FUNDAMENTALS OF WORKSHOP

Dr. Sudhansu Sekhar Das

Faculty
School of Mechanical Sciences

Contents
• Welding
• Machine Shop
• Fitting shop
• Robotics and Automation
• General Knowledge

WELDING
Q. What is Welding shop?

A. WELDING SHOP means a building or part of a building where material working involves the
joining of two or more pieces of metal by applying heat, through various means, to produce a
localized union through fusion across the interface.

Q. Define WELDING.

A. Welding is a fabrication process whereby two or more parts are fused together by means
of heat, pressure or both thereby forming a joint.

Q. Can two dissimilar metals be welded?

A. Yes, Joining dissimilar metals is very difficult, especially when the thermal conductivity of
each is substantially different. Generally speaking, intersolubility is required in welding
dissimilar metals. However, in some cases, a third metal which is soluble with the other two
is needed to produce a successful joint.

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Q. What is the Difference between Welding, Soldering and Brazing?

Welding, soldering, and brazing are all techniques to join two or more pieces of metal and in
some cases, other materials.

The main difference between welding and soldering is melting. In soldering, metal producers
heat up the metal to be bonded but never soften them. In welding, metal producers melt the
base metal.

Soldering is most just like brazing since it uses capillary action to flow the metal into the joint
until it cools and hardens.

Q. What is the melting point of iron?

A. 1539oC

Q. Which material have highest thermal conductivity?

A. Copper then Aluminium

Q. Which material have highest thermal conductivity?

A. Silver

Q. What is Cast Iron?

A. An alloy of iron that contains 2 to 4 percent carbon, along with varying amounts of silicon
and manganese and traces of impurities such as sulfur and phosphorus.

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Q. What is mild steel?

A. Mild steel is a type of carbon steel with a low amount of carbon (typically 0.05% to 0.25%);
these are also known as “low carbon steels.” Low carbon steel is considered a relatively
inexpensive and versatile material that is commonly used in various construction and
manufacturing applications.

Q. What is carbon percentage in cast iron?

A. 2-4%

Q. What is carbon percentage in mild steel?

A. 0.05% to 0.25%

Q. What material was used in the job of machine shop?

A. Mild steel rod

Q. What material was used in the job of welding shop?

A. Mild steel

Q. What is the color code of the cylinder for storing oxygen gas?

A. Black

Q. What is the color code of the cylinder for storing Acetylene gas?

A. Maroon

Q. What is the color code of the cylinder for storing Argon gas?

A. Blue

Q. What is the color code of the cylinder for storing Propane gas?

A. Red

Q. Which gas is used as cooking gas or LPG?

A. Propane

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Q. What is arc welding?

A. Arc welding is a fusion welding process where electric arc is created to generate intense
heat (around 3500 °C) which melts the metal at the joint between two workpieces.

Q. How much temperature is generated in arc welding?

A. he temperature of the arc between two conductors is approximately 3500 °C to 4000 °C.

Q. What is the value of current and voltage in electric arc welding?

A. The arc voltage varies from 20 to 40 volts and current from 50 A in sheet metalwork to
1,000 A in heavy automatic welding.

Q. What is the composition of arc welding electrode?

A. The core is made of steel or another conductive metal. The coating is made of flux or other
material that protects the weld pool from contamination.

Flux materials generally consist of borax, hydrochloric acid, or zinc chloride.

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Q. Describe the arc welding circuit?

Q. What are different types of arc welding?

A. Types of Arc Welding

Arc welding is classified into different types which include the following.

• Plasma Arc Welding

• Metal Arc Welding
• Carbon Arc Welding
• Gas Tungsten Arc Welding
• Gas Metal Arc Welding
• Submerged Arc Welding
• SMAW – Shielded Metal Arc Welding
• FCAW (Flux Cored Arc Welding)
• ESW (Electro-Slag Welding)
• Arc Stud Welding

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Q. Which welding procedure is used for welding aluminium?
A. Gas welding (Tungsten Inert Gas)
Q. Which electrode is used for welding aluminium?
A. Tungsten
Q. Why its difficult to weld aluminium?
A. Aluminum has high thermal conductivity and a low melting point(660oC) . This attribute can
lead to distortion, burn-through, and cracking of welds.

Q. What is Gas welding procedure?

Q. What is Tungsten Inert Gas(TIG) welding procedure?

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Q. What is Metal Inert Gas welding procedure?

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 MACHINE SHOP
Q. What is a ‘Machine shop’?

A. A machine shop or engineering workshop is a room, building, or company where machining,

a form of subtractive manufacturing, is done.

Q. What were different machines present in the Machine shop?

A. Lathe, Milling Machine, Drilling machine, Grinding machine, Shaper machine, Planer
machine etc.

Q. Define ‘Lathe’

A. A lathe is a machine tool that rotates a workpiece around an axis of

rotation to perform various operations such as cutting, grinding, knurling, drilling, deforming,
facing, and turning.

