WORKSHOP PRACTICE (FE 131)

CYCLE OF EXPERIMENTS
1. CARPENTRY : (Any Three) C-1. LAP TEE JOINT C-2. CROSS LAP JOINT OR LAP + JOINT C-3 DOVETAIL LAP JOINT C-4. MORTISE & TENON JOINT 2. HOUSE WIRING : (Six) H-1. ONE LAMP CONTROLLED BY ONE SPT SWITCH H-2.TWO LAMPS CONTROLLED BY TWO SPT SWITCHES H-3. SERIES LAMP CONNECTION H-4. STAIR CASE CONNECTION H-5. GODOWN CONNECTION H-6. FLOUROSCENT CONNECTION 3. TIN SMITHY : (Any Three) T-1. PLAIN PIPE T-2. RECTANGULAR TRAY T-3. TRIANGULAR TRAY T-4. FUNNEL 4. WELDING : (Any Three) W-1. SINGLE V BUTT JOINT W-2. LAP JOINT W-3. LAP T JOINT W-4. VEE CORNER JOINT TOTAL No. OF EXPERIMENTS (3+6+3+3) = 15 1

WORKSHOP PRACTICE (FE 131)

Instructions to the students
1.

Enter the lab with proper dress- code ( khaki apron and shoes) Maintain a 200 pages white long note book and divide it into four parts with the titles of the trades namely Carpentry, House wiring, Tin smithy and Welding.

2.

3.

Draw the figures of tools and equipments proportionately using pencil only on the left side of the page.

4. 5.

Write the related theory part only on the right side of the page. For every experiment, draw the related figure and write the individual procedure in the observation book and take signature by the concerned technician. Write the date and Experiment number in the observation book. And take signature of staff member on index page of lab manual.

6.

Only after taking signature in the observation book, write the record. Both will be checked. Marks are allotted for your regularity. Performance of the students will be assessed for every session of workshop being conducted.

7.

The records should be written up to date without delay. They should be signed by the concerned faculty.

8.

Medical kits provided in the First Aid Box. The students can utilize the available medicines if at all there is any necessity.

Freshman Engineering Department

BASIC WORKSHOP TOOLS DISPLAY BOARD
1.

ADZE
FIRMER CHISEL MORTISE CHISEL C-CLAMP REBATE PLANE HAND SAW AUGER WOOD RASP FILE CLAW HAMMER METAL JACK PLANE HAND VICE HAND DRILL TRIANGULAR FILE WOOD CUTTER OIL STONE BEVEL SQUARE MARKING GUAGE CUTTING PLIER SIDE CUTTING PLIER NOSE PLIER WIRE CUTTER SCREW WRENCH
4

2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48.
49.

DOUBLE ENDED SPANNER COMBINATION SPANNER RING SPANNER RING SPANNER MONKEY PLIER COLD CHISEL (Round Nose) PLUG WRENCH WIRE CLIPS SCREW DRIVER STAR SCREW DRIVER LINE TESTER PLUG WRENCH PINCER WIRE REMOVER BABY SAW JIG SAW ALLEN KEY ELECTRICAL LUG ELECTRICAL LUG DRILL BIT SET BOLT & NUT BOLT & NUT BOLT & NUT EXPANDING BOLT STRAIGHT SNIP CURVED SNIP
DIVIDER 5

50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. 65. 66. 67. 68. 69. 70. 71. 72. 73. 74. 75. 76.

OUTSIDE CALIPER INSIDE CALIPER JENNY / ODD LEG CALIPER BALL PEEN HAMMER CROSS PEEN HAMMER RUBBER MALLET NYLON MALLET STEEL RULE (12 Inch) SCRIBER TRY SQUARE STEEL TAPE BELT PUNCH STANDARD WIRE GAUGE (SWG) WELD SCREEN HACK SAW BABY VICE FLAT FILE COLD CHISEL (Flat Nose) FLAT TONG CHIPPING HAMMER HAND GLOVES ELECTRODE (4 mm) ELECTRODE (3.15 mm) ELECTRODE (2 mm) ELECTRODE HOLDER WIRE BRUSH SAFETY GOGGLES 6

