V.S.B.

ENGINEERING COLLEGE, KARUR - 639 111

(AFFILIATED TO ANNA UNIVERSITY– CHENNAI)

DEPARTMENT OF MECHANICAL ENGINEERING

GE8261-ENGINEERING PRACTICES LAB MANUAL

(REGULATION - 2017)
ACR 07

1
 GE8261 ENGINEERING PRACTICES LABORATORY
LTPC0042
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

Buildings:
(a) Study of plumbing and carpentry components of residential and industrial buildings.
Safety aspects.

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, planning and cutting.

II MECHANICAL ENGINEERING PRACTICE

Welding:
(a) Preparation of butt joints, lap joints and T- joints by Shielded metal arc welding.
(b) Gas welding practice

Basic Machining:
(a) Simple Turning and Taper turning
(b) Drilling Practice

Sheet Metal Work:

(a) Forming & Bending:
(b) Model making – Trays and funnels.
(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 V – fitting models.

OUTCOMES:
On successful completion of this course, the student will be able to

 Fabricate carpentry components and pipe connections including plumbing works.

 Use welding equipments to join the structures.

 Carry out the basic machining operations

 Make the models using sheet metal works

 Illustrate on centrifugal pump, Air conditioner, operations of smithy, foundary

and fittings

 Carry out basic home electrical works and appliances

 Measure the electrical quantities

 Elaborate on the components, gates, soldering practices.

 LIST OF EXPERIMENTS

Ex. Page Marks

Date Name of the Experiment Signature
No. No. Awarded
Ex. Page Marks
Date Name of the Experiment Signature
No. No. Awarded
EX.NO:
STUDY OF PLUMBING TOOLS AND EQUIPMENTS
Date:

Introduction

Plumbing deals with the laying of a pipeline. A craftsman may be perfectly proficient
with the hammer, saw and other tools, but the faces difficulties with leaking pipes and
overflowing toilets. Many people rush to a plumber on seeking a tripping pipe, but a person
with a little knowledge of the sanitary system can control this problem easily, saving time and,
one with help of few tools.

Plumbing tools

The tools used by a plumber can be classified as follows

1. Pipe wrench 4. Pipe vice 6. Pipe cutter

2. Hacksaw 5. Dies 7.Files and Rasps
3. Plumb bob

Pipe wrench

A pipe wrench is used for holding and turning the pipes, rods and machine parts.
Wrenches are classified as follows.1.Fixed wrenches 2. Adjustable wrenches.

Pipe vice

A pipe vice is fitted on the work bench. This has a set of jaws to grip the pipe and
prevent it from turning while cutting, threading and fitting of bends, couplings etc.
Pipe cutter

The pipe cutter mainly consists of three wheels which are hardened with sharp cutting edges
along their periphery. Of these three wheels, one can be adjusted to any desired distance to
accommodate different size of pipes. After adjusting the cutter on a pipe, it is around the
pipe, so that the cutter wheels cut the pipe along a circle as shown in fig.

Hacksaw

A hacksaw is used for cutting metal rods, bars, pipes, etc.

Threading dies and taps

It is used for cutting external thread on pipes. Threads are produced in various shape

and sizes which are used for fitting inside a handle.

Files and rasps

The file surface is covered with sharp edged teeth and its used for removing metal
by rubbing. A rasp is used for finishing the surface of the work piece.

Plumb bob

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

Pipe fittings
 Pipe fittings are made up of wrought iron. The size of pipe fitting is designated by the size of
the pipe on which it fits. some of the common pipe fittings are shown in fig.

Coupling

It is a short a cylindrical sleeve with internal threads throughout. A couplings is used for
joining two pipes in a straight and bend where at least one pipe can be turned.

Union

A union is used for joining two pieces of pipes, where either can be turned. It consists of
three parts, two parts joint can be screwed, in to two pipe ends, and the third on for tightening called
centre part.

Nipple

A nipple is a short piece of pipe with external threads at both ends. It is used to make up the
required length of a pipe line.

Elbow

An elbow is to make an angle between adjacent pipes.

Tee

A tee is a fitting that has one side outlet at a right angle to the run. It is used for a single
outlet branch pipe.

Reducer

It is used to connect two different sized of pipes

Plug

It is used to screw on to a threaded opening, for closing it temporarily.

Valves

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

9
 1. Gate valve 2.Globe valve

3. Plug valve 4.Check valve 5. Air relief valve.

CONCLUSION:
PLUBING LINE PREPARATION FOR A PUMP
 EX.NO:2 A
PLUBING LINE PREPARATION FOR A PUMP
Date:

AIM
To lay pipe connections in the suction & delivery lie for the given pump.

