GE3271 Engineering Practices Laboratory

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 air conditioner.

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
Course Outcomes
Upon 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.
 Department of Mechanical Engineering
GE3271 Engineering Practices Laboratory

Index

S. No. Date Title Marks Signature

Group - A

Part - I Civil Engineering Practices

1. Study of Plumbing Tools and Equipments

2. Basic Pipe Connections Involving the

Fittings Like Valves, Tapes and Bends

3. Preparation of Plumbing Line Sketches for

Water Supply and Sewage Works

4. Plumbing Line Preparation for a Pump

(Suction & Delivery)

5. Study of the joints in Roofs, Doors, Windows

and Furniture

6. Sawing, Planning and Making of T-Joint

7. Sawing, Planning and Making of Mortise

joint and Tenon joint

8. Sawing, Planning and Making of Dovetail

joint.

9. Study of Common Industrial Trusses using

Models

Group - B

Part - III Mechanical Engineering Practices

10. Study of Welding Tools and Equipments

11. Gas Welding Practice

12. Welding of Square Butt Joint

13. Welding of Lap Joint

14. Welding of Tee-Fillet Joint

15. Study of Basic Machining

(Lathe and Drilling Machine)

16. Facing and Plain Turning

17. Taper Turning

18. Drilling and Tapping

19. Assembling of Centrifugal Pump.

20. Assembling of Household Mixer

21. Assembling of Air Conditioner

22. Study of Sheet Metal Tools and

Operations

23. Making of a Square Tray

24. Study of Foundry

25. Moulding of Gear Pattern

26. Moulding of Stepped Cone Pulley

Experiments
 Ex.No. :
Study of Plumbing Tools and Equipments
Date :

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 4. Hacksaw 7. Plumb bob
2. Pipe vice 5. Dies
3. Pipe cutter 6. Files and Rasps

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.

1
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.

Hacksaw

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.

2
Plumb bob
It is used for check the vertical line and made up of steel or brass.

Pipe fittings

3
 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.

4
Valves
Valves are used for regulating the flow of fluid through a pipe. The commonly used
valves in plumbing’s are

Gate valve
Wheel

Stem
Feed

Bonnet

Fluid in Disc fluid out

Plug Value

Globe valve

Packing nut

Packing

Disk stem ring

Disk

Air relief valve

Check valve

Conclusion

5
Basic Pipe Connections involving the Fittings
like Valves, Tapes and Bends

6
 Ex.No. : Basic Pipe Connections involving the
Date : Fittings like Valves, Tapes and Bends

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

Materials Supplied
1. Pipe Wrench
2. Thread 6. Cast Iron Pipes
3. Elbow 7. Coupling
4. Valves 8. Pipe Vice.
5. Taps

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

Result

7
Preparation of Plumbing Line Sketches for
Water Supply and Sewage Works

Water supply and Sewage plumbing system

8
 Ex.No. : Preparation of Plumbing Line Sketches for
Date : Water Supply and Sewage Works

Aim
To prepare the plumbing line sketches for water supply and sewage works

Descriptions
Plumbing line sketch includes pipes, fixtures and accessories which carry water
from the main source of supply to the required user ends. The plumbing line sketches
represent the pipe distribution system. There are different symbols used to represent
each component in the piping system. There are two types of piping drawings.

a. Single line piping drawing

Single line piping drawings use a single line to show the arrangements of the
pipe and fittings. The single line piping drawing is prepared in orthographic
or pictorial projections. Orthographic pipe drawings show single pipe either
straight or bent in one plane only. Pictorial projection is used for pipes bending
more than one plane.

b. Double line piping drawing

Double line piping drawing is generally used in applications structures,
catalogs, where visual appearance is more important than drawing eye.
Orthographic pipe drawings are sometimes used on more complicated piping
systems.

Procedure for Drawing Plumbing Line Sketches

1. Identify pictorial, schematic and orthographic drawings, and discuss how
different views are used to depict information about objects.
2. Explain the types of drawings that may be included in a set of plumbing
drawings and the relationship among the different drawings.
3. Identify the basic symbols used in schematic drawings of pipe assemblies.
4. Interpret plumbing related information from a set of plumbing drawings.
5. Sketch orthographic and schematic drawings.

Result

9
Plumbing Line Preparation for a Pump

10
Ex.No. : Plumbing Line Preparation for a Pump
Date : (Suction and Delivery)

Aim
To lay pipe connections in the suction & delivery line for the given pump.

Material Supplied
1. Pump 6. Foot Valve with Strainer
2. Spanner 7. Bend
3. Pipe Wrench 8. Coupling
4. Hammer 9. Concentric Reducer
5. Flange

Procedure
1. Take a length pipe and at extreme end, fit the foot valve and strainer.
2. Check for leakage in foot valve because it is very necessary.
3. Connect pipe with coupling to sufficient length as required.
4. Use 90° bend connecting a pipe with a flange.
5. Now, the flange is connected with pipe to the pump inlet.
6. Similarly, connect the fittings like check valve, gate valve, elbow etc. to the
delivery pipe knowing the length or height of delivery.
7. Pour water into the pump outlet through priming hole.
8. Check for leakage in flange and fittings.
9. Run the pump for removing air lock in pump.
10. Now, the pump is tested and ready for normal use.

Result

11
Work Sheet

12
 Ex.No. : Study of the Joints in Roofs, Doors,
Date : Windows and Furniture

Aim
To study the tools, equipments and processes used in carpentry

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

Types of Woods
1. Woods are generally classified into three types:
2. Softwood (Deodar, Kail, Chir)
3. Hardwood (Teek, Shirham, Sal, Mango, Oak)
4. Plywood

Carpentry Tools
1. Measuring and Marking tools 4. Boring tools
2. Cutting tools 5. Striking tools
3. Planing tools 6. Holding tools

Measuring and Marking tools

Some of the measuring and marking tools are listed as,
1. Calipers and compasses 5. Gauges (Marking gauge, mortise
2. Steel rule gauge)
3. Try square 6. Dividers
4. Mitre square 7. Scribers

Cutting Tools
The two cutting tools used in carpentry are
1. Saws
OO Rip saw (Fig)
OO Cross cut saw
OO Tenon saw
OO Compass saw (Fig)
OO Coping

13
 a ck
ght b
Strai

(a) Rip Saw

(d) Bow Saw

back
S ke w

(b) Cross Cut Saw

(e) Coping Saw

(c) Flooring Saw (d) Pad Saw

(g) Tenon Saw

(h) Two Man Crosscut Saw

Chisels
Chisels are the tools produced from forges steels or tool steel blades

Firmer chisel
Firmer chisel is the most commonly used chisel. It is used for light and heavy work.
Tang, Handle, ferrule and cutting edge are the parts of firmer chisel.

Parting Chisel

Firmer Chisel

Framing Chisel

14

Mortise Chisel
 Framing Chisel

Mortise Chisel

Outside bevel
Gouge Chisel

Inside bevel
Gouge Chisel

Dovetail Chisel
Paring chisel has thinner blade and used for light work. This chisel is used for
shaving or paring plane surfaces. The blade has either square or beveled edges.

Mortise chisel
It is used to make mortises. Mortise chisel is used for heavy cuts. The blade
thickness varies from 5 mm to 12 mm. Because of wider thickness this blade is stronger
in comparison to other chisels of same size, therefore it is capable of taking the heavy
blows.

Gauge chisel
It used to finish curved holes; Gauge chisels are of two types i.e., insider and outside
gauge chisels

Planning Tools
Planes are used to produce flat surfaces on wood. A plane is like a chisel fitted
in a block of metal on wood. The cutting blade is fixed in a wood or metal with some
inclination
There are many types of planes are used, but in general use are
OO Wooden jack plane OO Smoothing plane
OO Iron jack Plane (Fig.) OO Rasp file
OO Trying plane (Fig.)

15
 Rasp File

Blade
Blade Wedge

Wedge Blade

Wedge

Lever cap
Blade Plane iron
Wedge
Back iron

Body
Trying Plane
Iron Jack Plane

Boring Tools
To make holes in wood, boring tools are used

Brace
It holds and turns the bit and boring of hole is achieved. It may be of ratchet brace
or wheel brace.

Bradawl
Gimlet
Bradawl and Gimlet are used to bore small holes

Striking Tools – Hammers

Hammer is one of the mostly used striking tools. The types are

Nail

Claw Hammer Cross Peen Hammer Mallet

16
 Cross - peen Hammer
The cross – peen hammer is mostly used for positioning small nails. The head is
tightly used in the handle with the help of iron wedges.

Claw Hammer
It is effective in removing very large nails and also for driving the nails using end
of the hammer
Mallet (Fig.): It is used to give light blows. The head is made up of wood and round
in section. The striking face is flat.

