SRM Institute of Science and Technology

(Deemed to be University)
Tiruchirappalli Campus
SRM Nagar, Tiruchirappalli – 621 105

21MES101L
BASIC CIVIL AND MECHANICAL WORKSHOP
 SRM Institute of Science and Technology
(Deemed to be University)
Tiruchirappalli Campus
SRM Nagar, Tiruchirappalli – 621 105

Registration No : ……………………………

BONAFIDE CERTIFICATE

This is to certify that this is a Bonafide record of practical work done

by………………………………………….of………………Semester of

……………………………………………………………….Department in

the 21MES101L - Basic Civil and Mechanical Workshop laboratory

during the Academic year……………to………….

Head of the Department Staff Incharge

Submitted for University Examination held on……………. Session……

Internal Examiner - I Internal Examiner - II

 SCHEME OF EVALUATION

Course Code: 21MES101L

Course Name: BASIC CIVIL AND MECHANICAL WORKSHOP

The marks assigned to a student consist of

a. Practical Component = 60 Marks

Continuous Learning Assessment (CLA - I) = 30 Marks
Continuous Learning Assessment (CLA - II) = 30 Marks
b. End Semester Exam Component = 40 Marks

Aim and Procedure = 10 Marks

Fabrication of model = 20 Marks

Accuracy of model = 05 Marks

Viva – voce = 05 marks

c. Total Component = 100 Marks

(a). Practical component (60 Marks) + (b) End Semester Exam Component (40 Marks)

i
COURSE OBJECTIVE:

The course aims to impart practical skills, reinforce theoretical knowledge, and cultivate
safety awareness in handling equipment and professionalism in civil and mechanical engineering
laboratories. The hands-on experiments are

❖ Machining Process – Lathe and Drilling Operations

❖ Metal Joining Process – Arc and Gas Welding

❖ Carpentry and Sheet metal works

❖ Foundry and Smithy – Moulding process

❖ Plumbing – PVC connections

COURSE OUTCOMES:

Upon completion of this course, students will be able to:

1. Machine in a lathe. Drill using drilling machines. Cut glass. Create new components
according to specifications.
2. Weld joints using arc and gas welding. Fit pipes and fixtures. Make new assembly
for given dimensions and tolerances.
3. Practice basic carpentry joints used in household furniture items and sheet metal
items used in shop floor practices.
4. Practice casting, moulding, and smithy trades.
5. Make GI and PVC pipeline connections used in the plumbing trade.

ii
 LIST OF EXPERIMENTS

Ex. Staff
Date Name of the Experiment Mark
No. Initial

1. Perform Facing and Plain Turing operation for the given cylindrical
rod

2. Perform Step Turing operation for the given cylindrical rod

3. Perform Drilling and Tapping operations on the given workpiece

4. Make a Single V-Butt Joint from two Mild Steel plates using arc
welding

5. Make a Lap Joint from two Mild Steel plates using arc welding

6. Make a T - Joint from two Mild Steel plates using arc welding

7. Make a Middle Lap Joint from the given two wooden pieces

8. Make a Cross-lap joint from the given two wooden pieces

9. Make a Dovetail Joint from the given two wooden pieces

10. Make a Rectangular Tray using a GI sheet

11. Make a Funnel using a GI sheet

12. Make a Scoop using a GI sheet

13. Make the mould for the given Stepped-Cone Pulley Pattern

14. Prepare the water line connection for the wash basin and water heater
using plumbing components like pipes, elbows, reducer, flexible
hose, etc., for household applications
Content Beyond Experiment

1. Prepare a Step cutting from the given workpiece

2. Demo on Tungsten Inert Gas (TIG) Welding process

3. Demo on Metal Inert Gas (MIG) Welding process

iii
MACHINING PROCESS
(Lathe)

1
2
 VARIOUS PARTS AND DIFFERENT OPERATIONS OF LATHE

Lathe Machine

Working Principle:
❖ A lathe is a machine tool that holds the workpiece between two rigid and strong supports
called centres or in a chuck or faceplate that revolves.
❖ The cutting tool is rigidly held and supported in a tool post against the revolving work.
Construction:
The main parts of the lathe are the bed, headstock, quick-changing gearbox, carriage and
tailstock.

1. Bed: The bed is a heavy, rugged casting in which the working parts of the lathe are mounted.
2. Legs carry an entire machine load and are firmly secured to the floor by foundation bolts.
3. Headstock: The headstock is clamped on the left-hand side of the bed, and it serves as
housing for the driving pulleys, back gears, headstock spindle, live centre and the feed reverse
gear.
4. Gear Box: The quick-change gearbox is placed below the headstock and contains several
different-sized gears.

3
 5. Carriage: The carriage is located between the headstock and tailstock and serves to support,
guide, and feed the tool against the job during operation. The main parts of the carriage are:

a) The saddle is an H-shaped casting mounted on the top of lathe ways. It provides support
to cross-slide, compound rest and tool post.

b) The cross slide is mounted on the top of the saddle, and it provides a mounted or
automatic cross-movement for the cutting tool.

c) The compound rest is fitted on the top of the cross slide and supports the tool post and
the cutting tool.

d) The tool post is mounted on the compound rest, and it rigidly clamps the cutting tool
or tool holder at the proper height relative to the work centre line.

e) The apron is fastened to the saddle, and it houses the gears, clutches and levers required
to move the carriage or cross slide.

6. Tailstock: The tailstock is a movable casting located opposite the headstock on the ways of
the bed.

LATHE OPERATIONS:
The Engine lathe is an accurate and versatile machine on which many operations can be
performed. These operations are

1. Plain Turning
Plain turning is the operation of removing
excess material from the surface of a
cylindrical job.

2. Facing
The facing is a machining operation by which
the end surface of the workpiece is made flat
by removing metal from it

4
3. Step Turning
Step turning produces various steps of
different diameters

4. Parting

Parting or cutting off is the operation of

cutting away a desired length of the
workpiece, i.e., dividing the workpiece into
two or more parts.

5. Drilling
Drilling is the operation of producing a
cylindrical hole in the workpiece.

6. Reaming
The holes produced by drilling are rarely
straight and cylindrical. The reaming
operation finishes and sizes the hole already
drilled into the workpiece.

7. Boring
The tedious operation enlarges a hole already
produced by drilling.

5
8. Knurling
The knurling is a process of embossing
(impressing) a diamond-shaped or straight-line
pattern into the surface of the workpiece.

9. Grooving
Grooving makes grooves of reduced diameter
in the workpiece.

10. Threading
Threading cuts the required form of threads on
the internal or external cylindrical surfaces.

11. Forming
The forming is an operation that produces a
convex, concave or irregular profile on the
workpiece.

6
12. Taper Turning
Taper turning produces a conical surface by
gradually reducing the diameter of a
cylindrical workpiece.

