Engineering Workshop Manual_B22ME0104

REVA UNIVERSITY
Bengaluru, India
WORKSHOP PRACTICE LAB MANUAL
For I Semester B.Tech Students
SCHOOL OF MECHANICAL ENGINEERING
NAME
SRN
CLASS
BRANCH
SUBJECT
School of Mechanical Engineering

REVA UNIVERSITY
Bengaluru, India
LABORATORY CERTIFICATE
This is to certify that Ms./Mr.....................................................................................

Has satisfactorily completed the course of experiments
in………………….………...........….............…………. Practical prescribed by the REVA
University, Karnataka for B.Tech course in the laboratory of this University in the year
20__/__
SRN : ______________________
Marks
Maximum Obtained
Signature of the faculty in-charge
Date: Director of School
School of Mechanical Engineering

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Department/School Vision:
“Aspires to be recognized globally for outstanding value-based education in mechanical and allied areas and research
leading to well-qualified engineers, who are innovative, entrepreneurial, successful in their career and committed to
the development of the country.”
Department/School Mission:
1.To impart quality education to the students and enhance their skills to make them globally competitiv
engineers in mechanical and allied areas.
2. To promote multidisciplinary study, cutting edge research and expand the frontiers of engineers’ profession in
mechanical and allied areas.
3. To create state-of-art facilities with advanced technology for providing students and faculty with opportunitie
for innovation, application and dissemination of knowledge.
4. To prepare for critical uncertainties ahead for mechanical engineering and allied areas and to face the
challenges through clean, green and healthy solution.
5. To collaborate with industries, institutions and such other agencies nationally and internationally to undertak
exchange programs, research, consultancy and to facilitate students and faculty with greater opportunities fo
individual and societal growth
WORKSHOP
PRACTICE
Objectives 1. To train students about Engine parts, speed ratio, power trains and
3D printing.
2. To educate students on Fitting and welding processes.
3. To impart skill in fabricating simple components using sheet metal.
4. To cultivate safety aspects in handling of tools and equipment.
Expected outcome On completion of this course, the students will be able to
1. Explain parts of engine, speed ratio, power train and 3D printing
concepts.
2. Obtain fitting models, weld joints and sheet metal models
3. Handle tools and equipment’s with safety concern.
Course Contents:
PART-A 1. Dismantling and Assembly of 2-Wheeler (2–stroke) Engine Parts.
2. Identification of parts of an engine of Toyota Innova and Toyota
Fortuner
3. Calculation of Speed ratio of belt, chain and gear drives.
4. Study of Power train of Bicycle, 2-Wheeler and 4-Wheeler.
5. Demonstration of laser engraving process and 3D printing process.
School of Mechanical Engineering Page 3

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PART-B 1. Study of Fitting tools and preparation of fitting models.
2. Study of sheet metal tools and development of pen stand and funnel
3. Hands on training on welding.
4. Study of power tools.
Demonstration of all BOSCH tools and their applications.
Program Educational Objectives (PEOs)
After few years of graduation, the graduates of B.Tech Mechanical Engineering will:
PEO 1: Exhibit skills as a member of a team in national and international organizations with highest
ethics through lifelong learning
PEO 2: Pursue higher education through continuous learning with effective communication skills
PEO 3: Start own enterprise and provide solutions in mechanical engineering and allied areas.
Program Outcomes (POs)
On successful completion of the program, the graduates of B.Tech Mechanical Engineering will be able to:
•PO-1: Engineering Knowledge: Apply the knowledge of mathematics, science, engineering fundamentals, to solve
mechanical engineering problems.
•PO-2: Problem Analysis: Identify, formulate, review research literature, and analyse complex engineering
problems reaching substantiated conclusions using first principles of mathematics, natural sciences and engineering
sciences.
•PO-3: Design/Development of Solutions: Design solutions for complex engineering problems and design system
components or processes that meet the specified needs with appropriate consideration for the public health and
safety, and the cultural,
societal, and environmental considerations.
•PO-4: Conduct Investigations of Complex Problems: Use research-based knowledge and research methods
including design of experiments, analysis and interpretation of data, and synthesis of the information to provide valid
conclusions for complex problems
•PO-5: Modern Tool Usage: Create, select, and apply appropriate techniques, resources, and modern engineering
and IT tools including prediction and modelling to complex engineering activities with an understanding of the
limitations.
•PO-6: The Engineer and Society: Apply reasoning informed by the contextual knowledge to assess societal,
health, safety, legal and cultural issues and the consequent responsibilities relevant to the professional engineering
practice.
•PO-7: Environment and Sustainability: Understand the impact of the professional engineering solutions in
societal and environmental contexts, and demonstrate the knowledge of, and need for sustainable development.

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•PO-8: Ethics: Apply ethical principles and commit to professional ethics and responsibilities and norms of the
engineering practice.
•PO-9: Individual and Team Work: Function effectively as an individual, and as a member or leader in diverse
teams, and in multidisciplinary settings.
•PO-10: Communication: Communicate effectively on complex engineering activities with the engineering
community and with society at large, such as, being able to comprehend and write effective reports and design
documentation, make effective presentations, and give and receive clear instructions.
•PO-11: Project Management and Finance: Demonstrate knowledge and understanding of the engineering and
management principles and apply these to one’s own work, as a member and leader in a team, to manage projects
and in multidisciplinary environments.
•PO-12: Life-long Learning: Recognize the need for, and have the preparation and ability to engage in independent
and lifelong learning in the broadest context of technological change
Programme Specific Outcomes (PSOs)
On successful completion of the program, the graduates of B.Tech Mechanical Engineering will be able to:
• PSO-1 Apply mechanical engineering knowledge and skills in Design, Manufacturing, Thermal and
Industrial Engineering to obtain realistic outcomes.
• PSO-2 Identify, formulate, analyze and solve problems in mechanical engineering and allied domains.
• PSO-3 Conduct investigations in Mechanical Engineering and allied areas to provide optimal and sustainable
solutions
TEXT BOOKS
1. K.R. Gopalkrishna, “Elements of Mechanical Engineering”, Subhash Publishers, 12th Edition, 2012.
2. SKH Chowdhary, AKH Chowdhary and Nirjhar Roy, “The Elements of Workshop Technology - Vol I & II”,
Media Promotors and publisher, 11th Edition, 2001.
3. Workshop Manual Prepared by REVA University Staff
REFERENCE BOOKS
1. David A. Crolla, “Automotive Engineering-Powertrain, Chassis System and Vehicle Body”, Butterworth-
Heinemann is an imprint of Elsevier, 1st Edition, 2009. 2. R.S.Parmar, “Welding Processes and Technology”,
Khanna Publishers, New Delhi, 2003.
JOURNALS/MAGAZINES
1. International Journal of Machine Tools and Manufacture

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2. https://www.shutterstock.com/search/disassembled-bike-engine
3. https://pdfcoffee.com/ex5-assembly-and-disassembly-of-ic-engine-parts-pdf-free.html
SWAYAM/NPTEL/MOOCs:
1. https://www.coursera.org/browse/physical-science-and-engineering/mechanical-engineering
2. https://www.my-mooc.com/en/categorie/mechanical-engineering
3. https://nptel.ac.in/cour
Mode of Evaluation Tutorials/Class Tests/Lab exam

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CONTENTS
Sl.No Experiments Page No.

.
1 Safety in workshop 08
2 Introduction of Engineering 09
PART-A
3 Dismantling and Assembly of 2-Wheeler (2–stroke) Engine Parts. 10-27
4 Identification of parts of an engine of Toyota Innova and Toyota 28-29
Fortuner
5 Calculation of Speed ratio of belt, chain and gear drives. 30-35
6 Study of Power train of Bicycle, 2-Wheeler and 4-Wheeler. 36-37
7 Demonstration of laser engraving process and 3D printing 38-43
+ SAFETY IN process
SHOP +
PART-B
8 Fitting Tools and Instruments 44-64
9 Types of files &Fitting Operation
10 Fitting Models 65-75
Welding
11 Welding Introduction& Tools 76-87

12 Welding Models 88-91
Sheet metal
13 Introduction to sheet metal 92-97
14 Sheet metal models 98-103
15 Power tools 104-106
16 Viva questions & answers’ 105- 118

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Observe the following safety to avoid injury to your self and co-workers
1. Be well dressed i.e., avoid loose garments, roll up sleeves, put on suitable footwear and remove
watch andring.
2. Keeptheworkplaceneatandcleani.e.,placethetoolsatproperposition.
The scraps and chips should be dropped in waste bins.
3. Concentrate on your job and avoid talking withco-workers.
4. The shops are no place to play. Running and pushing in the shop may cause accidents.
5. Understand the use of tools and machines beforehandling.
6. Never use dull tools. The use may damage the tools completely or may lead toinjury.
7. In case you are in doubt contact theinstructor.
8. Always chuck the fitting of the handle in the hammerhead.
9. Be familiar with the locations of First Aid Box and Fire Extinguisher in the shop. In case of
emergency one should reach themquickly.
10.Laziness and carelessness are your deadly enemies. Always be active and careful in theshop

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Engineering:-
• Engineering is a professional art of applying science and technology to optimize the
conversion of natural resources to the benefit of mankind. (Natural resources available in
the universe are Iron ore, Air, Sun, Water, Space, Humanetc.)
• Human resource is a supreme strength to develop Engineering to contribute the welfare
and progress of the society or to thisnation.
Engineer:-
• Engineer is a person having creative thoughts and ideas to develop technology for the
noble cause of the society or tonation.
• All objects begins an idea, Conceived and visualized by the Engineer. He makes an
internal representation of the object in his mind and communicates it to others through
media ofexpression.
Professional activities of an engineer:
1. Planning: (Proposal of doingsomething)

• It means a set of preparation is to do in order to achieve something or any kind of
task/work. (Preparation means programmes, drawings, Materials requirement and their
sources, time schedule, cost estimate, scheme and design and method of preparationetc.)
• It is a management function of defining goal of an individual /organizations.
• It determines the task/work and resources necessary to achieve setgoals.
• It helps to save materials, labor, time, money efforts and process etc. so that any kind of
work/task can be performed successfully without having any difficulty with full
confidence.
2. Visualization (related to vision / creating picture inmind)
• It is a behavioral technique of improving performance of hisindividual.
• It encourage for creating metal picture for successful execution of anywork.
3. Hard work and practice (doing somethingrepeatedly)
There is no substitute for hard work. A spiritual person says that “Work is Worship”, “Practice
makes the man perfect”. Practice makes a person to acquire skill to use their knowledge for
gaining self assurance and confidence to handle any kind of work without any difficulty.
4. Punctuality (being in time):
Punctuality is a moral goodness, which is to be practiced very well punctuality is nothing but
courtesy to others. By being punctual you respect the value of time of others. This is more than
anything else. It helps you to plan your activities and schedule with precision and efficiency.
5. Work placeEnvironment:
Workplace environment is to be maintained neat and clean, and spread happiness, cheerful, love
& affection around your work place, at home and also to the community.

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PART-A
Expt. No.1 Dismantling and Assembly of 2-Wheeler (2–stroke) Engine
2- STROKE Engine dismantle and assembly

1. Lubrication system
2. Engine dismantling
3. Driven pulley, starter, clutch
4. Cylinder, piston,
5. AC generator
6. Transmission mechanism
7. Crankcase, crankshaft
8. Carburetor, reed valve
1. Lubrication system and oil pump
Fig. 1 Lubrication system diagram
➢ Engine over heating: The adjustment of oil pump is not properly. (1ack of oil), The quality of oil is not good.

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➢ Piston over burning: There is air in the oil pump system. Oil pump is out of order. The route from oil tank to oil
pump is blocked. Ventilation hole on the tank cover is blocked.
➢ Removing the oil pump
Fig. 2 Removing the oil pump
➢ Clean the oil pump and Crank case before operation.
a. Remove the luggage.
b. Remove the input/output oil pipe.

c. Take out the oil pump by removing the locking screw on oil pump and Oil gauge cable.
d. check the oil pump.
➢ Remove oil pump and check:
a. O-ring is distorted or not.
b. Contact area of crankcase is injured or not
c. Oil pump body is damaged or not
d. The gears are damaged or not.
e. Check seal and see if there is oil leakage or not
f. Never dismantle oil pump, itcannot function well after dismantling

➢ Assemble the oil pump.
a. Assemble the oil pump by reversing above procedure.
b. Be sure oil pump screw is tightened.

➢ Releasing air in the oil pump.

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(a)Fill up specific amount of oil-to-oil tank.
(b)Place dry cloth under the oil pump.
(c) Remove oil pipe. Use injector to fill up the oil in the oil pipe and oil pump body . Be sure the oil pipe and
oil pump are full of oil before assembling.
After assembling check if there is still air trapped in the oil pipe
Note: a. If there is air in the oil pipe, it will cause engine lubrication trouble
b. Re leasing air operation means the release of air trapped in the air pipeand oil pump. Please firstly release air from the oil
pipe
Fig. 3 Releasing air in the oil pump.
2. Engine Dismantling
a. Take off the luggage compartment.
b. Take off the left and right body covers.
c. Take off the lower mudguard fender
Fig.4 Schematic showing Engine dismantling
d. Remove vacuum pipe, fuel pipe, auto choke, cap of spark plug, rear Brake cable carburetor pipe, engine flywheel
shelf’ s nut, starter Motor cable plate and rear damper bolt.
e. Remove the engine.

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3. Drive pulley, starter & clutch
1. Troubleshooting:
A. Engine starts, but vehicle does not move.
1.Driving belt worn out
2.Driven plate worn out
3.Clutch lining worn out
4.Driving plate’ s spring broken
B. The vehicle stops or trembles when running,
1.Clutch lining spring cracked or broken.
C. Can’t reach high speed, no pick-up
1.Driving belt worn out.
2.Driving plate spring distortion.
3.Weight roller worn out.
4.Driving plate abnormal.
Note: No grease and oil allowed to stain on driving belt and driven plate.
2. CVT parts measurement data

Item Standard value(mm) Limit of use(mm)
Model 50cc 50cc
The inner dia. of 20.035-20.085 20.123
Slide driving plate
The outer dia..of boss, movable 19.960-19.974 19.911
Driving plate
Belt width 18.0-19.0 17.0
Clutch lining thickness 3 1.5
Clutch outer diameter 117.0~117.2 117.5
Driving plate spring, free length 87.9 82.5
The outer diameter of driven 33.965~34.025 33.95
plate sets
The inner diameter of slide 34.000~34.025 34.070
Driven plate
The outer diameter of weight 15.992~16.008 15.50
Roller set
3. Driving pulley. 1.Take off the 10 screws of left Cover, remove the left cover.
Fig. 5 Showing left cover

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2.Take off the left cover.
Fig. 6 Showing left cover and 10 screws
3.Remove the fixing nut of the clutch.
Fig. 7 Removing of fixing nut of clutch

4.Take off the ramp plate.
Fig. 8 Showing ramp plate

5.Take off the belt and the rear clutch.

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6.Take off the driving plate. Take off the driving gear start set.
7.Remove the start idle gear fixing plate.
Fig. 9 Removing of idle gear
8. Take off the idle gear.

9. To assemble the driving pulley, please reverse above procedure.
Locking torque:
1.Nut of driving pulley:M10: 3.2~4.0kg- m
2.Locking nut of clutch:M10: 3.5~4.0kg- m
10.Checking the driving belt
1. check whether it is cracked or not or its rubber and fiber are loose or not check also if they are extraordinarily
worn out.
2. driving belt width: limit of use : change it below 17.0mm.
11.Disassemble the slide driving plate set (1) Remove the bush of slide driving plate (2) Remove the screw, and
disassemble the cover of slide driving plate.
(3) Remove RAMP plate.(4) Remove weight roller
12.Checking list:
1. Check the wearing condition of the weight roller. limit of use:change it when below 15.5mm.
2.Check inner dia of slide driving plate’ s gasket.
3. Check the wearing condition for driving pulley surface.
4. Check the outer diameter of the driving plate’ s boss.
13.Assemble the slide driving plate.
(1) Clean the inner surface of slide driving plate, then assemble the roller.
(2)Assemble the ramp plate.
(3) Please reverse the procedures of disassembling to finish assembling.

