SIR J C BOSE SCHOOL OF ENGINEERING(DIPLOMA)

MANUFACTURING PROCESS I LAB MANUAL

 SUPREME KNOWLEDGE FOUNDATION GROUP OF
INSTITUTION
SIR J.C. BOSE SCHOOL OF ENGINEERING

NAME:
DEPARTMENT:
ROLL NO:
SUBJECT:
REG. NO:
Engineering Work Shop Department of Mechanical Engineering

FITTING
The term fitting, is related to assembly of parts, after bringing the dimension or shape to the required size
or form, in order to secure the necessary fit. The operations required for the same are usually carried out
on a work bench, hence the term bench work is also added with the name fitting.
The bench work and fitting plays an important role in engineering. Although in today's industries
most of the work is done by automatic machines which produces the jobs with good accuracy but still it
(job) requires some hand operations called fitting operations. The person working in the fitting shop is
called fitter

FITTING TOOLS:
Fitting shop tools are classified as below:
 Work Holding Devices/ Clamping Tools.
 Measuring and Marking Tools.
 Cutting Tools.
 Striking Tools.
 Drilling Tools.
 Threading Tools.
I. WORK HOLDING DEVICES /CLAMPING TOOLS:
1. Work Bench
A fitting process can be done at various places, but
most of the important operations of fitting are generally
carried out on a table called work bench.
The work bench is a strong, heavy and rigid table made
up of hard wood.
The size of the work bench required is about 150 to 180
cm length, nearly 90 cm width and approximately 76 to
84 cm height.

2. BENCH VICE:
It is firmly fixed to the bench with the help of nuts and bolts. It consists of a cast Iron body and cast
iron jaws. Two jaw plates are fitted on both the jaws. The holding surface of the jaw plates is knurled in
order to increase the gipping. Jaw plates are made up of carbon steel and are wear resistant. One jaw is
fixed to the body and the second slides on a square threaded screw with the help of a handle.
The jaws are opened upto required length; job is placed in the two jaws and is fully tightened with the
help of handle. Handle is used to move the movable jaw

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Engineering Work Shop Department of Mechanical Engineering

3. V Block
In V Block, V grooves are provided to hold the round objects longitudinally. The screw of the
clamp applies the holding pressure. When the handle is rotated there is movement in the screw.

II. MEASURING TOOLS

1. Steel Rule
These are made up of stainless steel and are available in many sizes ranging from 1/2 ft. to 2 ft. These
are marked in inches or millimetres. All the faces are machined true. The edges of steel rule should be
protected from rough handling.

2. Calipers
These are generally used to measure the inside or outside diameters. Different types are:
i. Outside Caliper: It is used to measure the outside dimensions.
ii. Inside Caliper: It is used to measure the inside dimensions.
iii. Spring Caliper: Spring is provided to apply the pressure and lock nut is provided to lock any
desired position.
iv. Hermaphrodite, Jenny or Oddleg Caliper: One leg is bent at the tip inwardly and the other has a
straight pointed end. It is used to scribe lines parallel to the straight edges.

Fig. Calipers

3. Vernier Caliper: It is used for measuring the outer dimensions of round, flat, square components and
also the inner size of the holes and bore. A narrow blade is used to measure the depth of bar slots etc. The
reading accuracy in metric system is 0.02 mm and British system it is 0.001”. It is made of stainless steel.

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Engineering Work Shop Department of Mechanical Engineering

III. MARKING TOOLS:

1. Surface Plate
It is used for testing the flatness, trueness of the
surfaces. It is made up of cast iron or graphite. Its upper
face is planed to form a very smooth surface. It is also
used in scribing work.
While not in use, it should be covered with a wooden
cover.

2. Angle Plate
It is made up of cast iron in different sizes; it has two planed surfaces
at right angles to each other and has various slots in each surface to
hold the work by means of bolts and clamps.
Never do hammering on the angle plate to fasten (lighten) the nuts
and bolts.
3. Scriber and Surface Gauge
It consists of a cast iron bass on the center of which a steel rod is fixed vertically. Scriber is made
up of high carbon steel and is hardened from the front edge. It is used for locating the centres of
round bars or for marking of the lines.

