5 6280779123619004524 PDF

KONGU ENGINEERING COLLEGE
(Autonomous)
PERUNDURAI, ERODE - 638 060
DEPARTMENT OF MECHANICAL ENGINEERING
Record Note Book

Year / Semester :I/I
Course Code & Name :18MEL11 & ENGINEERING
PRACTICES LABORATORY
Name of the Student :
Roll No :
18MEL11 – ENGINEERING PRACTICES LABORATORY

(ODD SEMESTER-2019-2020)
KONGU ENGINEERING COLLEGE
(Autonomous)
PERUNDURAI, ERODE - 638 060
School of Building and Mechanical Sciences
Department of Mechanical Engineering
18MEL11 - ENGINEERING PRACTICES LABORATORY
BONAFIDE CERTIFICATE
Name of the Student :
Roll No. Year / Semester /
Completion of all the experiments conducted by the student of

18MEL11 – Engineering Practices Laboratory during the year 2019 - 2020
is certified for attending the end semester exam.
Signature of Lab Course Faculty
Certified that this is bonafide record of work done by the above student
of the 18MEL11 – Engineering Practices Laboratory during the year
2019 - 2020.
Signature of the HOD
The bonafide record is submitted for the End Semester Examination held on
Examiner- I Examiner - II

18MEL11- ENGINEERING PRACTICES LABORATORY
(Common to all branches)
0
Objectives:
To emphasize the safety norms and methods to be followed while in workshop
To inculcate knowledge of cutting and joining operations and the tools used in processing of
materials like metals, wood, PVC etc.,
To provide hands on training involving basic mechanical operations like cutting, joining,
drilling, tapping, grinding, polishing, assembling etc.,
To show the enhancement in the comfort level of the person carrying out the job by providing
hands on training using modern power tools.
To compare the expected dimensional characteristics with the obtained values with the
design/expected values and understand the concepts of accuracy and precision.
LIST OF EXPERIMENTS:
1. To prepare square or rectangular shaped MS plates using power tools for cutting, polishing and
shaping to the required dimensions.
2. To carry out drilling, tapping and assembly on the given MS plates.
3. To carry out thread forming on a GI/PVC pipes and prepare water leak proof water line from
overhead tank
4. To prepare a wood or plywood box/tray/any innovative models using modern power tools like
cutting machine, router, jigsaw, power screw driver etc.
5. To prepare a leak proof sheet metal tray/box/funnel using modern power tools.
6. Welding practice using the welding simulator along with a conventional welding process
7. Project: Preparing innovative articles using wood/sheet metal

REFERENCES / MANUALS / SOFTWARE:
1. Introduction to basic manufacturing processes and workshop technology by Rajender Singh,
New Age International (P) Limited, 2006.
2. Elements Of Workshop Technology by S.K.Hajra Choudhury, Media Promoters, 2009.
COURSE OUTCOMES: Blooms Taxonomy

Mapped
On completion of the course, the students will be able to (Highest Level)
CO1: plan the sequence of operations for effective completion of the K6
planned models/innovative articles.
CO2: identify and use appropriate modern power tools and complete
K2
the exercises/models accurately.

18MEL11- ENGINEERING PRACTICE LABORATORY
Instructions to the course faculty:
To instruct and ensure safety precautions

Students are to be trained in both cutting and joining of materials.
Work pieces will be cut by the student themselves as part of learning of cutting process by
way of using conventional and modern power tools.
Course faculty to ensure variation in dimensions of components and avoid repeated
dimensions and identical components.
At the end of the course the students to carry out and submit an innovative article
demonstrating the comprehensive skill acquired.
PROBABLE EXPERIMENTS (MODELS TO BE DECIDED BY THE COURSE

FACULTY)
FITTING
Square or rectangular work pieces
Square/V/L projection and counter projection on metal pieces
Drilling and tapping
CARPENTARY
Preparation of wood joints-Plus./Corner/Lap – locking of pieces using wooden pin, screws,
nails.
Square or rectangular box-Electrical switch box, Letter box, office tray etc.,
PLUMBING
Thread forming- PVC and GI pipes
Water leak proof pipe fitting /assembly-to be tested in a water line.
SHEET METAL
Leak proof Tray
Leak proof Funnel or round hopper
Demonstration of Spot welding of sheets.
WELDING
Welding practices using simulator
Demonstration of gas welding and cutting of metals
Demonstration of TIG/MIG and ARC welding
PROJECTS/INNOVATIVE ARTICLES:
Window/door frame and its assembly(fitting and carpentry)
Useful articles from metal waste(Cutting, welding and assembly)
Memento articles ( carpentry and sheet metal)

Index (List of experiments)
Marks
S. Experiment Page Faculty

Name of the Experiment No.
No. Date CoE Accuracy Viva Record Sign
15 15 10 10
EXERCISES IN FITTING OF METAL PLATES
1.
2.
EXERCISES IN CARPENTRY
3.
EXERCISES IN SHEETMETAL WORK
4.
EXERCISES IN PLUMBING
5.
EXERCISES IN WELDING
6.
Total
Average
SIMPLE FABRICATION/INNOVATIVE ARTICLE (DEMONSTRATION OF COMPREHENSIVE SKILL-

ANY ONE ONLY)
1. Preparing a simple PVC window/door frame assembly.
2. Preparing a simple memento using wood/sheet metal
3. Preparing innovative articles involving waste metals.
Date of Exam Marks out CA Marks Signature of the

Assessment Test of (25) Total (50) Student
Note: The procedures for extra exercises to be written by self.

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

fundamentals, and an engineering specialization to the solution of complex engineering
problems.
2. Problem analysis: Identify, formulate, review research literature, and analyze complex
engineering problems reaching substantiated conclusions using first principles of mathematics,
natural sciences, and engineering sciences.
3. Design/development of solutions: Design solutions for complex engineering problems and

design system components or processes that meet the specified needs with appropriate
consideration for the public health and safety, and the cultural, societal, and environmental
considerations.
4. Conduct investigations of complex problems: Use research-based knowledge and research

methods including design of experiments, analysis and interpretation of data, and synthesis of
the information to provide valid conclusions.
5. Modern tool usage: Create, select, and apply appropriate techniques, resources, and modern
engineering and IT tools including prediction and modelling 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.
Course Outcome and Program Outcome mapping:
Mapping of COs with POs and PSOs

COs/POs PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11 PO12
CO1 3 3 3
CO2 3 3 3
1 Slight 2 Moderate 3 Substantial

SAFETY INSTRUCTIONS:
All students must read and understand the information in this document with regard to
laboratory safety and emergency procedures prior to the first laboratory session. Your personal
laboratory safety depends mostly on you. Effort has been made to address situations that may
pose a hazard in the lab but the information and instructions provided cannot be considered all-
inclusive.
Students must adhere to written and verbal safety instructions throughout the academic
term. Since additional instructions may be given at the beginning of laboratory sessions, it is
important that all students arrive at each session on time.
With good judgment, the chance of an accident in this course is very small. Nevertheless,
research and teaching workplaces (labs, shops, etc.) are full of potential hazards that can cause
serious injury and or damage to the equipment. Working alone and unsupervised in laboratories
is forbidden if you are working with hazardous substances or equipment. With prior approval, at
least two people should be present so that one can shut down equipment and call for help in the
event of an emergency.
Safety training and/or information should be provided by a faculty member, teaching

assistant at the beginning of a new assignment or when a new hazard is introduced into the
workplace.
Emergency Response
1. It is everyone’s responsibility to read safety and fire alarm posters and follow the
instructions during an emergency.
2. Know the location of the fire extinguisher, eye wash, and safety shower in your lab and
know how to use them.
3. Notify your instructor immediately after any injury, fire or explosion, or spill.
4. Know the building evacuation procedures.
Common Sense
Good common sense is needed for safety in a laboratory. It is expected that each student
will work in a responsible manner and exercise good judgment and common sense. If at any time
you are not sure how to handle a particular situation, ask your Teaching Assistant or Instructor
for advice. DO NOT TOUCH ANYTHING WITH WHICH YOU ARE NOT COMPLETELY
FAMILIAR. It is always better to ask questions than to risk harm to yourself or damage to the
equipment.

Personal and General laboratory safety
1. Do not use any equipment unless you are trained and approved as a user by your
supervisor.
2. Wear safety Glasses or face shields when working with hazardous materials and/or
equipment.
5. Wear gloves when using any hazardous or toxic agent.
6. Wash hands before leaving the lab and before eating.
7. Avoid using extension cords where ever possible. If you must use one, obtain a heavy-
duty one that is electrically grounded, with its own fuse, and install it safely. Extension
cords should not go under doors, across aisles, be hung from the ceiling, or plugged into
other extension cords.
8. When using compressed air, use only approved nozzles and never directs the air towards
any person.
9. Guards on machinery must be in place during operation.
10. Exercise care when working with or near hydraulically- or pneumatically driven
equipment. Sudden or unexpected motion can inflict serious injury.
11. Always wear safety goggles if instructed by your Instructor or Teaching Assistant.
12. Never do unauthorized experiments.
13. Never work alone in laboratory.
14. Keep your lab space clean and organized.
15. Do not leave an on-going experiment unattended.
16. Do not use corridors for storage or work areas.
17. Clean your lab bench and equipment, and lock the door before you leave the laboratory.
18. Follow dress code and ensure you are not wearing loose dress in order to avoid dress
material getting trapped in power tools
19. Long and loose hairs to be avoided. To avoid hair getting trapped in m/c wheels or
rotating parts use knots or clips.

1. FITTING
The term fitting, is related to assembly of parts, after bringing the dimension or shape to the
required size or form, in order to secure the necessary fit. The operations required for the same are
usually carried out on a work bench, hence the term bench work is also added with the name fitting.
The bench work and fitting plays an important role in engineering. Although in today's
industries most of the work is done by automatic machines which produces the jobs with good
accuracy but still it (job) requires some hand operations called fitting operations. The person
working in the fitting shop is called fitter
Fitting shop tools are classified as below:
1.1. WORK HOLDING DEVICES /CLAMPING TOOLS
1.1.1 Work Bench
A fitting process can be done at various places, but most of the important operations of fitting are
generally carried out on a table called work bench.
The work bench is a strong, heavy and rigid table made up of hard wood.
The size of the work bench required is about 150 to 180 cm length, nearly 90 cm width and
approximately 76 to 84 cm height. Ref. Fig: 1.1.1.
Fig: 1.1.1-Work bench
1.1.2 Bench Vice
It is firmly fixed to the bench with the help of nuts and bolts. It consists of a cast Iron body and
cast iron jaws. Two jaw plates are fitted on both the jaws. The holding surface of the jaw plates is
knurled in order to increase the gripping. Jaw plates are made up of carbon steel and are wear
resistant. One jaw is fixed to the body and the second slides on a square threaded screw with the
help of a handle.
The jaws are opened up to required length; job is placed in the two jaws and is fully tightened with
the help of handle. Handle is used to move the movable jaw. Ref Fig: 1.1.2.