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4. Starter dismantling
1.Dismantle the left crankcase cover

2.Remove the hexagon nut, then remove the starter lever.
3.Remove five screws of isolating plate.
4.Remove the stater spring from the start returning position.
5.Remove the driven gear comp of kick starter.
6.Remove the retaining c-type clip
7.Remove the spindle comp.
Of kick starter.
8.Checking the starter
a.Check the wearing condition of the outer diameter of the spindle comp and the inner diamter of bush and gear.
b.Check the wearing condition of the shaft of driven gear comp, gear sets and ratchet.
9.Assembling the starter
To assemble the starter, please follow the opposite procedures of dismantling.Locking torque: M6:1.0~1.2kg-m
Note: Make sure that on end of the torsion spring is hooked on the groove ofdriven gear, and another end of the torsion spring is
hooked on the poledinside the left crankcase.
Put some grease on shaft and gear sets before assembling.
5. Clutch driven pulley
1.Dismantle the clutch
a.Remove left crankcase cover.
b.Remove driving plate.
c.Remove driving belt.
d.Remove the M10 locking nut, then the clutch.
Locking torque: M10:

3.5~4.0kg- m
2.Assembling the clutch: please follow the opposite procedure of dismantling.
3.Checking the clutch:
Dismantling the clutch needs the special

Tool. please contact your dealers.
a.Check the clutch driven face.

b.Check the clutch cover about its wearing Condition and inner diameter measurement.

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Limit of use:
50cc:Change it when above 117.5mm
c.Check the clutch lining wearing condition and measure the lining thickness
limit of use: change it below 2.5mm.
Check driven spring free length: standard: 87.9mm Limit of use: change it as it Is below 82.5mm(50cc)
e.Check wearing condition of driving plate set.

Outer diameter measurement: Limit of use: change it as it
Is above 33.950mm
f.Check wearing condition of slide driven plate.

Inner diameter measurement: Limit of use change it as it
Is above 34.070mm
g.Check is there any wearing occur to the ditch.
h.Check wearing condition of seal location, if necessary change a new one.
4.Cylinder and piston:

A. Troubleshooting.
a. compression pressure is too low, difficult to start engine and running unsmoothly.
1. Cylinder head gasket cracked.
2. Spark plug is not well- locked.
3. Piston ring worn out or cracked.
4. Cylinder, piston worn out.
5. Reed valve is defective.

b. compression pressure is too high, engine overheating or abnormal noise. 1.piston tip has too much carbon piled up.
c. Abnormal piston noise
1. cylinder and piston worn out.
2. Piston pin hole or piston pin worn out.

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3. Connecting rod small-end or bearing worn out.
d. Abnormal piston or cylinder noise
1.Piston ring worn out or cracked.
2.Cylinder worn out or cracked.
B. The operation notice:

1. clean before operation to avoid particles dropping into engine.
2. The connect surface of gasket must be clean.
3. Dismantle the cylinder and the cylinder head by screw driver.Do not scratch the contact surface.
4. Cylinder inner surface and piston outer surface can’ t be scratched.The contact surface should be lubricated by
specified oil.
C.Piston & cylinder datas:
Standard Value(mm) Limit of use(mm)
Part name/description
Cylinder head Flatness 0.100
cylinder Bore 39.995~40.015 40.050
Piston/ Clearance b/w Pistonring Lst ring
0.05~0.06 0.10
Piston ring piston and
2nd ring 0.05~0.06 0.10
Piston outer diameter 39.950~39.970 39.895
Measuring location of piston outer dia.
(12mm from the lower end of skirt)
Clearance b/w piston and cylinder 0.045~0.065 0.10
Piston pin hole inner dia 13.022~13.013 13.045
Piston pin hole inner diameter 10.002~10.008 10.025
Piston pin outer diamerer 9.994~10.000 9.970
Clearance between piston and piston pin 0.004~0.018 0.030
Connecting rod small end inner dia 13.996~14.007 14.025
D.Cylinder head, cylinder, and piston dismantling.

1.Remove the engine.
2.Screwing out the two M6-bolt of cooling cowl.
3.Screwing out the two M6-blot of fan cover.
4. Remove the cooling cowl and fan cover.

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5.Remove the spark plug.

6.Remove the two M6 nuts on the muffler and cylinder. Also remove the two M8-bolt of crankcase.
7.Remove muffler.
8. Remove the four M7-nut on the cylinder head, then remove the cylinder headand cylinder head gasket.
9. Remove the Cylinder and the gasket.
10. Remove the c type clip on the piston and piston pins by the nipper.
• Take off piston.
11. Dismatling of the piston ring Take off the first piston ring then the second ring.
12. When assembling please reverse the procedures of dismantling.
Opening end of piston ring
Locking torque:
M7:1.0-1.4kg- m
M6:1.0-1.2kg- m
E. Check for the flatness of cylinder head & cylinder.

Check the flatness of contact surface of cylinder head & cylinder.
Limit of use: If it exceeds 0.1mm
Change a new one.

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F. Combustion chamber cleaning
⚫ Clean out the carbon piled up in combustion chamber.

⚫ Do not scratch the combustion chamber and contact surface of the cylinder duringcleaning operation
G. Check cylinder and piston:

1.Check the wearing and damage condition on the contact surface of the cylinder and piston.2.Clean out the carbon
on the cylinder exhausting port.
Be careful not to scratch the inner

Surface of cylinder.
Cylinder bore measurement:

A. Measure each point (A)(B)(C) orderly, and in X.Y. axis to find the smallest value.
Limit of use: 50cc-change it when over 40.050mm.
Piston outer diameter measurement:
A.Measure at the skirt area where is 12 mm from the skirt lower end of skirt.(2)Limit of use: 50cc-change if when
below 39.895mm

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(3)Calculate the clearance between the piston and cylinder
Limit of use: change it when over 0.100mm
(4) Inner diameter measurement of the piston pin holeLimit of use: change it when over 14.032mm
Outer diameter measurement of the piston pin limit of use: change it when under 9.970mm (50cc)
(3) Check piston ring:

Measure piston ring gap:
Limit of use: replace a new one when over 14.025mm .( 50cc)

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Installing cylinder and piston
i. Place the piston ring into the second ring ditch first, then install thepiston ring into the first ditch.
2. Piston ring should be installed into piston ring ditch by even force
1. After assembling, be sure that the piston ring sliding surface is at the same height asthe piston outer surface. 2. If the
piston ring can not fit into the ditch, please clean up the carbon in the piston ringditch or piston ring itself.
3. a.Piston ring must be installed in the correct location.
a. After installing the piston ring, it should be able to rotate freely.
b. If it is necessary to change the new piston ring, it must change the whole set.
4.a.The location of the piston ring gap and the lock pin must be in opposite side.
a. The mark”→” on the piston tip must be pointing to the exhaus ting port.
b. Lubricate the piston pin before installation.
5.Please follow the opposite procedure of dismantling to install cylinder and cylinder head.
5. A.C. Generator, Flywheel
A.Dismantling AC generator
1.Remove fan cowl.
2.Remove the M6 screws(4)
3.Remove Screws of flywheel magneto
4. Remove the AC flywheel magneto by special tool.

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5.Remove the flywheel.
6. Remove the electric plug of AC Flywheel magneto. Take out the magneto.
B.Install AC generator
To install, please reverse the dismantling procedures.
Locking torgue:
M6: 1.0~1.2kg- m
M10: 3.2~4.0kg- m
6.Final Transmission Mechanism

A. Trouble shooting
• Engine can be started, but vehicle doesn’ t move.
1.Gear worn-out or cracked.

2.Gear burnt out.
• Noise occurs when running.
1. Gear worn out, burnt or gear surface damaged.
2. Bearing worn out or loosen.
• Oil leakage
1.Too much oil.
2. Seal worn out or damaged.
B. Disassemble the final transmission mechanism.

1.Remove the rear wheel.
2. Drain off the oil in the gear box.
3. Remove the 6 bolt in gear box cover

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4. Take off the gear box.
5. Take out the final reduction gear and idle gear shaft.
6. Clean up the gear box
7.
8. Check the final transmission mechanism
1. Check the wearing condition of the driving shaft and gears.
2. Check the wearing condition of the idle gear shaft and idle gears.
3. Check the wearing condition of the final reduction gear

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4. Check the wearing condition of the oil seal and bearing.
7.Crankcase, Crankshaft:
A. Disassembling diagram
B.Troubleshooting.
Engine noise:
1. The bearing of final transmission mechanism is loose. 2.Crank pin bearing is loose.
3.The bearing of gear box is loose
C. Dismantle the crankcase and crankshaft please follow the following procedures:
1. Remove the engine. 2.Remove the left crank case, the driving pulley (driving plate) clutch and belt. 3.Remove the air
cleaner 4. Remove the carburetor. 5. Remove the intake manifold and reed valve. 6. Remove the oil pump, fan cowl
and fan itself. 7. Remove the AC flywheel magneto. 8. Dismantle the right and left crankcase.There are all together 7
bolts
9.Remove center stand, left and right crankcase and take out the crankshaft.
C.Assemble the crankcase.
1. To assemble the crankcase, please reverse the procedures of disaseembling. 2. The locking torque value for bolts
and nuts are all described in the previous chapters Please refer

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8.Carburetor, Reed Valve
Carburetor dismantling diagram
B. Troubleshooting:
Engine can not be started.
1.No fuel in the fuel tank.
2.Fuel pipe is blocked.
3.There is too much fuel in the cylinder.
4.Air cleaner is blocked.
Engine idling(RPM) unsteady, running not smoothly
1.Improper adjustment of the carburetor idling.
2.Ignition disorder.
3.Compression pressure is too low.

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4.Air mixture is too thick.
5.Air mixture is too lean.
6.Air cleaner is blocked.
7.Air injection is not in good function.
8.Fuel is dirty
Air mixture is too lean.
1.Carburetor main jet is blocked
2.The ventilation hole of the fuel tank cover is blocked.
3.Fuel filter is blocked.
4.Fuel pipe bended, squeezed or blocked.
5.Float valve is abnormal.
6.Fuel level is too low.
7.Air pipe is blocked.
Air mixture is too thick
1.Float valve is abnormal.
2.Fuel level is too high.
3.Air jet is blocked.
C. Dismantling carburetor
1.Remove the luggage box.
2.Loose the hose clamp between the carburetor and the air cleaner.
Then remove the air cleaner.
3.Unscrew the fuel draining screw of the
carburetor. Drain off the fuel inside the carburetor.
4.Remove the fuel pipe and the vacuum pipe on the carburetor.
5.Remove the oil pile on the carburetor.
6.Remove the bolts on the intake manifold and carburetor.
D. Dismantling float, nozzle
E. Reed valve
Dismantling reed valve.

(1) Take off the luggage box (2) Remove the air cleaner
(3) Remove the carburetor. (4) Unscrew the locking screw of the intake manifold.
(5) Remove the intake manifold. (6)Remove the reed valve.
checking for the reed valve.

(1) change a new one when the reed valve is worn out or distorted.
(2) change a new one too when the base of the reed valve is cracked, injured or distorted.

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Expt. No. 2 Identification of parts of an engine of Toyota Innova and Toyota
Fortuner
Fig. Toyota Centre of Excellence
Brief Description:
REVA-TOYOTA Centre of Excellence is established in association with Toyota Kiroloskar Motors Pvt. Ltd
under CSIR scheme to educate the engineering students in the area of automobiles in particular to working of
engines. It is indeed an initiative to train the students to know the working of an Engine through the cut section
assembled model of Innova Diesel engine. the practical knowledge on Internal Combustion Engine with parts
associated like piston, connecting rod, crank shaft, fuel injection system valve operating system , power
transmission, clutch operation, gear box working etc. are given hands on. In eight semesters, the students are
given Automobile as Elective subject, all of them will be trained in making part modelling by disassembling
the engine and again trained to assemble it back.
Objectives:

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Through the centre of excellence in association with REVA University can help to drive the quality of training
and provide more comprehensive learning opportunities for the students at the grass route level.
This empowers the students to be industry ready with desired skill sets and competencies, while contributing to
the nation’s growth and industry’s employability ratio.
Toyota Centre of Excellence enables the students gain an in-depth knowledge engine composition at the gross-
root level.
Fig. Parts of Toyata diesel engine

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Expt. No.3 Calculation of Speed ratio of belt, chain and gear drives
The belt drive and rope drive used in power transmission suffers the same extent of slipping. Then chain drive
come into compete with other type by avoiding slipping. The chain drive is a way of mechanical power
transmission. It consist of endless series of chain link known as roller chain which meshed with toothed
sprocket gear. The rigid links of chain hinged together by pin joint, that provide the chain necessary flexibility
to wrap around the sprocket. The sprocket have projecting teeth of special profile and it perfectly fit in to the
recess of chain link. Thus, the sprocket and chain constrained to move together. The first sprocket in on the
driving shaft, it will pull the chain. The chain then drag the second sprocket is on the drive shaft. By varying
the diameter of input and output gears, the gear ratio can be altered. For example, one rotation in bicycle pedal
cause more than on one rotation of gear mounted on wheel. Without slipping, chain drive ensures the perfect
velocity ratio.
CHAIN DRIVES
Chain drive is a way of transmitting mechanical power from one place to another. It is often used to convey
power to the wheels of a vehicle, particularly bicycles and motorcycles. It is also used in a wide variety of
machines besides vehicles. Most often, the power is conveyed by a roller chain, known as the drive
chain or transmission chain, passing over a sprocket gear, with the teeth of the gear meshing with the holes in
the links of the chain. The gear is turned, and this pulls the chain putting mechanical force into the system.

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Some Features of Chain Drive:- The alignment of the shaft should be more precise than that of the belt.
Center distance is not as important as gear drives. Proper lubrication must be provided for satisfactory service
life. Their efficiency is compared to any other type of positive motivation.
Chain drives have greater versatility, adaptability, and reliability. They are an important component of lifting
and moving machinery. Their cost is competitive due to automated production and extremely high rates of
demand. Chains are low in cost, easy to install and maintain.
GEAR DRIVE
Gear drives, sometimes referred to as gear trains and gearboxes, are mechanisms consisting of an assembly of
gears, shafts, and other machine elements for mounting the rotating parts. They form a mechanical system used
for transmitting shaft power from a driver such as an engine, turbine, or motor to a driven piece of machinery.
Gear drives can alter the transmitted power by using different configurations of gears.
Gear drives can increase or decrease the rotational speed of the output shaft. A common use of gear drives is
for reducing speeds of motors and engines that typically run at thousands of revolutions per minute (rpm).
These are known as speed reducers. By reducing the speed, torque is increased. This force amplification
characteristic is one of the main functions of speed reducers.
Gears are the main components of gear drives. Gears are toothed rolling elements which mesh with one another
by engaging their teeth. Because of the large dynamic forces involved, gears are made with alloyed steel. The
properties of these metals are also modified by heat treatment to reach the right toughness and rigidity required
for its application.

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Fig. Shows gear drive
Other components of gear drives are the shafts, keys, couplings, bearings, housing, and flanges. The shafts are
the components that connect the gear drive with input and output systems. Keys and couplings are used to lock
the shafts of the driver and driven equipment onto the gear drive. Bearings are the machine elements that
support the shafts while reducing friction. The housing and flanges are usually made monolithic. The housing
encloses and supports the whole assembly while the flanges are used for mounting.
Functions of Gear Drives

• Changing the Speed of Rotation
• Increasing or Decreasing the Output Torque.
• Modifying the Axis of Rotation
• Reversing the Direction of Rotation
Types of Gears
1. External Gear:
External gear is a general classification of gears in which the teeth are cut at the outer surface of the stock.
They mesh externally with other gears. These are the most common type of gears and are seen in every gear
drive
2. Internal Gear:
Internal gears have teeth formed on the inner surface. They are always mated with an external gear with a
smaller number of teeth. Internal gears are used for more specific applications such as a planetary gear set. The
short center-to-center distance of using an internal gear set makes it desirable for compact applications.

