DEPARTMENT OF MECHANICAL ENGINEERING

LAB MANUAL

Course/Branch: 114-BE / Mechanical Engineering

Subject code: GE 8261

Subject name: ENGINEERING PRACTICES LAB

Regulation: 2017

Academic year: 2017-2018

PREPARED BY APPROVED BY

S.P.SAKRAVARTHI, AP/MECH G. SELVARAJ, HOD/MECH

 SYLLABUS
GE8261 ENGINEERINGPRACTICESLABORATORY L T PC
0 0 42
OBJECTIVES:
To provide exposure to the students with hands on experience on various basic
engineering practices in Civil, Mechanical, Electrical and Electronics Engineering.

GROUP A (CIVIL & MECHANICAL)

I CIVILENGINEERINGPRACTICE 13

Buildings:
(a) Study of plumbing and carpentry components of residential and industrial buildings.
Safety aspects.

Plumbing Works:
(a) Study of pipeline joints, its location and functions: valves, taps, couplings, unions,
reducers, elbows in household fittings.
(b) Study of pipe connections requirements for pumps and turbines.
(c) Preparation of plumbing line sketches for water supply and sewage works.
(d) Hands-on-exercise:
Basic pipe connections – Mixed pipe material connection – Pipe connections with
different joining components.
(e) Demonstration of plumbing requirements of high-rise buildings.

Carpentry using Power Tools only:

(a) Study of the joints in roofs, doors, windows and furniture.
(b) Hands-on-exercise:
Wood work, joints by sawing, planing and cutting.

II MECHANICALENGINEERINGPRACTICE 18
Welding:
(a) Preparation of butt joints, lap joints and T- joints by Shielded metal arc welding.
(b) Gas welding practice
Basic Machining:
(a) Simple Turning and Taper turning
(b) Drilling Practice

Sheet Metal Work:

(a) Forming &Bending:
(b) Model making – Trays and funnels.
(c) Different type of joints.

Machine assembly practice:

(a) Study of centrifugal pump
(b) Study of air conditioner

Demonstration on:
(a) Smithy operations, upsetting, swaging, setting down and bending.
Example – Exercise – Production of hexagonal headed bolt.
(b) Foundry operations like mould preparation for gear and step cone pulley.
(c) Fitting – Exercises – Preparation of square fitting and V – fitting models.

TOTAL: 31 PERIODS
OUTCOMES:
On successful completion of this course, the student will be able to
 Fabricate carpentry components and pipe connections including plumbing
works.
 Use welding equipments to join the structures.
 Carry out the basic machining operations
 Make the models using sheet metal works
 Illustrate on centrifugal pump, Air conditioner, operations of smithy, foundry
and fittings
 Carry out basic home electrical works and appliances
 Measure the electrical quantities
 Elaborate on the components, gates, soldering practices.

LIST OF EQUIPMENT FOR A BATCH OF 30 STUDENTS:

CIVIL
1. Assorted components for plumbing consisting of metallic pipes, plastic
pipes, flexible pipes, couplings, unions, elbows, plugs and other fittings.
15Sets.
2. Carpentry vice (fitted to work bench) 15Nos.
3. Standard wood working tools 15Sets.
4. Models of industrial trusses, door joints, furniture joints 5 each
5. Power Tools: (a)Rotary Hammer 2 Nos
(b) Demolition Hammer 2 Nos
(c) Circular Saw 2 Nos
(d) Planer 2 Nos
(e) Hand Drilling Machine 2 Nos
(f) Jigsaw 2 Nos
MECHANICAL

1. Arc welding transformer with cables and holders 5 Nos.

2. Welding booth with exhaust facility 5 Nos.
3. Welding accessories like welding shield, chipping hammer,
Wire brush, etc. 5 Sets.
4. Oxygen and acetylene gas cylinders, blow pipe and other
Welding outfit. 2Nos.
5. Centre lathe 2 Nos.
6. Hearth furnace, anvil and smithy tools 2 Sets.
7. Moulding table, foundry tools 2 Sets.
8. Power Tool: Angle Grinder 2 Nos
9. Study-purpose items: centrifugal pump, air-conditioner One each.
 Workshop Safety Rules

 Always listen carefully to the teacher and follow instructions.

 Do not run in the workshop, you could bump into another pupil and
cause an accident.
 Know where the emergency stop buttons are positioned in the workshop.
If you see an accident at the other side of the workshop you can use the
emergency stop button to turn off all electrical power to machines.
 Always wear an apron as it will protect your clothes and hold loose
clothing such as ties in place.
 Wear good strong shoes. Training shoes are not suitable.
 When attempting practical work all stools should be put away.
 Bags should not be brought into a workshop as people can trip over them.
When learning how to use a machine, listen very carefully to all the
instructions given by the teacher. Ask questions, especially if you do not
fully understand.
 Do not use a machine if you have not been shown how to operate it safely
by the teacher.
Always be patient, never rush in the workshop.
 Always use a guard when working on a machine.
Keep hands away from moving/rotating machinery.
Use hand tools carefully, keeping both hands behind the cutting edge.
Report any damage to machines/equipment as this could cause an
accident.
 INDEX

Ex. No. TITLE OF EXPERIMENT Page No.

GROUP A (CIVIL & MECHANICAL)

1. Plumbing Works:
(a) Study of pipeline joints, its location and functions: valves,
taps, couplings, unions, reducers, elbows in household
fittings.
(b) Study of pipe connections requirements for pumps and
turbines.
(c) Preparation of plumbing line sketches for water supply and
sewage works.
(d) Hands-on-exercise:
Basic pipe connections – Mixed pipe material connection –
Pipe connections with different joining components.
(e) Demonstration of plumbing requirements of high-rise
buildings.
2. Carpentry using Power Tools
(a) Study of the joints in roofs, doors, windows and furniture.
(b) Hands-on-exercise:
Wood work, joints by sawing, planing and cutting.
3. Welding
(a) Preparation of butt joints, lap joints and T- joints by
Shielded metal arc welding.
(b) Gas welding practice
4. Basic Machining
(a) Simple Turning and Taper turning
(b) Drilling Practice
5. Sheet Metal Work
(a) Forming & Bending:
(b) Model making – Trays and funnels.
(c) Different type of joints.
6. Machine assembly practice
(a) Study of centrifugal pump
(b) Study of air conditioner
7. Demonstration on
(a) Smithy operations, upsetting, swaging, setting down and
bending. Example – Exercise – Production of hexagonal
headed bolt.
(b) Foundry operations like mould preparation for gear and
step cone pulley.
(c) Fitting – Exercises – Preparation of square fitting and V –
fitting models.
PLUMBING
EX. NO. STUDY OF PIPELINE JOINTS, ITS LOCATION AND FUNCTIONS: DATE
VALVES, TAPS, COUPLINGS, UNIONS, REDUCERS, ELBOWS IN
HOUSEHOLD FITTINGS.

Introduction:
Plumbing is the art of design, installation and maintenance of pipe, pipe fittings and
other accessories in a building. It plays a major role in the construction of every building.
Plumbing includes the pipes, fixtures and accessories which carry water from the main
source of supply to the building. It also conveys the used fluids from a building to other place
of local disposal. Water distribution system consists of a supply pipe leading to a fixture and
a drain pipe taking the used water away.
Purpose of plumbing:
Plumbing is installed in a building for the comfort and convenience of the inhabitants
as well as sanitation and health. Water is brought by supply pipes and used water is carried
off by drainage pipes. Good plumbing is necessary in houses, apartments, commercial and
other public buildings.
Tools used by plumber:
The tools used by plumber can be classified as follows.

TOOLS EXAMPLE

1. Guiding & testing tools Straight edge, Level, Plumb bob

2. Marking tools Pencil, Chalk liner, punches, scriber

3. Measuring tools Rule, Tape

4. Holding tools Pliers, Clamps, Wrenches, Vices

5. Cutting tools Saws, Files, Chisels

6. Scraping & Grinding tools Scraper, Grinders

7. Boring & Threading tools Drills, Taps, Pipe vice, Pipe cutter

8. Striking & Fastening tools Hammers, Screwdrivers

Pipe threading dies:

(a) It is also called stocks and dies.
(b) Two types of dies are available viz., solid and adjustable.
(c) There are fitted into the centre of the frame. Dies are held in position by a block which
is adjustable by means of a tommy bar.
(d) This stock cuts parallel threads.
(e) Separate set of dies are required for each pipe size.

