GE6162 ENGINEERING PRACTICES LABORATORY LTPC

0032
OBJECTIVES:
 To provide exposure to the students with hands on experience on various
basic engineering practices in Civil, Mechanical, Electrical and Electronics
Engineering.
GROUP A (CIVIL & MECHANICAL)
I CIVIL ENGINEERING PRACTICE 9
Buildings:
(a) Study of plumbing and carpentry components of residential and industrial
buildings.
Plumbing Works:
(a) Study of pipeline joints, its location and functions: valves, taps, couplings,
unions, reducers, elbows in household fittings.
(b) Study of pipe connections requirements for pumps and turbines.
(c) Preparation of plumbing line sketches for water supply and sewage works.
(d) Hands-on-exercise: Basic pipe connections – Mixed pipe material connection
– Pipe connections with different joining components.
(e) Demonstration of plumbing requirements of high-rise buildings.
Carpentry using Power Tools only:
(a) Study of the joints in roofs, doors, windows and furniture.
(b) Hands-on-exercise: Wood work, joints by sawing, planing and cutting.
II MECHANICAL ENGINEERING PRACTICE 13
Welding:
(a) Preparation of arc welding of butt joints, lap joints and tee joints.
(b) Gas welding practice 11
Basic Machining:
(a) Simple Turning and Taper turning
(b) Drilling Practice
Sheet Metal Work:
(a) Forming & Bending:
(b) Model making – Trays, funnels, etc.
(c) Different type of joints.
Machine assembly practice:
(a) Study of centrifugal pump
(b) Study of air conditioner
Demonstration on:
(a) Smithy operations, upsetting, swaging, setting down and bending. Example –
Exercise – Production of hexagonal headed bolt.
(b) Foundry operations like mould preparation for gear and step cone pulley.
(c) Fitting – Exercises – Preparation of square fitting and vee – fitting models.
 INDEX

Ex.No Date Name of the Exercise Page No Staff Initial Date

10

11

12

13

14

15

16

17

18

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 CONTENT

S.No Title Page No

1 Safety Precautions 1
2 Study of Plumbing 3
1. Suction Pipe Assembling 13
2. Delivery Pipe Assembling 15
3. Assembling of Non-Return Valve 17
3 Study of Carpentry 19
1. Planing 33
2. Tee Halving (Middle Lap) Joint 35
3. Dovetail Joint 37
4 Study of Welding 39
1. Square Butt Joint 47
2. Lap Joint 49
3. Tee – Fillet Joint 51
5 Study of Lathe & Drilling Machines 52
1. Turning & Facing 59
2. Step Turning & Chamfering 61
3. Drilling & Tapping 63
6 Study of Sheet Metal Work 64
1. Development of Rectangular Tray 71
2. Development of Cone 73
7 Study of Centrifugal Pump & its Assembly Sequence 75
8 Study of Air Conditioner 79
9 Viva vice 81

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1
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Ex.No: STUDY OF PLUMBING Date:

Plumbing is defined as that profession or process which deals with the designing, detailing,
specifying and executing all works related to laying, fixing, joining and connecting of the
pipelines, conduits, hoses, etc. along with various fixtures and fittings (such as taps, valves,
regulators, cisterns, siphons, tanks, meters, etc.) for the purpose of transporting conveying fresh
water, waste water, rain water, compressed air, gases, etc. into and/or out of the buildings.
Plumber is that artisan who executes all these tasks as per the drawings, details and
specifications provided by architects, engineers and manufacturers.

PLUMBING TOOLS
Plumbing work requires tools like pipe wrenches, hacksaw pipe cutter, threading
equipment, pipe, etc.

Pipe Wrenches: It is used for holding and turning the pipes, rods and machine parts. Wrenches of
size 300mm and 450mm are more useful. The adjustable pipe wrench shown in figure consists of
fixed jaw and a movable jaw. The movable jaw facilitates the adjustment of the opening between
the jaws. The jaws are serrated inside for firm grip over the pipes.

Chain Wrench: A chain wrench is used on very large diameter pipe work and fittings. Wrap the
chain tightly round the work and engage the chain with hook at the end of the wrench. Then lever
the handle towards the toothed jaw to apply the tightening force.

Die: A pipe die is used for making external threads on pipes. One or two piece dies are used in the
die stock. It is a hand operated tool, which may be considered as a hardened steel nut, having flutes
cut along its inside surface. These flutes serve the same purpose as in a twist drill. In case of two
piece die, the two pieces are set at a desired distance and secured in position by means of a set
screw.

Pipe Cutter: Pipe cutter is used where considerable amount of pipe work is drawn in. the pipe
cutter mainly consists of three wheels, which are hardened and with sharp cutting edges along their
periphery. Of these three wheels, one can be adjusted to any desired diameter/distance from the
other two fixed wheels.

Adjustable Spanner: Adjustable spanners are available in several sizes and different designs.
These are used to fix the parts having hexagonal nut arrangement, of different sizes.

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PIPE & PIPE FITTINGS
Pipes are used for carrying fluids such as water, steam, gas, oil from one place to another.
As pipes are made to standard lengths, the desired length of pipe may be obtained by joining them.
The type of joint used depends upon the material of the pipe and the purpose for which it is used.
The material selection is based on the nature of the fluid to be conveyed, viz., pressure,
temperature, chemical properties, etc.

Generally pipe and pipe fittings are made up of cast iron, wrought iron, plastic, steel, brass,
etc. Now a days PVC (Poly Vinyl Chloride) pipes are extensively used in all types of works.

Coupling: It is used for joining two pipes in a straight line and where atleast one pipe can be
turned. The materials used for coupling are GI iron, PVC and brass. It is made up of plastic, brass,
cast iron or GI.

Elbow: It is used for connecting pipes at right angles. It is made up of plastic, brass, cast iron or
GI.

Bend: It is used at corners in pipe fitting jobs. Its diameter is equal to the size of the pipe.

Tee: Tee is used to divert the flow in two directions. It is both threaded and non-threaded.

Stop Cock or Tap: A tap is a valve for controlling the flow of fluid. It is made up of copper,
plastic or steel.

Reducer: It is used to connect two different sized pipes. Reducers are classified into two types:
a) Concentric Type
b) Eccentric Type

Bush: It is a short sleeve-like piece, used to reduce the size of a threaded opening. It is threaded
fully on the side and one end on the outside.

Flange: Flange is used to connect two pipes in same line by means of bolts, thread or welded way.
It is used where-ever pipe lines need to be assembled and dismantled.

Pipe Vice: It is used to hold a piece of metal or pipes rigidly for cutting, screwing and removing.
Pipe vice is specially designed to hold cylindrical objects.

Taps: Taps are used for cutting internal threads on a pipe fitting.

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Nipple: Nipple is a pipe threaded at both sides. It is used to join two internally threaded fittings
together. It is made up of GI, steel, brass and steel.
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Union: The function of union is to unit or joins two pipes together. It facilitates to connect or
disconnect pipe easier. It is made up of GI, brass and steel.

Plug: It is used to screw onto a threaded opening, for closing it temporarily. Plug is usually made
up of wrought iron.

PLUMBING VALVES
Valves are the kinds of control devices, which are used in pipeline system for controlling the flow
of fluid. The first step for choosing valve is to understand the function of valve.

Gate Valves or Sluice Valves: Gate or sluice valves are used to regulate the flow of water through
the pipes. They are similar to gate valves used in dams but are not so large.

Air Valves: Air valves are the special kind of valves which are generally placed along the pipe
line at summits on both sides of the sluice valves and also on the downstream side of all other
sluice valves.

Butterfly Valve: The butterfly valve consists of a shaft-mounted disc that rotates in a 90º arc from
full open to full close. When the disc is rotated into the closed position, it compresses the rubber
seat, which is slightly smaller in diameter than the disc, and a tight seal is made.

Pressure Relief Valve: Water hammer pressures in pressure pipes can be reduced by using
pressure relief valves. Such a valve is adjusted to open out automatically as soon as the pressure in
the pipe exceeds a certain fixed predetermined valve. Due to the opening of this valve, certain
water will get out of the pipe, and thus, reducing the pressure in the pipe.

Check Valve or Non Return Valve: It is used to prevent reverse flow in a pipe line. The swing
type valve is more commonly used in this category.

PIPE JOINTS

Bell and Spigot Joints: A connection between two sections of the pipe, i.e., the straight spigot end
of one section inserted into the flared end of the adjoining section.

