A

Practical File
On

MANUFACTURING PRACTICE
(BT-106)

Submitted in the partial fulfillment for the award of

Bachelor of Technology
In
_______________________________

Submitted to: Submitted by:

Dr. Manoj Narwariya Name: - ……………………

Professor, Dept. of Mech. Eng. Roll No. - ………..…………………
Branch - ……………………………
Semester - ………………………….

IPS College of Technology & Management,

Gwalior, (M.P.) INDIA
June 2024
S.
Name of Experiment Experiment Date Remark
No.

To Study the Carpentry Shop and to

1 prepare a T- lap joint or Dovetail Lap joint
as per specification in carpentry shop.

To Study the Fitting Shop and to make a

2 V- fitting from the given two M.S pieces
as per specification in fitting shop

To Study the Foundry Shop and to prepare

3 a sand mould cavity using One Stepped
Shaft (single piece pattern)

To Study the Welding Shop and to make

a double lap joint or V-Butt Joint, using
4
the given mild steel pieces and by arc
welding.
To Study the Black Smithy Shop and to
5 make a screw driver using the given
cylindrical M.S rod.
 Experiment No. 1
Aim: To Study the Carpentry Shop and to prepare a T- lap joint or Dovetail Lap joint as per
specification in carpentry shop

INTRODUCTION

Carpentry may be defined as the process of making wooden components. It starts from a marketable form of
wood and ends with finished products. It deals with the building work, furniture, cabinet making. Etc. joinery,
i.e., preparation of joints is one of the important operations in all woodwork. It deals with the specific work ofa
carpenter like making different types of joints to form a finished product.
Timber
Timber is a name obtained from well grown plants or trees. The timber must be cut in such a way that the grains
runparallel to the length. The common defects in timber are knots, wet rot, dry rot etc.
Classification of Timber
Wood suitable for construction and other engineering purposes is called timber. Woods in general are divided
into two broad categories: Softwoods and Hardwoods.

Soft woods are obtained from conifers, kair, deodar, chir, walnut and seemal.
Hard wood are obtained from teak, sal, oak, shisham, beach, ash mango, and neem.

Seasoning of Wood
A newly felled tree contains considerable moisture content. If this is not removed, the timber is likely to wrap,
shrink, crack or decay. Seasoning is the art of extracting the moisture content under controlled conditions, at a
uniform rate, from all the parts of the timber. Only seasoned wood should be used for all carpentry works.
Seasoning makes the wood resilient and lighter. Further, it ensures that the wood will not distort after it is made
into an object.

Characteristics of Good Timber

The good timber must possess the following characteristics
a. It should have minimum moisture content, i.e., the timber should be well seasoned.
b. The grains of wood should be straight and long.
c. It must retain its straightness after seasoning.
d. It should produce near metallic sound on hammering.
e. It should be free from knots or cracks.
f. It should be of uniform color, throughout the part of the wood.
g. It should respond well to the finishing and polishing operations.
h. During driving the nails and screw, it should not split easily.

TOOL USED IN CARPENTARY

WORK HOLDING TOOLS

Carpentry vice
It is a work holding device. When handle vice is turned in a clockwise direction, the sliding jar forces
the work against the fixed sawn. The greater the force applied to the handle, the tighter to the work
held.
Bar clam
It is a rectangular (or) square block with V-groove on one or both sides opposite to each other. It holds
cylindrical work pieces.

C-Clamp

This is used to hold work against an angle plate or V-block.

MARKING AND MEASURING TOOLS:

Try square
It is used for marking and testing the square ness of planed surfaces. It consists of a steel blade, fitted
in a cast iron stock. It is also used for flatness. The size of a try square used for varies from 150 mm to
300 mm, according to the length of the blade. It is less accurate when compared to the try square used
in fitting shop.

Steel rule Marking Gauge

Steel tape Try square

Carpentry vice Bar clamp

 Metal jack plane Compass and divider

Marking gauge

It is a tool used to mark lines parallel to the edges of wooden pieces. It consists of a square wooden
stem with a riding wooden stock on it. A marking pin, made of steel is fitted on the stem. A mortise
gauge consists of two pins. In these it is possible to adjust the distance between the pins, to draw two
parallel lines on the stock.

