DEPARTMENT OF MECHANICAL ENGINEERING

LABORATORY MANUAL

ENGINEERING WORKSHOP PRACTICE

( SUBJECT CODE : 2009 )
( SCHEME : 2021 )

Name……………………………………………………………

Branch…………………………………………………………..

Class……………………Roll No……………Reg.No…………

MALABAR POLYTECHNIC CAMPUS

( Run by: Malabar Education & Charitable Trust )
(Approved by AICTE & State Board of Technical Education, Kerala)
EMS/Market Road, Cherpulassery, Palakkad Dt, Kerala Pin-679503
 Engineering Workshop Practice Manual (S1-S2)

Program : Diploma in Engineering and Technology

Course Code : 2009 Course Title: Engineering Workshop Practice

Semester : 1 & 2 Credits: 1.5

Course Category: Engineering Science

Periods per week: 3 Periods per semester: 45 + 45

(L: 0 T: 0 P: 3)

Course Objectives:

• To familiarize safety precautions practiced in the workplace.

• To prepare drawings models for fabrication.
• To identify various measuring, marking, holding, striking, and cutting tools &
equipment.
• To practice electrical wiring and soldering.
• To prepare a drawing of models for fabrication.
• To operate machines, power tools and equipment safely.

Course Outcomes:
On completion of the course, the student will be able to:

Duration Cognitive
COs Description (Hours) Level

Identify the safety precautions, tools and

CO1 devices required to make carpentry joints 18 Applying

Make use of various tools, machines,

instruments and power tools used in the Fitting
CO2 18 Applying
shop to make fitting joints
Make use of various tools, machines,
instruments and power tools used in the
CO3 18 Applying
Welding shop to make welding joint.
Utilize different sheet metal tools and
CO4 measuring instruments to make sheet metal 18 Applying
joints.
Make use of various tools and accessories to
practice electrical wiring, motor connection
CO5 18 Applying
and soldering

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CO – PO Mapping

Course
PO1 PO2 PO3 PO4 PO5 PO6 PO7
Outcomes
CO1 3 - - - - - -

CO2 3 - - - - - -

CO3 3 - - - - - -

CO4 3 - - - - - -

CO5 3 - - - - - -

3-Strongly mapped, 2-Moderately mapped, 1-Weakly mapped

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INDEX

Sl. Page
Description Date Remarks
No. No.
Study
1 Introduction and Safety 01-02
2 Carpentry 03-33
3 Fitting 35-57
4 Welding 59-77
5 Sheetmetal 79-103
6 Electrical wiring & Soldering 105-131

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PERFORMANCE RECORD
SL NO DATE EXERCISE DETAILS MARK / SIGN

CO 1: Identify the safety precautions, tools and devices required to make

carpentry joints.

1 Planing practice.

2 Chiseling practice
3 Cross halved Joint

CO 2 : Make use of various tools, machines, instruments and power tools used in
the Fitting shop to make fitting joints

4 Filing practice
5 Hacksaw cutting practice
6 L Joint
CO 3 : Make use of various tools, machines, instruments and power tools used in
the Welding shop to make welding joint.

7 Edge preparation and Arc striking

practice

8 Straight line weld deposit in down hand

position
9 Square butt welding

CO 4 : Utilize different sheet metal tools and measuring instruments to make sheet
metal joints.

10 Straight cutting practice

11 Locked grooved joint
12 Paned down and Knocked up Joint
13 Double groved Joint

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CO 5 : Make use of various tools and accessories to practice electrical wiring,

motor connection and soldering

14 One lamp controlled by One switch

15 Stair case wiring
16 Single phase motor starter wiring
diagram
17 Soldering and De-soldering

OPEN ENDED EXERCISES

SL NO DATE EXERCISE DETAILS MARK SIGN

1 Box and Bridle Joint
2 Step Cutting
3 Corner Joint
4 Rectangular Box
5 One lamp and a socket outlet each
controlled independently

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Safety Precautions

Personal Safety

Wear tight clothes; beware of hanging hair, ties, clothing, scarves or belts
getting caught.
Never enter the workshop without safety shoes.
Do not use rings, watches etc. while working.
Keep the workshop clean and tidy. The floor should be free from oil and
grease; the slippery floor is always dangerous.
Wear goggles whenever there is danger of flying matter.
Never attempt to measure the job in running.
Always stand in respectful distance from moving and hanging parts.
Practice cleanliness and orderliness in the shop.
Do not run or play on the shop floor.
Keep your body behind the sharp edges of cutting tools.
Do not attempt to lift heavy articles without assistance.
Never handle chips or shavings with bare hands; use special hooks, brushes
etc.
Never place sharp tools on the floor or at the edges of the workbench; keep
them in proper place assigned for them.
Be aware the cause of electrical hazards such as bare wires, poor earthing,
return connections, wet floors etc.

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Machine Safety
Never operate the machine unless you have been properly instructed.
Never work on the machine having unguarded moving parts.
Stop the machine immediately, if it produces any unusual sounds.
Before starting an operation, always check whether the work and
cutting tools are secured fast.
Never leave a machine when it is running.
Never mount or remove the work, replace tools, clean or lubricate the
machine, or remove the cover while the machine is running.
Do not run the machine in an incorrect speed.
Do not talk or disturb others while they are operating a machine.

Job Safety
Use right tools for right job.
Use metal strips to hold work pieces like Brass or Aluminum, to avoid
gripping marks on the finished surface.
Put oil lightly on finished jobs to avoid rust.
Tools with loose fitting or broken handles shall not be used.
To save the time and material, frequent checking has to be made.
Do not mix the precision measuring instruments with other tools and
equipments.
Store inflammable materials like kerosene, turpentine etc. away from
the shop.
Be aware of the details and location of fire fighting devices like fire
buckets, fire extinguishers etc. and first aid box in the workshop.

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CARPENTRY
 Engineering Workshop Practice Manual (S1-S2)

CARPENTRY

Module Duration Cognitive

Description
Outcomes (Hours) Level

Identify the safety precautions, tools and devices required to make

CO1 carpentry joints
i) Explain safety precautions
M1.01 ii) Demonstrate various wood 3 Understanding
working Tools/equipment and
power tools.
Demonstrate various wood working process
M1.02 like Marking, Planning, Cutting, Chiseling, 3 Understanding
Grooving.
M1.03 Construct a simple joint like open halved joint 12 Applying

Introduction

Carpentry involves cutting, shaping and fastening wood and other materials together to
produce desired product. A carpenter may be involved in making furniture, a new building or
repairing or re modelling an old one.

Timber

Timber is the basic materials used for any class of carpentry work. The term timber is
applied to the trees which provide us with wood. Timber for commercial purpose is divided in
to two classes.

1. Soft wood

2. Hard wood

1. Soft wood

Soft wood is obtained from trees having needle leaves. It is light in weight and color, and
has straight fibers. The annual rings are visible. It has good tensile strength.

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Bark
Annular ring
Cambium layer
Sap wood
Medullary rays
Heart wood

Pith or Medulla

CROSS SECTION OF A TIMBER

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2. Hard wood

Hard wood is obtained from trees having broad leaves. The annual rings are not visible and
its fibers are close and compact. It is heavier than soft wood and is difficult to work on. Teak
and mango trees are examples.

The cross section of a timber is shown in figure. It has the following parts.

Structure of a Tree
a. Pith or medulla

The centre of the trunk is called the pith or medulla and is often soft. It is the remains of
the original sapling.

b. Heart Wood

The wood around and near the pith is known as heart wood. The heart wood contains resins,
more durable, stronger and darker than softer sapwood. It resists decay, attack by insects and
fungi, and is the most useful part of the tree from which to make furniture.

c. Sap Wood

The outer annular rings form the sap wood. This part of the wood is not very useful for
engineering works. It is largely used as fuel. It is lighter in color and softer.

d. Annual Rings

Each time the growth cycle is completed, the tree gains one or more growth ring, called
annual ring. It is by counting these rings that the age of a tree can be determined, as each ring
represents one year of growth.

e. Medullary Rays

The food is distributed to all parts of the trees by means of small cells which are called rays.
These are more noticeable in the hard woods than in soft woods. This rays which run radial
from the pith towards cambium layer, crossing the annual rings almost normally.

f. Cambium Layer

This layer is in between the sapwood and bark. As time passes the inner portion is
gradually converted into sapwood.

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MITRE SQUARE

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g. Bark

It is the layer on the outer side of the trees. It protects the cambium layer of the tree from
excessive heat and cold attack from insects and animals.

Carpentry Tools

In order to successfully work different forms to accurate shapes and dimensions, the wood
worker must know the use of a large number of tools. The principal types which are
manipulated by hand are described and illustrated below:

1. Marking and Measuring Tools

Marking and measuring tools have been developed in order to work truly and accurately.
The most common are as follows:

a. Rules

Rules of various sizes and designs are used by wood workers for measuring and setting out
dimensions.

b. Straight Edges

The straight edge is a machined flat piece made of wood or metal having truly straight
and parallel edges. One of the longitudinal edges is generally made levelled. This is used to
test the trueness of large surfaces and edges.

c. Mitre Square

Mitre squares are used to measure an angle of 45°. Different sizes of mitre squares are
available.

d. Try Square

Try squares are used for marking and testing angles of 90°. It consists of hardened and
tempered steel blade which is riveted in to a stock.

e. Bevel Square

It is similar to the try square but has a blade that may be swivelled to any angle from 0° to
180°. This tool is adjusted by releasing with a turn screw of suitable size in a machine screw
running in a slot in the blade.

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Head (Stock)

Stem

Thumb Screw

MARKING GAUGE
Pin (Spur)

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f. Combination Square

A combination square is a tool used for multiple purposes in woodworking. It is composed

of a ruler and one or more interchangeable heads that may be affixed to it. The most common
head is the standard or square head which is used to lay out or check right and 45° angles.

g. Marking Knife

Marking knifes are used for converting the pencil lines to cut lines.

h. Gauges

Gauges are used to mark lines parallel to the edge of a piece of wood. It consists of a
small stem sliding in stock. The stem carries on one or more steel marking pointers or a cutting
knife. The stock is set to the desired distance from the steel pointer and fixed by the thumb
screw.

