Lab Manual

Engineering Workshop Practice Lab (MEE 1082)

FITTING SHOP

DEPARTMENT OF MECHANICAL ENGINEERING

 Lab Manual
Engineering Workshop Practice Lab (MEE 1082)

SAFETY PRECAUTION

1. Never operate any machine unless you know how to operate it.
2. Always wear uniform in the workshop, never wear loose clothes.
3. Never touch moving parts, belts or rotating tools etc.
4. In case of any fire, the electric supply should be disconnected.
5. Always move the hacksaw in perfect straight and horizontal direction.
6. Never tilt the hacksaw blade while sawing.
7. The blade should be tightened sufficiently.
8. Grip the job in bench-wise properly.
9. Hacksaw blade should be fixed in proper direction and tightened.
10. Use water as a coolant while sawing.
11. Hold the chisel firmly while chipping.
12. Drill the holes centralizing on pop marks, give gradual feed.
13. Check the dimensions time to time carefully with Vernier clipper.
14. Tap should be held perpendicular and rotated every half turn forward reverse quarter turn
backward.
15. Use lubricating oil during tapping.
16. Always keep your mind on the job.

LIST OF PRACTICALS
.
1. To study the different type of hand tools use in fitting shop.

2. To perform the operations of marking, Filling & Sawing on the given Mild steel work piece as
per given dimensions

3. To perform the operations of Drilling for making the holes on the given Mild steel work piece
(M.S. Flat) by the use of drilling machine..

4. To perform the operations of making internal threads by the use of Tapes.

INTRODUCTION

Fitting jobs involves the removal of excess/ unwanted material from blanks with the help of
hand tools so that they could be assembled as specified in drawing. It is done for the assembly
practice by mating surfaces/edges of components leading to assembly.

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EXPERIMENT NO.1

OBJECTIVE: - To study the different type of hand tools use in fitting shop.

CLAMPING TOOLS
Clamping tools are used for holding the job firmly during various fitting operations.

(i) Bench vice: It is a common tool for holding the jobs. It consists of cast iron body and
iron jaws .The jaws are opened up to required length, job is placed in the jaws and is fully
tightened with handle (see fig.1)

(ii) Leg vice: It is stronger than bench vice and used for heavy work.( see fig.2)

(ii) Hand vice: It is used to grip very small objects (see fig.3)
(iii) Pin vice: Pin vice is used to hold wire or small diameter rods. (see fig.4)

(v) Pipe vice: It is used to hold pipes. It grips the pipe at four places and is fixed on bench
or can be grouted. (see fig.5)

fig.1 fig.2

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fig.3 fig.4

fig.5

MEASURING AND MARKING TOOLS

(i) Try Square: It is used for checking squarness of two surfaces. It consists of a blade
made up of steel, which is attached to base at 90°(see fig.6)
(ii) Bevel Protector: It consists of a steel dial divided into 360° divisions, used for
measuring angles (see fig.7)

fig.6 fig.7

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(iii) Scriber and Surface Gauge – It is used for marking of lines parallel to a surface.
Scriber mounted on a vertical bar is called surface gauge.( see fig.8)
(iv) Dot Punch –It is used for marking dotted lines. Angle of punching end is 60°( see fig.9)

fig.8 fig.9

(v) Centre Punch – It is like a dot punch used to mark the centre of hole before drilling.
Angle of punch end is 90°(see fig.10)
(vi) Surface Plate – Surface plate is used for testing the flatness, trueness of surfaces; it
upper face is planned to form a very smooth surface. (see fig.11)

fig.10 fig.11

(vii) ‘V’ Block:It is used for supporting as well as marking of round jobs(see fig.12)

(viii) Steel Rules – It is made up of stainless steel and marked in inches or millimeters,
available in various sizes 6” ft to 36 “(see fig.13)

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(ix) Dividers – Dividers have two legs having sharp feet. It is used for marking arcs,
dividing a line or transferring the dimensions.( see fig.14)
(x) Calipers: it is generally used to measure the inside or outside diameters. (see fig.15)
(xi) There are four types of calipers.
(xii) a) Outside calipers b) Inside calipers
(xiii) c) Spring calipers d) Odd leg calipers

fig.12 fig.13

fig.14 fig.15

CUTTING TOOLS

1. Hacksaw – It is used of cutting of flats, rods etc. The blade of hacksaw is made up of high
carbon steel and frame is made from mild steel. The blade is placed inside the frame and is
tightened with the help of a flange nut. The teeth of hacksaw blades are generally forward
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cut. There are two types of hacksaw frames, fixed frames and adjustable frame. The material
to be cut with hacksaw is clamped in a vice. The hacksaw should be moved perfectly straight
and horizontal. (see fig.16 &17)

fig.16 fig.17

2. Files-It is used to remove material by rubbing it on the metal.

Classification of files.
i) Size – The length of file vary from 4 inch to 14 inch.
ii) Shape–The shapes available are flat, square, round, half-round, triangular etc.
iii) Cuts – Single and Double Cut.
iv) Grade –Rough - 20 Teeth per inch.
Bastard - 30 Teeth per inch.
Second Cut - 40 Teeth per inch.
Smooth – 50-60 Teeth per inch.
Dead Smooth - 100 Teeth per inch.
Rough and Bastard files are used for rough cutting, smooth and dead smooth files are used for
finishing work. Files should be used in perfect horizontal position. Pressure should be applied on
the forward stroke only. Work is held in a vice (see fig.18)

fig.18
STRIKING TOOLS
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Hammers: - are the only tools used for striking in fitting shop like chipping, fitting, punching etc.
They are three types mostly use in fitting shop.

1. Ball Peen Hammer 2. Straight Peen Hammer 3.Cross Peen Hammer

Ball Peen Hammer

A ball-peen hammer, also known as a machinist's hammer, is a type of peening hammer used in
metal working. It is distinguished from a cross-peen hammer, straight-peen hammer, cross peen by
having a hemi spherical head. (see fig.19)

Straight Peen Hammer

A straight peen hammer is used like the cross peen but differs from the cross peen since its
penning edge is turned ninety degrees. This keeps the handle parallel to the struck surface. (See
fig.20)

Cross Peen Hammer

A cross peen hammer is used as a chisel for removing rivet heads and for stretching or bending
metal. (see fig.21)

Fig. 19 Fig. 20 Fig. 21

Result: - Experiment is completed.

Outcomes:- On successful completion of this experiment, the students will be able to

understanding the working of hand tool and demonstrate it.
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EXPERIMENT NO.2

OBJECTIVE: - To perform the operations of Marking, Filing and Sawing on the given Mild steel
work piece as per given dimensions.

Tools and equipment used: - Bench vice, Hacksaw. Files, Scriber, Steel rule, Try square,
Hammer, Surface plate, surface gauge, Ball peen hammer etc.

Materials required: - Mild steel flat 48mm x 48mm x 7mm.

Drawing: - (See fig.22)

Theory:-

Marking – Measurement is performed on the job by measuring instrument and scriber does
marking.

Filing – This operation is performed with the help of files, pressure should be exerted in the
forward stroke and backward stroke is ideal.

Sawing –This operation is required to cut the metal in different sizes and shapes by hacksaw.

Procedure:-

1. Mark the M.S flat 50 x 50mm and cut the metal pieces with Hacksaw, clamping in a Bench
vice.

2. File the two sides at right angle, check with try square.

3. Mark the other two sides with surface gauge on a surface plate supporting by angle plate to
dimension 48 x 48 mm.

4. Cut extra metal and file to accurate 48 x 48 mm square piece. Finish the surface with smooth
file keeping tolerance ± 0.5 mm; check the dimension with steel scale.

