Diploma I Year Workshop Practice -I Manuals MEchanical Engg

WORKSHOP PRACTICE-1 CONTENTS

1. Fitting Shop

1-7

2. Forging Shop

9-17

3. Carpentry Shop

19-33

4. sheet metal Work

35-49

WORKSHOP PRACTICE-1 SUBJECT TITLE

:

SUBJECT CODE

:

PERIODS/WEEK

:

PERIODS/YEAR

:

WORKSHOP PRACTICE-1

SCORING POLICY 1. Sessional Marks

:

40M



Day – to Day evaluation

:

10M



Record

:

05M



Viva

:

05M



Internal exam

:

20M

:

60M

2. End Exam Marks

WORKSHOP PRACTICE-1 SUBJECT TITLE

:

SUBJECT CODE

:

PERIODS/WEEK

:

PERIODS/YEAR

:

WORKSHOP PRACTICE-1

SCORING POLICY 1. Sessional Marks

:

40M



Day – to Day evaluation

:

10M



Record

:

05M



Viva

:

05M



Internal exam

:

20M

:

60M

2. End Exam Marks

LIST OF EXPERIMENTS FITTING SHOP 1. Marking and Chipping Chipping on Mild – Steel flat 12 mm thick. 2. Cutting with hacksaw, M.S. Flats Flats of 6 mm thick 3. Marking, Cutting, Drilling and Tapping on an M.S.Flat 12 mm thick. 4. Assembling of two pieces, pieces, matching by filling (6 mm thick M.S. plate). FORGING SHOP 1. Conversion of Round Round to to Square. 2. Conversion of Round Round to to Hexagon. Hexagon. 3. Preparation of of Chisel from Round Rod. 4. Preparation of of Ring and Hook from M.S.Round. M.S.Round. 5. Preparation of of a Hexagonal Bolt and Nut. CARPENTRY SHOP 1.

Cutting of wood with handsaw.

2. Planning of Wood. 3. Planning and Chiseling Chiseling of Wood. 4. Orientation of Wood Grain. 5. Preparation of Dovetail Joint. 6. Mortise and Tenon joint. 7. Wood Turning on a lathe. 8. Preparation of one household article (stool). SHEET METAL WORK 1. Practice on cutting of sheet. 2. Formation of of Joints like grooved joints, locked groove joint. 3. Preparation of of a rectangular open open type tray. 4. Preparation of hollow cylinder. 5. Preparation of pipe elbow.

6. Preparation of Mug. 7. Preparation of Funnel. 8. Preparation of utility articles such as dustpan, Kerosene Kerosene Hand Pump. FOUNDRY 1. Practice on cutting of sheet. 2. Formation of of Joints like grooved joints, locked groove joint. 3. Preparation of of a rectangular open open type tray. 4. Preparation of hollow cylinder. 5. Preparation of pipe elbow. elbow. 6. Preparation of Mug.

FITTING SHOP

DATE SHOP : FITTING

TITLE : MARKING & CHIPPING ON MILD STEEL

Exp. No : Time

1. To be able to file the flat. OBJECTIVES

: 1

:

SKETCH

2. To be able to square the flat. 3. To be able to mark the material. 1. Skill in fixing the flat in bench vice

SKILLS TO BE DEVELOPED

2. Skill in using files. 3. Skill in using vernier calipers, try square.

SPECIFICATION OF MATERIAL

TOOLS &  EQUIPMENT

50 x 50 x 12mm M.S.Flat.

Bench vice, Surface plate, Steel rule, Vernier Calipers, Try square, Dot punch, Scriber, Rough flat file, Angle plate. 1. Checking the raw material with vernier calipers. 2. Holding the material properly in the bench vice. 3. Filling two adjacent edges of the flat fil e and checking with try square for

SEQUENCE OF OPERATIONS SAFETY PRECAUTIONS

flatness and squareness. 4. Filling the other two edges and checking with try square. 5. Marking the surfaces and applying chalk on one surface. 6. Filling the edges upto the punched lines. 7. Checking the finished flat with vernier calipers. 1. Ensure that the handle of the fi le is firmly fitted. 2. Pressure is applied on the file during forward stroke and pressure is relieved during the return stroke. 3. File is prevented from clogging. 4. File is cleaned from file card.

ACCURACY &  FINISH

± 1 mm

DEVIATION :

1. How do you specify a file?

2. What is the constructional and functional difference between single cut and double cut files?

3. What is meant by scraping? How scraping is done?

SELF ASSESSMENT QUESTIONS

4. How files are classified, describe briefly?

5. State the relations between length of the file and roughness.

Accuracy Finish

EVALUATION

Skill in handling Measuring tools Skill in handling Tools & Equipment Viva - Voice

10

TOTAL MARKS SIGNATURE

10

40 10 10

DATE SHOP: FITTING

:

TITLE : CUTTING WITH HACKSAW

Exp. No : Time

2

:

SKETCH

To be able to use hacksaw for cutting the work piece at the given positions. OBJECTIVES

To be able to chisel the material to remove the extra material.

1. Skill in using hack saw. SKILLS TO BE DEVELOPED

2. Skill in using chisel.

75 X 50 X 6 mm M.S.Flat. SPECIFICATION OF MATERIAL

Bench vice, Surface plate, Steel rule, Try square, Dot punch, Scriber, Flat file,, Scriber, Odd leg caliper, TOOLS & EQUIPMENT

Hacksaw, Cape Chisel.

1. Checking the raw material with for size. SEQUENCE OF OPERATIONS

2. Filling the material to size. 3. Marking the job as per dimensions. 4. Chiseling the ends. 5. Cut the material as required using Hack saw.

1. Ensure that the handle of the file is firmly fitted. SAFETY PRECAUTIONS

2. Pressure is applied on the file during forward stroke and pressure is relieved during the return stroke. 3. File is prevented from clogging. 4. File is cleaned from file card.