Compass and dividers

This is used for marking circles, arcs, laying out perpendicular lines on the planed surfaceof the wood.

CUTTING TOOLS

Hack saw

It is used to cross cut the grains of the stock. The teeth are so set that the saw kerfs will bewider than
the blade thickness. Hard blades are used to cut hard metals. Flexible blades are having the teeth of
hardened and rest of the blade is soft and flexible.

Chisels
These are used for removing surplus wood. Chisels are annealed, hardened and temperedto produce a
tough shank and a hard cutting edge.

Rip saw
It is used for cutting the stock along the grains. The cutting edge of this saw makes a sleeperangle
about 60o whereas that saw makes an angle of 45o with the surface of the stock.

Tenon saw
It is used for cutting tenons and in fine cabinet works. The blade of this saw is very thin and so it is
used stiffed with back strip. Hence, this is sometimes called back saw. The teeth shapes similar to cross
cut saw.

DRILLING AND BORING TOOLS:

Auger bit:-

It is the most common tool used for boring holes with hard pressure.
Gimlet:-
This is a hand tool used for boring holes with hand pressure.

Hand drill:-
Carpenters brace is used to make relatively large size holes, whereas hand drill is used fordrilling
small holes. A straight shank drill is used with these tools. It is small light in weight and may be
conveniently used than the brace. The drill is clamped in the chuck.

Cross cut saw Tenon saw Compass saw

Chisels Carpenter’s brace Auger bit

Gimlet Wood rasp file Mallet

 Hand drill Trammel Claw hammer

MISCELLANEOUS TOOLS:

Ball peen hammer

It has a flat face, which is used for general work and a ball end is used for riveting.

Mallet
It is used to drive the chisel, when considerable force is to be applied, steel hammer should not be used
for these purpose, as it may damage the chisel handle. Further, for better to apply a series of light taps
with the mallet rather than a heavy single blow.

Claw hammer
It is a striking flat at one end and the claw at the others. The face issued to drive nails intowood and for
other striking purpose and the claw for extracting nails out of wood.

Pinches
It is made of steel with a hinged and is used for pulling out small nails from wood.

Wood rasp file

It is a finishing tool used to make the wood smooth, remove sharp edge finishing fillets and other
interior surfaces. Sharp cutting teeth are provided on its surface for the purpose.This file is exclusively
used in wood work.
 JOB NO. 1
Aim: To prepare a T- lap joint or Dovetail Lap joint as per specification in carpentry shop
Tools required
1. Carpenter’s vice
2. Steel Rule
3. Try square
4. Jack plane
5. Scriber
6. Cross cut saw
7. Marking gauge
8. Firmer chisel
9. Mallet
10. Wood rasp file and smooth file
Material required: Wooden pieces of size 50 x 35 x 250 mm–2 Nos.

Sequence of operations
1. Measuring and Marking
2. Planning
3. Check for squareness
4. Removal of extra material
5. Sawing
6. Chiseling
7. Finishing
Procedure
1. The given reaper is checked for dimensions.
2. They are planed with jack plane and checked for straightness.
3. The two surfaces are checked for squareness with a try square.
4. Marking gauge is set and lines are marked at 30 and 45 mm to mark the
thickness and width of the model respectively.
5. The excess material is first chiseled with firmer and then planned to correctsize.
6. The mating dimensions of the parts X and Y are then marked using steel ruleand
marking gauge.
7. Using the crosscut saw, the portions to be removed are cut in both the pieces,followed
by chiseling.
8. The ends of both the parts are chiseled to the exact lengths.
9. The fine finishing is given to the parts, if required so that, proper fitting is
obtained.
10. The parts are fitted to obtain a slightly tight joint.
Safety precautions: -

1. Loose cloths are to be avoided.

2. Tools to be placed at their proper placed.
3. Hands should not be placed in front of sharp edged tools.
4. Use only sharp tools.
5. Care should be taken, when thumb is used as a guide in cross cutting andripping.
6. Handle while chiseling, sawing and planning with care.7.