Cross Peen Hammer Mallet

Mallet

Holding Tools
During woodworking, job is shaked. So maintaining accuracy is tough. To maintain
accuracy, the wood is to be held rigidly.
Carpentry Vice (Fig.) : It is most common work holding device. It consists of one
fixed jaw and movable jaw. The fixed haw is fastened to the workbench and the movable
jaw mounted over the screw rod and guide pins.
C-clamps (Fig.): It is made up of malleable iron. The opening capacity varies from
50 to 350 mm. It can be used for clamping small work. The swivel shoe allows fixing
angled work.

Trigger for quick opening

Carpentry Vice

17
 C -Clamp B - Block

Power Tools
In modern carpentry there is a wide variety of power tools are available to make
ease of the work.
Some of the important power tools are listed as below:
OO Planing Machine / Palner OO Jig-saw
OO Power Hacksaw OO Circular saw
OO Hand drilling machine OO Rotary hammer

Carpentry Processes
To finish a work to the required size and shape in wood working shop, several
operations are performed. These operations are
OO Measuring & Making OO Boring
OO Planing OO Grooving
OO Chiseling OO Moulding
OO Sawing OO Recession
OO Mortising and tenoning

Carpentry Joints
Following are the various types of carpentry joints, which are commonly used in
various applications.
OO Middle lap joint OO Tenon joint
OO Cross lap joint OO Dovetail joint

18
Conclusion

19
Sawing, Planning and Making of T - Joint

* All dimensions are in mm

20
Ex.No. :
Sawing, Planning and Making of T - Joint
Date :

Aim
To make a T- joint to the required dimensions from the given work piece.

Material Supplied
A soft wooden Piece of size, L.B.T = 200 x 45 x 45 mm

Tools Required
1. Machine Planer 5. Rip Saw
2. Marking Gauge 6. Circular Saw
3. Mallet 7. Try Square
4. Calipers

Sequence of Operations
1. Planing 4. Fitting
2. Chiseling 5. Sawing
3. Marking

Procedure
1. The given work piece is clamped in the carpentry vice and two adjacent faces
are planed to get right angles, using machine planer.
2. The work piece is cut into two halves using rip saw.
3. With the finished face as reference the required size is marked on the work
piece by means of steel rule and marking gauge.
4. In one half of the work piece, the unnecessary portions are removed using
mitre saw and firmer chisel.
5. Similarly the unwanted portions are removed in the other half of the work
piece using circular saw and firmer chisel.
6. Now, the two pieces are assembled to check proper fitting.
7. Finally, the accuracy and proper dimensions are verified by using steel rule
and try square.

Result

21
Sawing, Planning, Making of Mortise Joint and Tenon Joint

* All dimensions are in mm

22
 Ex.No. : Sawing, Planning, Making of Mortise Joint
Date : and Tenon Joint

Aim
To make a Mortise joint and Tenon joint to the required dimensions from the given
work piece.

Material Supplied
A soft wooden Piece of size, l.b.t = 200 x 45 x 45 mm

Tools Required
1. Machine Planer 4. Try Square 7. Circular Saw
2. Mallet 5. Marking Gauge
3. Rip Saw 6. Calipers

Sequence of Operations
1. Planing 3. Sawing 5. Fitting
2. Marking 4. Chiseling

Procedure
1. The given work piece is clamped in the carpentry vice and two adjacent faces
are planed to get right angles, using machine planer.
2. The work piece is cut into two halves using rip saw.
3. With the finished face as reference the required size is marked on the work
piece by means of steel rule and marking gauge.
4. In one half of the work piece, the unnecessary portions are removed using
mitre saw and firmer chisel.
5. Similarly the unwanted portions are removed in the other half of the work
piece using circular saw and firmer chisel.
6. Now, the two pieces are assembled to check proper fitting.
7. Finally, the accuracy and proper dimensions are verified by using steel rule
and try square.

Result

23
Sawing, Planning and Making of Dovetail Joint

* All dimensions are in mm

24
Ex.No. :
Sawing, Planning and Making of
Date : Dovetail Joint

Aim
To make a dovetail joint from the given wooden piece as per the given dimensions.

Material Supplied
A soft wooden piece of size, L.B.T = 200 x 45 x 45 mm.

Tools Required
1. Machine Planer 5. Rip Saw
2. Marking Gauge 6. Circular Saw
3. Mallet 7. Try Square
4. Calipers

Sequence of Operations
1. Planing 4. Fitting
2. Chiseling 5. Sawing
3. Marking

Procedure
1. The given work piece is clamped in the carpentry vice and two adjacent faces
are planed to get right angles, using machine planer.
2. The work piece is cut into two halves using rip saw.
3. With the finished face as reference the required size is marked on the work
piece, by means of steel rule and marking gauge.
4. In one half of the work piece, the unnecessary portions are removed, using
mitre saw and firmer chisel.
5. Similarly, the unwanted portions are removed in the other half of the work
piece, using circular saw and firmer chisel.
6. Now, the two pieces are assembled to check proper fitting.
7. Finally, the accuracy and proper dimensions are verified, by using steel rule
and try square.

Result

25
Study of Common Industrial Trusses using Models

26
 Ex.No. : Study of Common
Date : Industrial Trusses using Models

Aim
To study the common industrial trusses using models.

Types trusses
Trusses comprise assemblies of tension and compression elements. Under gravity
loads, the top and bottom chords of the truss provide the compression and tension
resistance to overall bending, and the bracing resists the shear forces. A wide range of
truss forms can be created. Each can vary in overall geometry and in the choice of the
individual elements. In Types of trusses, 5 main types of roof trusses which are mainly
used on typical single storey industrial buildings like sheds, factories, warehouses. The
roof trusses are widely used to serve two main functions:
OO To carry the roof load
OO To provide horizontal stability

Pratt truss (‘N’ 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.This has a few effects – it reduces the cost
of the structure due to more efficient members, reduces the self-weight, and eases the
constructability of the structure. This type of truss is most appropriate for horizontal
spans, where the force is predominantly in the vertical direction.
Pratt trusses are commonly used in long span buildings which range from 20 to 100
m in span. In a conventional Pratt truss, diagonal members are in tension for gravity
loads. This type of truss is used where gravity loads are predominant. An alternative
Pratt truss is shown (below right) where the diagonal members are in tension for uplift
loads. This type of truss is used where uplift loads are predominant, which may be the
case in open buildings such as aircraft hangers.

Warren Truss
The Warren truss consists of longitudinal members joined only by angled cross-
members, forming alternately inverted Equilateral triangle-shaped spaces along its

27
North Light Roof Truss

28
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.
Loads on the diagonals alternate between compression and tension (approaching
the center), with no vertical elements, while elements near the center must support both
tension and compression in response to live loads. This configuration combines strength
with economy of materials and can therefore be relatively light. The girders being of
equal length, it is ideal for use in prefabricated modular bridges.Warren trusses are
commonly used in long span buildings ranging from 20 to 100 m in span. This type of
truss is also used for the horizontal truss of gantry/crane girders.

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.
This roof consists of a series of trusses fixed to girders. Therefore, it allows
maximum benefit to be gained from natural lighting by the use of glazing on the steeper
pitch which generally faces north or north-east to reduce solar gain.
On the steeper sloping portion of the truss, it is typical to have a truss running
perpendicular to the plane of the North Light truss, to provide large column-free spaces.
The use of north lights to increase natural day lighting can reduce the operational
carbon emissions of buildings although their impact should be explored using dynamic
thermal modelling.

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.

Conclusion

29
 Study of Welding Tools and Equipments

High volts
Low amps
INPUT
Electrode Primary

A Transformer

Output
B
High amps
Low volts

Secondary

Metal table
Arc

Arc Welding Principle

60°-70° 40°-50°

30°-40° 30°-40°

Direction of Direction of
travel travel
a - Leftward b - Rightward

Metal Arc Welding setup

30
 Ex.No. :
Study of Welding Tools and Equipments
Date :

Aim
To study the welding process and the tools equipments used in welding.

Introduction to Welding
Welding is the process of joining similar metals by application of heat with or
without application of pressure and addition of filler materials.
The welding method is broadly classified as
Plastic or Pressure Welding
Fusion or Non-Pressure Welding
Pressure Welding
The piece of metals to be joined are heated to a plastic state and then forced together
by external pressure.
Example : Resistance Welding, Forge Welding, Gas Welding

Non-Pressure Welding
The material at the joint is heated to molten state and allowed to get solidity.
Example: Arc Welding, Gas Welding.

Arc Welding Principle

Heat required for welding is obtained from the arc struck between flux coated
Electrode and the work piece. The arc temperature and thus the arc heat can be
decreased by employing higher or lower arc currents. A high current arc with a similar
arc length produces a very intense heat.
The arc is transformed from electrode to the job metal and thus it melts the metal
as shown in fig.
Then the two metals get welded / joined along the time which arc is deposited.

