Heritage Institute Of Technology

Department of Mechanical Engineering

LAB MANUAL

Paper Name: Workshop / Manufacturing Practices

Paper Code: MEC1051

 A.Syllabus

Course Name: WORKSHOP /MANUFACTURING PRACTICES

Course Code: MEC 1051
Contact Hours L T P Total Credit Points
per week 1 0 3 4 2.5

A.1.Course Outcomes:

On successful completion of the course, students will be able to

CO1: Follow the various safety practices in workshop and personal protective elements.
CO2: Identify tools, work material and measuring instruments useful for fitting, carpentry and
sheet metal practices.
CO3: Operate machine tools, components and processes to prepare jobs of specific shape and
size.
CO4: Acquire knowledge of foundry process and casting of a product.
CO5: Perform welding, brazing and soldering processes.
CO6: Assemble a simple product.

A.2. Course Articulation Matrices (CAMs)

PO PO PO PO PO PO PO PO PO PO PO PO PSO PSO PSO
CO
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3

CO 1 3 1 1 - - - - 2 2 - - 2 1 1 1

CO 2 3 2 2 - - - - 2 3 - - 2 2 3 3

CO 3 3 2 2 - - - - 2 3 - - 2 2 3 3

CO 4 3 2 2 - - - - 2 3 - - 2 2 3 3

CO 5 3 2 2 - - - - 2 3 - - 2 2 3 3

CO 6 3 2 3 - - - - 2 3 - - 2 2 3 3
A.3. Detail Syllabus

(i) Lectures: (13 hours)

Detailed contents
1. Introduction on Workshop and familiarization with safety norms (1 lecture)
2. Carpentry and Fitting (2 lectures)
3. Sheet metal (1 lecture)
4. Metal casting (1 lecture)
5. Welding (arc welding & gas welding), brazing and soldering (2 lectures)
6. Manufacturing Methods- machining (Lathe, Shaping and Milling) (4 lectures)
7. Additive manufacturing (1 lecture)
8. Assembling of a product (1 lecture)

(ii) Workshop Practice: (39 hours)

1. Safety practices in workshop (3 hours)
2. Carpentry shop (3 hours)
3. Fitting shop (6 hours)
4. Foundry shop (3 hours)
5. Machine shop (9 hours)
6. Welding shop-Arc welding (3 hours)
7. Sheet metal shop and brazing (6 hours)
8. Soldering operation (3 hours)
9. Assembling of a product (3 hours)

A.4. Suggested Text/Reference Books:

1. Hajra Choudhury S.K., Hajra Choudhury A.K. and Nirjhar Roy S.K., “Elements
ofWorkshop Technology”, Vol. I 2008 and Vol. II 2010, Media promoters andpublishers
private limited, Mumbai.
2. Kalpakjian S. And Steven S. Schmid, “Manufacturing Engineering and Technology”,4th
edition, Pearson Education India Edition, 2002.
3. Gowri P. Hariharan and A. Suresh Babu,”Manufacturing Technology – I”
PearsonEducation, 2008.
4. Roy A. Lindberg, “Processes and Materials of Manufacture”, 4th edition, Prentice
HallIndia, 1998.
5. 5. Rao P.N., “Manufacturing Technology”, Vol. I and Vol. II, Tata McGrawHill
House,2017.
 B. SCHEME OF MEC 1051 FOR THE PARALLEL GROUPS

To be followed from session 2023-2024

Faculty: 1 Faculty: 2

Scheme-I (CME B06) Scheme-II (CME B12)

Job Day Job

Carpentry 1 Fittings 1

Foundry and Casting 2 Fittings 2

Fittings 1 3 Carpentry

Fittings 2 4 Foundry and Casting

Lathe 1 5 MMA Welding

Lathe 2 6 Assembling of Computer

Sheet Metal and Brazing

[CE, ME, CHE , BT]
Shaping Machine 7 Sheet metal and soldering
[EE, ECE, It, AEIE, CSE,
CSBS]

Milling Machine 8 Lathe 1

MMA Welding 9 Lathe 2

Assembling of Computer 10 Shaping Machine

Sheet Metal and Brazing [CE, ME,

CHE , BT]
Sheet metal and soldering [EE, ECE, 11 Milling Machine
It, AEIE, CSE, CSBS]

