( J.\.

fi PEf\J TA S f-f OP
...
R·'f ·

1,1 IN1HODUt'11<HJ
h) t:11:, ,·/1.1;)!1·1 :.1,1.i,•111'; \", ·:I 1,,,,,, !11,Jl/ (1 ; ,)If J ;,,,, '•,(;i'> IJ!.,'.:0 .t,, 1

,:, (.!lf'•'n1.,,v,,i:\ p
1
11,, r; .'Jl'' ,.,\·,1111 ''! 11 :I 1J·, d 11, 1,.irJ1•:ri!:,1•1 • hop ,s
\\\.·-,· ◄ I;, 1:11.· ::,l•I lit·lp:r,,i :11:t11•r,;1'•. d,,. 11 1:: ;,et,::,', p :inf' aricJ
r\.J -:. ! !it• ,\,)\l() ::. ,lV.1il=1 1lt 1
1•. tl1'.· lllc1rk,:t /rl drlf•·f•.?:i! <,11:J[,1:;, and ',llf-'S
l th' 'f()Cl. t ,Ju 11 t · 1· 1 ·,' o,, : \ vo I k ;::r •:• , ., m;:: 1:,'.;,·Jrrnr,'J r,d
,,n.,,". ;
c-hit.')St'):1t11; ct,: \\,'l1l•t"Ji"'ll !u1ri.!111c:.', dc1i';r . ·;:1r, 1
_;•· • , J . , · ,_: ; , :: r !,! •: - r I..:
,r ,
g•, nt:-r.ii ly : • 1;!(L:i rn Cd; pc- r ! ! d r v shop
\Vood: \:\food is dVc1rlc1LJ!,;,,·, /'I ,IIJil·: Ill :lie i 1(t;• ';( ;r,,;:S U:-;,:hi part 1

;,.")! the tree ,s ct:! ...:nd i w;r::,..: f,)r caq•c•r·irar,1 1/,1;;:. ;:,i;, ;· thr- rnost

u:Sc--:rul
Timber: ti11:wood
part ofThe tri.l..:, nbta,n-_d fiom fu/:y_ gro,:: 1; tr,:;:'.:; i ,r_1t ·Hid
,

rough fOI :T: and ,ifrer sa\.'.'.inq it-ro mark(;t:

J
prepared for engmcer 11''::J purpc:-- s This_wco -J i$ L-n?:.:: ::· i1:-r,:,i··r T1 nt--2r
a!so h2ve three forms. \>\:hen n !:; in t!F: furr;; c·: 2 (_,-,·:,;:;, £: rr,:r:- ther
, i LS 1e! n e•j as sta tior:2 r y. a:; e, -¢u t!! r ! g th ej t, ee Ir. tt F: f:.:,;,:, c•f i oy ,t i
t ''... r r' ; .._ rr:-:. · ; . '-1 ltrr.lx r
f
T :mber has si./e
,')! !;.:.r !:: 3 ;;: !!·
the following advantages over the
..c/ , to \''C"'r!.t c"'r1 •r h" t·h-·, he.,!p 01 0'11';:.•,:,· •:,·.,;,
1
' "'J, ! (_
L- "--" ,... J • J r, ..; . , , -_., 1 • t_ . 1 , _ l t ,_ ,, ,
•,

:r:,_; :eql/lr, ·.j. sr:=,2c;ficat1on

2 L1ohte r iq
J
'-'\'•::>u h
-
1n co:;: parison to other:\;ct,/.i: · 1
,_- ·::.::,-, , ,. i:., but
having the rsqwreduength.
3 lt i.s chE:ci;JEr 1 comµ red to other _r:_ t\· ·11.1!'..,;.i' ed':>ii,
availar:ie
l G0•'jj r,_·SiJ(V: 1: to poi1:::i1in,:J
2r1CJ µ
. '
:! 1 r-,:::;
5 \/81•: •-,i.J,t·.-: 1-: hr Un,_·,;- v;rr,dO\.'J·:: ·ind t·.. · .lt;:. ._:_..•
'. :.. - ,....f•
:!,,:·-.: : ,..;rr;s ,•ooh.·1 1(11 .-,; jOllliS 2.11r t•i"'l(', .. . ' ..! ..,
1n1- :,, ,r; ;t,: r,:"1
f.,, < ., ,- .
, . ' ., , ! , ; . : 'I '! ll -.: t: / f I: l/).-) y,1(11[ ;t,',_!pJ \ .. ; I•.
I
.
I (_·. •, 4 ,'.fl-r:( :•1
1

I ; I; ' ,, i.,,.,,.!,
, ,f I I I . . 'I \" ·-..i; ,, _·.:,,),:

-----..._.... ,.,.;..,,,..,..........
 :-.· ... ·"' '
'"Jl''"· .,, \·. ,1
, / 1 I' C / / :
-
St.:.s::.or,11,;:_i t.1r-In:;::i

l. N&tural se.:.1$0:-:irig I:, n.,IL,:,11 ::.easor.1ng ionrcJs «:1, •-tc1. k.,-<!

1
: \\'ft()IJ on to each oll1e,,n d sh0u ..is shown 1n the.Fig.' 1 ? Tl'? t.,r,.Jrrlc,
are
,, .:.,· r..,1,1 Ct111, Hdr(l WP,.JJ
prsv 111 d fror,., ;,r-ct e> JW>,l,IS of <sun and.,rain A, ptatfr,,rn i!,
4 fr•'"\ Sh,:::.h;.t•n s.., l\ ,in :..·• r:\,J ' h..J(J
rr•,;de aboul SO c,;, fro111 :hr; g:, u•,d 1. v1.01 c111d _r t i s properly le:v
I T(·.h ci.,. Oe,;jan
ill·d me
,terns such:1s i) ,, (); 'S spr ycd on ih;s fayr-r for ;,)ICV<:ntin9 from
i f,-,:d wood 17,,5!osu0 structure hr:-,.,,1, 111 . •erulq dark,n colour
1 expoE:u:. ct 1110, tl'IE ;,r,r' 1h shed Is fatH1ca·1erl or, 1h15 p:ntfo:rr)fn0n
''"''l·' durable .'.lild, ·,i fi1,.;u1! to wo,k. on 1i . n11,n.1ri71os .:11e not d1s!rnct the !S!ePpers i:\re .-1c
1
1-·0 11, the shed J...eer,,ng ,3 9,1 . bel-...\·<::-er ihe :,,l ep
,md llas good ten,-,,k, stre11g1h. Whereas thP soi1vvot't: hns less wP,oht ers f-: r fr
1
CIIC.11 ,:!10·1 .•' &ir Frne c:rculatiori is c.ll V/1.:d 2rc Jrd ihe
ipss
a; durable and 1s P.isy to work on 11 Soft 1vciod c,11,·hp:,; i11E:'soon·
01:
wood Thepos,t,r·; o' 'he!r,ep r hould b.e ch;inged periodically which
comp1-:red to ll.:Hu\·-t·0d annuc1I rings are CJU!lt' a1<0.:,11,1
wil! incrP.asP.the •,:t. t:f r:!ry,ng (GuP. lo rh,s -tre excess mo,stwF.
Plywood: It consists of more thaq three gets
f;c;yers M1ddte icJyer ,s c21ied core which :s evaporated •1F.ry i? ,si:y ?.nrJ th& lceper becomes dry y this m=ihno
1111ck znd not of good qu;:if,:y The top and best seasoned wn,-:.:; , riva!1?.ble ;:it ci cheaper rate T1rne requirec 101
bGltcm art:- calleo .:is face plys which 1s g! seasoning also depend5 upon the type of wood to beseasoned I e.
ued on the core 21 lop and bottom The 9;a,n r.ard wood takes r;10 e timt" &s corr.parea to soft woc.:J II is kept for 6
months to 2 yea:
- , dd!ac:eri; lavers are kept peroen- he d :
: 1,cul;:,.r
.. 0; IC 6clCh
t:cm \Va:pa otner
c=- which prei.•ents ply
---==
:}l::v:, C'•J 11<1s ih lo!lo v,ng advantages.
Fig. 1.1 ,I! --
1. ' ._,
i i;:-1·,-:c• :·: .·.,::,:;,;,; ..i1,u easy r0 work

I!
Ca, be:used for decorating Ifie furn1!111es as well as houses rr1:: :,,... · 1' :,.'.rJ,_p; ; :, !.JCt..1
i! •:.• also .3\'a!lable 111 bigger srzes. f1 • :< f:• r• , . :'":'";;n,m,sAd
P s,es'>t:'S berte, st:ength !han solid W<?._Od of same 1h,--kiless ·. , •..,,. r.· •,:;•• ,, ,n,pr<;v d

- SE ASO:W·.JG OF WOOD
•.. •
••, ·. t:'::; 'Ji re'l'')v,ng mo1s1_ure from
::,,\ ,., c ls : €-.1::(A 1,, icJ ,: :r.ese trees thepercent
:,;n fr; .',. C. ,:S0'1 it:'' : g:11earing purposes C

:· ; -; ;:,:-_-•·,:,,;\:.: •d- :
'l;o •;i,;,,·. ·, .0• • LJ:..«: •rir1n rypes of prob

:
,vantages o:
O,J'3, .,.,.,,
o
seasoning:

-..v,,r:..;-" -.-.1&· :.. ,:r,r,r ,."ed

•:, it•er,gu, 1s ,

. 7,7-
 .F,g 1 '- N.11unt1 seas,-••t 1•

2. Kiln seasonin\l: 111 1111",nell)OU1111 \,q ,,, • :.-.:..,-,..·H :t. llt <w
, ..''◄;:. r,o!,it:-! ,in,j II·,,,, · · 0 • '· •·• .: ' •• • -
 J ,,. ·:r.r r r-,
•
1 '
I ,. t••,....,• , •
r·sirrr,,,,.,_,!-!'., ... - "rt:in ,-,y ::,HOP
,
1 l• t\J ::, 111,!f P ( ,.1 \Viti l
..-.-.- ·_:: '-; t...,-, 11, 1111t1lJ 'wVll11e ._•.,(;rK.1r;; i.'. i.;:1rf.-
SCi:ICS In 1111s SCule also 1:,,,,,, ,.,l•.Jdua:,or. Ill bot11 111r.hvs .:ind
G:li,:ry

loo/ 'JIH•uld be placb::Jproperly on work bench cen1!r.1etres and inches ani; r;.. r,:1111,•:•r ,He ;,Jso lu,tl, ro,,,,cJ,,c; 11?t0
;• WuodL•n pieces w,rh pru1ec!ed na,I:; !"'lould nol be acloweo to, Jma,r. sm;iller d1vrs1ons In this sr..'r th,:• • < •1v, 1 1011 t,,l>tc- 1J,-.1vv,..- 11 d,'f,,r
f"ll l/llllS is -1Is0 mE-11:IO11.,j
:·,,1110 cm thE:cstiop floor.
Ct•nM ·,, .. , /
3 t.Jc•vcr stand in lron1 of the blade while working on a circtJlar saw
4 IJlunr tools should not be used.
(c)l,i,h"'l""""'/•'·"'"•l'IITTTmjTT:7n'r:pr,r.-,• :: •:: • =/_;i-;r,11 1T -;· jlf:T.. ,-,,--••· :-,-,1~-;-·-------------]

5 The wooden pieces should not be fed tc the sawing machines las;er
ttian the cutting speed of the machine. \ ,I , , ·,I , " , I, , , Z'-LuJ., u i, al ,u, l ,_ .,_I u, d., "J
6 Before starting cu:trng, a!low the saw to at1ain the lull speed. ,I
l"'lr>, }',

7 While working on wood lathes. rhe Job should be properly held

between the centres
8. D.o not try ro operate the machrne or tools withou.thaving. proper
knowledge. (c) Contraction Scafe: It,s c1lso a rtJIL., lV(l<s sc3le used 101 rnc1k111g
pa:tcrns Casting allownrces are c1d:Jcr1 to !h1!>scale
1.11 CARPENTARY TOOLS
(d) Inch Tnµe: II is made U[) ol a fl,:;xcble thin steel strip. It i:.-lulded
The efficiency oi the workman depends upon the tools used en the
Around ;i centre pifl <1ltached with a small h;:indle ll , g,aduated
workshop. Good quali1y tools always make the work easy. In thecarpenra,y

< - -
shop the tools are classified as under:
- < '- z -:-,

((1 )
(r) Measuring too!s (ii) Marking Tools
(i1:l Cutting Tools 11v) Planning Tools
(v/ Drilling and Boring Tools (vi) Holding Devices
(vii) Stril-;rng Tools (v11i) Sharpening tools

1.12 MEASURING TOOLS

(a) Four Fold box wood rule: It Is yenerally 2 feet long and Is foldr:d
trcm rhree places. It is marked with inch and millrmerre scale. Tile
'-..·-..... /

- h.- 1
i11.-l1es are further d1v1ded Inro 8 and 16 parts, whereas theccnt,meire
ar,=, Sl:b d1v11.fod 1r1lo m1/li1nc1res 11 1s used for marking Andmeasuring

Fig 1 10 l'lCh Tape

1.-.. t...a'c; 1. 13 MARKING rooLs

/.),i: ""'l)C!: S :)k, / .,,,./ I .,/ •

. tt'
(a) Pencil: Lead pencil 1s gPnr:rally use_rl tu,· rndrkcng purpr,c-,, s
/ / -1/'1
/ I,.:. .:..:::..=::)::.;::==:..:..:z· -,,.- - (b) Scriber: Scriber has a sl1ar"p C'Jn,,::al ec:·Je 11sed tGman-. Gr, >'•:c:r,
haru suricices The fron: edge ,s t1ardenP.d so as lo Ie:e·s1wa2..-,nc:
.,),/._;:?".::,)
t .:) ./.. I - ·---• • ..J -::-,- ,,'
\ / ::::-- -. -
r· . . . --- --- ---L. .'"-- .
 of carbon steel It i used !or rne.7';ur,ng arid
:. .-' iecir
Ir :, -r1r1rk11,:d:1-,, points and lines on the wooden stuc-1<t) in,,_.•,r0:: - s,119
m<t
de
up
-
 ----- {,.., :..•'9 .;

-- -..-· i i
i "- , ;
•
\)·
111 Oc.,vcJ;
1,1.(ll(• ,1,,11c,,r.
·.hri.•,11
1 I· r,11,,11
bl:,rJ,:,cant,,,
11, 11,,,,,,,,,,,. ;ftlfs.. ,,,,,,,,,., b,-•·J111:,r:JI.Jlo
•11,11, :1r,
rr,t,,11-rJ tf:(J w,11, C ,,
1<"••.pr-c.1 ,,, l,:,,.,Jf,, It ,. IJ'1·<1 t,,r '""'"'ng 11,111011•, ;in, ,,.-,
1
'ftjf-l't!;,{/
,";

<-

\I C
ltl§
.; ;-
-,

_,,-• l'"i 1 1: M .. :1011 Gauge C

li r."
1
' M<:>rfisE G.11..:ge: tr• uselJ lo araw rwopara/I,.,/ /11,es ,,._
/'.·.u !c n•.;r;., ',; g.:;uoe t.'XCEpt ,r has two Shi!10 f'<1,JP<, 1·.- •r 1r1g r<; l l
'f4
.....:; S'!:<:'-r.::t J· ;usr.;t!e o, 1,,. a

Ont- !1xcd

Fig I 15 Bevel

(g) Compass/dividers : These ::ire·,,s1:,u lor d1v1d1ng equal r,rnt,.,, or

,
i,;l
parts and for drawing arcs and Clfcles Ir con:,1,ts of 1-:,o 1,-9,,··••ih
F,g 1.13 M,;rlisc G.:iugt' a spr,ng on !he lop of the leqf, A screw Is ill o aaa.:n,•\.l ar illP
ce111re of legs for ad1usImen1 4w" ::s-::
1,., Squ.:ue. I;,s us;:,a to dral\, lrnes at 11gh1 angle p.;1
t1:,.1or
•
• •...·. . :r:;..-,.r.,·,.:;t:,;.1ro;tf,.. PlanecJ surface It 1s·m.::ic11: ur
_
":., srae10l

I "!-- -
r I ,l I" ·Z
• -,
'5 - '.

C- C-_::-·
Fig I 16 Oivioe, _ , .;;
;-;,.:!';.
,, 1.14 CU1TING TOOLS: _,
-
;/i1l.,:r·-·-
,= · Sc1w A.indsaw,.,
Saw: clliust-:1
" ,11,.> ll'>t.'I.J .is cuwng lOlll,, •n c,vp,'nl.lry sll0p
111\11!1luctn lt>ol m:i,1t.• up of tll:,, t,t•••t,1tr.1ch'-'<l
•
w,111 ti WOOdon l1,111dlt.•,, . i,·c.:>th ,II(· 910.,nda,,,J 'sh,1•p.-11r.i kl ,h•11e\
C. ? 1
,.,..
f.f1111l)lh <'llllllHj ( 111,,,,.,,, '\C1•;•; "' <,,II\ ,1 1

.
 (i) Air Sa\·, 11 ,s 11.inu saw from 30 cr11 to 1: ,.,1, , >11<:,1 tv111;,,:111,'.J
c:" IC o,c ·1·,•J '1,ilf eP.tr. per cm 11 sf101:lc.J .r: 1.. • ,1::,-d :1 ll·1111J
\ ......._.........,, ...' ""--...,, S,:,. l,1JI .i r;µ Sd1•; 01111 Culling uf :h0 ,,(•(,; , •., ,. ,,111!.g 11i..
...,, ......,........ ....................... ,, ......_..... ...
gr.:w1s. 11t:Mly ll1s i:nllr length of the saw r,I;",(' 1·. ,,. ,-n In:cut1ir1u
Cutl1119 t,:,c," p!dt-<' , '.lie forwilrdtrok') r,,,, : ,10 ·.:,1f.,. 1'., 11J,- 11
(ii) Tenon Saw: Ii cl 1ve:s its name from the tenor, forrn c,1JP•nl 11 1s

·· -1/4
Rip S;;w ;i 111111 $,.,w rcing1ng from 20 cm. to 40 en, 1r, 1<,ngtli and ,:.;
suppo:te:d b·1 b;-i,;._ o! wought iron or br?.s r,e·v e 11 Is al:..t, c;-'.lpc!