Flanged Joints: It helps to connect and disconnect two pipes as per the need.

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Bolted Joints: The use of bolted joints is advantageous in the following circumstances.
i) The components that cannot be serviced in line.
ii) The components being jointed that are not capable of being welded.
iii) Quick field assembly is required.

Threaded Joints: Threads are cut in pipe, flange coupling to connect them with each other and
these joints are said as threaded joints. Threaded joints are rigid, when compared to other joints.

Flexible Joints: The flexible joints are generally used to connect between wash basin and angle
valve.

TAPS
Piller Taps: These are draw-off taps that are fitted to sanitary appliances such as sink units, wash
basins and bath. They have a long threaded shank that follows them to be fitted.

Bib Taps: These are draw-off fitted above sanitary appliances such as sinks or on their own to
supply water for buckets or hoses.

Mixer Taps: These are basically a pair of draw-off pillar taps, hot and cold, joined together by a
common joint mixing chamber and or delivery spout to provide a mixed flow of hot and cold
water. The hot and cold controls are separated by spout joint. They are used for sink units or baths.

Stop Taps: These are used to shout off flow or control the rate of flow in pipe line. They are
commonly fitted to the incoming water main in a building or on the fed pipe to individual
appliances or fittings to shut off the water flow for repair and maintenance purpose.

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PLUMBING SYMBOLS:
10
 90º 45º

ELBOW UNION TEE BEND

REDUCER PLUG FLANGED SCREWED WELDED

STOP COCK GLOBE VALVE GATE CHECK VALVE

VALVE

RESULT:

Thus the various plumbing tools, symbols, pipes and pipe fittings and their uses in
plumbing are studied.

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SUCTION PIPE ASSEMBLING

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Ex.No: SUCTION PIPE ASSEMBLING Date:

Aim:

To join the various pipes and assemble of suction pipe.

Tools Required:

Pipe vice, die and die holder, pipe wrench, and adjustable spanners.

Materials Required:

 ½" x 6"- 2Nos

 ½" x 12"- 1No
 ½" elbow-1No
 ½" flange
 ½" Foot valve
 ½" Union

Procedure:

1. ½" flange is connected with the ½" x 6" pipe line.

2. The other end of the pipe line is connected by a ½"elbow.
3. The other side of the elbow is connected by a ½" pipe line of length 6".
4. ½" union is connected with the other side ½" pipe line.
5. The ½" x1 2"pipe line is connected to the other side of the ½" union.
6. Then the pipe line is finally connected with the ½" foot valve.

Result:

Thus the Various Pipe fittings and pipes are assembled for suction pipe.

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DELIVERY PIPE ASSEMBLING

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Ex.No: DELIVERY PIPE ASSEMBLING Date:

Aim:
To join various pipe fittings and pipes by threading.

Tools Required:
Pipe vice, die and die holder, pipe wrench, and adjustable spanners.

Materials Required:
 ¾" x 6"- 2Nos
 ½" x 12"- 3Nos
 ¾"elbow - 1No
 ¾" x ½"reducer - 1No
 ½" elbow - 2Nos
 ½" coupling - 1No
 ½"tap-1No, Thread ball and Shellac

Procedure:
1. ¾" x 6"is connected with the ¾"elbow.
2. ¾" x 6"pipe is connected at the other end of the ¾"elbow.
3. The other end of the ¾"pipe is connected with one end of the ½" x ½"reducer.
4. ½" x 3"pipe is connected to the one end of the ½"elbow.
5. The other end of the ½"elbow is connected by a ½" x 12"pipe.
6. Then the ½"pipe is connected by a ½"elbow which is connected by a ½" x 12"pipe.
7. Then the ½" x 12"pipe is connected to the ½"tap.

Result:
Thus the Various Pipe fittings and pipes are joined by threading.

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ASSEMBLING OF NON-RETURN VALVE

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Ex.No: ASSEMBLING OF NON-RETURN VALVE Date:

Aim:

To connect overhead tank and sump in a single pipe line.

Tools Required:

Pipe vice, die and die holder, pipe wrench, and adjustable spanners.

Materials Required:

 ½" x 6"- 4Nos

 ½" NRV - 1No
 ½" elbow - 1No
 ½" Tee - 1No

Procedure:

1. ½" pipe line is connected with a ½"elbow is made to connect with the ½" Non-return valve.
2. The other side of the Non-return valve is connected to the ½"pipe line and it is connected
to the ½" Tee joint.
3. One end of the Tee joint is fitted with a ½" pipe.
4. The other end of the Tee joint is also connected with ½" pipe line.

Result:

Thus over head tank and sump are connected in a single pipe line.

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Ex.No: STUDY OF CARPENTRY Date:

Carpentry / Wood work 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.

WOOD

Wood, also called timber, is the universally used material for making the above said items. The
advantages of wood are
 It is abundantly available.
 It is tough and strong and can be worked easily.
 It is lighter and comparatively cheap.
 It can be beautifully painted and polished for good aesthetics.
 It is moreover environment friendly.

Types of Woods:
Woods are classified into two types (1) Soft wood and (2) Hard wood

Soft Wood: It is obtained from soft and quickly growing trees. Pine, Redwood, Firs, Larch,
etc.. are all having soft wood. These are used to make furniture, light weight boats etc…

Hard Wood: It is obtained from hard trees having broad leaves. Teak, Mahogany, Oak,
Rose wood, Maple, Elm are very hard. These are used to make furniture, doors, windows,
wardrobes, etc…

CARPENTRY TOOLS

For successful making of a wooden item one has to use many tools, both hand tools and
machines. In this respect the carpentry tools are classified according to the following categories.
1. Measuring tools
2. Marking tools
3. Cutting tools
4. Planning tools
5. Boring tools
6. Striking tools
7. Holding tools
8. Miscellaneous tools

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MEASURING TOOLS

The following measuring tools are used in carpentry

1. Steel rule

2. Caliper (Inside and Outside)

3. Divider

4. Carpenter’s folding rule

5. Carpenter tape

Steel rule: It is used to measure the lengths. It is usually available in lengths of 150mm and
300mm, graduated both in mm and inches, and is made from tempered rust free steel or stainless
steel.

Caliper: It is used to measure or transfer the diameters or lengths from one object to other. It is
having a pair of curved and pinned legs. The two types of calipers are

1. Inside Caliper

2. Outside Caliper.

Inside Caliper: It is used to measure or check the diameters of holes, recesses, gaps or openings.

Outside Caliper: It is used to measure or check the diameter of rods, thicknesses or small lengths.

Divider: It has a pair of pointed and sharpened legs, using this, circles and arcs can be drawn. The
radius can be set by adjusting the screw.

Carpenter’s folding rule: It consists of four pieces, each 150mm long, one pair is pinned and the
other two are hinged with the pair, so that it can be folded and carried easily. It has graduations
both in mm and inches.

Carpenter’s tape: It is used to measure or mark larger lengths. It is made up of a toughened

spring steel strip, so that would wind automatically after use in the form of spool, because of
spring action. It is available in lengths 2m to 5m, graduated both in mm and inches.

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MARKING TOOLS

Marking tools are used to set or mark lines for working on the wood. The various types of marking
tools are
1. Try Square
2. Mitre Square
3. Bevel Square
4. Marking Knife
5. Gauges – Marking Gauge, Cutting Gauge and Mortise Gauge

Try Square: It is used to mark and check the right angles. It consists of a steel blade, riveted into a
hard wood stock or metal. It is available with the steel blade length ranging from 150mm to
300mm.

Mitre Square: It is used to mark and measure the angle of 45º. It is also made up of steel blade
riveted into rose wood stock at an angle of 45º. It available with the steel blade length ranging
from 150mm to 300mm.

Bevel Square: It is similar to the try square but here the steel blade has a slot, in which the wood
stock is fixed by screw. With respect to the wood stock the steel blade can be moved and tilted at
an desired angle between 0º to 180 º.

Marking Knife: It is used for converting the pencil line marks into cut line. It is made of steel
having a pointed end with handle.

Marking Gauge: It is used to mark lines at uniform distance, from one end of the wood. It
consists of a wooden stem, having a pin or tooth at one end, on which the wood stock moves. Its
position can be set with the help of thumb screw.