Final Viva 12 Final Viva

Semester Exam 13 Semester Exam

 C. JOB Title

Paper: Workshop / Manufacturing Practices Paper Code: MEC 1051

Sl. No. Shop Name Job No Job Title

Carpentry
1. MEC 1051/01 Making a wooden pattern (dovetail joint)
Shop

Making a Aluminum Alloy casting of a given

2. Foundry Shop MEC 1051/02
pattern
Making a Gauge from MS Plate
3. MEC 1051/03 (50% student will make half part and half part will
be made by rest 50% student), 2 student in a group
Fitting Shop
Making a M8 stud and Nut by die and taps
4. MEC 1051/04 (50% student will make M8 stud and 50% student
will make Nut part), 2 student in a group
Making a Stepped pin.
Day 1 – Student will first make the stepped pin
Machine Shop
5. MEC 1051/05 using turning and facing.
- Lathe
Day 2 – Student will make the thread at one end of
the stepped pin
Removing 2 mm layer from a flat surface of a
Shaping
6. MEC 1051/06 metallic cube by shaping machine. (Group size:
Machine
7-8) (Total Group: 4)
Removing 2 mm layer from a flat surface of a
Milling
7. MEC 1051/07 metallic cube by Up and Down milling. (Group
Machine
size: 7-8) (Total Group: 4)
Make a double V butt joint after edge
Welding Shop
preparation
8. – Arc MEC1051/08
(50% student will make one side and other side will
Welding
be made by rest 50% student)
Assembling of
9. MEC1051/09 Assembling of a computer
Computer
Sheet metal work on GI sheets to cut into pieces
Sheet Metal of different shapes. Brazing operation to make a
and Brazing/ cylindrical component using GI sheet/
10. MEC 1051/10
Sheet metal Sheet metal work on GI sheets to cut into pieces
and soldering of different shapes. Soldering operation o make
an electronic circuit.
VIVA VOCE will be taken based on the theoretical
11. Final VIVA - and practical portions of the course. The date of
Semester exam has to be announced on that day
Semester Semester Exam of 40 marks will be conducted in
12. -
Exam two parts. Written descriptive and Job
 D. Tentative Lecture Plan for MEC 1051 Theory

Paper: Workshop / Manufacturing Practices Paper Code: MEC 1051

Contact: 1L Credit: 1

Class
Contents Topics need to be covered in the THEORY classes
No
1. Introduction Introduction to workshop - various shops in a typical workshop - Carpentry,
to Workshop Fitting, Foundry, Sheet Metal Shop, Welding and Brazing Shop, Machine Shop ,
and Safety Forging & Smithy - Safety precautions to be followed in a workshop.
precautions Manufacturing Process – classification of manufacturing processes
Introduction to Carpentry – Timber - Market forms of converted Timber e.g.
2. Carpentry log, balk, plank, batten, beam -Types of Wood - Hard Wood-Soft Wood-
Seasoning of wood-Natural seasoning-Artificial seasoning, Carpentry joints.
Introduction to casting and moulding –
 Pattern – Importance of pattern – pattern material – Types of pattern –
Pattern Allowances –
Foundry and
3 and Metal  Mould making – Constituents of moulding sand – Types of moulding
4 Casting sand - Preparation of sand (silica, clay, moisture, and miscellaneous
items and their functions) - Properties of a good sand mould.
 Melting of metals in muffle furnaces – Pouring of molten metal in
cavity – Solidification – removal of casting.
 Casting defects-different types of casting defects.
 Introduction to Fittings – Importance of fittings – Fitting operations
(job holding, filing, measuring, marking, sawing, chipping, drilling,
Fitting reaming)
Operation  Thread - Thread nomenclature, Different types of standard threads –
5. metric thread, BSW, BSP, TPI.
 Tapping – Tap drill size calculation, Dieing, Twist drill and its
nomenclature.
 Power tools – details about upright drilling machine.
6. VIVA VIVA of 5 marks
7. Machine 1. Basics of machining. Cutting motion and cutting speed, Feed
shop Motion and feed, Depth of Cut, MRR.
Lathe 2. Discuss the following components of a Lathe and their functions
especially the following components : (a) Head Stock (b) Tail
Stock (c) Carriage (d) Cross slide (e) Tool post (f)Lead Screw (g)
compound rest (h) Bed
3. Lathe specification (a) Height of dead centres from the bed. (b)
Distance between two dead centres (c) No of spindle speed
available (d) Horse Power of Motor(e) Height of bed from its
base.(f) Type of chuck
4. Describe with the help of a diagram various operations that may
be performed in a standard Lathe Machine.(a) Straight Turning
(b) Facing (c) Chamfering.(d) Grooving (e) Thread cutting
8. Machine Thread cutting operation in Lathe- basic principle- Different standard threads-
shop different mechanisms and components associated in thread cutting by Lathe-
thread cutting tool
9 and Machine Description and working principle of a milling machine-Specification of Milling
10. shop machine-Types of Milling-Up Milling-Down Milling (differences between
them)- Types of milling machine-Vertical Milling Machine-Horizontal Milling
 Machine.
Description of a Shaping machine- working principle -Quick return mechanism
and ratio -Feed Mechanism-purpose of shaping machine
11. MMA Welding - Types of Welding – MMAW– Electrode - Functions of Flux -
Welding Equipment for MMAW - Different types of welding joints - AC Welding - DC
Welding - Safety precautions in Welding Shop.
12 and Gas welding Introduction to Gas welding – Chemistry of Oxy-acetylene gas welding – Oxy-
13 ,Brazing, Acetylene ratio control by regulators - Welding torch - Different types of
soldering Flames in Gas Welding and Gas Cutting - Neutral Flame – Oxidizing Flame –
Sheet metal Carburizing Flame – Brazing, principle and application – Soldering principle
and application
Sheet, Specification of sheet metal, SWG, different types of sheets (HR sheet -
CR sheet - GI Sheet - Stainless Steel Sheet - Aluminum sheets - Tin Plates),
Sheet metal operation (Shearing, blanking, punching, bending)
14. Written Test A written test (objective) 10 marks

