Workshop Practice Manual

Workshop Practice Manual

Essential Exercises for Creativity

JATINDER MADAN

and

PRINCE PAL SINGH

Copyright © 2023, Authors

All rights reserved.

No part of this book may be reproduced, or stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without express written permission of the authors.

Disclaimer

The book covers topics on workshop practices which are meant to be performed with the help of machines, equipment and tools following established procedures and guidelines. Many workshop practices involve application of heat, force, sharp tools and moving parts. Although the description of the various processes involved in workshop practice has been provided with utmost care, it may not be complete from all aspects. The procedures described for each practice provide a general description and is not claimed to be a complete stepwise procedure. Therefore, it is recommended that in the beginning the workshop practices are performed by the learners under the supervision of a trained person.

Contents

About the Authors

Foreword

Preface

Acknowledgements

CHAPTER 1: INTRODUCTION AND SAFETY

CHAPTER 2: CARPENTRY SHOP

CHAPTER 3: FOUNDRY SHOP

CHAPTER 4: WELDING SHOP

CHAPTER 5: FITTING SHOP

CHAPTER 6: ELECTRICAL SHOP

CHAPTER 7: ELECTRONICS SHOP

CHAPTER 8: SMITHY AND FORGING SHOP

CHAPTER 9: MACHINE SHOP

CHAPTER 10: SHEET METAL SHOP

CHAPTER 11: POWER TOOLS

CHAPTER 12: 3D PRINTING

MULTIPLE CHOICE QUESTIONS

About the Authors

Dr. Jatinder Madan has teaching and research experience in mechanical engineering with a focus on manufacturing engineering and allied topics. He received his Ph.D. in Mechanical Engineering from IIT Delhi, New Delhi. He was a visiting researcher at the System Integration Division of the National Institute of Standards and Technology (NIST), Gaithersburg, MD, USA, during August (2011- 2013) and May – June 2019. He traveled to the USA multiple times for participating in ASME’s Manufacturing Science and Engineering Conference (MSEC), which is an international event of repute where scientists from across the world showcase their manufacturing focused research work.

Currently, Dr. Madan is serving as Professor and Head of the Mechanical Engineering department at the Chandigarh College of Engineering and Technology (Degree Wing), Chandigarh, India. Dr. Madan has been instrumental in developing the workshops at his college and has been an instructor for the Workshop Practice course to the undergraduate engineering students. He has published several research papers in reputed international journals and international conferences, supervised PhDs, Master’s Thesis and completed funded research projects. He has research interests in Sustainable Design and Manufacturing, CAD/CAM, Design Automation, Design for Manufacturing and Assembly (DFMA), and Smart Manufacturing.

Dr. Prince Pal Singh is a mechanical engineer with specialization in manufacturing engineering. He did M. Tech. in Manufacturing Systems Engineering from Sant Longowal Institute of Engineering and Technology, Longowal, Punjab, India and B. Tech. in Mechanical Engineering from Kurukshetra University, Kurukshetra, Haryana, India. He received Ph.D. in Mechanical Engineering with specialization in reconfigurable manufacturing systems from I.K. Gujral Punjab Technical University, Kapurthala, Punjab, India. He has taught several courses to undergraduate students of mechanical engineering, such as manufacturing systems, workshop technology and manufacturing processes. His current research focus is on manufacturing systems design, sustainable manufacturing, and reconfigurable manufacturing systems. He has published many research papers in reputed refereed journals and international conferences. He currently serves as Data Analyst in the Engineering and Analytics Department of the Spyglass Analytics Software Private Limited, Gurugram, Haryana, India.

The authors have contributed equally for preparing the manuscript.

Foreword

I am pleased to write a foreword for the Workshop Practice Manual co-authored by Dr. Jatinder Madan and Dr. Prince Pal Singh. The course on workshop practice is part of first year curriculum of Engineering Degree Programs in most of the Universities. This course provides much needed exposure to the students to exercise creativity, which leads to innovation and development at later stage.

The book covers the essential topics of basic workshop practices with a chapter on 3D Printing. Understanding of the conventional workshop practices is important to correctly understand the newer manufacturing processes. Further, 3D printing process has come as a disruptive technology with the potential of replacing the subtractive manufacturing techniques, presently in use. With the focus being on manufacturing processes, the book also covers power tools. In addition, authors have covered the safety precautions in the workshops, which is also an important aspect for learning often neglected. The book chapters are well designed and presented using several useful illustrations to explain the processes, tools, and exercises in a unique way. The response sheets given for each chapter make the learning experience very interactive.

Dr. Jatinder Madan and Dr. Prince Pal Singh have shared their rich experience in the field of Mechanical Engineering and Manufacturing Processes in this book. I am sure that the book will become a valuable resource in the hands of the learners and instructors of the workshop practice.

Dr. B S Pabla

Professor, Mechanical Engineering Department

National Institute of Technical Teachers Training and Research Chandigarh

Ex Principal, Chandigarh College of Engineering and Technology Chandigarh

Preface

This book is about learning workshop practices, techniques, and tools which are essential for exercising creativity, project work and making jobs. Workshop practice is generally introduced in undergraduate engineering programs to the freshman in several universities throughout the world. Several diploma-level and vocational courses also introduce workshop practice in their programs. The objective of this course is to provide the learners and students a practice-based exposure to the most basic manufacturing processes which we also call as workshop practices, such as carpentry, fitting, foundry (or casting), welding, sheet metal, electrical, electronics, smithy and forging, and machining. Although there have been notable developments in manufacturing technologies, with many new manufacturing processes being introduced, the importance of the above-mentioned workshop practices has not waned. Moreover, knowledge of the conventional processes is needed to correctly understand the newer manufacturing processes. In recent years, newer manufacturing processes like additive manufacturing or 3D printing have gained importance, which also needs to be introduced to the students in their first year so that they can use it for exercising creativity in the remaining years of their program. Power tools, such as hand drills are also very important to perform different tasks in many projects.

