THIS NOTE IS EXCLUSIVELY MEANT FOR STUDENTS OF GB PANT ENGINEERING COLLEGE NEW

DELHI AND NOT TO BE SHARED WITH OTHERS UNDER ANY CIRCUMSTANCES.

Guidelines:

Write the report on A-4 size paper (one or both side ruled ) in your own hand writing and
bound it by spiraling after preliminary checking .
Draw sketches of all the instruments, marking and measuring devices, cutting tools, holding
devices , processing machines/ equipments etc used by you during the training at appropriate
place of its description in the report.
Sketches should be neatly drawn free hand or by use of drawing instruments ( no photocopy
allowed ) with all their parts duly labeled . For sketches you may refer any textbook,
educational chart displayed in the workshop , internet etc.
As regard reporting of jobs performed, write in your own language step by step as directed
inside.
Draw the sketches with dimension / shape arrived, starting from basic raw material to each
stages upto finishing the job,.
Aim, result , Precautions etc. should be as per requirement for the job/ operations.
For clarification, if needed, you may consult Workshop Supdt.
 Report on practical training on Manufacturing processes

Name:
Enrolment/ Roll No.:
Batch No.: 1/2/3/4
Programme: Computer Science Engineering/ Mechanical & Automation
Engineering/ Electronics & Communication Engineering
Semester: First Semester
Session: 2010-11

GB Pant Engineering College

Okhla Industrial Estate, Phase-III,
New Delhi-110020.
 CONTENT
TOPICS PAGE NO
Introduction about Mechanical Workshop of the College
General Safe practices in workshop activities
Declaration
Brief description of the instruments and measuring devices used in engineering workshop
Chapter-I Carpentry Work
Introduction
Safe practices for carpentry work
Measuring instruments & allied equipments used in carpentry work
Holding and cutting Tools used in carpentry work
Jobs performed
Job No.-1 Mitre( Corner) joint
Job No.-2 Halved Cross lap joint
Job No.-3 Dovetail/ Mortise & Tenon joint
Chapter-II Sheet Metal Work
Introduction
Safe practices for Sheet Metal work
Measuring instruments & allied equipments used in Sheet Metal work
Holding and cutting tools used in sheet metal work
Jobs performed
Job No.-1 Different types of joints ( Single seam, Double seam, Flanged seam, wire beading ,
riveting etc. )
Job No.-2 One face open rectangular box
Job No.-3 Funnel/ truncated cone
Chapter-III Fitting and Bench Work
Introduction
Safe practices for Fitting and Bench work
Measuring instruments & allied equipments used in fitting and Bench work
Holding and cutting Tools used in Fitting and Bench work
Jobs performed
Job No.-1- Matching Plates fitting
Job No.-2 – M10 x1.5 Bolt
Job No.-3 – M10x1.5 Hexagonal nut
Chapter-IV –Welding work
Introduction
Safe practices for Welding work
Measuring instruments & allied equipments used in Welding work
Holding Tools and processing equipments used in Welding work
Jobs performed
Job No. -1 Butt joint by Metal Arc welding
Job No.-2 Corner joint by Metal Arc welding
Job No.-3 T joint by Metal Arc welding
Job No.-4 Demo. of stud joint and lap joint by MIG process
Chapter-V Foundry Work
Introduction
Safe practices for Foundry work
Measuring instruments & allied equipments used in Foundry work
Tools and processing equipments used in foundry work
Jobs performed
Job No.-1 Preparation of green sand mould out of single piece pattern
Chapter-VI Black Smithy Work
Introduction
Safe practices for Black Smithy work
Measuring instruments & allied equipments used in Black Smithy work
Holding and processing tools used in Black smithy work
Jobs performed
Job No.-1 Manufacture of hexagonal bolt blank (Demonstration by Instructor)
Introduction about Mechanical Workshop of the College

(WRITE TWO PAGES NOTE ABOUT OUR WORKSHOP AS OBSERVED BY YOU )

HIGHLIGHT ON:
Location of workshop in the college and its approximate area
(Workshop I & II )
Organizational staff in the workshop
Different sections
Facilities available in various sections
Time allocated for work in different sections
Guidance obtained from instructors
Educational charts displayed and their usefulness
General safety arrangement in the workshop
Suggestion for improvement for better learning, if any
Any other point as felt worthy to mention.
Safe practices in Workshop activities

Do not use loose garments and chappals while working in the workshop. Clip your hairs and
other loose parts of your clothing , if any properly tied.
USE APRON WHILE DOING THE WORK. It gives cleanliness as well as safety in work.
Always follow the instructions of the workshop instructors. Please feel free to contact them as
and when required.
Do not loiter in the workshop without any purpose. Be attentive in your work and allow others
to work . unnecessarily do not keep others engaged in talk or discussion while he is engaged in
work.
The heavy work should not be lifted by hands.
Keep all the tools in proper place. Keep your work place neat and tidy. Be systematic in your
work. Hapazard way of working may be a cause of accident.
Do not use any tool for hammering purpose, hammering should be done with proper hammer
only.
Do not light match stick or lighter in a place where inflammable articles are lying.
SMOKING IS STRICTLY PROHIBITED IN THE WORKSHOP.
Do not turn on any switch in the workshop without being sure of its application.
Before staring a machine it should be cleaned and oiled properly. Before operating the
machines, the work and the tools should be clamped securely. The machines should be
operated only by a skilled workman. The machines should not be left in running position while
going for any urgent call.
Keep safe distance from the moving parts/ machines. Do not lean towards the machine in
running condition.
In case of fire, accident or earth quake like incident, please do not be panicky and run here and
there. Try to position yourself in safer place as far as possible. Help the authority in reducing
the damage caused due to such calamity, as far as practicable.
Fire due to electricity should be handled with proper fire extinguisher and do not use water
directly to put off the fire.
During electrical shock etc ., switch off the mains as quickly as possible.
 Declaration
I am aware of the safe practices for working in the workshop in general and special attention
needed in specific areas of workshop activities. This has been explained to me by the Workshop
In charge and I commit to abide by the same in letter and spirit. Further, I declare that I will not
indulge in any activity in the workshop which may harm my co- workers ( Students working
with me ) and will also maintain cleanliness and discipline in the workshop .

