Fitting and Welding Processes PDF

# FITTING ## Page: 01 Component Female ↓ Component Male - Run fit - Force fit - Push fit ## Page: 02 **Fitting is the assembling of parts together and removing metals to secure usage of large number of hand tools and devices or equipments that involve a no. of operations for accomplishing the...

# FITTING ## Page: 01 Component Female ↓ Component Male - Run fit - Force fit - Push fit ## Page: 02 **Fitting is the assembling of parts together and removing metals to secure usage of large number of hand tools and devices or equipments that involve a no. of operations for accomplishing the work to the desired shape and size. The person who performs the fitting operation is called the fitter. The place where fitting operation takes place is called as the fitting section.** ## Types of Fitting There are three types of fitting: a) Running fit b) Push fit c) Force fit **• Push Fit** If the dimension of the both of the components are the same and the two components can be fitted by gentle push the fit is known as Push Fit **• Running Fit** In the dimension, of one component say that female component is slightly more than male, the other component, say component male and female can be dismantled easily, then that fit is called Running fit ## Page: 03 - Beam - Steel Rule - Try Square - Blade **• Force Fit** If the dimension of male component is slightly more than female component and can be fitted by using force is called force fit ## Tools and Equipments Used in Fitting ### Measuring Tools - **Steel Rule:** Steel rule is used to measure thickness breadth, length, etc. Steel rule is generally employed for purpose of measuring rough dimension and laying them out. The L.C. of steel rule is 0.5 mm, 1/64 in inch scale. The component of steel rule could be mild steel, Carbon. - **Try Square:** It is used to check the right angle of the job, The blade of try square is made of mild steel. The beam or stock is made of light carbon steel. ## Page: 04 - Scriber - Divider - Prick Punch ### Marking Tools: - **Scriber:** Scriber is used to make straight lines on the metal surface with a high gauge of accuracy. It is made up of high carbon steel. The percentage of carbon is more. The point is hardened and tampered so that it does not wear out easily. The angle of scriber is 13° to 15°. If point becomes blunt, we use aidstone. They are sometimes called the metal worker pencil. Scriber is used for scratching lines on the sheet metal during process of laying out the job. - **Divider:** It is used for marking and drawing arcs and circles on sheet metal. It is used to find the centre of a round job. The main advantage of divider is that: - It is easily set - Once we measure the dimension, it remains the same - **Punch:** It is used for making the scribing line. It is made up of high carbon steel. The middle part of a punch has a grid. There are three types of punch: a) Dot Punch b) Centre Punch" C) Prick Punch ## Page: 05 - Face - Ball Pane - Neck - Pane neck - Pole Pole - Hammer - Length of hande ### Striking Tools Various types of hammer such as ball pane hammer, straight pane hammer, cross pane hammer, double face hammer and soft face hammer Parts of a common ball pane hammer: 1) Pane - It is ball shaped, used for striking rivet head 11) Face - It is a plane flat surface 111) Eyehole - IV) Neck - V) Check - It is made up of rough forged steel. Hammer is a totat tool meant to deliver an impact to an object. The most common uses for hammer are to deliver nails, fit, forge metal and break apart object. ## Page: 06 - Handle - Blade - Eye Holes - Frame - A Fixed frame hacksaw - Wing Nut - Length - Shoulder - Fang - Edge - Handle - Cutting points - Heel - Face - File ### Cutting Tools a) **Hacksaw:** Hand hacksaws are made in two types namely a fixed frame and adjustable from/frame orientation. The former possesses solid frame in which the length cannot be changed. Wheras the latter comprises the adjustable frame which has a back that can be shortened to hold the blades on different a sides. The hand hacksawes are commonly used for sawing all soft metal They consist of: - Frame - Hangle - Wing Nut - Staw - Retaining Pin - Blade The teeth should be in forward direction. The blade is made up of high carbon steel. Blade is of two types: - all harder - flexible b) **File:** The widely used hand cutting tool in a workshop is the file. It is hardened piece of high grade steel with slanting rows of teeth. It is used to cut, smooth or fit metal parts. It is used to file or cut softer metal. ## Page: 07 - On the basis of Shape: - Flat - Round - Square - Triangular - Knife edge - On the basis of Grade: - Rough - Smooth - Dead Smooth - Bastard **Hard File:** Hard files are commonly used for finishing square