MATERIAL SUPPLIED

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

PROCEDURE

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

RESULT
PLUMBING LINE PREPARATION FOR A TURBINE
 EX.NO:2B
PLUMBING LINE PREPARATION FOR A TURBINE
Date:

AIM

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

MATERIALS SUPPLIED

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

PROCEDURE

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

RESULT
PREPARATION OF PLUMBING LINE SKETCHES FOR WATER SUPPLY AND SEWAGE
WORKS

Water supply and Sewage plumbing system

 EX.NO:3 PREPARATION OF PLUMBING LINE SKETCHES FOR WATER SUPPLY
Date: AND SEWAGE WORKS

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

Descriptions:
Plumbing line sketch includes pipes, fixtures and accessories which carry water from the main source of
supply to the required user ends. The plumbing line sketches represent the pipe distribution system. There are
different symbols used to represent each component in the piping system. There are two types of piping
drawings.
a) Single line piping drawing
Single line piping drawings use a single line to show the arrangements of the pipe and fittings. The single
line piping drawing is prepared in orthographic or pictorial projections. Orthographic pipe drawings
show single pipe either straight or bent in one plane only. Pictorial projection is used for pipes bending
more than one plane.

b) Double line piping drawing

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

PROCEDURE FOR DRAWING PLUMBING LINE SKETCHES

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

Result:
BASIC PIPE CONNECTIONS INVOLVING THE FITTINGS LIKE VALVES, TAPES AND BENDS
 EX.NO:4 HANDS –ON- EXERCISE BASIC PIPE CONNECTIONS
Date:

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

MATERIALS SUPPLIED

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

PROCEDURE

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

RESULT
 EX.NO:5
STUDY OF THE JOINTS IN ROOFS, DOORS, WINDOWS
Date: AND FURNITURE

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

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

TYPES OF WOODS

Woods are generally classified into three types:

1. Softwood (Deodar, Kail, Chir)
2. Hardwood (Teek, Shirham, Sal, Mango, Oak)
3. Plywood

CARPENTRY TOOLS
 Measuring and Marking tools
 Cutting tools
 Planing tools
 Boring tools
 Striking tools
 Holding tools

Measuring and Marking tools

Some of the measuring and marking tools are listed as,
 Calipers and compasses
 Steel rule
 Try square
 Mitre square
 Gauges (Marking gauge, mortise gauge)
 Dividers
 Scribers
Cutting Tools
The two cutting tools used in carpentry are
1. Saws
 Rip saw (Fig 1)
 Cross cut saw
 Tenon saw
 Compass saw (Fig 2)
 Coping

Fig 1 Rip Saw Fig 2 Compass Saw

2. Chisels
Chisels are the tools produced from forges steels or tool steel blades
2.1. Firmer chisel (Fig 3)
Firmer chisel is the most commonly used chisel. It is used for light and heavy work .Tang, Handle,
ferrule and cutting edge are the parts of firmer chisel.

Fig 3 Firmer Chisel

 2.2. Paring Chisel (Fig 4)
Paring chisel has thinner blade and used for light work. This chisel is used for shaving or paring
plane surfaces. The blade has either square or beveled edges.

Fig 4 Paring Chisel

2.3. Mortise chisel

It is used to make mortises. Mortise chisel is used for heavy cuts. The blade thickness varies from 5
mm to 12 mm. Because of wider thickness this blade is stronger in comparison to other chisels of same size,
therefore it is capable of taking the heavy blows.
2.4. Gauge chisel
It used to finish curved holes; Gauge chisels are of two types i.e., insider and outside gauge chisels
Planning Tools
Planes are used to produce flat surfaces on wood. A plane is like a chisel fitted in a block of metal on
wood. The cutting blade is fixed in a wood or metal with some inclination
There are many types of planes are used, but in general use are
i. Wooden jack plane
ii. Iron jack Plane(Fig 5)
iii. Trying plane (Fig 6)
iv. Smoothing plane
v. Rasp file
 Fig 5 Iron Jack Plane Fig 6 Trying Plane

Boring Tools
To make holes in wood, boring tools are used
i. Brace
It holds and turns the bit and boring of hole is achieved. It may be of ratchet
brace or wheel brace.
ii. Bradawl
iii. Gimlet
Bradawl and Gimlet are used to bore small holes
Striking Tools – Hammers
Hammer is one of the mostly used striking tools. The types are
i. Cross – peen Hammer (Fig 7): The cross – peen hammer is mostly used for positioning small
nails. The head is tightly used in the handle with the help of iron wedges.

Fig 7 Cross Peen Fig 8 Claw Hammer

 ii. Claw Hammer (Fig 8): It is effective in removing very large nails and also for driving the
nails using end of the hammer
iii. Mallet (Fig 9): It is used to give light blows. The head is made up of wood and round in
section. The striking face is flat.

Fig 9 Mallet

Holding Tools
During woodworking, job is shaked. So maintaining accuracy is tough. To maintain accuracy, the
wood is to be held rigidly.
i. Carpentry Vice (Fig 10): It is most common work holding device. It consists of one fixed jaw and
movable jaw. The fixed haw is fastened to the workbench and the movable jaw mounted over the
screw rod and guide pins.
ii. C-clamps (Fig 11): It is made up of malleable iron. The opening capacity varies from 50 to 350 mm.
It can be used for clamping small work. The swivel shoe allows fixing angled work.