--"--
:i txu;k ,,...,. 11 ,:1,11tt11ns ;ibout 4 teeth to ;j cri1 !1 ,5 U',Pd r•ffnt111ly
----------- for ,ho:i cuts suc:l1 8S for tenons So thP b1 r;e 1s r,r,)J1dvcl ,qth
3 re;n!orc.1ng str:p or back at the too sn :t1?i: I !:,Je ,.., p1ev n1.-,d
frorn bending during opr,rat,on
81adC'
1

"-.,,-J{•, w--- . - -.~~•-J

(iii) Coping Savi: It rs used for cutting qlJic?.- o• sri.ir:, ~u1·1es e:1ther
internal or extern.=;I F,y cutting !lie rntern:il suil;ice first-drilling 1s
Tenon S.;w done and 1he1 the Stlw biade 1s inserted :r 11,e ;1r.1..-. for cuitrng
!t co,1sis:s of approxrmRtely iO teeth per c-r,

(iv) Compass Saw: It IS a short narr&:v sa-.v. \a,ier•:,:;; ;owarcls the

point, ust cJ for cui:ing sweeps and largi:: rntt-rror curves b,· hand,
some:1mco. termeci as a table saw

(v) Keyhole Saw or Pad Saw: It 1s used for cu1i:ng thick internal
curves wt1ern it is impossible to U$E' other saws

(vi) Cross-Cut Saw: It is a saw provided with tv.-o h,rndlcs one at

1Jach en<i Lb=d for cutting heavy iirnber oc.ross the gra,ns

(vii) Buw Sav, In consists of a woot.len frame. a bar, a string. leverand

two handles It i, used-.to produce curved surhccs \·:1th o_u:r k turns
Keyhole Saw The b!ad.: is tightened with· the heip ot st,ing and lever

Setting of Saw teeth: The tee:h "f snwn1e b•3nd in C>ppos11e direc
tion ii!tPn, atively It is known as saw tee:\t, setting It 1s made to form
;i clear:illce between two -cutting edges so lh.:.t t!1e Sdw ma,, work
w1tl,ct1t any 1e .11ic1ion

Cross cut Saw (2) Chiesels: l lwre are three types of ch,2sr::i::: com:·,only used in
C:-i.;pentary shop

(i) ·Firmer Chiesel: It is a general purpose• sll:-:::sel us:?d to finish

insiue g100v1:s It has v2rious sizes o! : ·,:!ing edgt: dt:pend1no:,

·. -------,-·fI
upon !he work 10 be done. Width varies tron1 5 mm :o 35 mm
Thecrossseci1on of the blade is rectangular rn sh2 'e thewide,
portion of the 1ecte111y1e shows llH: w,dtt, 21'1d th, smalle, "j
th ethickness

lU1 --= --=-= - =--wic_--_-_ J

..
 , •• , ,,.,, • •r• ,. 1,1r1rr 1 h1 ,"I..::01 sJ1n.' ,:, n,..,,
1._"'' ,:, \.·ljt1
'1t•,lV} l'l,•1·.-:-,

Firmer Chiescl
(a) Wooden J;ick Piiln"

(b) Iron Jack Plane: T111s plane ,s used t()r br-11,,, lir11::,h If •s m;i ,.
ol c.:ist Iron w1tl, a wooden han<:tle M tt1c bach. and cs wooden
knob .11 I;1e lro111.- ;,o
so 30·
that- 11 can b llcld by bot11 lt1(• hands
d11ri119 operrt!1011 f/11s rlane have a r,g,cJ drtr! <:trongt:•, body• 111
compc.111s1on lo woouen Jack Piorw bul 11 Is costlier

Mortise Chiesel

G:iuge Chiesel
f-iot101n
Fig 1 1'8 Wood Chlesels
(b) Iron Jack Pi;ine
(itil Gauge Ch1esel: It I!, used IO fin,sh curved holes Gt1ugc Chlt'Sr>/
;.,r.:: c· tv., • hi.JP!> i c•• inside and outs1uc (c) Trying Plnne: ThL- length of !his plane ,,. _;c- J,J lr'•J '•, •k
, 1
lik e Jack plane II 1s used alter suri.:icc Is ;:ilrc.1 I/ "'·•=•··d
(c) Adz: 11 ,. ,l "1r:J 100! ust'd to 1ai(0 very 11111.;I,. <.,ul:, Houyh V'vulk 1s bv a Iron J;ick r'l;inp to, making ,t true
e•, :ra!i-,· :10·•._ ,11th ad/ II hci, n f,.-;wy bo-iv with a lo11q wo•Kl1 n
li;,,••1le I: c111·,r,q 'dg<,: '""· il,,rpem=·d whE"n required It ,;a,, dlso
r·t •,!;eJ .1-. srri ·'l-J 1-101

1_•5 PLANING TOOLS

1 Planes: Pl.arr;·,,; IO.:>tt. are UStd lo, SIIIOlllli, r.ing PLirl)OSt:fi, pl,!·
r,,,,.,,.,,ope, -;1z,, Jr,cf tor le 1r--11,g ..:u,ved wood,.:n strips Many rype!:
c,: r-1;,,,,.. are useo in nup r,1,:r, :-.h,1p

Wooden Jact,: Plane: 11!> h-·nqrh 1s 2'J 30·· ;:ind u uo 101

grnera, r,urpok Ir r;r,n•..sl ol & wooden hody called as:.wi,;t,._
t ,Hon• fa 1& Coll •; ,lo:; sole: Jt1e bla,,t- 1s l11ced ,n lht> flt,i.:i..
,.. ar, ,,rigl,• 4 wilt; ritr•,,, ";t lo • ul1• a,,t.J nt«1IE.:rinl ot the lllo:1cJfJ
111g1. rnrt.C'n $It-el fr,t· 01!•1•·'·"'''' of 11,<· tJ1,1du from rh-, •'"'''
till Rc:b:,tr, Pl,1ne: 111,:- plarn· •!> u ,. 0 prt ,, l't' 111. •·1h1, \,: 1
 • 1·.r.1

1 Hand drrll: H:ir,d dr,!I co,,:,,:;;:, •,f " p,rnuP urill chuck. cr
1,Jndle ;in<i INO bevel QE,,,rs B<:v ,, g._..'1rS are fitt,a<l c,n the bot.ly
, r,1::1<,1n cnuck and rot,d1c--n r,J sp,,,,!::-, ,s iveri through
ge,irs th!! nP.lp 0f crnnk Th<> hand!e , prr;s<.,-;(J .11t !h°'" v,00den
r· cc ,

fi
ro•,ir,rig the dr,11 Thus hole is forme,,

j H.>••:JI,:-, -;, -:,J

1
i·r
;

J ,,•••

§,
I••· ..

_:0,@/0-
,•
(d/ Rebate .Plane
it.!. Plough Plane: Th,s plane is used for making grooves al rhe
sa,;n, i1me there 1s also another plane r::al1ed hollow piane rhat
is ::self for oroducing the curved grooves· ·
-=- <:1£<::d'',

(I) Spoke Shave: It ,s shown in the iigure. 1he blade of the spoke

s h' " v E <time becan

- :-an11 ad1usted 1.e , bladelaterally
be adiusted can be also
raised
byor
the help of
lh <
_ c-;;r.ic
11

loweredat
'..Ji:-, tn c-.1s12 ofrnoorhing a concane inside surfaces a spoke
st1..,,r: h,iv•ng round bottom 1s used.
Fig. 1.21 Hand Drill
813<!,c-----..... Han<.l!e
2. Ratchet Brace: It cons,s1s of a crank. a l1eaa. a ra1ch2,-::in

.c,fff?f_ ,-
1
8 - chuck,for holding the drill Any type oi dn/1 or dr;II b•: c.z:n be
/. ··,·; ,n thechuch. The he2d,s pressed w,tn cne h2.r.1J ancl tr•f' c:rar,
. '-· ... / rotated by rh second hand.
( f/Spok e Shave
F19 I. 19 Wood Planes

/"'\l--R-.asp·:r ,s ·'''··--,, . , ,•,nas a r,1sp fife. Ir ,s a l1111sn1n,1 tuol used

i,_., rn:o,t- lllr_•.-.·,·,01• -:;,:_ '-'": srnooth. remove sharp t>dge. hn1sh1nq
111 fillets
:irnl "?.-r '"'-=- 11
<,: .,:11,.J. ·-:,., S/J.irp <:111t1ng teeth :ire provided on 11s
!:1,r:.. .- •· :o, :tt,:; r,1,r1,1,.-:. nus 1,,.,. •s us_ed in woo<J-work only

F:g I 20 Rasp
J 16 om, LING AND ROHING TOOLS

11 1 ,·..1 ,v ,,,1;.....; l,'-.-•l'......

1
-'"''H ·• •• · ::•,.,, ! U:rn1; 1:•r/ t,orir.g lool : 1,e
 3. Gimlot drili: Gimlet drill 1s a very simple
typ,· nf drilling fool. It consists c,f two parts. 2 .Bench Hook: It ,s a simple type ol holding 1001 used fo1 supporting
On,· • gimlet and sesond 1s handle Gimlet the wood wl1.:e working on it It is used on wnrk bench Sawing, and
,. ..,.1'1e from a long tw,stc j bar It has a planning are most'! done on it.
:.u cw type starting edge While drilling it is
,otat€'d and pressed on to the wooden
workpiece with the help of the handle

Fig. 1.25 Bench Hook

3. Clamping Vice: Clamping vice 1s usec.J lor sawrng 1oinrng or cutting

more than one strip of wood at the S.:lme time It's one end,s
clamped to the table while the other 1s kept moveable Vice 1s made
1. HOLDING TOOLS up of cast steel and 1aws are lined w1!11 hard wood

1. Work Bench: It is .:i table which is made of

Sal or Sheasour wood. Size of the table rs
6' x 3' Two lo four carpenter's vice are fixed
at the four corners of the table. This table
acts as a base for all the carpentry or wood' Fig. 1.23 Gimlet Oriti
working operations

Fig. 1.26 Clamping Vice

4. C-Clamp: C-clamp 1s a simple type of clamping device It 1s generally

used to paste one wood on the other or for alignment purposes.

Body
Fig 1.27 C-C.lamp

1. 18 STRIKING TOOLS
Striking tools are used to force :he r,atls or chiesels into the wood
Main ,_,,. ,nc '"')IS are a unde•
1,,:,.:. ;Ldn Hon:n1c--1
1

,:1 1,."1 Hc.,rnmt:,;

 •• t r,1....1., ,1 1'

,1•- 11,, "..,, ,.111 I, " pt,, ,t llll' """ ;indv,111·

' 'n,:,.:. •·L'Jll t"lan1n1c1: 11 11,\/:- .t c,ist st,:,,•I t,,,\fv .inu ,1 v.onde11
: 1\,1111''· 111 11.ttl ,ill' '-IHo,Vll Ill 1111• l,(l\/lt
hH,h1h• P.ody h:is tw1.1 t1-1:t t.1c ,Hld PP n In ,1<).:,.:- 1•e.,n l·,1mmc1.
·• "' p,','ln 1:s m tt1e torm ,,t
.1 11,111ow-n1u11d 0op,' 1,dg,' pl,1t:,,d ;11 11ght

·'"l:1,· le> th,, ;1,is of the h.111,ilc

Fig. 1.28 Cross Pean H:immer

2. Claw Hammer: tt is used for st11k111g as weil as for pulling the nails
horn tht wood The material of the wood is case steel. O11e end is
made st11i,.ing and the second is claw face. Its weight varies trom
0.25 kg to O 75 1-.g
3. Mallet: 11 1s used to strike the ch1esels whicl1 have wooden handles.
11 rs made 1p ot a hard wood and is round 01 rcctangul.-11 in shape.
Cla,., Fae

Mre-t ._·

-- LJ.J-
4. 3_ Bolls and Nuts: Bolts

I -- ----,- J.:.. -·
wooden
Tliesc are :,.pec1!1cd by
on· it Bolt 13 1nse1t d 111
k:'---./" placing a washer 1n,t. ;..nov.ii
d I o1n1nw v,i11ou ,,,, ,><..!1·11,,.:rt 3rt
.. . i
4. Glues: l he pastesuse o1 I . w1tti Y' ,,. S1 rt,}(.- tn !>.;ddC:C
as glues A pe1nianent 1u1nt ,s t01n1t 1 m ·d·· \.·, t•11:'=!, G!uc art

.
F19. 1.29 Claw Hammer Fig. 1.30 Mallet ar« 'nade ut, of ;r,y. c;Htlo" s,eeJ t:-1::r c,• c, r- Jt, rt·H..-> ,.. :1,,... ,1vr.il
'1" ·"
1. 1S SHARPENING TOOL
lf:, · 1••11•,., !,,t :,•,, ,c ;,, .. 11 H·t- .,.,·.·,.,-:· i : .. ,1• .. ,;,
1. Water Stone: It rs a rectangular prece of stone generally 1--ept. in
111woouon base II is used to re-sharpen lhe chiesels. hits. plane blades
urio ot•1t11 tooth While sharpening water is sprinkled on the stone

1.20 1-UXILIARY MATERIALS USED IN CARPENTARY

Na,;c; Scrt-w . holts, glues, paints and varnist,1:s art tr,e ma111 auxiliary
ma1c-11a• usE-d lf1 wood won, A Imel on,crrp:ior, ol thesr 1s g1vP11 b1:1low:
Ni1,ls. Nail:. ,Ht: u!-t-0 lor fastening d1lf1:::1tf\l v,L·0den rrnrts 11,f'&l"
 1
and lace to lacr 101nts cz.n De e:.:.: 'f ·•, ,,-iuf'S ar-3 2·1111,al • ;,',
, i·ot The common v u.-•. ci ,.
used cold as \ e as ' I mill,. glue !11 ,,<J :!lk,:nen g!t;C ,:(le' 11
glue:, resin glue, vegetable g ue, .
contact cement
5. Paint: l'a1nt is a sem1-l•qu1d paste- p,'=p.irF,1r- ,n":r g;: D s
,:,
vehicle and a pigment Or1E:r!> 3n1i liller ;i·, .'ll G ., , f'
r obtai;, good quality
Functions of paint:
(I) Tc p10IPCl lht' surta,·e trom moi,fur(· "''c
30

' w
,
w -'.
-
t; ;
e r1"
I
.

i
i
i
 2 2. S CLASSIFIC.Al ION OF Mf T/1.L
Mc:.;!$ are classified,r-10 tv,n c;;il•'\;;Oll(·S
(;:;) Ferrou:o= Mt=tzls: , r l.':ild l•'f 1 (;;; '. i:cJ: H1gli r''--l c: ':,,,..,;
(b) Non-Ferrous Met::ils c- [! , Copp<·: llra alurninium
FITTING SHOP
tlll

Ferrous Metals
In ferrous nietals ti,<: p,·,cen,a (' of 1ror, i vl•ry h!gl, l h•.:sc- are
commonly used for enginec11ng p•Hpo .:, Sor:1c- olt..-r ma1Pr1<1's likP
2. TAODUCl carbon, su!p!ldl nicl,.p! c,c are 2.lu, m!·,00 1nlo !c-rro•.1 rJ1u1;ils to c:I,ang
ION
LFill,ng work is a very important worl-. in engneering. In iitting shop the pio1-1e:-rt:,.:; f e11ou. :;;·:r;ilr, <1r<:: rn:-;gnet..; ;11 natu:," ar,d h;::,vc rr,orr
unwar.tEd material is rernc ,ed w,th the help of hand tools 11 is dor ,e for hardnesf cin!.. terio-1.-=. :n£>!ct1c:.. ar discussed 2.'- u11(1Pr
ma,ing. repair and m;:inufac:uring purposes The person working in !itllng 1. S1€-e:: StE-r-i i!> ,; m1xlurr o1 rrcn and c.:;rt:,c,-, 11 i VPI\ w,dely
shop is called fit1er. A. fitier s-hou!d have the complete knowidge of tr.e 1001s
us,;.,.i in en;:;1nc•c;ing for ci1!1erpnf•JrJJ.'.> ,,
used in the shop. Commoniy used tools a,e hacksaw. files. chiesels. e'y
Table Showing tlH? <::fassificatron of StE!el i!S Given Below:
2.2 PHYSICAL PROPERTIES OF METALS
As d1tteren: types of metals are used in fitting shop, therefore it is Table 2.1
necessarr !01 the students to have some knowledge about !he physical --------·-·-
properties oi metals. ! Steecf ! Carbon Con1.
:>nl
Usc-s

1. Lustre: Lustre_is theability of a meta! surface to refiect light ;ays.· ! Go11,_ r.,: eng1nr,r:1n<;;
2. Colour: Colour is the property of a metal to show a specific surface
appearance. !t depends upon tr-,e composition oi the metal.
I Low c,,!t,or. Steel 0.08 - I
1-------· ----'---------------------···-'
0.2:i':•v 11:rro!'r:S e.g , br 1n9
l -= •11s. c!n£lf? ...

