Laboratory Manual

For
23GE121- ENGINEERING PRACTICES LABORATARY

Regulation 2023

Name :

Reg. No. :

Branch :

Year / Sec :
 Gnanamani College of Technology
(An Autonomous Institution)
Accredited by NBA & NAAC with “A” grade
A.K.Samuthiram, Pachal (PO), Namakkal – 637 018

B.E. MECHANICAL ENGINEERING

INSTITUTE:
VISION

Emerging as a technical institution of high standard and excellence to produce quality Engineers, Researchers,
Administrators and Entrepreneurs with ethical and moral values to contribute the sustainable development of the
society.

MISSION
We facilitate our students
 To have in-depth domain knowledge with analytical and practical skills in cutting edge technologies by imparting
quality technical education.
 To be industry ready and multi-skilled personalities to transfer technology to industries and rural areas by
creating interests among students in Research and Development and Entrepreneurship.

DEPARTMENT:
VISION
To produce competent Mechanical Engineer capable of working in an interdisciplinary environment
contributing to benefits of society through innovation, leadership and entrepreneurship.
MISSION
 Imparting the highest quality education through state-of-the-art facilities to build students’ professional practice
and make them globally competitive Mechanical Engineers by enhancing their knowledge.
 Fostering professional and ethical values and training the students to build leadership and entrepreneurship
qualities for their career development.
 Undertaking research and developmental activities to provide service for the sustainable development of the
society.

PROGRAM EDUCATIONAL OBJECTIVES (PEOs)

Graduates of Mechanical Engineering will

PEO 1: Apply their mechanical and allied knowledge to address technical and societal problems with
creativity and ethical value.
PEO 2: Design and analyze mechanical systems with strong fundamentals and work in synchronization with
industries and research organizations as team members on multi-disciplinary projects
PEO 3: Seek out positions of leadership actively within their profession and their community through lifelong
learning.
 Gnanamani College of Technology
(An Autonomous Institution)
Accredited by NBA & NAAC with “A” grade
A.K.Samuthiram, Pachal (PO), Namakkal – 637 018

B.E. MECHANICAL ENGINEERING

PROGRAM OUTCOMES (POs)

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)

Graduates of the program will be able to

PSO-1: Apply principles of basic sciences, machine design, manufacturing, thermal engineering and management to identify,
formulate and solve real time problems and societal issues for the sustainable development.

PSO-2: Develop their abilities to qualify for Employment, Higher studies and Research in Mechanical Engineering .
 SYLLABUS
23GE121 ENGINEERING PRACTICES LABORATARY LTPC
0 04 2
OBJECTIVE:
 To provide exposure to the students with hands on experience on various basic engineering practices
in Civil, Mechanical, Electrical and Electronics Engineering.

GROUP – A: (CIVIL AND MECHANICAL)

PART I: CIVIL ENGINEERING PRACTICES (15)
Plumbing Work:
1. Connecting various basic pipe fittings like valves, taps, coupling, unions, reducers, elbows and other
components which are commonly used in household.
2. Preparing plumbing line sketches.
3. Laying pipe connection to the suction side of a pump
4. Laying pipe connection to the delivery side of a pump.
5. Connecting pipes of different materials: Metal, plastic and flexible pipes used in household appliances.
Wood Work:
1. Sawing,
2. Planing and
3. Making joints like T-Joint, Mortise joint and Tenon joint and Dovetail joint.
Wood Work Study:
1. Studying joints in door panels and wooden furniture
2. Studying common industrial trusses using models.

PART II: MECHANICAL ENGINEERING PRACTICES (15)

Welding Work:
1. Welding of Butt Joints, Lap Joints, and Tee Joints using arc welding.
2. Practicing gas welding.
Basic Machining Work:
1. (Simple)Turning.
2. (Simple)Drilling.
3. (Simple)Tapping.
Assembly Work:
1. Assembling a centrifugal pump.
2. Assembling a household mixer.
3. Assembling an air conditioner.

