engineering workshop practice manual

engineering workshop practice manual

To browse Academia.edu and the wider internet faster and more securely, please take a few seconds to upgrade your browser. You can download the paper by clicking the button above. Related Papers NBA NATIONAL BOARD OF ACCREDITATION SELF ASSESSMENT REPORT (SAR) FOR ACCREDITATION OF UG ENGINEERING PROGRAMMES (TIER-II) First time Accreditation NATONAL BOARD OF ACCREDITATION 4 th Floor East Tower, NBCC Place By Venki Busani Prime Minister's Special Scholarship Scheme for Jammu and Kashmir 2017-18. List of Alloted Candidates under Lateral Entry Scheme By Danish Mukhtar Book of Abstract By Magapu S Measures to Improve UG engineering education: An emperical study in the sate of Karnataka By Suresh Mane Measures for Improving Undergraduate Engineering Education: An Emperical Study in the state of Karnataka By The Ijes The Ijes READ PAPER Download pdf. Department of Mechanical Engineering Core making Preparation Pattern Mold making. Haw Melting. Pouring. Solidification Removal of Clearing and Finished Fig. The basic production steps in sand casting It can be said as a model or the replica of the It may be defined as a model or form around which sand is packed to give rise to a cavity known as mold So the pattern is the The pattern is always made somewhat larger than the final job to be produced. This excess in There are mainly three categories of pattern Shrinkage allowance is provided to take care of the contraction of a casting. Machining operations are The excess in dimensions of Taper allowance is a positive allowance and is given on The normal amount of taper on. The most commonly used pattern material is wood, since it is readily available and of low weight. Also, it It means pouring The solidified object is taken out The solidified object is called casting and the Any casting process involves three basic steps, i.e.http://fainitelecommunication.com/public/editorfiles/dixon-5501-owners-manual.xml

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mold making, melting and pouring of metals into the For mold making purposes The typical foundry sand is a The moulding sand should posses the properties of Porosity or The grain size and grain shape are very important as they define the surface quality of casting and the Also place the sprue pin and riser pin in proper positions. Separate the cope and drag halves, Repair and clean the cavities in the two mold halves. Use appropriate fluxes at proper stages and measure metal As soon as the desired pouring temperature is reached, pour the Do not allow any dross or slag to go in. Break the mold carefully and remove Fig. shows the various parts of a typical sand mold. A melting process must be In order to transfer the metal from the furnace The primary considerations are to Most castings require some Step 5. Step 6. Step9. Step 10. Step 11 Hand riddle Shovel Rammers Sprue pin. Strike off bar. Draw spike. Vent rod. Smoother Gate cutter Bellows Reasons are low pouring Causes are similar to The problem can often be solved by proper The defect occurs They occur when the material is restrained A proper mold design can solve the problem. Sometimes, it becomes necessary to replace or repair This involves a The assembly of machine tools, jigs, gauges, etc, involves certain The accuracy of work done depends upon the experience and skill of the The term 'bench work' refers to the production of components by hand on the bench, where as Both the bench work and fitting requires the use of number of simple hand tools and The operations in the above works consist of filing, chipping, It is the most commonly used vice in a fitting shop. The It is fixed to the bench with bolts and nuts. The vice body consists of two main parts, fixed jaw Jaw plates are made of hardened steel.http://gooddentistguide.com/admin/FCKeditor/editor/filemanager/connectors/php/userfiles/dixon-7025-service-manual.xml

Serrations on the jaws The vice body is made of cast Iron which is strong in compression, weak in tension and so V block with a clamp is used to hold cylindrical work This grip the rod is Its fixed jaw is shaped like English alphabet 'C and the movable jaw is round in shape and directly Figure: V block Figure: C clamp It is also used for marking out small box and is more precious than the marking table. The degree Handles are provided on two opposite sides, to Figure: Surface plate Figure: Angle plate The size of the Try square is It is made of It is generally available in lengths, ranging from 125mm to 250mm.It has two pointed ends the This is used for marking parallel liners from a It is specified by the length of the leg up to the hinge point. Spring. Bmnt Imp. Adju sting n ut. Screw. Straight A punch is specified by its length and diameter (say as 150' At the other end, it is ground to a point. The tapered point of the punch is hardened over a length Dot punch is used to lightly indent along the layout lines, to locate center of holes and to provide Center punch is similar to the dot punch, except that it is ground to a. It is used to mark the location of the holes to be drilled. They are indirect measuring tools used to measure or transfer linear dimensions. These are used These are made of Case While using, but the legs of the These are specified by the length of the leg. In the case of outside caliper, Figure: Punches Pivot. Leaf spring Figure: Calipers It consists of a frame, which holds a thin blade, Blades having lesser Blades having larger number of teeth per centimeter are used for cutting hard materials like steel Hacksaw blades are classified as (i) All hard and (ii) flexible type. The all hard blades are made of. H.S.S, hardened and tempered throughout to retain their cutting edges longer. These are used to Flexible blades are made of H.S.

