DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

I/II SEMESTER

ACADEMIC YEAR 2012 – 2013

BASIC ENGINEERING WORK SHOP

LABORATORY MANUAL (MEL-109)
(FOR ALL BRANCHES)

NAME OF THE STUDENT :

BRANCH :

UNIVERSITY SEAT NO. :

SEMESTER & SECTION :

BATCH :

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CONTENTS
Fitting Shop
1. Study of Fitting Tools
2. Study of Fitting Operation and Joints
a. Rectangular Joint
b. Triangular Joint
c. Semicircular Joint
d. Dove –tail Joint

Welding
1. Study of Welding Tools
2. Study of welding Joints and Operation
a. Lap Joint
b. Butt Joint

Carpentry
1. Study of Carpentry Tools
2. Study of operation and Joints
a. Plain Turning
b. Step Turning
c. Taper Turning
d. Contouring

Sheet Metal
1. Study of Sheet Metal Tools
2. Study of operation and Joints
a. Hollow Cylinder
b. Square Prism

VIVA Question

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FITTING SHOP

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INTRODUCTION
Even in the most mechanized industry, although majority of the work can be finished with the help of
machines, there are certain operations, which have to be carried out manually using hand tools.
For example,
i) In production shops, when two or more parts are to be assembled
ii) Sometimes it necessary to replace or repair a component, which must fit accurately with another
component on re-assembly.
Ex-Fitting
FITTING
Fitting is the process of assembling two or more metal parts together by removing excess material so as to
obtain a required fit.
OR
It is the process of removing unwanted material with the help of hand tools, from a given stock (work piece)
for making a component or fitting one in the other to form a matting or fitting pair.
Ex:- 1) key and key hole 2) A Bush and a shaft.
Fitting requires the use of various hand tools and considerable manual effort. Fitting work involves a large
number of hand operations to finish the work to desired shape, size and accuracy. The hand operations in
Fitting shop include marking, sawing, chipping, Filing, scraping, drilling, tapping, Dieing, Fitting etc.
Fitting Engineering Materials
Materials that are used in the engineering Practice are called Engineering Materials. These have physical,
mechanical and chemical properties.
Classification of
Engineering Materials

Metals Non-Metals

Ferrous Metals Non-Ferrous Metals

Iron Steel

1.Metals
A metal is a solid (Exception: Mercury) having weight. It is opaque and a good conductor of heat and electricity.
1.1Non-Metals
These are available in the form of liquids, gases or solids such as wood, stone, Rubber, plastic, ceramic,
concrete, asbestos etc.
Ferrous Metals
Iron containing metals such as pig iron, cast iron, wrought iron, carbon steel, Alloy steel, Nickel steel etc., are
called ferrous metals. These can be attracted by magnets and are susceptable to rusting.
1.2Non-Ferrous Metals
Non-Ferrous metals are those, which do not contain iron. Metals like Gold, Silver, Copper, Aluminium, Tin,
Platinum, and Nickel, Bronze etc, and its alloys are Non-Ferrous metals. These can neither rust nor can be
attracted by magnets.
1.3Cast iron
It is an Iron based material containing 91-94% iron and other elements such as Carbon (2-4%), Silicon (0.4-
2.8%), Manganese (0.25-1.25%), Sulfur (0.2%max) and Phosphorous (0.6%max).
Types of Cast iron: - Gray cast iron, malleable iron, white cast iron.
1.4Steel:-may be defined as an alloy of iron and carbon. Besides this, it also contains Silicon, Manganese,
Sulfur and Phosphorous. One of the differences between Cast iron and steel is the amount of carbon
percentage.
Based on the carbon content, steel is divided into
a) Low Carbon Steels- the carbon content ranges from 0.03-0.35%.
Low carbon steels are also called as soft or Mild steel (M.S).
b) Medium Carbon Steels-the carbon content ranges from 0.35-0.6%.
c) High Carbon Steels-The carbon content ranges from 0.6-1.7%

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1.5Mild steel (MS)
Mild steel may be defined as an alloy of iron (91-94%), and carbon (0.15-0.35%). Besides this, it also contains
Silicon, Manganese, Sulfur and Phosphorous. Low carbon steels are also called as soft or mild steel. These
steels are used for bolts and nuts, structural work, axles, shafts etc
1.5Alloy Steel
In alloy steel in addition to carbon and iron, alloying elements such as chromium, Nickel, Vanadium etc. are
mixed. Ex: - Stainless steel, High Speed steel (H.S.S) (Tool steel).
Tool steel is widely used in the manufacturing of cutting tools.
A).FITTING TOOLS
The Tools used in Fitting practice may be classified into the following categories.
1) Holding Tools 2) Marking and Measuring Tools 3) Cutting tools 4) Finishing Tools e) Striking Tools
f) Miscellaneous Tools

1. Holding Tools
1. Vice
AVice is a tool used to hold the wok piece (job) in position while various operations are being carried out.
a) Bench vice b) Machine vice c) leg vice d) pipe vice e) hand vice
1.1 Bench vice
The vice used for bench work is called bench vice. The bench work includes filing, sawing, and threading
operations.
It consists of a cast iron body carrying a fixed jaw and movable jaw. Both the jaws are made of cast steel and
are brought together by means of hand operated Screw.Seperate cast steel plates known as ‘jaw plates’ are
fixed to the jaws my means of set screws which can be replaced when worn out. The face of the jaw plates
have teeth (serrations), which helps in gripping the work firmly.
Specification: - the width of the jaws determines the size of the vice.
1.2 Machine vice
Machine vice is used to hold work piece in Machine tools. Machine vice is able to tilt and swivel. It is
mounted on the table of a Machine. Ex:-Drilling Machine, Milling Machine and Shaping Machine.
1.3 Leg vice or Black smith’s vice
It is used for holding work piece that has to be cut, chipped or hammered. It consists of a fixed jaw with long
leg and movable jaw that can be moved by means of a hand operated screw.
1.4 Pipe vice
It is used for holding round section parts such as pipes, tubes.
1.5 Hand vice
It is used for carrying work on small jobs, such as screws, keys, rivets etc., which cannot be held in the Bench
vice. It consists of two jaws that can be operated by means of a wing nut.
1.6 V-block with Clamp
V-block is a rectangular or square block with v-groves on one or both the sides, opposite to each other. The
angle V is usually 90 degrees. V-blocks are used for checking the roundness of cylindrical work piece and for
marking centers accurately. Material- Hardened Steel or Cast Iron.

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2. Marking and measuring tools

2.1 Surface plate
Surface plate is a plain surface. The surface is machined to very fine limits. The plate is constructed in such a
way that it will not wrap or twist. It is used for –testing the flatness of finished work piece. Providing a base
support for ‘marking gauges’ or ‘scribing block’. Testing the accuracy of Try square.
Material- Cast iron or hardened steel or granite stone.
Specification: - It is specified by length x width x height x grade.
2.2 Angle plate
It consists of two faces machined at right angles (90 degrees) to each other. A number of slots are cut on both
the horizontal and vertical faces as shown in figure. These slots enable the work piece to be held firmly by
means of bolts and nuts. It is also used to support work piece, when you are using the surface gauge for
marking out.
Material- Gray Cast iron

2.3 Scribing block or Surface gauge

A scribing block has three parts-base, spindle and scriber. The base of the scribing block is machined to have
a flat surface. A Vertical spindle fitted on the base carries a scriber and by adjusting the screw, the scriber can
be fixed to any inclination and height along the spindle.
It is used for scribing lines on work pieces and also used for checking parallel surfaces.
The Scribing block can be used to locate accurately the centers of round bars in conjunction with the Vee-
block.
Specification- Height of the Vertical spindle

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2.4 Scriber
A Scriber is a thin steel rod with a pointed end or ends, one of the ends may be bent at right angles to allow
access to holes. It is used to scribe (or) mark lines on the metal work pieces. Scribers are available in several
sizes and types. The point should be ground to a 30 degrees angle and kept sharp for accuracy.
Material- High carbon steel (Hardened &Tempered).
Specification-It is specified by its length and diameter.
2.5 Try Square or Engineers Square
Try square also called ‘Engineering Square’ is one of the basic tool used in fitting work. It consists of a steel
blade riveted exactly at 90 degrees into a hard steel stock of rectangular cross section as shown in figure. The
stock acts as a fence and the blade as guide for marking.
It is used for 1) checking squareness or perpendicularity of work piece.
2) Testing for Straightness and 3) marking straight lines (at right angles) on work piece.
Material-Steel (hardened and tempered).
Specification-the Size of Try-square is specified by the length of the blade (100mm, 150mm, and 200mm).

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2.6 Steel rule or Steel scale

It is used for measuring and marking the required dimensions on the work piece. The scale is graduated in
millimeters, centimeters and inches. Least count of normal steel rule is1mm.

Spring Divider
It is used for scribing (marking) circles, arcs, bisecting lines and perpendicular lines on metal work piece. It
also used for transferring dimensions from scales to objects.
Material- Tool steel (Hardened &Tempered).
Specification-Max length /radius which can be scribed.
2.7 Spring caliper:
Caliper are devices used for measuring and transferring the inside \outside dimensions of components.
Calipers are of two types, viz, outside spring caliper and inside spring caliper.
Material- Tool steel
2.8 Outside spring caliper-It is used for measuring the outer diameter of shafts (rods) and thickness of parts.
2.9 Inside spring caliper- It is used to measure the inner diameter/dimensions of parts

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.
Use of Inside calipers Use of outside calipers

2.10 Jenny calipers- Jenny calipers are used for marking and layout work. It is used to draw parallel lines,
locating
the centre of round bars .It is also known as odd leg caliper or hermaphrodite caliper.

2.11 Center Punch

It is used for marking round indentations on metal surfaces. This provides a center for locating the sharp end
of the divider point and center for holes that are to be drilled. It is also used for marking points along a line,
which enables to cut the work piece easily. The point angle should be ground to 90 degrees
Material- High carbon steel.
Specification-By length and angle.

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2.12 Dot punch

It is used for marking points along a line which enables to cut the work piece easily. The point angle should
be ground to 60 degrees.
2.13 Letter punch
It has square body with a tapered end. At this end, a projection, corresponding to the replica of the letter to be
marked is made. It is used to punch Alphabetic letters (A to Z) on metal work piece

2.14 Number punch

It is similar to letters punch in construction but has numbers at its end. The numbers used are from 0 to 8 (six
used as nine also). It is used to punch numbers on metal work piece.
2.15 Vernier caliper
These are used for measuring outside as well as inside dimensions accurately. It may also be used as a depth
gauge.
Example- to measure outer diameter of shafts and cylinders, to measure inner diameter of holes and depth of
holes.
The main scale is divided into millimeters. In this case 49 main scale divisions ie 49 mm is divided into 50
vernier scale divisions.
One vernier scale division equal to (49/50) 0.98 mm
Hence, Least count of the vernier caliper (LC) = 1 main scale division – 1 vernier scale division
= 1MSD - 1 VSD
= 1mm- (49/50) mm =0.02 mm
Total reading =Main scale reading (MSR) + Least count (LC) X Vernier Coinciding Division.
,

2.16 Vernier height Gauge

The vernier height gauge, clamped with a scriber, is shown in Fig.Vernier height gauges are particularly
suitable for marking off accurate distances and center locations. It is also used in inspection of work pieces.
The accuracy and working principle of this gauge are the same as those of the vernier caliper.

1) Outside Jaw 2) Inside Jaw 3) Depth Probe 4) Main Scale (cm) 5) Main Scale(Inch) 6) Vernier (cm) 7) Vernier(Inch) 8) Retainer

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(Vernier Height Gauge)

2.17 Micrometer:
External micrometer is used to measure external diameters and lengths. The degree of accuracy is high.
Pitch = distance moved on barrel
No. of rotations given to thimble
= 0.5 mm
1
= 0.5 mm
Least count of micrometer = pitch/ No of divisions on the thimble.
= 0.5 mm / 50 = 0.01 mm.
Total reading =Barrel scale reading (MSR) + Least count X Thimble scale reading (TSR)

(MICRO METER)

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3. Cutting tools
3.1 Hack saw frame with blade.
The hacksaw is used for cutting metal by hand. The hacksaw blade has a number of teeth ranging from 5 to 15
per centimeter. Lesser number of teeth is used for cutting materials like Aluminium, brass and Bronze and
large number of teeth is used for cutting hard materials like steel, C.I etc. Hack saw blades are fitted either in a
solid frame or adjustable frame to accommodate different lengths of blade.
It is made of high-speed steel. The hacksaw blades are specified byits material, length, width, thickness and
pitch of the teeth. The common dimensions are length 250-300 mm, width 13 mm-16 mm, thickness 0.6 to 0.8
mm, pitch 1 to 1.8 mm. The blades are fixed with teeth facing forward and the teeth are staggered, which are
known as ‘set of teeth’. These make slots wider than blade thickness, preventing the blade from jamming

3.2 Twist drill

The twist drills are used for making holes. The drills are made of HSS (high speed steel) with a straight or
taper shank. The straight shank drills are held in drill chuck and fitted to the spindle of drilling machine and
the taper shank is directly fitted to the spindle. The drills are manufactured to standard sizes in specified steps.
A bench-drilling machine is commonly used in workshops

Twist drill.