( Signature )
BRIEF DESCRIPTION OF THE INSTRUMENTS AND MEASURING DEVICES USED IN ENGINEERING
WORKSHOP

Adjustable Bevel
It is an instrument used for checking , measuring and transferring angles and laying out of work.
The actual angle is obtained with the help of other angle measuring instrument as it is not
having direct reading arrangement in the instrument.
Angle plate
The angle plate which is made of grey cast iron has two plane surfaces at right angles to each
other. This is used in conjunction with surface plate for supporting work in the perpendicular
position.. It has various slots in it to enable the work to be held firmly by bolts and clamps.
Bevel square
The bevel square is similar to the try square but has blade that may be swiveled to any angle
from 0 to 180 degree. It can be adjusted by releasing with a turn screw of suitable size in a
machine screw running in a slot in the blade.
Calipers
These are used to measure indirectly or transfer of linear dimension from job to measuring
instrument and vice versa. It may be out side caliper or inside caliper. The outside caliper has
the shaped in such a way that can be conveniently placed on a the outside diameter of a
circular job whereas the legs of inside calipers are bent outward to get into the inside surface
of circular hole .
Circumference rule
It is used for measuring , laying out or as a straight edge. In addition to this, the rule
also shows the circumference or circle.The top edge of the rule is graduated in centimeter for
regular measuring and the lower half Is graduated to indicate circumference. That’s why it is
called Circumference Rule.
Combination set
It is having all the essential features of try square , bevel protractor, rule and scriber. It consists
of four parts viz., square head, protractor head , centre square head and a blade or rule on
which the other three parts can slide. The protractor and square heads are usually provided
with spirit levels
Combination square:
It is similar to the combination set used in bench work . It is a combination of a square , 45
degree bevel , set square , rule , straight edge and centre finder.
Divider
This tool is used for transferring dimensions, marking out curves and circles and for doing
general lay out works. The dividers are made with each leg tapered to a needle point. The
dividers may be of firm joint type or spring type. Spring type dividers are used for smaller and
more accurate works. The legs of the spring dividers are adjusted by turning the knurled nut.
The adjustment of the wing divider by loosening the screw on the wing.
Depth Gauge
It is used for measuring the depth of blind holes , grooves , and height of shoulders in holes
etc.
Micrometer
Micrometers are used to measure dimensions by the principle of making axial movement of the
screw by rotation of fixed nut. Micrometers are available for checking outside, inside , depth as
well as screw thread parameters. Micrometers are generally available in sizes of steps of 25
mm.
Outside micrometer
It is mainly used to measure the outside diameter of a job or length of a small part. It can
measure the dimension to an accuracy of 0.01 mm.
Inside Micrometer
The inside micrometer is used for measuring large internal diameters ( over 50 mm ) to an
accuracy of 0.01 mm. It works on the same principle as that of outside micrometer.
Screw thread micrometer
It is designed to measure the pitch of screw threads to an accuracy of 0.01 mm . In
construction , the screw thread micrometer is similar to outside micrometer with the following
differences:
The moveable spindle is pointed.
The end of the anvil is of the same form as the screw thread to be measured.
The different pairs of interchangeable vee-anvils and spindle points are used with this
micrometer.
Depth Gauge Micrometer
The depth gauge micrometer ( also known as depth micrometer ) is used to measure the depth
of holes , slots and recessed areas to an accuracy of 0.01 mm.
Gauges
The gauges are fixed dimension instruments. These are generally used to check the particular
dimensions of a work piece within their tolerance. The instruments differ from measuring
instruments because they have no graduations to measure various lengths and angles and
normally no adjustment can be made in their uses.
Ring gauges
The ring gauges are used to check the diameter of shafts or studs . These are cylindrical in
shape and has a hole of the exact size specified for the part to be checked. . The limit ring
gauges with ‘ Go’ and ‘Not Go’ ends are also available.
Plug Gauges
The plug gauges are used to test the accuracy of holes. A standard plug gauge has its diameter
finished to the standard size. It is used in general engineering workshop. , tool rooms etc. The
limit plug gauges are used where large quantities are to be produced and the variations in the
standard size is allowed. The single ended limit plug gauge has separate ‘Go’ and ‘ Not Go’
members , the progressive limit plug gauges has ‘Go’ and ‘Not Go’ members on the same side
of a handle and the double ended limit plug gauge has ‘Go’ member at one end and ‘Not Go’
member on the other end of the handle.
Snap Gauges
The snap gauges are used for checking the external dimensions. They are made with the
openings to fit over a part to be checked. The part may be cylindrical or flat.
Thread gauges
The thread gauges are used to the pitch diameter of srew threads. The internal limit thread
gauge is a plug gauge having screws on both ends. One end has ‘Go’ member and ther other
end has’ Not Go’ member.
Slip Gauges
The slip gauges ( also known as precision gauge blocks ) are used for checking the accuracy of
measuring instruments such as micrometers, vernier calipers , snap gauges , dial indicators etc.
The slip gauges are hardened steel blocks accurately ground and lapped and are available in
sets of various sizes and in various grades of accuracy.
Feeler gauges
The feeler gauges is used to check the clearances between two mating surfaces. It consists of a
series of thin steel sheet strips ( known as leaves 0 hardened and ground to various thickness.
Each leaf is marked and its thickness which varies from 0.05 mm to 1 mm.
Radius or Fillet gauge
The radius or fillet gauge is used to check the radii of curvature of concave or convex surfaces. It
consists of a number of steel blades having standard radii ground and lapped on the ends and
sides .
Marking gauge
It is used to mark lines parallel to the edge of a piece of wood. The stem carries one or more
steel marking point s or a cutting knife . The stock is set to the desired distance from the steel
point and fixed by the thumbscrew. The gauge is then held firmly against the edge of the wood
and pushed along the sharp steel point marking the line.
Mitre square
It is used for measuring an angle of 45 degree. It is made of all metal with a nickel-plated finish
or with a steel blade and an ebony or rose wood stock. The blade varies from 200 to 300 mm
long.
Odd leg caliper
It is used to mark parallel lines from a finished edge and to locate the centre of round bars.
Protractor:
It is the most simple device used to measure the angle between the two faces of a component.
It consists of a base in the form of a steel flat bar and an angle measuring device graduated in
degrees and minutes. The instrument can read upto ½ degree and with vernier scale
attachment upto 5 minutes.
Swing blade protractor
It is a made of steel having angular graduation in degree on semi circular plate with a scale like
blade screwed at the centre . The blade can be swung over the graduated scale and set tight at
the desired position by tightening the screw , to mark or measure the angle on the job.
Plumb bob
The plumb bob is a tomb shaped brass weight attached at one end of cotton thread and is used
to check the verticality of a surface when it is beyond the scope of try square to do so. A
combination of spirit level and plumb bob gives the perpendicularity of two adjoining surfaces.
Steel rule
It is used for taking linear measurement to an accuracy of 1 to 0.5 mm in metric uinit and 1/8
to 1/64 inches in British unit. This is usually marked in both inches and in millimeter and are
available in sizes of 150, 300 , 500 and 1000mm. The width x thickness ranges from 18x0.8 mm
to 76x1 mm depending on the length of the scale.
Steel tape
It is a flexible scale having length of 1/2/3 metre which can be rolled inside the small boxed
shaped casing. It is having arrangement to fix the scale at the desired position to facilitate
marking/ measurement. It is used to measure and mark large dimensions of the larger work
pieces.
Spirit Level
It is used for checking or testing the levelness verticalness of the surfaces. Its use is wide made
for the static leveling of the machinery and the other equipment , but it is based precision angle
measuring principle . These are available in various sizes . It is specified by its length such as
200 mm spirit level. A spirit level consist of a glass tube ground to a large radius enclosed in a
wooden or a metal body . The tube is partially filled with spirit so that a bubble of air is left,
which comes to the top when the spirit level is place horizontal. The graduation on the glass
scale indicate the variation in the level and amount of correction required to make the surface
horizontal.
Straight edge
It is used for testing the straightness and flatness of plane surfaces , particularly to test the
accuracy of the ways of a lathe, planer , shaper etc. The straight edge, is like a solid bow . It is
made of cast iron , ribbed intervals and have machined straight flat edges made true. These are
made in varying length and widths. The accuracy in straightness and flatness is tested by placing
the straight edge on the surface to be tested and watching the light between the surface and
the straight edge .
Surface plate
It is used for testing the flatness of work pieces and is also used for marking out work. This is
used for It is available in sizes of 1.5mx 5m, 1.5x 3 m, 2x2m, 2x4m and are placed at a height of
about 800mm from the floor. The top of surface plate must always be cleaned and dry. After
completing the work , it should be carefully cleaned and oiled to prevent corrosion and cover
with a wooden shield or plastic cover.
Surface gauge
The surface gauge ( also known as scribing block ) is used for checking the parallelism of work ,
for scribing lines at specific heights and for marking out parts that have to be fitted or
machined. Generally, its base has a V-groove so that it can rest on round bars also. It is
generally used in conjunction with surface plate.
Scriber
It is a piece of hardened steel about 150 to 300 mm long and 3-5 mm in diameter. Pointed
one or both ends like a needle. The bent end is used to scratch line in places where the straight
end can not reach. The ends are sharpened on an oil stone whenever necessary.
Steel square
It is a L-shaped piece of hardened steel with graduation marks on the edges for measuring and
reading linear dimensions.. The tongue ( FRAME/ BEAM ) is fixed at 90 degree with the blade
and is also having graduation on its top face. This is generally used in sheet metal work.
Standard wire gauge(SWG)
Wire gauges are used for finding diameters of wires by inserting the wires in the notches
provided and finding out which it fits. The diameter and the number marked on the disc are
read off from the gauge. The wire gauge has the range from 0.1 to 10 mm. The device is
conveniently used to check the thickness of steel sheets.
Trammel
The trammel is a form of beam compass , with a wooden beam , to take in the work that is
beyond the scope of compass.
Try square
It is used for testing right angles. It consists of a steel blade fixed at right angles to the edge of a
machined stock of metal. It is available in various sizes such as 100mm, 150mm and 300mm.
V-block
The V-block is a block of steel with V-shaped grooves . Roundly shaped work pieces which are
to be marked or drilled are placed on V support. For long cylindrical works V-blocks are used in
set. It is available in sizes from 50 to 250 mm width and 50 to 100 mm height .
Vernier caliper :
It is a precision instrument which is used for measuring external as well as internal diameters
of shaft , thickness of parts etc. to an accuracy of 0.02 mm. It can also be used to measure the
depth of slots and holes. The principle of vernier is that when two scales or divisions slightly
different in size are used , the difference between them can be utilized to determine with
better accuracy of measurement.
Vernier height gauge :
It is mainly used for measuring height of parts to an accuracy of 0.02 mm. It is also used for
scribing lines in lay out works. The principle of this instrument is similar to a vernier caliper.
Vernier height gauges with the lower and upper measuring limits e.g., 20 to 250 mm, 30 to 300
mm, 40 to 500 mm , 60 to 800 mm and 60 to 1000 mm are also available in the market.
Vernier depth gauge :
It is used to measure the depth of holes, recesses and distance from the plane surface to a
projection. It can measure to an accuracy of 0.02 mm. It works on the same principle as that of
a vernier caliper.
Wing compass
Wing compasses are composed of two finely pointed steel legs which are set to the desoired
position and held by a set screw and quadrant. They are used when stepping off a number of
equal spaces , marking circles or arcs , and when scribibg parallel lines to straight or curved
work.
 CHAPTER-I

