LABORATORY RECORD

for

23ME221 – ENGINEERING PRACTICES LABORATORY

(MECHANICAL & CIVIL)

of

B.E. / [Link] – ALL BRANCHES

(Anna University Regulation 2023)

For the Batch (2023 to 2027)

Semester II
Academic Year 2023-2024

DEPARTMENT OF MECHANICAL ENGINEERING

KCG COLLEGE OF TECHNOLOGY,

CHENNAI – 600097
 KARAPAKKAM, CHENNAI 600 097

REG. No. …………………………….

LABORATORY RECORD
Course Code: ………………….

Name of the course: ………………………………………………………………..........

It is to certify that this is a bonafide record of the work carried out by

…………………………………………………………………………………………………………………… of

…………………. Semester ……………………………………… department, during the even

semester of the academic year 2023 - 2024.

Faculty In-charge: ………………………………… HOD: …………………………………………….

Int. Examiner: …………………………………

Date of the Examination: …………………………………

 VISION OF THE COLLEGE

KCG College of Technology aspires to become a globally recognized centre of excellence for
science, technology & engineering education, committed to quality teaching, learning, and
research while ensuring for every student a unique educational experience which will promote
leadership, job creation, social commitment and service to nation building

MISSION OF THE COLLEGE

 Disseminate knowledge in a rigorous and intellectually stimulating environment

 Facilitate socially responsive research, innovation and entrepreneurship

 Foster holistic development and professional competency

 Nurture the virtue of service and an ethical value system in the young minds

VISION OF THE DEPARTMENT

The department aspires to become a globally recognized centre of excellence by producing

competent professionals in Mechanical Engineering to serve as a valuable resource for industry
and society

MISSION OF THE DEPARTMENT

 Impart intellectually rigorous and holistic education to the students in the field of
Mechanical Engineering.
 Establish state of-the-art facilities for research and consultancy work.
 Enhance the knowledge and skills of the faculty with the latest advancements in the
mechanical engineering domain.
 Mentor the students to develop research and entrepreneurial capabilities.
 Inculcate a high degree of professionalism and contribute to the needs of industry and
society.
 PROGRAMME EDUCATIONAL OBJECTIVES
On completion of the program, the students will achieve the following
Excel as competent professional or entrepreneur or researcher in related fields of Mechanical
PEO 1
Engineering.
Analyze, design/develop innovative solutions for real world engineering problems using
PEO 2
appropriate modern tools.
Exhibit professionalism, ethical attitude and adapt to the changes in the industry and society
PEO 3
supporting sustainable development.
PEO 4 Lead and manage teams for effective execution of projects.

PROGRAMME OUTCOMES AND PROGRAMME SPECIFIC OUTCOMES

After successful completion of the programme, the students will be able to:
PO
Description of the PO
No.
1 Apply the knowledge of mathematics, science, engineering fundamentals, and an engineering
specialization to the solution of complex engineering problems.
Identify, formulate, review research literature, and analyse complex engineering problems reaching
2 substantiated conclusions using first principles of mathematics, natural sciences, and engineering
sciences
Design solutions for complex engineering problems and design system components or processes
3 that meet the specified needs with appropriate consideration for the public health and safety, and
the cultural, societal, and environmental considerations
Use research-based knowledge and research methods including design of experiments, analysis and
4
interpretation of data, and synthesis of the information to provide valid conclusions.
Create, select, and apply appropriate techniques, resources, and modern engineering and IT tools
5 including prediction and modelling to complex engineering activities with an understanding of the
limitations
Apply reasoning informed by the contextual knowledge to assess societal, health, safety, legal and
6
cultural issues and the consequent responsibilities relevant to the professional engineering practice.
Understand the impact of the professional engineering solutions in societal and environmental
7
contexts, and demonstrate the knowledge of, and need for sustainable development.
 Apply ethical principles and commit to professional ethics and responsibilities and norms of the
8
engineering practice.

Function effectively as an individual, and as a member or leader in diverse teams, and in

9 multidisciplinary settings.

Communicate effectively on complex engineering activities with the engineering community and
10 with society at large, such as, being able to comprehend and write effective reports and design
documentation, make effective presentations, and give and receive clear instructions.
Demonstrate knowledge and understanding of the engineering and management principles and
11 apply these to one’s own work, as a member and leader in a team, to manage projects and in
multidisciplinary environments.

Recognize the need for, and have the preparation and ability to engage in independent and lifelong
12 learning in the broadest context of technological change.

PSO
Description of PSO
No.

Model, analyze, design and realize physical systems, components or process by applying principles
1 of three core streams of Mechanical Engineering, i.e., Design, Manufacturing, Thermal and Fluid
Engineering.

2 Ideate innovative concepts, develop prototypes and implement sustainable systems to meet societal
needs both individually and as a team

3 Engage in lifelong learning and follow professional ethics, codes and standards of
professional practices.
 23ME221 ENGINEERING PRACTICES LABORATORY
(Common to all Departments)
LTPC
0042
COURSE OBJECTIVES:
The learning objective of this course is to,

 Familiarize students with basic engineering tools and equipment.

 Educate students on the importance of safety practices, including proper handling of
equipment, adherence to safety protocols, and understanding potential hazards in the
laboratory environment. Develop basic manufacturing and fabrication skills.
 Provide hands on training to the students in plumbing and wood working.
 Provide hands on training to the students in welding various joints in steel plates using
arc welding work; Machining various simple processes like turning, drilling, tapping in
parts; Assembling simple mechanical assembly of common household equipment;
Making a tray out of metal sheet using sheet metal work.
 Demonstrate the wiring and measurement methods in common household electrical
applications.
 Study the basic electronic components, gates and provide hands on training in
soldering.

GROUP A (CIVIL & MECHANICAL)

PART I CIVIL ENGINEERING PRACTICES 15

PLUMBING WORK:

a) Connecting various basic pipe fittings like valves, taps, coupling, unions, reducers, elbows
and other components which are commonly used in household.
b) Preparation of plumbing line sketches.
c) Laying pipe connection to the suction side of a pump
d) Laying pipe connection to the delivery side of a pump.
e) Connecting pipes of different materials: Metal, plastic and flexible pipes used in household
appliances.

WOOD WORK:
a) Sawing
b) Planning
c) Making of T-Joint, Mortise joint and Tenon joint and Dovetail joint.
Wood Work Study:
a) Study of joints in door panels and wooden furniture
b) Study of common industrial trusses using models.

PART II MECHANICAL ENGINEERING PRACTICES 15

WELDING WORK:
a) Study of Welding and its tools.
b) Welding of Butt Joints, Lap Joints and Tee Joints by metal arc welding.
c) Study of Gas Welding.

BASIC MACHINING PRACTICE:

a) Facing and Plain Turning
b) Taper Turning
c) Drilling and Tapping

SHEET METAL WORK:

a) Forming and Bending
b) Making of a square Tray

MACHINE ASSEMBLY WORK:

a) Study of Centrifugal Pump
b) Study of Air Conditioner

FOUNDRY PRACTICE:
a) Demonstration on Foundry operations like mould preparation.

COURSE OUTCOMES:

At the end of the course, students will be able to,

 CO1: Draw the pipe line plan; lay and connect various pipe fittings used in common
household plumbing work.
 CO2: Use welding equipment to join the structures, perform the basic machining
operation, make joints in wood materials and make the models using sheet metal works.
 CO3: Demonstrate on centrifugal pump, air conditioner and foundry operations.
 CO4: Demonstrate the electrical wiring connections for household applications and
study the working of iron box and fan regulator.
 CO5: Identify the basic electronic components and explain the gates and soldering
methods.
 CO6: Examine the performance and operation of CRO, LED TV and Smart phone.
MAPPING OF COURSE OUTCOMES WITH PROGRAM OUTCOMES (PO’s)
& PROGRAM SPECIFIC OUTCOMES (PSO’s)

PO PSO
CO
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3
1 3 2 - - 1 1 1 - - - - 2 2 1 1
2 3 2 - - 1 1 1 - - - - 2 2 1 1
3 3 2 - - 1 1 1 - - - - 2 2 1 1
4 3 2 - - 1 1 1 - - - - 2 2 1 1
5 3 2 - - 1 1 1 - - - - 2 2 1 1
6 3 2 - - 1 1 1 - - - - 2 2 1 1
Avg. 3 2 - - 1 1 1 - - - - 2 2 1 1
Low(1); Medium (2); High (3)
 INSTRUCTION TO STUDENTS

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

7. Do not touch the hot work pieces with bare hands.

8. Always use aprons, gloves and face shield during welding.

9. After completing the experiments wash your hands.

10. Handle the cutting tools and sheet metals carefully to avoid any injury.

11. Wash your eyes with plenty of cold water after doing a welding operation.

In case of any irritation in your eyes after doing welding do not strain our eyes by
12.
watching Television or bright lights on that day.
 23ME221 – ENGINEERING PRACTICES LABORATORY
INDEX

Sl.
No Name of the Page Signature of
Date
Experiments No the Faculty

1 Welding – study

2 Butt joint

3 Lap joint

4 Tee- joint

5 Basic machining – study

6 Facing and turning

7 Drilling - study

8 Drilling and tapping

9 Study of centrifugal pumps

10 Study of air conditioning system

11 Study of foundry operations

12 V-grooved pulley

13 Study of sheet metal work

14 Projection of tray

15 Plumbing – study

16 Pipeline to a wash basin

17 Pipeline to a washing machine

18 Pipeline to a water heater

19 Carpentry – study

20 Sawing and planning

21 Half lap joint

22 Tee lap joint

23 Dovetail halving joint

WELDING
2
 STUDY OF TOOLS USED IN WELDING SHOP

Ex. no: 1

Date:

Aim:

To study the various types of tools used in the welding shop.