Fig. Scriber and Surface Gauge

4. Punches
Punches are used for marking purposes. Dot punches are used for marking dotted line and centre
punch is used to mark the centre of hole before drilling. Punches are made up of high carbon steel
or high speed steels. One end is sharpened. Hammering is done on the second end while working.
For dot punch, angle of the punching end is 60 degree while in centre punch; angle of punching
end is 90 degree.

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5. Try Square
It is used for checking squareness of two surfaces. It consists of a blade
made up of steel, which is attached to a base at 90 degree. The base is
made up of cast iron or steel. It is also used to mark the right angles and
measuring straightness of surfaces. Never use try square as a hammer.

6. Vernier Height gauge:

A Vernier height gauge consists of a heavy base, a graduated beam, a
sliding head with Vernier sliding jaws holding the scriber and a fine
adjustment clamp. It is similar to large Vernier calipers in construction,
except that it consists of a heavy base which allows the gauge to stand
upright instead of a fixed jaw in a Vernier. The movable jaw of Vernier
height gauge consists of a projection or extension which is levelled to
sharp edge for scribing lines at any required height.
METHOD OF MARKING
Marking means setting out dimensions with the help of a working
drawing or directly transferring them from a similar part. The procedure
of marking is as follows: Fig. Vernier height gauge
A-Fine Adjustment of nut B-Vernier
1. The surface to be marked is coated with the paste of chalk or red slide C-Scriber clamp screw D – Scriber E
lead and allowed to dry. – Vernier Scale F – Main Scale G – Base
X,Y – Lock Screws
2. Then the work is held In a holding device depending upon shape
and size. If it is flat, use surface plate, if it is round use V block and clamp, else use angle plate
etc.
3. Lines in horizontal direction are scribed by means of a surface gauge. Lines at right angles can be
drawn by turning the work through 90 degree and then using the scriber. If true surface is
available, try square can also be used.
4. The centre on the end of a round bar can be located by using an odd leg caliper, surface gauge etc.
5. The circles and arcs on a flat surface are marked by means of a divider.
6. After the scribing work is over, indentations on the surface are made using dot punch and
hammer.
IV. CUTTING TOOLS
1. Hacksaw
Hacksaw is used for cutting of
rods, bars, pipes, flats etc. It
consists of a frame, which is
made from mild steel. The
blade is placed inside the
frame and is tightened with
the help of a flange nut. The
blade is made up of high
carbon steel or high speed
Fig. Hand Hacksaws
steel.

The points of the teeth are bent in a zig-zag

fashion, to cut a wide groove and prevent the body

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of the blade from rubbing or jamming in the saw cut. The teeth of the blades are generally forward cut so
in the case, pressure is applied in the forward direction only.
Depending upon the direction of cut, blades are classified as:
o Forward cut
o Backward cut.
Depending upon the pitch of the teeth (Distance between the two consecutive teeth) blades is classified as:
 Coarse (8-14 teeth per Inch)
 Medium (16-20 teeth per inch)
 Fine (24-32 teeth per inch)
2. Files
Files are multi points cutting tools. It is used to remove the material
by rubbing it on the metals. Files are available in a number of sizes,
shapes and degree of coarseness.
Classification of files
i. On the basis of length
4”,6”,8”,12”
ii. On the basis of grade:
 Rough (R)(20 teeth per inch)
 Bastard (B)(30 teeth per inch)
 Second cut (Sc) (40 teeth per inch)
 Smooth file (S)(50 teeth per inch)
 Dead smooth (DS)(100 teeth per inch)
Rough and bastard files are the big cut files. When the material removal is more, these files are used.
These files have bigger cut but the surface produced Is rough.
Dead smooth and smooth files have smaller teeth and used for finishing work. Second cut file has
degree of finish in between bastard and smooth file.
iv. On the basis of number of cuts:
 Single cut files.
 Double cut files.
 Rasp files.
In single cut files the teeth are cut in parallel rows at an angle of 60 degree to the face. Another row of
teeth is added in opposite direction in case of double cut files. Material removal is more in case of
double cut files.

iii. On the basis of shape and size:

The length of the files varies from 4' to 14*. The various shapes of cross-section available are hand
file, flat file, triangular, round; square, half round, knife-edge, pillar, needle and mill file.