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3.3 Flat chisel

Chisels are used for removing surplus metal from the work piece. They can be used as a substitute when files
and hacksaw blades are impossible to use.
Material - High carbon steel or tool steel having octagonal or hexagonal cross-section.
Specification- Length and width of the edge.
The process of removing metal using a chisel is called ‘chipping ‘and is shown in fig

3.4 Taps and Tap wrenches

A tap is a hardened steel tool, used for cutting internal threads in a drilled hole. Hand taps are usually
supplied in sets of three for each diameter and thread size. Each set consists of a i) Taper or first tap ii)
Intermediate or second tap and iii) plug or bottoming or third tap. In hand tapping, the tap is rotated with the
help of a tap wrench. These taps are identical in all features except in the taper lead. For identifying the type
taps quickly the taps are either numbered as 1, 2, and 3 or rings are marked on the shank.

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3.5 Dies and die –holder

Dies are the cutting tools used for marking external threads. Dies are made either solid or split type. They are
fixed in a die –holder for holding an adjusting the die gap. They are made of tool steel or high carbon steel.

4. Finishing tools
4.1 Files
A file is a cutting tool used to remove small amount of material from the surface of the work piece and also
helps in giving a smooth surface finish. A number of teeth, parallel and inclined at suitable angle are cut on
the flat surface of the file. The various parts of a file are shown in figure the main parts of the file include,
Tang-It is the pointed part that fits into the wooden handle.
Heel – It is end of the tang that forms a curved edge.
Face -It is the portion of the file on which cutting teeth are formed.
Point – It is the end opposite the tang
Files are often tapered along their length but they may also be parallel.
Material -tool steel (hardened)
Specification- length, single cut /double cut, shape and pitch.
Example Length (say 400 mm)
Single cut /Double cut
Shape (say square cross –section)
Pitch or grade (say smooth)

Files are classified and named according to a) Size/length b) cut c) shape and d) pitch /grade.

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Size: the size of the file is identified by its length. It is the distance from the point to the heel excluding tang.
The selection of the length of the file varies depending on the size of the job .
Sl.no Size(length) Application
1 100-150mm Used for fine work and small sized jobs
2 150-250mm Used for medium sized work
3 250-400mm For general and large sized work

Cut: Based on the cutting teeth , files are classified as single cut files and double cut files

Single cut file Double cut file

Single cut file: In single cut file, the teeth are cut in parallel rows across the faces of the file and normally
inclined at an angle of 60 degrees with the centerline of the face.
Double cut file: A double cut file has two sets of teeth crossing each other as shown fig. one set of teeth are
cut similar to a single cut file and the other set runs diagonally across the first set and are normally inclined at
an angle of 10 degree to the center line of the face .
Single cut files gives better finish when compared to double cut files but at the same time removes material at
a comparatively slower rate.

(C)Shape of files -Files is classified based on the shape of their cross-section.

Various types of files.

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4.1Flat files are used for general work or finishing flat surfaces.
4.2Squares files are used for filing square corners, rectangular slots, keyways, enlarging a square or a
rectangular
holes etc.
4.3Triangular file or three-square files are used mainly for filing corners with angles less than 90 degrees.
4.4Round files are used for filing concave surface and also for enlarging round holes.

4.5Half-round file the curved face of the half-round file is used for filing concave surfaces and the flat face is
used
for filing convex surfaces.
4.6Knife edge file is used for filing narrow slots and corners having angles less than 90 degrees

(D) Pitch of teeth /grade

Pitch refers to the spacing between two consecutive teeth. Table shows the classification of files based on
their
pitch. The files are listed in descending order of their roughness.
Description Single cut Double cut Uses
Rough. For rapid removal of
8 teeth/cm Large amounts of
material from softer
materials.
Bastard Rapid removal of
12 teeth/cm Small amounts of
material.

Second cut. Used for filing on

16 teeth/cm harder materials. Gives
good surface finish

Smooth. Used for smooth

20-24 teeth/cm surface finish.
Removes small
amounts of material.
Dead Smooth. Used for accurate and
>40 teeth/cm smooth surface finish.

5. Striking Tools

5.1 Hammers: The hammer is defined as a device used to deliver blows to an object or strike another object,
in the sense that it is used for driving nails, fitting parts and breaking up objects. It is also used for striking
purposes while punching, bending, chipping, and riveting. Available in various shapes and structures,
hammers are designed for specific purpose. The hammer consists of a handle to which a heavy head, usually

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DEPARTMENT OF MECHANICAL ENGINEERING
made of metal is attached, with one or more striking surfaces. The hammer is specified by its weight (125
grams to 1500 grams) and the shape of the pein.
Different types of hammers are straight pein hammer, ball pein hammer, cross –pein hammer
Material Cast steel or carbon steel.
Ball pein hammer:-This is the most common type of hammer which has a ball-shaped end of the head
opposite to the striking face. It is used for all kinds of engineering works. The ball end being useful for sheet
metal forming and it is made in weights from 1000gm to 1.5kg. It is used for riveting and chipping.
Cross –pein and straight pein hammer:-These have blunt, chisel-shaped ends on the head opposite to the face.
It is used for bending, stretching, hammering into shoulders, curves.
6. Miscellaneous Tools
6.1 Anvil : It provides the necessary support during punching and chipping by resisting the heavy blows
given to the work piece by hammer .The beak is used in sheet metal work for bending the sheet metal to round
shapes.
Material-The body is made of mild steel or cast steel with a hardened top face.

6.2 File card: It is a metal brush used for cleaning the files.

7. FITTING OPERATIONS
7.1 Marking and Measuring
The marking is the first step in fitting. Marking on the work can be done by setting out dimensions with the
help of a working drawing. Generally one end of work piece is filed flat and the measurements are taken from
this reference end. The measuring instruments used in fitting are scale, Calipers, vernier caliper, micrometer,
height gauge etc. Marking tools used in fitting are Scriber, Dot punch, scribing gauge etc.

7.2 Filing: Filling is the process of removing burrs from cuts; clean the face of cuts and to give the final shape
to a work piece. The flatness and square ness of the surfaces finished by filing are checked with try square.

7.3 Methods of filing- a) Cross-filing b) Draw filing

Cross-filing- this method is used for efficient removal of maximum amount of metal in the shortest possible
time. It may be noted that the file must remain horizontal throughout the stroke (long, slow and steady) with
pressure only applied on the forward motion.
Draw filing-this method is used to remove file marks and for finishing operations. Here, the file is Griped as
close to the work as possible between two hands. In this method of filing, a fine cut file with a flat face should
be used.

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7.4 Sawing: It is the method of removing excess material quickly with the help of hand hack –saw. The
surfaces are to be finish filed after sawing.

7.5 Chipping: It is the process of removing unnecessary thick layers of metal using cold chisel and hammer.

7.6 Drilling: It is the operation of producing circular holes in a metal piece with the help of bench drilling
machine and drilling tools.

7.8 Tapping: It is the process of generating internal threads in a ready hole using a set of three hand taps.

7.9 Dieing: It is a manual operation of generating external threads on a round rod or pipe using a die and die
holder.

7.10 Fitting /Assembly: After finishing the individual pieces as per dimensions they are joined /fitted for an
assembly.

8. Safe and correct practices:

1) All the tools and measuring instruments are to be cleaned and kept in the respective places when not is use.
2) The sliding parts and pins are to be properly lubricated.
3) The vice should not be over tightened; otherwise it may damage the spindle.
4) The sharp edges of a chisel or scriber are to be covered with a cap to avoid getting damaged and to prevent
accidents.
5) The handles of hammers are to be checked for cracks etc.
6) The surface plate has to be covered and kept when not in use and tools and jobs should not be thrown on
the surface plate to avoid damage to the surfaces

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Use of Different Types of Files

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How to hold the Hacksaw

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Model No: 1

AIM: To fabricate the fitting model as per the sketch given below.

40

50

15
17,5
MATERIAL: Mild Steel (M.S
TOOLS REQUIRED

1,2,3,4,5,6,7,8
PROCEDURE:

1. Check the dimensions of the given work piece with respect to the given model.
2. File the one edge of the given work piece to straightness and checked with Try square.
3. File the adjacent edge so that it is square with first edge filed and checked with Try square. File the upper
and
bottom surfaces of work piece.
4. Paste white color on the upper surface of the work piece (with chalk powder and water).
5. By marking gauges (Scale, Try square, Scriber, Divider), mark the dimensions on the given work pieces.
6. Using Dot punch and Hammer, make the punch marks (dots) on the marked dimensions on the given work
piece.
7. By using hacksaw remove the extra material from the work piece and use cold chisel, if necessary to
remove the
material. Removing small amount (1 mm to 2mm) of material Files can be used.

Model No: 1
AIM: To fabricate the fitting model as per the sketch given below.

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50

17,5
50

15
10

MATERIAL: Mild Steel (M.S)

TOOLS REQUIRED

1,2,3,4,5,6,7,8,

PROCEDURE:
1. Check the dimensions of the given work piece with respect to the given model.
2. File the one edge of the given work piece to straightness and checked with Try square.
3. File the adjacent edge so that it is square with first edge filed and checked with Try square. File the
upper and bottom surfaces of work piece.
4. Paste white color on the upper surface of the work piece (with chalk powder and water).
5. By marking gauges (Scale, Try square, Scriber, Divider), mark the dimensions on the given work
pieces.
6. Using Dot punch and Hammer, make the punch marks (dots) on the marked dimensions on the given
work piece.
7. By using hacksaw remove the extra material from the work piece and use cold chisel, if necessary to
remove the material. Removing small amount (1 mm to 2mm) of material Files can be used.
8. Then male and female work pieces are assembled (joined) in order to make firm joint.

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Model No: 2

AIM: To fabricate the fitting model as per the sketch given below

45

15
15
R
60

15
MATERIAL: Mild Steel (M.S)
TOOLS REQUIRED

1 , 2,3,4,5,6,7,
PROCEDURE
Check the dimensions of the given work piece with respect to the given model.
File the one edge of the given work piece to straightness and checked with Try square.
File the adjacent edge so that it is square with first edge filed and checked with Try square. File the upper and
bottom surfaces of work piece.
Paste white color on the upper surface of the work piece (with chalk powder and water).
By marking gauges (Scale, Try square, Scriber, Divider), mark the dimensions on the given work pieces.
Using Dot punch and Hammer, make the punch marks (dots) on the marked dimensions on the given work
piece.
By using hacksaw remove the extra material from the work piece and use cold chisel, if necessary to remove
the material.. Removing small amount (1 mm to 2mm) of material Files can be used.
Model No: 3

AIM: To fabricate the fitting model as per the sketch given below.

60
15

R 15
60

15

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MATERIAL: Mild Steel (M.S)
TOOLS REQUIRED
1
2
3
4
5
6
7
8
PROCEDURE
a. Check the dimensions of the given work piece with respect to the given model.
b. File the one edge of the given work piece to straightness and checked with the help of Try square.
c. File the adjacent edge so that it is square with first edge filed and checked with Try square. File the
upper and bottom surfaces of work piece.
d. Paste white color on the upper surface (Front View) of the work piece (with chalk powder and water).
e. By marking gauges (Scale, Try square, Scriber, Divider), mark the dimensions on the given work
pieces.
f. Using Dot punch and Hammer, make the punch marks (dots) on the marked dimensions on the given
work piece.
g. By using hacksaw remove the extra material from the work piece and use cold chisel, if necessary to
remove the material. Removing small amount (1 mm to 2mm) of material Files can be used.
h. Then male and female work pieces are assembled (joined) in order to make firm joint.

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Model No: 4

AIM: To fabricate the fitting model as per the sketch given below

45

22,5
60

30
15

15

MATERIAL: Mild Steel (M.S)

TOOLS REQUIRED
1,2,3,4,5,6,7,8
PROCEDURE

a. Check the dimensions of the given work piece with respect to the given model.
b. File the one edge of the given work piece to straightness and checked with Try square.
c. File the adjacent edge so that it is square with first edge filed and checked with Try square. File the
upper and bottom surfaces of work piece.
d. Paste white color on the upper surface of the work piece (with chalk powder and water).
e. By marking gauges (Scale, Try square, Scriber, Divider), mark the dimensions on the given work
pieces.
f. Using Dot punch and Hammer, make the punch marks (dots) on the marked dimensions on the given
work piece.
g. By using hacksaw remove the extra material from the work piece and use cold chisel, if necessary to
remove the material. Removing small amount (1 mm to 2mm) of material Files can be used.