work. Both faces of the files are double cut. Either both edges are single cut or one is uncut to provide & safe edge **Flat File:** These files are generally used for filing flat surfaces in fitting shop **Triangular Files:** These are commonly used for filing corners between 60° and 90°. They are double cut on all faces **Square Files:** These are commonly used for filling in corners in jobs. They are double out on all sides I tapers. ## Page: 08 - Tip or point - Face - it has double teeth - Edge - it has single teeth - Hed - blank portion having no teeth - Shoulder - Tang - Handle - Ferrule A file & consists of the following parts: The files are made up of hardened carbon steel. The tang portion is soft because it avoids breaking **★ Size of a File:** *Size of the file is specified by its length. It is the distance from the point to the hed without tang. Files for fine work are usually 200 to 200 mm and those for heavier work are from 200 to 450 mm in length * **Classification of File:** *The file are classified on the basis of types of cut, grade and shapes. These are classified as under A) Type of Cut: (i) Single (ii) Double (ii) Rasp ## Page: 09 - Smooth - Second Cut - Bastered - Rough ### Grade of Cut ### Shape of File Common shapes of files are having different cross sections, which cover most requirements ## Drilling **Drilling is a common process widely used for making holes in metal piece in a fitting shop. It is generally held in chuck of bench drilling machines. It usually consists of two cutting edges set on angle with the axis.** There are three types of drills? a) Flat Drill b) Straight fluted Drill c) Twist Drill **For fast and accurate drilling work, Twist drill comprises the cutting angle of 118° and obtain the current diameter of hole it means or moves at 1400 rpm** **It should be ground with both lips at 59° to the axis of the drill, with equal length of cutting edges.** ## Page: 10 - Hand vice - Bench vice - Machine vice - Carpenter vice - Shaper vice - Leg vice - Pipe vice - Pin vice ### Holding Tools Holding tool used in fitting shop comprises of basically vices & clamps. The clamps are Cor G clamp, plane slot, goose neck, double end finger, u-clamp, parallel jaw and clamping block The various types of vices used in fitting shop are: ## Page: 11 - 4 mm - 50 mm - 50 mm - 16 mm - Square Base Paperweight **Aim of the Experiment :** **To prepare a square base paper weight** **Raw Materials:** - Mild sheet of flat size = 50 mm x 50mm x 6 mm - Mild steel round rod of size = 40 mm x 64 **Tools and Equipments:** 1. Steel Rule 2. Try square 3. Divider 4. Punch 5. Hammer 6. Hacksaw 7. File 8. Bench vice 9. Drilling 10. Scriber **Procedure:** 1. The work-piece is taken and fitted inside the bench vice. 2. Using a flat file "the four edges of the 50mm x 50mm x 6 mm piece and check the perpendicularity of the piece using try square. 3. The surface of the metal piece is filed ## Page: 12 1. I apply wet chalk on the piece and keep it in sunlight to dry. 2. Using a scriber, we draw two diagonal lines and find the centre. 3. Using a punch and hammer, I make a dot to mark the centre. 4. Vsing a divider, I made a circle of radiuss 24 mm and mark 6-arcs on the circumference. 5. Using a scriber, I joined the 6 point and using a punch and hammer, we make dots on lines for long lasting impression. 6. I fit the metal piece in the bench vice and then using a hacksaw, we start cutting along the line. 7. After cutting the square piece we file the edges. 8. I fit in the drilling machine and match the centre of the piece and drill to make a cylindrical hole. 9. I cut the round rod and fix in the cylindrical hole. 10. I fit the round rod into cylindrical hole of the piece. 11. I fit the round rod into cylindrical hole of the piece. 12. Using a file, I file one end of the round rod and decrease the diameter from 6mm to 5mm. 13. I fit the round rod into cylindrical hole and cut extra portion. 14. The round rod inserted properly into the cylindrical hole of piece finishes the job. ## Page: 13 ### Safety and Precautions 1. The piece should be fixed tightly in the bench vice 2. The teeth of the hacksaw should be in forward direction 3. The tang portion should inserted into handle of file. 4. While drilling, the centre of piece and blade should match 5. The flat file should not soak moisture ### Conclusion The job is done from the raw material of the dimension 50 mm x 50mm x 6mm. The square base paper weight is completed. This is under the guidance of teacher. # WELDING ## Page: 14 ## Page: 15 ### Introduction Welding is a process in which two similar or dissimilar metals are joined by heating them to a suitable temperature with or without the application of pressure and with or without the use of filler metal