EEPW 1240 Engineering Workshop (Mechanical)

Ministry of Manpower Salalah College of Technology Engineering Department

PROCEDURES TO BE FOLLOWED IN MECHANICAL WORKSHOP In the first engineering workshop class, students need to be taken for a walk around the workshop to let them know about the various divisions of the workshop (Such as Machine shop, Welding Shop, Fitting Shop and Sheet metal shop) and to know the location of the fire safety devices, important operating controls, first aid box , emergency exits etc., In the same class, students need to be given the appropriate overalls and safety shoes, after getting the signatures for the receipt of the same. At the same time they need to be informed about the safe handling and maintenance of those items as it will not be given again during their study in the college, irrespective of the level unless the situation warrants in the opinion of the HoS or HoD. Then Instructions need to be given to the students by the lecturer regarding the Health and Safety Practices in the workshop and the proper code of conduct inside the workshop which are given below Students and staff should wear the overalls and safety shoes when they are in the workshop without which the entry is prohibited. Tools need to be obtained from the stores, only through the window provided for that purpose. Students entry is prohibited inside the stores. While working, all the safety items (Such as goggles, gloves etc.,) required for the work should be used. In case of an accident, the people involved should be given the first aid and the medical attention immediately. Then an accident report need to be prepared by the workshop in charge and submitted to the higher authorities. All near miss incidents need to be recorded and reported After the work, students should clean their workplace and have to return all the tools and safety items that were borrowed, before they leave. Proper follow up is the responsibility of the lecturer and technician of that class. It is the technicians duty to make sure that all the tools and equipments that are required to handle the class is ready, before the starting of the class.
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EEPW 1240 Engineering Workshop (Mechanical) Littering inside the workshop is an offense. Students should concentrate in their work when they are inside the workshop. Playing, shouting, Joking and not obeying the instructions will invite punishments. After the work, the machines and the equipments need to be switched off. Malfunctioning of the equipments and the breakage of the tools need to be immediately reported by the students to the technicians they in turn should record the report and should take measures to correct the failure. Eating and drinking inside the workshop is strictly prohibited All malfunctions of the equipments and the misbehaviors of people need to be immediately brought to the notice of the workshop in charge in turn to the HoS and HoD. Following are the various maintenance activities which are to be carried out in the workshops by the technicians in charge of that workshop Routine and periodic checking and inspections. Ensuring proper functioning of different Parts and elements in the equipments. Cleaning and lubrication of contacts and bearings. Corrective actions against failures and malfunctioning Maintaining the stock register, equipment maintenance register and the accident report file is the responsibility of the technician in charge of the workshop.

Duties of the lecturers who are handling the workshop classes are as follows: Lecturers should prepare the required teaching materials.
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EEPW 1240 Engineering Workshop (Mechanical) Lecturers should teach the students about the concepts, theory and procedures related to the job before they start the work. Students shall be taught to understand the drawings, required list of tools /instruments and materials etc. Detailed description of the procedural steps of the skill /practice shall be given to the students before they start working on the machines. Special precautions to be taken while doing a particular job shall be stated with stress and emphasis. The quality of the work done by the students shall be checked in real time when they work. They must ensure that the machines/work tables are cleaned neatly by the students. Overall performance of the students and reports of the skill/ practice presented by the students along with the results shall be evaluated and respective grades/mark shall be entered in the assessment record. Scheduling, conducting the examinations and assessment is the responsibility of the lecturers. Maintenance of attendance records and reporting the absentees when they cross 10%, 20% and 30% limits is also the responsibility of the lecturers. At the end of the day/week, the technician in charge should lock all the doors after ensuring the equipment shutdown.

Chapter 1 Safety in Workshop (i) Introduction to Safety Personal Safety

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Always wear overalls in the workshop Always protect the eyes by wearing goggles when using machinery. Always wear safety boots in the workshop Wear a suitable respiration when dust and fumes are present Keep hair shorts or wear a cap.

Dont wear rings or watches when working on a machine

Gloves should always be worn when handling sharp components.

