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Lecture 01

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Lecture 01

Uploaded by

ranganamanoj
Copyright
© © All Rights Reserved
Available Formats
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Workshop Technology

Module Outline

 Introduction and Machine Safety


 Basic Workshop machines and Tools
 Introduction to Metrology
 Introduction to Welding processes
 Casting Processes
 Introduction to Forging Processes
 Operations of Lathe machine
 Introduction to technical drawings
What is a workshop?

 Defined as a workspace ( a room or a building) which consist of space,


Machines and tools to carry out manufacturing processes of a product or
repairing of a Product.
 There are different types of workshops defined based on the available
machines and the primary function of the workshop.
• Machine shops
• Fitting shops
• Welding shops
• Motor vehicle shops, metal shops, foundry shops and forging shops.
Manufacturing Processes

 Manufacturing process is a part of a


production process which is directly
concerned with the change of form
or dimensions of the part produced.
 Raw materials are converted to
finished or semi-finished product
according to the dimension and
required properties specified by the
product design.
Classification of Manufacturing processes

 Manufacturing processes can be categorized into following six major


categories
1. Primary Shaping Processes
2. Secondary shaping or machining processes
3. Metal forming processes
4. Joining processes
5. Surface finishing processes
6. Processes effecting change in properties
Primary Shaping Processes

 Convert raw materials or scraps to basic primary shaped and sized


products
 The finished product may require further working to finish component to
the desired shape and size because the surface finish is rough.
 Typical examples of the products that are produced by these process are
machine beds, automobile engines, carburetors, flywheels etc.
 Ex: Machine beds – Casting or Forging
Primary Shaping Processes Contd.

 Casting
 Powder metallurgy
 Bending
 Forging

Figure 01 : Sand casting

Figure 02 : Closed die steel forging


Secondary shaping or machining processes

 The process of removing the undesired or unwanted material from the


workpiece or job or component to produce a required shape using a cutting
tool is known as machining.
 This can be done by a manual process or by using a machine called machine
tool(lathe, milling machine, drilling, shaper, planner, slotter).
 The secondary processes require the use of one or more machine tools,
various single or multi-point cutting tools (cutters), job holding devices,
marking and measuring instruments, testing devices and gauges etc.
Classification of Machine Tools

 Conventional or traditional machine tools like Lathes, Milling machines, etc.


are used more widely for faster material removal by shearing or brittle
fracturing.
 Non-conventional or non-traditional machine tools: like EDM, ECM, USM,
etc. which remove material from exotic materials slowly by electro-physical,
electro-chemical processes.
 Modern numerical and computer-controlled machine tools: Like CNC
lathe, CNC milling
Generally used Manual Machine tools

Figure 03 : Universal Milling Machine Figure 04 : Lathe Machine


Generally used Manual Machine tools

Figure 05 : Shaping Machine Figure 06 : CNC Lathe Machine


Different types of Machining operations

 Turning  Shaping

 Threading  Slotting
 Broaching
 Knurling
 Grinding
 Milling
 Gear cutting
 Drilling  Thread cutting

 Boring Figure 07 : Machining operations


Metal forming processes

 In metal forming processes raw material is permanently deformed to get


the desired shape by applying suitable force, pressure or stresses, like
compression, tension and shear or their combination.
 Metal forming can be categorized in to two main categories

 Hot Working processes


 In hot working processes raw material (billet) is preheated before starting the
process

 Cold Working Processes


Metal forming processes contd.

Hot working processes Cold working processes


 Forging  Cold forging

 Rolling  Cold rolling

 Hot spinning  Cold heading

 Extrusion  Cold drawing

 Hot drawing  Wire drawing

 Hot spinning
Joining Processes

 The process of putting the parts together to form the product, which
performs the desired function, is called assembly
 Most of the products cannot be manufactured as single unit they are
manufactured as different components using one or more of the above
manufacturing processes, and these components are assembled to get the
desired product.
 The joining processes are carried out by fusing, pressing, rubbing, riveting,
screwing or any other means of assembling.
Joining Processes contd.

 Welding (plastic or fusion)


 Brazing
 Soldering
 Riveting
 Screwing
 Press fitting
 Nut and bolt joints

Figure 08 : Basic arc welding


Joining Processes contd.

Figure 09 : Pop riveting process Figure 10 : Screwing process


Surface Finishing Processes

 Surface finishing processes are utilized


for imparting intended surface finish on
the surface of a job. By imparting a
surface finishing process, dimension of
part is not changed functionally.
 Example : Polishing , Grinding, Powder
coating
Figure 11 : Powder Coating process
What Is Workshop Practice ?

 Workshop practice gives the basic working knowledge required to produce


various engineering products.
 It explains the construction, function, use and application of different
working tools, equipment, machines as well as the technique of
manufacturing a product from its raw material
“ THANK YOU.

Annual Review
20

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