Q. Describe various parts of lathe.

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Q. What are different types of chuck?

A.

• A. Four jaws independent chuck: has four jaws that can be adjusted individually to hold
irregular shapes.

• Three jaws universal chuck: has three jaws that move together to center and grip
round or hexagonal shapes.

• Combination chuck: has both independent and universal jaws.

• Magnetic chuck: uses a magnetic field to hold ferrous materials.

• Collet chuck: uses a tapered sleeve to grip the workpiece.

• Drill chuck: has three jaws that tighten around a drill bit or tool.

• Air or hydraulic chuck: uses air or hydraulic pressure to actuate the jaws.

Q. What is the purpose of lead screw?

A. The lead screw of a lathe is used to advance the carriage of the lathe in time with the
rotation of the spindle.

It is used to make threads by having different gearing between the spindle and the drive for
the lead screw.

Q. What are the different types of Lathe Machines?

Ans: The different types of Lathe Machines are: Engine Lathe, Bench Lathe, Speed Lathe,
Turret Lathe, and Automatic Lathe.

Q. What is the cutting tool in a Lathe Machine?

Ans: The cutting tool in a Lathe Machine is the tool that is used to remove material from the
workpiece.

Q. What is the tool post in a Lathe Machine?

Ans: The tool post in a Lathe Machine is the component that holds the cutting tool in place
and allows it to be rotated and adjusted as needed.

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Q. What is the purpose of the Chuck in a Lathe Machine?

Ans: The Chuck in a Lathe Machine is used to hold the workpiece in place while it is being
shaped or cut.

Q. What is the function of the Tool post in a Lathe Machine?

Ans: The Tool post in a Lathe Machine is used to hold and support the cutting tool, and to
allow it to be adjusted and rotated as needed for the cutting operation.

Q. How does the coolant system work in a Lathe Machine?

Ans: The coolant system in a Lathe Machine is used to cool the cutting tool and workpiece
during the cutting operation, reducing heat and friction and extending the life of the tool. The
coolant is typically delivered to the cutting area through a nozzle or spout, and is either a
liquid, such as oil or water, or a mist or spray.

Q. What is the function of the apron in a Lathe Machine?

Ans: The apron in a Lathe Machine is used to control the movement of the carriage and cutting
tool, allowing the operator to adjust the feed rate and cutting speed. The apron is typically
attached to the carriage and is equipped with gears and hand cranks that are used to control
the movement of the carriage.

Q. What is the significance of the bed ways in a Lathe Machine?

Ans: The bed ways in a Lathe Machine are the surfaces on which the carriage and tailstock
move, and are critical to the accuracy and stability of the cutting operation. The bed ways
should be smooth and level, and should be lubricated to reduce friction and wear.

Q. How does the cutting speed affect the quality of the final product in a Lathe Machine?

Ans: The cutting speed affects the quality of the final product because it determines the
amount of material that is removed from the workpiece during each revolution. If the speed
is too high, the cutting tool may become overheated and lose its sharpness, while if the speed
is too low, the cutting process may take too long and cause the tool to wear out.

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Q, How does the feed rate affect the cutting operation in a Lathe Machine?

Ans: The feed rate in a Lathe Machine determines the speed at which the cutting tool moves
along the workpiece, and affects the amount of material that is removed during each pass of
the tool. If the feed rate is too high, the cutting tool may become overheated or break, while
if the feed rate is too low, the cutting process may take too long.

Q. What is the function of the steady rest in a Lathe Machine?

Ans: The steady rest in a Lathe Machine is used to support the workpiece and prevent it from
vibrating or moving during the cutting operation.

Q. What was name of the cutting tool you have used in making job?

A. Single point cutting tool

Q. Difference between Single point and Multipoint cutting tool?

A. The major difference between single and multi-point cutting tools is that single-point
cutting tools have only one main cutting edge, whereas multi-point cutting tools have multiple
cutting edges. A cutting tool can have one or more main cutting edges.

Multipoint Cutting tool: Milling cutter, Hacksaw blade, Drill bit, reamer etc.

Q. What are the different types of operations that can be performed on Lathe?

A. 1. Facing · 2. Tapper · 3. Parting · 4. Grooving · 5. Turning · 6. Drilling · 7. Boring · 8. Reaming.

Q. What are the different types of operations that was performed on Lathe while
manufacturing your job?

A. Facing , turning, chamfering

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Q. What is step turning?

Q. What is Chamfering?

A.

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Q. What is Facing?

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 FITTING SHOP
Q. What is a ‘Fitting shop’?