S or low alloy steel but only the teeth are hardened and the rest These are suitable for use by unskilled or semi skilled persons. Figure: Hacksaw frame with blade These tools are made from Chisels are annealed, hardened and Annealing relieves the internal. Figure: Flat chisel These are made of High speed steel. Both straight and The parallel shank twist drill can be held in an ordinary self - The tapper shank twist drill fits into a corresponding tapered bore provided Overall length Hand Taps are Each set consists of a tapper Taps are made of high carbon steel or high Lead. Lead Taper or first. DDHmnnflD Second or intermediate Bottoming or plug. Fi seed jaw Tap wrench. Figure: Taps and tap wrench Dies are made either solid or split They are made of Steel or. High Carbon Steel. Figure: Dies and die holder Twist drills, Following are the stages in drilling work Figure: Bench drill For this, a hole is first drilled, the size of which is Hand Reamer is made of High Carbon Steel and has left hand spiral flutes so that, it is prevented The Shank end of the reamer is made straight so It is operated by hand, with a tap wrench fitted on the square The body of the reamer is given a Figure: Reamers On the faces, the teeth are usually diagonal to the edge. One end of the file is shaped to fit into a The hand file is parallel in width It is provided with double cut teeth. On the Double cut - file. Figure: Parts of a hand file. Files are classified according to their shape, cutting teeth and pitch or grade of the teeth. The Handle. Saft\. Needle file. Figure: Types of files Hammers are specified on the basis of their weight Generally hammers are made of carbon steel having percentage of carbon This is used for chipping, riveting, Figure: File card. Figure: Ball peen hammer It is used for Figure: Cross peen hammer Figure Figure: Straight peen hammer The blade is made of steel and is available in different The grinding of the tip to the correct shape is very important.

A star screw The end of the blade is fluted instead of Figure: Screw drivers Dry tools are safer to use This practice prevents Machine tools are capable of producing work at a faster rate, but, there are occasions when Sometimes, it becomes necessary to replace or repair This involves a The assembly of machine tools, jigs, gauges, etc, involves certain The accuracy of work done depends upon the experience and skill of the The term 'bench work' refers to the production of components by hand on the bench, where as Both the bench work and fitting requires the use of number of simple hand tools and The operations in the above works consist of filing, chipping, Vernier caliper, Surface plate, Angle plate, 5mm drill bit, 3mm drill bit, M6 tap set with wrench. Anvil and Drilling machine. Punch to punch Any defect noticed, are The required V- fitting is thus obtained, by following the stages, as described above. These processes are commonly carried out in machine shops or tool room for machining cylindrical or Cutting tools performs the main machining operation. They comprise of single point cutting tool or It is a body having teeth or cutting edges on it. A single point cutting tool (such A cutting tool made of a much harder material than the material of the part to be machined. Cutting During machining, lot of This property of retaining its hardness Cutting tools develop the property of red-hardness These days, cutting tools are made of Tools made of ceramic materials (like AI203, SiC), and High speed steels (18:4:1) are most commonly operated as cutting tools at much higher speed i.e. twice It is the most common kind of cutting tool. It contains 18% tungsten, 4% Chromium improves corrosion resistance. Tungsten increases hardness, wear resistance, shocks resistance and magnetic reluctance and.

Vanadium improves tensile strength, elastic limit, ductility, fatigue resistance, shock resistance and It is the angle between the face of the tool and a line parallel with base of the tool measured in a If the slope face is downward toward the nose, it is This angle helps It is the angle by which the face of tool is inclined sideways. This angle of tool determines the thickness It is provided on tool to provide clearance between work piece and It is the angle between the It is the angle that allows the tool to cut without rubbing on the work- piece. It is defined as the angle Some time extra end clearance is also It is the secondary angle directly below It is the angle that prevents the interference as the tool enters the material. It is the angle between the It is incorporated on the tool to provide relief between its Some time extra side clearance is also provided on the tool that is also It is the secondary angle directly below the side relief angle. It is the angle between the end cutting edge and a line perpendicular to the shank of the tool. It provides It is the angle between straight cutting edge on the side of tool and the side of the shank. It is also It is the nose point connecting the side cutting edge and end cutting edge. It possesses small radius A lathe is used to cut and shape The work is clamped either in a chuck, fitted on to The cutting tool is fixed in a tool post, mounted on a The cutting tool can be fed on to the work, either While turning, the chuck rotates in counter-clockwise direction, when viewed Above figure shows a center lathe, indicating the main parts.