Fig: 1.1.2-Bench Vice
1.1.3 V Block
In V Block, V grooves are provided to hold the round objects longitudinally. The screw of
the clamp applies the holding pressure. When the handle is rotated there is movement in the screw.
Ref .Fig: 1.1.3
Fig: 1.1.3-V Block
1.2 MEASURING TOOLS

1.2.1 Steel Rule
These are made up of stainless steel and are available in many sizes ranging from 1/2 ft. to 2 ft.
These are marked in inches or millimeters. All the faces are machined true. The edges of steel rule
should be protected from rough handling. Ref. Fig: 1.2.1.
Fig: 1.2.1Steel Rule

1.2.2 Calipers
These are generally used to measure the inside or outside diameters. Different types are
i. Outside Caliper: It is used to measure the outside dimensions. Ref. Fig:1.2.2(i)
ii. Inside Caliper: It is used to measure the inside dimensions. Ref. Fig:1.2.2(ii)
iii. Spring Caliper: Spring is provided to apply the pressure and lock nut is provided to lock any
desired position. Ref. Fig:1.2.2(iii)
Fig: 1.2.2(i) Outside Caliper Fig: 1.2.2(ii) Inside Caliper Fig: 1.2.2(iii) Spring Caliper
1.2.3 Vernier Caliper

It is used for measuring the outer dimensions of round, flat, square components and also the
inner size of the holes and bore. A narrow blade is used to measure the depth of bar slots etc. The
reading accuracy in metric system is 0.02 mm. Ref Fig: 1.2.3
Fig: 1.2.3-Vernier Caliper

1.2.4 Micrometer
It is used for measuring the outer dimensions of round, flat and square components.
Micrometers are accurate measuring devices with precision commonly utilized to measure 0.01mm
onwards. Its include several parts, including the anvil, stirrup, spindle, sleeve, thimble, internal
screw, ratchet, and knurled knob. It is worth noting that the essential component is the internal
screw.
1.3 MARKING TOOLS:

1.3.1 Surface Plate
It is used for testing the flatness, trueness of the surfaces. It is made up of cast iron or graphite.
Its upper face is planned to form a very smooth surface. It is also used in scribing work. While not
in use, it should be covered with a wooden cover. Ref Fig: 1.3.1.
Fig: 1.3.1Surface Plate
1.3.2 Angle Plate

It is made up of cast iron in different sizes; it has two planed surfaces at right angles to each
other and has various slots in each surface to hold the work by means of bolts and clamps.
Never do hammering on the angle plate to fasten (lighten) the nuts and bolts. Ref Fig 1.3.2.
Fig: 1.3.2Angle Plate

1.3.3 Scriber and Surface Gauge
It consists of a cast iron bass on the center of which a steel rod is fixed vertically. Scriber is
made up of high carbon steel and is hardened from the front edge. It is used for locating the centers
of round bars or for marking of the lines. Ref Fig: 1.3.3
Fig: 1.3.3-Scriber and Surface Gauge
1.3.4 Punches
Punches are used for marking purposes. Dot punches are used for marking dotted line and
centre punch is used to mark the centre of hole before drilling. Punches are made up of high carbon
steel or high speed steels. One end is sharpened. Hammering is done on the second end while
working. For dot punch, angle of the punching end is 60 degree while in centre punch; angle of
punching end is 90 degree. Ref Fig 1.3.4
Fig: 1.3.4
1.3.5 Try Square

It is used for checking squareness of two surfaces. It consists of a blade made up of steel, which
is attached to a base at 90 degree. The base is made up of cast iron or steel. It is also used to
mark the right angles and measuring straightness of surfaces. Never use try square as a hammer.
Ref Fig 1.3.5
Fig: 1.3.5-Try Square

1.4 CUTTING TOOLS
1.4.1 Hacksaw
Hacksaw is used for cutting of rods, bars, pipes, flats etc. It consists of a frame, which is made from
mild steel. The blade is placed inside the frame and is tightened with the help of a flange nut. The
blade is made up of high carbon steel or high speed steel. Ref Fig: 1.4.1.
The points of the teeth are bent in a zig-zag fashion, to cut a wide groove and prevent the body
Fig: 1.4.1-Hacksaw
1.4.2 Files
Files are multi points cutting tools. It is used to remove the material by rubbing it on the metals.
Files are available in a number of sizes, shapes and degree of coarseness.
1.4.2.1 Flat file This file has parallel edges for about two-thirds of the length and then it tapers in
width and thickness. The faces are double cut while the edges are single cut. Ref Fig: 1.4.1.1
Fig: 1.4.2.1-Flat file

1.4.2.2 Hand file for a hand file the width is constant throughout, but the thickness tapers as given
in flat file. Both faces are double cut and one edge is single cut. The remaining edge is kept uncut in
order to use for filing a right-angled corner on one side only.Ref Fig 1.4.2.2
Fig: 1.4.2.2-Hand file

1.4.2.3 Square file It has a square cross-section. It is parallel for two-thirds of its length and then
tapers towards the tip. It is double cut on all sides. It is used for filing square corners and slots.
Ref Fig 1.4.2.3.
Fig: 1.4.2.3-Square file

1.4.2.4 Triangular file It has width either parallel throughout or upto middle and then tapered
towards the tip. Its section is triangular (equilateral) and the three faces are double cut and the edges
single cut. It is used for filing square shoulders or comers and for sharpening wood working saws.
Ref Fig 1.4.2.4.
Fig: 1.4.2.4-Triangular file

1.4.2.5 Round file It has round cross-section. It carries single cut teeth all round its surface. It is
normally made tapered towards the tip and is frequently known as rat-tail file. Parallel round files
having same diameter throughout the length are also available. The round files are used for opening
out holes, producing round comers, round-ended slots etc. Ref Fig 1.4.2.5.
Fig: 1.4.2.5-Round file

1.4.2.6 Half-round file Its cross-section is not a true half circle but is only about one-third of a
circle. The width of the file is either parallel throughout or upto middle and then tapered towards
the tip. The flat side of this file is always a double cut and curved side has single cut. It is used for
filing curved surfaces. Ref Fig 1.4.2.6.

Fig: 1.4.2.6-Half-round file
1.4.2.7 Knife edge file It has a width tapered like a knife blade and it is also tapered towards the tip
and thickness. It carries double cut teeth on the two broad faces and single cut teeth on the edge. It
is used for finishing sharp corners of grooves and slots. Ref Fig 1.4.2.7.
Fig: 1.4.2.7-Knife edge file
1.4.2.8 Diamond file Its cross-section is like a diamond. It is used for special work. Ref Fig 1.4.2.8.
Fig: 1.4.2.8-Diamond file
1.4.2.9 Needle file These are thin small files having a parallel tang and a thin, narrow and pointed
blade made in different shapes of its cross-section to suit the particular need of the work. These are
available in sizes from 100 mm to 200 mm of various shapes and cuts. These files are used for
filing very thin and delicate work. Ref Fig 1.4.2.9.
Fig: 1.4.2.9-Needle file

1.5 METHODS OF FILING
The following are the two commonly used methods of filing: 1. Cross-filing 2. Draw filing.
1.5.1 Cross - Filing

This method is used for efficient removal of maximum amount of metal in the shortest
possible time. It may be noted that the file must remain horizontal throughout the stroke (long, slow
and steady) with pressure only applied on the forward motion. Ref Fig 1.5.1.
Fig: 1.5.1-Cross - Filing
1.5.2 Draw Filing

This method is used to remove file marks and for finishing operations. Here, the file is gripped as
close to the work as possible between two hands. In this filing method, a fine cut file with a flat face
should be used. Ref Fig 1.5.2.
Fig: 1.5.2-Draw Filing

EX.NO:
DATE:
WORKPIECE PREPARATION FOR FITTING OPERATION

AIM:
To prepare square or rectangular shaped MS plates using power tools for cutting, polishing and shaping
to the required dimensions.
MATERIALS REQUIRED:
Mild steel flats with its dimensional values that are marginally higher than the required
dimensions.
WORK PIECE DIMENSIONS (CUT FROM FLATS): First piece:…… mm X…… mm and
….. mm and Second piece:…… mm X…… mm and ….. mm)
TOOLS REQUIRED:
1. Metal cutting machine- Abrasive tool /circular cutting saw
2. Bench Vice
3. Try Square
4. Steel rule
5. Cutting Machine
6. Cutting Wheel, Grindng Wheel, Buffing Wheel
PROCEDURE
1. Study the required work piece dimension and mark the requirement on the MS flat.
2. Give allowance for cutting and filing operation and mark the line of cut on the MS flat.
3. Two MS flats are cut as per the marking.
4. The dimensions of the work piece are now measures and recorded.
5. Plan the portion of the work piece to be removed to precisely get the required dimensions.
6. The work piece is clamped in between the jaws of the bench vice with the surface to be
filed remains horizontal and also at the top.
7. The height of projection of the work piece above the clamp is not to exceed 5 mm in order
to minimize/avoid vibration and noise during filing operation.
8. Use Grinding machine for removing excessive material and flat (smooth) file and
buffing machine for finishing operation.

9. Carry out filing operation on this top surface of the work piece without any irregularity in
material removal and ensure a perfect flat surface. This new flat surface will be used as one
of the reference plane (say X axis) for marking the required dimensions.
10. Unclamp the work piece from the bench vice and clamp it again after tilting the work piece
to 90 degrees such that this new surface comes on top, for filing operation. This new
surface will be the reference plane in Y axis. Carry out filing operation on this new top
surface and ensure flatness.
11. Using Tri square check the two right angled surfaces that are machined for
perpendicularity. Carry out further filing on these two surfaces if required to ensure
perpendicularity of its surfaces.
12. Mark the required geometry in the work piece as per the geometry using steel rule, scriber
and punch.
13. Use hacksaw frame fitted with sharp blade to remove the excessive material (only if
required) and carrying out filing operation of the other two unfinished surfaces. Ensure the
new surfaces are parallel to the reference X axis and Y axis respectively and to the required
dimensions.
14. Measure the dimensional values of the finished work pieces and compare it with the
standard / required values for accuracy.
RESULT: (All dimensions are in mm)
Dimensional Parameter Required Obtained
Dimension Dimension
Tools/Equipments used:
Procedure: To be conceived and written in short not exceeding 6 to 7 lines. No copying from
any sources and it should be your own English.