1.1 Introduction:

Welding is the process of joining similar metals by the application of heat. It can be
done with or without the application of pressure and with or without the addition of filler
metal called "electrode". The joint obtained is a homogeneous mixture of metal of
composition and characteristics of the two parent materials. The process of welding has been
classified under two basic categories as hereunder

3
 Fig. Electrode Holder

1.2.1 Fusion or Non-Pressure Welding

In fusion welding, the metal near the joint is heated to a molten state and allowed to
solidify. Since no pressure is applied in this process, it is known as Non-pressure welding.

1.2.2 Pressure or Plastic Welding

In the plastic welding, the metal parts are heated to a plastic state. Then they are
pressed together to make the joint. Hence it is also known as pressure welding.

1.3 Electrical Arc Welding

Electric arc welding is one of the most efficient methods. This method makes use of
the heat produced by the electric arc to fuse weld metallic work pieces. Arc welding may be
defined as the process of joining two metal parts by melting their edges by an electric arc
using filler rod without the application of pressure.

1.3.1 Principle

The source of heat for electric arc welding is an electric arc. The arc is produced
between an electrode and the work. The electrical energy is converted into heat energy. For
arc welding processes, filler metal is required and no mechanical pressure is applied. Hence
this is one type of fusion welding. Thus arc welding is defined as the process of joining two
metal parts by an electric arc using filler rod without the application of pressure.

1.3.2 Procedure

1. Primarily, the metal parts to be welded are cleaned first using wire brush to
remove rust, grease, oil or paint. The electrode is suitably selected and held
in a holder.

2. The work and the electrode are brought nearest with a small air gap of 3mm
approximately when current is passed an electric arc is produced between the
electrode and the work. The arc melts both the electrode and the work.

3. After solidification, both the molten pieces of the metal become one.

4
1.3.4 Arc welding Equipment

1. DC Generator (or) AC transformer

2. Cable (2 Numbers)

3. Electrode holder

4. Chipping hammer

5. Wire brush and

6. Safety devices such as goggles, hand gloves etc.,

5
[Link] DC Generator (or) AC transformer

DC supply is obtained from a generator driven by an electric motor, or if noelectricity

is available, by an internal combustion engine.

AC transformer is employed when main electricity supply is available. The

transformer steps down the usual supply voltage to the normal open circuit welding voltage
of around 40 to 80 volts.

The AC voltage is also converted to DC in the control unit

[Link] Cables

Two cables are used in arc welding, one for positive terminal and another for
negative terminal. Positive terminal is connected with the electrode holder and the negative
terminal is connected to ground.

[Link] Electrode Holder

Electrode holder is used to hold the electrode firmly in its position. During welding,
the electrode is kept inclined at about 70° with the work piece to achieve the depth of
fusion.

Electrode

Electrode for an arc welding are classified into two categories as

a. Consumable electrodes and

b. Non-Consumable electrodes

Consumable electrode: when the arc is obtained with a consumable electrode, the
weld metal under the arc melts and also tip of the electrode melts or consumed.

Non-consumable electrode: when the arc is obtained with a non-consumable

electrode, the arc is produced between the electrode and the work piece to bewelded,
but the filler metal required has to be deposited through a separate filler rod.

[Link] Chipping Hammer

Chipping hammer is used to remove the slag formed during the welting.

[Link] Wire Brush

Wire brush is used to remove broken slag particle from the welded area.

[Link] Safety Devices

Goggles are must in an arc welding. The goggles protect the eyes of the welder from
heat and Ultra-violet rays while welding. Instruct the welder don't weld without goggles.

[Link] Leather gloves: Leather gloves the hand from any possible burn injuries.

6
7
 1.4 Gas Welding

Gas welding is a type of fusion non-pressure welding. It is also called as''

OXY-FUEL '' gas welding. A gas flame is used to melt the edges of metal to be joined.

1.4.1 Principle

In gas welding, a high-temperature flame obtained by a mixture of two gases,supplies

the required heat to melt the parts. These gases are mixed in proper proportion in a welding
blowpipe called welding torch.

1.4.2 Procedure

1) Initially oxygen and Acetylene gases have been mixed up in the gas- welding
torch.

2) Mixture of gases are get ignited at the tip of the torch. The flame is directed
to the region to be melted.

3) Filler rod is the metal rod, is added to the molten metal area. The flame melts
it and it is deposited over the base metal.

4) During welding, the metal gets contact with the gases, so oxidation will take
place at the joint. To avoid this, flux, which is in powder or liquid form, is
added and it quickly reacts with metallic oxides and prevents the oxidation
process.

1.4.3 Gas Welding Equipment

1) Gas cylinder

2) Pressure regulator

3) Pressure gauges

4) Welding torch

5) Hoses

6) Safety devices.

Gas Cylinder

Oxygen and acetylene are stored under high pressure in separate cylinders. The
oxygen cylinder is generally painted black while the Acetylene cylinder is painted inmaroon
color for easy identification.

8
9
Pressure Regulator

Each cylinder is provided with a regulator to regulate the proportion of the two gases
and to control its working pressure.

Pressure Gauges

There are two pressure gauges on each regulator. One shows the cylinder pressure
and the other shows working pressure.

Welding Torch

This is a device in which oxygen and acetylene are mixed in the desired volume and
the mixture is ignited at the end.

Hoses

The hoses used for the oxygen and acetylene cylinders are respectively black and red
in colour. Safety Devices

Apron, this is used to protect the human body from the sparks and harmful gases.

Type of Gas Flames

Flame temperature is a very important characteristic in gas welding. The flame

temperature is not constant throughout the entire length of flame. It may vary with the gas
composition. There are three kinds of gas flames.

1. Neutral flame

2. Oxidizing flame and

3. Carbonizing flame

Neutral Flame

Neutral flame has a well-defined luminous cone gradually rounding off towards the
tip. Oxygen and acetylene gases are mixed in the ratio of 1:1 in the mixing chamber of the
welding torch.

Oxidizing Flame

Oxidizing cone has similar appearances to that of the neutral flame except that the
inner luminous cone is much shorter. It contains 1.2 to 1.5 parts of oxygen and one part of
acetylene.

Carburizing Flame

If the gas ratio is changed to the ratio of oxygen to acetylene and which is 0.9 to 1, the
flame produced is called carburizing or reducing flame. This flame is similar to the neutral
flame, only with addition of a intermediate cone between the luminous cone and outer
envelope.

10
11
1.5 Types of Welding Joints

Welding joints are properly designed according to the services for which it isintended.
A few of the common types are given below.

1. Lap Joint

It is used to join two overlapping sheets or plates. The edge of each sheets or plates
is welded to the surface of the other. Common types of lap joints are single lap joint and
double lap joint.

2. Butt Joint

Butt joint is used to join the ends of two sheets or plates kept in the same plane.

3. Tee Joint

It is used for welding sheets or plates which are kept in the form of T and at 90° to each
other.

4. Corner Joint

This joint is used to weld two sheets or plates kept at 90° to each other. (e.g.) Tanks,
Boxes etc.,

5. Flange Joint

This type of joint is used to join two sheets or plates by bending the edges to form a
flange. Both gas and arc welding use the same kind of joints. Lap and butt joints are ordinarily
used in resistance welding.

Result

Thus the various types of welding processes and the tools used for welding have been
studied.

12
 SIZE: 100 x 50 x 6

All dimensions are in mm

13
 BUTT JOINT-BY ELECTRIC ARC WELDING
Ex. no: 2

Date:

Aim

To make a butt joint from the given work piece by an Electric Arc welding process.

Tools Required

1. Electric Arc Welding Machine. 2. Holder. 3. Shield. 4. Gloves. 5. Electrodes.

6. Chipping hammer. 7. Wire brush and 8. Apron.

Procedure

1. The given work pieces are measured and the acting edges are chamfered by filing and
then checked by using the try square.

2. The work pieces are placed on the worktable touching each other

3. Make the worktable with proper earthing. Wiring cables are connected with the
suitable voltage. Welding is done on both sides and also on the center.

4. Then the entire joining portions are welded. After completing the welding, the slags
are removed by chipping hammer from the welded area. Then the slag is cleaned by
wire brush.

Evaluation Rubrics
Assessment Max. Marks Obtained Marks
Aim/ Procedure 15
Experimental 25
methodology
Final product 50
Viva 10
Total 100

Result

Thus the butt joint is made as per the given dimensions.