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Fig. Internal and external gears. Fig. Shows spur gears.
3. Spur Gear:
Spur gears are the most extensively used gear type. They are cylindrical with straight teeth formed along the
lateral surface of the cylinder. Spur gears can be external and internal. An external spur gear is considered the
usual type that has teeth on its outside surface. An internal spur gear, on the other hand, is a hollow cylinder
with teeth cut on its inner lateral surface
4. Helical Gear:
This type of gears has a cylindrical form similar to spur gears. The difference is their teeth which are cut in a
spiral wrapping around the cylinder. Helical gears are used because of their smooth and quieter operation. They
are also stronger and have a longer lifespan than spur gears with similar ratings. However, the downside of
using helical gears is the larger thrust load imposed on the supporting bearings.
Fig. Helical gears.
VELOCITY RATIO IN BELT DRIVE

Velocity ratio can be defined as the ratio of velocities of the driver and the follower/ driven.
Let, d1, d2 = Diameter of the driver and the follower respectively,
and N1, N2 = Speed of the driver and the follower resp. in r.p.m.
∴ Length of the belt that passes over the driver= π d1. N1 Similarly,
length of the belt that passes over the follower= π d2 .N2
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Since the length of belt that passes over the driver in one minute is equal to the length of belt that passes over the
follower,
therefore
Fig. Schematic of belt drive
π d1 N1 = π d2 N2
Velocity Ratio = N2/ N1= d1/ d
If we take the thickness of belt into account then above expression can be written as
N2 / N1 = d1 + t / d2 + t
Velocity ration of gear drive

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Expt. No. 4 Study of Power train of Bicycle, 2-Wheeler and 4-Wheeler
A powertrain is an assembly of every component that pushes your vehicle forward. Your car's powertrain
creates power from the engine and delivers it to the wheels on the ground. The key components of a
powertrain include an engine, transmission, driveshaft, axles, and differential. Let's break down each one by
one:
The words “powertrain” and “drivetrain” are often used interchangeably, but they are a little bit
different. Simply put, a drivetrain transmits power to the wheels. A powertrain consists of an engine (or a
motor) and a drivetrain. The drivetrain, like the powertrain, is not a single component of your vehicle. The
drivetrain is made of the transmission, driveshaft, axles, differential, and wheels.
Function: The function of the drivetrain is to couple the engine that produces the power to the driving wheels
that use this mechanical power to rotate the axle. This connection involves physically linking the two
components, which may be at opposite ends of the vehicle and so requiring a long propeller shaft or drive
shaft. The operating speed of the engine and wheels are also different and must be matched by the correct gear
ratio. As the vehicle speed changes, the ideal engine speed must remain approximately constant for efficient
operation and so this gearbox ratio must also be changed, either manually, automatically or by an
automatic continuous variation.
Engine: As the heart of your vehicle, an engine generates power to drive the car. An engine consists of
pistons that move up and down inside cylinders and a crankshaft that translates the reciprocating motion into a
rotating motion.
Transmission: A transmission is a basic component in your car that makes sure the proper amount of power
is transmitted to the wheels. Like a car's gearbox, the transmission takes the power from the engine and
adjusts it according to driving conditions, ultimately transferring it to the wheels.
Driveshaft: A driveshaft is a component that transfers the torque from the transmission to the wheels. To
perform this task, it has to work through various angles and change its length to adjust to movement in the
suspension.
Axles: Axles are an important member of a powertrain. It lies between the wheels and mainly performs two
functions: first, it puts up with the weight of the vehicle and it also rotates and transmits the power of the
engine to the wheels.
Differential: A differential is a part of the rear axle. It allows each rear wheel to turn at a different speed. For
instance, the differential is important when turning a corner, as the outside wheel needs to rotate faster than
the inside wheel.
The powertrain is crucial because without the system working properly, your vehicle cannot move forward.
To sum up, it's a group of parts that generate, convert, and consume energy to thrust your vehicle into motion.
Why is power train is important?

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When people talk about a high-performance sports sedan, we often hear how the vehicle is capable of smooth
steering, acceleration, and brakes, as well as excellent body control and enhanced safe driving. Well, these
techniques are important but not the 'be-all-and-end-all' of a successful sports car. Its staggering performance
numbers such as hundreds of horsepower or reaching 0-100km/h in seconds come from your powertrain, and
nowhere else. As a source of power generation, a good quality powertrain is a key to a better operating range,
acceleration, and top speed. So, next time you accelerate your car from a standstill and feel a push of your
engine power, just know that your powertrain propelled your vehicle.
These days, the importance of the Powertrain Control Module (PCM) has been recognized for its role in
improving fuel economy and responding to global environmental regulations by controlling exhaust
emissions. The PCM is the electronic control system that controls what your engine and transmission do.
Thus, it is like the main computer of your car that controls fuel delivery, emissions functions, and many
others. It also affects your engine's performance and drivability significantly.
Fig. Power train of a bicycle
Fig. Power train of a Two- wheeler Fig. Power train of a Four- wheeler

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Expt. No. 5 Demonstration 3D printing process and laser engraving process.
INTRODUCTION TO 3-D PRINTING

3D printing or additive manufacturing is a process of making three dimensional solid objects from a digital file. The
creation of a 3D printed object is achieved using additive processes. In an additive process an object is created by laying
down successive layers of material until the object is created. Each of these layers can be seen as a thinly sliced cross-
section of the object. 3D printing is the opposite of subtractive manufacturing which is cutting out / hollowing out a piece
of metal or plastic with for instance a milling machine. 3D printing enables you to produce complex shapes using less
material than traditional manufacturing methods. 3D printing allows for rapid prototyping and onsite manufacturing of
products.Initially done with plastic, 3D printing now uses new techniques with new materials, such as aluminum, bronze,
and glass. Biomaterials are also being incorporated, such as 3D printing ear cartilage and liver tissue. As the 3D printing
industry grows, 3D printing will become a big part of many engineering fields.
Flow layout of Pre 3D Printing
Fig. 3-D Printing Machine

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Components of 3D Printer: -
1. axes
Fixed Rods The three axes that the 3D printer utilizes are on the Cartesian coordinate system. The linear fixed rods are
maintained at right angles to each other and each represents a coordinate axis.
Movement The timing belts and pulleys allow the movement of the hot end (or the print bed, depending on the type of 3D
printer) along each axes according to the g-code (generated by slicing software). The stepper motors power this
movement.
2. Extruder
Extrusion is the feeding of filament into the hot end of the 3D printer. This movement is also powered by a stepper
motor.
Retraction this mechanism is the pulling of the melted filament from the hot end. Thismovement is primarily programmed
through the g-code to prevent the formation of unwanted filament creating a bridge between two areas. The bridging of
unwanted filament is referred to as stringing or the formation of cobwebs. Dual Extrusion some models of 3D printers are
equipped with dual extrusion capabilities
3. Hot End
The hot end is heated to temperatures ranging from 160 C to 250 C, depending on the type of filament to be used. The
hot end melts the filament and pushes the melted filament through the nozzle. The hot end needs to be thermally insulated
from the othercomponents of the 3D printer to prevent any damage.
4. Print Bed
Heated Print beds that are heated improve print quality of 3D printed objects. The heated bed is heated to the glass
transition temperature of the filament being used. Thisallows the model layers to slightly melt and stick to the heated bed.
Non-Heated Print beds that are not heated require adhesion in the form of glue, tape, hairspray, etc. In the innovation lab,
painters tape is frequently used for adhesion.
5. Filament
Filament is a consumable used by the 3D printer to print layers. Filament comes in a variety of materials and colors.
Filament can be composed of metal, wood, clay, biomaterials, carbon fiber, etc.
i). ABS: - ABS is a thermoplastic that needs to be heated to temperatures from 210C to 250C. ABS can
only be printed on a 3D printer with a heated bed, which prevents the cracking of the object. When ABS is
heated, it emits a strong unpleasant odor. ABS requires a complete enclosure while printing.
ii). PLA: - PLA is a thermoplastic that needs to be heated to temperatures from 160C to 220C. PLA is
also biodegradable and emits slight odors. PLA is most frequently usedin the Innovation Lab on all 3D printers.

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PLA MATERIAL 3-D PRINTING MODEL
PVA is a water soluble plastic that is frequently used for support in dual extrusion 3D printers. The printed object is left
in water where the PVA support is dissolved and the finishedobject printed in the other filament remains.
Preparing your 3D Model in CAD Software: -

CAD software is used to create 3D models and designs. This software is available on our computers and the level of
difficulty varies. With the exception of Sketch up Pro and the industry standard software mentioned, all of these programs
are available on the computers.lab
Solid works main idea is user to create drawing directly in 3D or solid form. From this solid user can assemble it directly
on their workstation checking clashes and functionality of it. Creating drawing is pretty easy just drag and drop the solid
to drawing block.
Preparing your 3D Model for print in Idea maker software: -

These are following step for 3D printing of model
1. Install the 3D print software idea maker

2. Check repair option in this software
3. Set the nozzle parameter and build tack temperature according to the printer guide.
Step:-1 Prepare the design Model using Designing Software(Solids Work,Autocad etc.)
Step:-2 Convert the designed Model file in Stl ,obj format.
Step:-3 Prepare the design model for printing Using Software Idea Maker and Ultimaker. Then set all parameter (nozzle
temp., buildtak temp and support) and also repair your design using software option. Then after generate the file in gcode
format
Step:-4 ON the 3D Printer and load the filament in nozzle and give the command print by using3D Printing Machine.

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3D Software
There are many different software tools available. From industrial grade to open source. We’ve created an
overview on our 3D software page. We often recommend beginners to start with Tinkercad. Tinkercad is free
and works in your browser, you don’t have to install it on your computer. Tinkercad offers beginner lessons
and has a built-in feature to export your model as a printable file e.g. .STL or .OBJ.
Slicing: From printable file to 3D Printer

Slicing basically means slicing up a 3D model into hundreds or thousands of layers and is done with slicing
software. When your file is sliced, it’s ready for your 3D printer. Feeding the file to your printer can be done
via USB, SD or Wi-Fi. Your sliced file is now ready to be 3D printed layer by layer
Examples of 3D Printing
3D printing encompasses many forms of technologies and materials as 3D printing is being used in almost all
industries.
A few examples:
• consumer products (eyewear, footwear, design, furniture)

• industrial products (manufacturing tools, prototypes, functional end-use parts)
• dental products
• prosthetics
• architectural scale models & maquettes
• reconstructing fossils
• replicating ancient artefacts
• reconstructing evidence in forensic pathology
• movie props
LASER ENGRAVING MACHINE
Laser engraving machine is mainly used in the advertising industry, leather products, identification industry,
clothing processing, textile industry, decorative building, textile industry and so on. Laser engraver is the art
of using the laser to engrave, mark, or etch an object. Unlike other types of engraving, the laser machine does
not require tool bits that wear out and have to be replaced. The laser engraving machine is widely used in all
kinds of lines and fields. Different designs have been used in production to meet different line’s requirements.
We believe that the type of machine you’ve chosen will surely be of great help to your work. The following
introductions might provide you information for enlarging the field of usage and to use laser machine well.

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Fig. Laser engraving machine
Clean and crisp marking with consistency is an essential requirement of the automotive industry. Laser Marking of Data
matrix for traceability & security purposes is an important aspect of the automotive industry. Industrial Laser marker and
marking systems are the ideal sword for marking legible alphanumeric serial code, 1 D barcodes and 2D data matrix
codes on nearly all materials like Gears, bearing, Automotive Housing, are very useful in automotive manufacturing to
trace each and every part.
The Automotive part like dashboard interior of the gear and bearing is made up of materials like Stainless steel, light or
heavy metals and plastics like nylon, abs, PP, PVC is marked for tracing throughout the life cycle for Quality control.
This laser Marking must be corrosion resistance & weather resistance. The oxidation may lead to damage of marking. .
Product traceability using laser engraving

Product traceability in the automotive industry has become an essential element, as these automotive
manufacturers don’t manufacture all the parts by themselves, the huge number of vehicle components are
supplied by various suppliers. So it has become very necessary for each manufacturer to laser mark them with
serial code or data matric code so that the component can be traceable. This will help, when there will be any
fault in any of the components, the component can be identified well which in result helps us
identify the manufacturer of that particular part. To keep the huge supply chain under control there is a need for
data management software or can be called as traceability software which helps in laser marking of 1D barcode
and 2D data-matrices or QR code. All of these codes help the OEM to trace and trace the supplier date place of
the automotive component and helps in identifying the defective component in the car thus reduces the recalls
and malfunction in the vehicle systems.

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Fig. showing examples of laser engraving or marking on machine components.

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FITTING
INTRODUCTION
Even in the most mechanized industry, although majority of the work can be finished with the help of
machines, there are certain operations, which have to be carried out manually using hand tools.
For example,
i) In production shops, when two or more parts are to beassembled
ii) Sometimes it necessary to replace or repair a component, which must fit accurately with another
component onre-assembly.
FITTING
Fitting is the process of assembling two or more metal parts together by removing excess material so
as to obtain a required fit.
OR
It is the process of removing unwanted material with the help of hand tools, from a given stock
(work piece) for making a component or fitting one in the other to form a matting or fitting pair.
Ex:- 1) key and key hole 2) A Bush and a shaft.
Fitting requires the use of various hand tools and considerable manual effort. Fitting work involves a
large number of hand operations to finish the work to desired shape, size and accuracy. The hand
operations in Fitting shop include marking, sawing, chipping, Filing, scraping, drilling, tapping,
Dieing, Fitting etc.
Fitting Engineering Materials
Materials that are used in the engineering Practice are called Engineering Materials. These have
physical, mechanical and chemical properties.
Classification of
Engineering Materials
Metals Non-Metals
FerrousMetals Non-FerrousMetals
Iron Steel
Metals
A metal is a solid (Exception: Mercury) having weight. It is opaque and a good conductor of heat and electricity.
Non-Metals
These are available in the form of liquids, gases or solids such as wood, stone, Rubber, plastic,
ceramic, concrete, asbestos etc.
Ferrous Metals

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Iron containing metals such as pig iron, cast iron, wrought iron, carbon steel, Alloy steel, Nickel
steel etc., are called ferrous metals. These can be attracted by magnets and are susceptable to rusting.
Non-FerrousMetals
Non-Ferrous metals are those, which do not contain iron. Metals like Gold, Silver, Copper,
Aluminium, Tin, Platinum, and Nickel, Bronze etc, and its alloys are Non-Ferrous metals. These can
neither rust nor can be attracted by magnets.
Cast iron
It is an Iron based material containing 91-94% iron and other elements such as Carbon (2-4%), Silicon
(0.4-2.8%), Manganese (0.25-1.25%), Sulfur (0.2%max) and Phosphorous (0.6%max).
Types of Cast iron: - Gray cast iron, malleable iron, white cast iron.
Steel:-may be defined as an alloy of iron and carbon. Besides this, it also contains Silicon,
Manganese, Sulfur and Phosphorous.
One of the differences between Cast iron and steel is the amount of carbon percentage.
Based on the carbon content, steel is dividedinto
a) Low Carbon Steels- the carbon content ranges from 0.03-
0.35%. Low carbon steels are also called as soft or Mild steel(M.S).
b) Medium Carbon Steels-the carbon content ranges from0.35-0.6%.
c) High Carbon Steels-The carbon content ranges from0.6-1.7%

Mild steel (MS)
Mild steel may be defined as an alloy of iron (91-94%), and carbon (0.15-0.35%). Besides this, it
also contains Silicon, Manganese, Sulfur and Phosphorous. Low carbon steels are also called as soft
or mild steel. These steels are used for bolts and nuts, structural work, axles, shafts etc
Alloy Steel
In alloy steel in addition to carbon and iron, alloying elements such as chromium, Nickel,
Vanadium etc. are mixed. Ex: - Stainless steel, High Speed steel (H.S.S) (Tool steel).
Tool steel is widely used in the manufacturing of cutting tools.
FITTING TOOLS
The Tools used in Fitting practice may be classified into the following categories.
1.Holding Tools
2. Marking and Measuring Tools
3.Cutting tools
4.FinishingTools
5.Striking
6. Miscellaneous Tools
Holding
Tools Vice
AVice is a tool used to hold the wok piece (job) in position while various operations are being carried out.
1) Bench vice 2) Machine vice 3) leg vice 4) pipe vice 5) handvice
Benchvice
The vice used for bench work is called bench vice. The bench work includes filing, sawing, and
threading operations.
It consists of a cast iron body carrying a fixed jaw and movable jaw. Both the jaws are made of cast
steel and are brought together by means of hand operated Screw.Seperate cast steel plates known as
‘jaw plates’ are fixed to the jaws my means of set screws which can be replaced when worn out. The
face of the jaw plates have teeth (serrations), which helps in gripping the work firmly.
Specification: - the width of the jaws determines the size of the vice.