Diagram:2D and 3D the model with dimensions
Conclusions:
Verification note and marks awarded
COE Accuracy Viva Record Total Faculty sign with

date

EX.NO:
DATE:
ASSEMBLY OF MS PLATES USING FITTING, DRILLING AND TAPPING

OPERATIONS
AIM:
To assemble the MS plates using fitting, drilling and tapping operations.
MATERIALS REQUIRED:
Two Mild steel plates (two nos) with thickness sufficient for carrying out drilling, tapping .
GIVEN WORK PIECE DIMENSIONS: First piece:…… mm X…… mm and ….. mm and
Second piece:…… mm X…… mm and ….. mm)
TOOLS REQUIRED:
1. Drilling machine
2. Drill bit
3. Drill chuck
4. Tap and tap wrench
5. Try Square
6. Steel rule
7. Prick punch
8. Hacksaw
9. Files
10. Surface plate
11. Ball peen hammer
PROCEDURE
1. Cut and prepare the work piece to the specifications
2. Mark the axis of the hole to be drilled and punch the mark.
3. Select drill bit and machine to suit the diameter of hole and fit the tool in the machine.
4. Select the Machine parameters like speed for hand feed drilling
5. Fix the work piece in the Work table of the drilling machine.
6. Adjust the work table to carryout drilling
7. Carryout drilling by suitably bringing the point of drill just below the drill bit. Axis of drill
bit and axis of hole should match.
8. Remove the work piece from the machine and fit it in the bench wise for tapping.
9. Select suitable tap and complete tapping by ensuring axial match and rotating the tap in
suitable (clockwise/anticlockwise) direction.

10. Check the threads against the standards and repeat the drilling and tapping process to get
the required holes on the plates.
11. Use bolts and nuts for metal joining as required.
12. Double end spanners/Ring spanners may be used for assembly and dismantling of plates.

Dimension Dimension

Conclusions:

date

Viva Questions:
1. What do you mean by fitting? (or) Define fitting? Give practical example
2. Name the tools, which are used in fitting?
3. Name work holding devices used in Fitting
4. What are the types of vices?
5. Name Marking and measuring tools used in Fitting
6. What is the purpose of Marking?
7. What is meant by Measurement?
8. Name measuring tools used in Fitting.
9. Name Finishing and cutting tools used in Fitting.
10.What is the classification of materials?
11.What is the use of try square?
12.What is the use of Dot punch?

2. CARPENTRY
Wood work / Carpentry is the art of making articles, with wood, like chairs, Tables, cots,
doors, windows, wardrobes, partitions etc.,.. These articles are made by joining several pieces with
proper types of joint using tools and machines.The word "carpenter" is the English rendering of
the Old French word charpentier which is in turn derived from the Latin carpentries which means
maker of a carriage.
Carpentry is required for Civil Engineering for various purposes like
1. Doors and Windows
2. Furniture
3. Wood Houses
4. Roof Trusses
5. Scaffoldings, Centering etc.
Wood also called timber is the universally used material for making the above said items. The
advantages of wood are
It is light in weight than other construction material and comparatively cheap.
It is much suitable for making doors, windows, cabinet work fittings and it is very easy to
work with tools.
It can be beautifully carved painted and polished for good aesthetics.
2.1 Wood
Knowledge on fundamentals of wood is essential for an engineer involved in study of carpentry. It
is elementary that the parts of a tree are the roots, stem (or) trunks, branches and leaves.Tree stems
or Trunks consist mainly of support and transport tissues (xylem and phloem). Wood consists of
xylem cells, and bark is made of phloem. Trees may be grouped into exogenous and
endogenous trees according to the way in which their stem diameter increases. Exogenous trees
grow by the addition of new wood outwards, immediately under the bark. Endogenous trees grow
by the addition of new wood inwards, immediately under the wood. Wood for Carpentry is taken
only from exogenous trees.It is important to understand the various stages in wood. The wood
in the tree before cutting is referred to as timber or lumber. The wood obtained from the tree is
termed as raw wood. When the wood is ready to use for carpentry purposes, it is called as
finished wood. One important stage in- between raw and finished wood is seasoned wood
obtained through seasoning process.
2.1.1 Purpose of Seasoning
To reduce the moisture content of timber.
To avoid the shrinkage, crack & bend.
To increase the strength and durability.
To avoid decaying of timber.

2.1.2 Types of Seasoning
Natural seasoning
a) Air seasoning
b) Water seasoning
Artificial seasoning
c) Chemical seasoning
d) Kiln seasoning
Wood is generally classified into three types namely

Hard Wood – A strong, dark colored, heavy wood obtained from hard trees (e.g. Teak,
Mango, Sal, Oak etc.)
Soft Wood - A weaker, more combustible, soft and light wood obtained from soft trees
(e.g. Deodar, Kail, Chir etc.)
Plywood – An engineered and laminated wood made from thin sheets of wood called
plies. It is also called engineered wood. Plywood is widely used due to its resistance to
cracking, shrinkage, twisting, warping etc. and its general high degree of strength.
2. Classification of Carpentry Tools
The carpentry tools can be divided into three categories namely

Hand Tools – operated by hand
Portable Power Tools – operated by electricity & portable
2.1 HAND TOOLS

Hand planes are generally the combination of a cutting edge, such as a sharpened metal
plate, attached to a firm body, that when moved over a wood surface, take up relatively uniform
shavings, by nature of the body riding on the 'high spots' in the wood, and also by providing a
relatively constant angle to the cutting edge, render the planed surface very smooth. A cutter which
extends below the bottom surface, or sole, of the plane slices off shavings of wood. A large, flat
sole on a plane guides the cutter to remove only the highest parts of an imperfect surface, until,
after several passes, the surface is flat and smooth. When used for flattening, bench planes with
longer soles are preferred for boards with longer longitudinal dimensions. A longer sole registers
against a greater portion of the board's face or edge surface which leads to a more consistently flat
surface or straighter edge. Conversely, using a smaller plane allows for more localized low or high
spots to remain.

The following hand tools
Try Square
Saws
Chisels
Hammer
Jack Plane
Steel Rule
2.1.1 TRY SQUARE:
The try square is a measuring tool as well as marking tool. It is used for
testing the square ness of edges, frames etc and flatness of surfaces. They are
Also employed in marking of joints. The try squares are commonly
available for blade lengths 150mm, 225mm and 300mm.
Ref Fig 2.1.1.
Fig:2.1.1-Try Square
2.1.2 SAWS:
Saw is the mostly used carpentry tool having a metal blade or disk with a
sharp edge and used for cutting wood, metal, or other hard materials. It has two
parts namely steel blade andwooden handle. The wooden handle is rigidly
fixed to the blade using rivets. There are many types of saw like rip saw, cross cut
saw, coping saw, compass saw, key hole saw etc. Ref Fig 2.1.2.
Fig: 2.1.2- Saw
However the most popular types of saw are ripsaw and cross cut saw. Rip Saws are the largest and
coarsest of all saws. They are designed to cut along the grain. Cross Cut Saws are used for cutting
across the grain in the thick woods.They are useful for cutting carpentry joints.
2.1.3 CHISELS:
Chisels are the tools produce from forged steel with a sharp edge, used
to cut and shape woods. The common types of chisel are
a. Firmer Chisels
b. Mortise Chisels
c. Paring Chisels
d. Beveled Edge Chisels
Fig: 2.1.3- Chisels

are much longer and lighter. They are used for shaving, paring and other light
should never be hit with striking tools .Ref Fig: 2.1.3- Chisels.
2.1.4 JACK PLANE:

Generally planes are used to produce flat and smooth surfaces on wood. A plane is like
a chisel fitted in a block of metal or wood. Jackplane is a general purpose plane. It is used for
quick removal of materials, removal of saw marks, surface smoothening and other rough works. Jack
Planes are either made of wood or of metals (iron). Metal planes are more expensive than wood, but
they are more accurate. Apart from Jack planes, trying planes are used for planing large surfaces
and smooth planes are employed for smoothening surface after jack planing.
2.1.5 HAMMER:
Hammer is a commonly used hand tool that has a handle with a perpendicularly attached head of
metal or other heavy rigid material, and is used for striking or pounding. A wide range of Hammers
are available, varying in shape, size and weight.
2.1.6 STEEL RULE:

It is used to measure or mark the lengths. It is usually available in lengths of 150 mm and 300 mm,
graduated both in mm and inches, and is made from tempered rust free steel or stainless steel.
2.2 PORTABLE POWER TOOLS
Portable Powered Hand Tools Portable powered hand tools are becoming more and more
popular for everyday use. There is a wide variety of these tools available for use in the workshop
and on site and for home use.
These tools are powered by:
•Mains electricity at 240V (usually for home use as this voltage is not recommended for site use, as
an electric shock from this tool can prove fatal).
•Mains electricity stepped down by using a transformer which reduces the voltage to 110V.
•Electricity supplied at 110V (used on all sites and in workshops).
•Electricity supplied by battery to cordless power tools (9–15V) which can be recharged.

2.2.1 Drills
There are two main types of drills available:
Mains driven – the motor is driven by electricity obtained from a mains power source. These drills
are usually rated at 240 volts although 110 volts tools can be used if a transformer is plugged into
the mains circuit. Battery driven (Often referred to as cordless drills) – the motor is driven by a
rechargeable battery. These batteries range from 12 volts to 18 volts.
In addition, to these two main types there are variations of each type:
•Rotary drills.
•Rotary and impact (percussion) drills.
•Hammer drills. All of these types are available with key operated drill chucks or keyless operated
Fig: 2.2.1- Driller

2.2.2 Screwdrivers
Some manufacture’s make power operated screwdrivers which provide the operator with
a fast effortless way to insert or remove screws. These tools are available with a range of bits in all
different sizes and types to engage all types of screw head shapes and slots. The tools usually have
a drive cover which, when in contact with the surface of the timber, engages a clutch mechanism
which disengages the drive mechanism. This allows the head of the screw to be driven flush with
the surface.
Most modern drills can be adapted to perform as a screwdriver. There are countless types of bits to
accommodate all types of screws and fixings. Ref Fig: 2.2.2.

