EPL_Manual_Full

DEPARTMENT OF MECHANICAL ENGINEERING
LABORATORY MANUAL CUM OBSERVATION
GE3271-ENGINEERING PRACTICES LABORATORY

II – Semester (R-2021)
Prepared by
DEPARTMENT OF MECHANICAL ENGINEERING
KIOT / MECH / EP LAB (CIVIL & MECHANICAL)
NAME : ___________________
ROLL NO : ______________________
REG. NO : ______________________
DEPT : ______________________
YEAR/SEC : ______________________
Manual Cum Observation

Vision and Mission of the Institute
Vision of the Institute

 To be a world class institution to impart value and need based professional
education to the aspiring youth and carving them into disciplined world class
professional who have the quest for excellence, achievement orientation and social
responsibilities.
Mission of the Institute
To promote academic growth by offering state-of-art undergraduate, postgraduate
A and doctoral programs and to generate new knowledge by engaging in cutting –
edge research
To nurture talent, entrepreneurship, all-round personality and value system
B
among the students and to foster competitiveness among students
To undertake collaborative projects which offer opportunities for long-term
C
interaction with academia and industry
To pursue global standards of excellence in all our endeavors namely teaching,
D
research, consultancy, continuing education and support functions
Vision and Mission of the Department
Vision
To create competent and industry relevant Mechanical Engineers with professional and
social values to meet global challenges.
Mission
M1 Enabling environment for effective teaching - learning and research to meet global
challenges.
M2 Motivating students to pursue higher education and to excel in competitive
examinations and entrepreneurship.
M3 Establish a continuous Industry Institute Interaction to make the students
employable.
M4 Inculcate the students’ leadership quality with ethical values and spirit of team
work.
Programme Educational Objectives (PEOs)
PEO 1 Graduates will apply the knowledge of Mechanical Engineering to solve real
world Engineering problems.
Graduates will have the required attributes to pursue advanced education in
PEO 2
Engineering and Technology.
PEO 3 Graduates will have the leadership skills with ethical values and team spirit.

PROGRAM OUTCOMES (POs)
Engineering Graduates will be able to:
1. Engineering knowledge: Apply the knowledge of mathematics, science, engineering

fundamentals, and an engineering specialization to the solution of complex engineering
problems.
2. Problem analysis: Identify, formulate, review research literature, and analyze complex
engineering problems reaching substantiated conclusions using first principles of
mathematics, natural sciences, and engineering sciences.
3. Design/development of solutions: Design solutions for complex engineering problems
and design system components or processes that meet the specified needs with appropriate
consideration for the public health and safety, and the cultural, societal, and environmental
considerations.
4. Conduct investigations of complex problems: Use research-based knowledge and
research methods including design of experiments, analysis and interpretation of data, and
synthesis of the information to provide valid conclusions.
5. Modern tool usage: Create, select, and apply appropriate techniques, resources, and
modern engineering and IT tools including prediction and modeling to complex
engineering activities with an understanding of the limitations.
6. The engineer and society: Apply reasoning informed by the contextual knowledge to
assess societal, health, safety, legal and cultural issues and the consequent responsibilities
relevant to the professional engineering practice.
7. Environment and sustainability: Understand the impact of the professional
engineering solutions in societal and environmental contexts, and demonstrate the
knowledge of, and need for sustainable development.
8. Ethics: Apply ethical principles and commit to professional ethics and responsibilities
and norms of the engineering practice.
9. Individual and team work: Function effectively as an individual, and as a member or
leader in diverse teams, and in multidisciplinary settings.
10. Communication: Communicate effectively on complex engineering activities with the
engineering community and 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.
11. Project management and finance: Demonstrate knowledge and understanding of the
engineering and management principles and apply these to one’s own work, as a member
and leader in a team, to manage projects and in multidisciplinary environments.
12. Life-long learning: Recognize the need for, and have the preparation and ability to
engage in independent and life-long learning in the broadest context of technological
change.

Program Specific Outcomes (PSOs)

After the successful completion of B.E. Programme in Mechanical Engineering, the
graduates will able to
Apply the knowledge of Computer Aided Design and Computer Aided
PSO 1 Engineering tools to design and analyze the products and process related to
Mechanical Engineering systems.
Develop the knowledge and skill relevant to Heating Ventilation and Air-
PSO 2 Conditioning industries.
PSO 3 Exhibit the ability to make a product related to Mechanical Engineering and
allied engineering fields.

GE3271 ENGINEERING PRACTICES LABORATORY LTPC
0 0 42
COURSE OBJECTIVES:
The main learning objective of this course is to provide hands on training to the students in:
1. Drawing pipe line plan; laying and connecting various pipe fittings used in common
household plumbing work; Sawing; planing; making joints in wood materials used in
common household wood work.
2. Wiring various electrical joints in common household electrical wire work.
3. 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 equipments; Making a tray out of metal sheet using
sheet metal work.
4. Soldering and testing simple electronic circuits; Assembling and testing simple
electronic components on PCB.
GROUP – A (CIVIL & ELECTRICAL)

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) Preparing 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) Planing and
c) Making joints like T-Joint, Mortise joint and Tenon joint and Dovetail
joint.
Wood Work Study:
a) Studying joints in door panels and wooden furniture
b) Studying common industrial trusses using models.
PART II ELECTRICAL ENGINEERING PRACTICES 15

a) Introduction to switches, fuses, indicators and lamps - Basic switch board
wiring with lamp, fan and three pin socket
b) Staircase wiring
c) Fluorescent Lamp wiring with introduction to CFL and LED types.
d) Energy meter wiring and related calculations/ calibration
e) Study of Iron Box wiring and assembly
f) Study of Fan Regulator (Resistor type and Electronic type using
Diac/Triac/Quadrac)
g) Study of emergency lamp wiring/Water heater
GROUP – B (MECHANICAL AND ELECTRONICS)

PART III MECHANICAL ENGINEERING PRACTICES 15
WELDING WORK:
a) Welding of Butt Joints, Lap Joints, and Tee Joints using arc welding.
b) Practicing gas welding.

BASIC MACHINING WORK:

a) (simple) Turning.
b) (simple) Drilling.
c) (simple) Tapping.
ASSEMBLY WORK:
a) Assembling a centrifugal pump.
b) Assembling a household mixer.
c) Assembling an airconditioner.
SHEET METAL WORK:

a) Making of a square tray
FOUNDRY WORK:
a) Demonstrating basic foundry operations.
PART IV ELECTRONIC ENGINEERING PRACTICES 15
SOLDERING WORK:
a) Soldering simple electronic circuits and checking continuity.
ELECTRONIC ASSEMBLY AND TESTING WORK:

a) Assembling and testing electronic components on a small PCB.
ELECTRONIC EQUIPMENT STUDY:

a) Study an elements of smart phone.
b) Assembly and dismantle of LED TV.
c) Assembly and dismantle of computer/ laptop.
TOTAL: 60 PERIODS
COURSE OUTCOMES:
Upon the completion of this course the students will be able to
1. Draw pipe line plan; lay and connect various pipe fittings used in common household
plumbing work; Saw; plan; make joints in wood materials used in common household
wood work.
2. Wire various electrical joints in common household electrical wire work.
3. Weld various joints in steel plates using arc welding work; Machine various simple
processes like turning, drilling, tapping in parts; Assemble simple mechanical
assembly of common household equipments; Make a tray out of metal sheet using
sheet metal work.
4. Solder and test simple electronic circuits; Assemble and test simple electronic
components on PCB.

COURSE OUTCOMES
1. Draw pipe line plan; lay and connect various pipe fittings used in common household
plumbing work; Saw; plan; make joints in wood materials used in common household
wood work.
2. Wire various electrical joints in common household electrical wire work.
3. Weld various joints in steel plates using arc welding work; Machine various simple
processes like turning, drilling, tapping in parts; Assemble simple mechanical
assembly of common household equipments; Make a tray out of metal sheet using
sheet metal work.
4. Solder and test simple electronic circuits; Assemble and test simple electronic
components on PCB.
CO - PO MAPPING
PO PO PO PO PO PO PO PO PO PO PO PO PSO PSO PSO
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3
3 - 3 1 2 - 2 - 2 1 2 3 2 - 3
3 1 3 1 2 - 1 - 2 1 2 2 2 - 3
3 - 3 1 2 - 1 - 2 1 2 2 2 - 3
3 2 3 1 2 - 1 - 2 1 2 2 1 - 2
1 - LOW 2 - MEDIUM 3 - HIGH

GENERAL INSTRUCTIONS TO THE STUDENTS
1. Wear Shoes and Uniform while entering in to the Laboratory.
2. Remove ID cards while entering in to the Laboratory.
3. Remove all Jewelry that could be caught in moving Machinery. This includes rings
and loose bracelets. Remove necklaces and the like, if not securely restrained.
4. Come with the observations/Manuals and the previous experiments getting signed
from the lab in charge, well in advance. Fail to do so, will not be allowed to do the
next experiment.
5. Loose clothing should be avoided.
6. No short dresses or skirts allowed when working in the Laboratory.
7. Long hair must be tied back.
8. Have a clear idea about the experiment which has to be done at a particular class.
9. Operate the equipment/instruments only in the presence of lab in charge/ lab
technician.
10. Do not use any equipment unless you are trained and permitted.
11. Report any damaged tools, Equipment etc. to the Lab In-charge Lab Technician.
12. Eye protection must be worn if operating any machinery.
13. Always store tools in the appropriate place when not in use.
14. Work benches and machines must always be swept clean after use.
15. Working alone after hours is not permitted.
16. Obtain first aid immediately for any injury. Report all accidents/injuries to the Lab
In-charge/Lab Technician immediately.
17. Medical kits provided in the First – Aid Box. The students can utilize the available
medicines if at all there is any necessity.
18. Don’t use mobile phones in the Laboratory.

CONTENTS
LIST OF EXERCISES
Ex.No. Date Name of the Experiment Page Staff

Marks
No. Signature
PLUMBING
1. Basic pipe connections involving the
fittings like valves, taps and bends
2. Basic pipe connections for wash basin
and water heater and pipe connection
to the suction side of a pump
3. Pipe connections for water supply line
for delivery side of a pump
CARPENTRY (WOOD WORKING)
4. Planning
Tee joint Facing, Plain Turning and
5.
Taper Turning
6. Mortise and Tenon Joint
7. Dovetail Joint
Studying Joints in Door Panels and
8.
Wooden Furniture
Studying Common Industrial Trusses
9.
Using Models
WELDING DRILLING
10. Butt Joint
11. Lab Joint
12. Tee Joint
13. Gas welding Practices

BASIC MACHINING (LATHE)
14. Facing and Plain Turning using lathe
15. Taper Turning
16. Drilling and Tapping
SHEET METAL
17. Making of a Rectangular tray

ASSEMBLY WORK
18. Assembling a centrifugal pump

19. Assembling an air conditioner
20. Assembling a household mixer
DEMONSTRATING OF BASIC FOUNDRY OPERATIONS
Demonstrating on mould preparation
21.
On Gear Pattern

PLUMBING
INTRODUCTION:
Plumbing deals with the laying of a pipeline. A craftsman may be perfectly

proficient with the hammer, saw and other tools, but the faces difficulties with leaking
pipes and overflowing toilets. Many people rush to a plumber on seeking a tripping pipe,
but a person with a little knowledge of the sanitary system can control this problem easily,
saving time and, one with help of few tools.
Plumbing tools:
The tools used by a plumber can be classified as follows
1. Pipe wrench 2. Pipe vice 3. Pipe cutter
4. Hacksaw 5. Dies 6. Files and Rasps
7. Plumb bob
Pipe wrench:
A pipe wrench is used for holding and turning the pipes, rods and machine parts.
Wrenches are classified as follows.1.Fixed wrenches 2. Adjustable wrenches.
Pipe vice:
A pipe vice is fitted on the work bench. This has a set of jaws to grip the pipe and
prevent it from turning while cutting, threading and fitting of bends, couplings etc. The
yoke vice is commonly used in plumbing used in plumbing practice.
1 Manual Cum Observation

Pipe cutter:
The pipe cutter mainly consists of three wheels which are hardened with sharp
cutting edges along their periphery. Of these three wheels, one can be adjusted to any
desired distance to accommodate different size of pipes. After adjusting the cutter on a
pipe, it is around the pipe, so that the cutter wheels cut the pipe along a circle as shown in
fig.
Hack saw:
A hacksaw is used for cutting metal rods, bars, pipes, etc.