Sheet Metal Work:

1. Making of a square tray
Foundry Work:
1. Demonstrating basic foundry operations.
OUTCOMES:
Upon completion of the course, students will be able to:
 Fabricate carpentry components and pipe connections including plumbing works, use welding
equipment to join the structures.
 Carry out the basic machining operations.
 Make the models using sheet metal works.
 Illustrate on centrifugal pump, Air conditioner, operations of smithy, foundry and fittings.
 CONTENTS

Ex. No Date NAME OF EXPERIMENT Remarks

PLUMBING
Introduction
1. Connection of Two Galvanized Iron Pipes
2. Connections of PVC Pipes
Basic Pipe Connections Involving The Fitting Like Valves, Taps and
3.
Bends
CARPENTRY
Introduction
4. Cross Lap Joint
5. Tenon joint
6. Dove - Tail Joint
WELDING
Introduction
7. Single V-Butt Joint
8. Lap Joint
9. T-Fillet Joint
BASIC MACHINING
Introduction
10. Facing, Turning, Step Turning, Chamfering and Taper
11. Drilling and Tapping
SHEET METAL
Introduction
12. Rectangular Tray
MACHINE ASSEMBLY PRACTICE
Study of Centrifugal Pump
Study of Air Conditioner
Assembling a household mixer.
FOUNDRY WORK

Demonstrating basic foundry operations.

CONTENT BEYOND SYLLABUS

Butt Welding Practice
OPEN ENDED EXPERIMENTS
Making of Truss
 CO – LABORATORY MAPPING
Department of Mechanical Engineering

Programme & Branch: B.E & Common to All Branches Regulation: 2023
Course Code & Name: 23GE121& Engineering Practices Laboratory Year/Semester: I/I & II

CO List of Experiments

CO 1: 1. Connection of Two Galvanized Iron Pipes

Design the knowledge of pipeline 2. Connections of PVC Pipes
connections to household fittings
and Industrial buildings 3. Basic Pipe Connections Involving The Fitting Like Valves,
Taps and Bends

CO 2 : 4. T – Joint & Mortise joint

Create different joints in 5. Tenon joint
carpentry 6. Dove - tail joint

7. Single v-butt joint

CO 3:
Design and fabricate the various 8. Lap joint
welding processes
9. T-fillet joint

CO 4: 10. Facing, turning, step turning, chamfering and taper turning

Classify the basic machining Facing, 11. Drilling and tapping
Turning, Step Turning Drilling &
Tapping.

CO 5: 12. Rectangular tray

Develop and fabricate various
processes in sheet metal works
CO3: Content beyond syllabus:
Design and fabricate the two pieces
of metal together by welding Butt Welding Practice
processes
PLUMBING
 PLUMBING

Introduction:

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

TOOLS EXAMPLE

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

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

3. Measuring tools Rule, Tape

4. Holding tools Pliers, Clamps, Wrenches, Vices

5. Cutting tools Saws, Files, Chisels

6. Scraping & Grinding tools Scraper, Grinders

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

8. Striking & Fastening tools Hammers, Screwdrivers

Pipe threading dies:

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

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

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

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

5. Four way cross:

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

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

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

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

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

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

12. Flange:
It contains internal threads in the hub and holes in the body to receive bolts. Two
pipes may be joined together in line, using flanges and bolts. Flanges are available either in
oval or in circular shapes.

13. Socket reducer:

It is used to connect a big pipe to a small pipe face to face.
 Pipe2

Socket
Back nut

Step 2:

Step 3:

Connection of two Galvanized iron pipes

EX.No.1 CONNECTION OF TWO GALVANISED IRON PIPES
Aim:

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

Materials supplied:

1. Two G.I Pipes

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

Procedure:

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

Result:

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

 Given Material For Running Joint

Pipe 1

Coupling

Given h4aterial For Tee JOtDt

Pipe 2

Tx
Solution:
Ex.No.2 CONNECTIONS OF PVC PIPES
Aim:

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

Material supplied:

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

Procedure:

Running Joint:

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

T- Joint:

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

Result:

Thus the given PVC pipes are connected using running joint and Tee joint.
Pipe Connections Involving the Fitting like Valves, Taps and Bends
 EX.No.3 BASIC PIPE CONNECTIONS INVOLVING THE FITTING LIKE
VALVES, TAPS AND BENDS
Aim:

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

Materials supplied:

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

Procedure:

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

Result:

Thus the basic connections of pipes with pipe accessories are made.
CARPENTRY
 CARPENTRY

Introduction:

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

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

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

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

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

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

Carpentry tools:
Large numbers of tools are used in carpentry. Following are the types of tools used in carpentry.
(1) Marking and measuring tools.
(2) Cutting tools.
(3) Planning tools.
(4) Boring tools.
(5) Striking tools and Holding tools and Power tools.
leg Try Square