Result: - T- lap joint/ Dovetail Lap Joint is made as per the required dimensions.
 Experiment No. 2
Aim: To Study the Fitting Shop and to make a V- fitting from the given two M.S pieces as per
specification in fitting shop

INTRODUCTION

Machine tools are capable of producing work at a faster rate, but there are occasions when components are
processed at a bench. Sometimes it becomes necessary to replace or repair a component that must fit
accurately with one another or reassemble. This involves a certain amount of hand fitting. The assembly
machine tools, jigs, gauges etc., involves certain amount of bench work.

TOOL USED IN FITTING SHOP

HOLDING TOOLS

Bench vice: It is a work holding device, when vice handle is turned in a clockwise direction the sliding jaw
forces the work against the fixed jaw, the greater the force applied to the handle, the tighter is the work held.

V- block with clamp: It is a rectangular (or) square block with v-groove on one or both sides, opposite to each
other. It holds cylindrical work pieces.
C-clamp: This is used to hold work against an angle plate or v-block.

MARKING AND MEASURING TOOLS:

1. Surface plate
2. Try square
3. Angle plate
4. Scriber
5. Universal scribing block
6. Odd leg caliper
7. Divider
8. Calipers
9. Dot punch
10. Vernier caliper

Surface plate
It is used for testing flatness of work piece, for marking out small works.
 Bench wise V- Block

C – Clamp Surface plate

Angle plate Dot punch

Try square Scriber

COMBINATION CUTTING PLIERS

This is made of tool steel and is used for cutting as well as for ripping work.

Taps and die holders

Tap and wrenches are used for cutting internal threads in a drilled hole.

Dies and die holders

They are used for making external threads. Dies are made either solid (or) split type.

Hand file

It is a rectangular in section tapered in thickness but parallel in width.

Flat file
Rectangular in section and tapered for 1/3rd length in width and thickness.

Square file
Square in section and tapered for 1/3rd length on all sides.

Half round file

It has one flat face, connecting by a curved (surface) face & tapered for 1/3rd length.

Round file:-
Circular in cross section and tapered for 1/3rd length, it has double cut teeth.

MISCELLANEOUS TOOLS

Ball peen hammer

It has a flat face, which is used for general work and a ball end is used for riveting.

Screw driver
It is designed to turn the screws. The blade is made of steel and is available in differentlengths and
diameters.

Spanners
It is a tool for turning nuts and bolts. It is usually made of forged steel.
 Odd leg clamp and divider

Calipers Vernier caliper

Parts of hand file

Types of files Ball peen hammer
 JOB No. 2
Aim: To make a V- fitting from the given two M.S pieces as per specification in fitting shop

Tools required: -
1. Bench vice
2. Steel rule
3. Try square
4. Ball peen hammer
5. Scriber
6. Hack saw with blade
7. Dot punch and Centre punch
8. Surface plate
9. Venire height gauge
10. Rough and smooth flat files
11. Flat chisel and triangular file
Material required: Mild steel (M.S) plate of size 48 x 34–2 Nos.

Sequence of Operations
1. Filing
2. Checking flatness and square ness
3. Marking and measuring
4. Punching
5. Sawing
6. Chipping
7. Finishing

Tools required
1. Bench vice
2. Steel rule
3. Try square
4. Ball peen hammer
5. Scriber
6. Hack saw with blade
7. Dot punch and Centre punch
8. Surface plate
9. Vernier height gauge
10. Rough and smooth flat files
11. Flat chisel and triangular file

Material required: Mild steel (M.S) plate of size 48 x 34–2 Nos.