3. Density: Density is defmed as the mass per unit volume of tne I i 'I, '·"°'I:, ct1..:.

m,=!dl It is measured i11 Kg/cm!_ Mediurr, Carb0r. Steel j 0 2:-

I
4. Melting Point : the temµerature ai which a me1a! i!ows like c1 fluic
is knov.'n as melting point Me,t!i1Q µo;nt ct 110n is 1539"C. High Carbor1 StePI •:•1,._t?! - 0-es
; :"Jl";.,.t ,-., (-1( ..
5 Boiling Point : The ternperaturf: at which a metal starts boii!na is
.r,,.v,n as boiling pc,ir,t c,! th€ m<:?tol. - Tool St1=cl
6. Plc!::1icity: Sy 1n:s property 01 !ilf• metai ii car. be convf;rteo into
rr c;vired snape ?,;d s;ze br cor. mercial u <"E!l :·r by applicat,on of 2. Ailey steel: Al:oy s1e.e1 1s made by C-):'"1bff:!n , so:-,1(' per\,·""':df-:
hec'!I O! pre:ssurc• or both of·additional e1er>1E-nt<:c ;mo plain ;:-;:;,:::,or. s1e1:-,s -.,. ...- m21;;:r::-;t to
1. Elasticity: It rs lh property ol the- metal 'v wt,:ch 11 car, re:oisl be mixed depends upon the propcnies :',-::o..;irc-ci ir, r:I:,,, <:eel
peril"lanent deformation u1 ne.-, sr.ape l:!rio s;ze d e to external pressure. Gf-nerally strength, h:,.roness, <<"-sistance to c,~rics;on a·, \! ,e
ff. Stiffness: Due lo lh1 property rnateria' res1s-ts- d )flr>ct,on due lo nv.111 desirable p1op&rt•e N1cke1, F-hosp11n!1.., ;-1,,:c,:- · h;,-::,
e-xt• rnal loao. n-,, irn. Molebden..m1 e>C . arE added tu ni2.kc a:I<'\ stt:f:''-
9. Malleability: It is the property b)' wh1cr-, metal c.;•1 be ':!lo11gated ir· 3 C;i!:-t Iron: The 110n conta1r.iC1g carbon ,.1c,1c- : :- :.', • is:-:,,·.-.-:,
all directions by the ai:,piicanon of r>·temal orcc;s-ure ouE lo this ,,, Casi iron I\ 1s 2. h rd anc bn\fit· 111,;!er1;a, :· c,·•-: \c:-r<1,1\ L,sed
prC>pP.rty metal can be convertea 1111L, hen fo, r11;:f-1ng machine bed'.3, ?.'ld h1::. \'') ,;r•c, ,. 11 .. !-(1 n,0 -1
1 !> Tou llness: Du to thrs orop.:-r:r 111f':a! can witt-i::;1;.:nd bP:idinc v.,thnui .::=
fort,.-:- - <if :_we, types

11 Ouc;t. ity: Br lhrc; pr.>.:·••lt\ ITI,:!lc,I r;;;ri t•€ Ofo\'.I. ;! ,.,E':(•":

V,."I . ,, j,-.1l11r:'"-
G: 'y· .:;:.s1 iron
 2 2.:3 CLASSIFIC:ATION OF Ml TALS
MctGI - are class1f1ed 1n10 tvm caln£;011,,s
(;:;) Ferrou Met;;ls: ,. r IA:ld Tt!fl S:-,r: fl( I\ Hrgl, !-fl•-'('., l•_-(,;

(t1) Non-Ferrous Mctnl!". <· g , Copp<-1. Bies . 2luininiwn 1:11

FITTING SHOP Ferrous Metals
In ferrou noftals ll,L pr·;c,.:-iri,ag of ,ro,, ,
vt,1y h,gt, Ttv.•:.'· ;:;r
commonly used f,,r c-nginl'crir,g r 111Jns,; . come: otr,H rnalr-r1B!s fil<P
I
carbon, !';Ulf)!li.JI, nickP! eic. are ;:::I: n m• Gc into 1l'r10•.;s r101it:3!s,., ' ,angec
2. TRODUCl ION the p1oµe:rtI.-s r e11ou•. r;,,;t;:I , ari:: rn;;i:Jn'.?t;r; _:11 1:a1u,,- a1,d r, vc- rr.orr
L F1tt;ng work is a very important worls in enQnE:ering. In fitt1no shop hardness SGifl!.) ferH..1d: tn\...1?.11.:; ar t!iSCUSS(:-d !:: uri,j\;r
um"'.aritE-d material is remc ,ec w;th the help o1 h nd tools It is d;ne fo:
ma,1119. repair and m,mufaciuring purposes. The person worki11g in fitting 1. Siee!: Str,r-l 1s ;, r:11xiurr ot iron ar·,d cart,c,r, It i!'- VE-f\ w,dely
she '. called litter. A finH-should have the compleie knowidge of tr.£: ·ools us,-,,,:J in en,Jincerrng for ci1!fer0nt !)'J,p-::,!',f>S
usea in the shop. Ccmmoniy used tools are hacksaw. files. chiesel . eo/
Table Showing tl1e Classification of Ste::el i Given Below.
2.2 PHYSICAL PROPERTIES OF METALS Table 2.1
As dit:ereni types of metals are used in fitting shop, therefore it is - -- I.
!L----------- - -·---------------·-

nece-ss r}' !or the st!.Jdents to have some lsr.owledge about !he physical
propert;es of metals.
Stee,I c_a_rt:_o_n_Com nt
Gon.:•r.:;: engin r:ins
Us1cs
l
l Low C,,,t,cn Slee! I!
1. Lustre; Lustre_is theability of c: metal sur!ace to refiect light ;ays.• pL:r00c:r:!:c e.g., f0:;.:i1n9
! ( :;.::r g. 2ngl0 ...
2. Coiour: Colour is the property of e metal to show a specific surface
ar:,pea!ance. lt depends upon the composition oi the metal.
. ~t. ... ..,t 1:: etc.

3. Density: Denstty is defined as the mass pe: unit volurne ot the 0 2:- .:r•·,-, 1
" s.haf: - r- .
metal. It is measured iri Kg/cm:'
Mediurr, Carbc>n Ste.el i ! f"'

4. MEiting Point : the temperature ai which a me1a1 i!ows like O flu1c

i!:: kr;ov:r. as melting poir.i Meitmg µomi ct iron is, 539°c.
H,gh Ca1bon Steel
5. Bolling Point : l he tempe1aturE: at which a r:1etal star!s· boil!ng is
.r,,.v,r, as bo;ling poi,-,: c,: th€ rn':!lo!
Tocl Si'?cl
6. Plasticity: 6-;- this prope•1y or 1i•1,· metai it car. be convE:rtbo into
12c;uired :s:--iape c=,:-,d s.;ze br cor."1mt:,cial u .-, eiti;_E·J by c1ppl1cat,on of 2. y steel: P.f!oy 1e.eI 1_s n1aiiE t:-y c,):"'l:1;,,::', s.J:-: ;.= pert,·-,•·_:!(,
he;it C! pre:ssu:t- or both of·additior.al e1erner.\5 ,mo pl2.:n ,-a,::,o•-. s1e1;, :re m2 ''"r:·:: le
7. El2sticity: 1: I!!- lht: prcperty : the metal b}' wh:ch II car, 1e51st be mixed depends upon the prcpert1,_,5 :1,LJ..ii1c-ci if, r1 Ii, , c:c-s i
pt=-r•r1anent de ormatron In ne,·. sr,2pe <lna s;ze due to external pressure. GFrierally strength, h::2roness. fi'sistance to c-cr,cs,nr, c, ,t.:
8 Stifiness: Due ic th1 property rna!erial resist d fl?cl1on due to :: n,.-.in desirable prop1;;rt•e Nick.el, F-hosr,hnh.,
E-xt•-rnal loaa. -:-,,,,,:2:- . ·_
h;.; rrn im Molebdenum ere . arE added Iv m,•ke-:i•:c s1.,e:,
9. Malleability 11 is thf: property b)' which metal can be Plorrgated if'
all directions by the a r.,1icat1on nl P>·ternai nrcc;$urP duG to this 3 Ca$! hon: Tne iron containing carbon ,01c,rc- :
can DE=- conve-•tec, 1111<., '1et•l!·i
properly metal · :,. Ca , tron It 1s a hard and bnt1.lt:· 1110!e.;;.:;1 ,·
19 Tou nncss: Due to this orOPf:-'l>-' mf-:at can w•l'1$1::r1d bP:idinc· v.olhnui to, m;:1,.ing machine beds. F.'ld ht'.:.\'\ ._,H"'-
fo•••• .,- - 1 .. I :we, types

11 Duer- i )'- By thit1; P••H·••H m r..,1 r.ar. r.,i; ora11., ;, 1,,,:. !v•r. ~' .,.,•._......
v,·.·1 •· ,;,,da:,,..-
 ,Ill

V./0ll[;! t lrc11:•::.""':!!,: 1,1..,1, ,::, ul111u::,1 µu11; 1101, L..f11 ,rr11ng ::' !:J'i
,,1iron Tl1e percentage of carbon is le,\,, It is ductiie ;:ind soft Dtff-::re-nt types· of v1u,s are as !ollow
1
It c,111 be rolled into f 1ercts or drawn into !0n9 1v1rf:s Iron 11ve1s
,1rc made of Wl('\ugh1 iron (a) Bench Vice: 11 is a c.;ornrnon 1001 11_ r,o :,·r holding job's It
c0nsists c' n c;ist iron body ;ind <"•Sl 1r<.;r, i:11•1s 1wo 1,,w p,,tes
- High Speed Steels: High speed sl1:;els c.:.re use,j for making
are Litcd on both the jaw Jaw plate!.. ,,•o made u1. of high
cutting toc,ls workrng at high speeds. Theyare ablE toretuin the
carhon steel and are wear resistant
hardness,!l high temperatures. The composrt1on ol li1g'1speed
steel 1s is " tu,.,gsten. 4% Chromi•Jm, 10,c Vanad1urn and O Jaw Plaie
7%
C?.rbon Body Slid,ng Jaw

6. Spring Steel: It 1s used for making spring::.or blodes It con

t;,1ns O 5-C 6°·c carbon

Non-Ferrous Metals

l hemfetals wh:ch contain negligible or no quantity of iron are known Handle

as non-ferrous metals Copper, aluminium, brass. bronze. 1111. lead are
the commoJJ e,cirnpl_es of non-ferrous metals.
Fig. 2.1 Bench Vice
1. Copper: It 1s widely used in engineering industry Copper is One jaw is fixed to the body and the second slid_es on a
ve··r sett ductile having reddish brown colour. I: has t1ioh elec
trrcal and tt1ermal conductivity. It is commonly used !or- electri square threaded screw with the help of a h_andle. The Jaws
calpurposes. Sulphur. Nickel. Tin and Cadmium a,l- added to it are opened upto required length, job is placed in the two Jaws
to change 1he properties of copper.
and is fu11y tightened with handle. It is fixed at the fo r comers
2. Brass: Bras!:. 1s an alloy of c pper and zinc.There 1s no efiect of th:,)itters's working b_ench_, and it is upto the. waist
ofcorros,or. on brass It can be easily soldered this is also a he:ght.
soi• and duct:le material.
(b)-1:eg Vice: It is made of mild steel and the Jaws are of cas1
3 . Bronze: 1; rs c:n alloy of Tin and Copper Bronze have a yood \. / steel, it is stronger than the parallel Jaw bench vice and used
• e:s,si n<:1:;10 atfYlosphenc corrosion and have no sttect o1 water tor heavy work It is used when the· ope,ation such as chipping
or.•'. :, . c. wear resistant material or hammering is to be performed. ----- Flange Nut
It is fixed on the Bench 01 grouted ,-- Jaw::,
d Gur,r, '°tal: G,.m metal 1 an affoy of copper Tin and zinc Tin
i'.;,--3,.,foundation.. .,
i6 1(,• . ariu Z1rJc ,s 2% 1n 11 It is used tor makmg castings
(c,Yi,and Vice: Hand vice 1s used lo
5. Aluminium: I! • a soft materral with a
while colour. It ,s very
,_,.,/ gnp very small objects. These are
hgn1 ar,c n v go-:>d elt:!C1rtcal and tl"1ermal conduct1v11y Alu
made in ditterent shapes and sizes
m,r,,urr. • u,;i:=-o 10, elcG!nc ano decorative worl,.
A comnioniy used hand vice is

'J .4 TOOLS USED IN FITTING SHOP shown in the figure. It consists of Spnilg
the two steel legs hingeo together
FitUng shop tools are classified as under at the bottom. A Spring is provided
between two legs The jaws may be
Clarnpiri9 Tool.!- ? Me:c:1&uring and Marking Tools
adiµsted troma flan;;e nut. Fig 2.2 Hand Vice
3 ClrtttttQ Tr. •:- 4 Stnll.tng ·ro-JIS
S Or:flir,g k,JI<, c Tr,1t•ad1ng Tools · (d) -Pin Vice: Pin vice is used to hold wire or s11ocdl j;amete, rods
· It is also used for grinding smali drills It consists ot ;i small
c :- CLAMPING TOvL

e/Nfflr--.J
ct,-;cJ.. fTlrldE up of tool steel and a m1!d slel:I 11anr•le

i,.<, ct.r,·••n,., !,,;!: 1:,,11 .;rt: USt:1d ,,, l:111nq stv.>:. ?r,. c,,:,,- v1...:E- r.a
1
.J •·· c··, . •f ;,;t, firml\ C]r,••nc \o8HO.i !:ttr, :- ••1il•••11-,
 I 11 f 11 (; , 1;( )I

Ml\f./tJ//,' 711r>11\f,._ t',,ft r:, !

· Cc) f'iµ,: Vic.,. it , usea to tiold p,pes. It consists uf a vert,cal screw

i c:.,cJ. S::.rc. 1
w,th square threads A handle is attached on 111e top of the screw
1

A moveable jaw is fixed on the lower end of ti 1<' sc,ew 11 grirs

lhe pipe a! tot•• paints The jaws of this , ,ir•" v,c, are V sli<1ped
T/11s vice can b.;; :ixed on the bench 01 ii c.111 be• grout .·d
Handle

1
J
j
,i67 :} .• b
(c)
1! le 2.6 BevGI Pro!E,CIOr

Cornbin2t;0n Ser: It ,-:; a mu!t,-purpose,nstn,r.-,e:nt tr.a: •·.n

used ct n protec,o: ?. /F.ve!, a mitre. a c.c:.!rf q..,«rE. ar a
squt1re
l>E
tr '

-1 Boor

J
• -I (b) Bevel Protector: It <,ons1s1t of a Slee/ dial divided ,nro 3h0
J

a,v,s,.-,r,s J,-,e dial can bf rotalF-d arou1cl the cenb: Tl ,

-l Fig. 2-4 Pipe Vice

1,, t.._,,,,;,
1:n } a• an.- fjr>gl1> UJt, tu m;.ri,,.,: ('' n t;&f,J'E'C b, 'l'r(
.,r ,p . •·•.!O•·
,J
."-• ,,!''J"! ed{it (.,nr, tv . l,c•• ,... ,,.,,,....
2.6 MEASURING AND MARKING TOOLS
i (aJ· Try Sqcare: II is used for checking squaren·ess of two sur
faces. II consists ol a blade made up of steel which is attached
to c; base at 90'. The base is r.iade up of cast iwn or steel. Try
square is also used for marking right angles and mcasunng
stra,ghtness ot surfaces !t :s an instrument used to draw straight

.
Imes a! r:ght angies to a true surface.

I
i1
' i
j
!

F19 2 fi lrt SquarE

 the csm:e, Hw rc1.,,d Jct ,s 'l!,1LY,d :1'.L'f nh,1> a•nv;.