1. Marking Gauge
The marking gauge has one marking point. It gives an accurate line parallel to a true
edge.

2. Mortise Gauge
The mortise gauge has two marking points, one fixed near to the end of the stem and
the other attached to a brass sling bar. These two teeth cut two parallel lines called
mortise lines.

3. Cutting Gauge
The cutting has a cutting knife held in position by a wedge so that its projection may be
varied for the depth of cut.

i. Wing Compass

Wing compasses are composed of two finely pointed steel legs which are set to the desired
position and held by setscrew and quadrant.

j. Spirit Level

It is used for checking the horizontality of flat surfaces.

k. Plumb Bob

It is used for checking the verticality of surfaces.

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RIP SAW

COMPASS SAW

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Cutting Tools

Cutting tools includes saws, chisels, planes etc.

I. Saws

The saw is probably the most abused of woodworking tools, chiefly because inexperienced
users force it too much. When cutting across the grain, a different action is required from the
saw teeth than when ripping with the grain. Saws are generally specified bythe length of its
blades and pitch of the teeth.

a. Rip saw

Rip saw is the largest and coarsest of all saws. It is used for cutting along the grain in
thick wood.

b. Cross cut saw

A cross cut saw is any saw designed for cutting wood perpendicular to the wood
grain. Crosscut saws generally have smaller teeth than rip saws.

c. Panel saw

This is similar to cross cut saw having finer blade and teeth, used for cutting panels of
doors or similar pieces.

d. Tenon saw or back 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 with a rigid steel back.

e. Bow saw

This saw has a narrow blade on a wooden frame of the shape of a bow. It is used to
cut along sharp curves.

f. Compass saw

The compass saw is used for sawing small curves in confined spaces and has a narrow
tempering blade.

g. Keyhole saw

This is the joiner’s saw about 250mm long used for cutting keyholes or the starting of
any interior cuts.
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TENON SAW

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II. Chisels

Wood chisels most commonly in use include firmer chisels, either square or bevel edged,
paring chisels and mortise chisels. They are usually specified by length and width of the blade.

a. Firmer Chisel

It is the most useful chisel for general purpose and may be used by hand pressure or
mallet.

b. Bevelled edge firmer chisel

It is used for more delicate or fine work. They are useful for getting into corners
where the ordinary chisel would be clumsy.

c. Paring chisel

Both firmer and bevelled edge chisels when they are made with long thin blades, are
known as paring chisels. This is used for shaping and preparing the surfaces of wood
and is manipulated by the hands.

d. Mortise chisel

The mortise chisel is its name indicates is used for chopping out mortises.

These chisels are designated to withstand heavy work.

e. Gouge Chisels

A gouge chisel serves to carve small pieces of the material, particularly concave
surfaces. A gouge typically has a ‘U’- shaped cross section.

III. Planing Tools

The plane can be likened to the chisel fastened in to a block of metal or wood and its blade
cuts exactly like a wide chisel. The planes in general use, are the jack, trying, and smoothing
planes, and are known as bench planes. Besides the bench planes are other planes which are
used for special work.

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Handle Body
Blade

Capiron

Wedge

Sole

WOODEN JACK PLANE

Lateral Adjustment
Lever
Blade or Plane Iron

Lever Cap

Knob Chip Breaker / Handle

Cap Iron

Toe Mouth Plane Body Sole Heel

METAL JACK PLANE

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a. Jack plane

This is the commonly used plane for the first truing up of a piece of wood. It consists
of a block of wood in to which the blade is fixed by a wooden wedge. The blade is set
at an angle of 45° to the sole. On the cutting blade, another blade is fixed; called cap
iron or back iron.

b. Trying plane

It is a finishing plane and is set with a very fine cut, used for producing a true surface
as possible as the smoothing plane does.

c. Smoothing plane

This plane is similar in action to a jack plane except that it is set to a much thinner
planning, after the use of a jack plane.

d. Rebate plane

The rebate is a recess along the edge of a piece of wood; this forms a ledge which is
used for position glass in frame and doors. It is used sinking one surface below another,
and shouldering one piece in to another.

e. Plough plane

The plough plane is used to cut grooves along the grains. A set of 8 to 9 interchangeable
blades are supplied with the plane, varying in width from 3mm to 15mm. Grooves up
to 30mm depth can be made with this plane.

f. Router plane

It is used for cleaning out and levelling the bottom of grooves or trenches to a constant
depth.

g. Spokeshave

This is a double handled plane used for cleaning up or dressing curved surfaces.

h. Metal jack plane

Metal planes serve the same purposes as the wooden planes but facilitate a smoother
operation and the better finish.

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IV. BORING TOOLS

Boring tools are frequently necessary to make round holes in wood and they are selected
according to the type and purpose of the hole. They include bradawl, gimlet, brace, bit and
drill.

a. Bradawl and gimlet

These are hand operated tools and are used to bore small holes.

b. Brace

The brace is a tool used for holding and turning a bit for boring holes. It has two jaws
which grip the specially shaped end of the bit. There are two types of braces in common
use.

1. Ratchet brace

It is used to drill holes in restricted places. They are also used when the cut is
particularly heavy and it is desirable to pull the handle through a quarter-turn only.

2. Wheel brace

It is used to hold round and parallel shanked drills. The tool is invaluable for
cutting small hole, accurately and quickly.

c. Bit

Most other forms of boring tools consist of bits. The most common used are follows.

1. Shell bit

This long bit is from 300 to 900mm in length and from 6 to 12mm in diameter.
Using a rest or a special attachment it is fed into work on the lathe, eg. For boring
deep holes such as in lamp bases.

2. Forstner bit

This has a shallow centre and a scribing ring inside which are two cutters. It bores
a clean shallow hole which is unaffected by knots or awkward grain. It is not
easily sharpened and should be stored carefully in a box. There are 24 sizes from 9
to 50mm.

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BRADAWL

CLAW HAMMER

CARPENTER'S BENCH VICE

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3. Counter sunk bit

It is used for counter sinking for screws. There are two types

Snail horn bit – for use in soft woods

Rose head bit – for use in hardwoods and mild steel

V. Striking tools

Striking tools include hammers and mallets.

a. Claw hammer

This is a hammer having steel head and wooden handle. The flat face of the head is
used to drive nails and the claw portion for extracting nails out of the wood.

b. Mallet

This is a wood headed hammer of round or rectangular cross section. The striking face
is made flat to the work. Mallet is used to give light blows to the cutting toolsand
has wooden handle.

6. Holding devices

To enable the wood worker to cut his wood accurately, it must be held steady. There are
many types of holding devices according to the nature of work to be done. They are as follows:

a. Carpenter’s bench vice

It consists of a jaw fixed on the table side and a movable jaw kept in position by
means of a screw and a handle. The body of vice is made of cast iron or steel. The
jaws are lined with hard wood which can be renewed when it is damaged. The screw
works inside a fixed half nut which can be engaged or disengaged by operating the
lever. By pulling the lever the nut is disengaged from the screw allowing the jaw to
move fast. When the lever is released, the nut engages and screwing action is obtained.

b. Bench stop

The bench stop is simply a block of wood projecting over the top surface of the
bench. This is used to prevent the wood from moving forward when being planned.

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C or G CRAMP

HAND SCREW CLAMP

RASPCUT FILE

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c. Sash (bar) cramp

This is made up of a bar of steel, two jaws and a screw. The work is clamped between
jaws by rotating the screw using handle. It is used for clamping glued pieces tightly or
holding the work pieces of large size together for various operations.

d. C or G cramp

It consists of a malleable iron frame that can be swivelled and a steel screw to which
is fitted a thumbscrew, used to hold small work pieces.

e. Bench hold fast

The bench hold fast is made up of steel and is used to hold the work piece on the table,
while doing the cutting or similar operations.

f. Hand screw

It is used for clamping or holding pieces tightly for various carpentry operations or
pasting sheets together when a wider area of pressure is required than a G-cramp.

7. Miscellaneous tools

There are number of tools other than the types explained above, which are used in carpentry
shops to meet the requirements. The frequently used tools of this group are given below.

a. Rasp cut file

Rasp is a rough file used to remove wood from the surface, corners etc., resting very
rough surface. Ordinary files are used to smooth such surfaces.

b. Scrapers

Scrapers are tools consist of a piece of thin steel, hardened and tempered with burr.
Scraping means removal of a very thin layer of wood similar to shaving.

c. Sand paper

This is a thick paper coated with sharp edged sand or glass particles of fine type on one
side of it. When the sand paper is rubbed on the surface, a thin layer of wood is removed
resulting smooth surface. The grades of sandpaper are usually stated as a number that
is inversely related to the particle size. A small number such as 20 or 40 indicates a
coarse grit, while a large number such as 1500 indicates a fine grit.

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FIRMER CHISEL

BEVELED FIRMER CHISEL

PARING CHISEL

MORTISE CHISEL

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d. Pincer

This is a tool similar to pliers and is used for pulling out nails, tacks etc.

e. Cabinet type screw driver

These are used for screwing and unscrewing screws in wood work. They are made in
various sizes to suit different sizes of screws. The handle may be of hardwood or
unbreakable plastic.

f. Ratchet screwdriver

These screwdrivers are used to insert the screw with one hand, leaving the other hand
free to hold the object in position.

Carpentry Operations

Carpentry work involves a number of hand operations to finish the work to the desired
shape and size with required accuracy. The following is the principal processes used in wood
work:

- Marking - Boring

- Sawing - Grooving

- Planing - Rebating

- Chiselling - Moulding

Wood working machines and power tools

Modern carpentry shop, in addition to the hand tools described earlier, requires the use of
some power-driven machines, where large scale production is to be obtained. The machines
commonly used are:

Wood working lathe : is employed primarily for turning jobs in making cylindrical parts.

Circular saw : used for ripping, cross cutting, mitering, bevelling, and grooving
in large scale.

Band saw : is designed to cut wood by means of an endless metal saw band
that travels over the rim of two or more rotating wheels.

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GOUGE CHISELS

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Wood planer : designed for planing large and heavy stock at a comparatively
faster rate.

Mortiser : is used for cutting mortise (deep square slot) which are very
laborious and time consuming operations.