Welding Equipments
Equipments used in welding are
OO AC and DC supply
OO Electrode Holder
OO Welding Leads or Electrode Chipping Hammer
OO Wire Brush

31
 Safety Equipments
Flexible hose

Thread connection
Pressure
gauge Control valve Filler rod

Pressure Work piece

Flame
gauge

Maroon
Black

Oxygen Acetylene cylinder

cylinder

Welding Equipments
Tip
Working pressure Cylinder pressure
gauge gauge
Oxygen regulator
Mixing chamber
Working pressure gauge
Acetylene
needle valve Oxygen needle
valve
Oxygen hose
Acetylene regulator

Cylinder pressure
Acetylene hose gauge Oxygen

Acety-
lene
Twin hose

Gas Welding

32
AC and DC Supply
The most commonly used power for Arc Welding is transformer. A transformer
may be operated from the main on single phase, two phase or three phase. Transformer
is either air cooled or oil cooled depending upon their ampere rating.

Electrode Holder
It is a device used for holding the electrode which is connected with the
power output of the transformer.

Electrode
Material in which the arc is produced between its tip and the job metal.

Chipping Hammer
Used for removing unwanted chips produced at the time of welding.

Wire Brush
It is for cleaning the welded job metals and make it as a finely finished one.

Safety Equipments
These are used for protecting the welder who involved in welding. Some of the
safety equipments which are normally used in welding are listed below:
OO Hand Shields
OO Gloves
OO Shoes
OO Aprons etc.,

Advantages of Arc Welding

OO Simplest.
OO Low cost.
OO Wide range of metals and their alloys can be welded.
OO Welding can be carried out in any position with high welding quality.

Gas Welding
A fusion welding process joints metal by burning a combustion gas with air or
oxygen in a concentrated flame of high temperature. The purpose of the flame is to heat
and melt the parental metal and the filler rod at joints.

Oxy- Acetylene Welding Principle

When acetylene is mixed with oxygen in correct proportions in welding torch and
ignited. The flame Resulting at the tip torch is sufficiently hot to melt and joint the
parental metal. The flame reaches a temperature of about 3200°C. A filler metal rod is
generally added to the molten metal to build up the screen for greater strength.

33
 Groove or included angle

Weld size leg

Weld size
Bevel angle
Toe Weld face

Thickness
Weld face Fusion zone
Fusion zone Toe

Root
face
Root

Base metal
Root opening Throat

Edge joint

Tee joint
Butt joint

Corner joint

Lap joint

Types of welded joints

70º
70º

90º
90º

Weaving First run no Second run

weaving action weaving action
Electrode 3.75mm Electrode 4mm
115 A 160 A
Single V-butt weld in 6mm mild steel plate

34
Flame Types
Neutral Flame
Produced when the volume of oxygen and acetylene are equal. Flame temperature
is about 3260°C. The flame has a nicely defined inner core of light blue surrounded by
an outer flame of darken blue. It is commonly used for welding of MS, SS, Cast Iron, Cu
and AI.

Oxidizing Flame
It is obtained by the excess supply of oxygen. It can be recognized by the small
white core, which is shorter, much blue and more pointed than neutral flame. The flame
temperature is 3482°C. The flame is when welding Cu and Zn based metals and not
used in welding of steel.

Reducing Flame
It is obtained when the volume of oxygen supplied to the neutral flame is reduced.
It can be recognized by acetylene further which exists between the inner core and the
outer envelope. The outer envelope is longer than that of the neutral flame. The flame
temperature is about 3038°C. it is used for low alloy steel rods and high carbon steel.

Welding Processes
OO Edge preparation OO Welding OO Chipping
OO Tracking
OO Cooling OO Cleaning

Types of Flames
Torch tip Torch tip Torch tip

Inner cone Inner cone Sharply pointed

Outer envelope Acetylene feather inner cone
Outer envelope Outer envelope

a b c

35
 Hand gloves

Equipments used in welding process

36
Conclusion

37
 Gas Welding Practice

Tip
Working pressure Cylinder pressure
gauge gauge
Oxygen regulator
Mixing chamber
Working pressure gauge
Acetylene
needle valve Oxygen needle
valve
Oxygen hose
Acetylene regulator

Cylinder pressure
Acetylene hose gauge Oxygen

Acety-
lene
Twin hose

Set up of oxy-acetylene gas welding

Solid extruded covering

Core wire
Strinking end

Bore end for gripping in electrode holder

Welding torch

38
Ex.No. :
Gas Welding Practice
Date :

Aim
To Join the given two work pieces as a required type of joint by gas welding.

Material Supplied
Mild Steel plate of size, L.B.T = 100 x 50 x 5 mm (two pieces).

Tools Required
1. Oxygen and acetylene gas cylinder with the Safety Goggles
2. Gloves equipment (Pressure gauge, regulators)
3. Gas Welding Torch
4. Chipping Hammer
5. Filler Rod
6. Wire Brush

Sequence of Operations
1. Edge Preparation 5. Tacking
2. Cooling 6. Cleaning
3. Positioning 7. Welding
4. Chipping

Procedure
1. The given work pieces are thoroughly cleaned, i.e. rust, scale are removed.
2. The joining work pieces are positioned properly.
3. Acetylene and oxygen cylinder valves are opened and then the acetylene torch
valve is opened.
4. Light the tip of the torch using a lighter.
5. Oxygen and acetylene torch valves are adjusted and the required flame is
obtained.
6. The welding torch and filler rod are moved along the line of weld and welding
is done by maintaining 3 mm gap between the plate and the inner cone of
flame.

Result

39
 Welding of Square Butt Joint

All Dimensions are in mm

40
Ex.No. :
Welding of Square Butt Joint
Date :

Aim
To make the square butt joint between the given work pieces using arc welding.

Material Supplied
Mild Steel plate of size, L.B.T = 100 x 50 x 5 mm (two pieces).

Tools Required
1. Welding Transformer 4. Chipping Hammer
2. Tongs and Wire Brush 5. Gloves and Goggles
3. Welding Electrodes 6. Flat File and Hand Shield

Sequence of Operations
1. Edge Preparation 5. Tacking
2. Cooling 6. Cleaning
3. Positioning 7. Welding
4. Chipping

Procedure
1. Clean the given work pieces using the wire brush to remove the rust, scale
and other impurities.
2. Fix the welding electrode (3.15 mm diameter) to the electrode holder and the
welding current is set to a proper value.
3. Appropriate power supply should be given to the electrode and the work
pieces.
4. When the current is passed, arc is produced between the electrode and work
pieces.
5. Now, set the two work pieces in correct position as shown in the figure and
maintain the gap 3mm. Then carry out the welding throughout the length.
6. As soon as the welding process is finished, switch off the current supply and
drop te work piece into water for cooling using tongs.
7. Finally, take the work piece and remove the slags using the wire brush.

Result

41
Welding of Lap Joint

All Dimensions are in mm

42
Ex.No. :
Welding of Lap Joint
Date :

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

Material Supplied
Mild Steel plate of size, L.B.T = 100 x 50 x 8 mm (two pieces).

Tools Required
1. Welding Transformer 6. Wire Brush
2. Flat File 7. Gloves and Apron
3. Welding Rod 8. Earthing Clamps
4. Chipping Hammer 9. Hand Shield and Goggles
5. Electrode Holder

Sequence Of Operations
1. Edge Preparation 5. Tacking
2. Cooling 6. Cleaning
3. Positioning 7. Welding
4. Chipping

Procedure
1. The given work pieces are thoroughly cleaned of rust, scale and other foreign
material.
2. The electrode is fitted in the electrode holder and the welding current is set
to a proper value.
3. When current is passed, arc is produced between the electrode and work
piece. Here the welding should be carried out on both sides.
4. As soon as the welding process is finished, switch off the current supply and
allow the work pieces to cool.
5. The slag formation on weld is removed by using a chipping hammer.
6. Finally, using wire brush, welded portion are cleaned.

Result

43
Welding of TEE - Fillet Joint

All Dimensions are in mm

44
Ex.No. :
Welding of TEE - Fillet Joint
Date :

Aim
To make the Tee-Fillet Joint using arc welding on the given work pieces.

Material Supplied
Mild Steel plate of size, L.B.T = 100 x 50 x 8 mm (two pieces).

Tools Required
1. Welding Transformer 6. Wire Brush
2. Flat File 7. Gloves and Apron
3. Welding Rod 8. Earthing Clamps
4. Chipping Hammer 9. Hand Shield and Goggles
5. Electrode Holder

Sequence of Operations
1. Edge Preparation 4. Chipping 7. Welding
2. Cooling 5. Tacking
3. Positioning 6. Cleaning

Procedure
1. The given work pieces are thoroughly cleaned of rust, scale and other foreign
material.
2. The electrode is fitted in the electrode holder and the welding current is set
to a proper value.
3. Keep one place on the welding table and keep the other at the centre of the
first piece and perpendicular to it using tongs.
4. When current is passed, ace is produced between the electrode and work
pieces. Here the welding should be carried out on the both side.
5. As soon as the welding process is finished, switch off the current supply and
allow the work piece to cool.
6. The slag formation on weld is removed by using a chipping hammer.
7. Finally, using wire brush, welded portion are cleaned.

