SCHOOL OF ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

19MEE181 MANUFACTURING PRACTICE

SHEET METAL WORKSHOP

LAB MANUAL
19MEE181 MANUFACTURING PRACTICE 0-0-3-1

Course Objectives:
CO1 To introduce basic concepts pertaining to product dismantling and assembly
CO2 To familiarize basic pneumatic components; design and validate simple circuits
CO3 To familiarize sheet metal tools and operations
CO4 To provide hands-on training on welding and soldering
CO5 To introduce basic plumbing tools and process
CO6 To inculcate the fundamental principle of operation and applications of 3D printing
Keywords: product dismantling, arc welding, 3D printing, plumbing, sheet metal work, pneumatic
circuits, soldering

1. Product Workshop
Disassemble the product of sub assembly-Measure various dimensions using measuring instruments-
Free hand rough sketch of the assembly and components-Name of the components and indicate the
various materials used-Study the functioning of the assembly and parts-Study the assembly and
components design for compactness, processing, ease of assembly and disassembly-Assemble the
product or subassembly.
2. Pneumatic and PLC Workshop
Study of pneumatic elements-Study of PLC and programming. Design and simulation of simple
circuitsusing basic pneumatic elements-Design and simulation of simple circuits using electro-
pneumatics.

3. Sheet Metal Workshop

Study of tools and equipment - Draw development drawing of simple objects on sheet metal (cone,
cylinder, pyramid, prism, tray etc.)-Fabrication of components using small shearing and bending
machines-Riveting practice.

4. Welding, Soldering and Plumbing Workshops

Study of tools and equipment - Study of various welding & soldering methods-
Arc welding practice - fitting, square butt joint and lap joint - Soldering practice. Plumbing tools –
Make a piping joint to a simple piping layout (should include cutting, threading and pipe fixing)

5. 3D-Printing Workshop
Introduction to Additive Manufacturing process, Fused Filament Fabrication, Materials for 3D
printing, Process parameters, CAD for 3D printing, G code generation, 3D printing of simple
geometries, Applications of 3D printing.

(Note: Classes will be conducted in sequence. End-Semester exam will be conducted in the last
class of the semester)
Course Outcomes:
At the end of the course, the student will be able to:
CO1: Dismantle and assemble various products
CO2: Design and simulate pneumatic and electro-pneumatic circuits
CO3: Fabricate sheet metal objects.
CO4: Performance welding and soldering operations
CO5: Make simple plumbing joints.
CO6: Design and build simple geometries using 3D printers
CO/PO Mapping
CO/PO PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11 PO12
CO1 2 1 2 1 1
CO2 2 2 1 1 2 1 1
CO3 2 2 2 1 1
CO4 2 1 2 1 1
CO5 2 2 2 1
CO6 2 2 1 1 2 1 1

REFERENCE:

Concerned Workshop Manuals

 Evaluation & course plan

‘19MEE181- Manufacturing Practice’ laboratory for first year students as per the example schedule given. (2
cycles

Laboratory Week 1 Week 2 Week 3 Week 4 Week 5 Week 6 Week 13

Product lab 1 to 20 1 to 20 21 to 40 21 to 40 41 to 60 41 to 60
Cycle 1

Sheet metal lab 21 to 40 21 to 40 41 to 60 41 to 60 1 to 20 1 to 20

Welding lab/Soldering 41 to 60 41 to 60 1 to 20 1 to 20 21 to 40 21 to 40
End Semester
Laboratory Week 7 Week 8 Week 9 Week 10 Week 11 Week 12 Examination
Plumbing 1 to 20 1 to 20 21 to 40 21 to 40 41 to 60 41 to 60
Cycle 2

FP lab 21 to 40 21 to 40 41 to 60 41 to 60 1 to 20 1 to 20
3D printing 41 to 60 41 to 60 1 to 20 1 to 20 21 to 40 21 to 40

Note: 1 to 20 - Faculty 1; 21 to 40 - Faculty 2; 41 to 60 - Faculty 3

(i) Division of students into 1 to 20, etc. is shown here assuming 60 students. You need to divide the class
into three.
(ii) The students will be divided by the academic coordinator under each faculty and sent to AUMS.
4. The faculty will move along with the students assigned to them, through each lab.
5. The course evaluation will be done as follows.

