GOVERNMENT COLLEGE OF ENGINEERING

BODINAYAKKANUR – 625582
(A Tamilnadu Government Education Institution Affiliated to Anna University, Chennai)

COMPUTER SCIENCE AND ENGINEERING ( DATA SCIENCE )

ME25C05 RE-ENGINEERING FOR INNOVATION

LABORATORY RECORD

Name:

Roll No.:

Reg No:
 GOVERNMENT COLLEGE OF ENGINEERING
BODINAYAKKANUR – 625582
(A Tamilnadu Government Education Institution Affiliated to Anna University, Chennai)

COMPUTER SCIENCE AND ENGINEERING ( DATA SCIENCE )

BONAFIDE CERTIFICATE

Certified that this is a bonafide record of practical work done by

Mr/Ms of
2nd Semester B.E. class of Mechanical Engineering Department
in ME25C05 RE-ENGINEERING FOR INNOVATION during the academic
year 2025-2026.

REGISTER NO:

Staff-in-charge Head of the Department

Submitted for the End Semester Examination held on

Internal Examiner External Examiner

 INDEX

[Link] DATE NAME OF EXPERIMENT SIGN

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Ex. No. 1 Date:

Introduction to Product Development Process

Aim

To study and understand the stages involved in product development from idea generation to
final product realization.

Apparatus / Tools Required

• Computer system
• Internet access / reference books
• Whiteboard / notebook
• CAD software (optional – for concept visualization)

Theory

Product Development is a systematic process of designing, creating, and improving products

to meet customer needs and market requirements. It integrates engineering, design, manufacturing,
and marketing activities. The objective is to convert an idea into a successful product by following
structured stages.

The main stages of product development include:

1. Idea Generation
2. Concept Development
3. Design and Analysis
4. Prototyping
5. Testing and Validation
6. Manufacturing
7. Product Launch

Each stage ensures feasibility, quality, cost-effectiveness, and customer satisfaction.

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Procedure

1. Identify a simple product idea (e.g., mobile stand, water bottle, tool holder).
2. Define the customer need and problem statement.
3. Develop multiple concepts and select the best one.
4. Prepare a basic design or sketch of the selected concept.
5. List the materials and manufacturing processes required.
6. Discuss testing methods for product validation.
7. Analyze possible improvements and cost considerations.

Flow Diagram (Description)

Market Need → Idea Generation → Concept Design → Detailed Design → Prototype →

Testing → Manufacturing → Product Launch

Applications

• Development of consumer products

• Industrial product design
• Mechanical and manufacturing engineering
• Innovation and entrepreneurship

Result

The product development process was studied and the various stages involved in converting an
idea into a final product were successfully understood.

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Ex. No. 2 Date:

Study of Reverse Engineering Process

Aim

To study and understand the reverse engineering process by analyzing an existing product and
extracting its design information.

Apparatus / Tools Required

• Existing mechanical component (e.g., bearing, clamp, bottle cap)

• Measuring instruments (vernier caliper, ruler)
• Computer system
• CAD software (optional)

Theory

Reverse Engineering is the process of analyzing an existing product to understand its design,
dimensions, materials, and working principles without referring to original design data. It is
commonly used for product improvement, redesign, documentation, and failure analysis.

The process involves disassembling the product, measuring components, creating design drawings
or CAD models, and analyzing functionality.

Procedure

1. Select an existing mechanical component.

2. Disassemble the component carefully (if applicable).
3. Measure all critical dimensions using measuring instruments.
4. Identify the material and manufacturing process used.
5. Prepare a sketch or CAD model of the component.
6. Analyze the function and possible design improvements.

Flow Diagram (Description)

Existing Product → Disassembly → Measurement → CAD Modeling → Analysis →

Redesign / Documentation

Applications

• Product redesign and improvement

• Failure analysis
• Spare part development
• Design documentation

Result

The reverse engineering process was studied by analyzing an existing product and understanding
its design and functionality.

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Ex. No. 3 Date:

Study of Product Life Cycle (PLC)

Aim

To study and understand the various stages of the Product Life Cycle.

Apparatus / Tools Required

Computer system, reference materials, notebook.

Theory

The Product Life Cycle (PLC) represents the different stages through which a product passes from
its introduction into the market until its decline. The main stages are Introduction, Growth,
Maturity, and Decline. Each stage differs in terms of sales, profit, competition, and design
changes.

Procedure

1. Select a common product for study.

2. Identify the stages of the product life cycle.
3. Study the characteristics of each stage.
4. Draw the Product Life Cycle curve.
5. Analyze design and cost changes at each stage.

Overview of the Product Life Cycle (PLC)

The Product Life Cycle (PLC) describes the stages a product goes through from its
introduction to its withdrawal from the market. It helps organizations plan design,
production, marketing, and improvement strategies.

Stages of Product Life Cycle

1. Introduction Stage
o Product is launched in the market
o Low sales and high development cost
o Focus on promotion and customer awareness
2. Growth Stage
o Rapid increase in sales and profit
o Product improvements and design modifications
o Increased competition
3. Maturity Stage
o Sales reach peak and stabilize
o High competition and price pressure
o Cost reduction and minor design changes
4. Decline Stage
o Decrease in sales and profit
o Product becomes obsolete
o Decision taken to redesign or withdraw product

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PLC Curve (Description)

Sales increase gradually in the introduction stage, rise rapidly during growth, remain stable
during maturity, and decline over time.

Importance of PLC

• Helps in product planning and redesign

• Supports cost control and quality improvement
• Aids in market and production decisions

Result

The stages of the Product Life Cycle were studied and understood.

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Ex. No. 4. a. Date:

Hands-on Disassembly of a Flashlight

Aim:

To study the construction, components, and working principle of a flashlight by performing

systematic disassembly and reassembly, and to understand the function of each internal part.

