WORKSHOP MANUAL

DEPARTMENT OF MECHANICAL ENGINEERING

AY 2023-24
 WORKSHOP MANUAL
DEPARTMENT OF MECHANICAL ENGINEERING

Subject code :

Name of subject : Engineering Work Shop

Name : ………………………………..

Reg no : ………………………………..

Branch : ………………………………..

Year& Semester : ………………………………..

 Vision
To be one of the nation’s premier Institutions for Technical and
Management Education and a key contributor for Technological
and Socio-economic Development of the Nation.

MISSION

M1 :-
To produce technically competent Engineers and Managers by
maintaining high academic standards, world class
infrastructure and core instructions.
M2 :-
M2 : To enhance innovative skills and multi disciplinary
approach of students through well experienced faculty and
industry interactions.
M2 :-
To inculcate global perspective and attitude of students to face
real world challenges by developing leadership qualities, lifelong
learning abilities and ethical values.

Quality Policy

We at Narayana Engineering College, Nellore aspire to establish

a system of Quality Assurance, which would contribute to the
growth of technical education, upholding the highest ethical and
professional standards and develop the Institute as a Centre of
Excellence.
 I B.TECH ALL BRANCHES

Contents:
Demonstration: Safety practices and Precautions to be observed in workshop. PPT.
LIST OF EXPERIMENTS
WOOD WORKING

1. HALF LAP JOINT

2. DOVETAIL JOINT

Sheet Metal Working

1. Tapered Tray
2. Conical Funnel
3. Brazing
Fitting
1. DOVE TAIL Fitting
2. V-FITTING
Electrical WIRING

1. One Lamp Controlled By Two Two-Way Switches

2. Two Lights Controlled By one Switch Series connection
DEMO
Foundry

1. Single Piece Pattern (Frustum)

2. Split Piece Pattern (Dum-Bell)

WELDING

1. Lap Joint
2. V-Butt Welding

PLUMBING
1. Joining of Pipes
2. Pipe Line with couplings

Lab in-charge H.O.D

 WOOD WORKING

HALF-LAP JOINT

EXPERIMENT NO: 1 DATE:

Aim: - To make a- Half lap joint as shown from the Given Reaper of Size 65 X 35 X 300
Tools required: -
1. Carpenter’s vice
2. Steel Rule
3. Try square
4. Metal Jack plane
5. Scriber or marking knife
6. Tenon saw
7. Marking knife
8. Firmer chisel
9. Mallet
10. Wood rasp file and smooth file
Material required: - Wooden pieces of size 65 x 35 x 300 mm–2 Nos.
Sequence of operations: -
1. Measuring and Marking
2. Planning
3. Check for squareness
4. Removal of extra material
5. Sawing
6. Chiseling
7. Finishing
Procedure: -
1. The given reaper is checked for dimensions.
2. They are planed with jack plane and checked for straightness.
3. The two surfaces are checked for squareness with a try square.
4. Marking gauge is set and lines are marked at 30 and 45 mm to mark the
thickness and width of the model respectively.
5. The excess material is first chiseled with firmer and then planned to correct
size.
6. The mating dimensions of the parts X and Y are then marked using steel rule
and marking gauge.
7. Using the crosscut saw, the portions to be removed are cut in both the pieces,
followed by chiseling.
8. The ends of both the parts are chiseled to the exact lengths.
9. The fine finishing is given to the parts, if required so that, proper fitting is
obtained.
 10. The parts are fitted to obtain a slightly tight joint.
Safety precautions: -
1. Loose cloths are to be avoided.
2. Tools to be placed at their proper placed.
3. Hands should not be placed in front of sharp edged tools.
4. Use only sharp tools.
5. Care should be taken, when thumb is used as a guide in cross cutting and
ripping.
6. Handle while chiseling, sawing and planning with care.
Result: - T- lap joint is made as per the required dimensions.
 WOOD WORKING

DOVETAIL LAP JOINT

EXPERIMENT NO: DATE:

Aim: - To make a Dovetail lap joint from the given reaper of size 65 x35 x300 mm.
Tools required: -
1. Carpenter’s vice
2. Steel Rule
3. Try square
4. Jack plane
5. Scriber
6. Cross cut saw
7. Marking gauge
8. Firmer chisel
9. Mortise chisel
10. Mallet
11. Wood rasp file and smooth file
Material required: - Wooden pieces of size 65 x 35 x 300 mm–1 Nos.
Sequence of operations: -
1. Measuring and Marking
2. Planning
3. Check for square ness
4. Removal of extra material
5. Sawing
6. Chiseling
7. Finishing
Procedure: -
1. The given reaper is checked for dimensions.
2. They are planed with jack plane and checked for straightness.
 3. The two surfaces are checked for square ness with a try square.
4. Marking gauge is set and lines are marked at 30 and 45 mm to mark the
thickness and width of the model respectively.
5. The excess material is first chiseled with firmer chisel and then planned to
correct size.
6. The mating dimensions of the parts X and Y are then marked using steel rule
and marking gauge.
7. Using the crosscut saw, the portions to be removed are cut in both the pieces,
followed by chiseling.
8. The ends of both the parts are chiseled to the exact lengths.
9. The fine finishing is given to the parts, if required so that, proper fitting is
obtained.
10. The parts are fitted to obtain a slightly tight joint.
Safety precautions: -
1. Loose cloths are to be avoided.
2. Tools to be placed at their proper placed.
3. Hands should not be placed in front of sharp edged tools.
4. Use only sharp tools.
5. Care should be taken, when thumb is used as a guide in cross cutting and
ripping.
6. Handle while chiseling, sawing and planning with care.
Result: - Dovetail lap joint is made as per the required dimensions.
 Sheet Metal Working

TAPPERED TRAY
EXPERIMENT NO: DATE:

Aim: - To make a tray using the given G.I. Sheet.

