Diploma I Year Workshop Practice - I Manuals MEchanical Engg

WORKSHOP PRACTICE-1
CONTENTS
1. Fitting Shop 2. Forging Shop 3. Carpentry Shop 4. sheet metal Work
1-7 9-17 19-33 35-49
WORKSHOP PRACTICE-1 SUBJECT TITLE SUBJECT CODE PERIODS/WEEK PERIODS/YEAR : : : : WORKSHOP PRACTICE-1
SCORING POLICY
1. Sessional Marks
Day to Day evaluation Record Viva Internal exam
:
: : : :
40M
10M 05M 05M 20M
2. End Exam Marks
60M
LIST OF EXPERIMENTS
FITTING SHOP 1. Marking and Chipping on Mild Steel flat 12 mm thick. 2. Cutting with hacksaw, M.S. Flats of 6 mm thick 3. Marking, Cutting, Drilling and Tapping on an M.S.Flat 12 mm thick. 4. Assembling of two pieces, matching by filling (6 mm thick M.S. plate). FORGING SHOP 1. Conversion of Round to Square. 2. Conversion of Round to Hexagon. 3. Preparation of Chisel from Round Rod. 4. Preparation of Ring and Hook from M.S.Round. 5. Preparation of a Hexagonal Bolt and Nut. CARPENTRY SHOP 1. Cutting of wood with handsaw.
2. Planning of Wood. 3. Planning and Chiseling of Wood. 4. Orientation of Wood Grain. 5. Preparation of Dovetail Joint. 6. Mortise and Tenon joint. 7. Wood Turning on a lathe. 8. Preparation of one household article (stool). SHEET METAL WORK 1. Practice on cutting of sheet. 2. Formation of Joints like grooved joints, locked groove joint. 3. Preparation of a rectangular open type tray. 4. Preparation of hollow cylinder. 5. Preparation of pipe elbow.
6. Preparation of Mug. 7. Preparation of Funnel. 8. Preparation of utility articles such as dustpan, Kerosene Hand Pump. FOUNDRY 1. Practice on cutting of sheet. 2. Formation of Joints like grooved joints, locked groove joint. 3. Preparation of a rectangular open type tray. 4. Preparation of hollow cylinder. 5. Preparation of pipe elbow. 6. Preparation of Mug.
FITTING SHOP
DATE SHOP : FITTING TITLE : MARKING & CHIPPING ON MILD STEEL
: 1
Exp. No : Time :
1. To be able to file the flat. OBJECTIVES 2. To be able to square the flat. 3. To be able to mark the material. 1. Skill in fixing the flat in bench vice SKILLS TO BE DEVELOPED 2. Skill in using files. 3. Skill in using vernier calipers, try square. 4. SPECIFICATION OF MATERIAL 5. 50 x 50 x 12mm M.S.Flat.
SKETCH
TOOLS & EQUIPMENT
Bench vice, Surface plate, Steel rule, Vernier Calipers, Try square, Dot punch, Scriber, Rough flat file, Angle plate. 1. Checking the raw material with vernier calipers. 2. Holding the material properly in the bench vice. 3. Filling two adjacent edges of the flat file and checking with try square for
SEQUENCE OF OPERATIONS SAFETY PRECAUTIONS
flatness and squareness. 4. Filling the other two edges and checking with try square. 5. Marking the surfaces and applying chalk on one surface. 6. Filling the edges upto the punched lines. 7. Checking the finished flat with vernier calipers. 1. Ensure that the handle of the file is firmly fitted. 2. Pressure is applied on the file during forward stroke and pressure is relieved during the return stroke. 3. File is prevented from clogging. 4. File is cleaned from file card.
ACCURACY & FINISH
1 mm
DEVIATION :
1. How do you specify a file?
2. What is the constructional and functional difference between single cut and double cut files?
3. What is meant by scraping? How scraping is done? SELF ASSESSMENT QUESTIONS
4. How files are classified, describe briefly?
5. State the relations between length of the file and roughness.
Accuracy Finish Skill in handling Measuring tools Skill in handling Tools & Equipment Viva - Voice
10 10
TOTAL MARKS SIGNATURE 40
EVALUATION
10 10
DATE SHOP: FITTING TITLE : CUTTING WITH HACKSAW
: 2
Exp. No : Time :
To be able to use hacksaw for cutting the work piece at the given positions. OBJECTIVES To be able to chisel the material to remove the extra material.
SKETCH
1. Skill in using hack saw. SKILLS TO BE DEVELOPED 2. Skill in using chisel.
75 X 50 X 6 mm M.S.Flat.
SPECIFICATION OF MATERIAL
Bench vice, Surface plate, Steel rule, Try square, Dot punch, Scriber, Flat file,, Scriber, Odd leg caliper, TOOLS & EQUIPMENT Hacksaw, Cape Chisel.
1. Checking the raw material with for size. SEQUENCE OF OPERATIONS 2. Filling the material to size. 3. Marking the job as per dimensions. 4. Chiseling the ends. 5. Cut the material as required using Hack saw.
SAFETY PRECAUTIONS
1. Ensure that the handle of the file is firmly fitted. 2. Pressure is applied on the file during forward stroke and pressure is relieved during the return stroke. 3. File is prevented from clogging. 4. File is cleaned from file card. 1 mm DEVIATION :
ACCURACY & FINISH
SELF ASSESSMENT QUESTIONS
1. What care is to be taken for the protection of files?
2. What is meant by pinning? How can it be avoided?
3. What do you understand by direct measurement and indirect measurement?
4. How do you specify Hacksaw Blade? What care do you take while fixing it in the frame?
5. What are various cutting tools used in Fitting?
EVALUATION
10 10 10 10
TOTAL MARKS
SIGNATURE
SHOP: FITTING
TITLE : MARKING, CUTTING, DRILLING & TAPPING
DATE
: 3
Exp. No : Time :
SKILLS TO BE DEVELOPED
1. Skill in using Drilling and Cutting. 2. Skill in using Tap sets.
50 X 50 X 12 mm M.S.Flat.
Finished job of experiment No.1 may be used.
TOOLS & EQUIPMENT
Bench vice, Vernier calipers, Steel rule, Tap set, Dot punch, Suitable Drill Bit.
SEQUENCE OF OPERATIONS
1. Checking the raw material with for size. 2. Mark the centre of the work piece with centre punch. 3. Holding the work piece on vice of drilling machine. 4. Cut the central hole of the work piece. 5. Select the suitable tap and cut internal threads on drilled hole.
SAFETY PRECAUTIONS
1. Ensure that the drill bit is firmly gripped in the Drill chuck while drilling. 2. Ensure proper feeding of tap while tapping. 3. Proper holding of the job and applying the proper tap be ensured while cutting internal threads.
ACCURACY & FINISH
1 mm
DEVIATION :
1. Distinguish between tapping and Dieing?
2. How do you calculate tap drill size?
3. How many types of taps are available in a set? What are they?
4. What is the difference between parallel shank and tapered shank twist drill?
5. How can a broken drill be removed from drill chuck?
EVALUATION
10 10 10 10
TOTAL MARKS
SIGNATURE
NAME OF THE STUDENT
PIN DATE : 4
SHOP: FITTING
TITLE : ASSEMBLING OF TWO PIECES Exp. No : Time To be able to match the two metal pieces with fitting operations. SKETCH :
OBJECTIVES
1. Skill in sawing and filling SKILLS TO BE DEVELOPED 2. Skill in using measuring tools.
50 X 50 X 6 mm M.S.Flat of two pieces.

