MECHANICAL ENGINEERING

WORKSHOP (19A03201)

LABORATORY MANUAL

NAME ______________________________

Roll No__________________ Class _____

Year ________________ Sem __________

Department Of Mechanical Engineering

GEETHANJALI INSTITUTE OF SCIENCE &
TECHNOLOGY

3rd Mile, Bombay Highway, Gangavaram (V), Kovur (M), SPSR

Nellore Dist, A.P - 524137.
 GEETHANJALI INSTITUTE OF SCIENCE & TECHNOLOGY
(Approved by AICTE, New Delhi & Affiliated to JNTU, Anantapur)
(Recognised Under section 2(f) of UGC Act 1956)
An ISO 9001: 2015 certified Institution – Unit of USHODAYA EDUCATIONAL SOCIETY
3rd Mile, Bombay Highway, Gangavaram (V), Kovur(M), SPSR Nellore (Dt), Andhra Pradesh, India- 524137
Ph. No. 08622-212779, 212781, Fax: 08622-212778, E-Mail: principal@gist.edu.in / geethanjali@gist.edu.in, Website: gist.edu.in

VISION
To emerge as a leading Engineering institution imparting quality education .
MISSION
The vision of the department is achieved by
 Effective teaching learning strategies for quality education.
 Congenial academic ambiance for progressive learning

 Skill development through Industry-Institute initiatives

 Nurturing environmentally conscious and socially responsible technocrats.

PROGRAM EDUCATIONAL OBJECTIVES (PEOs)

At the end of the programme, the student shall
1. Acquire strong foundations in mathematics, basic sciences and engineering fundamentals,
necessary to formulate, analyze and solve Mechanical Engineering problems.
2. Become a successful professional to handle complex technological issues in industry, academia,
research, consultancy and enterprise.
3. Contribute to the society as broadly educated, expressive, ethical and responsible citizen with
proven expertise through translating the acquired skills to emerging real-time technologies.
PROGRAMME SPECIFIC OUTCOMES ( PSOs )
The graduates of the program shall attain
PSO1: Proficiency in core streams of Mechanical Engineering such as Mechanics of Materials, Design of
Mechanical systems, Thermal & Fluid Engineering, Industrial Management, Production
Engineering and other allied subjects.
PSO2: Adequate skills in advanced Mechanical Engineering technologies like CAD/CAM/CAE,
Robotics, Renewable Energy, Unconventional Machining, FEA and inter-disciplinary
concepts such as Mechatronics and MEMS.
 LIST OF CONTENTS

INTRODUCTION TO WORKSHOP TECHNOLOGY

CARPENTRY

TOOLS 1

1. HALF LAP JOINT 14

2. MORTISE AND TENON JOINT 16

3. BRIDLE JOINT 18

TIN SMITHY

TOOLS 21

4. OPEN SCOOP 26

5. FUNNEL 27

6. ELBOW PIPE 29

HOUSE WIRING

TOOLS 31

7a. SERIES CONNECTION 36

7b. PARELLEL CONNECTION 37

8. STAIR CASE CONNECTION 38

9. SOLDERING PRACTISE 39

10. TUBE LIGHT CONNECTION 41

11. GODOWN CONNECTION 43

FITTING

TOOLS 45

12.. V-FITTING 60

13. HALF ROUND FITTING 62

14. DOVE TAIL FITTING 64

. 15. BICYCLE TYRE PUNCTURE AND CHANGE OF TYRE 66

 INDEX
S.NO. NAME OF THE EXPERIMENT PAGE NO MARKS INTIAL
INTRODUCTION :

Workshop practice imparts basic knowledge of various tools and their uses in
different sections of manufacturing such as Fitting, Tin Smithy, House Wiring,
Carpentry etc. It is true that engineers are not going to become carpenters or
blacksmiths or skilled workers on the shop floor, but by exposing themselves to all
working trades, they get a bird eye view of the basic practical activities associated
with all sections of manufacturing. It helps them, when they occupy managerial
positions, in understanding the activities and practical difficulties, so that they can
take appropriate decisions.

Even when large amount of mechanical equipment is available for producing

or repairing parts, there are still some elements of work which have to be performed
by manual methods. However it must be borne in mind that all workshops and work
areas are places of some risk. A healthy regard for rules and respect for all
equipment being used reduces the risk of an accident considerably.

Finally, the engineers must also be familiar with the first aid practices. In
case some minor injuries in the form of cuts, burns, fractures, fainting, electric shock
etc occur in the shop floor, they should know how to give first aid to the victims.

WORKSHOP DRESS
SAFETY RULES AND UNSAFE PRACTICES
GENERAL SAFETY RULES

Remember that “Accidents do not occur, they are caused”. With this in
mind, strictly follow the general safety rules given below and safe practices indicated
in brief under each section.

1. Safety first, works next.

2. Know your job and follow instructions.

3. Avoid wearing clothing that might catch, moving or rotating parts. Long sleeves
of shirts, long hair, neck tie and jewellery are definite hazards in the shop.

4. Wear safety shoes. Do not wear canvas shoes; they give no resistance to
hard objects dropped on the feet.
5. Keep the area around the machine or work clean.
6. Keep away from revolving work.
7. Be sure that all guards are in place.
8. One person only should operate the machine control.

9. Use tools correctly and do not use them if they are not in proper working
condition.

10. Wear safety goggles when working in areas, where sparks or chips of metal
are flying.

11. Never (a) operate a machine unless you are authorized to do so. (b) Start a
machine unless you know how to stop it. (c) Walk away and leave a machine
running. (d) Distract or interfere with any one, operating a machine.