13. Filing
The filing is the finishing operation that
removes burrs, sharp corners and feed marks
from the workpiece.

14. Polishing
After filing, the surface quality is improved by
the polishing operation, which improves the
workpiece with the help of emery cloth of fine
grades.

7
Facing and Plain Turning

Given workpiece

After facing After plain turning

Scale – 1:1

All dimensions are in mm.

8
 Ex. No.
Lathe: Facing and Plain Turning
Date:

Aim: To get the required shape and size of a given workpiece by facing and plain turning operations
done in the lathe.

Materials Given: Mild Steel rod diameter 32 mm and length 75 mm.

Tools Required:
1. Single Point Cutting Tool
2. Steel Rule
3. Scriber
4. Vernier Caliper
5. Tool Post Key
Procedure:
1. First, the given workpiece is checked for its dimensions.
2. The workpieces are fitted in the chuck properly and tightened by the chuck key.
3. Ensure the centre of the workpiece.
4. Hold the cutting tool in the tool post, check the tooltips whether it has coincided with
the tail stock spindle tip for centering and then tighten the nuts using the tool post key.
5. Facing operation is done with the cutting tool by moving it perpendicular to the lathe axis.
6. It is done on both sides of the workpiece up to the required length.
7. Then turning operation is done with the cutting tool, which removes the outer part
of the workpiece to reduce the diameter up to the dimension required.
8. Then, remove the workpiece from the chuck.
9. The dimensions of work piece are checked.

Result:
Thus, the required shape and size of the given workpiece are obtained on a lathe by facing and
plain turning operations.

9
Step Turning

Given workpiece

After step turning

Scale – 1:1

All dimensions are in mm.

10
 Ex. No.
Lathe: Step Turning
Date:

Aim: To get a required shape and size from a given workpiece by step turning operations in the lathe.

Materials Given: Mild Steel rod diameter 32 mm and length 75 mm.

Tools Required:
1. Single Point Cutting Tool 5. Vernier Caliper
2. Scriber 6. Tool Post Key
3. Lathe
4. Chuck Key

Procedure:
1. Dimensions of the given job is checked.

2. The workpiece is held in the lathe chuck properly and it is tightened by chuck key.

3. The single point cutting tool is held on tool post and it is tightened by tool post key.

4. The facing operation is done with the cutting tool on both sides of the workpiece to get the

required length.

5. The turning operation is done with cutting tool to reduce the diameter up to the required

dimension for the two steps of various diameters.

6. The workpiece from the chuck is removed and the dimensions of workpiece is checked

for the requirements.

Result:
Thus, the required shape and size on the given workpiece is obtained by step turning
operation in lathe machine.

11
12
MACHINING PROCESS
(Drilling)

13
14
VARIOUS PARTS AND DIFFERENT OPERATIONS ON DRILLING MACHINE

Upright Drilling Machine

Working principle:

These heavy-duty and versatile drilling machines operate on large and heavy workpieces.

• The workpiece with the exact location marked with the centre punch is clamped rigidly
on the work table.
• The spindle axis and centre punch indentation are in the same line.
• The machine is started, and a rotating feed handle lowers the drill bit.
• The drill bit touches the work and starts removing material.

DRILLING OPERATIONS
The upright drilling machine is an accurate and versatile machine on which many operations
can be performed. These operations are

15
1. Reaming

■ It is a process of smoothing the surface of

drilled holes with a tool.
■ The tool is called a reamer.
■ Initially, a hole is drilled slightly smaller in
size.
■ The reamer replaces the drill.
■ Speed is reduced to half that of the drilling

2. Boring

■ It is a process carried out by a drilling

machine to increase the size of an already
drilled hole.
■ Initially, a hole is drilled to the nearest size
and using a dull tool, the size of the hole is
increased.

3. Counter boring

■ This process involves increasing the size

of a hole at only one end.
■ The cutting tool will have a small
cylindrical portion called a pilot.
■ Cutting speed = two-thirds of the drilling
speed for the same hole.

16
4. Countersinking

■ This is an operation of making the end of a

hole into a conical shape.

■ Cutting speed = half of the cutting speed of

drilling for the same hole

5. Spot facing

■ It is a finishing operation to produce a flat

surface for a proper bolt head or nuts
seating, usually around a drilled hole.

■ It is done using a particular spot-facing

tool.

6. Tapping

■ Process of cutting internal threads with a

threading tool called tap.
■ Tap is a fluted threaded tool used for
cutting internal thread
■ Cutting speed is very slow.

17
Drilling and Tapping

Given workpiece Dimension marking

Final model (Drilled and Tapped plate)

Scale – 1:1

All dimensions are in mm.

18
 Ex. No.
Drilling and Tapping
Date:

Aim: To drill and tap the given workpiece as per the required dimensions.

Materials Given: Mild Steel plate of size 50 x 50 x 5 mm.

Tools Required:
1. Bench Vice 7. Try Square
2. Tap set 8. Scriber
3. Machine Vice 9. Dot Punch
4. Steel Rule 10. Drill Bit
5. Jenny caliper
6. Drilling Machine
Procedure:
1. The dimensions of the given workpiece are checked.

2. The chalk is applied throughout the surface of the workpiece.

3. Marking is done on the workpiece by using a scriber, dot punch and hammer.

With the help of a vernier height gauge and steel rule, measurement is taken.

4. The adjacent sides of the workpiece are filed, and then the punched workpiece is clamped

in the vice.

5. The required size of the hole is made on the workpiece by using a drilling machine.

6. During the drilling operation, the coolant is applied to avoid heat and to reduce wear.

7. Then, the drilling holes are tapped by using a tapping tool.

Result:
Thus, the drilling and tapping operation is done on the given workpiece for the required size.

19
20
METAL JOINING PROCESS
(Welding)

21
22
 WELDING TOOLS

Flat Rough File Try Square Welding Electrodes

Chipping Hammer Wire Brush Hand Gloves Face Shield

Apron Safety Shoe Welding Tongs

Arc Welding Machine Unit Oxy-Acetylene Gas Welding

23
 USES OF WELDING TOOLS

Welding is the metal joining method wherein localized coalescence is produced by heating
the metal to suitable temperatures with or without filler metal or by applying pressure. The filler
material has a similar composition and melting point temperatures as the base metal. It is used
to fill the gap between the joint surfaces.

❖ Electrodes: Filler rods used in arc welding are called electrodes. The electrodes are
made of metallic wire called core wire. It is used to transmit the total current from the
electrode holder to the front end of the electrode coating.
❖ Electrode Holder: It is a device used to mechanically hold the electrode and conduct
its current.
❖ Chipping Hammer: It is used chisel-shaped, and it is used to remove the slag from the
weld bead.
❖ Hand Gloves: These are used to protect the hands from electrical shock, arc radiation,
and hot spatters.
❖ Face Shield: It is used for shielding and protecting the face and neck of the welder, and
it is fitted with a suitable fitter lens.
❖ Wire Brush: A wire brush made up of stiff steel wire embedded in the wood removes
tiny slag particles from the weld bead after the chipping hammer has done its job.

