1.
Workshop Practice

2.
Fitting and Fabrication Workshop

3.
Layout
The plan or design or arrangement of something laid out is called Layout.

4.
Types Of Layout
Process Layout
The layout which group resources based on the similar processes or functions is called
process layout. This type of layout can be found in companies that use intermittent
processing systems. A process layout is used in contexts where many different items are
produced in small quantities.
Product Layout
When all the processing equipment and machinery are positioned according to the
product's sequence of operations, this type of layout is known as product layout. The
main focus of product layout is the sequence of operations regarding the production or
assembly needed for a product or some of its parts manufacturing and assembling.

5.
Combination Layout
A combination of process and product layouts combines the advantages of both types
of layouts. A combination layout is possible where an item is being made in different
types and sizes. Here machinery is arranged in a process layout but the process
grouping is then arranged in a sequence to manufacture various types and sizes of
products. It is to be noted that the sequence of operations remains same with the
variety of products and sizes.
Fixed Layout
The fixed layout permits a product to maintain at a particular place, and the needed
resources like manpower, machinery, material, equipment, etc. are transported to the
product's location. In other words, the place of the main element or the product
section remains fixed because of the larger size or substantial body.

6.
Safety Precautions

7.
Safety Precautions
• In shop area, it is necessary to wear safety glasses, face shields or cover googles
either working or not.
• Shoes must be worn in the shop area. No one wearing sandals or clippers in the shop
area.
• You do not use any equipment unless you are familiar with it. You do not use any
equipment without the permission of supervisor.
• No one can perform their work using power tools unless two people can see them.
• Don’t wear jewelry, ties and loose clothes.
• Practice orderliness and cleanliness in shop area.
• Never tilt the hacksaw blade while sawing.
• Drill the holes centralizing on pop marks, give gradual feed.
• Do not use a spanner as a hammer.
• Do not use a steel rule as a screw driver.

8.
Safety Precautions
• Always wear lab coat while working in the lab to avoid loose clothing.
• Wear safety gloves while handling the metal sheets and sharp tools and to avoid
electro-cautions.
• Use appropriate tools as told by lab staff.
• After usage, submit the tools back in the lab.
• Get full knowledge before operating any machine or using any tool.
• Files must have well fitted handles.
• See that work piece is perfectly clamped or fixed in the vice.
• Never use hammers with loose heads.
• Use the coolant at the time of hack-sawing and drilling.
• Keep the work place neat and clean after work.
• In case of emergency immediately call the attendant.

9.
Machines Used in Fitting and Fabrication Shop

10.
Drill Machine
The most widely used process of material-removing or cutting
process in which the tool uses a drill bit to cut a hole of
circular cross-section in solid materials. 75% of all metal
cutting material removed comes from the drilling operation.
Sensitive drilling machine is a small machine designed for
drilling small holes at a high speed in light jobs. They a
capable of rotating drills of diameter from 1.5 to 15.5
millimeters. A large number of spindle speeds and feeds can
accessible for various types of work. They are presented in
different sizes and with drilling capacity range able to 75
millimeters diameter drills.

11.
Working
The hole is generated by the rotating edge of a cutting tool which exerts large force on
work clamp on the table. As the machine exerts vertical pressure on work clamp to
drill hole it is called drill press. Holes may be produced by twist drill or flat drill or by
boring with one or more single point tools or cutters mounted in a bar or head.

12.
Power Hacksaw Machine
It is used to cut across materials like metal and bone. It
provides a vise for clamping the work and means for
reciprocating a U-shaped frame on which is mounted a
straight steel hacksaw blade that cuts when moving in
one direction only. Each blade of the power hacksaw is
composed of 14 to 24 teeth per inch of the blade.
Working
It has the same function as the saw machines is used to
cut metal in the machine shop, drawing a blade
containing cutting teeth through the power hacksaw uses
a reciprocating (back and forth) work piece. The saw
machine is faster and easier than hand cutting action
similar to the one used in a hand hacksaw.

13.
Double end Pedestal Grinder
It works on the same principle as the grinder that is mounted
on a pedestal, which may be bolted to the floor or may sit on
rubber feet. They are commonly used to hand grind various
cutting tools and perform other rough grinding.
Working
They are used to sharpen high-speed steel cutting tools used on
the lathes and milling machines, deburr, or used to remove
surface imperfections and to work extremely hard materials.
The grinding wheels are held between two flanged disks.