Result

45
Study of Basic Machining

Lathe

46
 Ex.No. :
Study of Basic Machining
Date :

Safety Precautions For Machining Work

OO Job should be tightly held in the chuck.
OO If the job is held in between the centres, then apply grease on the nose of dead
centre, otherwise it will burnt out due to excess heat.
OO Do not measure the job while the work piece is rotating.
OO Do not leave the chuck key in the chuck.
OO Do not try to stop the lathe chuck or job with hands.
OO Do not handle metal chips by hand.
OO Do not give more depth of cut while the job is rotating at high speed.
OO Tighten the tool in the tool post.
OO Do not stand close to the rotating work piece and do not bring your face close
it.
OO Do not reduce or increase the speed when the lathe operation is going on.

Study of Lathe

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 electric 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. Here the material is removed in form of
chips.
Lathe machine has the following parts as shown in figure:
OO Bed OO Cross slide OO Lead screw
OO Head stock OO Compound rest OO Tailstock
OO Carriage OO Tool post
OO Saddle OO Apron

Bed
It is the base of the machine on its left side the head stock is mounted.
A movable casing called tail stock is mounted on the right side.

47
Head Stock
It consists of a spindle, gears and speed change levers. It is used to transmit the
motion of the job.

Carriage
Carriage is used to carry a tool to bring it in contact with the rotating work piece
or to with draw from such a contact.

Saddle
It is ‘H’ shaped part fitted on the lathe bed. There is a hand wheel to move it on the
bed way. Cross slide, compound rest and tool post are fitted on this saddle.

Cross Slide
It is on the upper side of saddle in the form of dove tail. A band wheel is provided
to drive the cross slide.

Compound Rest
It is fitted over the cross slide on a turn table. It permits both parallel and angular
movements to the cutting tool.

Tool Post
It is fitted on the top most part of compound rest. Tool is mounted on this tool post.
Cutting tool is fixed in it with the help of screw.

Apron
It is the hanging part in front of the carriage. It accommodates the mechanism of
hand and power feed to the cutting tool for carrying out different operations.

Head Screw
It is a long screw with ‘ACME’ threads. It is used for transmitting power for
automatic feed or feed for thread cutting operating.

Tail Stock
It is located at the right end of the lathe bed and it can be positioned anywhere in
the bed. It is used for supporting lengthy jobs and also carries tool to carry out operations
such as tapping, drilling and reaming.

Lathe Operations
Simple Turning
It is operation for reducing the diameter of the work piece. The turning tool is used
for this operation. More feed of tool is given for rough turning. Then, less feed is given
for finishing. In this operation, work is held in chuck and tool is set to the centre height
of the work piece.

48
Taper Turning
Taper is defined as the uniform change in the diameter of a work piece measured
along its length. Calculation for taper turning
Taper = (D – d) / 2L
Where,
D = larger diameter
d = smaller diameter
L = length of taper
Taper turning operation shown in figure.
This can be done by the following methods:
1. Compound rest method 3. Using form tool
2. Tail stock set over method 4. Taper attachment method.

Drilling
Drilling is the operation of making a hole on the work piece. Here the job is held in
the tail stock sleeve. Feed is given by rotating the hand wheel in the tail stocks which
pushes the tailstock sleeve

Facing
It is done for getting fine finish on the face of the job. Facing tool is set at an angle
to the work piece. In this operation the tool is fed from the centre of work piece towards
the outer surface against the rotating work piece. Depth of cut is low for the facing
operation.

Step turning
It is similar to the process of turning but in this case different diameter in step of
various sizes are taken on the work piece roughing tool i.e. used for rough turning and
the knife tool is used for finishing cut.

Boring
It is the process of enlarging a drilled hole. A special type of boring tool is used for
this purpose.

Conclusion

49
Study of Drilling Machine

Drilling Machine

Radial Drilling Machine

50
 Study of Drilling Machine

The drilling machine is one of the most important machine tools in a workshop. In
a drilling machine holes may be drilled quickly and at a low cost. The hole is generated
by the rotating edge of a cutting tool known as the drill, which exerts large force on the
work clamped on the table.
The different parts of a radial drilling machine have been illustrated in Fig . They
are as follows:
1. Base 2. Drill head 3. Column 4. Spindle speed and feed mechanism 5. Radial
arm

Base
The base of a radial drilling machine is a large rectangular casting that is finished
on its top to support a column on its one end and to hold the work table at the other end.
In some machines T-slots are provided on the base for clamping work when it serves as
a table.

Column
The column is a cylindrical casting that is mounted vertically at one end of the
base. It supports the radial arm which may slide up or down on its face. An electric
motor is mounted on the top of the column, which imparts vertical adjustment of the
arm by rotating a screw passing through a nut attached to the arm.

Radial Arm
The radial arm that is mounted on the column extends horizontally over the base.
It is a massive casting with its front vertical face accurately machined to provide guide
ways on which the drill head may be made to slide. The arm may be swung round the
column. In some machines this movement is controlled by a separate motor.

Drill Head
The drill head is mounted on the radial arm and drives the drill spindle. It encloses
all the mechanism for driving the drill at multiple speeds and at different speed. All the
mechanisms and controls are housed within a small drill head, which may be made to
slide on the guide ways of the arm for adjusting the position of drill spindle with respect
to the work.

51
52
Spindle Drive and Feed Mechanism
A constant speed motor is mounted at the extreme end of the radial arm, which
drives a horizontal spindle, which runs along the length of the arm, and the motion is
transmitted to the drill head through bevel gears. By train of gearing within the drill
head, the speed of the spindle may be varied. Through another train of gearing within
the drill head, different feeds of the spindle are obtained. In some machines, a vertical
motor is fitted directly on the drill head and through gearbox multiple speed and the
feed of the spindle can be obtained.

Radial drilling machine

1. Base
2. Column
3. Radial arm
4. Motor for elevating the arm
5. Elevating screw
6. Guide ways
7. Motor for driving the drill

Conclusion

53
Facing and Plain Turning

All Dimensions are in mm

54
 Ex.No. :
Facing and Plain Turning
Date :

Aim
To get the required shape and size of a given work piece by facing and plain turning
operations done in lathe.

Material Supplied
Mild steel rod of diameter 35 mm and length 110 mm.

Tools Required
1. Single point cutting tool 4. scriber
2. Steel rule 5. Tool post key
3. Vernier caliper

Procedure
1. First the given work piece is cheeked for its dimension.
2. The work piece is fitted in the chuck properly and tightens by the chuck key.
3. Ensure the centre of work piece.
4. Hold the cutting tool in the tool post, check the tool tips whether it is coincide
with tail stock spindle tip for centering and then tighten the nuts using tool
post key.
5. Facing operation is done with cutting tool by moving it. Perpendicular to
lathe axis.
6. It is done on both sides of work piece up to the required length.
7. Then turning operation is done with cutting tool which removes the outer
part of the work piece to reduce the diameter up to the dimension required.
8. Then, remove the work piece from the chuck.
9. At last, the dimensions of work piece are checked.

Result

55
Taper Turning

All Dimensions are in mm

56
Ex.No. :
Taper Turning
Date :

Aim
To perform taper turning operation using compound rest in lathe.
(An operation performed on a lathe that feeds a tool at an angle to the length
of the work piece in order to create a conical shape)

Material Supplied
Mild steel rod of diameter 35 mm and length 100 mm.

Tools Required
1. Single point cutting tool
2. Steel rule
3. Vernier caliper
4. Scriber
5. Tool post key

Procedure
1. Set the tool in their respective position of the tool post.
2. The work piece is chucked and checked for the rotation.
3. Switch on the motor after selecting the proper speed.
4. First by moving the cross slide facing operation is completed.
5. After reducing the height of the work piece, by tilting the compound rest set
the calculated angle for tapering.
6. Make the taper turning operation as per the given dimension.
7. Chamfer the corners and check the dimensions.

Result

57
 Drilling and Tapping

All Dimensions are in mm

58
Ex.No. :
Drilling and Tapping
Date :

Aim
To Drill and tap the given work piece as per the required dimensions.

Material Supplied
Mild steel plate of size 50 x 50 x 6 mm

Tools Required
1. Bench vice 7. Surface plate
2. Vernier height gauge 8. File
3. Machine vice 9. Try square
4. Scriber 10. Tapset with Die holder
5. Steel rule 11. Dot punch
6. Drill bit 12. Drilling machine

Procedure
1. The dimensions of the given work piece is checked.
2. The chalk is applied throughout the surface of the work piece.
3. Marking is done on the work piece by using scriber, dot punch and hammer.
With the help of Vernier height gauge and steel rule measurement is taken.
4. The adjacent sides of work piece are filed and then the punched work piece is
clamped in the vice.
5. The required size of hole is made on the work piece 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 suing tapping tool.