' . --
' r4. ·,:.,
• h..!.J=!..l..-1

Fig
7
C..:'mb
Fi9 ; C Ce,,u, - •• 1

Sel
,

(£) S;-:ri I'' anoSurlace Gc1uge -,1!',· , , ·.;: ..,. -.,'-'

(d) Cen .._, ... t'° Ii• ft)• ► t
tre
Squ
;;;e:
;..
CtcP
l'r s
,.;3r
e iS
u,oF?
-j K
!,,j
m'=
c,cn
trC'
vi
l'1•·
roun
d
jobs
1!
co11
ist
c-! a
si
a,gh
t
edg
e
a'ld
•v.r_
.:::::.
. 1-
c."';
.1.,
-,J
out
 ·:.\11,,, 11, 11,,w,c, ;,11,,,_·1,u
I I l I IIH, ;t fl >I'

ll\C.1111\t•\l Ll't .i \'l;l\1 (CJ) Doi Punch; 11 1: 11•.r•d l<,1 r:1;,r 1r,g dollr:d Iv,,:, 11, rr,,rrJ,, up
C..tl b.:.1 !!- l,i!I•·-.:! SUI· n1 h,rJli r;,tl,•,1, · 1,,<.:1or h:'.JI• •.pr•t-rJ i,t0el Ont,.-wJ 1-:.,! ,,rr.,r-n•
lac._. \:l-' J, P ,'I. hC',W\' c1
li,immt·rir,-:; ,, rJ,,nr· rm 1':1 '1v0nd <'nd whdr v1<,r •r-': l,rr;!,, 01
ba a l''1.'\, !,•ti :1 the 1hr n1Jnrh,1uJ, ,,,: 1'. cc,
•,:
b0t:\'fl , f\. t.. · f"'\11
lo.ed "'' lh, l>,t! ;ind
l'Y t•us ··ut tit Crtl'C'I
ca'l i_,._. i. o enec.
onL
:1:..1:co,1, ·.t-ne>,nth,•
oa, 1•1 1h,s way thE
1'lchnat,_.,,, c,,n at a be
• Jariec It ,s i..ept l n Fig 2 11 Oc.r Punch
,m, !-.Jtfacic' p!?.:e du, (h) Centre Punch: I: ,5 like a dol p,,rr.h exa:rt th£: angle of puncr,
·f'lc anv nea u:err.ent 1ng end ,s cio II ,s u5td lo marl\ the centre of the hole be'orr-
p,-!fT'l.1°111\ ti ;5 US•JO
a'.or,;; \\1:n ' blocl.. to
-jraY, :rn s parallt>I to
drill,ng
\--- Pvnctu<'g E:tl,;;,

---- ·n
a sur:ace
(f) Univer al Marking
F,g 2.9 Scr1be1 & Surface Gauge

Surface Guage: 11 consists of a heavy case. a scribe, and 3

,. .. The scriber can t>e ad1usted 10 any pos,toon with the F,g. 2.12 Centre Punch
relp
of screw and nUl It ,s used for marking purposes It ,s used to (i) Surface Plate: Surlacf:! plate is used for testing rne tlalncss
'l aw parallel lines at any desired he,ght wItn respect tnsurlace trueness ol the surfaces. II is made u;> of cast iron or c;raphne
:) :!le Its uppei face Is planed to form a very smooth sunace rt Is
covered with a wooden cover wh11e not In use I,t s used to tesr
a try squarE and this plate ,s useo a5 a ba.s.e for V blocl... sin.
bat etc . and other measuring tns!rurnents during measuremen:
True Su.,ace

S erice,

= -==========--"
N ut
7 I

Stanc
Fig.,.1J Surlace Plate

(j) Angle Plate: It consist,; 01 <:'!st •ron In wh,.:-h l\ 0 nbs o: <nd:ll a•e
standing at right angle I•• t:· c•. otnt?r Holes ,.-., rro\tdC'd t.::r .:-
Sp,nou 1.1,nu,,,. purposes II Is used for ho·u1119 nnO SUPL'.;:t•n.; t! ,
"'"' 1uL'"
Holes to, -. n1p,n;, 0011!>
 ! } V H!ocl-:: :; ; :...i o u t.:G flJ' !'--llflP"'''''£ ?!" •,· c!: :;! r•.;.,L,,,:-4
u,pose- Round job!-=. &ff- genp1elly rl:JC.C er••: .., 11,cr;, \, lllft:'
hneetc. It ,s mad., up o! ca::;t iron 01 steei 11 is u,,ed akmg with
U-clamp lo hold cylindrieal piec<> during measur m,.,nt II holdf
--, l

.-.-_--]'_l _]!
/.5:eY-..,_
J -- • - o - -,,;

Ll['C11; w
the Job in 'V portion.

l
"= c·'~.-'_ ' " _1='

r-
Lj{ .
I I...l'-_ Sl,o,r.p Jaw•
L f-1r,c 1--r,u 1,ne1,'.
NA

1 f!g 17 Verni«::' Ca1•1per

(n) tliicrom1:le1: 11 ts us d tor me2sur!n9 01ar:1ci , or th1cknes o1

ariy job. I, is mort- precision than verr,ier cnll,µer It cons,sts o1
a hock type frame A hard anvil is screwed 0r. one end Or, the
second end a spindle moves to and !01 c21c,,ng anolhcr srnall
Fig. 2.15 V-Block
;;rwil on i,s end [.;y tum,ng 11,e spind:e kriob Jn(e job d,arneter
(f) Steel Rules: These are made up of stoIr.!e;,s steel and are is ;;-:easurad !rcff, th<' sca:e Thf:: slE.evc on thE sp1ndlr is g,ad"·
avaiiabie in many sizes ranging from ½ Ft to 2 l't. l he:oe a,e a:ed Anothe:--b0rrtJI v ·h:c!., iS fir ed or+ o tc.1 s:de: o1 the sleeve
marked i11 inches or millimetres. The edges of streel ruf,,s :<hould i ai;ached ,,.·,th t= E ptnale Tl11! ba;rel : al ,-.. graduated A
be pro!ected from rough handiling. r;;ii:h.:.1 = pr,:i·.-1,j, d 0 lhc side of tn..:. SfJITidlf"-
Centimeter Sc.;Ie 1:-·,,::. · .1Cu1:·n·1 ('"1 m:CrC,!Tii-'iEf 2rC· Z.Vc:-:'itl3t.,I( 1'1 :nc ,:S as
-.vt:n 25 : ;';•!'w·u-tres TfiE !€C::$1 cour.1 oi ti,€: rP•-:rornetre is

I ;
fTI I
10 :2
I I,
,4
I I.........................................._
16 ,s
O1
ge-r::erall·. "-'0 · u1 .(1(1.J1· r;, u, rr,r.i C'H OSri,·,

-- -...... , - · - ,
6
-/
Inch Scale

Fig. 2.16 Steel Aul

(m) Vernier Calliper: Vernier Calliper ,s a p,eci.,icr, im,trumenl used
for measuring lengths and diame!ers 11 can be used lo; meas
uring eX1erna1 and internal d•mensions It consists of a gradu
ared bar o1 rect,mgular section Ir has two ,aws. one is moveble
wrth a smarl vernrer head and n,e o!her is fixed. A line adjus1
men1 nut is also attached tc, the head The d1mens,on is meas
,;red by the Jaws and ,s ·IndIcated on graduated bar Mmimum Fig 2 ;e Microm te•

d•rnl•,is,on that can be e pres;,,;;o on vernier calliper •s know11 a (o) Dial lndicato1: 1-. 100nd gauge ,n wl·uc ,,,.,.·,, rnnvtS o,-, a
lt-aSI count 1 t,e least count nt ver n,pr ,s O 00 i .. or C 02 rn m gradt!Jted s,.;n,c. The n1ov1?men1 1 nHHJ11111rn ·r,,Gugh IInL t..
generally The material of tht: all pan!c 1s stainlc s IE>"'' sp•1nc; lood \J u1u·• e1 I f1t1ea o, j :,.. . · ! ,r'J:1, .:, ..· .-, c:.m;;n,.,,,n,•
p01n1 •!:- p,,,:..,ot11 ,.J'.'""I the lov,-:; t '•:: '1' t', lJ1,1, • --· • tuuclip.! tr-&:
1("1t' ,'Vf,1lc" rn,-r:··•JI.:'- ,.,, I I QPl1t-·;;1 I ... ,. 1,
0
'. ',.,nt'4'r :r,r,P

I • 'i, I.T\• t 1 , ,: -
 '
.:.:.

t•-=adfcr
Z •o-
1-.d,..:Siment
C rng
Dia!
Mam
,..._,.,.. T-""-Pointer

i
Fig. 2.19 Dial Indicator
(p} Dividers: These are made up of steel. Dividers have two legs
I
!
i
haYIIIQ sharp feel. These are hinged al the top. It is used for i
matking arcs. dividing a line or transferring the dime;,sion. Odd

I Leg

II
Legs
i
l
3 Spring callJpe, 4 J&nn; call,p&r e,; odd leg calliper

! f
Fig. 2.21 Callip&r:s

I GAUGES

(ij Depth Gauge: It consists of i;i stainless sieel head and a beam

I
The t")ee:1d slides e:11ong the beam and can be tightened witn the
help of a screw The beam is graduated in rnches or m,llimelres
f"rg. 2.20 Divider
l.f i6 generally used to measure the inside or outside
f( • made 111 different sizes and shapes. II consists
"'9 connected at one end by means of rivets or
a,e made to iust touch the job, then the dimen
with the help of steel rules. There are four Head
I
so

(i;) Fee1er G,HigE:: I\ 1..,_ ,1,..,0 ic- c c: , i:,'- <-!J Ut:'\wec;; two rriating
, . .,,Pc1rts 1t consi ts o1 a number al met I le;:iv€s. These !eaves
have di!ferent thir.l<.ness and are fastr:;ned toge1l1e1 in a sm2!I ho!
der. The mate1i2l of the lea·,e5 :5 stain:ess str'!ei

Fine Adiusirr.enl
Sc.•E-W
· O::d

' ·0 0 '

\
Fig. 2.23 Feeler Gauge
(iii) Radius Gauge: it is just !ii<.e a feeler g,3gue Every ie2·,,s has
dyrent radius.
, )' 1s 0t two !yp s
-. ...- Internal Fig. 2'.25 Vernier Height G.auge
(vj Thread Gauge: It is used to check the pitch ol tlireads. t;
; ,s used lo check :t-e i:}dius of cuter ar,d inr,e; surio::es consists of a number o! !eaves. On ·e11ery leaf cuts a1e provided
to fit into thread whiie checking Al1 leaves ar0 2.ssE.:o11b!ed in a
holder as shown in t,,9 f1gur1=;. The :r!ate,ia! of th€ le-'lVE:3 1s
stainelss steel.

Fig 2.24 Radius Gauge

(iv) Vernier Height Gauge: It is used to measure the height oi worl<
r,,eccs. it consists of a vertical bar mounted on a heavy base.
Fig. 2.26 Thread Gauge
A s!1ding head with pointer is carried on to the rec1angular par
1 he ba, and head are graduated He,ght gauge is also used as (v,; Wire Gauge: The figure shows a wire gauge 11 ,s ,;SF-0 to crif,-:,
marking thE- lines at !; )ecific he1g'11 11 ,s always u::;eo hy :,iac the diameter of wires It 1s made up of ;, :::tPel she '. t11sc
mg it on surface plate Tr-e basE> oi HH- he:ght gaug is rnace ur.•
ol cast iron aria t e t>o;:am is mad.? vP o! stainless st&ai
52
I ;j 111.Jf, '11•11

(11) [), p•:110,r,g 1iro11 tl1, J11lcl1 c,f 1rt(, 1r-r•rh

11) Conr ,c (8 H Tet•lf1 v·• ,,,c,t;J
(11) fv1f,d111in ( lf. ;,o Tc-,,111 ·i,, inch)
(111) f lfll.' (;•4 '.I?. 1Pf'lfl /JP/ fflC'I)

Types of hacksaw Frames:

T hr,c ;ire lwu lypc, . of h;-ir.k!,a•.v rrnmes
(,) F1>c<>d f1an,f (11) Ad1uslal,lf' fran,e
Irr f1>c1:d t,anw only one- tyrw of blo<Jb rs u:-.cd w•1 rcas 1n ad1uc.rabie
frame, tf10 lrnoll, of the IJ;irne car, bC' 1nc1eased nr dec,ea!>C:d ;:,5- per
reqIwe:munt A 1d H1f, I.Jlade fiom a· 10 14' long can be used ,,., 1t
I-..
.
ArlJu<,tab:<, Frame

Fig. 2.27 Wire Gauge

2.7 CUTTING TOOLS - " ,,--- - _-·._o•l tk
The tools which are used to remove the material a_re known as
cutting tools. These are described below:
(a) Hacksaw: Hacksaw is used for cutting c: ;ods, flats etc. The
blade ol the hacksaw is n,a:Je up of high C?.rban steel or high
speed steel. And the frame is made from mrld slec,1. The blade is Pitch ofHacksaw
hacksaw: It is Frami;)
(Adjustabti; the number of teeth on blade in cnP cen·
placed inside the frame and is tightened with t11e l,elp ol a flange timetre. Hacksaw. blades with small p:tch are us<?d for thin sc,ct,on and
nut. The teeth of saw blades are generally forward cut. The hack the large pitch are used for thid sections.
sav, should be used in straight direction otf1erwise it will resutl in
Use o: hacksaw: The material to be cut with hacksa\" is- clamped
breaking of the blade. The length of blade varies fro_m 8" to 14",
into vice. Marking is done with the help of a file. The handle of hacksaw
bu! generally 12· blade is used in fixed frame hacksaw
is held in right har:id and the left hcnd is kept on the frame Start s.:iwmg
al the marking, keeping the bladC' slrgtitly inclined to the horizontal The

-
Sohd Frame
saw 1s brought to the horizontal position after starting the cut. The
hacksaw should be moved perfecll}' straight and horizontal. The speed
of t11e hacksaw should be 15-25 strokes per minu:e Sutt,c,ent pressure
should be given to the frame with left hand while m forward stroke
Wate, can be used as a coolant for sawing

Care of hacksaw: The followrng precautions should oe observeo

whrle using hacksaw:
1 Always move the hacl<saw in pertect straight and ho•r;mnta
Scand Blade direction.
2 Never tilt the frame while sawing
f''9 2 28 Hacks•"' (Fixed Frame) 3 While cutting thin sect1011s w0oden pIe.::e must l't:' cI,11npe0 2.1,,.,
The and width of tne blade are 1m.m and W respectrvelr with tt1F w,Jrk pie:ces
t J,,da!lf4-ed fl& uno-.r l)lJ nnl u:--.r a neY..• t)ladr• II, Ult r-..11 n·,n t: l)\ ,1,,1..)t""'tl• l1• , ..1...
upon s • d1rect1c n of cut
·, • • 1,1.,,!L llould bP t1nn1 n.:-d ..... ·" · ··· ·
 --llla!i'llE¼W

•
-J
(b) Files: File 1s also a multi tooth tool it ,s used tc rPmove
_j material by rubbing it on the metal. Files a,e avnil,1blE- in a
cut files In "•ngle c:,1: /l1p t1;,•r" .,,c- u11 •n raral1e:I ro.v a: an ?.r>g•l 01
60.: 10 t:,c, frlt c- A:1 <J:t,e-, r(JV\ 01 tFCU',:_ addeC lfl cpposrlt;.· dpt:Clt<•; Ir,
number ot sizes. shape and degree of coarseness C c .sif,. case ot ootil"'}lc cui fd"..•:; M t: :,n1,pr,1ov111G rate 1s nir:,r, '" nrh,l11t
cation of !ties N1 the basis of grade.

I
1,1e tt," ,,, : ", I,· ._u1 Iii(;
- i (i) ',ougn (20 T,-eth pe; inch
-, l (i1) Bastard (30 Teeth per inch)
(iii) Second Cl., (40 Teeth per inch)
-f- (iv) Smooth File
(v) Dead Smooth
{50-60 Teeth per ir,ch)
(100 Teeth per inch)

-1 Tip

.
--
•' l
Fog 2.33 Dcublc cul F1le-
Picth: T ht numbe, ol Teeth ,r, or,p cen11met1e ,s callFd lhe p,tc.n ol
the file. The number of teeth varies fror.-, 1 O 10 4(1 in cne cent,mt't•e
Edge Use f File: The fiie should be usec in periect horizontal pos1t:0·1
Most of the fiies have their tEeth pointing forward. o the pressure
Fig. 2.30 Parts of a File
should be applied on the torward stroke only The work 1s held in a v•ce

'
j

;, I
Rough and bastard are !he big cut files. These are used tor rough
cutting where !he material removing is more. These files have bigger teeth.