Threading dies and taps:
It is used for cutting external thread on pipes. Threads are produced in various
shape and sizes which are used for fitting inside a handle.
Files and rasps:
The file surface is covered with sharp edged teeth and its used for removing metal
by rubbing. A rasp is used for finishing the surface of the work piece.
Plumb bob:
It is used for check the vertical line and made up of steel or brass.
Pipe fittings:
Pipe fittings are made up of wrought iron. The size of pipe fitting is
designated by the size of the pipe on which it fits. Some of the common pipe
fittings are shown in fig.
Coupling:
It is a short a cylindrical sleeve with internal threads throughout. A couplings is

used for joining
Two pipes in a straight and bend where at least one pipe can be turned.
Union:

A union is used for joining two pieces of pipes, where either can be turned. It
consists of three parts, two parts joint can be screwed, in to two pipe ends, and the third on
for tightening called centre part.
Nipple:
A nipple is a short piece of pipe with external threads at both ends. It is used to
make up the required length of a pipe line.
Elbow:
An elbow is to make an angle between adjacent pipes.
Tee:
A tee is a fitting that has one side outlet at a right angle to the run. It is used for a
single outlet branch pipe.
Reducer:
It is used to connect two different sized of pipes
Plug:
It is used to screw on to a threaded opening, for closing it temporarily.
Valves:
Valves are used for regulating the flow of fluid through a pipe. The commonly used
valves in plumbing’s are
1. Gate valve 2.Globe valve
3. Plug valve 4.Check valve 5. Air relief valve.

BASIC PIPE CONNECTIONS INVOLVING THE FITTINGS LIKE VALVES, TAPS AND BENDS

Ex.No: BASIC PIPE CONNECTIONS INVOLVING THE FITTINGS
Date: 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 bend
3. Valves
4. Taps
5. Cast iron pipes of different length
6. Flange
7. Bench vice
WORKING PROCEDURE:
1. Two pipes are taken and they are held in vice and they are connected by using a
flanged joint shown in figure.
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 bend-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 bend-2 for further extension.
6. A horizontal pipe is connected to this bend-2 as shown in figure.
7. Then tap is fitted to the end of the pipe for closing and opening the water supply.
RESULT:

Basic Pipe Connections for Wash Basin and Water Heater and Pipe connection to
the suction side of a pump

BASIC PIPE CONNECTIONS FOR WASH BASIN
AND WATER HEATER AND PIPE CONNECTION TO THE SUCTION SIDE OF A

PUMP
EX.NO:
DATE:
AIM:
To construct a basic pipe connections for wash basin and water heater.
MATERIALS REQUIRED:
1. Plumbing tool kit - 1no

2. Taps - 3nos.
3. Wash basin - 1no
4. Water heater - 1no
5. Elbow - 3nos
6. Tee - 2nos
7. Gate valve - 1no
8. PVC pipe - required length
9. Pump - Suction and delivery 01
WORKING PROCEDURE:
1. Study the given diagram

2. Mark the locations of wash basin, water heater and taps.
3. Fix the wash basin, water heater.
4. Make the tee and elbow connections in the main pipeline to connect it to the wash
basin, water heater and taps.
5. Fix the gate valve, near the water tank.
6. Connect all pipe fittings as per diagram.
7. The water tank as filled with water and the gate valve was opened slowly to supply
water into pipeline.
8. The taps were opened to check its functions
RESULT:


EX.NO: PIPE CONNECTIONS FOR WATER SUPPLY LINE FO DELIVERY OF A PUMP

DATE:
AIM:
To prepare plumbing layout sketch for give supply line.
TOOLS REQUIRED:
1. Screw driver
2. Hammer
3. Pipe wrench
4. Measuring tape
5. Hacksaw
COMPONENTS REQUIRED:
1. G.I. pipe
2. PVC pipe
3. Tee joint
4. Elbow
5. Reducer
6. Adaptor
7. Tap
8. Ball valve
WORKING PROCEDURE:
1. Locate the water tank at higher elevation compared to the exit/point to get the
pressure difference throughout the pipe distribution line.
2. Find out the total space available for the piping network.
3. Based on the space availability and the volume flow rate of water and distance,
estimate the size and length of pipe required.
4. Fix the reducer wherever the reduction in pipe size is needed.
5. Provide all necessary valves in the piping network to control over the water flow.
6. Fix all pipes in such a way that there should not be any misalignment problems.
7. Fix the tap at the end user point to control the flow.
8. Finally checkup the plumbing layout to ensure that there is no leakage in pipeline.
RESULT:

CARPENTRY
INTRODUCTION:
Carpentry may be designed as the process of making wooden articles and

components such as roots, floors, partitions, doors and windows. Carpentry involves
cutting, shaping and fastening wood and other materials together to produce a finished
product. Preparation of joints is one of the important operations in wood work. Joinery
denotes connecting the wooden parts using different points such as lap joints, mortise and
teman joints, bridle joints, etc.
Carpentry Tools:
Carpentry tools are used to produce components to an exact size.
The types of carpentry tools are as follows.
1. Marking tools 2.Measuring tools 3. Holding tools
4. Cutting tools 5.Planning tools 6.Boring tools
7. Striking tools 8.Miscellaneous tools
Marking tools:
It is used to marking lines parallel to the edges of a wooden piece. It consists of a
square wooden stem with a sliding wooden stock on it. On the stem, a marking pin is
attached which is made up of steel. This stem is provided with a steel nail to scratch the
surface of the work. It consists of two pins; the distance between the pins is adjustable. It is
used to draw parallel lines on the stock.
Measuring tools:
The carpentry measuring tools are classified as follows
1. Steel tape 2.Steel rule 3.Calipers
Steel tapes and steel rules are mainly used for measuring short and lengths in millimeters.
A try square is used for testing squareness and marking of joints.
A mitre square is used for marking and measuring an angle of 45 degree.
A bevel square is used for marking and listing angles between 0 degree to 180 degree.
Calipers are used for the precision measurement of cylindrical surface. Inside calipers are
used for measuring outside diameter and outside calipers are used to measure inner
diameter of a pipe
Holding tools
The carpentry holding tools are shown in fig.
Saws:
A saw is used to cut wood into pieces. There is different type of saws, designed to
suit different purpose. A saw is specified by the length of its tooled edge. The following
saws are used in the carpentry section.
Boring Tools:
Boring tools are used to make holes in wood .Common types of boring tools are as
follows.
1. Bradawl
2. Gimlet
3. Brace
4. Bit and drill

A brace bolds and turns the bit and boring of a hole is obtained. A brace having two jaws
is used for holing the bit in one end. It has two types, namely ratchet brace and wheel
brace. A bradawl and a gimlet are used for boring small holes. These tools are hand
operated.
Striking Tools:
CAPPENTRY MACHINES:
Carpentry machines are used for large production of components. The commonly
used carpentry machines are described below.

Wood Turning Lathe:
A wood turning lathe is the most important machines used in a carpentry shop. It is
used for producing cylindrical, spherical and tapered shape products.
A wood working lathe consists of a cost iron body, main motor, cone pulley
system, spindle, tool post, head stock, live and dead centers and speed control devices.

PLANNING

PLANNING
EX.NO:
DATE :
AIM
To plane the given work piece for the required shape
MATERIAL REQUIRED
Soft wood of size 305x55x55 mm.
TOOLS REQUIRED
1. Jackplane
2. Bench vice
3. Try square
4. Marking gauge
5. Steel rule
6. Tenon saw
7. Rip saw
8. Firmer chisel
9. Mallet
PROCEDURE
1. The given workpiece is firmly clamped in the bench vice and any two adjacent
surfaces are planed to get right angles using the jack plane.
2. Using the try square, the right angles of planed faces are checked.
3. Now the other two surfaces are planed to get smooth surface.
4. Based on the planed surfaces, the markings are made on the two sides by using
marking gauge.
5. After marking, the workpiece is planed such that it should have required
dimensions.
6. Finally, the finished job is checked for required size using the steel rule and try
square.
RESULT:

TEE JOINT

EX:NO: TEE JOINT
DATE :
AIM:
To make a T-joint from the given wooden piece for the desired dimensions.
MATERIALS SUPPLIED:
A wooden piece of size 300X40X40 mm.
TOOLS REQUIRED:
1. Jack plane
2. Try square
3. Marking gauge
4. Tenon saw
5. Carpentry vice
6. Steel rule
7. Firmer chisel
8. mallet
9. rip saw
SEQUENCE OF OPERATIONS:
1. Rough planning
2. Marking
3. Cutting (or) Sawing
4. Chiseling
5. Finish planning
WORKING PROCEDURE:
1. The given job is checked to ensure the correct size.

2. The job is firmly clamped in the carpentry vice and any 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. All the four sides of the wooden pieces are planned to get the smoother and
finished surfaces.
5. The job is cut into two halves using Rip Saw then proper marking is done for
the T-joint on the two pieces using steel rule and marking gauge.
6. One half is taken. Using tenon saw and former chisel the unwanted portions are
removed as per the drawing.
7. One half is taken. Using tenon saw and firmer chisel the unwanted portions are
removed as per the drawing.
8. The above procedure is repeated for the other half of the work piece.
9. Jack plane is used to plane the other two faces up to the marked portion. 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:

MORTISE AND TENON JOINT

EX.NO: MORTISE AND TENON JOINT
DATE:
AIM:
To make a mortise and tenon joint from the given wooden piece for the given dimensions.
MATERIAL REQUIRED:
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. Tenon saw 8. Mortise chisel
9. Mallet
SEQUENCE OF OPERATIONS:
1. Rough planning 2. Marking

3. Cutting (or) Sawing 4. Chiselling
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 jackplane 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 finishedsurface.
5. Now the job is cut into two halves using rip saw then proper
marking is done for mortiseand 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 removedas 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 steelrule.
RESULT:

DOVETAIL JOINT

EX:NO: DOVETAIL JOINT
DATE:
AIM:
To make a dovetail halving joint from the given workpiece.
MATERIALS REQUIRED:
Soft wood of size 300x50x50 mm.
TOOLS REQUIRED:
1. Jackplane
2. Bench vice
3. Try square
4. Mortise gauge
5. Mallet
6. Firmer chiesel
PROCEDURE:
1. The given workpiece is firmly clamped in the Bench vice and any two adjacent
surfaces are planed to get right angles using the jack plane.
2. Using the try square, the right angles of planed faces are checked.
3. Now the other two surfaces are planed to get smooth surface.
4. The workpiece is cut into two pieces by using the rip saw.
5. Mark the dimensions for the dovetail joint on the two pieces using the steel ruleand
marking gauge.
6. Remove the unwanted portions as per the drawing and assemble to check
proper fitting.
RESULT:

EX.NO: STUDYING JOINTS IN DOOR PANELS AND WOODEN FURNITURE
DATE:
INTRODUCTION
Wood working involves connecting two wooden work pieces together. While glue or
adhesives may sometimes be used, most wooden work pieces are connected via a joint. A
joint is a natural connection where the ends of two wooden work pieces meet. The
traditional method is Full Through Mortice and Tenon Joints which are then wedged top
and bottom of each Tenon and glued in position, the Tenon goes through to the door edges,
this has always been perceived as the best joint. Joints are an important component of a
woodworking project. Wood joinery allows cabinetmakers to assemble different
components of a piece together into an aesthetically pleasing and structurally sound whole,
and is crucial to producing quality work.
TYPES OF DOOR JOINTS
1. Butt joint
A butt joint is the most basic type of wood joint. Two different wood pieces simply sit side
by side, with the butt of one workpiece adjacent to the butt of another workpiece. Unlike
other wood joints, the two pieces are not shaped or carved to lock into each other,
and mechanical fasteners are typically used to hold them together.
2. Miter joint
“Miter” is another word for an angled cut—and the saw that makes the cut. In the term
“miter joint,” it refers to two 45-degree angled cuts where the pieces of wood adjoin to
create a 90-degree angle. While the most common miter joints are made of 45-degree
angles, miter butt joints can be cut at any range of angles. For example, if you want to
build an octagonal-shaped structure, then you would cut each miter to 22.5 degrees.
3. Coped joint
A coped joint is a variation on the miter joint that lays underneath the miter joint. It
addresses the reality that the corners of many rooms do not in fact meet at 90-degree
angles. Beneath the exterior (visible) miter joint, the two pieces of wood that make up a
coped joint are carved like puzzle pieces to form an irregular but custom fit.
4. Tongue-and-groove joint
These joints consist of a tongue, or a ridge, on one piece of wood and a groove, or channel,
on the other. The tongue slides into the groove to create a strong joint. These joints are
commonly used for elements that lie flat on a surface, such as hardwood floors. Most
contractors don’t have to worry about creating them as flooring materials typically arrive
with the joints already cut, and the only challenge is sliding the elements together.
5. Mortise joint
Mortise joints are also known as mortise-and-tenon joints. While they look like butt joints
from the outside, a protruding element is carved into one piece (the tenon) which slides
into a corresponding recess (the mortise) in the other piece. With the increased gluing
surface area where the two wood pieces are joined, it is a significantly stronger—and more
elegant—alternative to a butt joint.
6. Half-Lap joint
With a half-lap joint, the ends of the two adjoining pieces of wood are reduced to half their
thickness at the point where they overlap. There are stronger joints, but a half-lap has an
aesthetic appeal over butt joints because they maintain a uniform thickness with the rest of
the structure.
7. Dado joint
The dado joint gets its name from the Italian word for a die or plinth. It resembles a groove
a trench cut into one piece of wood parallel to the grain that another piece of wood slides
into. But unlike a groove, a dado runs perpendicular to the grain.
8. Rabbet joint
Another joint with an unusual name (in this case from a Middle French word meaning “to
force down”), a rabbet joint is related to the dado joint and consists of an open-sided
channel along the end of a piece of wood. It often matches a corresponding cut in the piece
it is paired with to create a double rabbet joint.
9. Pocket-hole joint
Pocket-hole joints rely on fasteners, namely pocket-hole screws. They are effectively a
butt joint with a small pocket-hole drilled into one of the pieces of wood. The two pieces
are then attached with a self-tapping pocket-hole screw. Pocket-hole joints are strong and
easy to make. Their downside is that they are less visually appealing than other joints
making them better for temporary uses, or places where the joint will not be visible
10. Dowel joint

Because dowel joints are more difficult to create than pocket hole joints, they are less
popular now than they once were. To make a dowel joint, drill holes where the two pieces
meet, place a small amount of glue in them, insert the dowels, and then clamp the pieces
together.Dowel joints serve the same purpose as pocket-hole joints but are more
aesthetically appealing, and wooden dowels offer greater strength than nails or screws.

11. Biscuit Joint

This unusual joint is formed by carving two curved grooves into two pieces of wood, and
then joining them with a wood biscuit that is glued into place. Biscuit joints are typically
used with sheet goods like plywood and particle board but can also be used with solid
panels of different types of wood. The advantage of this joint is that it is entirely invisible
creating a perfectly flush surface.
12. Dovetail Joint
A dovetail joint is of the most distinctive joints and is recognized as a sign of expert
craftsmanship. They are made of a series of interlocking pins and tails in trapezoidal
shapes. They were long covered by veneers, but today they are typically left visible in
appreciation of the skill involved in creating them. Their dominant characteristic is their
resistance to being pulled apart so they are most commonly used in constructing drawers.
A box joint, which lacks the trapezoidal shape, is a dovetail variation that is easier to
construct.
RESULT:

EX.NO: STUDYING COMMON INDUSTRIAL TRUSSES USING

DATE: MODELS
INTRODUCTION
Trusses are simply defined as triangulation of members to make the stabilized structure.
Triangulation is the stable configuration mathematically. Generally, a truss has the
members called as top chord, bottom chord, vertical chord and diagonal chord. The main
functions of the trusses are In engineering, a truss is a structure that "consists of two-force
members only, where the members are organized so that the assemblage as a whole
behaves as a single object". A "two-force member" is a structural component where force
is applied to only two points.
TYPES OF TRUSSES:
Simple truss – indicates a single triangular truss. These trusses are most often used
as the roof trusses.
Planar truss – as the name implies it is a two dimensional truss. If all the members and
the nodes are in a planar surface, then this truss is a planar truss.
Space frame truss – Contrast to planar truss, the members and the nodes are located in
the three dimensional space. Electrical and telecom towers are the one of the simplest
example that we are seeing in the day to day life.
FORMS OF TRUSSES:
1. Pratt truss
A Pratt Truss has been used over the past two centuries as an effective truss method. It is
commonly used in long span buildings which range from 20 to 100 m in span. The vertical
members are in compression, whilst the diagonal members are in tension. This simplifies
and produces a more efficient design since the steel in the diagonal members (in tension)
can be reduced.
2. Warren truss
The Warren truss consists of longitudinal members joined only by angled cross-members,
forming alternately inverted Equilateral triangle-shaped spaces along its length. This gives
a pure truss: each individual strut, beam, or tie is only subject to tension or compression
forces, there are no bending or torsional forces on them
3. North light truss

One of the oldest and economical methods of covering large areas is the North Light.
North light trusses are traditionally used for short roof spans in industrial workshop-type
buildings.
4. Saw-tooth Truss
A variation of the North light truss is the saw-tooth truss which is used in multi-bay buildings.
Similar to the North light truss, it is typical to include a truss of the vertical face running
perpendicular to the plane of the saw-tooth truss.

Examples of Truss:
RESULT :

WELDING
INTRODUCTION:
Welding is a process of joining two similar or dissimilar metals by the application
of heat with or without application of pressure and addition of filler material. The welding
is extensively used in manufacturing industry, construction industry and maintenance
work, replacing riveting and bolting, to a greater extent.
TYPES OF WELDING
1. Electric arc welding
2. Thermite welding
3. Resistance welding
4. Friction welding and
5. Gas welding
However only electric arc welding is discussed here. In this process, the work pieces
are melted along a common edge, to their melting point and then a filler metal is
introduced to form the joint on solidification. The materials to be welded must be free
from rust, scale oil or other impurities, so as to obtain a sound weld.
Electric Arc Welding:
In arc welding, the heat required for joining the metals is obtained from an electric
arc. Transformers or motor generator sets are used as arc welding machines. These
machines supply high electric currents at low voltages and an electrode is used to produce
the necessary arc. The coated electrode serves as the filler rod and arc melts the surfaces so
that the metals to be joined are actually fused together. In addition to the welding machine,
the following accessories and tools are needed for carrying out the welding work. The
given figure shows the principle of Arc Welding using a transformer.
Plastic welding
Forge welding
Resistance welding
Thermit welding
Welded Joints:
The relative positions of the two pieces being joined determine the type of joint. The
following joints are commonly used in fusion welding.

The Butt Joint: It is used to join the ends or edges of two plates or surfaces located
approximately in the same plane with each other.
The Lap Joint: It is used to join two overlapping plates so that the edge of each plate is
welded to the surface of the other.
The T-Joint: It is used to weld two plates or sections whose surfaces are at approximately
right angles to each other.
The Corner Joint: It is used to join the edges of two sheets or plates whose surfaces are at
the angle of approximately 90 degree to each other. It is common in the construction of
boxes, tanks, frames etc.
Preparation of Work:
Before welding, the work pieces must be thoroughly cleaned of rust, scale or other foreign
material. Thin pieces of metal are generally welded without beveling the edges. However,
thick work pieces should be beveled to ensure adequate penetration and fusion of all parts
of the weld. But, in either case, the parts to be welded must separate slightly to allow better
penetration of the weld. Different edge preparation is particularly used in fusion welding
process for welding butt joints.
These are: square Single-V, Double-V, Single-U and Double-U. The preparation of edges
depends upon the thickness of metal being welded.
Instructions:
General:
1. Always weld in a well-ventilated place. Fumes given off from welding are
unpleasant and in some cases may be injurious, particularly from galvanized or
zinc coated parts.
2. Do not weld around combustible or inflammable materials, where sparks may
cause a fire.
3. Never weld, containers, which have been used for storing gasoline, oil or similar
materials, without first having them thoroughly cleaned.
Arc welding:
1. Check the welding machine to make sure that it is properly grounded and that all
leads are properly insulated.
2. Never look at the arc with a naked eye. The arc can burn your eyes severely.
Always use a face shield while welding.
3. Prevent welding cables from coming in contact with hot metal, water oil or grease.
Avoid dragging the cables around sharp corners.
4. Ensure proper insulation of the cables and check for openings.
5. Always wear the safety hand gloves, apron and leather shoes.
6. Always turn-off the machine when leaving the work
7. Apply eye drops after welding is over for the day to relieve the strain on the eyes.
8. While welding, stand on dry footing and keep the body insulated from the
electrode, any bare parts of the electrode holder and the work
Safety Precautions for Arc welding:
1. Check the ground connection and insulation of all the wires.
2. The arc should be observed only through a shield or goggles.
3. Always wear the safety hand gloves, apron and leather shoes.
4. Use proper current capacity cables.
5. Switch –off the welding machine when leaving from the work.
6. Remove the slag by chipping hammer only.