Never wear gloves when operating machine tools. Use hand cream to remove oil or grease from the hands. Safety Precautions in Machines Dont start a machine without receiving operating instructions. You have to know how to stop the machine before start it. Make sure that all guards are in position. Isolate the machine before starting repair work on it. Do not lean on a machine whilst it is working. Safety Clothing Overalls Ear protection Caps Goggles Gloves Boots and shoes Respirators

Proper Clothings in Workshop

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Mandatory signs You can recognize these signs as they have a blue background colour. The symbol must be white. Figure shows five typical mandatory signs. These signs indicate things that you must do and precautions that you must take. These signs must be obeyed; you have no option in the matter. To disregard them is an offence in law as, again, you would be putting yourself at considerable risk.

Appearance
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Clothing For general workshop purposes a boiler suit is the most practical and safest form of clothing. However, to be completely effective certain precautions must be taken. Long hair Long hair is liable to be caught in moving machinery such as drilling machines and lathes. This can result in the hair and scalp being torn away which is extremely dangerous and painful. Permanent disfigurement will result and brain damage can also occur. Long hair is also a health hazard, as it is almost impossible to keep clean and free from infection in a workshop environment. Either adopts a short and more manageable head style or some sort of head covering that will keep your hair out of harms way. Sharp tools Sharp tools protruding from the breast pocket can cause severe wounds to the wrist. Such wounds can result in paralysis of the hand and fingers. Buttons missing and loose cuffs Since the overalls cannot be fastened properly, it becomes as dangerous as any other loose clothing and is liable to be caught in moving machinery. Loose cuffs are also liable to be caught up like any other loose clothing. They may also prevent you from snatching your hand away from a dangerous situation. Hole in pocket Tools placed in a torn pocket can fall through onto the feet of the wearer. Although this may not seem potentially dangerous, it could cause an accident by distracting your attention at a crucial moment. Overalls too long These can cause you to trip and fall, particularly when negotiating stairways. Lightweight shoes The possible injuries associated with lightweight and unsuitable shoes are: puncture wounds caused by treading on sharp objects; crushed toes caused by falling objects; Hand protection

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EEPW 1240 Engineering Workshop (Mechanical) Your hands are in constant use and, because of this, they are constantly at risk handling dirty, oily, greasy, rough, sharp, hot and possibly corrosive and toxic materials. Gloves and palms of a variety of styles and types of materials are available to protect your hands whatever the nature of the work.

Head and eye protection As has already been stated, long hair is a serious hazard in a workshop. If it becomes entangled in a machine, the operator can be scalped. If you wish to retain a long hairstyle in the interests of fashion, then your hair must be contained in a close fitting cap. This also helps to keep your hair and scalp clean and healthy. When working on site, or in a heavy engineering erection shop involving the use of overhead cranes, all persons should wear a safety helmet complying with BS 2826. Even small objects such as nuts and bolts can cause serious head injuries when dropped from a height.

The hazard of long hair (ii) Causes of Electrical shock

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An electric shock from a 240 volt single-phase supply (lighting and office equipment) or a 415 volt three-phase supply (most factory machines) can easily kill you. Even if the shock is not sufficiently severe to cause death, it can still cause serious injury. The sudden convulsion caused by the shock can throw you from a ladder or against moving machinery. To reduce the risk of shock, all electrical equipment should be earthed or double insulated. Further, portable power tools should be fed from a low-voltage transformer at 110 volts. The power tool must be suitable for operating at such a voltage. The transformer itself should be protected by a circuit breaker containing a residual current detector. The fuses and circuit breakers designed to protect the supply circuitry to the transformer react too slowly to protect the user from electric shock. The electrical supply to a portable power tool should, therefore, be protected by a residual current detector (RCD). Such a device compares the magnitudes of the current flowing in the live and neutral conductors supplying the tool. Any leakage to earth through the body of the user or by any other route will upset the balance between these two currents. This results in the supply being immediately disconnected. The sensitivity of residual current detectors is such that a difference of only a few mill amperes is sufficient to cut off the supply and the time delay is only a few microseconds. Such a small current applied for such a short time is not dangerous. (iii) Fire Fighting Fire fighting is a highly skilled operation and most medium and large firms have properly trained teams who can contain the fire locally until the professional brigade arrives. The best way you can help is to learn the correct fire drill, both how to give the alarm and how to leave the building. It requires only one person to panic and run in the wrong direction to cause a disaster.