Sequence of Operations
1. Filing
2. Checking flatness and square ness
3. Marking and measuring
4. Punching
5. Sawing
6. Chipping
7. Finishing

Procedure: -
1. The burrs in the pieces are removed and the dimensions are checked with asteel
rule.
2. The pieces are clamped one after the other and the outer mating edges are filedby using
rough and smooth files.
3. The flatness, straightness and square ness i.e. right angle between adjacentsides are
checked with help of Try-square.
4. Chalk is then applied on the surfaces of the two pieces.
5. The given dimensions of the V-fitting are marked with help of vernier heightgauge
carefully.
6. Using the dot punch, dots are punched along the above scribed lines.
7. Using the hack saw, the unwanted portions are removed.
8. Using the flat chisel, the unwanted material in the piece Y is removed.
9. The cut edges are filed by the half round file.
10. The corners of the stepped surfaces are filed by using a square or triangular fileto get the
sharp corners.
11. The pieces (X and Y) are fitted together and the mating is checked for the correctness of the fit.
Safety precautions: -
1. Care is taken to see that the marking dots are not crossed, which is indicated bythe half
of the punch dots left on the pieces.
2. Apply pressure in forward direction during hack sawing.
3. Don’t rub steel rule on the job.
4. Fix blade in hack saw frame with correct tension.
5. During hack sawing the coolant like water or lubricating oil is to be used.
6. Use precision instruments like vernier calipers and vernier height gauge
carefully.
7. Files are to be cleaned properly after using.

Result: - V- fit is made as per the required dimensions.

 Experiment No. 3
Aim: To Study the Foundry Shop and to prepare a sand mould cavity using One Stepped Shaft
(single piece pattern)

INTRODUCTION
-
Foundry practice deals with the process of making casting in moulds, formed in either sand or other material.
This is found to be the cheapest method of metal shaping. The process involves the operations of pattern
making, sand preparation, molding, melting of metals, pouring in moulds, cooling, shake out, fettling, heat
treatment, finishing, and inspection.

Mould is a cavity in a molding core, formed by a pattern. It is similar in shape andsize that of the actual
casting plus some allowance for shrinkage, machining etc., molding is the process of making molds.

Moulds are classified as

□ Temporary moulds
□ Permanent moulds

Temporary mould are made of sand and other binding materials and may be produced either through hand
molding (or) machine molding.

Permanent mould are made of ferrous materials and alloys i.e., cast iron, steel etc.

Molding Sand
Sand is the principal material used in a foundry. The principal ingredients of moulding sands are: Silica sand,
(ii) clay and (iii) moisture. Clay imparts the necessary bonding strength to the moulding sand. Moisture when
added in correct proportion, provides the bonding action to the clay.

Properties of Moulding Sand

The essential requirement of a good moulding sand is that it should produce sound castings which are free from
defects. For producing sound castings, molding sand or mold should possess the following properties;

Porosity or Permeability: When molten metal is poured into a mould, gases and steam will be formed. The
sand mould should have sufficient porosity to allow the gases and steam to pass through it. If they are not
removed, casting defects such as blow holes will be formed.

Plasticity: It is the property of the moulding sand by virtue of which, it flows to all the comers around the
pattern in the mold, when rammed. Only due to this property, the molding sand gets the shape of the pattern in
the mold.

Cohesiveness: It is the property by which the sand particles stick to each other. Coarse grained sand particles
give better cohesiveness than spherical grained sand particles.

Adhesiveness: Sticking of the sand particles to another body is known as adhesiveness. The moulding sand
sticks to the sides of the cope and drag parts of the moulding box.
 PATTERN
A pattern is the prototype of the desired casting, which when packed in a suitable material, produces a cavity
called the mould. This cavity when filled with molten metal, produces the desired casting after solidification.

Types of Patterns

Wood or metal patterns are used in foundry practice. Single piece, split, loose piece, multi-piece and cored
patterns are some of the common types.

Single Piece Pattern: It is the simplest of all the patterns. This has a flat surface on the cope side. This makes
possible a straight line parting on the joint between the cope and drag of the mould. It is used for making simple
castings.

Split Pattern: Split patterns are recommended for intricate castings, where removal of the pattern from the
mould is difficult. The two halves of the pattern are put together by dowel pins.

Loose Piece Pattern: When a pattern cannot be withdrawn from the mould due to its complexity, loose pieces
are provided to facilitate this. The loose parts or pieces are attached to the main body of the pattern with dowel
pins. However, only two moulding boxes are required for making a mould in this case.

Core Box: A core box is a pattern, made of either wood or metal, into which sand is packed to form the core.
Wood is commonly used for making a core box; but metal boxes are used when cores are to be made in large
numbers. Specially prepared core sand is used in making cores.

