J.C.

BOSE UNIVERSITY OF SCIENCE

AND TECHNOLOGY, YMCA, FARIDABAD
NAAC 'A' Grade Accredited State Govt. University

DEPARTMENT OF MECHANICAL ENGINEERING

WORKSHOP
MANUAL
WELDING WORKSHOP

ACADEMIC YEAR 2021-22

J.C. BOSE UNIVERSITY OF SCIENCE AND TECHNOLOGY, YMCA, FARIDABAD
NAAC 'A' Grade Accredited State Govt. University
(Established by Haryana State Legislative Act No. 21 of 2009, Recognized by U.G.C. u/s 2 (f) and 12(B) of U.G.C. Act 1956)

FABRICATION WELDING
&
SHEET METAL WORKSHOP

WORKSHOP MANUAL
B.Tech (Fourth Semester)
 Workshop Manual

B. Tech.
Mechanical Engineering

FWSMT WORKSHOP

Department of Mechanical Engineering

J.C. Bose University of Science and Technology, YMCA,
Faridabad
FWSMT WORKSHOP Page 1
 VISION of University

J.C. Bose University of Science and Technology aspires to be a nationally and internationally
acclaimed leader in technical and higher education in all spheres which transforms the life of
students through integration of teaching, research and character building.

MISSION of University

• To contribute to the development of science and technology by synthesizing teaching,

research and creative activities.
• To provide an enviable research environment and state-of-the-art technological
exposure to its scholars.
• To develop human potential to its fullest extent and make them emerge as world class
leaders in their professions and enthuse them towards their social responsibilities.

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 Department of Mechanical Engineering

VISION

To be a centre of excellence by producing high calibre, competent and self-reliant

mechanical engineers, who possess scientific temperament and would engage in activities
relevant to industries with ethical values and flair to research.

MISSION

• To provide efficient engineers for global requirements by imparting quality education.

• To explore, create and develop innovations in various aspects of engineering through
industries and institutions.
• To emphasize on practical skills and socially relevant technology.

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 DEPARTMENT OF MECHANICAL ENGINEERING

Program Educational Outcomes (PEO’S): B. Tech. Mechanical Engineering

PEO-1:

To train students with practical skills and experimental practices related to core and applied areas

of mechanical engineering to expand their knowledge horizon beyond books.

PEO-2:

To enable students to design, develop and maintain mechanical equipments which are useful for

the society.

PEO-3:

To improve team building, team working and leadership skills of the students with high regard for

ethical values and social responsibilities.

PEO- 4:

To enable students to communicate effectively and demonstrate the knowledge of project

management and independent research.

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 DEPARTMENT OF MECHANICAL ENGINEERING

PROGRAMME OUTCOMES (PO)

PO Engineering Graduates will be able to:

Engineering knowledge: Apply knowledge of mathematics, science, engineering

PO1 fundamentals, and mechanical engineering to the solution of engineering problems.
Problem analysis: Identify, formulate, review literature and analyze mechanical
PO2 engineering problems to design, conduct experiments, analyze data and interpret data.
Design /development of solutions: Design solution for mechanical engineering
PO3 problems and design system component of processes that meet the desired needs with
appropriate consideration for the public health and safety, and the cultural, societal and
the environmental considerations.
Conduct investigations of complex problems: Use research based knowledge and
PO4 research methods including design of experiments, analysis and interpretation of data, and
synthesis of the information to provide valid conclusions in mechanical engineering.
Modern tool usage: Create, select, and apply appropriate techniques, resources, and
PO5 modern engineering and IT tools including prediction and modeling to mechanical
engineering activities with an understanding of the limitations.
The engineer and society: Apply reasoning informed by the contextual knowledge to
PO6 assess societal, health, safety, legal and cultural issues and the consequent responsibilities
relevant to mechanical engineering practice.
Environment and sustainability: Understand the impact of the mechanical engineering
PO7 solutions in societal and environmental contexts, and demonstrate the knowledge and
need for sustainable development.
Ethics: Apply ethical principles and commit to professional ethics and responsibilities
PO8 and norms of the mechanical engineering practice.
Individual and team work: Function affectively as an individual, and as a member or
PO9 leader in diverse teams, and in multidisciplinary settings in mechanical engineering.
Communication: Communicate effectively on complex engineering activities with the

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PO10 engineering committee and with society at large, such as, being able to comprehend and
write affective reports and design documentation, make effective presentations in
mechanical engineering.
Project Management and finance: Demonstrate knowledge & understanding of the
PO11 mechanical engineering principles and management principles and apply these to one’s
own work, as a member and leader in a team, to manage projects and in multidisciplinary
environments in mechanical engineering.
Life- long learning: Recognize the need for, and the preparation and ability to engage in
PO12 independent research and lifelong learning in the broadest contest of technological
changes in mechanical engineering.

