Work Shop Manual

International Islamic University
Islamabad
Department of Mechanical
Engineering
ME 121
Workshop Practice
PREFACE
It is well known that hands-on experience is the best way to learn. This lab manual is
designed to give the student hands-on laboratory experience to better reinforce their
knowledge about certain basic machines and their operations used in mechanical
workshop. Each experiment begins with a detailed discussion that provides all the
information needed to understand that lab. The discussion section is followed by a
detailed step-by-step procedure. Figures are provided as and where required. Each
experiment concludes with a detailed exercise to help the student interpret the results.
It will be highly appreciated receiving feedback for revisions from the instructors and
students.
Engr. Muhammad Ibrahim
Department of Mechanical Engineering

CONTENTS
Safety in the workshop 5
Bench Vise 8
Hammers 9
Centre And Dot Punch 10
Try- Square 11
Vernier Caliper - Manual Version 14

Digital Vernier Caliper 17
Micrometer 20
Depth Gauge Micrometer 22
Hand Hacksaw 24
Hand Tap 25
Tap Wrench and T-Handle 26
Hand Reamers 28
Files 30
Welding 34
Lathe operations 47
SAFETY IN THE WORKSHOP
All hand and machine tools can be dangerous if used improperly or carelessly. Working
safety is one of the first things a student should learn because the safe way is usually the
correct and most efficient way. A person learning to operate machine tools must first
learn the safety regulations and precautions for each tool or machine. Far too many
accidents are caused by careless work habits. It is easier and much more sensible to
develop safe work habits then to suffer the consequences of an accident.
Accidents don’t just happen; they are caused. The cause of an accident can usually be
traced to carelessness on someone’s part. Accidents can be avoided, and a person
learning the machine tool trade must first develop safe work habits.
A Safe Worker Should

1. Be neat, tidy, and safely dressed for the job.
2. Develop a responsibility for personal safety and the safety of fellow workers.
3. Think safely and work safely at all times.
Safety in the Shop

Safety in the shop may be divided into two broad categories.
1. Those practices which will prevent injury to workers.
2. Those practices which will prevent damage to machine and equipment. Too often
damaged equipment results in personal injuries.
In considering these categories, we must consider personal grooming, proper
housekeeping (including machine maintenance), safe work practices and fire prevention.
Personal Grooming
The following rules should be observed when working in a machine shop.
1. Always wear approved safety glasses in any area of the machine shop.
2. Never wear loose clothing when operating any machine. Always roll up your
sleeves or wear half sleeves. Clothing should be made of hard, smooth material
ME-121 Workshop Practice, DME 5

that will not catch easily in the machine. Loose fitting sweaters would not be
worn for this reason.
3. Remove wrist watches, rings, and bracelets; these can be caught in the machine,
causing painful and often serious injury.
4. Never wear gloves when operating a machine.
5. Long hair must be protected by a hair net or approved protective shop cap.
6. Canvas shoes or open-toed shoes must never be worn in a machine shop because
they offer no protection to the feet against chips or filling objects.
Housekeeping
The operator should remember that good housekeeping will never interfere with safety or
efficiency; therefore, the following points should be observed.
1. Always stop the machine before you attempt to clean it.
2. Always keep the machine and hand tools clean. Oily surfaces can be dangerous.
Metal chips left on the table surface may interfere with the safe clamping of a
work piece.
3. Oily surfaces should be cleaned with a cloth.
4. Do not keep tools and materials on the machine table- use a bench near the
machine.
5. Keep the floor free from oil and grease.
6. Always use brush and not a cloth to remove any chips.
7. Sweep up the metal chips on the floor frequently. They become embedded in the
soles of the shoes and can cause dangerous slippage if a person walks on concrete
floor.
Safe Work Practice

1. Do not operate any machine before understanding its mechanism and knowing
how to stop it quickly. Knowing how to stop a machine quickly can prevent a
serious injury.
2. Before operating any machine, be sure that the safety devices are present for the
operator’s protection and should not be removed.

3. Always disconnect the power and lock it off at the switch box when making
repairs to any machine. Place a sign on the machine noting that it is out of order.
4. Always be sure that the cutting tool and the work piece are properly mounted
before starting the machine.
5. Keep hands away from moving parts. It is dangerous practice to stop the machine
by hand.
6. Always stop a machine before measuring, cleaning or making adjustments. It is
dangerous to do any type of work around moving parts of machine.
7. Never have more than one person operate a machine at the same time.
8. Get first aid immediately for any injury, no matter how small. Report the injury
and be sure that the smallest cut is treated to prevent the chance of serious
infection.
9. Before you handle any work piece, remove all burrs and sharp edges with a file.
10. Do not attempt to lift heavy or old-shaped objects which are difficult to handle on
your own.
11. Be sure the work is clamped securely in the vise or to a machine table.
12. Whenever work is clamped, be sure the bolts are placed closer to the work piece
than to the clamping blocks.
13. Never start a machine until you are sure that the cutting tool and machine parts
will clear the work piece.
Fire Prevention
1. Always dispose off oily rags in proper metal containers.
2. Be sure of the proper procedure before lighting a gas furnace.
3. Know the location and the operation of every fire extinguisher in the shop.
4. Know the location of the nearest fire exit from the building.
5. Know the location of the nearest fire-alarm box and its operating procedure.
6. When using a welding or cutting torch, be sure to direct the sparks away from any
combustible material.

BENCH VISE
Vise is a mechanical screw apparatus used for holding or clamping a work piece to allow
work to be performed on it with tools such as sawing, chipping, filing, polishing, drilling,
reaming, and tapping operations.
Vises usually have one fixed jaw and another parallel jaw which is moved towards or
away from the fixed jaw by
the screw.
Vises are mounted close to the
edge of the bench. They
permit long work to be held in
vertical position. Vises may be
made of cast iron or cast steel.
Vise size is determined by the
width of the jaws.
Kinds of vise
1. Hand vises (hand-held).
2. Machine vises - drill vises (lie flat on a drill press bed). Vises of the same general
form are used also on milling machines and grinding machines.
3. Compound slide vises are more complex machine vises. They allow speed and
precision in the placement of the work.
4. Off-center vises.
5. Angle vises.
6. Sine vises, which use solving triangles and gauge blocks to set up a highly
accurate angle.
7. Rotary vises.
8. Die makers' vises.
9. Table vises.
10. Pin vises (for holding thin, long cylindrical objects by one end).

