W&DM Lab

NIIS INSTITUTE OF ENGINEERING&TECHNOLOGY
(NIIS GROUP OF INSTITUITION)

CAMPUS-II CHATABAR, KHORDHA
Workshop & Digital Manufacturing Lab
STUDENT NAME:……………………………………………………
REGD NO:………………………………………………………………
BRANCH:……………………………..SECTION……………………
YEAR…………………………SEMESTER………………………..
FACULTY INCHARGE
SAFETY RULES & UNSAFE PRACTICES
Remember that “accidents do not occur, they are caused”. With this in mind, strictly follow the
general safety rules given below and safe practices indicated in brief under each section.
1. Safety first, work next.

2. Know your job and follow instructions.
3. Avoid wearing clothing that might catch, moving or rotating parts. Long sleeves of
shirts, long hair, neck tie and jewellery are definite hazards in the shop.
4. Wear safety shoes. Do not wear canvas shoes; they give no resistance to hard
objects dropped on the feet.
5. Keep the area around machine or work clean.
6. Keep away from revolving work.
7. Be sure that all gaurds are in place.
8. One person only should operate the machine controls.
9. Use tools correctly and do not use them if they are not in proper working condition.
10. Wear safety goggles when working in areas, where sparks or chips of metal are
flying.
11. Get to know who in-charge of first aid is and where boxes are placed and where the
first aid can be found in case of emergency.
CONTENTS
1. FITTING SECTION 04 - 16
2. CARPENTRY SECTION 17 - 27
3. BLACK SMITHY SECTION 29- 37
4. TURNING&MILLING 41-64
SECTION
4.ROBOTICS LAB
5.ADDITIVE LAB
NIET Workshop and Digital Manufacturing B.TECH 1ST YEAR
Laboratory
1. FITTING
Introduction
Machine tools are capable of producing work at a faster rate, but, there are occasions when
components are processed at the bench. Sometimes, it becomes necessary to replace or repair
component which must be fit accurately with another component on reassembly. This involves a
certain amount of hand fitting. The assembly of machine tools, jigs, gauges, etc, involves certain
amount of bench work. The accuracy of work done depends upon the experience and skill of the
fitter.
The term ‘bench work’ refers to the production of components by hand on the bench, where as
fitting deals which the assembly of mating parts, through removal of metal, to obtain the required
fit.
Both the bench work and fitting requires the use of number of simple hand tools and
considerable manual efforts. The operations in the above works consist of filing, chipping,
scraping, sawing drilling, and tapping.
Holding Tools:
Bench Vice
The bench vice is a work holding device. It is the most commonly used vice in a fitting shop.
The bench vice is shown in figure below.
It is fixed to the bench with bolts and nuts. The vice body consists of two main parts, fixed jaw
and movable jaw. When the vice handle is turned in a clockwise direction, the sliding jaw forces
the work against the fixed jaw. Jaw plates are made of hardened steel. Serrations on the jaws
ensure a good grip. Jaw caps made of soft material are used to protect finished surfaces, gripped
in the vice. The size of the vice is specified by the length of the jaws.
Fig: Bench Vice

The vice body is made of cast iron which is strong in compression, weak in tension and so
fractures under shocks and therefore should never be hammered.
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DEPARTMENT OF MECHANICAL ENGINEERING Page 4
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V‐block is rectangular or square block with a V‐groove on one or both sides opposite to each
other. The angle of the ‘V’ is usually 900. V‐block with a clamp is used to hold cylindrical work
securely, during layout of measurement, for measuring operations or for drilling for this the bar
is faced longitudinally in the V‐Groove and the screw of V‐clamp is tightened. This grip the rod
is firm with its axis parallel to the axis of the v‐groove.
Fig: V‐ Block Fig: C ‐ Clamp
C‐ Clamp
This is used to hold work against an angle plate or v‐block or any other surface, when gripping is
require Its fixed jaw is shaped like English alphabet ‘C’ and the movable jaw is round in shape
and directly fitted to the threaded screw at the end .The working principle of this clamp is the
same as that of the bench vice.
Marking and Measuring Tools:
Surface Plate
The surface plate is machined to fine limits and is used for testing the flatness of the work piece.
It is also used for marking out small box and is more precious than the marking table. The degree
of the finished depends upon whether it is designed for bench work in a fitting shop or for using
in an inspection room; the surface plate is made of Cast Iron, hardened Steel or Granite stone. It
is specified by length, width, height and grade. Handles are provided on two opposite sides, to
carry it while shifting from one place to another (refer figure in next page).
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It is measuring and marking tool for 900 angle .In practice, it is used for checking the squareness
of many types of small works when extreme accuracy is not required .The blade of the Try
square is made of hardened steel and the stock of cast Iron or steel. The size of the Try square is
specified by the length of the blade.
Scriber
A Scriber is a slender steel tool, used to scribe or mark lines on metal work pieces. It is made of
hardened and tempered High Carbon Steel. The Tip of the scriber is generally ground at 12oto
15o.
It is generally available in lengths, ranging from 125mm to 250mm .It has two pointed ends the
bent end is used for marking lines where the straight end cannot real.
Fig: Try Square Fig: Scriber
Odd Leg Caliper

