NAME OF THE JOB . | SAFETY PRACTICE 02. | FITTING SHOP 24 |Job-01 STUD AND A SQUARE NUT 2.2 | Job-—02 DIVIDER 23 | Job-03 PAPER WEIGHT 03. |SHEET METAL 3.1 | Job-04 TAPER TRAY 3.2 | Job-05 FUNNEL 04. | WELDING SHOP 44 | Job-08 SQUARE BUTT JOINT 42 | Job-07 LAP FILLET JOINT IN FLAT POSITION 05. |TURNING SHOP 5.1 | Job - 08 JOB OPERATION BY S.S AND S.C. LATHE CNC MILLING & LATHE MACHINE Assignment Mark :————-— Sessional Mark Final Viva Marks TOTAL MARKS 01-03 04-19 20-22 23-25 26-28 29-30 31-33 34-36 37-39 40-42 43-45 46-49 50-52 53-55 DATEOF | GRADE/| SIGN. OF | REMqz,, EXPERIMENT | MARK | SUBJECT PERFORMED LECTURER = a Signature of the H.0.D./Lect Of the Departmentsomehow be involved in an “accident” or “injury’ here danger i Y art shop depends on the hazard and risk involved with machi that an injury will occur. eae The causes of injury are varied, but they involve the following facto} va. b. “Fem pan 4 National Standards Institute, Safety im the workplaces such as : INTRODUCTION : a wane respect for the equipment being used ni Fe res0o9 he. ine or industrial or consumer prod i Safety” is a judgement of the inati and risk. Thus, the safety o is the combination of hazard Pe toh Horeca ifs generally recognized that there is no ma ws such a Having part of the body caught in or between machine components. Being struck by an object. Falling from equipment, structures, or ladders. Slipping or tipping on floor surfaces. Explosions and fire. Exposure to high voltage electrical wiring and switch box. Burns with or exposure to temperture extremes. Exposure to or injection of toxic, chemicals, Excessive physical strain. “ Sl Protection of eyes from metal chips. % In United States, various safety and health standards have been promulgated b' iterature is available from the National Safety Ca ie Created the folloiwng hierarchy for treat Safety professionals and organizatio Reduce the danger to a reasonable level through design. Apply safeguarding technology. Use warning signs and label, Train and instruct the workers. Prescribe personal protective Safety equipment (grooves, goggles, apron, shoes etc.) _ All workshops and work-areas are : i Places of some risks, but a health: : n : regard for the reduces the risk of an accident considerably. Sollowing are the golden rules of safe work-practices such as « If you open it, close it, If you turn it ‘ON’, turn it ‘OFF’. If you unlock it, lock it, If you break it, repair it If you can’t fix it, call in some one who can, If you make a mess, clean it up. If you move it, put it back. If it doesn’t concern you, leave it alone.i Provision of proper fencing around dan, : \gerous/ hazardous activity centre Devices : i i. Pull-back mechanism for the operator's hands wi, Deadman Controls — A system in which the power is automatically shut off in the event of ‘operator becoming senseless or collapsed. __ iti, Presence of sensing devices. ‘Safety During Maintenance of Machinery : > Normally, safety devices are temporarily removed during maintenance. It's the Employer! _ Manager's responsibility to ensure. The maintenance personnel are competent to interact with the types of hazards expected and supposed to perform the maintenance in a safe manner. The Maintenance staff should be familiar with safety practices related to their activities. Warnings : Sign Post, signals and instruction charts warn the worker about sudden hazards, danger control methods, or non-obvious consequences. The format, size, colour of warnings have been prescribed by Industry Standards and ISI codes. Personal Prtoective Equipment : Goggles, face-shields, earplugs, helmets, resit _ protective equipment that reduce worker's exposul ‘SAFETY IN WORKSHOP : < “ The first duty of the Manager or Instructor in a 40 brief a student or worker about various safety features and make them aware of various safety precautions to be observed while working on a particular machine/ machine tool. They should be sufficienctly briefed about causes/ sources of injury or accidents and how to guard against them _ Some of the Common Sources of Accident in Workshop are as Following : a. Revolving parts like shafts, spindles, tools etc. b. Projecting sharp edges of belt/ chain/ pulley joints/ fasteners etc. ¢. Revolving paris like gears, rollers, friction wheels, drum, crushers etc. - d. Contineously rotating parts like fans, open-arm pulleys, gear trains etc. e. Converyors and mixers. f. Grinding wheels and stones. _ g. Reciprocating parts/ tools. h. Intermittent feed mechanism. i. Moving cranes/ trolleys/ welding machines. |. Bare cables, joints, swtiches, switchboard etc. (COMMON METHODS OF PROTECTION IN A WORKSHOP : Some Common Methods of Protection in a Workshop are Discussed Given Below : By Design : When a new machine is designed, suitable housing should be designed as safety guards. For Example : i. Belt Drive/motor in a lathe or milling machine are enclosed in a housing. ji, _Allcontrol panels/handles should be carefully located to ensure adequate safety. HO2NFITTING SHOP | ents may be prodcued by working on metal either on a machine tool or on the bench. it becomes necessary to replace or repair a component which must fit accurately with ‘component on re-assembly. This involves a certain amount of hand fitting.\The assembly of ine tools, jigs, gauges, ete. inviolves a certain amount of bench work. The accuracy of work done upon the experience and skill of the fitter{Metal removal at the bench requires the use of a ‘of simple hand tools and considerable mantal effort. Working on components with hand tools u Mostly on work benches is generally refered to as, ‘Fitting Work’ JThe hand operations ‘work consist of filing, chipping, scraping, sawing, drilling, tapping, grinding etc. S AND EQUIPMENT REQUIRED IN THE FITTING SHOP : the bench work and fitting require the use of a number of simple hand tools.» and Measuring Tools : en dimensions are given in drawing without any indication about the tolerance, it has to be that measurement are to be made with a Steel Rule, which is used for measurement of Itis usually graduated in millimeter and inches: It's least count is 0.5 mm or 1/64 of an inch |Rulles are made of spring steel or stainless steel. The surface of the steel rule is stain — chrome d to reduced glare and to prevent rusting, a with a Steel Rule : LENGTH TO BE "The given figure indicates the method of using a try ne ‘square and a steel rule for accurate measurements. It is to read vertically and avoied errors arising out _ of parallax for accurate readings. The steel rule are accurately engraved, with line thickness ranging from 0.12 to 0.18 mm. ‘PRECAUTIONS { 2. For maintaining