STD: F.Y.J.C(2023-2024) QUE.

BANK FOR FIRST SEM EXAMINATION

SUBJECT: SMCS PAPER-I TIME: 2.00 HRS MARK: 50

Que. Fill in the blanks with proper words from those given below. 8 MARKS
a) In tapping process bottoming tap is used after Intermediate tap.
[Taper, Plug, Intermediate]
b) Feeler gauge is used for checking the spark plug gap.
[Slip Gauge, Feeler Gauge, Screw Pitch Gauge]
c) The ball peen hammer is generally used for riveting purpose
[Straightening, Riveting, Bending].
d) For testing parallelism try Square is used.
[Try Square, Protector, Scribing block]
e) To make an accurate hole reamer is used.
[Drill bit, Tap, Reamer]
f) The scraper is used to remove thin material from the surface.
[scraper/Hammer/Screw Driver]
g) The Feeler Gauge is used for checking gap between mating parts.
(Checking surface roughness/ Checking Gap between mating parts/ checking radius of work
piece)
h) Pipe vice is used for holding round jobs.
(Leg/ Hand/ Pipe)
i) cross tip Screw drive also known as Philips screw driver.
[Insulated, Jenny, Star or Cross tip].
j) Surface plate is used for checking flatness of job.
[Right angle , Flatness, Roundness]

Que Answer the following: 9 MARKS

a) Write a short note on “Feeler Gauge”?
These are used for checking clearances, between mating
surfaces such as clearance cylinder and piston. It consists
of a set of precision machined steel blades 0.3 to 1 mm
thick and 100 mm long. All the blades are pivoted in a
holder as in the case of a screw pitch gauge. Each blade is
engraved with its thickness. To find the size or clearance,
one or two blades are inserted and tried for a fit between
the contacting surfaces until blades of suitable thickness
are found.
b) Write a short note on “Torque Wrench” with a diagram?

This is the most important tool in automobile workshops. It is like a socket spanner, a drive
handle with a dial indicator, which indicates the amount of torque applied on a nut or bolt.
In automobiles, some fasteners are required specific tightening torque for better performance.
The torque may be specified by the manufacturers. They must be tightened to the correct
amount of distortion of vehicle parts. Since most of the parts are being made from aluminum
there are chances of slipped threads.

c) Describe Magneto Puller with a neat sketch?

Magneto puller is a tool used to remove the
deceleration plates and clutch plates without
damaging your motorcycle.
The puller is a new design with a small hole in
the center that allows the user to remove the
plugin the power tool. In the meantime, the
puller is a powerful tool to lift and pull the
flywheel.
d) State the precautions to be observed while carrying out chipping operation.
1. Towards slash off a strip, use vise as a show with shear the metal down the
line of jaws by a flat chisel. Equally, the side must be nick and after that detach the
strip.
2. Towards cut a hole in a slight sheet, use a traverse cut chisel and preserve
be cut quite lock to the line.
3. All-time put on clear goggles with seeing that chip which flies does not hit others.
4. While holding work in vise, place a packing block beneath the job to avoid its slip.
5. Don't seem at the head of the chisel except always stay an eye on the cover.
6. Never take a deep cut, 1.5 or else 2mm is sufficient.
7. Always chip towards vise jaws.
8. Never use a deadly chisel.
Que. Write the Difference between following: 9 MARKS
a) Tapping Dieing
Used to cut internal threads Used to cut external threads
It is available in set of three. It is available in single set.
It is made of Hight carbon steel or HSS. It is made of Hardened steel.
Examples of tapping process are Nut, Examples of tapping process are Bolt,
b) Lapping Honing
In the lapping process, flats and outer
cylindrical surfaces are preferred for a smooth In honing process internal cylindrical surfaces
finish. are preferred for a smooth finish.
Give fine finish like glass and It is finer than
honing. It is less fine than lapping.
IT 01 tolerance grade can be obtained in this Up to IT 4 tolerance grade can be obtained in
process. this process.
Sliding is not suitable for the surface because Sliding is suitable for surfaces.
it has more adhesive.
c) Screw Driver Plier
It is tool used for turning screw. It is an adjustable tool.
It is made of tough steel. It is made of carbon steel.
It handles are made of wood or plastic. Plier don’t required handle instead of this it
have legs.
Type of Screw Driver are, Type of Plier are,
Standard Screw driver, Philips Screwdriver, Combination plier, Nose plier, Side cutting
Offset Screwdrivers plier, Bend type nose pliers.
d) Brazing Soldering
Filler metal has the melting point above Filler metal has the melting point below
400°C. 400°C.
More stable joints can be made. Less stable joints can be made.
High pressure and temperature do not affect Joints are affected by high temperature and
the joint. pressure.
Equipment cost is more Equipment cost is very low.