Pipe fittings:
A lot of fittings are used for joining pipes. Cast iron pipes of larger size are joined
with flanges while small size pipes are joined by sockets. Some of the accessories used in
pipe fitting are
1. Socket:
(a) Its outside diameter is somewhat larger than the diameter of the pipe.
(b) Its inside diameter is equal to that of pipe s diameter.
(c) It is used to bring two pipes in a straight direction.

2. Elbow:
It is similar to the socket. It is used for fitting two pipes at right angles. Internal
threads are cut in the elbows.

3. Bend:
It is used at corners in pipe fitting jobs. Its diameter is equal to the size of the pipe.
Threads are cuts on both its ends and it is joined to the sockets and pipes.

4. T:
It is used for giving connection from the main pipe line to the branch line. By
using it, two or more lines can be made from the supply line.

5. Four way cross:

Its shape is like (+) signs. It is used for fitting a pipe in all four directions.
Threads are cut in all its four ends.

6. Valves:
Pipes can be joined with valves and according to our needs; we can stop or open
the flow of water through the pipes. Types of valves are: Safety valve, Check valve, Ball
valve, Air release valve, Silence valve, Non-return valve, Globe valve, Gate valve, Wheel
valve.

7. Cock:
(a) It serves the purpose of putting off or on the flowing water through the pipes.
(b) It is made up of copper, plastics, gun metal. Types of cock are: Bib cock, Stop cock,
Push cock, Plug stop cock, Plug bib cock, Surgeon cock, Pillar cock, Peot cock,
Locking cock, Combination cock.
8. Pipe union:
It connects two pipes. Water meter is fitted with union so that they can be removed
easily. It provides facility to disconnect pipes.

9. Coupling:
Short cylindrical sleeve with internal threads throughout its length. It is used for
joining two pipes in a straight line and where at least one pipe can be turned.

10. Bush:
It is a short sleeve like piece, used to reduce the size of a threaded opening. It is
threaded inside fully throughout its length and threaded outside at one outer end. The
other outer end is hexagon shape.

11. Plug:
Short piece with external threads at one end and square end on the other to receive
the spanner for operation. Used to screw on to a threaded opening, for temporary
closing. A cap may be used for closing external threaded openings temporarily.

12. Flange:
It contains internal threads in the hub and holes in the body to receive bolts. Two
pipes may be joined together in line, using flanges and bolts. Flanges are available either
in oval or in circular shapes.
13. Socket reducer:
It is used to connect a big pipe to a small pipe face to face.
EX. NO. DATE
STUDY OF PIPE CONNECTIONS REQUIREMENTS FOR
PUMPS AND TURBINE

Check valve:
Check valves are two-port valves, meaning they have two openings in the body, one for
fluid to enter and the other for fluid to leave. There are various types of check valves used in a
wide variety of applications. Check valves are often part of common household items. Although
they are available in a wide range of sizes and costs, check valves generally are very small,
simple, or inexpensive. Check valves work automatically and most are not controlled by a person
or any external control; accordingly, most do not have any valve handle or stem. The bodies
(external shells) of most check valves are made of plastic or metal.

Gate valve:
A gate valve, also known as a sluice valve, is a valve which opens by lifting a round or
rectangular gate/wedge out of the path of the fluid. The distinct feature of a gate valve is the
sealing surfaces between the gate and seats are planar, so gate valves are often used when a
straight-line flow of fluid and minimum restriction is desired. For extremely thick fluids, a
specialty valve often known as a knife gate valve is used to cut through the liquid. On opening the
gate valve, the flow path is enlarged in a highly nonlinear manner with respect to percent of
opening. This means that flow rate does not change evenly with stem travel. Also, a partially
open gate tends to vibrate from the fluid flow.

Eccentric Reducer:
An eccentric reducer is a fitting used in piping systems between two pipes of
different diameters. They are used where the diameter of the pipe on the upstream side of the
fitting (i.e. where flow is coming from) is larger than the downstream side. Unlike a concentric
reducer, which resembles a cone, eccentric reducers have an edge that is parallel to the
connecting pipe. This parallel edge results in the two pipes having offset center lines. The same
fitting can be used in reverse as an eccentric increaser/expander.

Flange coupling:
If essentially consists of two cast iron flanges which are keyed to the shafts to be joined.
The flanges are brought together and are bolted in the annular space between the hub and the
protecting flange. The protective flange is provided to guard the projecting bolt heads and nuts.
The bolts are placed equi-spaced on a bolt circle diameter and the number of bolt depends on the
shaft diameter d. A spigot A on one flange and a recess on the opposing face is provided for ease
of assembly.

Suction pipe:
The pipe leading from the bottom of a pump-barrel or -cylinder to the well, cistern, or
reservoir from which the water or other liquid is to be drawn up. See pump. An air-tight pipe
running from beneath a water-wheel to the level of the tail-race. It is said to render the whole fall
available.

Low radius elbow:

An elbow provides a change in material-flow direction. This adds pressure losses to the
system due to impact, friction and re-acceleration.
Foot Valve:
The foot valve prevents water from flowing backwards out of the jet pump and well
piping back into the well when the jet pump stops operating. You can see Carson Dunlop's sketch
of a foot valve here. Foot valves are also used on deep well installations to help protect against
loss of prime in the well piping system.
STRAINER:
A strainer is an object with holes which you pour a liquid through in order to separate the
liquid from the solids in it.
EX. NO. DATE
PREPARATION OF PLUMBING LINE SKETCHES FOR
WATER SUPPLY AND SEWAGE WORKS

Aim:
To preparation of plumbing line sketches for water supply and sewage works.

Materials supplied:

1 Vent stock 6 Elbow

2 Spanner 7 Bend
3 Back nut 8 Soil pipe
4 Socket 9 Waste pipe
5 Pipe wrench 10 Main hole

Procedure:
1. A main vent-and-soil stack, which is typically certain inches in diameter, runs
vertically from beneath the ground floor to above the roofline.
2. Waste drains connect to the stack, directing waste downward to the main sewer
drain.
3. Then exits the home below frost line and ties into the municipal sewer system or
runs to a personal septic system.
4. Without a constant source of air, water locks can form in drainpipes, causing clogs.
All drains require ventilation.
5. But a single vent, usually installed behind a sink, can serve additional fixtures and
appliances that connect within 10 feet of a common drain line.
6. Vent pipes, which are generally few inches in diameter, connect to the vent-and-
soil stack in the attic.
7. When a fixture sits too far from a common vent, it requires an additional vent pipe,
which connects to the stack or exits the roof separately, depending on the home’s
layout.
8. A drain trap is a U-shaped pipe that connects to the bottom of a sink, shower or tub
drain.
9. A trap retains a small amount of water that prevents smelly sewer gasses from
backing up into the house.
10. All plumbing fixtures require drain traps except the commode, which comes with
an internal trap in its base.

Result:
Thus the preparation of plumbing line for water supply and sewage works was
drawn.
EX. NO. DATE
CONNECTION OF TWO GALVANISED IRON PIPES

Aim:

To connect the given two galvanized iron pipes by running joint or connector joint.

Materials supplied:

1. Two G.I Pipes

2. Spanner
3. Back nut
4. Socket
5. Pipe wrench.

Procedure:

11. There are two pipes A and B shown in the figure which are to be joined.
12. Pipe wrench is used for holding the pipes.
13. Make external threads to both pipes A and B using pipe threading dies.
14. Some hemp and white lead paint is inserted in the threads to make the joint
sound.
15. Pipe B have threads of more length than the pipe A. Back nut (D) is screwed to the
pipe B. It is used for preventing the joint from running loose.
16. The socket C is screwed back to its full length on the pipe B.
17. Both pipes A and B are kept closer.
18. The socket is then screwed back such that it stands half on one pipe A and half on
the other pipe B.
19. A back or locking nut D is used which grips the socket and make it tight. Spanner is
used for tightening the joint.
Result:

Thus the given two G.I. pipes are connected.

EX. NO. DATE
CONNECTION OF TWO PVC PIPES

Aim:

To connect the given PVC pipes by running joint and other by T- Joint.