whose melting point is slightly lower or same as that of the base metal. The assembled parts that are joined by welding are called Weldment. ### Filler Metal Filler metals are alloys or unalloyed metals, which when heated, liquefy and melt to flow into the space between two close fitting parts, creating a welded, brazed or soldered joint. Not all welding process require filler metal - Autogeneous welding processes require filler metal, parts of existing base metal to be melted and this is sufficient, provided that the joint is already mechanically close fitting before welding - With electric arc welding, a major use for the filler rood is as a consumable electrode that also generates heat in the workpiece. An electrical discharge from this electrode provides that heat melts both the electrodes and heats the base metal. ## Page: 16 ### Application of Welding Welding processes are a foundational aspect of all large construction industries, ensuring strong, sustainable connections within buildings, bridges and other infrastructures - In the electrical and electronics industries, discharge capacitor welds are used in numerous speciality applications such as medical labs and small appliance fabrications. - In the automotive industry, arc welds bond heat shields, exhaust systems and hydraulic lines to the Chasis. Metal furniture pieces like office desks, file cabinets and shelving units are often welded. Welding has also been the traditional shipbuilding construction methods used since the advent of the industrial age, to secure hatches, fhid lines, control panels and many other components. - In Agriculture, farming tools and machines are welded throughout their frames and processes. - Manhole cover plate and the sewer and utility systems that frequently sun under roads are usually constructed with welding processes ## Page: 17 ### Classification of Welding Welding processes can be classified on the basis of following technological criteria - **Welding with or without filler metal** Following are those welding processes in which filler metal is generally not used: - Laser Beam Welding - Electron Beam Welding - Resistance Welding - Friction Stir Welding Following are those welding processes that may or may not use filler metal - Plasma Are Welding 0 - Gas Tungsten Welding - Gas klelding **★ Sources of Energy for welding** - **Chemical Energy:** Gas welding, explosive welding, thermite welding - **Mechanical Energy:** Friction welding, Vitrasonic welding ## Page: 18 ### Electrical Energy the welding process using - Are welding, Resistance welding - Radiation Energy: Laser Beam welding, Electron Beam Welding * Anc and Non- Are Welding: - Arc based welding processes: - Shielded Metal Arc Welding (SMAW) - Gas Tungsten Ane Welding (GTAW) - Plasma Arc Welding (PAN) - Gas Metal Arc Welding (GMAW) - Flux Cared Arc Welding (FCAWW) - Swbmerged Arc Welding (SAW) - Non-are based welding processes: - Resistance Welding - Gas Welding - Thermite Welding - Ultrasonic Welding - Diffusing Welding - Explosive Welding ## Page: 19 - PRIMARY - TRANSFORMER - SECONDARY - METAL TABLE - ELECTRODE ### ARC WELDING Arc welding is one of the several fusion processes for joining metals, By applying intense heat, metal at the joint between two parts is melted and caused to intermix directly, or more commonly. With an intermediate molten filler metal. Upon cooling and solidification, a metallurgical band is created. In arc welding, the intense heat is produced by an electric arc. The arc is formed between the actual work and an electrode (stick or wire) that is manually or mechanically guided along the joint. The electrode can either be a purpose of simply carrying in the current between the tip and the work. Or, it may be a specially prepared rod or wire that not only conducts the current, but also melts and supplies filler metal to the joint. Most weldings in the manufacture of steel products use the second type of electrode. The basic arc-welding circuit is given on the left. An Ac or DC power source, fitted with whatevers controls may be needed, is controlled by a work cable to the work-piece and by a hot cable to an electrode holder of same type, which makes an electrical contact with the welding machine. ## Page: 20 - WELDING BOOTH - MAKIIH ### An arc is created across the gap when the energized circuit and the electrode tip touches the workpiece and is withdrawen, yet still within close contact. The arc produces a temperature of about 6500° F at the tip. This heat melts both the base metal and the electrode producing a pool of molten metal sometimes called a "crater". The crater solidifies behind the electrode as it is moved along the joint. The result is a fusion bond. However, joining metals require more than moving an electron