Cutting Gauge: It is similar to the marking gauge, with a difference that it has a cutting knife
instead of tooth. It is used to cut parallel strips from thin wood and to obtain deep mark on the
wood.

Mortise Gauge: It has two marking points one near the end of the stem, which is fixed, and the
other is movable with the help of slide and screw arrangement. Using this, two parallel lines can be
marked in single stroke, called mortis lines and tenons. The distance between the fixed pin and the
movable pin can be set by adjusting the screw for the slider. Then offset distance can be set by
setting the screw on the wood stock.

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CUTTING TOOLS

To make wooden articles, the wood has to be cut into required size and shape and to
perform fine finishing. For these purposes the cutting tools to be used are broadly grouped into
three following categories
1. Saw
2. Chisels
3. Axe
Saws
It is a thin steel blade having series of sharp teeth at one end. It is rigidly fixed with a
wooden handle, by screws or rivets, for easy working. The front end of the blade is called point
and the back end is called heel. The teeth are bent alternately to the right and left of the blade to
facilitate it to pass through easily and to reduce the friction during cutting. The saw is specified by
the length of the blade and pitch of the teeth. The various types of saws used in carpentry are (1)
Cross-cut or Hand saw, (2) Rip saw, (3) Panel Saw, (4) Tenon or Back saw, (5) Dovetail saw, (6)
Bow saw, (7) Coping saw, (8) Compass saw and (9) Keyhole or Pad saw

Cross-cut or Hand saw: It is used to cut the wood across the grain. The number of teeth per inch
in this saw is from 6 to 10 and the blade length is about 550mm to 700mm. this saw is best suited
for hard woods.

Rip saw: It is used to cut the wood along the grain. The number of teeth per inch is from 3 to 5, its
angles are around 60 º and the blade length is about 700mm.

Panel saw: It is similar to cross cut saw and is used with preference to cross cut saw for accurate
work. The blade is finer with 10 to 12 teeth per inch and the length is about 500mm.

Tenon or Back saw: It is used to make short straight cuts, to do finer work than the cross cut saw
and panel saws, for the cutting of shoulders to tenons and when a clean cut is required. It is
generally has 13 teeth per inch and 250mm to 400mm.

Dovetail saw: It is used to perform very fine work and dovetails. It is a smaller version of the
tenon saw having about 20 teeth per inch and 200mm to 300mm long.

Bow saw: It is used to cut quick and sharp curve. It is 200mm to 350mm long and the width of the
blade is around 3mm to 12mm.

Coping saw: It is used to cut small radius curves, light work and special shapes. It consists of a
thin narrow blade fixed in a metal frame, tightened by screw. The blade is fixed such that the teeth
point towards the handle.

Compass saw: It is used to cut small curves in a restrained space. One model has a narrow tapered
blade about 250mm to 400mm long fixed to open type wooden handle. The other has one or more
blades that are fitted to the handle with a specified gap.

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Keyhole or Pad saw: It is used to make keyholes and similar kind of curved work. The blade
tapers in width from 10mm to 6mm and is about 250mm long. The teeth are parallel to bow saw.

Chisels
Chisels are the cutting tools for cutting joints and shaping the wood where the jack plane
cannot be used. It is made up of forged steel or tool steel blade. It is one of the oldest tools in
carpentry. The main parts of a chisel are

Handle: It is made of box wood / ash / high density plastic / nylon. It is so designed such
that it provides firm grip and easy hold.

Tang: It locates the chisel in its handle.

Ferrule: It prevents splitting of the handle.

Cutting edge: It is the sharp edge of the cutting tool where the cut is made.

Shoulder: It prevents the tang from moving further into the handle.

Firmer chisel: It is the most widely used chisel. The word “firmer” means “stronger”. It is
stronger than other chisels. It is used for both lighter and hard work.

Mortise chisel: It is used to cut rectangular mortise. One face of the blade is plain surface and the
other is gradually tapered towards the cutting edge. The blade is strong to withstand the heavy
blow of the mallet.

Parting chisel: It is similar to the firmer chisel but is longer and thinner. It is used for deep and
parting work. It should not be hit with mallet, but hand force only.

Dovetail chisel: It is used for fine finishing of dovetails and other V shaped grooves. Its blade is
beveled and has minimum thickness at the rear face.

Socket chisel: It is similar to mortise chisel and used for general cutting work. Its blade has a
socket so that the handle can be attached and detached and to prevent the handle from breaking.

Gouges: It is used for scooping and cutting round or curved surfaces. There are two types of
gouges, they are (i) Inside Gouge and (ii) Outside Gouge. Inside gouge is used for internal or
concave curves and the outside gouge is used for other types of curves.

Axe
The Axe is a cutting tool for cutting the wood into pieces. It is made of carbon steel with
hardening and tempering heat treatment.

The Side Axe is a cutting tool for making the surface of the wood approximately planer. It
is a L shaped one with the outer face is plane and the opposite face is tapered to form finer cutting
edge.
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 The Adze is a cutting tool to chop excess wood and to produce inward or concave curves.
It is similar to the side axe but it is a curved one and the inner face is a beveled one to form cutting
edge.

PLANNING TOOLS

It is a hand tool that is generally used for smoothening, shaping or to remove the saw cut
marks on the wood. It has a chisel or cutting edge fixed firmly to a wooden block or metal body,
which cuts or shears the wood. The various types of planes are

1. Jack plane
2. Metal jack plane
3. Trying plane
4. Smoothing plane

Jack plane: It is the generally used plane in carpentry. It consists of a wooden body that has an
opening or slot at the middle. The bottom face, which is in contact with the wood, is called sole. At
the rear end of the block there is a handle to hold. In the slot the cutting iron is fitted, which
actually makes the cut, supported by a back iron. The cutting iron has a slot and the back iron has
a screw. With the help of the screw the stiffness of the cutting iron can be increased. To tighten the
cutting iron there is a wedge. The distance of the edge of the cutting iron protruding beyond that of
the back iron is called the set of the iron and it depends on the nature of the wood to be planed.
Here the cutting is taking place by means of shearing. The shear thickness of the wooden chip
depends on the protrusion length of the cutting iron. It can be set by adjusting the cutting iron in
conjunction with the wedge. The set is approximately 3mm for the soft wood and 1.5mm for the
hard wood. The jack planes are available from 350mm to 425mm in length and the width of the
cutting iron from 50mm to 75mm.

Metal Jack plane: Since the main body here is made of metal or alloy it is called metal jack plane.
The material can be cast iron, cast steel, gun metal or aluminium or its alloy. The metal jack plane
is more robust and gives high degree of surface finish, but is more expensive than wooden jack
plane. It consists of a metal casting which forms the sole of the plane and has a knob at the front
and a handle at the rear for easy working. It has a rectangular slot through which the cutting iron
protrudes.

Trying plane: It is similar to the jack plane, but it is larger in size. It is used for squaring and
planning the larger surfaces and is used for precision work. It has a length ranging from 550mm to
650mm and a cutting iron width of 60mm.

Smoothing plane: It is similar to the jack plane, but it is smaller in size. It is used for smoothing
the surface of the wood after the jack plane or trying plane has been used. It is also called as
finishing plane. This smoothing plane is used for planning end grain, chamfering, edge shaping,
cleaning up and for working on small sizes of wood.

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BORING TOOLS

It is to make holes on wood in carpentry. Several type of boring tools are used based on the
size of the hole, nature of wood, depth of the hole, etc… and they are as follows

1. Brace – Ratchet Brace and Wheel Brace

2. Gimlet
3. Auger bit
4. Bradawl
5. Shell bit
6. Expanding bit
7. Centre bit
8. Countersink bit

Brace: The brace is a tool to hold and turn tool bit to make holes. There are two types of braces
commonly used in carpentry; they are (1) Ratchet Brace and (2) Wheel Brace. The ratchet brace
consists of a steel crank having a wooden head at the top, for holding, and wooden handle, at the
crank, and a chuck to hold the tool bit at the bottom. The wheel brace is having a shape something
like a crank shaft and the handle is fitted at the crank pin portion and the chuck is fitted at the
bottom end. The crank and the chuck spindle are connected by bevel gear arrangement so that the
rotation of the crank can in turn rotate the chuck to make holes.
Gimlet: It is used for making small holes in wood. There are two types of gimlet: (1) Plain gimlet
and (2) Twisted gimlet. It has a flute and a wooden handle to hold. The screw point at the bottom
acts as a pilot and helps in centering the tool.

