ME 2306 - Workshop Practice Manual (To Be Printed)

NATIONAL UNIVERSITY OF TECHNOLOGY (NUTECH)
DEPARTMENT OF MECHANICAL ENGINEERING
Workshop Practice
(ME 2306)
Session - 2023
NAME ___________________________________
REG NO ___________________________________
SECTION ___________________________________
INSTR ___________________________________
DEPARTMENT OF MECHANICAL
ENGINEERING
NATIONAL UNIVERSITY OF TECHNOLOGY
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Contents
COURSE LEARNING OUTCOMES ..................................................................................................................3
GRADING POLICY .............................................................................................................................................3
ASSESSMENT ......................................................................................................................................................4
PRACTICAL 1A ........................................................................................................................................................6
SAFETY MEASURES IN WORKSHOP .................................................................................................................................... 6
PRACTICAL 1B .......................................................................................................................................................12
PLANT AND SHOP LAYOUT ............................................................................................................................................. 12
PRACTICAL 2A ......................................................................................................................................................18
TO FILE THE GIVEN TWO MILD STEEL PIECES INTO A RECTANGULAR SHAPE FOR GIVEN PIECE......................................................... 18
PRACTICAL 2B .......................................................................................................................................................23
TO MAKE V‐ FIT FROM THE GIVEN TWO MS PLATES AND DO DRILLING AND TAPPING. ................................................................. 23
PRACTICAL 3A ......................................................................................................................................................29
TO MAKE A T‐LAP JOINT FROM THE GIVEN REAPER IN CARPENTRY SHOP. ................................................................................. 29
PRACTICAL 3B .......................................................................................................................................................33
TO MAKE A DOVETAIL LAP JOINT FROM THE GIVEN REAPER IN CARPENTRY SHOP. ...................................................................... 33
PRACTICAL 4A ......................................................................................................................................................37
TO MAKE A MORTISE AND TENON JOINT FROM THE GIVEN REAPER IN CARPENTRY SHOP. ........................................................... 37
PRACTICAL 4B .......................................................................................................................................................41
TO MAKE ALPHABETS FROM THE GIVEN REAPER IN CARPENTRY SHOP. ..................................................................................... 41
PRACTICAL 5A ......................................................................................................................................................46
TO PERFORM FACING AND PLAIN TURNING ON A GIVEN CYLINDRICAL WORKPIECE USING LATHE MACHINE. ...................................... 46
PRACTICAL 5B .......................................................................................................................................................51
TO PERFORM TAPER TURNING AND STEP TURNING ON A GIVEN CYLINDRICAL WORKPIECE USING LATHE MACHINE. ............................ 51
PRACTICAL 6 .........................................................................................................................................................56
TO PERFORM KNURLING, BORING AND REAMING OPERATION ON A GIVEN CYLINDRICAL WORKPIECE USING LATHE MACHINE.............. 56
PRACTICAL 7 .........................................................................................................................................................60
TO PERFORM THREADING ON A GIVEN CYLINDRICAL WORKPIECE USING LATHE MACHINE. ............................................................ 60
PRACTICAL 8 .........................................................................................................................................................65
TO PERFORM HORIZONTAL CUTTING, VERTICAL CUTTING, AND GROOVING ON A GIVEN WORK PIECE USING SHAPER MACHINE. ............ 65
PRACTICAL 9A ......................................................................................................................................................69
TO MAKE A LAP JOINT, USING THE GIVEN MILD STEEL PIECES USING ARC WELDING. .................................................................... 69
PRACTICAL 9B .......................................................................................................................................................73
TO MAKE A CORNER JOINT, USING THE GIVEN MILD STEEL PIECES USING ARC WELDING. .............................................................. 73
PRACTICAL 10A ....................................................................................................................................................77
TO MAKE A T JOINT, USING THE GIVEN MILD STEEL PIECES USING TIG WELDING. ....................................................................... 77
Mechanical Engineering Department Workshop Practice

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PRACTICAL 10B .....................................................................................................................................................82

TO MAKE A BUTT JOINT, USING THE GIVEN MILD STEEL PIECES USING TIG WELDING. .................................................................. 82
PRACTICAL 11A ....................................................................................................................................................87
TO MAKE A DOUBLE LAP JOINT, USING THE GIVEN MILD STEEL PIECES USING MIG WELDING. ....................................................... 87
PRACTICAL 11B .....................................................................................................................................................92
TO MAKE AN EDGE JOINT, USING THE GIVEN MILD STEEL PIECES USING MIG WELDING................................................................ 92
PRACTICAL 12A ....................................................................................................................................................98
INTRODUCTION AND USAGE OF ELECTRICAL TOOLS, WIRE GAUGES AND EARTHING................................................................... 98
PRACTICAL 12B ................................................................................................................................................... 104
TO MAKE DIFFERENT WIRING JOINTS.............................................................................................................................. 104
PRACTICAL 13A .................................................................................................................................................. 111
TO CONTROL SINGLE LAMP WITH ONE SWITCH .................................................................................................................. 111
PRACTICAL 13B ................................................................................................................................................... 116
TO CONTROL TWO LAMPS (IN SERIES & PARALLEL) WITH ONE SWITCH ................................................................................... 116
PRACTICAL 13C ................................................................................................................................................... 121
TO WIRE FOR A STAIRCASE ARRANGEMENT USING A TWO-WAY SWITCH. ................................................................................ 121
PRACTICAL 13D .................................................................................................................................................. 126
TO WIRE FOR A GODOWN WIRING ARRANGEMENT USING ONE AND TWO-WAY SWITCHES.......................................................... 126
PRACTICAL 13E ................................................................................................................................................... 131
TO USE AN ANALOG AND DIGITAL MULTIMETER ............................................................................................................... 131
PRACTICAL 13F ................................................................................................................................................... 137
TO WIRE A DISTRIBUTION BOARD. .................................................................................................................................. 137
PRACTICAL 14 ..................................................................................................................................................... 141
OPEN ENDED LAB ...................................................................................................................................................... 141

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Course Learning Outcomes

S. Taxonomy
CLOs Domain PLOs
No Level
Imitate operations related to various shops in

1 Psychomotor 2 4
Mechanical Workshop
Demonstrate knowledge of basic workshop tools

2 Affective 3 9
while working individually and in a team
Grading Policy
Type of exam Percentage
Lab Reports + Rubrics (Psychomotor) 20
Rubric based Assessment in Affective domain 10
Open Ended Labs 10
Mid Term Exam 25
End semester Exam 35

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Assessment
AFFECTIVE (To be judged in the lab during experiment)
Levels of Achievement
Unacceptable Just acceptable Basic Good Excellent

(1) (2) (3) (4) (5)
I. Completely
Totally ignores Casual in Follows Follows desired
Adherence to adheres to
safety following safety adequate safety safety
Safety safety
procedures procedures procedures procedures
Procedures procedures
Distinguishes
Is able to make
Not able to between facts
Able to recall or Has applied the deductions
recall or and inferences.
appropriately concepts about other
II. appropriately Can trouble
interpret correctly for extensions/appl
Knowledge interpret shoot and
instructions the conduct of ications of the
instructions explain
provided the experiment experimental
provided problems/devia
results
tions
III. Demonstrates
Demonstrates
Participation Shows some commitment , Active
commitment
& Shows no commitment but but has participation
and also carries
Contribution commitment fails to perform difficulty and effective
out assigned
towards assigned roles performing contribution
roles
Group Goals assigned roles

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b) PSYCHOMOTOR (To be judged in the lab during experiment)
Levels of Achievement
Just
Unacceptable Basic Good Excellent
acceptable
(1) (3) (4) (5)
(2)
Learn skills Learns Learns

Unable to learn
I. and applies adequate skills desired Masters and applies
and apply
Procedural under and applies skills and desired skills with ease
appropriate
Skills repeated under applies with and confidence
skills
guidance guidance confidence
Uses Uses
II. Uses Masters use of
equipment equipment
Proficiency Unable to use equipment equipment proficiently
with minimal with adequate
in Use of the equipment skilfully and with precision
level of skills skills and
Equipment accurately
and accuracy accuracy
III.
Management Poor
Manages Manages work Manages
of Work management of Manages work area
work area to area work area
Area & work area proficiently
some extent adequately effectively
equipment
Care

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Practical 1A
Safety Measures in Workshop
Objectives:
1. To educate students regarding the safety principles

2. To prevent loss of life, permanent disability, and the loss of income of worker by
eliminating causes of accident
3. To increase production means to a higher standard of living
4. To have better morale of employees
5. To eliminate accidents causing work stoppage and production loss
Scope:
1. Decrease in direct and indirect cost of an accident.

2. Minimization of cost to society
3. To have better working conditions and morale of employees
Equipment:
1. First aid kit

2. Safety Gadgets
Introduction:
The danger of life of human being is increased with the advancement of scientific development
inn different fields. The importance of industry safety was realized because every year millions
of industrial accidents occur which result in either death or in temporary disablement or
permanent disablement of the employees. This result in large amount of loss in terms of damage
to property, wasted man-hours, machine hours. In order to avoid these accidents, workers should
be aware of the basic safety principles and dangers which may exist in an industry.
Safety Measures in Mechanical workshop
1. All equipment and machinery should be inspected for safety.

2. All moving and rotating parts should be properly guarded.
3. Ventilation system should be proper.
4. Efforts should be taken to minimize the dust.
5. Worker should wear all safety devices (goggles, apron/overalls)
6. File extinguishers should be mounted wherever it is necessary.
Safety measures in material handling
1. Each crane should carry proper guards for all moving and rotating parts.
2. All material handling equipment should be operated only by trained operators.

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3. Maintenance work should be done after switching off power supply and it should be done
by trained persons.
4. Crane should not be allowed to move with suspended loads.
5. Periodical inspection of all equipment’s should be done to detect faults or damage.
6. All electric wires should be properly insulated.
7. An effective lubrication schedule should be worked out and implemented.
8. Riding on a conveyor should be strictly prohibited.
9. Workers should be properly trained and should wear all protective clothing, helmets,
goggles etc.
10. The hands of the operator should be kept free from oil or grease while loading, moving
and unloading the material.
11. Pathways should not be slippery.
12. The body position of operator should be proper while doing loading and unloading.
13. Warning signals should be properly followed.
Safety measures against electric shocks
1. Only authorized persons should carry ut the electric works.

2. All operators associated with electric work should wear proper dress.
3. All equipment’s and tools used should be properly insulated.
4. Broken fittings like switches, plugs etc. should always be properly replaced.
5. Do not play with live wire. Do not work with damaged wires.
6. Inflammable material should not be kept near electrical machinery.
7. The fuses used should be of correct rating.
8. Circuit breakers should be mounted in proper numbers.
9. While doing the maintenance, the power supply should be switched off. Only authorized
person should be allowed to switch ‘on and off’ the power supply.
10. Avoid overloading on any single point.
11. Proper type of wiring should be provided in all locations.
12. Periodical inspection should be done to detect the damages.
Fire prevention and protection
1. Always select the least flammable liquid that will serve the purpose.
2. Keep all flammable liquids in closed containers or in safe cylinders.
3. Prohibit smoking, open flames and sparks near flammable materials.
4. Provide ventilation to prevent any accumulation of vapors.
5. Provide safe disposal for flammable liquid wastes.
6. Do not permit accumulation of fuels or other combustions near the source of open fire.
7. Provide suitable and adequate means of fire extinguishment.
8. Every operator should be familiar with the location of fire extinguishers and their use.
9. Provide suitable means for safe storage and handling device and any combustible
material.
10. All doors and windows should be opened towards the outside.