Tools required: -
1. Steel rule
2. Scriber
3. Straight snip
4. Bench vice
5. Stake
6. Cross peen hammer
7. Wooden mallet
8. Cutting pier
Material required: - Galvanized Iron (G.I) sheet 110 x 125 mm size.
Sequence of operations: -
1. Cleaning
2. Surface leveling
3. Marking
4. Cutting
5. Folding
Procedure: -
1. Clean the given sheet with cotton waste.
2. The size of the given sheet is checked with the steel rule.
3. Flatten the surface of the given sheet with wooden mallet.
4. Check the G.I. Sheet for dimensions and remove extra material, if any.
5. Mark all the measuring lines on the given sheet with scriber.
6. Cut the given sheet with straight snips as required.
7. Fold the given sheet by using stakes and ball peen hammer to the required
shape.

Safety precautions: -
1. For marking purpose use scriber only. Do not use pencil or pen.
2. Sufficient care is to be taken while cutting and folding of G.I. sheet.
3. Remove the waste pieces immediately from the work place.

Result: - Tray is prepared as per the required dimensions.

 Sheet Metal Working
CONICAL FUNNEL
EXPERIMENT NO: DATE:

Aim: - To make a Conical funnel using the given G.I. Sheet.

Tools required: -
1. Steel rule
2. Scriber
3. Straight snip
4. Bench vice
5. Stake
6. Cross peen hammer
7. Wooden mallet
8. Cutting pier
Material required: - Galvanized Iron (G.I) sheet 160 x 80mm size.
Sequence of operations: -
1. Cleaning
2. Surface leveling
3. Marking
4. Cutting
5. Folding

Fig: conical funnel

 Procedure: -
1. Clean the given sheet with cotton waste.
2. The size of the given sheet is checked with the steel rule.
3. Flatten the surface of the given sheet with wooden mallet.
4. Check the G.I. Sheet for dimensions and remove extra material, if any.
5. Mark all the measuring lines on the given sheet with scriber.
6. Cut the given sheet with straight snips as required.
7. Fold the given sheet by using stakes and ball peen hammer to the required shape.

Safety precautions: -
1. For marking purpose use scriber only. Do not use pencil or pen.
2. Sufficient care is to be taken while cutting and folding of G.I. sheet.
3. Remove the waste pieces immediately from the work place.

Result: - conical funnel is prepared as per the given dimensions.

 Sheet Metal Working

Brazing Of Pipes
EXPERIMENT NO: DATE:

Aim: - To braze two pipes using the given filler material.

Material required: - Galvanized Iron (G.I) pipes x 80mm size.
Tools Required: Wire brush, Hand gloves, Chipping hammer, Spark lighter
Description: Brazing is coalescence of a joint with the help of a filler metal whose melting
temperature is 450°C and is below solidify temperature of the base metal. The filler metal is
drawn into the joint by means of capillary action. Brazing is a metal filler metal is heated above
melting point and distributed between two or more close parts by capillary action. The filler metal
is brought slightly above its melting (liquidus) temperature while protected by a suitable
atmosphere, usually a flux. It then flows over the base metal (known as wetting) and is then
cooled to join the work-pieces together. It is similar to soldering, except the temperatures used to
melt the filler metal are higher.
Sequence of operations: -
1. Cleaning
2. Surface leveling
3. Marking
4. Cutting
5. Folding
Procedure: -
1. The surface to be joined is cleaned properly.
2. Pipes are joined and laid by giving proper clearance.
3. Flux is applied to the joint.
4. Joint is to be heated by using welding torch to heat the filler metal to its melting temperature when the
filler material is placed at the joint.
5. The filler material is flown into the service by capillary action and joint is made.

Safety precautions: -
1. As the filler metal fills the joint by capillary action, give only needed clearance.
2. See that the joints are extremely clean

Result: - Two pipes are joined using brazing process.