(i) Continuous Assessment = 80 marks

- Each lab will be evaluated based on Observation write-up, Model/Experiment evaluation and
Viva, as appropriate.

- After all the labs are completed, the total marks will be converted to 80 marks.

(ii) End Semester Examination = 20 marks

- The end semester examination will be held after completion of all the labs.

- Students will have to choose any one question from the question set, which will be pertaining to
one of the labs and will be evaluated for 20 marks based on his Observation write-up,
Model/Experiment evaluation and Viva.

- All the faculty assigned to the class are responsible for the conduct of the exam and should assist
the mentor/main faculty in grading. We should normalize the marks, if needed.

6. One of the faculty has been assigned as ‘Main faculty’ for each class (marked in Bold letters above). He/She will
be in-charge of the class and will consolidate the final marks and submit final grades for the subject.
7.Course plan for 19MEE181 Manufacturing Practice

Laboratory Course Plan Number of Sessions

Cycle 1
Dismantling and Assembly of any two products, like
1. Worm gear box (10:1, 20:1, 30:1, 50:1)
2. Gear pump – Internal/External 2
Product lab 3. Centrifugal pump (0.5 hp, 0.25 hp)
4. Pneumatic double acting cylinder
5. Two-stage centrifugal pump
6. Rotary gear pump
Development and Fabrication of
2
Sheet metal lab 1. Electrical Switch box
2. Cone
Welding lab 1. Square butt joint using Arc Welding 1
2. Lap joint using Arc Welding
1. Straight joint
Soldering lab 2. T- joint 1
3. Britannia joint
Cycle 2
1. Study of various plumbing tools and fittings and their
usage in household plumbing activity.
2. Build a water pressurized bath shower or overhead tank
Plumbing 2
to tap plumbing work.
3. Understanding rainwater harvesting and tracing the Roof
Top Rain Water Harvesting (RTRWH).
1.Introduction to fluid power systems
2. Design and simulation of pneumatic circuits using single
and double acting cylinders
FP lab 2
3. Design and simulation of electro-pneumatic circuits
using single and double acting cylinders
4. Study of Programmable Logic Controllers (PLC)
1. Study of 3D printing process
3D printing 2. Building 3D prototype from CAD model using 2
thermoplastic material
 SHEET METAL WORKSHOP EQUIPMENTS LIST

SL. NAME OF THE

SPECIFICATION Qty(Nos)
No. EQUIPMENT
1 Bench Vice 4" 6

2 Anvil 75 kg 2

3 Cone Stake MFG 2

4 Sheet Bending Machine 3 feet 1

5 Hand Shear Cutter 12" 4

6 Bench Grinder 1/2 HP 1

7 Bench Drilling Machine Standard 1

 SHEET METAL WORKSHOP

LIST OF EXPERIMENTS

SL. No. Name of the Experiment

1 FABRICATION OF ELECTRICAL SWITCH BOX

2 FABRICATION OF CONE
 INDEX
Sl. No. TOPICS PAGE No.
1 INTRODUCTION 1
2 WORKERS BENCH 5
3 BENCH VICE 5
4 STEEL RULE 6
5 SCRIBER 6
6 TRY SQUARE 7
7 DOT PUNCH 7
8 CENTRE PUNCH 7
9 HACKSAW 8
10 CHISEL 10
11 FILES AND FILING TECHNIQUES 11
12 METHODS OF FILING 12
13 HAMMERS 13
14 BENCH DRILLING MACHINE 15
15 DIVIDERS 15
16 INSIDE CALIPER 16
17 VERNIER CALIPER 16
18 CUTTING TOOLS 17
19 ANVIL 17
20 COMBINATION CUTTING PLIER 18
21 TRAMMEL 18
22 WIRE GAUGE 19
23 STAKES 20
24 HAND SHEARING MACHINE 21
25 BENDING MACHINE 22
26 RIVET 23
27 SWITCH BOX 24
28 CONE 28
29 SAFTEY PRECAUTIONS 32
 1. INTRODUTION

Sheet metal work is doing different operations like cutting, forming into
shape and joining the metal sheets of 16 to 30 gauges with hand tools and simple
machines. Sheet metal work is one of the major applications in engineering
industry. It has its own significance as useful trade in engineering work.