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Engineering Work Shop Department of Mechanical Engineering

a. Flat file: This file has parallel edges for about two-thirds of the length and then it tapers in width
and thickness. The faces are double cut while the edges are single cut.
b. Hand file: for a hand file the width is constant throughout, but the thickness tapers as given in flat
file. Both faces are double cut and one edge is single cut. The remaining edge is kept uncut in
order to use for filing a right-angled corner on one side only.
c. Square file: It has a square cross-section. It is parallel for two-thirds of its length and then tapers
towards the tip. It is double cut on all sides. It is used for filing square corners and slots.
d. Triangular file: It has width either parallel throughout or upto middle and then tapered towards
the tip. Its section is triangular (equilateral) and the three faces are double cut and the edges single
cut. It is used for filing square shoulders or comers and for sharpening wood working saws.
e. Round file: It has round cross-section. It carries single cut teeth all round its surface. It is
normally made tapered towards the tip and is frequently known as rat-tail file. Parallel round files
having same diameter throughout the length are also available. The round files are used for
opening out holes, producing round comers, round-ended slots etc.
f. Half-round file: Its cross-section is not a true half circle but is only about one-third of a circle.
The width of the file is either parallel throughout or upto middle and then tapered towards the tip.
The flat side of this file is always a double cut and curved side has single cut. It is used for filing
curved surfaces.
g. Knife edge file: It has a width tapered like a knife blade and it is also tapered towards the tip and
thickness. It carries double cut teeth on the two broad faces and single cut teeth on the edge. It is
used for finishing sharp corners of grooves and slots
h. Diamond file: Its cross-section is like a diamond. It is used for special work.
i. Needle file: These are thin small files having a parallel tang and a thin, narrow and pointed blade
made in different shapes of its cross-section to suit the particular need of the work. These are
available in sizes from 100 mm to 200 mm of various shapes and cuts. These files are used for
filing very thin and delicate work.

Methods of filing
The following are the two commonly used methods of filing:
1. Cross-filing 2. Draw filing.
Cross - filing. Refer Fig. (a).
This method is used for efficient removal of maximum amount of
metal in the shortest possible time. It may be noted that the file must remain
horizontal throughout the stroke (long, slow and steady) with pressure only
applied on the forward motion.

Draw filing. Refer Fig. (b)

This method is used to remove file marks and for finishing operations. Here, the
file is gripped as close to the work as possible between two hands. In this filing
method, a fine cut file with a flat face should be used.

FILE CARD:
It is a device fashioned like a wire brush used to clean dirt and chips
from the teeth of a file. When particles of metal clog the teeth the file is
said to the pinned, a condition that causes scratching of the surface of
the work. Files, therefore, require cleaning by means of a file card or
by dislodging the material between the teeth by means of a piece of
soft iron, copper, brass, tin plate and so on, sharpened at the end.
Hardened steel should never be used

Fig. File Card

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Engineering Work Shop Department of Mechanical Engineering

EXPT.NO: 01 SQUARE CUTTING Date

AIM: To make a Square fit from the given mid steel pieces.
MATERIALS REQUIRED: mild steel flat (40*40*3mm).
TOOLS AND EQUIPMENT REQUIRED:
1.6”try square
2. 6”sriber
3. Odd leg caliper
3.12”hack saw Frame
4 Blades (12 TPI)
5. 10”rough file
6. 10”smooth file
7. 10”Square file
8. Dot punch
9. Ball peen hammer (0.5 Ib).
10. Steel Rule
Sequence of OPERATIONS:
1. Filling
2. Marking
3. Punching
4. Sawing
5. Filling
6. Finishing

PROCEDURE:
1. The given mild steel flat piece is checked for given dimensions.
2. One edge of given is filled to straightness with rough and smooth files and checked with try square.
3. An adjacent is also filled such that is square to first edge and checked with try square.
4. Wet chalk is applied on one side of the flat and dried for making.
5. Lines are marked according to given figure, using odd leg caliper and steel rule.
6. using the dot punch are made along the marked lines.
7. The excess materials removed from the remaining two edges with try square level up to half of the
marked dots.
8. Finally buts are removed by the filling on the surface of the fitted job.