Screw thread

Handle
Holding tools:
During the wood working job is shacked, so marking accuracy is tough. To maintain accuracy
the wood is to be held rigidly.
(a) Bench vice:
It is the most common work holding device. It consists of one fixed jaw and one
movable jaw. The fixed jaw is fastened to the work bench. The gap between the jaws are
adjusted using the screw rod.
(b) C-clamps:
It is made up of malleable iron. The operating capacity rates from 50 to 350mm. it can
be used for clamping small work. The swivel shoe allows to fix angled work.
 40

40

40
20

4. CHISE LING

40 15
40 0

40 40 40

150

40
5. FINISHING
EX.No.4 CROSS LAP JOINT
Aim:
To make a cross lap joint from the given wooden piece for the given dimensions.

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

Tools required:
1. Steel rule 2. Carpentry vice
3. Jack plane 4. Try square
5. Marking gauge 6. Rip saw
7. Saw 8. Firmer chisel
9. Mallet

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

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

Result:
Thus the desired cross lap joint is obtained.
 40

40
“ 4IJ

CHISELINC

40

FINISH ING
EX.No.5 T-JOINT
Aim
To make the T-joint the required dimensions from the given work piece.

Material Required

Soft wood of size 300x50x50 mm.

Tools Required
1. Jackplane
2. Carpentry vice
3. Try square
4. Marking gauge
5. Steel rule
6. Saw
7. Rip saw
8. Firmer chisel
9. Mallet

Procedure
1. The given work piece is firmly clamped in the carpentry vice and any two adjacent surfaces
are planned to get right angles using the jack plane.
2. Using the try square, the right angles of planned faces are checked.
3. Now the other two surfaces are planned to get smooth surface.
4. The work piece is cut into two pieces by using the rip saw.
5. Using the steel rule and marking gauge, marking is done for T-joint on the two halves.
6. In one half, the unwanted portions of wood are removed by using the saw and firmer
chisel. The same procedure is done for the other half of work piece.
7. Using the jack plane, the other two faces of work piece is planned to the required size.
8. The finished two pieces are assembled to getter to form the T-joint.
9. Finally, the finished job is checked for required size and shape using the steel
rule and try square.

Result

Thus the required T-joint is obtained.

 L HISEL ING

40
40

40

FINISHING
EX.No.6 DOVETAIL JOINT
Aim

To make the Dovetail joint the required dimensions from the given work piece.

Material Required

Soft wood of size 300x50x50 mm.

Tools Required

1. Jackplane
2. Carpentry vice
3. Try square
4. Mortise gauge
5. Mallet
6. Firmer chisel

Procedure
1. The given work piece is firmly clamped in the carpentry vice and any two adjacent
surfaces are planned to get right angles using the jack plane.
2. Using the try square, the right angles of planned faces are checked.
3. Now the other two surfaces are planned to get smooth surface.
4. The work piece 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 rule and marking gauge.
6. Remove the unwanted portions as per the drawing and assemble to
check proper fitting.

Result

Thus the desired dovetail joint is obtained.

WELDING
 WELDING

Introduction:

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

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

Types of welding:

Welding process is mainly divided into the subdivisions as follows:

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

2CO + O2 → 2CO2

2H2 + O2 → 2H2O
Types of flames:
1. Neutral flame (oxygen, acetylene in equal proportions)
2.Oxidizing flame (excess of oxygen)
3. Reducing flame (excess of acetylene)
Limitations:
In this method, only those metals whose combustion temperature is below their melting
point can be cut. So iron and steel can be cut flame cutting.
Principle:
The heat required for joining the metal is obtained from an electric arc. The electric motor
generator or transformer sets are used to supply high electric curr ent and the electrodes are
used to produce the necessary are. The electrode saves as the filler rod and are melts the
surfaces so that the metals to be joined are fused together.
Tots

Hand Gloves
Welding bed cleaning accessories:

1. Wire bush:

A wire bush made up of stiff steel wire.