This is also called ‘Jenny Caliper’ or Hermaphrodite. This is used for marking parallel
liners from a finished edge and also for locating the center of round bars; it has one leg pointed
like a divider and the other leg bent like a caliper. It is specified by the length of the leg up to the
hinge point.
Divider
It is basically similar to the calipers except that its legs are kept straight and pointed at the
measuring edge. This is used for marking circles, arcs laying out perpendicular lines, by setting
lines. It is made of case hardened mild steel or hardened and tempered low carbon steel. Its size
is specified by the length of the leg.
Fig: Odd Leg Caliper and Divider
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Trammel is used for drawing large circles or arcs.
Punches
These are used for making indentations on the scribed lines, to make them visible clearly. These
are made of high carbon steel. A punch is specified by its length and diameter (say as 150’
12.5mm). It consists of a cylindrical knurled body, which is plain for some length at the top of it.
At the other end, it is ground to a point. The tapered point of the punch is hardened over a length
of 20 to 30mm.
Dot Punch is used to lightly indent along the layout lines, to locate center of holes and to
provide a small center mark for divider point, etc. for this purpose, the punch is ground to a
conical point having 60° included angle.
Center Punch is similar to the dot punch, except that it is ground to a conical point having 90°
included angle. It is used to mark the location of the holes to be drilled.
Fig: Punches
Calipers:
They are indirect measuring tools used to measure or transfer linear dimensions. These are used
with the help of a steel Rule to check inside and outside measurements. These are made of Case
hardened mild steel or hardened and tempered low carbon steel. While using, but the legs of the
caliper are set against the surface of the work, whether inside or outside and the distance between
the legs is measured with the help of a scale and the same can be transferred to another desired
place. These are specified by the length of the leg. In the case of outside caliper, the legs are bent
inwards and in the case of inside caliper, the legs bent outward.
Fig: Calipers
Cutting Tools:
Hack Saw
The Hack Saw is used for cutting metal by hand. It consists of a frame, which holds a thin blade,
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firmly in position. Hacksaw blade is specified by the number of teeth for centimeter. Hacksaw
blades have a number of teeth ranging from 5 to 15 per centimeter (cm). Blades having lesser
number of teeth per cm are used for cutting soft materials like aluminum, brass and bronze.
Blades having larger number of teeth per centimeter are used for cutting hard materials like steel
and cast Iron.
Fig: Hacksaw Frame with Blade
Hacksaw blades are classified as (i) All hard and (ii) flexible type. The all hard blades are made
of H.S.S, hardened and tempered throughout to retain their cutting edges longer. These are used
to cut hard metals. These blades are hard and brittle and can break easily by twisting and forcing
them into the work while sawing. Flexible blades are made of H.S.S or low alloy steel but only
the teeth are hardened and the rest of the blade is soft and flexible. These are suitable for use by
un‐skilled or semi‐skilled persons.
The teeth of the hacksaw blade are staggered, as shown in figure and known as a ‘set of teeth’.
These make slots wider than the blade thickness, preventing the blade from jamming.
Chisels
Chisels are used for removing surplus metal or for cutting thin sheets. These tools are made from
0.9% to 1.0% carbon steel of octagonal or hexagonal section. Chisels are annealed, hardened and
tempered to produce a tough shank and hard cutting edge. Annealing relieves the internal
stresses in a metal. The cutting angle of the chisel for general purpose is about 60°.
Fig: Flat Chisel
Twist Drill
Twist drills are used for making holes. These are made of High speed steel. Both straight and
taper shank twist drills are used. The parallel shank twist drill can be held in an ordinary self –
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centering drill check. The tapper shank twist drill fits into a corresponding tapered bore provided
in the drilling machine spindle (see figure in next page).
Taps and Tap Wrenches
A tap is a hardened and steel tool, used for cutting internal thread in a drill hole. Hand Taps are
usually supplied in sets of three in each diameter and thread size. Each set consists of a tapper
tap, intermediate tap and plug or bottoming tap. Taps are made of high carbon steel or high speed
steel (see figure in next page).
Bench Drilling Machine
Holes are drilled for fastening parts with rivets, bolts or for producing internal thread. Bench
drilling machine is the most versatile machine used in a fitting shop for the purpose. Twist drills,
made of tool steel or high speed steel are used with the drilling machine for drilling holes.
Following are the stages in drilling work
1. Select the correct size drills, put it into the check and lock it firmly
2. Adjust the speed of the machine to suit the work by changing the belt on the pulleys. Use
high speed for small drills and soft materials and low speed for large diameter drills and hard
materials.
3. Layout of the location of the pole and mark it with a center punch.
4. Hold the work firmly in the vice on the machine table and clamp it directly on to the machine
table.
5. Put on the power, locate the punch mark and apply slight pressure with the Feed Handle.
Fig: Bench Drill
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Finishing Tools:
Reamers
Reaming is an operation of sizing and finishing a drilled hole, with the help of a cutting tool
called reamer having a number of cutting edges. For this, a hole is first drilled, the size of which
is slightly smaller than the finished size and then a hand reamer or machine reamer is used for
finishing the hole to the correct size.
Hand Reamer is made of High Carbon Steel and has left‐hand spiral flutes so that, it is prevented
from screwing into the whole during operation. The Shank end of the reamer is made straight so
that it can be held in a tap wrench. It is operated by hand, with a tap wrench fitted on the square
end of the reamer and with the work piece held in the vice. The body of the reamer is given a
slight tapper at its working end, for its easy entry into the whole during operation, it is rotated
only in clock wise direction and also while removing it from the whole.
Fig: Reamers
Files
Filing is one of the methods of removing small amounts of material from the surface of a metal
part. A file is hardened steel too, having small parallel rows of cutting edges or teeth on its
surfaces.
On the faces, the teeth are usually diagonal to the edge. One end of the file is shaped to fit into a
wooden handle. The figure shows various parts of a hand file. The hand file is parallel in width
and tapering slightly in thickness, towards the tip. It is provided with double cut teeth. On the
faces, single cut on one edge and no teeth on the other edge, which is known as a safe edge.
Fig: Parts of a Hand File
Files are classified according to their shape, cutting teeth and pitch or grade of the teeth. The
figure shows the various types of files based on their shape.
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Fig: Single and Double Cut File
GRINDING MACHINE
Introduction Grinding
is a metal cutting operation like any other process of machining removing metal in comparatively
smaller volume. The cutting tool used is an abrasive wheel having many numbers of cutting edges.
The machine on which grinding the operation is performed is called a grinding machine
Grinding is done to obtain very high dimensional accuracy and better appearance. The accuracy of
grinding process is 0.000025mm. The amount of material removed from the work is very less.
GRINDING MACHINE SAFETY