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 DEPARTMENT OF MECHANICAL ENGINEERING

PROGRAMME SPECIFIC OUTCOMES (PSO)

PSO Engineering Graduates will be able to:

To empower the students to apply practical skills, knowledge in major streams such as
thermal, design, manufacturing and industrial engineering.
PSO1

To enable the student to take-up career in industries or to pursue higher studies in mechanical
and interdisciplinary programs with high regard for ethical values, environmental and social
PSO2
issues.

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 SEC-WS-401/21 WORKSHOP-IV

B. Tech (Mechanical Engineering) IV Semester

No. of credits: 2 Sessional: 30 Marks

L T P Total Practical: 70 Marks

0 0 4 4 Total: 100 Marks

Duration of Exam: 3 Hours

Pre-requisite: Workshop-I, Workshop-II, Workshop-III

Successive: Workshop-V, Workshop-VI, Workshop-VII

Course Objectives: To carry out various exercises using conventional machines, welding
processes & refrigeration and air conditioning system.
Course Outcomes (COs): After studying this course the students will be able to:

CO 1- Perform various operations on lathe, milling, shaper, drilling and grinding machines.

CO 2- Understand the functions and use of various metrological tools and gauges used in machine
shop.
CO 3- Prepare various jobs by using arc, gas and MIG /MAG welding processes.

CO 4- Dismantle and assemble compressors used in refrigeration system.

CO 5- Identify different parts , functions of reciprocating and rotary compressors.

List of Exercises:

Section (A) Machine shop:

1. To perform multi operational job (facing, centering, turning, knurling,

threading,grooving, chamfering etc) on lathe machine.

2. To understand the use of various metrological tools and gauges namely

bore gauge, micrometer (inside and outside), slip gauge, sine bar, snap gauge
and plug gauge etc.

3. To perform a job of taper machining/V-shape machining on milling/shaping machine.

4. To prepare a job on surface grinder/cylindrical grinder maintaining

dimensions with inclose tolerance.

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 Section (B) Welding shop:

1. To lay weaved bead & prepare T-joint in flat position by arc welding on mild steel
plate.

2. To prepare closed butt joint on mild steel plate in flat position by MIG/MAG welding.

3. To perform cutting operation on mild steel plate by oxy-acetylene gas welding.

4. To create fillet weld lap joint on mild steel plate in flat position by arc welding.

Section (C) RAC shop:

1. To carry out dismantling and assembling of single& dual reciprocating compressor.

2. To carry out dismantling and assembling of rotary open &closed type compressor.

3. To perform gasket cutting for single &dual cylinder, rotary open & close type compressor.

4. To study and testing of relays, capacitors &troubleshooting of single phase A.C motor.

Note: - Total nine exercises should be performed from the above list. At least two from each
section and remaining three may either be performed from above list or designed by the
concerned institution as per the scope of the syllabus and facilities available in the
institute.

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 Welding Safety Guidelines

1. Shop staff approval is required before using any welding equipment.

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

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Arc welding
In arc welding, the edges of two metal parts are melted by an electric arc and the joint is made. An
electrode made of a suitable metal is utilised for this purpose. The electrode is taken closer to the parts to be
joined and electric current is supplied to both the parts and the electrode. An electric arc is made between the
electrode and the metal parts.
This arc generates high temperature and melts the metal parts. The parts are joined at this molten state. The
filler metal in the form of electrode is deposited along the joint. The metal parts are joined without the
application of any pressure. Electrical energy is covered into heat energy in arc welding.
The distance between the metal parts and the electrode should be around 3mm. The heat generated during arc
welding ranges from 5000°C to 6000°C. A generator or a transformer supplies the required current to both
the electrode and the metal parts. The electrodes are flux coated to prevent the molten metal from reacting
with the atmosphere.