7. To relieve strain or irritation on the eyes, eye drops may be applied.

Safety Precautions for Gas welding:
1. As far as possible use a spark lighter for igniting the flame.
2. Oil, petrol, gas and other explosive materials should be kept away from the welding
location.
3. Goggle, face shields and gloves must be used while welding.
4. Secure cylinders in use, against falling, which may knock-off the valve.
5. Any repairable parts of the welding equipment should be sent to manufacturer for
necessary repairs.
Advantages of arc welding
1. Flux shielded manual metal arc welding is the simplest of all the arc welding
process.
2. The equipment can be portable and the cost is fairly low.
3. This process finds innumerable applications, because of the availability of a wide
variety of electrodes.
4. A big range of metals and their alloys can be welded.
Disadvantages of arc welding
1. Because of the limited length of each electrode and brittle flux coating on it,
Mechanization is difficult.
2. In welding long joints, as one electrode finishes, the weld is to be progressed with
the next electrode. Unless properly cared, a defect may occur at the place where
welding is
restarted with the new electrode.
3. It cannot be used to weld metal thickness less than 1.6 mm.
Gas Welding or Oxy-Acetylene Welding:
In oxy-acetylene welding oxygen and acetylene are the two gases used for
producing flame. Oxygen is mainly used for supporting the combustion intensity. The
oxygen and acetylene under high pressure in cylinders which are fitted with pressure
regulator. Each cylinder is connected to the blowpipe by flexible hoses. The oxygen
cylinders are painted block and acetylene cylinders are painted maroon.
When acetylene is mixed with oxygen in correct proportions in the welding torch,
ignition is takes place. The flame resulting at the tip of the torch is sufficient enough to
melt and the parent material .The flame temperature is about 3200ºC.The filler metal rod is
generally added to the molten metal pool to build up the seam for greater strength.
Types of flames:
1 .Neutral Flame (Oxygen, Acetylene in equal proportions)
2. Oxidizing Flame (excess of Oxygen)
3. Reducing Flame (excess of Acetylene)
Neutral Flame
A neutral flame is produced when approximately equal volumes of oxygen and
acetylene are mixed in the welding torch and burnt at the torch tip. The temperature of the
neutral flame is of the order of about 3260ºC. The flame has inner cone which is light blue
in color. The neutral flame is used for welding of mild steel, copper, aluminum, cast iron,
etc.
Oxidizing Flame
If the volume of the oxygen supplied to the neutral flame is increased, then
resulting flame will be oxidizing flame. The temperature of oxidizing flame is of the order
of about 3482ºC. Normally the outer flame envelope is much shorter. It has very small
white inner cone. This flame is used to weld copper-base metals, zinc-base metals.
Reducing Flame (Carburizing Flame)

If the volume of the oxygen supplied to the neutral flame is reduced, the resulting
flame will be a reducing flame. In this case, flame is recognized by acetylene feather
which exists between the inner cone and outer envelope. The outer flame envelope is
longer than that of the neutral flame and is usually much brighter in color. It has an
appropriate temperature of 3038ºC. In this type, flames are used to weld the high-carbon
steel, non-ferrous alloys, zinc bearing alloys.


BUTT JOINT
Welded Joint Representation

EX.NO: BUTT JOINT

DATE:
AIM:
To make a butt joint using arc welding on the given work pieces.
MATERIALS REQUIRED:
Mild Steel plate of size 50 X 45 X 3 mm – 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 OPERATION:
1. Edge preparation (Removal of rust, scale etc.,)

2. Tacking
3. Welding
4. Cooling
5. Chipping
6. Cleaning

WORKING PROCEDURE
1. The work piece must be thoroughly cleaned to remove the rust, scale and other
foreign materials.
2. Then the given work piece are placed on the table in such a way that two work
piece 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 the work pieces.
4. Now the welding current output may be adjusted.
5. When current is passed, arc is produced between the electrodes and work pieces.
6. Now set the two work pieces in correct portion and maintain the gap 3mm and tack
at both ends of the work piece as show in figure.
7. Then the welding is carried on throughout the length
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

LAP JOINT

EX.NO: LAP JOINT
DATE:
AIM:
To make a Lap joint using arc welding on the given work pieces.
MATERIALS REQUIRED:
Mild steel plate of size 50X 45 X 3 mm – 2 Nos.
TOOLS REQUIRED:

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

2. Tacking
3. Welding
4. Cooling
5. Chipping
6. Cleaning

WORKING PROCEDURE:
foreign materials.
2. Then the given workpiece are placed on the table in such a way that two workpiece
are overlapped one over another as shown in figure.
at both ends of the workpiece as show in figure.
the workpiece to cool.
10. Finally using wire brush, welded portions are cleaned.
RESULT:

TEE-JOINT

EX.NO: TEE-JOINT
DATE:
AIM:
To make a T-joint using arc welding on the given work pieces.
MATERIALS REQUIRED:
Mild steel plate of size 50 X 45 X 3 mm – 2 Nos.
TOOLS REQUIRED:

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 OPERATION

2. Tacking
3. Welding
4. Cooling
5. Chipping
6. Cleaning

WORKING PROCEDURE
foreign materials.
2. Then the given workpiece are placed on the table in such a way that two workpiece
are brought closed to each other “T” shape as shown in figure.
at both ends of the work piece as show in figure.
the work piece to cool.
10. Finally using wire brush, welded portions are cleaned.
RESULT:

GAS WELDING
All dimensions are in mm

EX.NO: GAS WELDING

DATE :
AIM:
To perform the gas welding operation on the given metal strip.
MATERIAL REQUIRED:
A mild steel (MS) strip
TOOLS REQUIRED:
1. Flat file
2. Steel Rule
3. Try-square
4. Chipping Hammer
5. Hand Shield
6. Lever
7. Tongs
PROCEDURE:
1. The given workpieces are cleaned and positioned properly on the welding table.
2. Acetylene and oxygen cylinder valves are opened followed by acetylene torch
valve.
3. Light tip of the torch using a lighter, keeping its tip away from the cylinder.
4. Oxygen and acetylene torch valves are adjusted to obtain the required flame.
5. Tack-welding is done between the plate and inner cone of the flame.
6. Starting from one end, the welding torch and filler rod are moved along the line
of weld. The filler metal is added to the joint as welding progresses.
7. After completing gas welding, the torch acetylene valve is closed first and then
the torch oxygen valve.
8. The acetylene cylinder valve closed first and then oxygen cylinder valve.
RESULT:

LATHE

STUDY OF LATHE
BASIC MACHINING
Basic machining is the process of making the engineering components as per the
specifications. This is being carryout on a metal work piece by removing unwanted
portions, called metal removal process. Many machines are available under the metal
removal processes. The typical machines are lathe, Drilling machine, Milling Machine,
Shaping Machine, Planning Machine, Slotting Machine, Hobbing Machine, Special
Purpose Machine, etc.,
LATHE
Lathe is generally stated as the father of machine tools. It is defined as a machine in

which the work piece or job is turned or rotated and a sharp tool is made to come in
contact with it, as a result of which some material is removed from the work piece.
In a lathe the work piece is held firmly and rotated about the job’s axis against a
cutting tool. The cutting tool is generally a single point cutting tool, mostly; it is made of
high Speed Steel (HSS). When the work piece is rotated against the tool, it removes the
material which is unwanted. Lathes can be employed in metal removal process mainly on
cylindrical shaped work pieces. The main features of the lathe is to perform turning,
facing, thread cutting etc… it can also perform operations like drilling, boring, gear
cutting, hence it can be called a versatile machine tool.
PARTS OF A LATHE AND THEIR FUNCTIONS:
A schematic diagram of a centre lathe is shown in the figure that shows the various
parts of the lathe. The main parts of the lathe are
 Bed
 Head stock
 Tail stock
 Carriage
 Lead screw

 Feed Rod
OPERATIONS OF A LATHE
Chamfering tool
COUNTER BORING CHAMFERING

OPERATIONS OF A LATHE
In a lathe, various kinds of operations can be done according to the requirement
since it is a universal machine tool. These different operations are performed by holding
the work piece in the chuck and rotation it against the cutting tool. The normal operation in
lathe are tuning, facing, step turning, eccentric turning, drilling, boring, reaming, knurling,
scroll cutting, thread cutting, etc.,
Turning
Turning is an operation of reducing the diameter of a cylindrical work piece to the
desired dimension. The work piece is held in a chuck or between centres. The work piece
is rotated about the axis of the lathe. The tool is made to move parallel to the lathe axis.
When the tool makes a contact with the work piece, the material gets removed. If the tool
feed rate is fast and if the depth of cut is more than 6mm, then it is termed as rough
turning. If the tool feed rate is low and the depth of cut is less than 1mm then the turning is
called finish turning.
Facing
Facing is an operation of machining the end face of the work piece to make it flat.
Since only the face of work piece is machined this process is called facing. It is also called
squaring. Here, the tool is fed perpendicular to the axis of the lathe against the rotation of
work piece.
Grooving & Parting off

The groove is made on the work piece with the help of grooving tool. This is
usually done at the end of the threaded portions. This process is otherwise called recessing,
under-cutting or necking. Parting off is similar to grooving. But here the tool is fed to a
depth till the work piece is cut off or parted off. Parting off is performed by using a parting
tool, which is similar to the grooving tool.
Forming
It is a process in which concave, convex or irregular shapes are formed on the work
piece using form tools. The shape of the tool depends on the shape of the form required on
the work piece. If a concave shape is to be formed on the work piece, then the tool will be
of convex shape.
Knurling
Knurling is an operation that is done to give good gripping surface on the work
piece. It can also be used to increase the diameter slightly. Knurling is performed using
knurling tool. The knurling tool has one or two hardened steel rollers, which have patterns
over their surface when pressed against the work piece, product the pattern on the surface
of the work piece.

The rollers will have teeth cut on the cylindrical surfaces. The teeth may be fine, medium
and coarse.
Drilling
Drilling is the process of producing a cylindrical hole in the work piece. For the
drilling process to be carried on the lathe, the work piece is fixed to the chuck and is
rotated. Now the drill bit, which is the tool for drilling, is fit to the tail stock. When the
drill bit is fed into the rotations work piece using the hand wheel, the drill removes the
material and performs the drill.
Boring
Boring is the process of increasing the diameter of hole which may be produced by
drilling throughout the entire length of the hole.
Reaming
Reaming is the operation of finishing a drilled or bored hole to the accurate size.
The tool used for reaming is known as reamer which has multiple cutting edges. Similar to
that of drill bit, the reaming tool is also fixed to the tail stock.
Counter boring
It is a process of increasing the inner diameter of a hole through a certain distance

from one end instead of enlarging the whole drilled surface.
Chamfering
Chamfering is the operation of beveling or turning a slope at the extreme end of the
work piece. This operation is used to remove the burrs and to protect the end of the work
piece from being damaged.

Taper Turning
A taper is defined as the uniform change in the diameter of a work piece along its
length. A taper can also be produced in a lathe using the following methods.
Form tool method:
In this method, the tool itself has the required taper angle in its tip. Even though the
tool is fed perpendicularly to the lathe axis, since the tool has a taper, a taper is produced
on the work piece. This method is the simplest method of taper turning.
Compound rest method:
In this method the compound rest, which supports the tool, is rotated to an angle
equal to half of the taper angle. Then the tool is fed by rotating the hand wheel in the
compound rest. Since the axis of rotation of the work piece and the axis of feeding of the
tool are at some angle, the taper is produced.
Taper turning attachments:
This attachment is fit on the other side of the lathe, opposite to the carriage. In this
type of taper turning method, both live and dead centers are kept in alignment. So the same
taper may be turned on different pieces of varying length.
Thread cutting
Thread cutting is the formation of helical groove on a cylindrical surface. This is

made possible by rotating the work piece against the linearly moving tool at the same time.
The tool used for thread cutting operation is threading tool. When the lead screw is
engaged using half-nut, the tool moves through a distance equal to one pitch of the thread
for one revolution of the work piece. Thus the thread is produced on the work piece using
this operation.

TAPER TURNING


EX.NO: FACING AND PLAINING TURNING USING LATHE
DATE:
AIM:
To obtain the required shape and size of the work piece by turning and facing
operations.
MATERIALS SUPPLIED:
Cylindrical work piece of diameter 30 mm and length 107 mm mild steel rod.
TOOLS REQUIRED:
1. Lathe
2. Cutting tool
3. Vernier caliper
4. Try square
5. Scriber
6. Vernier height gauge
1. Checking
2. Work piece setting
3. Tool Setting
4. Facing
5. Turning
PROCEDURE:
1. The given work piece is checked for its dimensions.