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EEPW 1240 Engineering Workshop (Mechanical) Smoke is the main cause of panic. It spreads quickly through a building, reducing visibility and increasing the risk of falls down stairways. It causes choking and even death by asphyxiation. Smoke is less dense near the floor: as a last resort crawl. To reduce the spread of smoke and fire, keep fire doors closed at all times but never locked. The plastic materials used in the finishes and furnishings of modern buildings give off highly toxic fumes. Therefore it is best to leave the building as quickly as possible and leave the fire fighting to the professionals who have breathing apparatus. Saving human life is more important than saving property. Fire extinguishers The normally available fire extinguishers and the types of fire they can be used for are as follows. Water Used in large quantities water reduces the temperature and puts out the fire. The steam generated also helps to smother the flames as it displaces the air and therefore the oxygen essential to the burning process. However, for various technical reasons, water should be used only on burning solids such as wood, paper and some plastics. A typical hose point and a typical pressurized water extinguisher are shown in this figure.

Foam extinguishers These are used for fighting oil and chemical fires. The foam smothers the flames and prevents the oxygen in the air from reaching the burning materials at the seat of the fire.
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EEPW 1240 Engineering Workshop (Mechanical) Water alone cannot be used because oil floats on the water and this spreads the area of the fire. A typical foam extinguisher is shown in Fig. (a). Note: Since both water and foam are electrically conductive, do not use them on fires associated with electrical equipment or the person wielding the hose or the extinguisher will be electrocuted. Carbon dioxide (CO2) extinguishers These are used on burning gases and vapours. They can also be used for oil and chemical fires in confined places. The carbon dioxide gas replaces the air and smothers the fire. It can be used only in confined places, where it cannot be displaced by draughts. Note: If the fire cannot breathe neither can you, so care must be taken to evacuate all living creatures from the vicinity before operating the extinguisher. Back away from the bubble of CO2 gas as you operate the extinguisher, do not advance towards it. Figure (b) shows a typical CO2 extinguisher. Vaporizing liquid extinguishers These include CTC, CBM and BCF extinguishers. The heat from the fire causes rapid vaporization of the liquid sprayed from the extinguisher and this vapour displaces the air and smothers the fire. Since a small amount of liquid produces a very large amount of vapour, this is a very efficient way of producing the blanketing vapour. Any vapour that will smother the fire will also smother all living creatures which must be evacuated before using such extinguishers. As with CO2 extinguishers always back away from the bubble of vapour, never advance into it. Vaporizing liquid extinguishers are suitable for oil, gas, vapour and chemical fires. Like CO2 extinguishers, vaporizing liquid extinguishers are safe to use on fires associated with electrical equipment. A typical example of a vaporizing liquid extinguisher is shown in Fig. (c). Dry powder extinguishers These are suitable for small fires involving flammable liquids and small quantities of solids such as paper. They are also useful for fires in electrical equipment, offices and kitchens since the powder is not only non-toxic, it can be easily removed by vacuum cleaning and there is no residual mess. The active ingredient is powdered sodium bicarbonate (baking powder) which gives off carbon dioxide when heated. A typical example of a dry powder extinguisher is shown in Fig. (d).

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Various Types of Fire Extinguishers a) Foam type b) Co2 type c) Vaporizing liquid d) Dry powder

Chapter 2
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FITTING SHOP (i) Safety precautions in fitting shop Use a file with a properly fitted, tight handle. Check the hammer each time before it is used. The handle must be securely welded. Select the type, shape and size of wrench opening most suitable for the application. Position the jaws as close to the work as possible to prevent slipping. Start a new blade in another place when a blade breaks during a cut. This prevents binding and blade breakages. Apply force only on the forward (cutting) stroke; relieve the force on return stroke. Position the work piece area such that the cut to be making is close to the vice. (ii) Tools used in Fitting Shop Bench vice The wise is common tools used for holding jobs. It consists if a cast iron body and cast iron jaws. Two jaws plates are fitted on both the jaws. Jaw plates are made up of high carbon steel and are wear resistant. One jaw is fixed to the body and the second slides on a square threaded screw with the help of the handle. The jaws are opened up to required length; job is placed in the two is fully tightened with handle.