12. Get to know who in-charge of first-aid is and where boxes are placed and
where the first aid can be found in case of eme
CARPENTRY

Introduction:

Carpentry deals with the processing of wood to obtain desired

shapes and sizes. The process dealing with the technique of making
wooden pattern is called pattern making.
Classification of carpentry tools:
1. Marking and measuring Tools
2. Cutting and planning tools
3. Drilling and boring tools
4. Striking tools
5. Holding tools
1. Marking and measuring tools:
Steel rule Marking knife
Steel tape Marking gauge
Folding rule Mortise gauge
Try square Wing compass
Bevel square Divider
Meter Square Trammel
2. Cutting and Planning Tools:
Saws: Cross cut saw (Hand saw)
Rip saw
Tenon saw
Chisels: Firmer chisel
Dovetail chisel
Mortise chisel
Outside chisel
Inside chisel
Planning Tools: Wooden jack plane
Metal jack plane
Smooth plane

01
 3. Drilling & Boring Tools:
Gimlet
Ratchet
brace Hand
drill Auger
4. Striking Tools:
Warrington hammer
Claw hammer
Mallet
Straight peen Hammer
5. Holding Tools:
Bench Vice
Bar Clamp
G-Clamp
6. Miscellaneous Tools:
Screw driver
Wood rasp
file Pincer
Marking and Measuring Tools:

Marking is one of the most important features of wood work and

success of completing a job accurately depends on accuracy of marking and
measuring.

Steel Rule: It is used for marking and measuring linear dimensions

and is specified by its length.

Steel Tape: The steel tape is used for measuring longer dimensions.
They are available in different sizes running from 0.6 to 2.5 m. It is flexible
can be coiled and pressed in a case.

Folding Rule: Four – fold box wood rule is made of 4 pieces of each15
cm length. They are hinged is such a way that they can be folded. It is
adapted to carpentry up to 60 cm length.

Try square: The try square is used for testing flatness of surface
marking parallel lines and also for marking and testing of right angles. It has

02
a steel blade fitted at right angles in wooden or cast iron stock. It is available
in various sizes ranging from 100 to 300mm.
0
Meter Square: It is used for marking and testing 45 . It consists of a
0
steel blade fitted in a wooden or metal stock at an inclination of 45 with
horizontal.

Bevel square: It is used for marking and testing of any angle between
0 0
0 to 180 . It has a slotted blade and stock. The blade can be fixed at any
position by means of a screw.
Marking knife: All dimensional lines marked with pencil are cut with
marking knife. It has a chisel edge at one end and sharp point at other end.
It is made of steel and generally used with a try square.

Marking gauge:-The marking gauge is commonly used when absolute

accuracy is required. It has a stem with a sharp pin at one end. It is used to
cut line along the grains and parallel to an edge. The distance can be
adjusted by sliding the stock (head) on a stem. This can be achieved by
thumbscrew.

Mortise Gauge: It has two sharp pins. One is fixed to the stem and
other to a brass slide, which can be secured at any position by a screw. It is
used to cut two parallel lines in a single stroke. It is particularly adapted for
marking in mortise and tenon joints.

Wing Compass: It is made of steel and consists of two pointed legs.

The legs secured in position by means of a setscrew and quadrant. It is used
for marking equal dimensions and for marking arcs and circles on the plane
surfaces of the wood.

Divider: It consists of two pointed legs. The points are hardened and
tempered to prevent wear. It is used for transferring the sizes and scribing
curves or circles on wooden surface.

Trammel: It is used for drawing very large circles and arcs which are
beyond the scope of a compass. It consists of a wooden beam on which the
two puns are located and the distance between them can be adjusted by
means of thumb screws.

03
 STEEL RULE

STEEL TAPE

TRYSQUARE BEVEL

04
 MARKING GAUGE

MORTISE GAUGE

COMPASS AND DIVIDER

05
Cutting and planning tools:

Cutting tools are used for cutting timber to approximate size, cutting
excess wood to obtain desired shape and accuracy. Planning tools are
intended to make smooth and accurate surface.

SAWS:

Cross cut saw: It is used for cutting the wood across the grains
(Hand saw). Its teeth are pointed. The pitch of the teeth is about 2.5 to
3.0mm and blade length is about 600mm. Its teeth have less ‘set’ than
the rip saw.

Rip Saw: It is used for cutting the wood along the grains. Its
teeth have chisel edge. The pitch of the teeth is about 5 to 8mm and
length of the blade is about 700mm.The process of cutting the wood
along the grains is called ripping. Because of high flexibility of the
blade and also number of cutting points per cm (i.e., high pitch) it
is not suitable for cutting across the grains.

Tenon Saw: Tenon saw or back saw is used for cutting small
work. It is mostly adapted in joint work. It has a brass or steel back
which strengthens the blade, but it restricts the depth of cut. Its
fine teeth (6 to 8teeth/cm) and stiff back permits the smooth,
accurate cutting for marking joints. The saw is available in different
length ranging from 250 to 400 mm.
Inside Chisel:
It is leveled inside and is used for marking curved profiles.

Planning tools:
Planning tools are used for reducing and smoothing the surface.

Wooden jack plane: It consists of a wooden body or stocks in

which blade or stock cutter is fastened at an angle of 45° to the sole.
The plane is on (blade or cutter) and the cap iron (back iron) is

06
 assembled and assembly is inserted in the mouth of plane along with
the wedge. The back iron supports the cutting edge and also breaks
the shavings so that they air away from the blade. The blade can be set
for taking deeper or shallower cuts. The length of the jack plane is
about 350to 425mm. The blade is made of high carbon steel and has a
width of 50 to 75 mm. Its cutting edge is tempered and ground to an
angle of 25 to 30° and it is slightly curved (Convex).

Metal jack plane: Its body is made of gray cast iron and it is
provided with a wooden handle at the back and a wooden knob at the
front for holding with both the hands. A fine screw is used for
adjusting the depth of cut i.e.; the thickness of shaving removed and
a level is used for lateral adjustment of the blade. It is very durable
and gives better finish.
Chisels:

Chisels are used for cutting excess wood in shaping and

joint making.

Firmer chisel: The firmer chisel is capable of doing heavy work

and is used for jointing and shaping the wood, with or without mallet.
The chisel blade is made of rectangular section with beveled edge
length of the blade is about 125mm and the width of the edge varies
from 3 to 5mm.

Dovetail chisel: It is similar to firmer chisel but sides are

leveled so that it can cut sharp corners. It is used for cutting sockets
where the angles are less than a right angle.

Mortise Chisel: These chisels are robust, and can withstand

heavy blows. It has a thick stock and narrow cutting edge. It is used
for cutting mortises, and its width is ground to exact size of mortise
to be out.
Outside Chisel: It is level on outside and it is used for
making hallows.

