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Kl University Department of Basig Engineering Sciences-2 Workshop Manual

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Kl University Department of Basig Engineering Sciences-2 Workshop Manual KL UNIVERSITY DEPARTMENT OF BASIG ENGINEERING SCIENCES-2 WORKSHOP MANUAL LIST OF EXPERIMENTS 1. Carpentry a. Lap tee joint b. Mortise and Tenon joint 2. Fitting a. Square Fit b. “L” Fit 3. Tin-smithy a. Rectangular Tray b. Pipe “T” Joint 4. Basic Electrical House Wiring a. Stair case connection b. Godown connection. 5.Trades for demonstration a.Demo on grinding,milling and power hacksaw b.demo on welding machine. c.Demo on mimic panel board,(Double bedroom house wiring) Instructions to the students 1. Enter the lab with proper dress- code ( khaki apron and shoes) 2. Maintain a 200 pages white long note book (Drawing&workshop) 3. Draw the figures of tools and equipments proportionately using pencil only on the left side of the page. 4. Write the related theory part only on the right side of the page. 5. For every experiment, draw the related figure and write the individual procedure in the observation book and take signature by the concerned faculty. Write the date and Experiment number in the observation book. And take signature of staff member on index page of lab manual. 6. Only after taking signature in the observation book, write the record. Marks are allotted for your regularity. Performance of the students will be assessed for every session of workshop being conducted. 7. The records should be written, up to date without delay. They should be signed by the concerned faculty. 8. Medical kits provided in the First – Aid Box. The students can utilize the available medicines if at all there is any necessity. Safety in Workshop In order to achieve a safe working environment, knowing and practicing safety is the necessary pre-requisite in all Workshop activities. Safe equipment processes and operations are necessary to avoid any accidents in Workshop. Safe working environment can be achieved by following the instructions given below. 1.General& Hygiene: • Present yourself neat and tidy inside the Workshop. No student will be allowed to work without safety shoes. • Always be alert inside the Workshop. • Horseplay during work should be strictly avoided and it will be viewed very seriously. • Trim off your nails to reduce hand injury while working. • No bangles, rings, watches etc should be worn when working in Workshop. • Students (especially girls) should ensure that their hairs are kept intact. • The wash basin area should be kept clean and soaps after every hand wash should be washed and kept for others use. • The specified toilets should be used by the specified people. 2.Housekeeping: • Ensure that the place around you is kept neat and tidy. • See that there are no loose materials like tools, finished product, and personal belongings lying on the shop floor. • Oil, grease, lubricants, coolant, saw dust etc spilled on the floor is to be completely cleaned before start and completion of the work. • The walk ways inside the workshop should be kept free for easy movement of persons using it. • The best housekeeping ensures safe working environment. 3.Fire: • Be vigilant about sparks and small fires in and around the Workshop. • Inflammable materials like diesel, kerosene, petrol and chemicals should be kept away from welding, smithy, grinding areas, etc. • Avoid contact lenses when you are exposed directly to welding sparks and chemical fumes. • Familiarize yourself with the basic types of fire extinguishers and their usage. • In case of tire immediately evacuate yourself and assemble at the “Emergency assembly point” 4.Electrical: • Be careful about all electric connections and do not tamper with them. • If you spot any loose wires or loose connections inform the authorities immediately. • Do not switch ‘on’ any electrical switches, unless you are asked to do so. • Sharp objects including tools should be avoided colliding with electrical wires. • Do not tamper with the chemical bath in the Electroplating section. 5. Care about others: • Be aware that unsafe practices of a person also affect others directly / indirectly. Hence proper care should be taken towards safety. • Loose material should not be kept on the floor near machines or in public areas like walkways, passages, entrance etc. • While using tools in your work area ensure that you are keeping a safe distance from others. • Do not cramp between Machine tool areas.(blocking the way for others.) • Be co-operative and helpful to your fellow students. 6.Communication: • Before starting any exercise, ensure that the procedures are understood properly by you. • Do not hesitate to ask for any doubt, In the procedure. (even if It is silly.) • Any untoward incident (major or minor) in the Workshop should be immediately informed to the authorities. • If you spot out any loose wires, loose objects, unsafe conditions and your doubts about any unsafe area, should be reported to the concerned immediately. • If you are uncomfortable, unhealthy do not hesitate to inform the authorities. 