Signature of the Faculty

14
 SIZE: 100 x 50x 6

All dimensions are in mm

15
 LAP JOINT-BY ELECTRIC ARC WELDING
Ex. no: 3

Date:

Aim

To make a Lap joint from the given work piece by an Electric Arc welding process.

Tools Required

1. Electric Arc Welding Machine. 2. Holder. 3. Shield. 4. Gloves. 5. Electrodes.

6. Chipping hammer. 7. Wire brush and 8. Apron.

Procedure

1. The given work pieces are measured and the acting edges are champered by filing and
then checked by using the try square.

2. The work pieces are placed on the worktable and keep them in touch.

3. Make the worktable with proper earthing. Wiring cables are connected with the
suitable voltage. Weld is done on both sides and also on the center.

4. Then the entire joining portions are welded. After completing the welding, the slags
are removed by chipping hammer from the welded area. Then the slag is cleaned by
wire brush.

Evaluation Rubrics
Assessment Max. Marks Obtained Marks
Aim/ Procedure 15
Experimental 25
methodology
Final product 50
Viva 10
Total 100

Result

Thus the Lap joint is made as per the given dimensions.

Signature of the Faculty

16
 SIZE: 100 x 50x 6

All dimensions are in mm

17
 TEE JOINT-BY ELECTRIC ARC WELDING
Ex. no: 4

Date:

Aim:

To make a Tee joint from the given work piece by an Electric Arc welding process.

Tools Required

1. Electric Arc Welding Machine. 2. Holder. 3. Shield. 4. Gloves. 5. Electrodes.

6. Chipping hammer. 7. Wire brush and 8. Apron.

Procedure

1. The given work pieces are measured and the acting edges are made inclined to one
another of the adjacent sides by filing and then checked by using the try square.

2. The work pieces are placed on the worktable and keep them in touch.

3. Make the worktable with proper earthen. Wiring cables are connected with the
suitable voltage. Weld is done on both sides and also on the center.

4. Then the entire joining portions are welded. After completing the welding, the slags
are removed by chipping hammer from the welded area. Then the slag is cleaned by
wire brush.

Evaluation Rubrics
Assessment Max. Marks Obtained Marks
Aim/ Procedure 15
Experimental 25
methodology
Final product 50
Viva 10
Total 100

Result

Thus the Tee joint is made according to the specified dimensions

Signature of the Faculty

18
 VIVA QUESTIONS

1. Classify the welding methods

2. Describe the temperature obtained in gas and arc welding?

3. List the equipment’s needed to carry out arc welding operation.

4. Illustrate the necessary precautions you have to take while welding

5. Identify the material used for coating on electrode.

6. Compare the welding is different from machining

7. Describe the polarities of work piece and electrode?

8. Discuss why you should not see the flame during the welding operation

9. List the equipment’s needed to carry out gas welding operation.

10. Explain the different types of joints, you make in the lab?

19
BASIC MACHINING

20
21
 STUDY OF CENTRE LATHE
Ex. no: 5

Date:

Aim:

To study the parts of the center lathe and its functions.

1.1 Introduction:

Machining is the process of shaping a work piece by removing excess material from
it. A machine tool is a motor driven machine for machining parts of a given shape, size and
accuracy by removing metal from the blank. Since the parts produced in a machine tool are
used to fabricate other machines, equipment, tools etc., a machine tool is called as mother of
all machines.

1.2 Machine Tools:

The machine tools used for machining are broadly classified into three types:

1. General Purpose: Used for general machining like turning, facing, drilling, etc.,
Example: Lathe, Drilling Machine, etc.

2. Special Purpose: Used for special machining like gear cutting. Example: Capstan
and Turret Lathe, Gear Hobbing Machine, etc.

3. Automatic Machine tools: Used for mass production of components. Example: CNC
(Computer Numerical Control) Lathe, CNC Milling Machine, etc.

1.3 Lathe:

In a Lathe, the work piece is rotated, and if the cutting tool moves parallel to the axis
of rotation, cylindrical surface is produced and if the tool moves perpendicular to the axis,
flat surface is produced.

1.3.1 Belt Driven Lathe:

The Centre lathe is driven by an electric motor. The headstock of a centre lathe has a
mechanism to provide a number of spindle speeds. Also, the feeding of tool in the longitudinal
and lateral (cross feed) directions can be done, mechanically by means of carriage, feed rod
and lead screw. It receives power from overhead line shaft via a counter shaft. Different
spindle speeds areobtained using cone pulley drive.

22
23
1.3.2 Components of a lathe:

..

1. Headstock: The headstock supports the spindle and the spindle bearing. It houses the
speed changing mechanisms. The spindle holds the chuck that holds the work piece

2. Lathe Bed: The lathe bed is the base of the machine; the headstock, tailstock,
compound rest and carriage are mounted on the bed. The lathe bed is rigid and absorbs
vibrations while machining.

3. Tail Stock: The tailstock supports the long size work piece that is held in the
headstock. It is also used to hold the drilling tool.

4. Carriage: It moves over the lathe bed. It consists of two parts saddle and apron. The
saddle carries the cross slide over which the compound rest is fitted. The cross slide
is used to produce a transverse movement for the cutting tool

5. Compound Rest: It carries the tool post on a swivel base. These arrangements help
cutting tool movement at an angle to the lathe axis in taper turning.

6. Tool Post: It is located at the top of the compound rest and is used to hold the tool.
The tool post can be adjusted to a convenient working position.

1.4 Work Holding Devices:

This is used to hold the work piece firmly during the operation. Following are the
commonly used work holding devices in lathe.

1.4.1 Three-jaw chuck:

It is also called universal chuck (or) self-centering chuck. A chuck key is engaged and
rotated in one of the jaws, which simultaneously moves the other jaws to grip the work piece.

1.4.2 Four-jaw chuck:

Each of the four jaws of the chucks can be actuated independently by rotating the
screw which meshes with the corresponding teeth (thread) cut on the backside of the jaw.

1.4.3 Feed Mechanism:

Feed refers to the movement of the tool during metal cutting operation. The tool
movement may be longitudinal, transverse or angular. The tool movement parallel to the axis
is called longitudinal movement. The tool movement perpendicular to the axis is called
transverse or cross movement. The movement at specified angle to the axis is called angular
movement.

Angular movement is used for taper turning operation. Metal removal rate is high in
larger feed rate but the surface finish will be poor. Usually, high speed is given to get smooth
surface finish. Feed is expressed in mm/revolution or mm/minute.

24
25
1.6 Operations using Lathe:

1. Turning: Turning is the process of removal of excess material from a work

piece to produce a cylindrical surface and to reduce the diameter of the work
piece.

2. Facing: Facing is done to remove material at the ends of a work piece to

produce a flat surface and to reduce the length of the work piece.

3. Taper turning: Taper turning is the process of removing excess material from
a work piece to produce c conical surface.

4. Knurling: The process of embossing a diamond shaped pattern on a work piece

having a cylindrical surface is called knurling.

5. Chamfering: chamfering is the process of beveling the extreme ends of a work

piece. Using the chamfering angle is set to 30° to 45°.

6. Grooving: Grooving removes a small length (2mm or 3mm) of material from

a work piece.

7. Drilling: Drilling is done to produce a hole in a work piece. The work piece
is held in the chuck and the drilling tool is held in the tailstock. Feed is given
by rotating the wheel slowly in the tailstock.

1.7 Tools:

A single point cutting tool is commonly used for turning, facing and taper turning.
This tool is made by High-speed steel (HSS).

A knurling tool is used to produce a rough surface with diamond cuts. Here, knurled
rollers will be passed against the cylindrical surface to be knurled.

A drill bit is used to drill a hole in the work piece. The tools are made by HSS, alloy
of steel like tungsten, chromium and vanadium.

Result:

Thus the Centre lathe and its parts, operation, tools, specification etc., have
been studied.

26
All dimensions are in mm

27
 FACING AND TURNING OPERATION
Ex. no: 6

Date:

Aim:

To make the given work piece to a required size by facing and turning operation.

Tools Required:

1. Steel Rule 2. Spanner 3. Chuck key 4. Single point cutting tool,

5. Tool post-key 6. Vernier Caliper 7. Work piece.

Procedure:
1. First open the jaws in the chuck using the chuck key to position the work piece and then tighten
the jaws. Fix the cutting tool in the tool post.

2. Switch on the lathe and move the carriage near the work piece. Give it small cross
feed, and then move the carriage longitudinally to the required length slowly.

3. Bring the carriage to the original position, give a small cross feed and move the
carriage longitudinally. (Turning) Repeat this step until the required diameter is
obtained and using a Vernier Caliper to check the diameter regularly.

4. To get smooth surface, give very small feed when the diameter is nearing the required
value. (Approximately 0.2mm feed)

5. To face the end surface of the work piece, move the carriage to make the tool touch
the end surface of the work piece.

6. Give a small feed in longitudinal direction, and then move the tool towards the axis
of the work piece using the cross slide to complete facing.

Evaluation Rubrics
Assessment Max. Marks Obtained Marks
Aim/ Procedure 15
Experimental 25
methodology
Final product 50
Viva 10
Total 100

Result:

The given work piece is turned to the given diameter and faced to the given length.