 Grinding machines are used daily in a machine shop.
 To avoid injuries follow the safety precautions listed below.
 Wear goggles for all grinding machine operations.
 Check grinding wheels for cracks (Ring Test Figure 5-11) before mounting.
 Never operate grinding wheels at speeds in excess of the recommended speed.
 Never adjust the workpiece or work mounting devices when the machine is operating
 Do not exceed recommended depth of cut for the grinding wheel or machine.
 Remove workpiece from grinding wheel before turning machine off.
 Use proper wheel guards on all grinding machines.
 On bench grinders, adjust tool rest 1/16 to 1/8 inch from the wheel.
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4.2
Types of grinding machines
According to the accuracy of the work to be done on a grinding machine, they are classified as
1. Rough grinding machines

2. Precision grinding machine
Rough grinding machines
The rough grinding machines are used to remove stock with no reference to the accuracy of results.
Excess metal present on the cast parts and welded joints are removed by rough grinders.
The main types of rough grinders are:
1. Hand grinding machine
2. Bench grinding machine
3. Floor stands grinding machine
4. Flexible shaft grinding machine
5. Swing frame grinding machine
6. Abrasive belt grinding machine
Precision grinding machines
Precision grinders are used to finish parts to very accurate dimensions. The main types of precision
grinders are:
1. Cylindrical grinding machines
2. Internal grinding machines
3. Surface grinding machines
4. Tool and cutter grinding machines
5. Special grinding machines
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Miscellaneous Tools:
Ball‐ Peen Hammer

Ball‐ Peen Hammers are named, depending upon their shape and material and specified by their
weight. A ball peen hammer has a flat face which is used for general work and a ball end,
particularly used for riveting.
Cross‐Peen Hammer
It is similar to ball peen hammer, except the shape of the peen. This is used for chipping,
riveting, bending and stretching metals and hammering inside the curves and shoulders.
Fig: Cross Peen Hammer Fig: Straight Peen Hammer
Straight‐Peen Hammer
This is similar to cross peen hammer, but its peen is in‐line with the hammer handle. It is used
for swaging, riveting in restricted places and stretching metals.
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Viva Questions
Question: Define the terms: Fitting and Bench work.

Question: Name the material with which a vice body is normally made of. What is the
characteristic of this material?
Question: What for a C-clamp is used?
Question: Classify hacksaw blades.
Question: Differentiate between ‘Single cut’ and ‘Double cut’ files.
Question: Differentiate between ‘Cross filing’ and ‘Draw filing’. Question:
Name the different types of hammers used in fitting work.
Question: Differentiate between cross-peen hammer and straight-peen hammer.
Question: What is meant by pinning of files?
Question: With what the size of a spanner is denoted?
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CARPENTRY
Introduction
Carpentry may be defined as the process of making wooden components. It starts from a
marketable form of wood and ends with finished products. It deals with the building work,
furniture, cabinet making. Etc. joinery, i.e., preparation of joints is one of the important
operations in all woodworks. It deals with the specific work of carpenter like making different
types of joints to form a finished product.
Timber:
Timber is the name given to the wood obtained from well grown trees. The trees are cut, sawn
into various sizes to suit building purposes.
The word, ‘grain’, as applied to wood, refers to the appearance or pattern of the wood on the cut
surfaces. The grain of the wood is a fibrous structure and to make it strong, the timber must be so
cut, that the grains run parallel to the length.
Timber Sizes
Timber sold in the market is in various sizes and shapes. The following are the common shapes
and sizes.
a. Log ‐ The trunk of the tree which is free from
branches.
b. Balk ‐ The log, sawn to have roughly square cross section.
c. Post ‐ A timber piece, round or square in cross section, having its diameter or side from
175 to 300mm.
d. Plank ‐ A sawn timber piece, with
more than 275 mm in width, 50 to
150 mm inthickness and 2.5 to 6.5
meters in length.
e. Board ‐ A sawn timber piece, below 175 mm in
width and 30 to 50 mm in thickness.
f. Reapers‐ Sawn timber pieces of assorted and
non‐standard sizes, which do not confirm to
theabove shapes and sizes.
Classification of Timber
Wood suitable for construction and other engineering purposes is called timber. Woods in
general are divided into two broad categories: Soft woods and Hard woods.
Soft woods are obtained from conifers, air, deodar, char, walnut and seemly. Woods obtained
from teak, sal, oak, shisha, beach, ash mango, neem and babul are known as hard wood, but it is
highly durable.
Another classification of woods is based on the name of the trees like teak, babul, shisham,
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neem, kair, chir, etc.
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Seasoning of Wood
A newly felled tree contains considerable moisture content. If this is not removed, the timber is
likely to wrap, shrink, crack or decay. Seasoning is the art of extracting the moisture content
under controlled conditions, at a uniform rate, from all the parts of the timber. Only seasoned
wood should be used for all carpentry works. Seasoning makes the wood resilient and lighter.
Further, it ensures that the wood will not distort after it is made into an object.
Characteristics of Good Timber
The good timber must possess the following characteristics
a. It should have minimum moisture content, i.e., the timber should be well seasoned.
b. The grains of wood should be straight and long.
c. It must retain its straightness after seasoning.
d. It should produce near metallic sound on hammering.
e. It should be free from knots or cracks.
f. It should be of uniform color, throughout the part of the wood.
g. It should respond well to the finishing and polishing operations.
h. During driving the nails and screw, it should not split easily.
Marking and Measuring Tools:
Accurate marking and measurement is very essential in carpentry work, to produce parts to exact
size. To transfer dimensions onto the work; the following are the marking and measuring tools
that are required in a carpentry shop.
Steel Rule and Steel Tape
Steel rule is a simple measuring instrument consisting of a long, thin metal strip with a marked
scale of unit divisions. It is an important tool for linear measurement. Steel tape is used for large
measurements, such as marking on boards and checking the overall dimensions of the work.
Fig: Steel Rule and Steel Tape
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Marking Gauge
It is a tool used to mark lines parallel to the edge of a wooden piece. It consists of a square
wooden stem with a sliding wooden stock (head) on it. On the stem is fitted a marking pin, made
of steel. The stock is set at any desired distance from the marking point and fixed in position by a
screw. It must be ensured that the marking pin projects through the stem, about 3 mm and the
end are sharp enough to make a very fine line. A mortise gauge consists of two pins. In this, it is
possible to adjust the distance between the pins, to draw two parallel lines on the stock.
Marking gauge Mortise gauge
Fig: Marking Gauges
Try ‐ Square
It is used for marking and testing the squareness and straightness of planed surfaces. It consists
of a steel blade, fitted in a cast iron stock. It is also used for checking the planed surfaces for
flatness. Its size varies from 150 to 300 mm, according to the length of the blade. It is less
accurate when compared to the try‐square used in the fitting shop.
Fig: Try Square