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First Aid
The accident may occur at any time in the factory. The doctor is also not available at that time
and that place for the treatment. Therefore, it is necessary to have first aid facilities in the factory,
so that preliminary treatment may be given to the person immediately after the accident. First
aid boxes should be easily available, properly equipped and in adequate numbers.
First Aid Materials
1. Roller bandages
2. Sterilized Dressing
3. Knife, Scissors
4. Dettol
5. Sterilized cotton wool
6. Eye Drops
7. Glass for taking medicine
8. Eye Washing Glass
9. KMnO4
10. Necessary Capsules and Tablets
11. Burnol
Introduction to Mechanical Workshop:

Mechanical Workshop is divided into five shops: -
a. Machine Shop: This shop deals with different machines used in mechanical workshop.
This mainly includes Lathe Machine, Milling Machine, Shaper Machine, Radial
Drilling Machine, CNC Lathe Machine, Hobbing Machine etc. In this Lab, students
will be able to perform different operations like facing, step turning, taper turning,
threading, knurling on Lathe Machine. Both lathes and milling machines are used to
remove material from a workpiece. Lathes, however, involve rotating a workpiece
against a single-bladed cutting tool, whereas milling machines involve rotating a multi-
bladed or -pointed cutting tool against a stationary workpiece.
b. Welding Shop: Welding is the process of joining similar metals by the application of
heat, with or without application of pressure or filler metal, in such a way that the joint
is equivalent in composition and characteristics of the metals joined. In the beginning,
welding was mainly used for repairing all kinds of worn or damaged parts. Now, it is
extensively used in manufacturing industry, construction industry (construction of ships,
tanks, locomotives, and automobiles) and maintenance work, replacing riveting and
bolting, to a greater extent. The various welding processes are:
i. Electric arc welding
ii. TIG welding
iii. MIG welding
iv. Thermal welding

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v. Electrical Resistance welding

vi. Friction welding
c. Carpentry Shop: The useful work on wood is generally carried out in the most common
shop known as carpentry shop. The work performed in carpentry shops comprises of
cutting, shaping, and fastening wood and other materials together to produce the products
of wood. Timber is a common name imparted to wood suitable for engineering,
construction and building purpose. Commercial timbers are commonly classified as
hardwoods and softwoods. Hardwoods comprises of oak and beech that have a broad leaf.
Whereas softwoods include pine and spruce which have narrow needles like leaf. A
comparison between hard and soft wood is given in the table below.
Hard Wood Soft Wood
It is dark in color Its color is light

It is heavy in weight It is light in weight
Hard woods are harder and denser Soft woods are comparatively lighter
It does not split quickly It gets splitted quickly

It is difficult to work It is easy to work.
Its annual rings are close and often Its annual rings are well spaced and quite
indistinct distinct
It is slow growing It is fast growing.
It has good tensile and shear It has good tensile resistance but is weak
resistance across the fibers.
It does not catch fire very soon It catches fire very soon
Shisham, Sal, Teak, Deodar, Mango, Mahogany, Kail, Chir, Babul, Fir wood, Walnut and
Haldu are common names of commonly used timber. Extracting wood from trees include
following steps cutting, sawing, and seasoning.
Felling or Cutting:
Cutting of living or standing trees to obtain timber is called felling of trees. Trees are cut
at appropriate time. The best time for sawing the tree is immediately after the tree has
achieved its full growth or maturity age so that the maximum quantity and best quality of
wood can be obtained.
Conversion or Sawing:
Conversion means sawing of timber logs into different commercial sizes. A notable
feature in conversion is to provide an adequate allowance for shrinkage that takes place
during seasoning of sawn or converted wood. The shrinkage of wood usually varies
between 3.2 mm to 6.4 mm, according to the type of wood and its time of cutting. The
three methods of conversion commonly adopted are discussed as under.
• Flat or ordinary cutting
• Tangential cutting

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• Quarter or radial cutting

Seasoning:
Seasoning of wood is the reduction of the moisture or sap content of it to the point where,
under normal conditions of use, no further drying out will take place. The main objective
of seasoning is to reduce the unwanted amount of moisture from the timber.
Seasoning is classified into two categories namely natural seasoning and artificial
seasoning.
• Natural seasoning is carried out generally in air, or in water or in smoke.
• Artificial seasoning is controlled by application of both heat and humidity which
enables to reduce the moisture content quickly and accurately.
d. Fitting Shop: Machine tools are capable of producing work at a faster rate, but, there are
occasions when components are processed on the bench. Sometimes, it becomes
necessary to replace or repair components which must be fit accurately with another
component on reassembly. This involves a certain amount of hand fitting. The assembly
of machine tools, jigs, gauges, etc, involves a certain amount of bench work. The accuracy
of work done depends upon the experience and skill of the fitter. The term ‘bench work’
refers to the production of components by hand on the bench, whereas fitting deals which
the assembly of mating parts, through removal of metal, to obtain the required fit. Both
the bench work and fitting require the use of a number of simple hand tools and
considerable manual efforts. The operations in the above works consist of filing, chipping,
scraping, sawing drilling, and tapping.
e. Electric Shop: This shop deals with different electrical components used in mechanical
workshops like different type of switches, types of wiring, bulbs, series and parallel
boards.
• One- and Two-way Switch: One way switch is mostly used in single room.
Two-way switches are used in hallways. The casing is made of plastic and
internal contacts are made up of brass and copper.
• MCB Box: Known as the Miniature Circuit Breaker Box.
• Metal Conduit Pipe with Junction Box: Metallic hollow pipe, which is
• used as a passage for electrical house, hold wires. It is fixed to the walls with the
help of metallic saddle.
• Fuse: Mostly used in circuit to prevent short circuiting. Use of MCB, RCCB and
Isolator Fuse.
• Electrical Wiring: Use of electric wires according to American Wire Guage
standards. Use of 3/29 and 7/29 wires.
• Bulbs and Holders.
• PVC Casting and Lapping: Long rectangular box made of 2 parts. It is made of
PVC and used mainly to pass wires through walls during wiring.

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Comments:
Evaluation Rubrics
Performance Exemplary Satisfactory Developing Unsatisfactory Marks
Criteria (5) (3-4) (1-2) (0)
Steps of experiment are Steps of experiment Steps of

clear, sequential, and in are present but lacking experiment are Procedure is
Procedure Complete sentences. Completeness. incomplete and missing.
Picture of steps are Conclusion is complete procedure is Conclusion is
included. Conclusion is and written in lacking. missing.
complete and written in incomplete sentence Conclusion is
complete sentence. incomplete
Understanding
the concept Understands Understand majority of Understand few Didn’t able to
everything of the topic the portion. things. understand the
concept.
Lab Instructor: Engr. Khubaib Haider Khan

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Practical 1B
Plant and Shop Layout
Objectives:
1. Integration of production center facilities like workers, machinery, raw material etc. in a
logical and balanced manner.
2. Minimum movement of workers and materials
3. Elimination of bottlenecks and congestion points
4. Proper utilization of space
5. To create flexible and hazards free environment
Scope:
1. To achieve most efficient utilization of men, machines and materials by systematic and
functional arrangement of different departments, machines, equipment’s, tools and
services in an industry
2. Utilization of all available resources in most efficient and economical manner to optimize
production.
Factors in Plant Layout
The location of plant depends on many factors, which are as follows:
1. Decision of a new product.
2. Nearness to raw material and marks
3. Availability of space, power, labor, water, transport facilities.
4. Good climate conditions.
5. Financial and other aids
6. Local bylaws, taxes, security, hospitality etc.

7. Facilities for expansion.
8. Prescience of related industries

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After deciding size and location of enterprise, the next step is to plan the internal layout of the
factory based on the following
1. Manufacturing processes to be adopted
2. Type of production
3. Specification and size of raw material and product
4. Material handling devices
5. Extent of automation
6. Scope for further expansion or modification
7. Service facilities
8. Links between various shops
The next step is to plan the layout of a shop, which depends on following factors:
1. Size and types of components to be produced
2. Types of machines available
3. Number of machines available sequence of operations
4. Power requirements
5. Store location
6. Inspection
7. Utility of individual machine
8. Interior and exterior set-up of the shop
Types of plant layout
Fixed position layout
This type of layout is used in ship building, automobile industry, railway wagon industry, aero
plane manufacturing etc. in the automobile industry the chassis are kept are fixed place and all
components are brought to it for assembly from different sections.
Process layout of functional layout

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In this type of layout similar operations are performed at one location i.e. lathes will be at one
place, all drilling machines at another and so on
Product layout of line layout
In this layout all machines are arranged according to the sequence of operations needed to form
a product. For example, in order to manufacture a product, the sequence of operations consists
turning, drilling, milling and grinding. The layout will consist of a lathe machine then drilling
machine, then milling machine and then the grinder to perform turning, drilling, milling and
grinding.
Combination Group layout
Advantages of process layout and product layout is combined in one layout and that layout is
called the combination layout or group layout. This is used for products that needs similar
sequence of operations to manufacture despite their shape and size.

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Layout of Workshop Practice Lab

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Comments:
Evaluation Rubrics
Criteria (5) (3-4) (1-2) (0)

missing.
included. Conclusion is and written in lacking.
Understanding
concept.

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FITTING
SECTION

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Practical 2A
To file the given two Mild Steel pieces into a rectangular shape for given piece.
a. Raw Material b. Finished Job
Figure 2.1A: Square Filing
Objectives:
1. To get familiar with bench work, filing operation in fitting shop.

2. Categorization of different tools for fitting shop.
3. Learn to take measurements on Vernier caliper and screw gauge.
Scope:
1. Quality Control
2. Assembly of Parts
Tools and Equipment:
• Vernier Caliper
• Micrometer Screw Gauge
• Files
• Workpiece
• Try square
• Steel rule
• Bench Vice

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Theory:
Bench Vice:
Bench vice is the common mechanical device used to hold workpiece. It is widely used in metal
working and wood working practices. It consists of two flat jaws, one fixed and the other being
moveable. Handle is used to tight an object in the vice.
Figure 2.2A: Cross section of Bench Vice
Try Square:
A try square or try-square is a woodworking tool used for marking and checking 90° angles on
pieces of wood. Though woodworkers use many different types of square, the try square is
considered one of the essential tools for woodworking. The square in the name refers to the 90°
angle.
Figure 2.3A: Try Square
Vernier Caliper:
It is an instrument used for precise measurement. The main body of the instrument includes the
main scale with a fixed anvil at one end. This carries a sliding anvil that is provided with a
second, vernier scale. Determination of the point where the two scales coincide enables very
accurate measurements to be made, with typical inaccuracy levels down to 0.01%.

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Figure 2.4A: Vernier Caliper
Micrometer Screw Gauge:
Micrometer is precision tool used to measure up-to an accuracy of 0.01mm. It is used to

measure outside diameter, inside diameter and thickness of objects.
Figure 2.5A: Micrometer Screw Gauge
Files:
File is used to cut, trim, or finish a job of metal or wood, to give them a shape according to our
needs such as making the job round, square or angular. File is made from high carbon steel. In
addition, a file is used to where other cutting tools cannot be used. Files are also used for
sharpening the edge of some other cutting tools.

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Figure 2.6A: Different type of Files
Figure 2.7A: Parts of a file
Sequence of Operation:
1. The dimensions of the given piece are checked with the steel rule.
2. The job is fixed rigidly in a bench vice and the two adjacent sides are filed, using the
rough flat file first and then the smooth flat file such that, the two sides are at right angle.
3. The right angle of the two adjacent sides is checked with the try square.
4. Chalk is then applied on the surface of the work piece.
5. The given dimensions are marked by scribing two lines, with reference to the above two
datum sides by using Vernier height gauge, Angle plate and Surface plate.
6. Using the dot punch, dots are punched along the above scribed lines.

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7. The two sides are then filed, by fitting the job in the bench vice; followed by checking
the flatness of the surfaces.
8. As the material removal through filing is relatively less, filing is done instead of sawing.
Discussion:
• Precautions:
Comments:
Evaluation Rubrics
Criteria (5) (3-4) (1-2) (0)

Understanding
concept.

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Practical 2B
To make V‐ fit from the given two MS plates and do drilling and tapping.
Figure 2.1B: V fitting
Objectives:
1. To get familiar with bench work, filing operation in fitting shop.

2. Categorization of different tools for fitting shop.
3. Learn to use the measuring, marking, drilling, and tapping tools.
Scope:
1. Quality Control
2. Assembly of Parts
• Vernier Caliper
• Micrometer Screw Gauge
• Files
• Workpiece
• Try square
• Steel rule
• Bench Vice

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Theory:
Bench Vice:
Bench vice is the common mechanical device used to hold workpiece. It is widely used in metal
working and wood working practices. It consists of two flat jaws, one fixed and the other being
moveable. Handle is used to tight an object in the vice.
Figure 2.2B: Cross section of Bench Vice
Try Square:
A try square or try-square is a woodworking tool used for marking and checking 90° angles on
pieces of wood. Though woodworkers use many different types of square, the try square is
considered one of the essential tools for woodworking. The square in the name refers to the 90°
angle.
Figure 2.3B: Try Square
Vernier Caliper:
It is an instrument used for precise measurement. The main body of the instrument includes the
main scale with a fixed anvil at one end. This carries a sliding anvil that is provided with a
second, vernier scale. Determination of the point where the two scales coincide enables very
accurate measurements to be made, with typical inaccuracy levels down to 0.01%.