E. Tentative Plan for MEC 1051 Practical

Paper: Workshop / Manufacturing Practices Paper Code: MEC 1051

Contact: 4P Credit: 1.5

Class Name of
Topics that need to be covered in the PRACTICAL classes
No Shop
Introduction to workshop - Safety precautions to be followed in a workshop.
Manufacturing Process – classification of manufacturing processesCarpentry
Tools - Marking Tools - Cutting Tools - Planning Tools - Boring Tools - Striking
Carpentry
1 Tools - Holding & Miscellaneous Tools - Carpentry Processes (marking, sawing,
Shop
planning, Chiseling, boring, grooving etc. ) - Safety precautions in Carpentry
Shop.
Job Title: Making a wooden pattern (dovetail joint).
Introduction to moulding – Pattern –General procedure for making a good sand
mould - Different tools used for preparation of a mould - Explanation of various
Casting and terms ( Cope and Drag Box, Runner, Riser, Gating and its utility, Parting sand,
2 Foundry Vent holes). placing of sprue – gate cutting – melting of metals in muffle
shop furnaces – Pouring of molten metal in cavity – Solidification – removal of
casting – Checking of casting defects – finishing
Job Title: Making a Aluminium alloy casting of a given pattern
Introduction to fittings,Fitting operations (Marking, Drilling, Reaming, Thread
Cutting, Holding tools (Vices, V-block, C-clamp etc) – Marking and Measuring
tools (Surface plate, Try square, Scriber, Calipers, Divider, Punch etc) – Cutting
Fitting Shop
3 tools (Hacksaw, Chisel, Twist drill, Tap and Tap wrenches, Dye and Dye-holders
-I
etc) – Finishing Tools (Reamers, Files – Rough; Bastard, Second cut, Half round,
Triangular etc).
Job Title:Making a gauge from MS plate
Fitting Operations – Marking – Drilling – Tapping(Rougher-Intermediate-
Fitting Shop Finisher taps)-Sawing-Dieing-Internal Thread-External Thread-.Safety
4
- II precautions in Fitting Shop.
Job Title:Making a M8 stud and Nut by dye and taps
1. Demonstration of all the components of Lathe.
5 Machine 2. Power Transmission mechanism: Motor- Belt drive- Gear Train-
Shop – Lathe Spindle Speed. Explain how speed may be changed. Explanation
of Cutting Speed calculation.
 3. Keep components ready to explain various operations that are done in
lathe and provide the other required information.
4. Tool and job centering. Facing and turning of the job

Job Title: Making a stepped pin

Thread cutting operation in Lathe- basic principle- Different standard threads-
different mechanisms and components associated in thread cutting by Lathe-
thread cutting tool- Grooving- chamfering
Machine
6 Shop – Lathe Performing Grooving, Chamfering and thread cutting, checking of thread using
thread gauge.

Job Title: Making a stepped pin.