07
CROSS CUT SAW TENON SAW

CROSS CUT TEETH RIP SAW TEETH

TYPES OF PLANES

08
PARTS OF CHISEL

CHISELS

09
Striking tools:
Striking tools are used to drive in nails and to operate chisels.

Warrington Hammer: It is mostly used for bench work and light work.
It is made of cast steel with tempered face and peen. The wooden handle fits
in the eye and steel wedge is driven in to form a rigid joint.

Claw Hammer: It is dual purpose hammer. It has a hammer face

which is used to drive in nails, and claw at the other end for pulling out nails
from the wood. It is designed by its weight and it varies from 375 to 675gms.

Mallet: It is used for operating the chisels and gauges. It is made of

hard wood and is provided with handle. The striking faces are made flat,
and may be in square or rectangular cross-section.

MALLET

WARRINGTON HAMMER
(PEEN HAMMER)

CLAW HAMMER

10
Drilling & Boring tools:
These tools are used for drilling and making holes in wooden jobs.

Gimlet: It is hand operated tool used for making small

holes for screws. It has a spiral flutes with screw like point.

Hand drills: It is used for drilling small holes. A straight shank

drill is used with this tool. It is small, light in weight. The bit is
clamped in the chuck at its end.

Auger: It is used for producing long deep holes. It is a steel

bar with an eye at the top in which a handle is fitted. The bottom
end is provided with a screw point.

HAND DRILL AUGER BIT

GIMLET

11
Holding tools:
The vice and cramp are used to hold work while operations are carried out.

Bench vice: It is made of gray cast iron or steel, and it has two
jaws one of which is fixed to the side of a bench and other is movable.
The faces of jaws are lined with hard wood to prevent damage of work
surface. It is used for holding the work for planning, sawing and
chiseling on the bench.

Bar Clamp: It is used for holding wide work such as box of

frame constructions and jointed broads. It consists of a steel bar
fitted with two jaws, one of which is movable by a screw and other
is fixed into one of the spaced holes by fastening pin.

C-Clamp: It is used for holding small work on the bench. It

consists of a frame with a jaw at one end, and movable jaw, which
is operated by a screw and a thumb nut, at the other end.

BENCH VICE

BAR CLAMP

C-CLAMP

12
.

SCREW DRIVER PINCER

WOOD RASP FILE

13
 EXP NO: 1

HALF LAP T-JOINT

Aim: To make a T-Lap joint as shown from the given reaper.
Tools required:
1. Carpenter’s vice 6. Steel rule
2. Marketing knife 7. Metal jack plane
3. Firmer chisel 8. Mallet
4. Wood rasp file 9. Try-square
5. Cross cut saw 10. Tenon saw.

Sequence of operation:
1. The given reaper is checked to ensure its
2. correct size.
3. The reaper is firmly clamped in the carpenters vice and to
adjacent faces is planned by the jack plane and the two faces
are checked for squareness with the Try-square.

4. Marking gauge is set and lines are draw at 30 and 60mm, to

mark the thickness and width of the model respectively.

5. The excess material first chiseled out with firmer chisel

and then planned to correct size.

6. The mating dimensions of the parts X and Y are then

marked using scale and marking gauge.

7. Using the cross- cut saw, the portion to be removed or cut in

both the pieces, followed by chiseling and also the parts X and
Y are separated by cross- cutting, using the tenon saw.
8. The end of both the parts are chiseled to the exact lengths.

9. A fine finishing is given to the parts, if required so that, proper

fitting is obtained.
10. The parts are fitted to obtain a slightly tight joint.

14
Precautions:
1. Do not keep the tools at the edge of the work bench.
2. Do not keep the plane horizontal in idle

Result:
The T-Lap joint is thus made by following the above sequence of
operations.

15
EXP NO: 2

MORTISE AND TENON JOINT

Aim: To make Mortise & Tenon Joint as per dimensions.

Tools required:
1. Carpenter’s vice 6. Steel rule
2. Marketing knife 7. Metal jack plane
3. Firmer chisel 8. Mallet
4. Wood rasp file 9. Try-square
5. Cross cut saw 10. Tenon saw.
Sequence of Operations:
1. The given wood is checked for dimensions.

2. One side is planned with metal jack plane and checked

for trueness by try-square.
3. The four sides are also planned.
4. The excess material is cut out by cross cut saw.
5. Now the positions for lapping portion are marked.
6. After sawing remove the waste material by firmer chisel.

7. If the material is still remained in 2 or 3mm, then remove by filing

by wood rasp file.

16
Precautions:
2. Do not keep the tools at the edge of the work bench.
3. Do not keep the plane horizontal in idle mode.
Result:

The mortise and tenon joint is thus made by following the above
sequence of operations.

17
 EXP NO: 3

T-BRIDLE JOINT
AIM: To prepare a T-Bridle joint

TOOLS REQUIRED:

1. Carpenter’s vice 6. Steel rule

2. Marketing knife 7. Metal jack plane
3. Firmer chisel 8. Mallet
4. Wood rasp file 9. Try-square
5. Cross cut saw 10. Tenon saw.

SEQUENCE OF OPERATIONS :

1. Check the wooden block for the given dimensions.

2. All the faces of the wooden block is planed for straightness using
metal jack plane.
3. Cut the wooden block into two equal parts-X and Y using the cross
cut saw.
4. Check the squareness of the adjacent sides by using try square.
5. Take the part-X and lines are marked according to the dimensions
as shown in figure by using marking gauge.
6. Remove the excess material with the help of mortise chisel.
7. Repeat the above steps 5 & 6 for the part Y but the removal of
excess material is accordingly by using the firmer chisel.
8. Using the wood rasp file joining faces are finished to fit properly.
9. Join the part-X and part-Y, ensure that no gap between X and Y.

18
19
PRECAUTIONS:

1. While handling the tools care must be taken.

2. Do not use chisels where nails are present.
3. Do not carry sharp tools in pocket.

RESULT: Finally T-Bridle joint is prepared successfully.

20
TIN SMITHY

The metal plank having less than 2mm thick is called sheet metal.
Sheet metal work deals with the production of components in wide variety of
shapes and sizes with the aid of tools or machines. Some of the important
metals used in sheet metal work are described below.

Galvanized Iron: It is a sheet of soft steel, which is coated with zinc.

Zinc resists corrosion and improves the appearance of the metal galvanized
iron in one of the least expensive metals and is used for making pans,
buckets, ducts, gutters, tanks, boxes, etc.