Bench vice, Try square, Surface plate, Surface gauge, Hack saw, Triangular rough file, Smooth file, TOOLS & EQUIPMENT Scriber, Dot punch, Hammer.
1. Cut the pieces to size using hacksaw. 2. Filling surface of flat for trueness. 3. Marking the surface as per dimensions. 4. Dot punching the marked lines and cutting with hacksaw. 5. Smoothing the surfaces with files and assembling the two pieces.
SAFETY PRECAUTIONS
1. Surface plate is checked for cleanliness and care is taken to prevent it from rust. 2. Ensure that hacksaw blade is properly fitted in the frame.
ACCURACY & FINISH
+ 1 mm
DEVIATION :
1. Name the various bench working process?
2. Name the marking and measuring tools used in fitting shop?
3. What are the properties of metals?
4. What is tapping? Explain step by step tapping operation?
5. What is Dieing? Explain the operation step by step?
EVALUATION
10 10 10 10
TOTAL MARKS
SIGNATURE
FORGING SHOP
NAME OF THE STUDENT
PIN DATE : 1
SHOP: FORGING
TITLE : CONVERSION OF ROUND TO SQUARE Exp. No : Time 1. To be able to heat the material to red hot condition in plastic state. SKETCH :
OBJECTIVES
2. To be able to convert the round section to square section.
1. Skill in lighting the forge and producing heat. SKILLS TO BE DEVELOPED 2. Checking constantly the heating condition of work piece. 3. Skill in Hammering and Flattering.
20 X 75 MS Round, Coke.
TOOLS & EQUIPMENT
Forge, Anvil, Sledge hammer, Hand Hammer, Flat tong, Round tong, Flatter, Brass rule. 1. Checking the material.
2. Lighting the forge. 3. Heating the forge. 4. Drawing the material through hammering by supporting the work piece on anvil. 5. Squaring the material through flattering. 6. Checking the dimensions by brass rule.
SAFETY PRECAUTIONS
1. The work piece is observed for proper heating (plastic stage). 2. Proper tongs and hammers are used. 3. Hammering of the material is done in red hot condition only. 4. Use gloves and gumboots. 5. Beware of your clothes. Do not expose them to heat. 6. Watch properly while hammering + 1 mm DEVIATION :
ACCURACY & FINISH
1. Distinguish between forging and smithy.
2. What is the desirable mechanical properties that facilitate material to be effectively forged?
3. What are the characteristics of fuel used in forging?
4. State the functions of hardie hole and punching hole of anvil. How do you specify an anvil?
5. Differentiate between open fire and stock fire.
6. What is the function of tuyers in forge?
EVALUATION
10 10 10 10
TOTAL MARKS
SIGNATURE
NAME OF THE STUDENT
PIN DATE : 2
SHOP: FORGING
TITLE : CONVERSION OF ROUND TO HEXAGON Exp. No : Time 1. To be able to heat the material to red hot condition. 2. To be able to convert the Round section to Hexagon SKETCH :
OBJECTIVES
section.
1. Skill in using forging tools. SKILLS TO BE DEVELOPED 2. Skill in rotating the bar by 60.
TOOLS & EQUIPMENT
Forge, Anvil, Sledge hammer, Hand Hammer, Round tong, Flatter, Brass rule, Hexagonal swages, Steel rule.
1. Checking the material. 2. Heating the raw material in forge to appropriate hotness. 3. Hammering the heated bar by supporting on anvil. 4. Converting into hexagonal cross section by rotating the work piece and hammering. 5. Finishing the section by using swages.
SAFETY PRECAUTIONS
1. Care is to be taken while heating the material to plastic state. 2. Material is protected from over heating as it may lead to melting of the material. 3. Proper tongs and hammers are to be used. 4. Use protective devices.
ACCURACY & FINISH
+ 1 mm
DEVIATION :
1. State the use of swages.
2. What is the difference between drawing down and setting down operations?
3. List out the specific tongs used in forging shop and state their specific uses.
4. What is meant by Red hot condition?
EVALUATION
10 10 10 10
TOTAL MARKS
SIGNATURE
NAME OF THE STUDENT
PIN DATE : 3
SHOP: FORGING
TITLE : PREPARATION OF CHISEL FROM ROUND ROD Exp. No : Time SKETCH To be able to make hexagonal chisel from round rod. :
OBJECTIVES
1. Skill in using forging tools. SKILLS TO BE DEVELOPED 2. Skill in obtaining cutting edge of chisel and hexagonal shank.
TOOLS & EQUIPMENT
Forge, Anvil, Sledge hammer, Hand Hammer, Round tong, Brass rule, Hexagonal swages, and Steel rule.
1. Checking the raw material. 2. Heating the raw material in forge. 3. Upsetting one end of the bar to form head. 4. Forging the bar to hexagonal shape by repeating striking. 5. Heating the other end to plastic state and drawing into a thinner section and making it as the cutting edge of a chisel. 6. Checking the finished product.
SAFETY PRECAUTIONS
1. 2. 3. 4.
Care is to be taken while heating the job firmly during upsetting. Do not divert your attention while working. The chisel end is cooled after heating and before upsetting. Protect the body, eyes etc., form heat.
ACCURACY & FINISH
+ 1 mm
DEVIATION :
1. What is meant by punching operation?
2. How do you specify a sledge hammer?
3. What is meant by Forge ability? List various forgeable metals..
4. Distinguish between Cold chisel and Hot chisel.
5. Define the term Fullering.
EVALUATION
10 10 10 10
TOTAL MARKS
SIGNATURE
NAME OF THE STUDENT
PIN DATE : 4
SHOP: FORGING
TITLE : PREPARATION OF RING AND HOOK FROM M.S. ROUND ROD
Exp. No : Time :
To be able to make ring and hook from M.S. Round rod. OBJECTIVES
SKETCH
1. Skill in using Swage block. SKILLS TO BE DEVELOPED 2. Skill in hammering.
10 X 250 mm MS Round, Coke.
TOOLS & EQUIPMENT
Forge, Anvil, Sledge hammer, Ball peen Hammer, swage block, Tongs.
1. Checking the raw material. 2. Heating the material. 3. Bending the heated material into ring shape. 4. Bending the remaining length into hook shape.