Material supplied:

1. 5 PVC Pipes
2. Couplings
3. Sand paper
4. Solution

Procedure:

Running Joint:

1. There are two PVC pipes A and B shown in the figure which are to be
connected.
2. Now with fine sand paper rub the corner end of the pipe, so that we can do a
perfect joint.
3. After the rubbing process is completed apply the solution on the two pipes
and also on the coupling.
4. Now with force the pipes are inserted in to the coupling.
5. For two minutes the pipes and coupling are kept undisturbed.

T- Joint:

1. There are 3 pipes D, E and F shown in the figure which are to be connected.
2. Now with fine sand paper corner ends of the pipe are rubbed, so that we can
geta perfect joint.
3. Now the solution is applied is applied on the pipe and also on the Tee.
4. Now with force the pipes are inserted into the Tee one by one.
5. For two minutes the pipes and coupling are kept undisturbed.

Result:

Thus the given PVC pipes are connected using running joint and Tee joint.
EX. NO. DATE
BASIC PIPE CONNECTIONS INVOLVING THE FITTING
LIKE VALVES, TAPS AND BENDS

Aim:

To connect the pipes with pipe fittings like valves, bends and taps with main supply
pipe using
joints.

Materials supplied:

1. Pipe wrench
2. Spanner
3. Bend
4. Valves
5. Taps
6. Cast iron pipes of different length
7. Flange
8. Bench vice.

Procedure:

1. Two pipes are taken and they are held in vice and they are connected by
using a flanged joint as shown in fig.
2. A gate valve is connected to the pipe for controlling the water supply.
3. Then bend-1 is connected to the end of the pipe. Make internal threads
using taps in the bent-1. So it can be screwed to the pipe.
4. One more pipe is connected to the bend for extension of the layout.
5. The pipe is then screwed to bent-2 for further extension.
6. A horizontal pipe is connected to this bent-2 as shown in fig.
7. Then tap is fitted to the end of the pipe for closing and opening the water
supply.

Result:

Thus the basic connections of pipes with pipe accessories are made.
EX. NO. DATE
CONNECTION OF TWO MIXED PIPE MATERIAL

Aim:

To connect the given two different pipe materials by running joint or connector
joint.

Materials supplied:

1. Two G.I Pipes

2. PVC pipes
3. Spanner
4. Back nut
5. Socket
6. Pipe wrench.

Procedure:

1. There are two pipes A and B shown in the figure which are to be joined.
2. Pipe wrench is used for holding the pipes.
3. Make external threads to both pipes A and B using pipe threading dies.
4. Some hemp and white lead paint is inserted in the threads to make the joint
sound.
5. Pipe B have threads of more length than the pipe A. Back nut (D) is screwed
to the pipe B. It is used for preventing the joint from running loose.
6. The socket C is screwed back to its full length on the pipe B.
7. Both pipes A and B are kept closer.
8. The socket is then screwed back such that it stands half on one pipe A and
half on the other pipe B.
9. A back or locking nut D is used which grips the socket and make it tight.
Spanner is used for tightening the joint.

Result:

Thus the given two given two different pipe materials by running joint or
connector joint.
EX. NO. DATE
DEMONSTRATION OF PLUMBING REQUIREMENTS OF
HIGH-RISE BUILDINGS

High-rise buildings have very complex and challenging plumbing systems. I find
that there is not much plumbing code language that specifically addresses how a high-
rise building should be designed to save energy, save water, and provide the owner and
occupants with a sustainable and safe installation.
All of the basic plumbing code language for backflow prevention, minimum and
maximum pressures, and waste and vent stack for buildings over three stories tall
applies to high-rise buildings. But, the code is silent in many other areas in which
money is wasted and equipment wears out in high-rise buildings, leaving building
occupants without water and basic hygiene.
There are many problems in high-rise buildings, and the problems have
included:

• booster pump sizing

• maximum and minimum pressure zone issues
• water heater pressure issues
• domestic hot water return pumping issues
• drainage and vent stack issues
The model plumbing codes are mostly silent with the exception of a few things,
like minimum and maximum pressures and waste and vent stack sizing.
Pressure reducing valves
Most of these developer-built buildings have pressure reducing valves or what I
call energy wasting valves on the bottom floors. On the top 10 floors, there is no
pressure reducing valves.
Pipe pressure ratings
The plumbing designer should determine the minimum required pressure for
the governing fixture on the top floor and make sure the minimum pressure will be
maintained during peak flow periods
Maintenance issues
As with any type of building that has full time maintenance staff some of the
problems associated with plumbing system failures begin with the hiring of the
maintenance staff.
Domestic water pressure booster pump start-up
Another common failure is when there is a prolonged power failure and the
tenants in the building are allowed to drain the water from the piping system before
the power is restored.
Pressure zones to avoid high pressure rated pipe, valves and fittings
There are several ways to design the water distribution system in a high-rise
building. The most efficient system design utilizes a separate booster pump for each
pressure zone in the building up to about 40-60 stories in height depending on floor to
floor height).
Material substitutions

There have been lots of cases where material substitutions have been made. It is
important for the engineer, contractor and owner to verify the pressure ratings,
thermal expansion properties and temperature ratings of the substituted materials.
CARPENTRY

Structure of Wood
EX. NO. DATE
STUDY OF THE JOINTS IN ROOFS, DOORS, WINDOWS
AND FURNITURE

Carpentry:
Carpentry is the process of working with wood for applications such as floor
works, roofs and partitions in a building. Preparation of other wood works such as
windows, stairs, cupboards, etc., is called as joinery.

Types of wood:
Wood is generally classified into three types.
(a) Soft wood
(b) Hard wood
(c) Ply wood

Soft wood:
It has straight fibers and is comparatively weaker. It is easy to work on the soft
wood. Weight and durability are less for soft wood. Soft wood catches fire soon.
Eg.Deodar, Kail, chir.

Hard wood:
Hard wood has closed structure, heavy in weight, dark in colour, more durable. It
is difficult to work on hard wood. So it is very strong. Eg.Teek, Shirham, Sal, Mango, Oak.

Ply wood:
Ply wood consists of three layers.
(a) Top face plys layer
(b) Core layer
(c) Bottom face ply layer
The top and bottom layers are called face ply laters. These two layers are
bonded to the centre core, which is thick and not of good quality.

Structure of wood:
The following are the main parts of the wood.
(a) Medulla: Medulla or Pith is the centre part of the tree. Medulla feeds the sap
from the roots to the leaves. It is dark in colour.
(b) Heart wood: It is the portion surrounding the medulla. The percentage of
moisture is less than the central part.
(c) Sap wood: Sap wood is the portion between cambium layer and heart wood. Sap
wood is light in weight and softer and consists of high percentage of moisture.
(d) Cambium layer: Cambium layer is the rings adjacent to the bark.
(e) Bark: Bark is the outer surface of the tree. It acts as the cover for inner portion of
the tree.
(f) Medullary rays: Medullary rays are radial layer starting from pith up to the
cambium layer.
(g) Annual rings: It is the concentric layer of the wood around the pith. In every
year, one such layer is added to the trees.
Carpentry tools:
Large numbers of tools are used in carpentry. Following are the types of tools used
in carpentry.
(1) Marking and measuring tools.
(2) Cutting tools.
(3) Planning tools.
(4) Boring tools.
(5) Striking tools and Holding tools and Power tools.

Holding tools:
During the wood working job is shacked, so marking accuracy is tough. To maintain
accuracy the wood is to be held rigidly.
(a) Bench vice:
It is the most common work holding device. It consists of one fixed
jaw and one movable jaw. The fixed jaw is fastened to the work bench. The
gap between the jaws is adjusted using the screw rod.

(b) C-clamps:
It is made up of malleable iron. The operating capacity rates from 50 to
350mm. it can be used for clamping small work. The swivel shoe allows to fix
angled work.
EX. NO. DATE
CROSS LAP JOINT

Aim:
To make a cross lap joint from the given wooden piece for the given dimensions.