Fig: 2.2.2- Screwdrivers
2.2.3 Electric Powered Circular Saw
Portable circular saws are available with blade diameters ranging from 175mm to 250 mm.The
depth of vertical cut can range from 65mm to 90mm. The design of the saw allows
angle cuts as well as vertical cuts to be made. However the depth of angle cut will be
Reduced because of the cutting angle. Ref Fig 2.2.3.
Fig: 2.2.3.Screwdrivers
This type of saw can be used to cut:

• Solid softwood timber.
• Solid hardwood timber.
•A range of wood-based sheet materials.
•Plastic laminate sheets.
There is a range of different saw blades that can fitted to this type of saw, each with different
teeth characteristics. The quality, ease of cutting, and safe use of the saw often relies on
the type of blade being used. The type of blade being used should reflect upon the material
being cut.

2.2.4 Jig saws
A powered jig saw drives a small narrow blade with teeth cut along its leading edge using
an up and down cutting action. Cutting only occurs on the upward stoke of the blade. Modern types
of this saw incorporate an orbital cutting motion that allows the blade to move away from the
cutting edge on the downward non-cutting stroke. This action helps clear away the waste material
from the saw cut reducing friction and prolonging the life of the saw blade.
There are various types and sizes of these machines ranging from the DIY type up to
industrial jig saws. The rating of these saws range from 500-800 watts and the more powerful types
can cut timber up to 60mm in thickness and metals of various hardnesses of 2-12 mm thick.There
are also various types of saw blades available which can be easily inserted into the tool, thus
making it a very versatile power tool. Ref Fig: 2.2.4.
Fig: 2.2.4. Jig saws
3. Carpentry Joints
A joint, in carpentry terms, is the place where two pieces of wood fit together. Carpenters attempt to
craft the wood so that the joint is as precise and correct as possible. The art of making joints is called as
Joinery. There are many carpentry joints which are chosen and implemented based on the quality of
wood and the nature of work. The joints are used in making doors, windows, roof trusses, cabinets etc.
Some of the common joints are listed below. Their diagrammatic representations are also recorded.
3.1 T Joint or Middle Lap Joint
The purpose of this joint is to secure the corners and

intersections of the framing. Middle lap joints are
employed in construction.

3.2 Cross Lap Joint
A cross lap joint is used where two pieces cross each other. This joint is widely used than lap joint.
These joints are used in construction of windows and heavy timber. It is also used in pattern making
for spokes in pulleys and wheels.
3.3 Mortise and Tenon Joint
It consists of a rectangular peg (tenon) fitting into a rectangular hole

(mortise). Two tools used for making mortise and tenon joint, those tools
are mortise gauge and mortise chisel. Generally in framing work, width of
the mortise is about one third of the thickness of the material to be
mortised and the length should not exceed six times the width.
3.4 Dove Tail Joint

The dovetail joint is the strongest of all
corner joints. Generally an angle of 1:6 ratios is
adopted. It is particularly used in joints between the
sides and back of drawers. It is also used for making
box or carcase-like constructions and small boxes to
large pieces of furniture.
3.5 Bridle Joint

Bridle joints have the same proportions as
the mortise and tenon joint and are rather like
the mortise and Tenon in reverse. The
central one-third is left-in one member while
the two outer thirds are cut away. These joints
are used where the members are of square
section and unsuitable for making mortise and
tenon joint.
4. Carpentry Process
To finish a work to the required size and shape in a wood working shop, several operations are
performed. These operations are
1. Marking and Measuring
2. Planing
3. Chiselling
4. Sawing
5. Mortising and tenoning

6. Boring
7. Grooving and tonguing
8. Moulding
9. Recessing
10. Rebating
4.1 Marking and Measuring

Marking is the process of setting out dimensions on a wooden
piece to produce the required shape. Marking and measuring
operations are carried out collectively on the wood to determine
dimensions of a job to be made. Marking guides the operator in
further operations to get accurate job.
The dimensions are to be accurately and correctly marked.

Tools and gauges are used in marking and measuring are
Calipers, Compasses, Steel Rule, Try Square, Mitre Square, Marking Gauge, Mortise Gauge and
Divider.
4.2 Sawing
It is the basic operation carried out in the carpentry shop for cutting wood to the required size and
shapes like straight, inclined or curved surfaces. The sawing of wood may be done along the grains
or and across the grains. Different types of saws used for sawing are Rip saw, Cross cut saw, Back
saw, Compass saw, Coping saw, Keyhole saw or Pad saw and Bow saw.
4.3 Planing
The operation of smoothing a wooden surface with the help of suitable plane is called planning.
This operation can be also” Facing” or “Edging”. Before carrying out planning operation, the
direction of wood grains should be checked. A properly planed surface should be perfectly straight,
parallel in width and thickness and all edges must be square to the face. Different types of planes
like Wooden Jack Plane, Iron Jack Plane, Trying Plane and Smoothing Plane are used for planing
operation.
4.4 Chiselling
It is the operation of cutting a small stock of wood from the given work piece to get the required
shapes by using chisel. Different types of chisels like Firmer Chisel, Paring Chisel, Mortise Chisel
and Gauge Chisel are used for chiselling operation.
4.5 Mortising and Tenoning
Mortising is the operation of producing a rectangular (or) square hole and tenoning is the operation
of making a corresponding projection so that it fits into the mortise to form an assembly.
4.6 Boring

It is the process of producing through (or) blind holes in wood. Boring operations can be done
straight (or) inclined to suit the type of work. Small holes are produced with a gimlet but large size
holes are produced by brazes.
4.7 Grooving and Tonguing
Grooving is the process of making grooves and tonguing is the process of producing
corresponding projection of wood to fit into grooves. This operation is applied in wood partitions
and drawing boards.
4.8 Moulding
It is the process of producing convex, concave and other complex types of curved surfaces on
a piece of wood. Moulding is done with the use of moulding plane. Moulding work may be done
for preparing photo frames and for decorative purpose in doors and window frames.
4.9 Rebating
It is the process of making a recess (also called as rebate) taken out of the edge of a piece of wood.
This is done with the help of rebating plane.
4.10 Recessing
It is the process of making slots in wooden pieces
5. Definitions of Technical Terms used in Doors and Windows.
The following are the technical terms applied to doors and windows.
Frame: This consists of an assembly of horizontal and vertical member which are placed along the
top, sides and the bottom of an opening so as to form an enclosure and a support for a door or a
window.
Style: This is outside vertical member of the shutter.
Top Rail: This is the top most horizontal member of the shutter.
Bottom Rail: This is the lower most horizontal member of the shutter
Panel: This is the area enclosed between the rails.
Hold Fast: This is generally in the form of mild steel flat bar of section 30mm x 6mm and of length
200mm. Three numbers of such hold fasts are provided on each side of the window / door frame.
They keep the frame in position.
Horn: This is a horizontal projection of head or sill beyond the face of the frame. It is usually 15cm
or so.
Shutters: These are the openable parts of a door or window. It is an assembly of styles, panels and
rails.
Mullion: This is a vertical member of a frame which is employed to subdivide a window or a door
opening vertically.
Transom: This is a horizontal member of a frame, which is employed to sub-divide a window
opening horizontally.

A router is a hand tool or power tool that a worker uses to rout (hollow out) an area in relatively hard
material like wood or plastic. Routers are mainly used in woodworking, especially cabinetry. Routers
are typically handheld or fastened cutting end-up in a router table.
The hand tool type of router is the original form. It is a specialized type of hand plane with a broad
base and a narrow blade that projects well beyond its base plate (giving it the nickname old woman's
tooth). The power tool form of router with an electric-motor-driven spindle is now the more common
form. The hand tool version is now often called a router plane, and for some tasks, still provides a few
advantages over the power tool. Some workers consider the electric router one of the most versatile
woodworking power tools.[1] CNC wood routers implement the advantages of CNC (Computer
Numerical Control).
Related to the router is a smaller, lighter version designed specifically for trimming laminates. It can
be used for smaller general routing work. For example, with an appropriate jig it can be used for
recessing door hinges and recessing lock faceplates. Even rotary tools can be used as routers when the
right bits and accessories (such as a plastic router base) are attached.

EX.NO:
DATE:
FABRICATION OF RECTANGULAR/SQUARE TRAY USING PLYWOOD
AIM:
To prepare a wood or plywood box/tray/any innovative models using modern power tools
like cutting machine, router, jigsaw, power screw driver etc.
MATERIALS REQUIRED:
Ply wood sheet of sufficient area and thickness to make the box as per specification.
GIVEN WORK PIECE DIMENSIONS: Ply wood size :……mm X…… mm and ….. mm and
Second piece:…… mm X…… mm and ….. mm)
TOOLS REQUIRED:
1. Try square
2. Marking gauge
3. Tenon saw
4. Carpentry vice
5. Steel rule
6. Firmer chisel
7. Mallet
8. Rip saw
WORK INSTRUCTIONS:
1. Check the given ply wood for its dimensional values and quality.
2. Analyze the given drawing for the required specifications and ensure the suitability of
the given material to make the required joint.
3. Study the base area and wall area of the wooden box/tray to be made.
4. Mark the outer edge dimensions of the base portion on the given plywood and carry
out cutting operation using tenon saw
5. Similarly mark all the side walls of the box/tray based on the height and width of the
box required and carryout remaining cutting operation using hand saw/power saw to get
the required work pieces.
6. Ensure proper cross sectional area and surface finish.

7. Mark the portion to be removed on each work piece in order to facilitate making part
and counterpart for the required wooden joint.

8. Clamp one of the work pieces firmly in the vice such that the portion to be removed
may be chiseled /operated.
9. Remove the marked portion from the work piece by chiseling or cutting and with the
help of power tools.
10. Use Power tools/ mallet and firmer chisel to remove the excess wood by chiseling
11. Complete all the parts in the same manner as per the specification.
12. Assemble the pieces to get the box as per the required specification with the help of
nails and adhesives.
13. Check the obtained joint against specification using try square and steel rule.
14. Carryout small corrections in work pieces if required.
15. Record the obtained dimensional values and compare it with desired values.

Dimension Dimension

Conclusions:

date

Viva Questions
1. What is wood work / Carpentry?

2. List commonly used wood in carpentry.
3. What is the advantage of using wood over the other materials?
4. What do you meant by seasoning and states its purpose?
5. List out various tools used in carpentry.
6. State the use of try-square.
7. List different types of saw.
8. Write brief note on chisels.
9. What are the different types of planes used in carpentry?
10. Name the different types of carpentry joints.
11. Write brief note on Middle Lap Joint and Cross Lap Joint.
12. Write down the important carpentry process during wood work.
13. Define the technical terms Hold fast, Horn, Frame, Mullion and Transom.
14. How do you specify a sample wood piece?
15. What do you meant by Planing, Mortising and Tenoning?