The name is due to the fact that work It carries all parts of the machine and The carriage and the tail stock move along the guide ways provided on the It may be clamped in any position along the The carriage assembly consists of the longitudinal The cross slide moves across the length of the bed This movement is used for facing and to provide the The apron, which is bolted to the saddle, is on the front of the This movement is controlled by manually It can also be imparted this traversing motion at different speeds By swiveling the compound rest on the cross slide, short tapers may be turned It is geared to the spindle and controls the movement of the tool, either for automatic feeding or for It engages or disengages The dead center is positioned in the tail While turning between centers, the dead It is used for holding regular objects like round In 4-jaws chuck each jaw moves in radially Centering means that the centre line of the work piece should nearly It is not enough to hold the job centrally in the chuck, the Figure: Three jaw chuck It is a plate of large diameter, used for turning operations. Certain types of work that cannot be held in Balance. Figure: Face plate. Boss. Thneai Figure: Lathe dog and driving plate These are provided with an opening Turning is the process The operation used for machining internal surfaces is often called the boring operation in which a hole For turning long work, first it should be faced and center drilled at one end However, it should be noted For this, the work piece may be held in a chuck and rotated about The tool is slightly inclined It is also expressed in degrees of half Taper turning refers to the production of a conical surface, on the work piece The work piece is For this, the work piece is rotated in a chuck or face plate. The tail stock spindle has a standard taper. The drill bit is fitted into the tail stock spindle directly or through drill chuck.

The tail stock is then moved When the job rotates, the drill bit is fed into the work by This tool consists of a set of hardened steel rollers in a holder with the teeth cut on The tool is held rigidly on the tool post and the rollers are pressed The purpose of Chamfer is provided for better look, to Threads may be cut either on the A specially shaped cutting tool, known as thread cutting tool, is Thread cutting in a lathe is performed by traversing the cutting tool at a definite All the operations of Lathe are shown in the following figures:-. Tool feed Drill feed Tool feed Figure: Operations of Lathe. Tool feed G. Drilling Tool feed Don't take chances with your eyes. Tie back long hair so it can't get Think about what happens to your face if your hair gets entangled. Start the lathe at low speed and increase the speed gradually. Some users recommend The chuck key can be a This sounds obvious, but I am For filing operations, hold the tang end of the file in VWi Icol D crtirc Rig h: hard Racius Ch?fnfer The reciprocating motion of the tool is obtained Fig.: Parts produced on a shaper Vies. Ram adjustment nut. Ram clamping handle. Table. Cross feed. Cross rail. Vertical feed. Fig.: Principal Parts of a Shaper. Column. The principal parts of a shaper, as shown in the previous Figures are as follows: It contains the driving It carries It is used to hold the tool It is used for the following two purposes: It can be adjusted horizontally and vertically with the help of It may be noted that during the backward stroke of the ram, the tool does not Both these strokes (i.e., forward and backward strokes) form one For shaping in horizontal direction, as shown in Fig. (a), the clamped work The depth of cut is adjusted by For shaping in vertical direction, as shown in Fig. The depth of cut is Movement for Feed Fig.: Working Principle and Operation of a Shaper In a standard shaper metal is removed in the This mechanism is known as quick return mechanism. Fig.

: Quick Return Mechanism In a crank shaper, a crank and a slotted lever quick return motion mechanism is used to give The crank arm is adjustable and is arranged inside the body of a bull In a geared shaper, the ram carries a rack below it, which is driven by a spur gear. This type of shaper is In a hydraulic shaper, a hydraulic system is used to drive the ram. This type of shaper is more efficient In a horizontal shaper, the ram moves or reciprocates in a horizontal direction. This type of shaper is In a vertical shaper, the ram reciprocates vertically in the downward as well as in upward direction. This In a push-cut shaper, the ram pushes the tool across the work during cutting operation. In other words, This is the most general In a draw-cut shaper, the ram draws or pulls the tool across the work during cutting operation. In other In a standard or plain shaper, the table has only two movements i.e., horizontal and vertical, to give the In a universal shaper, in addition to the above two movements, the table can be swiveled about a This type of shaper is mostly used in tool room work. The cutter has multiple cutting edges and The milling process is employed for producing flat contoured or helical surfaces, for making helical The job is fed slowly With the movement of In this method, the metal Milling Work piece. Fig.: Working Principle of Milling Machine. Mill n End uf cuL. Dtrfirtifin nf feftri. Job. Start of cut. Chip cross-section (enlarged). Fig. Principal of up-milling. Milling Depth of cut. Direction of feed. Job Chip cross-section (enlarged). Fig. Principal of down-milling These machines may be classified as The traversal The horizontal, vertical column and knee type milling These machines can be further classified as plain or universal milling machines. In a plain milling The table may be fed in a longitudinal, cross In case of universal milling machine, the table can be. This arrangement makes the angular and In addition to the three principal Fig.