Material supplied:
A wooden piece of size 300 x 40 x 40 mm

Tools required:

1. Steel rule 2. vice

3. Jack plane 4. Try square
5. Marking gauge 6. Rip saw
7. Tenon saw 8. Firmer chisel
9. Mallet

Sequence of operation:
1. Rough planning 2. Marking
3. Cutting (or) Sawing 4. Chiseling
5. Finish planning

Working steps:
1. The given job is checked to ensure its correct size.
2. The job is firmly clamped in the carpentry vice and two surfaces are planned by Jack
plane to get right angle.
3. Using try square, the right angle of the work piece is checked.
4. Now all the four sides of the wooden pieces are planned to get the smoother and
finished surface.
5. Now the job is cut into two halves rip saw then proper marking is done for cross
lap joint on the two pieces using steel rule and marking gauge.
6. One half is taken. Using tenon saw and firmer chisel the unwanted portions are
removed as per the drawing.
7. The above procedure is repeated for the other half of the work piece.
8. Jack plane is used to plane the other two faces up to the marked portion.
9. Now the two pieces are assembled to check proper fitting.
10. The finished job is again checked job is again checked for its accurate shape and size
using try square and steel rule.

Result:
Thus the desired cross lap joint is obtained.
EX. NO. DATE
MORTISE AND TENON JOINT

Aim:

To make a mortise and Tennon joint from the given wooden piece for the given dimensions.

Material supplied:

A wooden piece of size 300 x 40 x 40 mm

Tools required:

1.Steel rule 2.Carpentry vice

3.Jack plane 4.Try square
5.Mortise gauge 6.Rip saw
7.Tenor saw 8.Mortise chisel
9.Mallet

Sequence of operations:

1.Rough planning 2.Marking

3.Cutting (or) Sawing 4.Chiseling
5.Finish planning

Working steps:

1. The given job is checked to ensure its correct size.

2. The job is firmly clamped in the carpentry vice and any two surfaces are planed by jack plane to get
right angle.
3. Using try square, the right angle of the work piece is checked.
4. Now all the four sides of the wooden pieces are planed to get the smoother and finished surface.
5. Now the job is cut into two halves using rip saw then proper marking is done for mortise and tenon
joint on the two pieces using steel rule and marking gauge.
6. One half is taken. Using tenon saw and mortise chisel the unwanted portions are removed as per the
drawing.
7. The above procedure is repeated for the other half of the work piece.
8. Jack plane is used to plane the other two faces upto the marked portion.
9. Now the two pieces are assembled to check proper fitting.
10. The finished job is again checked for its accurate shape and size using try square and steel rule.

Result:
Thus the desired mortise and tenon joint is obtained.
 WELDING

Welding

Plastic Welding (non- Fusion Welding (no

Fusion)(Under pressure, pressure is required, but
Without addition of with the addition of
filler material filler material

Forge Resistance Gas Electric arc Thermit

Welding Welding Welding Welding welding

(a) Lap Welding (a) Spot (a) Oxy- (a) Metal Arc Welding
(b) Butt Welding Welding Acetylene (b) Arc Welding
(c) V – Welding (b) Projection Welding (c) Tungsten Welding
(d) T - Welding Welding (b) Air- (d) Argon Welding
(c) Seam Acetylene (e) Submerged Arc
Welding Welding Welding
(d) Butt (c) Oxy- (f) Atomic Hydrogen
Welding hydrogen Welding
(e) Percussion Welding
Welding
 WELDING

Introduction:

Welding is a metal joining process wherein localized coalescence is produced either by

heating the metal to a suitable temperature, with or without the use of filler metal, with or
without application of pressure. The filler material has similar compositional melting point
temperature as that of the base metal. It is used to fill gap between the join surfaces.

Types of welding:

Welding process is mainly divided into the subdivisions as follows:

1. Plastic welding:
The pieces of the metal to be joined are heated to the plastic state and then
forced together by external pressure without the addition of filler material. Plastic
welding is further classified as:
(a) Forge welding
(b) Resistance welding
2. Fusion welding:
In fusion welding, metal parts to be joined are melted and then allowed to solidify
pressure is not applied and filler metals may be used for this type of welding. Fusion
welding is further classified as:
(a) Gas welding
(b) Electric arc welding
(c) Thermit welding
3. Oxy-Acetylene welding:
Here, oxygen and acetylene are the two gases are used for producing flame. Oxygen is
mainly used for supporting the combustion intensity. A typical oxy-acetylene gas welding
setup is used.
Chemical reactions in gas welding:
C2H2 + O2 → 2CO + H2 + Heat

2CO + O2 → 2CO2

2H2 + O2 → 2H2O

Types of flames:
1.Neutral flame ( oxygen, acetylene in equal proportions )
2.Oxidizing flame ( excess of oxygen )
3. Reducing flame (excess of acetylene )
Limitations:
In this method, only those metals whose combustion temperature is below their melting
point can be cut. So iron and steel can be cut flame cutting.
Principle:
The heat required for joining the metal is obtained from an electric arc. The electric
motor generator or transformer sets are used to supply high electric current and the
electrodes are used to produce the necessary are. The electrode saves as the filler rod and are
melts the surfaces so that the metals to be joined are fused together.
Welding bed cleaning accessories:
1. Wire bush:

A wire bush made up of stiff steel wire.

2. Chipping hammer:

A chipping hammer is chisel shaped one and it is used to remove the slag from the
weld bed.

3. Hand screen:

It is a protective device used in arc welding. A hand shield is held in the hand of the
welder and it is fitted with a suitable fitter lens.

4. Helmet:

It is used for sheiding and protecting the face and neck of the welder and it is fitted
with a suitable fitter lens.

5. Tongs:

Tongs are used to handle the hot metal welding job while cleaning they are also
used to hold the metal for hammering.

6. Goggles:

Chipple joggle are used to protect the eyes while chipping the slay. They are fitted
with a plain glass to see the area to be cleaned.

7. Hand gloves:

Hand gloves are used to protect the hands from electric shocks, arc radiation
and hot spatters.
EX. NO. DATE
SINGLE V-BUTT JOINT

Aim:

To make a Single V-Butt joint using arc welding on the given work pieces.

Material supplied:

Mild steel plate of size 100 x 50 x 6mm - 2 Nos.

Tools required:
1. Power supply (AC or DC)
2. Welding Torch
3. Electrodes
4. Tongs
5. Chipping hammer
6. Wire brush
7. Gloves
8. Apron
9. Shield
10. Safety goggles
11. Earthing clamps

Sequence of operations:
1. Edge preparation (Removal of rust, scale etc.,) 2. Tacking 3. Welding 4.Cooling
2. Chipping 5. Cleaning.
Working steps:
1. First of all, the work pieces must be thoroughly cleaned to remove rust, scale and other
foreign materials.
2. Then the given work pieces are placed on the table in such a way that two work pieces
are brought close to each other so that it forms a V-Shape when the plates butt each
other.
3. Appropriate power supply should be given to the electrode and work pieces.
4. Now the welding current output may be existed.
5. When current is passed, arc is produced between the electrode and work pieces.
6. Now set the two work pieces in correct position and maintain the gap 3mm and drack at
both ends of the work pieces as shown in the figure.
7. Then the welding is carried out throughout the length.
8. As soon as the welding process is finished, switched off the current supply and allow the
work piece to cool.
9. Slags are removed by chipping process with the help of chipping hammer.
10. Finally using wire brush, welded portions are cleaned.

Result:
Thus the desired Single V-Butt joint is obtained using arc welding.
EX. NO. DATE
LAP JOINT

Aim:
To make a lap joint using arc welding on the given workpieces.

Material supplied:
Mild steel plate of size 102 x 51 x 6mm - 2 Nos.

Tools required:

1. Power supply (AC or DC)

2. Welding Torch
3. Electrodes
4. Tongs
5. Chipping hammer
6. Wire brush
7. Gloves
8. Apron
9. Shield
10. Safety goggles
11. Earthing clamps

Sequence of operations:
1. Edge preparation (Removal of rust, scale etc.,)
2. Tacking
3. Welding
4. Cooling
5. Chipping
6. Cleaning

Working steps:

1. First of all, the work pieces must be thoroughly cleaned to remove rust, scale and other
foreign materials.
2. Then the given work pieces are placed on the table in such a way that two work
pieces are overlapped one over another as shown in fig.
3. Appropriate power supply should be given to the electrode and work pieces.
4. Now the welding current output may be existed.
5. When current is passed, arc is produced between the electrode and work pieces.
6. Set the two work pieces in correct position like lap joint and tack at both ends of the
work pieces as shown in the figure.
7. Then the welding is carried out throughout the length of the work piece.
8. As soon as the welding process is finished, switch off the current supply and allow the
work piece to cool.
9. Slags are removed by chipping process with the help of chipping hammer.
10. Finally using wire brush, welded portions are cleaned.

