ACKNOWLEDGEMENT

I owe my gratitude to (teacher’s name) who helped us to get

on well with the workshop jobs. It is due to your help that I was
able to compile this report without much difficulty. Also it would
be my foolishness not to mention supervisor for his kind help on
the topics as well as teachers who were helpful in this way and
that during the workshop classes and the preparation of the
report.

Thanks to everybody!
Thank you.

Name
Faculty
 CONTENTS

Title Page no.

1. Bottle opener 1

2. Dust-pan 4

3. Lathe Operation 7

4. Shaper Machine 10

5. Arc Welding 12

6. Gas Welding 14

7. Safety Measures 17

8. Summary 19
 BOTTLE OPENER
Objective :

 To familiarise with different operations of bench works and to get basic

knowledge about hand tools, layout tools, machine tools etc. used in
bench works.

Material used :

1. Mild steel slightly bigger than the required size.

Tools used :

1. Files
a) Flat files
b) Half round files
c) Triangular files
d) Knife files

2. Bench vise
3. Drilling machine
4. Hacksaws
5. Scriber
6. Centre punch
7. Vernier callipers
8. Ruler
9. Divider

Procedure :

1. A metal stripe of 125mm, breadth 25mm and thickness 7mm was cut off
with hacksaw.
2. Surfaces of the metal stripe were filed and smoothened with the help of
flat file to remove rust. Try square was used to test the smoothness of the
surface on all ends.
3. Marking was done along the length and breadth using the scriber to cut
away the unwanted part of the work piece.
4. Keeping the smoothened surface as base, the work piece was clamped
carefully on the vise.
5. The stripe was then filed till the length was 120mm; breadth 20mm and
thickness 5mm. Ruler and vernier callipers were used to determine the
accurate measurement.
6. Then, as shown in the drawing, the markings were done with the help of
scriber and the locations of the holes were marked with the help of
centre punch.
7. On one end, the holes of diameter 6mm and 8mm were drilled with the
help of drilling machine using the approximate size of bits and the
unwanted portion were removed by filing.
8. After giving this end the desired shape, the tip was tapered by filing to a
thickness of 1mm. This was done so that this tip could be used as a
screwdriver.
9. On the other end, a semi-circle of radius 10mm was marked with the
help of spring divider and a circle of radius 8mm was drilled. This end
was made round with the help of hacksaw and flat file.
10. The inside surfaces of the holes were made smooth with the help of
triangular and circular files.
11. All the edges of the work piece were further filed a bit to ensure that it
wouldn’t cause any cuts.
12. Before the work piece was submitted, it was oiled in order to prevent it
from rusting.

Conclusion :

Hence, with proper guidance from the teachers and instructors, the job
was successfully accomplished within the assigned time period. We also got
familiar with the basic operations of several hand tools, measuring tools, etc.
 DUST PAN

Objective :

 To be familiar with sheet metal shop as well as different basic operations

performed in sheet metal such as riveting, bending, punching, folding,
shearing etc.

Tools used :

1. Snap-scissors 2. Bench vise

3. Plastic-faced soft hammer 4. Rubber-faced soft hammer
5. Centre punch 6. Ruler
7. Try square 8. Scriber
9. Drilling machine 10. File

Materials used :

1. G.I. plain sheet for pan body and handle (slightly bigger than the
required size)
2. Aluminium rivets

Procedure :

For pan body,

1. The plain sheet was made plane and uniform by hitting it all over with
rubber-faced hammer.
2. The plain sheet was first marked with the help of the scriber and ruler
according to the drawing. Then the excess portion was cut off with the
help of snap-scissors.
3. The sheet was folded and bent as shown in the drawing, with the help of
bench vise and plastic-faced soft hammer.
4. Then, it was hit by plastic-faced soft hammer to make the surfaces plane
and uniform.

For handle,
1. Another piece of same material of size slightly bigger than the required
size was taken.
2. It was marked with the help of scriber and the excess portion was cut off.
3. Then it was folded along the marked lines making required inclination.

For joining pan body and handle,

1. Two holes were marked with the help of centre punch on both pan body
and the handle.
2. The holes were drilled with the help of drilling machine.
3. The handle and the pan body were riveted together.

Conclusion :

Thus, we made a dustpan of given dimensions, out of a metal sheet,

within a very short duration of time due to proper guidance from the instructor.
We also gained basic idea about different operations like riveting, punching,
folding, shearing etc. performed in a metal sheet.
 LATHE OPERATION
Objective :

 To be familiar with basic operations that can be performed in a lathe

machine such as chamfering, facing, turning etc.

Tools Used :

1. Cutting tool of high-speed steel

2. Vernier callipers
3. File

Material Used :

1. A cylindrical mild steel rod

Parts of Lathe :

1) Bed : It forms the base of the machine and is the main guiding
member. The Headstock and Tailstock are located on either
side and the carriage slides on it.
2) Headstock : It provides a mechanical means of rotating the work at
multiple speed.
3) Tailstock : It supports the otherend of the work when it is being
machined between centres. It also holds a tool for
performing operations like drilling, reaming, tapping e.t.c.
4) Carriage : It consists of parts like saddle, cross-slide, compound-slide,
tool post and apron that control the cutting tool.
5) Tool Post : It holds the cutting tool used to machine the work piece.