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Machine vice
Machine vice is used to hold work piece in Machine tools. Machine vice is able to tilt and swivel. It
is mounted on the table of a Machine. Ex:-Drilling Machine, Milling Machine and Shaping Machine.
Leg vice or Black smith’s vice
It is used for holding work piece that has to be cut, chipped or hammered. It consists of a fixed jaw
with long leg and movable jaw that can be moved by means of a hand operated screw.
Pipe vice
It is used for holding round section parts such as pipes, tubes.
Hand vice
It is used for carrying work on small jobs, such as screws, keys, rivets etc., which cannot be held in
the Bench vice. It consists of two jaws that can be operated by means of a wing nut.
V-block with Clamp
V-block is a rectangular or square block with v-groves on one or both the sides, opposite to each
other. The angle V is usually 90 degrees. V-blocks are used for checking the roundness of cylindrical
work piece and for marking centers accurately. Material- Hardened Steel or Cast Iron.
Fig.1 Bench Vice

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Fig.2 Marking and Measuring tools

Surface plate
Surface plate is a plain surface. The surface is machined to very fine limits. The plate is constructed
in such a way that it will not wrap or twist. It is used for –testing the flatness of finished work piece.
Providing a base support for ‘marking gauges’ or ‘scribing block’. Testing the accuracy of Try
square.
Material- Cast iron or hardened steel or granite stone.
Specification: - It is specified by length x width x height x
grade. Angle plate
It consists of two faces machined at right angles (90 degrees) to each other. A number of slots are cut
on both the horizontal and vertical faces as shown in figure. These slots enable the work piece to be
held firmly by means of bolts and nuts. It is also used to support work piece, when you are using the
surface gauge for marking
Material- Gray Cast iron
Scribing block or Surface gauge
A scribing block has three parts-base, spindle and scriber. The base of the scribing block is
machined to have a flat surface. A Vertical spindle fitted on the base carries a scriber and by
adjusting the screw, the scriber can be fixed to any inclination and height along the spindle.
It is used for scribing lines on work pieces and also used for checking parallel surfaces.
The Scribing block can be used to locate accurately the centers of round bars in conjunction with the
Vee-block.
Specification- Height of the Vertical spindle

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Scriber Fig.3 AnglePlate

A Scriber is a thin steel rod with a pointed end or ends, one of the ends may be bent at right angles to
allow access to holes. It is used to scribe (or) mark lines on the metal work pieces. Scribers are
available in several sizes and types. The point should be ground to a 30 degrees angle and kept sharp
for accuracy.
Material- High carbon steel (Hardened
&Tempered). Specification-It is specified by its
length and diameter. Try Square or Engineers
Square
Try square also called ‘Engineering Square’ is one of the basic tools used in fitting work. It consists
of a steel blade riveted exactly at 90 degrees into a hard steel stock of rectangular cross section as
shown in figure. The stock acts as a fence and the blade as guide for marking.
It is used for 1) checking squareness or perpendicularity of work piece.
2) Testing for Straightness and 3) marking straight lines (at right angles) on work
piece. Material-Steel (hardened andtempered).
Specification-the Size of Try-square is specified by the length of the blade (100mm, 150mm, and 200mm).

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Steel rule orSteel scale Fig.4 Try Square and Steel Rule
It is used for measuring and marking the required dimensions on the work piece. The scale is
graduated in millimeters, centimeters and inches. Least count of normal steel rule is1mm.
Fig.5 Spring Divider

It is used for scribing (marking) circles, arcs, bisecting lines and perpendicular lines on metal work
piece. It also used for transferring dimensions from scales to objects.
Material- Tool steel (Hardened &Tempered).
Specification-Max length /radius which can be
scribed Spring caliper:
Caliper are devices used for measuring and transferring the inside \outside dimensions of
components. Calipers are of two types, viz, outside spring caliper and inside spring caliper.
Material- Tool steel
Outside spring caliper-It is used for measuring the outer diameter of shafts (rods) and thickness of parts.

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Inside spring caliper- It is used to measure the inner diameter/dimensions of parts
.
Fig.6 (a) Use ofInsidecalipers (b) Use of outsidecalipers
Jenny calipers- Jenny calipers are used for marking and layout work. It is used to draw parallel
lines, locating the centre of round bars .It is also known as odd leg caliper or hermaphrodite caliper.
Fig.7 Center Punch

It is used for marking round indentations on metal surfaces. This provides a center for locating the
sharp end of the divider point and center for holes that are to be drilled. It is also used for marking
points along a line, which enables to cut the work piece easily. The point angle should be ground to
90degrees
Material- High carbon steel. Specification-By
length and angle.

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Dot punch
It is used for marking points along a line which enables to cut the work piece easily. The point
angle should be ground to 60 degrees
Letter punch
It has square body with a tapered end. At this end, a projection, corresponding to the replica of the
letter to be marked is made. It is used to punch Alphabetic letters (A to Z) on metal work piece
Fig.8 Number punch

It is similar to letters punch in construction but has numbers at its end. The numbers used are from 0
to 8 (six used as nine also). It is used to punch numbers on metal work piece.
Vernier caliper
These are used for measuring outside as well as inside dimensions accurately. It may also be used as
a depth gauge.
Example- to measure outer diameter of shafts and cylinders, to measure inner diameter of holes and
depth of holes.
Hence, Least count of the vernier caliper (LC) = 1 main scale division Total number of division on the vernier
scale
= 150 =0.02 mm
Total reading =Main scale reading (MSR) + Least count (LC) X Vernier Coinciding Division
Vernier height Gauge

The vernier height gauge, clamped with a scriber, is shown in Fig.Vernier height gauges are
particularly suitable for marking off accurate distances and center locations. It is also used in
inspection of work pieces. The accuracy and working principle of this gauge are the same as those of
the vernier caliper.
Fig. 9 Vernier Caliper

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Fig. 10 Vernier Height Gauge
Micrometer:
External micrometer is used to measure external diameters and lengths. The degree of
accuracy is high.
Pitch= Distance coveredby one complete revaluation thimble

Total No. of division onthe thimble
= 0.5 mm
50 mm
Least count of micrometer = pitch/ No of divisions on the thimble.
= 0.5 mm / 50 = 0.01 mm.
Total reading =Pitch scale reading (PSR) + Least count X Thimble scale reading
(HSR)
Fig.11 Micrometer
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REVA UNIVERSITY
Cutting tools
Hack saw frame with blade.
The hacksaw is used for cutting metal by hand. The hacksaw blade has a number of teeth ranging
from 5 to 15 per centimeter. Lesser number of teeth is used for cutting materials like Aluminium,
brass and Bronze and large number of teeth is used for cutting hard materials like steel, C.I etc. Hack
saw blades are fitted either in a solid frame or adjustable frame to accommodate different lengths of
blade.
It is made of high-speed steel. The hacksaw blades are specified byits material, length, width,
thickness and pitch of the teeth. The common dimensions are length 250-300 mm, width 13 mm-16
mm, thickness 0.6 to 0.8 mm, pitch 1 to 1.8 mm. The blades are fixed with teeth facing forward and
the teeth are staggered, which are known as ‘set of teeth’. These make slots wider than blade
thickness, preventing the blade from jamming
Fig.12 HacksawFrame
Twistdrill:-
The twist drills are used for making holes. The drills are made of HSS (high speed steel) with a
straight or taper shank. The straight shank drills are held in drill chuck and fitted to the spindle of
drilling machine and the taper shank is directly fitted to the spindle. The drills are manufactured to
standard sizes in specified steps. A bench-drilling machine is commonly used in workshops
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REVA UNIVERSITY
Fig.13 TwistDrill
Fig.14 FlatChisel
Flat
chisel
Chisels are used for removing surplus metal from the work piece. They can be used as a substitute
when files and hacksaw blades are impossible to use.
Material - High carbon steel or tool steel having octagonal or hexagonal cross-
section. Specification- Length and width of the edge.
The process of removing metal using a chisel is called ‘chipping ‘and is shown in fig
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REVA UNIVERSITY
Fig. 15 Flat Chisel Uses
Taps andTapwrenches
A tap is a hardened steel tool, used for cutting internal threads in a drilled hole. Hand taps are
usually supplied in sets of three for each diameter and thread size. Each set consists of a i) Taper
or first tap ii) Intermediate or second tap and iii) plug or bottoming or third tap. In hand tapping,
the tap is rotated with the help of a tap wrench. These taps are identical in all features except in the
taper lead. For identifying the type taps quickly the taps are either numbered as 1, 2, and 3 or rings
are marked on the shank.
Fig.16 Tap and Wrench
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Fig.17 Dies and die –holder

Dies are the cutting tools used for marking external threads. Dies are made either solid or split type.
They are fixed in a die –holder for holding an adjusting the die gap. They are made of tool steel or
high carbon steel.
Finishing
tools
Files
A file is a cutting tool used to remove small amount of material from the surface of the work piece
and also helps in giving a smooth surface finish. A number of teeth, parallel and inclined at suitable
angle are cut on the flat surface of the file. The various parts of a file are shown in figure the main
parts of the file include, Tang-It is the pointed part that fits into the woodenhandle.
Heel – It is end of the tang that forms a curved edge.
Face -It is the portion of the file on which cutting teeth are
formed. Point – It is the end opposite the tang
Files are often tapered along their length but they may also be
parallel. Material -tool steel (hardened)
Specification- length, single cut /double cut, shape and
pitch. Example Length (say 400mm)
Single cut /Double cut
Shape (say square cross –
section) Pitch or grade (say
smooth)
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REVA UNIVERSITY
Fig. 18 Flat File

Files are classified and named according to
a) Size/length b) cut c) shape and d) pitch /grade
Size: the size of the file is identified by its length. It is the distance from the point to the heel
excluding tang. The selection of the length of the file varies depending on the size of the job .
Sl.no Size(length) Application

1 100-150mm Used for fine work and small sized jobs
2 150-250mm Used for medium sized work
3 250-400mm For general and large sized work
Cut: Based on the cutting teeth , files are classified as single cut files and double cut files
Fig. 19 (a) Singlecutfile (b) Double cutfile
Double cut file: A double cut file has two sets of teeth crossing each other as shown fig. one set of
teeth are cut similar Single cut file: In single cut file, the teeth are cut in parallel rows across the
faces of the file and normally inclined at an angle of 60 degrees with the centerline of the face.
to a single cut file and the other set runs diagonally across the first set and are normally inclined at an
angle of 10 degree to the center line of the face .
Single cut files gives better finish when compared to double cut files but at the same time removes
material at a comparatively slower rate.
(C) Shape of files -Files is classified based on the shape of theircross-section.
Various types of files.are used for general work or finishing flat

surfaces.
Squares files are used for filing square corners, rectangular slots, keyways, enlarging a square or a
rectangular holes etc.
Triangular file or three-square files are used mainly for filing corners with angles less than 90 degrees.
Round files are used for filing concave surface and also for enlarging round holes.
Half-round file the curved face of the half-round file is used for filing concave surfaces and the flat
face is used for filing convex surfaces.
Knife edge file is used for filing narrow slots and corners having angles less than 90 degrees
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Fig.20 Types of Files Flat files
(D) Pitch of teeth/grade

in descending order of their Pitch refers to the spacing between two consecutive teeth. Table
shows the classification of files based on their pitch. The files are listed roughness.
Table.1 Types of Files
Description Single cut Double cut Uses
Rough. For rapid removal
8 teeth/cm of Large amounts
of material from
softer materials.
Bastard Rapid removal
12 teeth/cm of Small
amounts of
material.
Second Used for filing on
cut. 16 harder materials.
teeth/cm Gives good surface
finish
Smooth. Used for
20-24 teeth/cm smooth surface
finish.
Removes small
amounts of
material.
Dead Smooth. Used for accurate and
>40 teeth/cm smooth surface finish.
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REVA UNIVERSITY
Striking Tools
Fig. 21 Types of Hammers

Hammers: The hammer is defined as a device used to deliver blows to an object or strike another
object, in thesensethatitisusedfordrivingnails,fittingpartsandbreakingupobjects.Itisalsousedforstriking
purposes while punching, bending, chipping, and riveting. Available in various shapes and structures,
hammers are designed for specific purpose. The hammer consists of a handle to which a heavy head,
usually made of metal is attached, with one or more striking surfaces. The hammer is specified by its
weight (125 grams to 1500 grams) and the shape of thepein.
Different types of hammers are straight pein hammer, ball pein hammer, cross –pein
hammer Material Cast steel or carbon steel.
Ball pein hammer:-This is the most common type of hammer which has a ball-shaped end of the
head opposite to the striking face. It is used for all kinds of engineering works. The ball end being
useful for sheet metal forming and it is made in weights from 1000gm to 1.5kg. It is used for riveting
andchipping.
Cross –pein and straight pein hammer:-These have blunt, chisel-shaped ends on the head opposite to
the face. It is used for bending, stretching, hammering into shoulders, curves.
Miscellaneous Tools
Anvil : It provides the necessary support during punching and chipping by resisting the heavy blows
given to the work piece by hammer .The beak is used in sheet metal work for bending the sheet metal
to round shapes. Material-The body is made of mild steel or cast steel with a hardened top face.
the files.
Fig. 22 Anvil File card: It is a metal brush used for cleaning

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REVA UNIVERSITY
FITTING OPERATIONS
Marking and Measuring
The marking is the first step in fitting. Marking on the work can be done by setting out dimensions
with the help of a working drawing. Generally one end of work piece is filed flat and the
measurements are taken from this reference end. The measuring instruments used in fitting are scale,
Calipers, vernier caliper, micrometer, height gauge etc. Marking tools used in fitting are Scriber, Dot
puntch, Scribing gauge etc..
Filing: Filling is the process of removing burrs from cuts; clean the face of cuts and to give the final
shape to a work piece. The flatness and square ness of the surfaces finished by filing are checked
with trysquare.
Methods of filing- a) Cross-filing b) Draw filing
Cross-filing- this method is used for efficient removal of maximum amount of metal in the shortest
possible time. It may be noted that the file must remain horizontal throughout the stroke (long, slow and
steady) with pressure only applied on the forward motion.
Draw filing-this method is used to remove file marks and for finishing operations. Here, the file is
Griped as close to the work as possible between two hands. In this method of filing, a fine cut file
with a flat face should be used.
Fig. 23 Filling Methods