Try square It is used for checking squareness of surface. It consists of a blade made up of steel which is attached to base at 90 degree. The base is made up of cost iron steel. Try square is also used for marking right angles and measuring straightness of surface.

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Jenny Caliper or Odd Leg Caliper This is used for marking parallel lines a finished edge and also for locating the center of round bars. They are specified by the height of the leg up to the hinge point.

Scriber This is the basic marking out tool. It consists of a handle with a sharp point. The pointed end is made from hardened steel so that it will stay sharp in use.

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Centre punch It is like a dot punch except the angle of punching end is 90. It is used to mark the center of the hole before drilling.

Hacksaw The hacksaw is used for cutting metal by handle. It consists of frame which holds a thin blade, firmly in the position. The blade has a number of cutting teeth. The number of teeth per 25 mm of the blade length or teeth inch (TPI) is selected on the basis of the work material and thickness being cut.

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Chisels There are used for chipping away the material from the work piece. These are made up of high carbon steel. Generally 6 to 8 long. The top is flattened and sharp cutting edge is made on the bottom side. Chisels are classified on the bottom side. Commonly used forms of chisels are flat, cross cut, half round and diamond point chisels. Flat chisel is used for general work, cross cut chisel and half round chisels are used for grooving and diamond point chisel is for precision work.

Hammer Hammer are named depending on their shape and material and specified by their weight. A ball peen hammer has a flat which is used for riveting. They weight from 200gm to 1.5kg.The different types of hammer are Ball peen hammer, Cross peen hammer, chipping hammer etc.,

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Steel rule It is made up of stainless steel and marked with graduation of scales. Files A file is hardened steel tool, having slant 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 wooden handle. The hand file is parallel in which in width and tapering slightly in thickness towards the top. It is provided with cut teeth on the face, single cut on one edge and no teeth on the other edge, which is known as safe edge.

Types of files Files are classified according to their shape, cutting teeth and pitch or grade of the teeth. Flat File It has double cut on both sides and single on both edges. It is mostly used for general work and filing flat surfaces. A large amount of metal can be removed with this file, and they dont produce smooth surfaces.
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EEPW 1240 Engineering Workshop (Mechanical) Square file It is double cut file on all sides, and used for enlarging square holes and filing of slot and keys. Triangular file Its section is triangular and faces are double cut and edges are single cut. Its each side on 60 degrees. It is used for filing internal angles, shoulders or corners and for sharpening wood working saws. Round file It is also a double cut file. It is used for enlarging holes, slots, and concave. Half round file It has one side flat and other side is half round. The flat side is double cut and curved side is single cut. It is used for filing curved surfaces.

Different Types of Files used for different profiles

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Ex: No: 1 Aim

SQUARE FITTING

To make a square fitting from the given two mild steel pieces.
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EEPW 1240 Engineering Workshop (Mechanical) Tools Required Bench vice Try square Steel rule Prick punch Hacksaw Files Surface plate Surface gauge Ball peen hammer Procedure 1) The original dimensions of the work piece are checked using the steel rule. 2) Then the work piece is clamped properly in the bench vice and using a flat file any two sides of the work piece are filed. Check whether the two sides are right angles using the try square. 3) The given dimension are marked using the surface plate and surface gauge by referring the two sides as bases. 4) Punch marks are put on the line marked using prick punch. 5) Now the remaining two faces are filed. 6) Filing is continued until the required dimension and smooth surface of the work piece is obtained. Result Thus the square fitting with required dimension is obtained