2. APPLICATION OF SHEET METAL WORK

Sheet metal is used for making hoppers, funnels, various ducts, chimneys,
ventilating pipes, machine tool guards, boilers etc.

It is also extensively used in major industries like aircraft manufacturing, ship

building, automobile body building and fabrication of ducts in air conditioning
equipment’s etc.

PRINCIPLE INVOLVED IN SHEET METAL WORK

Generally all the sheet metal work patterns are based on the development of the
surfaces of a number of geometrical models like prism, cylinder, pyramid and
cone. Besides development of surfaces, geometrical projections are also used for
sheet metal work.

3. GENERAL PROCEDURE FOR SHEET METAL WORK

 The exact size and shape of the sheet to be cut is given by the development
of the concerned object.
 The development is drawn on a flat sheet of metal and then the sheet is cut.
 The cut sheet is folded or rolled to the required shape before the joints are
made by welding or any other form of fastening.

4. SPECIFICATION OF SHEET METAL

The sheets are specified by standard gauge numbers. Each gauge designates a
definite thickness. The gauge number can be identified by standard wire gauge (or)
S.W.G. The following table shows gauge numbers and their corresponding
thickness of sheet. The larger the gauge numbers, the lesser the thickness and vice
versa.

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S.W.G 10 12 14 16 20 22 24 26 28 30

Thickness 3.25 2.64 2.03 1.63 0.91 0.71 0.56 0.46 0.38 0.32
(mm)

5. METAL USED IN SHEET METAL WORK

The most commonly used sheet metals are:

a) Black iron
b) Galvanized iron
c) Stainless steel
d) Copper
e) Aluminum
f) Tin plate
g) Lead etc.
A) BLACK IRON

CHARACTERISTICS:

i) Less expensive
ii) Bluish – black appearance.
iii) It can be rolled and annealed
iv) It is less resistant to corrosion.

APPLICATION:

It is used for making tanks, pans and stove pipes etc.

B) GALVANISED IRON:

CHARACTERISTICS:
i) A sheet of soft steel coated with molten zinc is known as galvanized
iron
ii) Zinc resists corrosion due to formation of a dense layer of corrosion
product which insulates it again continued corrosion.

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APPLICATION:

It is used for making pans, buckets, furnaces, heating ducts, cabinets etc.

C) STAINLESS STEEL

CHARACTERISTICS:

i) This is an iron based alloy having high resistance to corrosion.

ii) It can be welded.
iii) It is tougher than galvanized iron sheet.

APPLICATION:

 Domestic appliances such as vessels are made up of stainless steel due to its
effective anticorrosion property.
 It is ideally suited for handling and storage of liquid helium, hydrogen,
nitrogen and oxygen that exist at cryogenic temperature.

D) COPPER

CHARACTERISTICS:

i) Copper sheets are available either as cold rolled (or) hot rolled sheets.
ii) It is highly resistant to corrosion.
iii) Since it is ductile material, it can be formed into complex shapes.
iv) It can be easily welded and riveted.

APPLICATION:

Copper sheet is used to making cutters, expansive joints, roof flashing and
hoods.

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 E) ALUMINIUM

CHARACTERISTICS:

i) It is available in the market as wrought and cast products in the form of

ingots or notched bars for re melting.
ii) It is whitish in colour and light in weight.

APPLICATION:

It is used for making household applications, refrigerator trays, vessels used in

chemical and food industries, electrical industries, structural applications etc.

F) TIN

CHARACTERISTICS:

i) The size and thickness of tin plates are denoted by special marks and not
by gauge numbers.
ii) At the temperature of 1000 C, It can be rolled in to sheets or drawn into
pipes.

APPLICATION:

It is used in the making of roofs, food containers, dairy equipments, furnace

fittings, cans and pans etc.

G) LEAD

CHARACTERISTICS:

i) It is soft and weak, having high resistant to corrosion.

ii) Low strength.
iii) High co-efficient of thermal expansion.