the accuracy of a steel rule, it is important that to see it that its edges and surfaces are protected from damage and rust. b. Do not place a steel rule with any cutting tools. c Apply a thin layer of oil when not in use. el tool used to scribe or mark lines. It is made of steel or high carbon | wire of 3 mm to 5 mm, whose one end is straight and the other is bent at about 90° Angle. Its h varies from 150 mm to 300 mm. Both its ends are pointed. There are Five types of Scribers 0 ee. Improved, Adjustable Sleeve, Pocket and Knok Scriber. a Pacarater are ue be handled very carefully! rk on the point when not in use to prevent accidents.me i ut perm: Punch is a marking too! used in order to make certain dimensional features of the layot Basically, there are two types of punches such as : Dot and Centre Punch. Centre Punch : Centre Punch as made of high carbon steel. The angle of the point is 90° in a centre punch and the . a punch mark made by this is wide and not very deep, which is particularly used for locating 4 eS. Is length is from 35 mm to 125 mm. and its wide is from 4 to 12 mm. If this centre is not made bj ‘the centre punch, then there are chances of slipping of the point and drilling at a wrong point, whi shown as the given figure. Bot Punch : Dot punch is used in order to lightly indent along the layout lines to locate centre of holes and to provide a small DOT PUNCH centre mark for divider point etc. The ee ae ae main difference is that its point is at 60°Angle. Its length is from 80 mm to 100 mm. and its thick’ from 3 mm to 5 mm/ which is shown as given figure. There are also different types of punches available such 2s : Solid, Hallow, Pin, Bell, Prick and Automatic Punch. ARECAUTIONS : =) (CENTRE PUNCH @ Donotuse an ordinary punch ona hard metal, b. Use a punch after seeing its angle. 3 & Ifthe point of the punch is damaged, then itshould be repaired and the G. Selection of punch should be made according to the make-up of the job or metal punch should be ARY SQUARE : ‘Try Square is used for measuring right angle ofa job and for checking | 216 used in engineering field can be divided into Three parts such as » Solid, Adjustable and Diemakers try square. The accuracy of measurement by try square is about 0.002 mm per 10 mm length which is accurate enough for most workshop purposes. anne PRECAUTIONS : . fe shoul a, eee ne ute try square as a hammer ive. we should not use it to hit any job otherwis. b. Try square should be kept away from cutting tools, c. It should be cleaned properly before use, d. After making its use, it should be kept after applying grease. IRFACE PLATE : Surface Plate is used for marking purpose. The the surface plate and marked with the help of made of cast iron. It is usually rectangular in s} Job is placed over! bhevel protractor. 1 is shape.IS: marking or measuring a job, its Surface should be properly cleaned with a soft paper. le using it, it should not be hit as there are chances of damage to its surface. ‘order to make the marking of the job permanent it should not be used as a table. Cutting tool should never be used on it. . i ___ Angle Plate is placed over the surface plate for supporting ps at the time of marking. It is made of cast iron. The angle _ plate is built at 90° Angle which has rectangular grooves. Both ‘of heavy jobs, nut bolts are fitted in its grooves and marking is done. Angle plate is of two types such as : Fixed angle and Adjustable angle plate. S: a. Angle plate should be carefully handled and maintained. b. Any nicks or scratches can spoil the accuracy of the angle plates. © Inorder to make the marking of the job permanent it should not be used as a table. CALIPER : “The caliper whose leg bent toward the centre is called Outside CaliperjIt is used to measure the outside diameter of a cylinder, bar etc. It is also used for transfer dimension one place to another place by the help of steel rule. ‘Knob Spring : ; a. Adjusting Adjusting CE Sat ~The Caliper whose leg forward to the centre is called inside caliper. Its used to measure inside eter of a hole, bore, slot etc, It is also used for transfer dimension one place to anather place by p of steel rule. instrument, which is used to measure length, bredth and thickness of a job. is used for testing the levels of flat surface. testing Rs eg oa and flatness of plane surfaces. SEAT Pic. circles, arcs, laying out perpendicular lines, bisecting lines etc. SevenCOMBINATION SET : Combination Set is a very useful instrument having a , combination of five different instruments in one. A combination set consists of a rule, square head, centre head and a protractor. This may be used as a rule, a square, a depth gauge for marking degrees (45°) and for the measruing and marking angles. ser ER CALIPER : ‘ Vernier Caliper is a precision measuring instrument used for measurement of outside dia: insitie diameter and depth. The least count of vernier caliper is 0.001 inch and 0.02 mm. Vernic caliper is made by assembling several different parts as shown in the given figure. ® Depth Scale (/ METHOD OF TAKING READING : \ (a. Write that part of the scale which contains inch signs and which is on the left hand side of 0, on the vernier scale. . b. Look at the divisions of central distance. How’fany of them are on the left hand side of 0 of the vernier ? Their value is 0.1 and 0.2 inch. respectively. ©. Write the small parts of the main scale. Their value is 0.025, 4. Write down the part of the vernier scale which corresponds with the main scale after careful watching it. The sum total ofall the four items writen above is reading of the vernier caliper. TIONS : a Itis necessary that there is no play in its beam and movable jaw and it could be easily. b, After long use, the jaw-edges wear out. In such cases, it -—= — should be regrinded, c. A job fixed on a machine in operation should not be measured with it. d. Is should always be kept away from the cutting tools. e. Itis difficult to see the part of scale. Therefore, itis advisable to use a magnifying glass. Afier using it, we should clean it with thinner and keep it | Me in the case., IRNIER HEIGHT GAUGE : Vernier Height Gauge is similar to vernier calipers and used ean purpose by the help of ‘surface plate and angle plate. It consists of scriber by which lines are scribed on the job. In vernier height gauge, slide base remains joint with the beam permanently as shown in the figure. UT‘PRECAUTIONS : , Itshould always be used on the plain surface of the job. While marking, excessive Pressure should not be exerted on its scriber. f a be used on a surface plate only. a Atshould be used only for precision marking or measurement, __ reading should be noted down. ae Main IETER : 4 Seale Thimble Ratchet | in st | { Micrometer is a measuring instrument used for) “7” “4"""__ | Z easuring external, internal and depth dimensions ccurately. They are available in different ranges. Itis made | onthe basis of nut and screw bolt. The different parts of the | micrometer are given in the figure. There are Three types of | micrometer such as : Outside, Inside and Depth Micrometer. CAUTIONS : ____ MICRO METER &. Before using it, it should be properly cleaned with a soft cloth. 