Black Iron: It is an uncoated sheet of metal with bluish- back

appearance. It corrodes rapidly is not expensively due to difficulties of
soldering the block iron sheet are used for parts that are to be painted.

Tin plate: Tin plate is an iron or steel coated with pure iron. It has
very bright silver appearance and is used for food containers, cans, pans.

Stainless steels: It is an alloy steel possessing corrosion resistance.

General type stainless steel contains 18 percent chromium and 8 percent
nickel. This steel is commonly known as 18-8 stainless steel. These are
available various sizes and thickness. It is widely used for food containers,
dairy equipment.

Copper: It has reddish color and possesses good malleability, ductility

and resistance to atmospheric corrosion.

Aluminum: Sheet aluminum is never pure aluminum and it is always

allowed with small quantities of copper silicon, magnesium, and iron.

Tools and Equipment: The common hand tools used in sheet metal work
are, steel rule, wire gauge, dot punch, trammels, scriber, ball peen hammer,
straight –peen hammer, cross peen hammer, Mallets, Snips and Soldering
Iron etc.

Snips: Hand shear or snips are used to cut sheet metal. Although
there are many types, the sheet metal works generally use straight snips and
curved snips.

a. Straight snips: Straight snips have straight blades and are

used for cutting along the straight lines and for trimming edges.

b. Curved snips: Curved snips has a curved blade and used

for cutting circles and irregular shapes.

21
 Bench shears: Bench shear is used for cutting thick sheets. The lower
fixed blade is firmly secured by bracket at bottom. The movable blade is
pivoted at the rear end; the hand operating lever is attached to the front end
of movable blade link mechanism.

Stakes: Stakes are made of steel and forged in a variety of shapes and
sizes. Its working face is machined and polished to facilitate various
operations such as bending, seaming or forming.

The following types of stakes are mostly used.

a. Double seaming: These stakes has two horns and it is used to

make double seam for vessels.

b. Blow horn: These stakes have two horn tapering norms and it is
used to forming or seaming funnels.

c. Break horn: These stakes have a square tapered horn on one

side and a round tapered horn on opposite side. It is used for
shaping round and square surfaces, bending edges, and making
corners.

d. Conductor stake: These stakes has two cylindrical horns having

different diameters. It is used for forming pipes and cylindrical
pieces.

e. Funnel stake: It is used for forming conical shapes and

for making wire rings.

f. Hatchet stake: It has a horizontal sharp straight edge and can

be used for making straight sharp bends and for folding and
bending edges.

Wire gauge: The thickness of sheet metal is referred in number known

as standard wire gauge. The gaps in the circumference of the gauge are used
to check the gauge number as shown in figure.

Sheet metal joints: Various types of joints are used in sheet metal
work to suit the varying requirements. Some commonly used sheet metal
joints and folded edges are shown below. These are self secured joints,
formed by joining together 2 pieces of sheet metal and using the metal itself
to form the joint.

Hand Hammers and Mallets: The sheet metal worker uses a wide
variety of hammers and mallet by forming shapes by different operations.
The most commonly used hammers are follows.

22
a. Straight-Peen Hammer: It has a peen end similar to its bottom
size round shape and its top side is straight point. Square,
slightly curved face and its peen is tapered, it is used for
riveting.

b. Cross Peen Hammer: It has a square flat face and it is tapered

on one side. It is used for setting down the edges for making a
double seam.

c. Mallet: Mallet is generally made of wood and plastic. It is used

whenever slight blows are required. Wooden mallets don’t
damage the surface.

TRAMMEL

STANDARD WIRE GUAGE

23
TINSMITHY TOOLS

24
 TYPES OF SEAMS AND FOLDED EDGES

Safety precautions:

Never carry tools on pockets.

Do not try to hold the sheets with bare hands.
Do not remove any guards on squaring shears.
Care should be exercised when working on squaring shears.
Be sure that the fingers are away from the shearing blade.
. Be careful when cutting out a pattern. Remove scrap metal to
avoid injuries.

25
EXP NO: 4
OPEN SCOOP
Aim: To make a open scoop as per the given dimensions.
Tools required:
1. Ball peen hammer 6. Steel rule
2. Scriber 7. Curved snip
3. Straight snip 8. Mallet
4. Divider 9. Try-square
5. Hatchet stake 10.Cuttting Plier
Sequence of operation ;
1. The size of given sheet is checked with the steel rule.

2. The layout of the Open scoop is drawn in the sheet and cut as
shown in the development.
3. Single hemming is made on the two sides of the scoop.
4. The two sides of the scoop are bent to 90°.

5. Finally the third side is bent to 90° and seaming operation is done
to obtain the open scoop.

Precautions:
1. Do not try to hold the sheets with bare hands.
2. Be sure that the fingers are away from the shearing bend.
3. Markings should be done carefully.
4. Cutting should be done carefully to avoid cross cutting.
Result:
Thus open scoop is made from the given sheets as per given
dimension.
26
EXP NO: 5

FUNNEL
Aim: To make a cone as per the given dimensions.

Tools required:
1. Ball peen hammer 6. Steel rule
2. Scriber 7. Curved snip
3. Straight snip 8. Mallet
4. Divider 9. Try-square
5. Hatchet stake 10. Cutting Plier
Sequence of operation:
1. The size of given sheet is checked with the steel rule.

2. The layout of the cone is drawn in the sheet and cut as shown in
the development.
3. The allowance for folding and bending is added to the development.
4. The waste metal is cut away by using the straight and bent snips.

5. The development of the cone is folded by using the funnel stake,

after forming the single hemmed joint.

Note: The angle subtended by the arc of the sector is calculated from the
relation,

θ 360 x Radius of thebasecircleof

thecone Slant Height

27
 Precautions:
1. Do not try to hold the sheets with bare hands.
2. Be sure that the fingers are away from the shearing bend.
3. Markings should be done carefully.
4. Cutting should be done carefully to avoid cross cutting.

Result:
The Funnel is thus made, from the given sheet metal as
per dimensions

28
EXP NO: 6

ELBOW PIPE

Aim: To be able to prepare a pipe elbow

Tools required:
1. Ball peen hammer 6. Steel rule
2. Scriber 7. Curved snip
3. Straight snip 8. Mallet
4. Divider 9. Try-square
5. Hatchet stake 10. Soldering Iron.
.