Arc Welding:

❖ In the arc welding process, the source of heat is electricity.

❖ The coalescence is produced by heating the workpiece with an electric arc struck
between an electrode and the workpiece.

❖ The temperature of the arc is of the order of 3600 ⁰C.

Arc welding Principle:

❖ The heat required for joining the metals is obtained from an electric arc.

❖ The electric motor-generator or transformer sets are used to supply high electric current,
and the electrodes are used to produce the necessary arc.

❖ The electrode serves as the filler rod, and the arc melts the surfaces so that the metals to
be joined are fused.

24
 Principle of the arc welding process

Safety Recommendations for ARC Welding:

❖ The welding machine's body or frame shall be efficiently earthed.

❖ Welding arc, in addition to being very, is a source of infrared and ultra-violet light also;
consequently, the operator must use either a helmet or a hand shield fitted with a special
filter glass to protect the eyes.
❖ Excess ultra-violet light can cause an effect similar to sunburn on the skin of the welder.
❖ The welder’s body and clothing are protected from radiation and burns caused by
sparks and flying globules of molten metal with the help of the following:
➢ Gloves protect the hands of a welder.
➢ A leather or asbestos apron is very useful to protect a welder’s clothes and his
trunk and thighs while seated he is doing welding.
➢ For overhead welding, some form of protection for the head is required.
➢ A leather skull cap or peaked cap will do the needful.
➢ Leather jackets and leather leggings are also available as clothes for body
protection.
❖ Welding equipment shall be inspected periodically and maintained in safe working
order at all times.
❖ Arc welding machines should be of suitable quality.
❖ All parts of the welding set shall be suitably enclosed and protected to meet the usual
service conditions.

25
26
Single V- Butt joint

Workpiece (2 Nos.)

Tack weld Final model (Single V- Butt joint)

Scale – 1:1

All dimensions are in mm.

27
Ex. No.
Welding: Single V - Butt joint
Date:

Aim: To perform a single V- Butt joint between the given workpieces using arc welding.

Materials Given: Mild Steel Flat l×b×t = 75 x 30 x 3 mm (2 pieces)

Tools Required:
1. Arc Welding Transformer
2. Tongs and Wire Brush
3. Welding Electrodes
4. Chipping hammer
5. Gloves and Goggles
Procedure:
1. The two metal plates are filled on all sides for the right angle.
2. Clean the given workpieces using the wire brush to remove the rust, scale and other
impurities.
3. Make two workpieces to form a butt joint. Set the arc welding transformer and
connect the welding cables.
4. Fix the welding electrode (3.15 mm diameter) to the electrode holder and the ground
clamp to the welding table.
5. To check, the proper power supply should be given to the electrode and the work
pieces. When the current is passed, the arc is produced between the electrode and the
workpieces.
6. Now, set the two workpieces in the correct position as shown in the figure and
maintain the gap of 3 mm. Then, the welding will be carried out throughout the length.
7. As soon as the welding process is finished, switch off the current supply and drop the
workpiece into water for cooling using tongs.
8. Finally, take the workpiece and remove the slags using the chipping hammer and Wire
brush.

Result:

Thus, the required single V- Butt joint is obtained by arc welding process.

28
Lap Joint

Workpiece (2 Nos.)

Tack weld Final model (Lap Joint)

Scale – 1:1

All dimensions are in mm.

29
Ex. No.

Welding: Lap joint

Date:

Aim: To make the lap joint using arc welding on the given work pieces.

Materials Given: Mild Steel Flat l×b×t = 75 x 30 x 3 mm (2 pieces)

Tools Required:
1. Arc Welding Transformer
2. Tongs and Wire Brush
3. Welding Electrodes
4. Chipping hammer
5. Gloves and Goggles

Procedure:

1. The given two metal plates are filled on all sides to make a right-angle

2. The given workpieces are thoroughly cleaned of rust, scale and other foreign material.

3. The electrode is fitted in the electrode holder, and the welding current is set to the proper
value.

4. When current is passed, the arc is produced between the electrode and the workpiece.

Here, the welding should be carried out on both sides.

5. When welding is finished, switch off the current supply and allow the workpiece to cool.

6. The slag formation on the weld is removed by using a chipping hammer.

7. Finally, using a wire brush, welded portions are cleaned.

Result: Thus, the required lap joint is obtained by arc welding.

30
T - Joint

Workpiece (2 Nos.)

Tack weld Final model (T - joint)

Scale – 1:1

All dimensions are in mm.

31
Ex. No.
Welding: T – joint
Date:

Aim: To make the lap joint using arc welding on the given work pieces.

Materials Given: Mild Steel Flat l × b × t = 75 x 30 x 3 mm (2 pieces)

Tools Required:
1. Arc Welding Transformer
2. Tongs and Wire Brush
3. Welding Electrodes
4. Chipping hammer
5. Gloves and Goggles

Procedure:
1. The given workpieces are thoroughly cleaned of rust, scale and other foreign
material.
2. The electrode is fitted in the electrode holder, and the welding current is set to the
proper value.
3. Keep one piece on the welding table and the other at the centre of the first piece and
perpendicular to it using tongs.
4. When current is passed, the arc is produced between the electrode and the workpiece.
Here, the welding should be carried out on both sides.
5. When welding is finished, switch off the current supply and allow the workpiece to
cool.
6. The slag formation on the weld is removed by using a chipping hammer.
7. Finally, using a wire brush, welded portions are cleaned.

Result: Thus, the required T - joint is obtained by arc welding.

32
33
CARPENTRY

34
35
 CARPENTRY TOOLS

Steel Rule Machine Planer Marking Gauge

Wooden Mallet Hack Saw Rough Flat File

Chisel Bevel Square

36
 USES OF CARPENTRY TOOLS

❖ Carpenter’s steel rule: Large measurements can be made by the steel rule. It is also suitable for
measuring the circumference of curved surfaces.

❖ Planning tools: In general, planes are used to produce flat surfaces on wood. The cutting blade
used in a place is very similar to a chisel. The blade of a plane is fitted in a wood or metallic
block at an angle.

❖ Marking Gauge: A marking gauge is used in woodworking and metalworking to mark out lines
for cutting or other operations.

❖ Mallet: A mallet is a kind of hammer made of wood with a relatively large head. A wooden
mallet is usually used in carpentry to knock wooden pieces together or to drive dowels or chisels.

❖ Saw: A saw is used to cut the wood into pieces. It has different types as follows:

a) Mitre saw: It is often referred to as a large backsaw (20-30 inches or 60-90 cm) used in
a wooden mitre box or a metal frame.

b) Tenon saw: It has a parallel blade of width 60 mm to 100 mm, length 250 mm to 400
mm and 12 to 20 points or teeth per 25 mm length.

c) Rip Saw: It is used to cut along the grains of wood. Its blade is about 700 mm long and
has 3 to 5 points or teeth per 25 mm length. The teeth of the rip saw have a series of chisel
edges.

