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Sunday, June 6, 2010

GENERAL WORKSHOP PRACTICE

GENERAL WORKSHOP PRACTICE - I
L T P
- - 7
RATIONALE

In order to have a balanced overall development of diploma engineers, it is necessary to integrate theory with practice. General workshop practices are included in the curriculum in order to provide hand on experience about use of different tools and basic manufacturing practices.

This course aims at developing general manual and machining skills in the students. Besides above, the development of dignity of labour, precision, safety at work place, team working and development of right attitude are the other objectives.
DETAILED CONTENTS (PRACTICALS)

The following shops are included in the syllabus:
1. Carpentry and Painting Shop-I
2. Fitting Shop -I
3. Welding Shop-I
4. Electric Shop –I
5. Smithy Shop –I or Electronic Shop-I
6. Sheet Metal Shop-I
Note:
1. The branches e.g. Civil Engineering, Electrical Engineering, Mechanical Engineering, Mechanical (RAC), Production and Industrial Engineering will do Smithy Shop - I instead of Electronic shop- I
2. The branches e.g. Electronics and Communication Engineering, ECE (Spl. in Microprocessor), Electronics and Telecommunication Engineering, Instrumentation and Control, Computer Engineering and Information Technology will do Electronic shop-I instead of Smithy Shop-I.

3. The branches e.g Computer Engineering and Information Technology will do ONLY Workshop Practice –I. The details are given in their respective curricula.

1. Carpentry and Painting Shop – I
1.1 Introduction to various types of wood such as Deodar, Kail, Partal, Teak, Hollack, Sheesham, Champ, etc. (Demonstration and their identification).
1.2 Demonstration, function and use of commonly used hand tools. Care, maintenance of tools and safety measures to be observed.
Job I Marking, sawing and planing practice
Job II Extensive planing practice on soft wood
Job III Chiseling practice
1.3 Introduction to various types of wooden joints, their relative advantages and uses.
Job IV Preparation of half lap joint
Job V Preparation of Mortise and Tenon Joint
1.4 Demonstration of various methods of painting wooden items.
Job V Preparation of surface before painting.
Job VI Application of primer coat
Job VII Painting wooden items by brush/roller/spray

2. Fitting Shop – I
2.1 Introduction to fitting shop, common materials used in fitting shop, Identification of materials. (e.g. Steel, Brass, Copper, Aluminium etc.) Identification of various sections of steel such as Flat, Angle, Tee, Channel, Bar Girder, Square, Z-Section, etc.
2.2 Description and demonstration of various types of work benches. Holding devices and files, Precautions while filing
Job I Filing practice (Production of flat surfaces) Checking by straight edge.
Job II Marking of jobs, use of marking tools and measuring instruments.
Job III Filing a dimensioned rectangular or Square piece of an accuracy of +_ 0.25mm.
2.3 Introduction to chipping, Demonstration on chipping and its applications. Demonstration and function of chipping tools.
Job IV Chipping practice
2.4 Description and demonstration of simple operation of hack-sawing, demonstration and description of various types of blades and their specifications, uses and method of fitting the blade.
Job V Making a cutout from a square piece of MS Flat using Hand hacksaw.

3. Welding Shop – I
3.1 Introduction to welding and its importance in engineering practice; types of welding; common materials that can be welded, introduction to welding equipment e.g. a.c. welding set, d.c. rectifier, Electrode holder, electrodes and their specifications, welding screens and other welding related equipment and accessories.
3.2 Electric arc welding, (ac. and dc.) precautions while using electric arc welding, Practice in setting current and voltage for striking proper arc.
Job I Practice of striking arc while using electric arc welding set.
Job II Welding practice job on arc welding for making uniform and straight weld beads.
3.3 Various types of joints and end preparation.
Job III Preparation of butt joint by arc welding.
Job IV Preparation of lap joint by arc welding.
Job V Preparation of corner joint by using electric arc welding.
Job VI Preparation of Tee joint by arc welding.