PRECAUTIONS:
1. The perpendicularity of face ends edges is checked perfectly by using try square.
2. Finishing is given by using only with smooth files.
3. Marking is done without parallax error.

RESULT: The Square cutting is done successfully

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Engineering Work Shop Department of Mechanical Engineering

EXPT.NO: 02 V-FITTING
AIM: To make a V-Fit from the given mid steel pieces.
MATERIALS REQUIRED: Mild steel flat (40*40*3mm).
TOOLS AND EQUIPMENT REQUIRED:
1.6”try square
2. 6”sriber
3. Odd leg caliper
3.12”hack saw Frame
4 Blades (12 TPI)
5.10”rough file
6.10”smooth file
7.10”triangle file
8. Knife Edge file
9. Dot punch
10. Ball peen hammer (0.5 Ib)
11. Steel Rule
Sequence of Operations:
1. Filling
2. Marking
3. Punching
4. Sawing
5. Filling
6. Finishing

PROCEDURE:
1. The given mild steel flat piece is checked for given dimensions.
2. One edge of given is filled with rough and smooth files and checked with try square for
straightness.
3. An adjacent edge is also filled such that it is square to first edge and checked with try square.
4. Wet chalk is applied on one side of the flat and dried for marking.
5. Lines are marked according to given figure, using odd leg caliper and steel rule.
6. Using the dot punch, punches are made along the marked lines.
7. The excess materials removed from the remaining two edges with try square level up to half of
the marked dots.
8. Finally buts are removed by the filling on the surface of the fitted job.

PRECAUTIONS:
1. The perpendicularity of face ends edges is checked perfectly by using try square.
2. Finishing is given by using only with smooth files.
3. Marking is done without parallax error.

RESULT:
The V-fit is done successfully.

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 WELDING
Welding is a process for joining two similar or dissimilar metals by fusion. It joins different metals/alloys,
with or without the application of pressure and with or without the use of filler metal. The fusion of metal
takes place by means of heat. The heat may be generated either from combustion of gases, electric arc,
electric resistance or by chemical reaction.
Welding provides a permanent joint but it normally affects the metallurgy of the components. It is
therefore usually accompanied by post weld heat treatment for most of the critical components. The
welding is widely used as a fabrication and repairing process in industries. Some of the typical
applications of welding include the fabrication of ships, pressure vessels, automobile bodies, off-shore
platform, bridges, welded pipes, sealing of nuclear fuel and explosives, etc.

Most of the metals and alloys can be welded by one

type of welding process or the other. However,
some are easier to weld than others. To compare
this ease in welding term ‘weldability’ is often
used. The weldability may be defined as property
of a metal which indicates the ease with which it
can be welded with other similar or dissimilar
metals. Terminology of welding process
Elements of welding process used with common
welding joints such as base metal, fusion zone, weld face, root face, root opening toe and root are depicted
in Figure.

Edge preparations
For welding the edges of joining surfaces of metals are prepared first. Different edge preparations may be
used for welding butt joints, which are given in Figure.
Welding joints
Some common welding joints are shown in Figure. Welding joints are of generally of two major kinds
namely lap joint and butt joint. The main types are described as under.
1. Lap weld joint

Single-Lap Joint
This joint, made by overlapping the edges of the plate, is
not recommended for most work. The single lap has very
little resistance to bending. It can be used satisfactorily for
joining two cylinders that fit inside one another.

Double-Lap Joint
This is stronger than the single-lap joint but has the
disadvantage that it requires twice as much welding.

Tee Fillet Weld

This type of joint, although widely used, should not be employed if an alternative design is possible.