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All Dimensions are in mm

Ex: No: 2

VEE FITTING

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EEPW 1240 Engineering Workshop (Mechanical) Aim To make a Vee fitting from the given metal piece. Tools Required Bench vice Try square Steel rule Prick punch Hacksaws Files Surface plate Surface gauge Ball peen hammer Procedure 1) The original dimensions of the work piece are checked using the steel rule. 2) Then the work piece is clamped properly in the bench vice and using a flat file any two sides of the work piece are filed. Check whether the two sides are right angles using the try square. 3) The given dimension are marked using the surface plate and surface gauge by referring the two sides as bases. 4) Punch marks are put on the line marked using prick punch. 5) Now the remaining two faces are filed. 6) Cut and remove the excess materials using the hacksaw. Filling is continuity until the required size and smooth surface of the work piece is obtained this is repeated for the other work piece also. 7) Filing is continued until the required dimension and smooth surface of the work piece is obtained. Result Thus the Vee fitting with required dimension is obtained.

Chapter 3 SHEET METAL WORKING

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EEPW 1240 Engineering Workshop (Mechanical) (i) Sheet metal materials Black Iron It is also known as uncoated sheet since it carries no artificial coating on its surfaces. However, it is probably the cheapest of all types of sheets used in sheet metal work. Being uncoated, it is prone to corrosion. Consequently, its use is confined mostly to the manufacture of such items which are to be painted before shipment, e.g. block iron is used in tanks, pans, trunks, stove pipes, etc. Galvanized Iron Zinc coated iron is called 'Galvanized iron'. This soft steel sheet is popularly known as GI sheet. The zinc coating resist rust, improves the appearance of the metal and permits it to be soldered with greater ease; but welding is not so easy as zinc gives toxic fumes and residues. Because of zinc it can with stand contact with water and exposure to weather, e.g. articles like cabinets, trunks, buckers, pans, etc. are made of galvanized iron sheets Copper Sheets These sheets are relatively costlier but having specific advantages in being good corrosion resistant and good in appearance. They are reddish in color and their cold rolled variety, which is vastly used in sheet metal work, is highly ductile and malleable and therefore can be easily worked. Some representative examples are automobiles, various applications in chemical plants, domestic heating appliance, etc. Aluminum Sheets On account of its inherited weakness it is not used in its pure form. The useful variety of aluminum alloy which is rolled into sheet form carries additions of suitable amount of silicon, manganese copper and iron. It is whitish in color and light in weight. It offers very high resistance to corrosion and abrasion. Its common applications are aero plane bodies, kitchen ware, etc. (ii) Tools used in Sheet metal shop: Steel Rule It is useful in measuring and laying out small work. It can be measure with accuracy of 0.5 mm.

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Scriber This is sometimes called the metal workers pencil. It is a long wire of steel with its one end sharply pointed and hardened to scratch lines on sheet metal in laying out patterns. Dividers Dividers are used for drawing circles or arcs on sheet metal. They are also used to mark a desired distance between points and to divide lines into equal.

Punches A Punch is used in sheet metal work for marking out work, locating centers, etc. in a more permanent manner. Two types of punches are generally used: Prink Punch: It is used to make small marks on layout lines in order to mark the prick punch marks longer.

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Center Punch: It is used only to make the prick punch marks larger at the centers of holes that are to be drilled. Solid and hollow punches are very similar the other two puncher the inner and outer faces of the punch meeting at an angle of 40.These are used for making small holes from 2.5 mm to 10 mm.

Mallet These are soft hammers and made of saw hide, hard rubber, copper brass, lead or mostly of wood, used to strike a soft and light blow on the metal.

Snips of Shears A snip, also called a hand shear is used like a pair of scissors to cut thin, soft metal. It should be used only to cut 20 gauge or thinner metal. There are several types of snips available for making straight or circular cuts, the most common being straight snip have straight blade for straight line cutting while curved or bent snips have curved blades for making circular cuts. Both these snips are very light and can be easily handled by one hand. These are also double cutting shear, squaring shear, ring shear and circular shear used for particular requirements as the name indicates. The heavier classes are known as bench shears and block shears where one handle may be held in vice bench plate while the other handle is moved up and down to do the cutting.