SAFETY PRECAUTIONS
1. Work piece is properly bent in shape in Swage block. 2. Over heating should be avoided. 3. Hammering is done with proper support to the work piece. 4. Ensure adequate water before working.
ACCURACY & FINISH
+ 1 mm
DEVIATION :
1. State the function of Swage block.
2. What is meant by Forge Welding?
3. Explain the different Forging operations?
4. What are the characteristics of the forged product?
5. State the use of flatters..
EVALUATION
10 10 10 10
TOTAL MARKS
SIGNATURE
NAME OF THE STUDENT SHOP: FORGING TITLE : PREPARATION OF A HEXAGONAL BOLT & NUT
PIN DATE : 5
Exp. No : Time :
1. To be able to make a hexagonal bolt. OBJECTIVES 2. To be able to punch and drift the material.
SKETCH
1. Skill in punching. SKILLS TO BE DEVELOPED 2. Skill in using drift.
1. 2.
10 X 250 mm Round, Coke. 25 X 20 mm Round
TOOLS & EQUIPMENT
Forge, Anvil, Hammers, Round tong, Flatter, Punches, Drifts, Swage block, Tongs. Brass rule.
1. Checking the raw material. 2. Heating one end of the bar for sufficient length to make the head. 3. Jump up the heated end on an anvil. 4. Flatter head by hammering. SEQUENCE OF OPERATIONS 5. Swage head to size. 6. Dieing the other end of the bar. 7. Heating the other raw material. 8. Punching and drifting. 9. Tapping the punched bar to make it as nut. 1. 2. 3. 4. Keep the forge and its surroundings clean. Regulate proper air supply for heating the job forge. After completion of the work put off the forge. Tight dress and proper foot wear is to be used.
SAFETY PRECAUTIONS
ACCURACY & FINISH
+ 1 mm
DEVIATION :
1. What do you understand by drifting?
2. What are the basic elements of the forge?
3. What do you understand by Scale loss?
4. State the reason in opting for Brass rule in forging?
EVALUATION
10 10 10
TOTAL MARKS
SIGNATURE
10
CARPENTRY
NAME OF THE STUDENT SHOP: CARPENTRY TITLE : CUTTING OF WOOD WITH HAND SAW
PIN DATE : 1
Exp. No : Time :
1. Practice sawing on wooden piece. OBJECTIVES 2. To be able to use different saws accurately.
SKETCH
1. Skill in fixing the job in the vices. SKILLS TO BE DEVELOPED 2. Skill in sawing the wood in a straight line 3. Select suitable saw for specific operation.
Teak wood of 310 X 55 X 50 mm
TOOLS & EQUIPMENT
Steel rule, Try square, Marking gauge, Hand saw, Jack plane, Bench.
1. Marking the dimensions on job. SEQUENCE OF OPERATIONS 2. Fixing the job in the vice. 3. Cutting along the grains by using Rip saw. 4. Changing the position of work piece in the vice. 5. Cutting perpendicular to the grain using cross cut saw.
SAFETY PRECAUTIONS
1. 2. 3. 4.
Saws are used with handles fitted properly. Place all the tools in specified places after use. Job is clamped properly. Saw cut is made during forward stroke only with proper cutting force.
ACCURACY & FINISH
1 mm
DEVIATION :
1. What are the types of wood used in carpentry?
2. Define Seasoning and state its importance.
3. What do you understand by the term Setting in saw?
4. What are the different types of saws used in carpentry?
5. What is meant by ripping?
6. How do you specify a Hand saw?
EVALUATION
10 10 10
TOTAL MARKS
SIGNATURE
10
NAME OF THE STUDENT SHOP: CARPENTRY TITLE : PLANNING OF WOOD
PIN DATE : 2
Exp. No : Time :
1. Practice sawing on wooden piece. OBJECTIVES 2. To be able to use different planes used in carpentry.
SKETCH
1. Skill in fixing the job in the vices. SKILLS TO BE DEVELOPED 2. Skill in sawing the wood in a straight line 3. Select suitable Planes for specific operation.
TOOLS & EQUIPMENT
Steel rule, Try square, Marking gauge, Hand saw, Different Planes.
1. Marking the dimensions on the job by using Marking gauge. SEQUENCE OF OPERATIONS 2. Fixing the job in the vice. 3. Cutting along the grains by using Rip saw. 4. Changing the position of work piece in the vice. 5. Select suitable planes for the operation on four sides of the wood piece.
SAFETY PRECAUTIONS
1. 2. 3. 4.
Saws are used with handles fitted properly. Place blade of a plane to suitable thickness and projection of plane. Job is clamped properly. Planning must be straight and always checking with hand.
ACCURACY & FINISH
1 mm
DEVIATION :
1. Specify a carpentry plane?
2. Specify a metal jack plane?
3. Specify a blade which is used in the planes?
4. What are the different types of planes used in carpentry?
5. What are the common defects in timber?
EVALUATION
10 10
TOTAL MARKS
SIGNATURE
10
10
NAME OF THE STUDENT SHOP: CARPENTRY TITLE : PLANNING NAD CHISELLING OF WOOD
PIN DATE : 3
Exp. No : Time :
1. To be able to chisel various grooves on wooden OBJECTIVES block. 2. To be able to plane the wood.
SKETCH
1. Skill in accurate marking. SKILLS TO BE DEVELOPED 2. Skill in using of appropriate chisels. 3. Skill in preparing the jack plane for planning. 4. Skill in planning.
TOOLS & EQUIPMENT
Steel rule, Try square, Marking gauge, Hand saw, Tenon saw, Jack plane, Firmer Chisel, Rasp File, Wooden mallet.
1. Marking the dimensions on the job by using Marking gauge. SEQUENCE OF OPERATIONS 2. Fixing the job in the vice of grooves by marking gauge/pencil . 3. Cutting slides of grooves by hand saw. 4. Chip the material by using firmer chisel by applying pressure with mallet. 5. Finishing the grooves with rasp file.
SAFETY PRECAUTIONS
1. 2. 3. 4. 5.
Chiseling is proceeded in a direction away from the body. Usage of blunt tools is avoided. Work piece is to be rigidly clamped. Concentration is on the cutting edge of chisel but not on the handle during chiseling. Pressure is applied on the plane only during forward stroke.
ACCURACY & FINISH
1 mm