Procedure :

1. One end of the tool was at first clamped tightly in the chuck. The tool
was clamped in the tool post.
2. Then the centre was checked with the help of revolving centre in the
tailstock and it was then introduced in the facing operation.
3. The diameter of the rod was reduced to 11.8mm up to length 19mm.The
rod was then chamfered of 1x45 with the help of file.
4. The length of whole rod was reduced to 50mm by facing operation.
5. The work piece was then taken out and its other portion was clamped
and introduced to facing operation and the length was reduced to 50mm.
6. The diameter of the rod was reduced to 16mm up to 30mm length.
7. A chamfered surface of 2x45 was produced with the help of file by
placing it at 45 degrees with the work piece.
8. Thus the job was done.

Conclusion :

Thus, the assigned job was accomplished successfully within a short

duration of time. We also gained knowledge about the mechanism, parts and
operations performed by lathe machine.
 SHAPER OPERATION
Objective :

 To be familiar with shaper machine, its parts, its mechanism and basic
operations performed in it.

Tools Used :

1. Cutting tool of high-speed steel

Material Used :

1. Square rod made of mild steel

Parts of shaper :

1) Base : It is used to support the complete machine tool.

2) Column : It is mounted on the base and carries all mechanisms.
3) Ram : It carries the tool head and is a reciprocating member of
shaper.
4) Cross-rail : It is mounted on the front vertical guide ways of the
column.
5) Table : It is mounted on the cross-rail and it holds and supports the
work piece during operation.
6) Tool head : It holds the tool and can slide up, down or swing to a
desired angle.
7) Saddle : The crossrail holds the table firmly in its top and carries the
mounted saddle.

Procedure :

1. The given square rod was clamped on the vise.

2. The machine was turned on and the tool clamped on the tool post started
to slide against the work piece.
3. The job was slide left to right with the help of slider and made smooth.
4. A groove of about 2mm depth was made in the middle of the job.
5. The job was oiled before submission.

Conclusion :

Thus, the assigned shaper operation was performed and the basic
knowledge about the mechanism of shaper machine and its parts was attained.

BLOCK DIAGRAM OF SHAPER

MACHINE
 ARC WELDING
Introduction :

Arc welding is a process of joining two similar or dissimilar metals by

fusion with or without the use of filler metals. In this process, the source of heat
is an electric arc. The arc column is generated between an anode, which is the
positive pole of dc (direct current) power supply, and the cathode, the negative
pole. When the two conductors of an electric circuit are touched together and
then separated by a small distance such that there is sufficient voltage in the
circuit, an electric arc is produced. The heat of the arc raises the temperature of
the base metal forming a puddle of molten metal. The electrode metal and
welding rod is also melted and is transferred into the metal in form of globules
of metal. The deposited metal serves to fill and bond the joint. This is the
mechanism of arc welding.

Objective :

 To be familiar with mechanism involved in arc-welding operation and

with different types of tools used in welding operation.

Equipments Used :

1. Welding transformer 2. Earthing clamp

3. Chipping hammer 4. Electrode
5. Shield 6. Safety goggles
7. Wire brush 8. Hand gloves
9. Electrode holder 10. Ac or dc machine
11. Cables, cable connectors

Material used :

1. Two flat sheets of mild steel

2. Sulphur flux coated mild steel electrodes

Parts of arc welding equipment :

1) Source of power : D.C generator supplies the power required for arc-
welding process.
2) Electrode holder : It is used to hold electrode and is connected to the
welding machine and D.C generator by means of
cables. It has insulated handle.
3) Screen : It protects the user from sparks. Leather gloves and
leather aprons are used to protect the operator's
hands and clothes.
4) Chipping hammer : It is used to chip off unwanted slag accumulated on
the welded workpiece.
5) Wire brush : It is used to clean the welded workpiece after
chipping.

Procedure :

1. The two metal sheets were placed within a very small gap on a welding
table.
2. At the ends of the sheets, a small welding operation known as tracking
was performed in order to restrict the movement of the sheets during
main welding process.
3. The welding rod was moved slowly along the whole length of the gap
thus welding it.
4. Then, the slag so formed was removed with the help of chipping
hammer.
5. The welded metal sheet was then cleaned with a wire brush.
6. The work piece was then submitted after it was punched and oiled.

Conclusions :

Thus, the given pieces of metal sheets were joined by arc-welding

process and we gained basic idea about the mechanism involved in this process.
 GAS WELDING

Introduction :

Gas welding is a type of fusion welding in which a combustible gas is

burned with air or oxygen in a concentrated flame of high temperature. This
purpose of the flame is used to heat and melt the base metal and the filler rod
and to maintain the molten metal puddle. Acetylene is most widely used as the
fuel gas. When it is mixed with pure oxygen, it burns to produce the highest
flame of temperature 3200 C. Such flame is called oxy-acetylene flame.