Signature of the Faculty

28
29
 STUDY OF DRILLING MACHINE
Ex. no: 7

Date:

Aim:

To study of the various parts and its operation of the drilling machine.

1.1 Introduction:

One of the important machine tool after the lathe is drilling machine. Drilling
operations can be performed in a lathe also, but when performed in a drilling machine the
operation is faster and is done at a low cost. These drilling machines are sometimes called
"drill press".

1.2 Types of drilling machine:

1. Portable drilling machine.

2. Sensitive drilling machine.

3. Upright drilling machine.

4. Radial drilling machine.

5. Gang drilling machine.

6. Multiple spindle-drilling machine.

7. Automatic drilling machine.

8. Deep hole drilling machine.

1.3 Upright drilling machine:

There are two types of Upright drilling machine.

1. Round column section or pillar drilling machine.

2. Box column section.

1.3.1 Round column section or pillar drilling machine:

It consists of hollow cylindrical column, a base, an arm and round table assembly and
a drill head assembly.

These are three movement's help to locate a work piece under the spindle.

1. Up and down movement of arm (with table) along the column.

2. Rotation of arm with upto 180° about the column.

30
 3. Rotation of table through 360° about its own axis.

Both the base and table have "T" slots to hold the work pieces. It has several spindle speeds
ranging from 75 to 3500 rpm. The feed clutch is automatically controlled so that spindle
will be disengaged when it reaches its upper and lower limit of travel. It has also free
engagement of taps through clutch and rapid reversing mechanism for withdrawals. This
machine is ideally suited for small and big shops.

31
1.4 Radial Drilling Machine:

It is the largest and most versatile of the drilling machines and is very well suited for
drilling large number of holes. It is a single spindle machine intended for handling large and
heavy work or work which is beyond the capacity of the small drilling machines.

It consists of vertical column with a radial arm that can be swung through an arc of
180° or more.

On the radial arm, which is power driven for vertical movement, is an independently
driven drilling head equipped with a power feed.

The drilling head may be moved along the arm by hand or power on a gear and rank
arrangement.

Spindle speed ranging from 20 to 1600 rpm and feed from 0.05 to 3mm per revolution
are available.

In a plain radial drilling machine three movements i.e., Vertical movement of the arm,
Horizontal movement of the drill head and rotation of the arm are available.

In a universal machine the radial arm can also be rotated about a horizontal axis
passing through the arm. Hence five movements are possible and holes can be drilled on a
work piece at any angle.

1.5 Operations done on a Drilling machine:

1. Drilling operation 2. Reaming operation 3. Boring operation

4. Counter Boring operation 5. Counter Sinking operation

6. Spot facing operation 7. Tapping operation, etc.,

1.6 Drill holding methods:

1. By using a sleeve: only one size of drill can be directly fitted into the spindle bore.
The outside taper of the sleeve matches the spindle taper and the inside taper of the
sleeve matches the drill shank taper.

2. By using a socket: When the taper shank of a drill is larger than the taper hole in the
spindle, a socket is used. This consists of a solid tapered shank and a cylindrical body.
The taper hole in the socket is larger than the taper hole in the drill spindle.

Result:

Thus the various parts and operations of drilling machines have been studied.

32
All dimensions are in mm

33
 DRILLING AND TAPPING OPERATION
Ex. no: 8

Date:

Aim:
To drill the holes of required size and tap the drilled hole.

Tools Required:

1. Chuck key 2. Drill bit 3. Vernier Caliper 4. Steel rule,

5. Centre punch 6. Hammer 7. Scriber. 8. Tap set with Die holder

Procedure:

1. The work piece is measured using a Vernier Caliper.

2. The required places are marked with scriber block and punch should be made
in the appropriate place.

3. Then the work piece is fixed in the vice and the table is adjusted on the centre
of the tool.

4. The holes are drilled on the work piece.

5. After drilling, the dimensions are checked using the Vernier caliper

6. After drilling the holes, they are tapped by using tap set.

Evaluation Rubrics
Assessment Max. Marks Obtained Marks
Aim/ Procedure 15
Experimental 25
methodology
Final product 50
Viva 10
Total 100

Result:

Thus the given work piece is drilled and tapped to the required dimensions.

Signature of the Faculty

34
 VIVA QUESTIONS

1. Discuss in detail in the operation of machining

2. Identify the tools used in machining processes

3. List the parts of lathe

4. Classify the operations can be performed on lathe

5. Illustrate why turning operation is done?

6. Explain the facing operation?

7. List the material used for cutting tool and work piece in your lab

8. Describe the necessary precautions you have to take while machining?

9. List the parts of drilling

10. Explain the operations can be performed on drilling machine?

35
MACHINE ASSEMBLY
PRACTICE

36
.

37
 STUDY OF CENTRIFUGAL PUMPS & IT'S ASSEMBLY
SEQUENCE
Ex. no: 9

Date:

Aim:

To Study the parts of centrifugal pump and its assembly sequence.

1.1 Introduction:

In the olden days, the man has been trying to find out some convenient ways of
lifting water to higher levels for water supply and irrigation purposes.

A pump, in general may be defined as a machine, when driven from some external
source, lifts water or some other liquid from a lower level to a higher level.

The pump, which raises water or a liquid from a lower level to a higher level by the
action of a centrifugal force known as centrifugal pump.

1.2 Working principle

The centrifugal pump works on the principle of forced vortex flow which means that
when a certain mass of liquid is rotated by an external torque, a rise in pressure head of the
rotating liquid takes place. The rise in pressure head at any point of the rotating liquid is
proportional to the square tangential velocity of the liquid at that point (i.e. rise in pressure
head =V2/2g = w r2/2g) thus at outlet of the impeller where radius (r) is more. Due to this
pressure head, the liquid can be lifted to a high level.

1.3 Main parts of the centrifugal pump

1. Suction pipe(Nozzle)

2. Impeller

3. Casing (Volute casing, vortex casing and diffuser casing)

4. Delivery pipe (discharge Nozzle)

5. Seal Chamber

6. Shaft

1.3.1 Suction pipe

A Pipe whose one end is connected to inlet of the pump and other end dips into the
water sump is known as suction pipe. A foot valves that is a non -return valve.
38
1.3.2 Impeller

The rotating part of a centrifugal pump is known as Impeller. It contains series of

curvedvanes. Which is connected to the shaft of an electric motor, which runs the pump

13.3.3 Casing

Casing is an air tight passage surrounding the impeller and is designed in such a way
that kinetic energy of the water discharged at outlet of the impeller is converted into pressure
energy before the water leaves the casing and enters into the delivery pipe.

1.3.4 Seal Chamber

■ Seal chamber forms the region between the shaft and casing. The main function of this
sealing is to protect the pump against leakage at the point where the shaft passes out though
the pump pressure casing.

1.3.5 Shaft

Shaft is to transmit torques encountered and to support the impeller and other rotating
parts. This task is done with a deflection less than the minimum clearance between the rotating
and stationary parts.

1.4 Assembling sequence of the centrifugal pump:

Step 1: Vortex casing half section is assembled in the shaft.

Step 2: Insert the impeller and fix it in the right place.

Step 3: Another parts of the vortex casing should be assembled.

Step 4: Sealing is fixed in vortex casing suction and discharge nozzle side.

Step 5: Flange are assembled in the suction and delivery nozzle and then it is joint by bolt

and nut.

Step 6: Disassembling can be done by reversing the assembly sequence.

39
 Evaluation Rubrics
Assessment Max. Marks Obtained Marks
Aim/ Procedure 15
Experimental 25
methodology
Final product 50
Viva 10
Total 100

Result:

Thus the parts and assembling of the centrifugal pumps have been studied.

Signature of the Faculty

40
 STUDY OF AIR CONDITIONER AND ITS ASSEMBLY
SEQUENCE
Ex. no: 10

Date:

Aim:

To study the parts of air conditioner and its assembly sequence.

1.1 Introduction:

The air conditioning system dates back to the middle of nineteenth century, but it was
until the last time decades of that century that a reliable unit was developed. Air conditioning
is defined as conditioning of air for human comfort, food processing, and other industrial
purposes.

Air conditioning is a smart system of controlling temperature, humidity, cleanliness of

the air and movement of the air in the conditioned spaces.

The capacity of air conditioning is represented in Ton. One Ton is a heat unit equal to
3000Kcal. Generally, a small domestic air conditioning plant will have a capacity range of
0.5 Ton to 3 Ton.

1.3 Types of Air Conditioners:

These are broadly classified as follows.

1. Non-ducted air-conditioning system.
a) Window room air conditioning
b) Split air conditioning
2. Duct able air conditioning
a) Packaged air conditioners
b) Central air conditioning plants

1.4 Window Room Air Conditioner: -

"Window” air conditioner (also known as "Room air conditioner”) is designed to air
condition only one room. Several window units can be used to air-conditioning an entire
residence or even a multi room commercial building.

1.5 Mechanism and main parts of an Air Conditioner: -

An air conditioning system works on vapor compression cycle or vapor absorption

system. Here we have detailed the working of a vapor compression system. Thiscycle works
in following four phases.