Sanding machines : performs a sand preparing job (finishing wooden surface) to

produce a uniformly sanded surface.

*****

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Exercise No.1 Date:

PLANING PRACTICE

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Exercise No.1 Date:

PLANING PRACTICE

Aim :

To practice planing operation in the given work piece as per drawing.

Materials required :

A wooden reaper of size 260 x 50 x 30mm.

Tools required :

Steel rule, Try square, Marking knife, Marking gauge, Mallet, Metal jack plane,
Firmer chisel, Carpenter’s vice etc.

Operations to be carried out :

Measuring, marking, planing, chiselling, checking and finishing.

Procedure :

- Fix the given reaper horizontally on the vice and plane one of its broad surfaces with the
help of metal jack plane.

- Plane the long adjacent side perpendicular to the previously planed surface.

- Taking the planed surface as base, mark the required width and thickness using marking
gauge as shown in figure.

- Plane the marked faces to required size.

- Finally, cut the end faces with the help of firmer chisel and mallet.

- Check and finish the work.

Result :

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Exercise No.2 Date:

CHISELING PRACTICE
13
26

All dimensions are in mm

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Exercise No.2 Date:

CHISELING PRACTICE

Aim :

To practice sawing and chiselling operations in the given work piece as per drawing.

Materials required :

A wooden reaper of size 260x50x30mm.

Tools required :

Steel rule, Try square, Marking knife, Marking gauge, Mallet, Metal jack plane,
Firmer chisel (40,25), Tenon saw, Carpenter’s vice etc.

Operations to be carried out :

Measuring, marking, planing, sawing, chiselling, checking and finishing.

Procedure :

- Cut a wooden reaper of size 260x50x30mm from the given long reaper, using tenon saw.

- Fix it on a carpenter’s vice and plane its four sides so as to get a rectangular cross section
of size 45x26mm using a metal jack plane.

- Mark the dimensions on it by using a marking knife, marking gauge and try square.

- Cut the slots and remove excess material from the bar using tenon saw, firmer chisel and
mallet.

- Check and finish the work.

Result :

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Exercise No.3 Date:

CROSS-HALVED JOINT

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Exercise No.3 Date:

CROSS-HALVED JOINT

Aim :

To make a Cross-halved joint as per drawing.

Materials required :

A wooden reaper of size 260x50x30mm.

Tools required :

Steel rule, Try square, Marking knife, Marking gauge, Mallet, Metal jack plane,
Firmer chisel (40,25), Tenon saw, Carpenter’s vice etc.

Operations to be carried out :

Measuring, marking, planing, cutting, sawing, chiselling, checking and finishing.

Procedure :

- Cut a wooden reaper of required size from the given long reaper, using tenon saw.

- Fix it on a carpenter’s vice and plane its four sides so as to get a rectangular cross section
of size 45x26mm using a metal jack plane.

- Mark the dimensions on it by using a marking knife, marking gauge, try square and cut it
into two equal pieces.

- Cut recesses on both pieces as per drawing using firmer chisel and mallet to make a
Cross-halved joint.

- Check and finish the work.

Result :

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FITTING
 Engineering Workshop Practice Manual

SPRING OUTSIDE & INSIDE CALIPER

JENNY CALIPER SPRING DIVIDER

Page 36
 Engineering Workshop Practice Manual

FITTING

Module Duration Cognitive

Description
Outcomes (Hours) Level

Make use of various tools, machines, instruments and power tools

CO2
used in the Fitting shop to make fitting joints
i) Explain safety precautions

M2.01 ii) Demonstrate various tools, 3 Understanding

machines, instruments and power
tools used in the Fitting shop.
Demonstrate various operations like
M2.02 3 Understanding
Measuring, Marking, Cutting, and Filing.
Construct a simple fitting joint involving
M2.03 measuring, Marking, Cutting and Filing. 12 Applying

Introduction

These days small, medium and heavy industries are using automatic machines. But fitting
work also plays a significant role for completing and finishing a job to the desired accuracy.
Most of semi-finished works can be accomplished with fairly good degree of accuracy in a
reasonable time through various kinds of quick machining operations. They still require some
minor operations to be performed to finish the job by hand. The term ‘Bench work’ denotes the
production of an article by hand on the bench. Whereas ‘Fitting’ is the assembling of parts
together and removing metals to secure the necessary fit, by keeping accurate dimension and
may or may not be carried out at the bench. These two types of work require the use of a large
number of hand tools and other devices or equipment that involve a number of operations for
accomplishing the work to the desired shape and size. Some of the commonly used tools are
discussed as under.

1. Measuring & Marking tools

a) Calipers

A caliper is used to transfer and compare a dimension from one object to another or
from a part to scale or micrometer where the measurement cannot be made directly.
The commonly used calipers are shown in the figure.

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Dividers

Dividers are very useful instruments employed in marking work. They are similar in
construction to the calipers but their legs are not bent. Also, the free ends of the two
legs are sharp points. They may have either a friction-joint or a spring arrangement, as
shown in figure. Their principal use is in measuring distance between two points or
parallel lines on a flat surface, dividing a given length in a definite ratio, drawing circles
and arcs and transferring dimensions from scales to objects.

b) Outside caliper

An outside caliper is a two legged steel instrument with its legs bent inwards
as shown in figure. It is used for measuring or comparing thickness, diameters, and
other outside dimensions. A steel rule must be used in conjunction with them if a direct
reading is desired. The side of caliper is specified by the greatest distance it can be
opened at the tips of the legs.

c) Inside caliper

An inside caliper is exactly similar to an outside caliper in appearance with its leg
bent outward as shown in figure. This is used for comparing or measuring hole
diameters, distances between shoulders, or other parallel surfaces of any inside
dimensions. To obtain a specific reading steel scale must be used, as with the outside
calipers.
d) Spring caliper
For finer work the use of spring calipers both outside and inside advocated. A loop
spring on the top of the joint between two legs applies force tending to separate the legs
at the bottom. An adjusting screw and nut keep the legs in position. An inside spring
caliper has legs turned outward to make contact with the inside of holes and grooves.
A steel rule must be used in conjunction with them, as with ordinary calipers. When a
spring caliper is applied to an object, it must make sure contact but not be forced. A
sense of “fell” or “touch” is necessary to use a caliper successfully.

e) Hermaphrodite or jenny caliper

This is sometimes called odd – leg caliper. It has one pointed leg like a divider and one
bent leg as shown in figure. The caliper is extremely useful for scribing lines parallel
to the edge of the work and for finding the center of a cylindrical work. Asteel rule
is a necessary adjunct.

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Accurately Scrapped Edge Flat and Square

Flat surface to each other

SURFACE PLATE
Three point rest
for steadyness

V-BLOCK
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f) Ordinary scribing block or surface gauge

Figure illustrate the surface gauge which is a principal marking tool used generally in
the fitting and the machine shops. It is made in various forms and sizes. It consists of
a cast iron sliding base fitted with a vertical steel rod. The scriber or marker is positioned
or set into an adjustable device using a knurled nut at one end. The scriber can be
loosened or tightened by means of the nut. The marker is used to set it at any desired
inclination, moved to and fro inside the hole accommodating it or adjust its height along
the vertical pillar. It is commonly used in conjunction with either a surface plate or
marking table. It is used for locating centers of round rod held in V- block, describing
straight lines on work held firmly in its position by means of a suitable device like angle
plate and also in drawing a number of lines parallel to a truesurface.
g) Universal scribing block or universal surface gauge
It is a more accurate and more improve variety of simple surface gauge with some
additional features. This can be tilted or clamp at any height on the spindle and at any
convenient angle by engaging the clamping nut. Very minute adjustment in height can
be made by the fine adjustment screw at the base.
h) 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 the 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.
i) Bevel square

An instrument known as bevel gauge is widely used for checking, comparing or

transferring angles and laying out work. This tool is illustrated in figure. It consists of
two adjustable blades which may be moved into almost any position to give any desired
angle. But no direct reading is obtained, and the angle must be set or checked from
some other angular measuring device.
j) Surface plate

The surface plate as shown in figure is used for testing the flatness of work itself and
is also used for marking - out work. This is used for small pieces of work while the
marking – out table is used for larger jobs. Surface plates are made of grey cast iron and
of solid design or with ribs. They should be well and reflection-free illuminated and
rest horizontally on firm support, the working height being about 800 mm from the
floor. The marking-out surface must be protected from rust and dirt and wiped clean
and smeared with grease or oil after use.

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FLAT

HAND

SQUARE

PILLAR

ROUND

TRAINGULAR

HALF ROUND

KNIFE EDGE

TYPES OF FILES

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k) Vernier caliper

Vernier caliper is a precision measuring instrument which is used for outside, inside
and depth measurements. Its accuracy is 0.02mm. The vernier scale for 0.02mm least
count has the scale length of 49mm and it is divided to 50 equal divisions. Hence one
division of Vernier scale is 1/50mm less than 1mm. This gives a least count of 0.02mm.

l) Vernier height gauge

A Vernier height gauge consists of a heavy base, a graduated beam, a sliding head
with Vernier sliding jaws holding the scriber and a fine adjustment clamp. It is similar
to large Vernier calipers in construction, except that it consists of a heavy base which
allows the gauge to stand upright instead of a fixed jaw in a Vernier. The movable jaw
of Vernier height gauge consists of a projection or extension which is levelled to sharp
edge for scribing lines at any required height.

m) V – Block

The V-block is a block of steel with v-shaped grooves. Round shaped work pieces
which are to be marked or drilled are placed on v – supports. In this way they are firmly
supported in a horizontal position and cannot rotate easily. V-Blocks of the following
sizes are found to be most useful: length from 50 to 250 mm width and height from 50
to 100 mm. For long cylindrical work, several blocks of the same size are used as set.

n) Straight edge

Straight edges are commonly used for testing the straightness and flatness of plane
surfaces. The ordinary shape is rectangular but for accurate work one edge is bevelled
or formed into a thin knife edge as shown in figure the narrow edge is the working
surface, while the wide edge adds to the rigidity of the tool and serves as its base when
not in use. Placing the straight-edge on its edge protects the working surface from
damage and from getting dirty.

