Do’s & Don’ts Always listen carefully to the teacher and follow instructions. Do not run and rush in practical work. Don’t talk aloud or crack jokes in Lab. Know the location of power ON/OFF switch of the Lab. Wear good strong shoes. Bags should be stored away, during practical sessions. Do not use a machine, until you have not been shown how to operate it. Use proper safety devices while using machines. Keep hands, hairs and clothing away from moving parts of machinery. Use hand tools carefully, keeping both hands behind the cutting edge. Report any damage / faults to machines/equipment to the Lab Incharge. Keep your workbench tidy. Never distract another student. Do not eat food, drink or chew gum in the lab. On completion of practical work return the tools.Safety Precautions When operator enters into the workshop, he should pe first observe safety to save himselffherself and I. Precautions in Machine shop i) Do not lean against any machine, it is'very dangerous. ii) Do net work on a machine in Dim light. iii) Never switch on a machine unless o otherwise you know all mechanism and operation of machine. iv) When using any grinding parts, protect the eyes by wearing goggles or using shields. v) Do not clean metal chips by hand, use wire brush for cleaning. vi) Be in a habit of cleaning the machine, equipment and tools regularly. IJ. Precautions in workshop i) Keep the Workshop néat and tidy. Avoid tipping over things and trying over gangways ii) Do not nin in the workshop. Walk carefully. iii) See that the floor is free from slippery substances. vi) Keep pathways clean-and clear. v) Everything should be in place and throw waste material into the dustbin. vi) Workshop should have proper lighting and ventilation II (a) Precautions while using hammer i) There should be no grease or oil on the handle. ii) Hammer head should not he projecting outward, jii) Handle should not be too Tong oF 100 short (b) Precautions while using chisel jp1t should he handled carefully and must be grounded ii) Goggle must be used while chipping.(©) Precautions while using file 4) The finger of left hand must not be crooked under file as this may injure the fingers. ii) Metal chips must not be removed while doing job by bare hands, brushis to be used. 8) Files without handles or those with crook must not be used. (D)Precautions during welding {) Acetylene or oxygen cylinder must be kept separately. {iy Do not weld in continued space without adequate ventilation, iii) We should always use goggle while welding. iv) Make sure that connection are airtight by using soap water. v) Never use matches for lighting while welding. . vi) When welding is to-be stopped, close the cylinders and release gas pressure. vii) Do not touch the electrode or the wosk circuit viii) Always wear gloves without holes + ix) Wear eye protection at all times during welding. (E)Precautions on clothing a “ i) Tight fitting coats are safer than-loose fitting coats. ji) Avoid wearing rings, long sleeved shirts and watches white working. iii) Clear covered footwear having thick soles and tough above. iv) Hair must be tied up properly.LITT ee eat OBJECT:- To study of tools and operations in fitting shop. TOOLS VICES:- Vices are used for gripping different jobs in position during various operations. i ~ MATERIAL: Main body and Detachable jaws are made of case steel. Screw is of _mild steel. } < STA PLATES Bet Surping fS — Boe? a J SPINDLE ‘ i < \ ‘ ; : " {E76 usually works in conjunction with a u-clamp and is, the work in marking and drilling. | | used to support rt i ~ \ - Surface Plat tis used for testing trueness of finished surfaces, testing a “s+ try square. It made of cast iron. eoIt is used for testing true surface at right angles or testing the trueness of naturally normal syrfaces. / L Fig. Try Square. @ BEVEL PROTECTOR: - It consists of a steel dial divided into 360 divisions. eg Dial can be rotated around the center. The lines at \. v any angle can be marked or measured by the- | straight edge. Straight edge can be slide along the length. ment that can be used as acenter square and a try ; OMBINATION SET: - It is a multipurpose instru