Workshop Technology
Module Outline
Introduction and Machine Safety
Basic Workshop machines and Tools
Introduction to Metrology
Introduction to Welding processes
Casting Processes
Introduction to Forging Processes
Operations of Lathe machine
Introduction to technical drawings
What is a workshop?
Defined as a workspace ( a room or a building) which consist of space,
Machines and tools to carry out manufacturing processes of a product or
repairing of a Product.
There are different types of workshops defined based on the available
machines and the primary function of the workshop.
• Machine shops
• Fitting shops
• Welding shops
• Motor vehicle shops, metal shops, foundry shops and forging shops.
Manufacturing Processes
Manufacturing process is a part of a
production process which is directly
concerned with the change of form
or dimensions of the part produced.
Raw materials are converted to
finished or semi-finished product
according to the dimension and
required properties specified by the
product design.
Classification of Manufacturing processes
Manufacturing processes can be categorized into following six major
categories
1. Primary Shaping Processes
2. Secondary shaping or machining processes
3. Metal forming processes
4. Joining processes
5. Surface finishing processes
6. Processes effecting change in properties
Primary Shaping Processes
Convert raw materials or scraps to basic primary shaped and sized
products
The finished product may require further working to finish component to
the desired shape and size because the surface finish is rough.
Typical examples of the products that are produced by these process are
machine beds, automobile engines, carburetors, flywheels etc.
Ex: Machine beds – Casting or Forging
Primary Shaping Processes Contd.
Casting
Powder metallurgy
Bending
Forging
Figure 01 : Sand casting
Figure 02 : Closed die steel forging
Secondary shaping or machining processes
The process of removing the undesired or unwanted material from the
workpiece or job or component to produce a required shape using a cutting
tool is known as machining.
This can be done by a manual process or by using a machine called machine
tool(lathe, milling machine, drilling, shaper, planner, slotter).
The secondary processes require the use of one or more machine tools,
various single or multi-point cutting tools (cutters), job holding devices,
marking and measuring instruments, testing devices and gauges etc.
Classification of Machine Tools
Conventional or traditional machine tools like Lathes, Milling machines, etc.
are used more widely for faster material removal by shearing or brittle
fracturing.
Non-conventional or non-traditional machine tools: like EDM, ECM, USM,
etc. which remove material from exotic materials slowly by electro-physical,
electro-chemical processes.
Modern numerical and computer-controlled machine tools: Like CNC
lathe, CNC milling
Generally used Manual Machine tools
Figure 03 : Universal Milling Machine Figure 04 : Lathe Machine
Generally used Manual Machine tools
Figure 05 : Shaping Machine Figure 06 : CNC Lathe Machine
Different types of Machining operations
Turning Shaping
Threading Slotting
Broaching
Knurling
Grinding
Milling
Gear cutting
Drilling Thread cutting
Boring Figure 07 : Machining operations
Metal forming processes
In metal forming processes raw material is permanently deformed to get
the desired shape by applying suitable force, pressure or stresses, like
compression, tension and shear or their combination.
Metal forming can be categorized in to two main categories
Hot Working processes
In hot working processes raw material (billet) is preheated before starting the
process
Cold Working Processes
Metal forming processes contd.
Hot working processes Cold working processes
Forging Cold forging
Rolling Cold rolling
Hot spinning Cold heading
Extrusion Cold drawing
Hot drawing Wire drawing
Hot spinning
Joining Processes
The process of putting the parts together to form the product, which
performs the desired function, is called assembly
Most of the products cannot be manufactured as single unit they are
manufactured as different components using one or more of the above
manufacturing processes, and these components are assembled to get the
desired product.
The joining processes are carried out by fusing, pressing, rubbing, riveting,
screwing or any other means of assembling.
Joining Processes contd.
Welding (plastic or fusion)
Brazing
Soldering
Riveting
Screwing
Press fitting
Nut and bolt joints
Figure 08 : Basic arc welding
Joining Processes contd.
Figure 09 : Pop riveting process Figure 10 : Screwing process
Surface Finishing Processes
Surface finishing processes are utilized
for imparting intended surface finish on
the surface of a job. By imparting a
surface finishing process, dimension of
part is not changed functionally.
Example : Polishing , Grinding, Powder
coating
Figure 11 : Powder Coating process
What Is Workshop Practice ?
Workshop practice gives the basic working knowledge required to produce
various engineering products.
It explains the construction, function, use and application of different
working tools, equipment, machines as well as the technique of
manufacturing a product from its raw material
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