HAMMERS
The name hammer has also been used for devices that are designed to deliver blows. It is
a tool meant to deliver an impact to an object. The most common uses are for driving
nails, fitting parts, and breaking up objects. Hammers are often designed for a specific
purpose, and vary widely in their shape and structure. Usual features are a handle and a
head, with most of the weight in the head.
Many different types of hammers are used by the machinist. The most common being the
ball-peen hammer. The larger striking surface is called the face, and the smaller rounded
end is called the peen.
Soft-faced hammers have heads made of plastic, copper, or lead. These heads are
fastened to a steel body and can be replaced when worm. Soft-faced hammers are used in
assembling or dismantling parts so the finished surface of the work will not be marred.
Tools used in conjunction with hammers

1. Wood splitting wedge - hit with a hammer for spiting wood.
2. Chisel
3. Punch
4. Anvil

CENTRE AND DOT PUNCH
The center punch is made from mild steel with the point hardened and tempered so that it
withstands impact with the material it is marking. It is normally used to mark the center
of a hole to be drilled either by hand or on the drilling machine.
BALL PEIN HAMMER
CENTRE
PUNCH
MATERIAL
CENTRE DOT
PUNCH PUNCH
The dot punch is a lighter and thinner version of the center punch and is used basically
for the same job. However, it is more accurately as the dot produced is smaller.
Both the center and dot punches are used in the same way. A ball pin hammer is used to
tap the head of the punch and this delivers enough force to the point of the punch to put a
small indentation into the surface of the material.
Two Uses of the Dot Punch and Centre Punch

1. A hole is to be drilled in this material. One possible danger is that the hand drill
will slip when drilling first starts. If a center punch is used to mark the point of
drilling, slipping is unlikely to happen.
2. The copper is to be cut along the line. To
make it easier to see a dot punch had been
used to emphasize the line.
Copper sheet marked out for cutting

TRY-SQUARE
The engineers try-square is composed of two parts, the stock and the blade. They are
usually made from bright mild steel with the blade being hardened and tempered so that it
resists damage. It is normally used during engineering / metalworking projects
A typical use of an engineer’s try-square is to mark out material for cutting. The try
square is pushed against a straight side of the material (e.g. steel). An engineer’s scriber
is then used to scratch a line onto the surface of the metal. Sometimes engineers blue (a
dye/ink) is wiped onto the surface first so that the scratched line can be seen easily. The
material is then cut down to this straight line.
STOCK
(Fig 1) (Fig 2)
Look closely at try-square; you should see an interesting feature. There should be a small
slot that has been cut into the stock. This prevents small burrs caused by filing from
altering the try-squares accuracy. Dirt can also collect on metal surfaces, again the slot
helps prevent measuring angles inaccurately.
In the example seen below, the try-square is used to test that a 90 degree angle exists
across the edge of the steel. Although a burr exists on the edge of the steel, it fits into the
slot and does not affect the way the try-square is used.
SLOT
TRY-SQUARE

VERNIER CALIPER - MANUAL VERSION
The Vernier Caliper is a precision instrument that can be used to measure internal and
external distances extremely accurately. The example shown below is a manual caliper.
Measurements are interpreted from the scale by the user. This is more difficult than using
a digital Vernier Caliper which has an LCD digital display on which the reading appears.
The manual version has both an imperial and metric scale.
Manually operated Vernier Calipers can still be bought and remain popular because they
are much cheaper than the digital version. Also, the digital version requires a small
battery whereas the manual version does not need any power source.
How To Read A Measurement From The Scales

Example#1: The external measurement (diameter) of a round section piece of steel is
measured using a Vernier Caliper, metric scale.
1. The main metric scale is read first and this shows that there are 13 whole
divisions before the 0 on the hundredths scale. Therefore, the first number is 13.
2. The ‘hundredths of mm’ scale is then read. Only one division on the main metric
scale lines up with a division on the hundredths scale below it, whilst others do
not. In the example below, the 21st division on the hundredths scale lines up
exactly with a division on the metric scale above (each division on the hundredths
scale is equivalent to 0.02mm)..

3. This 21 is multiplied by 0.02 giving 0.42 as the answer.
4. The 13 and the 0.42 are added together to give the final measurement of 13.42mm
(the diameter of the piece of round section steel).
EXAMPLE #1 13+21×0.02
13+0.42
21
13.42mm (final answer)
METRIC SCALE
MAIN METRIC
SCALE
EXAMPLE #2
MAIN METRIC SCALE

HUNDREDTHS of mm

VERNIER CALIPER EXERCISE
MAIN METRIC SCALE

HUNDREDTHS of mm
MAIN METRIC SCALE

HUNDREDTHS of mm
MAIN METRIC HUNDREDTHS of mm

SCALE

DIGITAL VERNIER CALIPER
The Vernier Caliper is a precision instrument that can be used to measure internal and
external distances extremely accurately. The example shown below is a digital Vernier
Caliper as the distances are read from a LCD display. The most important parts have been
labeled.
Earlier versions of this type of measuring instrument had to be read by looking carefully
at the imperial or metric scale and there was a need for very good eyesight in order to
read the small sliding scale. The digital version requires a small battery.
Digital Vernier calipers are easier to use as the measurement is clearly displayed and
also, by pressing the inch/mm button the distance can be read as metric or imperial.
The display is turned on with the on/off button. The external jaws should then be brought
together until they touch and the zero button should be pressed. The Vernier Caliper can
then be used to measure distances. Always go through this procedure when turning on the
display for the first time.

Measuring External Distances
The material to be measured is placed between the external jaws and they are carefully
brought together. The locking screw is tightened so that the jaws do not move apart. The
digital display can then be read. The distance can be read by in metric and imperial by
pressing the inch/mm button.
Measuring Internal Distances

The example below shows a Vernier Calipers being used to measure the internal diameter
of a piece of copper tube. The internal jaws are adjusted carefully until they touch the
internal ‘sides’. The locking screw is tightened so that an accurate measurement can be
made even if the jaws are ‘knocked’ against the sides as the jaws are removed from the
hole. The measurement is shown on the LCD display.

Measuring Depths
Measuring the depth of a hole can be very difficult. However, using a Vernier Caliper
makes this task easy. The base of the Vernier Caliper rests on the top of the hole and the
depth measuring blade is adjusted until it touches the bottom of the hole. The locking
screw is tightened and the measurement can be read on the LCD display.