1. Compression 2. Condensation 3. Expansion 4. Evaporation i

41
42
1.5.1 Compression
Compression process takes place in the compressor. During suction stroke the low
pressure low temperature dry refrigerant or coolant vapor is drawn from the evaporator and
compressed to a high pressure and temperature until the vapor gets superheated.

1.5.2 Condensation:

From the compressor, the high pressure and high temperature vapor passes in to the
condenser and rejects heat to the cooling medium thus allowing the vaporized refrigerantto
return to liquid state.

1.5.3 Expansion:

After condensation, the liquid refrigerant is stored in the liquid receiver. It then passes
through an expansion device (expansion valve). Due to this the high pressure is reduced very
much to allow the vaporization of liquid at a very low temperature of about
-10°C.

1.5.4 Evaporation:

The low pressure and low temperature refrigerant vapor enters into the evaporator.
Here a considerable amount of heat is absorbed from the surrounding by the refrigerant.

After absorbing heat from the surrounding, the liquid refrigerant changes to vapor
state. Then this vapor again enters the compressor through the suction stroke and the cycle is
repeated.

1.6 Assembly Sequence:

Stepl: Keep the base plate in a comfortable place.

Step2: A compressor should be fixed to the base plate using appropriate fasteners.

Step3: A condenser should be connected with the compressor with help of muffler.

Step4: Evaporator should be placed as shown in the figure.

Step5: Fan and its assembly should be placed in between evaporator and condenser.

Step6: A control panel if required, should be fixed in an appropriate place to monitor and

Control the parameters.

Step7: Disassembling can be done by reversing the above said process.

43
 Evaluation Rubrics
Assessment Max. Marks Obtained Marks
Aim/ Procedure 15
Experimental 25
methodology
Final product 50
Viva 10
Total 100

Result:

Thus the parts and assembling of the Air conditioning have been studied.

Signature of the Faculty

44
 VIVA QUESTIONS

1. Discuss the principle of centrifugal pump

2. Explain why pumps are used?

3. List the different components of centrifugal pump

4. Define priming?

5. Identify the different types of casings in centrifugal pump

6. Define air conditioner?

7. Classify the various air conditioner

8. Illustrate which type of air conditioner do you prefer. Why?

9. List the parts of an air conditioner

10. Define refrigerant?

11. Explain the use of compressor in air conditioner

12. Discuss the usage of evaporator in air conditioner

13. Summarize the condensation process of an air conditioner

14. Explain the purpose of expansion device in air conditioner

15. Compare the difference between window room air conditioning and split

airconditioning

45
 STUDY OF FOUNDRY OPERATION
Ex. no: 11

Date:

AIM:

To study the various types of moulding tools and moulding process.

1.1 INTRODUCTION:

Casting is one of the most versatile methods for producing components. There is no
limit to the size, shape and difficulty of the components that can be produced by casting. It is
one of the cheapest methods and gives high strength and rigidity. Any shape can be cast in
this method at a low cost.

Casting or foundry is the process of forming metallic components by melting the

metals, pouring it into a cavity, known as the " Mould" of the desired shape and allowing it
to solidify. A shop where moulding, casting and their related processes are conducted is called
as "foundry shop". Basic steps in the foundry processes are

I. Pattern making

II. Moulding Process

III. Metal melting and pouring

1.2 PATTERN MAKING

A pattern is defined as a model, constructed in such a way that it can be used for
forming an impression in mould sand. The quality of casting produced depends on the design
construction, accuracy and the material of the pattern. In order to obtain a good casting, the
following aspects must be taken into consideration when making a pattern.

1. Pattern material

2. Pattern allowance and

3. Types of pattern

Pattern material

Mostly, Pattern material is made of wood because of its cheapness, availability, ease
of fabrication, lightness. Burma teak, pinewood and mahogany are the important wood pattern
material. Wood is easily affected by moisture and it wears out quickly by sand abrasion.
Aluminum alloy, brass or magnesium alloy are the higher capacity and strength. Steel or cast
iron pattern are preferred to mass production. But a wooden master pattern is first made from
which the metal pattern is made.

46
47
Pattern allowance:

The size of the pattern is never kept same as that of the desired casting. During cooling
the casting is subjected to various metallurgical effects. Consequently, shrinkage and
distortion will take place in casting. Hence to compensate shrinkage, sufficient metal is
provided with the pattern, known as pattern allowance.

Types of Pattern:

There are various types of pattern available. A particular type of pattern is chosen
depending upon the complexity of the job and size. The different types are

1. Single piece pattern

2. Split piece pattern

3. Cope and drag pattern

4. Match plate pattern

5. Loose piece pattern

6. Shell pattern

7. Sweep pattern

8. Skeleton pattern

But among these various types, solid pattern and split piece pattern are most
commonly used in foundry shop.

Solid pattern:

It is also a single piece pattern and is made without joints. Its removal from the sand is
easy. Solid pattern is used for simple shaped castings and inexpensive.

Split piece pattern

Split piece pattern is made of two parts. One part will produce the lower half of the
mould. The other part will produce the upper half of the mould. These two parts are assembled
together in correct position by means of dowel pins. The line separating the two parts is called
parting line.

48
49
MOULDING PROCESS

Mould is the cavity of the required shape made with moulding sand into which the
moulding metal is poured. To prepare a mould, pattern, moulding tools and moulding sand
are necessary.

Tools and Equipment

Moulding Box or Flask:

It is a box like structure made of rectangular walls without any bottom or top cover.
Metal boxes are made of wood, steel, cast iron and aluminum. But metallic boxes are most
common in the foundry shop. It is made of two parts held in alignment by dowel pins. The
upper part is called cope and the bottom part is called drag.

Moulding Board:

It is a smooth wooden board suitable for the moulding box. It is used to rest the
moulding box and the pattern.

Shovel:

It has a broad iron part fitted with a long wooden handle. It is used for mixing the
moulding sand. It is also used for carrying the moulding sand from the sand pit to moulding
box.

Riddle:

It has a circular or square wooden frame with a mesh at the bottom. It is a metal sieve
used for removing foreign materials from the moulding sand.

Rammer:

It is used for pressing and packing the moulding sand uniformly around the pattern. It
has two end: one end is wedge shaped, known as "peen" and other end is cylindrical in shape,
known as "butt end".

Trowels:

Trowels are used to shape and smoothen the surface of the mould. These are available
in various sizes and shapes. It consists of a steel blade fitted with wooden handle. The end of
trowel may be pointed, rounded or blend. Finishing trowel has round corners.

Slick:

It is a spoon shaped double-ended trowel. It is used for repairing the mould surfaces.

Sprue pin:

It is a tapered cylindrical wooden piece. It is used for making hole in the moulding sand,
called sprue hole. Through the sprue hole, molten metal is poured inside. The size of the sprue
pin depends on the size of the mould.

50
51
Bellow:

Bellow is used for blowing out dust and sand particles from the mould. If the bellow is
compressed, air will come out blowing off the sand particles.
Vent wire:
Vent wire is used to drill vent holes in the moulding sand. These holes are provided
for the vapor content to escape from the moulding sand.

Moulding sand is prepared with addition of water. When the molten metal is poured
into the mould, the water particles get evaporated due to heat. The gases and vapors thus
generated will be vent out through the holes made.

Draw spike:

Draw spike is used to remove the pattern from the mould. It is a pointed steel rod with
a ring at one end.

Mallet:

The mallet is similar to the wooden hammer used in the carpentry shop. It is used to
loosen the pattern in the mould. Light blows are given to pattern while removing it from the
cavity.

Lifter:

Lifter is used for removing the loose sand, which has fallen into the cavity during the
pattern removal.

Strike-off bar:

It is made of steel or wood with smooth perfect straight edge. It is used to strike - off
excessive sand in the top portion of the moulding sand.

Swab:

It is a small fiber brush. It is used for applying water around the edges of the pattern
while it is being removed from the mould cavity. Otherwise the pattern would carry some of
the moulding sand with it. Thus the mould cavity will require repair works at the edges.

Gate cutter:

Gate is the connection between the sprue hole and the cavity. Gate cutter is used to
cut the gate opening. It is made of metal sheet.

Moulding sand

Foundry sand contains silica, clay and moisture in suitable proportions. Silica sand is
in the form of granular quartz. Clay acts as a bonding medium around the silica grains

52
Properties of Moulding sand

The properties of good moulding sand are as follows.

Porosity or permeability:

The sand must be sufficiently permeable so that the gases and water vapor that are formed
in the mould can be escape.

Refractoriness:

The moulding sand must be capable of withstanding the high temperature of the molten
metal without fusing or breaking of sand.

Adhesiveness:

It is the property to stick with the other body. Sand should be adhesive so that it may
easily be attached itself with the sides of the moulding box and pattern material.

Collapsibility:

This property of moulding sand refers to the quickness and readiness of sand particles to
collapse by itself after the casting.

Cohesiveness or Strength:

This is the ability of the sand particles to stick together when moisture. The strength of
the moulding sand must be sufficient, then only the mould can take the desired shape and to
retain the shape even after the molten metal is poured into the mould.

Flow ability:

It is the ability of the sand to get easy pack around the pattern in the moulding box in
order to get the desired shape.

