Workshop Marks are divided as :

30 Internal (viva or job)

30 Viva
40 Prac Job
There was a file kept on the table :
Q1 What is the name of the file?
Ans : Flat File
Q2 What type of cut is shown?
Ans: Double Cut
Q3 What is the angle in a single and a double cut?
Ans: Single = 60
Double = 75 & 80
Q4 When is the double cut preferred?
when workpiece is made up of hard metal
when more metal has to be removed.
Q5 Should the hardness of workpiece be same as that of the file?
Ans: No. The hardness of Workpiece should be less otherwise it will not be able to file.

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Q6 Classify different types of files.

Can be classified on the basis of shapes:
1.flat 2. triangular 3.square 4.hand 5. pillar 6.round 7. half round 8.knife edge
Can be classified on the basis of cuts:
Single cut and double cut
Can be classified on the basis of coarseness:
Rough, bastard, second cut, smooth, dead smooth, super smooth
Can be classified on the basis of length
100, 150, 200 .450

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Q7 What is the other name for a lap joint?

Ans: Fillet joint

Q8 Name different types of forging tools

Anvil block, swage block, hammers, tongs, chisels, fuller, flatter, punch, drift

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Q9 Types of hammers
hand hammers have 3 types 1.ball peen hammer 2.straight peen hammer 3. cross peen hammer and
sledge hammer.

Q10 How to determine size of galvanized sheet?

Q11 Difference between electrode and filler rod!
Electrode is part of circuit
Can be consumable or non consumable
Responsible for starting of arc and subsequent temperature rise
Filler rod is not part of circuit
Its ofcourse consumable
Uses the heat of arc to get melt
Q: What are the different methods of filing?
There are 3 methods 1.Straight filing 2.Cross filing 3.Draw filing
Q.Which method results in the least/most removal of metal?
Least removal is in draw filing and most in cross filing

Q: How do we classify files on the basis of cut? Which type of file is used for
softer/harder metals: single cut or double cut and why?
Single cut for hard
Double cut for smooth
Q: (A punch was kept on the table) What is this? Which type of punch is this? What is the
difference between the 2 types of punches (which punch is used to make a larger hole)
and what is the angle of these punches?
There are 2 punches 1. Prick punch 2. Center punch
Prick punch has an angle of 40" and center has 60 degrees
Center punch is used to make a larger hole
Q: List all specifications you need to identify a file in a market.
Length, area of cross section (or shape), single cut/double cut, coarseness
What is file??
File is a tool with slanting rows of teeth used to remove burr, cut smooth or fit metal parts.
File can be made of HSS or HCS, we use HCS in fitting shop as its relatively cheap
Job made up of??
In WELDING: - mild steel
In FITTING: - mild steel
In SHEET METAL: - galvanized iron (iron with Zn coating or mild steel with coating of zinc)
Q: What will happen if the arc length is reduced while welding?
Ans. the rod which we move while welding will stick to workpiece.

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Q.what is the lefted out part of electrode after welding ...

Ans: stub

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Q similarities between casting and welding

Ans: only processes where molten metal is used.
Surrounding of molten metal should be good conductor of heat.

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Q what is bench vice made up of ?

Cast iron

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Q) What is open source voltage?

It is also known as no load voltage or open circuit voltage, i.e., voltage needed to strike an arc which
is higher than the arc voltagein order to facilitate easy starting of arc.

Q) Explain Resistance welding.