Fig 10 Carpentry Vice Fig 11 C-Clamp

POWER TOOLS
In modern carpentry there is a wide variety of power tools are available to make ease of the work.
Some of the important power tools are listed as below:
 Planing Machine / Palner
 Power Hacksaw
 Hand drilling machine
 Jig-saw
 Circular saw
 Rotary hammer
CARPENTRY PROCESSES
To finish a work to the required size and shape in wood working shop, several operations are
performed. These operations are

i. Measuring & Making

ii. Planing
iii. Chiseling
iv. Sawing
v. Mortising and tenoning
vi. Boring
vii. Grooving
viii. Moulding
ix. Recession
CARPENTRY JOINTS
Following are the various types of carpentry joints, which are commonly used in various
applications.
i. Middle lap joint
ii. Cross lap joint
iii. Tenon joint
iv. Dovetail joint

RESULT
T-JOINT OR MIDDLE LAP JOINT
 EX.NO:6A
HAND-ON-EXERCISE WOOD WORK, JOINTS BY SAWING,
Date: PLANNING AND CUTTING
T-JOINT

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

MATERIAL SUPPLIED
A soft wooden Piece of size, l.b.t = 205 x 52x 32 mm

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

SEQUENCE OF OPERATIONS

1. Planing 4. Chiseling
2. Marking 5. Fitting
3. Sawing

PROCEDURE

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

RESULT
CROSS LAP JOINT
 EX.NO:6B
CROSS LAP JOINT
Date:

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

MATERIAL SUPPLIED
A soft wooden piece of size, l.b.t = 205 x 52 x 32 mm.

TOOLS REQUIRED

1. Machine Planer 5. Marking Gauge

2. Mallet 6. Calipers
3. Rip Saw 7. Circular Saw
4. Try Square

SEQUENCE OF OPERATIONS

1. Planing 4. Chiseling
2. Marking 5. Fitting
3. Sawing

PROCEDURE

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

RESULT
DOVETAIL JOINT
 EX.NO:7A
HAND-ON-EXERCISE WOOD WORK, JOINTS BY SAWING,
Date: PLANNING AND CUTTING
DOVETAIL JOINT

AIM

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

MATERIAL SUPPLIED
A soft wooden piece of size, l.b.t = 205 x 52 x 32 mm.

TOOLS REQUIRED

1. Machine Planer 5. Marking Gauge

2. Mallet 6. Calipers
3. Rip Saw 7. Circular Saw
4. Try Square

SEQUENCE OF OPERATIONS

1. Planing 4. Chiseling
2. Marking 5. Fitting
3. Sawing

PROCEDURE

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

RESULT
 Fig 1 Arc Welding Principle

Fig 2 Metal Arc Welding setup

 EX.NO:8
STUDY OF WELDING TOOLS AND EQUIPMENTS
Date:

AIM

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

INTRODUCTION TO WELDING

Welding is the process of joining similar metals by application of heat with or without application of
pressure and addition of filler materials.

The welding method is broadly classified as

i. Plastic or Pressure Welding

ii. Fusion or Non-Pressure Welding
I. Pressure Welding
The piece of metals to be joined are heated to a plastic state and then forced together by
external pressure.

Example: Resistance Welding, Forge Welding, Gas Welding

II. Non-Pressure Welding

The material at the joint is heated to molten state and allowed to get solidity.

Example: Arc Welding, Gas Welding.

ARC WELDING PRINCIPLE (Fig 1)

Heat required for welding is obtained from the arc struck between flux coated Electrode and the
work piece. The arc temperature and thus the arc heat can be decreased by employing higher or lower arc
currents. A high current arc with a similar arc length produces a very intense heat.

The arc is transformed from electrode to the job metal and thus it melts the metal as shown in fig 2.
Then the two metals get welded / joined along the time which arc is deposited.

WELDING EQUIPMENTS (Fig 3)

Equipments used in welding are

 AC and DC supply  Chipping Hammer

 Electrode Holder  Wire Brush
 Welding Leads or Electrode  Safety Equipments
Fig 3 Welding Equipments

Fig 4 Gas Welding

AC and DC Supply

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

Electrode Holder

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

Electrode

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

Chipping Hammer

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

Wire Brush

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

Safety Equipments

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

ADVANTAGES OF ARC WELDING

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

GAS WELDING (Fig 4)

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

Oxy- Acetylene Welding Principle

When acetylene is mixed with oxygen in correct proportions in welding torch and ignited. The flame
resulting at the tip torch is sufficiently hot to melt and joint the parental metal. The flame reaches a
temperature of about 3200°C. A filler metal rod is generally added to the molten metal to build up the screen
for greater strength.
 Fig 5 Butt Joint Fig 6 Lap Joint

Fig 7 Corner Joint Fig 8 T – Joint

FLAME TYPES

Neutral Flame:

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

Oxidizing Flame:

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

Reducing Flame:

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

WELDING PROCESSES

 Edge preparation  Cooling

 Tracking  Chipping
 Welding  Cleaning
 Types of Flames

Fig 9 equipments used in welding process

RESULT
BUTT JOINT

40
 EX.NO:8A
SQUARE BUTT JOINT
Date:

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

MATERIAL SUPPLIED
Mild Steel plate of size, l.b.t = 75 x 25 x 5 mm (two pieces).

TOOLS REQUIRED

1. Welding Transformer 4. Tongs and Wire Brush

2. Welding Electrodes 5. Chipping Hammer
3. Gloves and Goggles 6. Flat File and Hand Shield

SEQUENCE OF OPERATIONS

1. Edge Preparation 5. Cooling

2. Positioning 6. Chipping
3. Tacking 7. Cleaning
4. Welding

PROCEDURE

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

RESULT
LAP JOINT
 EX.NO:8B
LAP JOINT
Date:

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

MATERIAL SUPPLIED
Mild Steel plate of size, l.b.t = 75 x 50 x 5 mm (two pieces).