14.
Arbor Press
It is a small hand-operated press. It is typically used to
perform smaller jobs, such as staking, riveting, installing,
configuring and removing bearings and other press fit
work. It can be the mounted on a work bench.
Working
It is a compact machine with different parts working
together to produce a press. The components of the arbor
press include the ram, a recoil spring, a lever arm, an arm
stop, the press caul, and the arbor base. When using an
arbor press, the item to be pressed is placed on the base
and the lever arm is pulled down.

15.
Surface Grinding Machine
It is the conventional finish machining Process
used for producing a good surface finish on
components. It is one of the widely accepted
finishing operations because of its material
removal capacity in a very small size of chips
ranging from 0.25 to 0.5 mm The abrasive
particles presses on the surface of a grinding
wheel will be acting as a single point cutting
tools for removing material from the work piece.

16.
Air Compressor
An air compressor is a pneumatic device that converts
power (using an electric motor, diesel or gasoline
engine, etc.) into potential energy stored in pressurized
air.
Working
Air compressors work by forcing air into a container and
pressurizing it. Then, the air is forced through an
opening in the tank, where pressure builds up. The
compressed air can be used as energy as it's released.

17.
Pneumatic Press
It is a machine using a pneumatic cylinder to generate a
compressive force. Frame, pneumatic cylinder and press
table are the main components of the pneumatic press
with various attachments. Presses are one of the most
commonly used machine tools in industry for the forming
of different materials press brake is typically narrow and
long so that large pieces of sheet metal can be bent by it.
Normally it contains pressure from 7 bar to 10bar.
Working
A press brake bends sheet metal by lowering a punch onto
sheet metal that has been positioned on top of a die. The
metal may be bent several times by a press brake until the
desired form has been achieved.

18.
Pneumatic Metal Sheet Shearing Machine
The shearing tool is provided at end of the pneumatic cylinder rod. When compressed
air is supply by the DCV to double acting cylinder , due to pressure & force created by
compressed air causes shearing action of the sheet metals strips & HSS cutting blades.
The sheet metal cutting machine works with the help of pneumatic double acting
cylinder. The piston is connected to the moving cutting tool. It is used to cut the small
size of sheet metal.

19.
Sheet Bending Machine
A machine for bending and straightening metal sheets and strips. Its purpose is to
assemble a bend on a work piece. It is stable in structure and simple is operation. It is
really the device necessary for construction of ventilation duct. Sturdy construction.
High operational fluency. Impeccable performance.

20.
Sheet Shearing Machine
A shearing machine is a one that is used for cutting sheet metal into desired shapes and
sizes. One thing that makes these metalworking machines ideal for industrial shops is
that the shearing process does not form chips or any residual material, reducing debris
in the air and on the floor.

21.
Tools used In Fitting and Fabrication Lab

22.
Tools used In Fitting and Fabrication Lab
File
It is tool which is used to remove fine amount of material from work piece during
filling. File is made up of high carbon steel. This is the reason; we use it on iron and
steel work piece. Typically the files are made of stainless steel or nickel titanium (NiTi).
The term 'coarseness' refers to how rough or smooth a file is. Coarse, or rough files,
have their teeth spaced far apart, whereas fine, or smooth files have their teeth much
closer together. Files are produced in a variety of different coarseness to cater for a
range of different uses.

23.
Types of Files
There are two types of file:
Single Cut File
This type of file is known so because one diagonal cut is present on cutting surface.
This means that it will cut in one direction. Since it cuts less, the main advantage of
using this type is that it will give a good finishing and shiny surface. But it has also a
disadvantage that because of slow cutting it takes too much time.
Double Cut File
This type of file is known so because it has two diagonals cuts on the cutting surface.
This means that it will cut in both directions. Since it cuts more, the main advantage of
using it is that it will take less time. But it has also a disadvantage that it would not
yield a smooth surface and finishing would not be good. But still we can have benefits
that whatever we want to remove more an more material, we will use double cut file.
File length
File length is measured from heel to the point of file.