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DEPARTMENT OF MECHANICAL ENGINEERING

Model No: 4

AIM: To fabricate the fitting model as per the sketch given below.

60

22,5
60

30

15
15

MATERIAL: Mild Steel (M.S)

TOOLS REQUIRED
1, 2, 3, 4, 5,
PROCEDURE

a. Check the dimensions of the given work piece with respect to the given model.
b. File the one edge of the given work piece to straightness and checked with Try square.
c. File the adjacent edge so that it is square with first edge filed and checked with Try square. File the
upper and bottom surfaces of work piece.
d. Paste white color on the upper surface of the work piece (with chalk powder and water).
e. By marking gauges (Scale, Try square, Scriber, Divider), mark the dimensions on the given work
pieces.
f. Using Dot punch and Hammer, make the punch marks (dots) on the marked dimensions on the given
work piece.
g. By using hacksaw remove the extra material from the work piece and use cold chisel, if necessary to
remove the material. Removing small amount (1 mm to 2mm) of material Files can be used.
h. Then male and female work pieces are assembled (joined) in order to make firm joint.

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DEPARTMENT OF MECHANICAL ENGINEERING

SKETCH OF THE FINISHED MODEL

1. Rectangular Joint 2. Half Round Joint

3 Dove tail Joint

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DEPARTMENT OF MECHANICAL ENGINEERING

WELDING

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DEPARTMENT OF MECHANICAL ENGINEERING

WELDING
Introduction: In mechanical industries all the parts cannot be casted or machined. Parts need
to be fabricated by joining. The joint may be temporary or permanent. Welding is a permanent
joint between two parts.

Definition: Welding is the process of joining similar metals by application of heat with or
without application of pressure and with or without use of filler rod.
Classification of welding:
Plastic welding or pressure welding – In this method, the metals to be joined are heated to
plastic state (red hot condition) and forced together by external pressure.
Eg: Resistance welding, forge welding, Thermit welding, Friction welding.
Fusion welding or Non-pressure welding – In this method, the metals to be joined are
heated to molten temperature at the joint and allowed to solidify.
Eg: Arc Welding, Gas welding
Arc welding: In this method, heat required to melt the metals is produced by striking an electric arc with the help of
an electrode. The electrode (negative terminals) and metals to be joined (positive terminals) form two different polarities
of an electric circuit. When the electrode is touched to the metals momentarily and is separated by a small gap (about 2
to 3 mm) after arching, the current in the circuit continues to flow due to ionization of air particles present in the gap.
This results in transfer of electrons from the electrode to the metal which results in an electric arc. The electric arc is
capable of producing very high temperature of the order of about 40000 c. this heat I used to melts and join them by
solidification.

Gas welding: In this method, heat requires to melt is produced by burning a

Combustible gas in the presence of oxygen
List of equipment and tools:
The most commonly used tools for an arc welding process are

Welding transformer – ac/dc type

Electrode holder

Electrode

Cables and its connectors

Chipping hammer

Earthing clamps

Wire brush

Helmet

Safety goggles

Hand gloves

Aprons

Tongs

Anvil

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DEPARTMENT OF MECHANICAL ENGINEERING
Electrode is made of mild steel rod coated with mineral particles. The electrode
coating helps to:
i) Stabilize the arc
ii) Provide alloying elements for the weld metal
iii) The coating melt to form a protective layer
iv) Form a refining slag for the weld pool.

Transformer: Used in welding is a step-down transformer used to reduce the

output voltage and increase the output current.

Current [AC] Voltage

In put 15A/30Amps 220v/440v
Out put 75-300Amps 35-80v

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DEPARTMENT OF MECHANICAL ENGINEERING
Different Types of Welding Tools:

Welding Leather Gloves

Names of the few different types welding joints:

• Butt joint
• T-joint.
• Lap joint
• Fillet/corner joint
• Angular joints

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DEPARTMENT OF MECHANICAL ENGINEERING

Experiment -1

LAP JOINT

Aim: To make a Lap joint as per the sketch using arc welding unit and
accessories

Welding Dimension: X*Y* Z mm each Material: Mild Steel

Finished Material

Note: All Dimensions are in mm

Scale 1:1
TOOLS REQUIRED: AC Arc welding transformer, Electrode holder,
Electrode, Face Shield, Chipping hammer, Wire brush,
Flat tongs, Leather gloves
OPERATIONS: Cleaning, Holding, Welding, Chipping
PROCEDURE:
 The given material’s welding surface is cleaned to be free from rust, oil ness, dirt, etc.

 Keep the work piece on the metal welding table to the required position and fix the
electrode into the electrode holder
 Switch on the transformer and bring the electrode near to the work piece till an arc
between work piece and electrode is struck
 This arc produces heat so that the welding metal [work piece] gets melted at the joint
and also the melted electrode fuses together
 Then slowly move this electrode along the length of welding joint with a gap at constant
speed to get a homogeneous joint
 After completion of all weld joints holding with tong take away from the wok table and
allow it to cool to room temperature
 Then clean the welded joint by using chipping hammer and wire brush remove the slag
and metal sputter
 Thus the model is completed. Record the dimensions in the table

RESULT: Lap joint is obtained.

CONCLUSION:

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DEPARTMENT OF MECHANICAL ENGINEERING

Experiment-2

BUTT JOINT

Aim: To make a BUTT JOINT as per the sketch using arc welding unit and
accessories

Welding Dimension: X*Y* Z mm each Material: Mild Steel

Raw Material Finished Material

Note: All Dimensions are in mm

Scale 1:1

TOOLS REQUIRED: AC Arc welding transformer, Metal welding table

with Earthing-Clamp, Electrode holder, Electrode,
Face-Shield, Chipping hammer, Wire-brush, Flat-
tongs, Leather gloves, etc.

OPERATIONS: Cleaning, Holding, Welding, Chipping

PROCEDURE:
• The given material is taken and clean the welding surface for rust and oil ness
• Keep the work piece on the table metal welding table to the required position and fix the
electrode into the electrode holder
• Switch on the transformer and bring the electrode near to the work piece till an arc
between work piece and electrode is struck
• This arc produces heat so that the welding metal[work piece] gets melted at the joint
and also the melted electrode fuses together
• Then slowly move this electrode along the length of welding joint with a gap at constant
speed to get a homogeneous joint
• After completion of all weld joints holding with tong take away from the wok table and
allow it to cool to room temperature
• Then clean the welded joint by using chipping hammer and wire brush remove the slag
and metal sputter
• Thus the model is completed

RESULT: Butt joint is obtained

Basic Engineering Work Shop Lab (MEL-109) 34

DEPARTMENT OF MECHANICAL ENGINEERING

CARPENTRY

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DEPARTMENT OF MECHANICAL ENGINEERING
CARPENTRY
Introduction:-
Carpentry may be defined as the process of making wooden components. It deals with the
building work, furniture, cabinet making etc. Jointly, i.e., Preparation of joints is one of the
important operations in all wood works. It deals with making joints for a variety of applications
viz, door frames, window frames, wardrobes, cupboards, stairs etc. In this chapter tools and
works associated with joinery are presented.

Carpentry Material:
Timber: Timber is the basic material used for any class of carpentry work. The term timber is
applied
to the wood obtained from; well-grown trees. The trees are cut, sawn into various sizes to suit
the required purpose.

Common Varieties of Indian Timber: Indian timbers most commonly used for various
carpentry words are as follows: Babul, Deodar, Mahogany, Mango, Sal, Sissy and teak.

Carpentry Tools: In carpentry large numbers of hand tools are used for processing the wood.
Here, the details of tools that are being used in our workshop only are presented.

Marking and Measuring Tools:

Steel Rule: It is strip of steel with graduations on its edges and is used for measuring and
setting out dimensions.

Try Square: Try squares are used for marking and testing of right angles and for testing
flatness of surface.

Marking Gauge: It is a tool which has one projected marking pin and is used to mark accurate
lines parallel to the true edge of a wooden piece.

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DEPARTMENT OF MECHANICAL ENGINEERING

Holding Tools:
Carpenter’s Vice: It is used for holding the work for planning, sawing and chiseling. The whole
vice is made of iron and steel. It has two jaws one of which is fixed to the side of the table while
the other is movable.

C-Clamp: It is used for holding the work projecting above the top surface of the Bench. This is
used to prevent the wood from moving forward when being planned.

Bench Stop: It is simply a block of wood projecting above the top surface of the bench. This is
used to prevent the wood from moving forward when being planned.

Cutting Tools:
Wooden Jack Plane: It consists of wooden body in which blade is set at an angle of 45
degrees to the body or sole. The cutting blade used is made of high carbon steel and is very
similar to a chisel. Jack Plane is a general purpose plane and is used to produce flat and smooth
surfaces on wood.

Hand or Cross-cut Saw: It is used to cut across the grains of the stock or thick wood. The
teeth are set alternately to the right and left of the blade, and its purpose is to make the cut
wider than the thickness of the blade. This allows the blade to move freely in the cut, without
sticking. Her teeth are set at 2.5 mm apart.

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DEPARTMENT OF MECHANICAL ENGINEERING
Tenon Saw or Back Saw : This saw is mostly used for cross cutting when a finer and more
accurate finish is required. The teeth are shaped in the form of an equilateral triangle and
generally have 13 teeth for 25 mm length.

Tenon or back saw

Firmer Chisel or Straight Edge Chisel: It is a general-purpose chisel and is used for cutting
and shaping wood accurately. The width of the blade varies from 1.5 to 50 mm.

Adze: Adze is a side axe used to chop extra wood quickly by carpenters. Adze with very long
handle is used to plane long palm tree barks in standing position and also used as a hammer.

Miscellaneous Tools:
Pincer: It is made of steel with a hinged joint and is used for pulling out small nails from wood.

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DEPARTMENT OF MECHANICAL ENGINEERING

Claw Hammer: It is a dual-purpose hammer. It has a hammer face, which is used to drive in
nails and claw at the other end for pulling out mails from the wood.

1 - Steel Handled Claw Hammer 2 - Beach Mallet 3 - Wooden Handled Claw Hammer 4 - Ball-
Pin Hammer 5 - Pin Hammer 6 - Cross-Pin (Warrington) Hammer

Wood Rasp File: It is a finishing tool used to make the wood surface smooth, remove the
sharp edges and other interior surfaces. Sharp cutting teeth are provided on its surface. This file
is exclusively used in woodwork.

Wood Joints:
There are many kinds of joints used to connect wood stock. Each joint has a definite use and
required marking, cutting and joining together. The strength of the joint depends on the
amount of contact area. If a particular joint does not have much contact area, then it must be
reinforced with nails, screws or dowels.

Lap Joint: Also called halving joint. The aim of this joint is to secure the corners and
intersections of the framing and at the same time in the same plane. They may be usefully
employed in many types of framing where strength and appearance are of secondary
consideration.

Mortise and Tenon Joint: This family of joints is a large one and does probably the wood
worker use the commonest. It consists of a rectangular peg (tenon) fitting into a rectangular
hole (mortise).

Briddle Joint: These are the reverse of mortise and tenon joints in form and are often called
the open mortise tenon. These joints are used where the members are of square or near square
or near-square section and thus unsuitable for making a mortise and tenon joint of good
proportions.

Instructions
1. When you are using your thumb as a guide for cross cutting and ripping, raise it sufficiently
high.
2. Planning should be done along grains only.
3. Push the chisel away from you while chiseling.
4. Always use marking gauge (or) a mortise gauge for drawing lines.
5. Check the squareness of planned surfaces with try square.
6. Use wooden mallets for driving chisel.
7. Do not test sharpness of the edge of the cutting tools on your hand.
8. Do not keep your hands In front of the sharp edged tools while they are in use.

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DEPARTMENT OF MECHANICAL ENGINEERING

Wood Turning
Woodturning is a form of woodworking that is used to create wooden objects on a lathe.
Woodturning differs from most other forms of woodworking in that the wood is moving while a
stationary tool is used to cut and shape it. Many intricate shapes and designs can be made by turning
wood.
Wood Turning Lathe Machine

Types Tools
Turning tools are generally made from three different types of steel, Carbon steel, High speed steel (HSS),
and more recently powdered metal. Comparing the three types, high speed steel tools maintain their edge
longer, requiring less frequent sharpening than carbon steel, but not as long as powdered metal tools. The
harder the type of high speed steel used, the longer the edge will maintain sharpness. Powdered steel is even
harder than HSS, but takes more effort to obtain an edge as sharp as HSS, just as HSS is harder to get as
sharp as Carbon Steel. Unlike other edged woodworking tools, woodturning tools require more frequent
sharpening, because the wood passes at a great speed. To maintain a clean cut, the sharpness of the tools
edge must be maintained. The sharpening process requires either skill of the craftsman, or one of the many
available sharpening jigs, which facilitate maintaining a specific bevel on the tool. High speed steel is not
prone to blueing (overheating) whereas carbon steel blues easily, requiring frequent quenching to avoid losing
temper (making the edge too soft.)