Objective :

 To be familiar with the mechanism involved in gas welding operation.

Tools Used :

1. Welding torch
2. Welding rods
3. Welding torch tip
4. Gas cylinders
5. Pressure regulators
6. Hose and hose fittings
7. Spark lighter

Materials used :

1. Two flat, thin sheets of mild steel

2. Copper-coated filler rod

Parts of gas welding equipment :

1) Cylinders : Two cylinders, one containing oxygen and another

containing acetylene, are used in this process to produce
oxy-acetylene flame. The flow of gas is regulated by a
regulator fitted to each cylinder.
2) Hose pipe : They are used to connect the gas cylinders to the welding
torch. They are coloured, red hose for acetylene and blue
 for oxygen to indicate the properties of gas flowing through
them.
3) Welding torch : Both gases enter from one end and pass out
through a nozzle fitted at the free end.
4) Spark Lighter : The gas coming out of the nozzle is ignited by
means of a spark lighter.
5) Chipping Hammer :It is used to chip off the unwanted slag formed
during welding process.
6) Wire Brush : It is used to clean the welded workpiece after
chipping.
7) Screen : Goggles and screens must be used to protect the
operator's eyes from harmful radiations produced
during welding process.

Procedure :

1. First of all, the acetylene gas was ignited with gas lighter and adjusted so
that there was no smoke in the flame.
2. Then oxygen needle valve was opened and was adjusted to the required
flame.
3. The given sheets of mild steel were placed very close to each other on
the welding table.
4. A small welding operation called tracking was performed at the two ends
of the sheets.
5. The filler rod was then moved throughout the length of the gap between
the two sheets thus welding it.
6. When the work was completed, the cylinders valves were closed.
7. The welded wok piece was carefully cooled with water.
8. Before submitting the welded work piece, it was oiled to prevent rust
formation.

Conclusion :

Thus, the given metal sheets were joined by gas welding process and we
learnt about the mechanism involved in this process.
 SAFETY MEASURES
Great care and precautions must be taken while working on the
workshop so as to avoid accidents and to protect the job and the tools from
being spoilt. The following safety measures must be followed:

1. One should concentrate on his work and devoted to accomplish the

assigned job.
2. Dress safety :
a) One should always wear aprons available at the workshop.
b) One should wear canvas shoes which resistance to a hard object,
whether it is falling or stumbling against.
c) The shirtsleeves should be kept shorter and properly rolled over.
d) Long hair should be properly tied.
e) One should not wear watches, bangles etc.
f) Sharp edge tools should not be carried in the pockets of apron.
g) Gloves should be worn at the time of cutting metal sheet, handling
metal chips etc.

3. Safety on drilling :
a) The work-piece should be securely held and bolted down.
b) Before drilling, the drill table should be free from other tools.
c) Drill bit should be set tightly.
d) The chips should not be removed while the machine is on.

4. Job safety :
a) Job should be clamped tightly and carefully on the bench vise
without damaging it.
b) Dropping of the work piece on hard surface should be prevented.
c) The edges of the work piece should be made smooth so that they
do not cause any cuts.
5. Safety on hand tools :
 a) One should always check the handles of hammers.
b) One should not use file without handle.
c) While using the hammer, one should make sure that its handle is
free from oil, grease and dirt.
6. Lathe safety :
a) The chips should be cleared from time to time with a wire brush.
b) The chuck key should not be left in the chuck.

7. Shaper Safety:
a) The chips should be removed with a brush on the return stroke of
the ram.
b) One should not stand very near to the shaper machine, as the chips
released from the shaper-cutting tool seem to fly with extra force.

8. Safety while gas–welding :

a) The cylinders should be checked for any leakages.
b) Proper adjustment of the flame must be done to achieve good
welds.
c) The welded work piece should not be touched with bare handed
immediately after welding as it is very hot and might cause severe
skin burns.
d) The welding torch should be held in the right hand firmly.
e) The cylinder key should be kept in position in acetylene cylinder
to close the cylinder at once in case of emergency.

9. Safety while arc-welding :

a) The positive and negative lines should not be touched with bare
hands.
b) One should have knowledge about main switch, in case of
emergency. The welded work piece should not be touched bare
handed immediately after welding as it is very hot and might
cause severe skin burns.
c) Heavy gloves and worn and a hand shield or helmet with a
window of coloured glass should be used to protect the face.
SUMMARY :
Hence we gained knowledge about various operations performed in a
workshop along with the mechanism and parts of various machines like lathe
machine, shaper machine etc. We also gained knowledge about bench work and
metal sheet work and made a bottle opener and a dust pan. We also learnt about
welding processes and the mechanism involved in it. We also performed arc
welding and gas welding on the given sheets of mild steel. Throughout our lab
hours, we got proper guidance due to which we were able to perform the given
jobs successfully.