CARPENTRY

Pad

Screw

Handle

Steel Rule

Blade Stock
Testing for Straightness Testing for Squareness

Body

C- Clamp

Try Square

Blade Wedge Back Iron

Solo

Wooden Jack Plane

Marking Guage

Cross cut hand saw

Trigger for quick opening

Carpernters vice

Tenon or back saw

CARPENTRY
Introduction:
Carpentry may be defined as the process of making wooden components. It deals with the building work, furniture, cabinet making etc. Jointly, i.e., Preparation of joints is one of the important operations in all wood works. It deals with making joints for a variety of applications viz, door frames, window frames, wardrobes, cupboards, stairs etc. In this chapter tools and works associated with joinery are presented. Carpentry Material Timber: Timber is the basic material used for any class of carpentry work. The term timber is applied to the wood obtained from; well-grown trees. The trees are cut, sawn into various sizes to suit the required purpose. Common Varieties of Indian Timber: Indian timbers most commonly used for various carpentry words are as follows: Babul, Deodar, Mahogany, Mango, Sal, Sissy and teak. Carpentry Tools: In carpentry large numbers of hand tools are used for processing the wood. Here, the details of tools that are being used in our workshop only are presented. Marking and Measuring Tools: Steel Rule: It is strip of steel with graduations on its edges and is used for measuring and setting out dimensions. Try Square: Try squares are used for marking and testing of right angles and for testing flatness of surface. Marking Gauge: It is a tool which has one projected marking pin and is used to mark accurate lines parallel to the true edge of a wooden piece. Holding Tools: Carpenters Vice: It is used for holding the work for planning, sawing and chiseling. The whole vice is made of iron and steel. It has two jaws one of which is fixed to the side of the table while the other is movable. C-Clamp: It is used for holding the work projecting above the top surface of the Bench. This is used to prevent the wood from moving forward when being planned. Bench Stop: It is simply a block of wood projecting above the top surface of the bench. This is used to prevent the wood from moving forward when being planed. 9

10

Cutting Tools: Wooden Jack Plane: It consists of wooden body in which blade is set at an angle of 45 degrees to the body or sole. The cutting blade used is made of high carbon steel and is very similar to a chisel. Jack Plane is a general purpose plane and is used to produce flat and smooth surfaces on wood. Hand or Cross-cut Saw: It is used to cut across the grains of the stock or thick wood. The teeth are set alternately to the right and left of the blade, and its purpose is to make the cut wider than the thickness of the blade. This allows the blade to move freely in the cut, without sticking. Her teeth are set at 2.5 mm apart. Tenon Saw or Back Saw : This saw is mostly used for cross cutting when a finer and more accurate finish is required. The teeth are shaped in the form of an equilateral triangle and generally have 13 teeth for 25 mm length. Firmer Chisel or Straight Edge Chisel : It is a general-purpose chisel and is used for cutting and shaping wood accurately. The width of the blade varies from 1.5 to 50 mm. Adze: Adze is a side axe used to chop extra wood quickly by carpenters. Adze with very long handle is used to plane long palm tree barks in standing position and also used as a hammer. Miscellaneous Tools: Pincer: It is made of steel with a hinged joint and is used for pulling out small nails from wood. Claw Hammer : It is a dual-purpose hammer. It has a hammer face, which is used to drive in nails and claw at the other end for pulling out mails from the wood. Wood Rasp File: It is a finishing tool used to make the wood surface smooth, remove the sharp edges and other interior surfaces. Sharp cutting teeth are provided on its surface. This file is exclusively used in woodwork.

Wood Joints : There are many kinds of joints used to connect wood stock. Each joint has a definite use and required marking, cutting and joining together. The strength of the joint depends on the amount of contact area. If a particular joint does not have much contact area, then it must be reinforced with nails, screws or dowels. Lap Joint: Also called halving joint. The aim of this joint is to secure the corners and intersections of the framing and at the same time in the same plane. They may be usefully employed in many types of framing where strength and appearance are of secondary consideration. 11

12

Mortise and Tenon Joint: This family of joints is a large one and does probably the wood worker use the commonest. It consists of a rectangular peg (tenon) fitting into a rectangular hole (mortise).

Briddle Joint: These are the reverse of mortise and tenon joints in form and are often called the open mortise tenon. These joints are used where the members are of square or nearsquare or near-square section and thus unsuitable for making a mortise and tenon joint of good proportions.

Instructions

1.

When you are using your thumb as a guide for cross cutting and ripping, raise it sufficiently high.

2. 3. 4. 5. 6. 7. 8. 9.

Planing should be done along grains only. Push the chisel away from you while chiseling. Always use marking gauge (or) a mortise gauge for drawing lines. Check the squareness of planned surfaces with try square. Use wooden mallets for driving chisel. Do not test sharpness of the edge of the cutting tools on your hand. Do not keep your hands In front of the sharp edged tools while they are in use. Only un wanted material should be removed.

13

14

Safety Precautions :

General : Make sure that your hands are not in front of sharp edged tools while you are using them.

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

Chisels : 1. 2. Never chisel towards any part of the body. Test the sharpness of the cutting edge on wood or paper, not on your hand.