Compass and Divider
Compass and divider, are used for marking arcs and circles on the planed surfaces of the wood
(refer fig in next page).
Scriber or Marking Knife
It is used for marking on timber. It is made of steel having one end pointed and the other end
formed into a sharp cutting edge (refer Fig. in next page).
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Bevel Square
It is used for laying‐out and checking angles. The blade of the bevel is adjustable and may be
held in place by a thumb screw. After it is set to the desired angle, it can be used in much the
same way as a try‐square. A good way to set it to the required angle is to mark the angle on a
surface and then adjust the blade to fit the angle
Fig: Compass and Divider Fig: Scriber and Bevel Square
Holding Tools:
Carpenter's Vice
It is used as a work holding device in a carpenter shop. Its one jaw is fixed to the side of the table
while the other is movable by means of a screw and a handle. The Carpenter's vice jaws are lined
with hard wooden' faces
Fig: Carpenters Vice Fig: C‐Clamp

C‐Clamp
It is used for holding small works (see figure above)
Bar Cramp
It is made of steel bar of T‐section, with malleable iron fittings and a steel screw. It is used for
holding wide works such as frames or tops.
Planing Tools:
Planing is the operation used to produce flat surfaces on wood. A plane is a hand tool used for
this purpose. The cutting blade used in a plane is very similar to a chisel. The blade of a plane is
fitted in a wooden or metallic block, at an angle.
Types of Planes:
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Jack Plane
It is the most commonly used general purpose plane. It is about 35 cm long. The cutting iron
(blade) should have a cutting edge of slight curvature. It is used for quick removal of material on
rough work and is also used in oblique planning.
Smoothing Plane
It is used for finishing work and hence, the blade should have a straight cutting edge. It is about
20 to 25 cm long. Being short, it can follow even the slight depressions in the stock, better than
the jack plane. It is used after using the jack plane.
Rebate Plane
It is used for making a rebate. A rebate is a recess along the edge of a piece of wood, which is
generally used for positioning glass in frames and doors.
Plough Plane
It is used to cut grooves, which are used to fix panels in a door. The following figure shows the
various types of planes mentioned above.
Cutting Tools:
Saws
A saw is used to cut wood into pieces. There are different types of saws, designed to suit
different purposes. A saw is specified by the length of its toothed edge.
Types of Saws:
Cross‐Cut Saw or Hand Saw
It is used to cut across the grains of the stock. The teeth are so set that the saw kerf will be wider
than the blade thickness. This allows the blade to move freely in the cut, without sticking
Rip Saw
It is used for cutting the stock along the grains. The cutting edge of this saw makes a steeper
angle, i.e., about 60° whereas that of crosscut saw makes an angle of 45° with the surface of the
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stock.
Tenon Saw
It is used for cutting the stock either along or across the grains. It is used for cutting tenons and
in fine cabinet work. However, it is used for small and thin cuts. The blade of this saw is very
thin and so it is stiffened with a thick back steel strip. Hence, this is sometimes called as
back‐saw. In this, the teeth are shaped like those of cross‐cut saw.
Compass Saw
It has a narrow, longer and stronger tapering blade, which is used for heavy works . It is mostly
used in radius cutting. The blade of this saw is fitted with an open type wooden handle.
Fig: Types of Saws

Chisels:
Chisels are used for cutting and shaping wood accurately. Wood chisels are made in various
blade widths, ranging from 3 to 50 mm. They are also made in different blade lengths. Most of
the wood chisels are made into tang type, having a steel shank which fits inside the handle.
These are made of forged steel or tool steel blades.
Fig: Types of Chisels

Types of Chisels:
Firmer Chisel
The word 'firmer' means 'stronger' and hence firmer chisel is stronger than other chisels.
It is a general purpose chisel and is used either by hand pressure or by a mallet. The blade of a
firmer chisel is flat, as shown in figure.
Dovetail Chisel
It has a blade with a beveled back, as shown in Figure, due to which it can enter sharp comers
for finishing, as in dovetail joints.
Mortise Chisel
It is used for cutting mortises and chipping inside holes, etc. The cross‐section of the
mortise chisel is proportioned to withstand heavy blows during mortising. Further, the
cross‐section is made stronger near the shank..
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Viva Questions
Question: Name the commonly available shapes of timber in the market.