Result:
Thus the desired lap joint is obtained using arc welding.
EX. NO. DATE
T- JOINT

Aim:
To make a T-Fillet joint using arc welding on the given workpieces.

Material supplied:
Mild steel plate of size 100 x 50 x 6mm - 2 Nos.

Tools required:
1. Power supply (AC or DC)
2. Welding Torch
3. Electrodes
4. Tongs
5. Chipping hammer
6. Wire brush
7. Gloves
8. Apron
9. Shield
10. Safety goggles
11. Earthing clamps

Sequence of operations:
1. Edge preparation (Removal of rust, scale etc.,)
2. Tacking
3. Welding
4. Cooling
5. Chipping
6. Cleaning
Working steps:
1. First of all, the work pieces must be thoroughly cleaned to remove rust, scale and other
foreign materials.
2. Then the given work pieces are placed on the table in such a way that two work
pieces are brought close to each other so that it forms a T shape is shown in the fig.
3. Appropriate power supply should be given to the electrode and work pieces.
4. Now the welding current output may be existed.
5. When current is passed, arc is produced between the electrode and work pieces.
6. Set the two work pieces in correct position like T-Fillet joint and tack at both ends of the
work pieces as shown in the figure.
7. The joint is placed on a welding table in a flat position by keeping the tack side down.
8. Then the welding is carried out throughout the length.
9. As soon as the welding process is finished, switched off the current supply and allow the
work piece to cool.
10. Slags are removed by chipping process with the help of chipping hammer.
11. Finally using wire brush, welded portions are cleaned.

Result:
Thus the desired T-Fillet joint is obtained using arc welding.
BASIC MACHINING
EX. NO. DATE
BASIC MACHINING

Introduction:
Machining is a process of converting the given workpiece into the required shape and size
with the help of a machine tool. The most widely used machine tool is lathe. There are different types
of tools used in lathe. Several operations can be carried out in the workpiece with the help of lathe. In
simple words, machining is a process of removing certain material from the workpiece.

Lathe:
Lathe is a machine tool which is used to perform several operations on the workpiece. Lathe is
useful in making several parts which is further assembled to make new machine. Hence lathe is
known as “mother of machines”.

Basic working principle of lathe:

In lathe, the workpiece is held in the chuck, a work holding device. The cutting tool is
mounted in the tool post. The chuck is rotated by means of power. When the chuck rotates, the
workpiece also rotates. The tool is moved against the rotating workpiece by giving small amount of
depth of cut. The material is removed in the form of chips. Continuous feed and appropriate depth of
cut is given until the required dimensions of the workpiece are obtained.

Types of lathe machines:

There are different types of lathe machines. They are
1. Centre lathe
2. Tool room lathe
3. Bench lathe
4. Capstan lathe
5. Turret lathe
6. Automatic lathe

Work holding devices:

1. Lathe centre
They are used to support work. It has two categories of centre.
(a) Live centre is one which is fitted in the headstock spindle.
(b) Dead centre is one which is fitted in the tailstock.
2. Chuck
(a) It is a device used to hold a job. It is easily fitted on the thread cut on the end
of headstock spindle.
(b) Various types of chuck are
i. Two jaw chuck
ii. Three jaw chuck
iii. Four jaw chuck
iv. Collet chuck
v. Magnetic chuck
3. Face plate
(a) It is a circular plate and it is screwed to lathe spindle.
(b) It is used for mounting the type of jobs which cannot be held by chucks.
(c) There are number of holes and slots on the face of the face plate.
 4. Catch plate
(a) It is a plain disc of steel or cast iron.
(b) It is screwed to the nose of the headstock spindle.
(c) It is used to drive the workpiece through a carrier or dog when it is held between
the centres.

5. Lathe carriers or Dogs

(a) It is used for transferring the motion from the rotating driving plate to the work
held between the centres.
(b) It is used for connecting end of workpiece to the driving

plate. The types of Dogs are

i. Bent Tail
ii. Straight Tail
iii. Clamp Tail

6. Steady Rest
(a) It supports long workpiece when machined between the centres or by a chuck.
(b) It is used for cylindrically long
jobs. Two types of steady rest are
i. Fixed steady rest
ii. Travelling steady rest

7. Mandrel
(a) It is used for holding hollow jobs.
(b) It is a hardened piece of round bar for holding bored or reamed jobs. It has drill holes
at both the ends.
(c) Workpiece is mounted over the mandrel and the mandrel is rotated between centres.

8. Follower rest
(a) It is made of cast iron and is used for supporting long slender workpieces, against
the cutting tool forces.
(b) It can be clamped to the carriage of the lathe, to make it travel along with the
cutting tool.
(c) It has two adjustable jaws to support the workpiece.

Cutting tools used:

For making a finished job on lathe machine, various types of cutting tools are used.
1. Facing tool
(a) It is used for facing the longitudinal ends of the job. Its shape is like a knife.

2. Rough turning tool

(a) It is used to remove excess material from the workpiece in quick time.
(b) It can be used to give large depth of cut and works at coarse feed.
Lathe operations:
1. Plain turning
(a) It is done for reducing the diameter of the workpiece.
0
(b) A cutting tool with 70 setting angle is used for roughing operation.
(c) More feed is given for rough turning while less feed is given for finishing.
(d) Workpiece is held in chuck and tool is set to the centre height of the
workpiece.

2. Taper turning
(a) Taper turning is different from the turning operation.
(b) Taper is defined as the uniform change in the diameter of a workpiece
measured along its length.

Taper = (D-d) / L

Where,
D is large diameter
d is small diameter
L is length of tapper.
After Machining
EX. NO. FACING, TURNING, STEP TURNING, CHAMFERING AND TAPER DATE
TURNING

Aim:

To obtain the required shape and size of the workpiece by turning and facing operations.

Material supplied:

Cylindrical work piece of dia 35mm and length 112mm mild steel rod.

Tools required:

1. Lathe
2. Cutting tool
3. Vernier caliper
4. Try square
5. Scriber
6. Vernier height gauge

Sequence of operations:

1. Checking
2. Workpiece setting
3. Tool setting
4. Facing
5. Turning
6. Taper turning
7. Chamfering

Working steps:

1. The given workpiece is checked for its dimensions.

2. The workpiece is held in the chuck. Chuck key is used to tighten the job firmly,
ensuring centering of workpiece.
3. The single point cutting tool is held in the tool post and tighten the nuts using spanner.
4. Facing is done with cutting tool moving from the centre of the workpiece towards
outside. It is done until the required length of the job is obtained.
5. Turning is done to reduce the diameter of the job. Sufficient depth of cut is given and it is
done until the required diameter of the job is obtained.
6. Next the taper turning is done on the workpiece, as per the taper angle already
calculated. Then the compound rest base is swivelled and set at half taper angle. Cutting
tool is moved at an angle to the lathe axis. Tool is moved by the compound rest hand
wheel.
7. For chamfering to be done at the end of workpiece, the tool is held at 45° to the lathe
axis and it is fed against the rotating workpiece.
8. Finally, the dimensions of the workpiece are again checked.

Result:

Thus the required size and shape of the given work piece is obtained.
Before Machining

After Machining
EX. NO. DATE
DRILLING AND TAPPING

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

Material supplied:
50 x 50 x 5mm Mild steel plate – 1 No.

Tools required:
1. Bench vice
2. Machine vice
3. Steel rule
4. Standard set of filling tools
5. Try square
6. Surface plate
7. Vernier height gauge
8. Scriber
9. Dot punch
10. Drill bit
11. Drilling machine
12.Tap set with Die holder.