Flatness is checked by a light test. The narrow edge of the tool is applied to the surface
to be tested and kept horizontally at eye level watching for light between the
straightedge and the surface along the straightedge. Light seen at one place or another
indicates deviation from straightness. This method proves very accurate and within 3
to 5 microns.

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Movable jaw for

internal measurement
Fixed jaw
Vernier head Lock Screw Auxiliary head Main scale

1 2 3 4 5 6 7 8 9 cm

1 2 3 4 5 6 12

Depth gauge
bar

Fixed jaw Movable jaw for Adjustment Nut

internal measurement

VERNIER CALIPER

Guiding edge Beam face

Scale Beam

Fine adjustment
Screw
Vernier scales
Scriber

Slider

Measuring
Jaw

Base

VERNIER HEIGHT GAUGE

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2. Cutting tools

a. Files

It is used for removing excess material to smoothen or fit metal parts. They are generally
forged out of high carbon steel or tungsten steel, followed by cutting of teeth, hardening
and tempering etc.

Classification of files

i. Cut of files

The files are divided into two groups as per cut of the teeth, ie. Single cut and Double
cut. On single cut files, the teeth are cut parallel to each other running across the faces
and at an angle of 60 to the center line of the file. These types of files are frequently
termed as flats and are used for very hard metals. In double cut files, there are two
sets of teeth. The first set is similar to those of single cut files. The second set of teeth
is cut diagonally across the first set of teeth at an angle of 80 to the center line of the
file. It is used for general work.

ii. Shape of files

The shape of file is its general outline and cross-section. Files are made in hundreds of
shapes. Figure show the most commonly used shapes.

a. Flat file : This is tapered in width and thickness, and one of the most commonly
used files for general work. They are always double – cut on the faces and single –
cut on the edges.

b. Hand file : This is parallel in width, and tapered in thickness. A hand file is used
for finishing flat surfaces. It has one edge (i.e., it is uncut) and therefore, is useful
where the flat file cannot be used. They are always double – cut.

c. Square file : This is square in cross section, double – cut, and tapered towards the
point. This is used for filing square corners, enlarging square or rectangular
openings as splines and keyways.

d. Pillar file : Pillar files are double – cut, narrow and of rectangular section. It has
one safe edge, and is used for narrow work, such as keyways, slots and grooves.

e. Round files : They are round in cross – section and usually tapered, when they are
termed rat – tailed. When parallel they are described as parallel round. Round files
are used for filing curved surfaces and enlarging round holes and forming fillets.
They may be single – cut or double – cut.
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Handle

Ferrule
Shoulder

File Length
Tang
Heel

Edge

Tip or Point

PARTS OF A FILE

Solid frame

Wing
Handle Nut
Sand Blade Pin

HACK SAW

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f. Triangular files: The square or triangular file is tapered, double – cut, and the shape
is that of an equilateral triangle. They are used for rectangular cuts andfiling
corners less than 90.

g. Half round file : This is tapered double – cut and its cross section is not a half circle
but only about one-third of a circle. This file is used for round cuts andfiling
curved surfaces.

h. Knife edge file : This is shaped like a knife, tapered in width and thickness and
double – cut. They are used filing narrow slots, notches, and grooves.

iii. Special type files

There are number of file in less common use. They are all used for special purposes and
not in general use. They are wording file, needle file, riffler etc. A wording file is a thin
flat file having fine cut teeth, about 100 mm long. This is widely employed for all kinds
of fine work. A needle file is made in sizes from 100 to 200 mm, of various shapes and
cuts. They are extremely delicate and are used for fine work. Rifflers are curved
upwards at the ends into an arc. They are used to reach the bottom of a sinkingand for
filing the insides of castings.

b. Hacksaw

It is used to cut metals of different sections. It is also used to cut slots and contours. It
consists a frame, blade and handle. There are two types of hacksaw frames.

(a) Solid frame

(b) Adjustable frame

The blade is fixed with its teeth facing forward so that it cuts material in the forward
stroke. The frame is made of mild steel whereas the blade is made of high carbon
steel.

c. Chisels

Chisels are used for cutting and chipping away pieces of metal and are made of
carbon steel usually rectangular, hexagonal or octagonal cross section. They areforged
to shape, roughly ground, and then hardened and tempered. Afterward the edge is
ground sharp to the correct cutting angle, care being taken not to overheat the steel and
draw the temper. The cutting angle given to the chisel is determined mainly by the
nature of the metal to chip. It varies between 35 and 70°, the less acute angles being for
the harder and tougher metals.

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FLAT CHISEL

CROSS CUT CHISEL

HALF ROUND CHISEL

DIAMOND POINT CHISEL

ROUND NOSE CHISEL

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i. Flat chisel

The flat chisel as shown in figure is the most common of all the chisels used in
engineering. It is the chisel which is used for most of the general chipping
operations. It may be used for removing surplus metal from surfaces of the jobs.

ii. Crosscut chisel

The cross-cut chisel figure or cape chisel as it is sometimes called, is used for cutting
grooves in large surfaces previous to using the flat chisel, and is also used in cutting
key ways in wheels and shafts. The cutting edge is slightly wider than the supporting
metal to provide clearance.

iii. Half round chisel

A half – round chisel is shown in figure and of particularly useful for cutting oil-
ways or grooves in bearing, bosses and pulleys, etc. they are also used for setting-
over pilot holes. When a hole is to be drilled a smaller or pilot hole is drilled first.
The shank is reduced to a half-round taper, which is bevelled at the end to give a
circular edge.

iv. Diamond point chisel

The diamond-point chisel as shown in figure is used for cutting vee grooves,
cleaning corners and squaring small holes. The chisel is drawn to a square section.
The end is ground off at an angle producing the diamond shape.

v. Side chisel

A side chisel is shown in figure. This is particularly useful in chipping and removing
the surplus metal in cotter ways and slots, which may have to be cut by hand after
having been drilled. The shank of this chisel is bent out a little sideway and then
vertically down again.

3. Striking tools

a. Ball peen hammer

It is a striking tool suitable for forming rivet head and weighs from 0.5 to 1.5 kg. It is
used for striking punches while marking.

b. Straight peen hammer

It is used to spread metal at right angle to the line of striking and for using in corners
and slot & weighs from 0.5 to 1.5 kg.

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Fixed Jaw Face Moving Jaw

Cast iron body

Screw Handle

PIN VICE

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c. Cross peen hammer

It is used to spread metal in the line of striking and weigh from 0.5 to .5 kg. it is also
used for striking small work piece.

d. Sledge hammer

It is a striking tool which is comparatively larger in size and heavier in weight and
weight of it range from 3 to 8 kg. It is used for striking flat surface.

4. Holding devices

a. Bench vice

It is made of cast iron or cast steel and it is used to hold work for filing sawing, threading
and other hand operation. It consists of a fixed jaws and movable jaws. The size of the
vice is specified by the width of the jaws and maximum opening between the jaws.

b. Leg vice

It is used by black smith but it is also suitable for heavy hammering, chipping and
cutting in fitters work.

c. Hand vice

It is used for holding screws, rivets, keys and other similar object which are too small
to be conveniently held in the bench vice. The vice is held in one hand and the required
operation is performed by other hand.

d. Pin vice

It is used for holding small diameter works, such as wire and pins. The work is gripped
between the jaws of the chuck by rotating the handle.

e. Tool makers vice

It is particularly useful for holding small work which require filing or drilling and for
such work as laying out small jobs on the surface plate. It is made of mild steel.

*****

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Exercise No: 1 Date:

FILING PRACTICE
48

68

All dimensions are in mm

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Exercise No: Date:

53
FILING PRACTICE

Aim :

To practice filing and make the shape as per given figure.

Materials required :

MS flat plate of size 70 x 50 x 6 mm.

Tools required :

Flat file, hacksaw frame with blade, try square, steel rule, & scriber.

Operations to be carried out :

Measuring, marking, cutting, filing & finishing.

Procedure :

- Make sure the required length of flat plate using a steel rule and scriber.

- Cut the work piece with hacksaw blade with frame.

- Hold the work piece in the bench vice and file its one edge to get a flat edge.

- Check its flatness using a steel rule and try square.

- File adjacent side and check the angle (90°) with a try square.

- File the other two edges of the work piece to get the dimension as per figure

- Check the work for inspection

Result :

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Exercise No: 2 Date:

HACKSAW CUTTING PRACTICE

30

30

12

48
10
10

14
18
18
10

16

30 6

All dimensions are in mm

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Exercise No: 2 Date:

HACKSAW CUTTING PRACTICE

Aim :

To make a hacksaw cutting practice.

Materials required :

MS flat plate of size 50 x 50 x 6 mm.

Tools required :

Flat file, hacksaw frame with blade, try square, steel rule, scriber, surface plate, V-
block, vernier height gauge, ball peen hammer, center punch, triangular file, & smooth
file.

Operations to be carried out :

Measuring, chalk applying, marking, cutting, filing & finishing.

Procedure :

- Cut the MS flat of size 50 x 50 x 6 mm using hacksaw frame with blade.

- File and finish the two adjacent sides up to 90º.

- Apply chalk on the one side of the work piece.

- Mark the dimensions as per the drawing using surface plate, V-block & vernier height
gauge.

- Punch the witness mark through the required lines.

- Cu the work piece in to V-shape and square shape and straight line cutting.

- File and finish the work for inspection.

Result :

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Exercise No: 3 Date:

L - JOINT
24

48
24

16 16 16 6

All dimensions are in mm

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Exercise No: 3 Date:

L - JOINT

Aim :

To make a L – joint.

Materials required :

MS flat plate of size 65 x 50 x 6 mm.

Tools required :

Flat file, hacksaw frame with blade, try square, steel rule, scriber, surface plate, V-
block, vernier height gauge, ball peen hammer, center punch, triangular file, & smooth
file.

Operations to be carried out :

Measuring, chalk applying, marking, cutting, filing & finishing.