CARPENTRY WORK
Introduction
Carpentry is the term used with any clas of work made by use of wood. Timber is the basic
material used for any class of wood working. Wood is having good machining characteristics
and can be sliced , bent , planed , sawed and sanded.
Safe practices in carpentry work
Tools that are not being used should always be kept at their proper places.
Make sure that the hands are not in front of the sharp edged tools while using them.
A dull tool may cause slip during use as it needs extra pressure to work on. As such, make sure
that the tools are sufficiently sharp before use.
Wooden pieces with nails, should never be allowed to remain on the floor.
Be careful w2hen you are using your thumb as a guide in cross cutting and ripping.
Test the sharpness of the cutting edge on wood or paper but not on your hand.
Select the longest screw driver that is appropriate for the job intended. The longer the tool , the
greater the effort applied.
The tip of the screw driver must fit in the slot without wobbling. The width of the tip should be
equal to the length of the screw slot.
Keep the screw driver properly pointed to prevent injury to hand.
Measuring instruments & allied equipments used in carpentry work
Steel rule, Straight edge , Try square, Mitre square, Bevel square , Combination square, Marking
gauge, Wing compass , Trammel, Divider, Caliper, Spirit level, Plumb bob etc.
Holding and cutting tools used in carpentry work
Cutting and holding tools used in carpentry work
Saws
Saws are used for thin and quick cutting of wood and is one of the extensively used cutting tool
in carpentry shop. When cutting across the grain , a different action is required from the saw
teeth than when ripping with the grain. A saw is generally specified by the length of its blade
measured along the toothed edge and pitch of teeth, expressed in millimeters.
Rip saw
Rip saws are used for cutting along the grain in thick wood. It is fitted in a wooden handle by
means of rivets or screws. Rip saws are about 700 mm long with 3-5 teeth per 25 mm length.
Cross cut saw
Cross cut saws are used for cutting across the grain in thick wood. They are 600-650 mm long
with 8-10 teeth per 25 mm length.
Panel saw
It has a finer blade and is used for fine work . This is often used for ripping as well as cross
cutting. A pane; saw is about 500 mm long with 10-12 teeth per 25 mm length.
Tenon saw
This saw is mostly used for cross cutting when a finer and more accurate finish is required. The
blade being very thin is reinforced by a rigid steel back. Tenon saw blades are 250-400 mm long
with 13 -14 teeth per 25 mm length.
Dovetail saw
A smaller version of the tenon, this saw is used where the greatest accuracy is needed and fine
shallow cuts are required. Dovetail saws are available of length200-350 mm length with 12-18
teeth per 25 mm length.
Bow saw
The bow saw consists of a narrow blade held in tension by twisting the string with a small
wooden lever. These saws are used for cutting quick curves and the blade can be adjusted to
any desired position when in use. The bow saw are 250-350 mm long.
Coping saw
The coping saw has a very similar blade , held rigid in spring metal frame. The blade is tensioned
by screwing the handle. This saw is used for small radius curves.
Compass saw
The compass saw is used for sawing small curves in confined spaces and has a narrow tapering
blade about 250 to 400 mm long, fixed to an open-type wooden handle.
Pad saw
This saw is used for cutting key holes or starting of any interior cuts and is the smallest ( 250
mm ) saw used in carpentry shop.
Chisel
Firmer chisel
It is a general purpose cutting tool used for removing wood either by hand pressure or mallet. It
has a flat blade and thee width varies from 1.5 to 50 mm.
Paring chisel
Chisels with long thin blades are termed as paring chisel. This is used for shaping and preparing
surfaces of wood and is manipulated by hand.
Mortise chisel
It is used for chopping out mortises. These chisels are designed to withstand heavy work.
Blades vary in width from 3 to 16 mm.
Gouges
Gouges are chisels with curved sections and may be either inside or outside ground.
Firmer gouges
Outside ground gouges are used for curving hollows and are known as firmer gouges
Scribing gouges
Inside ground gouges are known as scribing gouges and are used in exactly the same way for
inside curved edges as a chisel would be for straight one.
Planes
The plane can be likened to the chisel fastened into a block of metal or wood , and its blade
cuts exactly like a wide chisel.
Jack plane
Jack plane is the plane used for first truing-up of a piece of wood. Jack planes are obtained from
350 to 425 mm in length and with blades 50 to 75 mm wide.
Try plane
The trying plane is a finishing plane and is set with a very fine cut. It is used for producing as
true surface or edge as possible, and is set to cut a shaving as thin as the smoothing plane.
Smoothing plane
The plane is similar in action to a jack plane , except that it is set to cut a much thinner shaving.
A smoothing plane is used for smoothing or finishing after a jack plane.
Rebate plane
The rebate plane is used for sinking one surface below the another and shouldering one piece
into another.
Plough plane
The plough plane is used to cut grooves to make panel in a door to fit in grooves in door frame.
Spokeshave
This is a form of small plane used for cleaning up quick curves.
Router
The router plane is used for cleaning out and leveling the bottom of grooves or trenches to a
constant depth , after the bulk of waste material has been taken out with saw and chisel.
Metal jack plane
Metal jack plane serves the same purpose as wooden jack plane but facilitates a smoother
operation and better finish. The thickness of the shaving removed is governed by affine screw
adjustment , and a lever is used for adjusting the blade at right angles.
Boring tool
Boring tools are used for making round holes in wood and are selected according to the type
and purpose of the hole.
Bradawl and gimlet
These tools are used to bore small holes , such as for starting a screw or large nail.
Brace
The brace is a tool used for holding and turning a bit for boring holes.
Bit
Bits are the tools used cutting holes and are used in conjunction with braces or other form of
bit holders. Bits are available in various forms and sizes such as Shell bit, auger bit, Expansive bit
, Centre bit , Forstner bit , countersink bit etc.
Drill
Morse drills are very convenient for making screw holes . This is adapted for drilling holes when
wood working bits would be spoiled.
Reamer
Reamers are tapered bits shaped like bits and are used for enlarging holes.
Striking tool
Hammer
Various types of steel hammers available are ball peen hammer, cross peened hammers , claw
hammers , Warrington hammers etc.. Claw hammer has flat face at one end and claw at the
other. The carpenters more often favour the claw hammer because it serves the dual purpose
of a hammer and a pair of pincers.
Mallet
A wooden headed hammer of round or rectangular cross section . The mallet is used to give
light blows to the cutting tools.
Holding tool
To enable the cutting operation to perform properly , it is necessary to hold the work piece
firmly. Various work holding devices available are as follows:
Carpenter’s bench vice
Its one jaw is fixed to the side of the table while the other is kept movable by means of a screw
and a handle. Jaws are rectangular steel flats suitable to grip the wood pieces.
Bench stop
It is simply a block of wood projecting above the top surface of the bench and serves to prevent
the wood workpiece from moving forward when being planed.
Bench holdfast
It is a pillar type structure with and arm to hold the job. It can be placed anywhere on the table
by inserting it into the hole cut on table top. This is useful for holding a piece of wood down on
the bench when a vice is not adviceable.
Sash cramp
This is used for holding wide works such as frames or tops.
G-cramp
It is used for holding smaller works.
Hand screw
The hand screw is used where a wider area of pressure than that provided by G-cramp is
required.
Miscellaneous tool
Rasps and files
These are useful for cleaning up some curved surfaces. Scratches left by the file
can be removed with the scraper and glass paper.
Scraper
It scrapes very small shavings off the wood.
Oil stone
Oil stones are used for sharpening wood working tools such as chisel, blades of planers etc.
Glass paper
Glass papers are used to remove minute imperfections from the surface of finished wood.
Pincer
The pincer is mainly used for pulling out nails tacks etc. It is made of forged steel.
Screw driver
Screw drivers are used for screwing or unscrewing screws used in wood work.
JOBS PERFORMED
Sl. No. of the job
Job No. 1
Name of the job
Mitre Joint ( Corner Joint )
Aim
To make a corner joint at right angle oif the given wood piece.
Tools & instruments etc. used
Holding device, steel scale, jack plane, try square, marking gauge , chisel, cross cut saw / rip saw
, scriber , mallet , nail, fevicol etc.
Sequence of operations
1
2
3
4
Sketches of the job at each stages of operation with dimensions upto finished product
Result
The mitre joint was formed as per given dimension and accuracy has been formed .
Precautions
1.
2
3