TOOLS REQUIRED

1. Welding Transformer 6. Flat File

2. Welding Rod 7. Chipping Hammer
3. Electrode Holder 8. Wire Brush
4. Gloves and Apron 9. Earthing Clamps
5. Hand Shield and Goggles

SEQUENCE OF OPERATIONS

1. Edge Preparation 5. Cooling

2. Positioning 6. Chipping
3. Tacking 7. Cleaning
4. Welding

PROCEDURE

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

RESULT
T - JOINT
 EX.NO:8C
TEE - FILLET JOINT
Date:

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

MATERIAL SUPPLIED
Mild Steel plate of size, l.b.t = 75 x 50 x 5 mm (two pieces).

TOOLS REQUIRED

1. Welding Transformer 6. Flat File

2. Welding Rod 7. Chipping Hammer
3. Electrode Holder 8. Wire Brush
4. Gloves and Apron 9. Earthing Clamps
5. Hand Shield and Goggles

SEQUENCE OF OPERATIONS

1. Edge Preparation 5. Cooling

2. Positioning 6. Chipping
3. Tacking 7. Cleaning
4. Welding

PROCEDURE

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

RESULT
Set up of oxy-acetylene gas welding

Welding torch
 EX.NO:8D
GAS WELDING PRACTICE
Date:

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

MATERIAL SUPPLIED
Mild Steel plate of size, l.b.t = 75 x 25 x 8 mm (two pieces).

TOOLS REQUIRED

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

SEQUENCE OF OPERATIONS

1. Edge Preparation 5. Cooling

2. Positioning 6. Chipping
3. Tacking 7. Cleaning
4. Welding

PROCEDURE

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

RESULT
FACING AND PLAIN TURNING

All Dimensions are in mm

 EX.NO:9A
FACING AND PLAIN TURNING
Date:

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

MATERIAL SUPPLIED
Mild steel rod of diameter 35 mm and length 110 mm.

TOOLS REQUIRED

1. Single point cutting tool 4. Steel rule

2. Vernier caliper 5. scriber
3. Tool post key

PROCEDURE

1. First the given work piece is cheeked for its dimension.

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

RESULT
TAPER TURNING

All Dimensions are in mm

 EX.NO:9B
TAPER TURNING
Date:

AIM:

To perform taper turning operation using compound rest in lathe.

(An operation performed on a lathe that feeds a tool at an angle to the length of the work piece
in order to create a conical shape)

MATERIAL SUPPLIED
Mild steel rod of diameter 35 mm and length 110 mm.

TOOLS REQUIRED:

1. Single point cutting tool 3. Steel rule

2. Vernier caliper 4. Scriber 5. Tool post key

PROCEDURE:

1. Set the tool in their respective position of the tool post.

2. The work piece is chucked and checked for the rotation.

3. Switch on the motor after selecting the proper speed.

4. First by moving the cross slide facing operation is completed.

5. After reducing the height of the work piece, by tilting the compound rest set the calculated angle
for tapering.

6. Make the taper turning operation as per the given dimension.

7. Chamfer the corners and check the dimensions.

RESULT:
DRILLING AND TAPPING

All Dimensions are in mm

 EX.NO:10
DRILLING AND TAPPING
Date:

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

MATERIAL SUPPLIED
Mild steel plate of size 50 x 50 x 6 mm

TOOLS REQUIRED

1. Bench vice 7. Vernier height gauge

2. Machine vice 8. Scriber
3. Steel rule 9. Drill bit
4. Surface plate 10. File
5. Try square 11. Tapset with Die holder
6. Dot punch 12. Drilling machine

PROCEDURE

1. The dimensions of the given work piece is checked.

2. The chalk is applied throughout the surface of the work piece.
3. Marking is done on the work piece by using scriber, dot punch and hammer. With the help
of Vernier height gauge and steel rule measurement is taken.
4. The adjacent sides of work piece are filed and then the punched work piece is clamped in
the vice.
5. The required size of hole is made on the work piece by using drilling machine.
6. During the drilling operation the coolant is applied to avoid the heat and to reduce wear.
7. Then the drilling holes are tapped by suing tapping tool.

RESULT
 EX.NO:12
FORMING AND BENDING - STUDY OF SHEET METAL TOOLS AND
Date: OPERATIONS

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

SHEET METAL TOOLS

The types of hand shears or snips. They resemble with pair of scissors and are used like them to
cut thin soft metal sheets of 20 gauge or thinner. They are required to size and shape the sheets. They
can make straight or circular cuts. Different types of hand shears are:
(1) Straight hand shear: It is used for general purpose cutting, making straight cuts and trimming
away extra metal.
(2) Universal shear: Its blades are designed for universal cutting straight line or internal and external
cutting of contours. It may be of right hand or left hand type, easily identifiable, as the top blade is
either on the right of on the left.
(3) Curved hand shear: It is used for cutting circular or irregular curved shapes ranging from 20 to 35
cm.