Auger bit: It is used to make a deep, accurate and clean hole across the grains of the wood. It can
make holes up to 25mm diameter.

Bradawl: It is used for boring small holes in soft wood. The hole can be made either by hand
pressure or by using a mallet.

Shell bit: It is used to bore holes up to 12mm diameter that does not require high degree of finish.

Expanding bit: It is used to make holes of any size between certain ranges of values. These bits
are available in different sizes varying from 12mm to 35mm diameter.

Centre bit: It is used to form holes in wood across the grains. Its size varies from 5mm to 50mm
diameter.

Countersink bit: It is used to shape a hole to fit / seat the head of a countersunk headed screw.
The snail countersink bit is used on wood only, whereas the rose counter sink bit is used on wood,
plastic and metals.

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STRIKING TOOLS
The striking tools include hammers and mallet. The two types of hammers used in
carpentry are (1) Claw hammer and (2) Cross peen or Warrington hammer.
Claw hammer: It is used for heavy works. It is made of steel and has head at one end and a claw
at the other end. The head is used to drive nails and the claw is used to pull out nails from wood. It
is identified by its weight, which ranges from 250g to 675g.
Cross peen or Warrington hammer: It is used for general works and light hammering. It is made
of forged carbon steel. It has a head at one end and a peen at the other end. The cross peen is used
for driving small nails and is also used for pressing small inlays and veneers into correct position.
The handle is made of bamboo. It is identified by its weight, which ranges from 200g to 450g.

Mallet: It is used for giving light blows to the cutting tools having wooded handles. It is a wooden
headed hammer of round cross section. The surface of the striking face is flat. The traditional
wood working mallet has a square head on a papered handle.

Carpenter’s bench vice: The bench ice is fixed to the carpenter’s bench on which the work is
done. It has two jaws; one is fixed to the side to the side of the table whereas the other is kept
movable by means of a square threaded screw operated by a handle. It has guide rods to keep the
jaws parallel. It can be specified by the width of the jaws and the distance it can open.

Bench stop: It is a simple straight flat wood having two projected rectangular sections of wood
fixed on the carpenter’s table. It prevents the work piece from moving forward while planning or
other wood working.

C-cramp or G-cramp: It is called as C-cramp or G-cramp because of its shape. It consists of an

iron frame / jaw and a crew with a handle rod. To hold the work piece, after keeping it on the table,
one jaw is butt with the top face of the work piece and the other jaw is butt with the bottom face of
the table, by way of tightening it.

CARPENTRY PROCESSES
The carpentry work involves variety of operations to finish the work piece to get required
shape and size. The carpentry operations are

Marking – is to set / mark dimensions on the wood for producing required shape.
Sawing – is cutting the wood to required size along, across or inclined to the grain.
Planning – is the operation of truing up the wood.
Chiseling – is the process of cutting a small stock of wood to get desired shape.
Boring – is to make holes either through or blind holes.
Mortising – is to produce rectangular holes.
Grooving – is making grooves and tongues to join the wood.
Rebating – is making a rebate or recess taken out of the edge of a piece of wood.
Moulding – is the process of cutting concave, convex and other curved surfaces.
Recessing – is the process of making blind holes in wood.

RESULT:

Thus the various carpentry tools, joints and processes are studied.
31
PLANING

32
Ex.No: PLANING Date:

Aim:

To plane the given work piece to the required size and shape.

Materials Required:

Soft wood – Silver wood

Tools required:

1. Steel rule 2. Try-square 3. Jack plane

4. Firmer Chisel 5. Mortise Chisel 6. Mallet
7. Rip Saw 8. Tenon Saw 9. Calipers
10. Marking Gauge

Sequence of operations:

1. Rough Planing 2. Marking

3. Cutting or Sawing 4. Finish Planing

Procedure:

1. The given work piece is clamped in the carpentry vice and two adjacent faces are planed to
get right angles, using jack plane.
2. The right angle is then checked by using try square.
3. With the finished faces as reference the required size is marked on the work piece by
means of steel rule and marking gauge.
4. Jack plane is used to plane the other two faces up to the markings.
5. The faces are again checked by try square and then the dimensions are verified using steel
rule.

Result:

The work piece is planed as per the required dimensions.

33
TEE HALVING / MIDDLE LAP JOINT

34
Ex.No: TEE HALVING (MIDDLE LAP) JOINT Date:

Aim:

To make a Tee Halving or Middle Lap-joint from the given work piece.

Materials Required:

Soft wood – Silver wood

Tools required:

1. Steel rule 2. Try-square 3. Jack plane

4. Firmer Chisel 5. Mortise Chisel 6. Mallet
7. Rip Saw 8. Tenon Saw 9. Calipers
10. Marking Gauge

Sequence of operations:

1. Planing 2. Marking 3. Sawing

4. Chiseling 5. Fitting

Procedure:

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

Result:

The tee halving / middle lap joint, with required dimensions, is made from the given work
piece using carpentry tools.

35
DOVETAIL JOINT

36
Ex.No: DOVETAIL JOINT Date:

Aim:

To make Dovetail Joint from the given work piece.

Materials Required:

Soft wood – Silver wood

Tools required:

1. Steel rule 2. Try-square 3. Jack plane

4. Firmer Chisel 5. Mortise Chisel 6. Mallet
7. Rip Saw 8. Tenon Saw 9. Calipers
10. Marking Gauge 11. Bevel Square 12. Parting Chisel

Sequence of operations:

1. Planing 2. Marking 3. Sawing

4. Chiseling 5. Fitting

Procedure:

1. The given work piece is clamped in the carpentry vice and two adjacent faces are planed to
get right angles, using jack plane.
2. The work piece is cut into two halves using rip saw.
3. With the finished faces as reference the required size is marked on the two halves using
steel rule, bevel square and marking gauge.
4. In one half, a tapered peg is made with the help of firmer and parting chisels.
5. In the other half a dovetail slot is cut with firmer chisel.
6. The finished work piece is checked for dimensions using steel rule and try square.
7. Finally the two pieces are assembled and fitting is checked.

Result:

The Dovetail joint, with required dimensions, is made from the given work piece using
carpentry tools.

37
38
Ex.No: STUDY OF WELDING Date:

Welding is the process of joining similar metals by the application of heat, with or without
application of pressure of filler metal, in such a way that the joint is equivalent in composition and
characteristics of metals joined.

The various welding processes are:

 Electric arc welding

 Gas welding
 Thermit welding
 Resistance welding and

However, only electric arc and gas welding are discussed here. In either process, the work pieces
are melted along a common edge, to their melting point and then a filler metal is introduced to
form the joint on solidification. The materials to be welded must be free from rust, scale, oil or
other impurities, so as to obtain a sound weld.

ARC WELDING

It is the process of joining two metals by melting their edges by an electric arc using filler
rod without the application of pressure. This process is also called Electric Arc Welding. The
filler rod is called electrode, which has a flux coating. The filler rod (welding rod) melts on the
electric arc produced and welds the metal plates. Electric arc welding is widely used to join metal
plates using a filler rod.

Arc Welding Procedure

1. The surface to be welded is cleaned and the edges of the plates may be filed for perfect
joint and more strength.
2. The welding rod is held in the electrode holder and the ground clamp is clamped to the
plate to be welded.
3. The electric arc produced melts the welding rod and joins the two metal plates. Maintain a
gap of 3mm between the plate and the welding rod.
4. Complete the welding process by removing slag using chipping hammer.

Arc welding set up

For the electric arc welding set up the following equipments are necessary.

 An A.C. Transformer or a D.C. Transformer

 Electrode or Filler rod
 Electrode holder
 Welding cables
39
40
  Ground clamp
 Safety devices like face shield, hand gloves etc.
 Other devices like chipping hammer, wire brush, tongs etc.

1. An A.C. Transformer or a D.C. Transformer

An A.C. transformer or a D.C. transformer is used for supplying current. The arc
temperature can be increased or decreased by employing high or low current. Both alternating
current and direct current can be used for arc welding.

2. Electrode or Filler rod

Filler rods used in arc welding are called electrodes. These are made of metallic wire called
core wire. It can be consumable or non-consumable type. An electrode is called consumable
electrode when the electrode itself melts and joins with the molten metal. In the case of non-
consumable electrodes, they do not melt.