2. Chipping hammer:

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

3. Hand screen:

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

4. Helmet:

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

5. Tongs:

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

6. Goggles:

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

7. Hand gloves:

Hand gloves are used to protect the hands from electric shocks, arc radiation and hot
spatters.
 Tacks

Welded Joint Representation

Ex.No.7 SINGLE V-BUTT JOINT
Aim:

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

Material supplied:

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

Tools required:

1. Power supply (AC or DC)

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

Sequence of operations:

1. Edge preparation (Removal of rust, scale etc.,)

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

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

Result:
Thus the desired Single V-Butt joint is obtained using arc welding.
I02

102

Welded Joint Representation

Ex.No.8 LAP JOINT
Aim:

To make a lap joint using arc welding on the given work pieces.

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

Tools required:

1. Power supply (AC or DC)

2. Welding Torch
3. Electrodes
4. Tongs
5. Chipping hammer
6. Wire brush
7. Gloves
8. Apron
9. Shield
10. Safety goggles
11. Earthing clamps
Sequence of operations:
1. Edge preparation (Removal of rust, scale etc.,)
2. Tacking
3. Welding
4. Cooling
5. Chipping
6. Cleaning

Working steps:

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

Result:
Thus the desired lap joint is obtained using arc welding.
 50
100

Welded Joint Representation

Ex.No.9 T-FILLET JOINT
Aim:

To make a T-Fillet joint using arc welding on the given work pieces.

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

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

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

Working steps:
1. First of all, the work pieces must be thoroughly cleaned to remove rust, scale and other
foreign materials.
2. Then the given work pieces are placed on the table in such a way that two work pieces
are brought close to each other so that it forms a ‘T’ shape is shown in the fig.
3. Appropriate power supply should be given to the electrode and work pieces.
4. Now the welding current output may be existed.
5. When current is passed, arc is produced between the electrode and work pieces.
6. Set the two work pieces in correct position like T-Fillet joint and tack at both ends of the
work pieces as shown in the figure.
7. The joint is placed on a welding table in a flat position by keeping the tack side down.
8. Then the welding is carried out throughout the length.
9. As soon as the welding process is finished, switched off the current supply and allow the
work piece to cool.
10. Slag’s are removed by chipping process with the help of chipping hammer.
11. Finally using wire brush, welded portions are cleaned.

Result:
Thus the desired T-Fillet joint is obtained using arc welding.
 BASIC
MACHINING
 BASIC MACHINING

Introduction
:

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

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

Basic working principle of lathe:

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

Types of lathe machines:

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

Work holding devices:

1. Lathe centre
They are used to support work. It has two categories of centre.
(a) Live centre is one which is fitted in the headstock spindle.
(b) Dead centre is one which is fitted in the tailstock.
2. Chuck
(a) It is a device used to hold a job. It is easily fitted on the thread cut on the end
of headstock spindle.
(b) Various types of chuck are
i. Two jaw chuck
ii. Three jaw chuck
iii. Four jaw chuck
iv. Collet chuck
v. Magnetic chuck
3. Face plate
(a) It is a circular plate and it is screwed to lathe spindle.
(b) It is used for mounting the type of jobs which cannot be held by chucks.
(c) There are number of holes and slots on the face of the face plate.
 RQ&mHm
d Teralag Teel

L*AMzxdTsrsAg
Tot
Reasd
NozcTurzJag Tool

Borin g Tool

Knu•ling Tool

Right Hsnd Fsclng Tool

 4. Catch plate
(a) It is a plain disc of steel or cast iron.
(b) It is screwed to the nose of the headstock spindle.
(c) It is used to drive the work piece through a carrier or dog when it is held
between the centers.

5. Lathe carriers or Dogs

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

The types of Dogs are

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

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

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

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

Cutting tools used:

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

2. Rough turning tool

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

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

Taper = (D-d) / L

Where,
D is large diameter
d is small diameter
L is length of
tapper.
After Machining
 EX.No.10 FACING, TURNING, STEP TURNING, CHAMFERING AND TAPER
TURNING
Aim:

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

Material supplied:

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

Tools required:

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

Sequence of operations:

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

Working steps:

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

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

After Machining
 EX.NO.11 DRILLING AND TAPPING
Aim:
To drill the holes of required size and tap the drilled hole.