2. Butt weld joint

a. Single-Vee Butt Weld
It is used for plates up to 15.8 mm thick. The angle of the vee depends upon the technique being used,
the plates being spaced approximately 3.2 mm.
b. Double-Vee Butt Weld
It is used for plates over 13 mm thick when the welding can be performed on both sides of the plate.
The top vee angle is either 60° or 80°, while the bottom angle is 80°, depending on the technique
being used.
Welding Positions
As shown in Fig. 17.4, there are four types of welding positions, which are given as:
a. Flat or down hand position
b. Horizontal
position
c. Vertical
position
d. Overhead
position

Flat or Down-hand Welding Position

The flat position or down hand position is one in which the welding is performed from the upper side of
the joint and the face of the weld is approximately horizontal.
Horizontal Welding Position
In horizontal position, the plane of the workpiece is vertical and the deposited weld head is horizontal.
This position of welding is most commonly used in welding vessels and reservoirs.

Vertical Welding Position

In vertical position, the plane of the work-piece is vertical and the weld is deposited upon a vertical
surface. It is difficult to produce satisfactory welds in this position due to the effect of the force of gravity
on the molten metal.

Overhead Welding Position

 The overhead position is probably even more difficult to weld than the vertical position. Here the pull of
gravity against the molten metal is much greater.

ARC WELDING PROCESSES

The process, in which an electric arc between an
electrode and a work-piece or between two
electrodes is utilized to weld base metals, is called
an arc welding process. The basic principle of arc
welding is shown in Figure1. However the basic
elements involved in arc welding process are
shown in Figure2. Most of these processes use
some shielding gas while others employ coatings or
fluxes to prevent the weld pool from the
surrounding atmosphere. Fig1.The basic principle of arc welding

11) Channel for cable

1) Switch box. protection.
2) Secondary terminals 12) Welding cable.
3) Welding machine. 13) Chipping hammer.
4) Current reading scale. 14) Wire brush.
5) Current regulating hand 15) Earth clamp.
wheel. 16) Welding table
6) Leather apron. (metallic).
7) Asbestos hand gloves. 17) Job.
8) Protective glasses strap
9) Electrode holder.
10) Hand shield
Fig2.The basic elements of arc welding

Arc Welding Equipment

Arc welding equipment, setup and related tools and accessories are shown in Figure. However some
common tools of arc welding are shown separately through Figure. Few of the important components of
arc welding setup are described as under.

1. Arc welding power source

Both direct current (DC) and alternating current (AC) are used for electric arc welding, each having its
particular applications. DC welding supply is usually obtained from generators driven by electric motor
or if no electricity is available by internal combustion engines. For AC welding supply, transformers are
predominantly used for almost all Arc-welding where mains electricity supply is available. They have to
step down the usual supply voltage (200-400 volts) to the normal open circuit welding voltage (50-90
volts). The following factors influence the selection of a power source:
a. Type of electrodes to be used and metals to be welded
b. Available power source (AC or DC)
c. Required output
d. Duty cycle
e. Efficiency
f. Initial costs and running costs
g. Available floor space
h. Versatility of equipment
2. Welding cables
Welding cables are required for conduction of current from the power source through the electrode
holder, the arc, the work piece and back to the welding power source. These are insulated copper or
aluminum cables.

3. Electrode holder
Electrode holder is used for holding the electrode manually and
conducting current to it. These are usually matched to the size of the
lead, which in turn matched to the amperage output of the arc welder.
Electrode holders are available in sizes that range from 150 to 500 Fig. Electrode Holder
Amps.

4. Welding Electrodes
An electrode is a piece of wire or a rod of a metal or
alloy, with or without coatings. An arc is set up
between electrode and workpiece. Welding
electrodes are classified into following types-
(i) Consumable Electrodes
(a) Bare Electrodes Fig. Parts of a electrode

(b) Coated Electrodes

(ii) Non-consumable Electrodes
(a) Carbon or Graphite Electrodes
(b) Tungsten Electrodes
Consumable electrode is made of different metals and their alloys. The end of this electrode starts
melting when arc is struck between the electrode and workpiece. Thus consumable electrode itself acts
as a filler metal. Bare electrodes consist of a metal or alloy wire without any flux coating on them.
Coated electrodes have flux coating which starts melting as soon as an electric arc is struck. This
coating on melting performs many functions like prevention of joint from atmospheric contamination,
arc stabilizers etc.
Non-consumable electrodes are made up of high melting point materials like carbon, pure tungsten or
alloy tungsten etc. These electrodes do not melt away during welding. But practically, the electrode
length goes on decreasing with the passage of time, because of oxidation and vaporization of the
electrode material during welding. The materials of non-consumable electrodes are usually copper
coated carbon or graphite, pure tungsten, thoriated or zirconiated tungsten.

