Wa0256.

CHAPTER - 1
INTRODUCTION
Our minor project is to fabricate a CUPBOARD for welding workshop. We

know that it is difficult to store work pieces in welding work shop, so we have made
cupboards then it will be easier to keep work pieces safely.
Minor project work included in our curriculum is intended to enable a student
to develop a model of a product. Learn financial planning and to enhance team spirit
and creative talents for achieving goal. It is easy to understand a student to take
steps to begin a small scale industry as an entrepreneur by preparing a minor project
and its report.
Usually the minor project in our syllabus in its academic way, enable a youth
to design a product or to modify an existing product and find out a methodto
manufacture it economically. Contrary to the above concept we the second year
mechanical engineering students decide to take minor project work the
“DESIGNING AND MAKING OF CUPBOARD” with a view keeping in mind
that it should be useful to the student & to the students in coming years. Really we
succeeded in the work and this gives us a confidence to make contract with any type
of mechanical work. Overall a satisfaction with a fruitful gift to a student
community.
Page 1
CHAPTER – 2
FIELD OF WORK
2.1 WELDING
Welding is the process of joining two plastic or metal parts by melting them,
with or without using a further molten material. The heat produced by an arcis used
in welding to melt metal rods, which solidify to provide a strong joint between two
metal surfaces.
2.2 ARC WELDING

Arc welding is a type of welding process using an electric arc to create heat
to melt and join metals. A power supply creates an electric arc between a
consumable or non-consumable electrode and the base material using either direct
(DC) or alternating (AC) currents.
Fig 2.1 Arc Welding Process
An arc welding machine is a machine that uses electricity to join pieces of

base metal together by way of an electrode that is either consumable or non-
consumable. The main components of an arc welder are: electrode, ground, power
supply. Either AC or DC may be implemented to accomplish this process.
Page 2
2.3 MAIN PARTS OF A WELDING MACHINE
A. Step down transformer

B. Electrode cable
C. Current control unit
D. Earth clamp
E. Electrode holder
Fig 2.2 Arc Welding Machine
A: STEP DOWN TRANSFORMER
Fig 2.3 Stepdown Transformer
A welding power supply is a device that provides an electric current to

perform welding. Welding usually requires high current (over 80 amperes) and it
can need above 12,000 amperes in spot welding. Low current can also be used;
welding two razor blades together at 5 amps with gas tungsten arc welding is a good
example. A welding power supply can be as simple as a car battery and as
sophisticated as a high-frequency inverter using IGBT technology, with computer
control to assist in the welding process.
Page 3
B: ELECTRODE CABLE
Welding cable is designed for use in electric arc-welding machines topower
an electrode, a specially designed metal rod that conducts a charge. The charge
carried by the electrode is needed to produce an electric arc, the heat source,
between the electrode and the metals being welded.
Welding cable is made to be extremely durable and flexible. Arc-welding
requires a person to move the electrode around the shop and along the joints being
welded, so it is essential to have a flexible welding cable that allows for ease of
movement. High strand count and rubber insulation help increase the cable's
flexibility.
A durable cable is important in industrial environments where abrasions,
cuts, burns from sparks, and oil and water exposure can quickly wear out a weaker
cable.
Fig 2.4 Electrode Cable
C: CURRENT CONTROL UNIT
Fig 2.5 Current Control Unit
Page 4
A welding power supply is a device that provides an electric current to
perform welding. Welding usually requires high current (over 80 amperes) and it
can need above 12,000 amperes in spot welding. Low current can also be used;
welding two razor blades together at 5 amps with gas tungsten arc welding is a good
example. A welding power supply can be as simple as a car battery and as
sophisticated as a high-frequency inverter using IGBT technology, with computer
control to assist in the welding process.
D: EARTH CLAMP
The earth clamp is a tool that, via the earth cable, ensures the electrical circuit
to be closed between the welding power source and the piece to be welded.
Fig 2.6 Earth Clamp
E: 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 exchange.
Fig2.7Electrode Holder
Page 5
2.9 GRINDING
A grinding is one of the power tools or machine tools used for grinding .it is a type
of machining using an abrasive wheel as the cutting tool. Each grain on the abrasive
on the wheels surface cuts a small chip from the work piece via shear formation
grinding is used to finish work pieces
Fig 2.8 GRINDING