2. The work piece is held in the chuck. Chuck key is used to tighten the job firmly,
ensuring centering of work piece.
3. The single point cutting tool is held in the tool post and tightens the nuts using
spanner.
4. Facing is done with cutting tool moving from the center of work piece towards
outside. It is done until the required diameter 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. Finally, the dimensions of work piece are again checked.
RESULT:

TAPER TURNING
All dimensions are in mm

EX. NO:
DATE :
TAPER TURNING
AIM:
To make a taper turning on the given work piece as per the required dimensions
using the Lathe.
MATERIALS REQUIRED:
MS rod of Size mm.
TOOLS REQUIRED:
1. Single point cutting tool (HSS)

2. Vernier Caliper
3. Chuck Key
4. Surface Gauge
5. Tool post key
PROCEDURE:
1. The dimensions of the given work piece were checked, as per the requirement.
2. The work piece is fixed on the lathe chuck. It is centered by surface gauge, if
the Lathe is fitted with four jaw chuck.
3. The cutting tool is fixed on the tool post and the center height is checked.
4. The cutting tool is tilted by 45° for facing operation.
5. Then the cutting tool is tilted perpendicular to the work piece for turning
operation after getting the required length.
6. Then the tool post is tilted according to the required angle of taper and the
turning operation is repeated until getting the accurate dimension by giving the
gradual depth of cut and feed.
7. The dimensions are checked using Vernier Caliper, as per the specification.
RESULT:

DRILLING MACHINE
INTRODUCTION:
Holes in the work piece are necessary for many purposes such as fastening the
object with nuts and bolts, Screws, for fixing assembly purpose so it is necessary to make
holes in the work piece. So the Drilling is a process of making a hole in the blank work
piece, or enlarging the existing hole. The Machine which is used for this purpose is called
as drilling machine. It consist of spindle which is rotated by the motor and transmitting
mechanism, The spindle in turn rotates the drilling tool called as drill, as drill is press fitted
into the spindle. Drill is fed into work by feed mechanism. The work piece is fixed on the
table, as the drill fed into the workpiece, the hole is created by removing material in the
form of chips. All the components are supported by frame. Cutting fluid is commonly used
to cool the drill bit, increase tool life, increase speeds and feeds, increase the surface finish,
and aid in ejecting chips.

Parts of Drilling machine and their function:
Base: base is the lowest horizontal part which supports the entire structure of drilling
machine. It is made up of cast iron because cast iron absorbs vibrations. So the vibrations
transmitted to foundation get reduced.
Work table: It is mounted on column which supports the work. Generally it has two types
of motions.
a. It can swing about column
b. it can move up and down. This facilitates the positioning of work piece while drilling.
Spindle: It is a hollow portion which is provided with rotary motion spindle imparts this
rotator motion to drill.
Head: It consist of drive mechanism and feed mechanism.
Operations Performed on the drilling machine:
Drilling: It is the process of making a hole in blank work piece with tool known as drill.
Drilling
Reaming: It is process of finishing and sizing of drilled hole with the help of tool called as
reamer.

Reaming
Boring: It is process of enlarging the already existing hole to meet the required Size and
finish.
Boring
Spot facing: It is the process of machining a flat circular surface around a hole to provide
a seat for a bolt head nut or washer.
Spot facing
Counter boring: It is the process of cylindrically enlarging the face of existing hole.
Counter Boring
1. Dot Punch.
2. Vernier Height.
3. Scriber.
4. Drill Bit.
5. File.
6. Tap set with Die Holder.
7. Drilling Machine.

DRILLING AND TAPPING

DRILLING AND TAPPING
EX.NO:
DATE:
AIM:
To Drill and Tap the given Workpiece as per the required dimensions.
MATERIALS SUPPLIED:
Mild Steel plate of Size 50x50x6mm.
TOOLS REQUIRED:
1. Bench Vice.
2. Machine Vice.
3. Steel Rule.
4. Try Square.
5. Surface Plate.
PROCEDURE:
1. The dimension of the given work piece is checked.

2. The Chalk is applied throughout the surface of the workpiece.
3. Marking is done on the workpiece by using scriber, dot punch and hammer. With
the help of Vernier height gauge and steel rule measurement is taken.
4. The adjacent side of workpiece is filled and then the punched workpiece is clamped
in the vice.
5. The required size of hole is made on the workpiece by using drilling machine.
6. During the drilling operation the coolant is applied to avoid the heat and to reduce
wear.
7. Then the drilling holes are tapped by using Tapping tool.
RESULT:

STUDY ON SHEET METAL
Introduction:
Sheet metal work is the working on the metal of 16 gauges to 30 gauges with hand
tools and simple machines into different forms by cutting, forming into shapes and joining.
Application of Sheet Metal:
It is used for making hoppers, funnels, various ducts chimneys, ventilating pipes,
machine tool guards, boilers etc. It is extensively used in major industries like air craft
manufacturing, ship building, automobile body building and fabrication of ducts in air
conditioning equipment.
Principle involved:
Generally all sheet metal work patterns are based on the development of the
surfaces of a number of geometrical models like prism, cylinder, pyramid and cone.
Besides development of surfaces, geometrical projections are also used for sheet metal
work.
General Procedure for Sheet Metal Work:
The exact size and shape of the sheet to be cut is given by the development of the
concerned object. The development is drawn on a flat sheet metal and then the sheet is cut.
Then it is folded or rolled to the required shape before the joints are made by welding or
any other form of fastening.
Specification of Sheet Metal:
The sheets are specified by standard gauge numbers. Each gauge designates a
definite thickness. The gauge number can be identified by standard wire gauge or SWG.
SWG 10 12 14 16 18 20 22 24 26 30
Thickness (mm) 3.2 2.6 2.0 1.6 1.2 0.9 0.7 0.6 0.4 0.3

Metals used in Sheet Metal work:
The most commonly used sheet metals are:
1. Black iron
2. Galvanized iron
3. Stainless steel
4. Copper
5. Aluminum
6. Tin plate
7. Lead etc.
Selection of these metals is based upon the type of process.
TOOLS USED IN SHEET METAL WORK

Tools used in Sheet Metal Work:
The various types of tools used in sheet metal work are explained below.
Cutting Tools:
Chisels
Chisels are used in sheet metal work for cutting sheets, Rivets, bolts and chipping
operations. Through there are many types of Chisels available, round nose chisel and flat
chisel are mostly used for sheet metal work
Snips (or) Shears
Snips are hand shear, varying in length from 200mmto 600mm. 200mm and
250mm length is most commonly used. In sheet metal work, straight and curved snips are
mostly 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 Hammers
Hammers are used in sheet metal work for hollowing, stretching, leveling, riveting,
strengthen of sheet metal joints etc. The following hammers are mostly used in sheet metal
work
a. Ball peen hammer

b. Straight peen hammer
c. Riveting hammer

d. Mallet
Punches
In sheet metal work, punch is used for marking out work locating centers etc. The
following two types of punches are widely used.
 Dot punch
 Center punch
Supporting Tools:
Stakes
Stakes are nothing but sheet metal workers anvil used for bending, hemming,
forming etc., using hammers or mallet.
Bending Tools:
Pilers
Pliers are mainly 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 measures with an
accuracy of up to 0.5mm.
Scriber
It is a long wire of steel with its one end sharply pointed and hardened to scratch
line on sheet metal for laying out patterns.
Dividers:
Dividers are used for drawing circle or arcs on sheet metal. They are used to mark a
desired distance between two points and divide lines into equal parts.

Trammels:
It is used for making of arcs and circles. Maximum size of the arc that can be
scribed depends on the length of the beam in scribers.
Sheet Metal operations
The major types of operations are given below.
a. Shearing
b. Bending
c. Drawing
d. Squeezing
STEEL RULE: It is used to measure and mark dimensions. It is graduated on both sides
in millimeters and centimeters or inches.
DIVIDER: It is used in sheet metal jobs for circle making. With the divider we can also
do making the parts of the job.
Steel Square: It is used for checking the right angle of the jobs.
Trammel: It is used to draw large circles and arcs. This is also a marking tool
Wire Gauge: The thickness of sheet metal is referred in numbers known as Standard Wire
Gauge (SWG). The gaps in the circumference of the gauge are used to check the gauge
number.

Bench Shear:
Sheet metal may be cut by shearing action. In this, the force is applied through a
compound lever, making it possible to cut sheet metal up to 4 mm thick.
Snips:
This tool is used for cutting thin metal sheets, before or after marking, according to
the jobs, is called snips. The straight snip is used for cutting along outside curves and
straight lines and curved snip or bent snip is for trimming along inside curves.
Hammers:
Light weight hammers and mallets are used in sheet metal work. Ballpeen Hammer
has a cylindrical slightly curved face and a ball head. It is a general purpose hammer used
mostly for riveting in sheet metal work. The cross-peen hammer and straight peen
hammers are used for folding the sheet and to work in the corners of the object.
Mallet:
Mallet is used for bending and folding work. It is called as soft hammer. Generally,
it is made of wood.
Stakes:
Stakes are nothing but anvils, which are used as supporting tools and to form,
seam, bend or rivet, sheet metal objects. They are made from wrought iron, faced with
steel.
Scriber:This tool is used for making sheet metal jobs.
Punch:Punch is used in sheet metal jobs for punching or deep marking

SHEET METAL OPERATIONS
BENDING
It means that the metal is stresses beyond the elastic limit, so that the metal is bend
in to right angle and forming occurs when complete items or parts are shaped. It
incorporates angle bending, roll bending, and roll forming and seaming.
DRAWING
It is the operation of producing cut shaped components from sheet metal by many
number of punching storkes. It is performed by placing a metal blank over a stationary die
and exerting a calculated pressure from a punch against the blank.
SQUEEZING
Squeezing is one of the method of forming ductile material, riveting, cold heading
and rotary swaging are common process of squeezing.
RIVETING
Rivets are used to join two or more sheets of metal together.
Round rivets, conical rivets, flat rivets and counter sunk rivets are commonly used in the
sheet metal work.
CUTTING-OFF: Shearing of sheet metal by cutting.

PARTING: Removable of scrap between the two pieces to part them.
BLANKING: Cutting a whole piece from the sheet metal.
PUNCHING: Making circular holes on a sheet metal using punch and die.
NOTCHING: To prevent bulging at such a place, it is necessary to slit or clip the metal or
provide small openings. The openings left at the corners of seams and edges are known as
notching.
SLITTING: Cutting the sheet metal using rotary blades.
LANCING: To make a small cut, but without any removal of sheet metal.
NIBBING: Cutting any shape from the sheet metal without special tools.
TRIMMING: Cutting away excess metal or burs from the sheet metal.
SHEET METAL OPERATIONS
SHEET METAL JOINTS

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
 Single hem
Single hem is the process of bending the edge of a sheet to 180oone time to
make it stiff and smooth.
 Double hem
Double hem is the process of bending the edge of the sheet twice to make it
stiff and smooth
 Wired edge
It is made by wrapping a piece of wire inside the edge of a sheet. It
strengthens the edge twice than the other two processes viz., single hem and
double hem.
SEAM
Seam is a joining made by fastening two edges together.
Types of seam
 Single seam
Single seam is used to join between bottom and vertical bodies of various
shapes.
 Double seam
Double seam is similar to single seam. But its formed edge is bent upward
against the body to increase the strength of the joint.
 Grooved seam
Grooved seam is made by holding two single hems together and then
locking them by a groover.
RESULT:

RECTANGULAR TRAY

EX.NO: RECTANGULAR TRAY
DATE:
AIM:
To make a rectangular tray from the given sheet metal
MATERIALS SUPPLIED:
28 gauge Galvanized Iron (G.I) sheet.
TOOLS REQUIRED:
1. Steel rule
2. Mallets
3. Scriber
4. Divider
5. Protractor
6. Snips
7. stakes
8. Rivet set
9. Ball pen Hammer
1. Checking
2. Leveling
3. Marking
4. Cutting
5. Bending
6. Hemming Riveting
WORKING PROCEDURE:
1. The size of the given sheet is checked for the 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 the figure.