ACCURACY & FINISH

± 1 mm

DEVIATION :

SELF ASSESSMENT QUESTIONS

1. What care is to be taken for the protection of files?

2. What is meant by pinning? How can it be avoided?

3. What do you understand by direct measurement and indirect measurement?

4. How do you specify Hacksaw Blade? What care do you take while fixing it in the frame?

5. What are various cutting tools used in Fitting?

EVALUATION

Accuracy Finish

10

Skill in handling Measuring tools

10

Skill in handling Tools & Equipment Viva - Voice

10 10

TOTAL MARKS

SIGNATURE

SHOP:

TITLE :

FITTING

DATE MARKING, CUTTING, DRILLING & TAPPING

Exp. No : Time

SKILLS TO BE DEVELOPED

: 3

:

1. Skill in using Drilling and Cutting. 2. Skill in using Tap sets.

50 X 50 X 12 mm M.S.Flat. SPECIFICATION OF MATERIAL

Finished job of experiment No.1 may be used.

TOOLS & EQUIPMENT

SEQUENCE OF OPERATIONS

Bench vice, Vernier calipers, Steel rule, Tap set, Dot punch, Suitable Drill Bit.

1. Checking the raw material with for size. 2. Mark the centre of the work piece with centre punch. 3. Holding the work piece on vice of drilling machine. 4. Cut the central hole of the work piece. 5. Select the suitable tap and cut internal threads on drilled hole.

1. Ensure that the drill bit is f irmly gripped in the Drill chuck while drilling. SAFETY PRECAUTIONS

2. Ensure proper feeding of tap while tapping. 3. Proper holding of the job and applying the proper tap be ensured while cutting internal threads.

ACCURACY & FINISH

± 1 mm

DEVIATION :

SELF ASSESSMENT QUESTIONS

1. Distinguish between tapping and Dieing?

2. How do you calculate tap drill size?

3. How many types of taps are available in a set? What are they?

4. What is the difference between parallel shank and tapered shank twist drill?

5. How can a broken drill be removed from drill chuck?

EVALUATION

Accuracy Finish

10

Skill in handling Measuring tools Skill in handling Tools & Equipment Viva - Voice

10 10 10

TOTAL MARKS

SIGNATURE

NAME OF THE STUDENT

PIN DATE

SHOP: FITTING

:

TITLE : ASSEMBLING OF TWO PIECES

Exp. No : Time

4

:

SKETCH

To be able to match the two metal pieces with fitting operations. OBJECTIVES

1. Skill in sawing and filling SKILLS TO BE DEVELOPED

2. Skill in using measuring tools.

50 X 50 X 6 mm M.S.Flat of two pieces. SPECIFICATION OF MATERIAL

Bench vice, Try square, Surface plate, Surface gauge, Hack saw, Triangular rough file, Smooth file, TOOLS & EQUIPMENT

SEQUENCE OF OPERATIONS

Scriber, Dot punch, Hammer.

1. Cut the pieces to size using hacksaw. 2. Filling surface of flat for trueness. 3. Marking the surface as per dimensions. 4. Dot punching the marked lines and cutting with hacksaw. 5. Smoothing the surfaces with files and assembling the two pieces.

SAFETY PRECAUTIONS

1. Surface plate is checked for cleanliness and care is taken to prevent it from rust. 2. Ensure that hacksaw blade is properly fitted in the frame.

ACCURACY & FINISH

+ 1 mm

DEVIATION :

SELF ASSESSMENT QUESTIONS

1. Name the various bench working process?

2. Name the marking and measuring tools used in fitting shop?

3. What are the properties of metals?

4. What is tapping? Explain step by step tapping operation?

5. What is Dieing? Explain the operation step by step?

EVALUATION

Accuracy Finish

10

Skill in handling Measuring tools

10

Skill in handling Tools & Equipment Viva - Voice

10 10

TOTAL MARKS

SIGNATURE

FORGING SHOP

NAME OF THE STUDENT

PIN DATE

SHOP: FORGING

:

TITLE : CONVERSION OF ROUND TO SQUARE

Exp. No : Time

1

:

SKETCH

1. To be able to heat the material to red hot condition in plastic state. OBJECTIVES

2. To be able to convert the round section to square section.

1. Skill in lighting the forge and producing heat. SKILLS TO BE DEVELOPED

2. Checking constantly the heating condition of work piece. 3. Skill in Hammering and Flattering.

SPECIFICATION OF MATERIAL

TOOLS & EQUIPMENT

20 X 75 MS Round, Coke.

Forge, Anvil, Sledge hammer, Hand Hammer, Flat tong, Round tong, Flatter, Brass rule.

1. Checking the material. SEQUENCE OF OPERATIONS

2. Lighting the forge. 3. Heating the forge. 4. Drawing the material through hammering by supporting the work piece on anvil. 5. Squaring the material through flattering. 6. Checking the dimensions by brass rule. 1. The work piece is observed for proper heating (plastic stage).

SAFETY PRECAUTIONS

2. Proper tongs and hammers are used. 3. Hammering of the material is done in red hot condition only. 4. Use gloves and gumboots. 5. Beware of your clothes. Do not expose them to heat. 6. Watch properly while hammering

ACCURACY & FINISH

+ 1 mm

DEVIATION :

SELF ASSESSMENT QUESTIONS

1. Distinguish between forging and smithy.

2. What is the desirable mechanical properties that facilitate material to be effectively forged?

3. What are the characteristics of fuel used in forging?

4. State the functions of hardie hole and punching hole of anvil. How do you specify an anvil?

5. Differentiate between open fire and stock fire.

6. What is the function of tuyers in forge?

EVALUATION

Accuracy Finish

10

Skill in handling Measuring tools Skill in handling Tools & Equipment Viva - Voice

10 10 10

TOTAL MARKS

SIGNATURE

NAME OF THE STUDENT

PIN DATE

SHOP: FORGING

:

TITLE : CONVERSION OF ROUND TO HEXAGON

Exp. No : Time

2

:

SKETCH

1. To be able to heat the material to red hot condition. 2. To be able to convert the Round section to Hexagon OBJECTIVES

section.