7.Personal protective equipments: • Personal protective equipments commonly used in workshop are safety shoes, coveralls, gloves, goggles, welding shield, fireman helmet, leather apron, nose mask etc. • Personal protective equipments are only the last protective items for an accident, it is always better to have a sate working environment and ensure zero accidents. 8. Handling. (Tools, Measuring Instruments & Machine tools): • Material handling and handling of tools, measuring instruments and machine tools play a vital role in the workshop safety. • Ensure that all the materials and tools are received from stores as per the requisition slip and the same is returned to the stores after proper cleaning. • Use the carry box available for carrying the tools and materials and see that you use only the walkways while carrying them. 9. Tools: • Tools are generally precise and sharp in nature hence handled with utmost care. • Ensure that the tools are properly placed in the workplace. • Never load the tool more than the required limits it may tend to break leading to accidents. • While working on bench, ensure that the work piece is held rigid on the holding devices. (Vices etc.) • Never try to use a tool without knowing how to use it. • Use a tool for the specified operation it is meant for, ( eg. Do not use a dot punch for scribing lines.) • Avoid heavy hammer blows on the job while it is fixed in the vice. The job may slip leading to an accident. 10 Measuring instrument: • Ensure utmost care while handling measuring instruments which are highly precise and costly. • At any point of time measuring instruments should not be dropped down and penalty will be imposed for such acts. • Learn to differentiate high precision and low precision measurements and use the appropriate tool. (Do not use a vernier caliper to measure a job forged in smithy section.) • Never use the measuring instrument while the machining is in progress. (eg. Do not measure a revolving job in a Lathe.) 11 Machine tools: • While working on Machine tools instructions of the concerned staff are to adhered very strictly. Deviation of the above will lead to serious accidents and damages. • Ensure that the work piece is held rigidly in the work holding device, (chuck, machine vice etc.) • Ensure that the tool/cutter is held rigidly in the Machine tool. • Do not shift any levers when the machine is in operation. • While working in a Machine tool never exceed the limits of operation due to curiosity, as this may lead to accident. (eg. Never give automatic feed in a machine toot unless you are instructed to do so.) • Never exceed the limits while giving depth of cuts. This may lead to accident. CARPENTRY Screw Handle Steel Rule C- Clamp Blade Body Testing for Testing for Stock Straightness Squareness Try Square Blade Wedge Back Iron Solo Wooden Jack Plane Marking Guage Cross cut hand saw Trigger for quick opening Carpernter’s vice Tenon or back saw CARPENTRY Introduction: Carpentry may be defined as the process of making wooden components. It deals with the building work, furniture, cabinet making etc. Jointly, i.e., Preparation of joints is one of the important operations in all wood works. It deals with making joints for a variety of applications viz, door frames, window frames, wardrobes, cupboards, stairs etc. In this chapter tools and works associated with joinery are presented. Carpentry Material – Timber: Timber is the basic material used for any class of carpentry work. The term timber is applied to the wood obtained from; well-grown trees. The trees are cut, sawn into various sizes to suit the required purpose. Common Varieties of Indian Timber: Indian timbers most commonly used for various carpentry words are as follows: Babul, Deodar, Mahogany, Mango, Sal, Sissy and teak. Carpentry Tools: In carpentry large numbers of hand tools are used for processing the wood. Here, the details of tools that are being used in our workshop only are presented. Marking and Measuring Tools: Steel Rule: It is strip of steel with graduations on its edges and is used for measuring andsetting out dimensions. Try Square: Try squares are used for marking and testing of right angles and for testingflatness of surface. Marking Gauge: It is a tool which has one projected marking pin and is used to markaccurate lines parallel to the true edge of a wooden piece. Holding Tools: Carpenter’s Vice: It is used for holding the work for planning, sawing and chiseling. Thewhole vice is made of iron and steel. It has two jaws one of which is fixed to the side of the table while the other is movable. C-Clamp: It is used for holding the work projecting above the top surface of the Bench. This is used to prevent the wood from moving forward when being planned. Bench Stop: It is simply a block of wood projecting above the top surface of the bench.
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