Plasticity:

The moulding sand should have plasticity so that it can be shaped easily to the form of
the pattern. This property of sand mainly depends on the contents of clay and moisture.

Green Strength: It prevents the sand from easy collapsing and disturbing.

Grain size and shape, the grains must be irregular and annular in shapes; this will provide
sufficient bonding strength. The size and shape of the grain depends on the mouldingto be
produced.

Chemical Resistivity:

It is an essential one so that the sand should not be Chemically reactive with molten
metal, which is poured into the metal,

53
METAL MELTING AND POURING

Furnace is used for melting the metal. Ladle is used to carry molten metal from the
furnace to the pouring area. According to the type of metal and quantity of the metal to be
melted, furnace may be name as,

1) Crucible furnace

2) Cupola furnace

3) Electric furnace

Crucible furnace is used for melting non-ferrous metals and a small amount of ferrous
metals. Its capacity ranges from 30 to 150Kg.

Cupola furnace is used for melting ferrous metals like pig iron in order to Produce cast iron.
Its capacity ranges from 1 to 15 tones.

Electric furnace is also a one type of furnace in which heating coil is introduced to melt the
metals in a crucible.

Result

Thus the various moulding tools and moulding process have been studied.

54
GROOVED PULLEY PATTERN

55
 STUDY OF GROOVED PULLEY PRODUCTION
Ex. no: 12

Date:

AIM:

To make a mould with the help of grooved pulley pattern

TOOLS REQUIRED:

1) Moulding box 2) Shovel 3) Rammer 4) Trowel 5) Sprue pin 6) Bellow 7) Vent wire
8) Draw spike 9) Mallet 10) Strike off bar 11) Gate cutter 12) Runner and 13) Riser 14)
Grooved pulley pattern (Split piece)

PROCEDURE:

1) Moulding board is placed on a bench board. Then the parting sand is spread
over the board.

2) The drag of the moulding box is placed on the moulding board such that the
dowel pins are facing downwards.

3) The bottom portion of the grooved pulley pattern is positioned at the center
and the moulding box is filled with the moulding sand.

4) The sand is pressed by hand and subsequently by the round and peen hammers

5) After ramming, the excess amount of sand is removed and leveled by using
strike off bar.

6) The drag is turned such that the dowel pins are facing upwards.

7) The surface of the sand is smoothened by the trowel and parting sand is spread
over the surface to prevent the striking of cope and drag.

8) Top portion of the grooved pulley pattern is placed over the bottom portion
with proper alignment then the cope is placed over the surface of the drag with
proper alignment with the dowel pin.

9) Runner is placed at the side of the pattern and the riser is placed near the
highest point of the pattern.

10) The sand is properly filled, rammed and leveled by the use of rammer and
strike off bar.

11) The surface of the cope is smoothened by the trowel.

12) Vent holes are made on the surface using vent wires in number of places.

56
 13) Thus the runner and riser are drawn out from the box and the edges are
smoothened.

14) Then the cope is lifted from the drag and corners are smoothened.

15. The pattern is lifted from the box using the draw spike.

16. Gate cutter cuts a gate from the sprue hole opening to cavity.

17. Excess of sand particles are removed from the cavity by the lifter.

18. Again the cope is lowered and positioned on the drag and the moulding is
ready for casting

Evaluation Rubrics
Assessment Max. Marks Obtained Marks
Aim/ Procedure 15
Experimental 25
methodology
Final product 50
Viva 10
Total 100

RESULT:

Thus the mould is made according to the given pattern.

Signature of the Faculty

57
 VIVA QUESTIONS

1. Define foundry?

2. Describe the pattern in detail

3. List the foundry tools

4. Explain the gate which is used in the moulding process?

5. Illustrate the purpose of vent rod

6. Classify the types of moulding boxes

7. Define the casting process?

8. List the points of the application of casting.

9. Define the purpose of the green sand in the moulding process?

10. Summarize the two important points, why ramming is done in the moulding process?

58
SHEET METAL WORK

59
 STUDY OF SHEET METAL
Ex. no: 13

Date:

AIM:

To study the various types of tools used in the sheet metal shop.

1.1 INTRODUCTION:

Sheet metal study deals with the working of metal sheets. Many engineering and house
hold articles such as boxes, cans, funnels, ducts, etc., are made from a flat sheet metal. The
process being termed as sheet metal or tin smithy. For this, the development of article is
first drawn on the sheet metal, then cut and folded, to form the required shape of the article.
The edges of the article are then secured through welding, brazing, soldering, riveting, etc.,
For successful working in the trade, one should have a thorough knowledge of projective
geometry and development of surfaces.

Sheet metal is generally worked on metal sheets ranging from 16 gauges to 30 gauges with
simple tools and machines.

1.2 TOOLS AND EQUIPMENTS:

The various tools are used in the sheet metal shops are as follows.

♦ Trammel
♦ Bench shears
♦ Hammer
♦ Steel rule
♦ Divider
♦ Protractor head
♦ Punch
♦ Chisel
♦ Bench vice
♦ Wire gauge
♦ Snips
♦ Stakes
♦ Scriber
♦ Rivet set
♦ Mallet

60
61
 ♦ Hack saw

♦ Flat file

♦ File card and

♦ Soldering iron

TRAMMEL:

Trammels are used to draw larger arcs and circles that are beyond the limit of dividers.
It consists of a longer rectangular bar, with markings. The length of the beam decides the
maximum size of the arc that can be scribed. Beam consists of two adjustable vertical legs
with needle points and attached to separate heads. These heads slide on the beam and fixed
in position by knurled nut.

BENCH SHEARS:

Bench shear is belonging to the heavier type cutting machineries of sheet metal. It
hasa higher capacity for cutting metal sheets. It consists of frame with base that can be easily
fixed on a bench. Two blades are provided with the frame; fixed blade and movable blade.
Fixed blade is firmly fixed with frame. Movable blade is hinged with the frame and which
can be operated by means of hand levers.

SNIPS:

A snip, also called a hand shear is used like a pair of scissors to cut thin metal and
which is limited to cut up to 20- gauge thickness metal. There are several types of snips are
available for cutting straight and circular cuts. The most common types are straight snips and
curved snips.

♦ Straight snips are used for cutting along a straight line.

♦ Bend snips are used for cutting the metal along a curvature.

WIRE GUAGE:

It is used to check the diameter of wire or thickness of sheet metal. The gaps in the
circumference of the gauge are used to indicate width sizes. The commonly used wire gauge
is imperial standard wire gauge (SWG). The following table shows the swage number with
corresponding thickness of the most common wire gauge (21 slots).

CHISEL:

The cold chisels are used to cut. It is made by high carbon steel. There are many
different types of chisels, but the flat chisel is mostly used in sheet metal work.

62
STAKES

Stakes are the sheet metal anvils used for bending, scanning, forming. It works as
supporting tools as well as forming tools. The stakes consist of three parts: the shank, the head
and the horn. In operation, shanks are inserted into the holes of the bench and then required
to be worked. They are available in different shapes and size to suit the requirements of the
work. Some important forms are shown in figure.

PROTRACTOR HEAD:

A protractor head is used to measure an angle. The protractor is marked in degrees and
with care reading to the nearest half degree may be made but for accurate, a Vernier
protractor may be used.

63
RIVET SET:

This is hardened steel tool with a cup- shaped hole in one end. The hole is used to
shape the end of rivet into a round, smooth head.

SOLDERING IRON:

It is used to join two pieces of metal of an alloy of tin and lead. It consists of a forged
piece of copper joined to an iron rod with a wooden handle. It involves spreading of low
melting point alloy (solder) in molten condition between the edges to be joined and allowing
it to solidify.

1.3 TYPES OF SHEET METAL JOINTS

As per requirements, various types of sheet metal joints are commonly used to fasten
bottoms to cylinders, square and rectangular containers.

1. Lap Joint

It is very frequently used in sheet metal work and can be prepared by means of Soldering or
Riveting.

2. Seam Joint

This joint is very generally used in sheet metal work. It is locked as shown in the
diagram, so as to ensure a positive grip and also to make the joint flush with the surface.

64
1.4 BENDING OF SHEET METAL

Some common kinds of sheet metal bends are shown is figure.

RESULT:

Thus the various sheet metal tools and the applications were studied.

65
 PROJECTION OF TRAY

DEVELOPMENT OF TRAY AND ITS FOLDING SEQUENCES

66
 TRAY
Ex. no: 14

Date:

AIM:

To develop a tray in the given sheet metal.

TOOLS REQUIRED:

 Steel rule

 Scriber

 Strakes

 Shears

 Calipers

 Solder

 Compass

PROCEDURE:

 Draw the front and top views of given tray.

 The development of tray is drawn on a white paper.

 The developed white paper is placed on sheet metal and marks the actual cutting
lines by using scribers.

 Finally using hand shear or forming shear cut off the required portions.

 Folding and bending is done as per the given dimensions by using mallet and stake.

 The extreme ends are bent and joined by using stakes, bending machine and
soldering or any other method.