Sequence of operations:

1.Checking
2.Filling
3.Marking
4.Punching
5.Drilling
6.Tapping

Working steps:
1. The raw material is checked for its size 50 x 50 x 5mm using steel rule.
2. The given work piece is clamped in a vise and any two surfaces are filled to get right angle .
3. Chalk is applied uniformly on the surfaces of the work pieces.
4. With the help of vernier height gauge, surface plate, angle plate steel rule and scriber the
given dimensions are marked.
5. The midpoint of the required holes is punched by using a dot punch.
6.The punched dots are drilled by drilling machine.
7.After drilling the holes, they are tapped by using tap set.
8.Finally, the dimensions of the work piece are again checked.

Result:
Thus the given work piece is drilled and tapped to the required dimensions.
SHEET METAL
EX. NO. DATE
Forming & Bending

Introduction:
Sheet metal work is working on the metal of 16 gauge to 30 gauge with hand tools and
simple machines into different forms by cutting, forming into shape and joining. Sheet metal
work is one of the major applications in the engineering industry. It has its own significance as
useful trade in engineering work.

Application of sheet metal:

Sheet metal work is used for making hoppers, funnels, various ducts, chimneys, ventilating
pipes, machine tool guards, boilers, etc., It is also used in major industries like aircraft
manufacturing, ship building, automobile body building and fabricating ducts in air conditioning
equipments etc.,

Tools used:

Cutting tools (chisels, snips or shears):

Chisels:
Chisels are used for cutting sheets, rivets, bolts and clipping operations. Round nose
chisel and flat chisel are the often used ones.

Snips or shears:
Snips are hard shears, varying in length from 200mm to 600mm. 200mm and 250mm
length is commonly used. Straight snips are used for cutting along outside curves and straight
lines.Curved snips or bent snips are used for trimming along inside curves.

Striking tools:

Hammer:
Hammers are used in sheet metal work for hollowing, stretching, levelling, revetting,
strengthening of sheet metal joints etc., the following joints are used in sheet metal.Ball peen
hammer, Straight peen hammer, Rivetting hammer, Mallet

Punches:
In sheet metal work, punch is used for making out work locating centers etc., the
following two types of punches are widely used. Dot punch & Centre punch.

Supporting tools:

Stakes:
Stakes are nothing but sheet metal worker s anvils used for bending, hemming, seaming, forming
etc., using hammers and mallet

Bending tools:
Pliers:
Pliers are used for bending the sheet metal to the required shape. It is also used for
holding and cutting the sheet metal. Flat nose pliers and round nose pliers are used in sheet
metal work for forming and holding work.
Layout tools:
Steel rule:
It is used for measuring and laying out small work it can measure with as accuracy of
up to 0.5mm.

Scriber:
It is a long wire of steel with its one and sharply pointed and hardened to scratch line
on sheet metal for laying out patterns.

Dividers:
Dividers are used for drawing circles or arcs on sheet metal.

Trammels:
It is used for marking areas and circles. Maximum size of the arc that can be scribed
depends on the length of the beam in scriber.

Sheet metal gauge:

It is used tom find the thickness of the sheet metal. The various types of gauges
are: Standard Wire Gauge (SWG), Birham Wire Gauge, Burmingham Wire Gauge and
American Wire Gauge.

Other tools:
Groover:
Grooving:
In order to join the sheet metal joints, their ends are grooved with the help of grooving
tools. This process is called grooving. It is a most widely used tool made up of hardened and
tempered carbon steel. These are used for making locked joints in sheet metal works such as
wired edges, slots etc., These are available in different sizes.

Bench plate:
A special type of plate made of carbon steel. Types of bench plate: fixed bench
plate, revolving bench plate.

Hand dolly
It is a steel block rectangular in shape and fitted with a handle in the bottom of the
block.

Sheet metal joints:

Sheet metal working incorporates a wide variety of hems and seams.

Hem:
A hem is an edge or border made by folding. Types of hem are Single hem, Double
hem, wired edge.
EX. NO. DATE
RECTANGULAR TRAY

EX.No.
Aim:

To make a rectangular tray from the given sheet metal.

Material supplied:

22 gauge Galvanized Iron (G.I) sheet.

Tools required:

1. Steel rule
2. Mallet
3. Scriber
4. Divider
5. Protractor
6. Snips
7. Stakes
8. Rivet set
9. Ball peen hammer

Sequence of operations:

1. Checking
2. Levelling
3. Marking
4. Cutting
5. Bending
6. Hemming
7. Riveting

Working steps:

1. The size of the given sheet is checked for its dimensions using a steel rule.
2. Then the sheet is leveled on the leveling plate using a mallet.
3. The development procedure is followed same as square taper tray.
4. The dimensions are marked as shown in fig.
5. The sheet is cut as per the marked dimensions by straight snips.
6. Then a single hemming is made on the four sides of the tray as shown in fig.
7. This four sides of the tray are bent to 90° using stakes anvil.
8. Finally all the corners of the tray are joined by riveting.

Result:

Thus the desired rectangular tray is made from the given sheet metal.
EX. NO. DATE
FUNNEL & JOINTS

Aim:
To make a funnel from the given sheet metal.

Material supplied:
22 gauge Galvanized Iron (G.I) sheet.

Tools required:
1. Steel rule
2. Mallet
3. Ball peen hammer
4. Scriber
5. White paper
6. Straight snips
7. Groover
8. Solder

Sequence of operations:
1. Checking
2. Levelling
3. Marking on paper
4. Marking on sheet metal
5. Cutting
6. Folding
7. Hemming
8. Soldering

Working steps:
1. The size of the given sheet metal is checked for its dimensions using a steel rule.
2. The required development of surface is being made on the white paper which is
overlapped on the sheet metal.
3. The marking is done on the sheet metal as per the development being done on the paper.
4. Now using straight snips, unwanted materials are removed.
5. Now fold and bend the work piece to make the funnel shape and joint is made
on the work piece.
6. Then using groover, locked grooved joint is made for about 5mm. Also, hemming is
done in the bottom of the funnel.
7. In between top face and bottom face, butt joints are made using solder.
8. Finally, trimming and finishing operations are being carried out.

Result:
Thus the funnel of the required dimensions is made from the given sheet metal.
MACHINE ASSEMBLY
EX. NO. DATE
STUDY OF CENTRIFUGAL PUMP

Ex.No.

Introduction:

The pump is a hydraulic machine which converts the mechanical energy into hydraulic energy
in the form of pressure. The Centrifugal pump is a hydraulic machine which convert the mechanical
energy into pressure energy by means of centrifugal force.

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, the rise I pressure head of the rotating liquid
take place. The rise in the pressure head at any point of the rotating liquid is proportional to the square
of tangential velocity of the liquid at that point.

Main parts of Centrifugal pump:

The followings are the main parts of a centrifugal pump,

1. Sunction pipe
2. Impeller
3. Casing
4. Delivery pipe.
All the main parts of the centrifugal pump are shown in the following figure.

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 valve which is a non- return valve or one-
way type of valve is fitted at the lower end of the suction pipe. A strainer is also fitted
at the lower end of the suction pipe for filtering purpose.
2. Impeller
The rotating part of a centrifugal pump is known as Impeller. It contains series of
curved vanes. The Impeller is mounted on a shaft which is connected to the shaft of an
electric motor which runs the pump.
3. Casing
Casing is an air- tight passage surrounding the impeller and is designed such a way that
the kinetic energy of the water discharge at outlet of the impeller is converted into
pressure energy before the water leaves the casing and enter into delivery pipe. Three
common types of casings are,

i. Volute casing
ii. Vortex casing
iii. Diffuser casing
4. Delivery pipe:
A pipe whose end is connected to outlet of the pump and the other end delivers the
water at required level is known as Delivery pipe.
EX. NO. DATE
STUDY OF AIRCONDITIONER