2.10 GRINDING WHEEL
A grinding wheel is a wheel composed of an abrasive compound and used for
various grinding (abrasive cutting) and abrasive machining operations. Such wheels
are used in grinding machines.
The wheels are generally made from a composite material consisting of coarse
particle aggregate pressed and bonded together by a cementing matrix (called the
bond in grinding wheel terminology) to form a solid, circular shape.
Fig 2.9 GRINDING WHEEL

2.11 HAND CUTTER
A disc cutter is a specialized, often hand-held, power tool used for cutting hard
materials, ceramic tile, metal, concrete, and stone for example. This tool is very
Page 6
similar to an angle grinder, chop saw, or even a die grinder, with main difference
being cutting disc itself, (circular diamond blade, or resin-bonded abrasive cutting
wheel for disc cutter vs. abrasive grinding wheel for angle grinder). This tool is
highly efficient at cutting very hard materials especially when compared to hand
tools.
Fig 2.10 HAND CUTTER

2.12 CUTTING WHEEL
A cutting disk, the edge of which is impregnated with an abrasive, such as

diamond dust or aloxite.
Fig 2.11 CUTTING WHEEL
Page 7
2.13 STRAIGHT SNIP
Fig 2.12 STRAIGHT SNIP

The straight snips are used to cut sheet metal along straight lines and outer sides
of curves. While cutting a sheet metal, blades are pressed against the sheet, which
causes shearing tension from both sides and the cutting action takes place.
2.14 ABRASIVE SAW

An abrasive saw, also known as a cut-off saw or chop saw, is a circular saw (a kind
of power tool) which is typically used to cut hard materials, such as metals, tile, and
concrete. The cutting action is performed by an abrasive disc, similar to a thin
grinding wheel.
Fig2.14 ABRASIVE SAW
Page 8
2.15 CUTTING WHEEL
MS cutter is the easiest way to cut the mild steel ,cast iron etc. it is made up of high
quality silicon carbide which provide aggressive abrasive action while cutting.
Double coating net for preventing sudden breakage while usage. Widely used in
construction industries
Fig 2.15 CUTTING WHEEL
Page 9
SCMS COLLEGE OF POLYTECHNICS, Vaikkara, Perumbavoor – 683549. Ernakulam.
CHAPTER – 3
PROCESS
3.1 : MATERIALS REQUIRED

3.2 GI square pipes of 1 inch
3.3 GI sheet of 1.22mm thickness
3.4 Thinner
3.5 Metal primer
3.6 M Seal
3.7 3.15x350mm Welding Electrode
3.2 GI SQUARE PIPES OF 1 INCH

GI (Galvanised Iron) square pipes are manufactured using mild steel strips of Low
Carbon Steel Coils. The GI Pipes are generally used for distribution of treated or
raw water in rural or urban areas. These pipes are cheaper, light weight and easy
to handle.
Fig 3.1GI SQUARE PIPES

3.3 GI SHEET OF 1.22mm THICKNESS
Galvanized iron (GI) sheets are steel sheets which are basically coated with zinc
and include a range of hot dip galvanized and electro-galvanized steel sheets.To
protect the steel from corrosive attack
Fig 3.2 GI SHEET
Department of Mechanical Engineering Page 10

3.4 THINNER
The Paint thinner is a solvent used to thin oil-based paints or clean up after their
use. Commercially, solvents labeled "Paint Thinner" are usually mineral spirits
having a flash point at about 40 °C (104 °F), the same as some popular brands of
charcoal starter.
Fig 3.3 THINNER

3.5 METAL PRIMER
Metal that is exposed to the elements requires a primer before it can be painted. ...
Tin is one metal that does not oxidize. It is used to coat other metals such as steel
to prevent oxidation. In the case of tin as with pre-painted metals, primer is used
primarily to provide a bonding surface for the paint.
Fig 3.4 METAL PRIMER

