Workshop Practice Lab Manual 1 - WordPress
Workshop Practice Lab Manual1INSTRUCTIONS FOR STUDENTS1.1.General InformationLaboratory experiments are integral part of the course. It is said that “You see youforget; you read you remember; you do you understand”. That makes thepractical as an integral part of learning process.Some of the purpose of conducting experiments can be enumerated as below:To get familiarized with the basic components, measuring instruments,workbench and basic machines.Observing basic phenomena and characteristics of machine .Reporting and analyzing the observations.Verify observations, basic rules and understanding physical concepts.Hands-on experience on machines.Observing safety and developing group-working culture.To make laboratory experiments safe and effective, each student must obey thefollowing rules.1.2.SafetyDress:Boys: Loose clothes not allowed. Shirt should be tucked-in properly, shoes with therubber sole, no slippers.Girls: Skirts with large flares not permitted, shoes with the rubber sole, no slippers.Make sure that all the power sources are off, when you are connecting the circuit.Keep safe distance from machines.Follow the instructions given by the faculty or course instructor.Failure to obey safety rules may result in the disciplinary action.1.3.AttendanceAll students are required to attend and contribute adequately while performingexperiments in the group. Performance will be judged based on experimentsconducted, quality & punctual submission of the lab report for each experiment.Faculty will take attendance. Failure to be present for an experiment will result inlosing entire mark for the corresponding lab. However, genuine cases may beconsidered to repeat the experiment.Students must not attend a different lab group/section from the one assigned at thebeginning of the class (unless otherwise approved by the instructor).If a student misses a lab session due to unavoidable circumstances, can provide alegitimate proof as soon as possible, he/she may then be allowed by the labinstructor, to make-it-up with a different section.
Workshop Practice Lab Manual1.4.2Preparation and performanceBefore leaving the laboratory, each student must ask the lab instructor for theexperiment number to be conducted on the next lab turn, so that the studentscome prepared after reading and reviewing the reallocated experiment. Facultymight check your preparedness and understanding of the experiment andfailure to satisfactory reply may de-bar you from conducting the experiments.Record your observations and calculations in the Lab Manual’s observationtables. Do not hesitate to clear any of your doubts concerning the experiments.Leave the work place clean after you have finished with your experiments.Dismantle the circuit and put all the wires and equipment back at its originalplace.1.5.General working discipline in the LabStudents are advised to strictly follow the instructions given below while workingin the Workshop Practice Lab:1. Attendance in the laboratory is mandatory. For any absence, students have to fillup the format available in the lab to indicate reasons for absence.2. Students will not be allowed after 10 minutes from the scheduled time.3. No student will leave the Lab without permission.4. Students should bring their Lab Manual and are understood to have gone throughthe manual thoroughly.5. Any confusion may be clarified from the faculty before starting the experiments.6. Students must maintain discipline and silence in the lab.7. Students are to remain within their allotted experimental area.8. Be attentive all the time.1.6.Lab Reports1.2.3.4.5.Each student is required to write reports for the experiments conducted.Reports are due one week after the completion of the experiment.All reports must be neatly written.The Lab report must contain the following:Duly completed Title pages.Each report to include Objective, Material required, Tools required,Operations involved, Procedure and Precautions.Summary section can be included explaining what you have learned doingthe experiments and subsequent calculations.(Note: Summary space is notprovided on the report page, thus students are requested to write it in thefooter space.)Questions given under the lab report to be answered by student in the spaceprovide in the Lab Manual.Individual comments/Notes must be written for the further improvement ofthe lab manual, on the space provided at the end of the manual, howeverextra pages could be attached if required.
Workshop Practice Lab Manual3QUESTIONS FOR VIVA-VOICE:1.FITTING SHOP1.1)What do you mean by fitting shop?Ans.Fitting shop means a place where dimensional accuracy are produced in metalWork pieces by manual operation.1.2)How will you specified a steel scale?Ans.Steel scale is made up of the thin steel strip which is calibrated inches and mmboth. It is specified by total length of calibration such as 150 mm, 300 mm and600 mm etc.1.3)Ans.Why scale is made up of steel and not of mild steel. Explain.Steel is selected for making steel scale due to following main reasons:a) steel has good corrosion resistance ability.b) It has low coefficient of thermal expansion than mild steel.c) Due to low coefficient of thermal expansion effect of change in temperature willdiminished up to a certain extent.d) Its shining and appearance far better than mild steel.1.4)What is the material used to made surface plate and why?Ans. Surface plates made up of casting of high carbon steel and properly hardened andtempered after making top surface ture leveled through machining other materialdoes not take in place of high carbon steel due to following reasons:a) Economical considerationb) Hardness at room temperature.c) Stability surface trueness at room temperature.d) High resistivity against corrosion etc.1.5)What do you mean by temporary marking and permanent marking?Ans.Temporary marking carried out where one or two processes are to be performedon job. In this marking only scratched lines are produced over job containing anymarking media.