Fig. Arc welding operation

Advantages
1. Shielded Metal Arc Welding (SMAW) can be carried out in any position with highest weld quality.
2. MMAW is the simplest of all the arc welding processes.
3. This welding process finds innumerable applications, because of the availability of a wide variety of
electrodes.
4. Big range of metals and their alloys can be welded easily.
5. The process can be very well employed for hard facing and metal resistance etc.
6. Joints (e.g., between nozzles and shell in a pressure vessel) which because of their position are
difficult to be welded by automatic welding machines can be easily accomplished by flux shielded
metal arc welding.
7. The MMAW welding equipment is portable and the cost is fairly low.

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 EXERCISE-1 (A)
AIM: - To lay weaved bead in flat position by arc welding on mild steel plate.

TOOL + EQUIPMENTS: - Welding m/c with accessories, chipping hammer, tong, wire brush, leather
apron, leather hand- gloves, scriber, scale etc.

MATERIAL REQUIRED: - (I) M.S. plate 130x50x6mm = 1no.

(II) M.S. electrode: - ∅3.15 X 350 mm
PROCEDURE: -To be written by students as per job.
Note: - All dimensions are in mm.

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 EXERCISE-1 (B)
AIM: - To prepare T- joint in flat position by arc welding on mild steel plate.

TOOL + EQUIPMENTS: - Welding m/c with accessories, chipping hammer, tong, wire brush, leather
apron, leather hand- gloves, scriber, scale etc.

MATERIAL REQUIRED: - (I) M.S. plate 130x40x6 mm = 1no.

(ii) M.S. plate 130x32x5 mm = 2nos.
(iii) M.S. electrode: - ∅2.50 x 350mm (for tacking)
∅3.15 x 350mm - (for welding)
PROCEDURE: -To be written by students as per job.
Note: - All dimensions are in mm.

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 GAS METAL ARC WELDING (GMAW) OR METAL INERT GAS WELDING (MIG)

Metal inert gas arc welding (MIG) or more appropriately called as gas metal arc welding (GMAW)
utilizes a consumable electrode and hence, the term metal appears in the title. There are other gas shielded
arc welding processes utilizing the consumable electrodes, such as flux cored arc welding (FCAW) all of
which can be termed under MIG. Though gas tungsten arc welding (GTAW) can be used to weld all types of
metals, it is more suitable for thin sheets. When thicker sheets are to be welded, the filler metal requirement
makes GTAW difficult to use. In this situation, the GMAW comes handy. The typical setup for GMAW or
MIG welding process is shown in Fig. The consumable electrode is in the form of a wire reel which is fed at
a constant rate, through the feed rollers. The welding torch is connected to the gas supply cylinder which
provides the necessary inert gas. The electrode and the work-piece are connected to the welding power
supply. The power supplies are always of the constant voltage type only. The current from the welding
machine is changed by the rate of feeding of the electrode wire. Normally DC arc welding machines are used
for GMAW with electrode positive (DCRP). The DCRP increases the metal deposition rate and also provides
for a stable arc and smooth electrode metal transfer. With DCSP, the arc becomes highly unstable and also
results in a large spatter. But special electrodes having calcium and titanium oxide mixtures as coatings are
found to be good for welding steel with DCSP. In the GMAW process, the filler metal is transferred from the
electrode to the joint. Depending on the current and voltage used for a given electrode, the metal transfer is
done in different ways.

Fig. Gas metal arc welding (GMAW) set up

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 EXERCISE-2
AIM: - To prepare closed butt joint on mild steel plate in flat position by Mig/ Mag welding.

TOOL + EQUIPMENTS: - Mig/ Mag welding m/c with accessories, chipping hammer, tong, wire brush,
leather apron, leather hand- gloves, scriber, scale, no of punch set etc.

MATERIAL REQUIRED: - (i) M.S. plate 130x40x6mm = 2nos.

(ii) M.S. consumable electrode:-∅ 0.8mm
(iii) Working pressure of co2 gas: - 10 to 15 lit/ min. or 20 to 30 cft (cubic feet
per hour)
(iv) Entry spatter spray
SETTING OF VOLTAGE & CURRENT: - Voltage: - 25-30 volts
Current: - 90-130 amps.
PROCEDURE: -To be written by students as per job.
Note: - All dimensions are in mm.