1. Skill in using forging tools. SKILLS TO BE DEVELOPED

SPECIFICATION OF MATERIAL

TOOLS & EQUIPMENT

2. Skill in rotating the bar by 60⁰.

Ф20 X 75 MS Round, Coke.

Forge, Anvil, Sledge hammer, Hand Hammer, Round tong, Flatter, Brass rule, Hexagonal swages, Steel rule.

SEQUENCE OF OPERATIONS

1. Checking the material. 2. Heating the raw material in forge to appropriate hotness. 3. Hammering the heated bar by supporting on anvil. 4. Converting into hexagonal cross section by rotating the work piece and hammering. 5. Finishing the section by using swages.

SAFETY PRECAUTIONS

1. Care is to be taken while heating the material to plastic state. 2. Material is protected from over heating as i t may lead to melting of the material. 3. Proper tongs and hammers are to be used. 4. Use protective devices.

ACCURACY & FINISH

+ 1 mm

DEVIATION :

SELF ASSESSMENT QUESTIONS

1. State the use of swages.

2. What is the difference between drawing down and setting down operations?

3. List out the specific tongs used in forging shop and state their specific uses.

4. What is meant by Red hot condition?

EVALUATION

Accuracy Finish

10

Skill in handling Measuring tools Skill in handling Tools & Equipment Viva - Voice

10 10 10

TOTAL MARKS

SIGNATURE

NAME OF THE STUDENT

PIN DATE

SHOP: FORGING

:

TITLE : PREPARATION OF CHISEL FROM ROUND ROD

Exp. No : Time

3

:

SKETCH To be able to make hexagonal chisel from round rod. OBJECTIVES

1. Skill in using forging tools. SKILLS TO BE DEVELOPED

2. Skill in obtaining cutting edge of chisel and hexagonal shank.

SPECIFICATION OF MATERIAL

TOOLS & EQUIPMENT

Ф20 X 75 MS Round, Coke.

Forge, Anvil, Sledge hammer, Hand Hammer, Round tong, Brass rule, Hexagonal swages, and Steel rule.

SEQUENCE OF OPERATIONS

1. Checking the raw material. 2. Heating the raw material in forge. 3. Upsetting one end of the bar to form head. 4. Forging the bar to hexagonal shape by repeating striking. 5. Heating the other end to plastic state and drawing into a thinner section and making it as the cutting edge of a chisel. 6. Checking the finished product.

SAFETY PRECAUTIONS

1. Care is to be taken while heating the job firmly during upsetting. 2. Do not divert your attention while working. 3. The chisel end is cooled after heating and before upsetting. 4. Protect the body, eyes etc., form heat.

ACCURACY & FINISH

+ 1 mm

DEVIATION :

SELF ASSESSMENT QUESTIONS

1. What is meant by punching operation?

2. How do you specify a sledge hammer?

3. What is meant by Forge ability? List various forgeable metals..

4. Distinguish between Cold chisel and Hot chisel.

5. Define the term Fullering.

EVALUATION

Accuracy Finish

10

Skill in handling Measuring tools

10

Skill in handling Tools & Equipment Viva - Voice

10 10

TOTAL MARKS

SIGNATURE

NAME OF THE STUDENT

PIN DATE

SHOP: FORGING

TITLE : PREPARATION OF RING AND HOOK FROM M.S. ROUND ROD

Exp. No : Time SKETCH

To be able to make ring and hook from M.S. Round rod. OBJECTIVES

1. Skill in using Swage block. SKILLS TO BE DEVELOPED

SPECIFICATION OF MATERIAL

TOOLS & EQUIPMENT

SEQUENCE OF OPERATIONS

2. Skill in hammering.

Ф10 X 250 mm MS Round, Coke.

Forge, Anvil, Sledge hammer, Ball peen Hammer, swage block, Tongs.

1. Checking the raw material. 2. Heating the material. 3. Bending the heated material into ring shape. 4. Bending the remaining length into hook shape.

SAFETY PRECAUTIONS

1. Work piece is properly bent in shape in Swage block. 2. Over heating should be avoided. 3. Hammering is done with proper support to the work piece. 4. Ensure adequate water before working.

ACCURACY & FINISH

+ 1 mm

DEVIATION :

:

:

4

SELF ASSESSMENT QUESTIONS

1. State the function of Swage block.

2. What is meant by Forge Welding?

3. Explain the different Forging operations?

4. What are the characteristics of the forged product?

5. State the use of flatters..

EVALUATION

Accuracy Finish

10

Skill in handling Measuring tools

10

Skill in handling Tools & Equipment Viva - Voice

10 10

TOTAL MARKS

SIGNATURE

NAME OF THE STUDENT

PIN DATE

SHOP: FORGING

PREPARATION OF A HEXAGONAL BOLT & NUT

Exp. No : Time

5

:

SKETCH

1. To be able to make a hexagonal bolt. OBJECTIVES

:

TITLE :

2. To be able to punch and drift the material.

1. Skill in punching. SKILLS TO BE DEVELOPED

SPECIFICATION OF MATERIAL

TOOLS & EQUIPMENT

2. Skill in using drift.

1. 2.

Ф10 X 250 mm Round, Coke. Ф25 X 20 mm Round

Forge, Anvil, Hammers, Round tong, Flatter, Punches, Drifts, Swage block, Tongs. Brass rule.

1. Checking the raw material. 2. Heating one end of the bar for sufficient length to make the head. 3. Jump up the heated end on an anvil. 4. Flatter head by hammering. SEQUENCE OF OPERATIONS

5. Swage head to size. 6. Dieing the other end of the bar. 7. Heating the other raw material. 8. Punching and drifting. 9. Tapping the punched bar to make it as nut.

1. Keep the forge and its surroundings clean. SAFETY PRECAUTIONS

2. Regulate proper air supply for heating the job forge. 3. After completion of the work put off the forge. 4. Tight dress and proper foot wear is to be used.