24.
Try square
It is use to check the level of work piece and the angle (90 degree). It is used during
filling. It is consisting of thick beam sometimes called stock. It also consists of thin blade
which is set at the angle of 90 degree. It also uses as a ruler. It is usually made up of
steel.

25.
Bench Vise
The bench vise is a holding device that is used to hold the work piece while application
of multiple processes i.e. Filling, tapping, dieing, Cutting etc. on the work piece. Bench
vice has two jaws one is fixed (Stationary jaw) and another is movable (Sliding jaw).
Sliding jaw slide over the slide face, when the handle is rotated in the clockwise
direction it is subjected to tight by mean of the thread which is mounted on the rod.
The body is not movable to any direction is called a fixed body and the lower part of
bench vise is called base. It is made up of cast iron.

26.
Scriber
It is used for the marking purposes by the removal of material from work piece. It is a
thin high carbon rod with a sharp tip. It is commonly made up of high carbon steel.

27.
Steel Rule
The steel rule is an easy and quickest means to measure the linear dimensions of a
component with limited accuracy. It is frequently used in the workshop. They may be
'rigid' or 'flexible' depending upon the thickness and the quality of steel used in their
manufacturing. It is commonly made of high-carbon spring steel.

28.
Ball Peen Hammer
A ball-peen or ball pein hammer, also known as a machinist's hammer, is a type
of peening hammer used in metalworking. It has two heads, one flat and the other,
called the peen, rounded. the ball-peen hammer is useful for many tasks, such
as striking punches and chisels (usually performed with the flat face of the hammer).
The peening face is useful for rounding off edges of metal pins and fasteners, such as
rivets. Ball-peen hammer heads are typically made of heat treated forged high-carbon
steel or alloy steel.

29.
Center punch
It is just like a needle which is used to highlight the point that we mark by the scriber.
We use ball peen hammer to apply pressure on the needle. It is made up of mild steel.

30.
Tapping tool
It is used for the internal threading in the holes which is made by the drilling machine.
They are known as a tap. A screw like tool that has threads like a bolt and two, three, or
four longitudinal flutes or grooves and that is used to cut screw threads in a nut or a
hole. They are three type of taps
o Tapper tap
o Plug tap
o Bottom tap
It is made up of high speed steel or carbon steel.

31.
Tapper tap: Tapper Taps typically have 8-10 threads that are tapered. The shape of this
tap helps the thread to start. They can be used to start a thread before using a plug or
bottom tap.
Plug tap: Plug taps have about 3-5 threads. These are extremely popular and are used
for through holes or to start blind holes.
Bottom tap: A bottoming tap has nearly no taper with a thread count of 1-1.5. These
are used to get close to the bottom of a blind hole.

32.
Hacksaw
A hacksaw is a hand-powered, small-toothed saw used for cutting metal pipes, rods,
brackets, etc. Hacksaws can also cut through plastic. The hacksaw has a U-shaped
frame and a handle at one end. Hacksaws have small pins at each end of the frame that
receive a blade. Blade is made up of carbon steel or high speed steel.

33.
Drill Bit
Drills are cutting tools used to remove material to create holes, almost always of
circular cross-section. Drills come in many sizes and shapes and can create different
kinds of holes in many different materials. In order to create holes drill bits are usually
attached to a drill, which powers them to cut through the work piece, typically by
rotation. The drill will grasp the upper end of a bit called the shank in the chuck. It is
made up of high speed steel.

34.
Reamer
A reamer is a tool that is used to widen the size of a pre-existing hole in a metal by a
small amount to leave smooth sides and edges removing any burrs or rough edges. It is
generally made up of high speed steel material.

35.
Die and die stock
Dies are cutting tools that produce external screw threads, also known as male screw
threads. They're commonly used with die stocks, which are tools that hold round and
hex dies to ensure proper alignment and uniform threads. Dies are used to create new
threads, and to repair worn and damaged threads. It is commonly made up of cast
steel or mild steel.

36.
Working Processes

37.
Dimensions of Work Piece

38.
Process Details
A work piece is given which is full of rust and unparalleled edges. We have to perform
different processes on it. The work piece is made up of Mild Steel.
Filling Process
Firstly, we have to fixed the work piece on table firmly. With the help of file, we will
furnish it or level its surfaces. It has two types
• Cross filling
• Draw filling
Cross filing done when we use the file vertically and slowly. This removes more
material but not good finishing and therefore takes less time. When ever we are
removing rust, we use this filling. The work piece is tightly clamped in the voice with
the surface to be filled is kept horizontal. File is held in the position of work piece. The
hand of file is kept in the right hand and left is on the other end pressing it downward
and forward through its full length.