Procedure:
1. Cut the MS flat of size 65 x 50 x 6 mm using hacksaw frame with blade.
2. File and finish the two adjacent sides up to 90º.
3. Apply chalk on the one side of the work piece.
4. Mark the dimensions as per the drawing using surface plate, V-block & vernier
height gauge.
5. Punch the witness mark through the required lines.
6. Separate metal into two pieces by hack sawing.
7. File and finish the work using flat file and triangular file.
8. File and finish the all edges, surface & check the dimensions.
9. Remove the burrs and apply thin coat of lubricating oil.

Result :

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WELDING
 Engineering Workshop Practice Manual

WELDING

Module Duration Cognitive

Description
Outcomes (Hours) Level

Make use of various tools, machines, instruments and power tools

CO3
used in the Welding shop to make welding joint.
i) Explain safety precautions
M3.01 ii) Demonstrate various tools/equipment 3 Understanding
and protecting devices used in
welding shop.
Demonstrate an Arc welding machine,
M3.02 electrodes, earthing cable, poles etc. and 3 Understanding
practice on welding machine
Construct Straight line welding and Butt joint
M3.03 Welding. 12 Applying

Welding safety precautions:

To prevent injury to personnel, extreme caution should be exercised when using any types
of welding equipment. Injury can twill from fire, explosions, electric shock, or harmful agents.
Both the general and specific safety precautions listed below must be strictly observed by
workers, who weld or cut metals,

Do not permit unauthorized persons to use welding or cutting, equipment;

Do not weld in a building with wooden floors, unless the floor', are protected from hot
metal by means of fire, resistant fabric, and, or other fireproof material. Be sure that hot
sparks or hot metal will not fall on the operator or on any welding equipment
components.

Remove all flammable material, such as cotton, oil, gasoline, etc from the vicinity of
welding.

Before welding or cutting, warn those in close proximity who are not protected to wear
proper clothing or goggles.

Remove any assembled parts from the component being welded that may become
warped or otherwise damaged by the welding process.

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Core wire
Electrode
Coating

Gaseous shield Direction

of travel

Drops of metals
being deposited
Arc crater

Bead
Slag Base metal
Arc

Penitration
Soldified weld metal Molten metal

ARC WELDING OPERATION

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Do not leave hot rejected electrode stubs, steel scrap, or tools on the floor or around
the welding equipment. Accidents and/or fires may occur.

Keep a suitable fire extinguisher nearby at all times. Ensure the fire extinguisher is in
operable condition.

Introduction:

Welding is a process of joining similar metals by application of heat with or without

application of pressure and with or without the use of filler metal.

Types of Welding

Welding may be classified under two broad headings

1. Plastic welding or pressure welding

2. Fusion welding or non pressure welding

In the plastic welding or pressure welding the piece of metal to be joined are heated to a
plastic state and then forced together by external pressure. This procedure is used in forge
welding, resistance welding, in which pressure is required.

In fusion welding or non pressure welding, the material at the joint is heated to a molten
state and allowed to solidify. This includes gas welding, arc welding, thermit welding etc..

Welding Processes

1. ARC Welding

a). Carbon Arc b). Atomic Hydrogen Arc c). Metal Arc

d). Plasma Arc e). Gas Metal Arc (MIG) f). Submerged Arc

g). Gas Tungsten Arc (TIG) h). Electro Slag

2. GAS Welding

a). Oxy Acetylene gas welding b). Air Acetylene gas welding

c). Oxy Hydrogen gas welding

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Outside coating Core

ELECTRODE

FLAT TONGS

ELECTRODE HOLDER

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3. Resistance Welding

a). Butt b). Spot c). Seam

d). Projection d). Percussion

4. Thermit Welding

5. Solid State Welding

a) , Friction b).Ultrasonic c). Diffusion d). Explosive

6. Modern Welding

a). Electron Beam b). Laser Beam

The arc welding is a fusion welding process in which the welding heat is obtained from
an electric arc between the work and an electrode. The electric arc is produced when two
conductors of an electric circuit are touched together and then separated by a small distance.
The temperature of heat produced by the electric arc is of the order of 6000º C to 7000º C.

The most common method of arc welding is with the use of a metal electrode which
supplies filler metal. The welding is done by first making contact of the electrode to a proper
distance to produce an arc.

The direct current (DC) or alternate current (AC) may be used for arc welding, but the
direct current is preferred for most purposes.

ARC Welding Equipment

The most commonly used equipment for arc welding consists of the following

1. AC or DC machine 7. Earthing Clamp

2. Electrode 8. Wire Brush

3. Electrode holder 9. Face Shield

4. Cables and cable connectors 10. Hand Gloves

5. Cable Lug 11. Aprons, Sleeves etc.

6. Chipping hammer

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WIRE BRUSH

CABLE LUG LEATHER APRON

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The welding circuit consists of a power source, two cables, the electrode cable and the
ground cables, ground clamp, electrode holder and the electrodes. The two basic types of power
supplies for arc welding are the d.c generator and a.c transformer

ARC Welding Machine

Both DC and AC are used for electric arc welding each having its particular applications in
some cases either is suitable DC welding supply is usually obtained from generators driven by
electric motor. For AC welding supply, transformers are predominantly used for almost all arc
welding where mainly electricity supply is available. They have to step down the usual supply
voltage (200-400V) to normal circuit welding voltage (50-90V).

A (100-200A) machine is small but portable and satisfactory for light manual welding. A
(300 or 400A) big size is suitable for manual welding of average work. Automatic welding
requires capacities between (800A and 300 A) either in a single unit or a number of small units
in parallel.

Electrodes
It is the usual term or name given to the metallic filler rod used in arc welding to fill up
the gap. There are mainly two types of electrode arc used in arc welding process. They are
bare wire electrode and coated electrode.
Bare Wire Electrode
Coated electrode means the original metal wire is coated on covered with a flux compound
which contains some chemical substances.

The basic weld movements depend upon the operation of the welding machine. Fig shows
the different types of weld movements

Popular weld movements are the j type of movements, c type of movements, circle and u
shaped movement.

Chart for different electrode size and current:

Electrode size in diameter (mm) Current (amp)

Φ2.00 x 350 50-75
Φ 2.50 x 350 60-90
Φ3.15 x 350 100-140
Φ4.0 x 450 140-180
Φ5.0 x 450 180-230
Φ6.3 x 450 240-300

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GROUND CLAMP

FLAT HORIZONTAL

VERTICAL OVERHEAD

WELDING POSITIONS

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Welding Tools

1. Electrode Holder

It is fitted at the end of the electrode cable. It should be light in weight and well insulated
the holder should have sufficient current carrying capacity.

2. Cables and Cable Connectors

Cables or leads are intended to carry the electric energy from welding machine to work.
The cables are flexible and well insulated .the cables are generally made up of copper or
aluminum wire. Welding cables are connected by mechanical connectors soldering,
welding or brazing. The mechanical connectors are the connection leads that are probably
most used because they can be more easily assembled and dismantled.

3. Cable lugs

Cable lugs are used for connecting the cables to the welding machine. One of the cables
fastened to the c able lug by means of soldering or pressing

4. Chipping Hammer

A special type of hammer having one end sharpened and the other end flattened. It is used
for chipping the slag after welding and it is made with mild steel or high carbon steel.

5. Earthing Clamp or Ground Clamp

The ground clamp that complete the circuit between the electrode and the welding machine
is generally fastened to the metal being welded either with a clamp, a bolt or some other
means depending on the size of the metal

6. Wire Brush

The wire brush, which removes small particles of slag , is generally made of stiff steel wire
embedded in wood.

7. Face Shield

The face shield may be handheld or it may be head helmet with either a slid lens or a flip
front. The solid lens is stationary. The flip front lens shading revolves upwards so that the
welder can be seeing the weld heading order to clean it. It also allows maximum eye
protection from hot slag while chipping. The face shield generally covers the entire face,
down to the lower throat which protects eyes from infrared and ultra violet rays. The lens
is capable of stopping 99.5% of these rays.

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FACE SHIELD HAND GLOVES

Cutting edge Head

40-45°

Beveled edge

FLAT CHISEL

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8. Hand Gloves

Hand gloves are used to protect the hands from the ultra violet and infra red radiations as
well as the heat that is given off by the arc column. Hand gloves also protect the hand from
minor burns during the chipping operations. The gloves should be worn at all times during
the welding process.

9. Aprons

Aprons are two types, asbestos apron and lead limed leather aprons. Apron is alsoprotective
clothing used to prevent the hot metal and harmful hot rays attack on the body.

Welding Positions

There are four basic positions in which arc welding can be done: flat, horizontal, vertical
and over head of the four. The flat position is the easiest most economical and generally results
in the strongest weld joints.

1. Flat Position

In this position the filler metal is deposited from the upper side of the joint with the face
of the weld to horizontal.

2. Horizontal Position

In this position, the weld is deposited upon the side of a horizontal and against a vertical
surface. if the horizontal welding position is required a shorter. Arc column should be
used which is true for the flat position too. A shorter arc column helps to prevent the molten
from slagging.

3. Vertical Position

In this position, the lines of welding is I vertical plane and the weld is deposited upon a
vertical surface. If the welding is to be done in the vertical position the welder can choose
whether to deposit the lead in uphill (top to bottom) or downhill (bottom to top) direction.
Downhill welding is much faster than uphill welding. Uphill welding is generally result a
stronger welding.

4. Over Head Position

In this position, the weld is deposited from the underside of the joint and the weld is
horizontal. It is the reverse of flat welding.

*****

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Exercise No.1 Date:

EDGE PREPARATION AND ARC STRIKING PRACTICE

6
80°

All dimensions are in mm

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Exercise No.1 Date:

EDGE PREPARATION AND ARC STRIKING PRACTICE

Aim :

To make a rectangle MS piece as per given dimensions and arc striking practice.

Materials Required :

MS flat 102 x 40 x 6 mm - 1 No.

MS Electrode – ∅3.15mm x 350 mm – 1 No.

Tools and Equipments Required

Steel rule, Try square, scriber, hacksaw, bench vice, flat file, face shield, apron,
gloves, tongs, chipping hammer, wire brush, flat chisel and ball peen hammer.

Operations to be Carried Out

Measuring, marking, cutting, holding, filing, checking, setting, arc striking and
maintaining, chipping and cleaning.