along a joint. Metals at high temp. tend to react chemically with oxygen and nitrogen. When the metal in the molten pool comes in contact with air, oxides and nitrides from which destroys the strength and toughness of the welding joints. Therefore, many arc welding processes provide some means of covering the arc and the molten pool with the protective whield of gas, vapour slag. This is Called Ane Shielding. - **Arc Length:** It is the distance from the tip of the welding electrode to the adjacent surface of the weld pool. It should be roughly same as the diameter of the mod. The arc length can easily be determined by the sound and visible light from the arc. A good short arc length will result in the consistent sharp crackling sound. Precautions should be taken to keep the are length short because excessive threat length leads to unstable anc ## Page: 21 - LAP JOINT - BUTT JOINT - TRANSVERSE Aties - FILLET WELD - LONGITUDINAL - FILLET WELD ### Welding Joints There are five basic types of welding joints, with each having a number of variations to meet different needs - **BUTT JOINT** A butt weld or a square-groove consists of two flat pieces that are parallel to one another. It is the universally used method of joining a pipe to itself, as well as flanges, valves, fittings or other equipment. Following are the types of butt joints * Single V-Buttjoint: In this type, the edge of the two metals are cut in such a way that when they are joined, they form a v-shaped channel. They are welded after that * Double V-Butt Joint: In this type, the edges are cut in such a way that when they form two V-shaped channels, one on the top and other at the botton and are then welded - **LAP JOINT** A lap joint is formed when two pieces are placed atop each other. While also overlapping each other for a certain distance along the edge. Consider a fillest type of welding joint, the weld can be made on one or both sides. It is most often used to join two pieces together with different levels of thickness. ## Page: 22 - LAP JOINT - TEE JOINT - CORNER JOINT ### CORNER JOINT A corner weld is a joint in which two metal parts are Located at right angles to other one another in the form of L. As the name suggests, it is used to connect two pieces together, forming corner. It is used in sheet metal industry and is performed on the outside edge of the piece - **EDGE JOINT** Edge joint is a groove type of weld, in which metal pieces are placed side by side and welded on the edge. They are the most commonly replaced type of joints due to build up accumulating on the edge. - **TEE JOINT** It is a fillet type of weld in which two metal pieces intersect at 90° resulting in the edges coming together in the middle of a component or a plate. ## Page: 23 - Frame - Blade - Handle - Wing nut - Eye holes - HACKSAWW - Sliding jaw - Stationary jaw - Slide - Screw - Handle - Base - Fixed body - BENCH VICE - RECTIFIER ### Tools and Equipments of Arc Welding - **ARC WELDING MACHINE** This transformer Type of welding machine produces Al current. It takes power directly from a power supply lines and transforras it to the voltage required for welding. It is available in single phase and three phase in market. - **RECTIFIER** These are essentially transformer's control containing an electric device which changes alternating current to direct current. - **HACKSAWW** A hacksaw is a fine-toothed saw used for cutting metal. The components of a hacksaw includes handles, frames, wing nuts, studs and blades. The blade can be mounted with the teeth facing toward or away from the handle, resulting in cutting action on either the push or pull stroke. In the normal use, cutting vertically downwards with work held in a bench vice, hacksaw blades should be set to be facing forward. - **BENCH VICE** A bench vice is a mechanical apparatus that is attached to a bench and is used to secure an object to allow work to be performed on it. It has two parallel jaws. One fixed and one movable, threaded in and out by a screw and a lever. ## Page: 24 - CABLE - WORK CLAMP - ELECTRODE - HANDLE - Cutting points - Edge - Heel - HAND SCREEN - Length - Shoulder - Tang - Handle - FLAT FILE - Serun for viewing welding process - ELECTRODE HOLDER - TONG ### Arc Welding Cables These are required for conduction of current from the power source through the electrode holdere, the are, the workpiece and back to welding power source. These are insulated copper or aluminium Cables ### Electrode Holder It is used for holding the electrode manually and conducting current to it. These are usually matched to amperage output of arc welding ### Tong It is used to hold the welded metals after welding (welded) in hat conditions ### Flat File It is used to remove unwanted material and make the metal