protector, a level, a meter, square. i Files is used to remove extra material by rubbing the.metal. Files are available in a number of sizes and degree of coarseness. ar G Heer FACE pphanpwe si \\ Ss POINT SSEDIe De ail La LENGTHLASSIFICATION OF FILES ON THE BASIS OF GRADE: (i) Rough’ ~ (20 Teeth per inch) & (i) “Bastard (30 Teeth per indh) : (ii) Second Cut (40 Teeth per inch) tas (iv) Smooth files (50-60 Teeth per inch) (vy) Dead Smooth (100 Teeth per inch) ROUGH io BASTARD FILES: — Are big cut files and used for cutting where the material removing is more. DEAD. SMOOTH AND SMOOTH FILES:- These files are used for finishing_Wwork. Second cut files have -the degree of finish mid way between bastard and smooth file. . | SCRIBERS:- It is used for making of lines. It is made of high Carbon | steel. (CHISELS:- Chisels are used for chipping away the material from the work piece. Chisels are generally made of high carbon steel. They are 6” to 8” long. The top is flattened and a sharp cutting edge js made. (i) Flat Chisels. (ii) Cross cut Chisels. (iii) Half round Chisels. (iv) Diamond point. Chisels are classified with their shape and width CLASSIFICATION of the cutting edge. Cutting of Chiseis 1s kept as:- (a) For hard materials — 70° to 75° (b) For medium hard — 60" (c) For soft’materials — 40°HAWKSAW: - Hacksaw is used for cutting rods, flats etc. in fitting shu. ae It consists of a metal frame, fitted with a wooden handle, carryjng metal - clips with wing nuts at its end to old and stretch. the metal blade. Teeth of the blade are generally forward cut, The hacksaw should be used in straight direction otherwise it will result in breaking of blades. * pr sotie Frans HANDLE ‘oll, : 5 | BLaDe WING NUT Fig. Hacksaw Frame The thickness and width of blade are Imm and 4” respectively. @ Blades are classified as under:- (2) Depending upon the direction of cut. (i) Forward Cut. (ii) Backward Cut. (b) Depending upon the pitch of the teeth () Coarse - (8 to 14 Teeth per inchesy. (i) Medium - _ (16-20 Teeth per inches) (ii) Fine - "(24-32 Teeth per inches) 23 UNIVERSAL MARKING SURFACE GAUGE - It consist of a heavy base, a scriber and a bar. The scriber can be adjusted to any position with the help of screw and nut. It is used for marking purpose. | TEEL RULES:- It is made of stainless steel and are available from ¥% feet to 2 feet. These are marked in inches or millimeters.; * PUNCH! | It is used for marking round indentation on the metal su face Ih for providing location of marking for further operation such as culting, sawing, drilling and chipping etc. “! {a) DOT PUNCHES: It is used for marking dotted lines. | Punching angle is 60° boa ‘b) CENTER. PUNCHES:- It is used to mark the center of the hole before | drilling. Angle of punching end is 90° }AMMERS:-_ Are used for striking chisels in chipping and cutting and the punch in marking. A hammer consists of a heavy iron body with a wooden handle. The weight ranges from 0.25 kg to 2 kg. The main types of hammiers are as follows: CR (i) Ball Pean hammei. (ii) Straight Pean hammer. (iii) Cross Pean hammer. ctw Node oe m It is generally ‘used to measure the inside or o diameters. It is made up of different size and shapes..It consists of two b. legs connected to one end by means of rivet or-bolt. The edges aré made" just to touch the job, and then the diameter is measured with the help of steel rule. These are of four types:- , CALLIPER: (a) Out Side Calliper. (b) Inside Calliper. (c) Spring Calliper. (d) Odd leg Calliper. 8 . a / (6 he { / / \7 3 pies-Hl \ i : ie MICROMETER:-_It is used for measuring diameter or thickness of ans job. It is more precision then vernier caliper. It consist hook type frame. ‘A hard anvil is screwed on one end. On the second end a spindle move to ond fro carrying another small anvil on its end. The graduation ony micrometer is available in inches as well as in millimeters. ANVIL 4 L “BARREL A—> FRAME Fig. Metric outside micrometerpoo teal’ e @ VERNIER CALLIP] It is used for measuring lengths and diameters. It can be used for measuring external and internal diameters. It can.be used for measuring external and internal