APPLICATION:

It is used for lining in the tank, flooring in chemical plants, it is used in battery
plated etc.

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WORKERS BENCH:

The work bench should be strong and rigid. It should be made of hardwood.
Thickness of the bench top board is above 50 mm. The height is usually from
760 mm to 840 mm. the vice is fitted at the top and front edge of the

The front edge of the top has an angle – iron fitted to protect the edge. There
are some cupboards to store the tools and instruments.

BENCH VICE (fitter’s vice)

The most commonly used in the engineer’s parallel jaw bench vice,
sometimes called fitters vice. It must be fitted on the bench by means of bolts and
nuts. It consists of cast iron body, a fixed jaw, a movable jaw – both made of cast
steel. Separate cast steel jaw plates are fixed on the jaws by means of set screw.
When holding soft material jobs use the protective grips or “clamps” made of
lead, fiber, tinplate etc.

The size of vice is known by the width of its jaw. The width suitable for
common work varies from 80 mm to140 mm, the maximum opening being 95 mm
to 180 mm.

5
STEEL RULE:

Steel rule is a liner measuring instrument 1.0 to 0.5 mm accuracy. It is also

used for drawing straight lines. It consists of a strip of hardened steel having line
graduations. Etched or engraved the units of centimeters and inches. Length of the
steel rules is made from 150 to 1000 mm and the thickness varies due to its length.
They may be made in folded from for easy handling.

SCRIBER

Scriber is a marking rod made up of hardened steel. The two ends are very sharp.
Some scribers may have a knurled handle in the middle and bend at one end as
shown in the fig.

6
TRY SQUARE

Try square is used for checking or marking right angles 90 0 accurately. It

consists of a steel blade Riveted into a hard Woodstock which has a protective
brass plate on the working edge another type of the stock is made up of cast iron
various size are available in the mark from 150 to 300 mm of blade length.

DOT PUNCH

Dot punch is a punching tool which is made of high carbon steel. The point angle
should be ground to 60°. It is used to define a line that has to be worked. It should
be knurled for easy handling.

CENTRE PUNCH

Centre punch is a punching tool to locate the centre of hole to be drilled. It is made
of high carbon steel. Its point angle should be ground to 90°it should be knurled
for easy handling as shown in the fig. Centre punch dots to guide the point of twist
drill.

7
HACK SAW

Hack saw is a cutting tool for sawing all metals except hardened steel. It consists
of a solid frame or adjustable frame with a handle, prongs, tightening screw, nut
and blade as shown in the fig. the blade is made of high carbon steel, low alloy
steel or high speed steel. The cutting edge must be hardened. The blade is specified
by its length, width, thickness and pitch of teeth. For hand operation, the common
lengths are 250 and 350 mm, widths are 13 and 16mm, and thickness are 0.63 and
0.80 mm respectively

There are three grades. They are coarse, medium and fine according to its
pitch of teeth as 1.8 mm, 1.4 mm and 1.0 mm respectively. According to the
arrangements of teeth, there are three types as Raker, Alternate and wavy as shown
in the fig.

HACK SAW

8
SAWING POSITIONS

Generally the metal cutting positions are shown in the following figs.

9
CHISEL

Chisels are used cutting the metals in industries. Cold chisels are used
cutting metals.

The chisels are made of high carbon steel or cast steel. Varieties of chisels
are available for various cutting operations. According to the shape of cutting point
and details of the cutting angles, there are many types. The five most common
types are the FLAT, CROSS CUT, DIAMOND POINTED, HALF ROUND and
the SIDE CHISEL. Three important angles are: RAKE ANGLE, FORGING
ANGLE and CLEARANCE ANGLE.

10
FILES AND FILING TECHNIQUES

File is a metal cutting tool. It is made up of hardened and tempered high

carbon steel (or) high speed steel (or) tungsten steel. The arrangement of teeth is
in single row cut type and double row cut (cross cut). Files are named according to
the shape of its cross section. Angle of single cut is 600 and double cut is 600 and
800 crossed. Single cut files are used for soft metal, and double cut files are used
for slightly hardened metals.