MICROMETER
The micrometer is a precision measuring instrument, used by engineers. Each revolution
of the rachet moves the spindle face 0.5mm towards the anvil face. The object to be
measured is placed between the anvil face and the spindle face. The rachet is turned
clockwise until the object is ‘trapped’ between these two surfaces and the rachet makes a
‘clicking’ noise. This means that the rachet cannot be tightened anymore and the
measurement can be read.
ANVIL SPINDLE SPINDLE LOCK SLEEVETHIMBLE RACHET

FACE FACE NUT
FRAME
Example Measure Readings

Using the first example seen below:
1. Read the scale on the sleeve. The example clearly shows12 mm divisions.
2. Still reading the scale on the sleeve, a further ½ mm (0.5) measurement can be
seen on the bottom half of the scale. The measurement now reads 12.5mm.
3. Finally, the thimble scale shows 16 full divisions (these are hundredths of a
mm).The final measurement is 12.5mm + 0.16mm = 12.66

DEPTH GAUGE MICROMETER
The depth gauge micrometer is a precision measuring instrument, used by engineers to
measure depths. Each revolution of the rachet moves the spindle face 0.5mm towards the
bottom of the blind hole. The diagram below shows how the depth gauge is used. The
ratchet is turned clockwise until the spindle face touches the bottom of the blind hole.
The scales are read in exactly the same way as the scales of a normal micrometer (see
previous information sheets).
RACHAT
THIMBLE
SLEEVE
SPINDLE
SPINDLE
FACE

MICROMETER EXERCISE

HAND HACKSAW
The pistol-grip hand hacksaw is composed of three main parts; the frame, the handle, and
the blade. The frame can be either solid or adjustable. Hacksaw blades are made of high
speed molybdenum or tungsten-alloy steel that has been hardened and tampered.
How to Use Hacksaw

1. Check to make sure that the blade is of proper pitch for the job and that the teeth
point away from the handle.
2. Adjust the blade tension so that the blade cannot flex or bend.
3. Grasp the hacksaw as shown in the figure. Assume a comfortable stance, standing
erect with the left foot slightly ahead of the right foot.
4. Start the saw cut just outside and parallel to a previously scribed line.

HAND TAPS
Taps are cutting tools used to cut internal threads. They are made from high-quality tool
steel, hardened and ground. Two, three or four flutes are cut lengthwise across the threads
to form cutting edges, provide room for the chips, and admit cutting fluid to lubricate the
tap. The end of the shank is square so that a tap wrench can be used to turn the tap into a
hole. Hand taps are usually made in sets of three: taper, plug, and bottoming taps.
Taper taps have the longest bevel angle with 8 to 10 undeveloped threads.
All three tools are identical except for the bevel angle at the tip. The bevel at the tip
serves two purposes, it guides the tap into the hole and it ramp cuts the undeveloped first
threads. Taper taps have the longest bevel angle with 8 to 10 undeveloped threads.
Plug taps are the most popular of the three and have 3 to 5 undeveloped threads on the
bevel. Bottoming taps have only 1 to 1 1/2 undeveloped threads at the tip and should be
used only when full amount of threads specified on the drawing cannot be achieved by
the other two taps.
The bottom tap should only chase the threads originally cut by the taper or plug tap (for
hand tapping). The bottom tap is only forming the last few threads. In the past this
chasing of the bottom tap has caused some confusion with serial hand taps.

TAP WRENCH AND T-HANDLE
There are two tapping tools used to turn the tap and form the threads, the Tap Wrench
and the T-handle. Tap Wrenches have adjustable jaws that permit the use of a variety of
tap sizes (from 1" down to 1/16" diameter. The tap wrench is often used where there is
limited space between the spindle and the work piece.
T-HANDLE
TAP WRENCH
Some T-handles have jaws or split-collets for holding more than one size but not as wide
a range as Tap Wrenches. The largest T-handles will hold a maximum of a 1/2 inch
square-shanked tap and are used in confined areas where a Tap Wrench would not be
able to rotate. For the smaller taps such as 0-80 (.060 Dia.), ratchet T-handles allow the
thumb and forefinger to advance the tap into the hole.
It is important to use a tapping wrench that is proportional in size to the tap. Too large of
a wrench on a small tap can easily break the tap.
Tap a Hole By Hand

1. Select the correct taps and tap wrench for
the job.
2. Apply a suitable cutting fluid to the tap.
3. Place the tap in the hole as vertically as
possible, press downward on the wrench,
applying equal pressure on both handles
and turn clockwise (for right-hand thread)
for about two turns.
4. Remove the tap wrench and check the tap
for square ness.

5. If the tap has not entered squarely, remove it from the hole and restart it by
applying pressure in the direction from which to tap leans. Be careful not to
exceed too much pressure in the straightening process.
6. When a tap has been properly started, feed it into the hole turning the tap wrench.
7. Turn the tap clockwise one-quarter turn, and then turn it backward about one-half
turn to break the chip. Turning must be done with a steady motion to prevent the
tap from breaking.

HAND REAMERS
The reamer is a multi-fluted tool. A hand reamer is a tool used to finish drilled holes
accurately and provide a good finish. Reaming is generally performed by machine, but
there are times when a hand reamer must be used to finish a hole. Hand reamers, when
used properly, will produce holes accurate to size, shape, and finish.
Amount of material removed by the reamer is usually a small amount, from .001” to
.005”.
Problems that are encountered if the amount is too large are flute chipping, excessive
wear.
Purposes of hand reaming:

1. Obtaining a better surface finish for a hole
2. Enlarging a hole that is too small.
3. Straightening a crooked hole.
4. Achieving a close tolerance for a hole.
5. Rounding an oblong or oval hole.
Solid hand reamer with straight flutes for straight holes will produce straight and round
holes of a specific diameter from 1/8" to 1.5".
Solid hand reamer with spiral flutes for straight holes. Their spiraled flute allow them to
maintain a continuous cutting action in more difficult work conditions such as reaming a
hole in which a keyway has been previously cut.
REAMER WITH STRAIGHT FLUTES REAMER WITH SPIRAL FLUTES

Solid hand reamer with straight flutes for tapered holes will produce tapered holes of a
specific taper size and of a good surface finish. These reamers exist in various sizes
depending on the manufacturer’s standard.
SOLID HAND REAMER WITH STRAIGHT

FLUTES FOR TAPERED HOLES
One common standard is the Morse taper and another is the Brown and Sharp taper. A
set of two tapers is often used to create tapered holes where the first tapering tool is a
roughing taper with a distinct geometry.
The spiraled flutes of Solid hand reamer with spiral flutes for tapered holes allow them to
maintain a continuous cutting action in more difficult work conditions such as reaming a
hole in which a keyway has been previously cut.
SOLID HAND REAMER WITH SPIRAL

FLUTES FOR TAPERED HOLES

FILES
Hand files are used in the workshop to smooth rough edges, remove surplus material and
to produce finished surface. They can be used for a range of materials including wood
based material and metals such as brass and steel. They are made from high carbon steel
and they are heat treated so that they are tougher than the steel or other materials that they
are to be applied to.
Filing Methods
1. Through or cross filing
2. Draw filing
Hand files are normally held in both hands. The file is held flat against the surface it is to
cut / smooth. The file is then pushed forward and it cuts on the forward stroke. It is then
lifted away from the metal and returned to the starting point for the next push forward.
This is called ‘through filing’
Front view Top view

Through filing is normally the first stage in smoothing a piece of metal or plastic
If the surface produced by through filing is not good enough - the next stage is ‘draw
filing’. The diagram below shows how the file is held during this process. The file is held
in both hands by the blade and pushed forwards and backwards along the material. This
will further smooth the material.
The safe edge of a file does not have teeth. This is extremely useful when filing in
corners as shown in the diagram below. The safe edge is placed into the corner and
because it is smooth it does not damage the surface of the metal
Types of File
There are many different shapes / sections of files, some are shown below. They are
used for a variety of types of work. Files are classified according to their length, section /
shape and cut (tooth shape).