❖ File: File is used to finish the surface of the wood.

❖ Chisel: They are particularly useful for cutting purposes with the help of a mallet.

a) Mortise Chisel: Thick, rigid blade with straight cutting edge and square sides to make
mortises and similar joints.

a) Dovetail Chisel: Made specifically for cutting dovetail joints.

b) Bevel Chisel: Edged chisels are slightly undercut, making them easy to push into corners.

❖ Bevel square: It is used to test the flatness of the surfaces or whether the adjacent surfaces are
at right angles to each other.

37
 CARPENTRY PROCESSES

In a carpentry shop, a number of operations are performed to get the finished workpiece. The
different types of processes performed in a carpentry shop can be classified as follows.

❖ Marking and Measuring: It is the process of setting of dimensions on wooden pieces to

obtain the required shape. This is the first step for further carpentry operations. The marking
operation is done with the use of marking tools. Before marking, one end is planned for
reference.

❖ Sawing: Sawing is the process of cutting wood to the required shape and size, such as
straight, inclined or curved. Sawing can be done along the grains or across the grains. In
sawing, wooden work is fixed in a vice and wood is moved up to prevent vibrations during
sawing.

❖ Planning: Planning is an operation of obtaining a smooth, dimensionally true surface of

wood by using a planer. It is done along the grains. So, a smooth surface is achieved. This
process can also be called facing or edging.

❖ Chiseling: It is the process of cutting a small stock of wood to produce the required shapes.

❖ Mortising and Tenoning:

• Mortising is the process of producing a mortise, i.e. rectangular or square holes and
recesses in wooden pieces.

• A tenon is a projected piece of wood that fits into the corresponding mortise. This process
is done by using mortise chisels and a mallet.

❖ Boring: Boring is the process of producing through holes or blind holes in wooden pieces.
This process can be done straight or inclined according to the type of work. The small holes
are produced using bradawl and gimlet, whereas large holes are produced using braces and
drills.

❖ Grooving: Grooving is the process of making grooves. Tonguing is the process of producing
corresponding projections of wood to fit into grooves. Grooving and tonguing operations can
be seen in drawing boards, floorboards and partitions. Grooving is done with a plough plane
tool, and tonguing is done with a Moulding plane tool.

38
Middle Lap Joint

Given workpiece After cutting

Final model (Middle Lap Joint)

Scale – 1:1

All dimensions are in mm.

39
 Ex. No.
Carpentry: Middle Lap Joint
Date:

Aim: To make a middle lap joint with the required dimensions from the given workpiece.

Materials Given: A soft wooden piece of size l×b×t = 200 × 50 × 30 mm.

Tools Required:
1. Machine Planer 5. Wooden Marking Gauge
2. Mallet 6. Steel rule
3. Hack Saw 7. File
4. Chisel 8. Bevel Square

Procedure:
1. The given workpiece is clamped in the carpentry vice, and two adjacent faces are
planned to get right angles using a machine planer.
2. The workpiece is cut into two halves using a rip saw. With the finished face as a reference,
the required size is marked on the workpiece by means of the steel rule and marking gauge.
3. In one half of the workpiece, the unnecessary portions are removed using the mitre saw
and firmer chisel.
4. Similarly, the unwanted portions are removed in the other half of the workpiece
using a circular saw and firmer chisel.
5. Now, the two pieces are assembled to check proper fitting.
6. Finally, the accuracy and proper dimensions are verified using the steel rule and try
square.

Result:
Thus, the middle lap joint is obtained in the required size and shape from the given
workpiece.

40
Cross Lap Joint

Given workpiece After cutting

Final model (Cross Lap Joint)

Scale – 1:1

All dimensions are in mm.

41
 Ex. No.
Carpentry: Cross Lap Joint
Date:

Aim: To make a cross-lap joint from the given wooden workpiece as per the given dimensions.

Materials Given: A soft wooden piece of size l×b×t = 200 × 50 × 30 mm.

Tools Required:
1. Machine Planer 5. Wooden Marking Gauge
2. Mallet 6. Steel rule
3. Hack Saw 7. File
4. Chisel 8. Bevel Square
Procedure:
1. The given workpiece is clamped in the carpentry vice, and two adjacent
faces are planned to get right angles using a machine planer.
2. The workpiece is cut into two halves using a rip saw.
3. With the finished face as a reference, the required size is marked on the workpiece
by means of steel rule and marking gauge.
4. In one half of the workpiece, the unnecessary portions are removed using
a mitre saw and firmer chisel.
5. Similarly, the unwanted portions are removed in the other half of the workpiece
using a circular saw and firmer chisel.
6. Now, the two pieces are assembled to check proper fitting.
7. Finally, the accuracy and proper dimensions are verified by using the steel
rule and try square.

Result:
Thus, the cross-lap joint is obtained to the required size and shape from the given
workpiece.

42
Dovetail Joint

Given workpiece After cutting

Final model (Dovetail Joint)

Scale – 1:1
All dimensions are in mm.

43
 Ex. No.
Carpentry: Dovetail Joint
Date:

Aim: To make a dovetail joint from the given wooden piece as per the given dimensions.

Materials Given: A soft wooden piece of size l×b×t = 200 × 50 × 30 mm.

Tools Required:
1. Machine Planer 5. Wooden Marking Gauge
2. Mallet 6. Steel rule
3. Hack Saw 7. File
4. Chisel 8. Bevel Square

Procedure:
1. The given workpiece is clamped in the carpentry vice, and two adjacent faces

are planned, to get right angles using a machine planner.

2. The workpiece is cut into two halves using a circular saw.

3. With the finished face as a reference, the required size is marked on the workpiece

by means of the steel rule and marking gauge.

4. In one half, a tapered peg is made with the help of firmer and parting chisels.

5. In the other half, a dovetail slot is cut with a firmer chisel.

6. The two pieces are assembled to check proper fitting.

7. Finally, the accuracy and proper dimensions are verified by using the steel rule

and trying square.

Result:
Thus, the dovetail joint is obtained in the required size and shape from the given

wooden piece.

44
45
SHEET METAL

46
47
 SHEET METAL TOOLS

Standard Wire Gauge Steel Rule Scriber

Straight Snips Trammels

Bench Stakes Ball-Peen Hammer Wooden Mallet

Bench Vice

48
Applications of sheet metal work:
Sheet metal is involved in the bodybuilding of Aircraft, Railway coaches, Automobiles,
Drums and shells in chemical industries, Chimneys, Tanks in fertilizers, Cement industries, etc.

Specification of the sheet metal:

Standard gauge numbers specify the sheet; each gauge designates an actual thickness.
Standard Wire Gauge can identify the gauge (SWG). The larger the gauge numbers, the lesser
the thickness and vice versa.