3. SHEET METAL WORKING
3.1 INTRODUCTION
Sheet metal is simply metal formed into thin and flat pieces. It is one of the fundamental
forms used in metalworking, and can be cut and bent into a variety of shapes. Countless everyday
objects are constructed of the material. Thicknesses can vary significantly, although extremely thin
thicknesses are considered foil or leaf, and pieces thicker than 6 mm (0.25 in) are considered plate.
3.2. SHEET METAL PROCESSING

The raw material for sheet metal manufacturing processes is the output of the rolling process.
Typically, sheets of metal are sold as flat, rectangular sheets of standard size. If the sheets are thin and
very long, they may be in the form of rolls. Therefore the first step in any sheet metal process is to cut
the correct shape and sized ‘blank’ from larger sheet.
3.3 SHEET METAL FORMING PROCESSES

Sheet metal processes can be broken down into two major classifications and one minor
classification
Shearing processes -- processes which apply shearing forces to cut, fracture, or separate
the material.
Forming processes -- processes which cause the metal to undergo desired shape changes
without failure, excessive thinning, or cracking. This includes bending and stretching.
Finishing processes -- processes which are used to improve the final surface
characteristics.
3.3.1 Shearing Process

Punching: shearing process using a die and punch where the interior portion of the
sheared sheet is to be discarded.
Blanking: shearing process using a die and punch where the exterior portion of the
shearing operation is to be discarded.
Perforating: punching a number of holes in a sheet
Parting: shearing the sheet into two or more pieces
Notching: removing pieces from the edges
Lancing: leaving a tab without removing any material .Ref Fig 3.1.
Fig.3.1Shearing Operations: Punching, Blanking and Perforating

3.3.2 Forming Processes

Bending: forming process causes the sheet metal to undergo the desired shape change by
bending without failure. Ref fig.3.2 & 3.3
Stretching: forming process causes the sheet metal to undergo the desired shape change
by stretching without failure. Ref fig.3.4
Drawing: forming process causes the sheet metal to undergo the desired shape change
by drawing without failure. Ref fig.3.5
Roll forming: Roll forming is a process by which a metal strip is progressively bent
as it passes through a series of forming rolls. Ref fig.3.6
Fig.3.2 Common die-bending operations
Fig.3.3 Various bending operations

Fig.3.4 Schematic illustration of a stretch-forming process.
Fig.3.5 Schematic of the drawing process.
Fig.3.6 Eight-roll sequence for the roll forming of a box channel

3.3.3 Finishing processes
Material properties, geometry of the starting material, and the geometry of the desired final
product play important roles in determining the best process.
3.4 SHEET FORMING PROCESS EQUIPMENTS

Basic sheet forming operations involve a press, punch, or ram and a set of dies
3.4.1 Presses
Mechanical Press - The ram is actuated using a flywheel. Stroke motion is not
uniform. Ref fig 3.7
Hydraulic Press - Longer strokes than mechanical presses, and develop full force
throughout the stroke. Stroke motion is of uniform speed, especially adapted to
deep drawing operations. Ref fig 3.8.
Fig.3.7 Mechanical Press
Fig.3.8 Hydraulic Press

3.4.2 Dies and Punches
Simple- single operation with a single stroke
Compound- two operations with a single stroke

Combination- two operations at two stations
Progressive- two or more operations at two or more stations with each press stroke,
creates what is called a strip development. Ref Fig.3.9.
Fig. 3.9 Progressive dies Punches
3.5 Tools and Accessories

The various operations such as cutting, shearing, bending, folding etc. are performed
by these tools.
3.5.1 Marking and measuring tools

Steel Rule - It is used to set out dimensions.
Try Square - Try square is used for making and testing angles of 90degree
Scriber – It used to scribe or mark lines on metal work pieces.
Divider - This is used for marking circles, arcs, laying out perpendicular lines,
bisecting lines, etc. Ref Fig.3.10.
Fig.3.10 Marking and measuring tools

3.5.2 Cutting Tools
Straight snip - They have straight jaws and used for straight line cutting. Ref
fig.3.11
Curved snip - They have curved blades for making circular cuts. Ref fig. 3.12

Fig.3.11 Straight snip
Fig.3.12 Curved Snip

3.5.3. Striking Tools
Mallet - It is wooden-headed hammer of round or rectangular cross section. The
striking face is made flat to the work. A mallet is used to give light blows to the
Sheet metal in bending and finishing. Ref fig. 3.13
Fig.3.13 Types of Mallets

3.6 Applications
Roofings
Ductings
Vehicles body buildings like 3 wheelers, 4 wheelers, ships, aircrafts etc.
Furnitures, House hold articles and Railway equipment

EX.NO:
DATE:
FABRICATION OF A LEAK PROOF SHEET METAL RECTANGULAR/SQUARE TRAY
AIM:
To prepare a leak proof sheet metal tray/box/funnel using modern power tools.
Galvanized Iron (G.I) sheet of thickness ranging from 18-28 gauge and cut to an area
sufficient for making the box.
GIVEN WORK PIECE DIMENSIONS: …… mm X…… mm and thickness ….. ….gauge /mm)
TOOLS REQUIRED:
1. Steel rule
2. Mallets
3. Scriber
4. Divider
5. Protractor
6. Standard wire gauge/ Sheet thickness measuring gauge
7. Snips/Tin cutter
8. Stakes
9. Rivet set
10. Ball peen Hammer
WORKING PROCEDURE
1. Check the dimensions of the given sheet using steel rule and thickness measuring gauge.
2. Draw the development of the tray on a white paper and obtain various dimensions. Provide
allowances for edge folding and also for flap. Mark the obtained dimensions on the given
work sheet surface using scriber.
3. Cut and remove the unwanted / excess materials using tin cutter.
4. Hold the work piece suitably in a bench vice and bend the sheet along the edges of the box
using Stakes and Mallet.
5. Complete bending process of the work piece.
6. Fold the flaps to the inner surface of the wall for riveting / soldering if required for leak
proof joints.
7. Complete edge folding along the open edges of the box to avoid sharp edges.
8. Complete trimming and finishing operations to ensure accuracy and safety..

Dimension Dimension

Conclusions:

date

Viva Questions:
1. What do you mean by sheet metal work?
2. List the application of sheet metal working.
3. List types of material used in sheet metal work.
4. Which topic of Engineering Graphics deals with the sheet metal working and why is it important?
5. What is pattern in sheet metal?
6. What are the various methods available to get a pattern?
7. Write in brief about Parallel line method and where it is used.
8. Write in brief about Radial line method and where it is used.
9. List out the various tools used in sheet metal work.
10. List the various marking tools used in sheet metal work.
11. List the cutting tools used in sheet metal work.
12. List the supporting tools used in sheet metal work.
13. What is stake? List the different types of stakes.
14. List different types of joints used in sheet metal work.
15. Write in brief about some important sheet metal operations.

4. PLUMBING
Plumbing is a skilled trade of working with pipes or tubes and plumbing fixtures. The
process is mainly used for the supply of drinking water and the drainage of waste water, sometimes
mixed with waste floating materials in a living or working place. A plumber is someone who
installs or repairs piping systems, plumbing fixtures and equipment such as valves, washbasins,
water heaters, water closets, etc. Thus it usually refers to a system of pipes and fixtures installed in
a building for the distribution of water and the removal of waterborne wastes.
The latin word plumbum, means metal lead pipe, is the origin for developing the term plumbing.
Plumbing process was originated during the ancient civilizations such as the Greek, Roman,
Persian, Indian and Chinese civilizations as they developed public baths and needed to provide
potable water, and drainage of wastes carried by water.
4.1 PIPES AND THEIR JOINTS:
Pipes are manufactured by using different types of materials like steel, cast iron, galvanized
iron, brass, copper, aluminum, lead, plastic, concrete, asbestos etc. They are usually classified
according to the material. They are also grouped as cast, welded, seamless, extruded etc. For
conveying large quantity of water, cast iron, steel or concrete pipes having large diameter are
usually used. Galvanized iron pipes (GI pipes) are popular for medium and low pressure water
supply lines.
Plastic pipes are preferred for household uses at low pressure. Pipes are generally specified by
their inner diameter (Nominal diameter specified in inches). Hence, the pipe fitting size is also
based on this dimension. But for plastic pipes, this rule is not strictly followed because threading is
not usually required for them. For engineering uses, along with the nominal diameter, the pipe
thickness is also specified as light, medium or heavy.
4.1.1 Types of pipe joints:
According to the pipe material, size and application, different methods are used to join pipes.
The most common types of pipe joints are:
1. Screwed pipe joint – For GI Pipes
2. Welded pipe joint – for steel, copper, aluminum and lead pipes
3. Flanged pipe joint – for cast iron and steel pipes
4. Soldered pipe joint – for brass and copper tubes
5. Glued or cemented pipe joint – for PVC pipes
Pipes made of iron (GI Pipes) and brass of small and medium diameters (10 mm to 100 mm) are
usually joined by screwing the pipe specials with internal or external threads. Welding is used to
make permanent joint of medium and large diameter steel pipes. Flanged pipe joints are common
in medium and large diameter pipes of cast iron and steel, along with rubber/CAF (Compressed
asbestos fibre) gaskets. The flanged are screwed to the pipe for smaller diameter but made integral
for large diameters. Pipes of copper and brass are usually joined by soldering.
PVC (Poly Vinyl Chloride) pipe is the most popular choice in plastic group. It is rigid and uses
thread and solvent weld (glue) connections. It also can be heat fused. PVC pipes are available in
various pressure ratings for water supply, and are a very choice for landscape irrigation. The
reasons for the popularity are the economy, no corrosion and easiness to work. CPVC is a different
type of plastic, which has an extra chlorine atom in the compound, can be used for the hot water
supply, and in industry.
To join plastic pipes, gluing or cementing method is used. Solvent cement is the gluing material
and it partially melts the surface of the plastic pipe to make the joint. As the glue evaporates within
two minutes, a strong joint is obtained.