Hand File: Used for general filing of metals such as steel. They are rectangular in section
and are the most common type of file used in workshops.
Half Round File: Used for filing curved surfaces. A normal hand file with its flat
cutting edges is unsuitable for filing curved surfaces. However, the half round file has a
curved surface which is especially useful for filing internal curves.
Three Square File: Is triangular in section and very useful when filing ‘tight’ corners /
angles. The sharp edges allow the file to fit into corners when filing.
Knife File: Knife files are very useful when filing where there is little space. Knife files
are very thin and can fit into small gaps

Square File: The square file is quite thin and fits into corners well. They can be used to
file slots in metal or for filing where there is little space.
Files are often graded according to the roughness / smoothness of cut. The file that has
the least harsh teeth is graded as ‘very smooth’. The most abrasive of files is graded as
‘rough’. Some of the grades of cut are shown below.
Filing Tips
Filing is an important hand operation and one that can be mastered through patience and
practice. The following points should be observed when cross filing.
1. Never use a file without a handle.
2. Fasten the work to be filed, at about elbow height, in a vise.
3. To produce a flat surface, hold the right hand, right forearm, and left hand in a
horizontal plane. Push the file across the work in a straight line.
4. Apply pressure only on the forward stroke.
5. Never rub the fingers or hand across a surface being filed.
6. Keep the file clean by using a file card frequently.

WELDING
Definition
A materials joining process which produces coalescence (union) of materials by heating
them to suitable temperatures with or without the application of pressure or by the
application of pressure alone and with or without the use of filler material. Following are
the types of welding.
1. Arc Welding
Arc welding is further divided into following four groups
a) Shielded metal arc welding (SMAW) is a manual arc welding process that uses
a consumable electrode covered with a flux to lay the weld. An electric current, in
the form of either alternating current or direct current from a welding power
supply, is used to form an electric arc between the electrode and the metals to
be joined. The work-piece and the electrode melt forming a pool of molten metal
(weld pool) that cools to form a joint.
b) The Carbon Arc Welding (CAW) process is the oldest of all the arc welding
processes and is considered to be the beginning of arc welding. The Welding
Society defines carbon arc welding as "an arc welding process which produces
coalescence of metals by heating them with an arc between a carbon electrode and
the work-piece. No shielding is used. Pressure and filler metal may or may not be
used." It has limited applications today, but a variation or twin carbon arc welding
is more popular. Another variation uses compressed air for cutting.
c) Gas Tungsten Arc Welding (GTAW) is frequently referred to as TIG welding.
The need to weld nonferrous metals, particularly magnesium and aluminum,
challenged the industry. A solution was found called gas tungsten arc welding
(GTAW) and was defined as "an arc welding process which produces coalescence
of metals by heating them with an arc between a tungsten (non-consumable)
electrode and the work piece. Shielding is obtained from a gas or gas mixture."
TIG welding is a commonly used high quality welding process. TIG welding has
become a popular choice of welding processes
when high quality, precision welding is required.
In TIG welding an arc is formed between a non-
consumable tungsten electrode and the metal being
welded. Gas is fed through the torch to shield the
electrode and molten weld pool. If filler wire is
used, it is added to the weld pool separately.

TIG Welding Benefits
1. Superior quality welds
2. Welds can be made with or without filler metal
3. Precise control of welding variables (heat)
4. Free of spatter
5. Low distortion
Shielding Gases
1. Argon
2. Argon + Hydrogen
3. Argon/Helium
Helium is generally added to increase heat input (increase welding speed or weld
penetration). Hydrogen will result in cleaner looking welds and also increase heat
input; however, Hydrogen may promote porosity or hydrogen cracking.
GTAW Limitations
1. Requires greater welder dexterity than MIG or stick welding
2. Lower deposition rates
3. More costly for welding thick sections
Common GTAW Concerns
We can help optimize your welding process variables. Evaluate your current welding
parameters and techniques. Help eliminate common welding problems and
discontinuities such as those listed below:
Weld Discontinuities
1. Undercutting
2. Tungsten inclusions
3. Porosity
4. Weld metal cracks
5. Heat affected zone cracks
TIG Welding Problems
1. Erratic arc
2. Excessive electrode consumption
3. Oxidized weld deposit

4. Arc wandering
5. Porosity
6. Difficult arc starting
c) MIG WELDING: Gas Metal Arc Welding (GMAW) is frequently referred to as

MIG welding. MIG welding is a commonly used high deposition rate welding
process. Wire is continuously fed from a spool. MIG welding is therefore referred to
as a semiautomatic welding process.
MIG Welding Benefits

1. All position capability
2. Higher deposition rates than SMAW
3. Less operator skill required
4. Long welds can be made without starts and stops
5. Minimal post weld cleaning is required
MIG Welding Shielding Gas
The shielding gas, forms the arc plasma, stabilizes the arc on the metal being welded,
shields the arc and molten weld pool, and allows smooth transfer of metal from the
weld wire to the molten weld pool. There are three primary metal transfer modes:
1. Spray transfer
2. Globular transfer
3. Short circuiting transfer

The primary shielding gasses used are:
1. Argon
2. Argon - 1 to 5% Oxygen
3. Argon - 3 to 25% CO2
4. Argon/Helium
CO2 is also used in its pure form in some MIG welding processes. However, in some
applications the presence of CO2 in the shielding gas may adversely affect the
mechanical properties of the weld.
Common MIG Welding Concerns
We can help optimize your MIG welding process variables. Evaluate your current
welding parameters and techniques. Help eliminate common welding problems and
discontinuities such as those listed below:
Weld Discontinuities
1. Undercutting
2. Excessive melt-through
3. Incomplete fusion
4. Incomplete joint penetration
5. Porosity
6. Weld metal cracks
7. Heat affected zone cracks
MIG Welding Problems
1. Heavily oxidized weld deposit
2. Irregular wire feed
3. Burn-back
4. Porosity
5. Unstable arc
6. Difficult arc starting
d) Plasma arc welding (PAW) is defined as "an arc welding process which produces a
coalescence of metals by heating them with a constricted arc between an electrode
and the work piece (transferred arc) or the electrode and the constricting nozzle (non-
transferred arc). Shielding is obtained from the hot ionized gas issuing from the