SWG 10 12 14 20 22 24 26 30

Thickness in mm 3.2 2.6 2.0 0.9 0.64 0.56 0.4 0.3

• STEEL RULE: It is used for measuring and laying out small work. It can measure with
an accuracy of up to 0.5 mm.

• TRAMMELS: It is used for marking arcs and circles. The maximum size of the arc that
can be scribed depends on the length of the beam inscriber.

• SCRIBER: It is a long steel wire with one end sharply pointed and hardened to the
scratch line on sheet metal to layout patterns.

• STRAIGHT SNIPS: It is used for cutting along outside curves and straight lines.

• BALL PEEN HAMMER: It is used in sheet metal work for hollowing, stretching,
levelling, riveting, and strengthening of sheet metal joints.

• WOODEN MALLET: It is used for levelling sheet metal surfaces.

• BENCH STAKES: Stakes are nothing but sheet metal work anvils used for bending,
hemming, seaming, forming, etc.

• BENCH VICE: The bench vice is holding the device. The faces of the jaws are usually
hardened to ensure a firm grip on the work.

49
 SHEET METAL PROCESSES

❖ Shearing processes: The processes that apply shearing forces to cut, fracture, or separate the
material.

a) Punching: It is a shearing process using a die and punch where the interior portion of the
sheared sheet is to be discarded.

b) Blanking: It is a shearing process using a die and punch where the exterior portion of the
shearing operation is to be discarded.

c) Perforating: Punching a number of holes in a sheet.

d) Parting: Shearing the sheet into two or more pieces.

e) Notching: Removing pieces from the edges.

f) Lancing: Leaving a tab without removing any material

❖ Forming processes: The processes that cause the metal to undergo desired shape changes
without failure, excessive thinning, or cracking. This includes bending and stretching.

a) Bending: The forming process causes the sheet metal to undergo the desired shape
change by bending without failure.

b) Stretching: The forming process causes the sheet metal to undergo the desired shape
change by stretching without failure.

c) Drawing: The forming process causes the sheet metal to undergo the desired shape
change by drawing without failure.

d) Roll forming: It is a process by which a metal strip is progressively bent as it passes

through a series of forming rolls.

❖ Finishing processes: These are the processes that are used to improve the final surface
characteristics.

50
Rectangular Tray

Given workpiece Dimension marking

After cutting Final model (Rectangular Tray)

Scale – 1:1

All dimensions are in mm.

51
 Ex. No:

Sheet metal: Rectangular Tray Making

Date:

Aim: To fabricate a Rectangle Tray from the given sheet metal.

Materials Given: Galvanized iron sheet thickness of 0.64 mm (24 standard wire gauge), and
the size of the sheet metal is l × b = 150 mm × 90 mm.
Tools Required:

1. Steel rule 5. Straight Snip

2. Scriber 6. Protractor
3. Divider 7. Mallet
4. Standard wire gauge

Procedure:

1. The size of the given sheet is checked with the steel rule.
2. Sheet metal of length 150 mm and breadth 90 mm is marked on the given sheet.
3. The layout of the tray is cut by using a straight snip.
4. Bending is done as per the given dimensions using the stake and mallet.
5. Folding is done as per the following order using a mallet and stake.
6. The first fold edge is fixed on the bench vice, folded upwards manually, and finished
using a wooden mallet. Similarly, the other opposite edge is also folded.
7. The second fold edge (5 mm edge) is folded outwards using a bench vice and ball
peen hammer. Similarly, the opposite side is also folded outwards with 5 mm edges.
8. Finally, the tray is riveted using the given rivets and hammer.
9. The dimensions length of 120 mm, breadth of 60 mm, and height of 15 mm are
verified using the steel rule.

Result:

Thus, the desired rectangular tray is made from the given sheet metal.

52
Fabrication of Funnel

Given workpiece Dimension marking

Top

Bottom

After cutting Final model (Funnel)

Scale – 1:1

All dimensions are in mm.

53
 Ex. No.
Sheet metal: Funnel Making
Date:

Aim: To fabricate a funnel from the given sheet metal.

Materials Given: Galvanized iron sheet thickness of 0.64 mm (24 standard wire gauge), and
the size of the sheet metal is l × b = 150 mm × 110 mm.

Tools Required:
1. Steel rule 5. Curved Snip
2. Scriber 6. Protractor
3. Anvil 7. Standard wire gauge
4. Wooden Mallet
Procedure:
1. The given metal sheet is checked for its dimensions using a steel rule.
2. The required shape is first produced on paper, which is used for reproducing
the exact size of the sheet metal.
3. The slanting angle of the sector is calculated by using the formula 0 = 360° x
R/L, where R is the base circle radius and L is the slant height. The required
shape is cut from the paper.
4. Then the exact shape of the paper cut is placed on the GI sheet so that the
the same size can be reproduced on the sheet metal using the scriber.
5. Now, the sheet is folded using the funnel stake to make a top portion into a cone
shape.
6. After that, the cone edges of the folded portion are joined together by a seaming
process using an anvil.
7. Similarly, the bottom portion of the cylinder is marked for its dimensions and
cut by straight snip. It is made to a circular shape manually using funnel stakes.
8. The folded GI edges are locked using the wooden mallet. Also, the joint is
formed with 5 mm using an anvil and a wooden mallet.
9. Finally, the top and bottom portions are joined together to form a Funnel shape.

Result:
Thus, the given sheet metal is formed into a funnel shape as per the required dimensions.

54
Fabrication of Scoop

Given workpiece Dimension marking

After cutting Final model (Scoop)

Scale – 1:1

All dimensions are in mm.

55
 Ex. No.
Sheet metal: Scoop Making
Date:

Aim: To fabricate a scoop from the given sheet metal.

Materials Given: Galvanized iron sheet thickness of 0.64 mm (24 standard wire gauge), and
the size of the sheet metal is l × b = 90 mm × 120 mm.

Tools Required:
1. Steel rule
2. Scriber
3. Wooden Mallet
4. Standard wire gauge
5. Straight Snip
Procedure:

1. The given metal sheet is checked for its dimensions using a steel rule.

2. The required shape is first produced on paper, which is used to reproduce the

exact size of the sheet metal.

3. The scoop layout is marked on the given sheet and cut using a straight snip.

4. Folding is done as per the given order: first, the complete back portion of the

scoop is bent, and second, the side part of the scoop back portion is stretched.

5. Third, the side portion of the scoop is bent and fourth, 5 mm edges of the scoop

back centre portion are folded outwards using a mallet and stake.

6. Finally, the tray is riveted using the given rivets and hammer.

Result:

Thus, the required Scoop is made from the given GI sheet metal piece as per the given

dimensions.