Sl. No. of the job

Job No. 2
Name of the job
Halved cross lap joint
Aim
To make a halved cross joint from the given piece of wood.
Tools & instruments etc. used
Holding device, steel scale, jack plane, try square, marking gauge , chisel, cross cut saw / rip
saw , scriber , mallet , nail, fevicol etc.
Sequence of operations
1
2
3
4
Sketches of the job at each stages of operation with dimensions upto finished product
Result
The halved cross lap joint of the given wood piece has been formed as per requirement.
Precautions
1
2
3

Sl. No. of the job

Job No. 3
Name of the job
Dovetail lap joint
Aim To make a dovetail lap joint as per given sketch from the piece of wood supplied.
Tools & instruments etc. used
Holding device, steel scale, jack plane, try square, marking gauge , chisel, cross cut saw / rip
saw , scriber , mallet , nail, fevicol etc.
Sequence of operations
1
2
3
Sketches of the job at each stages of operation with dimensions upto finished product
Result The dovetail lap joint was formed as per given dimension and accuracy.
Precautions
1
2
3
 CHAPTER-II

SHEET METAL WORK

The sheet metal shop is very important for every engineering concern . it deals with the
working of the metal sheets. The various operations performed in sheet metal shop are cutting
, shearing , bending etc.
SAFETY PRACTICES FOR SHEET METAL WORKSHOP
Use hand leather gloves while handling heavy sheets.
Avoid feeling the cut portion by hand while cutting with snip.
Do not let sheet metal slip through your hands. Most cuts from sheet metal result from
allowing it to slide trough the hands.
Snips
Use snips only for metal that can be cut by force applied by hand.
Hand snips should never be used to cut wires. Such practices ruins the cutting edges of the
blades.
Soldering
Be cautious and avoid inhalation of harmful smoke and fumes produced during soldering.
Ground properly , the exposed metal parts of electrically heated soldering irons.
Place the electric iron on fire proof holder and never allow it to be on atable where it can come
in contact with the combustible material.
After performing the work, wash hands thoroughly before eating , as solders and fluxes contain
material , which should not enter the stomach.
Brazing
Avoid the inhalation of fumes produced because of fluorides and fluorine compounds that are
present in brazing fluxes , particularly those used with silver , magnesium and aluminum
silicon brazing filler metals.
Material used
In our work we shall use galvanized sheet of 22 to 26 SWG thickness. However, other sheet
metals such as black iron sheet , copper, aluminum, stainless steel , tin plate , terne plate etc
are used in sheet metal work according to requirement of the products.
Measuring instruments and allied equipments used
Sttel rue, folding rule, steel tape , circumference rule, steel square, swing blade protractor,
straight edge, scratch awls or scribers , standard wire gauge (SWG)
Marking and cutting tools used in sheet metal work
Punches
The various hand punches are:
Prick punch
It is a tool steel rod whose one end has tapered point ground at an angle of 30 degree and is
used for making small indentations or establishing points for dividers and trammel points.
Centre punch
It is similar to prick punch but its point is ground to an angle of approximately 90 degree and is
used to mark the location of bend lines on heavy metals and to mark the centres of holes to be
drilled.
Solid punch
It is used for punching small holes in thin metal sheets.
Hollow punch
It is used for punching holes upto 10mm or above from metal sheets.
Hand lever punch
It is sometimes used for making holes when too much holes are to be punched. The tools
consists of a punch and die and is operated by hand. The die and punch may be replaced
depending upon the size of the hole required.
Chisel
The cold chisels are used to cut or shear metal sheet. Flat chisels are mostly used for cutting
sheet metals , rivets , bolts and in chipping operations.
Snips
The snips are somewhat similar to a pair of scissors but are considerably heavier . There are
several types of snips available for making straight or circular cuts , but the most common are
the straight snips and the curved snips.
Hammers
The hammers in sheet metal works are used for forming shapes by hollowing, raising, stretching
or throwing off processes. The commonly used hammer for sheet metal works are:
Ball peen hammer, Riveting hammer, Setting hammer Hollowing or blocking hammer , raising
hammer , Planishing hammer , Collect hammer , Tray hammer
Mallets
The mallets may be made of hide, fibre or wood. They may be obtained in various shapes to
suit special work.
Pliers
The pliers are used in sheet metal work for holding, cutting and bending work. The various
types of pliers commonly used are as follows:
Flat nose plier
It has flat jaws with small grooves. It is used for forming and holding work.
Round nose plier
It has long jaws rounded on the outside. It is used for holding and forming the various shapes
and patterns.
Slip joint combination plier
The slip joint combination plier has an adjustable jaw. It is a general purpose tool.
Hacksaw and files
The hacksaws and files used in sheet metal shops are similar to those used in fitting works.
Stakes
Stakes are used to give the desired shape by bending , seaming or forming of the sheet metal.
Some of the commonly used stakes are :
Blow horn stake
It has short tapered horn at one end and along tapered horn at the other end. It can be held in
a vice or in a square hole in a wooden block or bench top. It is sued for forming , riveting or
seaming tapered objects such as funnels , pitched covers etc.
Beak horn stake
It has around tapered horn at one end and a square tapered horn at the other end. The round
tapered horn may be used for many purposes like bending of sheet metal into cylinders and
conical shapes , for setting down seams when used with a grooving punch or a seam set , for
truing work to make circular when the seam is folded or soldered etc. The square end of the
stake is used for bending and truing straight sided work.
Other types of stakes in use of sheet metal works are;
Candle mould stake, Creasing stake, Hollow mandrel stake, Sloid mandrel stake, Double
seaming stake, Conductor stake, Hatchet stake, Bevel edge stake, Common square stake,
Copper smith stake, Bottom stake, Hand dolly stake etc.
Stake holders
The stake holders mostly used in steel metal shop is a rectangular bench plate which is fastened
to the bench with bolts. The plate has tapered holes so that the stakes may be used in different
positions. Many sheet metal workmen prefer to use universal stake holder with a complete set
of stakes It does not require a bench plate. It has a holder which can be used to clamp the stake
in any desired position on the bench.
Hand groover
It is used for grooving a seam by hand. It is available in various sizes.
Rivet set
It has a deep hole in the bottom to draw a rivet through metal and acup shaped hole to form
the finished head of a rivet.
Hand seamers or tong
It is used in seaming operation s and bending in situations where it is impossible or
inconvenient to bend metal on the stake.
Soldering Iron
It is used to join two pieces of metal by means of an alloy of tin and lead ( known as soft solder
). The sloder is usually transferred to the joint by means of a heated soldering iron.
Folding Bar
These are used for bending and folding straight material. It is made out of pair of rectangular
mild steel bars.
JOBS PERFORMED

Sl. No.of the Job

JOB No. 1
Name of the job:
Preparation of Different types of joints ( Single seam, Double seam, Flanged seam, wire
beading , riveting etc. )
Aim
To prepare various sheet metal joints and edge formation as learning for manufacture of sheet
metal utility products.
Sequence of operation
Single seam
1.First of all , draw a line parallel to one edge of the body stretch out at a distance equal the
width of seam.
2.Draw two lines parallel to the edge of the bottom stretch-out . The plus and minus
dimensions of 1 mm are used to prevent the folded edge of the bottom from interfering with
the folded edge of the body.
3.Now from the flange on the body and on the bottom piece by folding the metal with a mallet
over a suitable stake or wooden block.
4. Insert the body of the container in the bottom piece and place the assembly parts on a flat
stake.
5. Bend the edge of bottom gradually over the edge of the body with a setting hammer.
Sketches at different stages of operation
Result
Precaution
Double seam
First of all , make a single seam as discussed earlier.
Place the container over a double seaming stake ( or any other stake having the required
curvature ) with its inside edge against the edge of the stake.
Now bend the single seam to approximately 45 degree with a mallet. Continue to strike the
partially bent seam with a mallet until it is flattened against the body of the container. The
bend is made gradually and the container is kept turning as the seam is bent.
When the seam has been completely flattened, remove the container from the double seaming
stake and place it on a square stake with its edge resting on the edge of the stake . Now, tap the
bottom lightly to straighten the seam.
Sketches at different stages of operation
Result
Precaution
Corner joint Flanged seam joint )
Mark the sheet at the edge to be 0folded. At the meeting point of the marking of the adjoining
face( corner of the finished product ) draw lines as shown in the drawing.
Cut the corner suitably and fold the two portions of the cut out edge as per drawing. Fold the
adjoin faces making it perpendicular to original face on wooden block, stake or bench vice by
lightly hitting with mallet. Join the corner as shown in the drawing.