4. Electric Shop – I
4.1 Study, demonstration and identification of common electrical materials such as wires, cables, switches, fuses, ceiling roses, battens, cleats and allied items, tools and accessories.
4.2 Study of electrical safety measures and demonstration about use of protective devices.
Job I Identification of phase, neutral and earth of domestic appliances and their
connection to two pin/three pin, plugs.
Job II Lay out of complete wiring of a house (i) batten wiring (ii) plastic casing and
capping.
4.3 Study of common electrical appliances such as electric iron, electric kettle, ceiling fan/ table fan, electric mixer, electric Geyser, desert cooler etc.
Job III Testing and rectification of simulated faults in above said electrical appliances.
4.4 Introduction to a Lead-acid battery and its working.
Job IV Installation of a battery and to connect in series and parallel
Job V Charging a battery and testing it with the help of hydrometer and cell tester.

5. Smithy Shop – I
5.1 Demonstration and detailed explanation of tools and equipment used. Forging operations in Smithy shop. Safety measures to be observed in the smithy shop.
5.2 Demonstration and description of bending operation, upsetting operation, description and specification of anvils, swage blocks, hammers etc.
5.3 Demonstration and description of tongs, fullers, swages
Job I To forge a L-Hook.
Job II To prepare a job involving upsetting process
Job III To forge a chisel
Job IV To prepare a cube from a M.S. round by forging method.
OR
5. Electronic Shop - I
5.1 Identification and familiarization with the following tools used in electronic shop:
Tweezers, Screw drivers (different sizes), Pliers, Cutter, Sniper, Philips Screw Driver (Star Screw Driver),L Keys, Soldering Iron
Also demonstrate their uses.
5.2 Identification and familiarization with the following electronic instruments:
a) Multimeter analog and digital (Three and half digit)
b) Single beam simple CRO, Signal Generator and Function Generator; function of every knob on the front panel
c) Audio-oscillator having sine and square wave output
d) Regulated Power supply -- fixed voltage and variable voltage, single output as well as dual output.
Job I - Practice in the use of above-mentioned equipment. For this small experiment may be done
5.3 Various types of protective devices such as : Wire fuse, cartridge fuse etc. ,
5.4 Identification and familiarization with ear phone speaker connector, telephone jacks and similar male and female connectors
5.5 Safety precautions to be observed in the shop

NOTE: Demonstration Boards for the above components should be made.
Job II - Cut, strip, join and insulate two lengths of wires/ cables (repeat with different types of cables/wires)
Job III - Cut, strip, connect/solder/crimp different kinds of wires/ cables (including co-axial and shielded cable) to different types of power/general purpose/Audio Video/Telephone plugs, sockets, jacks, terminals, binding posts, terminal strips, connectors. The tasks should include making complete recording/ playback/ antenna/ speaker leads for common electronic products such as Radio, TV, CD Players, VCD/DVD Players, Cassette Recorder and Players, Hi-Fi equipment, Hand- set, microphone
Job IV-Cut, bend, tin component, Leeds, inserts and solder components (resistor, capacitor, diodes, transistors, FETs, IFT coils, ICs etc) on a PCB

6. Sheet Metal Shop –I
Introduction to sheet metal shop, use of hand tools and accessories e.g. different types of hammers, hard and soft mallet, sheet and wire gauge, necessary allowance required during job fabrication, selection of material.
6.1 Introduction and demonstration of hand tools used in sheet metal shop.
6.2 Introduction and demonstration of various machines and equipment used in sheet metal shop e.g. Shearing Machine, Bar Folder, Burring Machine, Turning Machin, Wiring Machine, Setting Down Machine, Forming Machine , Brake etc.
6.3 Introduction to various raw materials used in sheet metal shop e.g. black-plain sheet, galvanized-iron plain sheet, galvanised corrugated sheet, aluminium sheets etc.
6.4 Study of various types of Nuts, Bolts, Rivets, Steel Screws etc.
Job I Shearing practice on a sheet using hand shears.
a) Single rivetted lap joint/Double rivetted lap joint
b) Single cover plate chain type/zig-zag type single rivetted Butt Joint

RECOMMENDED BOOKS
• Workshop Technology I,II,III, by S K Hajra, Choudhary and A K Chaoudhary. Media Promoters and Publishers Pvt. Ltd., Bombay
• Workshop Technology by Manchanda Vol. I,II,III India Publishing House, Jalandhar.
• Manual on Workshop Practice by K Venkata Reddy, KL Narayana et al; MacMillan India Ltd. New Delhi
• Basic Workshop Practice Manual by T Jeyapoovan; Vikas Publishing House (P) Ltd., New Delhi

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