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PRECISION FILING

METHODS OF FILING

THREE TYPES OF FILING TECHNIQUES ARE USED IN GENERAL.

(1) STRAIGHT FILING

In this method, the file is moving parallel to the working surface of the job
with required pressure. The straight filing is more useful to filing a thin work
piece. Generally the thickness of job should be less than the width of the file.

(2) CROSS FILING

The file stroke should run alternately from right and left as shown in the fig.
The aim in cross filing is always to move the whole file surface across the work
surface in one stroke.

(3) DRAW FILE

Both the hands of the worker should be placed close together on the file. While
draw filing, the file is placed at right angle to the work surface. The draw filling
operation is a finishing operation. This produces very fine and smooth surface.

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HAMMERS

BALL PEEN HAMMER

This hammer is also called engineer’s hammer, or chipping hammer. It is

used for chipping, riveting, sheet metal work and forming work etc. it’s weight
varies from 0.1 kg to 1.5 kg.

CROSS PEEN HAMMER

It is just like a ball peen hammer except the peen across the eye hole. This is
mainly used for bending, stretching, hammering, into shoulders, inside curves etc.
its sizes varies from 0.22 to 0.91kg.

STRAIGHT PEEN HAMMER

The peen is parallel to the axis of the eye hole. It is used for stretching or
peening the metal. The sizes vary from 0.11 to 0.91 kg.

PIN HAMMER

It is the smallest hammer, and it may be ball peen or cross peen in shape as shown
in the fig.

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SLEDGE HAMMER

Sledge hammer is a heavy duty hammer. Its two ends are similar in shape. It is
available in weight up to 15 kg according to the work. The hammer heads are made
from high carbon steel and its faces are hardened and tempered.

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BENCH DRILLING MACHINE

Bench drilling machines, also called table drilling machines, are single spindle
vertical drilling machines, which are firmly mounted on table tops. They are
suitable for smaller holes which work at moderate to high speeds.

DIVIDERS

It consists of two pointed legs hinged together by means of rivet or spring. It

is made of hardened steel. It is mainly used for measuring a distance, transferring a
distance and scribing lines and circles, when marking off.

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INSIDE CALIPER

VERNIER CALIPER

Vernier caliper is a measuring instrument. It is primarily intended for

measuring both inside and outside diameters of bores, shafts, thickness of parts,
etc. to an accuracy of 0.02 mm. It consists of beam scale called main scale, vernier
scale, main scale locking screw, vernier locking screw, fine adjustment screw of
vernier scale, inside measuring jaws, and outside measuring jaws.

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 CUTTING TOOLS

TINNERS HAND TOOLS

THE ANVIL

17
COMBINATION CUTTING PLIER

TRAMMEL

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 WIRE GAUGE

Wire gauge is used to determine the gauges of sheet metals and wires. Some of the
standard wire gauge numbers with its corresponding thickness in mm are given
below.

Standard wire Thickness in mm

gauge number
10 3.25
12 2.64
14 2.03
16 1.63
20 0.91
22 0.71
24 0.56
26 0.46
28 0.38
30 0.32

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 STAKES

A) BEAK HORN STAKE

B) FUNNEL STAKE

C) HALF MOON STAKE

D) ROUND BOTTOM STAKE

E) BICK IRON STAKE

F) HATCHET STAKE

WODDEN MALLET

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 HAND SHEARING MACHINE

Shearing machines are multipurpose devices used in the cutting of alloys and
other sheet metal. Some shearing machines use like scissor, angular shear action
to cut metal into sheets or strips. Other, larger machines use a straight shear action
with the blade fixed at an angle as opposed to the angular movement.

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 BENDING MACHINE

A bending machine is primarily used for forming a bend on the work piece.
The machine makes use of a bending tool for this process. Metal sheets are first
fixed on to the clamping device that holds them during the entire operation. It can
also be used for straightening metal sheets and strips. The drive of
such machines may be mechanical or hydraulic. Machines of this type are used
for bending sheets 0.8 – 5.0 mm thick.