orifice which may be supplemented by an auxiliary source of shielding gas."
Shielding gas may be an inert gas or a mixture of gases. Plasma welding has been
used for joining some of the thinner materials.
2. Brazing
Brazing is "a group of welding processes which produces coalescence of materials by
heating them to a suitable temperature and by using a filler metal, having a liquidus
above 450oC and below the solidus of the base materials. The filler metal is distributed
between the closely fitted surfaces of the joint by capillary attraction."
A braze is a very special form of weld, the base metal is theoretically not melted. There
are seven popular different processes within the brazing group. The source of heat differs
among the processes. Braze welding relates to welding processes using brass or bronze
filler metal, where the filler metal is not distributed by capillary action.
3. Oxy Fuel Gas Welding (OFW)
Oxy fuel gas welding is "a group of welding processes which produces coalescence by
heating materials with an oxy fuel gas flame or flames with or without the application of
pressure and with or without the use of filler metal."
There are four distinct processes within this group and in the case of two of them,
oxyacetylene welding and oxy-hydrogen welding; the classification is based on the fuel
gas used. The heat of the flame is created by the chemical reaction or the burning of the
gases. In the third process, air acetylene welding, air is used instead of oxygen, and in
the fourth category, pressure gas welding; pressure is applied in addition to the heat
from the burning of the gases. This welding process normally utilizes acetylene as the
fuel gas. The oxygen thermal cutting processes have much in common with this welding
process.
4. Resistance Welding (RW)
Resistance welding is "a group of welding processes which produces coalescence of
metals with the heat obtained from resistance of the work to electric current in a circuit of
which the work is a part, and by the application of pressure". In general, the difference
among the resistance welding processes has to do with the design of the weld and the
type of machine necessary to produce the weld. In almost all cases the processes are

applied automatically since the welding machines incorporate both electrical and
mechanical functions.
Resistance welding uses the application of electric current and mechanical pressure to
create a weld between two pieces of metal. Weld electrodes conduct the electric current
to the two pieces of metal as they are forged together.
The welding cycle must first develop sufficient heat to raise a small volume of metal to
the molten state. This metal then cools while under pressure until it has adequate strength
to hold the parts together. The current density and pressure must be sufficient to produce
a weld nugget, but not so high as to expel molten metal from the weld zone.
Resistance Spot Welding (RSW), Resistance Seam Welding (RSEW), and Projection
Welding (PW) are commonly used resistance welding processes.
Resistance Welding Benefits
1. High speed welding
2. Easily automated
3. Suitable for high rate production
4. Economical
Resistance Welding Limitations
1. Initial equipment costs
2. Lower tensile and fatigue strengths
3. Lap joints add weight and material
Common Resistance Welding Concerns
We can help optimize your welding process
variables. Evaluate your current welding parameters and techniques. Help eliminate
common welding problems and discontinuities such as those listed below:
Resistance Welding Problems and Discontinuities
1. Cracks
2. Electrode deposit on work
3. Porosity or cavities
4. Pin holes
5. Deep electrode indentation
6. Improper weld penetration

7. Surface appearance
8. Weld size
9. Irregular shaped welds
Other Welding Processes
This group of processes includes those, which are not best defined under the other
groupings. It consists of the following processes: electron beam welding, laser beam
welding, thermite welding, and other miscellaneous welding processes in addition to
electro slag welding which was mentioned previously.
Soldering (S)
Soldering is "a group of joining processes which produces coalescence of materials by
heating them to a suitable temperature and by using a filler metal having a liquidus not
exceeding 450 oC (840 oF) and below the solidus of the base materials. The filler metal is
distributed between the closely fitted surfaces of the joint by capillary attraction." There
are a number of different soldering processes and methods.
Soldering and Brazing are the joining processes where parts are joined without melting
the base metals. Soldering filler metals melt below 840 °F. Brazing filler metals melt
above 840 °F. Soldering is commonly used for electrical connection or mechanical joints,
but brazing is only used for mechanical joints due to the high temperatures involved.
Soldering and Brazing Benefits

1. Economical for complex assemblies
2. Joints require little or no finishing
3. Excellent for joining dissimilar metals
4. Little distortion, low residual stresses
5. Metallurgical bond is formed
6. Sound electrical component connection
Soldering and Brazing Issues
We can help optimize your joining process variables. Evaluate your current joining
parameters and techniques. Help eliminate common joining problems and discontinuities
such as those listed below:

Soldering and Brazing Joining Problems
1. No wetting
2. Excessive wetting
3. Flux entrapment
4. Lack of fill (voids, porosity)
5. Unsatisfactory surface appearance
6. Base metal erosion
Solid State Welding (SSW)
Solid state welding is "a group of welding processes which produces coalescence at
temperatures essentially below the melting point of the base materials being joined
without the addition of a brazing filler metal. Pressure may or may not be used."
The oldest of all welding processes forge welding belongs to this group. Others include
cold welding, diffusion welding, explosion welding, friction welding, hot pressure
welding, and ultrasonic welding. These processes are all different and utilize different
forms of energy for making welds.
Distortion
Welding involves highly localized heating of the metal being joined together. The
temperature distribution in the weldment is therefore non-uniform. Normally, the weld
metal and the heat affected zone (HAZ) are at temperatures substantially above that of the
unaffected base metal. Upon cooling, the weld pool solidifies and shrinks, exerting
stresses on the surrounding weld metal and HAZ
If the stresses produced from thermal expansion and contraction exceed the yield strength
of the parent metal, localized plastic deformation of the metal occurs. Plastic deformation
results in lasting change in the component dimensions and distorts the structure. This
causes distortion of weldments.
Several types of distortion are listed below:
1. Longitudinal shrinkage
2. Transverse shrinkage
3. Angular distortion
4. Bowing

5. Buckling
6. Twisting
Factors Affecting Distortion
If a component were uniformly heated and cooled
distortion would be minimized. However, welding
locally heats a component and the adjacent cold
metal restrains the heated material. This generates
stresses greater than yield stress causing
permanent distortion of the component.
Some of the factors affecting the distortion are listed below:
1. Amount of restraint
2. Welding procedure
3. Parent metal properties
4. Weld joint design
5. Part fit up
Restraint can be used to minimize distortion. Components welded without any external
restraint are free to move or distort in response to stresses from welding. It is not unusual
for many shops to clamp or restrain components to be welded in some manner to prevent
movement and distortion. This restraint does result in higher residual stresses in the
components.
Welding procedure impacts the amount of distortion primarily due to the amount of the
heat input produced. The welder has little control on the heat input specified in a welding
procedure. This does not prevent the welder from trying to minimize distortion. While the
welder needs to provide adequate weld metal, the welder should not needlessly increase
the total weld metal volume added to a weldment.
Parent metal properties, which have an effect on distortion, are coefficient of thermal
expansion and specific heat of the material. The coefficient of thermal expansion of the
metal affects the degree of thermal expansion and contraction and the associated stresses
that result from the welding process. This in turn determines the amount of distortion in a
component.