3. Electrode holder

It is a device used for mechanically holding the electrode and conducting current to it.
Electrode holder should be light, to minimize fatigue incurred by the welder.

4. Welding cables

Two welding cables are required, one from the machine to the electrode holder and the
other, from the machine to the ground clamp. Flexible cables are usually preferred because of the
ease of using and coiling the cables.

5. Ground clamp

It is connected to the end of the ground cable and is clamped to the work or welding table
to complete the electric circuit. It should be strong and durable and give a low resistance
connection.

6. Safety devices

Face Shield: A face shield is used to protect the eyes and face from the rays of the arc and
from scatter or flying particles of hot metal. It is available either in hand or helmet type.

Hand Gloves: Hand gloves are used to protect the hands from electric shock, arc radiation
and hot spatters.

41
 7. Other devices

Wire Brush and Chipping Hammer: A wire brush is used for cleaning and preparing the
work for welding. A chipping hammer is used for removing slag formation on welds. It is
generally made of tool steel.

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

GAS WELDING

Gas welding is a process in which the required heat to melt the surfaces is supplied by a
high temperature flame obtained by a mixture of two gases. Usually the mixture of oxygen and
acetylene is used for welding purpose. The filler rod and parent metal plates are melted by the heat
of the flame produced using oxygen and acetylene gas mixture. Gas welding is also widely used to
join metal plates.
Gas Welding Procedure

1. The surface to be welded is cleaned.

2. Open the acetylene and oxygen cylinder valve slowly, and then open the acetylene valve in
the torch. Keep the tip of the torch away from body and light it using lighter. Open oxygen
and acetylene valves in torch slowly to get the required flame for welding.
3. Maintain a gap of 3mm between the plate to be welded and the inner cone of the flame.
The torch and filler rod are moved backwards along the line to be welded.

Gas welding setup

The different equipments present in gas welding set up are

42
  Gas cylinder
 Pressure regulator
 Pressure gauges
 Welding torch
 Hoses
 Other accessories like goggles, welding rod, spark lighter, apron etc.

1. Gas cylinder

For gas welding, oxygen and acetylene are needed. These two gases are stored in separate
cylinders. Oxygen cylinder is generally painted black; the acetylene is painted with maroon.

2. Pressure regulator

There are two pressure regulators used in gas welding. There is one regulator in the oxygen
cylinder and another in the acetylene cylinder. The regulators are used to regulate and control the
working pressure of the gases.

3. Pressure gauges

There are two pressure gauges, one in the oxygen cylinder and the other in the acetylene
cylinder. One pressure gauge will show the cylinder pressure. The other one shows the welding
working pressure.

4. Welding torch

Welding torch is used to mix the gases in proper proportion. Oxygen and acetylene enter
the torch from the respective hoses in separate passages. Both the gases mix in the mixing chamber
of the torch. When ignited, a flam is produced at the tip of the torch. The tip of the welding torch
can be changed according to the thickness of metal.

5. Hoses

Both oxygen and acetylene gases can be satisfactorily piped through the reinforced flexible
rubber hoses. The green hose is commonly used to carry oxygen and the red hose is used to carry
acetylene.

6. Other devices

Goggles: Chipping goggles are used to protect the eyes while chipping the slag.

43
44
 Welding Rods: For oxy-acetylene gas welding, filler rods are not coated with flux.
However they are applied separately. Mild steel welding rods are usually copper coated to prevent
rusting. Cast iron rods are square shaped. Brazing rods are made of brass or bronze. They are
usually one metre long. Welding rod size increases as the metal thickness to be joined increases.

Types of Flames:

Neutral Flame: When oxygen and acetylene are supplied to the torch in nearly equal volumes, a
neutral flame is produced having a maximum temperature of 3200ºC. The neutral flame is widely
used for welding steel, stainless steel, cast iron, copper, aluminium, etc.

Oxidizing Flame: Oxidising flame with excess of oxygen is used for welding brass.

Reducing Flame or Carburising Flame: Carburising flame produced with an excess of

acetylene, is needed for welding lead.

WELDING TECHNIQUES:

There are two techniques in gas welding depending upon the ways in which the welding rod and
the welding torch are used.

1. Leftward Technique (or) Forehand welding method:

 Welding is done in a right to left direction.

 In this process, the welding flame is directed away from the finished weld i.e., the flame
follows the completed bead and the filler rod.
 Suitable for up to 3mm thick sheets and for other general purpose applications.

2. Rightward Technique (or) Backward welding method:

 In this welding process, the welding is done in a left to right direction.

 The filler rod follows the welding torch and the flame.
 Suitable for large size jobs.

WELDING JOINTS:

They are Butt joint, Corner joint, Lap joint and Edge joint. In this welding is done on top,
so that gravity helps pull the molten metal into the joint.

RESULT:

Thus the various types of welding process and the tools used for welding are studied.

45
SQUARE BUTT JOINT

46
Ex.No: SQUARE BUTT JOINT Date:

Aim:

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

Materials Required:

Two mild steel (MS) strips of size 100mm X 50mm and thickness 5mm.

Tools Required:
1. Welding transformer 2. Welding Electrodes 3. Electrode holder
4. Gloves & Apron 5. Hand Shield Goggles 6. Flat file
7. Tongs & Wire brush 8. Chipping Hammer 9. Earthing Clamps

Sequence of operations:

1. Edge preparation 2. Positioning 3. Tacking 4. Welding

5. Cooling 6. Chipping 7. Cleaning

Procedure:

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

Result:

Thus, the required square butt joint is obtained by arc welding process.

47
LAP JOINT

48
Ex.No: LAP JOINT Date:

Aim:

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

Materials Required:

Two mild steel (MS) strips of size 100mm X 50mm and thickness 5mm.

Tools Required:
1. Welding transformer 2. Welding Electrodes 3. Electrode holder
4. Gloves & Apron 5. Hand Shield Goggles 6. Flat file
7. Tongs & Wire brush 8. Chipping Hammer 9. Earthing Clamps

Sequence of operations:

1. Edge preparation 2. Positioning 3. Tacking 4. Welding

5. Cooling 6. Chipping 7. Cleaning

Procedure:

1. The given work pieces are through cleaned of rust, scale and other foreign material.
2. The electrode is fitted in the electrode holder and the welding current is set to a proper
value.
3. Appropriate power supply should be given to the electrode and the work pieces.
4. When the current is passed, arc is produced between the electrode and work pieces.
5. Now, set two work pieces in correct position as shown in the figure and maintain the gap
3mm. then carry out the welding throughout the length.
6. As soon as the welding process is finished, switch off the current supply and drop the work
piece into water for cooling using tongs.
7. Finally, take the work piece and remove the slags using the chipping hammer and wire
brush.

Result:

Thus, the required lap joint is obtained by arc welding process.

49
TEE - FILLET JOINT

50
Ex.No: TEE - FILLET JOINT Date:

Aim:

To make the Tee – fillet joint using arc welding on the given work pieces.

Materials Required:

Two mild steel (MS) strips of size 100mm X 50mm and thickness 5mm.

Tools Required:
1. Welding transformer 2. Welding Electrodes 3. Electrode holder
4. Gloves & Apron 5. Hand Shield Goggles 6. Flat file
7. Tongs & Wire brush 8. Chipping Hammer 9. Earthing Clamps

Sequence of operations:

1. Edge preparation 2. Positioning 3. Tacking 4. Welding

5. Cooling 6. Chipping 7. Cleaning

Procedure:

1. The given work pieces are through cleaned of rust, scale and other foreign material.
2. The electrode is fitted in the electrode holder and the welding current is set to a proper
value.
3. Appropriate power supply should be given to the electrode and the work pieces.
4. When the current is passed, arc is produced between the electrode and work pieces.
5. Now, set two work pieces in correct position as shown in the figure and maintain the gap
3mm. then carry out the welding throughout the length.
6. As soon as the welding process is finished, switch off the current supply and drop the work
piece into water for cooling using tongs.
7. Finally, take the work piece and remove the slags using the chipping hammer and wire
brush.

Result:

Thus, the required Tee – fillet joint is obtained by arc welding process.

51
Ex.No: STUDY OF LATHE & DRILLING MACHINES Date:

Aim:
To study about the Lathe & Drilling machines.

LATHE

Lathe is the father of all machine tools. It is a basic machine tool, probably the most
important one of all. Lathe was actually the first machine tool, the history of which dates back to
18th century. Later development led to a number of amendments, as year’s passes, and the result is
what we see today. Further, lathe formed the basis of production of all other machine tools which
are the results to later developments.