6. Before use, it should be ensured that it is faultless. _ It should not be used on machines in operation or on rough surface. Before measuring, job should be properly cleaned. x For setting it Ratchet Stop should be used. After measuring, it should be locked and then reading should be taken While keeping it, anvil and spindle should be It should be saved from water. DIFFERENCE BETWEEN CALIPER AND MICROMETER VERNIER CALIPER MICROMETER zemeae . Its range varies from 0 to 48 inch or 0 to | a. Its range is limited from 0 to 1 inch or 0 to 1200 mm. 25 mm. For measurement beyond this we require other micrometers. . With this we can measure both the external and internal jobs. . We can take measurement in inches and . Different micrometers are required for mm simultaneously. measurement in inch and mm. |. It is easy to make and also costs less. Itis difficult to make and it costs more. .. Measurement taken by Vernier caliper is not Its measurement is considered exact considered very exact because its touch is because appropriateness of touch is not always equal. Controlled by ratchet stop. Experiences required totake measurement | +." jtis easy to measure with the micrometer. with this caliper. |g. Its least count is 0.02 mm. } Its least count is 0.01 mm. ‘CUTTING AND FINISHING TOOLS : CHISEL: Chisel is a single point cutting tool. tis used for removing surplus metal or for cutting sheets. The tools are made from 0.9% to 1.0% carbon steel of octagonal or hexagonal section. Chisel is used to cut flat round or angle iron and 1/8 inch fitness of metal sheet, it also used to removed for unwanted metal from the surface of a job by cutting it in bits and smalll pieces, this act is known as chipping, cutting 1 WBN Different micrometers are needed for taking measurements.done by chisel is rough, therefore chisel are used to both hot and cold metal. The different types of chisels are available as shown in the figure as follows : A InLineAsphalt Cutter B. NailPoint C. Cross-CutAsphaltChisel D. In-Line Chisel E BuntToo! F Tamping Pad G Cross CutChisel H. Moil (Conical) Point 1 Cross-CutWide Chisel J. Inne AsphaltChisel METHOD OF USING CHISEL : a rn marking should be done on the metal to cut. b. Always hold the chisel properly with your left hand and the hammer in your right hand. ©. Set the chisel properly on the marked line then strike the hammer on its head. Before striking the second blow on the chisel, it should be set again. &. While cutting with a chisel we should conentrate on its cutting edge. ©. Strike the hammer blow at the centre of the head of chisel. METHOD OF CHIPPING : @. Select the chisel with appropriate cutting angle according to the metal. b. _Ifjobis:smallin size and it has to be heldina vie we should use a wooden block under the job ©. While chipping we should stand to thé left of vice\and near the bench. ¢. We should hold handle of the hammer from its end, aise it up to the height of our neck and then strike a blow. =| ©. Chisel should be inclined towards the user at an angle of 40°, while chipping. f. Ata time we should not chip any metal more thar’2 or 3 mm. Otherwise the edge of chisel may be demaged. g. If the surface to be chipped is broad, before using a cross cut chisel, we should make a groove on the job by making a cut. h. Only a flat chisel should be used for chipping. While chipping after hitting the chisel with a hammer three four times, we should withdraw for a while and then chipping. While chipping a job held in vice we should strike the hammer blow in the direction of its stationary jaw. PRECAUTIONS : a. At the time of chipping we must always use safety goggles. b. Keep your face towards the wall, while chipping. c. If someone is working in your front, you should fix chipping guard at the rear of vice so that i chips do not hit him. ; d. While chipping we should keep on applying grease on the edge of the chisel, HACKSAW = Hacksaw is a multi-point cutting tool. It is used for cutting }~/ metal by hand with a frame which holds a thin blade, finally in ition, The blade has a number of cutting teeth. The number of teeth per inch is selected on the bit of types of job. Hacksaw is a hand cutting tool, inorder to cut metal rods, pipes, plates or sheet of varied thickness. It can be operated by hand or by power. “on‘Mainly, itconsists of two parts such as : Frame and Blade. [tis available at 300 mm of length of blade. jis two types of Hacksaw such as : Fixed and Adjustable Hacksaw, OF USING HACKSAW : ‘Selection of hacksaw blade should be done according to the metal for which itis to be used i ere tec onthe frame it should be ensured that its teeth should cut the metal when they Job should be held in the vice in such a way that its cutting lines are clearly visible | Before starting a cut with hacksaw blade, blade should be kept on the marking line, the left hand © thumb should be placed withits support. ° eae You should stand on the left hand of the vice and keep your right foot backward and the left foot 2 little ahead of the right. bg -& The speed of operating hacksaw should be 40 to 50 strokes per minute. 4% Pressure should be exerted on forward stroke and it should be withdrawn on backward stroke. PRECAUTIONS : Hackasw blade should be fitted on the frame very carefully. Ttshould be neither be very tight nor very loose. The job which is to be cut should not be held in a vice much high otherwise there would be vibrations in it. Hacksaw blade should not be allowed to become slanting while using a hacksaw. If it becomes slanting, there are chances that it may break. Ifa blade get broken while working, then we should replace it with a new blade. If necessary, water should be used as a coolant. After using a hacksaw either its blade should be taken out or it must be made lose. SCRAPER : : - ‘Scraper is a cutting hand tool, which is used to remove the high spots left after machining has been done on a job. Scrapers may be fiat, triangular and half-round. The | material is a good quality forged steel and cutting edge is usually left very — $$$ $$$ — hard. Scrapers are made in a variety of lengths from 100 mm onwards and in many shapes. Scrapers ‘are used whose length is 100 mm to 250 mm and there thickness varies from 1 mm to 3.5 mm. METHOD OF USING HACKSAW : ’@. We should have our right hand on its handle and left hand on its body. 