Laboratory Manual of

Engineering Workshop Practices

[ME________]
Part-I

Name _________________________
Enrollment No. _________________
Division-Batch __________________
_________________

20 -20
Diploma in ____________________

SEM:
 Certificate
This is to certify that Mr./Ms. ______________________________
Enrollment No: _____________________________ of Diploma in
__________________, Semester ___ has satisfactory completed
his/her laboratory work of Engineering Workshop Practices during
the regular term in academic year 20 - .

No. of Practical Certified: ______/______

Date of Submission: __________

Sign of Subject Teacher Sign of Examiner Sign of

Head of Department/
Program coordinator,
Diploma Studies,
CGPIT, UTU
 INDEX
Part- I

NAME: Batch:
CLASS:

Sr. Started Completed Total Submitted Page

Shop Marks Sign.
No. on on Hour on No.

1 Introduction

2 Carpentry

3 Tin Smithy

4 Electric

5 Soldering
 GENERAL INSTRUCTIONS

 All students are expected to be in “Workshop Apron” while working in various shops.

The apron should be made of navy blue cotton cloth (without design print , half sleeve

and of a length at least 15 cm , below the knee level).

 All students are expected to wear shoes to avoid the injury while working.

 All students are expected to bring Workshop Practice Manual in each turn.

 The student, not following above instruction will not be allowed to work in the

workshop.

 Check and count the tools / instruments while getting and returning them to store.

 The drawing of jobs should be made in orthographic projection (1st Angle) method.

 Incomplete and improper exercises will not be evaluated.

 Use the right tool for the job.

 Make sure that work is steady and secured firmly.

 Familiarize yourself with the hardness of the the material to be worked.

 Be sure you are fully educated on the proper use and operation of any tool before

beginning a job.

 Maintain all the service records of machines and equipment. It will not only save time

but also help you to take care of repetitive break downs.

 Keep the work area free from slipping/tripping hazards (oil, cords, debris, etc.).

 Do not wear any neck tie, jewellery, rings, and watches during in the working in shops.
Details of Laboratory:
The objective of this lab is to get a hands-on knowledge of several Workshop Practices like
carpentry, fitting, joining (Soldering), wiring, plumbing, tin smithy etc and learn safety
regulations to be maintained in a shop floor. This laboratory is scheduled for 1 year Diploma
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.

SAFETY RULES & UNSAFE PRACTICES:-

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.
Dress code

Suitable and unsuitable working clothing for use in an engineering workshop is shown in the
figure. Apron or protective coats should be neatly buttoned and sleeves should be tightly
rolled. Safety shoes and boots should be worn.

Right Wrong
and and
Safe Dangerous
Chapter 1 Introduction to workshop facility & Safety precautions:
Introduction:

Workshop practice is a very vast one and it is very difficult for anyone to claim a mastery over it. It
provides the basic working knowledge of the production and properties of different materials used
in the industry. It also explains the use of different tools, equipment’s, machinery and techniques of
manufacturing, which ultimately facilitate shaping of these materials into various usable forms. In
general, various mechanical workshops know by long training how to use workshop tools, machine
tools and equipment. Trained and competent persons should be admitted to this type of mechanical
works and permitted to operate equipment.

Different shops of workshop:

- Machine shop.
- Welding shop.
- Smithy shop.
- Carpentry shop.
- Fitting shop.

1.1 Machine Shop

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 1.2 Welding Shop

1.3 Fitting shop and Carpentry shop

2
 1.4 Smithy and Tin smithy shop

1.5 Soldering shop and Electrical shop

3
1.1 Workshop safety

The safety in Workshops has been written not only to provide appropriate safety procedures but
also to assist trained workshop personnel with the provision of a reference document outlining the
general principles of safe working practices relevant to the mechanical engineering aspects. It relates
to specific are as where definite safety measures are required for workshop operations

1.1.1 Factories Act and Accident

Various acts relating to accidents are spelt out in workmen’s compensation Act-1923, the factories
act-1948 and Fatal Accidents Act-1855. These acts describe the regulations for fencing and guarding
the dangerous machinery, items and employer’s liabilities.