56
57
FOUNDRY

58
59
 MOULDING & FOUNDRY TOOLS

Moulding Box Sprue Pin & Riser Pin Riddle

Shovel Bellows

Trowel Round Rammer Strike Off B a r

60
 FOUNDRY
❖ A foundry factory produces metal castings from either ferrous or non-ferrous alloys.

❖ A sand casting or a sand moulded casting is a cast part produced by forming a mould from a sand
mixture and pouring molten liquid metal into the cavity in the mould.

❖ The mould is then cooled until the metal has solidified. In the last stage, the casting is separated
from the mould. There are six steps in this process:

1. Place a pattern in sand to create a mould.

2. Incorporate a gating system.

3. Remove the pattern.

4. Fill the mould cavity with molten metal.

5. Allow the metal to cool.

6. Break away the sand mould and remove the casting.

❖ There are two main types of sand used for moulding. "Green sand" is a mixture of silica sand,
clay, moisture and other additives.

❖ The "air set" method uses dry sand bonded to materials other than clay, using a fast-curing
adhesive. When these are used, they are collectively called "air set" sand castings to distinguish
these from "green sand" castings.

❖ Two types of moulding sand are natural bonded (bank sand) and synthetic (lake sand), which is
generally preferred due to its more consistent composition.

INTRODUCTION OF FOUNDRY SHOP

❖ Producing components by casting has been used since the earliest days of civilization. A lot of
shapes and sizes can be prepared in the casting process.

❖ To make the casting of a component, a cavity of the desired shape will be produced in which the
molten metal is poured.

❖ Mould is the cavity of the required shape made in moulding sand or other material. The process
of moulding consists of all operations done to make a mould.

61
Pattern: Pattern is the model used to get the required casting. It is used to produce the mould
cavity in the sand.

Moulding sand or green sand: It is a mixture of sand and additives such as water, bentonite,
inoculant, sodium silicate, etc., used to create a mould cavity.

1. Shovel: Used for mixing and transferring moulding sand.

2. Riddle: A metal sieve removes foreign material, such as stone, nails, etc., from the moulding

sand.

3. Rammer: It is a tool made of cast iron used for packing or ramming the moulding sand in the

moulding box.

4. Trowels: It is a rectangular metal blade with a round or square end used to smoothen mould

surfaces.

5. Slick: It is a double-ended tool used for repairing and finishing surfaces and round corners

of the mould.

6. Lifter: It is used to lift the openings of deep mould. It is also used to repair broken surfaces

of the mould.

7. Strike-off bar: It removes excess sand from the mould after ramming.

8. Sprue pin: It is a tapered cylindrical wooden piece. T is used to make a sprue hole in the

mould to facilitate metal pouring.

9. Bellows: It is used to blow off loose sand particles from the mould and pattern.

10. Swab: It is a small brush. This is used for applying a small amount of water around the

pattern before removing it from the mould.

11. Gate cutter: It is used for cutting gates and runners in the mould.

12. Draw spike: A pointed steel rod with a loop at one end. It is used to remove the pattern from

the mould.

13. Vent wire: The rod is used for making vent holes in the sand mould so that the molten gases

released during the pouring of molten metal can easily escape from the mould.

62
Stepped Cone Pulley

Scale – 1:1

All dimensions are in mm.

63
 Ex. No.
Moulding: Stepped Cone Pulley Pattern
Date:

Aim: To make the mould for the given stepped cone pulley pattern.

Materials Given: Moulding Sand, Parting Sand and Facing Sand

Tools Required:
1. Trowel 8. Round and Square hammer
2. Lifter 9. Moulding Box
3. Gate Cutter 10. Strike off bar
4. Swab 11. Riser
5. Rammer 12. Mould pattern
6. Runner 13. Sprue Pin
7. Vent rod 14. Bellow
Procedure:
1. The mould box, pattern, tools and the table/floor are cleaned. A suitable core is
prepared with the help of a core box.
2. The drag box is placed above the moulding board. Now, the pattern is kept at the
centre of the drag, and the parting sand is sprinkled before we keep the pattern.
3. Facing sand is sprinkled over the pattern to a depth of 5 mm. Then green sand
filled over it.
4. Proper ramming is done on the green sand to get an air-tight packing. Excess sand
is removed by a strike-off bar.
5. The drag box is inverted upside down and the cope box is placed over the drag
box and locked.
6. The riser pin and sprue pin are placed at the right position, and green sand is filled
over the pattern.
7. Proper ramming is done on the green sand to get air-tight packing with strike-off
bar levelling. The pattern is removed by the draw spike tool.
8. Gate is prepared using a gate cutter, and the core is placed vertically inside the
cavity. The vent holes are made with vent wire on the cope.

Result:
Thus, the mould for the given stepped cone pulley pattern is developed.

64
65
PLUMBING

66
67
 PLUMBING

❖ Plumbing also refers to a system of pipes and fixtures installed in a building to distribute potable
water and remove wastewater. Plumbing is the skilled trade of working with pipes, tubing and
plumbing fixtures for drinking water systems and waste drainage.
❖ The plumbing industry is a basic and substantial part of every developed economy due to the
need for clean water and proper collection and transport of wastes.
❖ In addition to the straight pipe or tubing, many fittings are required in plumbing systems, such
as valves, elbows, tees, and unions.

❖ Plumbing Tools:

1. Pipe wrench: The pipe wrench is adjustable for turning soft iron pipes and fittings with
rounded surfaces.
2. Pipe vice: The pipe vice is used to hold the pipes rigidly in position during thread cutting
and fitting of bends, valves, couplings, etc.
3. Pipe cutter: A pipe cutter is a type of tool used by plumbers to cut pipe. Besides producing a clean
cut, the tool is often a faster and more convenient way of cutting pipe than a hacksaw, although this
depends on the metal the pipe is made of.
4. Die set: A die head is a threading die that is used in the high-volume production of threaded
components. They may be used for either cutting a thread or rolling a thread. They may also be
used for internal or external thread cutting.
5. Hack saw: A hacksaw is a fine-tooth saw with a blade under tension in a frame used for cutting
materials such as metal. Hand-held hacksaws consist of a metal arch with a handle, usually a pistol
grip, with pins for attaching a narrow disposable blade.

❖ Pipe Fittings:

1. Elbow: A pipe fitting installed between two lengths of pipe or tube allowing a change of
direction, usually 90° or 45°.
2. Tee: A tee is used to either combine or split a fluid flow. Most common are tees with the same inlet
and outlet sizes, but 'reducing' tees are also available.
3. Cap: A type of pipe fitting, often liquid or gas-tight, which covers the end of a pipe. A cap
has a similar function to a plug.
4. Plug: A plug closes off the end of a pipe. It is similar to a cap, but it fits inside the fitting.
5. Coupling: A coupling connects two pipes to each other. If the material and size of the pipe are not
the same, the fitting may be called a 'reducing coupling' or reducer or an adapter.
6. Valve: A valve is a device that regulates the flow of a fluid (gases, fluidized solids, slurries,
or liquids) by opening, closing, or partially obstructing various passageways.
7. Flange: Flanges are largely used for pipe joints. Flange joints may be made with flanges
that are cast integral with the pipes (or) loose flanges, which are welded (or) screwed with
pipes.
8. Bush: It is a short-sleeved piece that is used to reduce the size of a threaded opening.