ACCURACY & FINISH

+ 1 mm

DEVIATION :

SELF ASSESSMENT QUESTIONS

1. What do you understand by drifting?

2. What are the basic elements of the forge?

3. What do you understand by Scale loss?

4. State the reason in opting for Brass rule in forging?

EVALUATION

Accuracy Finish

10

Skill in handling Measuring tools

10

Skill in handling Tools & Equipment

10

Viva - Voice

10

TOTAL MARKS

SIGNATURE

CARPENTRY

NAME OF THE STUDENT

PIN DATE

SHOP: CARPENTRY

CUTTING OF WOOD WITH HAND SAW

Exp. No : Time SKETCH

1. Practice sawing on wooden piece. OBJECTIVES

2. To be able to use different saws accurately.

1. Skill in fixing the job in the vices. SKILLS TO BE DEVELOPED

2. Skill in sawing the wood in a straight line 3. Select suitable saw for specific operation.

SPECIFICATION OF MATERIAL

TOOLS & EQUIPMENT

Teak wood of 310 X 55 X 50 mm

Steel rule, Try square, Marking gauge, Hand saw, Jack plane, Bench.

1. Marking the dimensions on job. SEQUENCE OF OPERATIONS

2. Fixing the job in the vice. 3. Cutting along the grains by using Rip saw. 4. Changing the position of work piece in the vice. 5. Cutting perpendicular to the grain using cross cut saw.

1. Saws are used with handles fitted properly. SAFETY PRECAUTIONS

2. Place all the tools in specified places after use. 3. Job is clamped properly. 4. Saw cut is made during forward stroke only with proper cutting force.

ACCURACY & FINISH

:

TITLE :

± 1 mm

DEVIATION :

:

1

SELF ASSESSMENT QUESTIONS

1. What are the types of wood used in carpentry?

2. Define “Seasoning” and state its importance.

3. What do you understand by the term “Setting in saw”?

4. What are the different types of saws used in carpentry?

5. What is meant by ripping?

6. How do you specify a Hand saw?

EVALUATION

Accuracy Finish

10

Skill in handling Measuring tools

10

Skill in handling Tools & Equipment

10

Viva - Voice

10

TOTAL MARKS

SIGNATURE

NAME OF THE STUDENT

PIN DATE

SHOP: CARPENTRY

PLANNING OF WOOD

Exp. No : Time SKETCH

1. Practice sawing on wooden piece. OBJECTIVES

2. To be able to use different planes used in carpentry.

1. Skill in fixing the job in the vices. SKILLS TO BE DEVELOPED

2. Skill in sawing the wood in a straight line 3. Select suitable Planes for specific operation.

SPECIFICATION OF MATERIAL

TOOLS & EQUIPMENT

Teak wood of 310 X 55 X 50 mm

Steel rule, Try square, Marking gauge, Hand saw, Different Planes.

1. Marking the dimensions on the job by using Marking gauge. SEQUENCE OF OPERATIONS

2. Fixing the job in the vice. 3. Cutting along the grains by using Rip saw. 4. Changing the position of work piece in the vice. 5. Select suitable planes for the operation on four sides of the wood piece.

1. Saws are used with handles fitted properly. SAFETY PRECAUTIONS

2. Place blade of a plane to suitable thickness and projection of plane. 3. Job is clamped properly. 4. Planning must be straight and always checking with hand.

ACCURACY & FINISH

:

TITLE :

± 1 mm

DEVIATION :

:

2

SELF ASSESSMENT QUESTIONS

1. Specify a carpentry plane?

2. Specify a metal jack plane?

3. Specify a blade which is used in the planes?

4. What are the different types of planes used in carpentry?

5. What are the common defects in timber?

EVALUATION

Accuracy Finish

10

Skill in handling Measuring tools

10

Skill in handling Tools & Equipment

10

Viva - Voice

10

TOTAL MARKS

SIGNATURE

NAME OF THE STUDENT

PIN DATE

SHOP: CARPENTRY

PLANNING NAD CHISELLING OF WOOD

Exp. No : Time

3

:

SKETCH

1. To be able to chisel various grooves on wooden OBJECTIVES

:

TITLE :

block. 2. To be able to plane the wood.

1. Skill in accurate marking. SKILLS TO BE DEVELOPED

2. Skill in using of appropriate chisels. 3. Skill in preparing the jack plane for planning. 4. Skill in planning.

SPECIFICATION OF MATERIAL

TOOLS & EQUIPMENT

Teak wood of 310 X 45 X 25 mm

Steel rule, Try square, Marking gauge, Hand saw, Tenon saw, Jack plane, Firmer Chisel, Rasp File, Wooden mallet.

1. Marking the dimensions on the job by using Marking gauge. SEQUENCE OF OPERATIONS

2. Fixing the job in the vice of grooves by marking gauge/pencil . 3. Cutting slides of grooves by hand saw. 4. Chip the material by using firmer chisel by applying pressure with mallet. 5. Finishing the grooves with rasp file.

1. Chiseling is proceeded in a direction away from the body. SAFETY PRECAUTIONS

2. Usage of blunt tools is avoided. 3. Work piece is to be rigidly clamped. 4. Concentration is on the cutting edge of chisel but not on the handle during chiseling. 5. Pressure is applied on the plane only during forward stroke.

ACCURACY & FINISH

± 1 mm

DEVIATION :

SELF ASSESSMENT QUESTIONS

1. How do you Specify a Chisel?

2. Distinguish between Mortise chisel and Firmer Chisel.

3. State the function of gauges?

4. What is meant by ‘cut’ in reference to a plane?

5. List various chisels used in carpentry.

EVALUATION

Accuracy Finish

10

Skill in handling Measuring tools

10

Skill in handling Tools & Equipment

10

Viva - Voice

10

TOTAL MARKS

SIGNATURE

NAME OF THE STUDENT

PIN DATE

SHOP: CARPENTRY

ORIENTATION OF WOOD GRAINS

Exp. No : Time SKETCH

Cutting the natural Wood to be cut across the grains OBJECTIVES

and along the grains for observing the grain structure and grain growth.