Roughing gouge - a wide fluted gouge used to initially round a wooden spindle, and to roughly shape it.
Generally not intended for cutting end grain due to the large cut it takes and the relatively weak tang
connecting the blade to the handle. Unsafe for making bowls or any faceplate work.

Spindle gouge or detail gouge - a shallow fluted gouge used to create details on spindles, including
beads (raised portions of the turning typically semi-circular in cross section) and coves (relieved portions of
the turning).

Bowl gouge - a deep fluted gouge used to turn the outside and inside of bowls and vessels. Often has a
thicker shaft and longer handle than a spindle gouge because it has to cut farther away from the hand rest
and deal with the forces of turning a large bowl.

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DEPARTMENT OF MECHANICAL ENGINEERING
Skew chisel - a wide, steeply pointed chisel with the edge running at an angle to the length of the tool.
Used to smooth flat spindles, cut beads, and add details. Skew chisels are only used on spindle work (never
on faceplate work) and are honed after sharpening to create a razor edge.

parting tool - a pointed tool used to separate (part off) work from the lathe, and to create a straight edge
separating large and small diameter sections - wide parting tools also called bedans are used to create evenly
sized spindle sections.

Hollowing tool - many different types of tools used to cut out the deep sections of steep bowls, vases and
hollow vessels. Often with very long handles, to maintain enough leverage when working in a deep vessel, far
away from the hand rest.

Scraper - a tool that scrapes the wood fibres instead of cutting - these are used to smooth off wooden items
cut with other tools, and to shape items that are not possible or difficult to shape with gouges. A sharp scraper
has a burr at the edge which cuts the wood, only a dull scraper actually scrapes.

Bowl saver - a tool used to core out the inside part of a bowl, allowing the waste piece to be used to create
a smaller bowl, and to limit the amount of wood chips created when hollowing out a bowl.

Auger - a drill bit used to drill a hole partway or all the way through a wooden item. For cutting the hole for a
lamp cord, or as the first step when hollowing out a bowl or vessel

Chatter tool - a flexible scraper used to add decorative chatter marks to turned items

Wire - a simple wire, sometimes with handles attached at either side, for the purpose of burning lines into the
piece with friction.

There are also several tool types for special purposes, as well as tools that are a combination design of the
above tools, i.e. skew/chisel combinations, thread cutting tools, ring cutting tools, medium fluted gouges, etc.

Wood Tuning Tools

Gouge

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DEPARTMENT OF MECHANICAL ENGINEERING
LAP TEE JOINT
Experiment No: 1
Aim: To prepare a Lap Tee Joint as per dimensions given in sketch.

Material Required: Two wooden pieces of required as per dimension.

Tools Required: Steel rule, Handsaw, Wooden jack plane, Try square, Marking gauge, C-
Clamp,
Firmer chisel, Adze
Sequence of Operations: 1. Marking 2. Planning 3. Cutting 4. Setting

Procedure:
• Select a teak wood material and mark the size as per drawing with the help of marking
tools like steel rule, marking gauge, try square.

• Planning of sides with the help of wooden jackplane to maintain the required
dimensions.

• Fix the work piece in carpentry vice and cut into two equal pieces of size
150mm X 30mm with the help of handsaw.

• Mark the two work pieces for male cutting and groove cutting as per dimensions.

• Fix the work pieces one by one on the bench with the help of ‘C’ Clamp and a groove is
made as shown in drawing with the help of chisels and adze.

• The two work pieces are fitted to make Lap Tee Joint as per drawing.

Precautions:
1. We should be careful while marking and planning.
2. Special care is required while cutting the groove with firmer chisel so that the
dimension is not exceeded.

Result: Lap Tee Joint is prepared as per given dimensions

Instructions
1. When you are using your thumb as a guide for cross cutting and ripping, raise it sufficiently
high.
2. Planning should be done along grains only.
3. Push the chisel away from you while chiseling.
4. Always use marking gauge (or) a mortise gauge for drawing lines.
5. Check the squareness of planned surfaces with try square.
6. Use wooden mallets for driving chisel.
7. Do not test sharpness of the edge of the cutting tools on your hand.
8. Do not keep your hands In front of the sharp edged tools while they are in use.

Basic Engineering Work Shop Lab (MEL-109) 42

DEPARTMENT OF MECHANICAL ENGINEERING

MORTISE/ TENIN JOINT

Experiment No: 2

Aim: To prepare a Mortise/Tenon Joint as per dimensions given in sketch.

Material required: - Two wooden pieces of required as per dimension.

Tools required: - Steel scale, try square, cross cut saw, rasp, firmer chisel, mortise and
tenon chisel and hammers.

Procedure:-

(1) Two wooden piece of required size are to be cut.

(2) The pieces are Squared using jackplane and rasp.
(3) One piece is marked for mortise rectangular hole.
(4) Another piece is marked for tenon T shape.
(5) The mortise hole is made using mortise and dove tail chisel.
(6) The tenon T- shape is made using saw.
(7) Both the pieces are finished usingrasp.

(8) Both pieces should be fitted with normal hand pressure.

Precautions:-
• Wear apron, shoes, gloves and tight fitted clothes.
• Be careful and attentive while working on carpentry
job.
• Use proper tools for each operation.
• Don’t keep any sharp tool in your pocket.
• While using chisel cutting should be in direction away from yours
body. Tools being used should be well sharpened.

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DEPARTMENT OF MECHANICAL ENGINEERING
Wood Turning
Experiment No: 3
Plain Turning
Aim: To prepare plain turning as per dimensions given in sketch.

Material Required: Soft Wood (Square Wood).

Raw Material Size: 165x46x46mm

Finished Model

Tools Required: 1. Steel Rule 2, Centre Punch 3. Outside Spring Caliper

4. Vernier 5.Skew Point (Flat Type) 6. Wood Turning Lathe Machine
Procedure:
1. Take the raw material and measure the work piece
2. Write two diagonal to both side and Mark the center using Centre punch
3. Take the work piece fix properly into the machine
4. Take Skew Tool (Flat Type) turn the work piece to our required Dimension.

Result:

Basic Engineering Work Shop Lab (MEL-109) 44

DEPARTMENT OF MECHANICAL ENGINEERING
Experiment No: 4

STEP TURNING TURNING

Aim: To prepare Step turning as per dimensions given in sketch.

Material Required: Soft Wood (Round Wood).

Raw Material Size: 165xdia 38mm

Finished Model

Tool required: Skew, Flat Type Skew, Steel Rule, outside spring Caliper,
Vernier

Procedure:

1. Mark the dimension as per given drawing with help of pencil, steel rule& vernier
2. Fix the raw material between two centers ( Head Stock & Tail Stock) and lock the
tailstock spindle
3. Take the skew Mark in to the work piece after take one more tool ( Flat Type Skew)
remove the material where you are marked.
4. Check dimension with help of Vernier

Result:

Basic Engineering Work Shop Lab (MEL-109) 45

DEPARTMENT OF MECHANICAL ENGINEERING

Experiment No: 5

TAPER TURNING TURNING

Aim: To prepare Taper turning as per dimensions given in sketch.

Material Required: Soft Wood (Round Wood).

Raw Material Size: 165xdia

38mm

Tool required: Skew, , Steel Rule, outside spring Caliper, Vernier

Procedure:

1. Mark the dimension as per given drawing with help of pencil, steel rule& vernier
2. Fix the raw material between two centers ( Head Stock & Tail Stock) and lock the
tailstock spindle
3. Take the skew tool hold in inclined position and remove material from work .
4. Check dimension with help of Vernier

Result :

Basic Engineering Work Shop Lab (MEL-109) 46

DEPARTMENT OF MECHANICAL ENGINEERING

SHEET METAL

Basic Engineering Work Shop Lab (MEL-109) 47

DEPARTMENT OF MECHANICAL ENGINEERING

SHEET METAL
Introduction: In industries for many engineering and household articles thin metal in the form
of a sheet is used. Metal Sheets up to 3.2mm thickness are called sheet metal. Over this, are
named as plates. Some of the examples are automobile body, ducts, chimney boxes, cans, etc.,
A wide variety of sheet metal is used for different applications.

Mild steel sheets: they are uncoated MS sheets and require painting for long life. Used in
almost all industries for a variety of uses.

Galvanized iron: it is made by dipping iron sheet in hot molten zinc, it resists corrosion,
improves soldering ability and improves appearance. It is known as GI sheet or zinc coated iron,
commonly used for air conditioner ducts, hoods, cabinets, boxes, etc.

Stainless steel: it is an alloy of carbon, nickel, chromium etc. It has high resistance to corrosion. It is strong and can be
welded. Used for medical, food processing, dairies, chemical plants, kitchen utility etc.

Aluminum sheets: they are light in weight and are used in aircraft industry, automobiles and
household articles.

Copper, Tin and Lead sheets are also used for various applications.

SHEET METAL HAND TOOLS:-

 Trammel
 Mallet
 Ball peen Hammer, Straight Peen Hammer, Cross Peen Hammer.
 Straight Snips, Curved Snip.
 Standard Wire Gauge
 Plain Soldering Iron (Soldering Copper), Electrical Soldering Iron
 Stakes
 Groover
SHEET METAL HAND TOOLS:-
Hammers: they are used for forming shapes by hollowing, stretching or raising. Different types
of hammers are riveting hammers, setting hammers and raising hammers.

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DEPARTMENT OF MECHANICAL ENGINEERING
Mallets: they are used to hammer softer metals and are made of wood, hard rubber Nylon
Inserts, or lead.

Stakes: stakes are used for bending, seaming, forming using hammer or mallet. They act as
supporting bench to form the work to the required shapes. The commonly used are hatchet,
funnel, tubular, beak-horn, round, and square type.

Snip and Shears: they are used for cutting Sheet metal. Snip is also called hand shear. It cuts
the thin material with scissoring action. Shears are similar to snips used to cut thick metal.
These range from hand shears of tin snips to power guillotines. The power guillotines are
capable of cutting metal of 9mm thick plate.

Hand shears machines: Hand shears are used to cut sheet metal up to 1mm thickness. They
are made in various shapes so that both flat and curved surfaces can be cut out easily.

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DEPARTMENT OF MECHANICAL ENGINEERING
Bench Shears: Bench shears are used to cut sheets unto 3mm in thickness. This is hand
operated. A system of levers multiplies the force acting on the shear blades. This helps to cut
thick metal easily.

Soldering Iron: it consists of copper bit held by steel rod and wooden handle. They are used
for joining metal using lead/tin as filler metal.

SOLDERING:-
It is a process of joining two metals under heat with the help of a soft metal called solder in the
molten state.

SOLDER: It is an alloy of metals that melt at low temperatures.

TYPES OF SOLDER: There are two types 1) Soft solder and 2) Hard solder

SOFT SOLDER: This solder is used for the light jobs or those jobs witch do not get much load or
shocks. In this solder the metals are mixed in the following proportion. Sometimes small
amount of bismuth and cadmium are frequently added to lower the melting point.

Hard solder: this is used for a strong joint. The melting point of hard solder will be around
3500 to 9000 C. The mixtures are as follows.
Copper + zinc.(4:1)
Zinc + copper+4 to 8 % silver or 66% tin and 34% antimony.

Flux: It is a cleaning agent used to prevent oxidation of the metals at the soldering points. It
helps the solder to melt quickly and allows it to flow freely to unite more firmly.

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DEPARTMENT OF MECHANICAL ENGINEERING

TYPES OF FLUX: There are two types. 1) Corrosive flux (active flux) 2) non corrosive flux
(passive flux)

CORROSIVE FLUX: These will harm the metal of the job .if they allowed to remain on the job
.Hence after soldering or brazing it should be washed with water. e.g.: zinc chloride .ammonium
chloride.
Hydrochloric acid. Sal – ammoniac etc. come under this type.

NON- CORROSIVE FLUX: These are harmless to the metal [job] even if they allowed to
remain on the job after soldering or brazing.

Though resin is non – corrosive. It does not have the cleaning properties of zinc. Chloride. Ex.:
Borax. Rosin. Turpentine oil etc.

MELTING
NAME OF THE SOLDER LEAD TIN FLUX
POINT
Soft solder 37% 63% 1500 C Zinc chloride
Tin main solder(coarse) 50% 50% 2050 C Zinc chloride
Tin main solder( fine) 40% 60% 1920 C Zinc or Ammonium chloride
Electrical solder 58% 42% 2200C Zinc chloride or rosin

BRAZING:-
It is the process of joining two or more pieces of metals with an alloy in the from of spelter.
Whose melting point should be around 6600 C and above. Here a blow lamp or a furnace is used
to heat the job. Proper flux viz ash, borax etc. should be used to avoid oxidation.