Weld joint design will affect the amount of distortion in a weldment. Both butt and fillet
joints may experience distortion. However, distortion is easier to minimize in butt joints.
Part fit up should be consistent to fabricate foreseeable and uniform shrinkage. Weld
joints should be adequately and consistently tacked to minimize movement between the
parts being joined by welding.
Welding Discontinuities
Some examples of welding discontinuities are shown below. Evaluation of the
discontinuity will determine if the discontinuity is a defect or an acceptable condition:
Incomplete Fusion - A weld discontinuity in which fusion did not occur between weld
metal and fusion faces or adjoining weld beads.
UNDERCUT
INCOMPLETE FUSSION
OVERLAP
INCOMPLETE FUSSION INCOMPLETE FUSSION
Undercut - A groove melted into the base

metal adjacent to the weld toe or weld root
and left unfilled by weld metal.
INCOMPLETE JOINT
PENETRATION
Overlap - The protrusion of weld metal beyond the weld toe or weld root.
Under-fill - A condition in which the
welds face or root surface extends below the adjacent surface of the base metal.
Incomplete Joint Penetration - A joint root condition in a groove weld in which weld
metal does not extend through the joint thickness
Partial joint penetration groove welds are commonly specified in lowly loaded
structures. However, incomplete joint penetration when a full penetration joint is required,
as depicted above, would be cause for rejection. A fix for an incomplete
penetration joint would be to back gouge and weld from the other side. Another
acceptable partial penetration joint is shown below.
Partial penetration joint on the left without discontinuities is an acceptable condition
where appropriate. Appropriate engineering decisions need to be applied to determine
what type of joint should be specified for a given application.
Several different representations of weld cracking
WELD METAL CRACK
Representation of a convex fillet weld without discontinuities
CONVEXITY
ACTUAL THROAT
LEG & SIZE
THEORETICAL THROAT

Welding Safety Guidelines
1. Shop staff approval is required before using any welding equipment.
2. Welders, assistants, and anyone else in the welding area shall wear glasses or
shields of recommended shades during welding operations.
3. The welder is responsible for erecting a screen around the welding area to protect
other personnel in the shop from eye injury.
4. Inspect all welding equipment to be used, prior to each use, for possible damage.
5. Avoid handling oxygen bottles with greasy hands, gloves or rags. Fatal explosions
have resulted from this cause.
6. Always strap tanks to a welding cart or a fixed object. Never allow a gas cylinder
to be free standing. Replace the safety cap on all cylinders when not in use.
7. When arc welding, make sure work and/or work table is properly grounded.
8. Do not arc weld in a wet area.
9. Be alert to possible fire hazards. Move the object to be welded to a safe location,
or, remove all flammable materials from the work area.
10. Never weld in the same area where degreasing or other cleaning operations are
performed.
11. Keep suitable fire extinguishing equipment nearby and know how to operate it.
12. Shut off the cylinder valves when the job is completed, release pressure from the
regulators by opening the torch valves momentarily and back out regulator
adjusting valves. Never leave the torch unattended with pressure in the hoses.
13. Utilize all protective equipment and clothing. Do not arc weld with any part of the
body uncovered, the arc light is actinic light (excessive ultraviolet) and will cause
burns similar to severe sunburn.
14. Never weld inside drums or enclosed spaces without adequate ventilation, or, the
use of airline respirators or self-contained breathing apparatus.
15. Check the ventilation system before starting to weld and periodically thereafter to
insure adequate performance. Welding fumes should not be allowed to get into
the rest of the shop working areas.
16. Never cut or weld any container that has held explosive or flammable materials.
Use prescribed methods for cleaning or flooding.

17. Never use wrenches or tools except those provided or approved by the gas
cylinder manufacturer to open valves. Never use a hammer to open or close
valves.
18. Abide by any other safety measures required for each particular type of welding.
19. Allow for proper ventilation when brazing or soldering. The fluxes are acidic and
toxic.
20. Do not weld on painted, galvanized or greasy, oily metals. Not only can the fumes
be toxic, but the welds will not be satisfactory and will fail in use.

LATHE MACHINE
Historically, the lathe is the forerunner of all machine tools. The first application of the
lathe principle was probably the potter’s wheel. This machine rotated a mass of clay to be
formed into a cylinder shape. The modern lathe operates on the same basic principle.
The workpiece is held and rotated on its axis while the cutting tool is advanced along the
lines of a desired cut. With suitable attachments, the lathe may be used for turning,
tapering, form turning, screw cutting, facing, drilling, boring, spinning, grinding, and
polishing operations. Cutting operations are performed with a cutting tool fed either
parallel or at right angle to the axis of the work. The cutting tool may also be fed at an
angle relative to the axis of the work for machining tapers and angles.
Modern production has led to the development of many special types of lathes, such as
engine, turret, single- and multiple-spindle automatic, tracer, numerically controlled
lathes and now computer controlled turning centers.

Parts of Lathe
Apron: Front part of the carriage assembly on which the carriage handwheel is mounted.
Bed: The bed is a heavy, rugged casting made to support the working part of the lathe.
On its top section are machined ways that guide and align the major parts of the lathe.
Carriage: The carriage consisting of three main parts, the saddle, cross-slide, and apron,
is used to move the cutting tool along the lathe bed. The saddle, an H-shaped casting
mounted on the top of the lathe ways, provides a means of mounting the cross-slide and
the apron.
CROSS FEED
HANDWHEEL
CARRIAGE
LOCK SCREW
Carriage Handwheel: A wheel with a handle used to move the carriage by hand by
means of a rack and pinion drive.
Center: A precision ground tapered cylinder with a 60º pointed tip and a Morse Taper
shaft. Used in the tailstock to support the end of a long workpiece. May also be used in
the headstock spindle to support work between centers at both ends.
Center Drill
1. A short, stubby drill used to form a pilot hole for drilling and a shallow
countersunk hole for mounting the end of a workpiece on a center.
2. The process of drilling a workpiece with a center drill.

Chucks: Lathe chucks are used for holding work for machining operations. The most
commonly used lathe chucks are: the three-jaw universal and four-jaw independent.
Compound: Movable platform on which the toolpost is mounted; can be set at an angle
to the workpiece. Also known as the compound slide and compound rest.
Compound Handwheel: A wheel with a handle used to move the compound slide in and
out. Also known as the compound feed.
Cross-slide: Platform that moves perpendicular to the lathe axis under control of the
cross-slide handwheel.
Cross-slide Handwheel: A wheel with a handle used to move the cross-slide in and out.
Also known as the cross feed.
Faceplate: A metal plate with a flat face that is mounted on the lathe spindle to hold
irregularly shaped work.
Halfnut:A nut formed from two halves which clamp around the lead screw under
control of the halfnut lever to move the carriage under power driven from the lead screw.
Halfnut Lever: Lever to engage the carriage with the leadscrew to move the carriage
under power.
Headstock: The main casting mounted on the left end of the bed, in which the spindle is
mounted. Houses the spindle speed change gears.
Lead screw: Precision screw that runs the length of the bed. Used to drive the carriage
under power for turning and thread cutting operations. Smaller lead screws are used
within the cross-slide and compound to move those parts by precise amounts.
Morse Taper: A taper of specific dimensions used to mate matching male and female
parts such that they lock together tightly and concentrically. Tapers are of various sizes
such as #0, #1, #2, #3, etc. with larger numbers representing larger sizes.
Quick-Change Gearbox: The quick-change gearbox, containing a number of different
sized gears, provides the feed rod and lead screw with various speeds for turning and
thread-cutting operations.
Saddle: A casting, shaped like an "H" when viewed from above, which rides along the
ways. Along with the apron, it is one of the two main components that make up the
carriage.