3.6 M-SEAL
M-seal is a multi-purpose sealant with 4 main applications – Sealing, Joining,
Fixing and Building. Its versatility and ease of application makes it commonly used
across multiple industry segments, as well as households (DIY) who can use it to
mend broken articles, fill gaps, cracks and plug leaks in pipes and joints.
Fig 3.5 M-SEAL

CHAPTER – 4
MEASURING THE MATERIALS USED
1. Galvanized Iron (GI) Square pipes
2 Galvanized Iron (GI) sheets

CHAPTER – 5
PROCEDURES
5.1 MEASURING & MARKING INSTRUMENTS

Measuring the length to cut the GI square pipe as per the required dimensions.
Measure the length using the tape and steel rule. Marked using the scriber.
5.2 : Tape
5.3 : Scriber
5.4 : Permanent Marker
5.5 : Steel Rule
5.2 TAPE
A tape measure or measuring tape is a flexible ruler used to measure size or distance.
It consists of a ribbon of cloth, plastic, fibre glass, or metal strip with linear-
measurement markings. It is a common measuring tool.
Fig 5.1 TAPE
5.3 SCRIBER
A scriber is a hand tool used in metal work to mark lines on workpieces, prior to
machining. ....It is used instead of pencils or ink lines, because the latter are hard
to see, easily erased, and imprecise due to their wide mark; scribe lines are thin
and semi-permanent.
Fig 5.2 SCRIBER

5.4 PERMANENT MARKER
A permanent marker or indelible marker is a type of marker pen that is used to create
permanent or semi-permanent writing on an object. In general, the ink comprise s a
main carrier solvent, a glyceride, a pyrrolidone, a resin and acolorant, making it
water resistant.
Fig 5.3 PERMANENT MARKER
5.5 STEEL RULE
A steel rule is the simplest and most common measuring tool. The flat steel rule is
usually 6 or 12 inches long, but longer sizes are available. Steel rules can be
flexible or nonflexible, thin or wide. The thinner the rule, the more accurately it
measures, because the division marks are closer to the work.
Fig 5.4 STEEL RULE

5.6 CUTTING
Cutting is the separation or opening of a physical object, into two or more

portions, through the application of an acutely directed force. Implements
commonly used for cutting are the knife and saw, or in medicine and science the
scalpel and microtome.
Fig 5.5 CUTTING
5.7 GRINDING
Grinding is an abrasive machining process that uses a grinding wheel as the cutting
tool. A wide variety of machines are used for grinding: ... Handheld power tools
such as angle grinders and die grinders. Various kinds of expensive industrial
machine tools called grinding machines.
Fig5.8 GRINDING

5.8 WELDING
Welding is a fabrication or sculptural process that joins materials, usually metals

or thermoplastics, by using high heat to melt the parts together and allowing them
to cool, causing fusion. ... Welding also requires a form of shield to protect the filler
metals or melted metals from being contaminated or oxidized.
Fig 5.7 WELDING
5.9 PAINTING AND FININSHING
Painting is the practice of applying paint, pigment, color or other medium to a solid
surface (called the "matrix" or "support"). The medium is commonly applied to the
base with a brush, but other implements, such as knives, sponges, and airbrushes,
can be used.
5.8 PAINTING AND FININSHING

CHAPTER – 6
STEPS TO CONSTRUCT A CUPBOARD
STEP 1: GI Square pipe marking& cutting
STEP 2: Welding frame & door GI square pipe
STEP 3: Apply primer coat to frame

STEP 4: GI sheet marking & cutting
STEP 5: Fixing GI Sheet to frame & door

Step 7: Painted And Final Look

CHAPTER – 7
FIGURE OF A CUPBOARD

MATERIAL REQUIREMENT PLANNING
&COST ANALYSIS
INDEX NO NAME SPECIFICATIONS UNIT QUANTITY COST(Rs)