5. Mark parallel lines at 15mm distance on a finished square piece of 48 x 48 mm as shown in

diagram.

6. Punch mark at equal distance Drill 7 mm dia. hole.

7. Draw an arc of radius 33 mm from centre of 7mmdia. Hole, and cut the exterior metal with
hacksaw and filing them with flat file.

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Safety Precaution

1. Grip the Job in the vice properly.

2. Always move the hacksaw in perfect straight and horizontal position.

3. Hacksaw blade should the fixed in proper direction and tightened sufficiently with correct
tension.

4. Check the dimension time to time carefully, check with Try square and steel scale.

Result: - The given work piece of mild steel is completed as per sizes & proper right angle.

Outcomes: - On successful completion of this experiment, the students will be able to

understanding the “Marking, Filling & Sawing process with hand tools.

fig.22

Note: - All dimensions are in mm

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EXPERIMENT NO.3
Objective: - To perform the operations of Drilling for making the hole on the given Mild steel
work piece (M.S. Flat) by the use of Drilling machine.

Tools and equipment used: - Drilling machine, vice, Scriber, Steel rule Ball peen hammer.etc

Materials required: - Mild steel flat 48mm x 48mm x 7mm.

Drawing: - See fig.23

Theory:-

A drilling machine, called a drill press, is used to cut holes into or through metal, wood, or other
materials. Drilling machines use a drilling tool that has cutting edges at its point. This cutting tool
is held in the drill press by a chuck or Morse taper and is rotated and fed into the work at variable
speeds. Drilling machines may be used to perform other operations. They can perform
countersinking, boring, counter boring, spot facing, reaming, and tapping Drill press operators
must know how to set up the work, set speed and feed, and provide for coolant to get an
acceptable finished product. The size or capacity of the drilling machine is usually determined by
the largest piece of stock that can be center-drilled. To determine the size of the drill press is by
the largest hole that can be drilled, the distance between the spindle and column, and the vertical
distance between the worktable and spindle.

Drilling – This is done to produce holes with the help of drills. It is done on a drilling machine and
job is held in a machine vice. Drill is fixed on the drilling machine.

Drill Bit– It is used for making round holes. Twist drill is most commonly used for making holes.
(See fig.24)
Procedure:-

1. Mark the M.S flat 50 x 50mm and cut the metal pieces with Hacksaw, clamping in a Bench
vice.

2. File the two sides at right angle, check with try square.

3. Mark the other two sides with surface gauge on a surface plate supporting by angle plate to
dimension 48 x 48 mm.

4. Cut extra metal and file to accurate 48 x 48 mm square piece. Finish the surface with smooth
file keeping tolerance ± 0.5 mm; check the dimension with steel scale.

5. Mark parallel lines at 15mm distance on a finished square piece of 48 x 48 mm as shown in

diagram.

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6. Punch mark at equal distance Drill 7 mm dia. hole.

7. Hold the work piece in drilling machine vice and doing drilling hole of 7mm dia. with the use
of drill bit and with the help of drilling machine.

Safety Precaution

1. Grip the Job in the vice properly.

2. Drill the holes centralizing on popper marks, give gradual feed.

Result: - The hole of given dimensions is completed by the use of drilling machine.
Outcome: - On successful completion of this experiment, the students will be able to
understanding the working drilling machine and also understand the different drilling machine
operation.

fig.23

Note: - All dimensions are in mm

fig.24
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EXPERIMENT N0.4
Objective: - To perform the operations of making internal threads by the use of Tapes.

Tools and equipment used: - Tape set & vice

Materials required: - Mild steel flat 48 x 48mm x 7mm.

Drawing: - See Fig.25

Theory:- Internal screw threads : Internal screw threads of usually small size are cut manually, if
needed, in plates, blocks, machine parts etc. by using taps which look and behave like a screw but
made of tool steel or HSS and have sharp cutting edges produced by axial grooving over the
threads (see fig.26). Three taps namely, taper tap, plug tap and bottoming tap are used
consecutively after drilling a tap size hole through which the taps are axially pushed helically with
the help of a handle or wrench. (See fig.27)

Threads are often tapped by manually rotating and feeding the taps through the drilled hole in the
blank held in lathe spindle.
The quality of such external and internal threads will depend upon the perfection of the taps or
dies and skill of the operator

Procedure:-

1. Mark the M.S flat 50 x 50mm and cut the metal pieces with Hacksaw, clamping in a Bench
vice.

2. File the two sides at right angle, check with try square.

3. Mark the other two sides with surface gauge on a surface plate supporting by angle plate to
dimension 48 x 48 mm.

4. Cut extra metal and file to accurate 48 x 48 mm square piece. Finish the surface with smooth
file keeping tolerance ± 0.5 mm; check the dimension with steel scale.

5. Mark parallel lines at 15mm distance on a finished square piece of 48 x 48 mm as shown in

diagram.

6. Punch mark at equal distance Drill 7 mm dia. hole.

7. Hold the work piece in drilling machine vice and doing drilling t hole of 7mm dia. with the use
of drill bit and with the help of drilling machine.

8. Hold the work piece in vice parallel to the jaws and fit the proper size tap in tape handle and
start tapping. During tapping process the lubricating oil should be use.

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Safety Precaution:-

1. Grip the Job in the vice properly.

2. Tap should be held perpendicular and rotated every half turn forward, reverse quarter turn,
backward.

3. Use lubricating oil during tapping.

Result: - Taping operation is successfully done on the given mild steel work piece.

Outcome: - On successful completion of this experiment, the students will be able to

understanding the different types of thread and also understand the taping operation.

Fig. 25

Note:- All dimensions are in mm

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fig.26

fig.27

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MACHINE SHOP

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SAFETY PRECAUTION

1. Always wear proper fitting apron before starting work in machine shop. Do not wear loose
clothes.

2. Always wear safety goggles to protect your eyes against any flying chips or dust.

3. Keep your hands away from the moving cutter or work piece.

4. Cover the pulleys & belts with safety guards while working.

5. Never let your clothes & hand come in contact with the revolving chuck, pulleys, belts, etc.

6. Work piece should be held tightly between the live & dead centers.

7. Don’t touch the chips while the same are being generated by the machine because these are
extremely hot.

8. Be sure that cutting tool is tightly held in tool post.

9. Do not touch the tool tip during grinding of the tool.

10. Don’t give excessive feed to the cutting tool. It damages the tool tip & may even cause
accident.

11. You must always know the position of fire extinguisher & first aid box in the shop.

LIST OF PRACTICALS

1. To Study the working of Lat machine tools like Lathe machine, Shaper machine,
Drilling machine, & grinding machine.

2. To perform the operations Facing, Center drilling, plain turning, Step turning, Taper
turning, Grooving, Knurling & Chamfering on Centre Lathe machine

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EXPERIMENT NO.1

OBJECTIVE - To Study the working of Lathe machine tool.