' Dead smooth and smooth files have smaller teeth and are used tor
finishing work. Second cul file has the degree of finish midway between
bastard and smooth file.
I l
Classification on the basis of shape and size:
F11es are available in a number of shapes and sizes. The length of
files vcs,}' from 4" to 14". The shapes available are llat, square. round,
triangular. half round etc
remov,ng 1s more a;,d fin,;,
files are used lor lm1shg1ng work
•
-fter markina Keeping r1ght hand on the handle and left hand on the ont end. fil ,s moved
to and for with a speed of 15 to 25 strol- e pc, minute. Rough files are useo. ,._,here materia!
I 2
3
F•ies should be stored in wooden rcd.s
File cleaner should be used fo• claaning the hies
When not ,n use. files should bt- c0atcd \\ ith O"
Soft edge File: It ,s a lile having one edge "'1thout 1eett1 Soft €'ug<::
Care of files: The foliow!ng points sh,-u1d r--1.: 1-eot in m,nd •.·.-hile using and storing lhe file ,s used ,n Cl mple:x shaped workpieces ,n 01dc-r to avoid cut11ng, ,...,,
files . . _ upper side of t11e file
1 The teeth should be protected lro,n exness1vo:- v.eanng (c) Chiesels: These are used for ch;pp,ng a"e.Y the material ' · ,.
3
the work piece These are made up of h•gn -.arbon steel Ql···-=
aliy 5· to a·· long The top ,s llattened anJ a sharp cutting 1:-J,::.-
1s n,act-> on the bottom side Ch1Ese1s are ctass,ried on t'"
bas,s of tlle1• shripe c:;nd widih nf 11,e c"nny Poge Cornll'c.;,•,!\
used ft,, m!" ot chiesels are llat. cros!" ct..1 l1a1t rou,,J 2 10 c ,,
)
6 mond po111l ch,e: el Cutti.ig angle of cn1esc1s 1!' !-.<?Dt as ui-,o;:-,
I
I
Triangular or lflree square 3. Round 4. Hair rvund ,,al Fu, ha,0 ma1erials - 70' to 75'
l) i:1a1e Hand Iii• 7 K.n,te edge 6 Oiam.,no fore
 '
Ii -,.. , it 1'- C"ilE:c" as Ball pean Ii In£ pe2n is para:1e1 to !ht' t1andle of the
ha~mme,.r HJ1r>n 11,s sIraI0 ht pea-n hammer II pean 1s ac,oss the hand. le

I
! . ]l
"' l :j u
of·thc- h;;mrner theri it is c,oss pean hcinmic•r II shape of th£' pcan rs
s2rnr :-: f;. .-.t•. thrn !l - dc,l.,,,_.... e-ncfr_·rl h2ri1ri1t;

i
£
u c
; 1111 o
C,

3
1
Ji /1 .JL_\
{!
V /
J 0

J
Cun,no •dgJY
·, . 2.34 Chiese/s

sdq: ;;" . '. : •ns :a:'c :;::7h: ' :h«k ess of

,:;
A halt round chiesel 0
c uWng
fh e
cu 1ng grooves
. --....
s used cut o;I grooves (a) Bali pean hammer
n Hie bushes arrd also (c) Cross pcan harnme,
·/ear,ng small round Fig. 2.36 (a) Main parts of a Hammer
orners
Different par! of a harnrner are also shown in lhP figure
-'.\
diamond Point
Ch,esel
•s used for
hrp111ng plates It ,s also
sea lor cleaning the
)rnH of lhe slots cut at
n ang1. or of square

with a chiese,
1 he
v- orkp,ec& rs Eyt> -
imped ',,to lhe vice The
:1tena1 1:: rt-moved wrth
3 ht,fp of a chie5el by Neck
mmf-,,ng rt with c: fland Chipping Operation
mme, The chie,,;el is held r 1
11
·o. lv firn,t} Whtie st11k,ng _a e
1 1 an ang to lhe work piece. Ttie ch,esel
; STRIKING TOOLS Face
Fig. 2.36 (b) Different types of Hammers
H,,r•,n,..," art- the ont t I
2.9 MISCELLANEOUS TOOLS
.
•
: : itH, useo . 10, Y chipprng,
oo s generally
fitting,
used for str1king ir, i1t11n
punching Fie /. h~m g Drill: The tool used for making round holes iscalled drill It 1s m?.de
:-
:•..: vy "< n t.,r,o-.,
., ;,1, h, · r' 11 with a WOOden handle The "•f-:c'l• ;,,n
•arn types ol hammers arc as .,: • g
rn_:: up of highspeed steel The parts ol a twis• drill are show,-,as urid<;:
' '·•: t·
1
' ,,,&,,'...;;,t '"
• 1 '""C a,e There are several types of drills Most-comrno1, \ypt' of drili ,s lla1
,o,- of a
hammer is
•' ! I.· .l·.;p,;. Of !hf- P iin j,;; i.,;,. : : :_; r,:r'. drril. It is flat 1n shar,e at the cuning
11 can be usE:o only fc,1 drdltng a ho1
edge and 11 . lhe ch"'?.oest drill
ot <;n·1;c,lle, c!epth iv.1-;;1 <1nll 10:,

cc,'." .,,,._ : ano1t1er fvrr. r: (!roll 11 r:c,ns15f I' ;; S('•r::;! "•Jll· rr-1.c · 1-;o 11Htl,er
, 58

.,. , .. u '-'d••!:-, t? ,1
MANUFACTURING PRACTICE

tne shank ,s parallel 1hen 1t 1s parallel

shank twist drill If the shank is tapered then it is Tapere-d shank twist 8 10 threa:'.l!
drtll The chips are dnven our of tile hole through ihe flutes

f
Body
Para/lei
t. Shank ·;aper !.'.lp

f: ,_L 3-4 threal!s

i Tapered Shan ;

Tang
Nc:ck

Fig. 2.37 Main Parts or a Drift

Point Angle
(118 • in general)
a
Reamer: Reamer is used to finish lhe drilled hoie. It has many
curting edges. Commonly used reamers are shown below: Pl"9tap
TnreaGe.:J har.d"e a<f! 'S!S ja·,:s
I
!f
I
\
I
I
Fig. 2.38 Reamers i
Counter Sink: Ccunicr sinks ar'!! taper cut,ers used !o make the hole
!i

cone snaped from the upper ens. It is made for fitti_ng screws and nails.
l
Counter Bore: It !S ;,:sed to enla;ge a portion of hole. It is also l

ll
made for fitting the ht-ads of bolts q11d screws. F,g. 2.40 (a) 1-ioldlng tap in a tzp ,-.-rench

,yP : Taps are used for making in

ternal threads. it is inserted into the face
of the hole at right angre. In hand tap I
i
ping, a set ot three tap is used as shown I
in the figure. Tap nave a toothed body !
with a cylindrical shape It also ccns1s1s
of a tlute and the laps are available in ;=,
set of three taps namely Taper. lnterme
diare and Plug tap nd during tapping :1
is used in the same order as sho\11n in ttte size of lhe root diameter of the thread Before lapping tap must
Fig 2 40 (a). The tap IS held b'j lap holde, be held nghr
ano before tapping hole musr be drilled 10
feeth
 .....
'., Scrc1p1n4 ll l)11ll111g
T>-ipp1119 R 01e1ng
I
M11rking. It Is fti; ftt<,I a11d Imr,<Jrficlt,(I or,::r,11I011 tnc1I Ii, ,,,rto,rncc,n
l1e11ch work1n9 .11,cr 1! ,,., ;icr:ur?.c:y· of the pr0rfucI rJ .rends upon
tt11s l:3otore nw11<.1ng 11,t-: sIirlncu to be·m;:,rl<ed Is 1uoterJ by the
chGlk paste iln(f ;illowed to dry Then ifit. JOb Is epl either on
surlace plate 01 on V bloc,, Then measuremE'<il I r ,;rfo,m(;d on the
JOb by 2.pprop11<.1t(, rnI',Isur1ng instrument n1e,n m· rk1<1g Is done ,y
::ac11ber. s,irface gGuge arirl indent,t,cattor, ,s dor r:y punche
2. Chipping: In this or,erat,on the material Is re overJ ,n a stock t,y
t E rif !p of chiesels at r0om temperatu_re Fo !arge surface first
the meta, ,s ,emoved by cross cul ch,e5E:I 11::J :hPn remaining
met;ii is chip off by other ch,esefs while ch ppIng lubrication Is
necessary tor better lite of ch,esels For ch, ping operat;on tilree
things ?.re important t,rst propc;r selection of chiPsel based ori
operat,or,, secondly proper grip of the ch·esels and appropriate
Fig. 2.4i (3) Dia o>r.d Die s:cck position of standing by the operator. ft Is very accurate method
of 1cmoving melal tn a more quantity w/'h
a reasonable finish
3. Sawing: It is an operation which is reg'u1red to cui the metal ,n
differr>nl sizes and shapes. ft should be c.lone slo·.viy, an.::! s,ar,d;ng
posit,on !S appropriate 101 this operation. Cutt1rg takr.s place ,n
forward s•roke ct hack saw back stroke Is ideal Du11ng operation
full length of the blZ1d1c,c.hould be used. The t-esl result Is obtained
1I t11e hack saw blade Is fixed 111 proper dtrect,on with correct
tension Coolant must be u ed du:ing sawing
· 4. Fifing: It is an oµernt,on which ,s performed by the help of f:les. The
pressure for culling sl10uld be exerted in :he tnm.1rd stroke and
backv:ard Sttoke IS Ideal. If tile file IS moved diagonally 011 the ilat
surtace then it gives ti IC' best results. lntl1ailv a 1ougli fl!e Is used
to remove the rougi1 rrwtaf followed by a smooth ftl? ior better finish
Filing Is don•] by t(1Ice ways first cross itli11g to, more metal removal
thon tollow,cd 'Ci jt1a1ght ttling and drill/\ t1l1ng tor t,nal finish.
5. Scraping: T111s is il manual ot,eration done ,n a fttt1ng shop for
producing more ftccurate fin,,,n than obt:i,ned by ltltng In this
operation removal oi m8ial tc,t-.-=-s place ,n a small quantity .lt a
localised po, tion In this fir : ,, prussIan hlue Is applied on the
Pig. 2.41 (b) Holding a Ole slock
surface in which higher spots ,vtll be noticeJ Gy this opeIa1,ori lne
Z 10 BENCH WORKING tROCESSES higher spots Gre removed till entire surface becomes perfectly
s111ooth and uniform ·
• COn41tsfS ol numbe, f operation, lhal are pmlormod mr1nur1fly
'>-.>nie of lhe ,rnpo,tanf l•rO$ arB as follows 6. Oriflinc;· It ,s "" ope,at,on d,'one to t•,,11i•,rc- nnlP:;: P.tlh<>, pI,,-,.-; ,,,
' -- -"- '.. '1 C111vp1119 rl11uu,;;1· '" J 11cral pt •ce b / tnt: hcllp,,, L ,1I, ,, l!1d1 are dtSClJSSecl
, .... ,,g 4 Fil•i, e;i,I,..,, 1, ,, d,>nP on th<::> d11.l11ng m,:1<:l"nv '" wh1cl1 t11::,t the JOb in
"''""d(f -,.r.lv ,:"11 n1::,--hHlt' v1rc,,lhc-n 011'"'1c1ril, I'-'•'<{· } UP thr' ll"l;\•"•l "
 1
,i, 1 1
11 :.. • ,J c !•1t:: hdno v,t"-.t:-<.-:1 AµL11u 111:!:':: cr.,of<i!r,1,,.., 1J<;PrJ
u
for
lL•v•, , 1
rrn:1nq <J•Jrr·,q ,)pt·rat,on

l
4
I

Hand1e

3
 Joh No '1

r WELD'NG SHOP

3.1 INTRODUCTION
Wedding Is a proc; ,,!'- of 1oir11ng two materials with the help of heat
or prE<,,,;,ure 01 by !>Orne otl,er means The cost of welding 1s very tes5
as comp,Hed to oltier processes and forms a strong joint. For this
reason 11 1s la•:Jtly used in the following fields of engineering:
1 Manuf;-ictu,:ng ol machine tools. autopc:<1s. cycle parts etc.
2 Fabrication of farm machinery and equipment
3 Fabricat;on of buildings, bridges and !.hips
4. Construction of boilers, lurnaces. railways, cars, aeroplanes,
1ockels and missiles.
5. Manufacturing of television sets, refrigerators kitchen cabinets
etc
Job No. 5 Dieing Practice Main pu,pose of welding is ro join two pieces. For this initially
temperature of the parent metal is raised upto melting point, then filler
metal is used as a suppliment for molten pool. A homogenous mixture
is fo1med at the -joint then it is allowed to solidify to form a weld. This
is fusion weldin9.
!,, ,ie::t process the ends to be joined are brought to the plasiic.
stage and then apply external pressure to join them It is pressure
oou welding. In both the above cases the source of heat is as follows for
ex it is furnace in forge welding. it is gases in gas welding it is electrical
energy in Arc wPld•ng, it Is chemical reactions in Therrnit welding etc.

3.2 TYPES OF WELDING

Many types ot welding processes has been developed depending upon
the field of their applications. Some of the proce·sses are listed below·
1. Forge welding 2 Gas welding
3 Electric arc we·J111\J <1. Spot welJing
5. Seam welding 6 Thermit welding
7. TIG welding 8. MIG ""elding
9 C07 -MIG welo,r.g 10 Plasma arc welding
'\ 7, r, rg \'\'('f i r1g- T ,, .. ,: :.-e!dtng ;£ 0 t-1· . ..':' t I= -="
-=:..:--·: :..,
t1,1s two s11nIl31 m,eta. piece,; arE heated upto ltlt? p'Jsl•c $!a<;:: 111 I''•.·
',,rnncr: Ti,t:ri Ii 1
i'li-3n"n,-?re11 so thar ,:i hon,cgenee>t,.._,n·)·tu,. :s r0r:,....
69
 ,'1

e
C11linde1r, l'SSLIIti?
GnuQe
Out1:,11-'i s!>Ut Gauge
C:
f"l10i;sur . Renlll,Jting
G.iuge
e
r111e1
fl,tn'lt_" Mct I
C
: :; .,. ft.
·
e.
Oxygen
Cylinder ---
Ac tylenc
Cylinde1 t
e\
3.,.2.1 Oxy-A, etylentt welding
l h'-' process 01oxy•,'h.".etylone welding can be used tor almost all
C.
II
flh."tals an\l alloys lot 0n9meering purposes. A high lllmperature flame
(3 l()O•'C) ('.In oo. produood by this method. There 3re two systems of
tl)r.'Y9ttn-ac-et -t<'ne \\tllding

I
:1J
(i) High pressure syste,n· In this process the oll.nJL·,1 ....-......,,v.

(Ii)
lene .:ue tal.. n for use from high pressure cyltntlers.
lo\\ p S.'-u•es -stt>m: In this system oll.ygen 1s taken horn high
p,essur cvltnder and th acetylene 1s produceo by th(' action
Hose pipes -
ol Calcium carbil1e and water. ·
Caci 2H:,0 :: Ca (OH):> + C:,H.,.
Apparatus to, Gas Welding
Fig. 3.2
3.2.2.2 Principle of oxy-acetylene welding. 1 . 0>.ygen cylinder 2. Acetylene cyl1nde1
A very hot flami: is proauced by burning of the gases coming J Pie:,sure Gauges 4 Valves C.
through the torch hp. The edges to be welded are heated up 10 r'fleltrng 6 ro,ct,
5 Hose pipes
A lino, metal is also i!dded to complete the welding This moltenm.-ta!

c
7 Welding tip 8 Piessure regulators
mi tu when sotidilit.'-' vn cooling forms a welded joint
10. Goggles
3.2.2.3 Apparatus

-
9 Lighte. r d d acetylene cylind1::r a,e filledw,thgases. Botti the
APJ)aratus used tor oxy-ac tylene (high pressure) welding 1s 3h0wn Oxy oe ncylin e r an lalorc :andcyl1nde1valves
, - - h ed with pressu,e gauges re9u -
·n the figure end consist!- ot the following: :v:17dPr5 "''" c1ttac 11 , H•· ,·,p,.ur,re;d t11ack wnere;:is 111€· acety-
: r.",: 1n..uer con1air ng UX>Y• · .-• "'"' are p ovidec wrth each

'"'.'c..
.
rn•Je, 1·nted maroon a n(>se pipe:_
to weldin
.: '-', 1h": ,eispa
pip es arc conn1::;l..c., ' g tore!.
-
 73

Wlwn tnc v01l;111e of ;x1yen gas 1s more

U:>.1O1:,rr,'.} r-1arne.
• tt t \J 11 I \1 f I U t; C S :
lhan ti,(; .,,ilume of acetylene mixed intc the torch This flame
lo ctnrt welding, the acetylene control valve rs turneo,,,;:.\ .-,,,,,n], 1s used !, 1 wcirliny brass and is also used 101 cutting lti
on,tylt1nt• comes out of the nozzle, it should be ignrted with sr,,.r, l•yhler j metals
It wrll grve a yellow-coloured smoke flame After it cxygen c,y1,1,11,,, valve
1
" nrioned and supply is i•reased until a best suitcJle !lame r:, r,,1,,,ned .'i. -;, Carburisrng Flame: When the 1,olum( cl acetylene m,xed,
mure tlr8n o,1gen. t;arburisrng ilamc> ,s ir,rn ::d Thrs tt2.me,s
Then the flame is locussed on the edges to be welded Flux and 1 used for welding nrckel. monel etc
filler metal are also added with the eat of flame, the edgf.s r:.nd frller ;l;: .
metal melts and a joint is formed after cooling of the moltf>n metal 'If · 3. Neutral Flame: 11 is known as balanced flame Oxygen and
The joint rnay be formed with or wilhoul using filler rnetdl 'ft'- acetylene gases are mixed in equal volumes Neutral flame is