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Figure 2.4B: Vernier Caliper
Micrometer Screw Gauge:
Micrometer is precision tool used to measure up-to an accuracy of 0.01mm. It is used to

measure outside diameter, inside diameter and thickness of objects.
Figure 2.5B: Micrometer Screw Gauge
Files:
File is used to cut, trim, or finish a job of metal or wood, to give them a shape according to our
needs such as making the job round, square or angular. File is made from high carbon steel. In
addition, a file is used to where other cutting tools cannot be used. Files are also used for
sharpening the edge of some other cutting tools.

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Figure 2.6B: Different type of Files
Figure 2.7B: Parts of a file
1. The burrs in the pieces are removed and the dimensions are checked with steel rule.
2. Make both pieces surface levels and right angles by fixing in the Vice, use Files for
removing material to get level.
3. With the help of Try square check the right angles and surface levels.
4. Using Surface plate and Angle plate mark the given two metal pieces as per drawing
with Vernier height gauge.
5. Punch the scribed lines with dot punch and hammer keeping on the Anvil. Punch to
punch give 5mm gap.

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6. Cut excess material wherever necessary with Hacksaw frame with blade, Drill bits and
Taps.
7. The corners and flat surfaces are filed by using square/flat and triangular file to get the
sharp corners.
8. Dimensions are checked by Vernier caliper and match the two pieces. Any defect
noticed, are rectified by filing with a smooth file.
9. Care is taken to see that the punched dots are not crossed, which is indicated by the half
of the punch dots left on the pieces.
Discussion:
• Precautions:
Comments:
Evaluation Rubrics
Criteria (5) (3-4) (1-2) (0)

Understanding
concept.

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CARPENTRY
SECTION

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Practical 3A
To make a T‐lap joint from the given reaper in Carpentry Shop.
Figure 3.1A: T-lap Joint
Objectives:
1. To get familiarization with wood types, wood cutting, seasoning, and drying
operations.
2. Identification of wooden defects
3. Getting acquaintance with different wood joint types, tools and machines used in wood
working shop.
Scope:
1. Building construction
2. Household
3. Patterns in sand casting
• Hack saw
• Glue

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• Planner
• Hammer
• Nails
• Screwdriver
• Wood pieces
Theory:
The useful work on wood is being generally carried out in a most common shop known as
carpentry shop. The work performed in carpentry shops comprises of cutting, shaping, and
fastening wood and other materials together to produce the products of woods. Timber is a
common name imparted to wood suitable for engineering, construction and building purpose.
Commercial timbers are commonly classified into hardwoods and softwoods. Hardwoods
comprises of oak and beech that have a broad leaf. Whereas softwoods include pine and spruce
which have narrow needle like leaf. Comparison between hard and soft wood is given in table
below.
Table 3.1A: Comparison of Hard and Soft Wood

Hard Wood Soft Wood


indistinct distinct
Shisham, Sal, Teak, Deodar, Mango, Mahogany, Kail, Chir, Babul, Fir wood, Walnut and Haldu
are common names of commonly used timber. Extracting wood from trees include following
steps cutting, sawing, and seasoning.
Felling or Cutting:
Cutting of living or standing trees to obtain timber is called felling of trees. Trees are cut at
appropriate time. The best time for sawing the tree is immediately after the tree has achieved its
full growth or maturity age so that the maximum quantity and best quality of wood can be
obtained.

31 | Page
Conversion means sawing of timber logs into different commercial sizes. A notable feature in
conversion is to provide an adequate allowance for shrinkage that takes place during seasoning
of sawn or converted wood. The shrinkage of wood usually varies between 3.2 mm to 6.4 mm,
according to the type of wood and its time of cutting. The three methods of conversion
commonly adopted are discussed as under.

Seasoning:
Seasoning of wood is the reduction of the moisture or sap content of it to the point where, under
normal conditions of use, no further drying out will take place. The main objective of seasoning
is to reduce the unwanted amount of moisture from the timber.
Seasoning is classified into two categories namely natural seasoning and artificial seasoning.

Common tools used in carpentry shop include Steel rule, Folding rule, Flexible steel rule,
Mortise gauge, Carpenter vice, bow saw, compass saw, rip saw, simple plane, Chisel, Adze,
Mallet, Claw hammer, Screw driver, Auger bit.
1. The given reaper is checked to ensure its correct size.

2. The reaper is firmly clamped in the carpenter's vice and any two adjacent faces are
planned by the jack plane and the two faces are checked for squareness with the try
square.
3. A marking gauge is set and lines are drawn to mark the thickness and width
respectively according to the dimensions provided of the model.
4. The excess material is first chiseled out with a firmer chisel and then planned to
correct size.
5. The mating dimensions of the parts X and Yare are then marked using scale and
marking gauge.
6. Using the cross‐cut saw, the portions to be removed are cut in both the pieces,
followed by chiseling and the parts X and Y are separated by cross‐cutting, using the
saw.
7. The ends of both the parts are chiseled to the exact lengths.
8. A fine finishing is given to the parts, if required so that, proper fitting is obtained.
9. The parts are fitted to obtain a slightly tight joint.

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Discussion:
• Precautions:
Comments:
Evaluation Rubrics
Criteria (5) (3-4) (1-2) (0)

Understanding
concept.

33 | Page
Practical 3B
To make a dovetail lap joint from the given reaper in Carpentry Shop.
Figure 3.1B: Dovetail Joint
Objectives:
operations.
working shop.
Scope:
2. Household
• Hack saw

34 | Page
• Glue
• Planner
• Hammer
• Nails
• Screwdriver
• Wood pieces
Theory:
below.
Table 3.1B: Comparison of Hard and Soft Wood
Hard Wood Soft Wood


indistinct distinct
Felling or Cutting:

35 | Page
obtained.

Seasoning:

Common tools used in carpentry shop include Steel rule, folding rule, Flexible steel rule, Mortise
gauge, Carpenter vice, bow saw, compass saw, rip saw, simple plane, Chisel, Adze, Mallet, Claw
hammer, Screw-driver, Auger bit.

square.
correct size.
5. The mating dimensions of the parts X and Yare are then marked using scale and
marking gauge.
6. Using the cross‐cut saw, the portions to be removed are cut in both the pieces,
followed by chiseling and the parts X and Y are separated by cross‐cutting, using the
saw.

36 | Page
7. The ends of both the parts are chiseled to the exact lengths.
8. A fine finishing is given to the parts, if required so that, proper fitting is obtained.
9. The parts are fitted to obtain a slightly tight joint.
Discussion:
• Precautions:
Comments:
Evaluation Rubrics
Criteria (5) (3-4) (1-2) (0)

Understanding
concept.

37 | Page
Practical 4A
To make a Mortise and Tenon joint from the given reaper in Carpentry Shop.
Figure 4.1A: Mortise and Tenon Joint
Objectives:
operations.
working shop.
Scope:
2. Household
• Hack saw
• Glue
• Planner
• Hammer
• Nails

38 | Page
• Screwdriver
• Wood pieces
Theory:
below.
Table 4.1A: Comparison of Hard and Soft Wood

Hard Wood Soft Wood


indistinct distinct
Felling or Cutting:
obtained.

39 | Page

Seasoning:

Mallet, Claw hammer, Screwdriver, Auger bit.

2. The reaper is firmly clamped in the carpenter's vice and one of its faces are planned by
the jack plane and checked for straightness.
3. The adjacent face is then planned, and the faces are checked for squareness with the
try square.
5. The excess material is first chiseled out with the firmer chisel and then planned to
correct size.
6. The mating dimensions of the parts X and Yare are then marked using the scale and
marking gauge.
7. Using the cross‐cut saw, the portions to be removed in part Y (tenon) is cut, followed
by chiseling.
8. The material to be removed in part X (mortise) is carried out by using the mortise and
firmer chisels.
9. The parts X and Yare separated by cross‐cutting with the saw.

40 | Page
10. The ends of both the parts are chiseled to exact lengths.
11. Finish chiseling is done wherever needed so that, the parts can be fitted to obtain a
near tight joint.
Discussion:
• Precautions:
Comments:
Evaluation Rubrics
Criteria (5) (3-4) (1-2) (0)

Understanding
concept.

41 | Page
Practical 4B
To make alphabets from the given reaper in Carpentry Shop.
Figure 4.1B: Alphabets using wood working
Objectives:
operations.
working shop.
Scope:
2. Household
• Hack saw
• Glue
• Planner
• Hammer
• Nails
• Screwdriver
• Wood pieces

42 | Page
Theory:
below.
Table 4.1B: Comparison of Hard and Soft Wood

Hard Wood Soft Wood


indistinct distinct
Felling or Cutting:
obtained.

43 | Page

Seasoning:

Mallet, Claw hammer, Screw driver, Auger bit.

square.
3. A marking gauge is set, and lines are drawn to mark the thickness and width
correct size.
5. Using wooden files remove extra material to make the desired alphabet.
6. A fine finishing is given to the part.

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Discussion:
• Precautions:
Comments:
Evaluation Rubrics
Criteria (5) (3-4) (1-2) (0)

missing.
Understanding
concept.

45 | Page
MACHINING
SECTION

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Practical 5A
To perform facing and plain turning on a given cylindrical workpiece using lathe
machine.
Figure 5.1A: Plain Turning & Facing
Objectives:
1. To get familiarization with lathe machine and its parts

2. To comprehend the process of facing on lathe
3. To adapt safety considerations while working with lathe
4. To accomplish turning process on lathe
Scope:
1. Turning (process performed on lathe) is used to produce rotational, typically axi-

symmetric, parts that have many features, such as holes, grooves, threads, tapers, various
diameter steps, and even contoured surfaces.
2. Parts that are fabricated completely through turning often include components that are
used in limited quantities, perhaps for prototypes, such as custom designed shafts and
fasteners.
3. Due to the high tolerances and surface finishes that turning can offer, it is ideal for
adding precision rotational features to a part whose basic shape has already been
formed.
4. Applications include Machine components, shafts, engine components (crankshaft).
• Lathe machine
• Headstock
• Tailstock
• Chuck
• Carriage

47 | Page
• Lathe bed
Theory:
Facing:
Facing is the process of removing metal from the end of a workpiece to produce a flat surface.
Figure 5.2A: Facing on Lathe
Turning:
Turning is machining operation in which a single point tool removes material from a surface of
rotating workpiece. Turning is carried out on a machine called a lathe. The basic lathe used for
turning and related operations is an engine lathe shown in figure. It is a versatile machine tool,
manually operated, and widely used in low and medium production.
Figure 5.3A: Tool Types

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Figure 5.4A: Lathe machine and its parts
Headstock:
The headstock contains the drive unit to rotate the spindle, which rotates the work.
Tailstock:
Opposite the headstock is the tailstock, in which a center is mounted to support the other end of
the workpiece. The cutting tool is held in a tool post fastened to the cross-slide, which is
assembled to the carriage.
Carriage:
The carriage is designed to slide along the ways of the lathe to feed the tool parallel to the axis
of rotation. The carriage is driven by a leadscrew that rotates at the proper speed to obtain the
desired feed rate. The cross-slide is designed to feed in a direction perpendicular to the carriage
movement. Thus, by moving the carriage, the tool can be fed parallel to the work axis to perform
straight turning; or by moving the cross-slide, the tool can be fed radially into the work to
perform facing, form turning, or cutoff operations.
Cutting Speed:
The rotational speed in turning is related to the desired cutting speed at the surface of the
cylindrical workpiece by the equation.
𝑣
𝑁=
𝜋𝐷
N rotational speed, rev/min; v cutting speed, m/min (ft/min); and D original diameter of the part,
m (ft)

49 | Page
The feed in turning is generally expressed in mm/rev (in/rev). This feed can be converted to a
linear travel rate in mm/min (in/min) by the formula
𝑓𝑟 = 𝑓𝑁
Reference values for cutting speed and turning feed is taken from reference tables depending
upon material type.
1. The given work piece is held in the 3‐jawchuck of the lathe machine and tightened
firmly with chuck key.
2. Right hand single point cutting tool is tightened firmly with the help of box key in the
tool post.
3. Machine is switched on and the tool post is swiveled, and the cutting point is adjusted
such that it positioned approximately for facing operation then the tool is fed into the
work piece and the tool post is given the transverse movement by rotating the hand
wheel of the cross slide.
4. With this facing is completed and the tool post is swiveled and cutting point is made
parallel to the axis of work piece.
5. Depth of cut is given by cross slide to the tool post according to the dimension
provided and the side hand wheel is rotated to give the longitudinal movement for the
tool post and job is turned to the required length and diameter.
6. After completion of the job, it is inspected for the dimensions obtained with the help
of steel rule and outside caliper or Vernier caliper.
Discussion:
• Precautions:

50 | Page
Comments:
Evaluation Rubrics
Criteria (5) (3-4) (1-2) (0)

missing.
Understanding
concept.