Working Principle:

The lathe is a machine tool which holds the work piece between two rigid and strong
supports called centers or in a chuck or face plate which revolves. The cutting tool is rigidly held
and supported in a tool post which is fed against the revolving work. The normal cutting
operations are performed with the cutting tool fed either parallel or at right angles to the axis of the
work.

The cutting tool may also be fed at an angle relative to the axis of work for machining tapers and
angles.

Construction: The main parts of the lathe are the bed, headstock, quick changing gear box,
carriage and tailstock.

1. Bed: The bed is a heavy, rugged casting in which are mounted the working parts of the lathe. It
carries the headstock and tail stock for supporting the work piece and provides a base for the
movement of carriage assembly which carries the tool.

2. Legs: The legs carry the entire load of machine and are firmly secured to floor by foundation
bolts.

3. Headstock: The headstock is clamped on the left hand side of the bed and it serves as housing
for the driving pulleys, back gears, headstock spindle, live centre and the feed reverse gear. The
headstock spindle is a hollow cylindrical shaft that provides a drive from the motor to work
holding devices.

52
4. Gear Box: The quick-change gear-box is placed below the headstock and contains a number of
different sized gears.
Principle parts of Lathe

5. Carriage: The carriage is located between the headstock and tailstock and serves the purpose of
supporting, guiding and feeding the tool against the job during operation. The main parts of
carriage are:

a) The saddle is an H-shaped casting mounted on the top of lathe ways. It provides support
to cross-slide, compound rest and tool post.

b) The cross slide is mounted on the top of saddle, and it provides a mounted or automatic
cross movement for the cutting tool.

c) The compound rest is fitted on the top of cross slide and is used to support the tool post
and the cutting tool.

d) The tool post is mounted on the compound rest, and it rigidly clamps the cutting tool or
tool holder at the proper height relative to the work centre line.

e) The apron is fastened to the saddle and it houses the gears, clutches and levers required
to move the carriage or cross slide. The engagement of split nut lever and the automatic feed lever
at the same time is prevented she carriage along the lathe bed.

6. Tailstock: The tailstock is a movable casting located opposite the headstock on the ways of the
bed. The tailstock can slide along the bed to accommodate different lengths of work piece between
the centers. A tailstock clamp is provided to lock the tailstock at any desired position. The tailstock

53
spindle has an internal taper to hold the dead centre and the tapered shank tools such as reamers
and drills.

7. Feed Mechanism: The movement of the tool relative to the work piece is termed as ‘feed’. The
lathe tool can be given three types of feed namely, longitudinal, cross and angular.

When the tool moves parallel to the axis of the lathe, the movement is called longitudinal
feed. This is achieved by moving the carriage.

When the tool moves at an angle to the axis of the lathe, the movement is called angular
feed. This is achieved by moving the compound slide, after swiveling it at an angle to the lathe.

Feed rod: The feed rod is a long shaft, used to move the carriage or cross-slide for turning,
facing, boring and all other operations except thread cutting. Power is transmitted from the lathe
spindle to the apron gears through the feed rod via, a large number of gears.

8. Thread cutting Mechanism: The lead screw is a long threaded shaft used as a master screw
and brought into operation only when threads have to be cut. In all other times the lead screw is
disengaged from the gear box and remains stationary. The rotation of the lead screw is used to
traverse the tool along the work to produce screw threads. The half-nut makes the carriage to
engage or disengage the lead screw.

Types of Lathe:

There are various types of lathe differing in size, design, purpose and method of drive.

1. Speed lathe
2. Engine lathe or Centre lathe
3. Bench lathe
4. Tool room lathe

LATHE OPERATIONS:

Facing, Turning, Taper Turning, Knurling, Chamfering, Drilling, Boring, Parting Off,
Forming, Threading, Grooving, etc

DRILLING

Drilling is the operation of producing circular hole in the work-piece by using a rotating
cutter called DRILL.

 The machine used for drilling is called drilling machine.

 The drilling operation can also be accomplished in lathe, in which the drill is held in
tailstock and the work is held by the chuck.
 The most common drill used is the twist drill.

54
Drilling Machine

 It is the simplest and accurate machine used in production shop.

 The work piece is held stationary i.e., Clamped in position and the drill rotates to make
a hole.

Types of Drilling Machines:

Drilling machines are classified according to the construction and the work performed.

1. Portable Drilling Machine

2. Sensitive Drilling Machine
3. Radial Drilling Machine
4. Up-right Drilling Machine
5. Gang Drilling Machine
6. Multi-spindle Drilling Machine

Components of Drilling Machine:

Spindle: The spindle holds the drill or cutting tools and revolves in a fixed position in a sleeve.

Sleeve: The sleeve or quill assembly does not revolve but may slide in its bearing in a direction
parallel to its axis. When the sleeve carrying the spindle with a cutting tool is lowered, the cutting
tool is fed into the work: and when it’s moved upward, the cutting tool is withdrawn from the
work. Feed pressure applied to the sleeve by hand or power causes the revolving drill to cut its
way into the work a fraction of an mm per revolution.

Column: The column is cylindrical in shape and built rugged and solid. The column supports the
head and the sleeve or quill assembly.

Head: The head of the drilling machine is composed of the sleeve, a spindle, an electric motor and
feed mechanism. The head is bolted to the column.

Worktable: The worktable is supported on an arm mounted to the column. The worktable can be
adjusted vertically to accommodate different heights of work or it can be swung completely out of
the way. It may be tilted up to 90 degree in either direction, to allow long pieces to be end or angle
drilled.

Base: The base of the drilling machine supports the entire machine and when bolted to the floor,
provides for vibration-free operation and best machining accuracy. The top of the base is similar to
the worktable and may be equipped with t- slot for mounting work too large for the table.

Hand Feed: The hand- feed drilling machines are the simplest and most common type of drilling
machines in use today. These are light duty machine that are operated by the operator, using a feed
handled, so that the operator is able to “feel” the action of the cutting tool as it cuts through the
work piece. These drilling machines can be bench or floor mounted.
55
Power feed: The power feed drilling machine are usually larger and heavier than the hand feed
ones they are equipped with the ability to feed the cutting tool in to the work automatically, at
preset depth of cut per revolution of the spindle these machines are used in maintenance for
medium duty work or the work that uses large drills that require power feed larger work pieces are
usually clamped directly to the table or base using t –bolts and clamps by a small work places are
held in a vise. A depth – stop mechanism is located on the head, near the spindle, to aid in drilling
to a precise depth.

Sensitive or Bench Drilling Machine:

 This type of drill machine is used for very light works.

 The vertical column carries a swiveling table the height of which can be adjusted according
to the work piece height.
 The table can also be swung to any desired position.
 At the top of the column there are two pulleys connected by a belt, one pulley is mounted
on the motor shaft and other on the machine spindle.
 Vertical movement to the spindle is given by the feed handle by the operator.
 Operator senses the cutting action so sensitive drilling machine.
 Drill holes from 1.5 to 15mm

Sensitive Drilling
Machine

56
Radial Drilling Machine:

 It the largest and most versatile used for drilling medium to large and heavy work pieces.
 Radial drilling machine belong to power feed type.
 The column and radial drilling machine supports the radial arm, drill head and motor.
 The radial arm slides up and down on the column with the help of elevating screw provided
on the side of the column, which is driven by a motor.
 The drill head is mounted on the radial arm and moves on the guide ways provided the
radial arm can also be swiveled around the column.
 Feed can be either manual or automatic with reversal mechanism.
 The drill head is equipped with a separate motor to drive the spindle, which carries the drill
bit. A drill head may be moved on the arm manually or by power.

Radial Drilling Machine

Result:

Thus the various parts and the mechanism of Lathe and Drilling Machines are studied.

57
58
Ex.No: TURNING & FACING Date:

Aim:

To make a plain turning and facing on a given work piece as per the required dimension
using the lathe.

Materials required:

MS rod of size 25mm X 75mm.