 FITTING SECTION
DOVE TAIL - Fitting
EXPERIMENT NO: DATE:

Aim: - To make M.S Plate into required model by DOVE TAIL fitting.
Tools required: -
1. Bench vice
2. Steel rule
3. Try square
4. Ball peen hammer
5. Scriber
6. Hack saw with blade
7. Dot punch and Centre punch
8. Surface plate
9. Vernier height gauge
10. 250mm Rough and smooth flat files
11. 6mm Rough and smooth flat files
12. Flat chisel and triangular file
Material required: - Mild steel (M.S) plate of size 50X50X5 mm–2 Nos.
Sequence of Operations: -
1. Filing
2. Checking flatness and square ness
3. Marking and measuring
4. Punching
5. Sawing
6. Chipping
7. Finishing

Fig: Dove Tail - Fit

Procedure: -
1. The burrs in the pieces are removed and the dimensions are checked with a
steel rule.
2. The pieces are clamped one after the other and the outer mating edges are filed
by using rough and smooth files.
3. The flatness, straightness and square ness i.e. right angle between adjacent
sides are checked with help of Try-square.
4. Chalk is then applied on the surfaces of the two pieces.
5. The given dimensions of the Dove tail -fitting are marked with help of
Compass and heightgauge carefully.
6. Using the dot punch, dots are punched along the above scribed lines.
7. Using the hack saw, the unwanted portions are removed.
8. Using the flat chisel, the unwanted material in the piece is removed.
9. The cut edges are filed by the half round file.
10. The corners of the stepped surfaces are filed by using a square or triangular file
to get the sharp corners.
11. The pieces (X and Y) are fitted together and the mating is checked for the
correctness of the fit.
Safety precautions: -
1. Care is taken to see that the marking dots are not crossed, which is indicated by
the half of the punch dots left on the pieces.
2. Apply pressure in forward direction during hack sawing.
3. Don’t rub steel rule on the job. Fix blade in hack saw frame with correct tension.
4. During hack sawing the coolant like water or lubricating oil is to be used.
5. Use precision instruments like venier calipers and vernier height gauge
carefully. Files are to be cleaned properly after using.
Result: - DOVE TAIL fit is made as per the required dimensions.
 FITTING SECTION
V- FITTING
EXPERIMENT NO: DATE:
Aim: - To make M.S Plate into required model by V- fitting.
Material Required:- Two M.S Flat of Size 50 X 50 X5 mm
Tools required: -
1. Bench vice
2. Steel rule
3. Try square
4. Ball peen hammer
5. Scriber
6. Hack saw with blade
7. Dot punch and Centre punch
8. Surface plate
9. Vernier height gauge
10. 250mm Rough and smooth flat files
11. 6mm Rough and smooth flat files
12. Flat chisel and triangular file
Sequence of Operations: -
1. Filing
2. Checking flatness and square ness
3. Marking and measuring
4. Punching
5. Sawing
6. Chipping
7. Finishing
Procedure: -
1. The burrs in the pieces are removed and the dimensions are checked with a
steel rule.
2. The pieces are clamped one after the other and the outer mating edges are filed
by using rough and smooth files.
3. The flatness, straightness and square ness i.e. right angle between adjacent
sides are checked with help of Try-square.
4. Chalk is then applied on the surfaces of the two pieces.
5. The given dimensions of the V-fitting are marked with help of vernier height
gauge carefully.
6. Using the dot punch, dots are punched along the above scribed lines.
7. Using the hack saw, the unwanted portions are removed.
8. Using the flat chisel, the unwanted material in the piece Y is removed.
9. The cut edges are filed by the half round file.
10. The corners of the stepped surfaces are filed by using a square or triangular file
to get the sharp corners.
11. The pieces (X and Y) are fitted together and the mating is checked for the
correctness of the fit.
Safety precautions: -
1. Care is taken to see that the marking dots are not crossed, which is indicated by
the half of the punch dots left on the pieces.
2. Apply pressure in forward direction during hack sawing.
3. Don’t rub steel rule on the job.
4. Fix blade in hack saw frame with correct tension.
5. During hack sawing the coolant like water or lubricating oil is to be used.
6. Use precision instruments like vernier calipers and vernier height gauge
carefully.
7. Files are to be cleaned properly after using.

Result: - V- fit is made as per the required dimensions.

 Electrical Wiring
ONE LAMP CONTROLLED BY TWO TWO-WAY SWITCHES
(STAIR CASE CONNECTION)
EXPERIMENT NO: DATE:
Aim: - to give connections to one lamp controlled by two two-way switches.
Tools required: -
1. Screw driver
2. Cutting pliers
3. Ball peen hammer
4. Insulation remover
5. Tester
Material required: -
1. Wooden wiring board
2. Silk wire
3. Electrical bulb - 1 No
4. Two -way switches - 2Nos
5. Wooden round block - 1 No
6. Batten lamp holder - 1 No
7. Wire clips
8. Nails
9. Screws

Fig:1 One lamp controlled by 2 two – way switches

Procedure: -
1. The outline of the wiring diagram is marked on the wooden wiring board.
2. Clips are nailed to the board, following the wiring diagram.
3. Wires are stretched and clamped with the clips.
4. Round blocks are screwed on to the board, as per the diagram.
5. Wires are connected to the holders and the switch, which are then screwed on
to the round blocks.
6. Bulb is fitted to the holder.
7. The wiring connections are tested, by giving power supply.