1.1.2 Concept of accident

It is very difficult to give a definition of the word ‘Accident’. However, a generally accepted
conception that an accident is a mishap, a disaster that results in some sort of injury, to men,
machines or tools and equipments and in general loss to the organization.

The said injury or loss may be of minor or major nature and the accident is termed as non-reportable
or reportable. For example, a small cut on the body will be reportable accident in a training
workshop. It can be treated by first aid and does not involve any appreciable loss of time, and will
not be considered a reportable accident in a production unit.

1.1.3 Causes of accidents

The 98% accidents could be easily avoided provided due precautions are taken well in time. A very
familiar slogan goes on to say that accidents do not just happen but are caused due to the failure of
one element or the other, and the most unfortunate factor is that the human element is the most
pronounced of all which fail.

The common causes which lead to accidents are the following:

1. Unsafe working position.

2. Improper or defective tools or their improper use.
3. Improper acts- which result in violation of safety rules and non-observance of safety precautions.

1.1.4 Common sources of accidents

The large number of machines in use and an even larger number of parts. This can be regarded as
sources of danger and require guarding for protection against accidents.
Some common sources of accident are listed below:
Projecting nips between sets of revolving parts, viz., gears, rolls and friction wheels, etc.

1. Projecting fasteners on revolving parts.

2. Revolving cutting tools, circular saw blades.
3. Revolving drums, crushers, spiked cylinder and armed mixers, etc.
4. Revolving shafts, spindles, bars and tools like drills, reamers, boring bars and chucks, etc.
5. Projecting sharp edges or nips of belt and chain drives viz., belt, pulleys, chains, sprockets and belt
fasteners.
6. Reciprocating tools and dies of power presses, drop hammers, and revolving presses, etc.
7. Grinding wheels and stones.

4
8. Reciprocating knives and saw blades such as cutting and trimming machines and power hack-
saws, etc.
9. Revolving drums and cylinders without casing, such as concrete and other mixers.
10. Intermittent feed mechanisms.
11. Projecting nips between various links and mechanisms, like cranks connecting rods, piston rods,
rotating wheels and discs, etc.

1.1.5 Common Methods of Protection

The common methods of protection against accidents are the following:
1. Safety by position.
2. Safety by construction.
3. Safety by using interlock guards.
4. Safety by using fixed guards.
5. Safety by using automatic guards.
6. Safety by using distance guards.

5
Layout of workshop

6
 Chapter 2 CARPENTARY

Introduction: Wood work or carpentry deals with making joints for a variety of applications
like door frames, cabinet making furniture, packing etc.,

Timber:- Timber is a name obtained from well grown plants or trees. The timber must cut in
such away that the grains run parallel to the length. The common defects in timber are
knots, wet rot, dry rot etc.,

Market sizes of Timber: - Timber is sold in market in various standard shapes and sizes.
They are:-

Log:- The trunk of a tree, which is free from branches.

Balk:- The log sawn to have roughly square cross section.

Post:- A timber piece, round or square in cross section with more than 275 mm in width, 50
to150 mm in thickness and 2.5 to 6.5 mts length.

Board:- A sawn timber piece, below 175 mm in width and 30 mm to 50 mm in thickness.

Reapers:- Sawn timber pieces of assorted and nonstandard sizes, which don’t conform to
the above shapes.

Work Holding Tools:

Carpentry vice:- It is a work holding device. When handle vice is turned in a clockwise
direction, the sliding jar forces the work against the fixed sawn. The greater the force
applied to the handle, the tighter to the work held.

Bar clamp: - It is a rectangular (or) square block with V-groove on one or both sides opposite
to each other. It holds cylindrical work pieces.