4.2 SCREWED PIPE FITTINGS:
These are removable or temporary pipe connections which permit necessary dismantling or
reassembly for the purpose of installation, maintenance, cleaning, repair, etc. The functions of pipe
fittings can be broadly classified as:
1. To join two or more pipe lines together
2. To effect change in diameter or direction
3. To close the end of a pipe line
The most common types of screwed pipe fittings used in galvanized iron (GI) pipe lines and plastic
(PVC) pipe lines are shown in Figure 1 (1 to 17). A brief description of these fittings is given
below
1. Coupler (coupling): Two pipe lines of equal diameter and in axial alignment can be joined
by a coupler (coupling). It is a short sleeve with internal thread.
2. Reducer coupler (Reducer coupling): This is a coupler to join two pipe lines of different
diameters in axial alignment.
3. 90°Elbow: This is a pipe special used or effecting abrupt change in direction through 90°.
Internal threads are provided on both ends. An elbow brings twice the head loss than a bend.
4. 90° Reducer elbow: This is an elbow with outlet diameter less than that of inlet diameter. It
is used to join two pipe lines having different diameters and meeting at right angle.
5. Bend: This is a pipe special used to effect gradual change in direction (usually 90°).The two
ends of the bend are externally threaded.
6. Return hand: This bend is used to return the direction of pipe line through 180°.The ends
are internally threaded for fitting the pipe lines.
7. Tee: This pipe special is used to make a branch connection of same diameter to the main pipe
line at right angle. A Tee is internally threaded and it connects three ends of pipes.
8. Reducer Tee: This is a pipe special similar to Tee used to take a branch connection of
reduced diameter from the main pipe line.
9. Cross: This pipe special is used to take two branch connections at right angles to the main
pipe line. The threads are provided internally.
10. Close nipple: A nipple is a short straight piece of pipe with external thread on both ends. A
close nipple is the shortest one of this category with external thread for the full length. They are
used to join two internally threaded pipe specials and valves.
11. Short nipple: A short nipple has the same shape and function of a close nipple, but it has a
short unthreaded portion at the middle of its length for gripping.
12. Short nipple with hexagonal grip: This nipple has an additional hexagonal nut shape at the
middle portion for easy screwing with spanner. It is similar to an ordinary short nipple, except
that difference.
13. Hose nipple: A hose nipple is used to connect a hose (flexible pipe-usually plastic or
rubber) to a pipe line. One end of the hose-nipple has a stepped taper to fit the hose, while other
end has thread. A hexagonal nut shape is given to the middle portion for gripping with a
spanner.
14. Male plug: A male plug is used to close an internally threaded end of a pipe line or pipe
special. It has external thread and a grip of square shape at the end.
15. Female plug (cap): A female plug is used to close an externally thread end of a pipe or pipe
special. It has internal thread and a grip of square shape at the end.
16. Screwed union: It consists of three pieces as shown in the drawing. The two end pieces
have internal threads at their ends which are connected to the pipe ends. The central hexagonal
(or octagonal) piece (union nut) has internal thread at one end and a collar at the other end.
After the end pieces are screwed on to the pipes, the central piece (union nut) is tightened to
draw the end pieces together to get a water tight joint.

17. Flange: This is a disc type pipe special having threaded hole at the centre for screwing to
the externally threaded end of a pipe line. It will have holes around the central hole at equal
angular spacing (3, 4, 6f or 8 Nos.) for joining to another similar flange or flat surface using bolt
or stud.
Fig 4.1: Various pipe joints
Fig 4.2: Application of various joints in the pipe fittings

4.3 VALVES AND METERS
Valves are used in piping systems to control or stop the flow of liquid or gas. The most common
types of valves used in low pressure water pipe line are:
1. Water tap

2. Water cock
3. Globe valve
4. Gate valve
5. Ball valve
6. Non-return valve
7. Foot valve
4.3.1 Water Tap:
Fig 4.3: Water tap

To collect water from low pressure pipe line, water tap (screw down valve) is commonly
used. Figure gives the cross section of the tap. Its leather or rubber faced valve disc is lifted or
lowered by rotating the spindle. Brass or gun-metal is the material used for the valve body and
the size is specified by the pipe to which it is fitted, usually ranging from 10 mm to 25 mm.
Ref Fig.4.3.
4.3.2 Water Cock:
Fig 4.4: Water Cock

This is the simplest and smallest form of a valve in which a conical plug called cock is
inserted into a conical hole having a matching taper. A rectangular hole is provided at the
centre across the conical potion so that, in one position it permits flow of water as shown in
Figure. A half turn of the handle will bring the solid portion of the cock to the water ways
preventing the flow. Cocks are used for low rate of water flow' or for tapping pressure line to
a manometer etc. Ref Fig.4.4.
4.3.3 Globe Valve:
Fig 4.5: Globe valve

Globe valves are used as control valves in fluid (gas and liquid) pipe lines. Figure shows
the simplest and smallest type of globe valve used in water pipe lines. Basically, the valve is a
variable opening flow device. The design of a globe valve also creates a slight retardation to the
flow because the fluid is forced to make a double turn and passes through the opening at 90° to
the axis of the pipe. The valve plug is raised or lowered to stop or regulate the flow through a
circular opening. A globe valve can be identified by the spherical body and the arrow mark for

the direction of flow. These valves are used in water pipe lines from 12 mm to 100 mm or even
larger diameter for the flow control purpose. Ref Fig.4.5.
4.3.4 Gate Valve:
Fig 4.6: Gate valve

A gate valve is on-off type valve. It allows a straight-line movement of fluid and offer very
little resistance to the flow in fully opened position. The central disc moves completely out of
the passage and leaves a full opening. Figure shows a simple type of gate valve partially opened
in position. These valves are very widely used in water pipe lines of diameter ranging from 12
mm to higher values. A gate valve can be identified by its slim body. It is to be noted that there
will be no arrow mark or the body of valve because it can be used in both ways. Ref Fig.4.6.
4.3.5 Foot Valve:
Fig 4.7: Foot valve

Foot valve is a kind of non-return valve used in centrifugal pumps. It is fitted at the bottom most
end of the suction pipe (Foot) to stop flow in the downward direction for priming purpose. The
strainer restricts the entry of floating materials to the pipe line. Figure gives the details of the
foot valve. The material used may be cast iron, brass, or PVC. Ref Fig.4.7.
4.4 PLUMBING TOOLS
Plumbing tools can be classified as:
1. Pipe wrench
2. Pipe vice
3. Pipe cutter
4. Hack saw
5. Threading dies and taps
6. Files and rasps
7. Plumb bob
4.4.1 Pipe Wrench

A pipe wrench is used for holding and turning the pipes, rods and machine parts. Wrenches are
broadly classified as:
Fixed wrenches
Adjustable wrenches . Ref Fig.4.8.

Fig 4.8: Pipe wrench
4.4.2 Pipe Vice

A pipe vice is shown in Fig 4.9. The pipe vice is fitted on the work bench. This has a set of
jaws to grip the pipe and prevent it from turning while cutting, threading and fitting of bends,
couplings etc. the yoke vice is the most commonly used in plumbing practice. Ref Fig.4.9.
Fig 4.9: Pipe vice

4.4.3 Pipe Cutter
The pipe 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 sizes and pipes. After adjusting the cutter on a pipe, it is turned around
the pipe, so that the cutter wheels cut the pipe along a circle as shown in Fig 4.10.
Fig 4.10: Pipe cutter

4.4.4 Hacksaw
A hacksaw is used for cutting metal rods, bars, pipes, etc. the hacksaw and its parts are
illustrated in Fig 4.11. the job to be sawed is held in a vice and the blade is moved to and fro
for cutting the job. The cutting operation takes only on the forward stroke. Ref Fig.4.11.
Fig 4.11: Hacksaw

4.4.5 Threaded Dies and Taps
Threading dies and taps are used for cutting external thread on pipes. Threads are produced in
various shapes and sizes which are used by fitting pipes inside a die handle. The length of the
thread depends on the size of the pipe. Ref Fig.4.12.

Fig 4.12: Threaded dies and taps
4.4.6 File and rasp
A file and rasp are shown in Fig 3.13 the file surface is covered with sharp-edged teeth and it is
used for removing metal by rubbing. A rasp is used for finishing the surface of the work piece.
Ref Fig.4.13.
Fig 4.13: File and rasp

4.4.7 Plumb Bob
A plumb bob is shown in Fig 3.14 it is used to check the vertical line and made up of steel or
brass. Ref Fig.4.14.
Fig 4.14: Plumb bob

EX.NO:
DATE:
THREAD FORMING ON GI AND PVC PIPES
AIM:
To form external threads on a given pipe for standard specification using dyes.
FACILITIES/TOOLS REQUIRED:
1. Pipe vice fitted on a work table
2. Pipe wrench
3. Thread cutting dyes of suitable size.
4. Spanner
MATERIALS REQUIRED:
1. PVC / GI Pipe
2. Gate valves
3. Water Taps
4. Flanges, Bolts, nuts
5. Couplings
6. Elbow, Tee fittings
7. L bends
8. Union etc.,
PROCEDURE:
1. Identify the given pipe material and measure the diameter of the given pipe.
2. Study the specification of thread (Length, diameter, pitch and type of thread) to be made
and select suitable thread forming dye.
3. Tightly fix the given PVC/GI pipe in the pipe vice. Ensure sufficient projection to
accommodate the dye rotation for the required length.
4. Select suitable dye and fix it in the dye set.
5. Align the axis of the dye set to the axis of the pipe without any error.
6. Rotate the dye set clock wise for making right hand thread.
7. Periodically rotate the dye set anti clock wise and ensure removal of chips from dye.

8. Continue the thread formation process(and anticlock wise) by rotating in the dye set in
clockwise direction until the required length of thread is achieved.
9. Apply lubricant to remove the heat generated by the thread forming process if the pipe is
made of GI
10. Remove the dye set and clean the chips if any.
11. Cut the threaded portion of the pipe and check the threads for form and dimensional
accuracy.
For Assembly
1. Plan/Study the pipe circuit for its constraints and the requirements.
2. Fix/identify a reference element in the circuit based on which the entire circuit will be built.
3. Identify the suitable joints for connecting pipes. Use flanges or couplings for connecting
pipes.
4. Ensure threads on the external surface of the pipe and internal surface of the coupling to
make leak proof joint.
5. Use elbow, L bends to make suitable bends in the pipe circuit.
6. Use Tee or 4 way joint for distribution or collection of fluid in the circuit.
7. Apply Shellac /Teflon tape/grease where ever necessary.
8. Fit gate valves to control the flow of liquid and taps to open or shut the flow in the place of
requirement in the circuit
9. Prefer threaded joint if the joint is temporary or GI pipe joint.