Description of a Shaping machine-Base –Column-Saddle-Clapper box-power and

motion transmission process in shaping machine-Feed Mechanism-Table-
Machine Rotation of table-Adjustment of stroke length and changing the position of
Shop – stroke.
7
Shaping
machine
Job Title: Removing 2 mm layer from a flat surface of a metallic cube
by shaping machine.
Description of a milling machine-components of machine-power and motion
Machine transmission process in milling machine- up milling-Down milling.
Shop –
8
Milling
Job Title: Removing 2 mm layer from a flat surface of a metallic cube
Machine
by Up and Down milling
Welding-Weldability-Types of Welding-MMAW-Gas Welding-Electrode –
Functions of Flux-Equipment for MMAW- Different types of welding joints-AC
Welding
Welding-DC Welding- Various types of welding joints-Butt joint-Fillet Joint-
9 Shop – Arc
Safety precautions in Welding Shop.
Welding
Job Title: Making a double V-Butt joint
Assembling
10 of a Job Title: Assembling of a computer
computer
Sheet metal working Tools – Micrometer-Chisels-Punches-Hammers – Mallets-
Hand Shear or Snips-Various sheet metal forming operations – Shearing –
Marking – Punching-Drilling-Bending – Drawing – Brazing- Safety precautions
Sheet Metal in Sheet Metal Working Shop.Introduction to Gas welding, - Different types of
and Flames in Gas Welding, Neutral Flame – Oxidizing Flame –Carburizing Flame –
Brazing-procedure-soldering- procedure
Brazing/
11
Job Title: Sheet metal work on GI sheets to cut into pieces of different
Sheet metal
and shapes. Brazing operation to make a cylindrical component using GI
soldering sheet/

Sheet metal work on GI sheets to cut into pieces of different shapes.

Soldering operation o make an electronic circuit.
FINAL
12 Viva-voce
VIVA

SEMESTER
13 Semester exam of 40 marks
EXAM
 HERITAGE INSTITUTE OF TECHNOLOGY
Department of Mechanical Engineering
F. Assignment

Paper: Workshop / Manufacturing Practices Paper Code: MEC 1051

Note:The report must be submitted in A4 Size paper on both sides with cover page, page no,
border line & roll no on each page in a channel file.

CARPENTRY SHOP
1. What are the differences between Hard Wood & Soft Wood?
2. Write and describe two methods of seasoning of wood.
3. Write three advantages of seasoning of wood.
4. Name a cutting, planning, striking, boring, holding, marking tool and draw the diagram of each
one in relation to carpentry shop.
5. Name different processes that are involved in a typical carpentry job and the tools used for those
operations.
6. Explain the terms Log, Batten, Plank, and Beam.
7. Write the specification/s and application/s of the following tools in association with carpentry.
i. Try Square v. Mortise Gauge
ii. Jack Plane vi. Rip Saw
iii. Vice vii. Bench Vice
iv. Marking Gauge

FITTING SHOP
1. Name five important operations that are performed in fitting shop and tools used to perform those
operations.
2. Draw the following tools used in a fitting shop with a neat sketch and write the specifications.
i. Bench Vice v. Half Round File
ii. Flat Chisel vi. Ball Peen Hammer
iii. Adjustable frame Hack Saw vii. Outside Spring Caliper
iv. Flat File
3. How do you calculate the drill size for doing internal thread in a job piece?
4. Why are three taps used for doing an internal thread by hand?
5. Name the tool used for making an external thread by hand and explain how to make an external
thread by hand using that tool?
6. Draw a typical thread profile and show major diameter, minor diameter, and pitch diameter, depth
of thread, angle of thread, crest and root.
7. What do the abbreviations mean- BSW, BSP, TPI stand for in relation to a thread?

FOUNDRY SHOP
1. Describe the following tools that are used in foundry shop .What purpose are they used for?
i. Trowel v. Strike off bar
ii. Lifter vi. Vent rod
iii. Rammer vii. Draw spike
iv. viii. Cope and Drag box.
2. Why is sand used for preparing a mould?
3. What are the ingredients that are mixed with sand in order to make a good mould and why are
they used?
4. Describe the following terms in relation to a mould
i. Runner iii. Vent holes
ii. Riser iv. Gate
 5. Draw typical green mould sand and label the following:
i. Cope Box
ii. Drag Box
iii. Runner
iv. Riser
v. Parting Line