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 the figure.
7. These four sides of the tray are bent to 90º using stakes anvil.
8. Finally all the corners of the tray are joined by riveting.
RESULT:

EX .NO: ASSEMBLING A CENTRIFUGAL PUMP
DATE:
INTRODUCTION:
The pump is a hydraulic machine which converts the mechanical energy into
hydraulic energy in the form of pressure energy. The centrifugal pump is a hydraulic
machine which converts 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 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 of tangential velocity of the liquid at the point (i.e. Rise
in pressure head = V²/2g = ω²r²/2g). Thus at outlet of the impeller where radius (r) is more,
the rise in pressure head will be more. Due to this pressure head, the liquid can be lifted to
high level.
PARTS OF CENTRIFUGAL PUMP:
The following are the main parts of a centrifugal pump.
1. Suction pipe
2. Impeller
3. Casing and
4. Delivery pipe
All the main parts of the centrifugal pumps as shown in figure 1.1.
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.

Figure1.3 VOLUTE CASING
Figure1.4 VORTEX CASING
Figure1.5

DIFFUSER CASING
Some of the points to remember regarding installation of suction pipe.
a) Length of the suction piper should be as small as possible

b) Try to avoid bending in the suction pipe. If it is unavoidable make the bend with
maximum radius (Radius = Five of the diameter of the suction pipe).
c) The inner surface of the suction pipe will be friction free.
d) Use an eccentric reducer to join the suction pipe with inlet of the pump.
e) Avoid the check valves in suction side of the pump.
f) Cross sectional area of the foot valve should be double the cross sectional area of
the suction pipe.
g) If the suction pipe is in horizontal position, the suction pipe must be in 2°
inclination with downwards.
All the main parts of the suction pipe as shown in figure 1.2.
IMPELLER:
The rotating part of the 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.
CASING:
Casing is an air-high passage surrounding the impeller and is designed such a way
that the 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. Three
common types of castings are
i) Volute casing
ii) Vortex casing
iii) Diffuser casing

Figure 1. 6 MULTISTAGE PUMP FOR HIGH HEAD

Figure 1.7 MULTISTAGE PUMPS FOR HIGH HEAD
i) Volute Casing:
Figure shows the volute casing, which surrounds the impeller. It is of spiral type in
which area of flow increases gradually. The increase in area of flow causes decrease in
velocity of flow. The decrease in velocity, increases pressure of the water flowing through
the casing. It has been observed that in case of volute casing, the efficiency of the pump
increases slightly as a large amount of energy is lost due to the formation of eddies in this
type of casing. As shown in fig 1.3.
ii) Vortex Casing:
In vortex casing a circular chamber is introduced in between the casing and the
impeller as shown in figure. The vortex casing reduces formation of eddies, results
reduction in loss of energy. Thus efficiency of the pump with vortex casing is more than
the efficiency with volute casing. As shown in fig 1.4.

iii) Diffuser Casing:
Here, the impeller is surrounded by a diffuser. The diffuser having a series of guide
vanes as shown in the figure. The guide vanes are designed in such a way that the water
from the impeller enters the guide vanes without stock. Increasing area of the guide vanes
reducing the velocity of flow consequently increasing the pressure. Also it reduces
vibration of the pump. In most of the cases, the surrounding concentric with the impeller as
shown in the figure. In the diffuser casing the diffuser and the outer casing are stationary
parts. As shown in fig 1.5.
DELIVERY PIPE:
A pipe whose one end is connected outlet of the pump and the other end delivers
the water at the required level is known as Delivery pipe.
Some of the points to be considered regarding installation of the delivery pipe.
a) Use a check valve and gate in the delivery side of the pipe. Gate valve is used to
regulate the flow of water. The check valve allows water from pump to delivery
side. But it will not allow the flow in the opposite direction.
b) The check valve must be placed in between the pump and the gate valve.
MULTISTAGE CENTRIFUGAL PUMPS:
If a centrifugal pump consists of two or more impellers, the pump is called
multistage centrifugal pump. A multistage pump is used for two important purposes, i.e.
1) To produce high head and
2) To produce large amount of discharge
MULTISTAGE PUMP FOR HIGH HEAD:
To get the high head, numbers of impellers are connected in series. i.e. on the same
shaft as shown in the figure. Here, the water from suction pipe enters the first impeller.
Water discharged at the first impeller outlet with increased pressure enters into the inlet of

second impeller with the help of a connecting pipe. Water from outlet of second impeller
having more pressure than water from the outlet of first impeller as shown in fig 1.6.
MULTI STAGE PUMPS FOR HIGH DISCHARGE:
To get the high discharge, the pump should be connected in parallel as shown in
figure. The parallel pumps are connected to a common delivery pipe. Here, all the pumps
are working for a same head as shown in fig1.7.
PRIMING:
Before starting the pump, air from suction pipe, casing and portion of delivery pipe
i.e. up to the valve is replaced by water. The operation of replacing the air with water in
the pump is called Priming.
If the priming is not taken place, the pump will not deliver the water. The head
generated by the pump is independent of density of fluid. It means that, when the pump is
run with air, the head generated will be in terms of meter of air. But the head must be in
terms of meter of water. The head generated in terms of air is negligible compared to the
head in terms of equivalent meter of water. So priming is necessary before starting the
centrifugal pump.
APPLICATIONS OF CENTRIFUGAL PUMPS:
1. Generally the most common type of pump in use is centrifugal pump.

2. In houses it is used to fill the overhead tank.
3. In agricultural sector centrifugal pump is used to deliver the water from the well.
4. Large size centrifugal pumps are used in industries.
5. Centrifugal pumps playing role in marine engineering too.
6. Very large size centrifugal pumps are used in power plants.
7. Chemical industries also using the centrifugal pumps.
8. Centrifugal pumps are used to feed the water to boilers in industries.
RESULT :

Fig 2.1. REFRIGERATION SYSTEM

EX.NO: ASSEMBLYING AN AIR CONDITIONER
DATE:
INTRODUCTION:
An air conditioner is defined as an assembly of different parts of the system used to

produce a specified condition of air within a required space or building below that of the
atmosphere or surroundings.
An ideal air- conditioner should maintain correct temperature, humidity and air-
movement etc. Generally a small domestic air-conditioning plant having the capacity of
0.5 ton. In a window air-conditioner all the components are locked in a box. As shown in
fig 2.1.
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 is takes place at the compressor. The low pressure, low temperature
dry refrigerant or coolant vapour is drawn from the evaporator into the 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 of the condenser through discharge line.
2. Condensation:
In the condenser the high pressure and high temperature refrigerant vapour rejects
heat and cooling medium thus allowing the vaporized 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 is reduced very much to allow the vaporization of liquid at a very low
temperature of about -10 c.

Fig 2.2 MAIN PARTS

OF AIR-CONDITIONER
Fig 2.3 COMPRESSOR

4. Evaporation:
Then the low pressure low temperature refrigerant vapour enters into the
evaporator. Where a considerable amount of the 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 moves into the 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 releases it to another place. Generally Freon 12 is used as a refrigerant in the
domestic air-conditioner. It is observed that all the Chloro Fluro Carbons (CFC) including
Freon affects the ozone layer causing global warming. Since now-a-days the newly
invented refrigerant Hydro Fluro Carbon (HFC) is used as refrigerant.
MAIN PARTS OF AN AIR-CONDITIONER:

The followings are the main parts of an air-conditioner
1. Compressor
2. Condenser
3. Expansion device
4. Evaporator and
5. Fan
As shown in fig.2.2
1. Compressor:
The most important part of the air-conditioner is hermatic compressor (also called
sealed compressor). In this hermatic compressor, the rotary compressor and motor are
assembled together and suspended inside a metal casing called “Dome”. The motor located
above the compressor operates horizontally
2. Condenser:
Function of the condenser is to provide heat transfer surface through which heat
passes from the refrigerant to the condensing medium. Normally the condenser is made by
copper aluminium or iron pipe. Here that high pressure high temperature vapour
refrigerant becomes to liquid state by losing heat because of the cooling medium.

3. Expansion device:
An expansion valve is used as an expansion device. Its function is to supply proper

amount of the refrigerant to the evaporator after reducing its pressure considerably.
4. Evaporator:
Its function is to provide a heat transfer surface through which heat can pass from
the air-conditioned space into the vaporizing refrigerant. The pressure inside the
evaporator is low and the liquid refrigerant vaporizes by absorbing heat from the air
surrounding the evaporator.
APPLICATION OF AN AIR- CONDITIONING SYSTEM:
 To get the chilled air for comfortable.

 To get the dust free air.
 Refrigeration system is used for food preservation.
RESULT:

EX.NO: ASSEMBLYING A HOUSEHOLD MIXER
DATE:
INTRODUCTION
India is one of the top ten nations having the highest foreign reserves of 590 billion
US dollars at number 8 position in the ranking. Having adequate foreign reserve keeps the
nation in high esteem club of nations and derives certain advantages such as maintaining
the value of the country’s currency, helps to manage the local market steady, builds the
confidence of the foreign investors and finally to meet the external obligations in the
international arena. It helps us to strengthen the bargaining power in international
commerce as well as commands respect in geo-political negotiations
As part of this mission, O/o DC (MSME), New Delhi has assigned the task of
preparing a report for domestic manufacturing of “ Domestic Electric Appliances – Food
mixer, wet grinder and food processor ” which is being imported considerably at present.
Domestic Electric Appliances refers to hundreds of electrical appliances such as Electric
water pump, refrigerator, Wet grinder, Television, Air conditioner, ceiling Fans etc. But
this report is prepared with a focus on Food mixer, Wet grinder and Food processor.
Because of their uses in automation of domestic works especially in food processing, these
domestic electric appliances have got good domestic and export market potential. This
report is a techno economic document which talks about the domestic potential for Food
mixer, Wet grinder & Food processor, Manufacturing process, Government of India
support for the clusters of such products and preparation of bankable project report. This
report will be a guide for the prospective entrepreneurs/unemployed youth to start a
MSME unit to manufacture the domestic electric appliances. This will also serves as a
reference to the existing entrepreneurs to understand the various schemes of Government
of India

TYPES OF MIXER
The two common types of mixer grinders are stand mixers and traditional mixers. A stand
mixer is powerful enough to mix ingredients. These kind of mixers are mainly used for
whipping cream and kneading dough.
Horizontal Mixer
Spiral Mixer
Planetary Mixer
1. Horizontal Mixer
This type of mixer has the capability of producing the largest volume of dough in
the shortest amount of time. It is configured so that as the dough is mixed, the next batch is
continually fed into the machine. The dough also easily exits the machine into a trough for
convenient transport after the mixing process is complete.One of the main drawbacks of a
horizontal mixer is its inability to keep the dough temperature low throughout the mixing
process. The friction of the dough rubbing against the sides of the bin causes the
temperature to rise, which isn’t ideal for some types of yeast doughs.
3. Planetary Mixer
The planetary mixer is the option most commonly used in home kitchens. The central
mixing wand rotates around a stationary bowl. You can change the wand attachment as
needed to accommodate your mixing goals.