DEVIATION :
1. How do you Specify a Chisel?
2. Distinguish between Mortise chisel and Firmer Chisel.
3. State the function of gauges?
4. What is meant by cut in reference to a plane?
5. List various chisels used in carpentry.
EVALUATION
10 10
TOTAL MARKS
SIGNATURE
10
10
NAME OF THE STUDENT SHOP: CARPENTRY TITLE :
PIN DATE ORIENTATION OF WOOD GRAINS : 4
Exp. No : Time :
Cutting the natural Wood to be cut across the grains OBJECTIVES and along the grains for observing the grain structure and grain growth.
SKETCH
1. Skill in using appropriate tools. SKILLS TO BE DEVELOPED 2. Skill in operating the jack plane. 3. Skill in estimation the grain Structure.
Take a suitable natural wood piece from the tree of a minimum 100 mm diameter and 100 mm length.
TOOLS & EQUIPMENT
Steel rule, Jack plane, Outside calipers, Gauges, Hand saw.
1. Using hand saw or band saw cut the wood across the grains. SEQUENCE OF OPERATIONS 2. Planning the work piece by using jack plane. 3. Cut the wood piece along the grains by using hand saw or with band saw.
SAFETY PRECAUTIONS
1. 2. 3. 4.
Do not divert your attention while working on band saw. Before switching on the machine, ensure that the job is held rigidly. Do not wear loose garments when working on band saw. Beware of your hands while working and applying tools on the job.
ACCURACY & FINISH
1 mm
DEVIATION :
1. Observe the grain structure of wood and explain different grains?
2. What is the difference between across the grains and along the grains with suitable figure?
3. What is the difference between hard wood and soft wood?
4. Write the qualities of a good timer?
5. Write any five advantages of wood over the other materials?
EVALUATION
10 10
TOTAL MARKS
SIGNATURE
10
10
PIN DATE DOVETAIL JOINT : 5
Exp. No : Time :
To be able to prepare dovetail joint. OBJECTIVES
SKETCH
1. Skill in using tools. SKILLS TO BE DEVELOPED 2. Skill in marking right dovetail and groove. 3. Skill in preparing a firm carpentry joint
2 pieces of 155 X 55 X 30 mm wood.
TOOLS & EQUIPMENT
Bench vice, Beveled edged firmer chisel, Metal jack plane, Mallet, Fold rule, Try Square, Marking Gauge, Rasp file.
1. Planning the wooden pieces on all sides. SEQUENCE OF OPERATIONS 2. Marking at an angles of 75 with bevel square. 3. Trimming the dovetail groove on Second piece. 4. Cutting the dovetail groove on second piece. 5. Finishing the groove. 6. Assembling the two pieces and preparing dovetail halving joint by using mallet. 1. Ensure proper cut to be used while planning. 2. Appropriate tools are selected and used. 3. Care should be taken in preparing accurate dovetails.
SAFETY PRECAUTIONS
ACCURACY & FINISH
1 mm
DEVIATION :
1. How are the uses of dovetail joints?
2. What are the specific characteristics of a dovetail halving joint?
3. What is meant by Rebating?
4. How do you specify a Bench vice.
5. Suggest a Carpentry joint to be used in making photo frames
EVALUATION
10 10
TOTAL MARKS
SIGNATURE
10
10
PIN DATE MORTISE & TENON JOINT : 6
Exp. No : Time :
To be able to prepare Mortise and Tenon joint. OBJECTIVES
SKETCH
1. Skill in cutting the tenon using Tenon Saw. SKILLS TO BE DEVELOPED 2. Skill in using various chisels, Mallets, Planes, Gauges etc.
Teak wood of two pieces of 155 X 55 X 30 mm.
Try Square, Mortise gauge, Tenon saw, Mortise Chisel, Firmer chisel, Mallet. TOOLS & EQUIPMENT
1. Plane the given two pieces to the required size by using jack plane. SEQUENCE OF OPERATIONS 2. Marking the dimensions to make Tenon using Mortise gauge. 3. Cutting Tenon with Tenon saw along the marked lines. 4. Using Firmer chisel to remove the excess material to set finished Tenon. 5. Mark the dimension to make Mortise on the second piece with mortise gauge. 6. Using Mortise chisel, provide recess in the second piece to accommodate Tenon. 7. Assembling the two pieces by fitting the Tenon into Mortise. 1. Right Mallet is only to be used in Chiseling. 2. While cutting, the work piece is to be held firmly and properly. 3. Provide Sufficient illumination and Ventilation in the work shop while doing the job.
SAFETY PRECAUTIONS
ACCURACY & FINISH
1 mm
DEVIATION :
1. What are the practical use of Mortise and Tenon joint?
2. What is the tool used for planning a convex surface?
3. What is the user of pincer?
4. When Spoke Shave used?
5. What are the wood working processes?
EVALUATION
10 10
TOTAL MARKS
SIGNATURE
10
10
PIN DATE WOOD TURNING ON LATHE : 7
Exp. No : Time :
To be able to prepare a Wooden Rolling stock with OBJECTIVES handle for rolling Chapathi in Kitchen.
SKETCH
1. Skill in using appropriate tools. SKILLS TO BE DEVELOPED 2. Skill in operating wood working lathe. 3. Skill in estimation of material required.
50 X 50 mm square section of 350 mm length teak wood.
Jack plane, Outside calipers, gauges, Steel rule, Firmer chisel, Wood Working Lathe. TOOLS & EQUIPMENT
1. Planning the four corners of the work piece by using Jack plane. SEQUENCE OF OPERATIONS 2. Marking the centers of jobs on either side. 3. Mounting the job between head stock & Tail stock centers. 4. Fixing tool in the tool post & positioning it to appropriate height. 5. Starting the lathe to make the work piece to revolve at desired speed. 6. Feeding the bevel gauge against the rotating work piece to get the required size and shape. 7. Using outside calipers check the diameter of work piece. 8. Using parting off tool reduce the diameter on either ends of the work piece. 9. Removing the rolling work piece between centers and cut off the excess material on either sides. 1. 2. 3. 4. 5. Do not divert your attention while working on lathe. Before starting the machine, ensure that the job is held rigidly. Dont wear loose garments, while working on lathe. Use safety goggles while working. Beware of your hands while working and applying tools on the job. DEVIATION :