Sequence of operation:
1. The operation consists of making two similar cylindrical pipes
truncated at an angle of 45 degrees.
2. Scribing the lines on the sheet by placing the pattern on it .
3. Hem the straight side of the sheet and flange the curved side of the
sheet.
4. Folding the edges of the joining sides and form the sheet into
cylindrical shape by using stakes .
5. Repeat the similar operation for making secnd pipe for making elbow.
6. Butt the treated portions of the cylindrical pipes at rectangles .
7. Soldering the two pipes and joints to make leak proof

29
 Precautions:
1. Do not try to hold the sheets with bare hands.
2. Be sure that the fingers are away from the shearing bend.
3. Markings should be done carefully.
4. Cutting should be done carefully to avoid cross cutting.

Result:
The Elbow pipe is thus made, from the given sheet metal as per
dimensions

30
HOUSE WIRING

Introduction:

Electrical wiring is defined as a system of electrical conductor,

components and apparatus, for conveying electric power from the source to
the point of use.

Electrical power is supplied to domestic installation through a phase

and a neutral forming a single phase A.C. 230V, two wire system. For
industrial establishment, power is supplied through 3-phase wire system to
give 440v. The figure below shows the power tapping for domestic and
industrial purpose. The neutral is earthed at the distribution sub-station of
the supply.

Elements of house wiring:

1. Fuses and Circuit Breakers: These are devices designed to provide
protection to a circuit against excess current.

2. Electric Switch: This is a device that makes and breaks or

changes the course of electric circuit.

3. Plug: It is a device carrying two or more metallic contacts in the form of

pins intended for engaging with the corresponding socket contacts.

31
Wiring methods

A circuit is a path along which the electric current flows the

negative side of the power source to the positive side. There are three
types of electrical circuits that are used for connecting devices or controls
to the power source i.e. series circuit, parallel circuit and combination of
the two.

The series circuit provides a single, continuous path through which

current flows. The devices are connected one after another and the
current flows through them until it returns to the power source. In
parallel circuit the devices are connected side by side so that, current
flows in a number of parallel paths.

Common House wiring connections:

One Lamp controlled by one-way switch:

Fig 1 shows the wiring diagram for a lamp controlled by a one-way

switch. This is the normal connection one comes across in house wiring.
Two Lamps controlled by one-way switch:

Two Lamps may be connected by one –way switch in parallel for

bright glow or in series for dull glow in fig(2).
One Lamp controlled by 2 two-way switches: Fig-3.

It is sometimes desirable to control a lamp from 2 different

places. One may come across this situation with staircase, long corridors
or hall containing two entrances etc.

32
Fig 1

Fig 2

Fig 3

33
ELECTRICAL CIRCUIT SYMBOLS

34
35
 EXP NO: 7A

TWO LIGHTS CONTROLLED BY ONE SWITCH

SERIES CONNECTION

Aim: To give connection to two lights controlled by one switch in series.

Tools required:

1. Wooden wiring board 6. Wires,

2. One way switch 7. Wire clips
3. Wooden round blocks, 8. Poker
4. Batten lamp holders, 9. Wire stripper,
5. Connector screw driver, 10.Cuttting Plier

Sequence of operations:
1. The outline of the wiring diagram is marked on the wooden wiring board.
2. Clips are nailed the board, following the wiring diagram.
3. Wires are stretched and clamped with clips.

4. Wires are connected to the holders and switch, which are then screwed
onto the wiring board.
5. Bulbs are fitted to the holders.
6. The wiring connections are then tested, by giving power supply.

Circuit Diagram:

NEUTRAL

230 V
50 HZ

PHASE
Result:
The electrical circuit, for two lights controlled by one switch in
series is thus made.

36
EXP NO: 7B

TWO LIGHTS CONTROLLED BY ONE SWITCH

PARALLEL CONNECTION

Aim: To give connections to two lights controlled by one switch in parallel.

Tools required:

1. Wooden wiring board 6. Wires,

2. One way switch 7. Wire clips
3. Wooden round blocks, 8. Poker
4. Batten lamp holders, 9. Wire stripper,
5. Connector screw driver, 10.Cuttting Plier
Sequence of operations:

1. The outline of the wiring diagram is marked on the wooden wiring board.
2. Clips are nailed the board, following the wiring diagram.
3. Wires are stretched and clamped with clips.

4. Wires are connected to the holders and switch, which are then screwed
onto the wiring board.
5. Bulbs are fitted to the holders.
6. The wiring connections are then tested, by giving power supply.

Circuit Diagram:

NEUTRAL

230 V
50 HZ

PHASE

Observation:
1. The bulb in parallel glows brightly than in series.
nd
2. If one bulb of the two is removed then also the other i.e. 2 bulb glows.
Result:
The electrical circuit, for two lights controlled by one switch in
series is thus made.

37
 EXP NO: 8

ONE LAMP CONTROLLED BY TWO TWO-WAY SWITCHES

STAIR-CASE CONNECTION

Aim: To give connection to one light controlled by 2 two way switches.

Tools used:

1. Wooden wiring board 6. Wires,

2. Two -way switches 7. Wire clips
3. Wooden round blocks, 8. Poker
4. Batten lamp holders, 9. Wire stripper,
5. Connector screw driver, 10.Cuttting Plier
.

Sequence of operations:

1. The outline of the wiring diagram is marked on the wooden wiring board.
2. Clips are nailed the board, following the wiring diagram.
3. Wires are stretched and clamped with clips.

4. Wires are connected to the holders and switch, which are then screwed
onto the wiring board.
5. Bulbs are fitted to the holders.
6. The wiring connections are then tested, by giving power supply.
Circuit Diagram:

Result:
The electrical circuit, for one light controlled by 2 way switches is thus
made.