Wire beading

Sequence of operation

Riveting

Sequence of operation

Sketches at different stages of operation for each type of joints

Result

Precaution

Sl No. of Job
Job No. 2
Name of the job
Manufacture of GI sheet truncated cone
Aim
To manufacture the truncated cone of given dimension from GI sheet.
Tools and equipments used
Drawing sheet and drawing instruments, scissor , dot punch, snip , bench vice sxcasle, swing
blade protractor, stake etc.
Sequence of operation
Drawing of pattern of a truncated cone by radial line method
First of all draw the front and top view of the cone on drawing sheet.
The outer generator ( i.e., 0-6 and 0-12) represent the true length of all the elements ( equal to
S ) and shall be radius of the arc of the stretch out line .
The position of the cut points , in the front view , is obtained by drawing the lines parallel to the
base and up to the slant side 0-6.
Draw an arc with centre O and radius equal to 0--6. This is the stretch out line for the pattern.
The included angle ( α ) may be calculated by the following relation
α= R/Sx360 degree, where R= Radius of base of cone.
Divide the arc into 12 equal parts and draw the lines 0-0, 0-1 etc. and cut these lines with
corresponding radii measured from O along the line O-6.
In similar manner , draw the inner arc for the truncated cone as per given dimension. Keep
suitable material at both slant edges for joining by double seaming.
The pattern is completed as shown in the figure. Cut the pattern out of the drawing sheet by
scissor and place it over GI sheet. Mark the profile on the GI sheet by dot punch and scriber.
Cut the sheet by snip and fold over stake by slowly hammering with mallet. Join the edges by
double seaming.
Sketches at different stages of operation
Result
Precaution

Sl. No.of the job

Job No.-3
Name of the job
Maufacture of rectangular box ( one face open ) from GI sheet.

Aim
To manufacture the rectangular box of GI sheet as per given dimensions
Sequence of operation
Draw the pattern of the rectangular box

First of all draw the front view and top view of the rectangular box.
Draw the stretch line equal to perimeter of the box.
Mark the distance on stretch out line from the top view.
Draw the perpendicular lines at each point and set the height of the box. Keep additional width
to form the folding and seaming operations. Cut the sheet , fold it and make seam joint of the
end as per drawing to prepare the four vertical walls of the box.
Draw the required shape and size of the bottom of the box , keeping suitable additional width
for joining of the edges with the sheet with vertical face of the box by seaming , to make the
bottom face .
Place the bottom sheet below the sides of the box where it is to be joined. Fold the edges step
by step to make clean joining of the bottom.

Sketches at different stages of operation

Result
The rectangular box of GI sheet of given dimension has been formed.
Precaution
 CHAPTER-III