LATHE
A lathe is a powered mechanical device in which the work is held and rotated against a suitable
cutting tool for producing cylindrical forms in the metal, wood or any other machinable material.
(See Fig.1)

Fig.1

THE PRINCIPLE OF LATHE

1. BED: It is the base of lathe. It is casting made in one piece. It holds or supports all other parts
of lathe. (See fig.1)
2. HEAD STOCK: It is a permanently fastened on the inner ways at the left hand end of the
bed. It supports spindle and driving arrangements. All lathes receive their power through head
stock. (See fig.1)

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3. TAILSTOCK: It is the counter part of head stock of is situated at the right end of the bed. It
is used for supporting the work when turning on centers or when a long component is to be
held in a chuck. (See fig.1)

4. CARRIAGE: It is located between headstock. It can slide along bed guide ways and be
locked at any position by tightening the carriage lock screws. It consists of following five
main parts of lathe. (See fig.1)

5. APRRON: It is fastened to saddle. It contains gears and clutches for transmitting motion from
feed rod and hand wheel to the carriage. Also split nut which engages with the lead screw
during threading. The Clutch mechanism is used for transmitting motion from feed rod
whereas the split nut along with the lead screw moves the carriage during thread cutting. (See
fig.1)

1. SADDLE: It is made up of H shaped casting. It aids saddle to slide on bed guide ways by
operating hand wheels. (See fig.1)

2. COMPOUND REST: It supports the tool post and cutting tool in its various positions. It
maybe swiveled on the cross-side to any angle in the horizontal plane. (See fig.29)

3. CROSS-SLIDE: It is provided with a female dovetail on one side and assembled on top of
saddle having a mail dovetail.(See fig.1)

4. TOOL POST: It is used to hold various tool holders and tools. (See fig.1)

SPECIFICATION OF LATHE
The size of the lathe is specified by one of the following ways:
A) Length of the bed.
B) Distance between centers
C) Diameter of the work which can be turned between the ways
D) Swing over carriage.

RESULT: - Experiment is completed.

OUTCOME: - On successful completion of this experiment, the students will be able to

understanding the specification & working of center lathe machine tool and demonstrate it.

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EPERIMENT NO.2
OBJECTIVE: - To perform the operations Facing, Center drilling, plain turning, Step turning,
Taper turning, Grooving, Knurling & Chamfering on Centre Lathe machine.
.
TOOLS REQUIRED: Lathe Machine, Steel Rule 12” or 6”, Outside caliper, Vernier caliper,
Single point cutting tool, Knurling tool, Center drill, Drill chuck ½”, Spanner set, Parting tool,
etc.
MATERIAL REQUIRED: Mild steel Bar of 25 mm dia. & 125mm length.
DRAWING: (See fig. 2 & 3).

THEORY:- LATHE OPERATIONS:

Turning:-Turning is the operation to remove the material from the outside diameter of a work
piece to obtain the finished surface. (See fig.4)

Facing: - Is the operation of machining the end of a work piece to make the end square with owns
axis and that of the lathe. The tool moves perpendicular to axis of the lathe. (See fig.4)

Drilling: - Drilling is operation of making hole in work piece. This is done by holding the drill in
the tail stock quill. (See fig.4)

Reaming: Reaming is the operation of finishing the drilled hole. This is done by holding the
reamers in the tail stock quill. (See fig.4)

Boring: - Boring is the operation of enlarging the drilled hole of the work piece is held in chuck
in lathe spindle and boring bar is mounted in the tool post. The boring is done by moving the
carriage towards the head stock. (See fig.4)

KNURLING: - It is the operation of plastically displacing metal in to a particular pattern for the
purpose of creating a hand grip or roughened surface on a work piece. The knurling tool is held in
the tool post and is pressed against the surface of the work piece by the cross feed. (See fig.4)

Threading: - Threading is nothing but cutting helical groove on a work piece. Threads may be
cut either on the internal or external cylindrical surfaces. A specially shaped cutting tool, known
as thread cutting tool, is used for this purpose. Thread cutting in a lathe is performed by traversing
the cutting tool at a definite rate, in proportion to the rate at which the work revolves. (See fig.4)

Chamfering: - It is the operation of beveling the extreme end of a work piece. Chamfer is
provided for better look, to enable nut to pass freely on threaded work piece, to remove burrs and
protect the end of the work piece from being damaged. (See fig.4)

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PROCEDURE:

1. Understand the job drawing thoroughly and plan the job.

2. Cut off a 130mm long piece from 25 mm dia. Bar.
3. Hold the work piece in the Lathe chuck and perform facing and center drill operations. Repeat
the same on the other side also.
4. Hold the job in between live and dead centers.
5. Perform plain turning, chamfering and knurling operations on one side and interchange the
faces axially.
6. Perform plane turning by swiveling the compound rest at required angle.
7. Now start threading by setting levers as per requirement.
8. After filing if required, take off the job from m/c and do oiling in the whole job for the
protection from the rust.

PRECAUTION:
1. Don’t wear loose clothes while working on the machine.
2. Work piece should be held tightly between the live and dead centers.
3. Always clean machine before use.
4. Cutting tools should be held tightly in the tool holder.
5. Never let your clothes and hand come in contact with the revolving chuck, pulleys etc.
6. Do not touch the chips when machine is removing them
7. Do not give large feed to the cutting tool.

RESULT: - The practice of machine operation like “Facing, Center drilling, plain turning, Step
turning, Taper turning, Grooving, Knurling & Chamfering are successfully done on Centre Lathe
machine.

OUTCOME: - On successful completion of this experiment, the students will be able to

understanding the different operation which can be done on center lathe machine.

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Fig. 2

Fig. 3

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Fig. 3

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CARPENTRY SHOP

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SAFETY PRECAUTION
1. Don’t talk with another during the working time.

2. Don’t enter without shoes in shop.

3. Tools should be kept at proper place.

4. Keep hands and tools wiped, clean and free from oil and grease.

5. Don’t carry hand tools in pocket.

6. Test the sharpness of the cutting edge of cutting tools.

7. Use the chisel and hammer with a properly fitted and tight handle.

8. Hold the work piece in the carpentry vice firmly.

9. Marking and measuring should be done carefully.

10. Be careful when you are using your thumb as a guide in cross cutting.

LIST OF EXPERIMENT
1. To study the different type of hand tools, and operation of carpentry shop.

2. To prepare a Cross halving lap joint by using wooden work piece as per given
dimensions.

3. To prepare a Dove tail halving lap joint by using wooden work piece as per given
dimensions.

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EXPERIMENT NO.1
OBJECTIVE: - To study the different type of hand tools, and operation of carpentry shop.

CARPENTRY:- Carpentry is a skilled trade in which the primary work performed is the cutting,
shaping and installation of building materials during the construction of buildings, ships, timber
bridges, concrete formwork, etc.

COMMON TOOLS USED IN CARPENTRY

Carpentry tools are dividing into the following category.

1. Marking & Measuring Tools

STEEL RULE: - It is made of steel. Millimeter (mm) & centimeter's (cm) marking marked on
one edge and inches (") marking marked on another edge. It is used for taking accurate dimensions
on the job. It is getting in the market in length of 6", 12", 24", 1 meter & 2 meter. (See fig.1)

TRY-SQUARE: - Try-square is used for testing the squareness of wood and enabling lines to be
marked at right angles (90°) to a given surface. (See fig.2) Its parts are
a) Blade b) Stock c) Rivets.