1. Skill in using appropriate tools. SKILLS TO BE DEVELOPED

2. Skill in operating the jack plane. 3. Skill in estimation the grain Structure.

SPECIFICATION OF MATERIAL

TOOLS & EQUIPMENT

Take a suitable natural wood piece from the tree of a minimum 100 mm diameter and 100 mm length.

Steel rule, Jack plane, Outside calipers, Gauges, Hand saw.

1. Using hand saw or band saw cut the wood across the grains. SEQUENCE OF OPERATIONS

2. Planning the work piece by using jack plane. 3. Cut the wood piece along the grains by using hand saw or with band saw.

1. Do not divert your attention while working on band saw. SAFETY PRECAUTIONS

2. Before switching on the machine, ensure that the job is held rigidly. 3. Do not wear loose garments when working on band saw. 4. Beware of your hands while working and applying tools on the job.

ACCURACY & FINISH

:

TITLE :

± 1 mm

DEVIATION :

:

4

SELF ASSESSMENT QUESTIONS

1. Observe the grain structure of wood and explain different grains?

2. What is the difference between across the grains and along the grains with suitable figure?

3. What is the difference between hard wood and soft wood?

4. Write the qualities of a good timer?

5. Write any five advantages of wood over the other materials?

EVALUATION

Accuracy Finish

10

Skill in handling Measuring tools

10

Skill in handling Tools & Equipment

10

Viva - Voice

10

TOTAL MARKS

SIGNATURE

NAME OF THE STUDENT

PIN DATE

SHOP: CARPENTRY

:

TITLE : DOVETAIL JOINT

Exp. No : Time

5

:

SKETCH

To be able to prepare dovetail joint. OBJECTIVES

1. Skill in using tools. SKILLS TO BE DEVELOPED

2. Skill in marking right dovetail and groove. 3. Skill in preparing a firm carpentry joint

SPECIFICATION OF MATERIAL

TOOLS & EQUIPMENT

2 pieces of 155 X 55 X 30 mm wood.

Bench vice, Beveled edged firmer chisel, Metal jack plane, Mallet, Fold rule, Try Square, Marking Gauge, Rasp file.

1. Planning the wooden pieces on all sides. SEQUENCE OF OPERATIONS

2. Marking at an angles of 75⁰ with bevel square. 3. Trimming the dovetail groove on Second piece. 4. Cutting the dovetail groove on second piece. 5. Finishing the groove. 6. Assembling the two pieces and preparing dovetail halving joint by using mallet.

1. Ensure proper ‘cut’ to be used while planning. SAFETY PRECAUTIONS

ACCURACY & FINISH

2. Appropriate tools are selected and used. 3. Care should be taken in preparing accurate dovetails.

± 1 mm

DEVIATION :

SELF ASSESSMENT QUESTIONS

1. How are the uses of dovetail joints?

2. What are the specific characteristics of a dovetail halving joint?

3. What is meant by Rebating?

4. How do you specify a “Bench vice”.

5. Suggest a Carpentry joint to be used in making photo frames

EVALUATION

Accuracy Finish

10

Skill in handling Measuring tools

10

Skill in handling Tools & Equipment

10

Viva - Voice

10

TOTAL MARKS

.

SIGNATURE

NAME OF THE STUDENT

PIN DATE

SHOP: CARPENTRY

:

TITLE : MORTISE & TENON JOINT

Exp. No : Time

6

:

SKETCH

To be able to prepare Mortise and Tenon joint. OBJECTIVES

1. Skill in cutting the tenon using Tenon Saw. SKILLS TO BE DEVELOPED

2. Skill in using various chisels, Mallets, Planes, Gauges etc.

SPECIFICATION OF MATERIAL

Teak wood of two pieces of 155 X 55 X 30 mm.

Try Square, Mortise gauge, Tenon saw, Mortise Chisel, Firmer chisel, Mallet. TOOLS & EQUIPMENT

1. Plane the given two pieces to the required size by using jack plane. SEQUENCE OF OPERATIONS

2. Marking the dimensions to make Tenon using Mortise gauge. 3. Cutting Tenon with Tenon saw along the marked lines. 4. Using Firmer chisel to remove the excess material to set finished Tenon. 5. Mark the dimension to make Mortise on the second piece with mortise gauge. 6. Using Mortise chisel, provide recess in the second piece to accommodate Tenon. 7. Assembling the two pieces by fitting the Tenon into Mortise.

1. Right Mallet is only to be used in Chiseling. SAFETY PRECAUTIONS

ACCURACY & FINISH

2. While cutting, the work piece is to be held firmly and properly. 3. Provide Sufficient illumination and Ventilation in the work shop while doing the job.

± 1 mm

DEVIATION :

SELF ASSESSMENT QUESTIONS

1. What are the practical use of Mortise and Tenon joint?

2. What is the tool used for planning a convex surface?

3. What is the user of pincer?

4. When Spoke Shave used?

5. What are the wood working processes?

EVALUATION

Accuracy Finish

10

Skill in handling Measuring tools

10

Skill in handling Tools & Equipment

10

Viva - Voice

10

TOTAL MARKS

SIGNATURE

NAME OF THE STUDENT

PIN DATE

SHOP: CARPENTRY

WOOD TURNING ON LATHE

Exp. No : Time

7

:

SKETCH

To be able to prepare a Wooden Rolling stock with OBJECTIVES

:

TITLE :

handle for rolling Chapathi in Kitchen.

1. Skill in using appropriate tools. SKILLS TO BE DEVELOPED

2. Skill in operating wood working lathe. 3. Skill in estimation of material required.

SPECIFICATION OF MATERIAL

50 X 50 mm square section of 350 mm length teak wood.

Jack plane, Outside calipers, gauges, Ste el rule, Firmer chisel, Wood Working Lathe. TOOLS & EQUIPMENT

1. Planning the four corners of the work piece by using Jack plane. SEQUENCE OF OPERATIONS

2. Marking the centers of jobs on either side. 3. Mounting the job between head stock & Tail stock centers. 4. Fixing tool in the tool post & positioning it to appropriate height. 5. Starting the lathe to make the work piece to revolve at desired speed. 6. Feeding the bevel gauge against the rotating work piece to get the required size and shape. 7. Using outside calipers check the diameter of work piece. 8. Using parting off tool reduce the diameter on either ends of the work piece. 9. Removing the rolling work piece between centers and cut off the excess material on either sides.