'b. While using a scraper it should be bent at about 30° angle. ‘¢. We should not keep a stroke of the scraper tool long. d. After scraping once, scraper should be driven at right angle. ‘Scraping should be considered accurate only when the colour of paste start appearing on the entire surface. PRECAUTIONS : a. ee ear fe erentement i he foh should have proper edge. Gant should be free from any ees tote. while scraping, Scraper should not be used without ‘ Scraper should be kept separate from other tools. After scraping surface should be properly cleaned, WA0N ere a sepTAPS AND TAP WRENCHES : ae a bam « | ere r ‘SECOND TAP : SECOND TAP | | THIRD TAP FIRST SECOND THIRD | TAP TAP TAP THIRD TAP LLL) Atap isa thread cutting tool, which is used for cutting internal threads in @drilled hole. Hand tap: are usually supplied in sets of three for each diameter and thread size. Each set consists of a taper tap intermediate tap and plug or bottoming tap. Taps are made of high carbon steel (HCS), high speed steel (HSS) and Aloy steel. The upper portion is square and four flutes are made on the entire partir which threads are formed. Taps is of three types such as : First, Second and Third taps. TAP WRENCH : Tap wrench is a tap holding device, which is used to hold the tap strongly and tightly. There are Three types of tap wrenche such as : T-type, Fixed and Adjustal METHOD OF CUTTING THREADS WITH TAP :/ . Bore a tap drill hole of appropriate size for the tap. \ a. ta \ Z| b. Chamfer or file the drill at the tap. a) ¢. Hold the job firmly in vice etc. ‘ j d. First of all, use the taper tap for cutting threads. i B @. After moving two or three threads ensure through the try square that tap is movig straight f. Tapping should be done by moving the tap forward and backward. g. Adequate lubricant should be used while tapping. h. After moving the taper tap, intermediate and finishing tap should be moved. i. While cutting threads in blind hole in between tap should be taken out to clean the metal particles. PRECAUTIONS : Tap drill hole of appropriate size is essential before tapping. Use tap handle according to the tap. Tap should be moved forward and backwards and we should prevent any jobs. i, Tap should be cleaned properly and kept safely. DIES AND DIE-HOLDERS : Dies are the cutting tools used for making external threads. Dies are made either solid or split type. They are fixed in a die-holder for holding and adjusting the die-gap. They are made of tool steel orhigh carbon steel. There are three types of dies such as : Circular Split, Half and Adjustable Screw plate Die. METHOD OF USING DIE : E 2. Before cutting outer threads, the end of pipe or fod should be chamfered with a grinder ora file. b. For cutting threads on a pipe, rod or any other job it should be firmly held in a vice. wa aogDe wile fitting die in ajob only the side of tapered threads should be fitted. ie After fitting the die on the job you should adjust it according to your requirement. ¢, Keep on moving the die forward and backwards. 4, Equal pressure should be exerted on the die handle. Jobs of large diameter, threads should be cut after adjusting two-three cuts. Proper lubrication should be used while cutting threads. i After cutting the threads, it should be checked with a nut or ring gauge. j_ After using the drill. It should be properly cleaned and replaced at its proper place. Centre Screw a Side Screw Side Screw / Die Stock Button Stock A Pattern Z CIRCULAR SPLIT DIE HOLDE HALF DIE COMBINATION PLIER : Combination Plier is a mechanical multipurpose tool, which is used to bend, cut and scrap the insulation of cables having lenath of 15 or 20cm, anda P.V.C. } ‘of rubber sleeve is covered on its arms ‘as shown in the figure. TWIST DRILL AND DRILLING MACHINE : " Diillingis a process of making holes on a workpiece. The tool used for boring hole is called dri bit, ‘he machine with which the dril is moved is called drilling machine. The process of boring holes with dri “and diling machine is called driling. Various types of driling machines are available such as : Sensitive, _ Pillar type and radial type drilling machine. The folloiwng are the sizes and designations of twist drills. & Wg wrenFrom 1/16" onward a er ae |_Numberarits 7 E Taper shank drills METHOD OF DRILLING : @. Drill should be choosen according to the material and the hole to be bored in it. It should hay appropriate edge and all its angles should be well edge and all its angles should be well grinde Drill should be properly fitted in the spindle or chuck of the drilling machine. ‘Speed of the machine should be set according to the metal of the job and diameter of 1! Job should be properly gripped in the machine vice or other medium. At the place where hole is to be made, marking should be done with the centre punch. Place the drill straight in the place of centre punch and check. If a blind hole is to be bored, set the depth of the drill with the machine. Place the drill exactly in the centre of drill punch mark. If the drill is operating exactly in the centre, speed can be given. Use of lubricant and coolant is essential to get clean and proper finish and to save the drill from vrpeseaos Cutting angle and clearance angle ete. of the drill should be grined according to the material . Speed on the machine should be set according to the metal and the diameter of the drill. Ifa hole of large diameter is to be bored, first the kote should be bored with a small drill. While drilling, a wooden socket should be placed below the job so that drill may not damage th ‘machine bed by going across. Drifi should be used to separate drill from the machine. Filing is one of the methods of removing Wa small amount of material from the surface of }S a metal part. A file is a hardened steel tool, having slant parallel role of cutting edges or teeth on its surfaces. On the faces, the teeth | are usually diagonal to the edge. On end of } % the file is shaped to fit into a wooden handle. | The hand file is of parallel width and tapering slightly in thickness, towards the teeth. It is provided with double cut teeth on the faces, single cut on one edge and no teeth. It is Provided with double cut teeth on the faces, single cut on one edge and no teeth on the other edge, which is known as the safe edge. Files are Classified according to the basic of length, shape, grade and cut. LENGTH OF FILE : According to the