68
Mixed Pipe Material Connection

69
 Ex. No.
Plumbing: Mixed Pipe Material Connection
Date:

Aim: To connect basic piping connections for a domestic house using different pipe materials.
Materials Given:

1. PVC Pipe 6. Bend

2. GI Pipe 7. Coupling

3. Gate Valve 8. Valves

4. Tee Bend

5. Elbow

Procedure:

1. Study the given single-line diagram using a legend chart.

2. Calculate exactly how much length of pipe is required.

3. Now, the pipe outlet is connected to the gate valve.

4. Use the Elbow, Tee bend and Gate valve wherever required,

as per the given layout diagram.

5. Fix the wash basin, washing machine and pump.

6. Check for leakage in the pump line and discharge line of the pipe.

7. If any leak occurs, arrest it and repair that area.

8. Finally, open the wash basin tap and check the water flows on it.

Result:

Thus, the basic piping connections for the domestic house are done using different pipe
materials.

70
71
FITTING

72
73
 FITTING TOOLS

Angle Plate Vernier Height Gauge Try Square Centre Punch

Ball Peen Hammer Hack Saw Frame with Blade Flat File

Bench Vice

74
 USES OF FITTING TOOLS

Fitting is defined as the art of producing making parts with the required fit. A good fitting

is based upon accurate marking, measuring, cutting and filling operations. If two machine parts

are connected or joined, they are fitted.

❖ Vernier height gauge: It is used to scribe line on a workpiece to known heights. It

consists of an upright steel bar fixed to a steel base. At the bar, there is a movable jaw

with an vernier scale. The screw is used to adjust the vernier scale to a required position.

❖ Try square: It is used to check the flatness and squareness of the workpiece. It is a

small, light square with a hardened steel blade without graduations.

❖ Center punch: It is used to make dots along marked lines and provide a small centre

mark for dividing points, etc.; it is made of steel. The angle of the conical point is usually

90⁰.

❖ Surface Plate: It tests the work’s flatness and carries the workpiece while marking.

❖ Angle Plate: It is used in conjunction with the surface plate for supporting work in the

perpendicular position.

❖ Hacksaw frame with blade: It is used for sawing metal plates or rods. There are two

types of frames, namely, solid frames and adjustable frames.

❖ Flat file: It is the principal hand tool used by a fitter; it has several teethes to remove

fine-material chips.

❖ Bench Vice: The bench vice is holding the device. It is the most favourable tool for

general shop work; it is firmly fixed to the bench with coach screws, bolts and nuts. The

faces of the jaws are usually hardened to ensure a firm grip on the work.

75
 DIFFERENT TYPES OF FILES

Flat File Half Round File

Square File Triangular File

Round File Knife Edge File

76
Step Cutting

Given workpiece Dimension marking

Final model (Step Cutting)

Scale - 1:1

All dimensions are in mm.

77
 Ex. No:

Fitting: Step Cutting

Date:

Aim: To perform step cutting on the given workpiece to the required dimensions.

Materials Given: Mild Steel Flat l×b×t = 50×50×5 mm.

Tools Required:

1. Bench Vice 5. Jenny Caliper

2. Steel Rule 6. Files

3. Try Square 7. Dot Punch

4. Hacksaw 8. Hammer

Procedure:
1. The dimensions of the given workpiece are checked using the steel rule.
2. After that, the workpiece is clamped in the bench vice, and two adjacent sides are filed
using a flat file to make the workpiece at a right angle.
3. Chalk is applied on the surface of the workpiece for marking.
4. With the finished face as a reference, the required dimensions are marked on the
workpiece using the Vernier height gauge, Jenny calliper and Steel rule.
5. The workpiece markings are made clear by punching dots on it using a dot punch.
6. After that, by using Hacksaw, the three small square pieces of 15×15 mm were cut and
removed from the MS flat.
7. Cut faces of MS flat are then smoothened and polished using round, flat, and triangular
files.
8. Finally, the workpieces are fitted to form a square fitting by step cutting operation.

Result:

Thus, the step cutting is formed on the given workpiece to the required dimensions.

78
Tungsten Inert Gas (TIG)
Welding

79
80
 Ex. No.
Tungsten Inert Gas (TIG) Welding
Date:

Aim: To study various parts, different operations and demonstrations of the Tungsten Inert Gas
(TIG) welding process.

Introduction:

❖ Tungsten inert gas (TIG) welding process, also called as gas tungsten arc welding (GTAW), is
named so because it uses a) an electrode primarily made of tungsten and b) inert gas for shielding
the weld pool to prevent its contamination from atmospheric gases especially when joining high
strength reactive metals and alloys such as stainless steel, aluminium and magnesium alloys,
wherever high-quality weld joints need to be developed for critical applications like nuclear
reactors, aircraft etc.

❖ The invention of this process in the middle of the twentieth century gave a big boost to
fabricators of these reactive metals as none of the processes (SMAW and Gas welding) available
at that time were able to weld them successfully primarily due to two limitations a)
contamination of weld from atmospheric gases and b) poor control over the heat input required
for melting.

Tungsten Inert Gas (TIG) welding

81
Working Principle:
❖ The Principle of TIG Welding is an electric arc welding process in which the fusion energy is
produced by an electric arc burning between the workpiece and the tungsten electrode.
❖ During the welding process, the electrode, the arc and the weld pool are protected against the
damaging effects of the atmospheric air by an inert shielding gas.
❖ A gas nozzle leads the shielding gas to the welding zone, where it replaces the atmospheric air.
❖ TIG welding differs from the other arc welding processes because the electrode is not consumed
like the electrodes in other processes such as MIG/MAG and MMA.

TIG welding principle

TIG Welding Equipment’s:

1. Welding torch: The main purpose of the TIG torch is to carry the welding current and
shielding gas to the weld. The TIG torch is constructed on the basis of the welding handle and
a torch head that is coated with an electrically insulated material.

2. Power supply: A power source that is capable of providing the necessary welding current. A
TIG unit with incorporated control systems that make it possible to adjust the welding current,
arc initiation etc.