Tools required:

1. Single point cutting tool (HSS) 2. Vernier caliper 3. Chuck key

4. Surface gauge 5. Tool post key

Procedure:

1. The dimensions of the given work piece were checked, as per the requirement.
2. The work piece is fixed on the lathe chuck. It is centered by using surface gauge, if the
lathe is fitted with four jaw chuck.
3. The cutting tool is fixed on the tool post and the center height is checked.
4. The cutting tool is tilted by 30º for facing operation.
5. Then the cutting tool is tilted perpendicular to the work piece for turning operation after
getting the required length.
6. The turning operation is repeated till to get the required dimension by giving the gradual
depth of cut and feed.
7. The dimensions are checked using vernier caliper, as per the specification.

Result:

Thus the given work piece is machined as per the dimensions required by means of turning
and facing operation using lathe.

59
60
Ex.No: STEP TURNING AND CHAMFERING Date:

Aim:

To make a step turning and chamfering on a given work piece as per the required
dimension using the lathe.

Materials required:

MS rod of size 25mm X 75mm.

Tools required:

1. Single point cutting tool (HSS) 2. Vernier caliper 3. Chuck key

4. Surface gauge 5. Tool post key

Procedure:

1. The dimensions of the given work piece were checked, as per the requirement.
2. The work piece is fixed on the lathe chuck. It is centered by using surface gauge, if the
lathe is fitted with four jaw chuck.
3. The cutting tool is fixed on the tool post and the center height is checked.
4. The cutting tool is tilted by 30º for facing operation.
5. Then the cutting tool is tilted by 45º for chamfering operation in order to avoid the sharp
corners.
6. Then the cutting tool is tilted perpendicular to the work piece for turning operation after
getting the required length.
7. The step turning operation is repeated till to get the accurate dimension by giving the
gradual depth of cut and feed.
8. The dimensions are checked using vernier caliper, as per the specification.

Result:

Thus the given work piece is machined as per the dimensions required by means of step
turning and chamfering operation using lathe.

61
62
Ex.No: DRILLING AND TAPPING Date:

Aim:

To make a drilling and an internal thread on a given work piece as per the required
dimension using drilling machine and tapping tool.

Materials required:

MS square rod of size 25mm X 50mm.

Tools required:

1. Drill bits 2. Tapping tool 3. Drill chuck 4. Dot punch

5. Hammer 6. Steel rule 7. Scriber 8. Drill chuck key

Procedure:

1. The dimensions of the given work piece were checked, as per the requirement.
2. The marking is done on the work piece using dot punch and hammer.
3. The work piece is fitted into the vice.
4. Drill chuck is fitted in the drill head with a drill bit of size smaller than the required size.
5. Then the required size hole is made.
6. During the drilling operation coolant is used to avoid the excessive temperature variation.
7. Then the internal thread is made using tapping tool.

Result:

Thus the drilling and internal thread is made on a given work piece as per the dimensions
required using drilling machine and tapping tool.

63
Ex.No: STUDY OF SHEET METAL WORK Date:

Aim:
To study about the tools and the operations in Sheet Metal work.

Introduction: Sheet metal work deals with working on the metal of 16-30 gauges, with hand tools
and simple machines. It is one of the major applications in engineering industry. It has its own
significance as useful trade in engineering work. Sheet works such as making a tray, box, funnel,
chimney, air duct, fabricated boiler shells and pipe joints from thin or thick plates, etc. are few
examples of its application. For successful working in the trade, one should have a thorough
knowledge of projective geometry and development of surfaces.

Parallel line Method:

This method is used to make the prismatic and cylindrical objects from the sheet metal, in
which the lines drawn, representing the different elements of the surfaces, are parallel to each
other. The figure shows the full development of the solids under this type (here it is a square prism
and cylinder). To make this square prism, first get the side length and height. Then for the side
surfaces draw four rectangles, each of size side x height. Draw two squares for the top and bottom
portions that complete the development of the prism. The development of the cylinder is a
rectangle of size = circumference x height. If this is rolled then the shape of the cylinder is
obtained.

Radial line Method:

This type is employed in the case of pyramids and cones in which the true length of the
slant edge or the extreme generator is used as radius. The figure shows the full development of the
solids under this type. In case of pyramid first find out the slant length of it. With that as radius
draw an arc. On that mark four divisions (since here it is a square pyramid) and draw lines joining
these points and also with the centre of the first arc, that completes the development of the side
surfaces of the object.

For the base draw square of size equal to side. The development of the cone is a sector of size R
and Ө such that

Ө = ( r / R ) x 360 degrees

Where Ө = subtended angle of the sector

r = base radius of the cone
R = slant height of the cone
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For the base, the development is a circle of radius r.

Triangulation Method:

The triangulation method is used for transition pieces. Pipes are used in many places to
convey fluids. When two different sizes and shapes of pipes are joined using special pipe joint, it is
known as transition piece. Transition means change. In this method all the surfaces are divided
into a number of suitable triangles, opened and laid out side by side after finding the true length of
each side of the triangle.

Metals used in sheet metal work:

Commonly used metals in sheet metal work are black iron, galvanized iron, stainless steel,
copper, aluminium, lead and tin plate. These sheets are specified by standard wire gauge (SWG).
Each wire gauge designated a definite thickness.
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S.W.G 10 12 14 16 18 20 22 24 26 30

Thickness 3.2 2.6 2.0 1.6 1.2 0.9 0.7 0.5 0.4 0.3
in mm

Sheet metal tools:

Steel Rule: It is used to measure and mark dimensions. It is graduated on both sides in millimeters
and centimeters or inches.

Divider: It is used in sheet metal jobs for circle marking. With the divider we can also do marking
the parts of the job.

Steel Square: It is used for checking the right angles of the jobs.

Trammel: It is used to draw large circles and arcs. This is also marking tool.
Wire Gauge: The thickness of sheet metal is referred in numbers known as Standard Wire
Gauge (SWG). The gaps in the circumference of the gauge are used to check the gauge number.

Bench Shear: Sheet metal may be cut by shearing action. In this, the force is applied through a
compound lever, making it possible to cut sheet metal up to 4mm thick.

Snips: This tool is used for cutting thin metal sheets, before or after marking, according to the
jobs, is called snips. The straight snip is used for cutting along outside curves and straight lines and
curved snip or bent snip is for trimming along inside curves.

Hammers: Light weight hammers and mallets are used in sheet metal work. Ball-peen hammer
has a cylindrical, slightly curved face and a ball head. It s a general purpose hammer, used mostly
for riveting in sheet metal work. The cross-peen hammer and straight peen hammers are used for
folding the sheet and to work in the corners of the object.

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Mallet: It is used for bending and folding work. It is called as soft hammer. Generally, it is made
of wood.

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Stakes: Stakes are nothing but anvils, which are used as supporting tools and to form, seam, bend
or rivet, sheet metal objects. They are made from wrought iron, faced with steel.

Scriber: This tool is used for marking sheet metal jobs.

Punch: Punch is used in sheet metal jobs for punching or deep marking.

Piler: It is used for holding, cutting and bending the sheet metal.

Groovers: It is used for grooving and flattening the seam joint.

Rivet set: It is used to obtain the required shape of the rivet head while riveting.

Chisels: Chisels are used to cut the sheet metal. It is made of high carbon steel or cast tool steel of
octagonal cross section. The various types of chisels are as follows.

Flat or Cold Chisel: It has a wide cutting edge about 20mm to 25mm. It is used for cutting off the
sheet metal.

Round Chisel: It is also used to cut the sheet metal by way of bending action.

SHEET METAL PROCESSES

The various sheet metal processes are cutting off, parting, blanking, punching, notching,
slitting, lancing, nibbing, trimming etc… The most common sheet metal cutting operations are

1. Cutting off – is shearing the sheet by cutting.

2. Parting – the scrap is removed between the two pieces to part them.
3. Blanking – obtaining the components after the holes.
4. Punching – making a hole in the sheet metal.
5. Notching – removing the metal from the side.
6. Slitting – cutting the sheet metal using rotary blades.
7. Lancing – is to make a small cut, but without any removal of sheet metal.
8. Nibbing – cutting any shape from the sheet metal without special tools.
9. Trimming – to cut away excess metal or burrs from the sheet metal.

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 According to the shape of the object, the required type of bend can be identified and
selected. Similarly for obtaining proper shape of the object the sheet metal joints are very much
necessary. Bending operation involves angle bending, roll bending, roll forming and seeming.

Result:

Thus the various sheet metal operations, development methods and the tools used for it are
studied.