SAFETY PRECAUTIONS

ACCURACY & FINISH

1. 2. 3. 4. 5.

Do not divert your attention while working on lathe. Before starting the machine, ensure that the job is held rigidly. Don’t wear loose garments, while working on lathe. Use safety goggles while working. Beware of your hands while working and applying tools on the job.

± 1 mm

DEVIATION :

SELF ASSESSMENT QUESTIONS

1. What are the components that can be made, using wood working lathes?

2. Name the parts of Wood turning lathe?

3. State the principle of operation of wood working lathe?

4. What is rebating? How is done?

EVALUATION

Accuracy Finish

10

Skill in handling Measuring tools

10

Skill in handling Tools & Equipment

10

Viva - Voice

10

TOTAL MARKS

SIGNATURE

NAME OF THE STUDENT

PIN DATE

SHOP: CARPENTRY

HOUSEHOLD ARTICLE (STOOL)

Exp. No : Time SKETCH

To be able to prepare a house hold article like OBJECTIVES

wooden stool.

1. Skill in using appropriate tools. SKILLS TO BE DEVELOPED

SPECIFICATION OF MATERIAL

2. Skill in estimation of material required.

300 X 300 X 25 mm one plank, 4 Nos. of 410 X 50 X 50 mm for legs and Nos. of 300 X 50 X 25 mm for supporters.

Jack plane, Marking gauge, Steel rule, Firmer chisel, Mortise chisel, Mallet. TOOLS & EQUIPMENT

1. Select the material for legs of correct size. SEQUENCE OF OPERATIONS

2. Select the plank of wood of correct size. 3. Marking and planning the selected material. 4. Marking of Mortise and tenon joint. 5. Select the surface chisels and cut the grooves. 6. Fixing the legs and plank. 7. Fixing the job with suitable joining process.

1. Do not divert your attention while working on lathe. SAFETY PRECAUTIONS

2. Before starting the machine, ensure that the job is held rigidly.

3. Don’t wear loose garments when working on lathe. 4. Use safety goggles while working. 5. Beware of your hands while working and applying tools on the job.

ACCURACY & FINISH

:

TITLE :

± 1 mm

DEVIATION :

:

8

SELF ASSESSMENT QUESTIONS

1. Name any three wood working machines?

2. Name the different joints in carpentry shop?

3. What are the various types of paints?

4. State the properties of good paints ?

EVALUATION

Accuracy Finish

10

Skill in handling Measuring tools

10

Skill in handling Tools & Equipment

10

Viva - Voice

10

TOTAL MARKS

SIGNATURE

SHEET METAL

NAME OF THE STUDENT

PIN

SHOP:

TITLE :

SHEET METAL

DATE CUTTING PRACTICE

Exp. No : Time

OBJECTIVES

1.

To be able to use different type of snips.

2.

To be able to cut various shapes from the

: 1

:

SKETCH

sheet.

1. Skill in using Scriber. SKILLS TO BE DEVELOPED

2. Skill in cutting the sheet properly from the stock. 3. Skill on using the different snips to accuracy.

24 SWG GI sheet 200 X 100 mm. SPECIFICATION OF MATERIAL

Steel rule, Scriber, Straight snip, Curved snip, Divider, Stake, Chisel, Wooden mallet. TOOLS & EQUIPMENT

1. Cutting the required sheet from the stock by using snips. SEQUENCE OF OPERATIONS

2. Marking the dimensions on the sheet by using scriber (or) pencil & Steel rule. 3. Drawing the circular shapes by using divider. 4. Do the rough cutting for the curved shapes by using chisel and curved snips for finishing process. 5. Using straight snips to cut the straight edges.

1. Always hold the snip in one hand and the nearest metal in the other hand. SAFETY PRECAUTIONS

2. During cutting the metal curl on the left hand side of the snip and curls down on the right hand side of the snips. 3. Always cut along the left hand edge of the sheet of permit the scrap to curl away. 4. Remove sharp projections to avoid injuries.

ACCURACY & FINISH

± 1 mm

DEVIATION :

SELF ASSESSMENT QUESTIONS

1. Distinguish between sheet and plate?

2. What are the various types of metals used in sheet metal shop?

3. What is meant by Galvanizing? How is it done?

4. What do you understand by circumferential rule why it is to be used in sheet metal shop?

EVALUATION

Accuracy Finish

10

Skill in handling Measuring tools

10

Skill in handling Tools & Equipment

10

Viva – Voice

10

TOTAL MARKS

SIGNATURE

NAME OF THE STUDENT

PIN

SHOP:

TITLE :

SHEET METAL

DATE GROOVED JOINT AND LOCKED GROOVED JOINT

Exp. No : Time

OBJECTIVES

1.

To be able to use different type of snips.

2.

To be able to cut various shapes f rom the

: 2

:

SKETCH

sheet.

1. Skill in using Mallet to form the metal properly. SKILLS TO BE DEVELOPED

2. Skill in bending the sheets properly along the marked line.

SPECIFICATION OF MATERIAL

TOOLS & EQUIPMENT

24 SWG G.I. sheet 100 X 75 mm (2 Nos.) 100 X 80 mm (1 No.)

Steel rule, Scriber, Straight snips, Pencil, Divider, Stakes, Mallet.

1. Drawing lines a different of 5 mm parallel to the edges of the two sheets using Scriber/Pencil. SEQUENCE OF OPERATIONS

2. Forming the flange on the sheet, by folding the sheet along the scribed lines using mallet & appropriate stakes. 3. Bending the edges of the sheets by applying moderate pressure using mallet. 4. Inter lock the bent edges and apply pressure with mallet to make required joints.