TYPES OF BRAZING:

1) Torch brazing
2) Dip brazing
3) Electric brazing
4) Furnace brazing

Difference between Soldering & Brazing:

SL
Soldering Brazing
no
1 Solder is used in the process Brass is used in the process
2 Joints are not very strong. Joints are very strong.
3 Cost less. Cost more.
4 Chloride of zinc or ammonia & rosin are Ash or borax is used as flux
used as flux
5 Joints could be made at even less Joints could be made at temperature
temperature than 2000 C more than 6000 C
6 Suitable only for thin sheet metals Suitable for thick sheet metals also

Soft solder – tin man solder – plumber’s solder:-

Soft solders are alloys of tin and lead. All the plain tin lead solders become solid at 183 degree
centigrade. If the lead content is increased then the melting temperature also increases. If tin
content is increased then the melting temperature is lowered. With higher tin content the
solders flow more freely. With higher lead content, solders do not flow freely.

Solder with 60% tin and 40 % lead is known as tin man’s solder. It has a very small
temperature interval between being completely liquid and becoming solid. The interval is 188
degree centigrade to 183 degree centigrade. This is the marked feature of tin man’s solder. It
changes from liquid to solid very rapidly. Same way from solid to liquid.

Plumber’s solder has 40% tin and 60% lead. It has a melting temperature of approximately 234
degree centigrade. The solder passes through a pasty stage in the transformation from liquid to

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DEPARTMENT OF MECHANICAL ENGINEERING
solid. This feature is useful in some plumbing applications. It is used for joining lead pipes or
lead sheeting of electric cables. In this solder the transition from liquid to solid is comparatively
slow. i.e., liquid – pasty – solid .because it takes more time to solidify, this solder can be
shaped as liked. This feature is useful in some plumbing applications or where dipping in a bath
of molten solders coats work. Where soldering is carried out by machine and where temperature
cannot be maintained 50/50, 40/ 60 ranges of solders are used.

Hard solder:-
Hard solder has a higher melting temperature and is considerably stronger than soft solder.
Silver solder 34%- Cu
50%- Ag
16%- Zinc
Silver solder has an average composition of 34% copper, 50% silver and 16% zinc. It is used
for making a strong joint in small parts unsuited to the higher temperatures of brazing. The
melting temperature is about 600 degree centigrade. The high silver content is expensive. This
limits it’s used. It is usually applied to the work with a small blowtorch.

Differentiate between Welding, Soldering, Brazing:-

Welding Soldering Brazing

Metals to be joined Similar Similar or Dissimilar Similar or Dissimilar
Filler metal Similar to parent Dissimilar alloy – Dissimilar alloy - Spelter
metals Solder
Melting temp range 2500-40000C 150-3500C(soft), 600-8500C
600-9000C(Hard)
Melting of Both base metals & Filler alloy only Filler alloy only
filler
Joint Stronger Weak Weak

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Experiment -1
Hollow Cylinder
Aim: - To prepare a Hollow Cylinder as per the sketch using sheet metal Accessories.

Material: G.I. Sheet

Development of Cylinder
FINISHED PART

TOOLS REQUIRED: Snips, Stakes, Mallet, Electric soldering, soldering wire and flux
OPERATIONS: Drawing of development for the given dimension [1:1 scale only]. Marking,
Cutting, Forming, Soldering
PROCEDURE:
• Draw the developed shape of the cylinder by using drawing equipments on a white
paper with appropriate allowances for folding
• Cut the paper according to the developed shape

• Transfer the development by pasting the paper on to the G I sheet and cut the G I
Sheet to the shape as per the drawing by using snips

• By using suitably shaped Stakes shape manually the G I sheet by bending/folding as

per the development

• Finish to the final shape by using suitable stakes and mallet

RESULT: cylinder is obtained.

CONCLUSION:
APPLICATION: Cylinders, Boilers, Structural, Automobile Engg, Aerospace Engg, Marine Engg
etc.

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Experiment -2
Square Prism
Aim: - To prepare a Square Prism as per the sketch using sheet metal accessories.
Material: G.I. Sheet
Developing Part

Finished Model

TOOLS REQUIRED: Snips, Stakes, Mallet, Electric soldering, soldering wire, and flux
OPERATIONS: Drawing of development for the given dimension [1:1 scale only], Marking,
Cutting, Forming, Soldering
PROCEDURE:
• Draw the developed shape of the square prism by using drawing equipments on a white
paper with appropriate allowances for folding
• Cut the paper according to the developed shape

• Transfer the development by pasting the paper on to the G I sheet and cut the G I
Sheet to the shape as per the drawing by using snips

• By using suitably shaped Stakes shape manually the G I sheet by bending/folding at

the corners as per the development

• Finish to the final shape by using suitable stakes and mallet

RESULT: square prism is obtained.
CONCLUSION:
APPLICATION: Cylinders, Boilers, Structural, Automobile Engg, Aerospace Engg, Marine Engg
etc.

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VIVA – QUESTIONS
I. Fitting Shop
1. What do you mean by fitting? (or) Define fitting? Give practical example.
Fitting is the process of assembling two or more metal parts together by removing excess material so
as to obtain a required fit. Ex: - 1) key and key hole 2) A Bush and a shaft

2. Name the tools, which are used in fitting?

a) Work holding tools b) Marking and Measuring tools c) Finishing and cutting tools

3) Name work holding devices used in Fitting. (or) What are the types of vices?
a) Bench vice b) Machine vice c) leg vice d) pipe vice e) hand vice

4) Name Marking and measuring tools used in Fitting

a) Surface plate b) Angle plate c) Scribing block/Surface gauge d) Scriber e) Try square f) Divider
g) Center punch h) Steel rule or Scale i) caliper (Inside caliper and Outside caliper)

5) What is the purpose of Marking?

a) To Transfer measurements and Dimensions from drawing to workpice for further operations.
b) To obtain shape on work piece to the design given in the drawing.
c) To check Dimensional suitability of raw material for a given Job.

6) What are the tools required for Marking.(or) Name Marking tools used in Fitting
a) Surface plate b) Angle plate c) “V” block d) Divider e) Scriber f) Punches g) Marking Hammer h)
Try
Square i) Steel Rule j) Scribing Block or Surface gauge

7) What is meant by Measurement?

Determining the Size of a job in terms of Standard unit is called measurement.

8) Name measuring tools used in Fitting.

a) Steel rule b) Vernier Caliper c) Micrometer d) Depth gauge e) caliper (Inside caliper and Outside
caliper)

9) Name Finishing and cutting tools used in Fitting.

a) Files b) Hack saw c) Chisel

10) What is the classification of materials?

Metals and Non-Metals.
Metals: A metal is a solid (Exception: Mercury) having weight. It is opaque and a good conductor
of heat
and electricity.
Non-Metals: These are available in the form of liquids, gases or solids such as wood, stone, Rubber,
plastic,
ceramic, concrete, asbestos etc.

11) What is the classification of metals?

a) Ferrous metals b) non-ferrous metals.

12) Differentiate between the ferrous and non-ferrous metals.

Ferrous Metals: Iron containing metals such as pig iron, cast iron, wrought iron, Mild Steel, carbon
steel,
Alloy steel, Nickel steel etc., are called ferrous metals. These can be attracted by magnets and are
susceptible to rusting.
Non-Ferrous Metals: Non-Ferrous metals are those which do not contain iron.Metals like Gold,
Silver,
Copper, Aluminum, Tin, Platinum, and Nickel, Bronze etc, and its alloys are Non-Ferrous metals.
These can neither rust nor can be attracted by magnets.

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13) What’s the composition of CI Material?
CI-Cast Iron – a) Iron (91-94%), Carbon (2-4%), Silicon (0.4-2.8%), Less percentage of, Manganese,
Sulfur
and phosphorous
14) What’s the composition of MS Material?
Iron (91-94%), Carbon (0.15-0.35%), Less percentage of Manganese Silicon, Sulfur and
phosphorous.
One of the differences between Cast iron and steel is the amount of carbon percentage
MS- Mild steel- may be defined as an alloy of iron and carbon (0.15-0.35%). Besides this, it also
contains Silicon, Manganese, Sulfur and Phosphorous.
Low carbon steels are also called as soft or mild steel.
These steels are used for bolts and nuts, structural work, axles, shafts etc.

15) What is the classification of steels based on carbon content?

Based on the carbon content, steel is divided into
a) Low Carbon Steels- The carbon content ranges from 0.03-0.35%. -Mild steel (MS)
b) Medium Carbon Steels-the carbon content a range from 0.35-0.6.
c) High Carbon Steels-The carbon content ranges from 0.6-1.7%

16) Name the commonly used material for preparing fitting models
Mild Steel (MS).

17) What is the use of Alloy steels?

In alloy steel in addition to carbon and iron, alloying elements such as chromium, Nickel etc. are
mixed.
Ex: - Stainless steel, High speed steel, Tool steel (0.8 to 1.5% carbon).etc.
Alloy steels are widely used in the manufacturing of Cutting tools .
18) Name the parts of the bench vice?
a) Body with Fixed Jaw b) Movable jaw c) Jaw Plate d) Screw spindle e) Handle f) Base
19) How will you specify a bench vice?
Width of the jaws determines the size of the vice
20) Which material is used to make the vices?
Cast iron
21) What do you mean by leg vice?
It is used for holding work piece that has to be cut, chipped or hammered
22) What is the use of Pipe vice?
It is used for holding round section parts such as pipes, tubes.
23) Why is it named as V-block?
V-block is a rectangular or square block with V-groves on one or both the sides, opposite to each
other. The angle V is usually 90 degrees.
24) What is the use of V-block?
V-blocks are used for checking the roundness of cylindrical work pieces and for marking centers
accurately.
25) What is a surface plate? Why it is used?
Surface plate:-Surface plate is a plain surface.
It is used for –testing the flatness of finished work piece. Providing a base support for ‘marking
gauges’ or ‘scribing block’. Testing the accuracy of Try square.
Material- Cast iron or hardened steel or granite stone.
Specification: - It is specified by length x width x height x grade.
26) What is the use of try square?
It is used for 1) checking squareness or perpendicularity of work piece.2) Testing for Straightness
and 3) marking straight lines (at right angles) on work piece.
27) How will you specify a try square?
The Size of Try-square is specified by the length of the blade (100mm, 150mm, and 200mm).
28) Define least count?
A smallest measurement that can be obtained from measuring instrument.
Or.
A smallest measurement that can be measured by using measuring instrument.

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29) What is the use of Vernier caliper?
It is used for measuring outside as well as inside dimensions accurately. It may also be used as a
depth gauge (to measure depth of holes).
Hence, Least count of the vernier = 1 main scale division – 1 vernier scale division.
30) What is the use of micrometer?
Micro meter: External micrometer is used to measure external diameters and lengths. The degree of
accuracy is high.
31) What is the use of steel rule?
It is used for measuring and marking the required dimensions on the work piece.
32) What are the types of spring calipers?
a) Outside spring caliper b) inside spring caliper
33) What is the use of outside spring caliper?
It is used for measuring the outer diameter of shafts (rods) and thickness of parts.
34) What is the use of inside spring caliper?
It is used to measure the inner diameter/dimensions of parts
35) What is the use of angle plate?
It consists of two faces machined at right angles (90 degrees) to each other. A number of slots are
cut on both the horizontal and vertical faces as shown in figure. These slots enable the work piece to be
held firmly by means of bolts and nuts. It is also used to support work piece, when you are using the
surface gauge for marking out.
36) What is the use of Dot punch?
It is used for marking points along a line which enables to cut the work piece easily.
37) What is the point angle of Dot punch?
60 degrees
Material- High carbon steel.
Specification-By length and angle.
38) What is the use of center punch?
1) It is used for marking round indentations on metal surfaces.
2) This provides a center for locating the sharp end of the divider point and center for holes that are to be
drilled.
3) It is also used for marking points along a line which enables to cut the work piece easily.
39) What is the point angle of Center punch?
90 degrees
40) What is the use of number punch?
It is used to punch numbers (0 to9) on Metal work piece.
41) What is the use of letter punch?
It is used to punch Alphabetic letters (A to Z) on Metal work piece.
42) What is the use of Universal Scribing block or surface gauge?
It is used for scribing lines on work pieces and also used for checking parallel surfaces.
The Scribing block can be used to locate accurately the centers of round bars in conjunction with the
Vee-block
43) What is the use of scriber?
It is used to scribe (or) mark lines on the metal work pieces.
44) What is the use of spring divider?
It is used for scribing (marking) circles, arcs, bisecting lines and perpendicular lines on metal work pieces
It also used for transferring dimensions from scales to objects.
45) What is the difference between divider and Caliper?
A divider is a marking device used to mark dimensions, But a caliper is a measuring device used to
measure dimensions.
46) Name finishing tools used in Fitting.
a) Files b) Sand Paper
47) What is a file?
A file is a cutting tool used to remove small amount of material from the surface of the work piece and
also helps in giving a smooth surface finish
48) Name the parts of the files?
Tang-It is the pointed part that fits into the wooden handle.
Heel – It is end of the tang that forms a curved edge.
Face -It is the portion of the file on which cutting teeth are formed.