length, a file is measured from heel to tip. It is available from 100 mm to 450 mm. _BHAPE OF FILE : Different shapes of file are used for different shape of jobs and it is classified as follows, Round, Halt-round, Triangular, Hand, Neodle and Knife edge file as sh eee Fiat, own in the given figure. MABHOLE FILE ROUND FILE HAND FILE ALE ROUND FILE FLAT Fike KNIFE FILE determined on the basis of distance between #8 of diatance between the tooth of tho file (TPH), On the basis Gf thoso teath tholr grades are made, On tho basis of the number of teeth on a filo, it is Glassified such as: Rough, Bastard, Second-cut, Smooth and Dead Smooth tile. ROUGH FILE ASTARD FILL _SUCOND CUT LL SMOOTH FILE___DIAD SMOOTH FILE _2UT OF FILE: foront shapos and types. Acéording to the cut, they are cl The tooth cut on the files are of diff Ingle-cut, Doublo-cut, Curved-cut, Splral-cut and Rasp cut Filo DOUBLE CUT SINGLE CUT RASP CUT “yfferHoD OF FILE: fed Choose the right type of file, according to the job. of th fila, In small {iles, a small handle should be There should be handle fitted on the tang ze fitted and a larger handle in larger file, Otherwise the power ‘would be unnecessary wasted. c. Hold the handle of the file with the right hand and keep the file end balanced with the left hand. d, Atthe time of filing, left leg ‘should be kept ahead and tho right leg a little behind. @. Pressure on the file should b ‘exerted while moving it ahead, not while driving hack, f, Only your hands should move with the file and not your whole body. As far as possible, keep jour body still ae ‘ ‘ile should be at the rate of 30 to 35 strokes por minute. 2 i ‘Speed of movng the fi IONS + Select ing to the job. Beas coring According to thesize, complete handle should be fixed on the file. ut While filing a sheet, we should cut it in length, Wial halance of the file would not be proper and oed. Keep the file away from other tools. They should not be heaped together. e, File should not be heated. L Donot apply oil or grease on the file. ) HOLDING . DEVICE FICE : fi A ‘Vice is a totaly holding device, which is use to hold the job strongly and tightly'to perform the oe types of operations such as : Filing, Drilling, Chipping, Milling and etc. For different types oF work, different types of vice are used such as : Bench, Machine, Pipe, Leg and Hand vice. BENCH VICE : vapLe HARD JAWS The vice, which is used for bench workisknown as | ~ saw ti ote UAW the bench vice. Bench Vice is made of cast iron or cast steel, which is used to hold work for filing, sawing, | spivpLe threading and other hand operation. It consists of two jaws, ie., one fixed jaw and another movable jaw. When the vice handle is turned in clockwise direction, the movable jaw forces the work against the fixed jaw. The job is held in between the two jaws at the time of filing, sawing and chipping. The size of the vice is-speci by width of the hard jaws. PIPE VICE / PIPE VICE : Pipe Vice is ued for holding cylindrical jobs (pipes and tubes). In this case, _moves in vertical «xis. It is used for holding pipes at the time of cutting and facie a / MACHINE VICE . Machine ice is used to hold a job strongly for carring out drilling, millin Y For fastening iton the table ’ bolts are used, which fasten the viee firmly ean een. made in the ble. Machine vice are classified based on holding the job such as : Plane. Flanged. swivel, Unive ‘sal and Vertical machine vice. : , Flanged, /LFG VICE: . . Leg vie: is a holding device, which is used in black-smithy shop. Hot job - bl ck-smit’ / operations like forging, bending and etc. done by the leg vice, eet pae rt banch ina —nging manner. It contains one leg which is straight way placed on wood. beled’ * are joined with each other through a hinge is entred body Is made of enone WASHice is very similar to leg vice with a long leg and opens like leg vice. The hand vice is used fivets, Keys and small drills and other similar objects which are too small to be Mice; Only small jobs can be held in the vice. It can not be fitlad on a work bench € a wing nut is used which is attached on the spindle fixed between the two jaws. ‘be fastened nearly at the centre and it should not be very high from the surface of the vice. g ‘care should be taken to ensure that the blow of hammer should not hit the vice. h be tightened in the jaw only by moving the handle manually. A hammer should not be used purpose. ‘Should be held in the jaw with a wood packing otherwise at the time of filing etc. chattering rusing the vice it should be cleaned. While cleaning it should be ensured that the tiny particles of ‘do not go into the spindle. is arectangular block, which has a ‘V' shaped groove on its upper Hwhich is shown in the given figure. The angle of the:'Vis during layout surements or for measuring operations. Heavy round jdbs‘are kept over |. There is no provision to clamp the job since becalige of heavy | {of the job, it remains fixed. { t fobs or two-three machine parts Tool-makers and 'C’ Clamp. TOOL MAKER, ~ CLAMP ch ‘screw and bolts are fitted. In both the jaws these are | direction. These jaws are brought closer or their distance shape of the ‘C' Clamp is ike the english letter'C’ Its a |“ pS CAME made of mild steel. On one of the frame is made flat and end threads are cut. It is made round in shape. Job is held | n flat side of the clamp and the swivel tp, According the |, which is used to beat or striking blows on jobs or metals or for driving ‘or bend a job made of metal. In addition it is also used for also used to cut hard wires with the help of a chisel as shown of are used in types of hammers engineering fields such as : Ball s Hammer, Claw Hammer and Soft. Hammers are named depending on a ‘specified by their weight. A ball peen hammer has a flat face, which is da ball end, particularly used foraiveltg: fits Ms» BALL PANE HAMMER CLAW HAMMER STRAIGHT PANE HAMMER, SOFT HAMMER CROSS PANE HAMMER B MALLET HAMMER SPANNERS = = ie A spanner is a tool used for tightening and opening nuts and bolts. It is usually made of forge steel. They are named accoridng to their applications. The size of the spanner denotes the size the bolt on which it can work. Generally, spanner are made of drop forge steel or carbon steel workshop, ‘there are different types of spanner are used such as : Single ended, Double ende Ring, Socket, Box, Combination, Hook, Adjustable, “T” Socket, Magneto, Allen Key and Pi AdjustablesSpanner. HOOK SPANNER: i 2} 4 | | MAGNETO SPANNER ‘ DOUBLE ENDED SPANNER RING SPANNER | ALLEN KEY SPANNER | —=» PIN FACE ADJUSTABLE SPANNERRete Sued Which is used for tightening and opening screws. The length ofits ‘bit’ Sra Tre enath of@ common sreweriveris em. General th bit made fat he tip but the given figure. icin» bit’ and "U — shaped bit. Screwdrivers with flat tips and star are Bee enidamese teas designed to tum screws, The blade is made of steel and available Bees a rs. The grinding o the tip tothe correct shape is very important. APhilips(str) aN ally designed to ft the head of Philips screw. The end of the blade is fluted instead of ned. A serew driver has three main part such as : Handle, Shank and Blade. HANDLE: = Sasically, wooden or plastic handles are fixed to the screw drivers. In order to shapeithe wooden from being broken, an iron ring is fixed to the handle. middle part between the blade and the handles called shank on its lower part'ip or blade On the upper part either there is a hole through which a wire is passed or this end is made ‘when this partis fixed the handle, it does ngt allow the shank to move separately. Shanks blade is lower part of shank: It is also known as ti This part is hardened and tempered. ? ‘SCREW DRIVER : ‘a screw driver is measured excluding handle. The length of screw driver varies from 50 "to 18”. Different types of screw drivers are available such as : Ordinary Flat, Offset, Watch Maker and Carpenter Screw Driver. boring holes in metal or wood, dil and driling machine 4, where dil is a too! which is fitted in a drill machine ‘When the drill rotates on the metal it bores a ‘drilled for fastening parts with rivets, bolts or internal threads. It is the most versatile machine shop for the purpose. 5 q c types of drills are used for boring holes inHAND DRILLING MACHINE RATCHET BRACE DRILLING MACHINE ELECTRICAL HAND DRILLING MACHINE PNEUMATIC DRILLING MACHINE © SURFACE GRINDER : A surface grinder having an emery wheel is generally used in a fitting shop and is useful in removing waste metal and sharpening drills, chisels, and other cutting tools. The hardness or softness of the whee is dependent on the amount and kind of binding material used. For this grinder, the job is held directly by magnetic chuck or work table race-protecting table of plaining or shaping machines also used. According to the spindle, they are of the following type such as : Vertical-and Horizontal Spindle Grinder. HORIZONTAL BENCH GRINDER SPINDERGRINGES SURFACE GRINDER SAFETY AND CARE OF GRINDING WHEELS : Before fitting a new ginding wheel, it should be verified that there are not cracks. Grinding whee! can set broken in case of a fall. Therefore, these should be handled carefuly. Grinding wheels should not be used without flange. While using wheel dress alertness should be observed else they would be broken. Grinding machine should be fitted property. Grinder should not be moved at more than the fixed speed. As far as possible ginder wheel should be used from side, As far as possible, grinder wheel should be covered, when not in use. POWER HACKSAW 7 Power Hacksaw is quite similar to hand hacksaw with the addition of a suitable driving mechanism. The drive is by a belt driven electric motor. Suitable mechanisms are provided whereby the length of the stroke and the weight applied may be varied. WightROLLNO. REGD. NO. MARKS COMPLETE -.. AIM OF THE EXPERIMEN To Prepare a Divider : OBJECTIVES OF THE EXPERIMENT : a. Use hacksaw to cut the required material after marketing. ». File the material to obtain the required Dimension cc. Join two components by riverting. SET UP OF JOB: Equipment Required : SL. NO.| NAME OF EQUIPMENT. SPECIFICATION / TYPE (QUANTITY 04 Bench Vice Los, 425mm 02 TrySquare 100mm 03 File Flat bastard 300mm | 04 File flat second cut 250mm 05 File half-round 150mm | 06 File triangular 150mm 07 “f Hacksaw frame with blade 300mm, | 08 ‘Surface plate 500 x 500 x 25 mm 09 Scriber 150mm 10 Centre punch 100 mm 11 Ball Pen hammer 200m 12 Radius and fillet gauge 13 Dring machine with machine vie 14 HSS. Drill Bit émm 15 Spring divider 150 mm, 16 Chisel fiat 400mm Ramaterial Required : a. MS. Sheet 110 x 202mm As Per Specified Given Job Diagram. b. MS. Rivet6émm : As Per Specified Given Job Diagram. n23uSen INTRODUCTION ; Many engineering and household articles such as bones, cans, funnels, duets etc are mad: 2 flat sheet of metal, the process being known as tim smithy. For this, the development of thear: first draw on the sheet metal, then cut and folded to form the required shape of the article. The of the article are then secured through welding, brazing, soldering and riveting etc. HAND TOOLS: Sheet metal worker does most of his job with the help of hand tools. These hand tools a a.| SheetMetal Hammer | b.| Scriber c.| Rule a] Divide .| Trammel f. | Stee! Square g. | Chisel A i. | Pliers i. | File k. | Snip 1 BENCH PLATE BULLET FACE HAMER MALLET HAMMER = G a Tua ra A ‘STEEL RULE a Ne: E EB) | WACHINE SHEAR ala) | STEEL SQUARE | SCRIBER CHISEL, ee PUNCH i STRAIGHT SNIP | Lightweight hammers and malllets are used in sheet metal work. Ball peer lindrical, slightly curved face and a ball head. It is a general-purpose hammer, ibd ee ae in sheet metal work. Cross peen hammer has a tapered peen end and is perpendicular to the handle. Mallets used for bending and folding work. Bullet head or bullet face hammer are used to make the job made of light sheets hollow and riveting hammer is used for revel joint Jobs in sheet metal work. SCRIBER : This tool is used for marking in sheet metal jobs. RULE : In sheet metal jobs a number of rules are u: i n discussed mn G&tah inne thanteee pa ey al eter ies have bee DIVIDER: Divider is used in sheet metal jobs for circle marking. Withthe divider we can also do marking the parts of a job. 5 = TRAMMEL : This is also a marking tool which has been discussed in the chapter on “Marking Tools” a z a = 2aSTEEL SQUARE : For right angle marking in sheet metal jobs steel square is used. In addition, this is also used for checking the right angle of the jobs. CHISEL : Several types of chisels are used for cutting metal sheets in different ways. These have been discussed in details in chapter on Cutting Tools” PUNCH : Punch is used in sheet metal jobs for punching or deep marking. Their detailed description is given in the chapter on “Marking Tools” PLIERS : Pliers are used for holding or cutting small jobs or wires etc. These have been described in detail in the chapter on “Dismentalling, Assembling and other Tools” FILE: ‘Several types of files are used for smoothing metal sheets. We can read about them in detail in the chapter on “Cutting Tools”. SNIPS : Snip is used for cutting thin sheet metal up to 20 S.W.G (Standard Wire Gauge). There are ‘several types of snips available for making straight and circular cut, the most