Sawing: It is the method of removing excess material quickly with the help of hand hack –saw. The
surfaces are to be finish filed after sawing
Chipping-It is the process of removing unnecessary thick layers of metal using cold chisel and
hammer. Drilling –It is the operation of producing circular holes in a metal piece with the help of
bench drilling machine and drilling tools.
Tapping- It is the process of generating internal threads in a ready hole using a set of three hand taps.
Dieing-It is a manual operation of generating external threads on a round rod or pipe using a die
and die holder.
Fitting /Assembly: After finishing the individual pieces as per dimensions they are joined /fitted for
an assembly.
Safe and correct practices:
1) All the tools and measuring instruments are to be cleaned and kept in the respective places when not isuse.
2) The sliding parts and pins are to be properlylubricated.
3) The vice should not be over tightened; otherwise it may damage thespindle.
4) The sharp edges of a chisel or scriber are to be covered with a cap to avoid getting damaged and to
prevent accidents.
5) The handles of hammers are to be checked for cracksetc.
6) The surface plate has to be covered and kept when not in use and tools and jobs should not be
thrown on the surface plate to avoid damage to thesurfaces
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REVA UNIVERSITY
Fig. 24 Different Methods of Filling
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REVA UNIVERSITY
Fig. 25 Use of Different Types of Files
62
Fig. 26 Different Methods of Sawing
63
Sequence of operation and methods for preparing Fitting Models (Step by step procedure)
Sl no Sequence of Operation Method/ System adopted Tools/ Equipments required to
perform the operation
Orthographic: 2D Using all conventions, notations
1 Sketching/ Drawing
Isometric: 3D and symbolic representations
Sketching separately A & By Projection Shift ‘A’ pieces to left side
2
B Pieces Shift ‘B’ pieces to right side
By cumulative i) ‘A’ piece from right toleft
3 Note down the ii) ‘B” piece from left toright
marking dimensions iii) Bottom to top for both ‘A’
&‘B’
Cross, draw and St. filling ( i) Hand file or flat file (300 mm
To identify the reference rough)
4 Filling adjacent edges to line for marking ii) Hand file or flat file (200 mm
correct level smooth)
iii) Try square (150mm)
iv) Granite surfaceplate
Similar dimensions to be i) Vernier height gauge(300mm)
5 Marking marked simultaneously ii) ‘V’block
to iii) Diveder(150mm)
A&B
Punch (thin mark) with i) Center punch(100mm)
6 Punching equal distance on the ii) Ball peen hammer(250mm)
marked lines iii) Anvil(50kg)
Drilling purpose i) Center punch(100mm)
7 Deep punching ii) Smith hammer (500gms0
Machining process Drilling machine 12.5 mm with
8 Drilling
4 mm drill bit
i) ‘A’ piece outsidethe i) Hack saw frame withsuitable
punchmark blade(12” or 300mm)
ii) ‘B’ piece insidethe ii) Teeth of the hacksaw blade
9 Hack sawing or cutting punch mark in forwarddirection
iii) keeping 0.5mm away iii) Movement of hacksaw is
from punchmark straight
iv) To fix line of cutting is iv) Apply pressure inforward
perpendicular strokeonly
Chipping/ chiselingon i) Flat chisel (150 x 12mm)
10 Chipping /Chiseling
both faces on theanvil ii) Smith hammer (500gms)
i) Punch mark is parallel to Different shapes of files
jaw plates of thevice
ii) keeping thehorizontal
11 Filing whenfiling
iii) Finish filing operation
up to half of thepunch
mark
Inspection / Check i) Vernier caliper (150mm)
12 Measurements ii) Micrometer(0-25mm)
iii) Temperature
64
Model No: 1 Square Joint
AIM: To fabricate the fitting model as per the sketch given below.
MATERIAL: Mild Steel (M.S)

TOOLS REQUIRED
1
2
3
4
5
6
7
8
PROCEDURE
• Check the dimensions of the given work piece with respect to the givenmodel.
• File the one edge of the given work piece to straightness and checked with Trysquare.
• File the adjacent edge so that it is square with first edge filed and checked with Try square. File the
upper and bottom surfaces of workpiece.
• Paste white color on the upper surface of the work piece (with chalk powder andwater).
• By marking gauges (Scale, Try square, Scriber, Divider), mark the dimensions on the given workpieces.
• Using Dot punch and Hammer, make the punch marks (dots) on the marked dimensions on the given
work piece.
• By using hacksaw remove the extra material from the work piece and use cold chisel, if necessary to
remove the material.. Removing small amount (1 mm to 2mm) of material Files can beused.
65
ModelNo: 2 V-JOINT

TOOLS REQUIRED
1
2
3
4
5
6
7
8
PROCEDURE
➢ Check the dimensions of the given work piece with respect to the givenmodel.
➢ File the one edge of the given work piece to straightness and checked with Trysquare.
➢ File the adjacent edge so that it is square with first edge filed and checked with Try square.
File the upperand bottom surfaces of workpiece.
➢ Paste white color on the upper surface of the work piece (with chalk powder andwater).
➢ By marking gauges (Scale, Try square, Scriber, Divider), mark the dimensions on the given workpieces.
➢ Using Dot punch and Hammer, make the punch marks (dots) on the marked dimensions
on the givenwork piece.
66
➢ By using hacksaw remove the extra material from the work piece and use cold chisel, if
necessary toremove the material.. Removing small amount (1 mm to 2mm) of material
Files can beused.
Then male and female work pieces are assembled (joined) in order to make firm joint.
ModelNo: 3 Semi circularJoint


TOOLS REQUIRED
1
2
3
4
5
6
7
8
PROCEDURE
➢ Check the dimensions of the given work piece with respect to the given model.
➢ File the one edge of the given work piece to straightness and checked with Try square.
File the upper and bottom surfaces of work piece.
67
➢ Paste white color on the upper surface of the work piece (with chalk powder and water).
➢ By marking gauges (Scale, Try square, Scriber, Divider), mark the dimensions on the
given work pieces. Using Dot punch and Hammer, make the punch marks (dots) on the
marked dimensions on the given work piece.
necessary to remove the material.. Removing small amount (1 mm to 2mm) of material Files
can be used.
.
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ModelNo: 4 Dovetail Joint

TOOLS REQUIRED
1
2
3
4
5
6
7
PROCEDURE.:-
➢ File the adjacent edge so that it is square with first edge filed and checked with Try square. File
the upper and bottom surfaces of work piece.
By marking gauges (Scale, Try square, Scriber, Divider), mark the dimensions on the given work pieces.
➢ Using Dot punch and Hammer, make the punch marks (dots) on the marked dimensions on
the given work piece
➢ the material.. Removing small amount (1 mm to 2mm) of material Files can be used. Then
male and female work pieces are assembled (joined) in order to make firm joint.
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ModelNo:5 HexagonalJoint
AIM: To fabricate the fitting model as per the sketch given below

TOOLS REQUIRED
1
2
3
4
5
6
7
8
➢ By marking gauges (Scale, Try square, Scriber, Divider), mark the dimensions on the given
work pieces. Using Dot punch and Hammer, make the punch marks (dots) on the marked
dimensions on the given work piece.
70
can be used.
ModelNo: 6 Half Dovetail Joint
AIM: To fabricate the fitting model as per the sketch
givenbelow.

TOOLS REQUIRED
1
2
3
4
5
6
7
8
PROCEDURE
➢ By marking gauges (Scale, Try square, Scriber, Divider), mark the dimensions on the given
71
work pieces. Using Dot punch and Hammer, make the punch marks (dots) on the marked
dimensions on the given work piece.
can be used.
Then male and female work pieces are assembled (joined) in order to make firm joint.
Models for Practice
72
74
75
WELDING
INTRODUCTION
Joining two or more elements to make a single part termed as a Fabrication process. A fairly large
number of industrial components are made by fabrication processes. Common examples are aircraft
and ship bodies, building trusses, welded machine frames, sheet metal parts etc.
The fabrication is often the most economical method and relies on raw material obtained from one of
the primary manufacturing process such as rolling and extrusion. Hence, it may be called a
secondary manufacturing process.
Classification Fabrication process
The Various fabrication processes can be classified according to Method of Joining as
follows. Mechanical Joining by means of bolts and nuts ,screws,rivets.
Adhesive joining by employing synthetic glues such as epoxy resins.
Metallurgical fusion process like Welding, Soldering and Brazing
The Various fabrication processes can be classified according to Type of assembly.
. .1) Temporary joiningprocess
2) Permanent. Joining process
Temporary joining process: - The joints obtained by these processes will be such that the
connected parts can be separated easily with out any damage. Example: - Joints obtained by brazing,
soldering, bolts and nuts. Studs and nuts, screwsetc
Permanent Joining process: - . The joints obtained by these processes will be such that the
connected parts have to be broken in order to separate them. Example: - Joints obtained by riveting,
welding etc;
Welding
Welding is the process of joining similar metals by application of heat, with or without
application of pressure or filler material.
Applications of welding
It is used in the manufacture of automobile bodies, aircraft frames, railway wagons, machine
frames, structural works, pressure vessels, furnaces, tanks, refrigerators, furniture, boilers, and
shipbuilding.
Repair and maintenance work. Example joining broken parts, rebuilding worn out components etc.
Classification of welding process.
Plastic welding:
In plastic welding, the metal parts to be joined are heated to the plastic state (or above) and then
fused together by applying external pressure. No filler metal is used in this process plastic welding is
also called ‘pressure welding processes.
Example: -Forge welding, resistance welding.
Fusion welding
In fusion welding process, the parts to be joined are heated above their melting temperature and then
allowed to solidify without application of pressure. A filler material is used during welding process.
Example: - arc welding and gas welding
Types of Arc welding process
1) Carbon arc welding 2) Metal arc welding 3) Metal inert gas welding4) Tungsten inert gas welding
5) Plasma arc welding6) Submerged arc welding
Electric Arc Welding (Metal Arc Welding):-
Arc welding is a fusion method of welding that utilizes the high intensity of the arc (generated by
current flow) to melt the work pieces. A solid continuous joint is formed uponcooling.
In arc welding process makes use of ‘filler material’ to supply additional material to fill the gap
between the workspaces. The filler material used in welding process is called ‘Electrode’. It is made
of a metallic wire called ‘core wire’, which is of the same material or nearly the same chemical
composition as that of the work piece metal or base metal. The core wire is uniformly coated with
flux.
76
Principle of Arc Welding:
The source of heat for arc welding process is an ‘electric arc ‘.The arc is produced by striking the
electrode on the work piece. The electrode is momentarily separated from the work piece by a small
gap such that the arc is still maintained between the work piece and the electrode .The electrical
energy is thus converted into heat energy. The high heat at the tip of the electrode is sufficient to
melt the work piece. The tip of the electrode melts and combines with the molten metal of the work
piece there by forming a homogeneous joint.
Operation
In arc welding process the electrode holder holding the electrode forms one pole of the circuit and
the parts to be welded forms the other pole. The electrode serves both to carry the arc and also acts as
a filler rod to deposit the molten metal into the joint. An arc is struck by touching the tip of the
electrode with the work piece and instantaneously the electrode is separated from the work piece by a
small distance of 2-4 mm such that the arc is still maintained between the electrode and the work
piece. The temperature of the arc ranges from 5000-6000 0C. The high heat of the arc melts the work
piece metal forming a small molten metal pool. At the same time, the tip of the electrode also melts
and the molten metal of the electrode is transferred into the molten metal of the work piece in the
form of globules of molten metal. The deposited metal fills the joint and bonds the joint to form a
single piece ofmetal.
Applications: arc welding process is used for fabrication work, repair and maintenance work. The
process finds applications in boiler and pressure vessel fabrication. Shipbuilding. Joining of large
pipes and penstock, building and bridge construction, automotive and aircraft industries etc.
Fig.1 Arc Welding Machine
77
The source of heat for arc welding process is an ‘electric arc ‘. To supply the current for welding, two
types of power sources are available, viz; alternating current (A.C) and direct current (D.C).
Current requirements:-
20-200 amperes for thin
materials 20-300 amperes for
general work 300- 600amperes
for heavy work.
Fig.2 AC Circuit for arc welding

Welding using A.C current: Fig shows the schematic representation of an A.C welding
circuit. The welding circuit consists of
Step–down transformer-to reduce the usual supply voltage (220-440 V) to that required for welding
(15-90V) Two cables – one cable, to the electrode holder holding the electrode and other, the
ground cable
Ground clamp – used to connect one end of the ground cable to the work piece or to the table
carrying the work piece ,Electrode holder and Electrode
78
Fig.3 Welding using D.C current
The schematic representation of a D.C welding circuit is shown in fig
In D.C welding, the electrode acts as one terminal and the work piece as the other terminal (either
+ve or -ve) with D.C generator, greater heat is generated at the positive pole. Hence. The work piece
should be connected to the positive pole of the D.C generator and the electrode to the negative pole
in order to melt greater mass of metal in the work piece material.
In A.C, the melting rate cannot be controlled, because equal heat is generated at the electrode and the
work piece.
Comparison between A.C and D.C

inWelding Alternating Current (from
Transformer) Moreefficiency
Power consumption
less Cost of equipment
is less
Higher voltage – hence not safe
Not suitable for welding non ferrous
metals Not preferred for welding thin
sections
Any terminal can be connected to the work or electrode
Direct Current (from Generator)

Less efficiency
Power consumption more
Cost of equipment is more
Low voltage – safer
operation
suitable for both ferrous and Non ferrous
metals preferred for welding thin sections
Positive terminal connected to the work
Negative terminal connected to the
electrode
Electrodes used in Arc welding:

Welding electrodes used in arc welding are of two types.
Consumable electrodes
Non-consumable electrodes.
Consumable electrodes:
These are made of metallic wire and are consumed during the welding process. The selection of a
particular metal for the electrode depends upon their purpose and the chemical composition of the
work piece metal to be welded. Consumable electrodes are further classified as coated electrodes and
plain/bareelectrodes.
Coated electrodes:-In these electrodes, the metallic wire is coated with ‘flux ‘.During welding, the
work piece melts and at the same time, the tip of the electrode also melts. As the globules of molten
metal pass from the electrode to the work piece, they absorb oxygen and nitrogen from the
atmospheric air. This causes the formation of some non- metallic constituents that are trapped in the
solidifying weld metal and thereby decrease the strength of the joint. In order to avoid this, a ‘flux’ is
coated on the metallicwire.
79
Flux: A flux is a “material used to prevent, dissolve, or facilitate removal of oxides and other
undesirable surface substances”.
Various constituents like titanium oxide, cellulose, manganese oxide, calcium carbonates, mica,
iron oxide etc. are used as flux materials forcoating.
The flux coated on the electrode performs the following

functions. prevents oxidation of molten metal
helps in the removal of oxides and other undesirable substances present on the surface of the work
piece Chemically reacts with the oxides and forms a slag. The slag floats and covers the top portion
of the molten metal thereby preventing it from rapid cooling.
To remove any oxide
formed.
To stabilize the arc
To make welding easy.
To avoid difficulties in welding.
Plain / Bare electrode: The metallic wire (core wire) is left plain or uncoated with flux. These
electrodes do not prevent oxidation of the weld and hence the joint obtained is weak.
Non –consumable electrode: -
Non-consumable Electrodes are made of carbon, graphite or tungsten that does not get consumed
during welding.
Oxidation
Metals in molten condition absorb oxygen from atmosphere and form metallic oxides. This process
is known as oxidation. The formation of metallic oxides must be prevented. To prevent oxidation, we
use coated electrodes.
❖ Advantages of Arc
welding: Most efficient way to
join metals Lowest-cost
joiningmethod
Affords lighter weight through better utilization of
materials Joins all commercialmetals
Provides design flexibility
❖ Limitations of Arc welding:
Manually applied, therefore high
laborcost. Need high energy
causingdanger
Not convenient for
disassembly. Defects are hard
to detect at joints.
Gas Welding Process:

Principle: Gas welding is a fusion type of welding that utilizes a strong flame, generated by the
combustion of gases to melt the work piece. The gases are mixed in proper proportions in a welding
blow pipe called ‘welding torch’. A solid continuous joint is formed upon cooling.
The combination of gases used in this process is
Mixture of oxygen and acetylene
Mixture of oxygen and hydrogen.
Oxy-Acetylene welding
Oxygen and acetylene mixture are most commonly used in gas welding and the process is widely
called oxy- acetylene process. It consists of supply of oxygen and acetylene under pressure in
cylinders, pressure regulators, a torch, hoses and accessories like goggles and lighter. The oxygen
and acetylene cylinders are connected to the torch through pressure regulators and hoses. The
80
regulator consists of two pressure gauges. One for indicating the pressure with in the cylinder and the
other shows the pressure of the gas fed into torch, which may be regulated. The torch mixes the two
gases and the flame may me controlled by adjusting the oxygen and acetylene supply.
Gas Welding Equipment.