Fig.1

PENCIL: - Used on drawing lines in the setting out the shapes of parts of the job. Always used
when setting out chamfers, levels or slopping edges etc. (See fig.2)

fig.2
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MARKING GAUGE: - Marking Gauge is used for marking lines parallel to a face or an edge.
(See fig.3)

Fig.3

2. Smoothing & Planing Tools

IRON JACK PLANE: - Plane is made of wood or metal. But now days, a metal jack plane or
Iron jack plane is used in carpentry. This is the quick adjustable plain. It is 14” in length. It's
blade's grinding and sharpening angle of 20-25° and 25-30°. It is used for smoothing as well as
removing rough surfaces quickly to bring in required size of sawn wooden piece. (See fig.4)

Fig. 4

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RASP: - A rasp is a tool used for shaping wood or other materials, rasps are used for rapidly
removing wood from curved surfaces. It consists of a point or the tip; it is a long steel bar, a heel or
bottom. The tang is joined to a handle, usually made of plastic or wood. The bar has sharp teeth.
Rasps generally cut more coarsely than files (See fig.5).

Fig.5

3. Cutting Tools

SAWS: - There are two types of saws used in carpentry shop.

Taper blade saw:- Hand saw or Rip Saw It is 15" to 18" in length, and the ratio of its blade slop
is 1:2, and 5 to 7 teeth per inch of blade length, the teeth of rip saw are 45 degree inclined, It is
used for cut the wood in along to the grain (parallel to the grain). (See fig.6).

Fig.6

Fig.7

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Parallel blade saw:-Tenon saw– it is used for fine and accurate cutting in joinery. It is 8”to 12” in
length with 8 to 12 teeth per inch with closed handle. The ratio of its blade slop is 1:1, and tenon
saw teeth are inclined at 60 degree and make an equilateral triangle, it is used for cut the wood in
across to the grain (perpendicular to the grain) (See fig.7).

CHISELS: - Mostly Firmer chisel and Mortise chisel are used in carpentry. Its size depends on
the width of blade, range in 3, 6, 9, 12, 18, 21, 25 mm, up to 50mm. Both chisel consist of two
main parts
a) Blade b) wooden handle.

Its angle of grinding and sharpening is 15 to 20° and 20 to 25°. Firmer chisel is used for
finish laps, mortise socket, pins, etc. And Mortise chisel is used for deep cutting or making
rectangular holes in wood called mortise. (See fig.8).

Fig.8

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4. Holding and Supporting Tools

BENCH VICE: - It is used to hold the job while performing various operations like planing,
sawing, trenching, chiseling, screwing, gluing etc (See fig.9).

Fig.9 Fig.10

THE WORK BENCH: - It is used for give support to the job while operations like cutting,
chiseling, planing etc. It is 6ft in length, 3ft wide and 33inch in height. It's top's lower portion is
called as “Well” to accommodate tools

BENCH HOOK: - A bench hook is a workbench accessory used in woodworking. The purpose
of the bench hook is to provide a stop which a piece of wood being worked can be placed against
to hold it steady whilst cutting, planing, or chiseling that piece of wood. Bench hooks make your
hand sawing safer and more accurate.
The bench hook is simply a short wooden board with a batten fixed top (the stop) and bottom (the
hook) at opposite ends (see diagram to the right). Usually, the stop is shorter than the width of the
bench hook's base and offset from one edge (See fig.10).

5. Striking Tools

MALLET: - It is used for driving chisel handle as well as assisting in assembling jobs. It is also
called as wooden hammer. They are rectangular or round in shape (See fig.11 & 12).

CLAW HAMMER: - It is used for where heavy hammering is necessary to drive large nails.
Useful size being 0.45 to 0.57kg. It is also has claws for extracting nails. (See fig.13).

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Fig.11 Fig.12

Fig.13

6. Miscellaneous Tools
SCREW DRIVER: - It has an alloy blade or bar (flat, round, or square) and wooden handle.
Common screw drivers used in carpentry is London pattern and Cabinet making screw drivers for
loosing or tightening the screws (See fig.14).

PINCER:- It is used for pull out the nails from wood. It is also called as a nail puller. It is used in
upholstery work to take out the nails(See fig.15).

HAND DRILL MACHINE: - It is used for making holes up to 12mm in wood (See fig.16)
.
OIL STONE: - It is used for sharpening the tools like chisels and planer blade (See fig.17).

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Fig. 14 Fig.15

Fig. 16 Fig.17

Result: - Experiment is successfully done.

Outcomes: - On successful completion of this experiment, the students will be able to

understanding the working of hand tool and demonstrate it.

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EXPERIMENT NO.2
Objective: To prepare a Cross halving lap joint by using wooden work piece as per given
dimensions.

Material Required: Soft wood (kail) of size: (300 x 50 x 22) mm, Quantity: 1No.
Drawing: See fig. 18

Tools to be used: Steel Scale, HB Pencil, Marking Gauge, Try-Square, Iron Jack Plane, Tenon
saw, Rip saw Hammer, & bench vice.

Procedure:-

1. Take a flat rectangular wooden work piece and holding it about 10mm above into the
wooden vice such as the surface of work piece is parallel to the jaws of vice and start
planning & smoothing operation with the help of Iron Jack Plane.

2. After smoothing then check flatness of the surface of work piece with the help of try-square,
if not done correctly then repeating step1.

3. After smoothing one surface then smoothing the adjacent side of the work piece with the help
of Iron Jack Plane and check the right angle between two smoothing sides with the help of
try-square.

4. After smoothing two adjacent surfaces, mark a parallel line both side the work piece 42mm
apart from the smoothing edge with the help of marking gauge and smoothing the work piece
to the marking line.

5. Again mark a parallel line on both side of the work piece 22mm apart from the smoothing
face and then smoothing the last face to the marking.

6. Doing marking on work piece according to given drawing with the help of HB pencil, steel
scale, try-square, and then cutting operation perform according to the marking.

7. Doing cutting and chiseling according to the drawing.

8. Assembly both part in cross shape with the help of hammer, and obtained the required joint.

Precautions:

1. Work piece should be hold properly in the vice.

2. Smooth the surface carefully and check the angle using a try square regularly at proper time
interval.
3. Iron jack plane should be driving slowly to both hands.
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4. Marking should be doing carefully.

5. Use saw in a proper direction for better cutting.
6. Paring with firmer chisel half way through from both edges.
7. While chiseling hold the piece with the help of 'G' clamp.
8. Don't saw or chisel without holding.
9. Always use proper sharpened tools.

Result: - Cross halving lap joint is prepared successfully according to dimensions provided.

Outcomes: - On successful completion of this experiment, the students will be able to prepare
itself any type of lap joint.

Fig.18

NOTE: All dimensions are in mm

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EXPERIMENT NO. 3
Objective: To prepare a Dove tail halving lap joint by using wooden work piece as per given
dimensions.

Material Required: Soft wood (kail) of size: (300x50x22) mm, Quantity: 1No

Drawing: See fig.19

Tools to be used: Steel Scale, HB Pencil, Marking Gauge, Try-Square, Iron Jack Plane, Tenon
saw, Rip saw Hammer, & bench vice.

Procedure:-
1 Take a flat rectangular wooden work piece and holding it about 10mm above into the
wooden vice such as the surface of work piece is parallel to the jaws of vice and start
planning & smoothing operation with the help of Iron Jack Plane.

2 After smoothing then check flatness of the surface of work piece with the help of try-square,
if not done correctly then repeating step1.

3 After smoothing one surface then smoothing the adjacent side of the work piece with the help
of Iron Jack Plane and check the right angle between two smoothing sides with the help of
try-square.

4 After smoothing two adjacent surfaces, mark a parallel line both side the work piece 42mm
apart from the smoothing edge with the help of marking gauge and smoothing the work piece
to the marking line.