Question: What is the sequence of operations in carpentry?
Question: What is the difference between marking gauge and marking knife?
Question: What is the difference C-clamp and bar cramp?
Question: What for a plane is used in a carpentry shop?
Question: Classify the planning tools.
Question: Classify the chisels and their applications.
Question: Name the tools used for pulling nails.
Question: Name the various joinery materials used in carpentry.
Question: Name the various types of joints.
Question: Name some holding, marking, measuring, cutting, planning and finishing tools.
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BLACKSMITHY
Blacksmith or Forging is an oldest shaping process used for the producing small articles for which accuracy
in size is not so important. The parts are shaped by heating them in an open fire or hearth by the
blacksmith and shaping the MTh rough applying compressive forces using hammer
thus, forging is defined as the plastic deformation ofmetalsatelevated temperatures into a predetermined
size or shape using compressive forces exerted through some means of hand hammers, small power
hammers, die, press or upsetting machine. It consists essentially of changing or altering the shape
and section of metal by hammering at a temperature of about 980°C, at which the metal is
entirely plastic and can be easily deformed or shaped under pressure. The shop in which the
various forging operations are carried out is known as the smithy or smith’s shop.
Hand forging process is also known as black-smithy work which is commonly employed for
production of small articles using hammers on heated jobs. It is a manual controlled process even
thoughs o m e m a c h i n e r y s u c h a s p o w e r h a m m e r s c a n a l s o b e s o m e t i m e s u s e d .
B l a c k - s m i t h y i s , t h e r e f o r e , a process by which metal may be heated and shaped to its
requirements by the use of blacksmith tools either by hand or power hammer
Forging by machine invo lves the use o f forging dies and is generally employed
f o r m a s s - production of accurate articles. In drop forging, closed impression dies are used and there is
drastic flow of metal in the dies due to repeated blow or impact which compels the plastic
metal to conform to the shape of the dies
Applications of forging
Almost all metals and alloys can be forged. The low and medium carbon steels are readily hot forged
without difficulty, but the high-carbon and alloy steels are more difficult to forge and require greater care. Forging is
generally carried out on carbon alloy steels, wrought iron, copper-base alloys, aluminium alloys ,and magnesium
alloys. Stainless steels, nickel-based super alloys, and titanium are forged especially for aerospace uses
FORGEABILITY
The ease with which for ging is done is called forgeability. The forgeability of a material can also
bed e f i n e d a s t h e c a p a c i t y o f a ma t er i a l t o u n d er g o d e f o r m a t i o n u n d er c o m p r es s i o n w i t h o
u t r u p t u r e. F o r g ea b i l i t y i n c r ea s es w i t h t e m p er a t u r e u p t o a p o i n t a t w h i c h a s e c o n d
p h a s e, e. g . , f r o m f er r i t e t o austenite in steel, appears or if grain growth becomes excessive.
COMMON HAND FORGING TOOLS
For carrying out forging operations manually, certain common hand forging tools are employed.
These are also called blacksmith’s tools, for a blacksmith is one who wor ks on the forging of metals
in their hot state. The main hand forging tools are as under.
Tongs
The tongs are generally used for holding work while doing a forging operation. Various kinds of
tongs are shown in Figure. a) Straight-lip fluted tongs are commonly used for holding square, circular
and hexagonal bar stock. b) Rivet or ring tongs are widely used for holding bolts, rivets and other work of circular
section’s)Flat tongs are used for mainly for holding work of r ectangular section .d)Gad tongs are used
for holding general pick-up work, either straight or tapered.
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Flatter
Flatter is shown in Fig. 14.7. It is commonly used in forging shop to give smoothness and accuracy to articles which
have already been shaped by fullers and swages
Swage
Swage is used for forging work which has to be reduced or finished to round, square or hexagonal form. Itis made
with half grooves of dimensions to suit the work being reduced. It consists of two parts, the top part having
a handle and the bottom part having a square shank which fits in the hard hole on the anvil face.
Fuller
Fuller is used in for ging shop for necking down a forgeable job. It is made in top
and bottom tools as in the case of swages. Fuller is made in various shapes and sizesaccording to needs, the size
denoting the width of the fuller edge
Punch
Punch is used in forging shop for making holes in metal part when it is at forging heat
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Rivet header
Rivet header (Fig. 14.7) is used in forging shop for producing rivets heads on parts.
Chisels
Chisels are used for cutting metals and for nicking prior to breaking. They may be hot or cold depending on whether
the metal to be cut is hot or cold. A hot chisel generally used in forging shop is shown in Fig. 14.7. The main
difference between the two is in the edge. The edge of a cold chisel is hardened and tempered with an angle of a b o u t
6 0 ° , w h i l s t t h e e d g e o f a h o t c h i s e l i s 3 0 ° a n d t h e h a r d e n i n g i s n o t necessary. The edge is made
slightly rounded for better cutting action
Hand hammers
There are two major kinds of hammers are used in hand forging :a . T h e h a n d h a m m e r u s e d b y t h e s m i t h
h i m s e l f a n d b. The sledge hammer used by the striker. Hand hammers may further be classified as (a) ball peen
hammer, (b)straight peen hammer, and (c) cross peen hammer.
S l e d g e h a m m e r s m a y f u r t h e r b e c l a s s i f i e d a s ( a ) D o u b l e f a c e hammer, (b) straight peen
hammer, and (c) cross peen hammer. Hammer heads are made of cast steel and, their ends are hardened and tempered.
The striking face is made slightly convex. The weight of a hand hammer varies fr om about 0.5 to 2 kg
wher eas the weight of a sledge hammer varies from 4 to 10 kg
Set hammer
A set hammer generally used in for ging shop is shown in Fig. 14.9. It is used for finishing cor ners in
shouldered work where the flatter would be inconvenient. It is also used for drawing out the gorging job.
Anvil
An anvil is a most commonly tool used in forging shop which is shown in. It acts as a
support for blacksmith’s work during hammering. The body of the anvil is made of mild steel with a tool
steel face welded on the body, but the beak or horn used for bending curves is not steel faced. The round
hole in the anvil called pritchel hole is generally used for bending rods of small diameter, and as a die
for hot punching operations. The square or hard hole is used for holding square shanks of
various fittings. Anvils in forging shop may vary up to about 100 to 150 kg and they should always stand
with the top face about 0.75 mt. from the floor. This height may be attained by resting the anvil on a
wooden or cast-iron base in the forging shop
Swage block
Swage block generally used in forging shop is shown in figur e. It is mainly used for heading,
bending, squaring, sizing, and forming operations on forging jobs. It is 0.25 mt. or even more wide. It may be used
either flat or edgewise in its stand.
FORGING OPERATIONS:
The following are the basic operations that may be performed by hand forging:
1.Drawing-down:
Drawing is the process of stretching the stock while reducing its cross-section locally. Forging the tapered end of a
cold is an example of drawing operation.
2.Ups etting:
It is a process of increasing the area of cross-section of a metal piece locally, with a corresponding reduction in
length. In this, only the portion to be upset is heated to forging temperature and the work is then struck at the end
with a hammer. Hammer ing is done by the smith (student) himself, if the job is small, or by his helper,
in case of big jobs, when heavy blows are required with a sledge hammer.
3.Fullering:
Fullers are used for necking down a piece of work, the reduction often ser ving as the
starting point for drawing. Fullers are made of high carbon steel in two parts, called the top and bottom fullers.The
bottom tool fits in the Hardie hole of the anvil. Fuller size denotes the width of the fuller edge.
4.Flattering:
Flatters are the tools that are made with a perfectly flat face of about 7.5 cm squar e. These are used
for finishing flat surfaces. A flatter of small size is known as set-hammer and is used for finishing
near corners and in confined spaces.
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5.Swag ing :
S w a g e s l i k e f u l l er s a r e a l s o m a d e o f h i g h c a r b o n s t e e l a n d a r e ma d e i n t w o p a r t s c a l l e d
t h e t o p a n d swages. These are used to reduce and finish to round, square or hexagonal forms. For this, the swages
are made with half grooves of dimensions to suit the work.
6.Bending:
Bending of bars, flats, etc., is done to produce different types of bent shapes such as angles, ovals, circles etc.
Sharp bends as well as round bends may be made on the anvil, by choosing the appropriate place on it
for the purpose.
7 . T w i s t i ng :
It is also one for m of bending. Sometimes, it is done to increase the rigidity of the wor k piece. Small
piece may be twisted by heating and clamping a pair of tongs on each end of the section to be twisted
and applying a turning moment. L a r g er p i e c e s ma y b e c l a m p e d i n a l e g v i c e a n d t w i s t e d w i t h a
p a i r o f t o n g s o r a m o n k e y w r e n c h . However, for uniform twist, it must be noted that the complete twisting
operation must be performed in one heating.
8.Cutting (Hot and Cold Chisels):
Chisels are used to cut metals, either in hot or cold state. The cold chisel is similar to fitter’schisel,
except that it is longer and has a handle. A hot chisel is used for cutting hot metal and its cutting
edge is long and slender when compared to cold chisel. These chisels are made of tool steel, hardened and tempered
9.Iron-Carbon Alloy:
If the carbon is less than 2% in the iron-carbon alloy, it is known as steel. Again, based on the carbon
content, it is called mild steel, medium carbon steel and high carbon steel. The heat treatment to begiven to these
steels and their applications are shown in table below.
NOTE:
The forging produced either by hand forging or machine forging should be heat treated. The following are the
purposes of heat treatment:
I. To remove internal stresses set-up during forging and cooling.
ii .To normalize the internal structure of the metal
.iii .To improve machinability.
iv. To improve mechanical properties, strength and hardness.
PRECAUTIONS
1.Hold the hot work downwards close to the ground, while transferr ing from the hearth to anvil, to
minimize danger of burns; resulting from accidental collisions with others
.2.Use correct size and type of tongs to fit the wor k. These should hold the wor k secur ely to prevent
tits bouncing out of control from repeated hammer blows.
3.Care should be exer cised in the use of the hammer. The minimum force only should be used and
the flat face should strike squarely on the work; as the edge of the hammer will produce
heavy bruising on hot metal.
4 . W a t er f a c e s h i e l d w h e n h a m m e r i n g h o t m e t a l
5 . W ea r g l o v e s w h e n h a n d l i n g h o t m e t a l .
6.Wear st eel-t oed s hoes.
7.Ensur e that hammers are fitted with tight and wedged handle
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NIET Workshop and Digital Manufacturing B. TECH 1STYEAR
YEAR
SYEAR
TURNING&MILLING SECTION
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MILLING MACHINE
INTRODUCTION
Milling the machining process in which the removal of metal takes place due to the cutting action of a rotating
milling cutter. In a milling machine, the cutter is rotating due to workpiece is fed against it. This machine can
hold more than one tool at a time. The cutter rotates at high speed, and because of the many cutting edges, it
removes metal at a very fast rate
The machine can also hold one or a number of cutters at a time. Thus, the milling machine is one of the most
important machines in the workshop. In this machine, all the operations can perform with high accuracy
The metal removal rate is high as compared toa lathe machine, planner machine, and shaper machine. It has
good accuracy and a better surface finish. This is why a milling machine finds wide application in production
work
PARTS OF MILLING MACHINE
Following are the different parts of milling machine:
 Base: The base is the foundational base component of the milling machine. The entire machine is mounted on the
base. It is made of rigid materials like cast iron that can support the machine’s weight. Additionally, the base also
absorbs the shock generated in the milling operation.
 Column: The column is the frame on which the machine’s moving parts are based. It provides fixtures for the
driving mechanism of the machine.
 Knee: The knee of the milling machine is present over the base. It supports the weight of the work table. The
knee contains a guideway and screw mechanism to change its height. It is attached to the column for vertical
movement and support.
 Saddle: The saddle connects the worktable to the milling machine knee. The saddle is connecte d to the knee with
guideways. This helps in the movement of the worktable perpendicular to the column.
 Spindle: The spindle is the part that mounts the cutting tool on the machine. In multi-axis milling machines, the
spindle is capable of rotary movements.
 Arbor: Arbor is a type of tool adapter (or tool holder) that supports adding a side cutter or niche milling tools. It
is aligned next to the spindle.
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 Worktable: The worktable is the milling machine part that holds the workpiece. The workpiece is tightly s ecured
on the worktable with the help of clamps or fixtures. The table is usually capable of longitudinal movements.
Multi-axis milling machines contain rotary tables.
 Headstock: Headstock is the part that holds the spindle and connects it to the rest of t he machine. The movement
of the spindle is made possible with the motors in the headstock.
 Overarm: The overarm bears the weight of the spindle and Arbor assembly. It is present on top of the column. It
is also known as overhanging arm
Working Principle of Milling Machine
We have a simple idea of the working of this machine with the knowledge of the parts. But let us however study
it technically. Refer to the image below.
The cutting action is accomplished by feeding the workpiece against a rotating cutter. The workpiece is
firmly secured to the table while a multitooth cutter positioned on the arbors rotates. The cutter rotates at
a rapid rate, while the material is fed.
The workpiece can be fed vertically, longitudinally, or diagonally. The spindle speed, table feed, depth of
cut, and direction of cutter rotation are the most important process factors .
Milling Machine Operations