Procedure :
- Measure and mark the MS flat in required dimension with steel rule, try square,
scriber
- Cut it with the help of hack saw and bench vice
- Hold the work in bench vice and file the adjacent edges and check the straightness
and 90° angle
- Place the work piece on the welding table and switch on the welding machine and set
the required current.
- Hold the electrode in the electrode holder and touch the electrode tip on the work
piece either scratching or hitting method.
- Strike the arc and maintain it with proper arc length, slow speed and electrode angle.
- Hold the hot work with tongs and allow to cool slowly.
- Chip out the slag and spatters with chipping hammer, chisel and ball peen hammer
- Clean the work by wire brush and subject to visual inspection.

Result :

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Exercise No.2 Date:

STRAIGHT LINE WELD DEPOSIT IN DOWN HAND POSITION

All dimensions are in mm

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Exercise No. Date:

75

STRAIGHT LINE WELD DEPOSIT IN DOWN HAND POSITION

Aim :
To make a straight line welding in down hand position by arc welding process

Materials Required :
MS flat 102 x 40 x 6 mm - 1 No.
MS Electrode – ∅3.15mm x 350 mm – 1 No.

Tools and Equipments Required :

Steel rule, Try square, scriber, hacksaw, bench vice, flat file, face shield, apron,
gloves, tongs, chipping hammer, wire brush, flat chisel and ball peen hammer.

Operations to be Carried Out :

Measuring, marking, cutting, holding, filing, checking, setting, arc striking and
maintaining, welding, chipping and cleaning.

Procedure :
- Mark the required length using a steel rule and a scriber cut the work piece with a
hacksaw.
- Hold the work piece in the bench vice and file the length side. Check the level with
steel rule.
- File the adjacent side and check the angle with try square. Mark the required width
and length then file that side.
- Check the angle with try square and Mark the center and punch through the center
line using dot punch and ball peen hammer.
- Put the work piece on the work table and connect the phase cable to the electrode
holder and neutral cable to the work.
- Start the AC transformer or DC generator set then Check the ampere before striking the
arc according to the diameter of the electrode and Insert the electrode into electrode
holder.
- Touch the electrode on the work piece. Then create Arc and maintain that arc up to
required length. Remove the slag using a chipping hammer.
- Clean the work with wire brush. Cool the work piece.

Result :

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Exercise No.3 Date:

SQUARE BUTT JOINT WELDING

All dimensions are in mm

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Exercise No.3 Date:

SQUARE BUTT JOINT WELDING
Aim :

To make a square butt joint welding in down hand position by arc welding process

Materials Required :

MS flat 102 x 40 x 6 mm - 2 No.

MS Electrode – ∅3.15mm x 350 mm – 1 No.

Tools and Equipments Required :

Steel rule, Try square, scriber, hacksaw, bench vice, flat file, face shield, apron,
gloves, tongs, chipping hammer, wire brush, flat chisel and ball peen hammer.

Operations to be Carried Out :

Measuring, marking, cutting, holding, filing, checking, setting, tacking, welding,

chipping and cleaning.

Procedure :
- Mark the required length using a steel rule and a scriber and Cut the work piece with a
hacksaw.
- Hold the work piece in the bench vice and file the length side and Check the level
with steel rule.
- File the adjacent side and check the angle with try square and Mark the required width
and length then file that sides and check the angle with try square.
- The gap between two work piece are 2 mm. Put the work piece on the work table and
connect the phase cable to the electrode holder and neutral cable to the work.
- Start the AC transformer or DC generator set. Then Check the ampere before striking
the arc according to the diameter of the electrode and Insert the electrode into electrode
holder.
- Tack the work piece and check the levels, Touch the electrode on the work piece. Then
create Arc and maintain that arc up to required length. Remove the using a chipping
hammer.
- Clean the work with wire brush. Cool the work piece.

Result :

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SHEET METAL
 Engineering Workshop Practice Manual

SHEET METAL
Module Duration Cognitive
Description
Outcomes (Hours) Level
Utilize different sheet metal tools and measuring instruments to
CO4
make sheet metal joints.

i) Explain safety precautions

M 4.01 ii) Demonstrate various tools/equipment 3 Understanding
used in sheet metal shop.
M 4.02 Demonstrate Sheet Metal operations like 3 Understanding
sheet Cutting, Bending and Edging.
M 4.03 Construct Simple joints involving sheet metal 12 Applying
operations.

Introduction

Sheet metal has its own significance as a useful trade in engineering and for our day to day
requirements. It is generally the working of metals from 16 gauge down to 30 gauge, with
simple tools and equipments.

In sheet metal work, the knowledge of geometry, mensuration and properties of metal is
most essential since nearly all pattern come from the development of the surfaces of a number
of geometrical models such as cylinder, prism, cone and pyramid.

Sheet metal works include various cutting, forming and joining processes in sheet metal.
Common examples of sheet metal work are hoppers, canisters, guards, covers, pipes, hoods,
funnels, bends, boxes etc. Such articles are found less expensive, lighter in weight and at many
places they easily replace the use of the castings or forgings.

Metals used in sheet metal work

The sheets used in sheet metal work are specified by standard gauge numbers. It is a series
of numbers known as standard wire gauge (SWG) numbers. Each gauge designates a definite
thickness; higher the SWG number of a sheet, lesser will be its thickness. Lower the SWG
number, higher the thickness of sheet.

The term ‘sheet’ normally used to describe metal sheets with a maximum thickness of 2
mm; above this, it is usual to use the term ‘plate’.

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SCRIBER

TRAMMEL POINTS

40° 90°

Prick Punch Centre Punch

PUNCHES

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Metal sheets used in sheet metal works are:

Black iron

Black Iron is the cheapest sheet metal and is uncoated. It corrodes rapidly.

Galvanized iron

Zinc coated iron is known as galvanized iron or GI iron.

Stainless steel

This is an alloy of steel with nickel, chromium and traces of other metals, it has good
corrosion resistance.

Copper

Copper is a non-ferrous metal and has corrosion resistance property.

Aluminium

Aluminium is a light weight and corrosion resistant metal. It cannot be used in pure form.

Tin plate

Tin plate is iron sheet coated with Tin to prevent corrosion.

Lead

Lead is very soft and heavy. It is used in highly corrosive acid tanks.

Sheet Metal Hand Tools

1. Marking Tools

a. Scriber

This is the metal worker’s pencil with its one end sharply pointed and hardened to
scratch lines on sheet metal in laying out patterns.

b. Divider

It consists of two pointed legs, and used for drawing circles or arcs or to divide lines
into equal parts.

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1 2 3 4 5 6 7 8 9 cm

Inches

12" = 30.48cm

STEEL RULE

Blade

Stock

TRY SQUARE

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c. Punching Tools

- Solid Punches are used for making small holes or markings. Different types of
solid punches commonly used are:

Prick punch - 40°

Centre punch - 90°

- Hollow Punches are also used to punch holes in thin sheet metal, leather, plastic,
cork etc.

- Hand Lever Punch is used where a large number of holes to be punched.

d. Trammel Points

It consists of a bar with two movable heads. It is used to draw large circles or arcs that
are beyond the limit of the dividers.

e. Straight Edge

This is a flat graduated steel bar with one longitudinal edge bevelled. It is useful for
scribing long straight lines.

f. Steel Square

It is an L-shaped piece of hardened steel with marks graduated on the edges for
measuring, used for marking perpendicular lines to any base line.

g. Try Square

Try square is used for marking in the perpendicular direction to any base line. Main
parts are stock and blade.

2. Measuring Tools

a. Steel Rule

It consists of a hardened steel strip having graduations etched in it. They are usually
150mm or 300mm long, and is used to take linear measurements to an accuracy of
0.5mm.

b. Folding Rule

This is useful in measuring and laying out larger works; the accuracy of being 0.5mm.
It can be folded in hinges.

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Gauge Approx.
No. thickness
(in mm)
0 7.937
1 7.142
2 6.846
4 5.895
6 4.935
10 3.175
15 1.775

11
20 0.996
22 0.794
24 0.629
25 0.560
26 0.498
28 0.396
30 0.315
32 0.256
35 0.177

STANDARD WIRE GAUGE

MALLET

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c. Circumference Rule

This is used to find out directly the circumference of a cylinder.

d. Bevel protractor

It is used for angular measurement. It consists of a semicircular steel disc graduated in

degrees from 0° to 180° and a bevel gauge pivoted centrally.

e. Micrometer

Micrometer is a precision measuring instrument with an accuracy of 0.01mm.

Thickness of sheets can be measured by this instrument.

f. Standard Wire Gauge

Both the thickness of the sheet metal and diameter of wires can be checked by means
of Standard Wire Gauge.

3. Striking Tools

a. Ball Peen Hammer

It is used useful for rounding off edges of metal pins and fasteners, such as rivets.

b. Setting Hammer

It is used to set up seams, flaring the edge of the cylindrical job and to set up the long
channels etc.

c. Riveting Hammer

It is used to jump the rivet shanks and finish the rivet heads.

d. Creasing Hammer

It is used to finish the wired edges, make the corner of the sheets with the help of
creasing stake, stretch sheets etc.

e. Raising Hammer

It is used for forming of a flat sheet of metal into a curved or hollow shape such as
saucer, bowl, tray or spoon.

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Turret Slow motion device

Body
Scale

Blade Stock

Blade locking nut Working edge

BEVEL PROTRACTOR

STRAIGHT SNIPS

BEND SNIPS

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f. Planishing Hammer

It is used to give smooth surface finish to the job. Soft nylon hammers are also used to
avoid damage to the metal sheet.

g. Mallet

Mallets are soft hammers and are made of hard rubber, copper, brass, lead, fiber or
wood. It is used to strike a soft blow on the metal so that nicks will not be made on
the surface of the sheet. Types of mallets are; ordinary wooded mallets, bossing mallets
and end faked mallets.