7
C-Clamp: - This is used to hold work against an angle plate or V-block.

Cutting Tools

Cross-Cut Saw

Compass Saw

Planning Tools

Wood Jack Plane Smooth Jack Plane

8
Type of Chisels

Types of Files

9
Measuring Devices

Steel Rule Try Square

Tape Marking Gauge

Striking Tool:

Claw Hammer Rip Hammer Sledge Hammer

Straight Peen Hammer Cross peen Hammer Ball peen hammer

10
Drilling Tools

Carpenter’s Brace Auger Bit Hand Drill Gimlet

11
 Model Details

Aim: To prepare Wooden T Joint of given dimensions.

List of Tools:

1. Carpenter’s vice
2. Scale
3. Right angle
4. Marking gauge
5. Drill bitt (12 mm)
6. Bevel chisel (12 &25 mm)
7. Mortise chisel (12 & 16 mm)
8. Hammer
9. Compass & Cross-cut Saw

Material size:

1. Part 1 size:
2. Part 2 Size

Sequence of Operation:

1. Measuring
2. Marking
3. Drilling
4. Cutting
5. Finishing
6. Assembling

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Drawing:

13
Drawing:

14
Procedure:

1.

2.

3.

4.

5.

6.

7.

8.

Safety

1. Loose cloths are to be avoided.

2. Tools to be placed at their proper placed.
3. Hands should not be placed in front of sharp-edged tools.
4. Use only sharp tools.
5. Care should be taken, when thumb is used as a guide in cross cutting and ripping.
6. Handle while chiselling, sawing and planning with care.

15
 Tools for Carpentry:

Sr. Specification /
Name of Tool Used Applications
No. Size

Operations for Carpentry:

Sr.
Operations Performed Tools Used
No

16
Name : Reg. No. :
Class : Shop Exercise No. :
Material required : Time Allowed hours :
Store keeper's /
Date Instructor's Sign. Student's sign
Material Issued on
Repeat material issued on

WORK DETAILS

TIME
DATE HOURS INSTRUCTORS REMARKS
FROM TO SIGN.

Date Sig. of Instructor Marks

Incomplete Exercise submitted on

Exercise completed on

17
 Chapter 3 Tin Smithy
Introduction:
Many engineering and house hold articles such as boxes, cans, funnels, ducts etc., are made
from a flat sheet of metals. These 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. The edge of the articles are then secured through welding,
brazing, soldering, riveting etc.

Sheet Metal Materials:-

A variety of metals used in a sheet metal shop such as black iron, aluminum, mild steel and
stainless steel. A sheet of soft steel which is coated with molten zinc is known as galvanized
iron. The zinc coat forms a coating that resists rust, improves the appearance of the metal
and permits it to be soldieries with greater care.
Tools required: -
1. Steel rule
2. Scriber
3. Straight snip
4. Bench vice
5. Cross peen hammer
6. Plastic/rubber mallet
7. Cutting pliers
Hand tools:-
The common hand tools used in sheet metals work are steel rule, usually of 60 cm length, dot
punch, scriber, trammels, ball peen hammer, and straight peen hammer, cross peen hammer,
snip straight and soldering iron.
Trammels:-
Sheet metals layouts require marking of arcs and circles. This may be done by using the
trammels. The length of the beam decides the maximum size of the arc that can be scribed.
Wire gauge:-
The thickness of the sheet metal is referred in numbers known as standard wire gauge (SWG).
The gaps in the circumstance of the gauge are used to check the gauge number.

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Bench shears:-
Sheet metal may be cut by shearing action. In this the force is applied through a compound
lever, making it possible to cut sheet metal up to 4mm thick. The chopping hole can shear a
mild steel rod up to 10mm diameter.
Snips:-
Snips are hand shears, varying in length from 200mm to 600mm. 200mm to 250mm being the
commonly used. The straight lines are curved snips or bent snips are for trimming along inside
curves.
Hammers:-
Ball peen hammer has a cylindrical slightly curved face and a ball head straight peen and
similar to the cross peen, but it is positioned paralleled to the handle which can be used
conveniently for certain operations of folding.