Safety precautions: -
1. Electricity has no respect for ignorance. Do not apply voltage or turn-on any device
until it has been properly checked.
2. Care should be taken from electrical shocks.
3. Don’t touch the connection points.
4. Avoid loose connection.
5. Don’t work at damped areas and with wet clothing.
6. Handle the lamp carefully.
Result: - Connections are given to one lamp controlled by two two-way switches and tested working
satisfactorily.
 Electrical Wiring
Two Lights Controlled By one Switch Series connection
EXPERIMENT NO: DATE:

Aim: - To give connection to two lights, controlled by one switch in series

Tools required: -
1. Screw driver
2. Cutting pliers
3. Ball peen hammer
4. Insulation remover
5. Tester
Material required: -
1. Wooden wiring board
2. Silk wire
3. Electrical bulbs - 2 No
4. One-way switch - 1No
5. Wooden round blocks - 2 No
6. Batten lamp holders - 2 No
7. Wire clips
8. Nails
9. Screws

Fig: Two lights controlled by one switch independent switch Series Connection

Procedure: -
 1. The outline of the wiring diagram is marked on the wooden wiring board.
2. Clips are nailed to the board, following the wiring diagram.
3. Wires are stretched and clamped with the clips.
4. Round blocks are screwed on to the board, as per the diagram.
5. Wires are connected to the holders and the switch, which are then screwed on
to the round blocks.
6. Bulb is fitted to the holder.
7. The wiring connections are tested, by giving power supply.

Safety precautions: -
1. Electricity has no respect for ignorance. Do not apply voltage or turn-on any
device until it has been properly checked.
2. Care should be taken from electrical shocks.
3. Don’t touch the connection points.
4. Avoid loose connection.
5. Don’t work at damped areas and with wet clothing.
6. Handle the lamp carefully.
Result: - Connections are given to two bulbs controlled by one switch in series and
Tested, Found working satisfactorily.
 FOUNDRY
Introduction: -
Foundry practice deals with the process of making casting in moulds, formed in
either sand or other material. This is found to be the cheapest method of metal shaping. The
process involves the operations of pattern making, sand preparation, molding, melting of metals,
pouring in moulds, cooling, shake out, fettling, heat treatment, finishing, and inspection.
Mould is a cavity in a molding core, formed by a pattern. It is similar in shape and
size that of the actual casting plus some allowance for shrinkage, machining etc., molding is the
process of making molds.
Moulds are classified as: -
• Temporary moulds
• Permanent moulds

Temporary mould are made of sand and other binding materials and may be produced either
through hand molding (or) machine molding.

Permanent moulds are made of ferrous materials and alloys i.e., cast iron, steel etc.,
Molding Sand: -
Sand is the principle material used in foundry. The principle ingredients of molding sands are

1) Silicon sand 2) Clay 3) Sand

Clay imparts the necessary bonding strength to the molding sand, moisture when added
to correct preparation provides the bonding action to the clay sand can withstand high
temperature and doesn’t react with molten metal.
Natural molding sand is either available in river beds are dug from pits. It possesses and
appreciable amount of clay and are used as received with the addition of water. Synthetic sands
are prepared by adding clay. Water and other materials to silica sand so that the desirable
strength and banding properties are achieved.
Most of molding is done with green sand i.e.; sand containing 6 to 8%, moisture and 10%
clay content to give it sufficient bond. Green sand moulds are used for pouring the molten metal
– immediately after preparing the moulds. Green sand moulds are cheaper and take less time to
prepare. These are used for small and medium size casting.
Parting sand, which is clay tree, fence grained silica sand, is used to keep the green sand
from sticking to the pattern and also to prevent the cope and drug from cleaning. Core sand is
used for making cores. This is silica missed with core oil and other oddities.
Pattern; -
A pattern is the replica of the desired coasting, which when packed in a suitable
materials produces a cavity called mould. This cavity when filled with molten metals,
produces their desired coasting of the solidification.
Types of pattern; -
Wood are metal patterns are used in foundry practice, single piece, split loose
piece and cored patterns are some of the common types.