;J\··
used for normal welding of steel. cast rron e-tc
Applications: ).2.2.5 Gas Welding Techniques
, .....
: ! .- There are two types of gas welding techniques

is: ·,.
Afl the rneta!s can be welded with proper filler metals. Sarne equip
ment may be used tor cutting purposes. Oxyacetylene welrji1g :s par 1. Lett ward welding
ticularly used for sheet metal work 2. Right ward welding

f::.
t
Advantages of oxy-acetylene welding: 3. Vartical welding
1 . Equipment is cheap. 1. Left ward welding: It this welding the tip oi the torch is heldat
2. It can be used for welding all metais 60to 70 degrees to the plates. Ano the fi:ler rod is inclined at 30

l
3. Maintenance of equipment is very less. to 40 decrees in opposite direction In this method the plate edges
4. :1 is a portable process. are heat;d in1mediately after the molten metal. 1 he torch tip and
5. It ca·n be used for cutting of metals. filler rod are moved slowly in the directron triwards Jett
6 II is specially used for sheet metal work. :'1 The technique is illustrated in the- figure.
Disadvantages: l·
Tcrch
:Jt•
1. II takes long time for heating the job as compared to the arc '. ./ Piller Rod
welding. ti
2 Heat affected area is more. ·1
3.2.2.4
3 Gases are expensive and difficult to store
Types of Gas Flames i
There are three types of gas flames:
1.,
.
1 Oxidising Flame 2. Carburising Flame 3 Neutral Flame Direction of Weld

Curer
..
'f
fnvelope Outc::1 'i

i Fig. 3.4 Lett ward Welding

Envelope

L\
Ou1c,1 2. Righi ward welding: In right ward welding he torch 1s kept ai
EnYGlope
i 40 to 50'' to the job to be welded. Torch is r:-,.lved towards right
1,,tenncdtdle
Cur
", as shown in the figure.
Right ward welding is done for heavy seclrons only.
Sn,_,
Cone
 .i
':.~.,1.
ti:4.:
•.• 73
MANLII I\( t Ul I , '"q;Tir,l IS mere e,-.-.
,c ux101s1n'J I-lame: V/t1cn Ilic volume ol oxyge:11 gas
if \
J '3 1f) ·:._:

To !ilRrl welding the acetylene control valve Is 1u1ned 111s; wr1en

·{-
thiln !Ile volume of acctyltme mixed into the torch This fla e w- It
acutylonf' comes out cf the noz:!le. it should be ign1t0d w11l1spark lighter. ;.
Is used for welding brass and 1s also used tor cut11ng the meta s q
It w,11 give a yellow-co_loured smoke flame After it cxyyencyl111de1valve
1- oponed andsupr,ly 1s 1, :re?.s0d until i:J bes1 suil;,.Jic, 11.:ime 1. oi-1t(Jmed. i :•, ';· Carburising Flame: When the volume ol acelylene mixed 1 e :
a_'··, e
·,.?·
Then the flame 1s locussed on the edges to be welded Flu.x and ino1e Uian 0,-.ygcn, ca1bur1sing flame IS fo1m d Thi$ flame IS
liller metal are also.a_dded with the !leat of flame, the edg6s and filler ; used fo1 welding nickel. monel etc
.
metal melts and a Joint 1s formed after cooling of the molte11n19lal : ,
·
The joint may be formed with or without using filler m t,,1
•i 3. Neutral Flame: It is known as balanced flame Oxygen an_d
acetylene gr1scs are mixed in equal volumes. Ntutrat flame 15
used for no,mal welding of steel, cast 110n et<: C
Applications: £·,1 ).2.2.5 Gas Welding Techniques

All the meta!s can be welded with proper fille1 metal . Sc1111eequip-l ·. Thc1e are twn types of gas welding technrque!>
:

r
lmiceunlat rlmy auysebde fuosredshefoert cmutetitnagl pwuorrpko. ses. Oxyacetylene 1. Lett ward welding
welding 1s par- -
al·t:· : -: -: ·-:-:·::...··.·.
2. Right ward welding
Adva11tages of oxy-acetylene welding: 3. Vertical welding
1. Equipment is cheap. 1. Left ward welding: It this welding the tip of the torch is held at C.
2. It can be used for welding all metals. 60 to 70 degrees to the plates And the fi:ler rod is inclined at 30
3. Maintenance of equipment is very less. to 40 degrees in opposite direction. In this method the plate edges
5. is abe
4. It can portable process.
used for cutting of metals. are heated immediately after the molten metal. The torch t,p and
6 It is specially used for sheet metal work.
-4,:: filler rod are moved slowly in the direction towards left e
Disadvantages: The technique is illustrated in the figure.
1. It takes long time lor heating the job as compared to the arc
welding.
'i/
-
:§ - Torch c..
'Piller Rod
2. Heat affected area 1s more. I
3. Gases are expensive and difficult to store. i·
3.2.2.4 Types of Gas Flames \ t1 -
There are three types of gas flames e i
l
1 ox;d;s;ng Flame 2 Cart>,ms;ng Fla \ 3 Neutral Flame
i
A-- l
j

f i l111e,111edldle
Oute1 Envelop
i
I',

\i
2. Right ward weldin J: In righ
40 to so• to the job to be w
as shown in the figure.
ard welomg :h torch is . ,'pt at
. Torch is moved toward::: right
c._-?l._
COl'P
 i
Inn
Con
;
Right ward welding is done f r heavy -;;ect,ons only 1 ·

0 -J
/ I

C'-
 . i: -\\i_
·--.,;;..:•;..

PPM 1 r.,. u,
n

.-,i; 1.
lrps art'
; .. -! ,.,, Ilic front l'nd or tt1e torch Va11ou:, ryp s ol

• '1.,,,:1 ,n thE: figure.

Threaded

r;r=
Replaceable P1ec€

fCSSlirt:
Gavg
I
Slow Prt sure Oullct

Fig. 3.10 Torch Tips

Goggles: Gas flames produce high

rr,t nsity light anc1 heat rays, whrch

--:-
orf, harmful to nal..ed eye. To pIotect

r
(1) Low pressure or Injector Torches the eyes from these rays, goggles
(1i) Medrun, pressure 01 Ecual pressure tcrches ore used. Goggles also protect the
eyes from flying spar ks.
l. Lighter: For starling the flame, the
spark shou!d be given by a lighter. Fig 3.11 1ooggll S
Match sticks should not be used, as
there is risk of burning hand.
Torch mouth 6. Fire EJCtinguishers: Fire extinguishers cJr,i IN!O topre,· 11t the
2 M,x,119 lube.
l•11c,101 lrre that may break out by chnnce. S;ind filled bud,·t!-i and
4 Mrxmg nnzle. closed cylinders are kept ready to nir-et s11t·'1accrc!enIs
flr1,s:,ure nuz lie
<D 6 Acetylene valve
f, Grrp

Fig 3.9 10
Welt1rn9 Torch Lhvgen en!rance :, 'J 2.9 Difference Between High Pressure and Low Pressure G;is
Wrlding

(i) Low pressure or injector torch: These iorches are designed iS. N :r High Press•Jre Welding -------·- -----
- o"'."_ r si;ur lcJ( _g
to· usn acetylene at low pressure The pressurp is kept very
2
low up to O 7 llglcm But the oxygM pressure rs very hrgh Acetytenp , geIIeIc1tr:d 1,-1
-
a,.,1
(ii) Medium pressure or Equal pressure torch: In thrs type of s ! 1· 7-A,etylene Is av;iilable
the ac1ion or water

i
torch the acetylene i!' takP.n at a pressure equal to 1 kg/cm Calcium C.i,brdE;
' rn cylinders

II
2
The oxyge11 rs always suoplieo ?.1 high pressure Pressure rs very hrgh rn tf1e> Pressurt" I'., lrJw I( railg•
Buth lypes uf lorche!' are provrdc:d wrtn lwo needle valves ,1r:etylene c;ylrnder. Mu ,m1um
One regulates the flow ot oxygen and the second valvecon Pressure 250 lb/inch2 lrom O 5 lo I 3 II.J11nr.ll'
trols
mix
the llow ,11 :icetvlPnp A, mrx• g <:hamber rs pro rded to
the gases
Pressure regulators are useo
I i
s • on btJlh cylinders , o need 01 presswe re(pIrc1t,·,r
on ?.Ce\ylecnc cylrnrter I
Tc-•::: t: s. F",J, L'•!i, ''="''' 11;. -= ..ii JOils.c,11,,.,.,r.t 1,p, dtf used
(),•,gen and dC<;tyl_ene gc1ses
lniecf()r Is i1 ed to rnr,
I ,,, d ,,,,,.,;-, L.nc.Hfltlf..!I I
' a,:et)II'i,_ .',rl11 0X/YL:n
Th., Stle 01 the trp rs SpF.cilic:d by the 0-.JIIPI hie •irarr.'?ter M-:•E • J (o-d tor hE:3v wor L_ s d lor '''.Jill .vork
than one to".lle rs alsl, rrc.-,a.,o ,n :·p, 11-i,, ''L' • ,,::re·.,· :-i n,
 /ft
Mt>tJ(J►A<:l'IJR11"G PAA( 11cr 7G

3?? 10 S11l ty Prc,;aution:; in r.;;, V/,·ld:r;f;

: ••clrlc power for WC'lding :•
' ·• IL.'""J'"''''-',,Jl•.dy J.)ll•L.dU'i<,n•._ r.,l:!:;. Ol:. OD E:f'Vl·d ""t...,;f,:
1 1-1,,•,q •n :.· AC curient or t,c cI,rr1or,t can 0.: used fer ,,,, ,,,,10111 !'or most
·"""'"'"0 5hop
j
l•
1 Always handle the gas c-yhncert, with :::are ;-."r,o:;(:-S, DC ,ec:,t,er,s
<><.•hd state currPnl 1 used
µr i ,rreo
D.C In DC wrt<i,11r1
mc1chInes C qenerator
a l) upto
arf- 11,ai1e tt,0 capacor
? l 11e adJust•ng screw en the reguiator musl bf' ru; y rf-tf r.1E• j ( , rnnge 600 arn ;;-11.:::. Tri,, voltage 11, op1:,1 c11c.,,11• - !sept a1ound 45 to
I
before opcr n9 cylmoc r va,vr, &•, volts and in clo e« c.rrr11It 1t 1s kept 17 1<, ?'.:. v«It< DC Currc11t can
3 Neve, use matchsticks lo, i19ht1ng a torch. A. · ·\.. (1)given
:
in two ways
" Neve, lubr,calf: th(> reyuta1cr valvi> with o•I o, grease, ,1 Stra1gl1t pc,larify w, lding
cause f!xplo!iion

f'
may :? (11) Reverse polarity welding

J
5 Always use go9gle5 while worl-.mg
6 Proper ventdat,nn must be provided ,n the shcp
7 /lcotylene cylinders shr,ufd t,., stored in up rich, pos,uon
8 Oo not op,rn ac.,lytP.ne c:y1Infkrs near sparks -◊, fire -i

[i;.,7
9 Never removf: lorc-h tips w,n. pl:ers ,J. Electr.:,de -\

.
i O Tho cyllndP.r should 'bf- le,iK nroct flecUMe

i 1. Always u e p,c,wct,ve c.::ips over 1he val•,e!'.

: -ron ,'; .tron
12 K&ep in m:nd lhl.' 1ocat•on ot tne r.,e e)(lingu1sh r£

3.2.3 ARC WELDING

-
1
Anode (High Heat) Cathode (Medium Heat)
Thrt weld1n11_in wn,ch the elPctnc; arc b f.Jroduccd t,) g•ve • ► lg 3.13 Slraighl Po•arlty Fig. 3.14 R,werse Polari1y Weldir,g
11 13
Welding
1

,
i:
ii

t
tor
the purpose ul 1c,in,ng twn surfaces 1s callr,d electric arc: weld•r;y e!ticlr,c energv 1s converted :ntf\ t1E,at anergy. procucing a t"moc::rnture

i
of :snoo· C lo -1000 C Tt·,,s heat n,elti; 111<> ed9"'s to t-i': \,,•ld,,o d/1d
i
Principle
rn,1t>?11p<io1,s tc, m,:-d On soltd11icn1ton u,e v.r>l1-n9 1011,· ,..
Power supply ,s g,ven to electrodf' and rt-.e work A suH,,bfe a,JL, ,s c•t!":n•:?d
li
l\upt hetw&,rn lh<? wor!< ar:d electrode A high cun-er,I •s passed tt;•m gh
the c1rcu1t An a·c 1s produceo around the area 10 t,e- w,.,:ceo nw I E• ctroae Holoe1
 i In straight p•Jl;,rny welding workpiece Is made anode and the elec
a
trode t£ rnad€: ,;,.t1,oc.Je, shown in the f1guru. Elef.lCQllS flow lrom

i cathode, to anodP 1hu!> heat,s produced at lhe rnate o bewelded.

In rev,orse r•, 1:.lll:y S)'Slcn1 the work is fTlade cathc.db and the elec
1

f trodE: 1s made anodo 1 ht welding Is done specrally for thin section.

i
AC welding h s ,r,p advantage ot being che.ip Equipment used 1s •
&1mple1 than DC wetC11ng A translorrnnr ,s used to Incre<1se the current
i output at the eleC110<.Je An AC welding cIrcu1t Is shown In tile figure The
current vary from 150 to 1000 amperes ::ler,end1ny upon the type of work.
3.2.3.1 Etfect of Arc Length
Clamp
Arc length Is the distance trom the top of me P.lectrode to the
Fig 3.12 Arc Welding
bvltom of the arc It should vary from 3 to 4 m.m :,, short arc length
the trme of contact will be shorter. And will make a wIcJe and shallow
\ bead The pene1ra11on Is low as compared to long arc lengllls
3 2.3.2 Equipment used for Arc Welding
Various equipments used for arc welding art: a unner

1. D.C. Welding Equipment

(a) AC MolOr - GenP.rator Sel
(o) Diesei Er,g1ne - Generator s1
(c) fransfo,n1e, - Rectifier weld••·g se1
\
\
 _ - •· , , l t ,,. ..... ••-::, tJ) \..•l.t,,_\, ,H • 4olt" 1, dhh.1,,..li1...,q ,Pt•

Int Welding Transformer set curient l1011-,0 1:1,ough the second.:rv coil llle output can lw
contrcl!ed as pe; requuerncnt
3 Equipment accessories
(a) Leads (b) Holoer AdJust,ng
(c) Coc1!'u- ·rs Sere'..·:
(d) Grc._ sj Cicm;:-s
4. Operator's tool
(a) Chipping hammer Reactor
(b) Wire brush
(c) A,c shield (d) Closed shoe
The de!ails of the above equipment and acessones are descrioed
below

1. AC Motor Generator: In this a generator is drive:n by a sunaul1..

AC motor. Thi? average voltage of the generator is 25 volt. The
current ranges from 25 to 100 amperes. the voltage in the Fig. 3.15 {b) Welding Transfo,,,.,er Set
generator is variable. The voltage can be set to th desired
value with the help ol rheostat. 5. Cables or Leads: These leaas ar<' made up of copper or_alu
minium wire. The wires are insulated with ruhher and cloth fibre
2. Diesel Engine Generator set: In this set, the drive is given by A heavy insulation is necessary for tt1esc cables.
a diesel engine. Rest of the system is same as in case of A.C.
motor generator. Diesi;! engine generator sets are used in the 6. Face Shield· When arc is produced a1ound the JOb. infre1red rays
areas where ele tricity is not available. and ultraviole' ;ays are produced To piotc1..I the face and eye$
from these dangerous rays, a shield is necessary.
3. Transformer rectifier set: It allows the current to llow through
,, only in one direction. Because it has a one way valve or soltd 7. Other accessories and Tools: Other acc<>ssor1cs and tools

..
rect1lier installed on the electrode side of the secondary coil. used for arc welding are shown 1n thr; l1gU'l'
The set can supply straight polarity and reverse polarity power
- supply. The rectifiers are of two types: IP01ni
{1} S1l1con diode.
(ii) Selenium plate
Electrode
Holder
- t·\ - :r-JRI
• •• · ··· <.ui: ,, , • t,i ;...-,-
,. ./- 4
•
·i

---· Chisel End

Face Shield Chipping hammer Wir,, bru"I,

7' .--c::J Fig. 3.16 Othet acessories

Prtrriary S.:i:ondary Wori<.
Cu11ent Welding Positions:
Flow In horiz.ontal position it is very easy to weld L3ul mAny t1n1u::, it 1s
Fig J 15 (a) lranslorme, i>ctlll r <;<', irnposs•ble to weld thP. ,ob in horiiontal oos11,,..,,, 011w, or,;111ons rir;i
4. Welding Transtormt-r set: It 1s us,00 to step dowr1 th.- voltagl
dass1l1ed ,s under
supply It consist-. of a pr,ma,y an,,i-;r.und. ry cirr.urt The 1n::,":
 1. Fl•t Poaltion: _In tlat position the work piece ,s kept in nearl
h0tlzontal position The surface to be welded ,s k pl 017 y 4. Overhead Position: As shown 1n the hgure the v:or,.,_p•eC":,: e
?.3 -·
r

eidt!. The welding 1 done as illustrated in the figuie upper rnrnns o·;er the head of thE: welder The workpreC(: anc !n<; a)(iS

I
of the weld remains approY1rr.;;te ,ri horizontal plane ;, ,c '1st
Weld ·J,11,c-• 11 pos1t1on _of welding

I f>-"-1-,,ol 3.2.3.3 Comparison Between AC and DC Welding

1_ -:- -- - e -1 -
-;:_'''---- --------------··11 ,;,
.
..,. d S _O_C_W_e_l_d-ing -_

:
\ Equipment 1s <::heapcr and -,,1m- \ Equ,pment is costlier anc coml

I
! pier I phca!ed
Wo,,Pie=
I In
.
( aF)l a t 2 AC trans:ormer !her1: 1s no \ DC generator set man, part!.
Pos.ition \ moving pan, therefore 11 rs easy \ mov;r.g ar,d rts ma1n1enance

I
to maintain. \ cost 1s h1ghe1 thar. AC trans
2. orizontal P sition: In this position th!:: work pie,;e: is kept as formers
th
in e _figure:._1wo surfaces rest one over the other v,ith their flat
3 It can be operated at large d!.S- In DC the vo:tzge orcp •s ·:ery
• ces n vertical plane. Welding is done from right side to left 1
\ tances lrom power -,,ources as 1\ h;gh,.herelore shcr1er cables
1
vertical
in • de. plane.
e axis of the weld is in a horizontal plane and ,ts face
,---_-_-_-_-_-----:...::-=--=-:::::
Groove
'\ the voltage drop is negligible. are used.
1

Wele1 Only coated eiectrodes ca.n be I\ Both coated end bare e:ectrods

./
L - - - " \
used in AC welding.