5 Again mark a parallel line on both side of the work piece 22mm apart from the smoothing
face and then smoothing the last face to the marking.

6 Doing marking on work piece according to given drawing with the help of HB pencil, steel
scale, try-square, and then cutting operation perform according to the marking.

7 Doing cutting and chiseling according to the drawing.

8 Assembly both part in Tee shape with the help of hammer, and obtained the required joint.

Precautions:
1 Work piece should be hold properly in the vice.
2 Smooth the surface carefully and check the angle using a try square regularly at proper time
interval.
3 Iron jack plane should be driving slowly to both hands.
4 Marking should be doing carefully.
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5 Use saw in a proper direction for better cutting.

6 Paring with firmer chisel half way through from both edges.
7 While chiseling hold the piece with the help of 'G' clamp.
8 Don't saw or chisel without holding.
9 Always use proper sharpened tools.

Result: - Cross halving lap joint is prepared successfully according to dimensions provided.

Outcome: - On successful completion of this experiment, the students will be able to prepare itself
any type of lap joint.

fig.19

NOTE: All dimensions are in mm

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WELDING SHOP

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SAFETY PRECAUTION

1. If you can smell gas – don’t light any gas torches or use electric welding equipment, but
don’t rely wholly on your sense of smell to warn you.
2. Wear eye protection and cover bare skin. Be aware that:
 arc flash can occur through the side of the eye.
 arc flash can cause ‘sunburn’ on exposed skin.
3. Mark hot surfaces as such. Better still, assume everything is hot.
4. Know how to use gas equipment safely.
 Oxygen under pressure can cause the spontaneous combustion of oil or grease.
 Keep all regulators and air hoses free of oil and grease, and avoid getting grease/oil on
hands, gloves and overalls.
 Use the right gases for the situation. Never substitute oxygen for compressed air.
5. Ensure the equipment has the correct current capacity.
6. Provide an isolating switch.
7. Where a flammable gas or solvent is present, an electrical spark might cause an explosion, so
welding should not occur.
8. Check the electrical safety of the rod holder or welding hand-piece regularly – maintain or
replace as required.
9. Use the shortest possible leads and ensure they are capable of carrying the required current
safely.
10. Dry your hands before welding. If you get sweaty, dry off, take a break and use a wooden
duckboard to insulate yourself.

LIST OF EXPERIMENT
(1) To study the different type welding processes, welding defect and hand tools used in
welding shop.

(2) To prepare a Lap joint by the use of Electric Arc Welding process.

(3) To prepare a Butt joint by the use of Electric Arc Welding process.

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EXPERIMENT NO. 1
Objective: To study the different type welding processes, welding defect and hand tools used in
welding shop.

VARIOUS TYPES OF WELDING

Forge Welding: This welding is done by the black-smiths. In this two similar metal pieces are
heated upto the plastic stage in the furnace. Then it is hammered so that a homogeneous mixture is
formed at the joint. The surface to be joined should be cleaned and made free of any foreign particle,
this is done by brushing.

Gas Welding: Gas welding is the process in which a gas flame is used to raise the temperature of
the metals to be joined. The metals are heated up the melting. The metal flows and on cooling it
solidifies. A filter metal may be added to the flowing molten to fill up cavity made during the end
preparation. Many combinations of gases are used in gas welding. But the most common of these is
oxygen and acetylene.

Arc Welding: The welding in which the electric arc is produced to give heat for the purpose of
joining two surfaces is called electric arc welding.

Principle: Power supply is given to electrode and the work. A suitable gap is kept between the work
and electrode. A high current is passed through the circuit. An arc is produced around the area to be
welded. The electric energy is converted into heat energy, producing a temperature of 3000ºC to
4000ºC.

 Two Basic Types of AW Electrodes

1. Consumable–consumed during welding process.

Source of filler metal in arc welding.

Forms of consumable electrodes: Welding rods are 9 to 18 inches and 3/8 inch or less in diameter
and must be changed frequently
 Weld wire can be continuously fed from spools with long lengths of wire, avoiding frequent
interruptions.
 In both rod and wire forms, electrode is consumed by arc and added to weld joint as filler metal
(See fig. 1)

2. Non-consumable – not consumed during welding process.

 Filler metal must be added separately.
 Made of tungsten which resists melting.
 Gradually depleted during welding (vaporization is principal mechanism).

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 Any filler metal must be supplied by a separate wire fed into weld pool.

Fig. 1
FLUX
A substance that prevents formation of oxides and other contaminants in welding, or dissolves
them and facilitates removal
 Provides protective atmosphere for welding
 Stabilizes arc
 Reduces spattering

Resistance Welding: Resistance welding is a group of welding processes wherein coalescence is

produced by the heat obtained from resistance of the work to the flow of electric current in a
circuit of which is the work is a part and by the application of pressure. No filler metal is needed.

Different types of Welding Defect

 A weld defect is any physical characteristic in the completed weld that reduces the strength
and/or affects the appearance of the weld.
 Defects that are not visible must be detect by using destructive or nondestructive testing.

Incomplete joint:
The depth of the weld is less than specifications (See fig.2).

Fig.2

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Improper fusion: The weld metal is not completely fused to base metal or passes are not
completely fused (See fig.3)

Overlap: The weld metal is not completely fused to base metal or passes are not completely fused
(See fig.4)

Fig.3 Fig.4

Insufficient Penetration: Weld bead does not extend to the desired depth.

Pits: Small indentions in the surface of the weld (See fig.5).

Fig. 5

Porosity: Small voids throughout the weld material (See fig.6)

Fig. 6 Fig.7

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Vertical Cracks: Usually visible cracks on the surface or through the weld (See fig.7)

Irregular Weld: Misshapen and/or uneven ripples (See fig.8).

Fig. 8

TOOLS USED IN WELDING SHOP

Welding Helmet: A welding helmet is a type of headgear used when performing certain types
of welding to protect the eyes, face and neck from flash burn, ultraviolet light, sparks, infrared
light, and heat. (See fig.9)

Welding Goggle
Green glass goggles are needed use for torch welding and also have ANSI standards.(American
National Standards Institute) When viewing metal that is visibly hot (even before)(or the torch) for
longer periods protection is needed for the eyes. While it seems to be low light the wavelengths
are bright in non-visible spectrum. These are easier to see through and wear than helmets (See fig.
10)

Fig. 9 Fig. 10

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Chipping hammer: A chipping hammer is a tool used to remove welding slag from a weld and
welding spatter from alongside welds.
It is used to remove slag when standard arc welding is performed as slag is not produced
when MIG or TIG welding is performed. Also used to remove welding spatter in all welding
processes (See fig.11).

Wire brush:- A wire brush is a tool, consisting of a handle, usually wood or plastic. The brush is
usually made from a large number of steel wire bristles.
This is used for cleaning rust and removing paint. It is also used to clean surfaces and to
create a better conductive area for attaching electrical connections (See fig.12).

Fig. 11 Fig. 12

Electrode Holder: An electrode holder, commonly called a stinger, is a clamping device for
holding the electrode securely in any position. The welding cable attaches to the holder through
the hollow insulated handle. The design of the electrode holder permits quick and easy electrode
ex-change. Two general types of electrode holders are in use: insulated and non-insulated.
The non insulated holders are not recommended because they are subject to accidental short
circuiting if bumped against the work-piece during welding. For safety reasons, try to ensure the
use of only insulated stingers on the jobsite (See fig. 13).

Fig.13
Result: - Experiment is successfully done.