1. To avoid injuries do not hold the sheets with bare hands. SAFETY PRECAUTIONS

ACCURACY & FINISH

2. Remove sharp projections on the sheet immediately on notching.

± 1 mm

DEVIATION :

SELF ASSESSMENT QUESTIONS

1. What is the desirable mechanical property of the sheet?

2. What are the various joints used in sheet metal?

3. What do you understand by seaming?

4. What is meant by hem?

5. What do you understand by reinforcement in Tin Smithy and how is it to be done?

6. Are the joints made in Tin Smithy leak proof?

EVALUATION

Accuracy Finish

10

Skill in handling Measuring tools

10

Skill in handling Tools & Equipment

10

Viva – Voice

10

TOTAL MARKS

SIGNATURE

NAME OF THE STUDENT

PIN

SHOP:

TITLE :

SHEET METAL

DATE

PREPARATION OF RECTANGULAR OPEN TYPE TRAY

:

Exp. No : Time

3

:

SKETCH OBJECTIVES

To be able to prepare a rectangular open tray

1. Skill in drawing the Development of the object. SKILLS TO BE DEVELOPED

2. Skill in using the tools to obtain desired shape.

G.I. sheet 200 X 150 mm SPECIFICATION OF MATERIAL

TOOLS & EQUIPMENT

Steel rule, Scriber, Straight snips, Stakes, Mallet.

1. Drawing the development of the object to be made. SEQUENCE OF OPERATIONS

2. By placing the pattern on the sheet, marking the dimensions by using scriber. 3. Shearing the required piece from the parent stock by using straight snips. 4. Marking the lines on the sheet, for marking bends for forming. 5. Strengthening the sides of sheet by making single hem using Hatchet stake. 6. Forming the sheet in to desired shape by using stakes. 7. Seaming the corners of the tray by inserting the laps of the adjacent sides with single hem.

1. Care is to be taken in avoiding wastage of sheet metal. SAFETY PRECAUTIONS

ACCURACY & FINISH

2. Proper pressure is to be applied with mallet. 3. Safe edges are made by properly bending the sheet.

± 1 mm

DEVIATION :

SELF ASSESSMENT QUESTIONS

1. Draw the layout of tray?

2. What are the various sheet metal operations commonly employed?

3. Distinguish between blanking and piercing?

4. State the use of Rivet set?

EVALUATION

Accuracy Finish

10

Skill in handling Measuring tools

10

Skill in handling Tools & Equipment

10

Viva – Voice

10

TOTAL MARKS

SIGNATURE

NAME OF THE STUDENT

PIN DATE

SHOP: SHEET METAL

:

TITLE : PREPARATION OF HOLLOW CYLINDER

Exp. No : Time

4

:

SKETCH

To be able to prepare a Hollow Cylinder OBJECTIVES

1. Skill in using Mallet to form the sheet to desired SKILLS TO BE DEVELOPED

shape. 2. Skill in Bending the sheet exactly along the marked line. 3. Skill in forming a single hem.

24 SWG G.I. sheet 200 X 112 mm SPECIFICATION OF MATERIAL

TOOLS & EQUIPMENT

Steel rule, Scriber, Straight snips, Stakes, Mallet.

1. Drawing the development (pattern) of the cylinder. SEQUENCE OF OPERATIONS

2. Marking the dimension of sheet to be cut by placing the pattern on the sheet using scriber using a straight snip. 3. Cutting the required sheet from the stock along the marked lines using a straight snip. 4. To strengthen the edges, make the single hem on top & bottom side using Hatchet stake. 5. Forming the flat sheet into cylindrical shape by cylindrical stake and applying pressure by using mallet. 6. Prepare a single hem on to longitudinal sides in opposite directions Inter lock the sides and apply pressure using Mallet to make a strong joint.

1. Care should be exercised when forming the sheet metal using mallets & stakes. SAFETY PRECAUTIONS

ACCURACY & FINISH

2. Do not keep tools on the edges of the work table. 3. Always wear shoes to protect feet from sharp objects in the shop.

± 1 mm

DEVIATION :

SELF ASSESSMENT QUESTIONS

1. Draw the layout of cylinder to prepare the given job?

2. What is the function of stakes in Tin Smithy list of various stakes?

3. How do you specify a sheet?

4. State the use of wire gauge?

EVALUATION

Accuracy Finish

10

Skill in handling Measuring tools

10

Skill in handling Tools & Equipment

10

Viva – Voice

10

TOTAL MARKS

SIGNATURE

NAME OF THE STUDENT

PIN DATE

SHOP: SHEET METAL

:

TITLE : PREPARATION OF PIPE ELBOW

Exp. No : Time

5

:

SKETCH

To be able to prepare a Pipe Elbow. OBJECTIVES

1. Skill in cutting the beveled end. SKILLS TO BE DEVELOPED

SPECIFICATION OF MATERIAL

2. Skill in making the seams.

24 SWG G.I. sheet 212 X 200 mm

TOOLS & EQUIPMENT Steel rule, Scriber, Straight snips, Stakes, Mallet, Soldering iron, Curved Snip.

The operation consists of Making two similar cylindrical pipes tr uncated at angle of 45˚ on the side of  SEQUENCE OF OPERATIONS

each pipe seamed at beveled ends. (a) Preparation

of one pipe :

1. Drawing the development of a cylinder pipe truncated at an angle of 45˚ on one side. 2. Scribing the lines on the sheet by placing the pattern on it. 3. Cutting the lines on the sheet by placing the pattern on it. 4. Hem the straight side of the sheet and flange the curved side of the sheet. 5. Folding the edges of the Joining sides. 6. Forming the sheet into cylindrical shape by using stakes. 7. Seam the sides by using Mallet. (b) REPEATING THE SIMILAR OPERATIONS FOR MAKING SECOND PIPE FOR MAKING ELBOW: 1. Butt the treated portions of the cylindrical pipes at rectangles. 2. Soldering the two pipes. 3. Solder the joint to make leak proof.