1. Gas
Cylinders
Pressure
Oxygen – 125
kg/cm2 Acetylene –
16 kg/cm2
2. Regulators
Working pressure of oxygen 1 kg/cm2
Working pressure of acetylene 0.15
kg/cm2
Working pressure varies depends upon the thickness of the work pieces welded.
3. PressureGauges
4. Hoses
5. Weldingtorch
6. Checkvalve
7. Non returnvalve
Fig.4 Some of the Important points related to Gas Welding.

Sound weld is obtained by selecting proper size of flame, filler material and method of
moving torch The temperature generated during the process is 33000C
When the metal is fused, oxygen from the atmosphere and the torch combines with molten metal and
forms oxides, results defective weld
Fluxes are added to the welded metal to remove oxides
Common fluxes used are made of sodium, potassium. Lithium and
borax. Flux can be applied as paste, powder, liquid. Solid coating or
gas.
Types of flames produced in gas welding
Three types of flames can be produced at the torch tip by regulating the ratio of oxygen to acetylene.
81
: (a) Neutral flame; (b) oxidizing flame; (c) carburizing, or reducing flame.
Neutral flame (Oxygen and Acetylene are mixed in equalproportions)

A neutral flame is produced when approximately equal volumes of oxygen and acetylene are burnt at
the torch tip (I has a balance of fuel gas and oxygen). The flame has a nicely defined inner whitish F
surrounded by sharp blue flame. The temperature of the neutral flame is around 32000C. . Used for
welding steels, aluminium, copper and cast iron etc and can also be used for metalcutting.
Oxidizing flame (Excess of Oxygen)

If more oxygen is added to the Neutral flame, the cone becomes darker and more pointed, while the
envelope becomes shorter and fiercer is called Oxidizing flame. Has the highest temperature about
34000C.Used for welding brass and brazing operation
Carburizing flame (Excess of Acetylene):-

If the volume of oxygen supplied to the Neutral flame is reduced, the resulting flame will be a
Carburizing or reducing flame i.e., rich in acetylene. A reducing flame can be recognized acetylene
feather that exists between the inner cone and the outer envelope. Has the highest temperature about
30000C .The outer flame envelope is longer than that of the neutral flame and is usually much
brighter in colour . This type of flame is used for welding non- ferrousmetals.
Soldering Fig.5 Types ofFlames

Soldering is a method of joining similar or dissimilar metals by means of filler
metal whose melting temperature is below 450 0C. The filler metal usually called ‘solder’ is an alloy
of tin and lead in various proportions.
Soldering is commonly used for joining circuits in electronic components. In sheet metal work and in
sealing of metal containers
Brazing
Brazing is a method of joining similar or dissimilar metals by means of a filler metal whose melting
temperature is above 450 0C, but below the melting point of the base metal.
The filler metal called ‘spelter’ is a non –ferrous metal or alloy. Copper and copper alloys
Silver and silver alloys and aluminum alloys are the most commonly used filler metals for brazing.
Welding Tools and Safety Equipments
Electrode holder:- It is used to hold the electrode during welding refer fig it consists of a handle and
a pair of jaws operated by means of spring. The electrode holder forms one element of the welding
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circuit. One cable (wire) from the transformer is connected to the electrode. Due to this reason, the
electrode holder should be well insulated.
Chipping Hammer:-During welding, the flux coated on the electrode reacts with the oxides and
other impurities and forms a slag. The slag being lighter floats over the surface of the molten metal
and on solidification forms a thin layer over the weld bead.
A chipping hammer is used for removing the slag formed on the weld bead. One end of the chipping
hammer is sharpened like a cold chisel and the other end to a blunt, round point.
Material- Tool steel
Wire brush: - The wire brush usually made up of steel wire is used for cleaning the work piece
before and after welding.
Tong:-A tong is used for holding the work piece during/after welding.
Ground clamp: - Ground clamp is connected to the end of the ‘ground cable’. Ground cable forms
one pole of A.C.
Goggles and Hand shields:-The sparks produced during welding are harmful and should not be seen
with naked eyes. Goggles are used to protect the eyes of the welder form the ‘rays of the arc’ and
‘flying particles of hot metal’. Hand shields and helmet type shields are used to protect the eyes and
also the face of the welder.
Hand gloves:-Hand gloves are used to protect the hands from the sparks produced during welding
and also from the heat of the electrode holder.
C- Clamp
The C-Clamp shown in fig is used for holding the job firmly on the work table during welding.
Common welding terms
Base metal: - The metal to be joined or cut is termed as the base metal.
Bead or weld bead:-Bead is the metal added during single pass of welding. The bead appears as a
separate material from the base metal.
Striking voltage: - The minimum voltage at which the arc may be struck.
Fillet weld:- The metal fused into the corner of a joint made of two pieces placed at approximately
90 degrees to each other.
Tack weld- A small weld, generally used to temporarily hold the two work pieces together during
actual welding, is the tack weld.
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84
.
Fig.7 Safety Tools and C-clamp
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Fig.8 Tong and
clamp Weld Joints: Different joints are adopted in welding
process.
Butt joint: A joint between two pieces lying in the same plane is called butt joint.
Lap joint: A joint between pieces, over lapping each other. They may be of single fillet or double
fillet joint. This does not require edge preparation.
Corner joint: A Joint forming a corner between pieces located at approximately right angles to each
other is known as corner joint. They are of flush corner joint , half open corner joints, full open
corner joint.
T-joint: A Joint between pieces located at a right angle, forming a ‘T’ is known as a t-joint. They
are of square –T or plain T-joint, single bevel T- Joint, double bevel T-joint. This joint requires edge
preparation except for plain T-joint.
Fig.9 Different Types of Joints

Safe and correct
practices.
Welding should be carried out in a well ventilated place and the place should be free of
inflammable materials.
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All the safety gadgets are to be used strictly.
Care should be taken to avoid dragging the welding cable and checked periodically for any open
insulation. The cables should be prevented from coming into contact with hot metal, water, oil etc.
Always keeps fire fighting equipment like water, sand, gas fire extinguisher, for any fire hazard
emergency. Before welding, the parts to be welded are thoroughly cleaned from dust, foreign
matter, oil grease, rust etc. The instructions given in the manufacture’s catalogue are to be strictly
followed.
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Model No–1 LAPJOINT
AIM: To do lap joint by welding as shown in thesketch.
50
5
50
50

TOOLS REQUIRED:
1.
2
3
4
5
6
7
8
PROCEDURE
➢ The given M.S work pieces are thoroughly cleaned of rust ,scale and other foreign materials
➢ Two work pieces are positioned on the work table (welding table) as shown in the figure.
➢ Connect the earth clamp of the welding machine to work table or base metal.
➢ Select the proper size of the Electrode according to the thickness of the metal piece and amperage.
➢ Use hand shields, hand gloves and apron etc
➢ After Selecting Proper size of the Electrode, place it in theElectrodeholder. Switch on the main
and then the starter of the machine.
➢ Bring the electrode near the weld joint and complete the circuit to maintain the correct arc
length. Move the electrode on the weld joint until the molten metal fills the parent metal.
➢ Cool the joint for few minutes and remove the slag by
chipping hammer Brush the weld joint by the wire brush.
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Model No–2 BUTTJOINT
AIM: To do butt joint by welding as shown in the sketch.
50
5
50
50

TOOLS REQUIRED:
1
2
3
4
5
6
7
8
PROCEDURE
➢ The given M.S work pieces are thoroughly cleaned of rust ,scale and
other foreign materials Two work pieces are positioned on the work table
(welding table) as shown in the figure.
➢ After Selecting Proper size of the Electrode, place it in
the Electrode holder. Switch on the main and then the
starter of the machine.
➢ Bring the electrode near the weld joint and complete the circuit to maintain the correct
arc length. Move the electrode on the weld joint until the molten metal fills the parent
metal.
chipping hammer Brush the weld joint by the wire
brush.
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Model No–3 T-JOINT
AIM: To do T joint by welding as shown in the sketch.
50
5
50
50

TOOLS REQUIRED:
1
2
3
5
4
5
6
7
8
PROCEDURE
➢ Select the proper size of the Electrode according to the thickness of the metal piece and
amperage.use hand shields, hand gloves and apron etc
metal.
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brush.
Model No–4 L-JOINT/CornerJoint
AIM: To do L joint by welding as shown in the sketch.

5
50
50
50

TOOLS REQUIRED:
1
2
3
4
5
6
7
8
PROCEDURE
metal.
brush.
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Sheet metal Work
Sheet metal working covers the use of thin metallic sheets with hand tools and sheet
metal machine many important engineering articles made up of sheet metal find their
application in air –conditioning ducts aircraft industry agriculture implements decorative
radicals and household goods for Effectively working in sheet metal one should have
knowledge of hand tools sheet metal machines properties of metals through knowledge of
projective geometry i.e.development of surfaces.
Sheet Metal Process:

1. Study ofdrawing
2. Developments
3. Patterns/Template
4. Operation of sheetmetals
5. Joining
Practical Applications
Many industries like automobile, aircraft, ship building, packing, air conditioning,
ventilating system, fabrication of funnels, hoppers, bins, paint tins, trays, oil tins, buckets,
storage tank, chimney boilers, involves sheet metal fabrication.
Development
The complete surface of an object is opened to one plane is drawn on paper provided
with suitable allowances for seam and hem is called Development.
Methods of Developments:
1. Parallel line method of development: The surfaces of right prisms, cylinders, cubes,
Rectangular Trays & Similarobjects.
2. Radial line method of development: The lateral surfaces of right pyramids and cone
s may be developed by thismethod.
3. Triangulation method of development: The surfaces are made of a No of
Triangular strips laid out in their true size. Ex. Square to round Rectangular to square
etc.
4. Approximate Method of development: This method is used to draw the
development of a sphereetc.
Pattern or Template
It is a metal sheet obtained by laying all the outer surfaces of the object together
provided with suitable allowances for seam and hem is called Pattern or Template.
Metal used in sheet metal work

A large variety of metals are used in the form of sheet & plate. The specifications of
metal sheets are given in terms of their gauge numbers and length & width.
The gauge number correspond to thickness of sheet is measured by using standard
wire gauge. The higher the gauge no, the smaller the thickness and vice versa.
Common metal sheets used in sheet metal Work are:
1. B.P or H R Sheet (Black plain sheet or Hot rolledsheet)

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2. C R sheet plain sheet (cold rolled sheet) – 0.1-0.3 % ofCarbon
3. Galvanized plain sheet (GalvanizingZinc)
4. Aluminumsheet
5. Coppersheet
6. TinSheet
7. Stainless steel sheet – (Alloy steel) contains 18%, Chromium 8%,
Nickel less than 1% carbon rest isiron
8. Brasssheets
Sheet Metal Hand Tools

a. Measuring and Marking Tools:
1. Steelscale
2. Wire gauge, Micrometer, VernierCaliper
3. Steelsquare
4. Scriber
5. Divider
6. Trammel point and
b. Cutting Tools
1. Hand snips or TinCutters,
(i) Straight snip (ii) Bend snip (iii) Combination blade hand snip and
(iv)Circularsnip
c. Punches:
(i) Prick Punch (ii) Solid Punch (iii) Centre punch and (iv) HallowPunch
d. Chisels. (Flat, cross cut, diamond point, circular shape)

e. Stakes of differentshapes.
f. Hammer,Mallets.
g. Files
h. Pliers
i. Soldering Iron
Sheet metal Operations
1. Measuring &Marking
2. Layingout
3. Cutting &shearing
4. Hand forming
5. M/c Shearing
6. Nibbing
7. CircleCutting
8. Piercing andblanking
9. Edge forming Orwiring
10. Joint making Orseaming
11. Bending
12. Notching
13. Soldering
14. Planising.
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1. Marking
Place the development on given sheet (G P sheet 28G) mark the boundary line
and punch the line of bending and draw all bending lines with scriber.
2. Cutting &Shearing
Cutting is normally used when the sheet metal is cut by mean of chisel.
The term shearing stand for cutting sheet metal manually by using hand snip
or tin cutter or by means of shearing machines is calledshearing.
3. CircleCutting
It is an operation of cutting circular blank or curved contours by curved
chisel/bent tin cutter/hand snip/with circle cutting m/c.
4. Handforming
The process of shaping or bending a sheet metal in three dimensions to give it
to the desire shape and size of the final product is termed as metal forming.
5. Hemming, Edge Stiffening andWiring

The edge of sheet is folded to ensure safety on hand stiffness of the product & it
gives good appearance.
6. Joint Making /Seaming:
The method used joining the sheet metal parts by means of folded joints or self
securing joint.
7. Bending
Sheet metal can be bent by hammering / over a stake by hand or by means of
bending or rolling m/c.
8. Notching
The opening left at the corners of seam and edges are known as notches in order
to prevent bulging at such a place, the operation is calledNotching
Straight Notch
Square Notch
‘V’ Notch etc.
9. Drawing
The drawing operation is carried out with the help of a die and a punch on a
suitablepress.
10. Hallowing
In this process of beating the sheet metal into a particular shape such as sauce pan
lid or bowl. It is usually done on the hallowing block, which is a worker block with
hallow cuts onit.
The hallowing process many also be done on a sand bag. There is no
indentation on the top.
11. Sinking
Sinking is a process used to sink the bottom for forming a tray with a flat rim.
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12. Rising
It is the process of dinting/ blows the metal down to shape over a tool with a
raising hammer ormallet.
13. Planishing
It is a process which is applied to sheet with the main object of shaping the
metal with an improved surface the process brings the article to it final shape & surface
finish.
14. Soldering
It is a very common method of joining sheet metal parts. It involves spreading of a
low melting point alloy known a solder in molten condition between the surfaces or edges to
be joined and allow it to solidity there.
Gauge number corresponding to the thickness of sheet or wire diameter.
Thickness of sheet or diameter

Sl. No Gauge No
of wire in mm
1 10 G 3.25
2 12 G 2.64
3 14 G 2.03
4 16 G 1.63
5 18 G 1.22
6 20 G 0.91
7 22 G 0.71
8 24 G 0.56
9 26 G 0.46
10 28 G 0.38
11 30 G 0.30
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POWER TOOLS
A Power tool is a tool that is actuated by an additional power source and mechanism other than the
solely manual labour used with hand tools. Power tools are used in industry, in construction, in the
garden, for housework tasks such as cooking, cleaning, and around the house for purposes of driving
(fasteners), drilling, cutting, shaping, sanding, grinding, routing, polishing, painting, heating and
more.
Power tools are classified as either stationary or portable, where portable means hand-held.
Portable power tools have obvious advantages in mobility. Stationary power tools however often
have advantages in speed and accuracy. Stationary tools are operated by main electric power and also
called Main powered (Corded) tools. Portable tools are battery operated tools and also called Battery
operated tools (Cordlesstools).
List of power tools
Power tools include:
-actuated tools
Advantages and Disadvantages of Power Tools