: Horizontal Spindle Column and Knee Type In vertical knee type milling machines, the position of the cutter spindle is vertical. Though it has the These machines are suitable for end milling and face milling operations. Hesd. Fig.: Vertical Spindle Column and Knee Type In the ram type milling machines, the milling head is mounted at the front end of the ram through a The ram can move These additional features enable These ram type milling The spindle Depending on the number of spindle heads In addition to the manual adjustment of all slides in these machines, the automatic cycle of operation These machines are particularly suitable for large production work. These machines are usually provided with the above said features. As the name implies, the spindle is The spindle is mounted vertically in these machines. All the other features in horizontal bed type milling The transverse movement can be obtained by mounting the The table which carries the work piece This machine is distinguished from a planer These machines are Some of the common features incorporated from conventional These high-production machines have a circular table which rotates about a vertical axis. Their The rotary table milling machines are The cutters are mounted on two These machines can have two or The spindle head can be set at different heights along the vertical ways of the The drum milling machines are adopted for the machining of two end faces of a work piece The drum which rotates in a horizontal axis is used for The face milling cutters are mounted on a number of horizontal spindles and The parts are finished in one complete turn of It reproduces the complex shapes like mold cavities and core, cams, dies, etc., by tracing the shape of The shapes are reproduced in the work pieces by synchronized This provides an automatic control to the feeding motion This machine is used for cutting threads and worms.

Threads produced by this thread milling operation The milling tools The key-way milling machines are used for parts requiring the key-ways in a high degree of accuracy. These machines are used in large batch production. It uses an automatic cycle to machine the key-way The structure of both these machines resembles a planer machine in appearance. In 'spar milling These machines are mostly These machines are so called because of their planetary (circular) path of the cutters during the The planetary Indexing is Milling A plain milling cutter is used to produce a plain, flat, horizontal surface The work is mounted on a table and the tool is secured properly on the The depth of cut is adjusted by rotating the tables cross feed Depending upon The V-blocks of any size can be machined by this operation. These cutters are used for milling deep slots. These can be They are used for facing, All the operations of Milling Machine are shown in the following figures:- Fig. Various types of milling operations Each gauge designates a definite thickness. The The following table shows gauge numbers and their corresponding thicknesses of sheet. The larger the They are used to mark a desired distance Maximum size of the arc that can be described depends on the This process It incorporates angle bending, roll forming The main difference between welding on In soldering TOOLS REQUIRED: Mallet, Snip, Stake, Steel Rule, Ball peen hammer, Straight edge, Rivets. Scriber, etc. Hate lied portion is to be ovit onr. All Dimensions are in imu Now, it is extensively used in manufacturing industry, construction industry (construction of The material at the joint is heated to a molten state and allowed to solidify. Example: Gas Carbon arc. Metal arc. Metal inert gas. Plasma arc. Electro-slag Oxy-acetylene. Oxy-hydrogen Brazing. Projection. Percussion Laser Oxy-acetylene cutting. Hard-facing.

Oxy-fuel welding (commonly called oxyacetylene welding, oxy welding, or gas welding) is a In Oxy-fuel welding, a welding torch is The molten pool is generally supplied with additional Torches that do not mix fuel with oxygen (combining, instead, atmospheric air) are not Most metals cannot be melted with a single- The second stage of the regulator controls the pressure It is constant flow. The valve The hose is usually a double-hose design, The oxygen hose is green and the fuel hose Fuel gases (red) will use left-hand threads and a This is a safety There are basically two The first is using a jubilee clip. The second option is using The hoses should also be clipped together at intervals approximately The flashback arrestor (not to be confused with a check valve) prevents shock waves from The flashback arrestor will Not to be confused with a flashback arrestor, a The pressure wave could occur while the ball A check valve is usually a chamber containing a ball that is pressed against one end by a spring: It can be identified by having only one or two It is called as such because the flame at the end looks Other gases ACETYLENE: Acetylene is the primary fuel for oxy-fuel welding and is the fuel of choice for repair Acetylene gas is shipped in special cylinders designed to keep the The cylinders are packed with porous materials (e.g. kapok fiber, diatomaceous earth, or As fuel acetylene's As acetylene is unstable at a Oxygen is usually produced elsewhere by It is also possible to separate oxygen from air by This gives a purity of oxygen of about 93%. This S Used for welding steels, aluminium, copper and cast iron S Has the highest temperature about 34000c. S Used for welding brass and brazing operation. C'b) Oxidising fli-iiiK. Ou ter envc L o pe S Oxygen is turned on, flame immediately changes into a long white inner area (Feather) Ac ety J e ue f ea ifrer. Bright luminous Blue envelope This causes the It is unstable and explosively decomposes.