A. Working on components with hand tools and instruments, mostly on work benches is
generally referred to as ‘Fitting work’. The hand operations in fitting shop include marking,
filing, sawing, scraping, drilling, tapping, grinding, etc., using hand tools or power operated
portable tools.

Measuring and inspection of components and maintenance of equipment is also considered

as important work of fitting shop technicians

Q. What is a Bench vice?

Q. What are different components of a Vernier Calliper?

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Q. What are different components of a Screw Gauge?

Q. What are the tools used in Fitting shop?

A. Tools used in bench and fitting shop are classified as under.

1. Marking tools

2. Measuring devices

3. Measuring instruments

4. Supporting tools

5. Holding tools

6. Striking tools

7. Cutting tools

8. Tightening tools, and

9. Miscellaneous tools

Q. What are Marking Tools?

A. These are sub classified as steel rule, circumference rule, straight edge, flat steel
square, scriber, semi-circular protractor, divider, trammel, prick punch, centre punch, try
square, bevel square, vernier protractor, combination set and surface gauge.

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Q. Name the Measuring Devices used in Fitting Shop?

A. Commonly used measuring devices and instruments used in bench and fitting shop are fillet
and radius gauge, screw pitch gauge, surface plate, try square, dial gauge, feeler gauge, plate
gauge and wire gauge.

Q. What are different parts of file?

Q. What are different types of file according to shape?

A. Following are the different types of file tools according to its shape:

1. Flat File

This file is of rectangular cross-section in shape. It is made slightly tapered both in width and
thickness. Double cut teeth are cut on the face and simple-cut teeth are cut on the edge.
These are used to reduce flat surface by filing of finishing.

2. Round File

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This type of file has a round section. It is used for rubbing or finishing keyhole of small
diameter.

3. Half-round File

It is a file which is on the side and curved on the other side. Double cut dents are cut on it and
like a round file, it is also tapered. With this file, the damaged hole can be set in order again.

3. Triangular File

It is triangular in shape. Its angles are of 60°. Filing of “V” slots job, square and rectangular
jobs of above 60° and below 90° angle are done with this file. It is also known as three square
files.

4. Square File

It is square in shape and is somewhat tapered. Filing of rectangular, square groove, slots and
key-way is done with this file.

Q. What are different types of file according to Grade?

A. . Rough File

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In this type of file, teeth are of big size and less in number. It is used for cutting soft materials
because its cutting is rough. Because of rough cutting, it cannot be used for hard metal.

2. Bastard File

Teeth of this file are comparatively smaller than those of the rough file. It is used initially to
shed metal (through filing) in large quantity.

3. Second-cut File

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This is a file of medium grade. In the filler trade, this file is mostly used to bring the job in the
proper size. As compared to the bastard file, filing done with this file makes the surface plain.

4. Smooth File

This file makes the surface quite plain, in addition to making a job of accurate size through
filing.

Q. What are different types of file according to Cut?

A. 1. Single-cut File

This is file has parallel lines of teeth running diagonally across its face in one direction only.
Metal surface is rubbed in little quantity and thus the surface becomes smooth. Therefore it
is used for hard metal and for finishing.

2. Double-cut File

This file has two rows of teeth crossing each other at an angle of 50° to 60° and the other row
has angles of 70° to 80°.

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Because of double teeth, this file cuts metal quickly but it cannot make the surface very
smooth. That is why it is generally used for normal filing as shown in fig (B).

3. Curved-cut File

It is also known as Vixen file. The curved-cut file is used for filing of the wide surfaces of soft
metal like aluminium, zinc, copper and brass. It has circular teeth as shown in fig.

4. Spiral-cut File

These types of teeth are cut in round or semi-round files. The shape of their teeth is like that
of threads.

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5. Rasp-cut File

This is a file of special thick teeth. These teeth are of triangle shape and are in a bulging state.
It is used for jobs of woods, plastic, fiber, hard rubber, and job of horns and hoof of animals.

Q. Describe the appropriate Methods of Filing a metal.

A.

• Choose the right type of file, according to the job.

• There should be handle fitted on the tang of the file. In small files, a small handle
should be fitted and a larger handle in a larger file. Otherwise, proper and power would
be unnecessarily wasted.
• Hold the handle of the file with the right hand and keep the file end balanced with the
left hand.

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• At the time of filing, the left leg should be kept ahead and the right leg a little behind
as shown in fig.
• Pressure on the file should be exerted while moving it ahead, not while driving it back.
• Only your hands should move with the file and not your whole body. As far as possible,
keep rest of your body still.
• Speed of moving the file should be at the rate of 30 to 35 strokes per minute.

Q. What are different parts of hacksaw?

A.

Q. How hack saw blades are classified?

A. TPI,

The number of teeth (cutting edges) per inch in the hacksaw blade for metal is described
by TPI. Blades usually have 14, 18, 24, 32 teeth for every 25 mm (inch).