dimensions. The minimum dimension that can be expressed on vernier caliper i¢ known as least count. Material ofall parts is stainless steel. Sy. ~ LOCK NUT ae ee A] ' o 4 Jul 4); (51-6) 57, 38, 9 °F ie ili lt a SL, HAIN SCALE VERNIER SCALE Te. URED SLIDING TAN eS te Gyo Fig. VERNIER CALLIPER DRILLS: The tools used for making round holes is called drill. It is made of high carbon steel. TAPS: Tapes are used for making internal threads in cylindrical holes or cleaning damaged threads in similar parts. Sy DIES: Dies are used for cutting external thread in cylindrical parts such as bolts and pipes. Dies, are made of tool steel. It is used to check the diameter of wires. It is made up of & steel sheet disc. es* EXPERIMENTNO.2 (FITTING Stor) > OBJECT: Making a perfect male-female joint from given material, > - MATERIAL USED:- Two piece of mild steel. ‘Thickness - 5mm, size 48mm x > | 33.55mm. ; > TOOLS REQUIRED:- Bench, Bench vice, Steel rule, Scriber, hand hacksaw, Try > square, fiat file (Bastard),flat smooth file, Triangular file, vernier caliper. > PROCEDURE: (1) To mark the flat with the help of steel rule and scriber. > (2) Hold the M. S. flat in the vice and cut two pieces of required dimensions with > the help of hacksaw. be (3) Do filing, make all the side surfaces flat and check with the try squire. > Repeat it for another piece. G2 —_(4) Now make a coating of chalk and water paste on one side of both workpieces f and dry it. » (5) Carryout marking on both work pieces with the help of one and steel rule according to the given drawing (fig. ii). (6) Remove unwanted material from the job piece with the help of hacksaw. (7) File the job surfaces, as per the required dimensions with the help of triangular file. : (8) Now check the final dimension of male and female part with the help of vernier caliper. (9) Male-fefnale parts come to required dimensions, fit male in to female Ensure that there is no gap between the fitting. oe OBSERVATiON:- (1) The metal removal by file is very less. (2) While cutting with hacksaw, it is some difficult but when use coolant, it cuts smoothly.i iss (3) Never usela file like striking tool. . {4) While filing the job should be hold firmly in the vice. (5) Blade in'hacksaw frame should’ not be foose. (6) Always use coolant while cutting with hacksaw to prolong the life of the blade.“pO N= 1 PDOOPDRN io oe i 4 DOODODDON OA Kae Manning oF wave & FEMALE ole 48, es V male Femme “HH HOH OOH ANORTHERN INDIA ENGINEERING COLLEGE MANUFACTURING PROCESS LAB SHEET METAL SHOP EXPERIMENT NO.1 NAME OF EXPERIMENT: Study of tools and operations in sheet metal shop. INTRODUCTION TO SHEET METAL Metal used in sheet metal work |. Galvanized iron: This is soft steel coated with zinc to resist corrosion and to improve its appearance. The zinc coating help to prevent oxidation. Galvanized iron is used for gutter work, furnace and air conditioners, ventilators, tanks. guards, < " place: Tin plate is made by coating iron sheets with pure tin. Tin sheets are ivailable in Imm te 6mm. These are used in food containers. dairy equipments ete, opper: Copper sheet is high cost but it is used for long lasting roofing materi: and ducts that demand resistance to corrosion. The metal is easily fabricated because of its malleability. | 4. Aluminium: It is a rust proof jnetal, light and has long-wearing qualities. It is used for boats, flashing, roofing material as a house siding and other industrial “= product. Stainless steel: \t has a high percentage of chromium, It has a higher tensile strength and hardness than ordinary steel. therefore is harder to work. It has a good corrosion resistance. Stainless steel used for sink and other products that require strength, hardness, beauty and resistance to corrosion. The term sheet metal implies metal and alloys in sheet rolled to g from 10 swg and thinner. Plates are above to 10 swe thickness. thickness ratigin! To DIN SHE] METAL Shit Cutting tools: i. Straight shear: The main purpose of the shear is to cut the sheet aiong the lines scritiéd-on it. The line may be straight line or curve. For cutting along straight lines, straight shear is used whose blades are straight. straight np >@ Marl cing tools are used to mark the sheet according to required dimensions. Various marking tools are: 1. Steel rute: These are available in variety of sizes. The rule could be stee! foot tule, folding rule or tape rule. 2. Steel square: It is a L-shaped piece of hardened steel. It is used to make square comers. It is also used for checking and making right angles. 