Based on the working principle, several operations are performed on milling machines in various industries
where they are employed. Below are a few discussed in brief.
Up-Milling Operation
The up-milling is also known as conventional milling. In this, a cutter revolving in the opposite direction of the
workpiece removes the metal in the form of tiny chips as shown in the figure below. The chip thickness varies
from minimum at the beginning and maximum at the end as the cutter advances.
The primary drawbacks of the up-milling technique are the tendency of the cutting force to lift the work
from the fixtures and the poor surface finish.
Down Milling Operation

A down-milling operation is also known as ‘climb milling’. In this operation, the cutter rotates in the same
direction as the feed. The chip thickness varies from maximum at the beginning to minimum at the end.
There is always less friction in climb milling which produces less heat. Thin slots, lengthy cuts, and sharpening
of the pieces can be easily achieved in this operation.
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Plain Milling Operation
The most commonly used milling machine operation is plain milling. It is also referred to as slab milling (Hence,
the labelling in the image below). The workpiece is firmly mounted on the machine before this operation. After
choosing the proper speed and feed, the machine is then turned on.
This operation creates a smooth and horizontal surface that is parallel to the axis of rotation of the cutter as
shown in the figure below.
Face Milling Operation

The most simple operation on a milling machine is face milling. This procedure is carried out with a face milling
cutter that is rotated about an axis perpendicular to the work surface as shown in the figure below.
By turning the cross feed screw of the table, the depth of the cut can be changed. This operation creates a flat
surface with the cutter positioned on a stub arbour.
Fig 6: Face Milling
Gang Milling Operation

The operation of simultaneously milling multiple surfaces of a workpiece by feeding the table against numerous
cutters with the same or various diameters mounted to the arbour is called gang milling operation.
The speed of this group of cutters is determined by the cutter with the greatest diameter. The approach reduces
machining time significantly and is commonly utilised for repeated tasks.
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Fig 7: Gang Milling Operation
Straddle Milling Operation

The milling operation in which two surfaces are milled simultaneously is a straddle milling operation. With two
side milling cutters mounted to the same arbour, straddle milling creates flat and vertical surfaces on both sides
of the workpiece.
Using adequate spacing collars, the distance between the two cutters is regulated. T-slot milling is an
exceptional illustration of straddle milling. The operation is used to create hexagonal or square surfaces.
Angular Milling Operation

The process of generating an angular surface on a workpiece which is not at right angles to the spindle axis of
the milling machine is known as angular milling.
The angular groove may have a single or double included angle which depends on the type and geometry of the
angular cutter employed. V-block manufacturing is an example of angular milling.
Fig 9: Angular Milling
Form Milling Operation

The process of creating an uneven shape like convex, concave, or any other form employing form cutters is
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called form milling operation. The selection of form cutters depends on the shape needed. This operation has a
20% - 30% slower cutting rate than plain milling.
Fig 10: Form Milling
Keyway Milling Operation

The operation of making keyways, grooves, and slots of various shapes and sizes is called keyway milling. It
can be done with an end mill, a side milling cutter, a plain milling cutter, or a metal slitting saw.
Keyways generally have minute dimensions of width or depth. Hence, a special tool is necessary for keyway
milling like standard helical or staggered teeth cutters.
Fig 12: Keyway Milling
Profile Milling Operation
The process of replicating an intricate shape of a master die on a workpiece is known as profile milling. For
milling profiles, various cutters like helical plain cutters are utilised. One of the milling cutters that is frequently
used in profile milling is the end mill cutter.
Fig 13: Profile Milling
Thread Milling Operation
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The precise threads are produced in small or big quantities using single or multiple thread milling cutters. The
thread is finished by feeding the rotating cutter longitudinally over a distance equal to the pitch length of the
thread. Thread milling operations are carried out on specialised thread milling machines .
Fig 14: Thread Milling
Gear Cutting Operation
A form-relieved cutter on a milling machine executes the gear-cutting operation. The cutter type may be either
cylindrical or end mill. The cutter profile is made to precisely match the gear tooth spacing. A universal diving
head is used to hold the workpiece while a process called indexing creates evenly spaced gear teeth on a gear
blank.
Fig 15: Gear Cutting or Milling Operation