You can use this type of machine to mix a range of substances too, not just dough.
The bowl is easily detached and moved quickly, once mixing is complete. These upright
machines are typically smaller, so if you have limited space, the planetary mixer might be
the best option for you.
WORKING
The spinning of the blades sets the food particles in a circular motion. The circular
swirling motion of the mixture creates a vacuum at the center. The central vacuum
displaces the contents toward the axis while the whirling motion forces them up on the
sides.
Whenever we switch on the mixer grinder, universal motor comes into action as
current passes through both the field winding and armature winding and as a result, a
torque is applied on the rotor, the rotor starts rotating which then rotates the blades of the
grinder and thus it helps in mixing and grinding
APPLICATIONS:
Pureeing
Chopping
Mincing
Grinding
Mixing
Blending
can be done in a matter of minutes to prepare any dish you want. You get the best mixer
grinder with efficient design and the latest technology from Crompton.
RESULT:

TOOLS USED IN FOUNDRY

EX.NO: DEMONSTRATING OF BASIC FOUNDRY OPERATIONS
DATE:
Foundry is the process of making casting by preparing moulds using pattern. A

pattern is the exact replica of the casting to be made, with some allowances. It is the
principal tool used during the casting process. The pattern is used to mould the sand
mixture into the shape of casting. The moulding material is then packed around the pattern
and the pattern is removed to produce a mould cavity, exactly of the size of the casting to
be produced.
Pattern
The selection of a type of pattern for a casting will depend on the ease or difficulty
of the moulding operation to be done, whether a small or large number of castings are
required, the type of moulding process etc., The commonly used types of pattern are single
piece pattern, Spilt pattern, Match plate pattern, Cope and Drag pattern, Gated pattern,
Loose piece pattern, Sweep pattern, Skeleton pattern, Segmental pattern and shell pattern.
MOULDING TOOLS AND EQUIPMENTS
The tools and equipment’s used for moulding are follows,
Shovel
It consists of a board iron fitted with a wooden handle. It is used in mixing and
conditioning the foundry sand and transferring into the flasks/moulding box.
Riddle
It consists of wooden frame fitted with a screen of standard wire mesh at its
bottom. It is used for hand riddling of sand to remove the foreign materials from it.

Rammer:It is used for striking the sand in the moulding box to pack it uniformity around
the pattern. The common form of rammer used in hand ramming are Peen rammer, Hand
rammer and Floor rammer.
Peen rammer: It has a wedge shaped construction formed at the bottom of a metallic rod.
It is a common hand tool and is used to pack the sand at pocket and corners.
Hand rammer: It is smaller than the former and generally made of wood or metal. It has a
wedge type constructing peen, and on the other end a solid cylinder shape called butt. It is
mainly used in moulding.
Floor rammer:It consists of a long steel bar carrying a peen at one end and a flat pattern
at the other. It is a larger and heavier tool than the above two. Its specific use is, in
Floor moulding and ramming, the mould is very large. Due to its large length, the moulder
can operate it in standing position in this type.
Strike off bar:It is a flat bar made of wood or iron to strike off the excess sand from the
top box after ramming. Its one edge is made beveled and the surface is perfectly smooth
and plane.
Vent wir:It is a thin steel rod or wire carrying a pointed edge at one end and wooden
handle or a bent loop at the other. After ramming and striking off the excess sand, it is
used to make small holes, called vents, in the sand mould to allow the exit of gases and
steam during casting.
Lifter:It is made of thin section of steel, of various width and length, with pin end, bent at
right angle. It is used for smoothening and cleaning out the depressions in a mould.

Swab
It is used to blow loose particles of sand from the cavities and surface of the mould.
Trowels
It is used for finishing and obtaining the flat surface of the mould to eliminate the
gap while fixing the mould boxes. It consists of a metal blade with a wooden handle. The
small trowels of various shapes are used for smoothing over the parting surface of the
mould. The usual trowel is rectangular in shape and has either a round or a square end.
Slick
It is a small double ended tool having a flat on one end and a spoon on the other
end. This tool is also made in a variety of other shapes and is used for repairing and
finishing the mould.
Sprue pin
It is a tapered wooden rod used to make a hole in the moulding sand through which
the molten metal is poured into the mould.
Gate cutter
It is a U-shaped piece of thin sheet and is used for cutting a shallow runner in the
mould to act as passage for the hot metal.
Draw spike and screw
The draw spike is a pointed steel rod with a loop at one end. It is driven into a
wooden pattern to hold it when the sand is withdrawn. The draw screw is similar in shape
but threaded on the end to engage metal patterns.
Mallet
It is wooden hammer, similar to the one which is used in carpentry. It is used for
work where light blows are required. It is used to drive the sharp end of draw spike into the
pattern and them to loft it from the mould.
Gaggers
It is made of iron rods bent at one end or both the end. It is used for the
reinforcement of sand in the top part of the moulding box and to support hanging bodies of
the sand and strengthen the cavity. The lengths of the gaggers vary from 125mm to
600mm and are coated with clay, to affect the sand to stick to it.
Clamps
It is used for holding the cope and drag of the mould so that the cope should not
rise when the molten metal is poured into the mould.
Rapping plate
It is made of sheet and is firmly fixed to the top of the pattern by screws or bolts. It
is used for lifting and rapping large patterns.

Moulding boxes
The sand moulds are prepared using the pattern in specially constructed boxes
called mould boxes. It is also called flasks. It is to impart the necessary rigidity and
strength to the sand in the mould. Irrespective of the shape and size of the object there are
usually two or more boxes. The top part or box is called the cope and the lower part is
called drag. If the mould is made with three boxes then the intermediate one is called
cheek. These boxes are made of either wood or metals depending on the shape and size of
the casting to be made. The moulding board is a flat and firm board made of wood or metal
over which the moulding boxes are placed and the moulding is performed.

GREEN SAND MOULDING

Moulding sand
The key material used in the foundry shop for moulding is the sand. The sand is
formed by breaking up of rocks due to the action of natural forces such as frost, wind, rain,
heat and water current. The main ingredients of moulding sands are silica, sand, and clay,
water for moistening and other additives. The moulding sands are generally classified into
three types: 1. Natural moulding sand, 2. Synthetic or high silica sand and 3. Special sand.
The natural moulding sand is then classified into the following categories: Green sand,
Loam sand, Facing sand, Backing sand, System sand, Parting sand and Core sand.
Green sand mould
It is the mixture of silica sand with 18% to 30% clay, having a total water of 6% to
8%. The clay and water, furnish the bond for green sand. It is fine and porous. It can be
squeezed by hand, since it is wet and damp, and the mould is prepared using various tools.
The various steps involved in green sand moulding are
 The wooden pattern is kept over the moulding board, with the holes for dowel pins
facing down.
 Then the drag portion of the moulding box is centrally kept over the moulding
board and he moulding sand is filled in the box. The sand is pressed around the
pattern by hand, for obtaining good cavity without any distortion.
 Extra sand is added and rammed till the top of the moulding box. The excess sand
on the top of the drag box is removed using strike off bar.
Number of holes is made in the mould using vent wire to facilitate the escape of the
gases when molten metal is poured. Then the drag is rolled over.
 Before keeping the core box, the dry parting sand is sprinkled over the mould for
separating the cope and for the removal of the pattern and to prevent sand in the
cope from sticking to the sand of drag.

 Now fit the top half of the box, called cope, over the drag and fix it using dowel
pins. In the case of split pattern type, keep the other half of the pattern over the first
half. The sprue pin is placed vertically, by the side of the pattern, to create the
 sprue hole for pouring the molten metal. Then the riser pin is placed in position
such that the lower end touches the tip of the pattern.
 Now the cope box is filled with sand and rammed without affecting the setup.
 After that the sprue pins and riser is withdrawn using draw spike. Then vent holes
are made in the moulding using vent wire.
 The cope is removed and placed to the side. Then the pattern is removed carefully
using draw spike and mallet. Now the cavity is made in the drag portion in the case
of solid pattern or the cavity is made combining cope and drag, in the case of split
pattern.
 The bottom of the sprue and the gatting is made in the drag portion for directing the
molten metal flow. Here the gate connects the sprue and the cavity.
 The cope is again placed over the drag correctly and is locked using dowel pins.
 Now the mould is ready for casting.
 The molten metal is poured through the sprue hole till the metal rises in the riser. It
is then allowed to solidify. After solidification the object is obtained after breaking
the mould.

EX.NO: DEMONSTRATION ON MOULD PREPARATION OF
DATE: GEAR PATTERN
AIM:
To make the mould of a flange pattern.
MATERIALS SUPPLIED:
Moulding sand, Parting sand, facing sand, Gear pattern, moulding boxes etc.
TOOLS REQUIRED:
1. Showel
2. Sieve
3. Trowel
4. Rammers
5. Sprue Pin
6. Strike off bar
7. Lifter
8. Gate Cutter
9. Runner
10. Riser
11. Vent Rod
12. Draw spike
13. Bellow
1. Sand preparation
2. Core preparation
3. Placing the pattern on the moulding board
4. Ramming of drag
5. Placing runner and riser
6. Ramming of cope
7. Removal of pattern, runner, riser

8. Gate cutting.
GEAR PATTERN

WORKING PROCEDURE:
1. The gear pattern is placed on the mouldig board.

2. A suitable core is prepared and placed in the hole of the flange 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 riser are removed and a funnel shape is made on the runner hole.
15. Cope is kept aside and the pattern is removed using draw pin.
16. Gate is prepared by using gate cutter
17. The cope is placed on the drag.
RESULT:

Viva – Voce Question and answers

1. Name the material used for coating on electrodes.
Copper, carbon and graphite.
2. What is the use of flux?.
During welding when the metal is heated in air, oxygen in the air reacts with the
metal to form oxides this oxidation result in poor quality and low strength welds.
To avoid this, flux is added during welding.
3. What is an electrode?
Filler rod used in arc welding is called electrode. This is made up of metallic wire
called core wire.
4. What are welding defects?
Lack of fusion, undercut, cracking, oxidized weld and incomplete penetration.
5. Types of welding.
Fusion or non-pressure and pressure or plastic welding.
6. Different types of flames used in gas welding.
Oxy-acetylene flame, neutral flame and carburizing flame
7. What is arc welding?
Arc welding is a process of joining two metal parts by melting the edges by an
electric arc using filler rod without the application of pressure.
8. Types of welding joints.
Butt joint, lap joint and T joint.
9. The diameter of the welding rod to be used depends upon the thickness of the
workpiece.
10. In arc welding the electric arc is produced between the work and the electrode by
contact resistance.
11. Name some work holding devices of a lathe.
Chuck, face plate, catch plate, lathe carrier, steady rest and mandrel.
12. State any three applications of lathe.
Production of shafts bolts and wheels.
13. What is use of caliper?
Caliper is used to measure inside and outside diameter / dimensions of a given job.
14. Define tool life.
Tool life is defined as the capacity of the tool between two regrinding operations.
15. List the name of tools used in a machine shop.
Steel rule, vernier caliper, surface gauge, micro meter, chuck key, drill, turning
tool, knurling tool and height gauge.
16. Parts of lathe.
Head stock, tail stock, tool post, carriage, cross slide, feed box, apron, base, leg,
spindle, compound rest, dead centre and feed rod.
17. State any four applications of drilling machine.
To drill holes in construction works like fitting, carpentry, plumbing and electrical
wiring.
18. What are the various types of chucks used in lathe?
Two jaw chuck, three jaw chuck, four jaw chuck, collet chuck and magnetic chuck.
19. A machine is a power driven machine, capable of cutting and removing metal
in the form of chips to produce a desired shape.
20. The tool material should be harder than workpiece material.

