm of shared sides were folded and bent as per the dimension. <i.e. Three sides of sheet
were folded>. For the handle part, the thin sheet having dimensions of 220mm×30mm was taken. Then
margin were done and folded as per the dimension and unwanted parts were cutogg and removed.

Then centre punch was made on the points where the drilling was to be done to join the sides of
pan and its handle.

Atlast, Handle and Side of pan were fixed by riveting gun and rivet and filling was done at the shape end
of the dustpan to remove sharpness. Finally, the dust pan was made.
Drill Machine

Drill machine is machine tool used for the formation of holes on various materials by rotator and aerial
moment of drill bit. Some of the types of drill bits are:

o Twist drills or Auger Bits (Slicing of this shaving)

o Wild drills (Grading of small particles)

o SOS mansory drill (Crushing and Removing pieces)

o Centre drill

o Flat drill etc.

The twist drill is the most commonly used for all these. The parts of the twist drill are shown in
figure with its shank and body.

The shank may be either straight for clamping in drill chuck or tapered for insertion into the taper socket
of the spindle or into sleeve the body has to helical flutes which form the faces of the cutting edges or
lips, chips produced pars along the flutes, margins are provided along the flutes.

Types of the drilling machine

Some of the types of the drill machines are as follows.

i. Hand Held, Portable

ii. Bench type for drilling in small works

iii. Upright type capacity upto 35mm having box column along which the drill head can be adjusted
vertically.

iv. Radial Drilling Machines for drilling large and heavy workpiece.
Function of drill machine

i. To bore holes in the workpiece.

ii. To broaden the bored hole.

iii. To bore holes to develop or make the joints.

iv. Helps to form the holes used in assembly of the tools.

The drill machine generally used in the workshop is bench drill machine.

# Parts of bench drill machine are;

i. Base: The base of the machine is made from cast iron material and supports the vertical column. The
base is provided with hole to secure it firmly to the table or bench with the help of bolts and nuts.

ii. Vertical Column: The column is hollow steel pipe mounted rigidly on the base. It supports the drill
head and the work table.

iii. Worktable: The worktable supports the workpieces to be drilled. It is usually provided with T-Slots
that help the workpiece to be clamped rigidly on the table. The table can be raised or lowered and can
be clamped to the vertical column at any desired position. This helps to accommodate different size of
workpiece on the table. The table can be swiveled around the vertical column to any desired position.

iv. Drill Head: A fixed drill head is located at the top end of the vertical column carries any electric motor
and a mechanism through which the spindle can be made to rotate as well as size up and down. The top
end of the spindle is connected to a stepped cone pulley which obtains power rotatory motion from the
motor shaped through a V-belt arrangement. The changing of belt position of the cone pulleys takes
place. The lower end of the spindle carries a socket drill chuck to hold the drill bit rigidly during
operation. The vertical moment of the spindle and hence of the drill bit is controlled by the hand feed
lever located at front end of the machine facing the operator.

Safety Measures
As we know that prevention is better than cure. So, one should keep in mind that he/she shoulg be
always aware of possible hazards during workshop. So, following steps can be applied as safety
measures.

v Safety on hand tools:

a. Files without handle should not be used.

b. The hacksaw blade should be fitted lightly in frame.

c. Only soft hammer should be used for hitting sheet and during bending of sheet.

v Safety on cutting operations:

a. Hand snip should be hold carefully.

b. The size of hand snip should be selected according to size of metal to be cutoff.

v Safety on drilling:

a. The drill table should be made free erom other tools before drilling.

b. Drill bit should be set tightly and properly in drill chuck.

v Safety for dress:

a. Apron should be worn whenever at work.

b. Sharp edges tools should never be carried in pockets.

v Marking, Cutting and Filing should be done carefully in order to avoid accident and also wrong
dimension.

Conclusion

Hence it was concluded that every operation needs bench work to perform even the single task at
critical case which was done by use of hacksaw, scales, markers and files. After completion of this
report, we come to know about the different components of workshop and description and procedure
to use different hand tools, machine tools etc. In order to make different equipments like hammers,
dustpans, etc. Similarly we got knowledge about different types of metals and their description and their
work in the workshop. Similarly, we become familiar about drilling, shaping, filing, threading, knurling
etc.

Finally, we hope this report will prove much useful to us in our current semester and hope that the
report will be fruitful for the future guidance and reference also.

Refrences

Course Manual on workshop technology by -Ishwari Man Pradhan,

Mechanical workshop practice by –K.C. John