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DEPARTMENT OF MECHANICAL ENGINEERING
Point – It is the end opposite the tang
49) Classification of files.
Files are classified according to a) Size or length b) Shape c) Grade d) Cut
50) Name the different types of files and their uses?
Round files are used for filing concave surface and also for enlarging round holes.
Half-round file the curved face of the half-round file is used for filing concave surfaces and the flat face
is used for filing convex surfaces.
Knife edge file is used for filing narrow slots and corners having angles less than 90 degrees

51) What are the methods of filing?

a) Cross Filing b) Draw Filing

52) Name the materials used in the manufacture of files?

Files are made of Hardened and Tempered Steel
53) Show me single cut file and double cut file.

Single cut file Double cut file

54) What do you mean by single cut and double cut files?
A single cut file has rows of teeth in one direction across the face, which is useful for filing soft materials
like Aluminium, Brass, and Bronze.
A double cut file has 2 rows of teeth cut diagonal to each other .The double cut file is useful in
removing materials at faster rate in Harder Material.
Single cut files gives better finish when compared to double cut files but at the same time removes
material at a comparatively slower rate.
55) Differentiate between rough and smooth file?
A rough cut file has very coarse spaced teeth.It is used for rough work. It removes more material.
A smooth cut file has more closely spaced teeth.It is used to get smooth surface.
56) What is the use of flat file?
Flat files are used for general work or finishing flat surfaces.
57) What is the cross-section of flat file?
Rectangle
58) What is the use of square file?
Squares files are used for filing square corners, rectangular slots, keyways, enlarging a square or a rectangular
hole etc.
59) A file removes the metal during ------ Stroke.
Forward stroke. The file removes metal during the forward stokes. No pressure is applied on the Return
Stroke, but the file is allowed to remain on the work piece.
60) What is the cross-section of Square file?
Square cross-section.
61) What is the use of triangular file?
Triangular file or three-square files are used mainly for filing corners with angles less than 90 degrees.
62) How will you specify a file?
Specification- length, single cut /double cut, shape and pitch.
Example Length (say 400 mm)
Single cut /Double cut
Shape (say square cross –section)
Pitch or grade (say smooth)
63) The edge of a file that does not have teeth on it is called a --------.
Safe edge.
64) What is the material used to make a chisel
Material - High carbon steel or tool steel having octagonal or hexagonal cross-section.
65) What are the types of hammers? What is the material used to make a hammers.
Different types of hammers are a) straight pein hammer, b) ball pein hammer, c) cross–pein hammer.
Material Cast steel or carbon steel
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DEPARTMENT OF MECHANICAL ENGINEERING
66) What type of hammer mostly used in fitting operations?
Ball pein hammer
67) What is a twist drill?
The twist drills are used for making holes.
The drills are made of HSS (high speed steel).A bench drilling machine is commonly used in workshops .

68) What is a hacksaw?

The hacksaw is used for cutting metal by hand. The hacksaw blade has a number of teeth ranging from 5 to 15
per centimeter. Hack saw blades are fitted either in a solid frame or adjustable frame to accommodate different
lengths of blade
69)Hacksaw blades having lesser number of teeth per cm are used for cutting -------- materials.
soft materials
Ex:-Aliminium.brass and Bronze.
70) Hacksaw blades having larger number of teeth per cm are used for cutting -------- materials.
Hard materials like steel, C.I etc.
71) Name the materials of hacksaw blade?
It is made of high speed steel. The hacksaw blades are measured by its length, width, thickness and pitch of
the teeth.
72) How hacksaw blades are specified?
The hacksaw blades are specified by its material, length, width, thickness and pitch of the teeth.

73) What is the specification of try square?

Specification-the Size of Try-square is specified by the length of the blade (100mm, 150mm, and 200mm).
74) What is the use of Taps? Name the tap types in an each set?
A tap is a hardened steel tool, used for cutting internal threads in a drilled hole. Hand taps are usually supplied
in sets of three for each diameter and thread size. Each set consists of a 1) taper tap 2) Intermediate tap and 3)
Plug or bottoming tap.
75) With what tool internal threads are cut.
Taps
76) What is the use of Dies in fitting?
Dies are used for cutting external threads. They are made of tool steel or high carbon steel.
77) With what tool external threads are cut.
Dies.
78) What are the steps to be carried out in fitting job?
1) Filing 2) Marking &Measuring c) Sawing d) Filing e)Fitting/Assembly.
79) What is the use of file-card?
It is a metal brush used for cleaning the files.
80) What is the use of Flat chisel?
Chisels are used for removing surplus metal from the work piece. They can be used as a substitute when files
and hacksaw blades are impossible to use.
Specification- Length and width of the edge.
The process of removing metal using a chisel is called ‘chipping ‘.
81) Name some of machine tools.
1) Lathe Machine 2) drilling Machine 3) Milling Machine 4) Grinding Machine.
82) Differentiate between a tool and an instrument?
The device used for measuring and inspection is called instruments ex:-Calipers, micrometers, Gauges etc.
The devices used for making the models are called Tools.
Ex:-Scribers, Punches, Files, Saws, Chiles, Hammers etc.
83) What are the operations carried out in a Fitting Shop?
1) Filing2) Marking &measuring 3) Sawing 4) Chipping5) Drilling 6) Threading 7) Fitting
84) Identify the spring in the inside and outside caliper?

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DEPARTMENT OF MECHANICAL ENGINEERING

85) What is the least count of your scale? Your watch?

Least count for normal Scale is 1mm.
Least count for normal Watch is 1Minute.
86) What is a wing-nut? Identify it in the hacksaw Frame.
It helps to hold the blade firmly in position.
87) ------- are designed on the principle of ‘Screw and Nut’.
Micrometer.
88) ------instrument used for Measuring outer and inner dimensions and depth of holes?
Vernier Caliper.
89) ------ file is also known as Rat-Tail file?
Round File.
90) What is the use of Vernier Height Gauge?
Vernier height gauges are particularly suitable for marking off accurate distances and center locations. It is
also used in inspection of work pieces.
91) What is a depth gauge?
It is used for measuring Depth of holes.
92) How do you specify a Hammer?
Weight of Hammer

VIVA – QUESTIONS

I. WELDING SHOP
1) Define Fabricating process.
Joining two or more elements to make a single part termed as a Fabrication process. Example: - aircraft and
ship bodies, building trusses, welded machine frames, sheet metal parts etc.
2) Classify Fabrication processes according to Method of Joining
Mechanical Joining by means of bolts screws and rivets.
Adhesive joining by employing synthetic glues such as epoxy resins.
Metallurgical fusion process like Welding, Soldering and Brazing
3) Classify Fabrication processes according to according to Type of assembly
1) Temporary joining process
2) Permanent. Joining process
4) Define Temporary joining process and give Example.
Temporary joining process: - The joints obtained by these processes will be separated easily with out any
damage to the connected parts. Example: - Joints obtained by brazing, soldering, bolts and nuts. Studs and
nuts, screws etc
5) Define Permanent Joining process and give Example.
Permanent Joining process: - . The joints obtained by these processes will be such that the connected parts
have to be broken in order to separate them. Example: - Joints obtained by riveting, welding etc
6) What is welding?
Welding is the process of joining similar metals by application of heat, with or without application of
pressure or filler material.
7) Name applications of welding process.
It is used in the manufacture of automobile bodies, aircraft frames, railway wagons, machine frames,
structural works, pressure vessels, furnaces, tanks, refrigerators, furniture, boilers, and shipbuilding.
Repair and maintenance work. Example joining broken parts, rebuilding worn out components etc.
8) Classification of welding. Or. Mention different types of welding process.

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1) Plastic welding 2) Fusion welding
9) Is welding a permanent or temporary fastening method.
Permanent fastening method.
10) Which welding process is most commonly used at present?
Arc welding
11) Name the different types of welding joints.
a) Butt joint b) Lap joint c) Corner joint
d) T-joint
12) Define pressure welding or plastic welding.
Name some pressure welding process.
In plastic welding, the metal parts to be joined are heated to the plastic state (or above) and then fused together
by applying external pressure. No filler metal is used in this process. Plastic welding is also called ‘pressure
welding processes.
Example: -Forge welding, resistance welding.
13) Define fusion welding, name some fusion welding process.
In fusion welding process, the parts to be joined are heated above their melting temperature and then allowed
to solidify without application of pressure. A filler material is used during welding process.
Example: - arc welding and gas welding
14) Differentiate between gas welding and arc welding.
In gas welding process combustion of oxy-acetylene (oxygen-hydrogen) gases in different proportions is used
for heating the work pieces. In gas welding filler rod is used for joining work pieces.
In case of Arc welding Electrical Arc (AC OR DC) is used for heating the work pieces. In arc welding
electrode is used for joining work pieces.
15) Why it is called arc welding?
Electrical arc used for (heating) melting of base metals.
16) List the different types of arc welding process?
1) Carbon arc welding 2) Metal arc welding 3) Metal inert gas welding4) Tungsten inert gas welding 5)
Plasma arc welding6) Submerged arc welding
17) Name some of the sources available for heating in arc-welding process.

1) Transformer (A.C)
2) Motor Generator (D.C)
3) Rectifiers (converts AC into DC).
18) What is the minimum Arc-gap should be maintained between electrode and work piece for existence of
arc.
2mm to 4mm.
19) Draw an A.C arc-welding circuit. (OR) Name the components used in welding ac-circuit

20) The amount of current required for arc welding circuit.

50 to 500 Appears
21) The amount of voltage required for arc welding circuit.
20Volts – 40 Volts
22) What type of Transformer used in Ac arc welding process.
Step down Transformer
23) What is the function of Step down Transformer?
Decrease the voltage to from 230V to50v-90v.
Increase the current to 50Amps-400 Amps.
24) The temperature developed in the arc welding process.

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5000 degrees-6000 degrees.
25) Draw a DC circuit for arc welding process.

26) What is DCSP? OR DCEN-Direct current Electrode Negative.

Direct current straight polarity. In this case work piece is connected to the positive terminal of the welding
Machine. Electrode holder is connected to the negative terminal of the welding machine. DCSP gives greater
depth of penetration, more heat at job, used for weld thicker plates.
Or – Electrode is cathode, work piece is cathode.
27) How many number cables required in arc-welding process.
Three cables are required in arc-welding.
1) Cable for connecting Main supply to Transformer.
2) Cable for connecting Transformer to electrode Holder.
3) Cable for connecting Transformer to work piece Table (for Farthing).
28) Amount of arc length required between electrode work pieces.
The distance through the center of the arc from the lip of electrode to the bottom of arc crater is termed as arc
length. It ranges from 3mm to 4mm.
29) What is oxidation?
Metals in molten condition absorb oxygen from atmosphere and form metallic oxides. This process is known
as oxidation. The formation of metallic oxides must be prevented. To prevent oxidation, we use coated
electrodes.

30) Mention the current requirements for thin and thick materials.
20-200 amperes for thin materials
20-300 amperes for general work
300 -600amperes for heavy work (thick materials).
31) What is an electrode?
A welding electrode is defined as a component of the welding circuit through which current is conducted.
OR.
Electrode forms one pole of the electric circuit, while work piece forms the other pole.
Electrode is used in Arc welding process.
32) What is Filler rod?
Filler metal supplies additional material to fill the gap between work pieces. Material of the filler rod is
same as the base metal. Filler rod is used in gas welding process.
33) What is the difference between electrode and filler metal.
Electrode forms one pole of the electric circuit, while work piece forms the other pole.
Filler metal supplies additional material to fill the gap between work pieces.
In case of arc welding process, the filler metal apart from supplying additional metal also acts as an electrode
by forming a component of the electric circuit.
34) Name parts of electrode.

35) specify a welding electrode, you have used.

Electrodes are specified by its diameter (diameter of core wire) and length.
The size of the electrode is measured in Standard wire gauge (SWG).