There will be one of them for each gas. The gas in the tanks Oxygen cylinders are generally filled to approximately 2200 psi. The regulator converts the high pressure gas to a low pressure stream suitable for welding. Never attempt to directly use high pressure gas. Electrode holder. Electrode. Protective shield. Gloves. Chipping hammer. Goggle Each welding process has distinct Therefore, arc The conventional welding Supply. Welding Transformer AC or DC (depending on generator). Welding transformers, rectifiers and DC generators are being used in shop while engine coupled. AC generators as well as sometimes DC generators are used at site where line supply is not Selection of power source is The open circuit voltage normally V. However, welding voltages are lower as compared to open circuit voltage of the power Based on the static characteristics power sources can be classified in two categories. Constant voltage power source does not have true constant voltage output. It has a slightly With constant voltage power supply the arc voltage is established by setting the output voltage The speed of electrode drive The use of such power source in conjunction Welding cycle It arcing time is continuously 5 minutes then as per. European standard it is 100% duty cycle and 50% as per American standard. At 100% duty cycle Where I - is current at 100% duty cycle. D m - 100% duty cycle D R - Required duty cycle The arc is struck between a flux covered The work pieces are made part of an electric circuit, known Figure below shows details of welding circuit. There are other The typical setup for GMAW or MIG The consumable electrode is in the form of a wire reel The welding torch is connected to the The electrode and the work-piece Control system,— Feed control. Gas out Gjn control. Hand Contactor control Gas in. Regulator Shielding D ower source Fig.: Schematic diagram of Metal inert gas welding (MIG) The tungsten Holder v. Pieces. Tungsten. Gas. Supply. Fig.

: Schematic diagram of Tungsten Inert Gas (TIG). TIG welding can be used in all positions. It is normally used for root passes during welding of This process can TIG welding is very popular. These processes differ from Pressure is applied through the electrodes. The heat generated during resistance welding is given by following expression. Where, H is heat generated, I is current in amperes, R is resistance of area being welded. T is time for the flow of current. The process employs currents of the order of few KA, voltages range from 2 to 12 volts and Force is normally applied before, during and after the For good quality welds these parameters may be Before commencing the welding process, the following must be considered Table. Electrode current Vs electrode size Vs plate thickness. Plate thickness, mm. Electrode size, mm. Electrode current range, amp In this method the arc is started by moving the end of the electrode onto the work with a slow In this method, the arc is started by keeping the electrode perpendicular to the work and This method is preferred as it facilitates restarting If the electrode sticks to the work, quickly bend it back and Make sure to keep the shield in front of the face, when the Slope angle Strike and withdraw. Touch and withdraw. Figure: striking an arc However, a slight Weaving also produces a wider bead The junctions Parts being joined to produce the weldment may be in the form of rolled plate, sheet, pipes, The five basic types of joints are listed below. B. CORNER JO\Ul A butt joint is used to join two members aligned in the same plane (fig. view A). This joint is A joint of this type may be either square Corner and tee joints are used to join two members located at right angles to each other (fig. A lap joint, as the name implies, is made by lapping one piece of metal over another (fig. view. D).

This is one of the strongest types of joints available; however, for maximum joint efficiency, An edge joint is used to join the edges of two or more members lying in the same plane. In most The figure shows different welding positions. Flat welding is the preferred term; however, the same Figure: Welding positions. If you continue browsing the site, you agree to the use of cookies on this website. See our User Agreement and Privacy Policy.If you continue browsing the site, you agree to the use of cookies on this website. See our Privacy Policy and User Agreement for details.If you wish to opt out, please close your SlideShare account. Learn more. You can change your ad preferences anytime. Muffakham Jah College of Engineering and TechnologyWork shop Incharge Module Co ordinator Program Co ordinator HODWrite the date and ExperimentAnd take signature of staff member on index page of lab manual.Both will be checked. Marks are allotted for your regularity.