PRICE
(Rs)
1. 1 INCH 350 6 2100
GI SQURAE
PIPE
2. SHEET GI 21GUAGE 600 4 2400
3. HINGES 1 INCH 15 8 120
4. CUTTING 4 INCH 15 5 75
WHEEL
5. HEXAGONA .5 INCH 3 16 48
L SELF
DRILLING
SCREW
WELDING 12 INCH 3.5 27 94.5
6. ROD
10 PAINTING THINNER,ENAMEL
MATERIAL PAINT,OILPRIMER -------- -------- 436
,BRUSH,COTTON
WASTE,
11. ALDROP 8INCH 80 2 160

12. PADLOCK PUSH LOCKING 120 2 240
13 DOOR MEDIUM SIZE 10 4 40

HANDLE
14 SELF .5INCH 2.25 200 450

DRILLING
STAR SCREW
TOTALCOST = 5927.5RS

CHAPTER – 8
CONCLUSION
The layout of the customized tool shelf was drawn in 2D. Based on the layout the
material requirements were calculated.
Once the material arrived at our workshop, we started working. After the marking,
cutting, welding & other works we finished making the customized tool shelf.
We carried out the entire work regarding the customized tool shelf in our workshop
only by utilizing the available machines and tools. No machines and tools were
brought from outside.
Once the work is finished, painting is done and we shifted the customized tool shelf
to our machine shop.
To ensure its worthiness, we kept all the tools of our college machine shop and
found as a useful one.
We thank our department faculty, staff members and workshop staffs for guiding
and assisting us in completing our work successfully.
This minior project work helped us to gain knowledge and experience about Steel
materials, Drawings, Assembling procedures, allowance in making and all
fabrication ideas.
Especially our project work gives us confidence, experience and knowledge to start
a fabrication workshop.

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CHAPTER - 1

Our minor project is to fabricate a CUPBOARD for welding workshop. We

2.2 ARC WELDING

Fig 2.1 Arc Welding Process

An arc welding machine is a machine that uses electricity to join pieces of

A. Step down transformer

Fig 2.2 Arc Welding Machine

A: STEP DOWN TRANSFORMER

Fig 2.3 Stepdown Transformer

A welding power supply is a device that provides an electric current to

Fig 2.4 Electrode Cable

C: CURRENT CONTROL UNIT

Fig 2.5 Current Control Unit

Fig 2.6 Earth Clamp

Fig 2.8 GRINDING

Fig 2.9 GRINDING WHEEL

Fig 2.10 HAND CUTTER

A cutting disk, the edge of which is impregnated with an abrasive, such as

Fig 2.11 CUTTING WHEEL

Fig 2.12 STRAIGHT SNIP

2.14 ABRASIVE SAW

Fig2.14 ABRASIVE SAW

Fig 2.15 CUTTING WHEEL

3.1 : MATERIALS REQUIRED

3.2 GI SQUARE PIPES OF 1 INCH

Fig 3.1GI SQUARE PIPES

Fig 3.2 GI SHEET

Department of Mechanical Engineering Page 10

Fig 3.3 THINNER

Fig 3.4 METAL PRIMER

Department of Mechanical Engineering Page 11

Fig 3.5 M-SEAL

Department of Mechanical Engineering Page 12

1. Galvanized Iron (GI) Square pipes

2 Galvanized Iron (GI) sheets

Department of Mechanical Engineering Page 13

5.1 MEASURING & MARKING INSTRUMENTS

5.4 : Permanent Marker

5.5 : Steel Rule

Fig 5.1 TAPE

Fig 5.2 SCRIBER

Department of Mechanical Engineering Page 14

5.4 PERMANENT MARKER

Fig 5.3 PERMANENT MARKER

5.5 STEEL RULE

Fig 5.4 STEEL RULE

Department of Mechanical Engineering Page 15

Cutting is the separation or opening of a physical object, into two or more

Fig 5.5 CUTTING

Department of Mechanical Engineering Page 16

Welding is a fabrication or sculptural process that joins materials, usually metals

Fig 5.7 WELDING

5.9 PAINTING AND FININSHING

5.8 PAINTING AND FININSHING

Department of Mechanical Engineering Page 17

STEP 1: GI Square pipe marking& cutting

STEP 2: Welding frame & door GI square pipe

STEP 3: Apply primer coat to frame

Department of Mechanical Engineering Page 18