SAFETY PRECAUTIONS
ACCURACY & FINISH
1 mm
1. What are the components that can be made, using wood working lathes?
2. Name the parts of Wood turning lathe?
3. State the principle of operation of wood working lathe?
4. What is rebating? How is done?
EVALUATION
10 10
TOTAL MARKS
SIGNATURE
10
10
PIN DATE HOUSEHOLD ARTICLE (STOOL) : 8
Exp. No : Time :
To be able to prepare a house hold article like OBJECTIVES wooden stool.
SKETCH
1. Skill in using appropriate tools. SKILLS TO BE DEVELOPED 2. Skill in estimation of material required.
300 X 300 X 25 mm one plank, 4 Nos. of 410 X 50 X 50 mm for legs and Nos. of 300 X 50 X 25 mm for supporters.
Jack plane, Marking gauge, Steel rule, Firmer chisel, Mortise chisel, Mallet. TOOLS & EQUIPMENT
1. Select the material for legs of correct size. SEQUENCE OF OPERATIONS 2. Select the plank of wood of correct size. 3. Marking and planning the selected material. 4. Marking of Mortise and tenon joint. 5. Select the surface chisels and cut the grooves. 6. Fixing the legs and plank. 7. Fixing the job with suitable joining process. 1. 2. 3. 4. 5. Do not divert your attention while working on lathe. Before starting the machine, ensure that the job is held rigidly. Dont wear loose garments when working on lathe. Use safety goggles while working. Beware of your hands while working and applying tools on the job.
SAFETY PRECAUTIONS
ACCURACY & FINISH
1 mm
DEVIATION :
1. Name any three wood working machines?
2. Name the different joints in carpentry shop?
3. What are the various types of paints?
4. State the properties of good paints ?
EVALUATION
10 10
TOTAL MARKS
SIGNATURE
10
10
SHEET METAL
NAME OF THE STUDENT
PIN
SHOP: SHEET METAL
TITLE : CUTTING PRACTICE
DATE
: 1
Exp. No : Time :
1. OBJECTIVES 2.
To be able to use different type of snips. To be able to cut various shapes from the sheet.
SKETCH
1. Skill in using Scriber. SKILLS TO BE DEVELOPED 2. Skill in cutting the sheet properly from the stock. 3. Skill on using the different snips to accuracy.
24 SWG GI sheet 200 X 100 mm. SPECIFICATION OF MATERIAL
Steel rule, Scriber, Straight snip, Curved snip, Divider, Stake, Chisel, Wooden mallet. TOOLS & EQUIPMENT
1. Cutting the required sheet from the stock by using snips. SEQUENCE OF OPERATIONS 2. Marking the dimensions on the sheet by using scriber (or) pencil & Steel rule. 3. Drawing the circular shapes by using divider. 4. Do the rough cutting for the curved shapes by using chisel and curved snips for finishing process. 5. Using straight snips to cut the straight edges.
SAFETY PRECAUTIONS
1. Always hold the snip in one hand and the nearest metal in the other hand. 2. During cutting the metal curl on the left hand side of the snip and curls down on the right hand side of the snips. 3. Always cut along the left hand edge of the sheet of permit the scrap to curl away. 4. Remove sharp projections to avoid injuries.
ACCURACY & FINISH
1 mm
DEVIATION :
1. Distinguish between sheet and plate?
2. What are the various types of metals used in sheet metal shop?
3. What is meant by Galvanizing? How is it done?
4. What do you understand by circumferential rule why it is to be used in sheet metal shop?
EVALUATION
Accuracy Finish Skill in handling Measuring tools Skill in handling Tools & Equipment Viva Voice
10 10
TOTAL MARKS
SIGNATURE
10
10
NAME OF THE STUDENT
PIN
SHOP: SHEET METAL
TITLE : GROOVED JOINT AND LOCKED GROOVED JOINT
DATE
: 2
Exp. No : Time :
1. OBJECTIVES 2.
To be able to use different type of snips. To be able to cut various shapes from the sheet.
SKETCH
1. Skill in using Mallet to form the metal properly. SKILLS TO BE DEVELOPED 2. Skill in bending the sheets properly along the marked line.
24 SWG G.I. sheet 100 X 75 mm (2 Nos.) 100 X 80 mm (1 No.)
TOOLS & EQUIPMENT
Steel rule, Scriber, Straight snips, Pencil, Divider, Stakes, Mallet.
1. Drawing lines a different of 5 mm parallel to the edges of the two sheets using Scriber/Pencil. SEQUENCE OF OPERATIONS 2. Forming the flange on the sheet, by folding the sheet along the scribed lines using mallet & appropriate stakes. 3. Bending the edges of the sheets by applying moderate pressure using mallet. 4. Inter lock the bent edges and apply pressure with mallet to make required joints.
SAFETY PRECAUTIONS
1. To avoid injuries do not hold the sheets with bare hands. 2. Remove sharp projections on the sheet immediately on notching.
ACCURACY & FINISH
1 mm
DEVIATION :
1. What is the desirable mechanical property of the sheet?
2. What are the various joints used in sheet metal?
3. What do you understand by seaming?
4. What is meant by hem?
5. What do you understand by reinforcement in Tin Smithy and how is it to be done?
6. Are the joints made in Tin Smithy leak proof?
EVALUATION
10 10
TOTAL MARKS
SIGNATURE
10
10
NAME OF THE STUDENT
PIN
SHOP: SHEET METAL
TITLE : PREPARATION OF RECTANGULAR OPEN TYPE TRAY
DATE
: 3
Exp. No : Time :
SKETCH OBJECTIVES To be able to prepare a rectangular open tray
1. Skill in drawing the Development of the object. SKILLS TO BE DEVELOPED 2. Skill in using the tools to obtain desired shape.
G.I. sheet 200 X 150 mm SPECIFICATION OF MATERIAL
TOOLS & EQUIPMENT
Steel rule, Scriber, Straight snips, Stakes, Mallet.