Tools and equipment; -

The tools are equipment needed for molding are; -
Molding board: -
It is wooden board with smooth surfaces. It supports the flasks and the pattern,
while the mould is being made.
Molding Flask: -
It is a base, made of wood or metal, open at both ends. The sand is rammed in
after placing the pattern to produce a mould it is made of 2 parts; cope is the top half of
the flask, having guides for the aligning paints to enter. Drag is the bottom half of the
flask having aligning pins.
Shovel: -
It is used for mixing and tempering molding sand and for transferring the sand in
to the flask. It is made of steel blade with a wooden handle.
Rammer: -
It is used for pocking or ramming the sand, around the pattern one of its ends
called the peen end, is wedge shaped and is used for packing sand in spaces, pockets and
corners in the early stages of ramming. The other end called the But – end has a surface
and is used for computing the sand towards the end of molding.
Strike of edge / strike of bar: -
It is a piece of metal or wood with straight edge. It is used remove the excess sand
from the mould after ramming to provide a level surface.
Spruce pin: -
It is tapered wooden pin used to make a hole in the cope sand through which the
molten metal is poured into the mould.
Riser pin: -
It is tapered wooden pin used to make a hole in the cope sand over the mould
cavity for the molten metal to rise and feed the casting to compassable the shrinkage that
take place during solidification.
Trowel: -
It is used to smoothen the surface of the mould. It may also be used for
reproducing the damaged portion of the mould. A trowel is made in many different styles
and sizes each one recallable for a particular hole.
 FOUNDRY
ONE STEPPED PATTERN
(SINGLE PIECE PATTERN)
EXPERIMENT No: DATE:
Aim: - To prepare a sand mould cavity using One Stepped Shaft (single piece pattern).
Tools required: -
1. Molding board
2. Molding flask
3. Shovel
4. Riddle
5. Rammer
6. Strike-off bar or Strike Edge
7. Sprue pin
8. Riser pin
9. Trowel
10. Spike or Draw pin
11. Slick
12. Lifters
13. Gate cutter
14. Bellows
15. Vent rod
Material required: -
1. Molding sand
2. Parting sand
3. Dum-Bell
Sequence of operation: -
1. Sand preparation
2. Sand mixing
3. Pouring
4. Finishing
Procedure: -
1. Place the pattern on the molding board, with its flat side on the board.
2. Place the drag over the board, after giving a clay wash inside.
3. Sprinkle the pattern and molding board, with parting sand.
4. Allow loose sand, preferably through a riddle over the pattern, unit it is
covered to a depth of 2 to 3 cm.
5. Pack the molding sand around the pattern and into the corners of the flask, with
fingers.
6. Place some more sand in the flask and pack the pattern with a rammer, using
first the peen end and then butt end.
7. Strike-off the excess sand from the top surface of the drag with the strike-off bar.
8. Turn the drag upside down.
9. Blow-off the loose sand particles with the bellows and smoothen the upper
surface.
10. Place the cope on to the drag in position. Locate riser pin on the highest point
of the pattern.
11. Place the sprue pin at about 5 to 6 cm from the pattern on the other side of the
riser pin.
12. Sprinkle the upper surface with parting sand.
13. Repeat steps 3 to 7, approximately.
14. Make holes with the vent rod to about 1 cm from the pattern.
15. Remove the sprue and riser pins by carefully drawing them out. Funnel shaped
hole is made at the top of the sprue hole, called the pouring cup.
16. Lift the cope and place it aside on its edge.
17. Insert the draw pin into the pattern. Wet the edges around the pattern. Loosen
the pattern by rapping. Then draw the pattern straight up.
18. Adjust and repair the mold by adding bits of sand, if necessary.
19. Cut gate in the drag from the sprue to the mold. Blow off any loose sand
particles in the mold.
20. Close the mold by replacing the cope and placing weights on it.
Precautions:-
1. Do not get the sand too wet. Water is an enemy of molten metals.
2. Provide adequate ventilation to remove smoke and fumes.
3. Never stand near or look over the mold during the pouring because of the
molten metal might be too hot.
4. Do not shake out a casting too hastily, which may result in second and third
degree burns.
Result: - A sand mold cavity is prepared by using one–Stepped Shaft.
 FOUNDRY
DUM-BELL
(SPLIT PIECE PATTERN)
EXPERIMENT No: DATE:
Aim: - To prepare a sand mould cavity using Dum-Bell (split piece pattern).
Tools required: -
1. Molding board
2. Molding flask
3. Shovel
4. Riddle
5. Rammer
6. Strike-off bar or Strike Edge
7. Sprue pin
8. Riser pin
9. Trowel
10. Spike or Draw pin
11. Slick
12. Lifters
13. Gate cutter
14. Bellows
15. Vent rod
Material required: -
1. Molding sand
2. Parting sand
3. Dum-Bell
Sequence of operation: -
1. Sand preparation
2. Sand mixing
3. Pouring
4. Finishing
 Fig: 1 Dum – Bell pattern

Fig: 2 mould of two piece pattern

Procedure: -
1. Place the pattern on the molding board, with its flat side on the board.
2. Place the drag over the board, after giving a clay wash inside.
3. Sprinkle the pattern and molding board, with parting sand.
4. Allow loose sand, preferably through a riddle over the pattern, unit it is covered to a
depth of 2 to 3 cm.
5. Pack the molding sand around the pattern and into the corners of the flask, with
fingers.
6. Place some more sand in the flask and pack the pattern with a rammer, using first the
peen end and then butt end.
7. Strike-off the excess sand from the top surface of the drag with the strike-off bar.
8. Turn the drag upside down.
9. Blow-off the loose sand particles with the bellows and smoothen the upper surface.
10. Place the cope on to the drag in position. Locate riser pin on the highest point of the
pattern.
11. Place the sprue pin at about 5 to 6 cm from the pattern on the other side of the riser
pin.
12. Sprinkle the upper surface with parting sand.
13. Repeat steps 3 to 7, approximately.
14. Make holes with the vent rod to about 1 cm from the pattern.
 15. Remove the sprue and riser pins by carefully drawing them out. Funnel shaped hole is
made at the top of the sprue hole, called the pouring cup.
16. Lift the cope and place it aside on its edge.
17. Insert the draw pin into the pattern. Wet the edges around the pattern. Loosen the
pattern by rapping. Then draw the pattern straight up.
18. Adjust and repair the mold by adding bits of sand, if necessary.
19. Cut gate in the drag from the sprue to the mold. Blow off any loose sand particles in
the mold.
20. Close the mold by replacing the cope and placing weights on it.