Introduction:
An air conditioner is defined as an assembly of different parts of the system used
to produce a specified condition of air within required space or building below that of
atmosphere or surroundings.
Mechanism:
An air- conditioning system works on vapour compression cycle. This cycle
works in following four phases.
1. Compression
2. Condensation
3. Expansion and
4. Evaporation
1. Compression
Compression takes place at the compressor. The low pressure, low
temperature dry refrigerant or coolant vapour is drawn from the
evaporator into compressor cylinder during suction stroke of the
compressor. During compression stroke pressure and temperature of the
vapour increases until the vapour temperature is greater than the
temperature of condenser cooling medium (Air or water). This high
pressure and high temperature vapour passes out to the condenser
through discharge line.
2. Condensation
In the condenser high pressure and high temperature refrigerant vapour
rejects heat to cooling medium thus allowing the vapourised refrigerant to
return to liquid state.
3. Expansion
After condenser, the liquid refrigerant is stored in the liquid receiver until
needed. Then it is passes through an expansion device (i.e. Expansion
valve). Due to the expansion the high pressure reduce very much to allow
the vaporization of liquid at very low temperature of about -100 C.
4. Evaporation
Then the low pressure low temperature refrigerant vapour enters into the
evaporator. Where a considerable amount of heat is absorbed from the
surrounding by the refrigerant. After absorbing heat from the surrounding,
the liquid refrigerant changes to vapour state. Then the refrigerant vapour
again move into compressor through the suction line. Again the vapour
compression cycle is repeated.
Boiling point of a refrigerant is very low. The refrigerant absorbs heat
from one place and release it to the other place. Generally Freon 12 is used as
a refrigerant in domestic air-conditioner. It is observed that all the
chlorofluro carbons (CFC) including Freon affects the ozone layer causing
global warming. Since now-a-days the newly invented refrigerant Hydro
Fluoro Carbon (HFC) is used as refrigerant.
DEMONSTRATION
EX. NO. DATE
SMITHY OPERATIONS, UPSETTING, SWAGING, SETTING DOWN
AND BENDING

Introduction:
Smithy is one of the manufacturing processes in which the metals are processed
to get the desired size and shape by applying the mechanical force or by heating the
metal and then applying smaller of force. Black smithy or hard forging is an ancient
trade. It is employed only for relatively small components where huge is to be applied.
Normally the heating of metal is done in open fire or hearth (it is like a small furnace).
The fuel used for furnace may be coke/coal or charcoal.

Tools used in Smithy shop:

Tools used in smithy is broadly classified as follows, Supporting tools, Striking
tools, Holding tools, Cutting tools, Finishing and shaping tools
1. Supporting tools
Anvil
It is most oftenly used smithy tool without which we cannot carry out
any smithy process. It is used as a support when hammering is
performed. It is made up of solid wrought
Swage block
It is used for squaring, sizing, heading, bending, and forming
operation. It may be used either flat or edgewise in its position.
2. Striking tools
Two different types of hammers are used in forging operations.
Hand hammers
These hammers are classified as Ball peen hammer, Straight peen
hammer and Cross peen hammer.
Sledge hammer
It is used for heavy work only. It is flat end on both sides. The
weight varies from 4.5 to 5.5 kg for ordinary work and around 9 kg for
heavy work.
3. Holding tools
Generally tongs are used for holding purpose. It is made up of mild steel.
Types of Tongs used are Tong, Flat Gad Tong, Ring Tong and Straight- lip fluted Tong
4. Cutting tools
It is cutting and necking and metals prior to breaking. Two types of chisel are
normally
used.
i. Cold chisel:
It is made up of tool steel with a cutting angle of about 600 and its
edge is hardened and tempered.
ii. Hot chisel:
It is made up of low carbon steel and has a cutting angle of 300 . Its
edge does not require hardening.
5. Finishing and shaping tools
These tools are used to give the desired forms and shapes.
Swages
1. Swages are used for wok which has to be reduced and finished to
round, square or hexagonal form.It is made up of high carbon steel.
2. The swages may be in separate top and bottom halves.

1. It is used after the job has been forged into shape with a hammer and
the hammer marks can be seen on the job surface.
2. It is used to achieve better finish surface especially when surface area
is large.
EX. NO. DATE
MAKING A ROUND ROD INTO HEXAGONAL HEADED BOLT

Aim :
To make a hexagonal headed bolt of size 10*9 mm on one end of the round rod. (Length of
the rod to be made is 50mm).

Material Supplied :

M S Round rod of diameter 10mm and length to be calculated (refer calculation).

Tools required :

1. Blacksmith furnace.
2. Tongs.
3. Anvil.
4. Swage block.
5. Sledge hammer.
6. Flatter.
7. Other relevant tools.

Sequence of operations:

1. Heating.
2. Flattering.
3. Forming hexagonal shape.
4. Checking.
5. Cooling.

Working steps:

1. First length of the given work piece is calculated and it is selected for operation.
2. Using tongs, the end of the work piece is kept in the smith furnace to attain to raise
the temperature to red hot condition.
3. Now the work piece is taken from the furnace and kept in the hole of the anvil for
further processing.
4. The hammering process is carried out to flatten the one end of the work piece.
5. Again it is heated and using flatter it is converted into a square headed bolt.
6. After that any two corner are hammered to form hexagonal bolt head.
7. Now the work piece is cooled using water to avoid deformation and to attain the
maximum hardness.

Result :

Thus the hexagonal headed bolt is made from the given round rod.
FOUNDRY
EX. NO. DATE
INTRODUCTION OF FOUNDRY

Introduction:
Producing components by casting has been since the earliest day of civilization. Lot of shape
and sizes can be prepared in a casting process. To make the casting of components, a cavity of
desired shape made in moulding sand or other material. The process of moulding consists of all
operations done to make a mould.
Pattern: Pattern is the model used to get required casting. It is used to produce to mould cavity
insand.

Foundry: The place where moulding and castings are done is known as foundry.

Moulding sand or Green sand: It is mixture of sand and additives such as water,
bentonite,inoculent, sodium silicate etc., used to create mould cavity.

Components required for moulding

The following components are essential for producing mould, Moulding Sand (Green
sand), Moulding Boxes, Pattern, Moulding tools.

I. Moulding Sand
It is a special type of sand used for making mould. Moulding sand has three constitutes.
They are,Sand, Binder, Additive.

Properties of moulding sand

A goodmoulding sand must have the following properties.
Porosity or permeability
Plasticity
Adhesiveness
Cohesiveness
Refractoriness

II. Moulding Boxes

Moulding box is also called moulding flask. It is a frame or box of wood or metal. Wood
is cheaper boxes made quickly. Wood wears out quickly. It is destroyed by contact with hot metal.
Metal boxes in steel, cast iron and aluminum alloys are used in mass production. Moulding boxes
are used for making sand moulds. Moulding flasks may have two or more parts. The main type of
flasks are:
a) Snap Flask
b) Tight or Box Flash
III. Patterns
A pattern is the replica of the desired casting used to produce a mould cavity into which
liquid metal is poured. When patter packed in a suitable material produces a cavity called the mould.
This cavity when filled with molten metal produces the desired casting.

IV. Moulding tools

1) Shovel 8) Bellows
2) Riddle 9) Swab
3) Rammer 10) Gate cutter
4) Trowels 11) Draw spike
5) Slick 12) Lifter
6) Strike off bar 13) Vent rod
7) Sprue pin
 EX.
DATE
NO. FOUNDRY OPERATIONS LIKE MOULD PREPARATION FOR GEAR

Aim :
To make the mould of a Gear pattern.

Material Supplied:

Moulding sand, Parting sand, Facing sand, Gear pattern, Moulding boxes etc.

Tools required:
1. Showel 2. Sieve 3. Trowel 13. Bellow
4. Rammers 5. Spure pin 6. Strike off bar
7. Lifter 8. Gate cutter 9. Runner
10. Riser 11. Vent rod 12. Draw spike
Sequence of operations:

1. Sand preparation.
2. Core preparation.
3. Placing the pattern on moulding board.
4. Ramming of drag.
5. Placing runner and riser.
6. Ramming of cope.
7. Removal of pattern, runner, riser.
8. Gate cutting.

Working steps :

1. The gear pattern is placed on the moulding board.

2. A suitable core is prepared and placed in the hole of gear pattern.
3. Clay washing is done inside the drag surface.
4. Parting sand is applied over the pattern.
5. Box is filled with smooth moulding sand and proper ramming is done using flat
and peen rammers.
6. Excess sand is removed using the strike off bar.
7. The drag is turned upside down.
8. The cope is placed on the drag after doing clay wash.
9. The runner and riser are placed over the pattern.
10. After applying parting sand, moulding sand is filled over the pattern.
11. Ramming is done to get a rigid mould.
12. Using strike off bar excess sand is removed.
13. Vent holes are made using vent rod.
14. Runner and raiser are removed a funnel shape is made on the runner hole.
15. Cope is kept aside and the pattern is removed using draw spike.
16. The cope is placed on the drag.