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Stakes Stakes are the sheet metal workers evils used for bending, seaming or forming, using a hammer or mallet. They actually work as supporting tools as well as forming tools. They also help in bending operation. They are made in different shape and sizes to suit the requirements of the work.

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All Dimensions are in mm

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EEPW 1240 Engineering Workshop (Mechanical) Ex: no: 1 Aim To make a rectangular tray from the given sheet metal. Material Required G.I Sheet Tools required Steel rule Mallet Scriber Divider Protractor Snips Stakes Ball peen hammer Procedure 1. The size of the given sheet is checked for its dimension using steel rule. 2. Then the sheet is leveled on the leveling plate using a mallet. 3. The development procedure is followed the same as the square taper tray. 4. The dimensions are marked as shown in figure. 5. The sheet is cut as per the marked dimensions by straight snips. 6. Then a single hemming is made on the four sides of the tray as shown in figure. 7. The four sides of the tray bent to 90 by using the stakes anvil. Result Thus desired rectangular tray is made from the given sheet metal. Rectangular Tray

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Ex: No: 2

Sheet metal Scoop

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EEPW 1240 Engineering Workshop (Mechanical) Aim To make a scoop from the given sheet metal. Material Required G.I Sheet Tools required Steel rule Mallet Scriber Divider Protractor Snips Stakes Ball peen hammer Procedure 1. The size of the given sheet is checked for its dimension using steel rule. 2. Then the sheet is leveled on the leveling plate using a mallet. 3. The development procedure is followed the same as the square taper tray. 4. The dimensions are marked as shown in figure. 5. The sheet is cut as per the marked dimensions by straight snips. 6. Then a single hemming is made on the three sides of the scoop as shown in figure. 7. The three sides of the scoop bent to 90 by using the stakes anvil. Result Thus desired scoop is made from the given sheet metal.

Chapter 4 WELDING

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EEPW 1240 Engineering Workshop (Mechanical) (i) Introduction Welding is a metal joining process wherein localized coalescence is produced either by heating the metal to a suitable temperature, with or without the use of filler metal, with or without application of pressure. The filler material has similar composition and melting point temperature as that of the base metal. It is used to fill gap between the joint surfaces. (ii) Electric Arc welding In the arc welding process, the source of heat is electricity. In arc welding process, coalescence is produced by heating the work piece with an electric arc struck between electrode and the work piece. Welding may be carried out in air or in an inert atm. Filler material may or may not be used. The temperature of the arc is of the order of 3600C. Principle of operation

The heat required for joining the metals is obtained from an electric arc. The electric motor generator or transformer sets are used to supply high electric current and the electrodes are used to produce the necessary arc. The electrode serves as the filler rod and arc melts the surfaces so that the metals to be joined are fused together. Electrodes Filler rods are used in arc welding are called as electrodes. The Electrodes are made of metallic wire called core wire. It is uniformly with a protective coating called flux while fluxing an electrode about 20 mm of length is left bare at one end for holding it using electrode holder. It is used to transmit full current from electrode holder to the front end of the electrode coating. Electrode Holder

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It is a device used for mechanically holing the electrode and conducting current to it. Electrode holder should be light, to minimize fatigue incurred by the welder. Jaws are made to hold the bare end of the electrode in either at vertical or at an angular position. Welding Cables Two cables are needed for welding purpose. One is used to connect the power source to electrode; another cable is connected to ground. The cables are well isolated with rubber. Welding Bead cleaning accessories

Chipping hammer A chipping hammer is chisel-shaped one and it is used to remove the slag from the weld bead. Wire Brush A wire brush made up of stiff steel wire, embedded in wood, removes small particles of slag from the weld bead after the chipping hammer is used.

Hand Screen
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EEPW 1240 Engineering Workshop (Mechanical) It is a protective device used in arc welding. A hand shield is held in the hand of the welder and it is fitted with a suitable fitter lens.