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SHEET METAL JOINTS:
Various types of joints are used in sheet metal work to suit the varying requirement. These
are self-secured joints, formed by joining together two pieces of sheets metal and using the
metal itself to form the joints. These joints are to be used on sheets of less than 1.6mm
thickness.
Riveting:
Rivets are used to fasten two of more sheets of metal together. It is the common practice to
use the rivets of the same material as that of the sheets having fastened.
Sheet metal screws:-
These are used in sheet metal work to join and install duct work for ventilation air
conditioning etc. These screws are also known as self-tapping screws since they cut their own
threads.
Soldering:
Soldering is one method of joining two pieces of metal with an alloy that melts at a lower
temperature than the metals to be joined for a good job. The metals to be joined must be
free from dirt, grease and oxide. Solder is made of tin and lead in equal proportions. It comes
either in the form of wire and bar.
Soldering iron:
Soldering requires a source of heating. A common method of transmitting heat of the metal
surfaces is by using a soldering iron.

Material required: Galvanized Iron (G.I) sheet 154 x 120 mm size.

Sequence of operations:
1. Cleaning
2. Surface levelling
3. Marking
4. Cutting
5. Folding

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TOOLS USED IN TIN SMITHY SHOP:

Flat Nose Pliers

Snip Straight

Wire Pliers

Plastic Hammer Press

21
Procedure: -
1. Clean the given sheet with cotton waste.
2. The size of the given sheet is checked with the steel rule.
3. Flatten the surface of the given sheet with plastic/rubber mallet.
4. Check the G.I. Sheet for dimensions and remove extra material, if any.
5. Mark all the measuring lines on the given sheet with scriber.
6. Cut the given sheet with straight snips as required.
7. Fold the given sheet by using stakes and ball peen hammer to the required shape.

Safety precautions: -
1. For marking purpose use scriber only. Do not use pencil or pen.
2. Sufficient care is to be taken while cutting and folding of G.I. sheet.
3. Remove the waste pieces immediately from the work place.

22
Drawing:-

23
 Tools for Tin Smithy:

Sr. Specification
Name of Tool Used Applications
No / Size

Operations for Tin Smithy:

Sr.
Operations Performed Tools Used
No

24
Name : Reg. No. :
Class : Shop Exercise No. :
Material required : Time Allowed hours :
Store keeper's /
Date Instructor's Sign. Student's sign
Material Issued on
Repeat material issued on

WORK DETAILS

TIME
DATE HOURS INSTRUCTORS REMARKS
FROM TO SIGN.

Date Sig. of Instructor Marks

Incomplete Exercise submitted on

Exercise completed on

25
 Chapter 4 Electrical Shop

Types of electrical Wiring:

1. Parallel Wiring

Parallel wiring combines all phase leads together and all neutral leads together. The diagram
of this would look like a ladder. Parallel circuits are simplest of electrical circuits to wire
because adding a new lamp (as for example) is as easy as connecting the new lamp’s phase
lead to the phase wires of the other lamps in a system. However, adding lamps in parallel
causes the overall resistance of the circuit to drop. This type of wiring is used for domestic
purpose.

Residential loads (lamps, fans, etc.) are never connected in series because of the following
reasons:

 If one of the series connected apparatus fails, the supply is disconnected to the
remaining apparatus.
 The drop across each series connected apparatus reduces the voltage available at the
successive connected load and hence this load does not work satisfactorily.

Circuit Diagram

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2. Staircase Wiring

The diagram shows the wiring of a lamp (e.g. in staircase wiring) that can be turned “ON” or
“OFF” from two switches ‘A’ and ‘B’ independently. The switches used are two way switches.

A lamp will be “ON” if both switches are in similar position.