10. PVC materials may be preferred if corrosion is to be controlled in the circuit.
11. Metal pipes may be preferred if large pressure exists in the flow circuit.
12. Check the circuit against the specification/requirement.
13. Connect the prepared circuit in water line for checking leaks.
14. Inspect leaks if any and make corrective action

Conclusions:

date

Viva Questions:
1. Define Plumbing.
2. List the Various materials used for Manufacture of Pipes and firings
3. List down the various tools and accessories used by a plumber
4. What is the use of pipe threading dies?
5. How internal threads are made in the Pipe and fittings?
6. Name some holding tools used in plumbing.
7. Briefly write about Elbow & Bend fittings used in plumbing.
8. What is the purpose of Hacksaw and files in plumbing?
9. What do you mean by GI, CI and PVC and write their unique advantages?
10. How do you specify a pipe?
11. What is the difference between a coupling and a reducer?
12. What is the function of Union in plumbing?
13. What is the purpose of pipe wrench and vice in plumbing?
14. Write the procedure of making External threads in a pipe?
15. Briefly write about different types of valves and their usages in piumbing?
Briefly write about different types of valves and their usages in plumbing

5. WELDING
5.1 INTRODUCTION:
Welding is a process in which two or more parts are joined permanently at their touching
surfaces by a suitable application of heat and/or pressure. Often a filler material is added to
facilitate coalescence. Welding is primarily used in metal parts and their alloys.
Welding is broadly classified into two different types namely,

1) Fusion or Non-pressure Welding.
2) Pressure or Plastic Welding.
5.2 FUSION or NON-PRESSURE WELDING:
In fusion welding, the metal at the joint is heated to a molten state and then allowed to
solidify. Since no pressure is applied in this process, it is also known as “non-pressure welding”.
Addition of filler metal may be required for fusion welding. Fusion welding is classified as
follows,
a) Homogeneous Welding.
b) Heterogeneous Welding.
5.2.1 HOMOGENEOUS WELDING:

In homogeneous welds, solidification occurs directly by growth mechanism without nucleation stage.
This type of solidification is called epitaxial solidification. The homogeneous welds are considered to be of
lesser prone to the development of weld discontinuities. This type of welding is further classified into two
types,
i) Gas Welding.
ii) Electric Arc Welding.
5.2.1.1GAS WELDING:
Gas welding is a type of fusion, non pressure welding. In this, the required heat to melt the
parts is supplied by a high-temperature flame obtained by a mixture of two gases. The gases are
mixed in proper proportions in a welding blow pipe called welding torch. The mixture of oxygen
and acetylene gases is extensively used for welding purposes. However the mixture of hydrogen
and oxygen can also be employed to some extent.
Ref Fig.5.1.
The oxyacetylene welding process uses a combination of oxygen and acetylene gas to
provide a high temperature flame. Oxy Acetylene Welding is a manual process in which the
welder must personally control the torch movement and filler rod application. The term oxyfuel

gas welding outfit refers to all the equipment needed to weld. Cylinders contain oxygen and
acetylene gas at extremely high pressure. The temperature generated during the process is 3300˚C,
when the metal is fused, oxygen from the atmosphere and the torch combines with molten metal
and forms oxides, results defective weld. Fluxes are added to the welded metal to remove oxides;
Common fluxes used are made of sodium, potassium, Lithium and borax. Flux can be applied as
paste, powder, liquid, solid coating or gas. Ref Fig.5.1.
5.2.1.1.1Gases used:
Oxygen extracted from air and compressed into cylinders at high pressure. Cylinder is black. Oil
should never be brought into contact and should not be used on fittings.
Acetylene (C2H2) is a fuel gas. Cannot be compressed directly as explodes at high pressures.
Cylinders are packed with porous material which is filled with acetone. Acetone absorbs acetylene.
Cylinder color coded maroon. Acetylene is extremely unstable in its pure form at pressure above
15 PSI. Acetone is also present within the cylinder to stabilize the acetylene.
5.2.1.1.2Gas welding equipment: Equipment’s use for gas welding process are- Pressure Gauges,
Hoses, Welding torch, Check valve, Non return valve.
5.2.1.1.2.1Oxygen Cylinders:
Oxygen is stored within cylinders of various sizes and pressures ranging from 2000- 2640
PSI. (Pounds Per square inch). Oxygen cylinders are forged from solid armor plate steel. No part
of the cylinder may be less than 1/4” thick. Cylinders are then tested to over 3,300 PSI using a
(NDE) hydrostatic pressure test. Cylinders are regularly re-tested using hydrostatic (NDE) while in
service. Cylinders are regularly chemically cleaned and annealed to relieve “jobsite” stresses
created by handling. Oxygen cylinders incorporate a thin metal “pressure safety disk” made from
stainless steel and are designed to rupture prior to the cylinder becoming damaged by pressure.
The cylinder valve should always be handled carefully
Regulators: Reduce high storage cylinder pressure to lower working pressure. Most regulators
have a gauge for cylinder pressure and working pressure. Regulators are shut off when the
adjusting screw is turn out completely. Regulators maintain a constant torch pressure although
cylinder pressure may vary. Regulator diaphragms are made of stainless steel
Working pressure of oxygen 1 kg/cm2
Working pressure of acetylene 0.15 kg/cm2
Working pressure varies depends upon the thickness of the work pieces welded.
Regulator Hoses: Hoses are fabricated from rubber. Oxygen hoses are green in color and have
right hand thread. Acetylene hoses are red in color with left hand thread. Left hand threads can be
identified by a grove in the body of the nut and it may have “ACET” stamped on it.
Check Valves & Flashback Arrestors: Check valves allow gas flow in one direction only.
Flashback arrestors are designed to eliminate the possibility of an explosion at the cylinder.
Combination Check/ Flashback Valves can be placed at the torch or regulator. These are
positioned on both the fuel gas and oxygen supply between the hose and the regulator. Their
purpose is to prevent the return of a flame through the hose into the regulator. In normal operation,
gas flows through the open cut off valves and check valves through the flame arrestor filter into the
hose. In the event of the flashback, the stainless steel filter stops the flame and the pressure
activates the cut-off valve, stopping the flow of gas to extinguish the flame. The check valves
operates when gas flow towards the cylinder. If the arrestor is exposed to fire, the thermal cut-off
valve shut the gas supply. It is reusable after a flashback.

5.2.1.1.2.2 Acetylene Cylinders:
Acetylene is stored in cylinders specially designed for this purpose only. Acetylene
cylinders should always be stored in the upright position to prevent the acetone form escaping thus
causing the acetylene to become unstable. Cylinders are filled with a very porous substance
“monolithic filler” to help prevent large pockets of pure acetylene form forming. Cylinders have
safety (Fuse) plugs in the top and bottom designed to melt at 212° F (100 °C).
Acetylene Valves: Acetylene cylinder shut off valves should only be opened 1/4 to 1/2 turn. This
will allow the cylinder to be closed quickly in case of fire. Cylinder valve wrenches should be left
in place on cylinders that do not have a hand wheel.
5.2.1.2 ELECTRIC ARC WELDING:
Electric Arc welding is the most widely used method of joining two metal parts. The source
of heat for Arc welding process is an electric arc. The arc is produced between an electrode and the
work. The electrical energy is converted into heat energy. For arc welding process, filler metal is
required and no mechanical pressure is applied. Hence this is one type of fusion welding. Thus arc
welding is defined as the process of joining two metal parts by melting their edges by an electric
arc using filler rod without application of pressure. Ref Fig.5.2.
Fig: 5.2.
5.2.1.2.1Welding Circuit
The circuit diagram for the Arc Welding process is shown in Fig. The equipment consists of a
power source, electrode holder, and welding cables that connect the power source to the electrode holder
and the work piece. Alternating current (ac), or direct current, electrode negative (DCEN), or direct current,
electrode positive (DCEP) can be used, depending on the electrode coating characteristics. The DCEN
source is also called dc straight polarity, whereas the DCEP source is also called dc reverse polarity.
The welding machine, or power source, is the crux of the Arc Welding process. Its primary
purpose is to provide electrical power of the proper current and voltage to maintain a controllable
and stable welding arc. Its output characteristics must be of the constant current (CC) type. SMAW
electrodes operate within the range from 25 to 500 A. The electrode producer should suggest a

narrow optimum range for each size and type of electrode. Operating arc voltage varies between
15 and 35 V.
The electrode holder: Which is held by the welder, firmly grips the electrode and transmits the
welding current to it. Electrode holders are available in several designs, such as the pincher type
and the collet, or twist, type, shown in Fig. Each style has its proponents and the selection is
usually a personal preference. Ref Fig.5.3.
Fig.5.3.
Electrode holders are designated by their current capacity. Selection factors, such as the current
rating, duty cycle, maximum electrode size, and cable size, are shown in Table 1. The most
lightweight holder that will accommodate the required electrode size is usually desired. All
electrode holders should be fully insulated. Because they are used in proximity to the arc and are
exposed to high heat, they will deteriorate rapidly. It is extremely important to maintain electrode
holders to ensure that they retain their current-carrying efficiency, their insulating qualities, and
their electrode gripping action. Manufacturers supply spare parts so that the holders can be rebuilt
and maintained for safe and efficient.
Electrodes: The electrodes used in the Arc welding have many different compositions of core wire
and a wide variety of flux- covering types and weights. Standard electrode diameters of the core
wire range from 1.6 to 8 mm. Electrode length usually ranges from 230 to 455 mm (9 to 18 in.);
the shorter lengths are associated with the smaller diameter electrodes. A bare, uncoated end of the
electrode (the grip end) is provided for making electrical contact in the electrode holder
Power sources: Welding power sources are also known as welder, and welding machines. All
welding machines are designed to change the high voltage alternating current main supply into a
safe, low voltage, heavy-current supply, suitable for arc welding. Arc welding machines produce
either a constant current or a constant voltage. Manual metal arc welding process requires a
constant current welding machine to minimize the changes in current whenever a welder changes
the arc length.
Constant current welding machines are classified into three types. They are:
1-Ac transformer
2-Dc generator
3-Ac /Dc Transformer-rectifier