67
 Evaluation Rubrics
Assessment Max. Marks Obtained Marks
Aim/ Procedure 15
Experimental 25
methodology
Final product 50
Viva 10
Total 100

RESULT:

Thus the development of tray is done using the given sheet metal.

Signature of the Faculty

68
 VIVA QUESTIONS

1. Define sheet metal.

2. Name the tool is used to measure the thickness of sheet metal

3. Discuss in detail in the gauge

4. Name the various tools used in sheet metal

5. List the application of sheet metal

6. List the operation used in sheet metal.

7. Identify the various metals used for sheet metal work

8. Define bending?

9. Define punching?

10. Explain the requirement of anvil in the sheet metal operation?

69
PLUMBING

70
71
 STUDY OF PLUMBING
Ex. no: 15

Date:

AIM:

To study the various types of tools used in plumbing

1.1 INTRODUCTION

Plumbing is a house’s/building’s circulatory system, running unseen behind the

walls sometimes and under the floor boards carrying water to and fro. It follows the basic
laws of nature-gravity and pressure. Every plumbing system basically comprise of two
separate subsystems. One subsystems bringing in fresh water and the other takes waste
water out. The exercises to follow will provide an exposure on some of the commonly
used plumbing tools and fittings to form an assembly for different domestic purposes.

1.2 Plumbing Tools

Plumbing tools are many. The following tools are commonly used to install 25 mm size
pipelines. PVC (Poly Vinyl Chloride) pipes and GI (Galvanized Iron) pipes are commonly
used in plumbing.

Pipe wrench A 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.

1.3 Pipe Fittings

A PVC pipe connection uses fittings like elbow, bend, coupling, tee reducer, etc.
Fittings like couplings, elbow, bend, union, nipple, tee reducer, plug, cap, flange,
etc. with V-threads are commonly used in GI pipe connections.

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 GI pipe Fittings

1.4 Valves and Taps

A gate valve or globe valve is commonly used in the main pipeline to control/
regulate the flow of water 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.
Taps are made of brass, steel or plastic.

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1.5 Flow Control Angle Valve

Flow control angle valve is used along with the appliances 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.

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75
 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.

Result

Thus the various types of tools used in plumbing have been studied

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77
 PIPELINE TO A WASHBASIN
Ex. no: 16

Date:

Aim

To prepare a pipeline connection to a washbasin.

Tools Required

1. Screwdriver
2. Hammer
3. Hacksaw
4. Pipe wrench
5. Measuring tape

Components Required

1. Washbasin
2. Flow control angle valve
3. Washbasin tap
4. Tee
5. Elbow
6. Flexible pipe and
7. Flexible drainpipe.

Procedure

1. Mark location of the washbasin and fix it.

2. Fix the washbasin tap in the required position.
3. Make a tee connection in the existing pipeline to connect it to the washbasin.
4. Fix the flow control angle valve near the washbasin.
5. Connect the flow control valve to the washbasin tap using a flexible pipe.
6. Fix the flexible drainpipe from washbasin to the common drain outlet.

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 Evaluation Rubrics
Assessment Max. Marks Obtained Marks
Aim/ Procedure 15
Experimental 25
methodology
Final product 50
Viva 10
Total 100

Result

The pipeline connection to a washbasin is made.

Signature of the Faculty

79
80
 PIPE TO A WASHING MACHINE
Ex. no:17

Date

Aim

To prepare a pipeline connection to a washing machine.

Tool Required

1. Screwdriver
2. Hammer
3. Hacksaw
4. Pipe wrench and
5. Measuring tape

Components Required

1. Washing machine
2. Flow control angle valve
3. Tee
4. Elbow
5. Flexible pipe and
6. Flexible drainpipe

Procedure

1. Mark location for the washing machine.

2. Make a tee connection in the existing pipe line to connect it to the washing
machine.
3. Fix the flow control angle valve near the washing machine.
4. Connect the flow control valve to the washing machine inlet line using a
flexible pipe.
5. Fix the flexible drainpipe from the washing machine to the common drain
outlet.

81
 Evaluation Rubrics
Assessment Max. Marks Obtained Marks
Aim/ Procedure 15
Experimental 25
methodology
Final product 50
Viva 10
Total 100

Result

The pipeline connection to a washing machine is made.

Signature of the Faculty

82
83
 PIPELINE TO A WATER HEATER
Ex. no:18

Date

Aim
To prepare a pipeline connection to a water heater or geyser.

Tools Required

1. Screwdriver
2. Hammer
3. Hacksaw
4. Pipe wrench and
5. Measuring tape

Components Required

1. Water heater
2. Flow control angle valve
3. Tee
4. Elbow
5. Flexible pipe
6. Tap and
7. Shower

Procedure
1. Mark location of the water heater and draw the pipeline.
2. Fix the water heater in the required position.
3. Make a tee connection in the existing pipeline to connect it to the water
heater.
4. Fix the flow control angle valve near the water heater.
5. Connect the flow control angle valve to the inlet of the water heater using a
flexible pipe.
6. Fix the outlet of the water heater to the domestic tap and shower.

84
 Evaluation Rubrics
Assessment Max. Marks Obtained Marks
Aim/ Procedure 15
Experimental 25
methodology
Final product 50
Viva 10
Total 100

Result

The pipeline to a water heater, shower and tap is made.

Signature of the Faculty

85
 VIVA QUESTIONS

1. Explain the purpose of plumbing?

2. List the different types of pipes commonly used

3. Identify the different types of pipe fittings used.

4. Compare the difference between the elbows and bend. Where are the recommended?

5. Describe the purpose of die cast

6. What is the difference between union and coupling?

7. List the advantage of flange joint

8. Compare the difference between a gate and a tap

9. What is the instrument used to form the thread on the pipes?

10. What are flexible pipes? What are their uses?

86
CARPENTRY

87
88
 WOOD WORK
(CARPENTRY)
Ex. no: 19

Date:

AIM:

To study the various types of tools used in carpentry

1.1 INTRODUCTION

The term carpentry is used with wood working. Wood works such as making wooden
partition, roofing, flooring, etc. are carpentry works. The term joinery is used with making
of doors, windows, wooden frames, etc. Teak, Mahogany, Sal, Mango, Deodar, Padak, etc.
are the commonly used woods in carpentry works.

1.2 STUDY OF TOOLS USED IN CARPENTRY SHOP

Proper knowledge of tools and their use is a prerequisite for a skilled carpenter. The following are
the commonly used tools in the carpentry shop.

Marking and Measuring Tools

Marking and measuring tools are used to produce components to an exact size. The
commonly used tools are given below.

Carpenter's folding rule: It is used to measure and mark dimensions. The commonly used
carpenter's rule is made of wood. It consists of four pieces each 150 mm long and hinged
together by means of pins and hinges. It is graduated on both sides in millimeters, centimeters
and inches. It can be folded and carried easily.

Steel rule: It is also used for measuring and marking dimensions. It is made of steel. It is
graduated on both sides in millimeters, centimeters and inches. It is available in 150 mm (6
inches) and 300 mm (12 inches) length.

Try square: It is used for marking and checking right angles. It consists of a steel blade riveted
at right angles to the edge of machined stock. The stock when in use acts as a fence and the
blade as guide for marking. The length of blade varies from 150 mm to 300 mm.

89
Bevel square: It is also called a sliding level. It is similar to the try square but has a blade
that can be swiveled to any angle from 0 to 180 degrees.

Mitre square: It is similar to a try square in construction, but its blade is fitted to the stock
at an angle of 45 degrees.

90
 Marking gauge: It is used for marking lines parallel to the edges of a wooden piece. It has
one marking pin. After the stem has been set to the required position, its face is placed
against the edge of the wooden piece. The marking pin is pressed down firmly and the stem
is moved against the edge. It marks a line parallel to the edge on the wooden piece.

1.3 Cutting Tools

Rip saw: It is used for cutting wood. The blade of rip saw is either straight or skew-backed.
The blade is fitted in a wooden handle. Rip saw is about 700 mm long and contains 3 to 5
teeth per 25mm length. The correct angle for rip sawing is 60 degrees.

Cross-cut saw: It is similar in shape to the rip saw. It is also called hand saw. Sawing and
cutting at right angles to the grain is called cross-cutting. The correct angle for cross-cutting
is 45 degrees. It is 550 to 650 mm long containing 6 to 8 teeth per 25 mm.

Tenon or back saw: It is used for fine and accurate work. It consists of a very fine blade,
which is reinforced with a rigid steel back. Its length varies from 350 mm to 450 mm with 10
to 12 teeth per 25 mm.

Dovetail saw: It is similar to the tenon saw but smaller in size. The number of teeth varies
from 12 to 18 teeth per 25 mm. It is used for carpeting works such as making dovetail joints.

Chisels: These are cutting tools used for shaping and fitting wooden pieces. It consists of a
steel blade and a wooden handle. The different types of chisels used in carpentry works are
given below.

Firmer chisel: It is used by hand pressure or with a mallet for cutting square recesses in
wooden pieces. It has a flat blade of 5 to 25 mm width and 125 mm length. The end of the
blade is beveled to form a cutting edge.

Beveled edge firmer chisel: It is used for delicate and fine work where the ordinary firmer
chisel cannot be used. It can cut sharp corners on wooden pieces.