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

FOLDING TERMINOLOGY OF SHEET METAL

Edge
The edges on part need to be folded to increase the strength and to eliminate the sharp edges of sheet
metal component.
1. Types of folded edges. The common types of folded edges are: (i) single hem, (ii) double hem and
(iii) wired edge
2. Single hem. It is made by folding the edge over. To layout such a hem, a line is drawn at a distance
equal to the desired hem width.
3. Double hem. It is a single hem with its end bent under. To layout such a hem, draw two parallel lines
each equal to the width of the hem.
4. Wired edge. It consists of an edge, which has been wrapped around a piece of wire.
This edge is used where more strength is needed. To layout wired edge the diameter of wire is to be
determined. The steel metal will be needed to roll around the wire.
Seam
A seam is the section where pieces of sheet metal are joined together. Most common types of seams
are:
(a) Single seam, (b) Double seam, (c) Grooved seam, (d) Lap seam, (e) Dovetail seam, and
(f) Burred bottom seam
1. Single seam
It is used to join a bottom to vertical bodies of various shapes. To layout such a seam, draw a line
parallel to one edge of the sheet metal body stretch out at a distance equal to the width of the seam.
Now draw two lines parallel to the edges of the bottom stretch out. The first line should be drawn at the
distance from the edge of sheet metal equal to the width of the seam minus 1 mm. approx. Second line
should be drawn at a distance from the first equal to the width to the seam on sheet metal plus 1 mm
approx. The plus and minus dimensions of 1 mm is used to prevent the folded bottom edge of sheet
metal from interfering with the body’s folded bottom edge. If the bottom is round, then mark the lines
on sheet metal part.
2. Double seam
The layout process for this seam on sheet metal part is similar to that used for a single seam on sheet
metal part. It differs from single seam in a manner that its formed edge is bent upward against the body.
3. Grooved seam
It is made by booking two folded edges of sheet metal part together and then off-setting the seam as
shown in Fig. On one piece draw one line equal to half the width of the seam from outer edge. Then
draw second line at a distance equal to the width of the seam from the first line. Same way draw two
lines on the other piece of sheet metal part.
4. Lap seam
It is the simplest type of seam made on sheet metal part because one edge laps over another and is
soldered or riveted. To layout lap seam on sheet metal part, draw line on the edge of piece at a distance
equal to the width of the required seam.
5. Dovetail seam
It is used to join a flat plate to a cylindrical piece. To layout such a seam, draw a line parallel to one
edge of sheet metal component at a distance of 6 to 20 mm. depending upon the size of the hole of sheet
metal part. Then draw lines to indicate where the sheet metal part is to be slit. The width of the piece
between slits ranges from 6 to 26 mm.
6. Flanged or burred bottom seam
It is used to fasten the bottom of a container made of sheet metal to its body in which upper part is the
sheet metal body and lower bottom of a container. To layout such a seam on sheet metal part, draw a
circle, which represents the outline of the bottom on sheet metal part. If it is square or rectangular
component, draw the bottom shape on the sheet metal part.
Then draw a second line to show the width of the flange. The width of this flange may range from 3 to
6 mm on sheet metal part.
Folded Sheet Metal Joints
As per requirements, various types of sheet metal joints are used in sheet metal work. Such joints are
commonly used to fasten bottoms to cylinders, square or rectangular containers. Some of the commonly
used such joints are shown in Fig.
1. Lap joint. It is very frequently used in sheet metal work and can be prepared by means of soldering
or riveting.
2. Seam joint. This joint is a very generally used in sheet metal work. It is locked, as shown in the
diagram, so as to ensure a positive grip and also to make the joint flush with the surface.
3. Locked seam joint. This joint is used for locking seam joints in sheet metal work.
4. Hem (single and double), wired edge, cup and angular joints. These enable the edges sheet metal
part to join the pieces along them.
5. Flanged joint. It is commonly used in sheet metal work frequently in making pipe connections.
6. Cap joint. It provides another useful form of locked seam joint on sheet metal component with good
appearance and strength. It is generally used for assembling cross seam of ducts made up of in sheet
metal part.
RESULT
SQUARE TRAY
 EX.NO:12A
SQUARE TRAY
Date:

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

MATERIAL SUPPLIED
Galvanized Iron sheet of l.w = 130 x 130 mm.

TOOLS REQUIRED

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

SEQUENCE OF OPERATIONS

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

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

RESULT
FUNNEL MAKING
 EX.NO:12B
FUNNEL MAKING
Date:

AIM
To make a funnel from the given sheet metal.

MATERIAL SUPPLIED
22 gauge Galvanized Iron (G.I) sheet.

TOOLS REQUIRED

1. Steel Rule 3. Straight Snips 7. Groover

2. Mallet 4. White Paper 8. Solder
3. Scriber 5. Ball Peen Hammer

SEQUENCE OF OPERATIONS

1. Checking 4. Marking on Sheet Metal 7. Hemming

2. Leveling 5. Cutting 8. Soldering
3. Marking on Paper 6. Folding

PROCEDURE

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

RESULT
CENTRIFUGAL PUMP
 EX.NO:13 A
STUDY OF CENTRIFUGAL PUMP
Date:

AIM
To study the working of centrifugal pump.

INTRODUCTION

The pump is a hydraulic machine which converts the mechanical energy into hydraulic energy
in the form of pressure energy. The centrifugal pump is a hydraulic machine which converts the
mechanical energy into pressure energy by means of centrifugal force. Pumps are generally used for
lifting liquids from a lower level to higher level. The advantages of a centrifugal pump are. Low initial
cost, high efficiency, uniform discharge, ease in installation and maintenance and so on.

TYPES OF PUMPS

1. Positive displacement pumps (piston pumps and helical-roto pumps)

2. Roto – dynamic pumps (centrifugal pumps, mixed flow pumps, mixed flow bore hole
pumps and axial pumps)

COMPONENTS OF CENTRIFUGAL PUMP

SUCTION PIPE:

A pipe whose one end is fitted to the inlet of the centrifugal pump and the other end dips into
water in a sump is known as suction pipe.