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 GAS WELDING
It is a metal joining process in which the ends of pieces to be joined are heated at their interface by
producing coalescence with one or more gas flames (such as oxygen and acetylene), with or without the use
of a filler metal.

Oxy-Acetylene gas Welding

Oxyacetylene welding, commonly referred to as gas welding, is a process which relies on combustion
of oxygen and acetylene. When mixed together in correct proportions within a hand-held torch or blowpipe, a
relatively hot flame is produced with a temperature of about 3,200˚C. The chemical action of the
oxyacetylene flame can be adjusted by changing the ratio of the volume of oxygen to acetylene. Three
distinct flame settings are used, neutral, oxidising and carburizing. Welding is generally carried out using the
neutral flame setting which has equal quantities of oxygen and acetylene. The oxidizing flame is obtained by
increasing just the oxygen flow rate while the carburising flame is achieved by increasing acetylene flow in
relation to oxygen flow. Because steel melts at a temperature above 1,500˚C, the mixture of oxygen and
acetylene is used as it is the only gas combination with enough heat to weld steel. However, other gases such
as propane, hydrogen and coal gas can be used for joining lower melting point non-ferrous metals, and for
brazing and silver soldering.

Equipment
Oxyacetylene equipment is portable and easy to use. It comprises oxygen and acetylene gases stored
under pressure in steel cylinders. The cylinders are fitted with regulators and flexible hoses which lead to the
blowpipe. Specially designed safety devices such as flame traps are fitted between the hoses and the cylinder
regulators. The flame trap prevents flames generated by a 'flashback' from reaching the cylinders; principal
causes of flashbacks are the failure to purge the hoses and overheating of the blowpipe nozzle. When
welding, the operator must wear protective clothing and tinted coloured goggles. As the flame is less intense
than an arc and very little UV is emitted, general-purpose tinted goggles provide sufficient protection.

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Types of Welding Flames
In oxy-acetylene welding, flame is the most important means to control the welding joint and the
welding process. The correct type of flame is essential for the production of satisfactory welds. The flame
must be of the proper size, shape and condition in order to operate with maximum efficiency. There are three
basic types of oxy-acetylene flames.
1. Neutral welding flame (Acetylene and oxygen in equal proportions).
2. Carburizing welding flame or reducing (excess of acetylene).
3. Oxidizing welding flame (excess of oxygen).

The gas welding flames are shown in Fig

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Neutral Welding Flame
A neutral flame results when approximately equal volumes of oxygen and acetylene are mixed in the
welding torch and burnt at the torch tip. The temperature of the neutral flame is of the order of about 5900°F
(3260°C). It has a clear, well defined inner cone, indicating that the combustion is complete. The inner cone
is light blue in color. It is surrounded by an outer flame envelope, produced by the combination of oxygen in
the air and superheated carbon
monoxide and hydrogen gases from the inner cone. This envelope is Usually a much darker blue than the
inner cone. A neutral flame is named so because it affects no chemical change on the molten metal and,
therefore will not oxidize or carburize the metal. The neutral flame is commonly used for the welding of mild
steel, stainless steel, cast Iron, copper, and aluminium.

Carburizing or Reducing Welding Flame

The carburizing or reducing flame has excess of acetylene and can be recognized by acetylene
feather, which exists between the inner cone and the outer envelope. The outer flame envelope is longer than
that of the neutral flame and is usually much brighter in color. With iron and steel, carburizing flame
produces very hard, brittle substance known as iron carbide. A reducing flame may be distinguished from
carburizing flame by the fact that a carburizing flame contains more acetylene than a reducing flame. A
reducing flame has an approximate temperature of 3038°C. A carburizing-flame is used in the welding of
lead and for carburizing (surface hardening) purpose. A reducing flame, on the other hand, does not carburize
the metal; rather it ensures the absence of the oxidizing condition. It is used for welding with low alloy steel
rods and for welding those metals, (e.g., non-ferrous) that do not tend to absorb carbon. This flame is very
well used for welding high carbon steel.