PATTERN MATERIALS

The following are the materials that are widely used for making patterns:

1. Wood,
2. Metals and alloys,
3. Plastics,
4. Plasters and waxes.

TOOLS AND EQUIPMENT FOR HAND MOULDING

The tools and equipment used for sand moulding process are grouped as mentioned below:-

(a) Sand preparation tools and equipments.

(b) Moulding flask.
(c) Moulders tools.
SAND PREPARATION TOOLS AND EQUIPMENTS

Shovel: It is used for mixing and tempering moulding sand and for transferring the sand into the flask. It is made of
broad steel blade with a wooden handle.

Riddle: Hand riddle consists of a square or circular wooden frame fitted with a screen of standard wire mesh (No.
8) at its bottom. It is used for hand riddling (sieving) of sand to remove coarse sand particles and other foreign
material from the foundry sand.

Molding Flask
It is a base, made of wood or metal, open at both ends. The sand is rammed in after placing the pattern to
produce a mould. It is made of 2 parts; cope is the top half of the flask, having guides for the aligning paints to
enter. Drag is the bottom half of the flask having aligning pins.

Rammer
It is used for pocking or ramming the sand, around the pattern one of its ends called the peen end, is wedge
shaped and is used for packing sand in spaces, pockets and corners in the early stages of ramming. The other
end called the But – end has a surface and is used for computing the sand towards the end of molding.

Strike of edge / strike of bar

It is a piece of metal or wood with straight edge. It is used remove the excess sand from the mould after ramming
to provide a level surface.

Spruce pin
It is tapered wooden pin used to make a hole in the cope sand through which the molten metal is poured into
the mould.
Riser pin
It is tapered wooden pin used to make a hole in the cope sand over the mould cavity for the molten metal to rise
and feed the casting to compassable the shrinkage that take place during solidification.

Trowel
It is used to smoothen the surface of the mould. It may also be used for reproducing the damaged portion of the
mould. A trowel is made in many different stylesand sizes each one recallable for a particular hole.

Spike or Draw Pin: It is a pointed steel rod with a loop at the other end. It is used to remove the pattern from the
mould. A draw screw, with a threaded end, may also be used for the purpose.

Slick: It is a small double ended tool having a flat on one end and a spoon on the other. It is used for mending and
finishing small surfaces of the mould.

Lifters: Lifters are made of thin sections of steel of various widths and lengths, with one end bent at right angles.
These are used for cleaning and finishing the bottom and sides of the deep and narrow pockets of the mould.

Gate Cutter: It is a semi-circular piece of tin sheet, used to cut gates in the mould. Gates are meant for easy flow
of molten metal into the mould.

Bellows: It is a hand tool, used to blow air, to remove the loose sand particles from the mould cavity.

Vent Rod: It is a thin rod used for making vents or holes in the sand mould to allow the escape of mould gases
generated during the pouring of molten metal.
 JOB No 3
Aim: To prepare a sand mould cavity using One Stepped Shaft (single piece pattern).

Tools required
1. Molding board 2. Molding flask 3. Shovel 4. Riddle
5. Rammer 6. Strike-off bar or Strike Edge 7. Sprue pin
8. Riser pin 9. Trowel 10. Spike or Draw pin
11. Slick 12. Lifters 13. Gate cutter
14. Bellows 16. Vent rod
Material required: -
1. Molding sand
2. Parting sand
3. Dum-Bell
Sequence of operation: -
1. Sand preparation
2. Sandmixing
3. Pouring
4. Finishing
Procedure: -
1. Place the pattern on the molding board, with its flat side on the board.
2. Place the drag over the board, after giving a clay wash inside.
3. Sprinkle the pattern and molding board, with parting sand.
4. Allow loose sand, preferably through a riddle over the pattern, unit it iscovered to a
depth of 2 to 3 cm.
5. Pack the molding sand around the pattern and into the corners of the flask, withfingers.
6. Place some more sand in the flask and pack the pattern with a rammer, usingfirst the
peen end and then butt end.
7. Strike-off the excess sand from the top surface of the drag with the strike-off bar.
8. Turn the drag upside down.
9. Blow-off the loose sand particles with the bellows and smoothen the uppersurface.
10. Place the cope on to the drag in position. Locate riser pin on the highest pointof the
pattern.
11. Place the sprue pin at about 5 to 6 cm from the pattern on the other side of theriser pin.
12. Sprinkle the upper surface with parting sand.
13. Repeat steps 3 to 7, approximately.
14. Make holes with the vent rod to about 1 cm from the pattern.
15. Remove the sprue and riser pins by carefully drawing them out. Funnel shapedhole is
made at the top of the sprue hole, called the pouring cup.
16. Lift the cope and place it aside on its edge.
17. Insert the draw pin into the pattern. Wet the edges around the pattern. Loosenthe
pattern by rapping. Then draw the pattern straight up.
18. Adjust and repair the mold by adding bits of sand, if necessary.
19. Cut gate in the drag from the sprue to the mold. Blow off any loose sandparticles
in the mold.
20. Close the mold by replacing the cope and placing weights on it.