Outcomes: - On successful completion of this experiment, the students will be able to

understanding the different welding process and working of hand tool.

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EXPERIMENT NO. 2
OBJECTIVE: To prepare a Lap joint by the use of Electric Arc Welding process.

MATERIAL USED: MS Plate of size (48x48x7)mm – Two Piece.

DRAWING:- See fig.14

TOOLS & EQUIPMENTS REQUIRED: Arc welding machine with all the accessories,
electrode holder, earth clamp, try square, hacksaw, steel rule, hammer, pair of tongs, chipping
hammer, face shield etc

MATERIAL REQUIRED:
Electrode: MS Electrode 3.15 mm dia. [SWG 10] length 350 mm.

Theory:- Lap Joint: This type of joint is used in joining two overlapping plates so that the
corner of each plate is joined with the surface of other plate. Common types of lap joints are single
lap, double lap or offset lap joint.

Procedure:
1. Marking and cutting the MS Flat
2. Start the welding transformer machine, and then set the current to approx. 100 amps.
3. Tack both the sides of joints. Keeping the flat position of the job, complete the layer.
4. Clean with a chipping hammer and a wire brush and then check the welding layer.

Precaution:

1. Never look at the welding arc without face shield.

2. Always wear flexible gloves and leather apparels.

3. Never touch the hot job with hands.

4. Use specified current and electrodes for arc welding.

Result: - Lap joint is successfully prepared by the use of electric arc welding process.

Outcomes: - On successful completion of this experiment, the students will be able for fabrication
work with the help of electric arc welding process.

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Fig. 14

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EXPERIMENT NO. 3
OBJECT: To prepare a Butt joint by the use of Electric Arc Welding process.

MATERIAL USED: MS Plate of size (100x50x7)mm – Two Piece

TOOLS & EQUIPMENTS REQUIRED: Arc welding machine with all the accessories,
electrode holder, earth clamp, try square, hacksaw, steel rule, hammer, pair of tongs, chipping
hammer, face shield etc.

Material Used:
Electrode: MS Electrode 3.15 mm dia. [SWG 10] length 350 mm

Drawing: See fig.15

THEORY: - Butt Joint: In this type of joint, the edges are welded in the same plane with each
other. V or U shape is given to the edges to make the joints strong (See fig.32).

Procedure:
1. Marking and cutting the MS Flat
2. Start the welding transformer machine, and then set the current to approx. 100 amps.
3. Tack both the sides of joints. Keeping the flat position of the job, complete the layer.
4. Clean with a chipping hammer and a wire brush and then check the welding layer.

Precaution:
1. Never look at the welding arc without face shield.
2. Always wear flexible gloves and leather apparels.
3. Never touch the hot job with hands.
4. Use specified current and electrodes for arc welding.

Result: - Butt joint is successfully prepared by the use of electric arc welding process.

Outcomes: - On successful completion of this experiment, the students will be able for fabrication
work with the help of electric arc welding process.

Fig.15

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FOUNDRY SHOP

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SAFETY PRECAUTION
1. Leather gloves, shoes, & apron should be wearing during the working period at foundry shop.

2. Vent hole for passing air & gas should be made proper in mould by vent wire.

3. Moisture content should be check before moulding.

4. Moulding box cope & drag should keep in proper alignment on the moulding bench.

5. Ramming of sand should be done properly during moulding.

6. Runner, Riser & gate should be set in proper alignment.

7. Remove carefully all the extra item like runner, riser, gate, and pattern etc. after complete
desire mould.

LIST OF EXPERIMENT
1. To study the different type of hand tools, materials and moulding processes used in
foundry shop.

2. To prepare a Sand mould for solid casting with the help of given Step Pulley Pattern.

3. To prepared the mould for hollow casting with the help of Step Pulley Pattern and core.

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EXPERIMENT NO. 1
OBJECTIVE:- To study the different type of hand tools and materials used in foundry shop.

FOUNDRY HAND TOOLS

SHOWEL: It consists of an iron pan with a wooden handle it can be used for mixing and
conditioning the sand and then transferring the mixture in some container (See fig.1)

TROWEL: These are used for finishing flat surface and corner inside a mould (See fig.2).

Fig.1 Fig.2

LIFTER: A lifter is a finishing tool used for repairing the mould and finishing the mould sand.
Lifter is also used for removing loose sand from mould. (See fig. 3)

HAND RIDDEL: It is used for ridding of sand to remove foreign material from it. It consists of a
wooden frame fitted with a screen of standard wire mesh at the bottom. (See fig. 4)

Fig. 3 Fig. 4

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STRIKE OFF BAR: It is a flat bar made of wood or iron to strike off the excess sand from the
top of a box after riming. (See fig.5)

VENT WIRE: It is a thin steel rod or wire carrying a pointed edge at one and a wooden handle or
a bent loop at the other. After ramming and striking of the excess sand it is used to make small
holes called vents in the sand mold to allow the exit of gasses and steam during casting. (See fig.
6)

DRAW SPIKE: It is a tapered steel rod having a loop or ring at it is one end and a sharp point at
the other it is used to tap and draw patterns from the mould.

Fig. 5 Fig. 6

RAMMER: Rammer are used for striking the sand mass in the molding box to pack it closely
around one pattern. (See fig. 7)
a) Peen rammer
b) Floor rammer
c) Hand rammer

SLICKS: This is used for repairing and finishing the mould surfaces and edges after the pattern
has been withdrawn the commonly used slices are heart and leaf square and heart spoon and bead
and heart and spoon. (See fig. 8)

Fig. 7 Fig. 8

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SMOOTHER AND CORNER SLICKS: They are also finishing flat and round surfaces round
or square corners and edges.

SWAB: It is a hemp fiber brush used for moistening the edges of sand mould which are in contact
with the pattern surfaces before withdrawing the pattern it is also used for coating the liquid
blocking on the mould faces in dry sand moulds. (See fig. 9)

Fig. 9 Fig. 10

Runner: The channel through which the molten metal is carried from the sprue to the gate. (See
fig. 10)

Riser: A column of molten metal placed in the mould to feed the castings as it shrinks and
solidifies. Also known as “feed head”. (See fig. 10)

DRAW SCREWS AND RAPPING PLATE: It is a long mild steel rod with a ring in one end
and threaded at the other, there is a plate known as rapping plate consisting of several tapped
holes. (See fig. 11).

MOULDING BOXES: The moulding boxes or flasks used in sand moulding are of two types
(See fig. 12).

(a) Closed moulding boxes. (b) Open type of snap flasks.

Fig. 11 Fig. 12
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MOULDING SAND
Moulding sand is one of the most important and materials in production of sand casting. Sand is
formed by breaking up of rocks due to natural forces such as frost wind, rain and action of water.
a. Natural sand
b. Synthetic sand

TYPES OF SAND USED IN MOULDES

1. Dry sand 2. Green sand
3. Loam sand 4. Facing sand
5. Parting sand 6. Backing sand
7. Core sand 8. Oil sand
9. Molasses sand

COMPOSITION OF GREEN SAND

1. Silica sand 75% 2. Coal dust 8%
3. Bentonite sand 12% 4. Water 5 to 6%
PROPERTIES OF MOULDING SAND
1. Porosity and permeability 2.Refractoriness
3. Adhesiveness 4. Cohesiveness
5. Chemical resistance 6. Plasticity
7. Moisture

MAIN CONSTITUENT OF MOULDING SAND

The principal constituents of moulding sand are
1. Silica sand 2. Binder
3. Additives 4. Water

BINDERS
The purpose of adding to the binder to the moulding sand is to impart it sufficient strength &
cohesiveness so to enable it to retain its shape after the mould has been rammed & the pattern
withdrawn. However it produces an obverse effect on the permeability of the sand mould.