Spindle: Main rotating shaft on which the chuck or other work holding device is
mounted. It is mounted in precision bearings and passes through the headstock.
Tailstock: The tailstock can be adjusted for taper or parallel turning by two screw set in
the base. The tailstock can be locked in any position along the bed of the lathe by the
tailstock clamp. The tailstock spindle has an internal taper to receive the dead center,
which provides support for the
right-hand end of the job. The
tailstock hand wheel moves
the tailstock spindle in or out
of the tailstock casting. It can
also be used to provide a hand
feed for drilling and reaming
operations.
Tailstock Handwheel:
A wheel with a handle used to
move the tailstock ram in and
out of the tailstock casting
Tailstock Ram: A piston-type shaft that can be moved in and out of the tailstock by
turning the tailstock handwheel.
Tool: A cutting tool used to remove metal from a workpiece; usually made of High
Speed Steel or carbide.
Tool Blank: A piece of High Speed Steel from which a cutting tool is ground on a bench
grinder.
Toolpost: A holding device mounted on the compound into which the cutting tool is
clamped.
Ways: Precision ground surfaces along the top of the bed on which the saddle rides. The
ways are precisely aligned with the centerline of the lathe.

Terms Associated With Lathe
Between Centers
1. A dimension representing the maximum length of a workpiece that can be turned
between centers. A 7x10 lathe is 10" between centers; a 7x12 lathe is 12" between
centers.
2. A method of holding a workpiece by mounting it between a center in the
headstock spindle and a center in the tailstock spindle
Centerline: An imaginary line extending from the center of the spindle through the
center of the tailstock ram, representing the central axis of the lathe around which the
work rotates.
Facing: A lathe operation in which metal is removed from the end of workpiece to create
a smooth perpendicular surface, or face.
Swing: A dimension representing the largest diameter workpiece that a lathe can rotate.
The 7x10 or 7x12 mini-lathe has a 7" swing, meaning that the maximum size workpiece
that can rotate without hitting the bed is 7" in diameter
Turning: A lathe operation in which metal is removed from the outside diameter of the
workpiece, thus reducing its diameter to a desired size
Basic Operation of a Lathe

A lathe is a machine tool which turns cylindrical material, touches a cutting tool to it, and
cuts the material. As shown in Figure, a material is firmly fixed to the chuck of a lathe.
The lathe is switched on and the chuck is rotated. And since the table which fixed the
cutting tool can be moved in the vertical direction and the right-and-left direction by
operating some handles. It touches a cutting tool tip into the material by the operation,
and make a mechanical part.

When we use a lathe, the following things must take great care.
1. Don't keep a chuck handle attached to the chuck; it flies at the moment of turning
a lathe.
2. Don't touch the cutting tool table into the rotating chuck. Not only a cutting tool
or the table but my also damage the lathe.
Three Important Elements
In order to get an efficient process and beautiful surface at the lathe machining, it is
important to adjust a rotating speed, a cutting depth and a sending speed.
A beginner of a lathe must operate with low rotating speed, small cutting depth and low
sending speed.
1. Rotating Speed: It expresses with the number of rotations (rpm) of the chuck of a
lathe. When the rotating speed is high, processing speed becomes quick, and a
processing surface is finely finished. However, since a little operation mistakes may
lead to the serious accident, it is better to set low rotating speed at the first stage.
2. Cutting Depth: The cutting depth of the tool affects to the processing speed and the
roughness of surface. When the cutting depth is big, the processing speed becomes
quick, but the surface temperature becomes high, and it has rough surface. Moreover,
a life of byte also becomes short. If you do not know a suitable cutting depth, it is
better to set to small value.
3. Sending Speed (Feed): The sending speed of the tool also affects to the processing
speed and the roughness of surface. When the sending speed is high, the processing
speed becomes quick. When the sending speed is low, the surface is finished
beautiful. There are 'manual sending' which turns and operates a handle, and

'automatic sending' which advances a byte automatically. A beginner must use the
manual sending. Because serious accidents may be caused, such as touching the
rotating chuck around the byte in automatic sending,
Cutting Tools for Lathe

There are various kinds of the cutting tools for a lathe. We must choose them by the
materials and shape of a part. Three typical cutting tools are introduced in follows.
(a) Side Tool (b)Parting (c)Boring Bar

Tool
Form of Typical Cutting Tools

Figure (a) shows the well-used cutting tool called a side tool. It can process to cut an
outside surface and an edge surface.The cutting tool shown in Figure (b) is used at
parting and grooving processes. Its pointed end is slim, thus it is too weak. Don't add a
strong side-force to the tool. This tool must only be send in vertical direction. The cutting
tool shown in Figure (c) is called a boring bar. It is used to cut at an inside surface. It can
make a big and a high accurate hole, which cannot be process by a drill machine.
Setting of a Cutting Tool

Adjust the cutting tool in such a way that the edge of the tool is align with the central axis
of workpiece.

When the edge is higher than the center of material, the edge of a blade does not hit the
material, and it cannot cut at all. And may also break the tool post. Conversely, if the
edge is low, it becomes impossible to cut the center of material and may cause the tool tip
to wear out more rapidly.

Lathe Safety Guidelines
1. Make sure that the chuck, driveplate, or, faceplate is securely tightened onto the
lathespindle.
2. When removing the chuck, driveplate, or faceplate do not use machine power.
3. When installing the chuck, driveplate, or faceplate do not use machine power.
4. Move the tool bit a safe distance from the collet or chuck when inserting or
removing work.
5. Don't run the machine faster than the proper cutting speed – consult a speed and
feed table to determine the best speed.
6. In setting up the tool holder place it to the left side of the compound slide to
prevent the compound slide from running into the chuck or spindle attachments.
7. Always clamp the toolbit as short as possible in the toolholder to prevent it from
breaking or chattering.
8. Always make sure that the toolbit is sharp and has the proper clearance. Ask for
assistance making adjustments.
9. If any filing is done on work revolving in the lathe, file left handed to prevent
slipping into the chuck. Never use a file without a handle.
10. If work is turned between centers, make sure that proper adjustment is made
between centers and that the tailstock is locked in place.
11. If work is being turned between centers and expands due to heat generated from
cutting, readjust centers to avoid excessive friction.
12. Do not grasp or touch chips or turnings with your fingers, but get rid of them
using a blunt instrument. It is safer to turn off the lathe before clearing chips then
to leave it running.
13. Don't cut work completely through when turning between centers.
14. Remove chuck key from chuck immediately after using.
15. Turn chuck or faceplate through by hand before turning on the power to be sure
there is no binding or clearance problem.
16. Stop the machine before taking measurements.
17. Before cleaning the lathe remove tools from the tool post and tailstock.