Precautions:-
1. Do not get the sand too wet. Water is an enemy of molten metals.
2. Provide adequate ventilation to remove smoke and fumes.
3. Never stand near or look over the mold during the pouring because of themolten
metal might be too hot.
4. Do not shake out a casting too hastily, which may result in second and thirddegree
burns.

Result: - A sand mold cavity is prepared by using one–Stepped Shaft.

 Experiment No. 4
Aim: To Study the Welding Shop and to make a double lap joint or V-Butt Joint, using the
given mild steel pieces and by arc welding.

INTRODUCTION

Welding is the process of joining similar metals by the application of heat, with or without application of
pressure or filler metal, in such a way that the joint is equivalent in composition and characteristics of the metals
joined. In the beginning, welding was mainly used for repairing all kinds of worn or damaged parts. Now, it is
extensively used in manufacturing industry, construction industry (construction of ships, tanks, locomotives and
automobiles) and maintenance work, replacing riveting and bolting, to a greater extent.
The various welding processes are:
1. Electric arc welding,
2. Gas welding
3. Thermal welding
4. Electrical Resistance welding and
5. Friction welding
However, only electric arc welding process is discussed in the subject point of view.

Electric arc welding

Arc welding is the welding process, in which heat is generated by an electric arc struck between an
electrode and the work piece. Electric arc is luminous electrical discharge between two electrodes
through ionized gas.

Any arc welding method is based on an electric circuit consisting of the following parts:
a. Power supply (AC or DC);
b. Welding electrode;
c. Work piece;
d. Welding leads (electric cables) connecting the electrode and work piece to the power supply.

Electric arc between the electrode and work piece closes the electric circuit. The arc temperature may reach
10000°F (5500°C), which is sufficient for fusion the work piece edges and joining them. When a long joint is
required the arc is moved along the joint line. The front edge of the weld pool melts the welded surfaces when
the rear edge of the weld pool solidifies forming the joint.
 Arc welding set up

Parts of an electrode

WELDING TOOLS

Electrode holder

The electrode holder is connected to the end of the welding cable and holds the electrode.
Itshould be light, strong and easy to handle and should not become hot while in operation.
Figureshows one type of electrode holder. The jaws of the holder are insulated, offering
protectionfrom electric shock.

Ground clamp
It is connected to the end of the ground cable and is clamped to the work or welding table to
complete the electric circuit. It should be strong and durable and give a low resistance
connection.

Wire brush and chipping hammer

A wire brush is used for cleaning and preparing the work for welding. A chipping hammer
isused for removing slag formation on welds. One end of the head is sharpened like a cold
chisel and the other, to a blunt, round point. It is generally made of tool steel. Removing the
spatter and slag formed on and around the welding beads on the metal surface is known as
chipping.

Welding table and cabin

It is made of steel plate and pipes. It is used for positioning the parts to be welded properly.
Welding cabin is made‐up by any suitable thermal resistance material, which can isolate
thesurrounding by the heat and light emitted during the welding process. A suitable draught
shouldalso be provided for exhausting the gas produced during welding.