Workshop Practice Lab Manual4Permanent marking is carried out over temporary marking by making dots withcenter punch and hammer.1.6)What is a try square, how it cab be specified?Ans.It is made up of hardened and tempered of high carbon steel having two arms rivetriveted at true 90 degree angle used for checking right angles of job etc., one armcalled stock and other arm called as blade. This blade is used for checking angle ofat 180 degree angle and it is specified by blade length.1.7)What is the difference between a) bevel square and try square b) surfacegauge and universal gaugeAns. A) Difference between Bevel square and Try square:Try SquareBevel SquareIt can used for 90 degree angle and 180It can used for various desired angle alongdegree angle both.with parallel line marking.B) Difference between Surface gauge and Universal gauge:Surface gaugeIt is consisting a fixed spindle or column.1.8)Universal surface gaugeIt consists adjustable spindle or column.Explain the files according to number of teeth?Ans.Rough8 TPCCoarse10 TPCBastard12-14 TPCSecond Cut14-16 TPCSmooth20-24 TPCDead Smooth24-40 TPCSupper Smooth40-60 TPC1.9)Explain center line marking method?Ans.For center line marking method a center line marked on the work piece and rest of
Workshop Practice Lab Manual5marking completed with respect to this center line.1.10)What do you mean by drill bit?Ans.It is bar shaped structure having a sharped cutting edge at its one end and all overits body. It is used for marking internal hole in work piece.2.WELDING SHOP2.1)What do you mean by Welding Process?Ans.Welding is a process of joining two or more than two similar or dissimilar metalswith or without application of pressure along with or without application of fillermaterial.2.2)What do you mean by electrical arc welding?Ans.In an open circuit two terminals carrying high amperage and low voltage current,brought closer till the resistance offered by air gap between both terminalsdimished by high value of current/voltage then a certain amount of electrons tendsto jump from one terminal to another terminal having currents of differentpolarities due to this jumping of electrons a large amount of heat generated and thisflow of jumping electrons termed as electric arc and this amount of heat used tomelt the base metal and filler material and this pool of molten metal and fillermetal make a welding joint. This is termed as electric arc welding.2.3)How much temperature produced at electric arc?Ans.Approx.3400 degree celcius.2.4)Explain the term”Polarity”?Ans.Polarity may be defined as operation as the relation of positive and negativeterminals with respect to the electrode and job. It may be classified in followingtypes:1)Straight polarity: work piece is made positive terminal and electrode is madenegative terminal. It is used for more thick plate etc.2)Reverse polarity: work piece is made negative terminal and electrode is madepositive terminal. It is used with thin plates welding etc.
Workshop Practice Lab Manual2.5)6Differenciate between A.C. and D.C. arc nstallationHigherLower2.Maintenance costHigherLower3.PolarityFixed polarityChange in everyhalf cycle.2.6)Ans.4.ElectrodeBare and coatedOnly coated5.Voltage dropsHigherLowerWhat do you mean by electrode?Electrode- is a filler metal rod used for filling the gap between welding jointsduring welding. This is made in thick wire shape of different metals as perrequirement.2.7)How will you classified a flux coated electrode?Ans.Depending upon its length, diameter, material flux, melting point and position ofwelding, etc specifies it.2.8)How will you classified a flux coated electrode?Ans.(a) Dust coated or light coated.(b) Electrode semi medium coated electrode.(c) Heavily coated or shielded electrodes.2.9)Ans.What do you mean by gas welding?It is a non-pressure welding and in this method of welding heat is produced due tocombustion of some inflammable gasses in presence of O2. For examplecombustion of acetylene with oxygen termed as oxy-acetylene gas welding.