38
EXP NO: 9

SOLDERING PRACTISE

Aim: To practise soldering and desoldering for given electronic circuit in

a general purpose printed circuit
Tools used:
1. PCB circuit board 6. Nose plier
2. Soldering Iron 7. Wires
3. Solder 8. Hand Gloves
4. Flux 9. Connector
5. Lead 10. Copper plate

Sequence of operations:
1. Clean the given PCB Board.
2. Clean the Soldering Iron before heating and also the component to
be soldered
3. Heat the soldering Iron and apply solder to the tip as soon as it is hot to
melt it on.
4. Considering given circuit and components are to be soldered in their
respective places by applying hot tip to the joints
5. Trim excess component lead with trim cutter .
6. The equivalent Etching diagram is taken and impression marked .When
the component like diode is to be soldered or connected in reverse, the
cathode in place of anode and anode in the place of cathode.
7. If the mirror image is only considered ,then the copper plateis ready to be
drilled and considered as a component for the circuit is taken.
8. The same prior can be done for fine circuit and equivalent etching diagram
is shown later.

39
Result:
Thus the soldering practise is done for the given electronic circuit
successfully .

40
EXP NO: 10

TUBE LIGHT CONNECTION

Aim:
To prepare wiring for a fluorescent tube light with switch control
Tools Required:
1. Screw driver
2. Hammer
3. Pliers
4. Line tester
Components Required:
1. Switch
2. Tube light with fitting
3. Joint clips
4. Wires
5. Screws
6. Switch board

Procedure:
1. Mark the switch and tube light location points
and draw lines for wiring on the wooden board.
2. Place wires along the lines and fix them with the help of clips.
3. Fix the switch and tube light fitting in the marked positions.
4. Complete the wiring as per the wiring diagram.
5. Test the working of the tube light by giving
electric supply to the Circuit.

41
 CIRCUIT DIAGRAM - TUBE LIGHT

STARTER

40 W, 230 V

TUBE
HOLDER FLUORESCENTTUBE
FLUORESCEN T TUBE
H
OLDER
1-WAY
CHOKE
SWITCH

P N
1 , 230V
50 Hz
AC

PRECAUTION-:
1. Check all the accessories as per the circuit.
2. Tools should be used carefully.
3. Fitting should be tightly fitted.
4. Connection should be tight

Result:
The wiring for the tube light is completed and tested.

42
EXP NO: 5

GODOWN CONNECTION

Aim:
To prepare Godown light connection with switch control

Tools Required

Single core stranded wire

Incandescent lamp (Bulb)
One way switch
Two way switch
3 pin socket outlet
Wooden board
Bulb holder

PROCEDURE-:

1. Collect the materials required for this experiment.

2. Draw the layout of the given circuit diagram in the circuit board.
3. Fix the necessary materials, by using drilling machine in the layout
board.
4. Terminal 2 of the bulb B1 is connected to neutral point (N) and
another terminal 1 is connected to terminal 1 of switch S2.
5. Terminal 1 of the switch S1 is connected to the phase line (P).
6. Now, The terminal 2 of switch S1 is connected with terminal 2 of
switch S2.
7. The terminal 3 of switch S2 is connected with terminal 2 of switch S3.
8. And terminal 3 of Switch S3 is connected with terminal 2 of switch
S4.
9. Terminal 1 of switch S3 is connected to terminal 1 of bulb B2.
10. Terminal 1 of switch S4 is connected to terminal 1 of Bulb B3.
11. Terminal 2 of Bulb B1 , B2, B3 and B4 are internally connected
with respect to neutral(N).
12. After this all process , give the 1 phase , 230 volts, 5oHz
AC supply to the main input P and N terminals.
13. The given lamp is fixed on the lamp holders.Controlling
the switches, the circuit is checked and results are tabulated

43
CIRCUIT DIAGRAM :

RESULT-: Thus the GODOWN WIRING has been connected and tested .

44
FITTING

INTRODUCTION:

Machine tools are capable of producing work at a faster

rate, but there are occasions when components are processed at the bench.
The term bench work refers to the production of components by hand on the
bench, where as fitting deals with the assembly of mating parts, through the
removal of metal to obtain the required fit. Both the bench work and fitting
operations consists of filing, chipping, sawing, drilling, tapping etc.,

CLASSIFICATION OF TOOLS: The tools commonly used in fitting may

be classified as
1. Holding tools
2. Cutting tools
3. Striking tools
4. Marking & checking tools
HOLDING TOOLS:
a. Bench vice
b. Pipe vice
c. Hand vice
d. Pin vice
e. Tool makers
f. Leg vice
g. C- clamp

BENCH VICE (OR) PARALLEL JAW VICE:

The bench vice is the work holding device. It has two jaws one of
which is fixed to the bench and other slides with the aid of square screw and
a box nut arrangement. The outer end of the screw carries a handle. The
jaws are made with hardened tool and the body is cast iron or cast steel. The
working faces of jaws are serrated to give additional grip for holding job. The
size of the parallel or bench vice is specified by the jaws width.
45
 BENCH VICE

V-BLOCK C-CLAMP

HOLDING TOOLS

46
CUTTING TOOLS:
Hacksaw:
I. Solid frame
II. Adjustable frame

The hacksaw is used for cutting metal by hand. It consists of a frame,

which holds a thin blade firmly in position. Hacksaw blades have a number
of teeth ranging from 5 to 15 per cm. Hacksaw blades are classified as 1. All
hard and 2. Flexible type.

The teeth of hacksaw blade are staggered or bending alternatively are

known as a “set of teeth”. These make slots wider than the blade thickness
preventing the blade from jamming.

Power Hacksaw: It is similar to hacksaw, but has a large size blade and is
driven by motor.

Drills: Drills are cutting tools used for making holes. These are naturally
made of high speed steel tools. Drills have two cutting edges and two helical
grooves (flutes). The flutes admit coolants and also allow the chips to escape
during the drilling. Its cutting angle (lips) is grounded to 118˚. The shank of
twist drill may be either straight or taper.

Reamer: A reamer is used for finishing a drilled hole to an accurate size and
to produce a good surface finish. It is made of HSS. There are two types of
reamers.
1. Hand reamer
2. Machine reamer

Chisels: Chisels are used for removing excess material from large surfaces
and cutting thin sheets. These tools are made from 0.9˚ to 1.0˚ carbon steel
of octagonal or hexagonal. The cutting angle for the chisel for general
purpose is about 60˚. The recommend angles for cutting different materials
at cold state are:

47
Aluminum : 35˚
Mild steel : 55˚

Cast iron : 60˚

Cast steel : 70˚

HACKSAW FRAME WITH BLADE

TWIST DRILL

48
 PARTS OF A REAMER

CUTTING TOOLS

49
5
The most commonly used chisels are:
1. Flat chisel
2. Cross cut chisel
3. Half round chisel
4. Diamond point chisel
5. Side chisel

Scrapers: Scrapers are used for producing finished surface. It removes the
surface irregularities at selected spots on a surface. The scrapers are made of
tool steel. The cutting edge is hardened but not usually tempered. The most
commonly used scrapers are:
1. Flat scraper
2. Triangular scraper
3. Half round scraper
Striking tools: Hand hammers are striking tools. They are made of medium
carbon steel. The various types of hand hammers in common use are ball
peen hammer, cross pen hammer and straight peen hammer.