1. Care should be taken in cutting the raw material without wastage. SAFETY PRECAUTIONS

2. Care is to be taken in joining the two pieces to form elbow without excess gaps.

ACCURACY & FINISH

± 1 mm

DEVIATION :

SELF ASSESSMENT QUESTIONS

1. Draw the layout of pipe elbow?

2. State the function of pipe elbow?

3. Explain piercing and blanking?

4. Why is flux used in soldering?

EVALUATION

Accuracy Finish

10

Skill in handling Measuring tools

10

Skill in handling Tools & Equipment

10

Viva – Voice

10

TOTAL MARKS

SIGNATURE

NAME OF THE STUDENT

PIN

SHOP:

TITLE :

SHEET METAL

DATE PREPARATION OF MUG

:

Exp. No : Time

:

SKETCH

To be able to preparation of mug. OBJECTIVES

1. Skill in cutting the beveled end. SKILLS TO BE DEVELOPED

SPECIFICATION OF MATERIAL

TOOLS & EQUIPMENT

SEQUENCE OF OPERATIONS

2. Skill in making the seams.

24 SWG G.I. sheet 212 X 200 mm

Steel rule, Scriber, Straight snip, Stakes, Mallet, Soldering iron, Curved Snip.

1. Drawing the development of a mug as per the specification. (2πr) 2. Scribing the lines on the sheet by placing the pattern on it. 3. Cutting the lines on the sheet by placing the pattern on it. 4. Forming the sheet into cylindrical shape by using stakes. 5. Seam the sides by mallet. 6. Joining the sides to become a permanent joint. 7. Soldering is done if necessary to become a leak proof joint.

1. Care should be taken in cutting the raw material without wastage. SAFETY PRECAUTIONS

2. Care is to be taken in joining the two pieces to form elbow without excess gaps.

ACCURACY & FINISH

± 1 mm

DEVIATION :

6

SELF ASSESSMENT QUESTIONS

1. Explain Brazing?

2. What is difference between Brazing and Soldering?

3. What do you mean by development of surface?

4. Name the few sheet metal joints?

EVALUATION

Accuracy Finish

10

Skill in handling Measuring tools

10

Skill in handling Tools & Equipment

10

Viva – Voice

10

TOTAL MARKS

SIGNATURE

NAME OF THE STUDENT

PIN DATE

SHOP: SHEET METAL

:

TITLE : PREPARATION OF A FUNNEL

Exp. No : Time

:

SKETCH

To be able to prepare a funnel. OBJECTIVES 1. Skill in marking dimensions on the sheet. SKILLS TO BE DEVELOPED

2. Skill in using the appropriate stakes for forming the sheet.

SPECIFICATION OF MATERIAL

24 SWG G.I. sheet 300 X 100 mm 80 X 65 mm

TOOLS & EQUIPMENT Steel rule, Scriber, Straight snips, Stakes, Mallet.

(a) Preparing Upper Conical part : SEQUENCE OF OPERATIONS 1. Drawing the development of upper conical part. 2. Placing he patterns on the sheet, cutting sheet of required size. 3. Marking the dimensions on the part by using the scriber & dividers.. 4. Hem the upper side of the sheet. 5. Flanging out he bottom of the part. 6. Folding the edges of the joining sides. 7. Forming the sheet into conical shape by using appropriate stakes and mallet.

(b) Preparing the Bottom Conical Part : 1. Drawing the development of bottom conical part. 2. Placing the patterns on the sheet & cutting to required size. 3. Hem the bottom side of the sheet. 4. Flanging the upper side of the sheet. 5. Folding the edges of the joining side. 6. Forming the sheet into conical shape. 7. Seaming the sides.

(c) Assembling : 1. Seaming the Top conical part & bottom conical part to obtain the required funnel. 1. Ensure that the Snips are properly used with appropriate cut. 2. Slow and uniform pressure is given to sheet while bending on stakes. SAFETY PRECAUTIONS ACCURACY & FINISH

± 1 mm

DEVIATION :

7

SELF ASSESSMENT QUESTIONS

1. Draw the layout of Funnel?

2. What is meant by Dovetail Seam?

3. What are stakes? Name the different types?

4. What are the applications of a Brazing?

5. What is the purpose of flux used with the solder?

EVALUATION

Accuracy Finish

10

Skill in handling Measuring tools

10

Skill in handling Tools & Equipment

10

Viva – Voice

10

TOTAL MARKS

SIGNATURE

NAME OF THE STUDENT

PIN

SHOP:

TITLE :

SHEET METAL

DATE PREPARATION OF A DUST PAN

Exp. No : Time SKETCH

OBJECTIVES

To be able to prepare Dust Pan.

1. Skill in using Snips. SKILLS TO BE DEVELOPED

2. Skill in making hems. 3. Skill in applying Mallet to set good finish

SPECIFICATION OF MATERIAL

24 SWG G.I. sheet : 180 X 160 mm

TOOLS & EQUIPMENT

Steel rule, Scriber, Straight snips, Stakes, Mallet.

1. Drawing the development of the given Dust Pan. 2. Scribing the lines on the sheet by placing the Development on the sheet. SEQUENCE OF OPERATIONS

3. Hem all the four sides to strengthen the edges. 4. Forming the sheet into designed shape by using suitable stakes & Mallet. 5. Soldering the corner lap joints to make the required Dust Pan.

1. Blunt snips be avoided. SAFETY PRECAUTIONS

2. Edges are properly folded and checked for safety.

ACCURACY & FINISH

± 1 mm

:

DEVIATION :

:

8

SELF ASSESSMENT QUESTIONS

1. Draw the development layout of Dust pan?

2. State the use of riveting. Explain with stages?

3. What is the purpose of zinc coating on a G.I sheet?

4. Sketch curved snip and label the parts.

EVALUATION

Accuracy Finish

10

Skill in handling Measuring tools

10

Skill in handling Tools & Equipment

10

Viva – Voice

10

TOTAL MARKS

SIGNATURE