Exercise: 1. 2. 3. 4. Lap Tee Joint Cross Lap Joint or Lap + Joint Dovetail Lap Joint Mortise & Tenon Joint

15

All dimensions are in mm

16

LAP TEE JOINT

Experiment No: Date:

Aim: To prepare a Lap Tee Joint as per dimensions given in sketch. Material Required: Teak wood 300mm X 45mm X 35mm Tools Required: 1. Steel rule 2. Handsaw 3. Wooden jack plane 4. Try square 5. Marking gauge 6. C-Clamp 7. Firmer chisel 8. Adze Sequence of Operations: 1. Marking Procedure: 1. Select a teak wood material and mark the size as per drawing with the help of marking tools like steel rule, marking gauge, try square. 2. Planning of sides with the help of wooden jackplane to maintain the required dimensions. 3. Fix the work piece in carpentry vice and cut into two equal pieces of size 150mm X 30mm with the help of handsaw. 4. Mark the two work pieces for male cutting and groove cutting as per dimensions. 5. Fix the work pieces one by one on the bench with the help of C Clamp and a groove is made as shown in drawing with the help of chisels and adze. 6. The two work pieces are fitted to make Lap Tee Joint as per drawing. Precautions : 1. We should be careful while marking and planning 2. Special care is required while cutting the groove with firmer chisel so that the dimension is not exceeded. Result: Lap Tee Joint is prepared as per given dimensions 2. Planning 3. Cutting 4. Setting 300mm 300mm 450mm 200mm 200mm 200mm 150mm 150mm

17

VIVA QUESTIONS : 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. What are the various types of wood material used in carpentry? What is the sequence of operations in carpentry? Classify the tools used in carpentry. Name some measuring tools. Name some marking tools. Name some cutting tools. Name some finishing tools. Name some work holding devices. What is the use of mortise gauge? What is the use of wooden jackplane? What are various types of saws? What are various types of chisels? What is the difference between saw and chisels? What is the use of try square? What is the use of C-Clamp? Differentiate between bench vice and C-clamp What is the use of adze? What are the various types of joints Which joint is more strongest.. justify your answer What is the difference between marking gauge and mortise gauge What is the use of claw hammer Why saw setting is required What are the safety precaution should be taken in carpentry Why butt joint is not performed in carpentry Identify the parts of wood jackplane Define carpentry What is the use of pincer Which chisel is convenient for making What is the max. length you can measure with steel rule Identify the given joint.

18

HOUSE WIRING

19

Single ended box spanner

Single ended spanner

Double ended spanner

Offset double ended box spanner

Adjustable Wrench

Allen Wrench

Spanners

Standard Wire Guage 20

HOUSE WIRING

Introduction:

Power is supplied to the domestic installations through, the phase and a neutral, forming a single phase A.C. 230V, two wire system. For industrial establishments, power is supplied through three-phase four-wire system to give 440V. Figure shows the power tapping for domestic and industrial purposes. The neutral is earthed at the sub-station of the supply. As a safe practice all single-phase devices such as switches, fuses etc., are connected to the live conductor. All electrical conductors and cables are colored coded and must be correctly connected up. Electrical wiring is defined as a system of electrical conductors, components and apparatus for conveying electrical power from the source to the point of use. The wiring system must be designed to provide a constant voltage to the load. Elements of House wiring: 1. 2. 3. 4. 5. 6. 7. 8. Fuses and circuit breakers Electrical switch Plug Socket outlet Lamp holder Ceiling Rose Main switch Incandescent light

21

22

Wires and wire sizes: A wire is defined as a bare or insulated conductor consisting of one or several strands. An insulated wire consists of a conductor (Silver/Copper/Aluminium) with insulating material made of vulcanized Indian Rubber (VIR) or Poly Vinyl Chloride (PVC). Wire sizes are specified by the diameter of the wire, using a standard wire gauge (SWG), which also gives an idea of the current carrying capacity. The specification consists of both the number of strands and diameter of each wire in it. For Example, the specification 3/18 PVC consists of 3 strands of 18 gauge each. Various systems of wiring: 1. 2. 3. 4. 5. 6. Cleat wiring C.T.S. / T.R.S.Wiring (Cap tyer sheathed/ Tough rubber sheathed wiring) Wooden casing & capping wiring Lead sheathed wiring Conduit wiring PVC casing & capping

Wiring methods: 1. 2. Series circuit Parallel circuit

Fundamentals of Electricity: Electricity: Electricity is a form of energy, which cannot be seen. But can be felt and effects like magnetic effect, Heating effect and Chemical effect. Voltage: It is a pressure which makes the electricity to flow. The unit of measure is Volt. The symbol used is V. The instrument used to measure is Voltmeter.