FOOT VALVE AND A STRAINER:

A foot valve which is a non-return valve or one-way type of valve is fitted at the lower end of
the suction pipe. The foot valve opens only in the upward direction. A strainer is also fitted at the lower
end of the suction pipe.

DELIVERY PIPE:

A pipe whose one end is connected to the outlet of the pump and the other end delivers the
water at a required height is known as delivery pipe. A delivery valve is fitted at the lower end of the
delivery pipe.
WORKING PRINCIPLE

The centrifugal pump works under the principle of forced vortex flow. This means that, when
certain mass of liquid is rotated, by an external torque, the rise in pressure head of the rotating liquid is
rotating liquid takes place. The rise in pressure head at any point of the rotating liquid is directly
proportional to square and tangential velocity of the liquid at any point.

CONCLUSION
AIR CONDITIONER
 EX.NO:13B
STUDY OF AIR CONDITIONER
Date:

AIM
To study the working of air conditioner systems.

INTRODUCTION

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

TYPES OF AIR – CONDITIONER

1. Central Air-conditioning 2.Window unit 3. Split system

COMPONENTS OF AIR CONDITIONER

1. Compressor – The function of the compressor is used to compress the low pressure and
temperature refrigerant into high pressure.
2. Condenser – The function of the condenser is to cool the high pressure vapours and
condensed into high pressure liquid refrigerant.
3. Evaporator – The function of the evaporator is to absorb the heat from the room.
4. Fan – The function of fan is to produce the air movements in the air – conditioning
apparatus.
5. Filter – The function of the filter is to remove the foreign matters such as direct fumes,
smokes and harmful bacterial present in the air.

WORKING PRINCIPLE

The air in the room is to be sucked by fan through the air filter and then passes over the cooling
coil. The cooling coil absorbs the heat from room. The cool air brings down the temperature
and humidity level in the room and provides the comfortable conditions.
A thermostat is provided for conditioning of the compressor to maintain the desired
temperature in the room. A damper is used to regulate the fresh air supply. The conditioned
chilled air is blown into room through the dampers.

CONCLUSION
HEXAGONAL HEADED BOLT
 EX.NO:14A
STUDY OF HEXAGONAL HEADED BOLT USING SMITHY OPERATION
Date:

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

MATERIALS SUPPLIED
Mild steel rod of length 100 mm and diameter 12 mm

TOOLS REQUIRED
1. Anvil 4. Flatter
2. Hand Hammer 5. Furnace, etc.
3. Tongs

SEQUENCE OF OPERATIONS
1. Heating 4. Checking
2. Forming Hexagonal Shape 5. Cooling
3. Flattening

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

RESULT
.
MOULDING GEAR PATTERN
 EX.NO:14B
FOUNDRY OPERATIONS - MOULDING GEAR PATTERN
Date:

AIM
To prepare mould for the gear pattern.

MATERIAL SUPPLIED
1. Moulding sand
2. Parting sand
3. Facing sand

TOOLS REQUIRED

1. Trowel 6. Rammer 11. Strike of bar

2. Lifter 7. Runner 12. Riser
3. Gate Cutter 8. Vent wire 13. Draw spike
4. Swab 9. Riddle 14. Sprue pin
5. Bellow

PROCEDURE

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

RESULT
STEPPED CONE PULLEY
 EX.NO:14C
STEPPED CONE PULLEY
Date:

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

MATERIAL SUPPLIED
1. Moulding sand
2. Parting sand
3. Facing sand

TOOLS REQUIRED

1. Trowel 6. Rammer 11. Strike of bar

2. Lifter 7. Runner 12. Riser
3. Gate Cutter 8. Vent wire 13. Draw spike
4. Swab 9. Riddle 14. Sprue pin
5. Bellow

PROCEDURE

10. The mould box, pattern, tools and the table / floor are cleaned.
11. The drag is filled with green sand after positioning the gear pattern on the table.
12. The green sand is rammed carefully and the excess sand is struck off.
13. Tilt the drag upside down and sprinkle river sand on top of it.
14. The cope is positioned on top of the drag.
15. Position the sprue pin and riser pin, then fill the cope with sand and ramming is done and the
excess sand is struck off.
16. The sprue pin and riser pin is removed carefully.
17. Apply water on the edges of the pattern and remove it carefully using the draw spike. Vent
holes are made using vent wire.
18. A funnel-shaped opening and gate is made to pour the molten metal.

RESULT
 EX.NO:
STUDY OF TOOLS AND EQUIPMENTS USED IN FITTING
Date:

AIM

To study the tools and equipments used in Fitting process

Introduction:

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

TOOLS USED IN FITTING SHOP:

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

Marking Tools:

These are sub classified as steel rule, circumference rule, scriber, semi-circular protractor,
divider, trammel, prick punch, centre punch, try square, bevel square, vernier protractor, combination
set and surface gauge.
1. Steel Rule
Steel rule is generally employed for purpose of measuring rough dimensions and laying out
them. It is always advisable to start measuring from 1 cm mark because the end of the rule is generally
worn out
2. Circumference Rule
It is commonly used for measuring or laying out or as a straight edge. The specialty in this rule
is that the circumference can be taken directly, below the diameter dimension.
3. Scribers
Fig. shows the various types of scribers, which are sometimes called the metal worker’s pencil.
These are made up of high carbon steel and are hardened from the front edge. Scriber is used for
scratching lines on the sheet metal during the process of laying out a job.