In this type of welding we heat the metal pieces to be joined up to their plastic state and then apply
pressure to complete the weld
Work piece is heated using heat generated in electric circuit.
H = I^2 RT
Q) why we cant use any instrument other than standard wire gauge for measuring
thickness of sheet?
Q)Why green sand is called green sand ?
Ans: Because it is used while wet.
Q)Why sheet metal sheet cant be made up of cast iron?
Q) Define NOTCHING, BLANKING & PUNCHING.
Notching blanking punching all r parts of sheet metal work...just different ways of sheet metal cutting.
Like in
Notching metal is removed from side or edges of sheet to get desired shape
Punching process of making circular holes in the sheet with punch & die.
Blanking process of cutting a small part of sheet (which will have to be converted to desired shape)
from the large sheet

Q) Flux used in soldering/ brazing

Soldering-zncl2 brazing-borax
Q) What is auto genous welding?
Joining of metal pieces by melting their edges w/o using any filler metal (a kind of fusion welding)
Q) Difference between piercing and punching?
Ans: Piercing is making hole of desired shape. Punching is making circular hole.
Q) What all will u tell the seller when you buy a electrode in market??
Q) Why we don't get electric shock when we touch the welding electrode?
Ans: This is because current follows the least resistance path so rather than passing through our
body it directly passes through earth which offers less resistance. We connect negative terminal with
ground which provides the less resistance path and current does not pass through our body.
Q) What is the code of electrode used? What does 60,1,3 represent ?
The electrode code 6013, a common electrode used in many general purpose applications. This is a
4-digit code so the first 2 digits (60) indicate a minimum tensile strength of 60,000 pounds per square
inch. The "1" in the third position means this electrode is suitable for all welding positions ("2" is for
horizontal and flat welding and a "4" is for vertical positions.). Referring to an electrode classification
chart, we see that a "3" in the last position means the electrode may be used with any power source,
has a rutile coating (titanium dioxide), a soft arc with light penetration and a coating consisting of up
to 10 percent iron powder.(last position tells about combination of characteristics including the power
source (AC, DC or both), type of coating (low hydrogen, mineral, organic or rutile), type of arc (soft,
medium or digging), penetration (light, medium or deep) and amount of iron powder in the coating)

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If instead 3 at d end we use 1 it means cellulose sodium coating DC+ ..2 means cellulose potassium
coating in AC DC+ or DC- ..4 means Fe powder titania with AC DC+ or DC- ..

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Q. Can Plaster of Paris be used to make a mould?

No because at higher temperature pop will lose its water (it remain in shape due to crystals formed
due to water presence), hence shape will not remain intact, so mould will get damaged

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Q) Why does the thickness decrease with increase in gauge no?

Gauge no. is the no. of sheets that can be fitted in 1 inch, so with increase in gauge no., individual
thickness of sheets will be reduced.

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Q) What casting type is used for jewellery?

Investment casting

Types of drills
3 types: twist drill, flat drill,straight fluted drill
Melting Point of grey cast iron- 1150-1300 degrees
psi stands for pound (force) per sq inch
Q) What is a fillet!?
Rounding of the corner is known as filleting, Fillet joint is curved out part in T joint, are used to curve
out sharp edges in welding when pieces to be weld are at right angles.
Fillet radii should be around 5mm to 8mm.
Q) Types of moulding sand : dry sand ,loam sand, facing sand, backing sand,green sand,parting
sand ,core sand
Q) Name cutting tool materials other than hcs and hss
Cemented carbides, diamond, satellites, ceramic tools, cermets, CBN (Cubic Boron Nitride)

Q) What is the machine used for welding? Is it step up out step down? What are input
and output voltages?
Its step down,
Input:220v Output: 80V, 120A for AC & 25-30V, 100A for DC
Other name of electrode
Stick or welding rod
How can Mercury be used to make a mould?
Used in investment casting
What is coating of electrode used in workshop
rutile coating
Can we use hacksaw to cut metal sheet used in sheet metal?
Why we call it sheet?
What is fitting?
What all will you tell the seller when you buy a electrode in market??
functional difference btw riser and pouring basin...
Investment casting, centrifugal casting
Mouldings classification

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What kind of iron are hacksaw's prong's and frame made up of ?

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Given a semicircular mould, how will you validate that the mould given is indeed a
semicircle?

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What will happen in spot welding if the 2 plates you're trying to weld/fuse are of unequal
thickness? Is it possible, and how?
In which welding methods is Hydrogen contamination possible?

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