Workshop Practice Lab Manual2.10)Ans.7List the inflammable gasses can used for gas welding.(a) Acetylene Gas(b) Hydrogen Gas(c) Retort Gas(d) Natural Gas3. SMITHY SHOP3.1)What do you mean by smithy process?Ans.In this the metal heated up to just below to it critical temperature and then byapplying external pressure ( like hammer blow) and required shape and sizeachived.3.2)Name important tools required for smith work?Ans.For heating:a) Coal fired furnace (open hearth furnace)b) Oil fired furnaceFor holding/ supporting:a) Leg vice b) Tongs c) Anvil d) Swage blockFor striking/ shaping:a) Various hammersb) Fuller set c) Hardid) Flatter e) Set hammersFor cutting: hot chiselsFor drilling: drift and punch etc.3.3)How many forms of tongs used in smithy work?Ans.Flat tong - for flat work piece.Flat mouth tong – for longer flat piece.Pincer tong – for round objects.Chisel or belt tong – for unsymmetrical jobs holding.Round hollow tong – for round unsymmetrical jobs.Sewer tong – for triangular and square jobs.Pick up tong – for very small jobs.3.4)What do you mean by punch and drift work piece?Ans.Punch is placed on red hot job and a blow of hammer applied. These punches areavailable in various shapes like round, triangular, square and hexagonal etc.Drift is the secondary and finishing tool used after punching for accuracy finishing
Workshop Practice Lab Manual8dimensions of hole.3.5)Differentiate between hot and cold chisel?Ans.S.NO.PropertiesHot ChiselCold Chisel1.ApplicationUsed for hot jobsUsed for coldcheseling2.Not hardenedHardnessHardened andtempered3.LengthComperatively lessMore length4.Cutting angleAlmost kept 30Almost 60 degreedegree3.6)What do you mean by poker?Ans.Poker is a mild steel rod pointed and bended at other end. It is used to removeClinker and to adjust heat at proper place by adjusting the position of burning coalsin furnace.3.7)Describe the mainly used materials along with their forging temperature?Ans.MaterialsForging temperature( in degree celceius)Wrought Iron850-1300Mild Steel750-1300Medium Carbon Steel750-1250Stainless Steel950-1200Brass, Copper Bronze300-850High Carbon Steel750-1150Aluminium, Magnisium300-8503.8)What do you mean by Up setting?Ans.Upsetting may be defined as the process in which the cross-section of the workMetal increased on the cost of its length.
Workshop Practice Lab Manual91) Head Upsetting: in this process cross-section of a complete work metal isincreased.2) Head Upsetting: The cross-section at the end of work piece is increased.3) Central Upsetting: The cross-section of the work pieces increases at middlepoint of work piece only.4. CARPENTRY SHOP4.1)Ans.Name various type of chisels used in carpentry shop?Chisel- it is another most important tool in wood working it is made up of highcarbon steel. It is specified by the width of cutting edge. It is used with the help ofany impact load such as blow of hammer etc.Farmer chiselDovetail chiselMortise chisel4.2) Difference of ripsaw and crosscut saw?Ans. Ripsaw: - It is used along the grain cutting.
Workshop Practice Lab Manual10Cross cut saw: - it is used across the grain cutting.4.3)Ans.1)2)3)4)5)Describe five safety precautions in carpentry shop?Five safety precautions in carpentry shop:Always adopt right tools and right procedure for every operation in carpentry shopWork piece should be well tight in vice in proper position.Tools should be in good condition and well sharped, if necessary, on the job.Teeth of saw should be well set and sharpened.During marking, keep suitable margin desired as per the operation to be carried outon the job.4.4) What is the difference between hard wood and soft wood?Ans.PREPARATIONSOFT WOODHARD WOODLight in colourComparatively dark inColour appearancecolourStraight fibre and fineFibres are closer andFibre abilityEasily workableDifficult to workworkability5. MACHINE SHOP5.1)What do you mean by machine shop?
Workshop Practice Lab ManualAns.11Machine shop is associated with performing different operation along with theapplication of different machine ans the plece used for these operation are knownas machine shop.5.2)What do you mean by lathe machine?Ans.It is most widely used machine tool for different operations like turning, threadingand knurling, etc. in the ancient time the lathe machine were powered by engine soit was termed as engine lathe machine. But in present it is known as center lathemachine it consists two center (one called as live center and other known as deadcenter) in which the work metal mounted and a stationary tool mounted in toolpost cuts the material is thin chips from to achieve the desired dimensions.5.3)Define the following tems:1) Centering 2) Facing 3) Turning 4) Step Turning 5) Form Turning 6) TaperTurning 7) KnuringAns. 1) Centering may be defined as process of mounting work piece in center in fourjaw chuck on lathe machine.2) Facing may be define as process of metal removing from the front face of workpiece on the cost of its length.3) Turning may be defined as the metal removing process on lathe machine in theform of chips on cost of diameter of work piece.4) Step turning may be define as the process of making certain different diametersof diameters of jobs of various certain lengths by turning.5) Form turning involves making different articles using form tool (griended toolbit as per the requirement) like handle of machine, etc.6) Taper turning may be defined as the turning process in which the diameter ofwork piece decreased gradually.7) Knurling-in this operation different types of hatch lines are made over thesurface of work piece.5.4)What do you mean by tool life?Ans.Tool life is a measure of gradually wear and tear occurred in tool bit which occursdue to regular service and its service condition.