L'::ss prob!em of a c blow.

can be :.:sed

\ More problern oi e;c c\o·.-,

6. It can not be useo for welding Almos. all tt·.e metals car, :>.: \
1

l
\ n•Jn-ferrous metals. \ welded
\

3.
(bl Horizontal Position

llertical Position: tn th,s Pv!:.ition the al(ls of the we,d remains

J ii can be used only when AC \
current - a1lab!e \ . ';cc :;: r n-::2,
An engine ger.erc:101 ca_no_e \

, •• app,oidmate 11erlica1 ptani:: :rhe welding is starte:d at the

ton?m andprOCE,eds !<.,wards top Welding process i$ 1llus:rr,1ad
in figure Electrodes:
Electrodes are oi two types
(i) Coated e1ec1rodes
(11) Bare electrode
Co.,led electrod€:-s dre gener;,•I:• appheo m arc \ eld•ng proc,:.ss;:s A me!
alhc cure is crJa1 wit\1 so-ne su11able m31en I :he m:?tetiel use<1
for co,., 1s m,!d stE:E:1. nicl<r, steel, chror.11um molvde;-u;m s1ee1 et;: One
end of thE: coated ore •s ,cept oare for hold•rg

w_ll.JJJJ»l_wp •, 2.1,.- 1::;,=.:;trv<:k'> p:01.h,;:e the welJ.ng of 001 :,ual1t,. These are
cheap.:' •1,::,r c.oa:c:d E:lcct;Qdes Tnese are gor,e•'.3•)· use<l r-o m i"
..•,.. -1..... .-- , , fJ -
· -. . " "..".,
l;c.aJ
Electrode s,,e
 t -
. ...
.
:: . '.

f j.:., ,:,, _._,,

. "''
(,,;1:1:,9 n.- r:ri c-l.:.?CliP:Jt:- serves !r--:t:"" !::illc."·· 11·c 1 unci1.1ns
1 t, nrt• f•11· v>·dc.i,..,n
Pntr"! :;:ac::..• :it"; ''1€-iB.I 1rn:.h.Plt!\ ••

1 lj :=-1l C..,,1? tf>£ .:I(,,

:,,c, a n .,nu qicn of rr-olu n rn 1al

J ( r nt,ois,-J{•pt:, cf ,:-ene:rat,t.,ri
t:, r,.-•n ·r•i!
1
tr:-: •-\.•Gi1;: f"-4{-i,.

7 ,"t !;: - i.
1
11.'\' r-!•,?ffl-e?'li to the J(,;rif
pecifica,ions of clectrooes:
Ane1,,,_-:r0op,s s:..,.,c,',,,,d by six c,91t5 l\ll/1 r,roftle:- le:te, I\'; 1 he,.e
"''><d1q,1:; ""J'Cc;fe 11,e folk".v:ng matter
1
M: !1 r><11rcilf,:!> 1!titf it ,s suitable I::>, metal ;:;re '.':eld111g

First dic;,t: r ,1st d1g11 nic:y oe irorn I to . v,h,ch ind;calP. H1P.

1yre of c, 21·,·,,,.1 ,..:-1 th, c-!cc:rode.

Second d:git: I: d noies t110 wefding p•·<;11Jor. fc,. v.t1:c11 ,kc,,odP,.s

1H2r.ui:1c-t:Jrt-r1 I' 1 ;J11-2s tron1 1 fo 6

Tt1ird digi,: Ii Je,101es the cuuenr ro be_UjP.O f.::, :in £-:,,,:,- ,t1,-, h
,s ta-.1en frPni O t, 7

Fuurth digit: i·owth d1g1t is irom 1 to e F ..,ch o,o: '.Cr.r'•s-·r.·f. :he

tens de slrr.1,9111 of wr•IJi::d joint

Fifth digit: It carri, s any number 1rorr. 1 , 5 Tn,s n--1•1 (,, ..,.!·,-s a
spec1t1c .-,1t g<1:i.--m in i:•'•ceniage uf the r.1e1.-1 ti::p,,s-1l:u

Sixth rli]it: II Cdrr:es any number frcm i 10 5 ci·,o rj;,nok'. ·mp c

• ,lft'ngth of tt:;c. iu•nt

3. 4. Spot Welding
H 1s a rnerh..i used' 101 mal>ini;i Lap wclu5 :,:,r :;n•.·Eots uotn 1 ' mr"
th1ckne,; It is P\:;•e"sed by the, l19we sn(•":r. 1,.,10,,,

It consrc;rs of a rranslorn:er hav,ng primary 3nd Sl3cc;,,c,ary w111d1n9s P

and C This Woi'ld:ng cc-.nsr l5 ol two arms. first is d rnc,vatile arrn E. ,1nd
the ome1 1s t,xe<i ;vm E, . bo!n :hc>s arms ;;. ;:: .: l c b;• :ne
Sl.'•,)1,dar, coi! of the trn1sforme1-In theproces:s 1,.,,, lake tv,c,snc..:i!o :3,
c1111J S:, lo
be joined .:1ndn rs µ1::,c,:,d ,nth.:? manner Shown bt-iW•. en rne '"" ;;:r11.-,.rhen
a supply .ii h19t,_ampcragP. ana lo" voi!age is :;uc,i'!•eo 0ei,:'::';:o1·, :Ile two
sheet!,; Tilt" pressur._::. ,-, ch ( ext?rJ;,(l hv ') .. f1) ">.j r:c ·:1-:.· ::I(•\• ::: :•.: df'Tl
as ?. rf- •J•T lit,=..rr-n1n,::),,v1.,:: ,••... •;: • . ,_. ._ ,r--,.,·: -: , ;JI,, '.-1·:c ,r'\.-
·.
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T·• ' ; • l,:::1

F,g 3, 8 $pot Wc1c1,o1n

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t,i, C 1
1 I, I I ( • ,, ,,I 'I} P1 fn, ► ''

(,.J

SMITHY s
or
(.1 INTRODUCTION
Th€ precess ot giving a desi,ed shape tc a metal piece by hE:at1ni;
snd hammering is known as forging. The metal piece is heated up to c
desired tempe1a\u1e, known cs forging temperature. The processes in
volved in forging HE l",amm1::ring, pressing, swaging·, bending and llal·
\ening e c. When the forging ;s done by the hand tools manw;lly \hen
it is Celled as hand :orging. When the same forging is per1ormerJ by tr.e
power ham:-ne1 then it is called as power fo1ging, in case it is d,rop
stamp then it is drop forging. The metal pieces a,e hea1ed t<lthe plastic
stage ithe! in smiths 1oige m in a furnace. Forging is widely done in
auto -end bicycle industries. It has th€: tallowing advantages over tl.e
other mactnning precesses:
1. It refines the structure ol the metal.
2. It increases the strengtn.
3. h saves time, material and labour.
Accessories tor c: to, £:ng furnace:
4.2 FORGING TOOLS AND EQUIPMENTS
(i) Showe!: ll , US(•d to place thf co.;: 1f1lu 1ne fi .rr.,!Ce neartl,
The 1ol!owing tools and equipments are used in a smithy shop:
(ii) Blower: 11 ,s used te, supplv a11 at h,gh,,,.ssu• 10 111e neat :h
1. Furnace or hearth 2. Anvil
3. Hammers 4. Tong
5. Chiesels 6. f'uncl,es and drihs
7. Flatters 6. Fullen,
9. $wage£ 10. Swage bloci<
1,1 Set hammers 12. Clami•ing devi1;es
13. Sick hon hearth II Is providet1 witn hre trirJ. hPing .1
1. Furnace or Hearth: A black smith u::-.'"'s a lurnace 101 heating (b) Tuyere: /. pipt1 coming from tt,e t,l,tltw or r ar ol \hf hearth ,
the metal pieces. Furnace consis 01 loJr legs, a cast iron or known a tuy&re I\ It uS6d 1n k!ppi. 1r1e ail a• high pre-;surr
steel body. iron bottom, a chimeny and a blower.
lhe main pa,u of a forging lurnace are st-.own as under:
(a) Hearth: The iron bonom where fi1t , !igtitened is known as
t ig ....
 ,11
.• ..j

9E MANUr AC1URING PRACl ICL 97

_ - ..

'7-- \ :",<
e

-
(iv) R gulato_r:11 is used to control the suoply ot a11 to tile henith.
Air supply 1s cont1olled by increasing 01 rlecr0,1si11g the pas '0 • -.:,"'""""'"

sage of air.

FllELS l'SED IN FORGING SHU'

Fuel
: :Joe/
e
Hom

,
Solid
, · ·-··- 7
Fig. 4.3 Anvil
,
C.-
Liquid G?.seous
(Coal. cokr-. charcol) The central part is known as f-Jody The pro1ected end is called horn.
(Oils) (Natural ga ;_ produce1 gas)
It is used lor making circular jobs. A steel plate r1vetted on the body

I,
Th€: fuels ir: common use a1e steam coal, coke and charcoal A is called face Most of the work is done on face Chipping block is used
good luE! shot-le have the following essen!ia! properiies for cutting purposes. Holes are used for ch1esels or ounches At the
Ii s'l0ulc be able lo maintain thr:, required forging tempeia1ure. bottom tour legs are attached. · e
I
eI
2 I: sl1::Jld be cheap and easily available
3. Hammers: Hammers are used as striking iools These are clas•
3 It shc,ulo be easy to fire. sified as under
4 It should not produce:' excess smoke and flying a:;h (i) Hand Hamrner
e
I-
Method of lightening the fire:
(1i) Sledge Hamnie,.
The si:ace inside the hearth is filled with sofi l'lood. Whi!e burning ,.,:fr.--
(iii) Power Hammer -
this wooa. hesh coke is placed on one side ol the hearth. Ii- is slowly Hand han1mer ;s light in 1·,e1ght used by t e sm:!h h1m::e!1 Sl,:;dge -· :-
brought to the cen!re of the hearth regulating the air suppl_y from the in r,,oriy size arid shapes Conrmon t}·pe of anvil u ed 1n
blower Wl",er. coke catches fire, the whole srace m the hearth is fillec forg1r;g !.••OP has the following parts.
with coke 1 h.=:fire should be as deep as possib!E i ide the centre of
the hearth. (al eoc1y (b) Horn
Then ,.,,,o, . is started on the furnace (c) Ch1pp"1g bloc!< (d) Fae<•
(e) Hn•d•t t,01c.- If) Row,o hOlf-
'J. Anvil: P. blccl- on which forging worl- 1s d•Jr'I€ 1s kn,Jw11 35 211.,:I
It · maoe up o! a cast iron, stee! r,: wrouahl ir,.n I! al.I:; .,!' ... (g'• '!:-,· (h) Stand e
suppo:11:1(; device for all forg;ng op€'r tions since it is car,able
ol w:th:.tr..r.d1ng very heavy blows Tile anvil is supported F.1the•
on ;, iron base. or wooden block or mounted on lhe 1oundation.
Wt1g111o• the anvrl vanes from 100 !o 150 kgs. It is avJilahlc,
C
 hammer is heavier 111 weight and is used of the handle then i1 is st,2.ighi pean hammer when the pean 1s
by the sm:ifi's helper All th<: hammers across the axis of t:1e hand,e tl,e11it 1s called r;ro s pcan hammer, in
are divided into lour parts namely pean. case shapt: of the pean in same as shcp,:>cf 1l1e fac1: lhen 11 is
eye. che •,,s and face. Hand hammer cJoublt: onded If th€' shape oi tt1e pean is sr,•1e,,c.:I tl1en 11 is ball
are of tour types based on the shape ol pean hamrner Tl1e weight 01 hand hammer variec; trom i kg to 2 kg
the pean If the pvan is along the axis and that of sied9e hammer if: 3 kg to 8 kg Commc•, types of
hammers used 8re shown in lhe ligure
 99
I I''. ':• I .\:'111\ 11 10! < t· •'

, · "•v,,:, u;:,c:::u IJdll:III :s 21e sp1111g r,a1nn,t--1s rrneurnJhc r

hfllnrnl-r'> steam hammers and drop hammers rower t1:=,mme1 are J
o<mr,rullv driven by Plectrrcal power 1 he job to be proouced IsplJcod
on lh<.• anvil ot rhe hammer With the help of a lever the we1gllt Is i
1tllowed to fall 011 the JOb The fa,10,s which 1nfluenr,t' he wor i•:'J of 1
'1arnme, are·
Pick up Tong
(i) Size and shape of ihe job
(ri) Falling weighi of the hammer ;
(iii) Herghi oi faff1nq weight .,;
- fr.
4. Tongs: Tongs are used for holding and turning he: metalpieces. ,f Rour,d Hallow Tor.;i
Depending upon their use, tongs are classified rnto many ty:Jes.
Afl types cf tongs have similar construction e cept the mouth. i Fig. 4 5 Various types of Tongs

A tong has two fegs rive:ted from a suitable pf2ce These are
made up of mifd steel. Variot.:s types 01 tongs used in forging
shop are shown in the frgure. II is made in two piecesand both
I
t'
5. Chii:se's: Chreseis are used fer cutting metal piE-ces In hot and
cold state Chiesets are divided into following categories

the pieces are joined by hinges The length ti the tongs vary i (a) Hot cn,esel
(b) Cold Chiesel
from 12" to tne 18"_ It is classified based on the shape of the :i
mouth of the tongs. (c) Hardie sot
- He;;d
j
.,ft
,2-

i
Squar Haliow Tong ; ;;.

i \ t ·( 5u«,ng ecgc

1· Fig. -1.f. (a) Hot Chieset Fig. <1 6 (c) Hard11; Set
H?ad
/
\l·,6.:>e,
Prncm Tong I.\ ... ./
g Il. '

;;
,i- --­
1 Cun ,,g icd ·s
1
j
§
t
 1/
11. SotHammers: SL't ll,11nnwrs t1.1vc s,11111..,, "•'I"", .,, 111,11 of
ll.1t1Prs lhei:C' ,1rr- u,-.,•u tor m.1 ., t: thl- -.,ulf,n ,. 1,l,J11o' lur1ni11q I
\
J

l
,md maki11g c,"n••IS It IS m,10( ol 1c,01 lt•,il T11, J()i, IS 1,p
ported 011 th0 anv11 ;-1110 SC'I hamm, , 1s h.1111nu,, vd n11 ,1

- -- l J

·i
r.

f. :j
Plan,:, F"ar tl

r,g. 4.12 Sel Hammer j

,t

IT
i
Comparison between a Flatter and a Set Hammer

.
,5; ,'.it;•. Fig 4.14 Ulc . lrnr,

2
haa :. ;•::, II has wire handle It has a woodc'r;..11,,nu!c i

. {
;i
.
4.3 The: edges of !he llat1er II h,J l1arn NJg,·s -
•.