1. Drawing the development of the object to be made. SEQUENCE OF OPERATIONS 2. By placing the pattern on the sheet, marking the dimensions by using scriber. 3. Shearing the required piece from the parent stock by using straight snips. 4. Marking the lines on the sheet, for marking bends for forming. 5. Strengthening the sides of sheet by making single hem using Hatchet stake. 6. Forming the sheet in to desired shape by using stakes. 7. Seaming the corners of the tray by inserting the laps of the adjacent sides with single hem. 1. Care is to be taken in avoiding wastage of sheet metal. 2. Proper pressure is to be applied with mallet. 3. Safe edges are made by properly bending the sheet.
SAFETY PRECAUTIONS
ACCURACY & FINISH
1 mm
DEVIATION :
1. Draw the layout of tray?
2. What are the various sheet metal operations commonly employed?
3. Distinguish between blanking and piercing?
4. State the use of Rivet set?
EVALUATION
10 10
TOTAL MARKS
SIGNATURE
10
10
NAME OF THE STUDENT SHOP: SHEET METAL TITLE :
PIN DATE PREPARATION OF HOLLOW CYLINDER : 4
Exp. No : Time :
To be able to prepare a Hollow Cylinder OBJECTIVES
SKETCH
1. Skill in using Mallet to form the sheet to desired SKILLS TO BE DEVELOPED shape. 2. Skill in Bending the sheet exactly along the marked line. 3. Skill in forming a single hem.
24 SWG G.I. sheet 200 X 112 mm SPECIFICATION OF MATERIAL
TOOLS & EQUIPMENT
1. Drawing the development (pattern) of the cylinder. SEQUENCE OF OPERATIONS 2. Marking the dimension of sheet to be cut by placing the pattern on the sheet using scriber using a straight snip. 3. Cutting the required sheet from the stock along the marked lines using a straight snip. 4. To strengthen the edges, make the single hem on top & bottom side using Hatchet stake. 5. Forming the flat sheet into cylindrical shape by cylindrical stake and applying pressure by using mallet. 6. Prepare a single hem on to longitudinal sides in opposite directions Inter lock the sides and apply pressure using Mallet to make a strong joint.
SAFETY PRECAUTIONS
1. Care should be exercised when forming the sheet metal using mallets & stakes. 2. Do not keep tools on the edges of the work table. 3. Always wear shoes to protect feet from sharp objects in the shop.
ACCURACY & FINISH
1 mm
DEVIATION :
1. Draw the layout of cylinder to prepare the given job?
2. What is the function of stakes in Tin Smithy list of various stakes?
3. How do you specify a sheet?
4. State the use of wire gauge?
EVALUATION
10 10
TOTAL MARKS
SIGNATURE
10
10
PIN DATE PREPARATION OF PIPE ELBOW : 5
Exp. No : Time :
To be able to prepare a Pipe Elbow. OBJECTIVES
SKETCH
1. Skill in cutting the beveled end. SKILLS TO BE DEVELOPED 2. Skill in making the seams.
24 SWG G.I. sheet 212 X 200 mm
TOOLS & EQUIPMENT Steel rule, Scriber, Straight snips, Stakes, Mallet, Soldering iron, Curved Snip. The operation consists of Making two similar cylindrical pipes truncated at angle of 45 on the side of SEQUENCE OF OPERATIONS each pipe seamed at beveled ends. (a) Preparation
of one pipe :
1. Drawing the development of a cylinder pipe truncated at an angle of 45 on one side. 2. Scribing the lines on the sheet by placing the pattern on it. 3. Cutting the lines on the sheet by placing the pattern on it. 4. Hem the straight side of the sheet and flange the curved side of the sheet. 5. Folding the edges of the Joining sides. 6. Forming the sheet into cylindrical shape by using stakes. 7. Seam the sides by using Mallet. (b) REPEATING THE SIMILAR OPERATIONS FOR MAKING SECOND PIPE FOR MAKING ELBOW: 1. Butt the treated portions of the cylindrical pipes at rectangles. 2. Soldering the two pipes. 3. Solder the joint to make leak proof. 1. Care should be taken in cutting the raw material without wastage. 2. Care is to be taken in joining the two pieces to form elbow without excess gaps.
SAFETY PRECAUTIONS
ACCURACY & FINISH
1 mm
DEVIATION :
1. Draw the layout of pipe elbow?
2. State the function of pipe elbow?
3. Explain piercing and blanking?
4. Why is flux used in soldering?
EVALUATION
10 10
TOTAL MARKS
SIGNATURE
10
10
NAME OF THE STUDENT
PIN
SHOP: SHEET METAL
TITLE : PREPARATION OF MUG
DATE
: 6
Exp. No : Time :
To be able to preparation of mug. OBJECTIVES
SKETCH
1. Skill in cutting the beveled end. SKILLS TO BE DEVELOPED 2. Skill in making the seams.
24 SWG G.I. sheet 212 X 200 mm
TOOLS & EQUIPMENT
Steel rule, Scriber, Straight snip, Stakes, Mallet, Soldering iron, Curved Snip.
1. Drawing the development of a mug as per the specification. (2r) 2. Scribing the lines on the sheet by placing the pattern on it. 3. Cutting the lines on the sheet by placing the pattern on it. 4. Forming the sheet into cylindrical shape by using stakes. 5. Seam the sides by mallet. 6. Joining the sides to become a permanent joint. 7. Soldering is done if necessary to become a leak proof joint.
SAFETY PRECAUTIONS
1. Care should be taken in cutting the raw material without wastage. 2. Care is to be taken in joining the two pieces to form elbow without excess gaps.
ACCURACY & FINISH
1 mm
DEVIATION :
1. Explain Brazing?
2. What is difference between Brazing and Soldering?
3. What do you mean by development of surface?
4. Name the few sheet metal joints?
EVALUATION
10 10
TOTAL MARKS
SIGNATURE
10
10
PIN DATE PREPARATION OF A FUNNEL : 7
Exp. No : Time :
To be able to prepare a funnel. OBJECTIVES 1. Skill in marking dimensions on the sheet. SKILLS TO BE DEVELOPED 2. Skill in using the appropriate stakes for forming the sheet. SPECIFICATION OF MATERIAL 24 SWG G.I. sheet 300 X 100 mm 80 X 65 mm
SKETCH
TOOLS & EQUIPMENT Steel rule, Scriber, Straight snips, Stakes, Mallet. SEQUENCE OF OPERATIONS
(a) Preparing Upper Conical part :