Scribers

4. Divider:
It is used for marking and drawing circle and arcs on sheet metal.
5. Trammel
Trammel is used for marking and drawing large circles or arcs, which are beyond the scope of dividers.
6. Prick Punch
Fig. shows the prick punch, which is used for indentation marks. It is used to make small punch marks
on layout lines in order to make them last longer. The angle of prick punch is generally ground to 30° or
40° whereas for centre punch it is kept 60 °or 90°.
7. Centre Punch
Fig. shows the centre punch, which is used for locating centre for indentation mark for drilling
purposes.
8. Try Square
Fig.shows the try square, which is also known as engineer’s try square. It is very important tool
required for scribing straight lines at right angles to a true surface or testing the trueness of mutually
normal surfaces. It is made in different sizes out of steel pieces. In construction, it is similar to a
carpenter’s try square but is comparatively more accurate. It can be made either in one piece or in two
pieces.
It consists of a steel blade fitted into a steel stock of rectangular cross-section. It is sufficiently hardened
and tempered to suit the need. Some precision kind of try squares is made with their blades having
beveled edges properly ground and finished square. Both inner and outer surface of the blade are kept
truly at right angles to the corresponding surfaces of the stock. In order to maintain this trueness, this
tool should be handled with due care and should never be used as a striking or supporting tool or other
work. The accuracy of this tool should be frequently checked to ensure the trueness as it affects the
accuracy of the finished job to a significant extent.
For checking the accuracy or trueness of a try square, the try square is made to lie flat on the top surface
of a surface plate with the stock touching a machined edge of the plate. A straight line is marked along
the outer edge of the blade and then the square turned over to take a new position. Another straight line
is described along the outer edge of the blade in this new position of the try square. If both lines
coincide with each other as they seems to be as one line only, then the try square can be said as true.

9.Vernier Caliper
Fig. shows the vernier caliper, which is commonly used to measure accurately
1) outside diameters of shafts,
 2) thicknesses of various parts,
3) diameters of holes or rings and
4) internal dimensions of hollow jobs or articles.

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

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

11. Holding Tools

Holding tools used in fitting shop comprises of basically vices and clamps. The clamps are C or G
clamp, plane slot, goose neck, double end finger, u-clamp, parallel jaw, and clamping block. The
various types of vices used in fitting shop are given as under:
12. Bench vice
Fig shows a bench vice commonly used in fitting shop for holding a variety of jobs.

13. C-clamp
A C-clamp is shown in Fig. 19.38 which is used for gripping the work during construction or assembly
work.

14. Cutting Tools

Files

The widely used hand cutting tool in workshops is the file. It is a hardened piece of high grade steel
with slanting rows of teeth. It is used to cut, smooth, or fit metal parts. It is used file or cut softer
metals. It consists of the following parts as shown in Fig.. The tang is the pointed part, which fitted into
the handle. The point is the end opposite the tang. The heel is next to the handle. The safe edge or side
of a file is that which has no teeth. It is classified on bases of type or cut of teeth and sectional form.
Size of a File
Size of a file is specified by its length. It is the distance from the point to the heel, without the tang.
Files for fine work are usually from 100 to 200 mm and those for heavier work from 200 to 450 mm in
length.
Classification of Files
The files are classified on basis of type of cuts, grade and shapes. These are further sub classified as
under
(a) Type of Cut
The most commonly used files according to cuts of teeth are shown in Fig.19.41.
a) Single
b) Double and
c) Rasp
(b) Grade of Cut
Files are cut with teeth of different grades. Those in general are
a) Smooth
b) Second cut
c) Rough
(c) Shape of File
Common shapes of files are having different cross sections, which cover most requirements.
Cut or teeth on files
Teeth or cuts of files can be categorized into two groups namely single cut and double cut. In single cut
files, the teeth are cut parallel to other across the file at an angle of about 60° to the centre line of the
file. Such types of file are named as flats and are widely used on hard metal.
Hand files
Hand files are commonly used for finishing surface work. Both faces of the file are double cut. Either
both edges are single cut or one is uncut to provide a safe edge.
Flat files
Flat files are generally used for filing flat surfaces in fitting shop.
Triangular files
Triangular files are commonly used for filing corners between 60° and 90°. They are double cut on all
faces.
Square files
Square files are commonly used for filing in corners in jobs. They are double cut on all sides and tapers.
Round files
Round files are generally used for opening out holes and rounding inside corners. Rough, bastard,
second cut and smooth files under 15 cm in length are single cut.
Half round files
These files comprises of flat and half round sides. The flat side of half round file is used for general
work and the half round side for filing concave surfaces. These files are double cut on the flat side. The
curved side is single cut, smooth or second cut.
Knife-edge files
These files are commonly used for cleaning out acute-angled corners. The two faces of these files are
double cut, while the edge is single cut. These files are made in sizes from 10 to 20 cm of various
shapes and cuts. They are extremely delicate and are used for fine work such as pierced designed in thin
metal.
Pillar files
These files are used for finishing narrow slots. Both faces are double cut and either both edges are
single cut or one is uncut to provide a safe edge of the file.
Needle files
Needle files are generally used for filling keys tooth wheels of clocks and other curved surfaces.
Mill files
Mill files are commonly used for filing half round recess and gullet of mill saw.