4. Supporting Tools

a. Stakes

They are the sheet metal worker’s anvil used for bending, seaming or forming
operations, using mallet or hammer. It consists of a shank and a head or horn. The
shanks are designed to fit into a hole in the bench.

i Hatchet Stake

It consists of a horizontal sharp straight edge and is used for making sharp bends,
folding the edges of the sheet metal, forming boxes and pans by hand.

ii Half Moon Stake

It has a sharp edge in the form of an arc of a circle, bevelled along one side. It is
used for circular folding and seaming.

iii Funnel Stake

It is used for shaping and seaming of funnels and tapered articles. It is also used to
obtain a conical shape in sheet metals for various purposes.

iv Creasing Stake

It has a square horn with grooved slots at one end and a tapered round horn at the
other end. These are used for wiring and heading and for conical shaped pieces.

v Beak Horn Stake (Bick Iron Stake)

It has two horns, one is tapered and the other is rectangular shaped. It is used as a
general purpose anvil, for riveting, forming etc.

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GROOVER RIVET HEADER

HATCHET STAKE HORSE STAKE

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vi Copper-Smith Stake

It has a rounded edge on one side of the head and a sharp rectangular edge on the
other.

vii Conductor Stake

It is having two cylindrical horns of different diameter.

viii Horse Stake

It is double ended holder for small stakes, one of which is cranked downwards for
clearance purpose and has square/round holes at both ends.

b. Folding Bars

It is used for bending and folding straight sheet metal held between its bars and
clamped to the vice. The folding line coincides with the top of the folding bars.

c. Groover

It is used for closing and locking of seams (joints) in sheet metal work. The end of the
tool is recessed to fit over the lock, making the grooved seam.

d. Rivet Set Or Rivet Header

This is a hardened steel tool, hollow in one end. It is used to shape the end of a rivet
into a round, smooth end.

5. Holding Tools

a. Bench Vice
It is made of cast iron or cast steel and is used to hold the work for filing, sawing,
threading and other hand operations. The size of the vice is stated by the width of the
jaws. It consists of fixed and movable jaws with jaw plates, a lead screw with handle
and a base.

b. Pliers
It is used to hold work pieces like wires, small work sheets etc.

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FUNNEL STAKE

CREASING STAKE

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6. Cutting Tools

a. Snips or Hand Shear

A snip, also called a hand shear is used like a scissors to cut thin, soft metals. It
should be used only to cut 20 gauge or thinner metal. These commonly used snipes are:
Straight snips and Bend snips.

b. 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.

c. Chisels
Chisels are generally used in sheet metal work for cutting sheets, rivets, bolts and
chipping operations.

7. Soldering Iron
Soldering iron also called soldering coppers. This is used for soldering work pieces. It
consists of a forged piece of copper joined to an iron rod with a wooden handle.

8. Sheet Metal Operations

The practical art of sheet metal lies in the making of different shapes by adopting
different operations. The major types of operations are given below:
1. Shearing
- Cutting off - Parting - Blanking - Punching
- Piercing - Notching - Slitting - Lancing
- Nibbing - Trimming
2. Bending
3. Drawing
4. Squeezing
5. Riveting

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CONDUCTOR STAKE

COPPER SMITH STAKE

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9. Hems and Seams

a. Hem
Hem is an edge or border made by folding. It stiffens the sheet of metal and does
away with sharp edge. Hems are three types; single hem, double hem and wired edge.

b. Seam

A seam is a joint made by fastening two edges together. Seams are lap seam, grooved
seam, single seam, double seam, dovetail seam and burred bottom seam.

Sheet Metal Machines

When a large number of jobs are made, particularly in heavier types of sheets, and
operations like shearing, punching, bending etc. is difficult, time consuming and uneconomical.
To cope with this problem, both hand and power operated machines have been developed.
Smaller machines are usually referred as ‘bench machine’ while the others as ‘floor machine’
which are particularly useful in mass production of identical parts.

******

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Exercise No.1 Date:

STRAIGHT CUTTING PRACTICE

10
100

All dimensions are in mm

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Exercise No.1 Date:

STRAIGHT CUTTING PRACTICE

Aim :

To practice, straight cutting in the given work piece as per drawing.

Materials Required :

GI sheet of 26 SWG – size 102x102 mm.

Tools Required :

Steel rule, Scriber, Try square, Flat file, Mallet, Straight snips, stakes etc.

Operations to be Carried Out :

Measuring, marking, filing, cutting, levelling, checking and finishing.

Procedure :
- Mark the given work piece as per dimensions with the help of steel rule, try square
and scriber.
- File the edges and size it into 100x100mm.
- Cut the sheet through the lines marked 10mm apart, as per drawing using straight
snips.
- Level the strips with mallet.
- Check and finish the work.

Result :

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Exercise No. Date:

98
Exercise No.2 Date:

LOCKED GROOVED JOINT

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Exercise No. Date:

99

LOCKED GROOVED JOINT

Aim :

To make a locked grooved joint as per drawing.

Materials Required :

GI sheet of 26 SWG – size 117x62 mm

Tools Required :

Steel rule, Scriber, Try square, Flat file, Mallet, Straight snips, Groover, Ball peen
hammer, stakes etc.

Operations to be Carried Out:

Measuring, marking, cutting, levelling, filing, folding, locking or grooving, checking
and finishing.

Procedure :

- Mark the given work piece as per dimensions with the help of steel rule, try square
and scriber.

- Cut two pieces from the given work piece as per dimensions.

- File the edges and size it to required dimensions.

- Fold one of the edges of each plate in 5mm width and hook it together by using bench
vice and mallet.

- Lock the seam with groover and hammer to form a locked grooved joint.

- Level, check and finish the work.

Result :

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Exercise No.3 Date:

PANED DOWN & KNOCKED UP JOINT

All dimensions are in mm

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Exercise No. Date:

101

PANED DOWN & KNOCKED UP JOINT

Aim :

To make a paned down and knocked up joint as per drawing.

Materials Required :

GI sheet of 26 SWG – size 117x62 mm.

Tools Required :

Steel rule, Scriber, Try square, Flat file, Mallet, Straight snips, stakes etc.

Operations to be Carried Out :

Measuring, marking, cutting, levelling, filing, folding, locking, checking and

finishing.

Procedure :

- Mark the given work piece as per dimensions with the help of steel rule, try square
and scriber.

- Cut two pieces from the given work piece as per dimensions.

- File the edges and size it to required dimensions.

- Fold one of the edges of each plate in 5mm width and hook it together
perpendicularly by using bench vice and mallet.

- Lock the seam by striking with mallet to form a paned down joint.

- Bend the locked seam portion upwards to lock the joint there by forming a knocked
up joint.

- Level, check and finish the work.

Result :

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Exercise No.4 Date:

DOUBLE GROOVED JOINT

10

50 50

All dimensions are in mm

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Exercise No.4 Date:

DOUBLE GROOVED JOINT

Aim :

To make a double grooved joint as per drawing.

Materials Required :

GI sheet of 26 SWG – size 132x62 mm.

Tools Required :

Steel rule, Scriber, Try square, Flat file, Mallet, Straight snips, stakes etc.

Operations to be Carried Out :

Measuring, marking, cutting, levelling, filing, folding, locking, checking and

finishing.

Procedure :

- Mark the given work piece as per dimensions with the help of steel rule, try square
and scriber.

- Cut three pieces from the given work piece as per dimensions.

- File the edges and size it to required dimensions.

- Fold one of the edges of each plate in 5mm width to match with the strap plate edge
which is to be folded 5mm in both ends.

- Hook the strap plate with folded edges of other plates to form double locked joint.

- Lock the seam with mallet to form a double locked joint.

- Level, check and finish the work.

Result :

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 ELECTRICAL
WIRING
AND SOLDERING
 Engineering Workshop Practice Manual

ELECTRICAL
Module Duration Cognitive
Description
Outcomes (Hours) Level

Make use of various tools and accessories to practice electrical

CO5 wiring, motor connection and soldering
i) Explain safety precautions
ii) Demonstrate various tools and 3 Understanding
M5.01
accessories required for Electrical
wiring.
M5.02 Explain wiring materials generally used. 3 Understanding
Develop a circuit and wire up to control one
M5.03 3 Applying
lamp by one switch in conduit wiring.
i) Develop a circuit and wire up for stair
case for one lamp by two switches.
M5.04 ii) Make a connection of single phase 6 Applying
/three phase induction motor with
DOL starter.
Demonstrate soldering iron and flex. Make
M5.05 simple circuit using soldering of electrical/ 3 Applying
electronic components.

Electrical safety precautions:

1. Avoid contact with energized electrical circuits.
2. Disconnect the power source before servicing or repairing electrical equipment.
3. When it is necessary to handle equipment that is plugged in, be sure hands are dry and,
when possible, wear nonconductive gloves and shoes with insulated soles.
4. If it is not unsafe to do so, work with only one hand, keeping the other hand at your side
or in your pocket, away from all conductive material. This precaution reduces the
likelihood of accidents that result in current passing through the chest cavity.
5. If water or a chemical is spilled onto equipment, shut off power at the main switch or
circuit breaker and unplug the equipment.
6. If an individual comes in contact with a live electrical conductor, do not touch the
equipment, cord or person. Disconnect the power source from the circuit breaker or pull
out the plug using a leather belt.
7. Do not make circuit changes or perform any wiring when power is on.

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8. Do not wear loose-fitting clothing or jewellery in the lab. Rings and necklaces are
usual excellent conductors in contact with your skin.
9. It is wise in electrical labs to wear pants rather than shorts or skirts.
10. Powered equipment can be hot! Use caution when handling equipment after it has
been operating.
11. Do your wiring, setup, and a careful circuit checkout before applying power.
12. Use wires of appropriate length. Do not allow them to drape over your equipment.
13. Do not pull wires out until you are absolutely sure that the circuit is completely dead.
Shocks can occur if an inductive load (motor or transformer) is disconnected while
conducting.
14. All the electrical equipment must be connected to the proper earth line.
15. All high voltage equipment must properly be marked and danger signs displayed.
16. If you are working on high voltage circuits, have a co-worker along with you who knows
how to break the circuit to get you free and how to give you mouth-to-mouth
resuscitation and closed chest heart massage.
17. When you are mentally or physically tired, avoid work on energized circuits.

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Electrical Wiring Tools

1. Screw driver:
It is used to turn, tighten or remove screws.

2. Ratchet:
It is used to allow rotary motion in only one direction and preventing the motion in opposite
direction. It is used to tighten nuts of various sizes.