common being straight Snip and curved or bent snip. The straight snip has straight blade for staight-line cutting while curved ‘or bent snip has curved blade for making circular cut. Both the snips are very light and can be easily handled by only hand. These are the following two types stich as : Straight Snip and Bent Snip. ‘SHEARS This is also used like snip for cutting a sheets but hiblsed to cut thicker sheets as compared to snip. This is of two types such as : Stock /Shear. SHEET METAL BENCH TOOL : a. Vice b. Stakes c. Gro d. Bench Plate VICE: Vice is used in sheet metal works for holding sheets or jobs. Normally, parallel jaw vice is used in sheet metal works. STAKE : ; Stake is the sheet-metal worker's anvil, used for bending, seaming or forming, using the hammers ‘and mallets. They actually work as supporting tools as well as forming tools. They help in bending _ operation. They are of different shapes and sizes to suit the requirements of the work. The double seaming stake is used to make double seam. The beak horn stake is used for round and square surfaces, bending straight edges and marking corners. The bevel edges square stake is used to form corners and edges. The hatchet stake is used to make straight * for folding and bending edges. Small tools and pipes may be formed on the needle stake and cone-shaped articles may be formed on blow-horn stake. The hollow mandrel stake ee tor riveting, seaming and forming. RIVET SETS : "Hand are used to groove and flattern a seam. This available in many shapes. Rivet a hardened steel too! with a hollow in one end. Itis used to shape the end of a rivet into a round 0 The bench plate is a Special type of plate made of carbon steel. Different types of holes, round, different shapes and sizes are made in this plate. Different types of stakes are fixed in and used. ie) 53 13001SECTION : ROLL NO. COMPLETE :.. Sign. of Sr AIM OF THE EXPERIMENT : To Prepare and Make a taper Tray : OBJECTIVES OF THE EXPERIMENT : a Use snips to cut the sheet for the development of a taper square tray b Make Double Hem on the edges. Bend the sheet on hatchet stake. d. Soft solder lap joint. SET UP OF THE JOB = Equipment Required : —$—$——— ———— NAME OF EQUIPMENT SPECIFICATION / TYPE Steel Rule a Folding Rule Straight Edge Try Square Scriber Divider Punch Chiset Raw Material Required a, MS. sheet : As Per Specified Given Job Diagram, b. Soft solder : As Per Specified Given, 8Athe size of the sheet as per the sketch using a steel Rule. the sheet on a leveling plate by a maliet. out the development of the sheet by the parallel line method as per dimension. ‘waste material YiSECTION :. ROLL NO. COMPLETE .......... ff ‘ Sign. of Sr. Lect/Lecturer AIM OF THE EXPERIMENT : To Prepare and Make a Funnel : OBJECTIVES OF THE EXPERIMENT : a. the sheet for the Development of funnel b. seam on the edge ©. Bend the sheet metal on a taper bar dF 1g a conical shape e if. si e sheet with grooved loke seam using grooves e sheet-metal to obtain a leak proof joint. =T UP OF THE JOB: ). OF TOOLS - ‘SPECIFICATION TTYPE - l QUANTITY jo Stee! Rule 300mm 2 Divider | Band Snip 1200 mm | Chisel | Straight edge | Hammer Try Square Snip (Straight) Scriber ring Iron - Required : : As Per Specified Given Job Diagram. 2 As Per Specified Given. N34imilar or dissimilar metal pieces. In this process, the two of heat, It results in a joint that is equivalent in composition Iding process such as : Electric Arc, Gas, ding, the work pieces are melted along a ced to form the joint on solidification INTRODCUTION : Welding is the process of joining two s! ‘metallic pieces are joined by the applicatioin and characteristics of the metals joined. The various wel Thermit, Resistance and Friction Welding. In gas and arc wol common edge to their melting point and then a filer metal is introdu In fact, welding is a quick cheap and simple technique of joining the metalic pieces. ELECTRIC ARC WELDING : The heat required for joining the metals is obtained from an electric arc. Transformers or motor generator sets are used as arc welding machines. These machines supply high electric currents at low voltage and an electrode is used to produce the necessary arc, The electrode serves as the filler rod and arc melts the ‘surfaces, so that the metals to be joined are actually fused together. The given figure shows the principle. of arc welding using a transformer. In addition to the welding machine, certain accessories are needed for carrying out the welding work. WELDING CABLES : Welding cable is used to connect the job with the earth line and the electro holder with the main line (Phase Line). Highly insulated | aluminium or copper cables are used for the purpose. Two welding cables are required, one from the machine to the electrode holder and ‘the other from the machine to the ground clamp or the other negative charge ELECTRODES : Filler rods used in arc welding are called electrodes. They are | generally made of a rod of alloying elements suitable for the job, coated with a flux. Flux acts as an insulator of electricity. ELECTRODE HOLDER : It consist of a handle and jaw. The electrode holder is connected to the end of the welding cable and holds the electrode. It should be light, strong and easy to handle and should not become hot while in operation. The jaws of the holder are insulated, GROUND CLAMP : It is connected to the end of the ground cable and is clamped to the work or welding table to complete the electric circuit. it should be strong and durable and have a low resistance connection, ust Seca ea Work Leadfor cleaning and preparing the work for ‘is used for removing slag fromed on weld: 1 is sharpened like a cold chisel and the other, toa generally made of tool steel. e hand type is convenient to use whenever the hand. The helmet type, though not comfortable OXYGEN HOSE. WELOING ow Top SaecoJOB NO. 06 | SECTION b......0000 ROLL NO. :. COMPLETE ...... ‘a Lap Fillet Joint in Flat Position by Gas Welding : at position welding, according to the nozzle size. | «JOB FIGURE: PROCEDURE : File flat and square Clean for Welding. Set the work pieces on welding table to form a lap joint with correct overlapping as per sk Settthe gas welding plant and attach the nozzle. Seta pressure of 0.15 kg/cm? for both oxygen/an acetylene gas. Select C.C.M.S. filler rod of 1.6 mmdia. \ Wear safety apron, goggles and gloves. i Setthe natural gas flame. J ‘Tack weld the pieces at both the ends and middle. Clean the tacks with a wire brush and set on the welding table in flat position. Start welding using leftward technique. ‘Stop at the left edge and fill the corner to complete the weld. m. Extinguish the flame, coo! the nozzle and place the blowpipe in safe place. 