Oxidizing Welding flame

The oxidizing flame has an excess of oxygen over the acetylene. An oxidizing flame can be
recognized by the small cone, which is shorter, much bluer in color and more pointed than that of the neutral
flame. The outer flame envelope is much shorter and tends to fan out at the end. Such a flame makes a loud
roaring sound. It is the hottest flame (temperature as high as 6300°F) produced by any oxy-fuel gas source.
But the excess oxygen especially at high temperatures tends to combine with many metals to form hard,
brittle, low strength oxides. Moreover, an excess of oxygen causes the weld bead and the surrounding area to
have a scummy or dirty appearance. For these reasons, an oxidizing flame is of limited use in welding. It is
not used in the welding of steel. A slightly oxidizing flame is helpful when welding (i) Copper-base metals
(ii) Zinc-base metals and (iii) A few types of ferrous metals such as manganese steel and cast iron. The
oxidizing atmosphere in these cases, create a basemetal oxide that protects the base metal.

Welding torch
Fig. shows the construction of the welding torch. It is a tool for mixing oxygen and acetylene in
correct proportion and burning the mixture at the end of a tip. Gas flow to the torch is controlled with the
help of two needle valves in the handle of the torch. There are two basic types of gas welding torches:
(1) Positive pressure (also known as medium or equal pressure), and
(2) Low pressure or injector type
The positive pressure type welding torch is the more common of the two types of oxyacetylene torches.

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 Fig. Welding torch
Torch tips
It is the portion of the welding apparatus through which the gases pass just prior to their ignition and
burning. A great variety of interchangeable welding tips differing in size, shape and construction are
available commercially. The tip sizes are identified by the diameter of the opening. The diameter of the tip
opening used for welding depends upon the type of metal to be welded.
Hose pipes
The hose pipes are used for the supply of gases from the pressure regulators. The most common
method of hose pipe fitting both oxygen and acetylene gas is the reinforced rubber hose pipe. Green is the
standard color for oxygen hose, red for acetylene, and black hose for other industrially available welding
gases.
Goggles
These are fitted with colored lenses and are used to protect the eyes from harmful heat and ultraviolet
and infrared rays.
Gloves
These are required to protect the hands from any injury due to the heat of welding process.
Spark-lighter
It is used for frequent igniting the welding torch.
Filler rods
Gas welding can be done with or without using filler rod. When welding with the filler rod, it should
be held at approximately 900 to the welding tip. Filler rods have the same or nearly the same chemical
composition as the base metal. Metallurgical properties of the weld deposit can be controlled by the optimum
choice of filler rod. Most of the filler rods for gas welding also contain deoxidizers to control the oxygen
content of weld pool.
Fluxes
Fluxes are used in gas welding to remove the oxide film and to maintain a clean surface. These are
usually employed for gas welding of aluminum, stainless steel, cast iron, brass and silicon bronze. They are
available in the market in the form of dry powder, paste, or thick solutions.

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 EXERCISE-3
AIM: - To perform cutting operation in m.s. plate by oxy-acetylene gas welding.

TOOL + EQUIPMENTS: - High pressure oxy-acetylene gas plant with accessories, tong, wire brush, gas
welding goggles , spark lighter, scale, mallet, scriber, Leather hand gloves, Leather apron, tip cleaner etc.

MATERIAL REQUIRED: - (i) M.S. sheet 130x50x1mm = 1no.

Torch flame: - Neutral or balancing (1:1:1½)
Working pressure of oxygen + acetylene cylinder 0.140kg/cm²

PROCEDURE: -To be written by students as per job.

Note: - All dimensions are in mm.

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 EXERCISE-4
AIM: - To create fillet weld lap joint on M.S. plate. In flat position by arc welding.
TOOL & EQUIPMENTS: - Welding m/c with accessories, chipping hammer, tong, wire brush, leather
apron, leather hand- gloves, scriber, scale etc.
MATERIAL REQUIRED: - (I) M.S. plate 130x40x6mm = 3nos.
(ii) M.S. electrode: - ∅2.50 x 350mm (for tacking)
∅3.15 x 350mm - (for welding)
PROCEDURE: -To be written by students as per job.
Note: - All dimensions are in mm.

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 J.C. BOSE UNIVERSITY OF SCIENCE
AND TECHNOLOGY, YMCA, FARIDABAD
NAAC 'A' Grade Accredited State Govt. University
(Established by Haryana State Legislative Act No. 21 of 2009,
Recognized by U.G.C. u/s 2 (f) and 12(B) of U.G.C. Act 1956)
NH- 2, SECTOR-6, MATHURA ROAD
FARIDABAD, HARYANA-121006

LAST UPDATED - OCTOBER 2021

jcboseust.ac.in /JCBoseUST