Que. Write short note with sketch on following 6 Marks

a) Describe “Vee Block” with neat sketch it application
V‐block is rectangular or square block
with a V‐groove on one or both sides
opposite to each other. The angle of the
‘V’ is usually 900. V‐block with a clamp is
used to hold cylindrical work securely,
during layout of measurement, for
measuring operations or for drilling for
this the bar is faced longitudinally in the
V‐Groove and the screw of V‐clamp is
tightened. This grip the rod is firm with
its axis parallel to the axis of the v‐groove
 b) Write down the precaution to be observed while drilling operation.
1. Fix the job firmly in the vice. Do not holt it in hand.
2. Before start drilling, mark the center of hole with the help of center punch.
3. Set the point of drill exactly over the center punch mark
4. Apply steady pressure. Do not apply excessive pressure.
5. Use coolant while drilling.
6. Use Safety goggles.
7. Use brush to remove the chips.
c) State the types of ‘Scrapers' and explain anyone.?
The following types of scrapers are most commonly used.
1) Flat Scraper
2) Half round scraper.
3) Triangular scraper.
4) Two handle scrapers.

Flat Scraper: Flat scraper is used for scraping flat sure like surface plate (C.I), slide,
machine bad and other so many flat surfaces. It can be made from old hand file. The
cutting edge is at the end. It is slightly rounded so that high spots may be removed and
outer corner do not touch the surface and no mark of deep scratches. After removing
only thigh sports its produces perfectly flat surface.
d) Describe 'Piston Ring Expander' with a neat and labelled diagram.?

Piston ring expander is used to remove and install piston ring easily and fast without
risk of breakage or distortion. Piston rings are very delicate part and can be break while
removing or installing, if we try without it. As it provides support around the
circumference of the piston ring, no risk of breaking the ring.
The main parts of piston ring expander are two jaws, two handles, T joint, levers and
link, returning spring etc. If the pressure applied on handles the jaws expands in a
circular form, when the piston ring fixed in it, it also expand and can be easily installed
in groove. After installation when pressure was released, the jaws returned to its
original position due to force of returning spring.
Que. Write Short Notes on the following 6 Marks
a) Piston Ring Compressor
It is used to compress the piston rings for
fitting piston assembly into the cylinder. It
consists of an iron sheet having high
elasticity. It is rolled in a circular from and
fixed in a strip. When compression handle
is turned, rachet pawl and button gets
operated causing decreased in diameter.
After fitting the rings on the piston, piston
rings are compressed with the help of
squeezer which enables easy assembly of
piston and cylinder.

b) Die Stock
Die is used to cut external threads on a
round bar or a pipe. It is made of hardened
steel. It is square or round in shape, which
contains three or four flutes which forms
cutting edges. There are two types of dies in
use.
1. Solid Die 2. Adjustable Die
The die stock is used to hold and turns
the die, it often called as stock only.
c) Circlip Plier
V‐block is rectangular or square block with a
V‐ groove on one or both sides opposite to
each other. The angle of the ‘V’ is usually
900. V‐block with a clamp is used to hold
cylindrical work securely, during layout of
measurement, for measuring operations or
for drilling for this the bar is faced
longitudinally in the V‐Groove and the
screw of V‐ clamp is tightened. This grip the
rod is firm with its axis parallel to the axis
of the v‐groove.
d) Allen wrench or Allen Key
Allen screws are the screw which are
having internal hexagonal surface instead
of hexagonal surface on outside incase of
ordinary bolts. In this ordinary spanner
are not useful. Hence Allen wrenches or
Allen keys are used. They also available in
various sizes. Allen screw are generally of
smaller size and therefore it is used for
precision work.
 Que. Write Short Notes on the following 12 Marks

a) Describe the Chipping process in detail & Give description of four types of chisels?
Ans:
Chisels are used for removing surplus metal or for cutting thin sheets. These tools are
made from 0.9% to 1.0% carbon steel of octagonal or hexagonal section. Chisels are
annealed, hardened and tempered to produce a tough shank and hard cutting edge.
Annealing relieves the internal stresses in a metal. The cutting angle of the chisel for
general purpose is about 60°. There are many verities of chisels used for chipping work by
a fitter.
Some very commonly used forms are

a) Flat (b) Cross-cut (c) Round nose (d) Diamond point.