1. Drawing the development of upper conical part. 2. Placing he patterns on the sheet, cutting sheet of required size. 3. Marking the dimensions on the part by using the scriber & dividers.. 4. Hem the upper side of the sheet. 5. Flanging out he bottom of the part. 6. Folding the edges of the joining sides. 7. Forming the sheet into conical shape by using appropriate stakes and mallet.
(b) Preparing the Bottom Conical Part :

1. Drawing the development of bottom conical part. 2. Placing the patterns on the sheet & cutting to required size. 3. Hem the bottom side of the sheet. 4. Flanging the upper side of the sheet. 5. Folding the edges of the joining side. 6. Forming the sheet into conical shape. 7. Seaming the sides.
(c) Assembling :
1. Seaming the Top conical part & bottom conical part to obtain the required funnel. 1. Ensure that the Snips are properly used with appropriate cut. 2. Slow and uniform pressure is given to sheet while bending on stakes. SAFETY PRECAUTIONS ACCURACY & FINISH 1 mm DEVIATION :
1. Draw the layout of Funnel?
2. What is meant by Dovetail Seam?
3. What are stakes? Name the different types?
4. What are the applications of a Brazing?
5. What is the purpose of flux used with the solder?
EVALUATION
10 10
TOTAL MARKS
SIGNATURE
10
10
NAME OF THE STUDENT
PIN
SHOP: SHEET METAL
TITLE : PREPARATION OF A DUST PAN
DATE
: 8
Exp. No : Time SKETCH :
OBJECTIVES
To be able to prepare Dust Pan.
1. Skill in using Snips. SKILLS TO BE DEVELOPED 2. Skill in making hems. 3. Skill in applying Mallet to set good finish
24 SWG G.I. sheet : 180 X 160 mm
TOOLS & EQUIPMENT
1. Drawing the development of the given Dust Pan. 2. Scribing the lines on the sheet by placing the Development on the sheet. SEQUENCE OF OPERATIONS 3. Hem all the four sides to strengthen the edges. 4. Forming the sheet into designed shape by using suitable stakes & Mallet. 5. Soldering the corner lap joints to make the required Dust Pan.
SAFETY PRECAUTIONS
1. Blunt snips be avoided. 2. Edges are properly folded and checked for safety.
ACCURACY & FINISH
1 mm
DEVIATION :
1. Draw the development layout of Dust pan?
2. State the use of riveting. Explain with stages?
3. What is the purpose of zinc coating on a G.I sheet?
4. Sketch curved snip and label the parts.
EVALUATION
10 10
TOTAL MARKS
SIGNATURE
10
10