Result

59
Assembling of Centrifugal Pump

60
 Ex.No. :
Assembling of Centrifugal Pump
Date :

Aim
To assemble the centrifugal pump.
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. Pumps are generally used for lifting liquids from a lower level to
higher level. The advantages of a centrifugal pump are. Low initial cost, high efficiency,
uniform discharge, ease in installation and maintenance and so on.
Types of Pumps
Positive displacement pumps (piston pumps and helical-roto pumps)
Roto – dynamic pumps (centrifugal pumps, mixed flow pumps, mixed flow bore
hole pumps and axial pumps)
Components of Centrifugal Pump Suction Pipe
A pipe whose one end is fitted to the inlet of the centrifugal pump and the other
end dips into water in a sump is known as suction pipe.
Foot Valve and a Strainer
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. The foot valve opens only in the upward direction. A
strainer is also fitted at the lower end of the suction pipe.
Delivery Pipe
A pipe whose one end is connected to the outlet of the pump and the other end
delivers the water at a required height is known as delivery pipe. A delivery valve is
fitted at the lower end of the delivery pipe.
Working Principle
The centrifugal pump works under the principle of forced vortex flow. This means
that, when certain mass of liquid is rotated, by an external torque, the rise in pressure
head of the rotating liquid is rotating liquid takes place. The rise in pressure head at
any point of the rotating liquid is directly proportional to square and tangential velocity
of the liquid at any point.

Conclusion

61
Assembling of Household Mixer

Mixer Grinder Wiring Connection Diagram

Electrical Mixer Grinder Internal Circuit Diagram

62
 Ex.No. :
Assembling of Household Mixer
Date :

Aim
To assemble the household mixer.

Introduction
A mixer, depending on the type, also called a hand mixer or stand mixer, is a
kitchen device that uses a gear-driven mechanism to rotate a set of “beaters” in a bowl
containing the food or liquids to be prepared by mixing them. Mixers help automate the
repetitive tasks of stirring, whisking or beating. When the beaters are replaced by a
dough hook, a mixer may also be used to knead.
A mixer may be a handheld mechanism known as an eggbeater, a handheld
motorized beater, or a drill mixer. Stand mixers vary in size from small counter top
models for home use to large capacity commercial machines. Stand mixers create the
mixing action by either rotating the mixing device vertically (planetary mixers), or by
rotating the mixing container (spiral mixers)

Types of Mixer
1. Horizontal Mixer
2. Spiral Mixer
3. Planetary Mixer
4. Dough mixer

Components of Mixer
Universal Series Motor: Universal series motors are those which are designed
to operate with both AC and DC supply. Here the word ‘series’ used because its field
windings are connected in series with the armature winding. In the above circuit
diagram, you can also see there are two series windings. One of these is tapped in
three positions and those tapings are connected to the speed control switch. So this
arrangement is for speed control of the motor. So we can obtain three different speeds
(low, medium, high) by rotating the switch.
Thermal Overload Relay or overload switch: A thermal Overload Relay or overload
switch is used to protect the device from overload or over current fault. If the motor
draws over current due to any internal fault, or improper use, the overload relay will
automatically disconnect the power supply to the motor. As the mixer grinder is a home

63
Work Sheet

64
appliance, so the thermal overload relay is very helpful to prevent accidents such as
burning of motor, fire, and melting due to over current. The overload switch also helps
to turn off the motor if you run it for a long time. After fully cool down it will be got
automatically turned on. You can see the mixer grinder overload switch connection
diagram below.
Three-Position Rotary Switch: It has a total of four terminals. The first one is
the input terminal and the other three are output terminals where the terminals of
the motor are to be connected. You can see the mixer grinder rotary switch connection
diagram below.
Power Switch: Most of the mixer grinders have the function to switch on and off in
their speed control switch but some mixer grinders come with a separate power switch
to on and off.

Working Principle
OO Whenever a current-carrying coil is placed in a magnetic field it experiences
a force, which produces a torque that can rotate the coil. The direction of force
is determined by the Fleming left-hand rule.
OO A motor is a machine that converts electrical energy into mechanical energy.
Universal motor is a special type of motor which can work for both A.C (single-
phase) and D.C current.
OO The main components of a mixer grinder are universal motor which consists
of rotor, carbon brushes, commutator, and field winding, rotary switch to alter
the speed, indication lamp, and a plug. 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 of the ingredients.

Conclusion

65
Assembling of Air Conditioner

Air Conditioner

66
 Ex.No. :
Assembling of Air Conditioner
Date :

Aim
To assemble the air conditioner systems.

Introduction
The term air conditioner refer to the technique of regulating the condition of air
in order to provide a comfortable environment for the persons staying in a room or a
favorable environment for making industrial products.
Air – conditioning deals with supplying and maintaining desirable properties like
temperature, humidity, purity, direction of floe etc., in a cool space.

Types of Air - Conditioner

1. Central Air-conditioning 3. Split system
2. Window unit
Components of Air Conditioner
OO Compressor : The function of the compressor is used to compress the low
pressure and temperature refrigerant into high pressure.
OO Condenser : The function of the condenser is to cool the high pressure
vapours and condensed into high pressure liquid refrigerant.
OO Evaporator : The function of the evaporator is to absorb the heat from the
room.
OO Fan : The function of fan is to produce the air movements in the air –
conditioning apparatus.
OO Filter : The function of the filter is to remove the foreign matters such as
direct fumes, smokes and harmful bacterial present in the air.
Working Principle
The air in the room is to be sucked by fan through the air filter and then passes
over the cooling coil. The cooling coil absorbs the heat from room. The cool air brings
down the temperature and humidity level in the room and provides the comfortable
conditions.
A thermostat is provided for conditioning of the compressor to maintain the
desired temperature in the room. A damper is used to regulate the fresh air supply. The
conditioned chilled air is blown into room through the dampers.
Conclusion

67
Study of Sheet Metal Tools and Operations

68
 Ex.No. :
Study of Sheet Metal Tools and Operations
Date :

Aim
To study the various tools and types of operations involved in the sheet metal
process.

Introduction
In sheet-metal working, there is no need for further machining as required for
casting and forging works. The time taken in sheet-metal working is approximately
half of that required in the machining process. For carrying out sheet metal work, the
knowledge of geometry, mensuration and properties of metal is most essential because
nearly all patterns come from the development of the surfaces of a number of geometrical
models such as cylinder, prism, cone, and pyramid. In sheet metal work, various
operations such as shearing, blanking, piercing, trimming, shaving, notching, forming,
bending, stamping, coining, embossing etc. are to be performed on sheet metal using
hand tools and press machines to make a product of desired shape and size. Generally
metals used in sheet metal work are black iron, galvanized iron, stainless steel, copper,
brass, zinc, aluminium, tin plate and lead.

Sheet Metal Tools

1. The types of hand shears or snips. They resemble with pair of scissors and
are used like them to cut thin soft metal sheets of 20 gauge or thinner. They
are required to size and shape the sheets. They can make straight or circular
cuts. Different types of hand shears are:

2. Straight hand shear: It is used for general purpose cutting, making straight
cuts and trimming away extra metal.

3. Universal shear: Its blades are designed for universal cutting straight line or
internal and external cutting of contours. It may be of right hand or left hand
type, easily identifiable, as the top blade is either on the right of on the left.
4. Curved hand shear: It is used for cutting circular or irregular curved shapes
ranging from 20 to 35 cm.

69
Hammers
The various types of hammers used in sheet metal work for forming shapes. The
uses of different kind of hammers are given as under:
Smoothing hammer. Smoothing hammer is used for leveling and smoothing a
sheet metal joint.
Stretching hammer. Stretching hammer is used for stretching sheet.Creasing
hammer. Creasing hammer is used to close down joint edges of sheets metal part.
Hollowing hammer. Hollowing hammer is used for hollowing sheet metal part. It
is used for generating sharp radii also.
Riveting hammer. Riveting hammer is used for forming riveted heads.
Planishing hammer. Planishing hammer is used for removing small marks or
indentations from the sheet metal job surface and to true the shape of the work. It
smoothens off the finished sheet metal work.
Soft hammer or Mallets. Mallets used during working with soft metal sheets. They
may be of wood, rubber or raw hide. A mallet strikes a blow with the minimum damage
to the surface.

Folding Terminology of Sheet Metal

Edge
The edges on part need to be folded to increase the strength and to eliminate the
sharp edges of sheet metal component.
Types of folded edges. The common types of folded edges are:
i. Single hem,
ii. Double hem and
iii. Wired edge

Single Hem
It is made by folding the edge over. To layout such a hem, a line is drawn at a
distance equal to the desired hem width.