RESULT: - Experiment is successfully done.

OUTCOMES: - On successful completion of this experiment, the students will be able to

understanding the proper name and working of moulding hand tools and material process and
moulding sand and their properties.

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EXPERIMENT NO. 2
OBJECTIVE:- To prepare a Sand mould for solid casting with the help of Step Pulley Pattern.

Material Required: Green sand

Tools to be used: Step Pulley Pattern, Moulding boxes or flasks, Trovels, Plane smoother Lifter
Vent wire, Swab, Gate Cutter Spru pin, Spru cutter, Slicks, Draw spike.

Drawing:- See fig. 13

Procedure:- Take the moulding box and properly placed it on the table. With the help of trovel
filled the green sand inside the drag of the moulding box. Now ram the sand using the rammer
leaving a very little space over drag in order to place the pattern. After placing the pattern match
the centre point of the pattern with that of the above part of drag. Hold the pattern over there for a
while and fill the sand around the pattern properly. Remove the extra sand with the help of
leveling scale or plane smoother. Adjust the gate cutter on either side of the pattern and place two
sprue pins on the respective gate cutter. One of the pin will act as a runner and other will be as
riser. Now place the cope of moulding box over drag and fill it properly with the sand with the
help of rammer. Remove the extra sand with plane smoother. After leveling, using vent wire
make small holes over the mould cavity in order to provide proper ventilation of gases. Slightly
pick up the cope . remove the pattern slowly and replace it on the drage. Also, remove gate
cutters from drag as well as sprue pins from cope. Now, make core using core box and core sand
of desired size. Place this core on core prints inside the mould cavity in order to get the desired
cavity of hollow cylinder.

Precautions:

1. Cope & Drag part of moulding box should be kept in proper alignment.
2. Runner and Riser should be placed in proper alignment.
3. Parting sand should be provided in between cope and drag.
4. Remove the extra item like runner, riser and pattern very carefully after completing the
desired mould.
5. Holes using vent wire should be made before removing the pattern from the moulding box.

Result: - Sand mould of Step Pulley for solid casting is successfully prepared.

Outcomes: - On successful completion of this experiment, the students will be able for prepare a
sand mould for solid casting at proper way.

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Fig. 13

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EXPERIMENT NO. 3
OBJECTIVE:- To prepared the mould for hollow casting with the help of pattern and core.

Material Required: Green sand.

Tools to be used: Pattern, Moulding boxes or flasks, Trovels, Plane smoother Lifter Vent wire,
Swab, Gate Cutter Spru pin, Spru cutter, Slicks, Draw spike

Drawing:- see fig. 14

Procedure:- Take the moulding box and properly placed it on the table. With the help of trovel
filled the green sand inside the drag of the moulding box. Now ram the sand using the rammer
leaving a very little space over drag in order to place the pattern. After placing the pattern match
the centre point of the pattern with that of the above part of drag. Hold the pattern over there for a
while and fill the sand around the pattern properly. Remove the extra sand with the help of
leveling scale or plane smoother. Adjust the gate cutter on either side of the pattern and place two
sprue pins on the respective gate cutter. One of the pin will act as a runner and other will be as
riser. Now place the cope of moulding box over drag and fill it properly with the sand with the
help of rammer. Remove the extra sand with plane smoother. After leveling, using vent wire
make small holes over the mould cavity in order to provide proper ventilation of gases. Slightly
pick up the cope . remove the pattern slowly and replace it on the drage. Also, remove gate cutters
from drag as well as sprue pins from cope. Now, make core using core box and core sand of
desired size. Place this core on core prints inside the mould cavity in order to get the desired
cavity of hollow cylinder.

Precautions:

1. Cope & Drag part of moulding box should be kept in proper alignment.
2. Runner and Riser should be placed in proper alignment.
3. Parting sand should be provided in between cope and drag.
4. Remove the extra item like runner, riser and pattern very carefully after completing the
desired mould.
5. Holes using vent wire should be made before removing the pattern from the moulding box.

Result: - Sand mould for hollow casting is successfully prepared.

Outcomes: - On successful completion of this experiment, the students will be able for preparing
a sand mould for hollow casting (pipe, hollow cylinder etc) at proper way.

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Fig. 14

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SHEET METAL SHOP

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SAFETY PRECAUTION

1. Since in sheet metal work we used sharp tools to cut sharp cutting edges. Be careful on
working on sharp edges to avoid injury.

2. Avoid using any tools whose edges are blunt or out of order.

3. Appropriate cutting tools and machine must be used for cutting tin sheets.

4. Extra allowance must be provided in the sheets while cutting so that furnished product is of
correct size and finish.

LIST OF EXPERIMENT

1. To study the different type of hand tools, used in sheet metal shop.
2. To make a Rectangular box using G.I Sheet as per given dimension

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Experiment No.1
OBJECTIVE: - To study the different types of sheet, joints, sheet metal operations and hand
tools, of sheet metal shop.

INTRODUCTION
Sheet metal working covers the use of thin metallic sheets with hand tools and sheet metal
machines. Many important engineering articles made up of sheet metal such as air conditioning
ducts, making component of aircraft industry, agriculture implements, decorative articles and
household goods. For effectively working in sheet metal one should have knowledge of hand tools,
sheet metal machines, properties of metals and thorough knowledge of projective geometry i.e.
development of surfaces.

TYPES OF METAL SHEET

1. Ferrous Sheet

i) Mild Steel sheets – These are black iron sheets, suspected to rust and corrosion, mostly used for
making water tanks and fabrication works.

ii) Galvanized Iron (GI Sheet) –It is soft steel sheet coated with zinc, which is corrosion
resistance due to zinc coating, used for making air-conditioning ducts, boxes, buckets, coolers
etc.

iii) Stainless steel sheets – It is an alloy of high-grade steel with chromium, nickel, phosphorous
and manganese. It is used in household goods, food-processing plants etc.

iv) Tin Plate: - steel coated with tin is called Tin steel. It is used for making food containers.

2. Non-ferrous sheets

i) Aluminum Sheets – It is two and half times lighter than iron but lacks in tensile strength. Small
percentage of other elements like copper, manganese and silicon is added to make it suitable
for production in aircraft industry and other industrial goods. It is also called aluminum alloy
sheets.

ii) Copper and Brass sheets – These are non-ferrous sheets used in electrical industry and various
other industrial and household articles.

MEASUREMENT OF SHEETS

Thickness of sheet is generally measured by gauge number, which is obtained by actually

measuring the sheet thickness with a sheet gauge or wire gauge. Each slot in the standard wire
gauge is numbered, a number, which represents gauge number such as 20 SWG (Standard Wire
Gauge). The more the SWG number, lesser is the thickness of sheet.
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TOOLS USED IN SHEET METAL

Marking Tools

1. Steel Rule:
Available in different sizes, it could be steel foot rule, folding rule or tape rule. (See fig. 1)

2. Scriber:
It is a steel wire with one end sharp and hardened to mark lines on metallic sheet. (See fig.2).

fig.1 fig.2

3 Divider: It is used to scribe arcs and circles on metallic sheets. (See fig. 3)

4 Trammel points: It is used for drawing large circles and arcs. (See fig. 4)

Fig. 3 Fig. 4

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3. Punches: Following punches are used in Sheet metal work.