pieces parallel and similar in vize and shape. ### Hand Screen (Face Shield) It is used for protection of eyes and supervision of weld bead. It protects our face and eyes from spatter or flying particles of hot metals. It is available in hand or face helmet type ## Page: 25 - Handle - CHEPPENG HAMMER - Beam - Blade - STEEL RULER - TRY SQUARE - WIRE BRUSH - CHIPPING HAMMER ### Weld Defects Common weld defects include: - **LACK OF FUSION** It resuts from too little heat input and/or too rapid transverse of the welding torch (gas or electric) - **LACK OF PENETRATION/EXCESS** It arises from a high heat input and/or too slow transverse ## Page: 26 - Underfile - Incomplete joint penetration - LACK OF FUSION & PENETRATION - Longitudinal root crack - Transverse crack - CRACKING - INCLUSION - Slag ### Porosity It occurs when gases are trapped in the weld metal. These may arise from damp consumables solidifying or from dirt or metal, particularly oil or grease on the metal in the vicinity of the weld. ### Cracking It occurs due to thermal shrinkage or due to combination of strain accompanying phase change and thermal Shrinkage ### Undercutting It happens when the base metal is burned away at one of the toes of a weld. It occurs due to the use of long electrodes, long arc set too high, and when the amperage is too low. ### Slag Inclusions When slag gets incorporated into the weld, the weld quality is ruined. Bits of flux, rust and even tungsten can be counted as slag and cause contamination in the welds, ## Page: 27 - Arc welding machine (inverter type welding) - Electrode Holder - Tong - Handscreen - Welding Cables - Bench vice - Hacksaw - Flat file - Wire Brush and Chipping Hammer - Apron and Handgloves - Steel wire and try square ### Aim of the Experiment To prepare a butt joint in mild steel Hat on flat position by are welding ### Raw Materials - Two pieces of mild steel flat size (80x40x6) mm², one piece. - electrode size 3.15 mm (diameter) ### Tools and Equipments ## Page: 28 ### Procedure A mild steel flat of size (160 ×40×6)mm is taken and cut into two with a hacksaw after fixing the piece on the bench vice - Both the halves are then filled using a flat file to make them almost equal in size. - By usage of trysquare and steel rule the two pieces were ensured the same level. - Wearing apron, gloves and taking a hand screen, the two pieces of mild steel are put into welding booth and joined side by side using electrode held with an electrode holder at an angle of 60° to 70° at 3600° C by using a inverter type of welding are. - Using tongs, the workpiece is held, and after it gets cooled, the unwanted slags on welds are removed using Chipping hammer and cleaned by wire brush ## Page: 29 ### Conclusion Thus the butt joint of mild steel (MS flat ) was prepared in flat position by arc welding process. ## Page: 30 # Turning ## Page: 31 ### Turning It is the process of removing undesired raw material from the piece of work and give it a cylindrical shape and size. It is done by fitting a cutting tool against a rotating work piece. The machine tood by which we carry out the turning operation is called Lathe. Turning is one of the most common metal cutting operatione ### Lathe Machine Lathe is a machine that helps in shaping several material pieces into desired shapes. A Lathe is a machine that rotates the work peace on the axis in order to prepare various operations like cutting, facing, knurling, deformation and more. Metal spinning, Thermal spraying are common operation performed with a Lathe Machine - Types of Lathe Machine: - Automatic - Speed - Bench - Engine - Capstan - Special Production Lathe - Pool Room ## Page: 32 - Head Stock - Tool post - Carriage - Leg - Bed - Tail stock - Speed - Liver - Principal components of a Central Lathe ### Different Types of Lathe Machine #### Conventional Lathe Machine : Under this, we have several machines! 1. **Engine Lathe:** It is most important machine tool in Lathe family and by far most widely used. Early machine tools were driven by seperate engine with overhead belts and shafts. The cutting tools are controlled either by hand or power. 2. **Speed Lathe:** It is the simplest form of Lathe Machine and consists of a simple headstock, tailstock, footpast. It has no gear box, lead screaw and carriage. This machine is intended for wood turning, metal spinning and polishing operation. 3. **Capstan Lathe:** More than ope operation can be carried out simultaneously by this machine. In it several tools are set on revolving capstan to facilitate doing of large no. of operation on a job. 4. **Tool Room Lathe:** It is the modern engineering Lathe quipped with all necessary arrangement for tool room work. It is generally head driven machine with considering range in spindle speeds. ## Page: 33 - Bench Lathe - Computer Controlled Lathe ### Different Parts of Lathe Machine 1. **Head Stock:** It is normally mounted rigidity to the bed and holds all the mechanisms, including various kinds and combination of pulleys or gears so that the spindle can be made to turn at different speeds. 