Face shield
A face shield is used to protect the eyes and face from the rays of the arc and from spatter or
flying particles of hot metal. It is available either in hand or helmet type. The hand
type isconvenient to use wherever the work can be done with one hand. The helmet type
though notcomfortable to wear, leaves both hands free for the work.

Shields are made of light weight non‐reflecting fiber and fitted with dark glasses to filter out
the Harmful rays of the arc. In some designs, a cover glass is fitted in front of the dark lens
to protectit from spatter.

Hand gloves
These are used to protect the hands from electric shocks and hot spatters

Electrode holder Ground Clamp

Wire brush Chipping hammer

Hand gloves Face shield

 JOB No. 4
Aim: To make a double lap joint or V-Butt Joint, using the given mild steel pieces and
by arc welding.

Material used: Two mild steel pieces of 100 × 40 × 6 mm.

Tools and equipment used:

1. Arc welding machine

2. Mild steel electrodes,
3. Electrode holder,
4. Ground clamp,
5. Flat nose Tong,
6. Face shield,
7. Apron,
8. Hand gloves,
9. Metallic work Table,
10. Bench vice,
11. Rough flat file,
12. Try square,
13. Steel rule,
14. Wire brush,
15. Ball peen hammer,
16. Chipping hammer.

Operations to be carried out

1. Cleaning the work pieces

2. Tack welding
3. Full welding
4. Cooling
5. Chipping
6. Finishing

Procedure
1. Take the two mild steel pieces of given dimensions and clean the surfaces thoroughly from
rust, dust particles, oil and grease.
2. Remove the sharp corners and burrs by filing or grinding and prepare the work pieces.
3. The work pieces are positioned on the welding table, to form a lap joint with the required over
lapping.
4. The electrode is fitted in to the electrode holder and the welding current is set to a proper
value.
5. The ground clamp is fastened to the welding table.
6. Wearing the apron, hand gloves, using the face shield and holding the over lapped pieces the
arc is struck and the work pieces are tack‐welded at the ends of both the sides
7. The alignment of the lap joint is checked and the tack‐welded pieces are reset, if required.
8. Welding is then carried out throughout the length of the lap joint, on both the sides.
9. Remove the slag, spatters and clean the joint.
 LAP JOINT V-BUTT JOINT

Precautions:
1. Use goggles, gloves in order to protect the human body.
2. Maintain the constant arc length.

Result The lap joint/ V-Butt joint is thus made, using the tools and equipment as mentioned above.
 Experiment No. 5
Aim: To Study the Black Smithy Shop and to make a screw driver using the given
cylindrical M.S rod.

Introduction:

Forging or Smithy may be defined as the plastic flow of heated metal by the application ofcompressive
forces in which a metal is altered in a shape permanently without rupture. Smithing is understood to
handle relatively small jobs. The shop in which the work is carried out is known as the smithy or
smith's shop. The various operations are performed by means of hand hammers or small power
hammers. The jobs of smithy shop can be heated in an open fire or hearth.

Forging refers to the production of those parts which must be heated in a closed furnace.

Forgeable Materials:

Forgeability of a material is the capacity of a material to undergo deformation under compression,

without rupture. Any metal or alloy which can be brought to plastic stage through heating can be
forged.

Some forgeable materials, in order of forging difficulties are listed below.

1. Pure Aluminum
2. Pure copper
3. Most of the pure metals.
4. Aluminum alloys
5. Magnesium alloys
6. Carbon and low alloy
steels.
7. Stainless steels

TOOLS AND EQUIPMENTS

.
Principal tools used in forging of metals are:

1. FORGE OR HEARTH: A smith's forge or hearth is used to heat the metal to be shaped. Hearths
are used for heating small jobs to be forged by hand. Gas, oil or coal firing may be used for the
purpose. The required air for the fire is supplied under pressure by a blower through the pipe into
the hearth. The blowers may either be hand operated or power driven

2. Anvil: Forging of hot metal piece is done by supporting the piece on the anvil.

3. Swage block: It is a solid rectangular block, used for giving finishing to a work piece.
4. Hammers: Hammers are the principal forged tools made up from forging steel.Forging
hammers are classified according to size and weight of the hammers.

• Hand hammers or smith's hammers.