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36) Classification of electrodes.
1) Consumable electrodes
a) Coated electrodes b) plain/bare electrodes
2) Non-consumable electrodes
37) What are the sizes of electrodes?
Core wire diameter-3.15, 4.0, 5.0, 6.3,10 mm and 12.5 mm.
Core wire length-350mm and 450 mm
as per Indian standard.
38) Differentiate between consumable electrode and non-consumable electrode.
Consumable electrode-These are made of metallic wire and are consumed during the welding process.
Non-consumable electrode- Non-consumable Electrodes are made of carbon, graphite or tungsten that does
not get consumed during welding.
39) Why electrodes are not coated fully.
One end of the electrode is left bare (uncoated with flux) which is usually held in the electrode holder.
The uncoated part helps in transmitting full current from the electrode holder to the front end of the electrode
coating. The flux coating acts as an insulator ofelectricity.Hence, electrodes are not coated fully.
40) What are the functions of flux on flux coated electrode?
prevents oxidation of molten metal helps in the removal of oxides and other undesirable substances present on
the surface of the work piece
Chemically reacts with the oxides and forms a slag. The slag floats and covers the top portion of the molten
metal thereby preventing it from rapid cooling.
To stabilize the arc
To avoid difficulties in welding.
41) Name the material of core wire of electrode.
Material of the core wire is same as the work pieces to be welded.
42) What is the material of flux used in the electrode?
Titanium oxide, cellulose, manganese oxide, calcium carbonates, mica, iron oxide etc. are used as flux
materials for coating.
43) What is a flux? Why is it used?
A flux is a “material used to prevent, dissolve, or facilitate removal of oxides and other undesirable surface
substances”.
prevents oxidation of molten metal
44) What are the defects that will result if flux is not used in welding?
a) Reduce the Strength of the joint.
b) Oxidation of molten metal will take place.
45) Define base metal.
The metal to be joined or cut is termed as the base metal.
46) What is the use of chipping hammer?
A chipping hammer is used for removing the slag formed on the weld bead
47) What is the use of electrode holder?
It is used to hold the electrode during welding
48) What is the use of wire brush?
The wire brush usually made up of steel wire is used for cleaning the work piece before and after welding.
49) What is the use of tong?
A tong is used for holding the work piece during/after welding
50) What is the use of ground clamp?
Ground clamp is connected to the end of the ‘ground cable’. Ground clamp is used to connect work table.
Ground cable forms one pole of A.C.
51) What is the use of goggles?
Goggles are used to protect the eyes of the welder from the rays of the arc and flying particles of hot metal.
52) What is the use of hand shields?
Hand shields and helmet type shields are used to protect the eyes and also the face of the welder
53) What is the use of c-clamp?
The C-Clamp shown in fig is used for holding the job firmly on the work table during welding.
54) Mention the welding flame conditions in gas welding? .Or. Name the types oxy-acetylene flames
a) Neutral flame b) oxidizing flame
c) Carburizing flame
55) Define neutral flame.

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Neutral flame (Oxygen and Acetylene are mixed in equal proportions)
A neutral flame is produced when approximately equal volumes of oxygen and acetylene are burnt at the torch
tip (I has a balance of fuel gas and oxygen). The flame has a nicely defined inner whitish cone surrounded by
sharp blue flame. The temperature of the neutral flame is around 32000C. Used for welding steels, aluminium,
copper and cast iron etc and can also be used for metal cutting
56) Define oxidizing flame.
Oxidizing flame (Excess of Oxygen)
If more oxygen is added to the Neutral flame, the cone becomes darker and more pointed, while the envelope
becomes shorter and fiercer is called Oxidizing flame. Has the highest temperature about 34000C.Used for
welding brass and brazing operation
57) Define reducing flame or carburizing flame.
Carburizing flame (Excess of Acetylene):-
If the volume of oxygen supplied to the Neutral flame is reduced, the resulting flame will be a Carburizing or
reducing flame i.e., rich in acetylene. A reducing flame can be recognized acetylene feather that exists
between the inner cone and the outer envelope. Has the highest temperature about 30000C .The outer flame
envelope is longer than that of the neutral flame and is usually much brighter in colour . This type of flame is
used for welding non- ferrous metals.
58) Differentiate between welding and soldering and brazing.
Welding is used for joining similar metals only
Soldering and brazing is used for joining similar or dissimilar metals.
In welding filler Material used is made of same material as that of the base metal (work piece).
In soldering and brazing filler material used is
Not the same as that of the base metal.
Strength of welding joint is stronger than base metal.
(Strength of welding joint is more compared to soldering and brazing).
Strength of brazing joint is more compared to soldering joint.
In case of welding base metal is heated above their melting temperature (High temperature process).
In case of soldering base metals are not melted (low temperature process).

In case of brazing base metals are not melted but broadly heated to a suitable temperature.
Surface finish of welding joints not good (It requires finishing operations like grinding, filing etc)
Surface finish of soldering and brazing joints is good.
59) Define soldering? Name soldering material.
Soldering is a method of joining similar or dissimilar metals by means of filler metal whose melting
temperature is below 450 0C. The filler metal usually called ‘solder’ is an alloy of tin and lead in various
proportions.
Soldering is commonly used for joining circuits in electronic components. In sheet metal work and in sealing
of metal container.
60) Define brazing? Name brazing material
Brazing is a method of joining similar or dissimilar metals by means of a filler metal whose melting
temperature is above 450 0C, but below the melting point of the base metal.
The filler metal called ‘spelter’ is a non –ferrous metal or alloy. Copper and copper alloys
Silver and silver alloys and aluminum alloys are the most commonly used filler metals for brazing.
This process is used in fastening of pipe fittings, tanks, radiators, heat exchanger.
61) Define weld bead?
It is the metal added during a single pass of welding. The bead appears as a separate material from the base
metal.
62) What is fillet weld?
The metal fused into the corner of a joint made of two pieces placed approximately at 90 degrees to each
other is termed as fillet weld.
63) What is SWG?
SWG-Standard wire gauge.
64) What is an electric arc and how is this arc struck? (Or) What is the working principle of Arc welding?
The source of heat for arc welding process is an ‘electric arc ‘.The arc is produced by striking the electrode on
the work piece. The electrode is momentarily separated from the work piece by a small gap such that the arc is
still maintained between the work piece and the electrode .The electrical energy is thus converted into heat
energy. The high heat at the tip of the electrode is sufficient to melt the work piece. The tip of the electrode
melts and combines with the molten metal of the work piece there by forming a homogeneous joint.

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65) Is gas welding slower than electric arc welding?
Yes, Gas welding is Slow process compared to Arc welding.
66) The movement of welding rod for better bead is known as –
Weavi
67) What is Autogeneous Welding & Heterogeneous Welding?
Autogeneous Welding:-It is the Process of Joining two similar metal pieces with or Without Filler material.
Heterogeneous Welding”:- It is the Process of Joining two dissimilar metal pieces with Filler material ex.
Friction welding.
68) What is the thickness of Sheet used in Sheet metal Work?
Up to 3 mm Thickness.
69) In arc Welding, Electric arc is produced between the work piece and the Electrode by ----------?
Contact Resistance.
70) How you can stop the arc between electrode work pieces
Increase the gap between work piece and Electrode.(More than 3mm)
71) What is resistance welding?
Where heat to form the weld is generated by the resistance of the welding current through the work pieces.
72) Mention some of the resistance welding methods?
Ex: - Resistance Spot Welding (RSW), Resistance Seam Welding (RSEW), and Projection Welding (PW)
are commonly used resistance welding processes.
73) Name some of welding defects?
a) Porosity b) undercut c) spatter d) In complete Fusion e) Under fill f) Incomplete Penetration and Excessive
Penetration.
74) Define Edge preparation?
The contour prepared on the edge of a joint member for welding.
75) Define weld Metal?
The Portion of the Base metal that has been melted during welding.
76) Define deposited Metal?
Filler material that has been added during a welding operation.

77) The oxygen cylinder is usually painted with – colour.

Black.
78) The Acetylene cylinder is usually painted with – colour.
Maroon.
79) Define blow holes?
A weld cavity caused by the Trapping of gases released by the metal when cooling.
80) Why edge preparation required before welding
To get proper welding Joint (sound Welding joint).

4.VIVA QUESTION WITH ANSWER

1. What is meant by fitting? Name the commonly used material for preparing fitting model.
Assembling or matching two or more parts & removing extra material by different operations
to secure necessary fit is called Fitting.
Mild steel is the common material used in fitting shop.
2. What is a Bench Vice? Name some of the other vices?
Bench Vice is a holding device between two jaws. This holds Work piece firmly & helps in
carrying out different operations. Leg vice, Pipe vice, Machine vice, Carpenters Vice.
3. Explain the working of vice?
Rotary motion of the handle is converted into linear motion of the screw thread.
Subsequently screw moves one of the Jaw block linearly.
4. Mention different operations in fitting work?
Marking, Filing, Sawing, Chipping, Scribing, Punching, Tapping, Drilling, Grinding.
5. What is the difference between bench work and fitting?
Production of a job on Bench is called Bench work. Assembling or matching of parts to get
necessary fit is called fitting.
6. What are jaw plates and why are they necessary in a bench vice?
Jaw plates are made up of mild steel which are fitted on to jaws of vice with the help of set
screws. It gives grip to clamp the material.
7. What is the difference between a mallet and a hammer?

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Mallet & Hammer are Striking devices. Mallet is made of Wood or Nylon as soft face, while
Hammers is made of forged steel as hard face, with wooden handle.
8. Name the three types of peen hammers and name the material from which they are made.
Ball Peen, Cross Peen, and Straight Peen Hammers. They are made up of Forged steel.
9. What is the importance of cutting angle in chisels?
Cutting angle denotes the amount of material to be chipped. Lesser the Cutting angle higher
the chipping of material.
10. Name the different types of chisels and their functions.
Flat Chisel, Cross-cut Chisel, Half-Round Chisel, Diamond-Point Chisel,
Flat Chisel – Used extensively in work shop for all general purpose work.
Cross Cut Chisel – Used to cut grooves in large surfaces & Used previous to Flat chisel.
Half Round Chisel – Used to cut oil grooves in Bearing.
Diamond Point Chisel - Used to cut Vee grooves & cleaning corners.
11. What do you understand by the term cold chisel?
Cold is a term used for chisels used in workshop which have cutting edges & different from
The one which is used in smith shops.
12. With the help of a diagram differentiate between: a] Rake angle & Clearance angle b]
Forging angle cutting angle

13. Differentiate between Chipping and Filing.Chipping means removing unwanted Material by
chisel. Filing is shedding unwanted material in the form of fine powder or chips using a file.
14. What is a File? Name the types of Files and Filing? Classify Files according to their cut?
A File is a Hardened piece of High Carbon steel. It is used to shed the unwanted Material by
filing. Flat File, Triangle File, Half Round File, Round File, Square File. Straight Filing, Cross
Filing, Draw Filing is the three different ways of filing.Single cut & Double cut.
15. With the help of a diagram illustrate different parts of a File.

16. Name the material out of which the Hacksaws are made.
Hack saws are made up of hollow mild steel sheets or solid Mild steel flats;
17. What are the different parts of a Hacksaw?
Frame, Handle, Prongs, Tightening Screw, & Nut.
18. Mention the specification of Hacksaw blades & what is the importance of pitch in a Hacksaw
blade?
Hacksaw Blades are made of Carbon Steel or High Speed Steel or Tool Steel. Length Varies
from 250 to 300 mm with a width of 12 to 16 mm having a thickness of about 0.65 to 0.8mm.
Pitch denotes the three grades of blade, 1) Coarse 2) Rough 3) Smooth
If the distance between the pitch is less & if it has 10 to 12 it is coarse grade, it is used to cut
hard materials.
19. Name some marking instruments and also some instruments for checking the accuracy of
then finished components.

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Scribers, Try Square, Dot punch, steel rule, are marking Instruments.Vernier height gauge,
Micrometer, Vernier Calipers are measuring Instruments, Inside Calipers, Outside Calipers,
Combination Square, Depth gauge etc
20. Is measuring an important part of fitting?
Measuring Instruments, method of marking and inspecting the finished components using
various instruments are essential for right type of fitting the accuracy the method of marking
the right tools and the correct method of working leads to precision and care all along makes
the job accurately.
21. Name the devices used for holding components for marking.
Surface plate, V-Block, Angle plate, Adjustable Scribing Block.
22. What is welding? Give its classifications.
Welding is Joining two similar metals by heat & with or with out application of pressure.
23. What is an electrode?
Electrode is a filling material. Cored wire Electrodes are available from 1.6 to 10 mm in
diameter 1.6 to 6.3 diameter electrodes are used for welding steel thickness of 1 to 25mm.
24. What are the functions of the flux [electrode coating]?
Flux acts a deoxidizing agent & helps in free flow of molten core material.
25. What is an electric arc and how is this arc struck? What is the temperature of the electric
arc?
When two Poles of an Electric circuit is brought together & Separated by a small distance,
current starts to flow in ionized path as Arc. Temperature varies between 6,000 to 7,000°c.
26. What is an AC Welding Transformer?
An AC main transformer consists of oil cooled or air cooled mains transformer. The voltage
is step down from 230 volts to about 85 volts by using a secondary coil having a small
number of turns than the primary, welding current is altered by a selector switch. This
switch taps the chock coil at different points to vary the current corresponding to the size of
component and type of electrode.
27. What is D.C current welding Machine?
D.C Current is obtained from a D.C generator that is by conversion of AC supply by a
rectifier. D.C is used in low current welding it gives a smoother arc. It could be used for
welding non ferrous metals.
28. Mention the advantages and disadvantages of Arc welding?
Advantages – the quality of weld obtained is of high grade, does not hamper the shape of
material when compare to other methods of welding,
Disadvantages - it requires higher amount of safety since it emits UV rays, only skilled
operators can carry out the welding.
29. What are the three different types of metal transfer in arc welding?
Dip transfer, Free Drop Transfer, Spray Transfer.
30. What are the advantages of using coated electrodes?
It protects the molten material from Oxidation, protects the core from rapid molting during
Welding Process.
31. Differentiate between lightly coated and heavily coated electrodes and their advantages.
Lightly Coated Electrodes may only be used for welding non essential Jobs, the weld
produced
have poor Mechanical properties due to lack of protection of molten material, where as
highly coated electrodes serves a superior when compared, Inducing alloy to material,
protect from oxidation, formation of slag to prevent material from rapid cooling.
32. Mention some of the other arc welding processes.
TIG (Tungsten inert Gas Welding), MIG (Molten Inert Gas Welding) Metal Arc, Carbon Arc
Welding.
33. Name some of the welding joints.
Butt Joint, Lap Joint, Corner Joint, Angular Joint.
34. What is Resistance welding?
Heating Material unto Plasticity State & applying Mechanical pressure to complete the Weld.
35. Differentiate between Brazing, Soldering and Welding.
Soldering – Temporary Fastening done by heating fusible alloys called as filler applied in
Molten condition state using flux.
Brazing – Semi permanent Joint done by Melting Harder Filler material called as Smelter.
Welding – Permanent Joint done by different welding methods.
36. Differentiate between Arc and Resistance welding.