SHEET METAL SHOP

1. What is the full name of SWG,HR sheet, CRCA sheet, GI sheet?
2. Name various sheet metal forming processes and the tools used to perform each of those
processes.
3. Name few sheet metal working processes and the tools used for each of those processes.
4. Draw the following tools used in Sheet metal work
i. Hand Shears
ii. Round Mallet
iii. Prick Punch
iv. Bench Vice
v. Sheet Metal Gauge

WELDING SHOP
1. What is Weldability?
2. Describe MMAW & Gas Welding.
3. Describe three types of flames in Gas welding with sketch.
4. What is the basic equipment that constitutes an Arc welding system?
5. Why is step down transformer used in Arc welding process?
6. What are the functions of flux used in electrodes?
7. Describe different types of welding joints
8. What are the safety precautions that need to be observed in welding shop?
MACHINE SHOP
LATHE
1. How is a lathe specified? Describe principal components of a centre lathe.
2. Describe the following operations with schematic diagram –Turning-Taper turning-Facing-
Grooving-Chamfering-Thread Cutting.
3. Explain Cutting speed, Feed & Depth of cut in relation to turning operation in lathe.
MILLING
1. How is a Milling machine specified?
2. What are the differences between UP milling and DOWN milling?
3. What are the operations can be done in a milling machine?
SHAPING MACHINE
1. Draw and explain a quick return mechanism in a shaping machine.
2. Explain the function of clapper box in shaper.
3. How is the stroke length and position of stroke in a shaping machine adjusted?
4. Describe automated table feed mechanism in a shaper.

1. the important parts of an Injection moulding machine?

 HERITAGE INSTITUTE OF TECHNOLOGY
Department of Mechanical Engineering

Paper Name: Workshop/ Manufacturing Practices Paper Code: MEC 1051

G. Scheme of Marking

The following scheme of marking for Workshop/ Manufacturing Practices (MEC 1051) is going to be
introduced from the very first day of odd semester of AY 2023-2024 till the further notice. All the
member of faculties and TAs are here by requested to evaluate students’ performance accordingly for the
above said paper.

G.1. Basic Scheme:

Full marks of the paper

(100)

Internal Evaluation
(Continuous Semester Exam (40)
Assesment) (60)

Theory (15)

Practical (45)
 G.2. Detail Scheme:

Theory  Written exam of Member of faculty taking the lecture class of a particular
(15) 10 marks group of a department must provide the marks according to
(Objective type) the scheme furnished in the previous column of this and send
 Viva voce of 5 it to the corresponding faculty taking the lab class of same
marks group.

Practical  Class  Class Performance (CP) will be provided by both the

(45) Performance faculty and TA conducting the lab class of the
(20) respective group of a department.
Faculty must provide CP of 10 marks based
on the Job or performance shown by the students at
the end.
TA will provide the CP of 10 marks based
on the overall performance of the same student during
the job operation.
At the end of the session, the respective TA
must send the marks in excel sheet with detail
breakup to the respective faculty taking the Lab.

 Report with  Respective faculty member will provide the 15 marks

questionnaire after checking the report and asking 1 or 2 question(s)
(15) based on the report in regular basis.

 Final Viva (10)  The second last class of the course must be reserved
for the VIVA VOCE of 10 marks. On that day, along
with viva the pending job may be done for the
absentees based on the faculty and TAs’ discretion.
Semester It is expected that on the last day of the session, the semester
exam exam will be taken by informing the date of exam to the
(40) students at least 7 days before.

 Written  A total 6 questions of 5 marks each have to be

Descriptive (20) selected satisfying 6 COs individually and students
are directed to answer any 4 from them.

 Job (20)  A small job is to be given to students in random basis.

At the end of the job 2 or 3 questions may be asked to
the respective students.

At the end of the course, the member of faculty taking the lab class of a particular group is responsible to
upload the total 100 marks in ERP system after the instructions of COE office.
 HERITAGE INSTITUTE OF TECHNOLOGY
Department of Mechanical Engineering

Chowbaga Road, Anandapur, P.O.-East Kolkata Township,

Kolkata 700107

REPORT
ON

Workshop / Manufacturing Practices

JOB NO ______________________ __________________SHOP

JOB TITLE ___________________________________________

DATE(S)OF WORK __________________________________________

DATE OF SUBMISSION __________________________________________

PREPARED BY

NAME ____________________________________________

DEPARTMENT ____________________________________________

GROUP ________________ ROLL NO. _________________

EVALUATED BY

Signature of Faculty/Examiner _________________________________________