Circuit Diagram & Truth Table

3. Go-down Wiring

This type of wiring is used in tunnel, godown, etc. Switch “ON” the Master switch (Switch-1)
first which makes the lamp-1 to glow. Next switch “ON” the switch-2 which makes lamp-2 to
glow at the same time lamp-1 will be “OFF”. This way nth lamp can be made “ON” with the
help of switch-nth and (n-1) lamp will be “OFF” simultaneously. While returning same process
is repeated.

Thus for connecting ‘n’ lamps in godown wiring, requires ‘1’ one-way switch and ‘n-1’ two-
way switches. Here, master switch (switch-1) is one-way switch and other (n-1) switches are
two-way switches.

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Circuit Diagram

TOOLS USED IN ELECTRICAL SHOP:

 Screw Drivers:  Electric Drill Motor

 Wire Stripper

 Needle Nose Pliers:

 Side Cutters  Diagonal Pliers

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 Open Ended Spanner  Combination Spanner

 Adjustable Spanner

 Scissors
 Utility Knife  Chisels

 Wiring tape  Tester  Digital Electrical Tester

 Hacksaw

 Hammers:
 Claw Hammer  Ball peen Hammer

29
  Voltmeter

Simple Circuit:
 Parallel Circuit
 Series Circuit

 Symbols used in circuit diagrams

30
31
Drawing:-

32
 Tools for Electrical:

Sr. Specification /
Name of Tool Used Applications
No Size

Operations for Electrical:

Sr.
Operations Performed Tools Used
No

33
Name : Reg. No. :
Class : Shop Exercise No. :
Material required : Time Allowed hours :
Store keeper's /
Date Instructor's Sign. Student's sign
Material Issued on
Repeat material issued on

WORK DETAILS

TIME
DATE HOURS INSTRUCTORS REMARKS
FROM TO SIGN.

Date Sig. of Instructor Marks

Incomplete Exercise submitted on

Exercise completed on

34
 Chapter 5 Soldering Shop

Soldering
What is soldering?

Soldering is a process in which two or more items are joined together by melting and putting
a filler metal (solder) into the joint, the filler metal having a lower melting point than the
adjoining metal. Unlike welding, soldering does not involve melting the work pieces.

Soldering may be used to join wires or attached components to a printed circuit board (PCB).
Wires, component leads and tracks on circuit boards are mostly made of copper. The copper
is usually covered with a thin layer of tin to prevent oxidization and to promote better bonding
to other parts with solder. When soldering bare copper wires, they are often “tinned” by
applying molten solder before making a joint.

Uses of a Soldering Iron

A soldering iron is a hand tool used to heat solder, usually from an electrical supply at high
temperatures above the melting point of the metal alloy. This allows for the solder to flow
between the workpieces needing to be joined.

This soldering tool is made up of an insulated handle and a heated pointed metal iron
tip. Good soldering is influenced by how clean the tip of your soldering iron is. To maintain
cleanliness, a user will hold the soldering iron and use a wet sponge to clean the soldering
iron tip prior to soldering components or making soldered connections.

In addition to the soldering iron, solder suckers are an important part of the soldering setup.
If excessive solder is applied, these small tools are used to remove the solder, leaving only
that desired.

TOOLS USED IN SOLDERING SHOP:

 Soldering Iron

 Tester

35
 Soldering Lead  Tweezer  Clippers

 Plier  Safety Glass  Solder Cleaner

 Electrical Tester

36
Drawing:-

37
Drawing:-

38
 Tools for Soldering:

Sr. Specification /
Name of Tool Used Applications
No Size

Operations for Soldering:

Sr.
Operations Performed Tools Used
No

39
Name : Reg. No. :
Class : Shop Exercise No. :
Material required : Time Allowed hours :
Store keeper's /
Date Instructor's Sign. Student's sign
Material Issued on
Repeat material issued on

WORK DETAILS

TIME
DATE HOURS INSTRUCTORS REMARKS
FROM TO SIGN.

Date Sig. of Instructor Marks

Incomplete Exercise submitted on

Exercise completed on

40