21. Sheet metal is the layout is known as development of surfaces of the object.
22. A sheet of steel which is coated with molten zinc is known as GI (Galvanized
Iron).
23. Stainless steel sheets are used for making dairy and food processing plant.
24. A hem is an edge or border made by folding.
25. A seam is a joint made by fastening two edges together.
26. Snip is a tool used for cutting thin metal sheets, before or after marking.
27. Mention any five applications of sheet metal works.
Boxes, funnels, hoppers, ducks and chimneys.
28. State any four commonly used sheet metals in practice.
Aluminium, tin sheet, G.I and Stainless Steel.
29. Mention types of tools used in sheet metal work.
Making and measuring tools, striking tools, cutting tools, bending tools and
supporting tools.
30. What are the methods of development used in practice?
Parallel line method, radial line method and triangulation method.
31. What is stake? State its use.
Stake is an anvil, used as supporting tool and to form, seam, bend or rivet sheet
metal objects.
32. The thickness of the sheet metal is termed as standard wire gauge.
33. Process of replacing air with water in pump before starting is called priming.
34. A centrifugal pump is a hydraulic machine. It converts mechanical energy in to
pressure energy by means of centrifugal force.
35. Foot valve is a non-return valve.
36. Window AC is installed in the window of a room at the window sill level.
37. Unit of refrigeration is expressed in terms of ton of refrigeration (TR).
38. Freon-12 is the refrigerant used in AC.
39. Centrifugal pump is used to fill up overhead tanks and used to deliver water
from well for agriculture purpose.
40. Types of casing of centrifugal pump.
Volute, vortex and diffuser.
41. Types of centrifugal pumps.
Mono block, jet pump and submersible pump.
42. Air cooling consist merely a blower with refrigerating unit. It provides only a
flow of cool filtered air.
43. Air conditioning is the simultaneous control of temperature, humidity purity
and motion of air for the purposes of human comfort, food processing, etc.,
44. What are the main components of an Air conditioner?
Compressor, condenser, expansion valve evaporation and fan.
45. Metal forming process is a process in which the desired shape and size of a
component are obtained through the plastic deformation of metal. This can
be achieved by heating the metal and applying mechanical force.
46. Forging is the forming of metal into the required shape by hammering or
pressing.

47. Swages are used for changing the sectional shape to round, square or
hexagonal.
48. Drawing is the process of increasing the length of the bar and reducing its
width or thickness.
49. Mild steel are most suitable metals for forge welding.
50. What is meant by smithying?
Smithying is an oldest form of forging. It is used where small parts are shaped by
heating them in an open fire or hearth.
51. What is upsetting?

It is one of the smithy forging operations to increase the thickness of the job and
reducing the length by the application of hammering.
52. State the applications of smithy.
Bolts, nuts, hooks, tongs, wrenches, cutting tools, spanners, springs, automobile
and agricultural parts.
53. Aluminium pattern itself is cast from a wooden pattern, called master pattern.
54. Molding box is made of two parts, cope and drag.
55. Molten metals enter the mold through the gates.
56. Mold surface is coated with graphite to give the smooth surface to casting.
57. Define the terms pattern and casting.
Pattern is a moder used to produce mould cavity and to get required casting.
Casting is the process of making parts by pouring molten metal into a mould and
allowing it to solidify.
58. What are the materials used to for making patterns?
Wood, metals and plastics.
59. Name any two types of patterns.
Solid and split.
60. Name two types of sand used in foundry work.
Green sand and dry sand.
61. Define fitting.
Fitting is the process of assembling the parts by removing unwanted metals using
hacksaw and files to get the necessary fit.
62. How to specify the files?
Files are named according to the shape of its cross section. Angle of single cut is
60o and double cut is 60o and 80o crossed together single cut files are used for soft
materials and double cut files are used for slightly hardened metals.
63. Cross filing is used when large amount of metal is to be removed.
64. State the various grades of files.
Single cut, double cut, rough cut, bastard cur, second cut, smooth cut and dead
smooth cut.
65. Straight filing is used on long and narrow pieces of work and whose width is less
than that of the file.
66. The angle of the V in a V block is 90o.
67. Name four holding tools used in plumbing.
Pliers, clamps, wrenches and vices.
68. List any four types of valves used in pipe lines.
Gate valve, ball valve, butterfly valve and check valve.

69. Name any four joints used in pipes.

Threaded joints, welded joints, spigot joints and flanged joint.
70. Pipe wrench is used to hold the pipes, rotate and tighten them.
71. Pipe vice is used to clamp pipes in position for cutting, threading, fitting etc.
72. Gate valve is used for domestic plumbing to control flow of water.
73. A short piece of pipe threaded at both ends of join two pipes is nipple.
74. Water meter is fitted with union so that it can be removed without disturbing the
pipe.
75. Elbow is used to for fitting two pipes at right angles.
76. Zinc is used for galvanizing. It protects ferrous metal from corrosion.
77. Plumbing line diagrams are used to show the size and location of pipes.
78. Double line diagram is used for catslogs, where the visual appearance is more
important.
79. What is timber?
Timber is a natural product, developed through many years of growth in the open
air, exposed to continual and varying climate conditions.
80. Name four types of tools used in carpentry shop.
Chisels, jackplane, mallet and try square.
81. A try square is used for making and testing angle of 90o.
82. Name two types of holding tools used in carpentry shop.
Bench vice and C clamp.
83. Name a few types of timbers and give examples.
Hard wood : sal, teak, oak, mahogany,etc.
Soft wood: pine deodar, etc.
84. What is the need of bench vice?
A bench vice is used to hold the work piece while wood working.
85. Name the various joinery materials used in carpentry.
Adhesives and other joinery materials are nails, screws, bolts, nuts and dowels.
86. Jack plane is used for planing end grains of wood.
87. Dowel is used to hold two pieces at proper position.
88. Bow saw is used to produce curved surfaces.
89. Cross lap joint is used where two pieces crossed each other.
90. Chisel is made up of forged steel.
ANNA UNIVERSITY: CHENNAI-600025

B.E./B.Tech. DEGREE EXAMINATIONS, JAN – 2013
MECHANICAL ENGINEERING – TOPIC : WELDING

1. Prepare a V - Butt joint using the given two M.S plates by arc welding (Fig.1).(All
dimensions are in mm)
Fig.1
2. Prepare a Corner joint (90º) using the given two M.S plates by arc welding (Fig.2).(All
Fig.2
3. Prepare a Lap using the given two M.S plates by arc welding (Fig.3).(All dimensions are in
mm)
Fig.3

MECHANICAL ENGINEERING – TOPIC : MACHINING
4. Drill and counterbore holes in the given M.S plate using drilling machine (Fig.4). (All
MECHANICAL ENGINEERING – TOPIC : SHEET METAL
5. Prepare funnal from the given 0.2mm thick metal sheet (Fig.5). (All dimensions are in
mm)
Fig.5
6. Prepare a rectangular tray from the given 0.2mm thick metal sheet (Fig.6). (All


I. MECHANICAL ENGINEERING – TOPIC : WELDING

1. Prepare a Square Butt joint using the given two M.S plates by arc welding (Fig.1). (All
Fig.1
2. Prepare a double parallel fillet joint using the given two M.S plates by arc welding (Fig.2)
Fig.2

3. Drill and counterbore holes in the given M.S plate using drilling machine (Fig.3). (All
Fig.3
4. Perform turning and facing operation in the M.S. cylindrical Work piece (Fig.4). (All
Fig.4
5. Perform step turning operation in the given work piece (Fig.5). (All dimensions are in mm)
Fig.5

6. Prepare frustum of a cone from the given 0.2mm thick metal sheet (Fig.6). (All dimensions
are in mm)
Fig.6

MECHANICAL ENGINEERING – TOPIC : WELDING
1. Prepare a ‘T’ joint using the given two M.S plates by arc welding (Fig.1). (All dimensions
are in mm)
Fig.1

2. Prepare a V - Butt joint using the given two M.S plates by arc welding (Fig.2).(All
Fig.2
3. Perform turning and facing operation in the M.S. cylindrical Work piece (Fig.3).(All
Fig.3
4. Drill and counterbore holes in the given M.S plate using drilling machine (Fig.4).(All
Fig.4
5. Drill holes in the given M.S plate using drilling machine (Fig.5).(All dimensions are in
mm)=

Fig.5
6. Prepare a Square tray from the given 0.2mm thick metal sheet (Fig.6).(All dimensions are
in mm)

CIVIL ENGINEERING – TOPIC : PLUMBING
1. Make the pipe fitting connections as per the drawing given below PVC pipe.

2. Cut the threads at the end of a given pipe by using a pipe-die.
3. Prepare a PVC pipe joint by using the given pipes reducers and an elbow with a solvent
cement.
CIVIL ENGINEERING – TOPIC : CARPENTRY

4. Make middle lap joint from the given reaper as shown in the drawing. (All dimensions are
in mm)

5. Make a mortise and tenon joint from the given wooden work piece as per the drawing
given below. .(All dimensions are in mm)
6. Make dovetail joint from the given reaper as shown in the drawing.(All dimensions are in
mm)


1. Make the pipe fitting connections as per the drawing given below for a G.I. pipe.
2. Prepare a model of metallic pipe layout for water supply in a house from the service
connection.
3. Prepare a PVC pipe joint by using the given pipes reducers and an elbow with a solvent
cement.
4. Make T – lap joint from the given reaper as shown in the drawing. (All dimensions are in
mm)
given below. (All dimensions are in mm)



1. Prepare a pipeline for any one of the following.
1. Water heater
2. Washing machine
3. Wash basin
2. Prepare a layout, the model of suction pipe to a given centrifugal pump.

3. Make T – lap joint from the given reaper as shown in the drawing. (All dimensions are in
mm)
given below. (All dimensions are in mm)

5. Make dovetail joint from the given reaper as shown in the drawing. (All dimensions are in
mm)

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DEPARTMENT OF MECHANICAL ENGINEERING

LABORATORY MANUAL CUM OBSERVATION

GE3271-ENGINEERING PRACTICES LABORATORY

Manual Cum Observation

Vision of the Institute

Vision and Mission of the Department

Programme Educational Objectives (PEOs)

Manual Cum Observation

Engineering Graduates will be able to:

1. Engineering knowledge: Apply the knowledge of mathematics, science, engineering

Manual Cum Observation

Program Specific Outcomes (PSOs)

Manual Cum Observation

GROUP – A (CIVIL & ELECTRICAL)

PART II ELECTRICAL ENGINEERING PRACTICES 15

GROUP – B (MECHANICAL AND ELECTRONICS)

Manual Cum Observation

BASIC MACHINING WORK:

SHEET METAL WORK:

PART IV ELECTRONIC ENGINEERING PRACTICES 15

ELECTRONIC ASSEMBLY AND TESTING WORK:

ELECTRONIC EQUIPMENT STUDY:

Manual Cum Observation

Manual Cum Observation

2. Remove ID cards while entering in to the Laboratory.

5. Loose clothing should be avoided.

6. No short dresses or skirts allowed when working in the Laboratory.

7. Long hair must be tied back.

9. Operate the equipment/instruments only in the presence of lab in charge/ lab

12. Eye protection must be worn if operating any machinery.

15. Working alone after hours is not permitted.

In-charge/Lab Technician immediately.

medicines if at all there is any necessity.

18. Don’t use mobile phones in the Laboratory.

Manual Cum Observation

Ex.No. Date Name of the Experiment Page Staff

11. Lab Joint

12. Tee Joint

13. Gas welding Practices

17. Making of a Rectangular tray

18. Assembling a centrifugal pump

Manual Cum Observation

Plumbing deals with the laying of a pipeline. A craftsman may be perfectly

The tools used by a plumber can be classified as follows

1. Pipe wrench 2. Pipe vice 3. Pipe cutter

4. Hacksaw 5. Dies 6. Files and Rasps

1 Manual Cum Observation

A hacksaw is used for cutting metal rods, bars, pipes, etc.

2 Manual Cum Observation

Threading dies and taps:

Files and rasps:

It is a short a cylindrical sleeve with internal threads throughout. A couplings is

4 Manual Cum Observation

It is used to connect two different sized of pipes

It is used to screw on to a threaded opening, for closing it temporarily.

1. Gate valve 2.Globe valve

3. Plug valve 4.Check valve 5. Air relief valve.

5 Manual Cum Observation

6 Manual Cum Observation

Ex.No: BASIC PIPE CONNECTIONS INVOLVING THE FITTINGS