• Sledge hammer: Heavier than smith's hammer.
• Power hammer.

5. Tongs: Tongs are used by the smith for holding and turning the hot metal work pieces.
6. Chisels: In forging, chisels are also known as hot setts or cold setts. Hot sett is used for cutting
hot material and a cold sett is used for cutting cold materials

7. Flatter: Flatters are the tools that are made with a perfectly flat face. These are used for finishing
flat surfaces. A flatter of small size is known as set hammer and is used for finishing near corners
and in confined spaces.

SMITHY OPERATIONS:

Smith forging operations are carried out to manufacture comparatively light weight components. The
following operations are used, for giving desired shapes to the products.

1. Drawing: Drawing is the process in which a red hot metal piece is beaten up by a hammer. The
thickness or diameter is decreased but length increases. The hammering is done by placing the
hot piece on the anvil.
2. Upsetting: It is the process in which the diameter of the hot work piece is increased and length
is reduced. Hot metal piece is placed on the anvil in vertical position. It is struck with a hand
hammer. The hot work piece is held in a tong.
3. Punching: Punching is the process in which a rough hole is made into the hot work piece. The
job is heated to a desired temperature and then it is placed on the anvil. Punch is placed on the
hot metal piece. With the help of a sledge hammer, the punch is forced to piece the metal up to
half of the metal thickness. Then the punching is done from the second side by inverting the work
piece. A rough hole isproduced.
4. Drafting: It is a process of finishing and enlarging the hole. The process is similar to punching.
5. Swaging: Swaging is a process used to form or finish different shapes such as circular, hexagonal
and square etc. The hot piece is held between the upper and lower part of the swages. With the
help of a hammer, blows are given to the upper part of the swage.
6. Fullering: Fullering process is done on an anvil. Lower part of the fuller set is kept in the hole
of the anvil. Hot work piece is placed in the groove of the lower fuller. Upper fuller is placed on
the job and hammering is done on the upper portion. Fullering is done for drawing and grooving.
7. Bending: The process of giving desired angles or curvature to hot pieces is known as bending.
The process is done on the edge of the anvil or on chipping block. Circular shapes, eye bolts
hooks or any other types of bent shape can be prepared with this operation. The hammering is
done on hot work piece with a hand hammer. Hot work piece is held in a tong.
8. Forge Welding: The process of joining two metal pieces by heating and hammering is knows
as forge welding. The metal pieces to be welded are cleaned and heated in a furnace up to the
welding temperature. Both pieces are picked fromthe furnace with the help of the tongs. Work
pieces are placed on each other and hammering is done on them and both the pieces get welded.
 JOB No. 5
Aim: To make a screw driver using the given cylindrical M.S rod.

Materials Required:

Cylindrical M.S rod of dia 25 mm and length 100 mm, and coke for heating.

Tools Required:

1- Hammer,
2- Tongs,
3- Flattener,
4- Anvil,
5- Forge,
6- Brass rule. Screw Driver

List of Operations:

1- Heating,
2- Hammering to square prism,
3- Jumping to reduce length.

Procedure:

1- Copy the given drawing.

2- Collected the tools and material for the model.
3- Heat the given work piece in the hearth to red hot temperature.
4- Take the work piece from the hearth and keep it on the anvil in lengthwise and then hammer.
5- Turned the work piece to 90 degree after flattening the opposite sides and continued the
heating & hammering to get exact shape of square prism.
6- To reduce the length of the prism to 122 mm, the jumping operation is performed by
keeping the square prism on the anvil in the vertical position.
7- Finally flattened the four faces of the prism using the flattener and finished the square prism.
8- Then checked the dimensions using steel rule.

Precautions:
1. Hold the hot work downward close to the ground, while transferring from the hearth to anvil.
2. Use correct size and type of tongs to fit the work
3. Care should be exercised in the use of hammer.
4. Wear face shield when hammering hot metal.
5. Wear gloves when handling hot mental.
6. Wear steel-toed shoes.
7. Ensure that hammers are fitted with tight and wedged handles.

Result:
The screw driver is thus made from the given round rod, by following the hand forging operations, as
mentioned above.