Diploma I Year Workshop Practice - I Manuals MEchanical Engg

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WORKSHOP PRACTICE-1

1. Fitting Shop 2. Forging Shop 3. Carpentry Shop 4. sheet metal Work

1-7 9-17 19-33 35-49

2. End Exam Marks

DATE SHOP : FITTING TITLE : MARKING & CHIPPING ON MILD STEEL

TOOLS & EQUIPMENT

SEQUENCE OF OPERATIONS SAFETY PRECAUTIONS

ACCURACY & FINISH

1. How do you specify a file?

3. What is meant by scraping? How scraping is done? SELF ASSESSMENT QUESTIONS

4. How files are classified, describe briefly?

5. State the relations between length of the file and roughness.

TOTAL MARKS SIGNATURE 40

DATE SHOP: FITTING TITLE : CUTTING WITH HACKSAW

1. Skill in using hack saw. SKILLS TO BE DEVELOPED 2. Skill in using chisel.

ACCURACY & FINISH

SELF ASSESSMENT QUESTIONS

1. What care is to be taken for the protection of files?

2. What is meant by pinning? How can it be avoided?

3. What do you understand by direct measurement and indirect measurement?

5. What are various cutting tools used in Fitting?

TITLE : MARKING, CUTTING, DRILLING & TAPPING

1. Skill in using Drilling and Cutting. 2. Skill in using Tap sets.

Finished job of experiment No.1 may be used.

TOOLS & EQUIPMENT

ACCURACY & FINISH

SELF ASSESSMENT QUESTIONS

1. Distinguish between tapping and Dieing?

2. How do you calculate tap drill size?

5. How can a broken drill be removed from drill chuck?

NAME OF THE STUDENT

50 X 50 X 6 mm M.S.Flat of two pieces.

ACCURACY & FINISH

SELF ASSESSMENT QUESTIONS

1. Name the various bench working process?

2. Name the marking and measuring tools used in fitting shop?

3. What are the properties of metals?

4. What is tapping? Explain step by step tapping operation?

5. What is Dieing? Explain the operation step by step?

NAME OF THE STUDENT

2. To be able to convert the round section to square section.

TOOLS & EQUIPMENT

ACCURACY & FINISH

SELF ASSESSMENT QUESTIONS

1. Distinguish between forging and smithy.

3. What are the characteristics of fuel used in forging?

5. Differentiate between open fire and stock fire.

6. What is the function of tuyers in forge?

NAME OF THE STUDENT

TOOLS & EQUIPMENT

ACCURACY & FINISH

SELF ASSESSMENT QUESTIONS

1. State the use of swages.

4. What is meant by Red hot condition?

NAME OF THE STUDENT

TOOLS & EQUIPMENT

ACCURACY & FINISH

SELF ASSESSMENT QUESTIONS

1. What is meant by punching operation?