2. **Tail Stock:** The unit is arranged to slide along the bed and can be locked to it at any convinient point, the upper position of the unit is fitted with what is variousky alled barel, spindle, ram that can be moved in and out of the main casting by hand lever feed and carries as "Dead Centre" that support other end of work held in head stock. 3. **Bed:** The bed of the Lathe provides the foundation for whole machine and hold the headstock, tailstock and carriage in alignment. The surfaces of bed that are finely machined upon which the courage carriage and tailstock slide are known as "ways" ## Page: 34 - Spindle - Carriage - Saddle - Apron - Tool past - Cross Slide - Feed Rod ### Spindle The spindle is made from high tensile steel and is well machined and grounded. It is hollow type and has screwed nose to receive the chuck. ### Carriage The whole assembly of Saddle, Apron, Top and cross slide is known as "Carriage" - **Saddle:** The casting that fits onto the top of the bed and slides along it is known as most universally as the saddle, a self explaination and very suitable term. - **Aption:** Attached to the front of the carriage it has mechanism and controls for moving carriage and cross slide. - **Tol past:** It rigidly clamps the cutting tool at the proper height relative to work centre. - **Cross Slide:** It provides automatic cross movement for cutting Hood - **Feed Rod:** It is a power transmission mechanism used for linear movement of carriage along longitudinal axis of Lathe. ## Page: 35 - Chuck Key - Tool Post key - Vernier Caliper - V-shaped Cutting tool - Knurling Tool - TOP VIEV) 60 T Logit - SIDE VIEN - Lead Rod ### Tools and Equipment 1. **Chuck key:** It is specialised type of clamp used to hold an object with radial symmetry especially a cylinder. 2. **Tool Past key:** It is a key kept in holder of the maching so that changes can be done easily. 3. **Vernier Caliper:** It is a visual tool that allows the user to measure the dimensions of the objects accurately 4. **V-shaped single point cut tool:** These tools are used in turning shaping etc. by means of one cutting edge to remove waster material. 5. **Knurling Tool:** It is normally used on knobs where better grips are needed. 6. **Packing:** Material of various thickness used to adjust the component of machine before being operated. 7. **Grooving Tool:** It is a tool to form a narrow cavity on a non-precision instrument used to draw parallel line and find the centre of round section metal 8. **Wooden Brush:** Brush required for removing the scraps of unwanted material work-piece. 9. **Drawing Sheet:** A sheet containing the pre-designed model of work-piece to be made. ## Page: 36 ### Lathe Operation 1. **Turning:** Procedure of producing straight, conical or grooved work pieces 2. **Facing:** To produce a flat surface at the end of the part or for making face grooves 3. **Boring:** To enlarge a hole or cylinder cavity made by a previous process or to produce circular internal grooves 4. **Drilling:** To produce a hole by fixing a drill in the tailstock. ## Page: 37 - Wonk Surface - Work piece rotation - D - D2 - Machined Surface - Turning Tool - Drilling, Boring & Reaming - Threading - Krurling ### Specification of Lathe Machine A Lathe is generally specified by 1. It's swing, the maximum diameter of workpiece that can be machined. 2. The maximum distance between the headstock and tailstock centre i.e., the distance between live centre to dead centre. 3. The length of the bed. 4. Total length of the machine. ### Accessories 1. **Live Centre:** Live centre fit on headstock spindle made of hardened stead. The workpiece is cut to a 60° inclined angle. It is called Live centre because it turns with the headstock spindle. 2. **Dead Centre:** These are two types said dead centre and revolving dead centre. It is called so because Unlike live centre it doesn't turn. It been lubricated so that to prevent damage caused by friction & heat ## Page: 38 - Drill Chuck - Revolving centre ### Drill Chuck It is a specialised self centering three jaw chuck usually with a capacity of 13mm or less used to hold drill bits er other rotatory tools. It's generally used on tools ranging from professional equipment to power drill for domestic use. ### Revolving centre A revolving centre is also known as Live centre. It is not used much because its not accurate as clearance in the bearing is transmitted to work piece ## Page: 39 ### Aim of the Experiment To prepare a job with multiple turing operations such as, a) Facing b) Plane Turning c) Step Turning d) Grooving e) Knurling f) Chamfering ### Raw Material Required: - Mild Steel Bar - Length = 80 mm - Diameter = 25 mm ### Tools Required: - Chucking - V-shape cutting tool - Packing - Tool Post key - Grooving Tool - Knurling Tool - Vernier Caliper - 17/13 DE Spanner - 14/15 DE Spanner - Brush ## Page: 40 ### Procedure 1. The workpiece is taken and fitted inside the spindle and is held using the chuck. 