(a) Prick Punch: Used for making indentation marks for locating center position for dividers, it
has a taper angle of 30º (See fig. 5)

(b) Centre Punch: Used for marking the location of points and centering hole to be drilled. It has a
taper angle of 90º. (See fig. 6)

Fig. 5 Fig. 6 Fig.7

Cutting Tools
Hollow Punch: Hollow punch is used to cut circular holes on thin sheets. (See fig. 7)

Straight Snips: It’s blades are straight and it is used to cut 22 SWG or lighter sheets along straight
line. (See fig. 8)

Bent snip: Blades are curved back from the cutting edges; it is used to cut discs and round articles
from sheets. (See fig. 9)

Fig. 8 Fig. 9

Chisels: This is used for cutting sheets, rivets and bolts.

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Striking Tools
Hammers: Hammers are used for bending of sheets, smothering of sheets, locking of joint sand
riveting work.

(a) Ball Peen Hammer: General purpose, face is slightly curved, and head is round (See fig.10).

(b) Square face hammer: It has square flat face, used for flattening of seams (See fig.11)

Fig. 10 Fig. 11 Fig. 12

(c) Raising Hammer: It is used to form flat surface of sheet into curved surface. (See fig.12)

(d) Riveting Hammer: Face is square slightly curved with beveled edges. (See fig.13)

(e) Mallet: Made of good quality of wood or plastic used whenever light force is required. (See
fig.14)

Fig. 13 Fig. 14

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Supporting Tools
1. Stakes – Stakes are used to support sheets in bending, seaming, forming, riveting, punching etc.
Some commonly used stakes are:

(a) Hand stake: It is handy with flat face, two straight edges one concave edge, other convex edge,
used for pressing the inner sides of straight joint.

(b) Half Round stake: It is used for pressing round seam joint on inner side. (See fig. 15)

(c) Taper stake: It is used for rounding of tapering jobs such as conical jobs. (See fig. 16)

Fig.15 Fig. 16

(d) Grooving stake: It is made up of forged steel, used for grooves of different sizes. (See fig. 17)

(e) Horse stake: There are two square holes for holding two stakes at a time for carrying out
different operations. (See fig. 18)

Fig. 17 Fig. 18
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SHEET METAL JOINTS

Lap Joint – It can be prepared by means of soldering or riveting.

Seam Joint – When two or more sheets are folded and fastened together is called seam joint.

There are two types of seam joints.

i) Single Seam Joint ii) Double Seam Joint

Groove Seam Joint – In this joint two single edges are hooked together and flattened with a small
mallet to make them tight, seam is then grooved with a hammer and a hand Grover.

Wired Edge – It is one of the methods of strengthening the thin metal by turning over the edge on
a wire in it.

Hinged Joint – It is used for easy movement of opening or closing doors, window etc.

Cap Joint – It provides another useful form of locked seam joint.

Hem Joint- This is turning over the edge of the sheet to give the strengthening on the edge of the
sheet.

SHEET METAL OPERATIONS

1. Measuring and Marking – Sizes are marked on large sheet to cut the latter into small pieces.

2. Development of Surface (Laying Out) – Operation of scribing the development of surface of

the component on the sheet together with the added allowance for overlapping, bending,
hammering etc.

3. Cutting and shearing – The term shearing stands for cutting of sheet metal by two parallel
cutting edges moving in opposite direction.

4. Hand Forming – It stands for shaping, bending of sheet in three dimensions in order to give
the desired shape and size of final product.

5. Nibbling– It is a process of continuous cutting along a contour which may be of straight or

irregular profile.

6. Piercing and Blanking– Piercing is basically a hole punching operation while blanking is an
operation of cutting out a blank.

7. Edge Forming or Wiring– Edges of sheet metal products are folded to provide stiffness to
the products and to ensure safety of hand due to sharp edges

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8. Joint Making– Sheet metal parts can be joined by folded joints, riveting, welding, brazing,
soldering, self-tapping screws, screwed fastening, and by adhesives.

9. Bending– Bend in sheet metal is to be bent at different angles to shape it to required form.

10. Circle Cutting– It is an operation of cutting circular blanks or curved contours with the help
of circular cutting machines.

11. Hollowing– It is the process whereby a flat sheet metal is beaten up into spherical shape by
placing the metal upon a sand bag or hollowing block, beating with hollowing hammer,
starting from boundaries towards center.

12. Raising– It is the process of hammering the metal from oxide to form a hollow article,
working around from center towards edge.

13. Turned over Edge– It is the method of strengthening the thin metal at edge. The edges are
turned with some radius.

14. Swaging– This is also a method of strengthening thin sheet metal by making impressions in the
bodies. It is done by machine or by hand.

Result: - Experiment is successfully done.

Outcomes: - On successful completion of this experiment, the students will be able to:

1 Acquire practical knowledge of different types of sheet and their practical uses.
2 Understand the proper uses of hand tool and demonstrate it.
3 Knowledge of different sheet metal joints & operation.

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Experiment No. 2
Objective: - To make a Rectangular box using G.I Sheet as per given dimension.

Tools Required: - Straight snip, steel rule, scriber, Mallet, Hammer, Stakes, pliers, soldering iron,
solder, flux, bench vice, file, spring divider.
Materials used: - Galvanized iron sheet 28 SWG.
Drawing: - (See fig.19).
Theory:-
Development of surfaces of various objects
A layout of the complete surface of a three dimensional object on a plane is called the development
of pattern. Development is the term frequently used in sheet metal work where it means the
unfolding or unrolling of a detail into a flat sheet called pattern.
Practically, the development consists of drawing the successive surfaces of the object in its true
shape and size with common edges joined together.
Methods of pattern development
There are three methods in general use by means of which surface of solids may be geometrically
developed.
(i) Radial Line Method: - a radial line method id used for those objects such as cones and
pyramids, the sides of which converge to an apex.

(ii) Parallel Line Method: - This method can be applied to the development of pattern for elbows,
T-pipes intersection of pipes of equal diameter, cylindrical articles.

(iv) Triangulation Method: - This method is universally applied to solve a large number of
developments
Procedure:
1. Draw a lay out as shown in development on drawing sheet.
2. Cut the pattern to shape along the line using a suitable snip.
3. Mark on the G.I Sheet as per the pattern and cut to required shape.
4. Make the hem edge using mallet and stake.
5. Make closed folds on both ends for lock seam joint
6. Make square folds on lines marked A, B, C, D, E, & F
7. Make lock seam joint after joining both the ends.
8. Make a bottom piece from G.I Sheet taking required allowance for double lock seam joints as
shown in diagram.
9. Join the bottom piece with square box by double lock seam joint using stakes and mallet.
10. Do the soft soldering operation on the corners of double lock seam joints?
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11. File all the sharp corners with file.

Precautions:-
1. Be careful while working on sharp edges of sheets to avoid injury.
2. Do not use blunt cutting edges tool.
3. Appropriate cutting tools and machines must be used for cutting tin sheets.
4. Extra allowance must be provided in the sheets while cutting so that finished product is of
correct size & finish.

Result: - Rectangular box of G.I. sheet is successfully prepared.

Outcomes: - On successful completion of this experiment, the students will have the practically
knowledge that how to prepare sheet metal object.

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Fig. 19 Development of Rectangular Box

Note: All Dimensions are in “mm”

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Fig. 20

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