BALL PEEN HAMMER

CROSS PEEN HAMMER

50
 STRAIGHT PEEN HAMMER

STRIKING TOOLS

Marking tools: Marking is a process of layout of sizes on work piece.

The following tools are used in marking operations.
1. Scriber
2. Divider
3. Jenny caliper
4. Scribing block
5. Angle plate
6. V-block
7. Punch
8. Try Square
9. Surface plate
Scriber: A scriber is a slender tool used to scribe or mark lines on metal
work piece.

Tap and Tap wrenches: A tap is hardened steel tool used for cutting
internal threads in a drilled hole. Hand taps are available in sets containing
three taps. Taper tap, Second tap, and plug or bottom tap.

Die and Die holders: Dies are cutting tools used for making external
threads. They are made of tool steel or high carbon steel.
Punch: It is made of tool steel and the various types of punches are
prick punch or dot punch, centre punch, number punch and letter punch.

51
 Prick punch: It is also called as dot punch and used for marking small
dots along the layout lines. The point is tempered and grounded to an angle
of 60˚.

Centre punch: This is similar to dot punch, except that its point is
grounded to angle of 90˚. It is used for marking the location of the holes to be
drilled.
V- block: V blocks are made of cast iron or hardened steel. They are
provided with V grooves on the top and bottom and rectangle dots on two
sides for location of clamps.

Try square: It is used for checking squareness of small works. The

size of the try square is specified by the length of the blade.

Surface plate: It is used for providing true surface support to the work
during marking. It is made of cast iron, hardened steel or granite and is
specified by length× width × height× grade.

Divider: This is used for marking circles, arcs, laying out

perpendicular lines, bisecting lines etc.

Jenny caliper: This is also called as odd leg or hermaphrodite caliper.

It is used for marking parallel lines from a finished edge and also for locating
the centre of round bars.

Scribing block: It is also known as universal scribing block. This is

used for scribing lines for layout and for checking parallel surfaces.

Angle plate: The angle plate is made of cast iron or hardened steel.
They are provided with v-grooves on the top and bottom and rectangular
slots on two sides for the location of clamps.

Vernier height gauge: It is clamped with scriber and is used when it

is required to take measurements from the surfaces on which gauge is
standing. The accuracy and working principles of this gauge is same as
vernier caliper.
Outside Micrometer: It is used for measuring
external dimensions accurately of 0.01mm.

52
 Inside micrometer: This is used to measure inside dimension
accurately to 0.01mm. It consists of a measuring unit, a number of
interchangeable extension rods and a handle.

SURFACE PLATE ANGLE PLATE

UNIVERSAL SCRIBING BLOCK TRY SQUARE

SCRIBER SPRING CALIPERS MARKING TOOLS

53
PUNCHES

FILE:
a. File is a cutting tool. A file is a hardened steel tool having slant parallel
rows of cutting edges or teeth on its surface on the faces. The one end of
the file is shaped to fit into wooden handle. The hand file is parallel in
width and tapering slightly in thickness towards the tip. It is provided
with double cut teeth on the faces, single cut on one edge and no teeth
on the other edge which is known as “safe edge”. 20 to 24 teeth per cm
b. Dead smooth: It has 40 to 48 teeth per cm

PARTS OF FILE

54
TYPES OF FILES CUT OF FILES

MEASURING AND CHECKING INSTRUMENTS:

Measuring tools may be classified as :
1. Linear measuring instruments
a. Steel rule
b. Caliper
c. Depth gauge
d. Vernier caliper
e. Micrometer
f. Gauge block
g. Dial indicator or dial gauge
2. Angular measuring instruments
a. Level protractor
b. Combination set
c. Sine bar
3. Surface measuring instruments
a. Spirit level
b. Straight edge
Steel rule: It is a strip of steel with graduation on its edges.

55
 Calipers: They are used for transferring the dimensions both external
and internal. They are made either with firm joint or spring caliper.
Outside caliper: It is used for measuring outside dimensions
of cylindrical shapes.
Inside caliper: It is used for measuring the diameter of
holes and width of key ways.

Vernier caliper: It is used for measuring outside as well as inside

dimensions accurately. It may also be used as depth gauge.
Least count of vernier = 1 main scale division – 1 vernier scale division
Combination set: It consists of rule, square head, centre head, and a
protractor and spirit level. This may be used as a rule, a square, depth gauge
for marking meters (45˚) for locating the centre on the end of the round bar
and for measuring and marking angles.

Gauges: Gauges are inspection tools used in production work to

control the size and shape of the components.
Feeler gauges: These are thin steel blades hardened and grounded to
various sizes. These are used to check the clearance between two mating
parts. The blade thickness varies from 0.03mm – 1.0mm and the length of
the blade is about 100mm.
Screw pitch gauge: It is used to check the pitch of the screw.
The pitch of the screw is directly on the gauge.

Wire gauge: The wire gauge is used to check the diameter of the
wire from 0.1mm – 10mm.

Plate gauge: Plate gauge (standard wire gauge) is used to measure

thickness of sheets of different thickness. Each slot is represented by
number (SWG number). As the number increases the thickness size
decreases. The most common gauge used in sheet metal has 21 slots with
gauge numbers ranging from 4 to 24.

Radius and fillet gauge: These are used to check the radii
of curvature of convex and concave surfaces.