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 RIVET

Rivets are short ductile and cylindrical bars which are used for making a
permanent mechanical joint. The process of forming a riveted joint is called
riveting. A rivet is divided into 3 parts i.e., the head at one end, the tapered tail and
shank, the portion between head and tail.

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24
SWITCH BOX

All Dimensions are in mm.

PART NAME: switch box

MATERIAL:Mild Steel SHEET THICKNESS: 0.6mm
SIZE : 220X220

SCALE :NTS

25
 FABRICATION OF SWITCH BOX

AIM:

Making a switch box using mild steel sheet to the given dimension.

TOOLS REQUIRED:

1. HAND TOOL – tri square, scriber, cutting snips, wooden mallet, centre
punch, Hammer.
2. MACHINE USED – drilling machine, bending machine, shear cutting
machine.
3. MEASURING TOOLS – steel rule and vernier caliper.

METHODOLOGY:

1. Prepare the sheet for the fabrication.

2. Prepare a development drawing using switch box specification.
3. Find out the optimum layout of the development.
4. Bend the sheet as per the development drawing.
5. Finish the box according to the specification.

PROCEDURE FOR PREPATATION OF DEVELOPMENT

1. Measure the given sheet.

2. Clean the given sheet using emery sheet.
3. Remove the tint using wooden mallet.
4. Mark the layout of the switchbox.
5. Mark the hole using centre punch.

FABRICATION AND FINISHING:

1. Cut the mild steel using the sheet cutter along the marked dimensions.
2. Using bending machine, bend the four sides of the sheet at an angle of 900.
3. Using the drilling machine, drill the hole at the punch mark.
26
 4. Fold the sheet using the wooden mallet, to make the corners get closed.
5. File the corner of the box and the sharp edges using a file.

APPLICATION AREAS:

The application areas of the sheet metal part similar to switch box prepared
are:

1. Tool box
2. First aid box.
3. Box for keeping spare parts.
4. Air conditioning ducts.
5. Furniture.
6. Electric panel board.
7. Chimney.
8. CPU covers.
9. Refrigerator covers.

RESULT:

The switch boxes have been made per the specifications.

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28
29
 FABRICATION OF CONE

AIM:

To make cone using Mild steel.

TOOLS REQUIRED:

1. Scriber
2. Steel rule
3. Snip cutter
4. Punch, drill hammer.

METHODOLOGY:

1. Prepare the sheet for the fabrication.

2. Draw the development of cone using the product dimension.
3. Find out the optimum layout of the development.
4. Cut the sheet as per the development.
5. Joint the edges of the sheet to form as cone.

PROCEDURE FOR LAYOUT MAKING:

1. Mark the layout on the given sheet.

2. Mark the drill location by marking punch holes.

PROCEDURE FOR FABRICATION AND FINISHING:

1. Cut the metal sheet along the mark.

2. Using the drilling machine, drill the holes.
3. Bend the sheet using anvil and mallet.
4. Join the ends of the sheet by rivets.
5. Remove burrs and sharp corners by filling.

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APPLICATION AREAS:

1. Chimneys
2. Pans
3. Buckets
4. Heating ducts
5. Cabinets
6. Drums etc….

RESULT:

A sheet metal cone was made using GI sheet as per the specifications. The
actual dimension of the cone are:

Height:

Diameter:

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 SAFTEY PRECATIONS
 Always use safety goggles to protect your eyes from fine particles that fly
during the bending process.
 Avoid running your hands over a sharp cut, even if you are wearing gloves.
 Always ensure that all the burr are filed properly.
 Make use of work boots. They prevent any scrap, or pointed material from
hurting your feet.
 Do not wear ties, loose clothing, Jewellery, gloves, etc. around moving or
rotating machinery. Long hair must be tied back or covered to keep it away
from moving machinery.
 Hand protection in the form of suitable gloves should be used for handling
hot objects, glass, or sharp-edged items.
 A brush, hook, or special tool is preferred for removal of chips, shavings,
etc. from the work area.
 A hard hammer should not be used to strike a hardened tool or any machine
part.
 Use a soft-faced hammer. Practice cleanliness and orderliness in the shop
areas
 Think through the entire job before starting.
 Don't rush or take chances. Obey all safety rules.

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