0. Clean the welded joint and inspect visually for correct size of fillet weld, (0. Weld the job from the other side following the above Process. OBSERVATION Frese sep aoe Peer | nen] nacdoats [Rew | | Quality ofthe welded | Uniform innature | joint | Finishing ‘Smooth witho | __|_blowholesCOMPLETE : Sign. of Sr. Lect/Lecturer Sn AIM OF THE EXPERIMENT : To Prepare and Make a Square Butt Joint by Arc Welding : OBJECTIVES OF THE EXPERIMENT : a. Setthe job for square butt joint. b. Tack weld two pieces to form square butt joint. _Weldalong the joint with correct arc length, correct electrode angle and uniform welding spee SET UP OF THE JO! , Equipment Required : NAME OF EQUIPMENT SPECIFICATION / TYPE : QUANTITY Are welding transformation 02 Electrodes \ Electrode holder ™~ Cable and cable connectors 05 | re hammer [ 06 | Wire brush 07 —_| Welding screen or helmet 1 | Apron 7 Pedestal grinding machine ‘Raw Material Required : a. MS. flat : As Per Specified Given Job Diagram, b. M.S. electrode : As Per Specified Given Job Diagram. WagSAFETY PRECAUTIONS : a a@aogc 1 2 3. 4 5. 6. ré No welding apparatus should be wet or damp: The arc should only be observed through a shied or goggles. Use proper current capacity cables. Remove the slagg by chipping hammer only. After finishing the job, put the machine to off and put all other tools to beet proper places. | ASIGNMENT QUESTIONS Whatis Arc gap and Arc blow? iE Name two welding defects. Name the positions in welding Write down the names of the different types of electric welding machine. Write the different faults in arc welding ? Write down the different types of arc length ? What are the advantages of arc welding ? —— — oa — | WRITTING SPACE FOR ASSIGNMENT | 4secon : Turning is the machining process to bring the raw material to the required, cylindrical shape and size by metal removal from the work surface. This is done by feeding a cutting tool against a rotating workpiece, This machine tool on which turning is carried out is called lathe. WORKING PRINCIPLE : { , Lathe removes considerable materials {rom rotating workpiece in the form of chips | with the help of tools, which is feed against the rotating workpiece. The tool material | should be harder than the workpiece and the father had surely and rigidly on the machine | The tool may size linear machine in any direction, Alathe is used to produce cylindrical ‘Surface and plane surface at right angle to ite axis of rotation. It can also produce a | taper below. /| 3 j Alathe, basically consists of a bed to/provide. support 9 head stock across side to transvers | The tool and tool post mounted on the across the spindle |sdfiven by a’motor through the gear box | te obtain a long speed to carriage moves over the bedside which is paralled to workpiece and | spindle provides transverse. It was the mo: Renginedathe which is equiped well, all necessary for acurate tool room work. It is generaily-bed driven machine with considerable range ‘spindle and feeds. _ TYPES OF LATHE : "Lathe machines are used in workshops can be divided into following types such as... Centre luction, engine and Special Lathe. —<—— —- = HE —.. Lathe is also known as SS and SC Lathe, the, Bench Lathe, Foot Lathe, Too! and Engine Lathe a LATHE = ion Lathes are used when a particular job is to be | in a large quantity. There are three kinds of production | chines are availabe such as : Capstan Lathe, Turret Lathe types of lathe machines are used for specific purposes. : Relieving Lathe, which are used are providing relief to | s or tap. There are three types of lathe are available ion such as : Axial turning Lathe, Copying Lathe and WAG ITENGINE LATHE : Engine Lathe machines is normally used by fitters in the workshop, when electric motors were not invented. This machines are operated with steam engines MAIN PARTS OF THE LATHE ; The following are the main parts of the lathe such as : a. Head stock b. Tail Stock c. Carriage d. Cross Slide €. Compounds Slide f Bed g. Feed Shaft h. Legs Ih Lead Sc j. Quick Change Gear Box C= Cannlage aie HEAD STOCK: See tis otherwise known as Live Centre. Head stock is fitted on the lathe bed on the left hand side of the lathe operator. The required ha gear and cone pulley is fitted in it for driving the lathe spindle. There are two types of head stock such as : All geared and Cone pulley | head stock. TAIL STOCK : The tail stock is otherwise known as Dead Centre. Itis fitted on the lathe machines bed, én the right hand side of the lathe operator it can be moved any désired space on the lathe bed in case of | need. It is used for centré,to centre tuming of lengthy workpiece CARRIAGE : Zo i Literal meaning of “carriage” is to carry. Through carriags, a job can be brought in contact with the Cutting tool or withdrawn from | Such a contact. It operates on bed ways between tail stock and | mn head stock. CROSS SLIDE: . \ It is provided by terminal dove tail in one side and assembles se inthe top of the saddles with its tool dove tail. Ataper grip is provided pa with saddle and cross slide dovetail to permit required but full| | movement of cross-section is provided with T-section to enable fixing of gear tool parts attachment from side is generated in degree | to failated tallated swiveling the compound next is movement on cross-section side which is directly assembles with cross slide and | = . be swivelted on either side to give desire angle to compound next. COMPOUND SLIDE: tsupports the tool post and cutting tools in its various positions. | It may be swivelled on the cross slide to any angle in the horizontal planes, as its has being graduated suitably. Its necessary in turning. MAT ITEee SECTION :,. ROLL NO. :. COMPLETE :........ Sign. of Sr. Lect/Lecturer AIM OF THE EXPERIMENT : To Prepare Different types of Job Operation By S.S and S.C. Lathe : OBJECTIVES OF THE EXPERIMENT : @ Toknowand identity the sliding surfacing and serew cutting (SS and SC) lathe machine. 6. Toknow and identify the main parts of the SS and SC lathe machine © Toknow main functions of the different parts of the lathe machine 4. Toknow different operations such as facing, centering, plain turning, step turning taper turning and grooving etc. TOOLS AND EQUIPMENT REQUIRED : NAME OF EQUIPMENT SPECIFICATION/TYPE | QUANTITY Facing Tool Grooving Too! | Tappering Tool Revolving Centre / Dead Centre St — t 1. a — — MEASURING INSTRUMENT : a. Slide Caliper b. Outside Caliper c. Steel Rule Raw Material Required : @. M.S. Round Rod : As Per Specified Given Job Diagram. 30 mm ——+-—20 mm—+e—— 40 mm——+le-t0 mma] ALL THE DIMENSIONS ARE IN MM