51 | Page
Practical 5B
To perform taper turning and step turning on a given cylindrical workpiece using
lathe machine.
Figure 5.1B: Step Turning
Objectives:

2. To comprehend the process of taper turning on lathe
4. To accomplish step turning process on lathe
Scope:
1. Provides rapid and accurate method of aligning machine parts and easy method of
holding tools i.e. taper shank of various tools
2. The machine taper, a system for securing cutting tools or toolholders in the spindle of a
machine tool or power tool, is a simple, low-cost, highly repeatable, and versatile tool
mounting system used in drills, lathe and milling
3. Other applications include conically tapered joints and tapered thread.
• Lathe machine
• Headstock
• Tailstock
• Chuck
• Carriage
• Lathe bed

52 | Page
Theory:
Step Turning:
Step turning is an operation performed on lathe machine where the excess material is removed
from the work piece to obtain various steps of different diameters. A step turning operation is
performed using a wide tool after the plain turning operation. The work is held in between the
lathe centers or with the chuck and the tool is held at the height of the axis of the work. The
depth of cut to obtain the step on the cylinder is provided by cross slide movement and feed by
the carriage movement. This operation is performed manually.
Figure 5.2B: Step Turning
Taper Turning:
When the diameter of a piece changes uniformly from one end to the other, the piece is said to
be tapered. Taper turning as a machining operation is the gradual reduction in diameter from one
part of a cylindrical workpiece to another part. Tapers can be either external or internal. If a
workpiece is tapered on the outside, it has an external taper; if it is tapered on the inside, it has
an internal taper.
Figure 5.3B: Taper Turning

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Figure 5.4B: Tool Types
Figure 5.5B: Lathe machine and its parts
Headstock:
The headstock contains the drive unit to rotate the spindle, which rotates the work.
Tailstock:
Opposite the headstock is the tailstock, in which a center is mounted to support the other end of
the workpiece. The cutting tool is held in a tool post fastened to the cross-slide, which is
assembled to the carriage.
Carriage:
The carriage is designed to slide along the ways of the lathe to feed the tool parallel to the axis
of rotation. The carriage is driven by a leadscrew that rotates at the proper speed to obtain the
desired feed rate. The cross-slide is designed to feed in a direction perpendicular to the carriage
movement. Thus, by moving the carriage, the tool can be fed parallel to the work axis to perform

54 | Page
straight turning; or by moving the cross-slide, the tool can be fed radially into the work to
perform facing, form turning, or cutoff operations.
Cutting Speed:
The rotational speed in turning is related to the desired cutting speed at the surface of the
cylindrical workpiece by the equation.
𝑣
𝑁=
𝜋𝐷
N rotational speed, rev/min; v cutting speed, m/min (ft/min); and D original diameter of the part,
m (ft)
The feed in turning is generally expressed in mm/rev (in/rev). This feed can be converted to a
linear travel rate in mm/min (in/min) by the formula
𝑓𝑟 = 𝑓𝑁
Reference values for cutting speed and turning feed is taken from reference tables depending
upon material type.
2. Right hand single point cutting tool is taken tightened firmly with the help of box key
in the tool post.
3. Machine is switched on and the tool post is swiveled and the cutting point is adjusted
such that it positioned approximately for facing operation then the tool is fed into the
work piece and the tool post is given the transverse movement by rotating the hand
wheel of the cross slide.
4. With this facing is completed and the tool post is swiveled and cutting point is made
parallel to the axis of work piece. It is important that the tip of the cutting tool be right
at the centerline of the lathe.
5. For Step turning, depth of cut is given by cross slide to the tool post according to the
dimension provided and the side hand wheel is rotated to give the longitudinal
movement for the tool post and job is turned to the required length and diameter.
Different depths are given at different lengths for step turning.
6. Taper turning step is like step 5, the only difference is that adjust the angle of tool holder
so that the tool is at angle θ (provided) to the central axis of work piece.
7. After completion of the job, it is inspected for the dimensions obtained with the help
of steel rule and outside caliper or Vernier caliper.

55 | Page
Discussion:
• Precautions:
Comments:
Evaluation Rubrics
Criteria (5) (3-4) (1-2) (0)

missing.
Understanding
concept.

56 | Page
Practical 6
To perform Knurling, Boring and Reaming operation on a given cylindrical
workpiece using lathe machine.
Objectives:

2. To comprehend the process of knurling on lathe
4. To accomplish boring and reaming operations on lathe
Scope:
1. To provide a better gripping surface

2. Straight knurling is often used to increase the workpiece diameter when a press fit is
required between two parts
3. Tool handles, mechanical pencils, the grips of pistols, barbell bars, and the control
knobs on electronic equipment are frequently knurled.
4. Enlarging holes for gun barrel and engine cylinders.
• Lathe machine
• Knurl tool
• Boring tool
• Reaming tool
• Workpiece
Theory:
Knurling:
Knurling is a process of impressing a diamond shaped, straight line or cross shaped pattern into
the surface of a workpiece by using specially shaped hardened metal wheels. By pressing the
teeth into the workpiece, the diameter of the knurled portion will increase by approximately half
the tooth pitch since there is no chip removal. Therefore, the diameter of the workpiece must be
turned smaller by 1 to ½ tooth pitch depending on the material. Knurling can be categorized
based on impression designs as straight, spiral, cross and depending on pitch as coarse, medium,
fine respectively.

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Figure 6.1: Knurling
Boring:
In machining, boring is the process of enlarging a hole that has already been drilled (or cast) by
means of a single point cutting tool (or of a boring head containing several such tools), such as
in boring a gun barrel or an engine cylinder.
Figure 6.2: Boring
Reaming:
Reaming is a finishing operation of high-precision holes performed with a multi-edge tool. High
surface finish, superb hole quality and close dimensional tolerance are achieved at high
penetration rates and small depths of cut.

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Figure 6.3: Reamer
2. Knurl / boring / reamer tool is tightened firmly with the help of box key in the tool
post.
3. Machine is switched on and the tool post is swiveled, and the tool is adjusted such that
it positioned approximately for knurling. For boring and reamer operation then the tool
is fed into the work piece and the tool post is given the transverse movement by
rotating the hand wheel of the cross slide to remove the material according to the
dimensions provided.
4. With this knurling and boring / reaming operation is completed and the tool post is
swiveled.

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Discussion:
• Precautions:
Comments:
Evaluation Rubrics
Criteria (5) (3-4) (1-2) (0)

missing.
Understanding
concept.

60 | Page
Practical 7
To perform threading on a given cylindrical workpiece using lathe machine.
Objectives:

2. To comprehend the process of threading on lathe
4. To get familiarized with thread terminologies.
Scope:
1. Temporary fastening like wood screws, machine screws, nut, and bolts
2. Gear reduction via Worm drive to increases torque
3. Convert circular motion to linear motion like lead screw of lathe
4. Used in measurement as in micrometer
• Lathe machine
• Headstock
• Tailstock
• Chuck
• Carriage
• Lathe bed
Theory:
Threading:
Thread is defined as continuous helical ribs on a cylindrical shank. Screw threads are used
principally for fastening, adjusting, and transmitting power. To perform these specific functions,
various thread forms have been developed. A thread on the outside of a cylinder or cone is an
external (male) thread; a thread on the inside of a member is an internal (female) thread. Most
important terms used for threads are that of the outer diameter and pitch. In the case of a metric
thread, the bolt is named in accordance with its outer diameter e.g. a bolt with a 5 mm outer
diameter is known as an M5 bolt.

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Figure 7.1: a) Male b) Female thread
Figure 7.2: Tool Types
Major Diameter:
Largest diameter of straight thread. The term replaces as “outside diameter” for screw thread
and “full diameter” for nut.
Minor Diameter:
Smallest diameter of thread. The term replaces as “core diameter/root diameter” for thread of a
screw and “inside diameter” for nut.
Pitch Diameter:
Diameter of an imaginary coaxial cylinder, the surface of which pass through thread profiles at
such points as to make the width of the groove equal to one half of the basic pitch.

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Pitch:
The distance from a point on a screw thread to a corresponding point on a next thread measured
parallel to axis.
Lead:
The distance the screw thread advances axially in one turn; on a single threaded screw pitch is
identical to lead, on a double threaded screw lead is twice the pitch, on a triple angle thread lead
is thrice the pitch.
Angle of Thread:
The angle included between sides of thread measured in an axial plane. Lead Angle: The angle
made by helix of thread at the pitch diameter (nominal diameter) with a plane perpendicular to
axis.
Crest:
The top surface joining adjacent sides or flanks of thread. Root: The bottom surface joining
adjacent sides or flanks of thread.
Flank:
The surface connecting crests and root.
Thread standards:
Whitworth Form applies to
• British Standard Whitworth (BSW)
• British Standard Fine (BSF)
• British Standard Pipe (BSP)
Unified Thread Form
• Coarse (UNC)
• Fine (UNF)
• Extra fine (UNEF)
• Or pitch/UN e.g. 32UN
International Standard Organization (Metric)

63 | Page
Figure 7.3: Threading
1. Set the speed of spindle.

2. Set the quick-change gearbox for the required pitch in threads. (Threads per inch)
3. Install threading tool bit and set the height to the lathe center point.
4. Set the tool bit at a right angle to the work.
5. Set the depth of cut for an initial test pass. Engage the auto-feed lever sharply whilst
your left hand is on the FORWARD/OFF/REVERSE (F/O/R) switch. As the tool
approaches the end of the desired thread, turn the switch to 'OFF'. Do not disengage the
auto-feed lever. Use a thread pitch gauge to check that the pitch is as required.
6. Retract the tool, using the cross-slide feed handle, noting the exact position on the scale
and the exact number of turns. Turn the F/O/R switch to 'REVERSE', whereupon the
saddle will wind back to the beginning and turn the switch to 'OFF'. Reset the tool by
winding in the cross-slide the exact number of turns previously wound out, plus the
desired depth of cut.
7. Turn the F/O/R switch to FORWARD. As the tool approaches the end of the desired
thread, turn the switch to 'OFF'. Do not disengage the auto-feed lever.
8. Repeat steps 6 & 7 until the thread is completed.

64 | Page
Discussion:
• Precautions:
Comments:
Evaluation Rubrics
Criteria (5) (3-4) (1-2) (0)

missing.
Understanding
concept.

65 | Page
Practical 8
To perform horizontal cutting, vertical cutting, and grooving on a given work
piece using shaper machine.
Objectives:
1. Getting introduced with shaper machine and its parts

2. Understanding of working principle of shaper
3. Understanding of slotting process on shaper machine
Scope:
1. Keyways in the boss of a pulley or gear can be machined without resorting to a

dedicated broaching setup
2. Dovetail slides
3. Internal splines and gear teeth
• Shaper Machine
• Wood piece
• Vernier Caliper
Theory:
Shaper is a reciprocating type of machine tool in which the ram moves the cutting tool backwards
and forwards in a straight line. A shaper is used to generate flat (plane) surfaces by means of a
single point cutting tool like a lathe tool. Cutting of material takes place during the forward
stroke of the ram. The backward stroke remains idle. The time taken during the idle stroke is
less as compared to forward cutting stroke and this is obtained by quick return mechanism.
Figure 8.1: Shaper Machine

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Figure 8.2: Parts of Shaper Machine
1. The two ends of the work piece are first smoothened by filing and apply chalk on its
surface.
2. Place the work piece on the V-block and mark center on the end face using surface
gauge, scriber, and Vernier height gauge.
3. Mark square on the end face according to the required dimensions.
4. By using dot punch made permanent indentation marks on the work piece.
5. The tool is fixed to the tool post such that the tool movement should be exactly
perpendicular to the table. The work piece is then set in the vice such that the tool is
just above the work piece.
6. Adjust the length of the stroke.
7. Make sure that line of action of stroke should be parallel to the surface of the work
piece.
8. Give depth of cut by moving the tool and feed is given to the work piece during return
stroke of the ram.
9. Continue the process, until the required dimensions are to be obtained.
10. Repeat the process for all the four sides.
11. Finally make a keyway on one side according to the given dimensions.

67 | Page
Discussion:
• Precautions:
Comments:
Evaluation Rubrics
Criteria (5) (3-4) (1-2) (0)

missing.
Understanding
concept.