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 DEVELOPMENT OF RECTANGULAR TRAY

ALL DIMENSIONS ARE IN mm

Ex.No: DEVELOPMENT OF RECTANGULAR TRAY Date:

70
Aim:
To make a rectangular tray with the given dimension.
Material required:

Galvanized steel sheet.

Tools required:

1. Steel Rule 2. Mallet 3. Ball peen hammer

4. Scriber 5. Straight edge 6. Hand Shear or snip
Sequence of operation:

1. Checking

2. Levelling

3. Marking

4. Cutting

5. Hemming

6. Bending

7. Riveting

Procedure:

1. The dimensions of the given sheets are checked, using steel rule.

2. The sheet is leveled using a mallet and level plate.

3. Suitable markings are done on the given sheet using steel rule.

4. The unwanted materials are removed by using straight snip.

5. Then a single hemming is made on the four sides of the tray as shown in fig.

6. These four sides of the tray are bend to 90° using stakes anvil.

7. Finally the corner of the four tray are joined by riveting.

Result:
The rectangular tray is made with the GI sheet under sheet metal working.
DEVELOPMENT OF A CONE

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 ALL DIMENSIONS ARE IN mm

72
Ex.No: DEVELOPMENT OF A CONE Date:

Aim:

To make a cone with the given dimension.

Material required:

Galvanized steel sheet.

Tools required:

1. Steel Rule 2. Mallet 3. Ball peen hammer 4. Groover

5. Scriber 6. Straight edge 7. Hand Shear or snip

Sequence of operation:

1. Checking

2. Marking on paper

3. Marking on sheet metal

4. Cutting

5. Folding

Procedure:
1. The given sheet metal is taken and checked for its dimensions.
2. The required shape is first produced in a paper which is used for reproducing the exact size
on the sheet metal.
3. Required dimensions are marked on a white sheet of paper.
4. The slanting angle of the sector is calculated by using the formula 360° x (r/L)
5. The required shape is cut from the paper.
6. Then the exact shape of the paper on the GI sheet, so that the same size can be produced on
the metal using scriber.
7. Then sheet is folded using funnel stake such that a cone shape is formed.

Result:
The cone of the required shape is made with the GI sheet under sheet metal working.

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74
Ex.no: STUDY OF CENTRIFUGAL PUMPS & ITS ASSEMBLY SEQUENCE
Aim:
To Study the parts of centrifugal pump and its assembly sequence.
Introduction:
In the olden days, the man has been trying to find out some convenient ways of lifting
water to higher or levels for water supply and irrigation purposes.
A pump, is general may be defined as a machine, when driven from some external source,
lifts water or some other liquid from a lower level to a higher level.
The pump which raises water or a liquid from a lower level to a higher level by the action
of a centrifugal force known as centrifugal pump.
Working principle
The centrifugal pump works on a principle of forced vortex flow which means that when a
certain mass of liquid is rotated by an external torque, the rise in pressure head of the rotating
liquid takes place. The rise in pressure head at any point of the rotating liquid is proportional to the
square tangential velocity of the liquid at that point (i.e. rise in pressure head =V2/2g = w2r2/2g)
thus at outlet of the impeller where radius (r) is more. Due to this pressure head, the liquid can be
lifted to a high level.
Main parts of the centrifugal pump
1. Suction pipe(Nozzle)
2. Impeller
3. Casing (Volute casing, vortex casing and diffuser casing)
4. Delivery pipe (discharge Nozzle)
5. Seal Chamber
6. Shaft
Suction pipe
A Pipe whose one end is connected to inlet of the pump and other end dips into the water
sump is known as suction pipe. A foot valves that is a non –return valve or one-way type of valve
is fitted at the lower end of the suction pipe.
Impeller
The rotating part of a centrifugal pump is known as Impeller .It contains series of curved
vanes. The impeller is mounted and shaft. Which is connected to the shaft of an electric motor,
which runs the pump.
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76
Casing
Casing is an air tight passage surrounding the impeller and is designed such a way that
kinetic energy of the water discharged at outlet of the impeller is converted into pressure energy
before the water leaves the casing and enters into the delivery pipe.
Three common types of casings are,
i) Volute casing ii) Vortex casing and iii) Diffuser casing
Seal Chamber
Seal chamber forms the region between the shaft and casing. Where sealing media are
installed when sealing is achieved by means of mechanical seal, the chamber is commonly referred
by to as a seal chamber. The main function of this sealing is to protect the pump against leakage at
the point where the shaft passes out though the pump pressure casing.
Shaft
Shaft is to transmit torques encountered and to support the impeller and other rotating
parts. This task is done with a deflection less then the minimum clearance between the rotating and
stationary parts.
Assembling sequence of the centrifugal pump:
Step 1: Vortex casing half section is assembled in the shaft.
Step 2: Insert the impeller and fix it in the right place.
Step 3: Another parts of the vortex casing should be assembled.
Step 4: Sealing is fixed in vortex casing suction and discharge nozzle side.
Step 5: Flange are assembled in the suction and delivery nozzle and then it is joint by bolt
and nut.
Step 6: Disassembling can be done by reversing the assembly sequence.

Result:
Thus the parts and assembling of the centrifugal pumps have been studied.

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78
Ex.no:11 Study of Air Conditioning and its Assembly Sequence
11.1Aim:
To study the parts of air conditioner and its assembly sequence.
11.2 Introduction:
The air conditioning system dates back to the middle of nineteenth century, but it was until
the last time decades of that century that a reliable unit was developed. Air conditioning is defined as
conditioning of air for human comfort, food processing, and other industrial purposes.
Air conditioning is a smart system of controlling temperature, humidity, cleanliness of the air
and movement of the air in the conditioned spaces.
The capacity of air conditioning is represented in Ton. One Ton is a heat unit equal to
3000Kcal. Generally, a small domestic air conditioning plant having the capacity range of 0.5 Ton to 3 Ton.
11.3 Types of Air Conditioners:
These are broadly classified as follows.
1. Non-ducted air-conditioning system.
a) Window room air conditioning
b) Split air conditioning
2. Duct able air conditioning
a) Packaged air conditioners
b) Central air conditioning plants
11.4 Window Room Air Conditioner:-
“Window ” air conditioner (also known as “Room” air conditioner) is designed to air condition
only one room. Several window units can be used to air-conditioning an entire residence or even a multi room
commercial building.
11.5 Mechanism and main parts of an Air Conditioner: -
An air conditioning system works on vapour compression cycle or vapour absorption system. Here
we discussed vapour compression system. This cycle works in following four phases.
1. Compression
2. Condensation
3. Expansion
4. Evaporation

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11.5.1 Compression :
Compression is takes place at the compressor. During suction stroke the low pressure. Low
temperature dry refrigerant or coolant vapour is drawn from the evaporator and in compression stroke
pressure and temperature of the vapour increases until the vapour temperature of the condenser-cooling
medium like air or water.
11.5.2 Condensation:
From the compressor, the high pressure and high temperature vapour passes in to the
condenser and rejects heat to cooling medium thus allowing the vapourised refrigerant to return to liquid
state.

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11.5.3 Expansion:
After condenser, the liquid refrigerant is stored in the liquid receiver, then it is passes through
an expansion device (expansion valve). Due to this the high pressure is reduced very much to allow the
vapourisation of liquid at a very low temperature of about -10ºC.
11.5.4 Evaporation:
The low pressure and low temperature refrigerant vapour enters into the evaporator. Here a
considerable amount of heat is absorbed from the surrounding by the refrigerant.
After absorbing heat from the surrounding, the liquid refrigerant changes to vapour state.
Then this vapour again enters in compressor through the suction stroke. Again the vapour compression cycle
is repeated.
11.6 Main Parts of an Air Conditioner are given below:
1. Compressor
2. Condenser
3. Expansion device
4. Evaporator
5. Fans (one for condenser and another for evaporator)
6. Control with display panel (on the front)
11.7 Assembly Sequence:
Step1: Keep the base plate in a comfortable place.
Step2: A compressor should be fixed in a bolt, which already attached in the base plate.
Step3: A condenser should be connected from the compressor with help of muffler.
Step4: Evaporator should be placed as shown in the figure.
Step5: Fan and its assembly should be placed in between evaporator and condenser.
Step6: If needed, the control panel should be kept in the right place.
Step7: Disassembling can be done by reversing the above said process.

11.8 Result:
Thus the parts and assembling of the Air conditioning have been studied.
.
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General Work shop

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Carpentry

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Welding

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Machining

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