82
3. Electrode:
• For TIG welding the applied electrode is mainly made of tungsten. Pure tungsten is a very
heat resistance material with a fusion point of approximately 3,380oC.
• By alloying tungsten with a few per cent of a metal oxide, the conductivity of the electrode
can be increased, which has the advantage that it can thereby resist a higher current load.
• The alloyed tungsten electrodes, therefore, have a longer lifetime and better ignition
properties than electrodes of pure tungsten.
• The most frequently used metal oxides used for alloying of tungsten are:
❖ Thorium oxide (ThO2)
❖ Zirconium oxide (ZrO2)
❖ Lanthanum oxide (LaO2)
❖ Cerium oxide (CeO2)
4. Shielding gas:
• The shielding gas has several functions. One of them is to replace the atmospheric air so it
will not combine with the weld pool and the incandescent tungsten electrode.
• Furthermore, the shielding gas also plays an important role in transferring current and heat
in the arc.
• For TIG welding, two of the inert gases used are argon (Ar) and helium (He), of which
argon is the more frequently used
5. Filler Rod:
• Filler metal is generally not used by TIGW for welding thin sheets. Welding thick steel
plates by TIG welding to produce high-quality welds for critical applications, such as
joining nuclear and aerospace components, requires adding filler metal to fill the groove.
• The filler rod can be fed manually or using some wire feed mechanism. For feeding small
diameter filler wires (0.8-2.4 mm), a push-type wire feed mechanism with a speed control
device is usually used.
6. Gas Nozzle:
• The Gas Nozzle The function of the gas nozzle is to lead the shielding gas down around
the welding zone and thereby replace the atmospheric air.
• The gas nozzle is screwed onto the TIG torch so it can be exchanged if required. It is
usually made of a ceramic material that can withstand massive heat.
• The size of the gas nozzle is often indicated by a number that refers to the interior diameter
of the orifice in 1/16”.

83
 Materials for TIG welding

The most important area of application is:

❖ Welding of thin materials in stainless steel

❖ Aluminium

❖ Nickel

❖ Nickel alloys

Advantages of TIG welding:

The TIG welding process has a very large area of application due to its many advantages, e.g.:

❖ It provides a concentrated heating of the workpiece.

❖ It provides effective protection of the weld pool by an inert shielding gas.

❖ It can be independent of filler material.

❖ The filler materials do not need to be finely prepared if only the alloying is all right.

❖ There is no need for after-treatment of the weld as no slag or spatter is produced.

❖ Places of difficult access can be welded.

Applications of TIG welding:

TIG welding is often used for jobs that demand high quality welding such as for instance:

❖ The offshore industry

❖ Combined heat and power plants

❖ The petrochemical industry

❖ The food industry

❖ The chemical industry

❖ The nuclear industry

Result:

Thus, the working principle of the Tungsten Inert Gas (TIG) welding process and its
various operations have been studied.

84
Metal Inert Gas (MIG)
Welding

85
86
 Ex. No.
Metal Inert Gas (MIG) Welding
Date:

Aim: To study various parts, different operations and demonstrations on the Metal Inert Gas
(MIG) welding process.

Introduction:

❖ Metal inert gas welding (MIG), otherwise known as gas metal arc welding (GMAW), is a
process in which an electric arc is created between the consumable MIG wire electrode and the
work material that heats the workpiece to join (fusion).

❖ The shielding gas protects from contamination via the welding gun. The welding process
involves the supply of constant voltage and direct current supply of power. The transfer of metal
in this welding process can be done in four distinct ways: short-circuiting, pulsed-spray, spray
and globular method.

Metal Inert Gas (MIG) welding

87
Working Principle:
❖ Gas Metal Arc welding or welding with shielding gas, as it is often called, is a welding arc
process that utilizes the heat of an electric arc established between a continuously fed wire and
the workpiece.
❖ During this process, the wire will melt, and the weld metal is transferred to the workpiece. The
weld pool is always protected by a shield of gas in order to protect both the melting wire and
the weld pool from the oxygen and nitrogen in the air.

MIG Welding:

❖ MIG welding is welding in an atmosphere of inert gas, which means welding with a shielding
gas that does not react with other substances. Inert gases are for instance argon and helium of
which argon is more used within the European region.

❖ Usually, the process is called MIG welding even when the inert gas is mixed with small
quantities of O2, CO2, H2 or similar substances.

88
MAG Welding:

❖ MAG Welding MAG welding is welding in an atmosphere of reacting gases, or as it is also

called, shielded by an active gas.

❖ This means that the gas is separated in the arc and, to a smaller or larger extent, reacts with the
weld pool. CO2 is mainly used as shielding gas, which is why the process is also known as CO2
welding.

MIG/MAG Welding Equipment’s:

Welding equipment for MIG/MAG welding consists in principle of:
❖ A shielding gas system with control
❖ A power source
❖ A wire feed unit
❖ A complete welding torch
❖ A reel of welding wire
❖ Gas cylinders with pressure-reducing valve and flow meter
1. Shielding gas system: The shielding gas is supplied in cylinders of various dimensions
and with a pressure of up to 150 kp/cm2.
• The gas cylinder is fitted with a pressure-reducing valve in order to decrease the high
pressure inside the cylinder to a lower and less dangerous working pressure before the
gas flows into the hoses.
• After the pressure-reducing valve (in connection with it) is a flowmeter indicating the
gas consumption, usually in litres per minute.
• The welding machine is equipped with a solenoid valve which controls the gas supply.

89
2. Power source: In order to obtain a stable arc, the power source used for MIG/MAG
welding must have a properly set or adjustable characteristic and an outlet for the
appropriate inductance values. The static characteristic is the curve for voltage (V) versus
current (A).
A normal power source has a falling static characteristic, while a power source with an
approximate flat characteristic is usually used for MIG/MAG welding.
3. Welding Wire: Welding wire is either delivered on wire reels or in coils for larger
industrial installations. The wire must always be strictly concordant with the base material
and the welding process.
4. Welding Torch: The welding torch can be either air-cooled or water-cooled. Generally,
air-cooled torches are used for all materials at low current intensities and for welding
ordinary mild steels at higher current intensities. An air-cooled torch will be rather heavy
if it is to be used at higher current intensities.

90
Advantages of MIG/MAG welding:
• The method is financially attractive due to a high welding speed and because a long arc
time can be maintained as there is no frequent changing of electrode rods.
• The method provides the opportunity for rational welding of materials that are difficult
to weld.
• Welding is possible in all positions.
• The arc and the weld pool are clearly visible.
• Usually, only a little after-treatment of the weld is necessary. Places of difficult access
can be welded.
Disadvantages of MIG/MAG welding:
• The method is very vulnerable to draughts from ventilation systems, open doors and
windows and the fans of air-cooled welding machines.
• There is a risk of serious welding errors, such as lack of fusion, etc., if the welder is not
sufficiently skilled with a profound knowledge of the process and its welding
parameters.
• The necessary but costly shielding of the welding place at outdoor jobs.
• Greater investments in welding equipment
• Greater expenses for maintenance of the welding equipment
Applications of MIG/MAG welding:
MIG/MAG welding is usually used with:
• Aluminium
• Ordinary mild steels
• Stainless steels
• Copper and copper alloys

In addition to the above metals, this method is suited for magnesium, nickel, and several other
metals and their alloys.

Result:
Thus, the working principle of the Metal Inert Gas (MIG) welding process and its
various operations have been studied.

91