As we just discussed, this operation involves a process called Indexing.
Indexing is the process of splitting the circumference of the workpiece into an arbitrary number of equal
sections. The perimeter of the gear blank is divided into 'n' equal sections, and each tooth is milled individually.
Almost all gear teeth divisions can be covered by index plates through crank rotation. The index crank is always
next to the spindle making it easier to index the divisions to fractions of a turn. This is done to accurately cut the
gear teeth spacing.
Fig 16: Indexing Plates
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The movement of the index crank is calculated by a formula which is given below,
Index Crank Movement = 40N40�, where N →→ is the required number of divisions.
Types of Milling Machines
As we concluded our learning about the various operations performed on the machines, it is natural to be
curious about the types. Let us study all the classification of milling machines.
Horizontal Milling Machine
These machines can hold and rotate the spindle horizontally to remove material from the surface of a fixed
workpiece. Cutting tools for these machines are thicker and shorter.
Vertical Milling Machine
This is a particular type of milling machine that can hold the spindle in a vertical configuration while rotating it
to remove material from the surface of a stationary workpiece. Cutting tools for vertical milling machines are
longer and thinner.
Column and Knee Type Milling Machine
This milling machine has a vertical column attached to the bed which has gear drives that can move the saddle
and knee. On top of the knee is a saddle that can move in transverse directions, allowing the worktable to move
along it.
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Fixed Bed Milling Machine
These devices are rigidly constructed. The table is fixed to the guideways of the bed. There are no options for
transverse or vertical adjustment and the table can only move at a right angle to the spindle axis.
Simplex Milling Machine
The spindle head can only move in one direction with this machine. Surfaces cut using these machines are flat
and have a good surface finish.
Duplex Milling Machine

This machine is a combination of two machines that are arranged across from one another. They operate
independently. Two spindles are used simultaneously to machine the workpiece on this machine while it
functions as one unit.
Triplex Milling Machine

The spindle of these machines travels in three directions: x, y, and z axes. These machines are extremely
accurate.
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Universal Milling Machine
It can be modified to fit a variety of milling tasks. The table is turned to any angle between 0 ∘∘ and 45 ∘∘ on
either side. In addition to the three motions previously stated, the table may have a fourth movement if it is fed
at an angle towards the milling cutter. This machine is capable of producing milling cutters, spur, bevel, spiral,
and twist drills.
There are other special types of milling machines apart from these which are listed below.
 Rotary table type
 Drum type
 Profile milling machine
 Planetary type
 Tracer controlled type
 Pantograph type
 CNC milling machine
Specification of Milling Machine
While working in an industry, the types of these machines are considered. But there are terms that the machine
shop operators discuss before shipping or considering investing in these machines. They are called a
specification of milling machines.
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1. Movement range of the worktable with its size measurements
2. Maximum longitudinal movement allowed
3. Maximum speed of the spindle in rpm
4. Power capacity of the motor
5. Total floor space required
6. Overall weight of the machine
These are some of the factors considered for each machine.
Advantages of Milling Machine
Every machine should have considerable advantages to be used for a longer period. Here are some of the
advantages of these machines.
1. The cutter having numerous cutting edges rotates at a high speed which results in a high rate of metal
removal.
2. It also follows that these machines produce better surface finishes
3. Considering the CNC machines, the software is used to manage the milling process. Hence, it has
improved accuracy and finish, increasing production overall.
4. Milling machines are known for their higher accuracy compared to other machines.
Disadvantages of Milling Machines
The machines have been noted with some disadvantages that hinder their use for some of the machining
applications.
1. It has a high rate of flank wear
2. High crater wear
3. Using a poor material cutter or machine with a loose arbour, vibration is generated. This can cause poor
work on the workpiece.
4. The chips formed during the machining can get clogged in the teeth of the cutter .
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NIIS INSTITUTE OF ENGINEERING&TECHNOLOGY

(NIIS GROUP OF INSTITUITION)

Workshop & Digital Manufacturing Lab

1. Safety first, work next.

3. BLACK SMITHY SECTION 29- 37

Fig: Bench Vice

Fig: V‐ Block Fig: C ‐ Clamp

Marking and Measuring Tools:

Fig: Try Square Fig: Scriber

Odd Leg Caliper

Fig: Odd Leg Caliper and Divider

Fig: Hacksaw Frame with Blade

Fig: Flat Chisel

Taps and Tap Wrenches

Following are the stages in drilling work

Fig: Bench Drill

Fig: Parts of a Hand File

Fig: Single and Double Cut File

GRINDING MACHINE SAFETY

1. Rough grinding machines

Ball‐ Peen Hammer

Fig: Cross Peen Hammer Fig: Straight Peen Hammer

Question: Define the terms: Fitting and Bench work.

Characteristics of Good Timber

The good timber must possess the following characteristics

Steel Rule and Steel Tape

Fig: Steel Rule and Steel Tape

Marking gauge Mortise gauge

Fig: Marking Gauges

Fig: Try Square

Scriber or Marking Knife

Fig: Compass and Divider Fig: Scriber and Bevel Square

Fig: Carpenters Vice Fig: C‐Clamp

Fig: Types of Saws

Fig: Types of Chisels

Question: Name the commonly available shapes of timber in the market.

Working Principle of Milling Machine

Milling Machine Operations

Down Milling Operation

Face Milling Operation

Fig 6: Face Milling

Gang Milling Operation

Straddle Milling Operation

Angular Milling Operation

Fig 9: Angular Milling

Form Milling Operation

Fig 10: Form Milling

Keyway Milling Operation

Fig 12: Keyway Milling

Profile Milling Operation

Fig 13: Profile Milling

Thread Milling Operation

Fig 14: Thread Milling

Gear Cutting Operation

Fig 15: Gear Cutting or Milling Operation

Fig 16: Indexing Plates

Vertical Milling Machine

Column and Knee Type Milling Machine

Simplex Milling Machine