PREC/\UTIONS WHILE USING FORGING TOOLS AND EOUIPr,1ENTS h 11

.
The· lollow;ng I'0Inls inust b<::ker•I 11, a n11nd while: working wit ,e
ar 'blunt l , lorging \ools
1 Hearth ,:hould rx, l1yhtenecl ,,, 1,rn1•;_r way
12. C mping vice: leg vice is only cl3n1p1ng deviceuspd 1nsmithy
shop. II is mounted with the table or wooden base. I! ronsists . ;> I br11111.-.11ng shou!'1 ri01 lJC' cj,;n,· ir, bzy muod
of twoJaws, a spring and a leg. Hot work p,eccs a,e clamped ·, 1 .. , ,v·- L,I, ,vvs siioulJ rv1l b.=l:!V£''1 r I thp tail ol \I\•' .:inv•I
1 in it while working.
4_ I i;rn,r'.ir,r:·, ::.huuld hi!ve prop,;r lt3fll!IC"· lenym
Nur OI Box
c, 1.t:;1gtii r,f the tong should he b•pt I,c1we n \ 5. to 18" Ttit:: hl "J
should i•e kepl co0I whil" v,O1k111 w11h ti
G r··ll:1l ch, ·s,ils -,\,oufd nut lk u,-,_J ,., the lu1g1ng sho
rv\,r,,i1100rn snould nol ren1,1111 or1 t:1e lace of the tlal\cr. pur,c:h
uI ,h,esel.
8. I 1,ver IIsc l li,:ns a11d sw;1l!'':; for cold me ctl
8 w111Ie \'.vking 0:1 furn:ice. k, ep the lire srnall but deep
Fig.
 ;c, [ .;l,:<V fr on1 c:rnkers. µarticularly whtlf' welding
)
l1 , l)') no! :vJd fresh coke on tllr l<'j• Qi the lire. put 1t al the side
, ln,1 n rli 111 later whc;1 IC(lUllt-d
4 .4 \:? J
I
OFORGING OPEAAl IONS
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t
l
h
e
:
f
i
r
e
:
b
u
r
n

l
i
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'
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-
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-
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 \_

CTEST-OUESTiONS)
1
r· ·" "' them,11n typPs '..>! •.,,,,11,i usually employed In 1cs1deI11,al buildings
,,•t.r·0s and indust11es Give :1,:- ;-;dvantages ;;nJ d15;:iav,111t::iges cl
6
C I S system of,,iring !June. 1987] \
1 Wt,;tt typeof 11·111•·9 \'Ou w,II provide 1n a w)1 :,no1,:,H1•1 ,.-.,lly't Exola1;·,
I 0UNDRY SHOP
1n detail. !Nov.. 1987] i
Wltat do you unoe1siand by the term batter)' ? WhJi a1e storage i
bat:enes? Give the <>rnpere hour capacity of battery used on 11113 {
6.1 INHWDUCTION
trucks · !June. 1988] }
Dr aw a schematic diagram for e!ectrif1cation ol a model house. FoLnd: y: 7 !,(; plac(, wh rE JU, arE prE:pared by ,nelring an,: P0•HI119
[Nov., 198[lj llie rnolkr mt-iai Irito rnou:d is knov,., ?S foundry
Nan1e the different types of wiring methods. Sketch and describe
Mould: A m,1u/d ,s a co·J:1)- sc preparE:d 1hat It can D-= use0 ,nake
any cne !June. 198 ]
c1stir.gs by mc--lte:n metal into It
h (a) Give the list ot materials used in Ba::eh-wH•ng
(bl Draw the connection dragram of stair ca;e wIrinq ,n 'On" posi- Pattern: Pat;1;;1n ,s a rr.odei o: anyth,(lg ·.vrdr.h ;s u-;ed t· ;;r•.:parr-
tion using two way switches (Nov., 1989j moulds b, plac'tng !l 1n sc1no
(a) Draw the actual connectron diagram for me;isuring voltage.arr.-.
castir,:;r Tl:l rr,0I1en meta! pc;ured !ntc mould.,..,, c,;c,imt::; o
perage and resistance 1n a -:ircuii.
"''> casru,g
lb) For 1eversing the direction of rototion, give !ht> conriections uf
capacitor 1n series with tne auxiliary .,v,nd,ng [May, 1990] Forg,:bility. fhe c;ap;::c,:y of a metal to gf't i, ,, qr I t_.1' Pd 1• '

ti (al Sl1ow a connect,on diagram of m,2ter-board for iix1ng of Energy-

meter. Iron :::lad main switch and fused on i! 6.2 HAND TOOLS
(bl Drnw th':' connec:ti-:::in diagram of .:1 single phase inot,_•r tosupply
,1nd rev rs,ng ,ts d1rect1on of rotation. [Feb.. 1991j
fht- cornrnc,r. haPd t;,o' u .:.c ,.., founrjry w0r art•
1. Showe!: 11 cur.$:Sl>' t>f ,rori p,rn with a v10ccien t•<1"d1e '.: ·:."!n
2'>

usec ior m1x::ig :-ind ceinditicn,, g t,,E: sand .,,,a :i-•er. t·an.sr .·,ng
u:'•
t:
( VIVA QUESTIONS)
rnixn;rp ,,. S("H' con: . .-,er
G:1:,.. 1-w tt1rep apphcot:,ins of electnc,tv 11se ,,., domestic ;ii:;pI1anu
Wt1:,; 1re :he m,w1 !ypc:s of cables,
;;.1.,:,1 .ire ,h.,. >'artous methor:s of ,.,,,;ng. 1n t,rn,se
tJ,.I"•: ·:..· ,·l:tttng tc--:>ls usec Ill ,;Ip· Iii[' Shvj._1
Whv 1•,11flu,g ,s done·?
I, Wr,,,t,._ ,1 l.J,lltery'>
I hg E. \ ShC">'o?I
l In wh11·h n,a,H'\er c I!::; <!It? con,1c=cl d ,.u ,n1·1 as0 :n0- ..li3yt 2 Trow,2ls: Ti1,2se a.1e -" tor !1n, 111n9 Ile•, ;·!.a·>-- >"
t
:
It• \•,rlf, tw rr:tr,npr c lls 1.re co, ,.1t. (•f,_.:,.1 to 1nc10-;1 t:.· "i't:' ,
,ns1de a,noc.,IC Cumn on shapes 0 tr0we:s .:.re 1
,r0:.r, ,,
.
Wt,,,t ,, M,11t,mete1•;

t,
,ftE:'nl
- .

r v,,111,..... • ''- used to mec;SlJI•." ih- ·.•J1re,11t (Yr.,:; Nn1 They "''"' n,dde of iron w1rh a ,·,oooEn a,,o 1:-
i
ANSWE-AS,, 11 Acfr•yt'fdtCH, A, C·.•:i.c:,.',Jr Tefuv1:;1•. n ;;.,1 ,, I H 1,.,/11--
0,
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ti-LJJ..-I
<:; ....,,,.. PVC V./110::. L,•ac st,,1. tt,.::,_1 . ire (3) CleJ! ,_., :ir,q I r
"' ;,,9 l ..,.1. 14,.,.I C,)pp;n,_, Wlfl"Y c,.,nJuil ,'/lr,11g 1-.1 Kn.ft: ,;11, , :,I l,1
'•rl"•·r1(H1'·'",,,,._ t•·>"' '-!,·)." {6; 8.:11::·v _... ,r11t.,111ar1cn ,t . 1,.. \" -- - -:-:-Ii
\_ ---- :.
 , ouNQRY s•,o,:,

3 _,tte, /! I,t1e1 1:0 a li:11shing 1001 used for rEpa;ring the mouia anc
.,.,,, r;y :r,e rr,oL''O Sand Ld1er is also us d for removing I-:,os€
11,11 iroin .mould e

-
Fig. 6 7 Ora. S 1kc

8. Rammers: R::immers are used to, s1riw.Irg tne sa'"ld mass In ,nt=
Fig 6.3 (a) Li1ter
mould,ng box to pack it closely clIounc! one pattern Common t\ pes ' -'
ol rammers are shown as under The 111st one is known as peen
ramrner. It consists of a metallic rod w11h a prowctIon in the f:ont, e
,t is used in packing the sand at the corners of the oxes The
rn:ddle one Is 1Ioor ramme· it cor.s;s:s of a long steel b::ir w1tb a
Fig. 6.3. (b)
4. Hand Riddle: It Is used 101 ridding of sand 10 rem
Yonkee Lifter
reign material
pee'l in the front portion It 1s heavier In we,gh1 and used In 1\oor
moulding lo; ramming sand in very large ;notflds. The bottom rammer c_
­
: om it 1: consists of a .vooden frame fitted with a sc een of stand is ca!led hand rammer, one end is calied peen and the othe, end is
' rd wire mesh at 1he bot1om. butt. IHs us in bench moulding
e­e e
- ·-'= ====== C:
<;
Q 6rVS1SMNS7SNv\7\7\tsMNVSZ:,NV€)

( \ Fig. 6.8. Rammers

Fig. 6.4. Riddle 9. Slicks: They are used for repairing and finishing the mould surfaces
5. Strike off bar: It is a flat bar, made of wood :>r iron to strike oti the and edges after the pa1tern has been withdrawn. The commonly
.: .<cess sand from the top o1 a box after ramming. used slicks are heart and leaf, square and heart. spoon and bead
Its one edge made bevelled and the suiace perfectly smooth and heart and spoon. 01 these the las1 type is shown in Fig 6 9
r1••d p,ane. The above nomenclature of slicks is largely due to their shapes.
==c. 3t==
Ftg. 6.5. A strike off bar t'
6 Vent w,re: It is a ti'lin steel rod or wire carrying a pointed edge at
0·1c end and a wooden handle or a bent loop al the other. After
Fig. 6.9. A heart and spoon sllclr. C.
to. Smoothers and corner slicks: They are also linishing tools used
, .. m,n,ng anc1 striking of! the excess sand it i-, used to make small for repairing and finishing flat and round surfaces, round o, square
,,-.1,-s. called vents. in the sand mould to allow the exit of gases and corners and edges. Th;,se to,:ls !ind a spec,2I favour in dry sand
• ."PJm uu11n9 casting and loam sand. work.
it
-
Fig 66 Vent wire
l. o a\', Spike. I! t!> ., t,, •-:::t:d st e. rod naving a loop or ring at ,ts one
-:: •Jand a shar p01'.11 a: tf-ie other. It is u3ed to tap and draw
1,.nern . from thr• niou:d

,
' - • w
(
 Fig. E.10. $moo1hn and c-011,er sl1cl<.
11. Mallet: It is ;:i s1mil,H 1•. ,,, o, ,, 111c1ilt"t ;:1 that u ed 1r1 caq.Jo.':ll'y \',.-,.,
In lcundry we,k it •s 1..'Sl'" :<>r dr ,·.<n li'f' draw sp1h.e in!" 1, ,1.: r,;r. ;,• ! ·
and iher> r pping,t

c ·_)J·- - :--, _:_-==:)

(

f ,g &.11 t, :illc:
12. Swab: 1: :c,i. t;e,,,
t :ush u:-uJ for IT\0Iste:111ng 11,c E:d r•' :·
f,b1,
5-:;r,,:: OlC'l.!1,: 1•.'licr. iH':- ,r. contact Wllh tl,e pilt!ern U:fc!C.2. br:,.,.
w•:hiiraw,r:g tr.€: pane-rn t; ,s o:s;:. u PO !er coat:ng 1hr: 1,qu1:j ,1,:,:,.:
,.,,;; on !ht' 1'7'Culd tacE-s •r dr; sand niou!ds

r 1 6.12 Swan

13 Srrue pin: 11 Is a tap..r .. c rao of 1·.ood or ·ran wh•ch 1.s ;,,,,br-c-c:; 11

:ht' Scl"d ar.;:t lc>ter-:tt•cra·,.,.r; tc product a ho!e ca::E-d,ur·ri, r. thrr v
wn,cr. the mciten metat • poured into me r.iculo
14 Sprue cuUer: ;: is a!!:C- .: c-c !er the same i:,urposf- 2 .,- o·t•,· I:'
b..it 1 ,1:rE- 1 ,. r.12.:i..ed c.rlt-•t'nt.t:· t>otweer l E-•1 tJ!'E' ,,, l'l.1' •• " r :.,,···.
, ::S': tc; o;<-cuce '!C'€ .;Ile• 1orrm1r.9 ,np rncu!d It 1:. 11, 11
fc .,,.....c.1 a l :i:,•t:"''-:-d r,c- •·•ubE::'wh,ch • ,,\.._r.fted in •he s.nnc

Wooden fiasks .::.re- 2:::nera,11 uSt.·;J 1r. .;·,""• - - ,·:...........(\;

sand mould a•,-.av!' 'EGL re meial,•c bu,e::,,e:: c"'"' :·;e. 0-.•...1, . .:
fer dry,r",g La,gE' an.:J hE-a'.), bo,es are rna(:.o :--- ._2,;· ••.Jr .••
a n dc a r . , t-,aro:es anc 011:::,s as they arE -,·:;_• C'..: ·•.t-; c :::·:·.
rig 6 13 Spue cutter ho1s1s ere Th., cics?'J .,-'..;Ilic t:as, r; ". ,. ,• , : " ••3:- _
1 . Clc1mp5. cotters and wedges: T1,e> are rnaoi- ot c;: el and areu•,
• ut r,1,.,,,µ-,,g fht- rnc\.:c •· h.-,,M' f;rrnt\' 1e,g,:.1t',,:r Jurrn,J p0ur10JQ
,,. l,l;t1ls and w-11rf prCC<'!> T►,q :•r. ur..1:,1 !r rt-,•J,.,ct- ltlf>II r,ro,,_-rt,<,'
n·:r•u•'! (.•· L'-"'":'! r,£l',JE:-:r: L"v "'tttl ,1t-...:
1
,• • .., ,. , ,1 : ,.

..
 h d 111 t'I 11_1 ·.' _, I , Ir I i 1• .:} II\) J 1,-J ; ff I )(/1·f'11 I,_ l;,1 ;•

\'·:- 0-..., 1' 1::,. l 1 1. • h. 'i'11! i-nq r,11 1 I; rI f\ , '

.. ·I '. t ! ;- .J{) :f\ ' 11 i1 1 <
,.11 ll1f y ·:, ''

I I' ',t!f, 1·1

1
1\,1 ii r \,J J 1 :... 1: r, • I•'• t·-'-, , ' I!,, •I • .111• • .l ',•,t· I ' ', 1 • Jtr '
',1<·11 J '11[:'.lt· o1 .h{I r; jJ!.,:, I,, 1/1 (H!Jfl(/ (,l1.Jµ'· af1 it,,,1 1,,•- .cJ

!,,·. ,1c 1111<..c. c1· •1l(' 1 1 ,,,v,cJ,- .. ,,:i1,1< 1.,,y 1,,,,111J i- 1:· 1,1 ,,,,,
< :1'-.Hl i'.:: !:l1(i'.1t· ('. 1, 11 .'I r.· \ • •1'11)\\, d ti!•1l ·;.,r-11 tlir, :,, ! I ,-_ c ,I

IL j
\-_-,,:::._-rj)l\.Y
: "< ,
Fig 6 16 (b) Round Flasl- \' . '
- ;:::·L,.:-
-> --,-
.. . ,;_/.:'.- ·.;·
•'-'.•./-- -
•

'. ·--<- :
I _. ...1..·
1

l ·, -,,..,,..1
.
fig Gc r d Crane·

· '-... ". '.

-17 (bi L OI<

' • ,. 21. Crucibles: They ·are m2.ce oi ,e1ractory matero,,I and ;1rp s,m,la, 11,
' ./·. ) · (? _,-
-' ..
.
.. .1 7 .. shape lo the ladles They 2.re used as metal melting 001;;. The raw
ma1er1al or charge ,s broken ,nto small p•ece ,,nd place:: 111 them
I
They a,e then placed :n crucible 01 pit lurn;:;ce,; which ;11e coke
!11ed In oil-lir;;d i,li,ng h,·naces they fo,m ar, ic1:egra1 1;,11i oi the
-.........., u_ R ./ .• fuinace itsell a:,d the chorge 1s pui into p--,r, whilP ·",ev a•e in
. '--.!J 'tf_Y position After mell'ng oi m2ial. the cruc1b:e ;,!ace1J ,, co,,2-:1red
F,g. 6.16 (c) Soap flasl- fu,naces are taken out,111d received 1n handles F'our:ng .s y<=nerally
20. ladle;.. : :i,· · rece,ve, molte1 1 121c,1 lrom the mtcltino
die u<;N1 10 oone d11ectly by the:n •ristecJrJ 61 transfe11,n9 ,.,--=<11oltc-r1 m':!tal to
lur:;,1,: ,;,,:J p •u! ti,€ ,same into the IT'•ould ft1oi1 size is des1grate; ladles But in ths-_case o! an oil-1,red furnacf- n,~ moliE:n metal ,s
l- :r."'" ri- ial holding capacity Small h,wd :s!•anl< ladles. usej 1.;1 Lrst received 1n a ladiP and !hen poured into •t"· n,o..,.,J._,
3 s11,g!<• ·•·-,.ul<le1 ,He provided with c,ri!y OP: t,.;c,dlr- ;,nd are n8d'
22. Pattern Making: Pat1e1•·, 1s cJn minor ,md\.JE: y ,, .. c:d·-1111q when it
111 d1ft,-r,,•>1 ,:;ip;,c,t1ec; upto il maximum ot ?C, ..:;
,s used with suirahlf '"( uld1r,g matena ,l t to•~ · .1 1 c2, ••-y c lled as
th-:,,_., and large size ladles a,e p1ov1u- <1 v..111 l1dnd1es on botn
:.1-.h:S i-: 1.; 1,a·1dlc-d by two moulders Tllt=y ,ir-2 d•So rnadp in dlf1Gr
mould When thrs cav111, •'., fillc-d l•v molten lllt·t. • ,, ,<1 atih :,vl1c.J1t,cat1on
wt- get the ce'.,11ed .:.,1•,11ny Some atlow;c,,,,., • ,,,,. µ,.,, •o;c,r, 1n the
,
•.!111 !,,, .\•tt1 lhl''' ,ao c,ty va,y,119 !furn·;L,;c,,,. i5l· kg A ty1)1ca pi.lttern Tiley a,.-,, a f,_ 1:0•1,s
han•.: .;1,,...,. l;,cJ1c ·!'- :.hown in F'"1 l' 17
f.:::::.:--
(t ,2, Al!n•,",1r111CP 11 I t,r,1H.,.1Ut.- ,)1 n1etcll
-:'1 --
.\' ". tl('" -
111• A!ll,i.' -1•,c·,.... I•
1 l)r<_1ll ,.,,'.t}\•, ·11",
,,, ,, ,,.,1r1 1
,, ,, •-> \ it-•t, t,,q, t.