68 | Page
WELDING
SECTION

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Practical 9A
To make a lap joint, using the given mild steel pieces using arc welding.
Figure 9.1A: Lap Joint
Objectives:
1. To understand the process of welding

2. Categorization of different types of welding processes
3. Application of weld types and joint types
4. To get hands on experience of arc welding process
Scope:
1. Today, almost all the commonly employed metals and their alloys can be welded.
Welding is used both as a fabrication process for maintenance and repair jobs. The
process finds applications in Building and Bridge construction, Automotive and aircraft
industry, tanks, boiler, pressure vessel fabrication, Ship building, Pipes and Penstock
joining.
• Arc Welding plant

• Welding rods
• Chipping hammer
• Safety goggles
• Lab apparel
• Gloves
Theory:
Welding processes divide into two major categories: (i) fusion welding, in which coalescence is
accomplished by melting the two-part surfaces to be joined, in some cases adding filler metal to
the joint; and (ii) solid-state welding, in which heat and/or pressure are used to achieve
coalescence, but no melting of the base metals occurs and no filler metal is added.

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Arc welding is a type of welding process that uses an electric arc to join two pieces of metal
together. In this process, an electric current is passed through an electrode, which creates an arc
between the electrode and the metal workpiece. The heat generated by the arc melts the metal,
which then cools and solidifies, forming a strong bond.
Figure 9.2A: Arc Welding Plant
Arc welding (AW) is a fusion-welding process in which coalescence of the metals is achieved
by the heat of an electric arc between an electrode and the work. generic AW process is shown
in Figure 9.3A. An electric arc is a discharge of electric current across a gap in a circuit. It is
sustained by the presence of a thermally ionized column of gas (called a plasma) through which
current flows. To initiate the arc in an AW process, the electrode is brought into contact with the
work and then quickly separated from it by a short distance. The electric energy from the arc
thus formed produces temperatures of 5500°C (10,000°F) or higher, sufficiently hot to melt any
metal. A pool of molten metal, consisting of base metal(s) and filler metal (if one is used) is
formed near the tip of the electrode. In most arc-welding processes, filler metal is added during
the operation to increase the volume and strength of the weld joint. As the electrode is moved
along the joint, the molten weld pool solidifies in its wake.
Figure 9.3A: Basic Configuration of Arc Welding

Types of Joints
There are five basic types of joints for bringing two parts together for joining. The five joint
types are not limited to welding; they apply to other joining and fastening techniques as well.
With reference to Figure 9.4A, the five joint types can be defined as follows:
a) Butt joint. In this joint type, the parts lie in the same plane and are joined at their edges.

71 | Page
b) Corner joint. The parts in a corner joint form a right angle and are joined at the corner of
the angle.
c) Lap joint. This joint consists of two overlapping parts.
d) Tee joint. In a tee joint, one part is perpendicular to the other in the approximate shape
of the letter “T.”
e) Edge joint. The parts in an edge joint are parallel with at least one of their edges in
common, and the joint is made at the common edge(s).
Figure 9.4A: Five basic types of joints: (a) butt, (b) corner, (c) lap, (d) tee, and (e) edge.
1. Take the two mild steel pieces of given dimensions and clean the surfaces thoroughly
from rust, dust particles, oil and grease.
2. Remove the sharp corners and burrs by filing or grinding and prepare the work pieces.
3. The work pieces are positioned on the welding table, to form a lap joint with the required
over lapping.
4. The electrode is fitted in to the electrode holder and the welding current is set to a proper
value.
5. The ground clamp is fastened to the welding table.
6. Wearing the apron, hand gloves, using the face shield and holding the over lapped pieces
the arc is struck and the work pieces are tack‐welded at the ends of both the sides
7. The alignment of the lap joint is checked, and the tack‐welded pieces are reset, if
required.
8. Arc welding is then carried out throughout the length of the lap joint, on both the sides.
9. Remove the slag, spatters and clean the joint.

72 | Page
Discussion:
• Precautions:
Comments:
Evaluation Rubrics
Criteria (5) (3-4) (1-2) (0)

missing.
Understanding
concept.

73 | Page
Practical 9B
To make a corner joint, using the given mild steel pieces using arc welding.
Figure 9.1B: Corner Joint
Objectives:

Scope:
joining.
• Arc Welding plant

• Welding rods
• Chipping hammer
• Safety goggles
• Lab apparel
• Gloves
Theory:
accomplished by melting the two part surfaces to be joined, in some cases adding filler metal to

74 | Page
Arc welding is a type of welding process that uses an electric arc to join two pieces of metal
together. In this process, an electric current is passed through an electrode, which creates an arc
between the electrode and the metal workpiece. The heat generated by the arc melts the metal,
which then cools and solidifies, forming a strong bond.
Figure 9.2B: Arc Welding Plant
Arc welding (AW) is a fusion-welding process in which coalescence of the metals is achieved
by the heat of an electric arc between an electrode and the work. generic AW process is shown
in Figure 9.3B. An electric arc is a discharge of electric current across a gap in a circuit. It is
sustained by the presence of a thermally ionized column of gas (called a plasma) through which
current flows. To initiate the arc in an AW process, the electrode is brought into contact with the
work and then quickly separated from it by a short distance. The electric energy from the arc
thus formed produces temperatures of 5500°C (10,000°F) or higher, sufficiently hot to melt any
metal. A pool of molten metal, consisting of base metal(s) and filler metal (if one is used) is
formed near the tip of the electrode. In most arc-welding processes, filler metal is added during
the operation to increase the volume and strength of the weld joint. As the electrode is moved
along the joint, the molten weld pool solidifies in its wake.
Figure 9.3B: Basic Configuration of Arc Welding

Types of Joints
With reference to Figure 9.4B, the five joint types can be defined as follows:

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the angle.
Figure 9.4B: Five basic types of joints: (a) butt, (b) corner, (c) lap, (d) tee, and (e) edge.
3. The work pieces are positioned on the welding table, such that L shaped is formed.
4. The electrode is fitted in to the electrode holder and the welding current is set to a
proper value.
6. Wearing the apron, hand gloves, using the face shield and holding the over lapped
pieces the arc is struck and the work pieces are tack‐welded at the ends of both the
sides
7. The alignment of the corner joint is checked, and the tack‐welded pieces are reset, if
required.
8. Arc welding is then carried out throughout the length of the corner joint.

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Discussion:
• Precautions:
Comments:
Evaluation Rubrics
Criteria (5) (3-4) (1-2) (0)

missing.
Understanding
concept.

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Practical 10A
To make a T joint, using the given mild steel pieces using TIG welding.
Figure 10.1A: T Joint
Objectives:

Scope:
joining.
• TIG Welding plant

• Welding rods
• Chipping hammer
• Safety goggles
• Lab apparel
• Gloves
Theory:

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Tungsten Inert Gas (TIG) welding, also known as Gas Tungsten Arc Welding (GTAW), is a
welding process that utilizes a non-consumable tungsten electrode to create a weld. The weld is
formed when an electric arc is created between the tungsten electrode and the workpiece. The
process is also referred to as Gas Tungsten Arc Welding (GTAW) and is known for producing
high-quality, precise welds. The equipment needed for TIG welding includes a power source, a
TIG torch, a tungsten electrode, a shielding gas, and a filler metal. The power source is used to
provide the electric current that is used to create the arc. The TIG torch holds the tungsten
electrode and directs the shielding gas to the weld area. The tungsten electrode is non-
consumable, meaning it does not melt and become part of the weld. The shielding gas is used to
protect the weld from contamination. The filler metal is optional and is used to fill gaps or
reinforce the weld. To perform TIG welding, the workpiece is first cleaned and prepared for
welding. The TIG torch is then positioned at the starting point of the weld, and the tungsten
electrode is brought into contact with the workpiece. The shielding gas is then turned on to
protect the weld area from contamination. The welder then initiates an arc between the tungsten
electrode and the workpiece by striking the electrode against the workpiece and then quickly
moving the torch back. The welder then feeds the filler metal into the weld pool as needed to
create the desired shape and strength.
Figure 10.2A: TIG Welding Plant
TIG welding offers several advantages over other welding processes. One of the main
advantages is that it produces high-quality, precise welds with little to no spatter. It can also be
used to weld a variety of materials, including aluminum, stainless steel, and copper. TIG welding
is also a clean process, as it does not produce harmful fumes or smoke. TIG welding is commonly
used in industries such as aerospace, automotive, and manufacturing. It is often used to weld
thin materials or materials that require precise welding, such as medical equipment or electronic
components. TIG welding is also used in artistic applications, such as creating sculptures or
custom metalwork.

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Types of Joints
With reference to Figure 6, the five joint types can be defined as follows:
the angle.
Figure 10.4A Five basic types of joints: (a) butt, (b) corner, (c) lap, (d) tee, and (e) edge.

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3. The work pieces are positioned on the welding table, to form a T joint with the required
over lapping.
proper value.
sides.
7. The alignment of the T joint is checked, and the tack‐welded pieces are reset, if
required.
8. TIG welding is then carried out throughout the length of the T joint, on both the sides.

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Discussion:
• Precautions:
Comments:
Evaluation Rubrics

Criteria (5) (3-4) (1-2) (0)

missing.
Understanding
concept.

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Practical 10B
To make a butt joint, using the given mild steel pieces using TIG welding.
Figure 10.1B: Butt Joint
Objectives:

Scope:
joining.
• TIG Welding plant

• Welding rods
• Chipping hammer
• Safety goggles
• Lab apparel
• Gloves
Theory:
Tungsten Inert Gas (TIG) welding, also known as Gas Tungsten Arc Welding (GTAW), is a
welding process that utilizes a non-consumable tungsten electrode to create a weld. The weld is

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formed when an electric arc is created between the tungsten electrode and the workpiece. The
process is also referred to as Gas Tungsten Arc Welding (GTAW) and is known for producing
high-quality, precise welds. The equipment needed for TIG welding includes a power source, a
TIG torch, a tungsten electrode, a shielding gas, and a filler metal. The power source is used to
provide the electric current that is used to create the arc. The TIG torch holds the tungsten
electrode and directs the shielding gas to the weld area. The tungsten electrode is non-
consumable, meaning it does not melt and become part of the weld. The shielding gas is used to
protect the weld from contamination. The filler metal is optional and is used to fill gaps or
reinforce the weld. To perform TIG welding, the workpiece is first cleaned and prepared for
welding. The TIG torch is then positioned at the starting point of the weld, and the tungsten
electrode is brought into contact with the workpiece. The shielding gas is then turned on to
protect the weld area from contamination. The welder then initiates an arc between the tungsten
electrode and the workpiece by striking the electrode against the workpiece and then quickly
moving the torch back. The welder then feeds the filler metal into the weld pool as needed to
create the desired shape and strength.
Figure 10.2B: TIG Welding Plant
TIG welding offers several advantages over other welding processes. One of the main
advantages is that it produces high-quality, precise welds with little to no spatter. It can also be
used to weld a variety of materials, including aluminum, stainless steel, and copper. TIG welding
is also a clean process, as it does not produce harmful fumes or smoke. TIG welding is commonly
used in industries such as aerospace, automotive, and manufacturing. It is often used to weld
thin materials or materials that require precise welding, such as medical equipment or electronic
components. TIG welding is also used in artistic applications, such as creating sculptures or
custom metalwork.

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Types of Joints
With reference to Figure 6, the five joint types can be defined as follows:
the angle.
Figure 10.4B Five basic types of joints: (a) butt, (b) corner, (c) lap, (d) tee, and (e) edge.

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3. The work pieces are positioned on the welding table, to form a butt weld joint with the
required over lapping.
proper value.
sides.
7. The alignment of the butt joint is checked, and the tack‐welded pieces are reset, if
required.
8. TIG welding is then carried out throughout the length of the butt joint, on both sides.
Discussion:
• Precautions:

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Comments:
Evaluation Rubrics
Criteria (5) (3-4) (1-2) (0)

missing.
Understanding
concept.