We got the idea of writing this book when we had to struggle a lot to make a customized manual for the workshop practice course for the undergraduate students. Most of the available resources and books provide a detailed discussion on the topics but a limited exposure to the practice-based learning. Moreover, safety, which is the most important aspect of learning in workshops, was described in the books on workshop practices to a limited extent only.

The topics in the book were selected to include the basic manufacturing processes, carpentry, fitting, foundry (or casting), welding, sheet metal, electrical, electronics, smithy and forging, and machining. Further, 3D printing processes, which have gained importance in recent times, have also been introduced. A chapter has been dedicated for describing essential power tools, which are often used for performing a variety of tasks and project work.

The book provides well-structured content for the learners to perform exercises on important workshop practices. Selected jobs are given at the end of each chapter along with the detailed procedure with illustrations. Response sheets have been provided at the end of each chapter where the learners can provide answers to specific questions after they make the given job to get feedback from the instructors.

Safety, which is the most important for carrying out workshop practices, has also been given due coverage throughout the book. Illustrations have been used to the maximum possible for clarity and understanding, making the learning of workshop practices enjoyable. We are hoping that the book will greatly help the students and learners of workshop practice.

We shall gratefully acknowledge the suggestions for the improvement of the book at Jatinder.madan@gmail.com or princepal123@gmail.com.

Jatinder Madan ​ ​                     Prince Pal Singh

ACKNOWLEDGMENTS

Initially, the book project on Workshop Practice Manual appeared to be simple. However, as we progressed, challenges of how to best describe the manufacturing processes/workshop practices and the exercises to be performed became apparent. We would like to thank Mr. Nishant Kumar and Mr. Vinay Dev Dutt, both senior (2019-23 batch) students of B. E. Mechanical Engineering program at Chandigarh College of Engineering and Technology (Degree Wing), Chandigarh, who helped in preparing the illustrations.

The support provided by the workshop staff of the Chandigarh College of Engineering and Technology (Degree Wing); Chandigarh was crucial during preparation of the manuscript. Mr. Manoj Kumar, Workshop Assistant, Mr. Malkeet Singh, Workshop Assistant and Mr. Mohit Kumar, Helper, whole heartedly supported us on various aspects of different chapters and refining the practical exercises.

No book project can be accomplished without support of the family. We are highly indebted to our families who supported us in this long project.

​Authors

CHAPTER 1

INTRODUCTION AND SAFETY

1.1 INTRODUCTION TO WORKSHOP PRACTICES

Workshop is a place to acquire basic knowledge for making products ranging from simple models to complicated ones using different raw materials. Workshop practice helps in developing and enhancing hands on use of engineering materials, tools, equipment, processes, and machines as well as manufacturing techniques. Hence, to develop engineering skills, one must practice the basics of manufacturing processes by learning from the experience of craftsmen through practical demonstrations and practice in the workshop. The term manufacturing process refers to the method of processing raw materials to obtain various products in different shapes and sizes to accomplish functional requirements. Manufacturing processes may be classified into the following five groups.

Primary shaping processes

Machining processes

Joining processes

Surface finish processes

Processes affecting change in properties

1.1.1 Primary shaping processes

Primary shaping processes are those which help to make near net shape parts that are very close to the desired geometry. This means that requirement of additional finishing operations to obtain part geometry as per the required specifications is minimal. Some processes produce finished parts that may not require further work to finish products to the desired shape and size. For example, in the foundry shop, molten metal is poured into a cavity, which is also called mold. After the molten metal cools and solidifies, a near net shape part is produced. Such a part can either be used after minimal further processing, such as cleaning or can be machined to get an excellent finish. Other important primary shaping processes are injection molding, diecasting, smithy, and forging, bending, and rolling.

1.1.2 Machining processes

Parts that need further processing after primary processes to make it of the required shape and size by removing material. A typical machine shop has a number of machines, such as lathe, milling, drilling and shaper, which can help remove the material from the workpiece. Some of the common machining operations are turning, facing, threading, knurling, boring and drilling.

1.1.3 Joining processes

Joining processes are used in general fabrication work to join metal parts permanently or temporarily with the application of heat and pressure. Some of the joining processes are gas welding, arc welding, spot welding, soldering, and brazing.

1.1.4 Surface finish processes

The surface finishing processes are meant to improve the appearance of the parts that may be produced using any of the above-mentioned manufacturing processes. Sometimes a protective coating onto the metal may be added, or a negligible amount of metal from the component is removed to get a good surface finish. Some of the surface finish processes are buffing, grinding, and painting.

1.1.5 Processes affecting change in properties

Most of the engineering components are made up of metals with sufficient strength. However, certain engineering applications require better properties, such as good surface hardness. Therefore, heat treatment processes are required to enhance the properties, such as strength and wear resistance of these metallic components. The heat treatment processes generally involve heating the metallic component to a certain temperature and cooling it in a controlled environment to enhance its engineering properties. Examples of heat treatment processes are hardening, case hardening and normalizing. Other processes that change the material properties are cold working, hot working and shot peening.

1.2 WORKSHOP PRACTICES

A number of workshop practices are available, the most notable being carpentry, welding, machining, smithy, sheet metal working, foundry, fitting, and electrical technology. The above-mentioned