5.2.2 HETEROGENEOUS WELDING:
The heterogeneous welds are similar to homogeneous only difference is in solidification

process; solidification takes place in conventional manner in two stages i.e. nucleation and growth.
This type of welding is further classified into two types,
i) Soldering.
ii) Brazing.
5.2.2.1 SOLDERING:
Soldering is a process of uniting two or more metal pieces under heat with the help of a solder
and a flux. There are two types:
Soft soldering
Hard soldering.
Flux: it is cleaning agent used to prevent oxidation of metals at the soldering point. It helps the
solder to melt quickly and allows it to flow freely to unite more firmly.
E.g. zinc chloride, ammonium chloride, hydrochloric acid, borax, rosin, turpentine oil etc.
Solder: generally it is an alloy of lead and tin. It melts at low temperature. For strong joints a
mixture of copper and zinc is used which has high melting point.
5.2.2.1.1Classification of solder:
Soft solder: For high joints using various proportions of lead and tin which has low melting point,
generally it is composed of lead and tin. They are mixed in various proportions to solder different
metals at different temperatures. The range of melting point for such solder lies between 150 to
300˚C. A suitable flux for the particular job is chosen. A small amount of bismuth and cadmium
are frequently added to lower the melting point if necessary. Soft solders are used to join the wires
and sheet metal works of light jobs which are subjected to light loads and slight shocks. A plain
soldering iron is used to heat the metal pieces during the process. Soldering using soft solder is
known as soft soldering. Ref Fig.5.4.
Fig.5.4.
antimony are frequently added to improve the quality. The range of melting point of such solder is

to heat the metal pieces during the process. Hard solders are used to make comparatively strong
joints compare to soft solder.e.g.: plumbing, heavy sheet metal works etc.
5.2.2.2BRAZING:
It is the process of uniting two or more metals of similar or dissimilar type with the help of
an alloy in the form of spelter and flux, like borax, ash etc. these are used in tanks, radiators,
carbide tips on tool holder etc.
Spelter is a harder filler rod is, having a melting temperature of about 600˚C which is
below the melting point of the work metals. Two classes of filler metals used for most work are
copper alloys and silver alloys. Copper alloys are made of copper; zinc and tin are used for brazing
ferrous materials. Silver alloys are made of silver and copper with melting range of 600-800˚C are
used for brazing any metals. Ref Fig.5.5.
Fig.5.5.
5.2.2.2.1 Types of brazing:

It is classified on the basis of actual heating as:-
Torch brazing
Electric brazing
Immersion brazing.
5.3 PRESSURE or PLASTIC WELDING:
In plastic welding, the metal parts are heated to a plastic state. Then they are pressed
together to make the joint. Hence it is also known as “pressure welding”. No filler metal is
required for pressure welding.
5.4 ADVANCED WELDING TECHNIQUES:
5.4.1 Autonomous robotic welding of large structures:

European manufacturing companies are facing increasing competitive pressures which are
encouraging a trend to the use of more automated welding methods. Customer preference for customized
products, the requirement for shorter delivery times and a shortage of skilled welders are also contributory
factors.
In response to these pressures, NOMAD, the name given to the EU framework project,
'Autonomous Manufacture of Large Steel Structures', was established. The goal of the project was to create
a fabrication system capable of welding small production runs and even unique 'one-off' structures, as easily
and quickly, as large multiples. This was to be achieved by eliminating as many of the current constraints as
possible, for example, eliminating the use of fixtures and dedicated work piece manipulation. The project

solution was to develop an autonomous mobile welding robot which moved around a stationary component
to complete the required weld joints
In the project, a demonstration cell was developed capable of fabricating steel structures in the 5 to
50 tonne range without the need for special tooling and dedicated handling equipment. Components were
loaded into the cell and identified by a vision system. The image of the component was matched to the
CAD model and offline programs generated path data to guide a robot arm on a moving platform into
position. A laser scanning sensor on the robot arm located the weld start position and welding was carried
out under adaptive control.
The project was concluded with a successful public demonstration of the welding system which
involved a representative bridge section and a stick, a typical component part of an excavator. The welding
system is equally suitable for many applications in offshore engineering.
5.4.2 Laser processes

The twentieth century was characterized by the harnessing of electrical energy to create broad economic
and societal benefits. Examples of developments enabled by electricity include transport, heating, lighting
and the recent explosive expansion of information and communication technologies. Looking to the future,
innovative applications of energy in the form of light have the potential to shape the twenty-first century.
Indeed, the previous century has been described as the century of the electron; the twenty-first century will
be the age of the photon.
Over the last forty years or so, lasers have matured from laboratory prototypes into reliable and efficient
industrial tools. Typical applications range from cleaning of artwork through automotive manufacture to
ship hull construction.
Irrespective of the component or structure, all manufacturers are continuously striving to gain a competitive
edge over their rivals and the advantages and disadvantages of each manufacturing route are thoroughly
evaluated before production begins. Fabrication or manufacture with lasers offers several potential benefits:
Increased productivity - more rapid part manufacture at reduced cost.
Improved quality - for example, minimal distortion and hence reduced levels of rework.
Enhanced performance - this can be seen by longer lifetimes or greater resistance
to corrosion or high temperature. Additionally, laser repair technologies can give
rise to significant life extensions of otherwise exhausted components.
Novel fabrication routes and components - where alternative technologies simply are not
available.
The choice of manufacturing route, however, is essentially an economic one. Consequently, there is a
continuous battle between manufacturing technologies to gain a competitive edge that is closely analogous
to the competition between individual manufacturers.

EX.NO:
DATE:
WELDING PRACTICE USING WELDING SIMULATOR
AIM:
Joining of two MS plates by arc welding method using welding simulator
COMPONENTS REQUIRED:
Welding simulator – Skillveory
PROCEDURE:
1. Switch on the welding simulator
2. Create user profile by adding your roll number and password (same as your roll number)
3. Select the type of welding 2G/3G/2F/3F
4. After selecting welding type, now select the method of welding as helping mode (get angle,
strikeout and speed)
5. Then select the safety materials as displayed
6. Perform the welding operation as per the instructions displaying instantly.
7. Now select assessment mode and repeat the same operation without helping texts.
8. Note down the assessment marks as per in the display.

Conclusions:

date

Viva Questions:
01 Define Welding.
02 What are the various types of welding?
03 What is the range of current in ampheres in arc welding?
04 What is the range of voltage in arc welding?
05 What is Electric Arc welding?
06 List various components in an electric arc welding setup.
07 What is the function of the Flux coating in the electrode?
08 Name the different types of welding.
09 Write briefly about how Welding Transformer works.
10 What is the importance of edge preparation?
11 What are the safety devices to be used in Arc Welding?
12 List some advantages of welding.
13 Write down some applications of welding.
14 List some important inspection procedures before and after welding operation.
15 What is gas welding?
16 Name the gases used in gas welding.
17 In which color the oxygen cylinder is painted?
18 In which color the acetylene cylinder is painted?
19 What is the use of filler rod in Gas welding?
20 List the three types of flames in gas welding.
21 List the advantages of gas welding,

PROBABLE MODELS
1. FITTING
ALL DIMENSIONS ARE IN mm

2. CARPENTRY
RECTANGULAR BOX

3. SHEET METAL
RECTANGULAR BOX
ROUND HOPPER

4. PLUMBING

4. PLUMBING
PIPES INVOLVING THE FITTINGS LIKE VALVES, TAPS AND BENDS

5. WELDING
LAP JOINT
BUTT JOINT

REFERENCES:
1. Carpentry and Joinery, Third Edition, Brian Porter LCG, FIOC Formerly of Leeds College of
Building.
2. Portable Power Tools by Carpentry and Joinery Theory.
3. www.wikipedia.com
4. www.shutterstock.com

INNOVATION PROJECT
Conclusions:

date


5 6280779123619004524 PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

5 6280779123619004524 PDF

Uploaded by

Copyright:

Available Formats

KONGU ENGINEERING COLLEGE

PERUNDURAI, ERODE - 638 060

DEPARTMENT OF MECHANICAL ENGINEERING

Record Note Book

18MEL11 – ENGINEERING PRACTICES LABORATORY

Name of the Student :

Roll No. Year / Semester /

Completion of all the experiments conducted by the student of

Signature of Lab Course Faculty

Signature of the HOD

18MEL11 – ENGINEERING PRACTICES LABORATORY

7. Project: Preparing innovative articles using wood/sheet metal

COURSE OUTCOMES: Blooms Taxonomy

18MEL11 – ENGINEERING PRACTICES LABORATORY

Instructions to the course faculty:

To instruct and ensure safety precautions

PROBABLE EXPERIMENTS (MODELS TO BE DECIDED BY THE COURSE

18MEL11 – ENGINEERING PRACTICES LABORATORY

S. Experiment Page Faculty

EXERCISES IN FITTING OF METAL PLATES

EXERCISES IN SHEETMETAL WORK

SIMPLE FABRICATION/INNOVATIVE ARTICLE (DEMONSTRATION OF COMPREHENSIVE SKILL-

Date of Exam Marks out CA Marks Signature of the

Note: The procedures for extra exercises to be written by self.

18MEL11 – ENGINEERING PRACTICES LABORATORY

Engineering Graduates will be able to:

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

3. Design/development of solutions: Design solutions for complex engineering problems and

4. Conduct investigations of complex problems: Use research-based knowledge and research

7. Environment and sustainability: Understand the impact of the professional engineering

10. Communication: Communicate effectively on complex engineering activities with the

18MEL11 – ENGINEERING PRACTICES LABORATORY

Course Outcome and Program Outcome mapping:

Mapping of COs with POs and PSOs

1 Slight 2 Moderate 3 Substantial

18MEL11 – ENGINEERING PRACTICES LABORATORY

Safety training and/or information should be provided by a faculty member, teaching

18MEL11 – ENGINEERING PRACTICES LABORATORY

18MEL11 – ENGINEERING PRACTICES LABORATORY

Fitting shop tools are classified as below:

1.1. WORK HOLDING DEVICES /CLAMPING TOOLS

1.1.1 Work Bench

Fig: 1.1.1-Work bench

1.1.2 Bench Vice

18MEL11 – ENGINEERING PRACTICES LABORATORY

Fig: 1.1.3-V Block

1.2 MEASURING TOOLS

Fig: 1.2.1Steel Rule

18MEL11 – ENGINEERING PRACTICES LABORATORY

1.2.3 Vernier Caliper

Fig: 1.2.3-Vernier Caliper

18MEL11 – ENGINEERING PRACTICES LABORATORY

1.3 MARKING TOOLS:

Fig: 1.3.1Surface Plate

1.3.2 Angle Plate

Fig: 1.3.2Angle Plate

18MEL11 – ENGINEERING PRACTICES LABORATORY

Fig: 1.3.3-Scriber and Surface Gauge

1.3.5 Try Square

Fig: 1.3.5-Try Square

18MEL11 – ENGINEERING PRACTICES LABORATORY

Fig: 1.4.2.1-Flat file

Fig: 1.4.2.2-Hand file