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Arc Welding – when two poles of electrical circuit brought together and separated by a small
gap current starts to flow in ionized path or arc, heating the material and filler material fills
the gap between the two materials.
Resistance Welding – the metals to be welded is heated unto plasticity state and mechanical
pressure is applied to complete the weld. No filler rod is used small parts can be welded
easily
than in any other methods.
37. What is Thermite welding?
It is also called fusion welding process In which Super heated thermit Steel is used to fill the
gap between the parts to be welded.
38. What is bronze welding?
Intermediate Between Welding & Brazing low melting alloy is introduced between two pieces
to be weld & it is done adhesion.
39. Mention some of the Resistance welding methods.
Spot Welding, Seam Welding, Flash Welding.
40. Name the gases commonly used in Gas welding.
Oxygen & Acetylene gases.
41. Mention the welding flame conditions in gas welding.
Oxidizing, Neutral & Carburizing.
42. Mention some of the defects in welding.
Cracks, Blow Holes, Poor Fusion, and Slag Inclusions are some of the common welding
defects.
43. Mention some of the solid welding methods.
Friction, Ultrasonic, Diffusion, Explosive are solid welding methods.
44. What do you understand by Electron welding?
Electron Beam Weld utilizes the energy from a fast moving beam of electron focused on
work piece Electrons strike the metal which gives up Kinetic energy almost completely into
heat.
45. What is development of surfaces?
A development is a flat surface pattern. The pattern can be cut out and bent or rolled to
form the article.
46. What are different types developments?
a. Parallel line Development – Is the procedure used to develop patterns for prisms,
cylinders, elbows etc.
b.Radial line Developments – Is the procedure used to develop patterns for tapering objects
such as pyramids and cones.
c. Triangulation developments – Is the procedure used to develop patterns for developing
oblique pyramids, oblique cones and transition pieces. Complex items that cannot be
developed by other processes can be developed by triangulation development.
47. What is sheet metal?
Sheet metal refers to thin sheet of metal of thickness varying from 16 gauges to 32 gauges
(1.626 t0 0.2743mm)
48. Name the major uses of sheet metal.
Pipes, Guards, Funnels, Boxes, Covers & used extensively in Automobile Sector, AC Ducts.
49. How do you measure the thickness of sheet metal?
Standard Wire Gauge is used to measure thickness of sheet metal.
50. Name some of the metals used in sheet metal operations.
G.I Sheets (Galvanized iron), Black Iron, Copper, Stainless Steel, Aluminums.
51. What are Stakes?
Stakes are Metal Blocks uses as forming tools.
52. Discuss Sheet metal operations.
Bending, Shearing, Drawing & Squeezing.
53. Differentiate between Tin sheet and Galvanized sheet.
Tin Sheet – Iron sheet coated with tin.
G.I Sheet – Iron sheet coated with zinc in order to protect it from rust.
54. Differentiate between Forming and Bending.
Forming – Complete Items are Parts are shaped to a desired pattern.
Bending – when force is applied to a localized area (for ex - allowance)
55. Differentiate between Shearing and Cutting-off.
Shearing – general name for sheet metal cutting

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Cutting Off – Severing a piece from a strip with a cut along a single line.
56. What do you understand by Tab in sheet metal working?
It is an edge or Border made by a folding.
57. What is meant by gauge thickness of a sheet?
Actual thickness of sheet metal which is read in “Standard Wire Gauge” from Gauge No.
0000 to 50 i.e., 10.160 mm to .0254 mm respectively.
58. Differentiate between: A] Press work and Forging B] Punching and piercing
Press Work – Refers to a bend done by manual operation.
Forging – Shaping of Material from an external agency like Hammer, Power Hammer, etc
Punching – Operation of producing holes on a sheet metal by a punch and die.
Piercing – Process of producing holes of desired shape by a tool.
59. Can a sheet metal be welded? If so which welding process could be used?
Only Stain less Steel Sheets Category can be welded by using gas welding and special
purpose methods.
60. Can sheet metal be plastically coated?
Yes Sheet Metal Can is plastically coated.
61. Discuss about the basic tools used in sheet metal work.
Mallet, Snip (straight, radious), Swage Block, Stakes, Dot Punch, Trammel, Length Square,
Pliers, Groover, Rivet Sets, Scriber, Measuring Tools, Standard Wire Gauge, Chisel,
Soldering
gun, Spring Divider, Wing Divider,
62. Differentiate between hard and soft solder.
Hard Solder – It Employs Solders which Melt at Higher temperatures and are stronger then
those used in soft soldering. Silver alloyed with tin is used. Temperature varies from 600 to
900°c
63. What is a Flux?
Flux is a deoxidizing agent and also dissolves the oxide that settles down on the metal
surface
during the heating process. It also acts as cleansing agent.
64. Name the different types of Fluxes.
1) Zinc Chloride, 2) Rosin. Zinc Chloride is the most commonly used flux since it has the
quality of cleaning.
65. What is a Soldering iron? Name its various parts.
Soldering Iron is bit with electrical Connection when heated it melts the solders and it
deposits the solder where the joint is required.1) Bit 2) wooden Handle 3) Insulated Wire
66. Name the different tools used in carpentry.
Mallet, Claw Hammer, Bevel Edge Chisel, Mortise Chisel, Paring Chisel, Firmer Chisel,
Wheel
Brace, Ratchet Brace, Rip Saw, Back or Tennon Saw, Dove-tail saw, Marking Gauge, C-
Clamps, Carpenters Vice, Augur, Jack plane, Wooden plane, Gouge.
67. Name the different joints in carpentry.
Lap Joint, Mitre Faced Joint, Dove Tail Joint, Mortise Tennon Joint. Bridle Joint.
68. Name the different types of wood used by carpentry.
Teak, Sal, Honne, Mathi, Sandal, Babul, Mahogany, Mango.
69.Name the various marking instruments used by carpenter.
Marking Gauge, Marked try Square, Steel Tape, Miters Square, Bevel Square, Four fold rule.
70. What is meant by steel? Name the different forms of steel? What is the raw material used in
Fitting & Welding Shop?
Steel is an alloy of Carbon & Iron. Steel is classified into 4 groups according to its carbon
content.
1) Low carbon Steel or Mild Steel – 0.05% to 0.30% of Carbon
2) Medium Carbon Steel – 0.03% to 0.06% Carbon
3) High Carbon Steel – 0.06% to 1.50%Carbon
4) Tool Steel 0.90% to 1.50% Carbon
Mild steel is the raw material used in Fitting & Welding Shops.
71. What is meant by High Speed Steel?
It contains 18% Tungsten, 4%Chromium, & 1%Vanadium & 0.75% Carbon. It withstands
high temperature (600 to 620°c) with out destroying their cutting ability.
72. Name the few tools used in workshop with the material they have been made?
Marking Tools: Cutting Tools

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Surface plate – Grey cast iron or Granite Files – High carbon steel
Scriber – Hardened steel Chisels – High carbon Steel
Dot punch – Hardened steel Scriber – Hardened steel
Try Square – Hardened Steel Hack saw Blades – High Speed Steel
V – Block – Hardened Steel Dot punch – Hardened steel
Angle Plate – Grey Cast Iron Scraper – Spring Steel
Holding & Striking Tools
Bench Vice – Body (Cast iron) Fixed jaw & Movable Jaw (Cast steel)
Handle, Square Threaded Screw, Nut – Mild steel.
Hammers - Forged Steel
Anvil – Body (Mild Steel) Upper Flat Surface (Tool Steel)
Mallet – Soft Faces such as Wood or Teflon or Rubber
Reference Books:
1. “Elements of Workshop”, S.K.H. Choudhry, A.K.H. Choudry, Nirjhar Roy 11thedition, 2001
Media Technology-Volume I Promoters & Publishers Mumbai.
2. “Workshop Technology”, R.S. Khurmi I, J.K. Guptha 2001 S. Chand New Delhi.
3. Workshop Practice Manual by Prof Vee Ess, MSRIT, Bangalore
Note: Answer briefly with “neat sketches” as applicable.

READ THE FOLLOWING INSTRUCTIONS BEFORE STARTING THE PRACTICE:

1. Use suitable tools properly,

2. Use appropriate nomenclature of the tools,
3. Tools & materials are to be properly handled and are to be kept safely,
4. Sharp tools & objects are to be delicately handled, never to be hurled.
5. Don’t damage/break any tool or equipment.
6. Any injury immediately inform the faculty incharge
7. Should maintain proper Housekeeping

FITTING:

1. Fitting is an exercise for precise marking and accurate working

2. This involves attentive, accurate, precise & clear marking
3. Cutting by hacksaw – is by Vertical & Filing by Files – Generally Horizontal & Chiseling by
Chisel – at an Angle on the Anvil
4. Mild Steel plates are generally used for fitting jobs
5. Mark carefully for the given dimensions – “Finishing line” by dot punch & “Cutting line”
by a thin line 1.5mm away from the finishing line
6. The tools are heavy, so requires careful handling. It is an exercise for the eyes, mind,
hand & body
7. Requires synchronization of eyes, hand, body and a concentrated continuous effort to
shape the metal to size.
8. The effort should be useful, purposeful and worthwhile.
9. Right tools and proper handling will bring results.
10. Work the first piece to near accuracy, don’t finish.
11. Work on the second piece to near accuracy, don’t finish.
12. Try to fit the pieces roughly.
13. Make suitable corrections by filing wherever necessary.
14. Take care, work very carefully and make a most accurate precise fitting of both the
pieces.
15. The accurate fitting will be a reflection of your skill, workmanship, concentration, and
effort to achieve perfection.
16. The results will be remarkable. Perfect fitting – will fetch more marks.

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SHEET METAL WORK:

1. Sheet metal work requires a systematic approach.

2. Study the shape of the model. Note the dimensions - Length, Width, height, Number of
sides, etc.
3. Draw the orthogonal views of the given object/model on a sheet of paper to Full scale
[1:1].
4. Then draw the development of the model to the actual size, as per the calculation.
5. Provide suitable bending allowance after marking each dimension and finally provision
for soldering.
6. Cut out the development from the paper. Fold it suitably and measure for the given
dimension, etc
7. Paste the cut-out development on the sheet metal.
8. Precisely maintain the shape and size by Folding and bending with proper tools &
equipments.
9. Solder neatly for a good and strong joint/s.

WELDING:

1. The surface of the workpiece should be free from oil, grease, dirt, etc,
2. Before welding set the ‘Welding Transformer’s Voltage & Current’ with respect to the
work-piece material and type of electrode.
3. Check for the proper insulation of the cables, earthing clamp & other connections.
4. An electric arc produced is an intense light. This light contains infra-red & ultra-violet
rays. These rays are very harmful to eyes. Face shield is used to protect the eyes. The
face shield uses a special glass. This glass is darker than that used for gas welding.
5. General purpose clear goggles are to be worn when chipping-off the slag & while
cleaning with wire brush after weld.
6. Leater Gloves, Shoes & Apron are to be used while doing the Arc Welding to protect the
body from the sparks and electric shocks.
7. Use tongs for holding hot objects. Never touch with bear hands.

CARPENTRY:

1. Mark properly, correctly and accurately.

2. Use proper tools for right operations
3. First make an undersize component i.e., cut within the marked size roughly. This is to
take care of commissions and omissions etc, even marking lines have thickness.
4. Slowly, carefully and confidently, work for the correct shape and size.
5. Prepare the other component in the same way – roughly.
6. Slowly work to bring it to shape and size.
7. Correct the fitting suitably – so that both the components make an accurate, perfect
and right fitting.
8. Finish – and present it for evaluation.

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