Q. What is the configuration of teeth of hacksaw blade?

A. The teeth of hacksaw blade are bent alternately towards right and left and every third
or fourth left straight.

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Q. What are different types of hammer used in fitting shop?

Q. What is Outside Calliper?

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 Q. What is an inside Calliper?

Q. What is least count of Vernier calliper and Screw gauge.

A. Vernier: 0.01, Screwgauge: 0.001

Q. What is the appropriate method of using Hacksaw?

• At the time of cutting, the left leg should be kept ahead and the right leg a little behind.
• Pressure on the hacksaw should be exerted while moving it ahead, not while drivi it
back.
• Only your hands should move with the hacksaw and not your whole body. As far as
possible, keep rest of your body still.

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 ROBOTICS AND AUTOMATION

Q. What is a robot?

A robot is a programmable machine which is capable of doing complex tasks automatically

with precision and efficiency. The robots can be guided by external or internal input to perform
any work.

Q. What are the Laws of the robotics?

The "Three Laws of the robotics" also known as "Asimov's law," given by the author Isaac
Asimov. The three laws are given below:

1. First law: A the robot may not injure a human being or, through inaction, allow a
human being to come to harm.

2. Second law: A the robot must obey the orders given it by human beings except where
such orders would conflict with the First Law.

3. Third law: A the robot must protect its own existence as long as such protection does
not conflict with the First or Second Laws.

Q. What are various types of sensors used in the robotics?

A. There are the following sensors which can be used in the robotics:

Light sensors- A light sensor detect light and create a voltage difference, which is equivalent
to the light intensity fall on the sensor.

The two main Light sensors which used in the robotics are:

A. Photovoltaic cells

B. Photo-resistor sensor

Sound sensors- This sensors are microphones which detects sound and return a voltage
difference equivalents to the level of sound. Example of a sound sensor is: Instruct a robot by
clap.

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Temperature sensor- Temperature sensors sense the change in temperature of the
surrounding. It provides a voltage difference equivalent to a change in temperature occurred.
Example of temperature sensor IC's are LM34, LM35, TMP35, TMP36, and TMP37.

Proximity sensor- Proximity sensor can sense any nearby object without any physical contact.
Following are the type of proximity sensor used in the robotics:

C. Infrared (IR) Transceivers,

D. Ultrasonic Sensor

E. Photo-resistor sensor

Acceleration Sensor- Accelerometer is a device which detects the acceleration and can tilt
accordingly.

Navigation sensor- These are the sensors which are used to identify the position of the robot.
Some of the navigation sensors are:

F. GPS (global positioning system)

G. Digital Magnetic compass

H. Localization

Q. What is Servo controlled robot?

A servo controlled robot is one which works on the servo mechanism. Servo controlled robots
are consist of servo motors which processed by the signals. A servo controlled robot can
accelerate, that means these robots can change their speed at a different point.

Q. What is meant by robot anatomy?

A. Robot anatomy means study of structure of robot. Manipulator is constructed of a series

of joints & links. A joint provides relative motion between the input link and the output link.
Each joint provides the robot with one degree of freedom.

Q. What is rapid prototyping?

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A. Rapid prototyping is the fast fabrication of a part, model or assembly using CAD-Computer
Aided Design. The prototype is usually created using additive manufacturing.

Q. Define Sensor, Transducer, Actuator?

A. A transducer is a device that converts one form of energy into another, such as converting
mechanical energy into electrical signals.

A sensor is a device that detects and responds to a specific input, such as light, temperature,
pressure, or motion and converts it into a measurable output.

An actuator is a device that produces a motion by converting energy and signals going into
the system. The motion it produces can be either rotary or linear. Electric linear actuators, as
the name implies, produce linear motion.

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 GENERAL KNOWLEDGE
Q. What are colour code of safety helmets?

A.

Q. What is ABC type fire extinguisher used in Workshops?

There are five basic classifications of fuel that exist in this sphere.

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Q. What is usual color code and colour range of Coveralls(Apron in general term) for
Mechanical engineering workshop?

A. Navy Blue

Q. What is the first aid if person shows no signs of circulation, such as breathing, coughing
or movement due to an electric shock?

A. CPR

Q. Describe the emergency procedures in case of electric shock?

A. Turn off the source of electricity, if possible. If not, use a dry, nonconducting object made
of cardboard, plastic or wood to move the source away from you and the injured person. Begin
CPR if the person shows no signs of circulation, such as breathing, coughing or movement.

Q. Define malleability and ductility?

A. Ductility is the property of metal associated with the ability to be stretched into wire
without breaking.

Malleability is the property of metal associated with the ability to be hammered into a thin
sheet without breaking.

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