Flat Chisel is a general-purpose chisel which is most widely used in cutting work, chipping
large surface, cutting metal sheets, rods, bar stocks and similar other purposes. Since it
cuts the metal in cold state it is also frequently known as cold chisel.
 Round nose chisel is used for drawing the eccentric hold back to correct center which has
run off-center during drilling operation. Another specific use of this type of chisel is in
cutting oil grooves and channels in bearings and pulley bushes and cleaning small round
corners.

Cross Cut is a comparatively narrow chisel having its cutting edge slightly broader than the
blade. It is made to keep the blade free when the chisel is used to cut deep groove into the
metal. Normal widths of the cutting edge vary from 3 mm to 12 mm. This chisel is used to
cut parallel grooves on large surfaces, before chipping by means of a flat chisel, cutting key
ways, etc.

Diamond point chisel is a special purpose chisel used for chipping rough plates and cutting
cast iron pipes, cutting ‘V’ grooves, chipping sharp corners, squaring up corners of
previously cut slots and cleaning angles.
b) Describe the “Vernier caliper” with neat labelled sketch and also explain in brief its term
“least count”.
Ans: -
 Vernier scale is a visual aid, That allows the user to read measurements more precisely
than any other instrument. Vernier scale indicates where the measurement lies in between
two of the graduations on the main scale.
It is used for both inside and outside dimeter of shafts thickness of the parts etc. It works
on the principle of the difference between two scales which are nearly but not quite like
for obtaining a small difference.

It consists of following parts: -

1) Beam or main scale having fixed graduations.
2) One fixed jaw
3) Another sliding jaw.
4) Vernier head having vernier scale graduations.
5) Auxiliary head of vernier clamp to specify the dimensions.

On main scale 1 cm is divided in to ten parts each being 1 mm.

Again 1 mm is divided in two parts which gives 0.5 mm.
Hence smallest division on main scale is 0.5 mm
Vernier scale is divided in to 25 parts.
The length of vernier scale (25 parts) is equal to the. length of 12 parts on main scale,
i.e. 12 mm. Hence each vernier division = 12 / 25 = 0.48 mm.
Now the difference between main scale and vernier scale is .0.50 - 0.48=0.02 mm.
This is least count of the vernier.

c) Explain welding process in detail and list the tools and equipment for the
WELDING process.?

Ans: -
 “Welding is a fabrication process to joining two similar or dissimilar metals by heating
them to a suitable temperature with or without use of filler metal, with pressure or
without pressure.
The filler metal has its melting point approximately the same as that of work pieces
metal.

Electric arc welding: - It is the type of fusion welding process. In his welding process
the heat required is obtained from an electric arc between the electrode and the work. The
electrode is first allowed to touch the work which forms an electric circuit and current flow
through the circuit. Then, separated by a small distance (4 to 6 mm) so there is break in
circuit but current continue to flow through the gaseous medium and forms the arc. The
temperature produced by an electric arc is about 6000°C to 7000°C. The base metal melted
by the temperature of the arc, forming a pool of molten metal, which cause the pool by the
blast from the arc metal of the electrode (used in metal arc) or welding rod (used in carbon
arc welding) also gets melted and deposited at the weld. A small depression is also formed
in the base metal, which is called as arc crater. The distance between the center of arc from
the tip of the electrode and bottom of the crater is called as arc length. It should be 3 to 4
mm.

Alternating current (A.C.) is used for arc welding where electric current is easily available.
Direct current (D.C) is most commonly preferred in cases where electric current is not
available.

Tools & Equipment for electric arc welding are:

1. D.C Generator or transformer
2. Electrodes
3. Electrode holder
4. Cable and cable connectors
5. Earthing clamp
6. Welding hamlet and face shield
7. Hand Gloves
8. Apron
9. Chipping Hammer
10. Wire bush
d) State different methods of filling with neat sketches.?

Ans: -
Filing is one of the methods of removing small amounts of material from the surface of a
metal part. A file is hardened steel too, having small parallel rows of cutting edges or teeth
on its surfaces. On the faces, the teeth are usually diagonal to the edge. One end of the file
is shaped to fit into a wooden handle. The figure shows various parts of a hand file. The
hand file is parallel in width and tapering slightly in thickness, towards the tip. It is
provided with double cut teeth. On the faces, single cut on one edge and no teeth on the
other edge, which is known as a safe edge.

1) Straight Filing: In this method, file stroke is made at right angles to the length of
the work. It is useful on long and narrow pieces of work whose width is less than
that of file.

2) Cross Filing: The filing strokes run alternately from left to right and from tight to
left. By this whole of the file surface moves across the whole of work surface in one
stroke.

3) Draw Filing: The filing is not held by its wooden handle. But gripped in both
hands at both ends on file blade and moved up and down along the length of
work . BY this filing material removed is less but rough file marks are removed to
obtain smooth finish.