Precautions:-
1. Do not get the sand too wet. Water is an enemy of molten metals.
2. Provide adequate ventilation to remove smoke and fumes.
3. Never stand near or look over the mold during the pouring because of the molten
metal might be too hot.
4. Do not shake out a casting too hastily, which may result in second and third degree
burns.
Result: - A sand mold cavity is prepared by using Dum-Bell.
 WELDING

INTRODUCTION
Welding is the process of joining similar metals by the application of heat, with or
without application of pressure or filler metal, in such a way that the joint is equivalent in
composition and characteristics of the metals joined. In the beginning, welding was mainly used
for repairing all kinds of worn or damaged parts. Now, it is extensively used in manufacturing
industry, construction industry(construction of ships, tanks, locomotives and automobiles) and
maintenance work, replacing riveting and bolting, to a greater extent.
The various welding processes are:
1. Electric arc welding,
2. Gas welding
3. Thermal welding
4. Electrical Resistance welding and
5. Friction welding
However, only electric arc welding process is discussed in the subject point of view.

Electric arc welding

Arc welding is the welding process, in which heat is generated by an electric arc struck between
an electrode and the work piece. Electric arc is luminous electrical discharge between two
electrodes
through ionized gas.
Any arc welding method is based on an electric circuit consisting of the following parts:
a. Power supply (AC or DC);
b. Welding electrode;
c. Work piece;
d. Welding leads (electric cables) connecting the electrode and work piece to the power supply.

Fig:1 Arc welding set up

 Fig :2 parts of an electrode

Electric arc between the electrode and work piece closes the electric circuit. The arc
temperature may reach 10000°F (5500°C), which is sufficient for fusion the work piece edges
and joining them. When a long joint is required the arc is moved along the joint line. The front
edge of the weld pool melts the welded surfaces when the rear edge of the weld pool solidifies
forming the joint.
Transformers, motor generators and rectifiers’ sets are used as arc welding machines.
These machines supply high electric currents at low voltage and an electrode is used to produce
the necessary arc. The electrode serves as the filler rod and the arc melts the surface so that, the
metals to be joined are actually fixed together.
Sizes of welding machines are rated according to their approximate amperage capacity at
60% duty cycle, such as 150,200,250,300,400,500 and 600 amperes. This amperage is the rated
current output at the working terminal.
Transformers
The transformers type of welding machine produces A.C current and is considered to be theleast
expensive. It takes power directly from power supply line and transforms it to the voltage
required for welding. Transformers are available in single phase and three phases in the market.
Motor generators
These are D.C generators sets, in which electric motor and alternator are mounted on the same
shaft to produce D.C power as pert the requirement for welding. These are designed to produce
D.C current in either straight or reversed polarity. The polarity selected for welding depends
upon the kind of electrode used and the material to be welded.
Rectifiers
These are essentially transformers, containing an electrical device which changes A.C into D.C
by virtue of which the operator can use both types of power (A.C or D.C, but only one at a
time).In addition to the welding machine, certain accessories are needed for carrying out the
welding work.
Welding cables
Two welding cables are required, one from machine to the electrode holder and the other,
from the machine to the ground clamp. Flexible cables are usually preferred because of the case
of using and coiling the cables. Cables are specified by their current carrying capacity, say 300
A,400 A, etc.

Electrodes
Filler rods are used in arc welding are called electrodes. These are made of metallic wire called
core wire, having approximately the same composition as the metal to be welded. These are
coated uniformly with a protective coating called flux. While fluxing an electrode; about 20mm
of length is left at one end for holding it with the electrode holder. It helps in transmitting full
current from electrode holder to the front end of the electrode coating. Flux acts as an insulator
of electricity. In general, electrodes are classified into five main groups; mild steel, carbon steel,
special alloy steel, cast iron and non‐ferrous. The greatest range of arc welding is done with
electrodes in the mild steel group. Various constituents like titanium oxide, potassium oxide,
cellulose, iron or manganese, Ferro silicates, carbonates, gums, clays, asbestos, etc., are used as
coatings on electrodes. While welding, the coating or flux vaporizes and provides a gaseous
shield to prevent atmospheric attack. The size of electrode is measured and designated by the
diameter of the core wire in SWG and length, apart from the brand and code names; indicating
the purpose for which there are most suitable
Electrodes may be classified on the basis of thickness of the coated flux. As
1. Dust coated or light coated
2. Semi or medium coated and
3. Heavily coated or shielded
Electrodes are also classified on the basis of materials, as
1. Metallic and
2. Non‐metallic or carbon
Metallic arc electrodes are further sub‐divided into
1. Ferrous metal arc electrode (mild steel, low/medium/high carbon steel, cast iron, stainless
steel, etc., )
2. Non‐ferrous metal arc electrodes (copper, brass, bronze, aluminum, etc., ).
In case of non‐metallic arc electrodes, mainly carbon and graphite are used to make the
electrods.
Fig :3 Electrode holder Fig :4 Ground Clamp

