Objective

Objective :This unit provides students with the fundamental knowlege and skills necessary for the various maching and various welding processes. It cover from the industrial safety in workshop practice to precision measurement in manufacturing processes.Workshop practice forms an important part of this unit.

Syllabus

1Industrial Safety

Mechanical and other accidents.Safety devices.Electrical accidents.Care and Order in the worksop. Safety Precautions

Occupational Safety and Health act 1994

2Fitting

Marking out, sawing , clamping , drilling and use of jig saw

3Checking and measurement of surface

Accuracy of measuring instruments, traceability of standard for measuring instrument.

Working principles and applications for one dimensional , digital tools and two measuring instrument instruments

concept of straightness , parallelism , flatness.

concept of cylindricity , concentricity , roundness coaxiallity.

Introduction to three dimensional coordinating measuring machine.


4principles of cutting tools

Rake angle , clearance angle. Cutting tool materials , Force acting on cutting tool , type of chips ,heat produced during cutting operation , functions of coolant

5Drilling

Drill bit: types , their features (ie angle) and functions ,grinding of drill

Drilling process :Drilling of an ordinary hole , countersinking , counterboring , spotfacing .

Drilling machines; types ,parts and functions

Drilling process parameters :Cutting speed and feed

cutting fluid ; types and uses

Safety precautions

set up and holding of work piece while drilling

6Shaping machine

Main features and driving meechanism. How to use clapper box and tools to machine inclined surface.

7Milling machine

Type and functions of main parts .

Various milling operation, gang milling , face milling, profiling, indexing , how to make a step and to make a slot

Milling cutters

Maching parameter; feeds and cutting speed .

8Grinding machine

Types of grinding machine and their uses

Grinding wheel : types and uses , specification

Balancing , dressing ,fixing and truing of wheels

9Lathe machine

Types of lathe machine

Functions of parts of lathe machine

Different method of holding workpiece : between centre , with face plate , with chucks

Cutting tool : materials , angle , shape

Other operations: Cutting of external thread , boring , drilling , knurling .

Machining parameters; Cutting speed , feed , depth of cut

10 Surface texture measurement

Concept of roughness and profiles .

Signifance of roughness

Allowable torelance for different types of process

Different types of expression of roughness; ie Average roughness ,RMs roughness , Bearing area curve

11Welding processes

Principle of oxyacetylene welding

oxyacetylene welding equpment

set up of oxyacetylene equipment

Oxyacetylene flames .

Welding techniques

Gas cutting

Weld testing and inspection

Arc welding machine

Polarity of welding machine

Types of weld and preparation

Terminology in welding

Electrodes

Weld defect , distortion

Weld symbol

MIG and TIG welding; characteristics of arc

shielding gas

advantage and disadvantages