56
Miscellaneous tools:

1. File card: It is a metal brush used for cleaning the files to free
them from filings logged in between the teeth.
2. Screw driver: It is used for tightening and loosening the screws. It is
made of steel and its tip is hardened. It is made in a variety of sizes
and shapes.
3. Spanners: Spanners or wrenches are used for tightening and
loosening of nuts and bolts. They are made of forged steel. The size of
spanner denotes the size of the bolt on which it can work.
Types of spanners:
1. Single end spanner
2. Double end spanner
3. Ring spanner
4. Box end spanner
5. Adjustable spanner
Allen key: It is used for hallow sunk head bolts and screws.
4. Pliers:

i. Cutting pliers: It is used for holding work and cutting thin soft
wires.
ii. Nose pliers: It is used for holding and bending thin wires.

iii. Circlip pliers: It is used for locking and removal of Circlip and
are available in outside and inside pliers.

COMBINATION PLIER FILE CARD

57
SCREW DRIVERS NOSE PLIER

FLAT CHISEL

SINGLE HEADED BOX SPANNER

SINGLE HEADED SPANNER

DOUBLE HEADED SPANNER

OFFSET DOUBLE ENDED BOX SPANNER

58
OFFSET SOCKET WRENCH

ADJUSTABLE WRENCH

MONKEY WRENCH

ALLEN WRENCH
SPANNERS

59
EXP NO: 1

V-FITTING

Aim: To make a V-fit from the given two M.S pieces.

Material: Two MS FLAT of size 50x50x5mm
Tools required:

150mm try-square, 250gm ball-peen hammer, dot punch, scriber, chisel,

300mm hacksaw frame, 18TPI hacksaw blade, 250mm rough and smooth
hand files, 6mm rough and smooth square files, Bench vice and steel rule.

Sequence of operations:

1. The burs in given materials are removed and the dimensions are
checked for 50x50x5mm with steel rule.

2. The pieces are clamped one after the other and outer mating edges are
filed and checked for their flatness, with the help of try-square.

3. The side edges of the two pieces are filed such that, they at right angles
to each other and widths are exactly 48mm.
4. Wet chalk is applied on surfaces of the two pieces.
5. The given dimensions of the V fitting are marked, by using jenny
caliper, steel rule scriber, and the surface plate.
6. The portion to be removed is then marked.
7. Using dot punch, dots are punched along the above scribed lines.
8. Using the hacksaw, the unwanted portions are removed.

9. Now the potions are filed and burrs are removed by filing on the
surfaces of fitted job.

60
Precautions:
1. Never remove chips with hand use a wire brush.
2. Working tool should not be kept at the edge of table.
3. While sawing secure work rigidity.

Result: The required V Fit is thus made by following the above sequences
of operations.

61
EXP NO: 2

HALF ROUND FITTING

Aim: To make a half round fitting from the given two M.S pieces.
Material: Two MS FLAT of size 50x50x5mm
Tools required:
150mm try-square, 250gm ball-peen hammer, dot punch, scriber, chisel,
300mm hacksaw frame, 18TPI hacksaw blade, 250mm rough and smooth
hand files, 6mm rough and smooth square files, Bench vice and steel rule.

Sequence of operations:

1. The burs in given materials are removed and the dimensions are
checked with steel rule.

2. The pieces are clamped one after the other and outer mating edges are
filed and checked for their flatness, with the help of try-square.

3. The side edges of the two pieces are filed such that, they at right angles
to each other and widths exactly
4. Wet chalk is applied on surfaces of the two pieces.
5. The given dimensions of the Half round fitting are marked, by using j
caliper, steel rule scriber, and the surface plate.
6. The portion to be removed is then marked.
7. Using dot punch, dots are punched along the above scribed lines.
8. Using the hacksaw, the unwanted portions are removed.

9. Now the potions are filed and burrs are removed by filing on the
surfaces of fitted job.
.

62
Note: The centers of the half rounds are marked by a centre punch. However,after
marking the centre of the half round in the piece Y, the edges of it is further filed,
till half of the punch dot is left.

Precautions:
1. Never remove chips with hand use a wire brush.
2. Working tool should not be kept at the edge of table.
3. While sawing secure work rigidity.

Result: The semi circular fit is thus made by following the above
sequences of operations.

63
EXP NO: 3

DOVE TAIL FITTING

Aim: To make a half round fitting from the given two M.S pieces.
Tools required:
150mm try-square, 250gm ball-peen hammer, dot punch, scriber, chisel,
300mm hacksaw frame, 18TPI hacksaw blade, 250mm rough and smooth
hand files, 6mm rough and smooth square files, Bench vice and steel rule.

Sequence of operations:

1.The burs in given materials are removed and the dimensions are
checked with steel rule.

2.The pieces are clamped one after the other and outer mating edges
are filed and checked for their flatness, with the help of try-square.

3.The side edges of the two pieces are filed such that, they at right angles to
each other and widths exactly
4.Wet chalk is applied on surfaces of the two pieces.
5.The given dimensions of the dove tail
fitting are marked, by using j caliper, steel rule scriber, and the surface
plate.
6.The portion to be removed is then marked.
7.Using dot punch, dots are punched along the above scribed lines.
8.Using the hacksaw, the unwanted portions are removed.

9.Now the potions are filed and burrs are removed by filing on the surfaces of
fitted job.
.

64
Precautions:
1. Never remove chips with hand use a wire brush.
2. Working tool should not be kept at the edge of table.
3. While sawing secure work rigidity.

Result: The semi circular fit is thus made by following the above
sequences of operations.

65
EXP NO: 4

BICYCLE TYRE PUNCTURE AND CHANGE OF TYRE

Aim: To replace the punctured wheel of a bicycle with new wheel .

Tools required :

Adjustable wrench , spanners , screw driver , pliers (for gear arrangement)

Sequence of operations:
1) Remove the tube from tyre with the help of pliers and also loosen the air
valve
2) Inflate the tube and immerse in water to identify the punctured location
3) Punctured location is identified based on air bubbles spotted from the
surface.
4) Mark the spotted area with the help of chalk .
5)Roughen the surface of leakage with the help of file.
6) Roughen the patch and apply adhesive gum .
7) Arrest the leakage with the help of patch
8)Inflate the tube and check for leakage by filling air
10)Replace the tube into tyre and tyre into its actual position.
11)Tighten the air valve and fill the air

66
Precautions:
1) Take care of your hands being forced to spokes and sharp edge parts to
minimise the risk of injuries
2) All the nuts and bolts should be removed with spanners and wrench only .
3) Check the balance of the wheel after fitting
4) Check the air pressure before riding .

Result: Thus punctured wheel is repaired and fit into its position..

67