BENCH WORK AND FITTING

The bench work and fitting plays an important role in every engineering workshop to complete
and finish the job to the desired accuracy. Even in the age of Mecanisation , some of the
operations need to be finished by hand work and the same is carried out conveniently at
benches and hence named as Bench work. However, fitting is the assembling of parts together
by filing , chipping , sawing scraping , tapping etc necessary after the machining operations. This
may or may not be carried out at the benches.
Safe practices for Bench and fitting work
Keep hand and tools wiped clean and free from dirt, oil and grease . Dry tools are safer to use
than slippery tools.
Keep tools sharp and in good adjustment. Dull or poorly adjusted tools need to be forced ,
causing accidents.
Do not carry sharp tools in pocket.
Wear leather shoes and not chappals or other shoe which have major opening at the top.
Do not wear loose clothes.
Remember that a slippery floor is always dangerous. Be careful.
Do not keep working tools at the edge of the table.
Put the sharp tools in proper place , immediately after completion of work with it.
Never work in a place where there is not sufficient light.
Avoid talking and unnecessary discussion s during working time and concentrate only on the
work.
Position the work piece such that the cut to be made is close to the vice. This practice prevents
springing, saw breakage and personal injury.
Position the work in the vice such that the work is held tight. A loose vice is dangerous.
Cut a small groove with sharp corner of a file. , where a saw cut is to be started. The groove
permits accurate positioning of the saw and also prevents slipping of the saw. teeth.
Start with a new blade in another place , when a blade breaks during a cut. This prevents
binding and blade breakage.
For cutting thin metal strips , clamp them between two pieces of wood. Cutting through and
the metal prevents the saw teeth from digging in and bending the metal.
Apply force only on the forward ( cutting ) stroke and relieve the force on the return stroke .
Take the longest possible stroke , but doesn’t allow the blade supporting pins to touch,the job.
Don’t hold the work piece in hand while cutting.
Wear goggles while chiseling.
Gring-off any mushroom that may form on the head of the chisel.
While using chisel, be careful that flying chips do not hit others in the shop.
Watch the chisel when striking, to avoid hitting of hand.
Work with a chisel, in a direction, away from yourself.
Cutting pliers
Never use a pliers when a spanner can do the job.
When applying pressure on the handles of the plier, keep the fingers away from the jaws.
Never try to cut hardened metals with cutting pliers.
Bench drill
Never wear gloves while operating a machine, as they can be caught by the revolving drill.
Files
Use the file with a properly fitted tight handle.
Never drive a file into its handle with a hammer or other objects. it may chip or break the file or
split the handle.
After filing, remove the burrs from the edges of the work, to prevent cuts to the fingers.
Hammer
Examine the hammer each time before it is used .the handle must be securely wedged.
Grip the handle properly by holding it at the end of it.
Do not strike with more force than necessary.
Spanner
Avoid ill-fitting spanner ; otherwise it may round the corners of the nut and cause the spanner
to slip , resulting
In an accident.
Do not use a second spanner at the end of another to obtain additional leverage.
Chipping
Ensure that chisel head is free from mushroom formation.
While chipping ,look at the cutting edge of the chisel and not at the head of it.
Wrench
Apply the turning force to the wrench , only in the direction of the movable jaw, so that the
force acts on the stationary jaw.
When using a wrench , always pull-never push. This gives greater control and leverage.
Never put a pipe or another wrench over the handle of a wrench to increase leverage.
Screw driver
Do not screw driver as a lever, chisel and on other works, for which it is not designed.
Never place a free the hand in front of a screw driver blade.
Select a screw driver such that .its tip fits snugly against the sides of the slot in the screw
heads.
Firmly press the screw driver tip in to the screw slot, while applying the turning force ,to
prevent the tip from slipping out o f the slot, causing burring of the screw head slot and
personal injury.
Never use a screw driver on a work piece held in hand.
Do not over- tighten the screw as it may slip the screw driver, causing injury.
Measuring instruments and allied equipments used in fitting works
Scriber, V-block, angle plate , surface gauge, surface plate , try square , thread pitch gauge ,
gauges , divider etc.
Holding and cutting tools used in fitting works
Vices
Bench Vice
It is used for holding the work and is firmly fixed to the bench with bolts and nuts.
The height of the bench should be such that the top of the vice jaws is at about the same height
as the operator’s elbow. The size of the vice is given by the width of the jaws and the maximum
opening between the jaws.
Hand Vice
It consists of two jaws and hands which are hinged together, on a pivot , on the opposite ends.
The work is held between the scratched surfaces of the jaws with a screw and the wing nut.
Pipe vice
It is used for holding pipes , shaft or round jobs. It works on the same principle as the bench
vice.
Leg Vice
It is generally used in a smithy shop but it is also suitable for heavy hammering, chipping and
cutting in fitting shop. The vice is secured to the top of the bench by an iron strap which is
fastened to a plate bolted to the bench top.
Pin Vice
This is a holding device for small diameter work such as wires , pins etc. It consists of affine self
centering chuck on a handle . The work is gripped between the jaws of the chuck by rotating
the handle.
Tool Maker’s vice
It is particularly used for holding small works for filing or drilling. It consists of a body with a
solid jaw , a movable jaw , a screw and a handle for the control of movement of moveable jaw.
Striking Tools
Hammer
The striking tool or hammer is used to strike the job or tool. A hammer consist of head , striking
face , peen and a shaft or handle. The size of the hammer is indicated by its weight The various
types of hammers in common uses are Ball peen hammer, Cross peen hammer, Straight peen
hammer, Double faced hammer, Soft hammer
Cutting Tools
The chief cutting tools used in fitting are;
Cold Chisels
The clod chisel is an important cutting tool used by the fitters to cut the cold metals and are
made by forging from cast tool steel of octagonal cross section. The various types of chisels
commonly used for fitting works are as follows;
Flat chisel
It is used for flat surfaces , cutting off sheet metals cutting bars and rivets.
Cross cut chisel or cape chisel
It is mainly used for grooves in large surfaces before using the flat chisel It is also used for
cutting keyways in wheels and shafts.
Half round chisel
It is used for cutting round or semi-circular oil grooves in bearings , bosses and pulleys.
Diamond pointed chisel
It is sued to cut V-grooves and to chip square corners.
Side Chisel
It is particularly used for chipping and removing surplus metal in cotter ways and slots which
are to be cut by hand after drilling.
Files
A file is a hardened piece of high grade steel with slanting rows of teeth. It is used to cut ,
smooth or fit metal parts. It cuts all metals except hardened steel and it cuts only on the
forward stroke. .The files are classified according to the size , cut of teeth , grade and shape of
cross section of the file. The general shape of the files are as follows:
Flat file
A flat file is parallel for about 2/3 rd. of its length and then tapers in width and thickness. It has
double cut on both faces and single cut on both edges. It is mostly used for general work and
for filing flat surfaces.
Hand File
A hand file has its width parallel throughout but its thickness tapers. The both faces are double
cut and one edge single cut. The uncut edge is called the safe edge and prevents cutting into
one face of a square corner while the other face is being filed. It is used for general surface
work , more particularly for filing steps or shoulders to square work without touching and
spoiling the adjacent surface, already made true.
Square file
A square file is parallel for 2/3rd. of its length and then tapers towards the tip. It is double cut
on all the sides and is used for filing square corners and slots.
Pillar file
A pillar file is similar to hand file , but is narrower and thicker than hand file . It has one or both
uncut edges( i.e., safe edges ) and is used for narrow work such as keyways , slots and grooves.
Triangular file
A triangular file has width either parallel throughout or upto middle and then tapered towards
the tip. Its cross section is triangular ( equilateral ) and the three faces are double cut and edges
single cut. It is used for filing square shoulders or corners and for sharpening wood working
saws.
Round file
A round file has round cross section. The round files are used for opening out holes , producing
round corners , round ended slots etc.
Half round file
The section of a half round file is not a true half circle but is only about 1/3 rd. of a circle. The
flat side of this file is always double cut and curved side has single cut. It is used for filing curved
surfaces.
Knife edge file
A knife edge file has a width tapered like a knife blade. It is also tapered towards the tip and
thickness. It is used for finishing sharp corners of grooves and slots.
Warding file
A warding file is similar to flat file but it is thinner and parallel on its thickness. It is used for
filing narrow slots.
Mill File
A mill file is similar to flat file but parallel on both width and thickness and have both edges
round. It is single cut and is suitable for forming the radius on saw teeth and in slots.
Needle file
The needle files are available in sizes from 100mm to 200mm of various shapes and cuts. These
files are used for fine works such as pierced design in sheet metal.
Scrapers
A scraper is a tool with sharp edges by means of which very small amount of metal can be
removed . The process of removing metal with a scrapper is known as scrapping. The scrappers
are made of tool steel or sometimes made from old worn out files and provided with a wooden
handle. The various types of scrapers used are as follows:
Flat scraper
The flat scraper is the most common and similar to flat file . It has a cutting edge at the end
which is slightly rounded. It is used for producing a perfectly flat surface.
Triangular scraper
The triangular scraper is made from worn out triangular files. It has three cutting edges. It is
used for finishing small holes and for removing sharp corners and burrs.
Half round scrapper
The half round scrapper is made out of half round files. It is used for scraping halves of bearings
and curved surfaces.
Hacksaw
The hacksaw is the chief tool used by the fitter for cutting rods, bars and pipes into the desired
lengths. Hacksaw blades are made of carbon or high speed steel and may be finished with the
cutting edge only hardened or they may be hard all over. The choice of the blade for any
particular class of work depends upon the pitch of the teeth and at least 2 or 3 teeth should be
ijn contact with the surface being sawn.
JOBS PERFORMED
Sl No. of Job
JOB NO. 1
Name of the job :
Fitting of match plates
Aim :
To learn the process of hand work of sawing, marking , filing and inspection make the two
given plates to fit properly matching with each other as per drawing.
Tools and measuring instruments used :
Hacksaw, Files, Scribers , surface plate , surface gauge , Prick punch, Hammer, Chalk pencil, Try
square, Scale Angle plate etc.
Sequence of operation
Cut the blanks from the given length of raw material according to required size by sawing.
While sawing hold the raw material tightly in the bench vice. Select a suitable blade and fx it in
the handle with sufficient tension by use of the wing nut. Keep the blade slightly inclined while
cutting and apply required pressure during the forward stroke and the pressure should be
relieved during the return stroke.
Two adjacent sides and one face of the blank are to be filed by use of proper files to make them
flat and mutually perpendicular to each other all over the surface. The following method should
be followed for filing.
Cross filing ( Quickest metal removal )The filing stroke may be given from left to right and from
right to left so that the whole of file surface moves across whole of work surface in one stroke.
Straight filing( job width less than file width ) The file stroke is made nearly at right angles to
the length of the work.
Draw filing ( Finishing operation ) The file may be gripped as close to the work as possible and
move lightly to and fro over the work. For this purpose a fine cut file with a flat face should be
used.
While filing the surface , check the flatness of the surfaces and their squareness with each other
as required b y suitably applying Try square.
Marking : The surface of the work is coated with a paste of chalk and allowed to dry. The blank
may be paced on the surface plate with side made flat at the bottom. The plate may be
supported by angle plate or V bock as per convenience. Now the horizontal lines may be scribed
by means of scribing block or surface gauge. The vertical lines are drawn by turning the work
through 90 degree and by using the scriber and surface gauge. After the scribing work is over ,
light indentations may be made along the scribed lines by means of a dot punch and a
hammer. These punch marks will act as guide for further operation of filing as per drawing size.
Cut the corner to be removed by saw keeping about 1mm material left out for finishing by
filing. Now all the surfaces may be finished properly by filing as per drawing size and matching
of the parts may be checked by light passing method as well as by use of try square. The
finished job may be lightly oiled to avoid rusting.
Result
The two MS plates have been finished to given dimension and correct fitment in assembly.

Precautions

Sl No. of Job
JOB No. 2
Name of the Job
Making of Nut
Aim ;
To learn the process of making of nut by filing , drilling and hand tapping process.
Tools and measuring equipments used
Hacksaw, Files,bench vice, drill vice, drill machine , drill bit , set of taps , thread pitch gauge,
threaded ring gauge, Scribers , Prick punch, Hammer, Chalk pencil, Try square, Scale etc.
Sequence of operation
Cut the required length of hexagonal MS section from the given bar. File both end to make
them flat and parallel. Chamfer to 30 degree at one end.
Apply wet chalk on the face of the work piece for marking hole. Get the approximate centre of
the face of the plate by joining the opposite corners by scriber. Mark the centre point by
punching. . Calculate the diameter of the tap size drill and draw a circle of the calculated
diameter on the marked centre. The marking may by firmly indicated by indentation with dot
punch and hammer.
For making of hole the following steps may be followed.
Get the tap size drill bit and make hole exactly at the centre point by fixing the job in drill vice
and using sensitive drill machine for the purpose.
After drilling the tapping hole , the taper tap is fixed in the tap wrench and screwed in the hole .
Before commencing to screw it round for cutting the thread , the tap position must be adjusted
until it stands square with the tap surface of the work and it must be maintained square.. Oil
need to be applied to lubricate its action and improve the finish of the thread.. When the taper
tap is felt to have started its work and its squareness has been checked, the cutting of thread
proceeds. After every half turn , the tap should be reversed slightly to clear the thread. On
completion of cutting by taper tap , the intermediate and finish tap may be used in similar
manner .
Finally , check the assembly with corresponding bolt or screw gauge. and take corrective
measures , if required. Oil the nut after finishing to avoid rusting.

Sketches at different stages of operation of the job

Result
The hexagonal nut of given dimension and thread profile has been manufactured.