Advantages:
• Power tools have the advantage ofspeed
• They are more efficient than handtools
• They are veryaccurate
Disadvantages:
• Additional features like compressor etc makes them difficult tohandle
• Initial cost ismore
• Requires continuousmaintenance
Power drills:
are the power tools used to drill holes. They are used to drill holes in the walls and in the metal
plates etc. They are available in both stationary and portable types. Example: Cordless Drill
driver, Main powered impact drill etc.
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Circular saw:
consists of a disc shaped blade used to cut the metal sheets, wooden boards, wires etc. It has
features like adjustable cutting depth, a mitre and bevel facility for angled cutting and vacuum
cleaner bag or ductbag.
Reciprocating saw:
Instead of rotary motion of the blade in the circular saw, there is a reciprocating motion of the blade
in the reciprocating saw. These saws are used for rough cutting and general cutting purposes. The
blades comes in different lengths upto 300 mm
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Pneumatic Power Tools:
These tools use compressed air as the power source. Pneumatic power is easily available,
economical and easy to apply.
List of Pneumatic tools:
Air impact wrench Air ratchet
Air brush Pneumatic hacksaw
Pneumatic drill Pneumatic polisher
Pneumatic screw driver Pneumatic paint spray
Advantages and disadvantages of Pneumatic Power tools
Advantages:
• Easy tooperate
• Accurate and precise operations can beobtained
• Safe to operate than electric powertools
Disadvantages:
• Since they incorporate compressor which is heavy and bulky, it is difficult to handleit
• They create a lot of noise duringoperation
• Mistakes made using these tools are difficult to becorrected
• They require high and continuousmaintenance
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VIVA – QUESTIONS
I. FittingShop
1) What do you mean by fitting? (or) Define fitting? Give example. practical
Fitting is the process of assembling two or more metal parts together by removing excess material so
as to obtain a required fit.
Ex: - a) key andkey hole b) A Bush and ashaft
2) Name the tools, which are used infitting?
a) Work holding tools b) Marking and Measuring tools c) Finishing and cuttingtools
3) Name work holding devices used in Fitting. (or) What are the types ofvices?
a) Bench vice b) Machine vice c) leg vice d) pipe vice e) handvice
4) Name Marking and measuring tools used inFitting
a) Surface plate b) Angle plate c) Scribing block/Surface gauge d) Scriber e) Try square f) Divider g)
Center punch h) Steel rule or Scale i) caliper (Inside caliper and Outside caliper)
5) What is the purpose ofMarking?
a) To Transfer measurements and Dimensions from drawing to work piece for furtheroperations.
b) To obtain shape on work piece to the design given in thedrawing.
c) To check Dimensional suitability of raw material for a givenJob.
6) What are the tools required for Marking.(or) Name Marking tools used inFitting
a) Surface plate b) Angle plate c) “V” block d) Divider e) Scriber f) Punches g) Marking Hammer h)
Try Square i) Steel Rule j) Scribing Block or Surface gauge
7) What is meant byMeasurement?
Determining the Size of a job in terms of Standard unit is called measurement.
8) Name measuring tools used inFitting.
a) Steel rule b) Vernier Caliper c) Micrometer d) Depth gauge e) caliper (Inside caliper and Outsidecaliper)
9) Name Finishing and cutting tools used inFitting.
a) Files b) Hack saw c)Chisel
10) What is the classification
ofmaterials? Metals andNon-Metals.
Metals: A metal is a solid (Exception: Mercury) having weight. It is opaque and a good conductor of
heat and electricity.
Non-Metals: These are available in the form of liquids, gases or solids such as wood, stone, Rubber,
plastic, ceramic, concrete, asbestos etc.
11) What is the classification ofmetals?
a) Ferrous metals b) non-ferrousmetals.
12) Differentiate between the ferrous and non-ferrousmetals.
Ferrous Metals: Iron containing metals such as pig iron, cast iron, wrought iron, Mild Steel, carbon
steel, Alloy steel, Nickel steel etc., are called ferrous metals. These can be attracted by magnets and
are susceptible to rusting.
Non-Ferrous Metals: Non-Ferrous metals are those which do not contain iron.
Metals like Gold, Silver, Copper, Aluminum, Tin, Platinum, and Nickel, Bronze etc, and its alloys
are Non- Ferrous metals. These can neither rust nor can be attracted by magnets.
13) What’s the composition of CIMaterial?
CI-Cast Iron – a) Iron (91-94%), Carbon (2-4%), Silicon (0.4-2.8%), Less percentage of,
Manganese, Sulfur and phosphorous
14) What’s the composition of MS Material?
Iron (91-94%), Carbon (0.15-0.35%), Less percentage of Manganese Silicon, Sulfur and
phosphorous. One of the differences between Cast iron and steel is the amount of carbon
percentage
MS- Mild steel- may be defined as an alloy of iron and carbon (0.15-0.35%). Besides this, it also
contains Silicon, Manganese, Sulfur and Phosphorous.
Low carbon steels are also called as soft or mild steel.
These steels are used for bolts and nuts, structural work, axles, shafts etc
[Type text] Page 107

15) What is the classification of steels based on carboncontent?
Based on the carbon content, steel is divided into
a) Low Carbon Steels- The carbon content ranges from 0.03-0.35%. -Mild steel(MS)
b) Medium Carbon Stees-the carbon content a range from0.35-0.6.
c) High Carbon Steels-The carbon content ranges from0.6-1.7%
16) Name the commonly used material for preparing
fittingmodels Mild Steel(MS).
17) What is the use of Alloysteels?
In alloy steel in addition to carbon and iron, alloying elements such as chromium, Nickel etc. are
mixed. Ex: - Stainless steel, High speed steel, Tool steel (0.8 to 1.5% carbon).etc.
Alloy steels are widely used in the manufacturing of Cutting tools .
18) Name the parts of the benchvice?
a) Body with Fixed Jaw b) Movable jaw c) Jaw Plate d) Screw spindle e) Handle f) Base
19) How will you specify a benchvice?
Width of the jaws determines the size of the vice
20) Which material is used to make
thevices? Castiron
21) What do you mean by legvice?
It is used for holding work piece that has to be cut, chipped or hammered
22) What is the use of Pipevice?
It is used for holding round section parts such as pipes, tubes.
23) Why is it named asV-block?
V-block is a rectangular or square block with V-groves on one or both the sides, opposite to each
other. The angle V is usually 90 degrees.
24) What is the use ofV-block?
V-blocks are used for checking the roundness of cylindrical work pieces and for marking centers accurately.
25) What is a surface plate? Why it is
used? Surface plate:-Surface plate is a
plainsurface.
It is used for –testing the flatness of finished work piece. Providing a base support for ‘marking
gauges’ or ‘scribing block’. Testing the accuracy of Try square.
Material- Cast iron or hardened steel or granite stone.
Specification: - It is specified by length x width x height x
grade.
26) What is the use of trysquare?
It is used for 1) checking squareness or perpendicularity of work piece.2) Testing for Straightness
and 3) marking straight lines (at right angles) on work piece.
27) How will you specify a trysquare?
The Size of Try-square is specified by the length of the blade (100mm, 150mm, and 200mm).
28) Define leastcount?
A smallest measurement that can be obtained from measuring
instrument.
Or.
A smallest measurement that can be measuredbyusing measuring instrument.
29) What is the use of Verniercaliper?
It is used for measuring outside as well as inside dimensions accurately. It may also be used as a
depth gauge (to measure depth of holes).
Hence, Least count of the vernier = 1 main scale division – 1 vernier scale division.
30) What is the use ofmicrometer?
Micro meter: External micrometer is used to measure external diameters and lengths. The degree of
accuracy is high.
31) What is the use of steelrule?
It is used for measuring and marking the required dimensions on the work piece.
32) What are the types of springcalipers?

a) Outside spring caliper b) inside springcaliper
33) What is the use of outside springcaliper?
It is used for measuring the outer diameter of shafts (rods) and thickness of parts.
34) What is the use of inside springcaliper?
It is used to measure the inner diameter/dimensions of parts
35) What is the use of angle plate?

It consists of two faces machined at right angles (90 degrees) to each other. A number of slots are
cut on both the horizontal and vertical faces as shown in figure. These slots enable the work piece to
be held firmly by means of bolts and nuts. It is also used to support work piece, when you are using
the surface gauge for marking out.
36) What is the use of Dotpunch?
It is used for marking points along a line which enables to cut the work piece easily.
37) What is the point angle of
Dotpunch? 60degrees
Material- High carbon steel.
Specification-By length and
angle.
38) What is the use of centerpunch?
1) It is used for marking round indentations on metalsurfaces.
2) This provides a center for locating the sharp end of the divider point and center for holes that
are tobe drilled.
3) It is also used for marking points along a line which enables to cut the work pieceeasily.
39) What is the point angle of
Centerpunch? 90degrees
40) What is the use of numberpunch?
It is used to punch numbers (0 to9) on Metal work piece.
41) What is the use of letterpunch?
It is used to punch Alphabetic letters (A to Z) on Metal work piece.
42) What is the use of Universal Scribing block or surfacegauge?
It is used for scribing lines on work pieces and also used for checking parallel surfaces.
The Scribing block can be used to locate accurately the centers of round bars in conjunction with
the Vee- block
43) What is the use ofscriber?
It is used to scribe (or) mark lines on the metal work pieces.
44) What is the use of springdivider?
It is used for scribing (marking) circles, arcs, bisecting lines and perpendicular lines on metal
work pieces It also used for transferring dimensions from scales to objects.
45) What is the difference between divider andCaliper?
A divider is a marking device used to mark dimensions, But a caliper is a measuring device used to
measure dimensions.
46) Name finishing tools used inFitting.
a) Files b) Sand Paper
47) What is afile?
A file is a cutting tool used to remove small amount of material from the surface of the work piece
and also helps in giving a smooth surface finish
48) Name the parts of thefiles?
Tang-It is the pointed part that fits into the wooden
handle. Heel – It is end of the tang that forms a
curved edge.
Face -It is the portion of the file on which cutting teeth are
formed. Point – It is the end opposite the tang
49) Classification offiles.
Files are classified according to a) Size or length b) Shape c) Grade d) Cut

50) Name the different types of files and theiruses?
Round files are used for filing concave surface and also for enlarging round holes.
Half-round file the curved face of the half-round file is used for filing concave surfaces and the
flat face is used for filing convex surfaces.
Knife edge file is used for filing narrow slots and corners having angles less than 90 degrees
51) What are the methods offiling?
a) Cross Filing b) DrawFiling
52) Name the materials used in the manufacture
offiles? Files are made of Hardened and
TemperedSteel
53) Show me single cut file and double cutfile.
Fig. 10 (a)Singlecut file (b) Double cutfile
54) What do you mean by single cut and double cutfiles?
A single cut file has rows of teeth in one direction across the face, which is useful for filing soft
materials like Aluminium, Brass, and Bronze.
A double cut file has 2 rows of teeth cut diagonal to each other .The double cut file is useful in
removing materials at faster rate in Harder Material.
Single cut files gives better finish when compared to double cut files but at the same time removes
material at a comparatively slower rate.
55) Differentiate between rough and smoothfile?
A rough cut file has very coarse spaced teeth.It is used for rough work. It removes more
material. A smooth cut file has more closely spaced teeth.It is used to get smooth surface.
56) What is the use of flatfile?
Flat files are used for general work or finishing flat surfaces.
57) What is the cross-section of flat
file? Rectangle
58) What is the use of squarefile?
Squares files are used for filing square corners, rectangular slots, keyways, enlarging a square or a
rectangular hole etc.
59) A file removes themetalduring ---- Stroke.
Forward stroke. The file removes metal during the forward stokes. No pressure is applied on
the Return Stroke, but the file is allowed to remain on the work piece.
60) What is the cross-section of Square
file? Squarecross-section.
61) What is the use of triangularfile?
Triangular file or three-square files are used mainly for filing corners with angles less than 90 degrees.
62) How will you specify afile?
Specification- length, single cut /double cut, shape and
pitch. Example Length (say 400mm)
Single cut /Double cut
Shape (say square cross –
section) Pitch or grade (say
smooth)
63) The edge of a file that does not have teeth on it iscalleda - --.
Safe edge.
64) What is the material used to make achisel
Material - High carbon steel or tool steel having octagonal or hexagonal cross-section.

65) What are the types of hammers? What is the material used to make ahammers.
Different types of hammers are a) straight pein hammer, b) ball pein hammer, c) cross–pein
hammer. Material Cast steel or carbon steel
66) What type of hammer mostly used in
fittingoperations? Ball peinhammer
67) What is a twistdrill?
The twist drills are used for making holes.
The drills are made of HSS (high speed steel).A bench drilling machine is commonly used in workshops .
68) What is ahacksaw?
The hacksaw is used for cutting metal by hand. The hacksaw blade has a number of teeth ranging from 5
to 15 per centimeter. Hack saw blades are fitted either in a solid frame or adjustable frame to
accommodate different lengths of blade
69) Hacksaw blades having lesser number of teeth per cm are usedforcutting -- materials.
soft materials
Ex:-Aliminium.brass and Bronze.
70) Hacksaw blades having larger number of teeth per cm are usedforcutting --materials.
Hard materials like steel, C.I etc.
71) Name the materials of hacksawblade?
It is made of high speed steel. The hacksaw blades are measured by its length, width, thickness
and pitchof theteeth.
72) How hacksaw blades arespecified?
The hacksaw blades are specified by its material, length, width, thickness and pitch of the teeth.
73) What is the specification of trysquare?
Specification-the Size of Try-square is specified by the length of the blade (100mm, 150mm, and 200mm).
74) What is the use of Taps? Name the tap types in an eachset?
A tap is a hardened steel tool, used for cutting internal threads in a drilled hole. Hand taps are usually
supplied in sets of three for each diameter and thread size. Each set consists of a 1) taper tap 2)
Intermediate tap and 3) Plug or bottoming tap.
75) With what tool internal threads
arecut. Taps
76) What is the use of Dies infitting?
Dies are used for cutting external threads. They are made of tool steel or high carbon steel.
77) With what tool external threads are
cut. Dies.
78) What are the steps to be carried out in fittingjob?
1) Filing 2) Marking &Measuring c) Sawing d) Filing e)Fitting/Assembly.
79) What is the use offile-card?
It is a metal brush used for cleaning the files.
80) What is the use of Flatchisel?
Chisels are used for removing surplus metal from the work piece. They can be used as a substitute
when files and hacksaw blades are impossible to use.
Specification- Length and width of the edge.
The process of removing metal using a chisel is called ‘chipping ‘.
81) Name some of machinetools.
1) Lathe Machine 2) drilling Machine 3) Milling Machine 4) Grinding Machine.
82) Differentiate between a tool and aninstrument?
The device used for measuring and inspection is called instruments ex:-Calipers, micrometers,
Gauges etc. The devices used for making the models are calledTools.
Ex:-Scribers, Punches, Files, Saws, Chiles, Hammersetc.
83) What are the operations carried out in a FittingShop?
1) Filing2) Marking &measuring 3) Sawing 4) Chipping5) Drilling 6) Threading 7) Fitting
84) Identify the spring in the inside and outsidecaliper?