Result :

Thus the gear mould is prepared and ready for casting.

 EX.
DATE
NO. FOUNDRY OPERATIONS FOR STEPPED CONE PULLEY

Aim :
To make the mould of a flange pattern.

Material Supplied :

Moulding sand, Parting sand, Facing sand, Stepped cone pulley pattern, Moulding
boxes etc.

Tools
Required:

1. Showel 2. Sieve 3. Trowel 13. Bellow

4. Rammers 5. Spure pin 6. Strike off bar
Gate
7. Lifter 8. cutter 9. Runner
10. Riser 11. Vent rod 12. Draw spike
Sequence of operations:
1. Sand preparation.
2. Core preparation.
3. Placing the pattern on moulding board.
4. Ramming of drag.
5. Placing runner and riser.
6. Ramming of cope.
7. Removal of pattern, runner, riser.
8. Gate cutting.

Working steps :

1. The gear pattern is placed on the moulding board.

2. A suitable core is prepared and placed in the hole of gear pattern.
3. Clay washing is done inside the drag surface.
4. Parting sand is applied over the pattern.
5. Box is filled with smooth moulding sand and proper ramming is done using flat
and peen rammers.
6. Excess sand is removed using the strike off bar.
7. The drag is turned upside down.
8. The cope is placed on the drag after doing clay wash.
9. The runner and riser are placed over the pattern.
10. After applying parting sand, moulding sand is filled over the pattern.
11. Ramming is done to get a rigid mould.
12. Using strike off bar excess sand is removed.
13. Vent holes are made using vent rod.
14. Runner and raiser are removed a funnel shape is made on the runner hole.
15. Cope is kept aside and the pattern is removed using draw spike.
16. The cope is placed on the drag.

Result :

Thus the flange mould is prepared and ready for casting.

FITTING
 EX.
DATE
NO.
INTRODUCTION OF FITTINGS

Introduction:

Fitting is the assembling together of parts and removing metals to secure the necessary
fit and it may or may not be carried out at the bench. An operator who does the fitting job is
called fitter and the work done by him is fitting. There are various group of fitters such as
bench fitter, assemble fitter and erection fitter etc.

Fitting tools

The fitting tools are classified into following groups

1) Work holding tools

2) Marking and Measuring tools
3) Cutting tools
4) Finishing tools
5) Other tools
1) Work holding tools:
a. Bench Vice
b. C- clamp
c. V- block with clamp
2) Marking and Measuring tools:
a. Steel rule h. Try Square
b. Caliper i. Trammel
c. Vernier Caliper j. Dot punch
d. Vernier height guage k. Surface plate
e. Jenney Caliper (or) Hermaphrodite l. Angle plate
Surface
f. Scriber m. gauge
g. Divider
3) Cutting tools:
a. Hacksaw Frame
Solid frame (length cannot be changed)
Adjustable frame (length can be changed)
b. Chisel
4) Finishing
tools: File

It is principal hand tool used by fitter.

It has several teeths to remove fine chips of materials.
a. Flat file
b. Square file
c. Round file
d. Half round file
e. Triangular file (or) three square file
f. Knife edge file
5) Other tools
a. Ball- peen hammer
b. Screw driver
 EX.
DATE
NO.
PREPARATION OF SQUARE FITTING

Aim :
To file the given workpiece (mild steel) into square shape.

Material Supplied :
Moulding sand, Parting sand, Facing sand, Stepped cone pulley .

Tools required :
1. Showel
2. Steel rule
3. Standard set of filing tools
4. Try square
5. Vernier height gauge
6. Surface plate
7. Dot punch

Sequence of operations:
1. Checking.
2. Marking.
3. Punching.
4. Rough filing.
5. Finish filing.

Working steps:

1. The dimension of the given work piece (job) is checked using steel rule.
2. Job is rigidly fixed on a bench vice and the two adjacent sides are filed using a flat file so
that they at right angles.
3. Then chalk is applied uniformly on the surface of the work piece.
4. The given dimensions are marked by using vernier height gauge with reference to the
datum.
5. Then using dot punch, dots are punched along the marked line.
6. The work piece is again fitted on the bench vice and the other two sides are filed in the
same manner.
7. Finally the required square shape is obtained by filing repeatedly using smooth and
triangular file so that the given dimension is obtained.

Result :

Thus the Square filing is done on the given work piece.

 EX.
DATE
NO.
PREPARATION OF V – FITTING MODEL

Aim :
To make a V- Joint on the given workpieces.

Material Supplied :

50 * 50 * 50 mm Mild steel plate - 2 Nos

Tools required :

1. Bench vice
2. Steel rule
3. Standard set of filling tools
4. Try square
5. Scriber
6. Vernier height gauge
7. Surface plate
8. Angle plate
9. Dot punch
10. Fixed hacksaw

Sequence of operations :

1. Checking 2. Rough filling 3. Marking

4. Punching 5. Sawing 6. Rough Filling
7. Finish Filling

Working steps :

8. The raw material is checked for its size 50*50*5 mm after deburring.
9. A given pieces are fixed rigidly on the vice separately and all edges are filed using flat
file so that they are at right angles.
10. Then chalk is applied uniformly on the surface of the work pieces.
11. The work piece is marked to given dimensions as per drawing with reference to the
datum using surface plate and vernier height gauge.
12. Now using dot punch, dots are punched along the marked line.
13. Using hacksaw frame, the unwanted portions are removed.
14. Cutting edges are filed by half round and triangular files.
15. Finally the assembly is checked for the required class of fit.

Result :

Thus the required V- Joint is obtained from the given work piece.
 APPLICATIONS
PLUMBING
 Household piping.
 Toiletries
 Sewages
CARPENTRY
 Wooden door
 Furniture
 Roof

WELDING
 In reservoir tank, boiler and pressure vessel fabrications
 Ship building
 Pipes and pen stock joining
 Building and bridge construction
 Automotive and air craft industry

SHEET METAL
 Car Bodies,
 Airplane Wings,
 Medical Tables,
 Roofs For Building
 Many Other Things
 Railway equipment
LATHE
 Car spare parts,
 Railway equipment
 Machine parts.
 VIVA VOCE QUESTIONS
WELDING

o What iswelding?
o Name the different types ofwelding.
o Explain the principle of arcwelding.
o What is gaswelding?
o Name the different types of flames in gaswelding.
o What is oxidizingflame?
o What is neutralflame?
o What is carburizingflame?
o Name the various parts of gas weldingequipment.
o Name few types of arcwelding.
o What are the differences between arc welding and gaswelding?
o What is meant by filler rod inwelding?
o List out the safety equipments used inwelding.
o What are the advantages of arcwelding?
o What are the disadvantages of arcwelding?
o List out various applications ofwelding.
o What are the different types of joints used inwelding?
o Differentiate butt joint from lapjoint.
o What is cornerjoint?
o What is the use ofgoggles?
o What is the function of flux inwelding?
o What is calledslag?
o What is the use of chippinghammer?
o List some of the safety measures to be taken inwelding.
o Name the gases used in gaswelding.
LATHE
o What is the use oflathe?
o What is feed, speed and depth of cut inlathe?
o Name the holding device inlathe.
o What is called livecentre?
o What is called deadcentre?
o List out various parts of alathe.
o What is headstock?
 o What is tailstock?
o What is the use ofcarriage?
o What is the use of crossslide?
o What is the use of compoundrest?
o List out various latheoperations.
o Differentiate turning from facingoperation.
o What is the use ofchamfering?
o What is the use ofknurling?
o Explain the functions of feed screw and lead screw inlathe.
o How the drilling operation can be carried out in alathe?
o What is step turning and taperturning?
o What is the use of drillingmachine?
o What are the different types of drillingmachines?

SHEET METAL
o What is sheet metalwork?

o Write down any four sheet metalcharacteristics

o What is meant byclearance?

o What isstretching?

o Define the term springback

o How force exerted on the form block iscalculated

o What are the formability testmethods?

o What is super plasticity ofmetals?

o What is metal spinningprocess?

o What is sheet metal?