Precaution

Sl. No. of the job

Job no. -3
Name of the job
Making of bolt
Aim
To manufacture a bolt by use of die and hand tools.
Tools and measuring equipments used
Bench vice, hacksaw , files, dies , scale etc.
Sequence of operation
The job may be cleaned of hard scale ( if any ) and its ends are slightly chamfered so that it can
enter into the die easily.
The job is held firmly in the bench vice making it vertical.
A die of suitable size may be selected and held in stock.
Before staring the cutting of thread, great care is needed to ensure that the face of the die is
square with the axis of the bar or work being threaded . The stock is now rotated with both
hands and at the same time the die is pressed on to the end of the bar to help the
commencement of cutting.
When the cutting has actually started , the die should be rotated backwards and forwards .
Cutting oil may be applied during cutting operation.
The required depth of thread is not obtained in a single operation. The stock is screwed back
and the jaws of the die are brought closer by tightening the adjusting screw. The process is
repeated twice or thrice till the correct depth of thread is reached. .
Similar operation may be repeated to make thread at both ends of the rod.

Sketches at different stages of operation of the job.

Result
The bolt of given dimension and accuracy has been manufactured.

Precaution
 CHAPTER-IV
WELDING WORK

The welding is a process of joining two similar or dissimilar metals by fusion , with or without
the application of pressure and with or without the use of filler metal. The fusion of metal takes
place by means of heat. The heat may be obtained from blacksmith’s fire , electric arc, electrical
resistance or by chemical reaction.The process of joining similar metals by melting the edge
together , without the addition of filler metal , is called autogenous welding.The process of
joining similar metals with the help of filler rod of the same metal is called homogeneous
welding. The process of joining dissimilar metals using filler rod of the same metal is called
heterogeneous welding. The filler rod material is such that its melting point is less than the
parent metals.
The welding is extensively used in fabrication as an alternative method for casting or forging
and as a replacement for bolted and riveted joints. It is also used as a repair medium e.g., to
reunite metal at acrack to built up a small part that has broken off such as gear tooth or to
repair a worn surface such as bearing surface.
Safe practices in welding work
Always weld in a well ventilated place.. Fumes given off from welding are unpleasant and in
some cases may be injurious , particularly from galvanized or zinc coated parts.
Don’t weld around combustible or inflammable materials , where spark may cause a fire.
Never weld containers, which have been used for storing gasoline, oil or similar materials,
without first having them thoroughly cleaned.
Place the hot jobs under the board , “Hot – Don’t touch “.
Arc welding
Check the welding machine to make sure that it is properly grounded and that all leads are
properly insulated.
Never look at the arc with the naked eye. The arc can burn your eyes severely . Always use a
face shield while welding.
Prevent welding cables from coming in contact with hot metal , water , oil or grease. Avoid
dragging the cables around sharp corners.
Ensure proper insulation of the cables and check for openings.
Always wear the safety hand gloves , apron and leather shoes.
Always turn off machine when leaving the work.
Apply eye drops after welding is over for the day, to relieve the strain on the eyes.
While welding , stand on dry footing and keep the body insulated from the electrode , any bare
parts of the electrode holder and the work.
Gas welding
Always wear welding goggles while doing gas welding.
Always use spark lighter to light the torch and never use a match.
Do not allow blow pipe to heat the cylinders , hoses or any other equipment .
Do not allow the hose to become excessively warm.
Do not remove the spanner used for operating the valve. Always keep it with the cylinders .
Secure cylinders in use , against falling , which may knock-off the valve.
To test the leakage in a valve or hose , use soap water but not lighted match.

Measuring instruments and allied equipments used in welding work

Steel rule, weld measuring gauge, magnifying glass, try square etc.
Machine , Tools & accessories for arc welding work
( will be shown and used during hand-on training )
AC or DC Welding machine (current source), Electrode, Electrode holder (Insulated), Cables
Cable connector, Cable lugs, Earthing clamps ,Chipping hammer, Wire brush, Helmet or hand
shield, Safety goggles, Hand gloves , Aprons Sleeves etc
Specially designed work table
AC or DC welding machine
Depending upon the application , AC or DC machines are used in arc welding, but in some cases
either of them can be used . DC supply is usually obtained from generator driven by electric
motor. The generators have varying voltage characteristics so that voltage itself adjusts
automatically to the varying voltage demanded by the arc. The DC welding is mostly used for
heavy work and at sites where electricity is not available. Where supply mains are available as
AC source, transformers are used. The function of the transformer is to step down the voltage
from 440 volts to the normal welding circuit voltage ( 80-100 volts )
Electrode
Generally two types of electrodes are used
Bare or non-coated electrodes
Coated electrodes
For general engineering works , coated electrodes are used:
In coated electrode, the core of the bare metallic wire is provided with a covering or coating of
some fluxing material . the coating thickness of the flux varies from 10 to 100% of the metallic
core diameter depending upon the type of material being joined. The standard diameter of the
electrode varies from 1.5 to 9.5 mm and length from 250 to 450 mm.
JOBS PERFORMED
Sl. No. of job
Job No.-1
Name of the job
Butt joint
Aim
Tools and measuring equipments used
Sequence of operation
Sketches of the job at each stage of operation
Result
Precaution
The hand , face and eyes should be protected from the heat and flare of the electric arc
welding. For this, the operator should wear hand gloves to protect hands and ahand shield or
helmet with a window of coloured glass should be used to protect face and eyes.
The space for the electric arc welding should be screened off from the rest of the building so
that the other workmen are safe from the glare of the arc which is very harmful for the eyes.
Sl. No. of job
Job No.-2
Name of the job
Corner joint
Aim
Tools and measuring equipments used
Sequence of operation
Sketches of the job at each stage of operation
Result
Precaution
The hand , face and eyes should be protected from the heat and flare of the electric arc
welding. For this, the operator should wear hand gloves to protect hands and ahand shield or
helmet with a window of coloured glass should be used to protect face and eyes.
The space for the electric arc welding should be screened off from the rest of the building so
that the other workmen are safe from the glare of the arc which is very harmful for the eyes.

Sl. No. of job

Job No.-3
Name of the job
T- joint
Aim
Tools and measuring equipments used
Sequence of operation
Sketches of the job at each stage of operation
Result
Precaution
The hand , face and eyes should be protected from the heat and flare of the electric arc
welding. For this, the operator should wear hand gloves to protect hands and ahand shield or
helmet with a window of coloured glass should be used to protect face and eyes.
The space for the electric arc welding should be screened off from the rest of the building so
that the other workmen are safe from the glare of the arc which is very harmful for the eyes.

Sl. No. of job

Job No.-4 ( Demonstrated by Instructor )- MIG Welding process
Name of the job
Lap joint & Stud joint
Aim
Tools and measuring equipments used
Sequence of operation
Sketches of the job at each stage of operation
Result
Precaution
The hand , face and eyes should be protected from the heat and flare of the electric arc
welding. For this, the operator should wear hand gloves to protect hands and ahand shield or
helmet with a window of coloured glass should be used to protect face and eyes.
The space for the electric arc welding should be screened off from the rest of the building so
that the other workmen are safe from the glare of the arc which is very harmful for the eyes.
Welding inspection
In order to have good quality of welding, it is very essential to have careful examination of the
welded parts at each stage of welding process. There are various destructive and non-
destructive tests to check the soundness in strength etc. of the welding joints. However, some
routine dimensional and visual examinations are necessary for producing good quality of weld
joints for general purposes.
Visual examination
Poor/ uneven fusion of metals. Oxidation of metal surface.
Presence of slag inclusion, non- metallic inclusion, blow holes, gas pockets or roughness of the
surface of the weld.
Presence of crack or non uniform deposition of weld metal.
Formation of cavity into the base metal adjacent to the toe of the weld.
Dimensional inspection
Warpage – with proper mechanical gauges or fixtures
Incorrect joint preparation- with approved weld gauges
Incorrect weld profile- with approved weld gauges.
 CHAPTER –V
FOUNDRY WORK
Introduction
Foundry or casting is a process of forming metallic products by melting the metal , pouring it
into a cavity known as the mould , and allowing it to solidify. When it is removed from the
mould it will be of the same shape as the mould.
Safety practices for Foundry work
Do not let the sand too wet. Water is an enemy of molten metals.
Never stand near or look over the mold during the pouring or immediately after pouring
because the metal might spurt out of the hole.
While working with molten metals , wear protective clothing such as face shield or safety
goggles , asbestos or leather gloves , which are tight at the wrist , protective aprons that will
protect from heat as well as molten particles of metal.
Provide adequate ventilation to remove smoke and fumes.
Do not shake-out a casting too hastily, which may result in second and third degree burns.
Measuring instruments and allied equipments used
Steel rule, outside caliper, Inside caliper, Thickness gauge, Template, spirit level, plumb bob etc
Tools and Equipments used in Molding work
Pattern
According to the shape and size of the product to be cast , patterns are made of different
materials such as wood , metal, plaster of paris etc. Patterns may be of the following types :
Single piece pattern, Split piece pattern, multiple piece pattern, loose piece pattern, matc h
plate pattern, cope & drag pattern, Gated pattern, skeleton pattern , sweep pattern etc.
Moulding flasks
These are wood or CI boxes open to both sides. The moulding sand is rammed after placing the
pattern in the box. The upper box is known as cope, bottom one is drag and intermediate boxes
( if any ) are checks.
Shovel
It is used to transfer sand into molding boxes.
Riddle
It is used to remove coarse and foreign materials from the foundry sand.
Rammer
It is used to ram the sand around the pattern.
Strike edge or strike off bar
It is a metallic or wooden piece with straight edge and used to remove excess sand from the
mold after ramming to provide a level surface.
Sprue pin
It is a tapered wood pin to make a sprue (hole ) in cope through which molten metal is poured
into the mold.
Riser pin
It is also wooden pin to produce a hole (riser) in the mold so that molten metal can rise in it to
compensate the shrinkage.
Trowel
It is used to make the mould surface smoothen and also to repair the mold.
Spike or draw pin
It is used to withdraw pattern from mold.
Slick
It is used to finish clean and finish the bottom and sides of the mold.
Gate cutter
It is used to cut gates in the mold.
Bellows
It is used to blow off air , to remove loose sand particles from the mold cavity.
Vent rod
It is used to produce small holes in the sand mold to allow the escape of mold gases.
Lifter
Lifters are made of thin sections of steel of various widths and lengths with one end bent at
right angles and are used to clean and finish the bottom and sides of deep, narrow opening in
the mold.
Swab
A simple swab is a small brush having long hemp fibres , a bulb swab has a rubber bulb to hold
the water and a soft hair brush at the open end . It is used to moistening the sand around a
pattern .
Mallet
A raw hide mallet is used to loosen the pattern for withdrawing it from mold.
Rapping plate
A rapping plate or lifting plate is used to facilitate rapping and lifting of the pattern from the
mold.
Gaggers
Gaggers are iron rods bent at one or both ends and asre used to reinforce the sand in the top
part of a moulding box and to support hanging bodies of sand.
Clamps
Clamps are used for holding together the cope and drag of the complete mould to prevent the
cope from floating during pouring of metal.
Moulding board and bottom board.
At start, the pattern and flask are placed on moulding board and the board holds the sand
poured in the box. The finished mold is placed on bottom board and it acts as a support for the
mould until it is poured.