International Islamic University Islamabad
Department of Mechanical Engineering
ME 121
Workshop manual
Lathe machine
Facing,Turning, Knurling and Threading

Submitted By Received By
Name: ____________________ Name: ____________________
Reg #: ____________________ Signature:________________
Date: _____________________ Date: _____________________

Lathe machine (Experiment#1)
Facing, Turning, Knurling and Threading
Job:
Tools:

Operations
1. Facing: Facing is the process of removing metal from the end of a workpiece to
produce a flat surface.
When a lathe cutting tool removes metal it applies considerable tangential force to the
work piece. To safely perform a facing operation the end of the work piece must be as
close as possible to the jaws of the chuck. The work piece should not extend more
than 2- 3 times its diameter from the chuck jaws unless a steady rest is used to
support the free end.
2. Turning: Turning is the removal of metal from the outer diameter of a rotating
cylindrical workpiece. Turning is used to reduce the diameter of the workpiece,
usually to a specified dimension, and to produce a smooth finish on the metal.
a) Straight Turning: Work turned in a lathe so that the diameter is constant over the
length of the work piece.

b) Taper Turning: An operation performed on a lathe that feeds a tool at an angle
to the length of the work piece in order to create a conical shape.
 d 2  d3 
 
2
 tan  L 
 
 
 d 2  d3 
  tan  
 2L 
 d 2  d3 
1  
θ  tan  2L 

3. Knurling: A knurling tool is used to press a pattern onto a round section. The pattern
is normally used as a grip for a handle.
Threading: Thread is defined as continuous helical ribs on a cylindrical shank. Screw

threads are used principally for fastening, adjusting, and transmitting power. To perform
these specific functions, various thread forms have been developed. A thread on the
outside of a cylinder or cone is an external (male) thread; a thread on the inside of a
member is an internal (female) thread. Most important terms used for threads are that of
the outer diameter and pitch. In the case of a metric thread, the bolt is named in
accordance with its outer diameter e.g. a bolt with a 5 mm outer diameter is known as an
M5 bolt. The "Pitch" of the tread is another important feature of a thread. The pitch is
defined as the interval (distance) between adjoining threads. e.g. Nuts & bolts must have
the same pitch as well as diameter if they are going to be used together.
Table 1
Table 2
External thread
Sr. d L d2 W pitch: P

Procedure
1. Clamped the work piece in a three- jaws chuck which mounts directly to the
spindle.
2. After clamping the work piece the second step is facing in which metal is
removed from the end of a work piece to produce a flat surface. Choose a cutting
tool with a slightly rounded tip. A tool with a sharp pointed tip will cut little
grooves across the face of the work and prevent you from getting a nice smooth
surface. Clamp the cutting tool in the tool post and turn the toolpost so that the tip
of the cutting tool will meet the end of the workpiece at a slight angle. It is
important that the tip of the cutting tool be right at the centerline of the lathe.
3. The third step is step or straight turning. Choose a tool bit with a slightly rounded
tip for the removal of small amount of metal. If you need to remove a lot of metal,
you might choose a tool with a sharper tip. Adjust the angle of the toolholder so
that the tool is approximately perpendicular to the side of the workpiece. The left
side of the tip should engage the work.
4. This step is similar to step 3, the only difference is that adjust the angle of tool
holder so that the tool is at angle θ to the central axis of work piece.
5. Knurling, The lathe is set so that the chuck revolves at a low speed. The knurling
tool is clamped in tool post and then pressed against the rotating workpiece and
pressure is slowly increased until the tool produces a pattern on the workpiece.
6. Next step is threading in which external threads are formed. Different tools are use
for external threads. There is setting available on lathe for threads on the basis of
pitch. After setting for a specific pitch the lead screw is geared to the work spindle
through a gear box or a change gear train. The carriages, when engaged to the lead
screw through a half nut, get the required lead motion with respect to the spindle
motion.

Work Shop Manual

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International Islamic University

Engr. Muhammad Ibrahim

Department of Mechanical Engineering

Vernier Caliper - Manual Version 14

A Safe Worker Should

Safety in the Shop

ME-121 Workshop Practice, DME 5

Safe Work Practice

ME-121 Workshop Practice, DME 6

ME-121 Workshop Practice, DME 7

ME-121 Workshop Practice, DME 8

Tools used in conjunction with hammers

ME-121 Workshop Practice, DME 9

BALL PEIN HAMMER

Two Uses of the Dot Punch and Centre Punch

ME-121 Workshop Practice, DME 10

ME-121 Workshop Practice, DME 11

How To Read A Measurement From The Scales

ME-121 Workshop Practice, DME 14

MAIN METRIC SCALE

ME-121 Workshop Practice, DME 15

MAIN METRIC SCALE

MAIN METRIC SCALE

MAIN METRIC HUNDREDTHS of mm

ME-121 Workshop Practice, DME 16

ME-121 Workshop Practice, DME 17

Measuring Internal Distances

ME-121 Workshop Practice, DME 18

ME-121 Workshop Practice, DME 19

ANVIL SPINDLE SPINDLE LOCK SLEEVETHIMBLE RACHET

Example Measure Readings

ME-121 Workshop Practice, DME 20

ME-121 Workshop Practice, DME 22

ME-121 Workshop Practice, DME 23

How to Use Hacksaw

ME-121 Workshop Practice, DME 24

ME-121 Workshop Practice, DME 25

Tap a Hole By Hand

ME-121 Workshop Practice, DME 26

ME-121 Workshop Practice, DME 27

Purposes of hand reaming:

REAMER WITH STRAIGHT FLUTES REAMER WITH SPIRAL FLUTES

ME-121 Workshop Practice, DME 28

SOLID HAND REAMER WITH STRAIGHT

SOLID HAND REAMER WITH SPIRAL

ME-121 Workshop Practice, DME 29

Front view Top view

ME-121 Workshop Practice, DME 30

ME-121 Workshop Practice, DME 31

ME-121 Workshop Practice, DME 32

ME-121 Workshop Practice, DME 33

ME-121 Workshop Practice, DME 34

ME-121 Workshop Practice, DME 35

c) MIG WELDING: Gas Metal Arc Welding (GMAW) is frequently referred to as

MIG Welding Benefits

ME-121 Workshop Practice, DME 36

ME-121 Workshop Practice, DME 37

ME-121 Workshop Practice, DME 38

ME-121 Workshop Practice, DME 39

Soldering and Brazing Benefits

ME-121 Workshop Practice, DME 40

ME-121 Workshop Practice, DME 41

ME-121 Workshop Practice, DME 42