Double Hem
It is a single hem with its end bent under. To layout such a hem, draw two parallel
lines each equal to the width of the hem.

70
Wired Edge
It consists of an edge, which has been wrapped around a piece of wire.
This edge is used where more strength is needed. To layout wired edge the diameter
of wire is to be determined. The steel metal will be needed to roll around the wire.

Seam
A seam is the section where pieces of sheet metal are joined together. Most common
types of seams are:
a. Single seam, d. Lap seam,
b. Double seam, e. Dovetail seam, and
c. Grooved seam, f. Burred bottom seam

Single seam
It is used to join a bottom to vertical bodies of various shapes. To layout such a
seam, draw a line parallel to one edge of the sheet metal body stretch out at a distance
equal to the width of the seam. Now draw two lines parallel to the edges of the bottom
stretch out. The first line should be drawn at the distance from the edge of sheet metal
equal to the width of the seam minus 1 mm. approx. Second line should be drawn at a
distance from the first equal to the width to the seam on sheet metal plus 1 mm approx.
The plus and minus dimensions of 1 mm is used to prevent the folded bottom edge of
sheet metal from interfering with the body’s folded bottom edge. If the bottom is round,
then mark the lines on sheet metal part.

Double seam
The layout process for this seam on sheet metal part is similar to that used for a
single seam on sheet metal part. It differs from single seam in a manner that its formed
edge is bent upward against the body.

Grooved seam
It is made by booking two folded edges of sheet metal part together and then off-
setting the seam as shown in Fig. On one piece draw one line equal to half the width of
the seam from outer edge. Then draw second line at a distance equal to the width of the
seam from the first line. Same way draw two lines on the other piece of sheet metal part.

71
Lap seam
It is the simplest type of seam made on sheet metal part because one edge laps over
another and is soldered or riveted. To layout lap seam on sheet metal part, draw line on
the edge of piece at a distance equal to the width of the required seam.

Dovetail seam
It is used to join a flat plate to a cylindrical piece. To layout such a seam, draw a
line parallel to one edge of sheet metal component at a distance of 6 to 20 mm. depending
upon the size of the hole of sheet metal part. Then draw lines to indicate where the sheet
metal part is to be slit. The width of the piece between slits ranges from 6 to 26 mm.

Flanged or burred bottom seam

It is used to fasten the bottom of a container made of sheet metal to its body in
which upper part is the sheet metal body and lower bottom of a container. To layout
such a seam on sheet metal part, draw a circle, which represents the outline of the
bottom on sheet metal part. If it is square or rectangular component, draw the bottom
shape on the sheet metal part.
Then draw a second line to show the width of the flange. The width of this flange
may range from 3 to 6 mm on sheet metal part.

Folded Sheet Metal Joints

As per requirements, various types of sheet metal joints are used in sheet metal
work. Such joints are commonly used to fasten bottoms to cylinders, square or rectangular
containers. Some of the commonly used such joints are shown in Fig.

Lap joint
It is very frequently used in sheet metal work and can be prepared by means of
soldering or riveting.

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

Locked seam joint

This joint is used for locking seam joints in sheet metal work.
Hem (single and double), wired edge, cup and angular joints. These enable the
edges sheet metal part to join the pieces along them.

72
Flanged joint
It is commonly used in sheet metal work frequently in making pipe connections.

Cap joint
It provides another useful form of locked seam joint on sheet metal component
with good appearance and strength. It is generally used for assembling cross seam of
ducts made up of in sheet metal part.

Result

73
Making of a Square Tray

All Dimensions are in mm

74
Ex.No. :
Making of a Square Tray
Date :

Aim
To make a square tray from the given sheet metal.

Material Supplied
Galvanized Iron sheet of L.W = 150 x 150

Tools Required
1. Steel Rule 5. Straight snip
2. Divider 6. Mallet
3. Scriber 7. Ball Pen Hammer
4. Stake

Sequence of Operations
1. Checking 5. Bending
2. Leveling 6. Hemming
3. Marking 7. Riveting
4. Cutting 8. Procedure

Procedure
1. The size of the given sheet is checked with the steel rule.
2. The layout of the tray is marked on the given sheet.
3. The layout of the tray is cut by using the straight snip.
4. Folding is done as per the given order using mallet and stake.
5. Bending is done as per the given dimensions using the stake and mallet.
6. Finally, the tray is riveted using the given rivets and hammer.

Result

75
Study of Foundry

76
 Ex.No. :
Study of Foundry
Date :

Aim
To understand the basic concepts of foundry by carrying out simple exercises
relevant to its principles.

Introduction
Foundry is a process of forming different shapes and sizes of metals in their molten
state. It is also called as metal casting. The shape of the metal cast obtained depends on
the shape and size of the cavity produced in sand mould by using a wooden model. This
wooden model is called a pattern.
The foundry process involves three steps:
a. Making the required pattern
b. Moulding process to produce the cavity in sand using the pattern
c. Pouring the molten metal into the cavity to get the casing

Pattern
A pattern is normally a wooden model which is the facsimile of the cast/product to
be made. There are many types of patterns and are either one piece or two - pieces.

Moulding Box
A moulding box is normally a rectangular wooden/metal box with bottom and top
surfaces open. The upper part (cope) and the lower part (drag) are aligned properly.

Sieve
A sieve is used to remove foreign materials from the moulding sand. A sieve is a
rectangular or circular frame with a wire mesh.

Rammer
A rammer is used to press or ram the moulding sand uniformly into the moulding
box.

Strike-off Bar
A strike off bar is a flat-edged rectangular bar made of wood. It is used to remove
excess sand on top of the mould box after ramming.

77
78
Mallet
A mallet is used to give light blow to the draw spike to drive it into the pattern in
order to lift the pattern with the help of draw spike. It is round or rectangular and is
made of hardwood.

Lifter
A lifter is used to remove the loose sand in the cavity produced in moulding. It is
also used to finish the walls of the cavity after removing the pattern.

Trowel
A trowel is used to finish the cavity obtained in the mould. Trowels of various
shapes and sizes are used in moulding process.

Sprue Pin
A sprue pin is a cylindrical and tapered wooden piece used to make a hole through
which the molten metal is poured into the mould cavity.

Core
The core is used to make a hole or hollow casting. The core is normally made of core
sand. The core sand can be removed easily after the casting. The core sand is having
90% silica sand and the remaining is binding materials (saw dust, asbestos, linseed oil,
molasses etc.)

Shovel
It is used to mix and move the mould sand from one place to another in the foundry
shop.It consists of a broad iron pan fitted with a long wooden handle.

Bellow
It is used to blow out sand particles and dust on the surface of the mould.

Swab
It is used to apply water on the edges of the pattern before removing it from the
mould. It is easy to remove the moisturized pattern, otherwise mould sand sticks along
with the pattern.

Slick
It is used to repair and smoothen the mould surface after removing the pattern. It
consists of spoon shaped double ended trowel.

Gate cutter
It is used to cut gates in the mould. The gate is connecting the runner hole and
the mould cavity.

79
Moulding of Gear Pattern

80
Ex.No. :
Moulding of Gear Pattern
Date :

Aim
To prepare mould for the gear pattern.

Material Supplied
1. Moulding sand
2. Parting sand
3. Facing sand

Tools Required
1. Trowel 8. Vent wire
2. Rammer 9. Draw spike
3. Strike of bar 10. Swab
4. Lifter 11. Riddle
5. Runner 12. Sprue pin
6. Riser 13. Bellow
7. Gate Cutter

Procedure
1. The mould box, pattern, tools and the table / floor are cleaned.
2. The drag is filled with green sand after positioning the gear pattern on the
table.
3. The green sand is rammed carefully and the excess sand is struck off.
4. Tilt the drag upside down and sprinkle river sand on top of it.
5. The cope is positioned on top of the drag.
6. Position the sprue pin and riser pin, then fill the cope with sand and ramming
is done and the excess sand is struck off.
7. The sprue pin and riser pin is removed carefully.
8. Apply water on the edges of the pattern and remove it carefully using the
draw spike. Vent holes are made using vent wire.
9. A funnel-shaped opening and gate is made to pour the molten metal.

Result

81
Moulding of Stepped Cone Pulley

82
Ex.No. :
Moulding of Stepped Cone Pulley
Date :

Aim
To make the mould for the given stepped cone pulley pattern.

Material Supplied
1. Moulding sand 3. Facing sand
2. Parting sand

Tools Required
1. Trowel 7. Gate Cutter
2. Rammer 8. Vent wire
3. Strike of bar 9. Draw spike
4. Lifter 10. Swab Riddle
5. Runner 11. Sprue pin
6. Riser 12. Bellow

Procedure
1. The mould box, pattern, tools and the table / floor are cleaned.
2. The drag is filled with green sand after positioning the gear pattern on the
table.
3. The green sand is rammed carefully and the excess sand is struck off.
4. Tilt the drag upside down and sprinkle river sand on top of it.
5. The cope is positioned on top of the drag.
6. Position the sprue pin and riser pin, then fill the cope with sand and ramming
is done and the excess sand is struck off.
7. The sprue pin and riser pin is removed carefully.
8. Apply water on the edges of the pattern and remove it carefully using the
draw spike. Vent holes are made using vent wire.
9. A funnel-shaped opening and gate is made to pour the molten metal.