Helmet It is used for shielding and protecting the face and neck of the welder and it is fitted with a suitable fitter lens. Tongs Tongs are used to handle the hot metal-welding job while cleaning; they are also used to hold the metal for hammering. Goggles Goggles are used to protect the eyes while chipping the slag. They are fitted while a plain glass to see the area to be cleaned. Hand Gloves Hand gloves are used to protect the hands from electrical shock, arc radiation and hot spatters.

Advantages of arc welding Flux shielded manual metal arc welding is the simplest of all the arc welding process. The equipment can be portable and the cost is fairly low. This process finds innumerable applications, because of the availability of a wide variety of electrodes. Disadvantages of arc welding

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Because of the limited length of each electrode and brittle flux coating on it,

mechanization is difficult. In welding long joints, as one electrode finishes, the weld is to be progressed with the next electrode. Unless properly cared, a defect may occur at the place where welding is restarted with the new electrode. It cannot be used to weld metal thickness less than 1.6 mm. (iii) Gas welding Gas welding is a process in which the required heat to melt the surfaces is supplied by a high temperature flame obtained by a mixture of two gases. Usually the mixture of oxygen and acetylene is used for welding purpose. Oxy-acetylene welding

In oxy-acetylene welding oxygen and acetylene are the two gases used for producing flame. Oxygen is mainly used for supporting the combustion intensity. The oxygen and acetylene under high pressure in cylinders which are fitted with pressure regulator. Each cylinder is connected to the blowpipe by flexible hoses. The oxygen cylinders are painted block and acetylene cylinders are painted maroon. When acetylene is mixed with oxygen in correct proportions in the welding torch, ignition is takes place. The flame resulting at the tip of the torch is sufficient enough to melt and the parent material .The flame temperature is about 3200C.The filler metal rod is generally added to the molten metal pool to build up the seam for greater strength.

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All Dimensions are in mm

Ex: No: 1 Aim

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LAP JOINT

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To join the given two work pieces as a lap joint by arc welding. Material used Mild Steel plates Tools required Welding power supply Flat file Welding rod Chipping hammer Electrode holder Wire brush Gloves and apron Earthing clamps Shield and goggles

Procedure
1. First of all, the work pieces must be thoroughly cleaned to remove rust, scale and 2.

3. 4. 5. 6.
7.

8. 9. Result

other foreign materials. Then the given work pieces are placed on the table in such a way that one work piece is placed on the other work piece like the LAP joint is formed. Appropriate power supply should be given to the electrode and the work pieces. Now the welding current output may be adjusted. When current is passed, arc is produced between the electrode and work pieces. Then the welding is carried out throughout the length. As soon as the welding process is finished, switch off the current supply and allow the work piece to cool. Slag is removed by chipping process with the help of chipping hammer. Finally using wire brush, welded portions are cleaned.

Thus the given two work pieces are joined as a lap joint by arc welding.

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All Dimensions are in mm

Ex: No: 2 Aim

TEE JOINT

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EEPW 1240 Engineering Workshop (Mechanical) To join the given two work pieces as a T joint by arc welding. Material used Mild Steel plates Tools required Welding power supply Flat file Welding rod Chipping hammer Electrode holder Wire brush Gloves and apron Earthing clamps Shield and goggles

Procedure
1. First of all, the work pieces must be thoroughly cleaned to remove rust, scale and

other foreign materials. 2. Now the work pieces are placed on the table in such a way that two work pieces area broad close to each other T shapes are formed as shown in figure. 3. Appropriate power supply should be given to the electrode and the work pieces. 4. Now the welding current output may be adjusted. 5. When current is passed, arc is produced between the electrode and work pieces. 6. Now set the two work pieces in correct position like T joint and tag at both ends of the work pieces as shown in figure. 7. The joint is placed on a welding table in a flat position by keeping the tag side down. 8. Then the welding is carried out throughout the work piece. 9. As soon as the welding process is finished, switch off the current supply and allow the work piece to cool. 10. Slag is removed by chipping process with the help of chipping hammer. 11. Finally using wire brush, welded portions are cleaned. Result Thus the required T-joint is made by arc welding process.