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

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

Sequence of operations:
1. Checkig
2.Filling
3.Marking
4.Punchig
5.Drilling
6.Tapping

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

Result:
Thus the given work piece is drilled and tapped to the required dimensions.
SHEET
METAL
 SHEET METAL
Introduction:

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

Application of sheet metal:

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

Tools used:

Cutting tools (chisels, snips or shears):

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

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

Striking tools:

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

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

Supporting tools:

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

Handle

ggll peen hammer

Scriber Divider
Bending tools:
Pliers:
Pliers are used for bending the sheet metal to the required shape. It is also used for holding
and cutting the sheet metal. Flat nose pliers and round nose pliers are used in sheet metal work
for forming and holding work.

Layout tools:
Steel rule:
It is used for measuring and laying out small work it can measure with as accuracy of up to
0.5mm.

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

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

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

Sheet metal gauge:

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

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

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

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

Sheet metal joints:

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

Hem:
A hem is an edge or border made by folding. Types of hem are Single hem, Double hem,
wired edge.
20 80

— — — — — — — Bending Lines

Flaps - Riveting

Edge Hemming
out slde
EX.No.12 RECTANGULAR TRAY
Aim:

To make a rectangular tray from the given sheet metal.

Material supplied:

22 gauge Galvanized Iron (G.I) sheet.

Tools required:

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

Sequence of operations:

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

Working steps:

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

Result:

Thus the desired rectangular tray is made from the given sheet metal.
 STUDY
EXERCISES
Ex.No.1 STUDY OF CENTRIFUGAL PUMP

Introduction:

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

Working principle:

The centrifugal pump works on the principle of Forced Vortex Flow which means that when
a certain mass of liquid is rotated by an external torque, the rise I pressure head of the rotating
liquid take place. The rise in the pressure head at any point of the rotating liquid is proportional
to the square of tangential velocity of the liquid at that point.

Main parts of Centrifugal pump:

The followings are the main parts of a centrifugal pump,

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

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

i. Volute casing
ii. Vortex casing
iii. Diffuser casing
4. Delivery
pipe:

A pipe whose end is connected to outlet of the pump and the other end delivers
the water at required level is known as Delivery pipe.
Working of Air conditioner
EX.NO.2 STUDY OF AIRCONDITIONER

Introduction:
An air conditioner is defined as an assembly of different parts of the system used to produce a
specified condition of air within required space or building below that of atmosphere or surroundings.
An ideal air- conditioner should maintain correct temperature, humidity and air- movement etc.
Generally a small distance air-conditioning plant having the capacity of 0.5 ton. In a window air-
conditioner all the components are located in a box.

Mechanism:
An air- conditioning system works on vapour compression cycle. This cycle works in
following four phases.
1. Compression
2. Condensation
3. Expansion and
4. Evaporation
1. Compression
Compression takes place at the compressor. The low pressure, low temperature dry
refrigerant or coolant vapour is drawn from the evaporator into compressor cylinder
during suction stroke of the compressor. During compression stroke pressure and
temperature of the vapour increases until the vapour temperature is greater than the
temperature of condenser cooling medium (Air or water). This high pressure and high
temperature vapour passes out to the condenser through discharge line.
2. Condensation
In the condenser high pressure and high temperature refrigerant vapour rejects heat to
cooling medium thus allowing the 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 reduce very much to allow the vaporization of liquid at very low temperature of
about -100 C.
4. Evaporation
Then the low pressure low temperature refrigerant vapour enters into the evaporator.
Where a considerable amount of heat is absorbed from the surrounding by the refrigerant. After
absorbing heat from the surrounding, the liquid refrigerant changes to vapour state. Then the
refrigerant vapour again moves into compressor through the suction line. Again the vapour
compression cycle is repeated.

Boiling point of a refrigerant is very low. The refrigerants absorb heat from one place
and release it to the other place. Generally Freon 12 is used as a refrigerant in domestic air-
conditioner. It is observed that all the chloro fluro carbons (CFC) including Freon affects the
ozone layer causing global warming. Since now-a-days the newly invented refrigerant Hydro
Fluoro Carbon (HFC) is used as refrigerant.

Main parts of an air- conditioner

The followings are the main parts of an air- conditioner Compressor
Condenser
Expansion device
Evaporator and Fan
CONTENT
BEYOND
SYLLABUS
EX NO. 1 BUTT WELDING PRACTICE

Aim:

To make a welding by using butt welding machine on the given work pieces.

Material supplied:

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

Tools required:

1. Power supply (AC or DC)

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

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

Result:
Thus the given work piece is welded by using butt welding machine.