3. Wire cutter and plier:

A wire cutter is used for striping and cutting wires whereas a plier is used to hold objects
like nuts and bolts firmly also used for cutting metal wires.

4. Tester:
It is used to verify the presence of electric voltage in electrical equipment.

5. Crimping tool:
It is used to cut various objects such as wires, cords, tapes and so on. It is also used to join
wires with metal or plastic objects.

6. Voltmeter:
It is used to measure potential difference between two points in the electric circuit.

7. Ammeter:
It is used to measure current flow in a circuit.

8. Watt meter:
It is used to measure electrical power of any given circuit (in watts).

9. Megger or Megohmmeter:
It is used to measure leakage in wires and earth resistance.

10. Multimeter:
It is used to measure various electrical quantities like resistance, voltage, current, etc.

11. Energy Meter:

The meter which is used for measuring the energy utilises by the electric load is known as
the energy meter. The energy is the total power consumed and utilised by the load at a
particular interval of time. It is used in domestic and industrial AC circuit for measuring
the power consumption.

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12. Combination Pliers

It is used for cutting, removing insulation, jointing and twisting the electric wires and cables
even on live-line. A lineman’s pliers have special design, which multiplies force through
leverage. These pliers usually have grips for better handling than bare metal handles. The
grips also have insulation for protection against electric shock when working with live
circuits. A lineman’s pliers are typically machined from forged steel. The two handles are
precisely joined with a heavy-duty rivet that maintains the pliers’ accuracy even after
repeated use under extreme force on heavy gauge wire.

13. Electric Drilling Machine

It has the below mentioned properties: It is a portable electric powered tool used for drilling
the surface. It has a high speed motor to revolve the chuck. It is used to make holes
smoothly and easily.

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Fuse Switch

+
Battery
Load

Fig.1

Fig.2

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Electric circuit
An electric circuit is defined as the network of different components such as battery, lamp,
switch etc which facilitate current flow. Fig.1 and Fig.2 shows simple electric circuits.
Generally an electric circuit may have five components as listed below.
1. The power source. or battery.
2. Load.
3. Conductors.
4. Control devices.
5. Protective devices.

Human Sensitivity to Electricity

500mA – Immediate cardiac arrest resulting in death.

70-100mA – Cardiac fibrillation; the heart begins beats at a steady.
20-30mA – Muscle contraction can cause respiratory paralysis.
10mA – Muscle contraction; the person remains stuck, to the conductor.
1-9mA – Prickling sensation

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WIRING MATERIALS

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Electrical wiring accessories

Wiring accessories are used for connecting appliances

1. Switch

A switch is used to make or break an electrical circuit. It is used to switch ‘on’ or ‘off ’
the supply of electricity to an appliance. There are various switches

a. Surface switch:

It is mounted on wooden boards fixed on the surface of a wall. It is of three types

1. One-way switch 2. Two-way switch 3. Intermediate switch

One-way switch : It is used to control single circuits and lamp

Two-way switch : It is used to divert the flow of current to either of two directions.
The two-way switch can also be used to controlone lamp
from two different places as in the case of staircase wiring

Intermediate switch : It is used to control a lamp from more than two locations

b. Flush switch:

It used for decorative purpose

c. Bed switch:

As the name indicates, it is used to switch ‘on’ the light from any place, other than
switch board or from near the bed. This switch is connected through a flexible wire.

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 Engineering Workshop Practice Manual

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 Engineering Workshop Practice Manual

Voltmeter Ammeter

Energy meter Wattmeter

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 Engineering Workshop Practice Manual

2. Holders

A holder is a device used for holding lamps firmly.

They are two types.

1. Pendant holder 2. Batten holder

3. Ceiling Rose

It is used to provide a tapping to the pendant lamp– holder through the flexible wire or a
connection to a fluorescent tube.

4. Socket Outlet/Plug

The socket outlet has an insulated base with the moulded or socket base having three
terminal sleeves.

***********

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 Engineering Workshop Practice Manual

Exercise No.1 Date:

ONE LAMP CONTROLLED BY ONE SWITCH

20 cm

230V
20 cm
AC Supply P
Supply 5A
Fuse
20 cm

S
S1
Switch
(1 way)

LAYOUT CIRCUIT DIAGRAM

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 Engineering Workshop Practice Manual

Exercise No.1 Date:

ONE LAMP CONTROLLED BY ONE SWITCH

Aim :

To wire up a circuit one lamp controlled by one switch in conduit wiring system.

Tools required:

Sl no Name of tool & Specification Quantity Remarks

1 Screw driver 200mm 1
2 Line tester 500V(neon) 1
3 Cutting pliers 150mm(insulated) 1
4 Combination pliers 150mm 1
5 Hammer(ball peen)225gm 1
6 Pocker150mm 1
7 Firmer chisel 25mm 1
8 Hack saw 300mm 1

Materials required:

Sl. Name of materials & Specifications Quantity Remarks

No.

Procedure:

1. Draw layout on the wiring board.

2. According to the layout, fix 20mm conduit on the board using saddles.
3. Draw cables through the conduit and connect as per connection diagram.
4. Fix lamp holder and switch on round block.
5. Give the specified supply and verify lamp status for different positions of switches.

Result :

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 Engineering Workshop Practice Manual

Exercise No.2 Date:

STAIR CASE WIRING

Lamp
L1 L1

15 cm

230V N
15 cm 15 cm 15 cm
AC Supply P
Supply 5A
Fuse
15 cm

15 cm

S1 S2
S1 S2

Switch Switch
(2 way) (2 way)

LAYOUT CIRCUIT DIAGRAM

STATUS TABLE

Sl.no. S1 S2 L1

1 OFF

2 ON

3 OFF

4 ON

S1 & S2 – Two way switches

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 Engineering Workshop Practice Manual

Exercise No.2 Date:

STAIR CASE WIRING

Aim
1. Prepare an estimate to carry out PVC Surface conduit wiring as per the given layout,
to control one lamp from two different places by two switches independently.
2. Carry out wiring on the wiring board.

Tools required

Sl no Name of tool &specification Quantity Remarks

1 Screw driver 200mm 1
2 Line tester 500V(neon) 1
3 Cutting pliers 150mm(insulated) 1
4 Combination pliers 150mm 1
5 Hammer(ball peen)225gm 1
6 Pocker150mm 1
7 Firmer chisel 25mm 1
8 Hack saw 300mm 1

Materials required
Sl. Name of materials & specifications Quantity Remarks
No.

Procedure
1. Draw layout on the wiring board.
2. According to the layout, fix 20mm conduit on the board using saddles.
3. Draw cables through the conduit and connect as per connection diagram.
4. Fix lamp holder and switches on round blocks.
5. Give the specified supply and verify lamp status for different positions of switches.

Result :

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 Engineering Workshop Practice Manual

Exercise No.3 Date:

SINGLE PHASE MOTOR STARTER WIRING DIAGRAM

Normally Normally
Open Closed
Switch Switch

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 Engineering Workshop Practice Manual

Exercise No.3 Date:

SINGLE PHASE MOTOR STARTER WIRING DIAGRAM

Aim:-
To study the wiring diagram of a single phase motor with a DOL starter.

Tools required:

Sl No Name of tool &specification Quantity Remarks

1 Screw driver 200mm 1
2 Connector screw driver 150mm 1
3 Line tester 500V(neon) 1
4 Cutting pliers 150mm(insulated) 1
5 Combination pliers 150mm 1

Materials required

Sl.No. Name of materials & specifications Quantity Remarks

Procedure:-
1. Connections were made as per connection diagram.
2. Check the circuit for continuity.
3. Given the supply to the circuit after checking.
4. Finished the work neatly and correctly.

Result:-

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 Engineering Workshop Practice Manual

Exercise No.4 Date:

SOLDERING & DE- SOLDERING

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 Engineering Workshop Practice Manual

Exercise No.4 Date:

SOLDERING & DE- SOLDERING

Aim :
To practice soldering and de-soldering for the given electronic circuit using a
soldering iron.

Apparatus required:-

Sl no Name of tool &specification Quantity Remarks

1 Soldering iron (10W or 35W) 1No
2 Solder (60/40grade ) 1
3 Flux 1
4 Connecting wires 1
5 Lead 1
6 Nose plier 1

Procedure:-

1. Clean the terminals of LED and connecting wires.

2. Clean the tips of soldering iron before heating.
3. Heat the soldering iron and apply solder to the tip as soon as it is hot to melt on it.
4. Solder the connections using soldering iron tip at joints.
5. Trim excess component leads with side cutter.
6. Connect the supply and observe the result.
7. Dismantle the components using soldering iron and clean the components.

Result:-

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PROGRAM OUTCOMES ( POs )
PO1: Basic and Discipline specific knowledge:
Apply knowledge of basic mathematics, science and engineering fundamentals
and engineering specialization to solve the engineering problems.
PO2: Problem analysis:
Identify and analyze well-defined engineering problems using codified standard
methods.
PO3: Design/ development of solutions:
Design solutions for well-defined technical problems and assist with the design of
systems components or processes to meet specified needs.
PO4: Engineering Tools, Experimentation and Testing:
Apply modern engineering tools and appropriate techniques to conduct standard
tests and measurements.
PO5: Engineering practices for society, sustainability and environment:
Apply appropriate technology in the context of society, sustainability,
environment and ethical practices.
PO6: Project Management:
Use engineering management principles individually, as a team member or a
leader to manage projects and effectively communicate about well-defined
engineering activities.
PO7: Life-long learning:
Ability to analyse individual needs and engage in updating in the context of
technological changes.

PROGRAM SPECIFIC OUTCOMES ( PSOs )

PSO1: 1. Design, process and development of products related with mechanical
engineering systems by using appropriate modern engineering techniques.

PSO2: Developing precision based machining culture with the help of general
machine codes & mathematical methods to calculate Cartesian Coordinates.
 DEPARTMENT OF MECHANICAL ENGINEERING

VISION

To be a hub of excellence for globally competent mechanical engineers with social

commitment to meet the needs of industry

MISSION
❑ Providing quality education in a creative environment.

❑ Upgrading skills of the students to make them globally competitive.

❑ Equip the students to overcome the challenges of the society.

❑ To develop professionals through Industry-Institution interaction.