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Practical 11A
To make a double lap joint, using the given mild steel pieces using MIG welding.
Figure 11.1A: Double Lap Joint
Objectives:

Scope:
joining.
• MIG Welding plant

• Welding rods
• Chipping hammer
• Safety goggles
• Lab apparel
• Gloves

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Theory:
MIG welding (Metal Inert Gas welding), also known as Gas Metal Arc Welding (GMAW), is
a welding process that uses a continuous wire electrode and a shielding gas to join two metals
together. The process is widely used in industrial, automotive, and DIY applications due to its
versatility and ease of use. To perform MIG welding, you will need the following equipment, a
MIG welding machine generates the heat required to melt the wire and fuse it to the base metal.
The machine can be powered by electricity or gas. Wire feeder equipment feeds the wire
electrode into the weld pool. The welding gun holds the wire electrode and the shielding gas
nozzle. The shielding gas is used to protect the weld pool from atmospheric gases that can cause
porosity and other defects. he MIG welding process involves the following steps. Clean the
surface of the metal to be welded and clamp it to the workbench, Adjust the voltage, wire speed,
and gas flow rate according to the thickness and type of metal being welded, Insert the wire
electrode into the wire feeder and secure it in place, Position the welding gun close to the
workpiece, but not touching it, Pull the trigger on the welding gun to start the flow of wire and
shielding gas. Move the gun in a straight line to create a bead of weld., continue the weld until
the desired length is achieved. Stop the welding process and release the trigger on the gun.
Figure 11.2A: MIG Welding Plant
MIG welding has several advantages over other welding processes. MIG welding is a fast
process that can join two metals together in a matter of seconds. MIG welding can be used on a
variety of metals, including steel, aluminium, and stainless steel. MIG welding produces clean,
high-quality welds with minimal spatter and splatter. MIG welding produces less distortion than
other welding processes, making it ideal for welding thin materials. MIG welding is widely used in
the following applications, MIG welding is used to repair and fabricate automotive components,
including body panels, frames, and exhaust systems. MIG welding is used to manufacture a

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variety of products, including appliances, metal furniture, and machinery. MIG welding is a
popular choice for DIY enthusiasts who want to build custom metal structures, such as gates,
fences, and outdoor furniture. MIG welding is used in the aerospace industry to join thin metal
sheets and components together.
Types of Joints
f) Butt joint. In this joint type, the parts lie in the same plane and are joined at their edges.
g) Corner joint. The parts in a corner joint form a right angle and are joined at the corner of
the angle.
h) Lap joint. This joint consists of two overlapping parts.
i) Tee joint. In a tee joint, one part is perpendicular to the other in the approximate shape
j) Edge joint. The parts in an edge joint are parallel with at least one of their edges in

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3. The work pieces are positioned on the welding table, to form a lap joint with the required
over lapping.
value.
7. The alignment of the lap joint is checked, and the tack‐welded pieces are reset, if
required.
8. MIG welding is then carried out throughout the length of the overlapping lap joint, on
both sides.
Discussion:
• Precautions:

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Comments:
Evaluation Rubrics
Criteria (5) (3-4) (1-2) (0)

missing.
Understanding
concept.

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Practical 11B
To make an edge joint, using the given mild steel pieces using MIG welding.
Figure 11.1B: Edge Joint
Objectives:

Scope:
joining.
• MIG Welding plant

• Welding rods
• Chipping hammer
• Safety goggles
• Lab apparel
• Gloves
Theory:

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MIG welding (Metal Inert Gas welding), also known as Gas Metal Arc Welding (GMAW), is
a welding process that uses a continuous wire electrode and a shielding gas to join two metals
together. The process is widely used in industrial, automotive, and DIY applications due to its
versatility and ease of use. To perform MIG welding, you will need the following equipment, a
MIG welding machine generates the heat required to melt the wire and fuse it to the base metal.
The machine can be powered by electricity or gas. Wire feeder equipment feeds the wire
electrode into the weld pool. The welding gun holds the wire electrode and the shielding gas
nozzle. The shielding gas is used to protect the weld pool from atmospheric gases that can cause
porosity and other defects. he MIG welding process involves the following steps. Clean the
surface of the metal to be welded and clamp it to the workbench, Adjust the voltage, wire speed,
and gas flow rate according to the thickness and type of metal being welded, Insert the wire
electrode into the wire feeder and secure it in place, Position the welding gun close to the
workpiece, but not touching it, Pull the trigger on the welding gun to start the flow of wire and
shielding gas. Move the gun in a straight line to create a bead of weld., continue the weld until
the desired length is achieved. Stop the welding process and release the trigger on the gun.
Figure 11.2B: MIG Welding Plant
MIG welding has several advantages over other welding processes. MIG welding is a fast
process that can join two metals together in a matter of seconds. MIG welding can be used on a
variety of metals, including steel, aluminium, and stainless steel. MIG welding produces clean,
high-quality welds with minimal spatter and splatter. MIG welding produces less distortion than
other welding processes, making it ideal for welding thin materials. MIG welding is widely used in
the following applications, MIG welding is used to repair and fabricate automotive components,
including body panels, frames, and exhaust systems. MIG welding is used to manufacture a
variety of products, including appliances, metal furniture, and machinery. MIG welding is a
popular choice for DIY enthusiasts who want to build custom metal structures, such as gates,
fences, and outdoor furniture. MIG welding is used in the aerospace industry to join thin metal
sheets and components together.

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Types of Joints
k) Butt joint. In this joint type, the parts lie in the same plane and are joined at their edges.
l) Corner joint. The parts in a corner joint form a right angle and are joined at the corner of
the angle.
m) Lap joint. This joint consists of two overlapping parts.
n) Tee joint. In a tee joint, one part is perpendicular to the other in the approximate shape
o) Edge joint. The parts in an edge joint are parallel with at least one of their edges in

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3. The work pieces are positioned on the welding table, to form an edge joint with the
required over lapping.
value.
7. The alignment of the edge joint is checked, and the tack‐welded pieces are reset, if
required.
8. MIG welding is then carried out throughout the length of the edge joint.
Discussion:
• Precautions:

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Comments:
Evaluation Rubrics
Criteria (5) (3-4) (1-2) (0)

missing.
Understanding
concept.

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ELECTRIC
SECTION

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Practical 12A
Introduction and Usage of Electrical Tools, Wire Gauges and Earthing
Objectives:
1. Introduction and use of Electrical tools, Electrical materials.

2. Series and Parallel connections
3. Wiring gauge and its uses
4. Earthing and its types
Scope:
1. Electrical tools are tools used to work on an electrical system. These can include a wide
range of tools such as wire and cable cutters, wire strippers, coaxial compression tools,
telephony tools, wire cutter/strippers, cable tie tools, accessories and even more.
2. Earthing is used to protect you from an electric shock. It also causes the protective device
(either a circuit-breaker or fuse) to switch off the electric current to the circuit that has
the fault.
• Basic Electric and Workshop Tools
Theory:
Tools: Plier:
Generally, three types of pliers are used in the electrical workshop. They are: -
i. Flat Nose Plier: Used for holding jobs or holding wires. It has got only two slotted jaws,
which are tapered. Thus it is used for tightening or loosening small nuts.
ii. Side Cutting Plier: Used for cutting of thin wires and removing insulations from them. It
has got cutting edge on its one of its sides.
iii. Round Nose Plier: Used only to hold or cut the wires. It has no gripping jaws. Its cutting
edge is long and rounded on the top.
Screwdriver:
It is used to loosen or tighten or to keep screws in position. It has a wooden or plastic handle and
a blade of high carbon steel.
Chisel:

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i. Firmer Chisel: Generally used for carpentry works and can be used by hand pressure or
with the help of mallet. It has flat blade, which varies from 12mm to 15mm.
ii. Cold Chisel: Used for cutting iron pieces (cold). It has cutting angle from 30° to 45°and
is made of high carbon steel.
Hammer:
Most used in the workshop. The head is made of cast iron or forged; the claw is hardened and
tampered. The striking place is slightly convex. The head is fitted with a wooden handle of
various lengths.
Hacksaw:
Used to cut metal such as iron strips, core pipes etc. it has a blade made of high steel or
tungsten.
Electrical Tools
Tumbler Switch: (6 A for light), this switch was used 3-4 decade ago. It is made of Bakelite.
MCB box: Known as the Miniature Circuit Breaker Box.
Batten Lamp Holder: Mainly used to hold electric bulbs and lamps.
Switch board with switches:
It contains the following:
i. Socket Outlets: It is a type of electrical material through which electric current flows
from wires to various electrical appliances. It is of 6A.
ii. 3. One-way switch: it is a device used to switch on lights of 6A
iii. Two-way switch: It is mainly used in staircase wiring to either on or off the light. It is
of 6A.
Series connection:
A circuit is said to be connected in series when the same current flows through all the
components in the circuit. In such circuits, the current has only one path. Let us consider the
household decorative string lights as an example of a series circuit. This is nothing but a series
of multiple tiny bulbs connected in series. If one bulb fuses, all the bulbs in series do not light
up.
Parallel connection:
A circuit is said to be parallel when the electric current has multiple paths to flow through. The
components that are a part of the parallel circuits will have a constant voltage across all ends.

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Figure 11.1A: Series and Parallel connections
Electric Wire Gauges:
While different wires serve specific purposes, knowing the right wire size, also known as the
gauge, will aid your electrical. The measurements determine the amount of current that can
safely pass through the wire without generating damages. In addition to this, each wire gauge
size has a safe Ampacity, which is a measure of electrical current.
Wire Gauge Chart:
American Wire Gauge standards range from 0000 (which can handle up to 302 amps) to 40
(which can handle up to 0.0137 amps). Most household and commercial wiring demands range
from 2 (95 amp maximum) or 3 (85 amp maximum) to 14 (15 amp maximum).

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Figure 11.2A: Wire Gauge Sizes
• 4-gauge are used for electric furnaces and large electric heaters protected at 60 amp
• 6-gauge are used for cook tops and ranges carrying 40-50 amps
• 10-gauge are used in electric clothes dryers, 240-volt window air conditioners, electric
water heaters supporting 30 amps
• 12-gauge are used in kitchen, bathroom, outdoor receptacles, and 120-volt air
conditioners supporting 20 amps
• 14-gauge are used for light fixtures, lamps, lighting circuits with 15 amps
• 16-gauge are used for light-duty extension cords supporting 13 amps
• 18-gauge are used for low-voltage lighting and lamp cords in 10 amps
Wire 3/29 means:
This is standard system of specifying the wire size. This mentions number of strands first, then
after the slash, the number is gauge (either swg or diameter) of individual strand. By this system,
3/29 means a wire having 3 strands of 29 swg wire.

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Earthing:
Earthing is defined as “the process in which the instantaneous discharge of the electrical energy
takes place by transferring charges directly to the earth through low resistance wire.”
To ensure safety, earthing can be done by connecting the electrical appliance to earthing systems
or electrodes placed near the soil or below the ground level. The electrode or earthing mat
equipped with a flat iron riser is installed under the ground level. It helps to connect all the non-
current-carrying metallic parts of the equipment.
Figure 11.3A: Electrical System with Earthing
Types of Earthing:
There are three types of earthing, they are:
• Pipe earthing
• Plate earthing
• Strip earthing
Pipe earthing is the best and efficient way of earthing and is also easily affordable. Pipe earthing
uses 38mm diameter and 2 meters length pipe vertically embedded in the ground to work as
earth electrodes.
In plate earthing, an earthing plate made of copper or G.I is buried into the ground at a depth
more than 3 meters from the ground level. This earthing plate is embedded in an alternative layer
of coke and salts.
Strip earthing is used in transmission processes. Strip electrodes of cross section not less than
25mm into 1.6mm of copper or 25 mm X 4mm of G.I. or steel are buried in horizontal trenches
of a minimum depth of 0.5m.

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Comments:
Evaluation Rubrics

Criteria (5) (3-4) (1-2) (0)

missing.
Understanding
concept.

104 | Page
Practical 12B
To make different Wiring Joints
Objectives:
1. Wiring Joints and its types
Scope:
1. Electrical wires together are essential for building, household and repairing circuits
• Side-cutting plier
• 1/18 SWG
• 3/29 SWG wires
Theory:
1. Straight Joint:
It is used to take connections from a horizontal line and it is also known as parallel point.
Remove the insulation: Use an insulation remover or knife to remove the insulation from the wire
to be joined. Then clean the conductor with a knife or sandpaper.
Figure 12.1B: Removing the insulation
Splicing the conductor: with the help of forefinger and thumb or plier, twist the wires. Make four
to eight on each side of the wire.