3. Scriber: It is used to mark lines on metallic sheets. It is made up of hardened steel. 4. Divider: It is used for scribing arcs and circles on the metallic sheets. It is also made up of hardened steel. One leg is rested at indentation point and the other lez is used to scribe arc and circles. Punch The following type of punch made of tool stee! are commonly used for sheet metal work: 1. Prick punch: These punches are used for making small dents or indentations marks for locating the center position for divider or trammel points. The punches have tapered point grounded to 30° included angles. 2. Center punch: These are used for marking the location of points and center of holes to be drilled. Its taper point is grounded to 90° included angles. Dot punch: It is used for making dotted lines. It is made up of high carbon steel or high-speed steel. One end is sharpened. Hammering is done on the second end while working. Its taper point is grounded to 60° included angles. Striking and Supporting tools: The hammers are used in sheet metal shop for bending of sheets, flattening of sheets. riveting works, to give hollow or curved shape, for locking seam joints etc. For these operations, the following hammers are generally used: 1. Mallet : This is the most used hammer in any sheet metal shop. These are made of good quality hard wood, plastic, hard fibre. These are used whenever working on soft metal. 2. Square face hammers: This hammer is also called setting hammer and has a square flat face. It is used for flattening the seams without damaging the metal sheet. Stak ; Stakes are supporting tools without which nearly most of the basic operations such as bending, seaming, forming , riveting , punching etc, cannot be carried out. They are fitted in wood and jobs are worked upon them.Mattet Ga ee Pe) Square Face Rammer Beok Bick TronkK Punch Pric Punch enter Dot PunchSteel Foot Rute oe Rule Steel Square ScriberExperiment No.2 Object:- ‘To make a rectangular tray with the help of given G.J.sheet metal piece. . Material Required:- ‘The material to be used for making rectangular tray is G.I. sheet of 28 swg thickness, the size of the sheet as per development (shown in figure) is 170mmx150 mm. _Tools-Required:- 1. straight shear (Snup) . Seriber . Try square . wood malict - Bick Iron . Steel Rule(foot rule) NYNAWAWND . Smooth file 8. Standard wire gauge (S.W-@.) - 9. Anvil . : 19. Bench vice ! Development of sheet metal component:- When the complete surface is open’ out and faid on plane, the surface of the solid hag been ‘developed’ and the figure obtained is called development, is the true length of the corresponding line on the surface are normally, developed with the inside face up.ee The knowledge of development of surfaces is frequently required in the design and manufacturing of an object, practical applications of developments occur in sheet metal work, pattern making ctc. Notchingis used to cut away a portion of the metal to prevent overlapping and bulging on seams and edges. The 7ofchingis done on the blanks or patterns prior to farming process. Procedure:- 1. Draw the development-of the tray as shown in figure. Cut a piece, (blank) of size 170mmx150mm from x 28swe thickness G.L. sheet. Mark the folding lines & portion to be notched on the blank. Notch out the portion with a straight 9 shear. Make the plain head on the blank. aos Bend the overlapping portions. Fold the blank to fosm the tray. Finish the job to the required shape & size. xno . Perform the operations as per sequences given in the procedure. Use stakes of proper size to give good shapes to Nv the job. w - Protect your hands from sharp comers of edges of the sheet. 4, Don’t allow any scratch mark fo come on the sheet surface