ABESIT WORKSHOP PRACTICE LAB (BWS151/BWS251) B.

TECH I YEAR

EXPERIMENT NO- 1
Layout, Safety Measures and Engineering Materials

OBJECTIVE: To study layout, safety measures and different engineering materials (mild
steel, medium carbon steel, high carbon steel and cast iron etc) used in workshop.

Layout: Plant layout is such a systematic and efficient functional arrangement of various
departments, machines, tools, equipment and other supports services of an industrial
organization that will facilitate the smooth processing of the product in the most effective,
efficient and economical manner in the minimum possible time.

Workshop: A building or a part of a building or a place where things are manufactured or

repaired.

Manufacturing: Manufacturing processes are broadly classified into four categories; (i)
Casting processes, (ii) Forming processes, (iii) Fabrication processes, and (iv) Material
removal processes. In all these processes, components are produced with the help of either
machines or manual effort. To performed these processes to manufacture a component,
workshop is divided into different shops according to the operations performed on the
components.

1. Fitting Shop - Working on components with hand tools and instruments, mostly on
work benches is generally referred to as 'Fitting work'. The hand operations in fitting
shop include marking, filing, sawing, scraping, drilling, tapping, grinding etc., using
hand tools or power operated portable tools. The term "bench work" generally denotes
the production of a part by hand on the bench.
2. Carpentry Shop - Carpentry may be defined as the process of making wooden
components. It deals with the specific work of carpenter like making different types of
joints to form a finished product.
3. Machine shop - A place where hand tools and power-driven tools are used for making,
finishing, or repairing machines or machine parts. Machine tool is a non-portable power
operated device in which the energy is utilized to produce jobs of desired shape and
size and surface finish by removing excess material. The oldest machine tool used in
machine shop is a lathe machine.

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ABESIT WORKSHOP PRACTICE LAB (BWS151/BWS251) B. TECH I YEAR

4. Welding Shop - Welding is a process of joining similar metals by application of heat

with or without application of pressure and addition of filler material. Welding is
extensively used in fabrication work in which metal plates, steel sections, casting of
ferrous materials are joined together. It is also used for repairing broken, worn out and
defective metal part.
5. Foundry Shop - Foundry practice deals with the process of making castings in molds,
formed in either sand or some other material. The process involves the operations of
pattern making, sand preparation, molding, melting of metals, pouring in molds,
cooling, shake-out, heat treatment, finishing, and inspection.
6. Black Smithy Shop - A smithy is a place where blacksmiths do their work, heating,
and shaping metal, especially to make tools. Smithy or Forging is the oldest shaping
process used for 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 them through applying compressive forces using a hammer.
7. Sheet Metal Shop – Sheet metal work is generally regarded as the working of metal
sheet from 0.3 to 1.6 mm with hand tools and simple machines into various forms by
cutting, forming and joining.

Safety Measures:

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 guards are in place.
8. One person only should operate the machine controls.

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ABESIT WORKSHOP PRACTICE LAB (BWS151/BWS251) B. TECH I YEAR

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.

Engineering Materials: Engineering materials are mainly classified into two categories.

a) Ferrous materials are those which have the iron as their main constituent, such as pig
iron, cast iron, wrought iron and steels.
b) Non-ferrous materials are those which have a metal other than iron as their main
constituent, such as copper, aluminium, brass, bronze, tin, silver zinc, invar etc.

Ferrous Materials: Main Types of Iron are

1. Pig iron
2. Wrought iron
3. Cast iron
4. Steel
A. Plain carbon steels
i. Low Carbon steels
ii. Medium Carbon steels
iii. High Carbon steels
B. Alloy steels
i. High speed steel
ii. Stainless steel

Pig Iron: The basic principal raw material for all ferrous materials is pig iron which is obtained
by smelting iron ore, coke and limestone in the blast furnace.

Wrought Iron: Wrought iron is the assumed approximately as purest iron which possesses at
least 99.5% iron. It is said as a mechanical mixture of very pure iron and a silicate slag.

Cast Iron: Cast iron is basically an alloy of iron and carbon and is obtained by re-melting pig
iron with coke, limestone and steel scrap in a furnace. The carbon content in cast iron varies

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ABESIT WORKSHOP PRACTICE LAB (BWS151/BWS251) B. TECH I YEAR

from 2% to 6.67% but practically it is in between 2% to 4.5% only. It also contains small
amounts of silicon, manganese, phosphorus and sulphur in form of impurities elements.

Steel: Steel is an alloy of iron and carbon with carbon content maximum up to 2%.

A. Plane Carbon Steel: Plain carbon steel is an alloy of iron and carbon. It is different
from cast iron as regards the percentage of carbon. It contains carbon from 0.05 to 2%
whereas cast iron possesses carbon from 2 to 6.67%. Depending upon the carbon
content, a plain carbon steels can be divided to the following types:
I. Low carbon or mild steel — 0.05% to 0.3% carbon
II. Medium carbon steel — 0.3% to 0.8% carbon
III. High carbon steel — 0.8% to 1.5% carbon
B. Alloy Steel: For improving the properties of ordinary steel, certain alloying elements
are added in it. The main purpose of alloying element in steel is to improve its
mechanical properties.
I. High Speed Steel: High speed steels (HSS) are most commonly operated as
cutting tools at much higher Speed. It contains 18% tungsten, 4% chromium
and 1 % vanadium, 0.8% carbon and remaining iron.
II. Stainless Steel: Stainless steel contains chromium together with nickel as
alloying element. Stainless steel surface is responsible for corrosion resistance.
Minimum chromium content of 12% is required for the film’s formation, and
18% is sufficient to resist the most severe atmospheric corrosive conditions. A
steel containing 18% chromium and 8% nickel is widely used and is
commonly referred to as 18/8 steel.

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