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

Sriking Tools
Various types of hammers (such as ball peen hammer, straight peen hammer, cross-peen hammer,
double face hammer and soft face hammer) are acting as striking tools. These types have been
described in chapters relating to sheet metal work and forging work. The common type of ball peen
hammer and their parts are shown in Fig.
Tightening Tools
The tightening tools include pliers, screw driver and wrenches, which are discussed as under.
Pliers
Pliers are namely ordinary needle nose and special type. Fig 19.52(a) shows a long nose pliers and Fig.
Shows combination pliers. These are commonly used by fitter and electrician for holding a variety of
jobs.

Screw driver
Screw driver is a screw tightening tool. The most commonly used standard screw driver with its parts is
shown in Fig 19.53. It is generally used by hand for tightening the screws. It is also of various types
depending upon the kind of work.
Wrenches
Wrenches are commonly known as spanners. These generally come in sets and are commonly identified
by numbers. These are of various types and few general types involve open single ended, open double
ended, closed ended adjustable, ring spanner, offset socket, t-socket, box wrench, pipe wrench and
Allen wrench.

OPERATIONS PERFORMED IN FITTING WORK

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

CONCLUSION
SQUARE FITTING
 EX.NO:14D
SQUARE FITTING
Date:

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

MATERIAL SUPPLIED
Mild Steel Plate (One Piece), l.w.t = 52 x 52 x 5 mm.

TOOLS REQUIRED

1. Bench Vice 7. Hammer

2. Try Square 8. Angle Plate
3. Dot Punch 9. Files
4. Jenny Caliper 10. Surface Plate
5. Steel Rule 11. Fixed Hacksaw
6. Vernier Height Gauge

PROCEDURE

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

RESULT
V – FITTING
 EX.NO:14E
V – FITTING
Date:

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

MATERIAL SUPPLIED
Mild Steel Plate (One Piece), l.w.t = 102 x 52 x 5 mm.

TOOLS REQUIRED

1 Bench Vice 7. Hammer

2 Try Square 8. Angle Plate
3 Dot Punch 9. Files
4 Jenny Caliper 10. Surface Plate
5 Steel Rule 11. Fixed Hacksaw
6 Vernier Height Gauge

PROCEDURE

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

RESULT
VIVA – VOICE QUESTIONS AND ANSWERS

1) What is plumbing?
Plumbing is the skilled trade of working with pipes, tubing and plumbing fixtures for drinking
water systems and the drainage of waste.

2) What is the purpose of plumbing?

The purpose of plumbing is to install, maintain and repair a dwelling’s pipes and sanitary
fixtures.

3) What materials are used to make plumbing systems for sewage?

Plumbing for sewage is made of cast iron, steel, asbestos cement, copper and plastic.

4) What are some common plumbing materials used today?

The common materials used today in water supply pipes are steel, brass, plastic and lead.
Plumbing for sewage is made of cast iron, steel, asbestos cement, copper and plastic.

5) List the types of plumbing valves.

1.Gate valve 2. Plug valve 3. Globe valve 4.Butterfly valve
5.Ball valve 6.Diaphragam valve 7. Angle valve 8. Safety valve
9. Needle valve 10. Relief valve 11. Check valve 12. Safe relief valve.

6) What is the use of bolted joints?

 The components cannot be serviced in line.
 The components being joined are not capable of being welded.
 Quick field assembly is required.
 The component or pipe section must be frequently removed for service.

7) List the types of centrifugal pump.

Monoblock pump, jet pump, and submerge pump

8) Compare pipe wrench and pipe vice.

Pipe wrench is used to hold and rotate the pipes tight them and pipe vice is used to clamp pipes
in position for threading, cutting, screwing, fitting.etc.,

9) List the name of some tools used in plumbing.

Pipe vice, pipe cutter, plumb bob, pipe threading dies and taps, measuring tape.

10) Define carpentry process.

Carpentry and joinery work involve a number of hand operations to finish the work to the
desired shape and size with required accuracy.
Marking, sawing, planning, chiseling, boring, grooving, rebating, moulding.
11) What is the use of chisels?
Used for cutting and shapping wood accurately. Three types are there, firmer chisel,
parting,chisel, and mortise chisel.

12) Name the cutting tools used in carpentry.

Saws, cross-cut or hand saw, rip saw, tenon saw, dovetail saw, chisels, firmer chisel, dovetail
chisel and mortise chisel.

13) What is welding?

Welding is a process which joining process which produces coalescence of materials by
heating them to suitable temperature with or without the application of pressure

14) What are different techniques of

welding? Leftward welding, rightward
welding

15) List the types of flames.

Neutral flame, oxidizing flame, reducing flame.

16) Name nay two safety devices.

Face shield, hand shield

17) What is hem and seam?

A hem is an edge or border made by folding. It stiffens the sheet of metal and does away with
the sharp edge. A seam is a joint made by fastening two edges together.

18) What are the different types of processes in sheet metal?.

Bending, raising, flanging, hollowing, flattering, planning

19) Name the tools used in arc welding process?

Electrode, electrode holder, earth cable, gloves, apron, transformer, face shield.

20) What is the use of goggles?

Goggles are used to protect the eyes from the rays which scattered during the welding
processes.