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Figure 12.2B: Splicing the conductor
Soldering the splice: In order to make the joint stronger, it has to be soldered for this a soldering
iron, soldering lead, and/or a blow lap is required. For a small splice a soldering iron and lead
are enough but for a large size just as in the case or of underground cables either a blow lamp is
used or solder will be heated or pored on the splice with the help of blowlamp while the splice
is heated to a certain temperature such that the solder wire (lead and tin) which when placed over
the splice should melt.
Figure 12.3B: Soldering the splice
Insulation the splice: The soldered splice should be provided with insulation. The tape should
cover the entire splice and part of the insulation on the cable on either side of the splice so that
it should be covered.
2. Married Joint:
to be joined. Then clean the conductor with a knife or sandpaper. Remove the insulation for
about 6 to 8 cm from one side of each cable in a tapered fashion
Figure 12.4B: Removing the Insulation

Splicing of the conductor: Splicing of the single-core conductor is explained above. In the case
of multi-core cables such as 3/20 or 7/20 wire, the following procedure is adopted. Remove the
braid if present for about 1 to 2 cm on each cable. Scatter the standards by twisting the conductors

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in opposite direction leading about 4 cm from the insulation end and bind it at this point with
binding.
Cleaning of conductor: Clean each strand neatly with emery paper and cut off the middle strand
only.
Joining: Bring both the cable end to end mix them intersecting each other alternately. Hold one
cable with the left hand and wrap the one strand around the twisted portion of the opposite
direction and complete the wrapping of other strands also. Repeat the method of wrapping
strands on the other side of the conductor. round off the ends of both the cable with the help of
a wooden hammer or mallet or plier.
Figure 12.6B: Joining
3. T Joint:
to be joined. Then clean the conductor with a knife or sandpaper. Making sure that none of the
strands are damaged. Remove the insulation about 3 to 4 cm from the running cable and from
one side of the branching cable in a tapered fashion.
Splicing of the conductor: In case of multicore core cables such as 3/20 or 7/20 wire the following
cable procedure is adopted. Remove the braid if present for about 1 to 2 cm on the running cable
and 3 to 4 cm on the branching cable. After cleaning the conductor s with the help of emery
paper, keeping the branching wire in a quadrature i.e, 90 degrees with the running cable turn the
branching wire around the running cable and complete at least 5 to 8 turns.

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Cleaning of conductor: Clean each strand neatly with emery paper.
Soldering: The joint is then soldering and insulated with insulation tape.
4. Western Union Joint:
Splicing the conductor: With the help of forefinger and thumb or plier, twist the wire and leave
a portion of 8 cm in the center and from the center twist one conductor around the other making 3
to 4 turns. Repeat the same for the other conductor from the other end and cut the surplus
conductor.
Soldering the splice: To make joint stronger, it has to be soldered for this a soldering iron,
soldering lead is required heat splice should be melted.
Insulation the splice: The soldered splice should be provided with insulation. Each turn of the
tape should overlap a part of the previous turn. The tape should cover the entire splice and part
of the insulation on the cable on either side of the splice so that it should be covered.
5. Pigtail Joint:

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When the single-core scale and flexibility cable are to be terminated, the joint is made.

Soldering the splice: To make the joint stronger, it has to be soldered for this a soldering iron,
soldering lead is required he splice should melt.
Insulating the splice: The soldered splice should be provided with insulation. Each turn of the
tape should overlap a part of the previous turn. The tape should cover the entire splice and part
of the insulation on the cable.
Sequence of Operation (T-Joint):
1. Take 2 horizontal and vertical lengths of wires 30cm and 20cm respectively to which
the joint is to be made.
2. Remove the insulation of taping vertical length of 7.5cm
3. Remove the insulation of straight length middle portion
4. Remove the insulation of 12mm on each side of the base wire.
5. Hold the wire at 90° to running and make a neck turn to void slipping of joint.
6. Wrap off conduction closely and tightly 6-8 turns on horizontal wire.
7. Round off the conductor with the help of a plier.
8. The joint is soldered and insulated with tape Use PVC case wiring to cover expose
wiring.
Figure 12.12B: T-Joint

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Sequence of Operation (Straight Joint):
1. Cut two pieces of cable of nearly the same length.

2. Remove the insulation from the end of both the cable pieces.
3. Separate the wire from both the cables and join the 2 cables in such a way that the
individual wires are joint separately
4. For half of the length of the di-insulated cable overlapped make a trust with the help of
a plier.
5. Complete the remaining half-length on the twist with the help of a plier
Figure 12.13B: Straight Joint
Sequence of Operation (Married Joint):
1. Cut two pieces of cable of nearly the same length.

2. Remove the insulation from the end of both the cable pieces.
3. Separate the wire from both the cables and make two equals of individual wires.
4. Join the 2 cables in such a way that the two equal sets of wires are joint separately.
5. For half of the length of the di-insulated cable overlapped make a trust with the help of
a plier.
6. Complete the remaining half-length on the twist with the help of a plier.
Figure 12.13C: Married Joint

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Discussion:
• Precautions:
Comments:
Evaluation Rubrics

Criteria (5) (3-4) (1-2) (0)

missing.
Understanding
concept.

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Practical 13A
To control single lamp with one switch
Objectives:
1. To understand controlling of a lamp through one switch
Scope:
1. The one-way switch is the most used switch in homes and in many applications where
one wants to control the flow of electricity.
• DMM
• Switch
• Holder
• Screwdriver
• Wire cutter
Theory:
One of the two wires (phase) of a single-phase supply is connected to the load through fuse and
one way switch. The other wire (neutral) is connected to the load directly. Fuse is provided to
protect the circuit from over current and the switch controls the load. The load can be a single
lamp as in figure 12.1A.
Figure 13.1A: One lamp controlled by one switch

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Digital Multimeter:
A digital multimeter or DMM is one of the most widely used pieces of test equipment today. A
digital multimeter, DMM is a test instrument used to measure electrical values including voltage,
current and resistance.
Figure 13.2A: Digital Multimeter
Switch:
A switch is an electrical component that can disconnect or connect the conducting path in
an electrical circuit, interrupting the electric current or diverting it from one conductor to
another.

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Figure 13.3A: Switch
Holder:
A device for securing a lamp to its support; specifically, a socket or holder fitted with electric
terminals, into which the top of the glass globe of an incandescent lamp is fitted, or from which
it hangs.
Figure 13.4A: Holder
Screwdriver:
Screwdriver, tool, usually hand-operated, for turning screws with slotted heads. For screws with
one straight diametral slot cut across the head, standard screwdrivers with flat blade tips and in
a variety of sizes are used.

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Figure 13.5A: Screwdriver
Wire cutter:
Wire cutters are commonly used to cut copper, iron or aluminum wires.
Figure 13.6A: Wire cutter
1. Use the cutter to make terminal of wire clear by removing the insulation from the end
switch.
2. Take screwdriver and open screws of both switch and holder.
3. Insert the uncover terminal of one wire in switch and other terminal in bulb.
4. Similarly join the other wire directly to bulb.
5. The circuit is then checked by providing the AC supply to the circuit through the test
board.

115 | Page
Discussion:
• Precautions:
Comments:
Evaluation Rubrics

Criteria (5) (3-4) (1-2) (0)

missing.
Understanding
concept.

116 | Page
Practical 13B
To control two lamps (in series & parallel) with one switch
Objectives:
1. To control two lamps through one switch in series

2. To control two lamps through one switch in parallel
Scope:
1. The one-way switch is the most used switch in homes and in many applications where
one wants to control the flow of electricity.
• DMM
• Switch
• Holder
• Screwdriver
• Wire cutter
Theory:
One of the two wires (phase) of a single-phase supply is connected to the load through fuse and
one way switch. The other wire (neutral) is connected to the load directly. Fuse is provided to
protect the circuit from over current and the switch controls the load. The load can be a lamp in
series as in figure 12.1B or even lamps in parallel as in figure 12.2B. During the series circuit,
current will flow equally through both the lamps. In case any lamp of the two is OFF, the other
lamp will also be OFF. During Parallel circuit, the current will be distributed. In case either of
the two is OFF, the other lamp will remain ON.
Figure 12.1B: Two lamps in series controlled by one switch

117 | Page
Figure 13.2B: Two lamps in parallel controlled by one switch
Digital Multimeter:
Figure 13.3B: Digital Multimeter

118 | Page
Switch:
another.
Figure 13.4B: Switch
Holder:
it hangs.
Figure 13.5B: Holder
Screwdriver:

119 | Page
Figure 13.6B: Screwdriver
Wire cutter:
Figure 13.7B: Wire cutter
1. Use the cutter to make terminal of wire clear by removing the insulation from the end
switch.
2. Take screwdriver and open screws of both switch and holder.
3. Insert the uncover terminal of one wire in switch and other terminal in bulb.
4. Similarly join the other wire directly to bulb.
5. The circuit is then checked by providing the AC supply to the circuit through the test
board.

120 | Page
Discussion:
• Precautions:
Comments:
Evaluation Rubrics

Criteria (5) (3-4) (1-2) (0)

missing.
Understanding
concept.

121 | Page
Practical 13C
To wire for a staircase arrangement using a two-way switch.
Objectives:
1. To understand staircase wiring arrangement
Scope:
1. The main purpose of two-way switching connection is to connect and control AC

appliances and equipment’s from two separate locations. It is mostly used in staircase
wiring where a light bulb can be control (Switch ON / Switch OFF) from different places,
no matter you are in the upper or lower portion of stair.
• DMM
• Switch
• Holder
• Screwdriver
• Wire cutter
• Line Tester
Theory:
A two switch is installed near the first step of the stairs. The other two-way switch is installed at
the upper part where the stair ends. The light point is provided between first and last stair at an
adequate location and height if the lower switch switches on the light. The switch at the top or
vice versa can switch it off. Two number of two-way switches are used for the purpose. The
supply is given to the switch at the short-circuited terminals. The connection to the light point is
taken from the similar short-circuited terminal of the second switch; other two independent
terminals of each circuit are connected through cables.

122 | Page
Figure 13.1C: Circuit diagram of Staircase wiring
Digital Multimeter:
Figure 13.2C: Digital Multimeter

123 | Page
Switch:
another.
Figure 13.3C: Switch
Holder:
it hangs.
Figure 13.4C: Holder
Screwdriver:

124 | Page
Figure 13.5C: Screwdriver
Wire cutter:
Figure 13.6C: Wire cutter

Line Tester:
A line tester is electrical equipment that can be used to detect the presence of electricity. A phase
line tester can be considered a protective device that can protect our body from accidental shocks.
So there would be a return electrical path because of the person who is using this equipment.
Figure 13.7C: Line Tester

125 | Page
1. Mark switch and bulb location points and draw lines for wiring on the wooden Board.
2. Place wires along the lines and fix them with the help of clips.
3. Fix the two-way switches and bulb holder in the marked position on the wooden Board.
4. Complete the wiring as per the wiring diagram.
5. Test the working of the bulbs by giving electric supply to the circuit through the test
board.
Discussion:
• Precautions:
Comments:
Evaluation Rubrics

Criteria (5) (3-4) (1-2) (0)

missing.
Understanding
concept.

126 | Page
Practical 13D
To wire for a godown wiring arrangement using one and two-way switches.
Objectives:
1. To understand godown wiring arrangement
Scope:
1. The primary purpose of godown wiring is to provide convenient and efficient lighting
control in large storage spaces being able to turn on lights upon entering or exiting the
godown from any point minimizing the risk of tripping or bumping into objects in low-
light conditions.
2. Workers can easily illuminate specific areas they need to access without having to walk
to a single switch location.
3. Lights can be turned off from any exit point, preventing them from being left on
unnecessarily in unoccupied areas.
• DMM
• Switches
• Holder
• Screwdriver
• Wire cutter
• Line Tester
Theory:
Godown wiring, also sometimes called godown circuitry, refers to the specific electrical wiring
scheme used in warehouses or storage facilities (godowns). A key feature of godown wiring is
the use of two-way switches. These allow you to control the lights from multiple locations
within the godown. This is particularly useful in large spaces where you might enter from one
end and want to turn on the lights before reaching the other end where the main switch might
be. A typical setup involves one way switch at the entrance and a two way switch at the other
end (or vice versa). These switches are wired in a way that allows the circuit to be completed
(lights turn on) regardless of which switch is toggled. Like any electrical circuit, godown
wiring uses separate neutral and phase wires. The neutral wire carries the return current, while
the phase wire carries the live current that powers the lights. Godown wiring offers easier light
control minimizes accidents due to poor visibility. Workers can navigate and work more
efficiently with proper lighting control. There are reduced chances of lights being left on in
unused areas. By implementing godown wiring, you can create a safer, more efficient, and
user-friendly lighting system for your warehouse or storage facility.