5. Hand Screen
Hand screen used for protection of eyes and supervision of weld bead.

6. Chipping hammer
Chipping Hammer is used to remove the slag by striking.

7. Wire brush
Wire brush is used to clean the surface to be weld.
 Fig. Earth Clamp Fig. Chipping Hammer Fig. Wire Brush

8. Protective clothing
Operator wears the protective clothing such as apron to keep away the exposure of direct heat to the
body.

Safety Recommendations for ARC Welding

The beginner in the field of arc welding must go through and become familiar with these general safety
recommendations which are given as under.
1. The body or the frame of the welding machine shall be efficiently earthed. Pipe lines containing
gases or inflammable liquids or conduits carrying electrical conductors shall not be used for a
ground return circuit All earth connections shall be mechanically strong and electrically adequate
for the required current.
2. Welding arc in addition to being very is a source of infra-red and ultra-violet light also;
consequently the operator must use either helmet or a hand-shield fitted with a special filter glass to
protect eyes
3. Excess ultra-violet light can cause an effect similar to sunburn on the skin of the welder
4. The welder’s body and clothing are protected from radiation and burns caused by sparks and flying
globules of molten metal with the help of the following:
5. Gloves protect the hands of a welder.
6. Leather or asbestos apron is very useful to protect welder’s clothes and his trunk and thighs while
seated he is doing welding.
7. For overhead welding, some form of protection for the head is required
8. Leather skull cap or peaked cap will do the needful.
9. Leather jackets and 1ather leggings are also available as clothes for body protection.
10. Welding equipment shall be inspected periodically and maintained in safe working order at all
times.
11. Arc welding machines should be of suitable quality.
12. All parts of welding set shall be suitably enclosed and protected to meet the usual service
conditions.
EXPT NO: 01 BUTT JOINT

Aim: To make a Butt joint using the given two M.S pieces by arc welding.

Material Required:

Mild steel plate of size 100X50X5 mm – 2 No’s

Welding Electrodes: M.S electrodes 3.1 mm X350 mm

Welding Equipment: Air cooled transformer

Voltage-80 to 600 V 3 phase supply, amps up to 350

Tools and Accessories required:

1. Rough and smooth files.
2. Protractor
3. Arc welding machine (transformer type)
4. Mild steel electrode and electrode holder
5. Ground clamp
6. Tongs
7. Face shield
8. Apron
9. Chipping hammer.

Sequence of operations:

1. Marking
2. Cutting
3. Edge preparation (Removal of rust, scale etc.) by filling
4. Try square leveling
5. Tacking
6. Welding
7. Cooling
8. Chipping
9. Cleaning

Procedure:
1. The given M.S pieces are thoroughly cleaned of rust and scale.
2. One edge of each piece is believed, to an angle of 300, leaving nearly ¼ th of the flat thickness,
at one end.
3. The two pieces are positioned on the welding table such that, they are separated slightly for
better penetration of the weld.
4. The electrode is fitted in the electrode holder and the welding current is ser to be a proper value.
5. The ground clamp is fastened to the welding table.
6. Wearing the apron and using the face shield, the arc is struck and holding the two pieces
together; first run of the weld is done to fill the root gap.
7. Second run of the weld is done with proper weaving and with uniform movement. During the
process of welding, the electrode is kept at 150 to 250 from vertical and in the direction of
welding.
8. The scale formation on the welds is removed by using the chipping hammer.
9. Filling is done to remove any spanner around the weld.
DRAWING:

Result:
The single V-butt joint is thus made, using the tools and equipment as mentioned above.