Result

83
Work Sheet

84
Additional Exercises
Plumbing Line Preparation for a Turbine

86
Ex.No. :
Plumbing Line Preparation for a Turbine
Date :

Aim
To lay, pipe connection for a prototype hydraulic turbine model.

Materials Supplied
1. Pipe Wrench 5. Nozzle
2. Thread 6. Cast Iron Pipes
3. Elbow 7. Coupling
4. Valves 8. Pipe Vice

Procedure
1. Two pipes are taken and they are held in vice and they are connected by using
a flanged joint.
2. A gate valve is connected to the pipe for controlling the water supply.
3. Then, elbow is connected to the end of the pipe. Make internal threads using
taps in the elbow. So it can be screwed to the pipe fixed in the dam.
4. Surge tank is connected with main pipe(penstock) using wye and elbow as
shown in the figure.
5. A nozzle or reducer is connected at the delivery end of the pipe to turbine.
6. Make other connections referring the line sketch of the prototype.
7. Finally, check for leakage in the joints, allowing water from the dam to
turbine.

Result

87
Making of Cross Lap Joint

88
Ex.No. :
Making of Cross Lap Joint
Date :

Aim
To make a cross lap joint from the given wooden work piece as per the given
dimension.

Material Supplied
A soft wooden piece of size, L.B.T = 200 x 50 x 30 mm.

Tools Required
1. Machine Planer 5. Rip Saw
2. Marking Gauge 6. Circular Saw
3. Mallet 7. Try Square
4. Calipers

Sequence of Operations
1. Planing 4. Fitting
2. Chiseling 5. Sawing
3. Marking

Procedure
1. The given work piece is clamped in the carpentry vice and two adjacent faces
are planed to get right angles, using machine planer.
2. The work piece is cut into two halves using rip saw.
3. With the finished face as reference the required size is marked on the work
piece, by means of steel rule and marking gauge.
4. In one half of the work piece, the unnecessary portions are removed, using
mitre saw and firmer chisel.
5. Similarly, the unwanted portions are removed in the other half of the work
piece, using circular saw and firmer chisel.
6. Now, the two pieces are assembled to check proper fitting.
7. Finally, the accuracy and proper dimensions are verified, by using steel rule
and try square.

Result

89
 Making of Funnel using Sheet Metal

80

Ø60

Development View - 'X'

5

Development View - 'Y'

126°

Formula for Cone Angle

R
θ = 360° x L

Where,
2 2
L= r +h
θ = 360° x 30
2 2
30 + 80
θ = 360°
All Dimensions are in mm

90
Ex.No. :
Making of Funnel using Sheet Metal
Date :

Aim
To make a funnel from the given sheet metal.

Material Supplied
22 gauge Galvanized Iron (G.I) sheet.

Tools Required
1. Steel Rule 5. White Paper
2. Straight Snips 6. Solder
3. Groover 7. Scriber
4. Mallet 8. Ball Peen Hammer

Sequence of Operations
1. Checking 5. Cutting
2. Marking on Sheet Metal 6. Soldering
3. Hemming 7. Marking on Paper
4. Leveling 8. Folding

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

Result

91
Making of Hexagonal Headed Bolt

V1

φ1 lo =100
2

8
V2

10
lc = ? V3

All Dimensions are in mm

92
Ex.No. :
Making of Hexagonal Headed Bolt
Date :

Aim
To make a hexagonal headed bolt from a given round rod.

Materials Supplied
Mild steel rod of length 100 mm and diameter 12 mm

Tools Required
1. Anvil 4. Furnace, etc.
2. Flatter 5. Tongs
3. Hand Hammer

Sequence of Operations
1. Heating 4. Hexagonal Shape
2. Checking 5. Cooling
3. Forming 6. Flattening

Procedure
1. One end of the given rod is heated in the furnace.
2. When the job is red hot, place it on the anvil with an end on it using the tong.
3. Hit the job hard using hammer from the top end of the rod; hold the job
carefully using the tong while hammering.
4. Repeat heating and hammering until a round head is formed.
5. Turn the job for 600 and repeat hammering to change the round rod to hexagon
6. Repeat heating and hammering until the required hexagonal head is obtained.
7. Also repeat hammering and heating to get the required size and shape of the
bolt.
8. The flatter is used to obtain a fine finish on the job.
9. Finally, the job is cooled by dipping it in water.

Result

93
Work Sheet

94
 Ex.No. :
Study of Tools and Equipments used in Fitting
Date :

Aim
To study the tools and equipments used in Fitting process

Introduction
These days small, medium and heavy industries are using automatic machines.
But bench and fitting work also plays a significant role for completing and finishing a
job to the desired accuracy. Most of semi-finished works can be accomplished with fairly
good degree of accuracy in a reasonable time through various kinds of quick machining
operations. They still require some minor operations to be performed to finish the job by
hand. The term bench work denotes the production of an article by hand on the bench.
Whereas fitting is the assembling of parts together and removing metals to secure the
necessary fit, and may or may not be carried out at the bench. These two types of work
require the use of a large number of hand tools and other devices or equipments that
involve a number of operations for accomplishing the work to the desired shape and
size.

Tools Used In Fitting Shop

1. Marking tools 4. Holding tools 7. Tightening tools
2. Measuring devices 5. Striking tools 8. Miscellaneous
3. Supporting tools 6. Cutting tools tools

Marking Tools
These are sub classified as steel rule, circumference rule, scriber, semi-circular
protractor, divider, trammel, prick punch, centre punch, try square, bevel square,
vernier protractor, combination set and surface gauge.

Steel Rule
Steel rule is generally employed for purpose of measuring rough dimensions and
laying out them. It is always advisable to start measuring from 1 cm mark because the
end of the rule is generally worn out.

Circumference Rule
It is commonly used for measuring or laying out or as a straight edge. The specialty
in this rule is that the circumference can be taken directly, below the diameter dimension.

95
Scribers
Fig. shows the various types of scribers, which are sometimes called the metal
worker’s pencil. These are made up of high carbon steel and are hardened from the front
edge. Scriber is used for scratching lines on the sheet metal during the process of laying
out a job.

15°

Scribers

Divider
It is used for marking and drawing circle and arcs on sheet metal.

Trammel
Trammel is used for marking and drawing large circles or arcs, which are beyond
the scope of dividers.

Prick Punch
Fig. shows the prick punch, which is used for indentation marks. It is used to make
small punch marks on layout lines in order to make them last longer. The angle of prick
punch is generally ground to 30° or 40° whereas for centre punch it is kept 60°or 90°.

Centre Punch
Fig. shows the centre punch, which is used for locating centre for indentation mark
for drilling purposes.
°
90

60° 90°

96
Try Square
Fig.shows the try square, which is also known as engineer’s try square. It is very
important tool required for scribing straight lines at right angles to a true surface or
testing the trueness of mutually normal surfaces. It is made in different sizes out of
steel pieces. In construction, it is similar to a carpenter’s try square but is comparatively
more accurate. It can be made either in one piece or in two pieces.
It consists of a steel blade fitted into a steel stock of rectangular cross-section.
It is sufficiently hardened and tempered to suit the need. Some precision kind of try
squares is made with their blades having beveled edges properly ground and finished
square. Both inner and outer surface of the blade are kept truly at right angles to the
corresponding surfaces of the stock. In order to maintain this trueness, this tool should
be handled with due care and should never be used as a striking or supporting tool
or other work. The accuracy of this tool should be frequently checked to ensure the
trueness as it affects the accuracy of the finished job to a significant extent.

For checking the accuracy or trueness of a try square, the try square is made to lie
flat on the top surface of a surface plate with the stock touching a machined edge of the
plate. A straight line is marked along the outer edge of the blade and then the square
turned over to take a new position. Another straight line is described along the outer
edge of the blade in this new position of the try square. If both lines coincide with each
other as they seems to be as one line only, then the try square can be said as true.

97
Vernier Caliper
Fig. shows the vernier caliper, which is commonly used to measure accurately
outside diameters of shafts,
OO Thicknesses of various parts,
OO Diameters of holes or rings and
OO Internal dimensions of hollow jobs or articles.