23

Cutting Edge Serrations

Shearing Edge

Combination Plier

Side Cutting Plier

Round Nose Plier

Chisel

Tenon Saw
Solid Frame Handle

Blade

Hacksaw

Knife

24

Current: The free flow of electrons is called as current. The unit to measure current is Ampere. The symbol is A. The instrument used to measure the current is Ammeter. Resistance: It is opposition to current. The unit of resistance is Ohm. The symbol of ohm is

. The resistance is measured by Ohmmeter.

Watt: It is the rate of doing work, when potential difference across the current is of volt and current flowing is ampere per second. The energy consumed is of Watt. 1000 Watts = 1 Unit 746 Watts = 1 H.P. The following are the formulae for calculation. Voltage V or E = W / I = WR = IR Current I = E / R = W / E = W / R Resistance R = E2 / W = E / I = W / I2 Wattage W = I2R = EI = E2 / R House Wiring Tools: Combination Pliers : Used for holding, twisting or cutting of wires. Side cutting Plier: Used for Cutting at narrow places or ordinary places for removing insulation. Round Nose Plier or Flat Nose Plier: Used for holding, twisting or joining the wire at narrow places. Firmer Chisel: Used for chipping, scrapping and grooving the wood.

25

Line Tester

Soldering Iron

Screw Drivers Poker Royal Jumper

Portable Drill Wedges Peen Eye Handle

Hand Drill

Head Face

Ball Peen Hammer

Piner

26

Cold chisel: Used for chipping, Boring and channeling in walls. Tenon saw or back Saw: Used for cutting wooden boards, Block casting etc. Hack saw: Used for cutting conduit GI pipes or mild steel. Mallet: Used as a hammer and made of wood Double Blade Electric knife: It has two blades, one for removing insulation of wires and another for cleaning the wires Soldering Iron: Used to solder small joint terminals Poker: Used for making pilot holes for fixing wood screws. Line Tester: Used for testing the current. Royal Plug Tool: It is made of steel and is used for making holes in the stone wall or concrete wall for fibre made Royal plugs. Screw driver: Used for loosening, tightening and to keep the screws in position. Ball Peen Hammer: Used for fitting nails in the walls or wooden boards. Instructions : 1. 2. 3. When closing the electric switch, always grasp the switch by the insulated handle. Do not run too many electrical items from one point. Use fuses and circuit breakers of proper capacity, so as to interrupt the current before it becomes dangerous. 4. Disconnect the units to be repaired free from power supply and make sure that they might not be energized while the repair work continues.

27

60 W

40 W

40 W

N N 230 V P P
230 V

40 W

40 W

60 W

N P

230 V

N
230 V

40 W

60 W

100 W

N P

230 V

230 V

28

5.

Do not pour water to put-off fires in electric wires and electric equipment. You will be subjected to electric shock or you will be electrocuted. Use sand to put-off fires in electric items.

6.

Whenever there is power failure, put-off the power supply to all equipment, in order to prevent spontaneous recovery.

7. 8.

Never remove a plug from an outlet by pulling cord. Always pull by holding the plug. While testing always keep one hand in your packet. If the hands are in contact with a circuit, current will flow across your body and is more dangerous.

9.

Electricity has no respect for ignorance. Do not apply voltage or turn-on any device until it has been properly checked. Check earth connection before switching on portable equipment

. Safety Precautions : 1. 2. 3. 4. First we should be insulated Care should be taken while fixing the fuse All the switches should be off before power supply. When power is on, the terminal wires should not be touched

Exercise: 1. 2. 3. 4. 5. 6. One lamp controlled by one SPT switch. Two lamps Controlled by two SPT switches. Series lamps connection. Staircase Connection. Godown Connection. Fluoroscent lamp Connection.

29

1. One Lamp Controlled by One SPT Switch

60 W

230 V
P

30

ONE LAMP CONTROLLED BY ONE SPT SWITCH

Experiment No: Date:

Aim: To give connections to one lamp controlled by one SPT switch. Sequence of Operations: 1. Circuit diagram 3. Fixing of wire connections Tools Required 1. Insulated cutting plier 200 mm 3. Double fold knife 100 mm Electrical Accessories: 1. Battery lamp holder, 5 Amp 2. SPT switch, 5 Amp 3. Electrical bulb, 230 V 4. 1/18 insulated wires, 900 mm length

2. Selection of colour 4. Testing of wire connections 2. Insulated screw driver 4. Line tester 300 mm 230 volts

1 No. 1 No. 1 No. 3 No.

Procedure: 1. Phase Connection (R) : Red color wire is connected from the phase of power supply to phase of SPT switch 2. Control Connection (C) : Yellow color wire is connected from control of SPT switch to control lamp holder. 3. Neutral Connection (B) : Blue or black color wire is connected from neutral of power supply to neutral connection of lamp holder. Safety Precautions: 1. First we should be insulated 2. Care should be taken while fixing the fuse 3. All the switches should be off before power supply. 4. When power is on, the terminal wires should not be touched or interchanged. Observations: 1. Connections should not be loose. 2. Avoid all the closed, open and short circuits. Uses: 1. Used for domestic purpose. 2. Used for power calculations. Calculations: Power supply E = 230V Bulb wattage, W = 60 watts R = E2 / W I = E/R Result: One lamp Connection controlled by one SPT switch connection is obtained. 31

VIVA QUESTIONS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. Name the three fundamental terms related to Electricity What is the relation between current, voltage and resistance. State ohms law. What are the units of current, voltage and resistance Write the symbol of ohm. Draw the circuit diagram of given connection What is the value of voltage of single phase supply What is the value of voltage of three phase supply What is the unit of power State the relation between HP and Watts What do you mean by SPT and DPT Why fluorescent lamp is white What is the use of choke in fluorescent lamp connection Once the fluorescent lamp glows, one item is not necessary in the circuit. What is that ? and why? What is the purpose of stair case connection What is the purpose of godown connection The electricity department gives the bill in units. What is meant by unit What do you mean by KWH In circuit diagram what is the significance of R,Y,B What are the different color wires used in electric circuit How will you represent SPT in circuit diagram State the difference between single phase and three phases connection What is the equivalent resistance When two resisters R1 and R2 connected in series What is the equivalent resistance When two resisters R1 and R2 connected in parallel What is the disadvantage in series lamp connection What type of connection is provided in domestic electric wiring What are the various tools used in House wiring State the function of given tool What is the relation between power, voltage and current What is meant by SWG

32

TIN SMITHY

33

Face (Steel) Cast Iron Body Sliding Jaw

Standard Wire gauge

Hole for Securing to Bench Handle Screw

Steel Rule
Wedges

Bench Vice

Penn Eye Bent End Handle Straight End

Scriber
Face

Head Ball Peen Hammer

Cutting Edges

Cross Peen Hammer Straight Snip Curved Snip Cutting Edge

Straight Peen Hammer

Snips

Serrations Shearing Edge

Divider

Cutting Plier

34

TIN SMITHY
Introduction : Many engineering and house articles such as boxes, cans, funnels, ducts etc. are made from a flat sheet of metal. The process being known as tin smithy. For this the development of the article is first drawn on the sheet metal, then cut and folded, to form the required shape of the article. Allowance should be given in the drawing stage for folding and bending. This allowance depends upon the radius of the bend and thickness of the sheet metal. Sheet Metal Materials : A variety of metals are used in a sheet metal shop such as galvanized Iron, black, Iron, tin, Stainless Steel, copper and Aluminium. Hand Tools : The common hand tools used in sheet metal work are steel, try square, Wire gauge, Scriber, Ball peen hammer, Nylon Mallet, Snips Divider, Stakes, Cutting plier and Soldering Iron. Here, the details of tools that are being equipped by our workshop purpose only are presented. Wire Gauge: The thickness of sheet is referred in numbers known as standard wire gauge (SWG). The gaps in the circumference of the gauge are used to check the gauge number. Steel Rule : It is a strip of steel with graduations on its edges. It is used for measuring and setting out dimensions. Scriber : A scriber is a slender steel tool, used to scribe or mark lines on sheet metal. Snips : Hand shears or snips are used to cut sheet metal. Straight Snips : These are having straight blades and are used for cutting along straight lines and for trimming edges. Curved Snips : These are having curved blades and are used for cutting circles and irregular shapes. Divider : It consists of two pointed legs. The points are hardened and tempered to prevent wear. It is used for transferring the sizes and scribing curves or circles. Bench vice : It is generally used for holding and bending the work piece.

35

1 Seam

Hem

Wire Edge 2

Cup

Nylon Mallets

Angular

Flanged

Bick Iron

Cap

Sheet Metal Joints

Hatchet
Pritchel Hole Punching Hole Hardle Hole Cutting Face

Funnel

Tail Beak or Horn Body

Horse Head

Pipe

Stakes

Base

Anvil

36

Hammers : Light weight hammers and mallets are used in sheet metal work. Ball Peen Hammer : It has a cylindrical, slightly curved face and a ball head. It is a general purpose hammer used mostly for riveting in sheet metal work. Cross Peen Hammer : It has a tapered peen end and is perpendicular to the handle. Because of this, it can reach awkward corners. Straight Peen Hammer : It has the peen end similar to the cross peen, but it is positioned parallel to the handle which can be used conveniently for certain operations of folding. Cutting Plier : Used for holding, cutting and bending works. Nylon Mallet : It is used for bending and folding work. It is light in weight, covers more area and do not damage the surface area. Stakes : Stakes are made of steel and forged in a variety of shapes and sizes. These are used as supporting tool and to form, seam, bend or rivet sheet metal objects. Anvil : Anvil provides the necessary support during hammering. It is also useful for operations such as bending. Its body is generally made of mild steel and a strip of high carbon steel about 20 mm thick is welded on top to provide hard face.

Sheet Metal Joints : Various types of joints are used in sheet metal work, to suit the varying requirement. Some commonly used sheet metal joints and folded edges are shown in the figure. These are self-secured joints, formed by joining together two pieces of GI sheet metal and using the metal itself to form the joint.

Sheet Metal Layout : The shapes of most articles made with sheet metal are in few geometrical forms. All these forms are made from flat sheet; therefore the first requirement is developing the lines, which forms the pattern. The development or stretch out of a job is called pattern and developing lines which forms a pattern is layout. It may be drawn on paper first and then transferred in the sheet or it may latyout directly on sheet metal. When a pattern is made repeatedly, it is generally made of metal and referred to as a template. 37

38

Insturctions :
1. 2. 3. 4. 5. 6. 7. Draw the development of object to be prepared with true dimensions only. Use curved snip for trimming along inside curves. Always provide folding (Hem) for top edges of the object to avoid sharp edges and to stiffen the sheet. Ground properly the exposed metal parts of electrically heated soldering iron. For good soldering the metals to be joined must free from dirt, grease and oxide. Do not pull (or) peel the cut portion by hand while cutting with snip. Do not bend the sheet with hand, always use nylon mallet with proper support.

Safetry Precautions : 1. 2. 3. 4. Use hand leather gloves while handling heavy sheets. Avoid feeling the cut portion by hand while cutting with snip. Do not let sheet metal slip through the hands. Never carry tools in pockets.

Exercise : 1. 2. 3. 4. Plain pipe Rectangular tray Triangular tray Funnel

39

All Dimensions are in mm

40

PLAIN PIPE
Experiment No. Aim : To prepare a plain pipe as per dimensions. Materials Required : 122 mm x 100mm size Galvanized Iron sheet. Tools Required : 1. Steel rule 2. Scriber 3. Try square 4. Straight snip 5. Ball peen hammer 6. Nylon mallet 7. Cutting plier 8. Cylindrical stake Sequence of Operations: 1. Marking 2. Cutting Procedure: 1. Take a galvanized iron sheet. 2. Mark the rectangular length of 122mm and 100mm with scriber as per sketch. 3. Cut the rectangular piece from sheet with straight snip. 4. Mark a bend of 4mm on two parallel sides for joining two edges of the sheet. 5. Using nylon mallet and cutting plier join the two edges of the sheet as per sketch. So that the final circumference length is 110mm. 6. Select the cylindrical stake and roll it to obtain correct shape of plain pipe. Precautions: 1. Should pay attention while marking. 2. Bending and finishing should be done neatly and straight. 3. Cutting should be done carefully along the marked lines, and while cutting care should be taken to cut it at the further end. Otherwise the metal sheet might bend giving wrong shape. Result: Required plain pipe having diameter 35mm and height 100mm is obtained. 3. Folding 4. Bending 5. finishing 300 mm 150 mm 200 mm 210 mm 750 gm 450 gm 200 mm 35 mm Date :

41

VIVA QUESTIONS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. What is the raw material used in Tin smithy for doing experiments Classify the tools used in Tin smithy Name some measuring tools Name some marking tools Name some cutting tools Name some finishing tools What is the use of Nylon mallet What is the purpose of given tool Differentiate between mallet and Hammer Differentiate between straight snip and curved snip What is the purpose of snip What is the use of anvil What is the purpose of Stake What is the use of scriber What is use of cutting plier What is the supporting tool used to obtain the final shape of the Model What type of development is applied for Plain Pipe What type of development is applied for Rectangular tray What type of development is applied for Funnel What is the full form of SWG Tell some precautions should be taken in Tin Smithy Trade What are the various types of hammer What do you mean by Galvanization Draw any sheet metal joint symbols Name different parts of anvil What is the difference between cross peen hammer and straight peen hammer What are the different types of metal sheets available What is the use of divider What is the sequence of operations in Tim Smithy How did you join metal sheets 42

WELDING

43

Principle of Arc Welding

Electrode Holder

Face (Steel) Cast Iron Body Sliding Jaw

Ground Clamps
Hole for Securing to Bench Handle Screw

Bench Vice

Solid Frame

Handle

Blade

Hacksaw

44

WELDING
Introduction : Welding is a process of joining two similar or dissimilar metals by the application of heat with or without application of pressure and addition of filler material. The welding is extensively used in manufacturing industry, construction industry and maintenance work, replacing riveting and bolting, to a greater extent. The various welding processes are 1. Electric arc welding 2. Gas welding 3. Thermit welding 4. Resistance welding and 5. Friction welding However only electric arc welding is discussed here. In this process, the work pieces are melted along a common edge, to their melting point and then a filler metal is introduced to form the joint on solidification. The materials to be welded must be free from rust, scale oil or other impurities, so as to obtain a sound weld. Arc Welding: In arc welding, the heat required for joining the metals is obtained from an electric arc. Transformers or motor generator sets are used as arc welding machines. These machines supply high electric currents at low voltages and an electrode is used to produce the necessary arc. The coated electrode serves as the filler rod and arc melts the surfaces so that the metals to be joined are actually fused together. In addition to the welding machine, the following accessories and tools are needed for carrying out the welding work. The given figure shows the principle of Arc Welding using a transformer. Welding Cables: Two welding cables are required, one from the machine to the electrode holder and the other, from the machine to the ground clamp. Cables are specified by their current carrying capacity say 300A, 400A etc. Electrodes: Filler rods used in arc welding are called electrodes. These are made of metallic wire called core wire, having approximately the same composition as the metal to be welded. These are coated uniformly with a protective coating called flux. While fluxing an electrode about 20mm of length is left bare at one end for holding it with the electrode holder. It helps in transmitting full current from electrode holder to the front end of the electrode coating. Flux acts as an insulator of electricity and protects from oxidization.

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Steel Rule

Bent End Face Screen Straight End Face Shield

Safety Shields Scriber

Flat File

Blade Stock
Testing for Straightness Testing for Squareness

Try Square

Chipping Hammer

Wedges

Flat bit tong

Penn Eye

Wooden Handle

File cording

Handle

Head Face

Wire brush or File cord

Ball Peen Hammer

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Electrode Holder: The electrode holder is connected to the end of the welding cable and holds the electrode. It should be light, strong, easy to handle and should not become hot while in operation. The jaws of the holder are insulated, offering protection from electric shock. Ground Clamp: It is connected to the end of the ground cable and is clamped to the work or welding table to complete the electric circuit. It should be strong and durable and give a low resistance connection. Bench Vice: It is commonly used for holding the work piece. It has to harden Steel jaws having serrations to ensure good grip. When the vice handle is turned to a clockwise direction, the sliding jaw forces the work piece against the fixed jaw and is fixed on the working table. Hack Saw: The hacksaw is used for sawing all metals except hardened steel. A hand hacksaw consists of frame, handle blade, prongs, tightening screw and nut. Steel Rule: The steel rule is one of the most useful tools in the workshop for taking linear measurements of blanks and articles to an accuracy of 1.0 to 0.5mm Scriber: A scriber is a slender steel tool, used to scribe or mark lines on metal work pieces. Try Square: Try square is used for making and testing angles of 90 degrees and is used for checking the squareness of many types of small works, when extreme accuracy is not required. Flat File: Flat file is used to remove small amount of material from the surface of the metal part. It is also used to remove sharp edges from the metal pieces. Wire Brush or File Card: A wire brush is used for cleaning and preparing the work piece before and after the welding. Welding Table: It is made of steel plate and pipes. It is used for positioning the parts to be welded properly. Welding Screen: When people are around where welding is done, they may be protected from the rays of the arc by means of a protected screen. Face Shield:A face shield is used to protect the eyes and face from the rays of the arc and from spatter or flying particles of hot metal. It is available in hand or helmet type. The hand type is preferred to use and they are made of light weight, non reflecting fiber fitted with dark glass. Hand Gloves: Hand gloves are used for protecting the arms while welding form sparks and from current. Flat Tong: A flat tong is used for holding works of rectangular shape during welding and after welding. 47

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Chipping Hammer: It is made of tool steel and is used for removing slag formation on welds. One end of the head is sharpened like a cold chisel and the other end to a blunt, round point. Ball Peen Hammer: Ball peen hammers are used to stride a job or a tool. It consists of hour parts namely peen, head, eye and face. Ball Peen hammer is chiefly used for chipping and riveting. Welded Joints: The relative positions of the two pieces being joined determine the type of joint. The following joints are commonly used in fusion welding. The Butt Joint : It is used to join the ends or edges of two plates or surfaces located approximately in the same plane with each other. The Lap Joint : It is used to join two overlapping plates so that the edge of each plate is welded to the surface of the other. The T-Joint : It is used to weld two plates or sections whose surfaces are at approximately right angles to each other. The Corner Joint : It is used to join the edges of two sheets or plates whose surfaces are at the angle of approximately 90 deg to each other. It is common in the construction of boxes, tanks, frames etc. Preparation of Work: Before welding, the work pieces must be thoroughly cleaned of rust, scale or other foreign material. Thin pieces of metal are generally welded without beveling the edges. However, thick work pieces should be beveled to ensure adequate penetration and fusion of all parts of the weld. But, in either case, the parts to be welded must separated slightly to allow better penetration of the weld. Different edge preparation is particularly used in fusion welding process for welding butt joints. These are: square Single-V, Double-V, Single-U and Double-U. The preparation of edges depends upon the thickness of metal being welded. Instructions : General: 1. Always weld in a well-ventilated place. Fumes given off from welding are unpleasant and in some cases may be injurious, particularly from galvanized or zinc coated parts.

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2. Do not weld around combustible or inflammable materials, where sparks may cause a fire. 3. Never weld, containers, which have been used for storing gasoline, oil or similar materials, without first having them thoroughly cleaned. Arc welding: 1. Check the welding machine to make sure that it is properly grounded and that all leads are properly insulated. 2. Never look at the arc with a naked eye. The arc can burn your eyes severely. Always use a face shield while welding. 3. Prevent welding cables from coming in contact with hot metal, water oil or grease. Avoid dragging the cables around sharp corners. 4. Ensure proper insulation of the cables and check for openings. 5. Always wear the safety hand gloves, apron and leather shoes. 6. Always turn-off the machine when leaving the work 7. Apply eye drops after welding is over for the day to relieve the strain on the eyes. 8. While welding, stand on dry footing and keep the body insulated from the electrode, any bare parts of the electrode holder and the work

Safety Precautions: 1. Use welding screen, leather apron and leather hand gloves while welding 2. Use flat tong and hand gloves for handling of work pieces during and after welding.

Exercise:

1. Single V Butt Joint. 2. Lap Joint. 3. Lap T Joint 4. Vee corner Joint.

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All Dimensions are in mm

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SINGLE V BUTT JOINT Experiment No.: Date: Aim: to prepare a single V Butt Joint as per dimensions given in the sketch. Material Required: Mild Steel plates: 80mm X 40mm X 6mm = 2 Nos Mild Steel electrode 3.15 mm Equipment required: A.C. Transformer with all welding accessories like Electrode holder, cables. Tool Required: 1. Steel rule 300mm 2. Scriber 150mm 3. Flat file 300mm 4. Try square 200mm 5. Flat Tong 450mm 6. Chipping hammer 200mm 7. Ball peen hammer 750mm 8. Wire brush 9. Welding screen Sequence of Operations: 1. Marking 2. Filing 3. Welding 4. Finishing

Procedure: 1. Take two Mild steel plates of size 80mm X 40mm X 6mm. 2. Fix the work pieces one by one in bench vice and file the faces of work pieces using flat file as per dimensions. 3. Then mark the pieces using steel rule and scriber as per drawing. 4. Again fix the work pieces one by one in bench vice and file the pieces to get the required shape of the edge as per drawing. 5. Select the appropriate welding fixture and hold the pieces as per drawing. 6. At some selective places of the joint perform some weld spots for perfect alignment of the job. 7. Start the welding from one end and proceed to another end. 8. Like this continue the welding operation for one more time to get weld bead. 9. Allow the welded joint for solidification. 10. After cooling, chip off the slag from welded joint with the help of chipping hammer and clean the joint by wire brush. Safety Precautions: 1. Use welding screen leather apron and leather hand gloves while welding 2. Use flat tong and hand gloves for handling of work pieces during and after welding. Result: Single V butt joint is prepared as per given dimensions.

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VIVA QUESTIONS :
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. Define welding What are the various types of welding What is the thickness of MS Plate used in welding What is the Job material used in welding experiments What is the main function of electrode What is the use of Flat file For what purpose you are using scriber While performing electric arc welding what is the safety device used in order to protect your eyes from sparks What type of welding you have done in the workshop lab When work piece is hard what is the holding tool used to carry it What is the sequence of operations in welding In welding process to which cathode is connected In welding process to which anode is connected What do you mean by cathode and anode As a result of welding a black bead is formed. What is its name How slag is removed What is the difference between butt joint and lap joint Draw the symbol of butt joint Draw the symbol of Lap joint Draw the symbol of T joint What is the purpose of try square What is the purpose of Bench vice Why slag is formed in welding What are the electrode materials How do you perform the finishing operations in the welding Why the coating is necessary in electrode Which material is coated on electrode What type of electricity is used in arc welding What is the tool used to cut the MS Flat How will you fix the blade in the Hack Saw Frame

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