39.
Draw filling is done when we use the horizontally to attain perfect level of smoothness.
It is a time taking process but gives smooth surface that's why whenever we find our
work piece to be unlevelled, we use this type of filling. It is used to remove marks and
scratches left over the work piece by cross filling and used smooth and flat surface on
the work piece. The process works by moving any type of single-cut file forwards and
backwards along the length of the materials edge.

40.
Marking Process
It is a process to mark those areas of work piece where we have to do some work. It is
not as simple as it seems because we were dealing with metal and we had to mark on
it without damaging it.
Here we took advantage of Scrubber and paint. While making the work piece, we paint
one face of the work piece with yellow color and let dry for 5-10 mins under the drying
fan on to the surface plate.
For marking first of all we have to paint the work piece and then using scriber, we mark
a line of 20mm at left bottom of work piece at 8mm from horizontal lower edge.
Similarly, make another line of 20mm at 8mm from the first line. Now, make two
points one at the upper left and one at the upper right of 20mm from each edge.

41.
Punching Process
Once the marking has done, highlight the points by using center punch and hammer. To
accomplish this task, place the center punch on the point one by one and punched by
hammer. We do this because the yellow color will be removed after some time.

42.
Drilling Process
Drilling is a cutting process that uses a drill bit to cut a hole of circular cross-section in
solid materials. The drill bit is usually a rotary cutting tool, often multi-point. The bit is
pressed against the work piece and rotated at rates from hundreds to thousands of
revolutions per minute. This forces the cutting edge against the work piece, cutting off
chips from the hole as it is drilled.
Now, drill a hole of 31/64 inches diameter at upper right point and another hole of
5/16 inches diameter at upper left point by using the drill machine.

43.
Sawing Process
Sawing is a process wherein a narrow slit is cut into the work piece by a tool consisting
of a series of narrowly spaced teeth, called a saw blade.
First marks are punched so that cut might not be curved or deviated from original line.
Sawing is used to separate work parts into two or more pieces, or to cut off an
unwanted section of a part. These processes are often called cut-off operations and
since many manufacturing projects require cut-off operations at some point in the
production sequence, sawing is an important manufacturing process. It is used to cut
the iron.

44.
Tapping Process
As we make two holes of different diameter, in left hole (smaller diameter) we make
the internal threads by tapping. As, there are three taps 1,2,3 in workshop. First of all,
we use tap 1 (taper tap), by using oil. Then we use tap 2 (Plug Tap) and 3(Bottoming
Tap) in similar manners. Oil is used for lubrication. It is because when two metals
rubbed against each other they causes frictional effects and hence causing wear and
tear.

45.
Reaming Process
On other hole (left hole on the right) we do the reaming by using a reamer and oil. The
purpose of reaming is to make the hole internally smooth and furnished.

46.
Dyeing Process
Dyeing and Tapping are the relevant procedures. We can say where we use tapping
there is also need of dyeing. Dyeing process is actually used to make the external
threads.
While making the work piece, we were asked to make a bolt of same diameter and
length 30mm as its fits within the smaller hole. With the help of the Dyeing we can
easily make a bolt or a nut by using the external threading. It is a process which is used
to form or cut a male thread on the outside of rods or bars.
Take a meter rod, fixed it in bench wise and give it a cone shape, so that it should be fit
in the dyeing tool. By using hand hacksaw mark a line at 30mm and another at 25mm
from cone shape of metal rod. Using the die tool start external threading on the rod up
to the 25mm length of the rod and also don’t forget oiling in this process. By using
hacksaw cut the rod at the mark of 30mm and make a cut of 2mm on it Then tight your
nut which is formed by dyeing process into your work piece at where you create
internal threading.

47.
Final Work piece

48.
Comments
• No light should be passed when we check level or angle by using try square.
• Hacksaw must be used with great care.
• Don’t use oiling when you are dealing with hacksaw.
• Not oil your tool at the beginning of reaming or dyeing process other they didn’t
work properly.