Fig :5Wire brush Fig :6Chipping hammer

Fig :7Hand gloves Fig :8Face shield

Fig :9Weld positions

WELDING TOOLS
Electrode holder
The electrode holder is connected to the end of the welding cable and holds the electrode. It
should be light, strong and easy to handle and should not become hot while in operation. Figure
shows one type of electrode holder. The jaws of the holder are insulated, offering protection
from electric shock.
Ground clamp
It is connected to the end of the ground cable and is clamped to the work or welding table to
complete the electric circuit. It should be strong and durable and give a low resistance
connection.
Wire brush and chipping hammer
A wire brush is used for cleaning and preparing the work for welding. A chipping hammer is
used for removing slag formation on welds. One end of the head is sharpened like a cold chisel
and the other, to a blunt, round point. It is generally made of tool steel. Molten metal dispersed
around the welding heads, in the form of small drops, is known as spatter. When a flux coated
electrode is used in welding process, then a layer of flux material is formed over the welding
bead which contains the impurities of weld material. This layer is known as slag. Removing the
spatter and slag formed on and around the welding beads on the metal surface is known as
chipping.
Welding table and cabin
It is made of steel plate and pipes. It is used for positioning the parts to be welded properly.
Welding cabin is made‐up by any suitable thermal resistance material, which can isolate the
surrounding by the heat and light emitted during the welding process. A suitable draught should
also be provided for exhausting the gas produced during welding.
Face shield
A face shield is used to protect the eyes and face from the rays of the arc and from spatter or
flying particles of hot metal. It is available either in hand or helmet type. The hand type is
convenient to use wherever the work can be done with one hand. The helmet type though not
comfortable to wear, leaves both hands free for the work.
Shields are made of light weight non‐reflecting fiber and fitted with dark glasses to filter out the
Harmful rays of the arc. In some designs, a cover glass is fitted in front of the dark lens to protect
it from spatter.
Hand gloves
These are used to protect the hands from electric shocks and hot spatters

TECHNIQUES OF WELDING
Preparation of work
Before welding, the work pieces must be thoroughly cleaned of rust, scale and other foreign
material. The piece for metal generally welded without beveling the edges, however, thick work
piece should be beveled or veed out to ensure adequate penetration and fusion of all parts of the
weld. But, in either case, the parts to be welded must be separated slightly to allow better
penetration of the weld. Before commencing the welding process, the following must be
considered
a) Ensure that the welding cables are connected to proper power source.
b) Set the electrode, as per the thickness of the plate to be welded.
c) Set the welding current, as per the size of the electrode to be used.

WELDING POSITIONS
Depending upon the location of the welding joints, appropriate position of the electrode and
hand movement is selected. The figure shows different welding positions.
Flat position welding
In this position, the welding is performed from the upper side of the joint, and the face of the
weld is approximately horizontal. Flat welding is the preferred term; however, the same position
is sometimes called down hand.
Horizontal position welding
In this position, welding is performed on the upper side of an approximately horizontal surface
and against an approximately vertical surface.
Vertical position welding
In this position, the axis of the weld is approximately vertical as shown in figure.
Overhead position welding
In this welding position, the welding is performed from the underside of a joint
 WELDING

Lap joint

EXPERIMENT No: DATE:

Aim
To make a double lap joint, using the given mild steel pieces and by arc welding.

Material used: Two mild steel pieces of 100X40X6 mm.

Tools and equipment used
1. Arc welding machine,
2. Mild steel electrodes,
3. Electrode holder,
4. Ground clamp,
5. flat nose Tong,
6. Face shield,
7. Apron,
8. Hand gloves,
9. Metallic work Table,
10. Bench vice,
11. Rough flat file,
12. Try square,
13. Steel rule,
14. Wire brush,
15. Ball peen hammer,
16. Chipping hammer.
Operations to be carried out
1. Cleaning the work pieces
2. Tack welding
3. Full welding
4. Cooling
5. Chipping
6. Finishing
 Fig: lap joint

Procedure
1. Take the two mild steel pieces of given dimensions and clean the surfaces thoroughly from
rust, dust particles, oil and grease.
2. Remove the sharp corners and burrs by filing or grinding and prepare the work pieces.
3. The work pieces are positioned on the welding table, to form a lap joint with the required over
lapping.
4. The electrode is fitted in to the electrode holder and the welding current is set to a proper
value.
5. The ground clamp is fastened to the welding table.
6. Wearing the apron, hand gloves, using the face shield and holding the over lapped pieces the
arc is struck and the work pieces are tack‐welded at the ends of both the sides
7. The alignment of the lap joint is checked and the tack‐welded pieces are reset, if required.
8. Welding is then carried out throughout the length of the lap joint, on both the sides.
9. Remove the slag, spatters and clean the joint.

Precautions:
1. Use goggles, gloves in order to protect the human body.
2. Maintain the constant arc length.
Result The lap joint is thus made, using the tools and equipment as mentioned above.
 WELDING

BUTT JOINT

EXPERIMENT No: DATE:

Aim: preparation of butt joint as shown in figure using shielded metal arc welding process.

Material required: 2m.s flat pieces of given size.

Tools required:
1. welding transformer,
2. connecting cables,
3. electrode holder,
4. ground clamp,
5. electrodes,
6. hipping hammer,
7. Welding shield etc.