It works on the principle of vernier and can measure the dimensions to an accuracy
of 0.02 mm. For making a measurement of external dimensions, the job is placed between
the fixed and the movable jaws. The movable or the sliding jaw is moved until it almost
contacts the job kept against the fixed jaw. The sliding jaw assembly of the vernier
caliper that carries the fine adjustment screw should be clamped to the graduated beam
with the help of adjustment clamp. The two jaws are then brought into contact with the
job by moving the sliding jaw with the help of fine adjustment screw. The jaws should
make now definite contact with the job but should not be tight. The main slide assembly
is then locked to the beam with help of clamp. The caliper is then carefully removed
from the job to prevent springing the jaws and the reading is taken. For making a
measurement of internal dimensions, the job is placed outward between the fixed and
the movable jaws meant for measuring inner dimension.

Measuring Devices
Commonly used measuring devices and instruments used in bench and fitting shop
are fillet and radius gauge, screw pitch gauge, surface plate, try square, dial gauge,
feeler gauge, plate gauge and wire gauge.

Holding Tools
Holding tools used in fitting shop comprises of basically vices and clamps. The
clamps are C or G clamp, plane slot, goose neck, double end finger, u-clamp, parallel

98
jaw, and clamping block. The various types of vices used in fitting shop are given as
under:Bench vice
Fig shows a bench vice commonly used in fitting shop for holding a variety of jobs.
Fixed jaw
Face
Sliding jaw

Hole for securing

Handle to bench

C-clamp
A C-clamp is shown in Fig. which is used for gripping the work during construction
or assembly work.

Cutting Tools Files

The widely used hand cutting tool in workshops is the file. It is a hardened piece of
high grade steel with slanting rows of teeth. It is used to cut, smooth, or fit metal parts.
It is used file or cut softer metals. It consists of the following parts as shown in Fig. The
tang is the pointed part, which fitted into the handle. The point is the end opposite the
tang. The heel is next to the handle. The safe edge or side of a file is that which has no
teeth. It is classified on bases of type or cut of teeth and sectional form.
Up cut
Shoulder Tang
Handle
80° 45°
Face Heel
Point 75°
Edge

Single cut Double cut Over cut

Length

99
Size of a File
Size of a file is specified by its length. It is the distance from the point to the heel,
without the tang. Files for fine work are usually from 100 to 200 mm and those for
heavier work from 200 to 450 mm in length.

Classification of Files
The files are classified on basis of type of cuts, grade and shapes. These are further
sub classified as under
Type of Cut
The most commonly used files according to cuts of teeth are shown in Fig.
OO Single OO Double and OO Rasp

Flat File Square File

Small Square File Triangular File

Round File Half Round File

Triangular File Triangular File Half Round File

Round File

Square File Flat File

Triangular File Small Triangular File

Grade of Cut
OO Files are cut with teeth of different grades. Those in general are
OO Smooth
OO Second cut

100
Rough
Shape of File
Common shapes of files are having different cross sections, which cover most
requirements.

Cut or teeth on files

Teeth or cuts of files can be categorized into two groups namely single cut and
double cut. In single cut files, the teeth are cut parallel to other across the file at an
angle of about 60° to the centre line of the file. Such types of file are named as flats and
are widely used on hard metal.

Hand files
Hand files are commonly used for finishing surface work. Both faces of the file are
double cut. Either both edges are single cut or one is uncut to provide a safe edge.

Flat files
Flat files are generally used for filing flat surfaces in fitting shop.

Triangular files
Triangular files are commonly used for filing corners between 60° and 90°. They
are double cut on all faces.

Square files
Square files are commonly used for filing in corners in jobs. They are double cut on
all sides and tapers.

Round files
Round files are generally used for opening out holes and rounding inside corners.
Rough, bastard, second cut and smooth files under 15 cm in length are single cut.

Half round files

These files comprises of flat and half round sides. The flat side of half round file is
used for general work and the half round side for filing concave surfaces. These files are
double cut on the flat side. The curved side is single cut, smooth or second cut.

Knife-edge files
These files are commonly used for cleaning out acute-angled corners. The two faces
of these files are double cut, while the edge is single cut. These files are made in sizes
from 10 to 20 cm of various shapes and cuts. They are extremely delicate and are used
for fine work such as pierced designed in thin metal.

101
Pillar files
These files are used for finishing narrow slots. Both faces are double cut and either
both edges are single cut or one is uncut to provide a safe edge of the file.

Needle files
Needle files are generally used for filling keys tooth wheels of clocks and other
curved surfaces.

Mill files
Mill files are commonly used for filing half round recess and gullet of mill saw.

Flat File Square File

Round File Half Round File

Triangular File Triangular File

Hand hacksaw
Hand hacksaws are made in two types namely a fixed frame and adjustable frame
oriented as shown in Fig. and Fig. The former possesses solid frame in which the length
cannot be changed and where as the latter comprises the adjustable frame which has
a back that can be lengthened or shortened to hold blades of different sizes. The hand
hacksaws are commonly used for sawing all soft metal. They consist of a frame, handle,
prongs, tightening screw and nut, and blade as shown in figure. Its frame is made to

102
hold the blade tightly. However a power operated hacksaw can also be used for cutting
raw materials in sizes in case of continuous cutting generally occurring frequently in
fitting or in machine shops.

Sriking Tools
Various types of hammers (such as ball peen hammer, straight peen hammer,
cross-peen hammer, double face hammer and soft face hammer) are acting as striking
tools. These types have been described in chapters relating to sheet metal work and
forging work. The common type of ball peen hammer and their parts are shown in Fig.

Tightening Tools
The tightening tools include pliers, screw driver and wrenches, which are discussed
as under.

103
Pliers
Pliers are namely ordinary needle nose and special type. Fig (a) shows a long
nose pliers and Fig. Shows combination pliers. These are commonly used by fitter and
electrician for holding a variety of jobs.

Long Nose Pillers Combination Pillers

Screw driver
Screw driver is a screw tightening tool. The most commonly used standard screw
driver with its parts is shown in Fig. It is generally used by hand for tightening the
screws. It is also of various types depending upon the kind of work.

Wrenches
Wrenches are commonly known as spanners. These generally come in sets and
are commonly identified by numbers. These are of various types and few general types
involve open single ended, open double ended, closed ended adjustable, ring spanner,
offset socket, t-socket, box wrench, pipe wrench and Allen wrench.

104
Operations Performed in Fitting Work
The operations commonly performed in bench and fitting work may be classified
as under.
1. Marking 6. Drilling
2. Chipping 7. Reaming
3. Filing 8. Tapping
4. Scrapping 9. Grinding
5. Sawing 10. Polishing

Conclusion

105
 Making of Square Fitting

3
44

44
a

3
44
44

All Dimensions are in mm

44

106
10
90 0
Ex.No. :
Making of Square Fitting
Date :

Aim
To make a square joint from the given work piece.

Material Supplied
Mild Steel Plate (One Piece), L.W.T = 44 x 44 x 3 mm.

Tools Required
1. Bench Vice 6. Jenny Caliper
2. Hammer 7. Surface Plate
3. Try Square 8. Steel Rule
4. Angle Plate 9. Fixed Hacksaw
5. Dot Punch Files 10. Vernier Height Gauge

Procedure
1. The given work piece is first checked for its size using steel rule. After that it
is clamped in the bench vice and two adjacent sides are filed using a flat file
so that work piece is made at right angle.
2. Chalk is applied on the surface of the work piece for marking.
3. With the finished face as reference, the required dimensions are marked on
the work piece with the use of Surface plate, Vernier height gauge, Jenny
caliper and steel rule. Then these marking are made clear by punching dots
on it using dot punch.
4. Then using Hacksaw the small square piece of 25 x 25 mm in cut and removed.
5. The cut faces are then smoothened and polished using smooth flat and
triangular files.
6. Finally, the work pieces are fitted to from a square fitting.

Result

107
Making of V – Fitting

All Dimensions are in mm

108
Ex.No. :
Making of V – Fitting
Date :

Aim
To make a V- joint on the given work piece.

Material Supplied
Mild Steel Plate (One Piece), L.W.T = 90 x 50 x 5 mm.

Tools Required
1. Bench Vice 7. Jenny Caliper
2. Hammer 8. Surface Plate
3. Try Square 9. Steel Rule
4. Angle Plate 10. Fixed Hacksaw
5. Dot Punch 11. Vernier Height Gauge
6. Files

Procedure
1. The given work piece is first checked for its size using steel rule. After that it
is clamped in the bench vice and two adjacent sides are filed using a flat file
so that work piece is made at right angle.
2. Chalk is applied on the surface of the work piece for marking.
3. With the finished face as reference, the required dimensions are marked on
the work piece with the use of Surface plate, Vernier height gauge, Jenny
caliper and Steel rule. Then these markings are made clear by punching dots
on it using dot punch.
4. Cut the work piece into two pieces using hacksaw.
5. All the above said operations are carried out in both the work pieces.
6. Then using Hacksaw the unwanted portions are removed.
7. The cut faces are then smoothened and polished using smooth flat and
triangular files.
8. Finally, the assembly is checked for the required Vee fitting.

Result

109
Work Sheet

110