2. Centre alignment is ensured by pulling the job and the chuck is tightened using the chuck key 3. The "V' shaped cutting tool is adjusted and tightened using tool post key. 4. Cutting tool is adjusted in the tool post in how there with the axis of rotation of workpiece and the facing action is done by moving the cutting tool along y-axis. 5. Bame process is carried out using the cutting tool for the facing of other side. 6. The cutting tool is adjusted again for turning action. The cutting tool is touched with the workpiece and is moved along the x-axis until the whole job is reduced to the desired depth. Repeat it for both the sides. 7. The knurling operation is desired part of the job by using knurling tool in tool past and moving it slightly along n-axis 8. Then chamfering operation is done on the moving part both sides of the job using the v-shaped cutting tool at 45° angle. ## Page: 41 - Final Job ### Conclusion - **Cutting Speed:** Peripheral speed of work piece over cutting tool In plane turning operation ```latex CS[V] = \frac{DN}{1000} ``` ```latex = \frac{3.14 x 23 x 50}{1000} ``` ```latex = 24.395 ``` - **Speed:** Distance of tod in one revolution of job In plane turning operation ```latex f = \frac{f}{NT} ``` ```latex = \frac{80 \text{ mm/rev}}{310x2} ``` ```latex = 0.040 \text{ mm/rev} ``` - **Depth cut:** The perpendicular distance between initial diameter and after matching diatmeter In plane turning operation ```latex = 1000 xvxdxf ``` ```latex = 1000 x 24.935×0.5×0.040 ``` ```latex = \frac{9734 \text{ mm²/ sec}}{60} ``` ## Page: 42 ### Safety Precaution - Stay away from moving part of the machine - Maintain a perfect distance between the edges and job getting work on prevent metal scrap - Tod should be kept on tray. # SHEET METAL SECTION ## Page: 43 ## Page: 44 ### Sheet Metal Works Sheet Metal Work is deforming process of Manufacturing with this process metal sheets are designed to different shape applying of pressure. With application of different tools, equipment and Machine. A sheet is generally known less thickness and large size cross-section area. Sheet metals are applied in many industries like Automobile sector, Aircraft manufacturing, railway, ship, and fabrication work. (Machine cover, roof, tanks, container, boxes, furniture and utensil, etc.) ### Types of Sheet: Many types of materials are used for sheet metal work as per requirement, following types of sheets are. 1. Iron Sheet 2. G.I. sheet 3. Aluminium Sheet 4. Copper Sheet 5. Tin Sheet 6. Lead Sheet 7. Alloy sheet ## Page: 45 - Steel Rule - Measuring Tape - Single paint pocket type scriber - Divider - Try square ### Tools and Equipment In the sheet sections following tools are used. - **Steel Rule:** A steel rule is used for measuring straight lines because of its straight edge. It can also be used as a guideline when lying out lines and also for cutting. - **Measuring Tape:** A tape measure or measuring tape is a flexible form of other ruler. It consists of a ribben of cloth, plastic, fiber glass, or metal strip with linear-measurement markings. - **Scriber:** A scriber is a hand tool used in metalworking to mark lines on work pieces, prior to matching. The process of using a scriber is called scribing. - **Divider** A divider is used for the drawing of circle, arc, and check the distance between two points. - **Try square:** A try square is a tool used for making marking and measuring the accuracy of a right angle. ## Page: 46 - Round Table - Drop - Anvil - Length of horn - Waist - Feet - Hammer - Stake - Snip - Mallet ### Anvil An anvil is a basic tool, a block with a hard surface on which another object is struck. The block is as massive as is practical, because the higher the inertia of the anvil, the more efficiently it causes the energy of the striking tool to be transferred to the work piece ### Hammer A hammer is a tool meant to deliver an impact to an object. The most common uses for hammers are to drive nails, fit parts, forge metal and break apart objects. Different types of hammer are used in this section. Like ball pane hammer, cross-pane hammer, straight pane hammer, claw hammer. ### Mallet A mallet is a kind of hammer, often made of wood; it is used for light blow to a metal sheet. ### Snip