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Chapter 5 STUDY OF LATHE (i) Introduction Lathe is called the father of machine tools. The main function of lathe is to remove metals from work piece to give a required shape and size. In the lathe the work piece is held in a chuck. The tool is moved at an angle 90_ to the axis. Various operations such as straight turning, taper turning, and chamfering, facing, knurling, grooving, thread cutting, taper turning are carried out. When the operations above set are done automatically, then the lathe is called automatic lathe. (ii) Working principle of lathe

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EEPW 1240 Engineering Workshop (Mechanical) In a lathe, the work piece is held in chuck and rotates about its axis by means of power. Single point cutting tool is mounted in tool post. When the chuck rotated the work piece also rotated. The tool moves parallel to the axis of rotation of work piece to produce a cylindrical surface, whereas the tool moves perpendicular to the work piece to produce a flat surface. The tool moves at an angle to the axis of work piece to produce a turn surface. The material is removed in the form of chip from the work piece by giving proper feed and depth of cut. So, there quire size and shape of the work is obtained. (iii) Parts of the lathe Bed Bed is the base of the lathe. The headstock is mounted on the left end; the carriage is in the middle and the tailstock at the right end of bed. The bed is made up of cast iron, alloyed with nickel, chromium. The bed is made up of cast iron to observe shock and vibration created during machining. The guide ways of the bed may be flatter inverted V shape. Headstock It is mounted on the left end of the bed. It carries a hollow spindle. The live center can be attached in the spindle. The spindle nose is threaded. In chuck faceplates can be attached to the spindle. The headstock may be back threaded type. The headstock has two types of driving mechanism. (i) Back geared mechanism (ii) Belt Tailstock It is located on the bed at the right end. It is used for supports right end of work and also for holding drills, reamer tools for drilling, reaming and such other operations. The tailstock can be moved along the bed and clamped at any position, to support the different length work. Carriage Carriage is used for giving various feed to the tool by hand or by power. The carriage is attached with the saddle. Saddle It is a H shaped casting fitted on the bed and moves along the guide ways. It carries the cross slide, compound rest and a tool post. Cross slide

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EEPW 1240 Engineering Workshop (Mechanical) It is attached to the upper side of saddle and carries compound slide and tool post. The cross slide can be moved cross wise by hand or power. The micrometer dial is mounted on the cross slide hand wheel, with an accuracy of 0.05mm. Compound Rest It is attached over the cross slide. It is used during the taper turning opening operations to set the tool for angular cuts. Here the micrometer dial is mounted to show the depth of cut. Tool post The tool is clamped over the tool post. It is fixed over the compound rest. Apron Apron is attached to the saddle and hangs in front of the bed. It has gears, levers, clutches for moving the carriage automatically. A split nut is attached for engaging and disengaging. The carriage from the lead screw is used in thread cutting work. Lead Screw It is a longer screw with standard ACME square threads and used for transmitting power for automatic feed for thread cutting operation. Feed rod The feed rod is the long shaft used for the movement of carriage along the axis of bed. It is used for operations like facing, turning and boring. (iv) Various lathe operations Turning produces straight, conical, curved, or grooved work pieces Facing produces a flat surface at the end of the part Boring to enlarge a hole Drilling - to produce a hole Cutting off to cut off a work piece Threading to produce threads Knurling produces a regularly shaped roughness

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(v) Work holding devices Work piece mounted between centers In this method, the long work pieces can be held between two centers( Live and Dead centers) for accurate machining.

Three Jaw chuck: It usually has three jaws; the jaws are moved simultaneously within the chuck

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EEPW 1240 Engineering Workshop (Mechanical)

Four Jaw chuck: This is independent chuck generally has four jaws, which are adjusted individually on the chuck face by means of adjusting screws

Face plates:

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EEPW 1240 Engineering Workshop (Mechanical) The face plate is used for irregularly shaped work pieces that cannot be successfully held by chucks or mounted between centers

Mandrels: A work piece which cannot be held between centers because its axis has been drilled or bored and which is not suitable for holding in a chuck or against a faceplate is usually machined on mandrel.

Collet chuck: Collet chuck is used to hold small work pieces.

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