JOB PERFORMED

Sl. No. of the job

Job No.-1
Name of the job
Preparation of green sand mould
Aim To prepare a green sand mould in cope and drag by use of solid flange.

Tools and equipments used

Moulding boxes ( cope and drag ( , moulding board , bottom board, moulding sand , parting
sand , rammer , strike off bar , riser , runner or sprue pin , vent wire , draw spike etc.
Sequence of operation

1. Place the given pattern on the moulding board . Now place the drag box on the board.
Sprinkle parting sand on the pattern and moulding board. Fill the drag box with
moulding sand and rammed it with the help of rammer. Remove the excess sand using
strike off bar.
2. Turn the drag box upside down . Place the cope box on the drag box . Place riser and
sprue pins in the cope box , fill moulding sand and ram it. Remove excess moulding
sand from the cope box using strike off bar , vent holes are made using vent wire .
Sprue and riser pins are then removed.
3. The cope is lifted and placed aside on its edge, the pattern is removed with the help of
draw spike . The mould is repaired of damages, if any. Cut the gate using gate cutter.
4. The mould is finally closed by replacing the cope on the drag and clamping together by
clamps. The mould box assy. Is placed on bottom board and is then ready for pouring
the molten metal for casting.

Draw sketches at different stages of preparation of the mould.

Result
The sand mould is prepared as per requirement
Precautions
During preparation of mould
Do not let the sand too wet, water is an enemy of molten metals.
Do not ram the sand too hard or too loose . Both are detrimental for good casting.
Do not moisten the pattern.
Do not handle sand with bare hand . It may affect your skin.
Screen the sand properly before use. Mix the sand thoroughly to get a homogeneous mixture.

During pouring of metal

Never stand near or look over the mold during the pouring or immediately after pouring
because the metal might spurt out of the hole.
While working with molten metals , wear protective clothing such as face shield or safety
goggles , asbestos or leather gloves , which are tight at the wrist , protective aprons that will
protect from heat as well as molten particles of metal.
Provide adequate ventilation to remove smoke and fumes.
Do not shake-out a casting too hastily, which may result in second and third degree burns.

CHAPTER-VI
 BLACK SMITHY WORK

Introduction
Black smithy is the act or art of working or forging of metal , as iron , into any desired shape by
heating the metal in an open fire or hearth . The shop in which the work is carried out is known
as the Smithy or black smith’s shop .The metal is heated to the plastic stage and generally
shaped to the desired size by hammering. By hand hammer for small jobs and machine hammer
or press by larger jobs.
SAFE PRACTICES FOR BLACK SMITHY WORK
Hold the hot work downwards close to the ground, while transferring from the HEARTH to the
ANVIL,to minimize the danger of the burns; resulting from the accidental collisions with others.
Use correct size and type of tongs to fit the works. These should hold the work securely to
prevent its bouncing out of control from repeated hammer blows.
Care should be exercised in the use of the hammer, the minimum only force should be used
and the flat face should be strike squarely on the work; as the edge of the hammer heavy
bruising on hot metal.
Wear face shield when hammering hot metal.
Wear gloves while handling hot metal.
Wear steel-toed shoes.
Ensure the hammers are fitted with tight and wedged handles.
Measuring instruments and tools used in forging works
Steel rule, outside caliper, Inside caliper, Thickness gauge, Template etc
Tools and equipments used in forging work
Black smith’s forge
It is used to heat the metal work pieces. Gas, oil or coal may be used as afuel. The necessary air
is supplied under pressure using a blower.
Anvil
It is used to support while carrying out forging operation.
Swage block
It is also a supporting tool used to facilitate the forming of round, square, hexagon section from
the round bar of iron. It is also used for heading and bending operations.
Hammers
Different types of hammers having different nweights are used in smithy shop. Ball peen
hammers are used to forge upto 1 kg. while sledge hammers are used from 3 to 8 kg. forge
products.
Tongs
The work pieces are held in tong while manipulating the heated job during forging operation.
These are made oif mild steel and are available in various sizes.
Chisels
Chisels are used for cutting mrtals and for nicking prior to breaking. The edge of the chisel is
mafde slightly round for better cutting.
Fuller
Fullers are used for necking down a piece of work . They are made in top and bottom tools as in
the case of swages.
Flatter
Flatters are used to give smoothness and accuracy to articles which have already been shaped
by fuller and swages.
Set hammer
It is really a form of Flatter. A set hammer is used for finishing corners in shouldered work
where the flatter would be inconvenient.
Punch and drift
A punch is used for making holes in metal parts when it is at forging heat and the hole is
opened out by driving through a larger tapered punch called adrift.
JOB PERFORMED ( DEMONSTRATED BY INSTRUCTOR )
Sl. No. of the Job
Job No.-1
Name of the Job
Manufacture of Hexagonal headed bolt
Aim
To make a hexagonal headed bolt as per given sketch.
Tool and measuring equipments required
Smith’s forge, anvil, ball peen hammer, flatter, tongs, sledge hammer, bolt header, round
swage, hot chisel, outside caliper, scale , Angle gauge etc.
Sequence of operation

1. Take a MS bar of 25mm diameter and 280 mm long.

2. Heat one end of the bar to a length about 100 mm in a forging furnace upto 1250⁰C.
3. Grip the heated rod to one end in tong , place it vertically on anvil and upset heated
part with sledge hammer.
4. Place cylinder part of the upset stock in a bolt header and place the bar on anvil in such
a way that the shank ot the bolt passes through the hardie hole ( rectangular hole ) in
the anvil and again upset of bolt with hand hammer.
5. Withdraw bolt from the bolt header.
6. Reheat the bolt and reduce the diameter of the shank from 25 to 22 mm using round
swage of 22 mm diameter.
 7. Insert shank of bolt in bolt header , place stock of anvil so that its shank passes through
hardie hole in anvil , place smoother on bolt head and strike with hammer , make top of
bolt head spherical in shape.
8. Straighten shank of bolt on anvil face, check its length. If it is more than 200mm long cut
off the excess length with hot chisel.

Draw Sketch of the job at different stages of operation

Result
The hexagonal headed bolt of required size was forged .
Precautions
Wear face shield when hammering hot metal.
Wear gloves while handling hot metal.
Wear shoe which fully cover your feet.
Ensure the hammers are fitted with tight and wedged handles.
Tightly hold the job by tong so that it does not fly away on hitting with hammer.