V – butt joint
Procedure:
1. The given metallic pieces filled to the desired size.
2. On both pieces beveled in order to have V groove.
3. The metallic pieces are thoroughly cleaned from rust grease, oil, etc.
4. The metallic pieces are connected to terminals of Trans former.
5. Select electrode dia based on thickness of work piece and hold it on the electrode holder.
Select suitable range of current for selected dia.
6. Switch on the power supply and initiates the arc by either striking arc method or touch and
drag method.
7. Take welding to be done before full welding.
8. In full welding process after completion one part before going to second part. Slag is removed
from the weld bed. With the metal wire brush or chipping hammer.
9. Then the above process will be repeated until to fill the groove with weld bed or weld
metal
10. .Precautions:
1. Use goggles, gloves in order to protect the human body.
2. Maintain the constant arc length.
Result: butt joint is prepared as shown in figure by using arc-welding process.
 PLUMBING

Introduction
Plumbing refers to installation of pipelines, water tanks and other pipe fittings to
distribute water in a building.
Best practices
1. Loose clothing should be avoided.
2. Wear shoes while working in the shop.
3. Tools should be placed in their respective places after proper cleaning.
4. Always use the right tool for the job.
5. Keep the cutting tools separate from the measuring tools.
6. Sharp edges of the cutting tools should be covered when they are not in use.
Plumbing Tools
Plumbing tools are many. The following tools are commonly used to install 25mm size
pipelines. PVC (Poly Vinyl Chloride) pipes and GI (Galvanized Iron) pipes are commonly used
in plumbing.
Pipe wrenchA pipe wrench is used to hold and rotate the pipes to tight them. It consists of a
fixed jaw, a movable jaw with adjusting screw.
Pipe vice A pipe vice in used to hold the pipe during cutting, making threads at the ends of the
pipe, fitting of couplings, etc. It also consists of a fixed jaw, a movable jaw and a screw with
handle for adjustment.
Pipe Fittings
A PVC pipe connection uses fitting like elbow, bend, coupling, tee reducer, etc. Fitting like
couplings, elbow, bend, union, nipple, tee reducer, plug, cap, flange, etc. with V-threads are
commonly used in GI pipe connections.
Valves and Taps
A gate valve or globe valve is commonly used in the main pipeline to control/regulate the floe
ofwater through it. Valves are usually made of cast iron or brass.
A domestic tap is commonly used to collect or tap water at desired points in the pipelines.
Tapsare made of brass, steel or plastic.
Flow Control Angle Valve
Flow control angle valve is used along with the applications to regulate the flow of water. The
outlet of the valve and the control knob are at 90 degrees which is convenient to operate it.
Hacksaw
A hacksaw is used to cut pipes. It has a frame where the blade is tightened by means of a wing
nut.
Screw Drivers
Screw drivers are used to tighten screws in the appliances. Screw drivers of various sizes are
used.
Hammers
Ball peen hammer is commonly used in plumbing work where greater power is required in
striking.
Measuring Tape
A measuring tape is used to measure the length of the pipe and also to mark the locations of the
fittings, valves and
appliances.

Fig: 1 pipe wrench Fig: 2 pipe vice

Fig: 3 PVC pipe fittings

 Fig : 4 GI Pipe fittings

Fig: 5 CI Pipe fitting

Fig: 6 valves and tap

 PLUMBING

PIPE JOINNING

EXPERIMENT No: DATE:

Aim: To Join the pipes as given in the diagram.

Material Required
1. PVC pipe
2. Elbows
3. Tap
4. Valve
5. Clamps

Tools Required
1. Pipe vice
2. Die
3. Die stock
4. Measuring scale

Procedure
1. The required diameter pipes were picked and cut to the desired length
2. The cut pipe is securely clamped in the pipe vice
3. Proper size of die stock and die is selected. It is inserted and aligned into the stock
4. The die is positioned at one end of the pipe, Pressure is applied and at the
sametime die is slowly turned by turning stock handle
5. Once the threading is started, applying pressure is stopped and die is
continued toturn till one thread projects through the die
6. In the same manner the ends of the pipes are threaded and checked with an elbow
7. Then the elbow and tap are fitted and clamped on the wall

Result:
Thus PVC pipe are joined to make plumbing as given below.
 PLUMBING

PIPE LINE WITH COUPLINGS

EXPERIMENT No: DATE:

Aim: To prepare a pipe line connection WITH COUPLINGS

Material Required:
1. PVC pipe
2. Elbows
3. Flexible pipe
4. Valve
5. Clamps
6. Wash basin with tap
7. Tee Joint

Tools Required:
1. Pipe wrench
2. Hammer
3. Screw driver
4. Hack saw

Procedure
1. Mark location of the wash basin and fix it
2. Fix the wash basin tap in the required position
3. Make the tee and elbow connections in the main pipe line to connect it to the
washbasin and taps
4. Fix the gate valve near the water tank
5. Connect all the pipe fittings as per the diagram
6. The water tank was filled with water and the gate valve was opened
slowly tosupply water into the pipe line
7. The tap were opened to check its function

Result: Thus the pipe line connection with couplings is made.