Mortise chisel: It is used for cutting heavy pieces or mortises. It consists of a heavy blade
with strong shoulder and is capable of withstanding heavy strains. It has an iron ridge fitted
at the shoulder of the blade to absorb the heavy shock of the mallet. One side of the mortise
chisel is plane while the other gradually tapers towards the edge.

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93
1.4 Planning Tools

These are used for smoothening plane surfaces. Some commonly used planes are given below.

Wooden jack plane: The main parts of a wooden jack plane are stock or body, nose, throat,
wedge, cap iron, plane iron and handle. The bottom of the stock is known as the sole which
is perfectly smooth. The throat in the stock is formed to adjust the irons and Wedge. The plane
iron is the main cutter which cuts and smoothens the wood. This is fitted in the stock and is
always inclined to an angle of 45 degrees with the sole. The cap iron is used to stiffen the
cutter and prevent rattling and breaking during use. Jack planes are available from sizes 350
to 450 mm length and the blade width varies from 50 to 75 mm.

Metal jack plane: It helps in smoother operation and produces a better finish than a wooden
jack plane. The body of a metal jack plane is made from grey iron casting or steel. The handle
is made of wood and the plane iron is secured in the plane casing by a screw.

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1.5 Striking Tools

Tools like chisels, nails, etc. require pressure from the top to drive them into the wood.
This pressure is obtained by striking operations using hammers and mallets.

Cross peen hammer or warrington hammer: It is made of forged high carbon steel. It
has a face, peen and a handle. The handle is made of bamboo and fitted tightly in theeye
with the help of a wedge to avoid any slip out when in use. These hammers are identified
by weight which ranges from 200 gm to 500 gm.

Claw hammer: This serves both the purpose of a hammer and a pair of pincers. The claw
is used for pulling out nails. These hammers are classified according to their weights. The
weight of its head ranges from 250 gm to 675 gm.

Mallet: It has a flat striking face which is used to give light blows to tools having wooden
handle like chisel. It is made of hard wood and is round or rectangular in cross- section.

1.6 Boring Tools

These are used for making round holes in wood. Some commonly used boring tools are
given below.

Gimlet: It is used for making small holes in wood. These are of two types: (a) plain gimlet
and (b) twisted gimlet. It has a flute and a wooden handle. It is held in bothhands,
rotated and pressed simultaneously downward to bore holes. The screw point at the
bottom acts as a pilot and helps in centering the tool.

Auger: It is used, for making big holes in wood. It has a steel bar with fluted teeth and a
handle. The upper portion of the bar is plain and its top end forms eye to fit in the handle.
It can bore holes of 25 mm diameter.

Ratchet brace: It is a device used for holding different tool bit to produce holes in woods.
It consists of a crank having a hemispherical wooden head at the top, a wooden handle in
the middle and a chuck to hold the tool bit at the bottom. The ratchet arrangement is
provided above the chuck to permit the rotation of the bit in only one direction. The brace
is rotated by hand and the head is pressed downward to produce a hole.

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Wheel brace: It is also used to produce a hole in wood. It consists of a forged body and
a wooden handle at the top. The central portion consists of two meshing gears and a crank
to rotate the chuck fitted at the bottom of the brace. The crank is rotated and the handle is
pressed downward to produce a hole. It is mostly used to produce small and accurate holes
using different kinds of drills.

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97
1.7 Holding Tools

To enable the carpenter to perform different operations accurately while the work piece
is held firmly.

Carpenter's bench vice: It is fixed in a carpenter's bench which is a heavy table of hard
wood usually 3 to 3.5 m long, nearly 70 cm wide and 70 cm high. It consists of a fixed
jaw and a movable jaw. The fixed jaw is rigidly fitted on the bench and the movable jaw
is mounted on a screw and two sliding rods. The screw head is projected outside the
movable jaw in order to carry a handle. The screw works inside a fixed half-nut that is
engaged to move the movable jaw.

C-cramp or G-cramp: It is used to hold smaller work piece. It consists of an iron frame
and a screw with a handle rod or thumbscrew.

1.8Miscellaneous Tools

Rasp file: It is used to file curved surfaces in wood. It is made of steel and has semi-
circular cross-section.

Screw driver: It is used to screw and unscrew the screws. It is available in various shapes
and sizes.

Result

Thus the various types of tools used in carpentry have been studied

98
 All dimensions are in mm

99
 SAWING AND PLANNING
Ex. no: 20

Date:

Aim

To make a planning from the given work piece.

Tools Required

1. Jack plane 2. Try square

3. Mallet 4. Firmer chisel

5. Mortise chisel 6. Rip saw

1. Tenon saw 8. Marking gauge, etc.

Procedure

1. The job is clamped properly in the vice and any two adjacent surfaces are planned
to get right angle using jack plane. The accuracy of right angle ischecked by using
try square.

2. Proper marking is done on the two portions based on the planned surfaces.

3. The other two faces of the work piece are planned to the marked dimensions.

4. The job is cut into two halves using rip saw.

5. Finally, the accuracy and proper dimensions are verified by using steel rule and
try square.

100
 Evaluation Rubrics
Assessment Max. Marks Obtained Marks
Aim/ Procedure 15
Experimental 25
methodology
Final product 50
Viva 10
Total 100

Result

The given work piece is planned to the required dimensions.

Signature of the Faculty

101
 All dimensions are in mm

102
 HALF LAP JOINT
Ex. no: 21

Date:

Aim

To make a half lap joint from the given work piece.

Tools Required

1. Jack plane 2. Try square

3. Mallet 4. Firmer chisels

5. Mortise chisels 6. Rip saw

7. Tenon saw 8. Marking gauge, etc

Procedure

1. The job is clamped properly in the vice and any two adjacent surfaces are planned to
get right angle using jack plane. The accuracy of right angle is checked by using try
square.

2. The job is cut into two halves using rip saw.

3. Proper marking is done on the two portions based on the planned surfaces.

4. One half is cut according to the given dimensions using tenon saw and firmer chisel.

5. The other half is also cut in the similar way so as to make correct fit on one another
and the extra portions are removed using firmer chisel.

6. Finally, the accuracy and proper dimensions are verified by using steel rule and try
square.

103
 Evaluation Rubrics
Assessment Max. Marks Obtained Marks
Aim/ Procedure 15
Experimental 25
methodology
Final product 50
Viva 10
Total 100

Result

Thus the required half lap joint is made from the given work piece.

Signature of the Faculty

104
 All dimensions are in mm

105
 TEE LAP JOINT
Ex. no: 22

Date:

Aim

To make a tee lap joint from the given work piece.

Tools Required

1. Jack plane 2. Try square

3. Mallet 4. Firmer chisels

5. Mortise chisels 6. Rip saw

7. Tenon saw 8. Marking gauge, etc

Procedure

1. The job is clamped properly in the vice and any two adjacent surfaces are planned to
get right angle using jack plane. The accuracy of right angle is checked by using try
square.

2. The job is cut into two halves using rip saw.

3. Proper marking is done on the two portions based on the planned surfaces.

4. One half is cut according to the given dimensions using tenon saw and firmer chisel.

5. The other half is also cut in the similar way so as to make correct fit on one another
and the extra portions are removed using firmer chisel.

6. Finally, the accuracy and proper dimensions are verified by using steel rule and try
square.

106
 Evaluation Rubrics
Assessment Max. Marks Obtained Marks
Aim/ Procedure 15
Experimental 25
methodology
Final product 50
Viva 10
Total 100

Result

Thus the required tee lap joint is made from the given work piece.

Signature of the Faculty

107
 All dimensions are in mm

108
 DOVETAIL HALVING JOINT
Ex. no: 23

Date:

Aim

To make a dove tail halving joint from the given work piece.

Tools Required

1. Jack plane 2. Try square

3. Mallet 4. Firmer chisels

5. Mortise chisels 6. Rip saw

7. Tenon saw 8. Marking gauge, etc

Procedure

1. The job is clamped properly in the vice and any two adjacent surfaces are planned to
get right angle using jack plane. The accuracy of right angle is checked by using try
square.

2. The job is cut into two halves using rip saw.

3. Proper marking is done on the two portions based on the planned surfaces.

4. One half is cut into a tapering slot having the required dimensions using tenon saw
and firmer chisel.

5. The other half is also cut in the similar way so as to fit in the dovetail slot of the other
job using chisels.

6. Finally, the accuracy and proper dimensions are verified by using steel rule and try
square.

109
 Evaluation Rubrics
Assessment Max. Marks Obtained Marks
Aim/ Procedure 15
Experimental 25
methodology
Final product 50
Viva 10
Total 100

Result

Thus the required dovetail halving joint is made from the given work piece.

Signature of the Faculty

110
 VIVA QUESTIONS

1. Define carpentry?

2. Name few types of timbers and some examples for each type.

3. Explain the instruments used for measuring in carpentry?

4. List the different types of joints in carpentry

5. What is the use of try square?

6. Compare the difference between mitre square and bevel square.

7. What is the use of Calipers?

8. List the different types of saw

9. Classify the types of chisel

10. Compare the difference between hammer and a mallet

111