Workshop Practice Lab Manual125.5)What do you mean by chips?Ans.During any machining process some material removed from work metal in theform of fine strips of metal that is known as chips.Types of chips:1) Continuous chips: the chips having certain length known as continuous chips.Normally these chips produced during machining of soft metals and ductilemetals.2)Discontinuous chips: these chips consists comperatively small length or insegments of chips. These are normally produced in machining of brittle metals andhard metals etc.INDEXSl.No.1.2.3.ExperimentPageDateDate ofFaculty’s GradeNo. Performed Submission Signature
Workshop Practice Lab Manual4.5.6.7.8.9.10.11.12.13
Workshop Practice Lab Manual14EXPERIMENT NO-1OBJECTIVE:To study of tools and operation in fitting shop.TOOLS USED: MEASURING TOOLS: Scale (Steel rule): -It is flat in shape and calibrated up to 1/16inches in BIS system and up to half mm in metric system. Its lengthspecifies it. Generally available in length of 6”, 12”, 24” and 1 meter.Out side caliper: used for out side measurements.
Workshop Practice Lab Manual15In side caliper: used for are inside measurementsDivider: It is basically similar to the calipers except of its legs which arekept straight pointed at measuring edge .it is used for dividing any lineardimensions, for marking arc /circle on a flat surface, and for transferring therequired dimensions from one Pointe to another.Try square: it may be defined as a measuring and marking tools for 90oangle. It has true machined stock and blade jointed together true 90oit isused through in direct measuring method.MARKING TOOLS: Scriber: - made up of hardened and tempered high carbon steel. Tip ofscriber is grinded at 12o to 15o and is generally available in 125mm to 250mm. It is for used fore tempered marking.
Workshop Practice Lab Manual16Punch: - used for permanent marking and it is made up of hardened highcarbon steel. It is specified by its length and dia. of center punch, forexample 150x 12.5 mm. It consists a cylindrical knurled body witch is planeup to some height at top of it. This plane part of its body is used forapplying impact load like hammer blow. At is other end of its knurled body,it consists grinded point with different angles of grinding.Classification of punchDot punch: -it is very much similar to prick punch except of its tips issharpened at an angle of 600. It is used in permanent marking of hardermetals. It is made by high carbon steel and specified by its total length.Center punch: - it is also similar to dot punch except of having sharpenedtip at an angle of 900. It is made by high carbon steel and specified by itstotal length. It is used in general-purpose permanent marking in almost allmetals having hardness below high carbon steel.
Workshop Practice Lab Manual17HOLDING DEVICES: Bench Vice: - The job is supported and holded in between the jaws of vice.In most of vices one jaw is kept fixed type and other is moving type witchmove witch the help of spindle rotated by the handle fixed at one of spindle.Classification of VicePipe viceLeg viceHand vicePipe vicePin viceMachine viceSurface plate: - It consists flat rectangular true mechanical surface. It ismade up of cast iron casting. It is generally used for caking surface flatnessof any job and also used for temporary marking.
Workshop Practice Lab Manual18V- blocks: -it is used to provide support for round object during marking andmachining etc. It is true machine at 900 at ever edge. It is made up gray castiron or high carbon steel. Its side length such as 2” to 4” etc specifies it.CUTTING TOOLS:Hacksaw frame: it is made up to case hardened mild steel in C shape having awooden handle and awing nut used fore tightening the blade.It is used for mounting hacksaw. The process of cutting by it is called hacksawing.Classification:Adjustable frameFixed frame
Workshop Practice Lab Manual19File: - it is a fine cutting tools, having number of cutting teeth on its face and it is used forfinishing purpose it is ma
Workshop Practice Lab Manual 7 2.10) List the inflammable gasses can used for gas welding. Ans. (a) Acetylene Gas (b) Hydrogen Gas (c) Retort Gas (d) Natural Gas 3. SMITHY SHOP 3.1) What do you mean by smithy process? Ans. In this the metal heated up to just below to it critical temperature and then by
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