85) What is the least count of your scale?
Yourwatch? Least count for normal Scale
is1mm.
Least count for normal Watch is 1Minute.
86) What is a wing-nut? Identify it in the
hacksawFrame. It helps to hold the blade firmly
inposition.
87) are designed on the principle of ‘Screw andNut’.
Micrometer.
88) instrument used for Measuring outer and inner dimensions and depth ofholes?
Vernier Caliper.
89) file is also known as Rat-Tailfile?
Round File.
90) What is the use of Vernier HeightGauge?
Vernier height gauges are particularly suitable for marking off accurate distances and center
locations. It is also used in inspection of work pieces.
91) What is a depthgauge?
It is used for measuring Depth of holes.
92) How do you specify
aHammer? Weight ofHammer
WELDING SHOP
1) Define Fabricatingprocess.
Joining two or more elements to make a single part termed as a Fabrication process. Example: -
aircraft and ship bodies, building trusses, welded machine frames, sheet metal parts etc.
2) Classify Fabrication processes according to Method
ofJoining Mechanical Joining by means of bolts screws
andrivets.
Adhesive joining by employing synthetic glues such as epoxy resins.
Metallurgical fusion process like Welding, Soldering and Brazing
3) Classify Fabrication processes according to according to Type ofassembly
1) Temporary joiningprocess
2) Permanent. Joiningprocess
4) Define Temporary joining process and giveExample.
Temporary joining process: - The joints obtained by these processes will be separated easily with
out any damage to the connected parts. Example: - Joints obtained by brazing, soldering, bolts and
nuts. Studs and nuts, screws etc
5) Define Permanent Joining process and giveExample.
Permanent Joining process: - . The joints obtained by these processes will be such that the
connected parts have to be broken in order to separate them. Example: - Joints obtained by
riveting, welding etc
6) What iswelding?
Welding is the process of joining similar metals by application of heat, with or without
application of pressure or filler material.
7) Name applications of weldingprocess.
It is used in the manufacture of automobile bodies, aircraft frames, railway wagons, machine
frames, structural works, pressure vessels, furnaces, tanks, refrigerators, furniture, boilers, and
shipbuilding. Repair and maintenance work. Example joining broken parts, rebuilding worn
out components etc.
8) Classification of welding. Or. Mention different types of weldingprocess.
1) Plastic welding 2) Fusionwelding
9) Is welding a permanent or temporary fastening

method. Permanent fasteningmethod.
10) Which welding process is most commonly used
atpresent? Arcwelding
11) Name the different types of weldingjoints.
a) Butt joint b) Lap joint c) Corner joint d) T-joint
12) Define pressure welding or plastic
welding. Name some pressure
weldingprocess.
In plastic welding, the metal parts to be joined are heated to the plastic state (or above) and then fused
together by applying external pressure. No filler metal is used in this process. Plastic welding is also
called ‘pressure welding processes.
Example: -Forge welding, resistance welding.
13) Define fusion welding, name some fusion weldingprocess.
In fusion welding process, the parts to be joined are heated above their melting temperature and
then allowed to solidify without application of pressure. A filler material is used during welding
process.
Example: - arc welding and gas welding
14) Differentiate between gas welding and arcwelding.
In gas welding process combustion of oxy-acetylene (oxygen-hydrogen) gases in different
proportions is used for heating the work pieces. In gas welding filler rod is used for joining work
pieces.
In case of Arc welding Electrical Arc (AC OR DC) is used for heating the work pieces. In arc
welding electrode is used for joining work pieces.
15) Why it is called arcwelding?
Electrical arc used for (heating) melting of base metals.
16) List the different types of arc weldingprocess?
1) Carbon arc welding 2) Metal arc welding 3) Metal inert gas welding4) Tungsten inert gas
welding 5) Plasma arc welding6) Submerged arc welding
17) Name some of the sources available for heating in arc-welding process.
1) Transformer(A.C)
2) Motor Generator(D.C)
3) Rectifiers (converts AC intoDC).
18) What is the minimum Arc-gap should be maintained between electrode and work piece for
existenceof arc.
2mm to 4mm.
19) Draw an A.C arc-welding circuit. (OR) Name the components used in weldingac-circuit
Fig.12 AC circuit for arc welding

20) The amount of current required for arc welding
circuit. 50 to 500Appears
21) The amount of voltage required for arc
weldingcircuit. 20Volts – 40Volts

Fig.13 DC Circuit for arc welding
22) What is DCSP? OR DCEN-Direct current ElectrodeNegative.
Direct current straight polarity. In this case work piece is connected to the positive terminal of the
welding Machine. Electrode holder is connected to the negative terminal of the welding machine.
DCSP gives greater depth of penetration, more heat at job, used for weld thicker plates.
Or – Electrode is cathode, work piece is cathode.
23) How many number cables required in arc-welding
process. Three cables are required inarc-welding.
1) Cable for connecting Main supply toTransformer.
2) Cable for connecting Transformer to electrodeHolder.
3) Cable for connecting Transformer to work piece Table (forFarthing).
28) Amount of arc length required between electrode workpieces.
The distance through the center of the arc from the lip of electrode to the bottom of arc crater is
termed as arc length. It ranges from 3mm to 4mm.
29) What isoxidation?
Metals in molten condition absorb oxygen from atmosphere and form metallic oxides. This process
is known as oxidation. The formation of metallic oxides must be prevented. To prevent oxidation,
we use coated electrodes.
30) Mention the current requirements for thin and
thickmaterials. 20-200 amperes for thinmaterials
20-300 amperes for general work
300 -600amperes for heavy work (thick materials).
31) What is anelectrode?
A welding electrode is defined as a component of the welding circuit through which current is conducted.
OR.
Electrode forms one pole of the electric circuit, while work piece forms the
other pole. Electrode is used in Arc welding process.
32) What is Fillerrod?
Filler metal supplies additional material to fill the gap between work pieces. Material of the filler
rod is same as the base metal. Filler rod is used in gas welding process.
33) What is the difference between electrode and fillermetal.
Electrode forms one pole of the electric circuit, while work piece forms the other
pole. Filler metal supplies additional material to fill the gap between work pieces.
In case of arc welding process, the filler metal apart from supplying additional metal also acts as an
electrode by forming a component of the electric circuit.
34) Name parts of electrode.
Fig.14 Cross-section Welding Electrode

35) specify a welding electrode, you haveused.
Electrodes are specified by its diameter (diameter of core wire) and
length. The size of the electrode is measured in Standard wire gauge
(SWG).
36) Classification ofelectrodes.
1) Consumableelectrodes
a) Coated electrodes b) plain/bareelectrodes
2) Non-consumableelectrodes
37) What are the sizes ofelectrodes?
Core wire diameter-3.15, 4.0, 5.0, 6.3,10 mm and 12.5 mm.
Core wire length-350mm and 450
mm as per Indian standard.
38) Differentiate between consumable electrode and non-consumableelectrode.
Consumable electrode-These are made of metallic wire and are consumed during the welding process.
Non-consumable electrode- Non-consumable Electrodes are made of carbon, graphite or tungsten
that does not get consumed during welding.
39) Why electrodes are not coatedfully.
One end of the electrode is left bare (uncoated with flux) which is usually held in the electrode holder.
The uncoated part helps in transmitting full current from the electrode holder to the front end of the
electrode coating. The flux coating acts as an insulator ofelectricity.Hence, electrodes are not coated
fully.
40) What are the functions of flux on flux coatedelectrode?
prevents oxidation of molten metal helps in the removal of oxides and other undesirable substances
present on the surface of the work piece
Chemically reacts with the oxides and forms a slag. The slag floats and covers the top portion of the
molten metal thereby preventing it from rapid cooling.
To stabilize the arc
To avoid difficulties in welding.
41) Name the material of core wire ofelectrode.
Material of the core wire is same as the work pieces to be welded.
42) What is the material of flux used in theelectrode?
Titanium oxide, cellulose, manganese oxide, calcium carbonates, mica, iron oxide etc. are
used as flux materials for coating.
43) What is a flux? Why is itused?
A flux is a “material used to prevent, dissolve, or facilitate removal of oxides and other undesirable
surface substances”.
prevents oxidation of molten metal
44) What are the defects that will result if flux is not used inwelding?
a) Reduce the Strength of thejoint.
b) Oxidation of molten metal will takeplace.
45) Define basemetal.
The metal to be joined or cut is termed as the base metal.
46) What is the use of chippinghammer?
A chipping hammer is used for removing the slag formed on the weld bead
47) What is the use of electrodeholder?
It is used to hold the electrode during welding
48) What is the use of wirebrush?
The wire brush usually made up of steel wire is used for cleaning the work piece before and after welding.
49) What is the use oftong?
A tong is used for holding the work piece during/after welding
50) What is the use of ground clamp?
Ground clamp is connected to the end of the ‘ground cable’. Ground clamp is used to connect work
table. Ground cable forms one pole of A.C.

51) What is the use ofgoggles?
Goggles are used to protect the eyes of the welder from the rays of the arc and flying particles of hot
metal.
52) What is the use of handshields?
Hand shields and helmet type shields are used to protect the eyes and also the face of the welder
53) What is the use ofc-clamp?
The C-Clamp shown in fig is used for holding the job firmly on the work table during welding.
54) Mention the welding flame conditions in gas welding? .Or. Name the types oxy-acetyleneflames
a) Neutral flame b) oxidizingflame
c) Carburizing flame
55) Define neutralflame.
Neutral flame (Oxygen and Acetylene are mixed in equal proportions)
A neutral flame is produced when approximately equal volumes of oxygen and acetylene
are burnt at the torch tip (I has a balance of fuel gas and oxygen). The flame has a nicely
defined inner whitish cone surrounded by sharp blue flame. The temperature of the neutral
flame is around 32000C. Used for welding steels, aluminium, copper and cast iron etc and
can also be used for metal cutting
56) Define oxidizing
flame. Oxidizing flame
(Excess ofOxygen)
If more oxygen is added to the Neutral flame, the cone becomes darker and more pointed,
while theenvelope becomes shorter and fiercer is called Oxidizing flame. Has the highest
temperature about 34000C.Used for welding brass and brazingoperation
57) Define reducing flame or
carburizingflame. Carburizing
flame (Excess ofAcetylene):-
If the volume of oxygen supplied to the Neutral flame is reduced, the resulting flame will
be a Carburizing or reducing flame i.e., rich in acetylene. A reducing flame can be
recognized acetylene feather that exists between the inner cone and the outer envelope.
Has the highest temperature about 30000C .The outer flame envelope is longer than that of
the neutral flame and is usually much brighter in colour . This type of flame is used for
welding non- ferrous metals.
58) Differentiate between welding and
soldering andbrazing. Welding is used for
joining similar metalsonly
Soldering and brazing is used for joining similar or dissimilar metals.
In welding filler Material used is made of same material as that of the base
metal (work piece). In soldering and brazing filler material used is
Not the same as that of the base metal.
Strength of welding joint is stronger than base metal.
(Strength of welding joint is more compared to soldering
and brazing). Strength of brazing joint is more compared to
soldering joint.
In case of welding base metal is heated above their melting temperature (High
temperature process). In case of soldering base metals are not melted (low
temperature process).
In case of brazing base metals are not melted but broadly heated to a suitable
temperature. Surface finish of welding joints not good (It requires finishing
operations like grinding, filing etc) Surface finish of soldering and brazing
joints is good.
59) Define soldering? Name solderingmaterial.
Soldering is a method of joining similar or dissimilar metals by means of filler metal

whose melting temperature is below 450 0C. The filler metal usually called ‘solder’ is
an alloy of tin and lead in various proportions.
Soldering is commonly used for joining circuits in electronic components. In sheet metal
work and in sealing of metal container.
60) Define brazing? Name brazingmaterial
Brazing is a method of joining similar or dissimilar metals by means of a filler metal whose
melting temperature is above 450 0C, but below the melting point of the base metal.
The filler metal called ‘spelter’ is a non –ferrous metal or alloy. Copper and copper alloys
Silver and silver alloys and aluminum alloys are the most commonly used filler
metals for brazing. This process is used in fastening of pipe fittings, tanks, radiators,
heat exchanger.
61) Define weldbead?
It is the metal added during a single pass of welding. The bead appears as a separate material from
the base metal.
62) What is filletweld?
The metal fused into the corner of a joint made of two pieces placed approximately at 90
degrees to each other is termed as fillet weld.
63) What isSWG?
SWG-Standard wire gauge.
64) What is an electric arc and how is this arc struck? (Or) What is the working principle of
Arcwelding?
The source of heat for arc welding process is an ‘electric arc ‘.The arc is produced by
striking the electrode on the work piece. The electrode is momentarily separated from the
work piece by a small gap such that the arc is still maintained between the work piece and
the electrode .The electrical energy is thus converted into heat energy. The high heat at the
tip of the electrode is sufficient to melt the work piece. The tip of the electrode melts and
combines with the molten metal of the work piece there by forming a homogeneous joint.
65) Is gas welding slower than electric arcwelding?
Yes, Gas welding is Slow process compared to Arc welding.
66) The movement of welding rod for better
bead is known as – Weavi
67) What is Autogeneous Welding & HeterogeneousWelding?
AutogeneousWelding:-It is the Process of Joining two similar metal pieces with or Without
Filler material. Heterogeneous Welding”:- It is the Process of Joining two dissimilar metal
pieces with Filler material ex. Friction welding.
68) What is the thickness of Sheet used in
Sheet metalWork? Up to 3 mmThickness.
69) In arc Welding, Electric arc is produced between the work piece and theElectrodeby - ?
Contact Resistance.
70) How you can stop the arc between electrode workpieces
Increase the gap between work piece and Electrode.(More than 3mm)
71) What is resistancewelding?
Where heat to form the weld is generated by the resistance of the welding current through the work
pieces.
72) Mention some of the resistance weldingmethods?
Ex: - Resistance Spot Welding (RSW), Resistance Seam Welding (RSEW), and
Projection Welding (PW) are commonly used resistance welding processes.
73) Name some of weldingdefects?
a) Porosity b) undercut c) spatter d) In complete Fusion e) Under fill f) Incomplete
Penetration and Excessive Penetration.
74) Define Edgepreparation?
The contour prepared on the edge of a joint member for welding.
75) Define weldMetal?
The Portion of the Base metal that has been melted during welding.
76) Define depositedMetal?
Filler material that has been added during a welding operation.
77) The oxygen cylinder is usually painted
with – colour. Black.
78) The Acetylene cylinder is usually painted
with – colour. Maroon.
79) Define blowholes?
A weld cavity caused by the Trapping of gases released by the metal when cooling.
80) Why edge preparation required before welding To get proper welding Joint (sound Weldingjoint).

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REVA UNIVERSITY

WORKSHOP PRACTICE LAB MANUAL

For I Semester B.Tech Students

SCHOOL OF MECHANICAL ENGINEERING

School of Mechanical Engineering

This is to certify that Ms./Mr.....................................................................................

Signature of the faculty in-charge

Date: Director of School

School of Mechanical Engineering

School of Mechanical Engineering Page 3

Program Educational Objectives (PEOs)

Program Outcomes (POs)

School of Mechanical Engineering Page 4

Programme Specific Outcomes (PSOs)

School of Mechanical Engineering Page 5

School of Mechanical Engineering Page 6

Sl.No Experiments Page No.

11 Welding Introduction& Tools 76-87

School of Mechanical Engineering Page 7

The scraps and chips should be dropped in waste bins.

3. Concentrate on your job and avoid talking withco-workers.

5. Understand the use of tools and machines beforehandling.

7. In case you are in doubt contact theinstructor.

8. Always chuck the fitting of the handle in the hammerhead.

emergency one should reach themquickly.

School of Mechanical Engineering Page 8

Professional activities of an engineer:

1. Planning: (Proposal of doingsomething)

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2- STROKE Engine dismantle and assembly

Fig. 1 Lubrication system diagram

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➢ Removing the oil pump

Fig. 2 Removing the oil pump

➢ Clean the oil pump and Crank case before operation.

a. Remove the luggage.

b. Remove the input/output oil pipe.

➢ Remove oil pump and check:

a. O-ring is distorted or not.

b. Contact area of crankcase is injured or not

c. Oil pump body is damaged or not

d. The gears are damaged or not.

e. Check seal and see if there is oil leakage or not

f. Never dismantle oil pump, itcannot function well after dismantling

a. Assemble the oil pump by reversing above procedure.

b. Be sure oil pump screw is tightened.

School of Mechanical Engineering Page 11

Fig. 3 Releasing air in the oil pump.

Fig.4 Schematic showing Engine dismantling

e. Remove the engine.

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2. CVT parts measurement data

Fig. 5 Showing left cover

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Fig. 6 Showing left cover and 10 screws

3.Remove the fixing nut of the clutch.

Fig. 7 Removing of fixing nut of clutch

Fig. 8 Showing ramp plate

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Fig. 9 Removing of idle gear

8. Take off the idle gear.

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1.Dismantle the left crankcase cover

Locking torque: M10: