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A workshop practice manual for mechanical engineering students at JISCE. It covers various topics such as carpentry, fitting, welding, machining, and safety regulations. The manual includes procedures, instrument names, and Bloom's Taxonomy level questions for each topic.
Typology: Lecture notes
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The objective of this lab is to get a hands on knowledge of several Workshop Practices like
carpentry, fitting, welding, machining etc and learn safety regulations to be maintained in a shop floor. This laboratory is scheduled for 1st^ and 2nd^ semester for all engineering students. Apart from curriculum, some additional experimental setups are there which
helps the students to enhance their knowledge. Students also get opportunity to implement their ideas through various application oriented micro projects.
Remember that “accidents do not occur, they are caused”. With this in mind, strictly follow the general safety rules given below and safe practices indicated in brief under each section.
1. Safety first, work next.
2. Know your job and follow instructions.
3. Avoid wearing clothing that might catch, moving or rotating parts. Long sleeves of
shirts, long hair, neck tie and jewellery are definite hazards in the shop.
4. Wear safety shoes. Do not wear canvas shoes; they give no resistance to hard objects dropped on the feet. 5. Keep the area around machine or work clean. 6. Keep away from revolving work. 7. Be sure that all guards are in place. 8. One person only should operate the machine controls. 9. Use tools correctly and do not use them if they are not in proper working condition. 10. Wear safety goggles when working in areas, where sparks or chips of metal are
flying.
11. Get to know who in-charge of first aid is and where boxes are placed and where the
first aid can be found in case of emergency.
C O N TE N T S
SL. Experiment Page no.
WORKSHOP PARCTICE MANUAL (^) JISCE
DEPARTMENT OF MECHANICAL ENGINEERING (^) JISCE
WORKSHOP PARCTICE WORKSHOP PARCTICE (^) MANUALMANUAL (^) JISCEJISCE
Introduction
A pattern is a model or the replica of the object (to be casted). It is embedded in molding sand and suitable ramming of molding sand around the pattern is made. The pattern is then withdrawn for generating cavity (known as mold) in molding sand.
Sl. No.
Procedure Instrument Name
Fig.
1 Cutting as per Length from the long Wood piece.
Hand Saw, Try Square, Steel Rule & Bench Vice.
2 Surface Plane Of Top, Bottom, Front & Back Side of the Wood piece.
Jack Plan & Bench Vice
3 Marking as per Drawing
Pencile & Try Square
WORKSHOP PARCTICE MANUAL (^) JISCE
Introduction:
The bench work and fitting plays an important role in engineering. Although in today's industries most of the work is done by automatic machines which produces the jobs with good accuracy but still it (job) requires some hand operations called fitting operations. The person working in the fitting shop is called fitter.
Fitting Tools:
Fitting shop tools are classified as below:
TOOLS REQUIRED WITH SPECIFICATION
Steel Rule 12” in length
Try Square 8” in length
Scriber 10” in length
Centre punch 4” in length
Hack Saw 300 X 12.5 X 0.
Cold Chisel 12” in length
Flat file 12” in length
Square File 8” in length
Ball Peen hammer 0.5 Kg.
WORKSHOP PARCTICE MANUAL (^) JISCE
Sl. No.
Procedure Instrument Name
Fig.
1 Make the Perpendicular Four corner Side with Respect a Particular Base.
Flat file and Try Square.
(^2) Marking as Per Drawing.
Scriber, Try Square, Center Punch and Hammer
Fig Hack Saw SawHacksaws
WORKSHOP PARCTICE MANUAL (^) JISCE
Mapping with CO and Bloom’s Taxonomy level:
Question No.
CO Bloom’s Taxonomy level
1 1 1
2 1 1
3 3 1
4 3 1
5 4 1
WORKSHOP PARCTICE MANUAL (^) JISCE
Machine workshop Introduction:
Machine shop is a place in which metal parts are cut to the required size and put together to form mechanical units or machines. The machines so made are to be used directly or indirectly in the production of necessities and luxuries of civilization. Machine shop is the base of all mechanical production.
PRECAUTIONS:
The following precautions should be taken during the experiment:
a) Do not remove metal or wood chips from the table or stock by hand. Use a brush or other tool to properly remove chips or shavings from the table or stock. b) Never leave the key in the chuck. Do not let go of the key until it is free of the chuck and secured in its proper holding place.
c) Never attempt to run the chuck on or off the spindle head by engaging the power.
d) Do not stop the rotation of the chuck by reversing the power to the lathe unless tapping holes.
e) Do not leave tools, bits or excess pieces of stock on the lathe bed. All belts and pulleys must be guarded.
f) Stop the machine immediately if odd noise or excessive vibration occurs.
JOB NAME:- MAKING A PIN FROM MS ROUND BAR
JOB FIGURE:-
OPERATING INSRTUCTIONS IN LATHE:
WORKSHOP PARCTICE MANUAL (^) JISCE
Mapping with CO and Bloom’s Taxonomy level:
Question No.
CO Bloom’s Taxonomy level
1 1 1
2 1 1
3 4 2 4 4 1
5 3 2
6 4 3
7 4 2
8 4 2
9 4 6
WORKSHOP PARCTICE WORKSHOP PARCTICE MANUALMANUAL (^) JISCEJISCE
Objective:
To study and observe the welding techniques through demonstration and practice ARC
WELDING PROCESSES:
Welding is a process in which two materials, usually metals, and is permanently joined together by coalescence, resulting from temperature, pressure, and metallurgical conditions. The particular combination of temperature and pressure can range from high temperature with no pressure to high pressure with any increase in temperature. Thus, welding can be achieved under a wide variety of conditions and numerous welding processes have been developed and are routinely used in manufacturing.
To obtain coalescence between two metals following requirements need to be met: (1) perfectly smooth, flat or matching surfaces, (2) clean surfaces, free from oxides, absorbed gases, grease and other contaminants, (3e) metals with no internal impurities. These are difficult conditions to obtain. Surface roughness is overcome by pressure or by melting two surfaces so that fusion occurs. Contaminants are removed by mechanical or chemical cleaning prior to welding or by causing sufficient metal flow along the interface so that they are removed away from the weld zone friction welding is a solid state welding technique. In many processes the contaminants are removed by fluxing agents.
The production of quality welds requires (1) a satisfactory heat and/or pressure source, (2) a means of protecting or cleaning the metal, and (3) caution to avoid, or compensate for, harmful metallurgical effects.
ARC WELDING
In this process a joint is established by fusing the material near the region of joint by means of an electric arc struck between the material to be joined and an electrode. A high current low voltage
Fig 4.1: The Basic circuit for arc welding
WORKSHOP PARCTICE MANUAL (^) JISCE
Material Supplied: Mild steel plate of size 100X50X5 mm – 2 No’s
Welding Electrodes : M.S electrodes 3.1 mm X350 mm
Welding Equipment : Air cooled transformer Voltage-80 to 600 V 3 phase supply, amps up to 350
Tools and Accessories required:
Sequence of operations:
Procedure:
WORKSHOP PARCTICE MANUAL (^) JISCE
required.
In this process, a joint is established by fusing the material near the region of joint by means of a gas flame. The common gas used is mixture of oxygen and acetylene which on burning gives a flame temperature of 3300OC. A filler rod is used to feed molten material in the gap at the joint region and establish a firm weld. The flame temperature can be controlled by changing the gas composition i.e. ratio of oxygen to acetylene. The color of flame changes from oxidizing to neutral to reducing flame.
LABORATORY EXERCISE:
WORKSHOP PARCTICE MANUAL (^) JISCE
Introduction:
Blacksmithy or Forging is an oldest shaping process used for the producing small articles for which accuracy in size is not so important. The parts are shaped by heating them in an open fire or hearth by the blacksmith and shaping them through applying compressive forces using hammer.
Hand forging process is also known as black-smithy work which is commonly production of small articles using hammers on heated jobs. It is a manual controlled process even though some machinery such as power hammers can also be sometimes used. Black-smithy is, therefore, a process by which metal may be heated and shaped to its requirements by the use of blacksmith tools either by hand or power hammer.
For carrying out forging operations manually, certain common hand forging tools are employed. These are also called blacksmith’s tools, for a blacksmith is one who works on the forging of metals in their hot state. The main hand forging tools are as under.
Anvil Swag
WORKSHOP PARCTICE MANUAL (^) JISCE
Job Name: To make a S-hook from a given round rod, by following hand forging operation.
Tools required:
Smith’s forge , Anvil , 500gm and I kg ball-peen hammers, Flatters, Swage block, Half round tongs, Pick- up tongs, Cold chisel.
Sequence of operations:
S- HOOK
WORKSHOP PARCTICE MANUAL (^) JISCE