127 | Page
Figure 13.1D: Circuit diagram of Godown wiring
Digital Multimeter:
Figure 13.2C: Digital Multimeter
Switch:

128 | Page
another.
Figure 13.3C: Switch
Holder:
it hangs.
Figure 13.4C: Holder
Screwdriver:

129 | Page
Figure 13.5C: Screwdriver
Wire cutter:
Figure 13.6C: Wire cutter

Line Tester:
A line tester is electrical equipment that can be used to detect the presence of electricity. A phase
line tester can be considered a protective device that can protect our body from accidental shocks.
So there would be a return electrical path because of the person who is using this equipment.
Figure 13.7C: Line Tester

130 | Page
1. Mark switch and bulb location points and draw lines for wiring on the wooden Board.
2. Place wires along the lines and fix them with the help of clips.
3. Fix the two-way switches and bulb holder in the marked position on the wooden Board.
4. Complete the wiring as per the wiring diagram.
5. Test the working of the bulbs by giving electric supply to the circuit through the test
board.
Discussion:
• Precautions:
Comments:
Evaluation Rubrics

Criteria (5) (3-4) (1-2) (0)

missing.
Understanding
concept.

131 | Page
Practical 13E
To use an Analog and Digital Multimeter
Objectives
1. To understand the working of analog and digital multimeter.
Scope:
1. The main purpose of analog and digital multimeters (DMMs) is to measure various
electrical properties in circuits. These properties typically include voltage (AC / DC),
current (AC / DC) and resistance in Ohms at different scales.
• AMM / DMM
• Electric Circuit
• Electric Test Board
• Line Tester
Theory:
A multimeter is a versatile tool used to measure various electrical properties in circuits. A

multimeter functions by having different internal pathways for each measurement function
(voltage, current, resistance). When you select a specific function (e.g., voltage), the meter
internally connects the circuit to measure that particular property. The meter then displays the
measured value on a digital screen (DMM) or through a needle on a dial (analog multimeter).
Every multimeter might have slightly different configurations. Refer to the manual for specific
instructions on your model. For safety, always turn off the power or remove batteries from the
circuit before connecting the multimeter. A multimeter typically has two test probes:
• Red probe: Usually connects to the positive terminal (higher voltage) or the measured
potential.
• Black probe: Usually connects to the negative terminal (lower voltage) or the reference
point (common ground)
While using multimeter, start with a higher measurement range and adjust down for better
accuracy if needed. Touch the probe tips only by the insulated areas to avoid electrical shock.
By understanding the working principle and proper usage techniques, you can effectively use a
multimeter to diagnose and troubleshoot electrical circuits.

132 | Page
Analog Multimeter:
An analog multimeter is a versatile tool used to measure various electrical properties in circuits.
It differs from a digital multimeter (DMM) in how it displays information and may have some
limitations, but it can still be a valuable tool. An analog multimeter relies on a mechanism called
a moving coil meter to deflect a needle across a calibrated scale which are used to measure
electrical values including voltage, current and resistance on a digital screen.
Figure 13.1E: Analog Multimeter

133 | Page
Figure 13.2E: Analog Multimeter

134 | Page
Digital Multimeter:
digital multimeter, DMM is a test instrument used to measure and displaying electrical values
including voltage, current and resistance on a digital screen.
Figure 13.3E: Digital Multimeter

135 | Page
Sequence of Operation (Measuring Voltage):
1. Rotate the dial or press the button to select the voltage (DC or AC) function with a
range exceeding the expected voltage in the circuit.
2. For DC voltage, connect the red probe to the positive side of the component (or higher
voltage point) and the black probe to the negative side (or common ground).
3. For AC voltage, polarity doesn't matter.
4. The multimeter will display the voltage measured in volts (V) or millivolts (mV). A
negative reading indicates reversed probe placement for DC voltage.
5. Connect the probes to the already designed circuits including staircase and godown
wiring using testboard.
6. Measure the Voltage of the circuit.
Sequence of Operation (Measuring Current):
1. Select the current (DC or AC) function with a range exceeding the expected current in
the circuit. Important: Never connect the multimeter in series with the circuit without
proper knowledge as exceeding the current rating can damage the meter.
2. For current measurement, you need to break the circuit and connect the meter in series.
How you do this depends on the circuit design. Consult a qualified electrician if unsure
about safe current measurement procedures.
3. For DC current, maintain proper polarity as with voltage measurement. For AC current,
polarity doesn't matter.
4. The multimeter will display the current measured in amperes (A) or milliamperes
(mA).
6. Measure Current of the circuit.
Sequence of Operation (Measuring Resistance):
1. Select the resistance (Ω) function with a range exceeding the expected resistance of the
component.
2. Ensure the circuit is completely off before measuring resistance.
3. Touch the probes to the two terminals of the component you want to measure (e.g.,
resistor).
4. The multimeter will display the resistance in ohms (Ω). An open circuit will show an
infinitely high resistance (OL on some meters).
5. A very low resistance might indicate a short circuit.
7. Measure the Current of the circuit.

136 | Page
Discussion:
• Precautions:
Comments:
Evaluation Rubrics

Criteria (5) (3-4) (1-2) (0)

missing.
Understanding
concept.

137 | Page
Practical 13F
To wire a distribution board.
Objectives:
2. To understand working of distribution board
Scope:
2. The main purpose of distribution board is to divide electrical power feed into subsidiary
circuits which are used everywhere in residential areas, commercial buildings etc.
• DMM
• Switch
• Holder
• Screwdriver
• Wire cutter
• Line Tester
• Fuse
• MCB, RCCB
Theory:
A distribution board (also known as panelboard, breaker panel, electric panel, DB board or DB
box) is a component of an electricity supply system that divides an electrical power feed into
subsidiary circuits while providing a protective fuse or circuit breaker for each circuit in a
common enclosure.
MCB:
MCB is an electromechanical device that protects the electrical circuit from overcurrent resulted
due to overload, short circuit, or anything which causes excessive current flow.
RCCB:
RCCB is a type of Residual current device operated by detecting the current imbalance in the
incoming and returning current.
Through the MCB phase lines are distributed to electrical wiring for lighting, fixed devices, and
power distribution points. This type of arrangement is the commonly used method of distribution
board for house wiring.

138 | Page
The cable or wire size, the rating of breakers, fuse, etc depends on the type of wiring, purpose,
and rating of loads. It should be properly selected as per the recommended standards and safety
requirements.
The neutral and earth lines are distributed to the subcircuits through the neutral link and earth
link respectively. The earth line running from the earth link is connected to the earth pit with an
earth rod. Earthing is very essential for the protection of the electrical system, so it should be
ensured that the earthing is proper.
Figure 13.1D: Components of a DB board
8. The Phase and Neutral supply lines (230V AC 50Hz/60Hz) are fed to the DB through
the service drop running from the utility pole. It is then connected to the energy meter
through a fuse.
9. The phase and neutral lines from the energy meter are connected to the main isolator.
10. The isolator is used to OPEN and CLOSE the lines manually, which is the main switch
of the electrical system.
11. The phase and neutral lines from the isolator are then connected to the RCCB.
12. The RCCB is a device used to protect from current leakage. It isolates the circuit during
fault conditions due to current leakage as well as during earthing, electric shock, when
somebody comes to contact with phase and earth.
13. From RCCB the Neutral lines are connected to the neutral link. And the phase lines are
connected parallel to MCB’s. The MCB is used to protect from overcurrent resulted due
to overload or short circuit. It isolates the phase line if the current exceeds its maximum
limit. Both MCB and RCCB can be turned off manually to isolate the line.

139 | Page
Figure 13.2D: Diagram of a Distribution Board

140 | Page
Discussion:
• Precautions:
Comments:
Evaluation Rubrics

Criteria (5) (3-4) (1-2) (0)

missing.
Understanding
concept.

141 | Page
Practical 14
Open Ended Lab
Project Submission Due Date: 15th Week of the Semester

Objectives:
Prepare a project which should cover the attributes given at the end of this document. Prepare
the projects in a group and submit the report and viva will be conducted from the report. Same
project title can’t be chosen by more than one group and the project details and report must be
unique. Details of project deliverables and assessment are given below.
CLO-1 Statement:
Imitate operations related to various shops in Mechanical Workshop.
CLO-2 Statement:
Demonstrate knowledge of basic workshop tools while working individually and in a team.
Marks distribution as per CLOs

CLO1 (P2-PLO4, Investigation) 30%
CLO2 (A3-PLO9, Individual and Teamwork) 70%
Marks distribution as per method of assessment
• Report 20 %
• Product 50 %
• Presentation/Viva 30 %
Deliverables
• Project Report
• Final Product
• Project Presentation/Viva
Topics
Requirement: Prepare a physical model using acquired knowledge of various shops. That
final product should be tagged with group member names, submission title etc
The project will be delivered in following report format:
1. Cover Page: Stating the Project Title, Group members Reg# and Name
2. Table of Contents

142 | Page
3. Introduction
4. Objectives
5. Sequence of operations.
6. Analysis
7. Conclusion
Rubrics for Assessment

CLO2 will be evaluated during product, ppts or viva and CLO1 during report. Each student is
supposed to understand the feasibility of the project apply in presence of instructor / lab
engineer who will grade the students for this portion.
Rubrics for Report
Marks Evaluation Criteria
1-4 Report is not according to the format.

No procedure is followed.
Many irregularities found in report.
5-7 Report is according to the format.
Procedure is there but conclusion is missing.
8-10 Report is according to the format with actual sequence of operations.
Conclusion is written well.
Rubrics for Product
Marks CLO2 – Level A2 mapped to PLO9 (Individual & Teamwork)
1-4 Not in working condition. No planning found, very limited understanding of

processes used in projects.
5-7 Partial working condition. Good planning found while doing the project and good
conceptual understanding of commands
8-10 Working condition. Excellent planning while doing the project, excellent conceptual
understanding of processes and know exactly what they have intended for.

143 | Page
Rubrics for Presentation/Viva
Marks CLO2 – Level A2 mapped to PLO9 (Individual & Teamwork)
1-4 PPT is not organized.

No understanding of the operation.
Lack of confidence.
5-7 Partial understanding of operations.
PPT is organized but lack confidence while presenting.
8-10 Organized Presentation with great understanding of operations.
Demonstrate operations with confidence

ME 2306 - Workshop Practice Manual (To Be Printed)

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NATIONAL UNIVERSITY OF TECHNOLOGY (NUTECH)

DEPARTMENT OF MECHANICAL ENGINEERING

Mechanical Engineering Department Workshop Practice

PRACTICAL 10B .....................................................................................................................................................82

Mechanical Engineering Department Workshop Practice

Course Learning Outcomes

Imitate operations related to various shops in

Demonstrate knowledge of basic workshop tools

Type of exam Percentage

Lab Reports + Rubrics (Psychomotor) 20

Rubric based Assessment in Affective domain 10

Open Ended Labs 10

Mid Term Exam 25

End semester Exam 35

Mechanical Engineering Department Workshop Practice

AFFECTIVE (To be judged in the lab during experiment)

Unacceptable Just acceptable Basic Good Excellent

Mechanical Engineering Department Workshop Practice

b) PSYCHOMOTOR (To be judged in the lab during experiment)

Learn skills Learns Learns

Mechanical Engineering Department Workshop Practice

1. To educate students regarding the safety principles

1. Decrease in direct and indirect cost of an accident.

1. First aid kit

Safety Measures in Mechanical workshop

1. All equipment and machinery should be inspected for safety.

Safety measures in material handling

Mechanical Engineering Department Workshop Practice

Safety measures against electric shocks

1. Only authorized persons should carry ut the electric works.

Fire prevention and protection

Mechanical Engineering Department Workshop Practice

First Aid Materials

Introduction to Mechanical Workshop:

Mechanical Engineering Department Workshop Practice

v. Electrical Resistance welding

Hard Wood Soft Wood

It is dark in color Its color is light

It does not split quickly It gets splitted quickly

Mechanical Engineering Department Workshop Practice

• Quarter or radial cutting

Mechanical Engineering Department Workshop Practice

Steps of experiment are Steps of experiment Steps of

Lab Instructor: Engr. Khubaib Haider Khan

Mechanical Engineering Department Workshop Practice

2. Minimum movement of workers and materials

3. Elimination of bottlenecks and congestion points

4. Proper utilization of space

5. To create flexible and hazards free environment

Factors in Plant Layout

The location of plant depends on many factors, which are as follows:

1. Decision of a new product.

2. Nearness to raw material and marks

3. Availability of space, power, labor, water, transport facilities.

4. Good climate conditions.

5. Financial and other aids

6. Local bylaws, taxes, security, hospitality etc.

8. Prescience of related industries

Mechanical Engineering Department Workshop Practice

1. Manufacturing processes to be adopted

3. Specification and size of raw material and product

4. Material handling devices

6. Scope for further expansion or modification