Objective:

• To understand the internal components of a flashlight.

• To practice disassembly, observation, and documentation for reverse engineering.
• To develop skills in measurement and component analysis.

Materials Required:

• Flashlight (battery-operated, small)

• Screwdrivers (flathead and Phillips)
• Tweezers
• Small containers for screws and parts
• Ruler or caliper
• Notebook/lab sheet
• Camera or smartphone (optional)

Step-by-Step Disassembly

Step 1: External Observation

• Examine the flashlight carefully.

• Note visible features:
o On/Off switch
o Battery compartment
o Lens/reflector
o Body/casing
• Sketch the flashlight from front, side, and top views.

Step 2: Identify Fasteners

• Look for screws or clips on the tail cap or body.

• Decide which tools are needed for opening.

Step 3: Remove the Tail Cap

• Unscrew the tail cap to access the battery compartment.

• Keep screws in a small container.
• Observe the spring at the tail end (conducts electricity and holds battery).

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Step 4: Remove Batteries

• Take out batteries carefully.

• Note their size (AA/AAA) and orientation (+/-).

Step 5: Disassemble the Head (LED/Bulb Area)

• Unscrew the head of the flashlight.

• Observe internal components:
o LED or bulb
o Reflector
o Lens
• Handle LED/bulb carefully to avoid damage.

Step 6: Separate the Switch Mechanism

• If the switch is removable, gently pry it out.

• Observe how the switch connects to the circuit.
• Identify contacts, wires, or spring mechanisms.

Step 7: Component Identification and Measurement

• List all components in a table:

Component Material Function Assembly Type Notes

LED/Bulb Semiconductor/Glass Light source Screw-fit/Push-fit 3V operation

Reflector Aluminum Focus light Press-fit Parabolic shape

Lens Plastic Distribute light Snap-fit Transparent

Switch Plastic/Metal On/Off Snap-fit Single-pole

Battery Holder Plastic/Metal Power supply Snap-fit 2 AA batteries

Spring Metal Electrical contact Press-fit Tail end

Casing/Body Plastic/Metal Protection Screws/Snap-fit Ergonomic design

• Measure dimensions using a ruler/caliper (length, diameter).

Step 8: Observation & Analysis

• Discuss how components work together:

o Electricity flows from batteries → switch → LED → tail spring.
o Reflector and lens focus the light.
• Identify design strengths (compact, lightweight) and limitations (battery replacement
access).

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Step 9: Reassembly

• Reassemble in reverse order:

1. Insert LED and reflector in head.
2. Reattach switch.
3. Insert batteries in correct orientation.
4. Screw tail cap.
• Test flashlight to ensure it works.

Result:
The flashlight was successfully disassembled and reassembled. The internal components such as
the tail cap, spring, battery holder, switch mechanism, reflector, LED, lens, and body casing were
identified and examined. The working principle of the flashlight and the role of each component
in completing the electrical circuit were clearly understood.

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Ex. No. 4. b. Date:

Hands-on Disassembly and Study of an Induction Stove

Aim

To disassemble an induction stove carefully and study the internal components, construction,
and working principle.

Tools Required

• Screwdriver set (Phillips & flat)

• Plastic pry tool
• Multimeter
• Nose pliers
• Insulation gloves
• Camera/mobile for recording steps

Safety Precautions

1. Ensure the stove is unplugged from the power supply.

2. Wait for 10–15 minutes to allow internal capacitors to discharge.
3. Do not touch the PCB or capacitor terminals directly.
4. Handle the glass top carefully to avoid breakage.
5. Keep screws and parts organized.

Procedure

Step 1: External Observation

• Note model number, power rating, and control panel.

• Observe glass top, air vents, and base cover.

Step 2: Remove Bottom Cover

• Turn the stove upside down.

• Unscrew all screws from the base.
• Gently remove the bottom plastic/metal cover.

Step 3: Identify Major Components

Inside the stove, identify:

• Cooling fan
• Induction coil
• Main PCB (control board)
• Heat sink with IGBT
• Rectifier and capacitor
• Control panel board
• Temperature sensor

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Step 4: Remove Cooling Fan

• Disconnect fan wires from PCB.

• Unscrew and remove the fan.

Step 5: Remove Induction Coil

• The flat copper coil is fixed below the glass plate.

• Unscrew the coil holder and carefully lift the coil.

Step 6: Observe Power Circuit

• Locate:
o Bridge rectifier
o Large electrolytic capacitor
o IGBT mounted on heat sink
• Trace wiring from power input to coil.

Step 7: Remove PCB

• Disconnect wire connectors.

• Unscrew PCB and remove it for observation.

Step 8: Control Panel Disassembly

• Separate the touch panel/control board from the front panel.

Main Components and Their Function

Component Function

Induction Coil Produces magnetic field to heat vessel

IGBT High-speed switching of current

Rectifier Converts AC to DC

Capacitor Filters and stores charge

Cooling Fan Prevents overheating

Temperature Sensor Monitors heat

Control PCB Controls operation and safety

Glass Top Supports vessel, heat resistant

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Working Principle (Observed)

• AC supply → Rectifier → DC.

• IGBT switches DC at high frequency through coil.
• Magnetic field induces eddy currents in the vessel.
• Vessel heats due to resistance.

Result

The induction stove was successfully disassembled and the internal components, layout, and
working principle were studied.

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Ex. No. 4. c. Date:

Hands-on Disassembly of CPU (System Unit)

Aim

To disassemble the CPU system unit (computer cabinet) and study the internal hardware
components and their functions.

Tools Required

Tool Purpose

Screwdriver Removing cabinet screws

Anti-static wrist strap (if available) Prevent static damage

Soft brush Cleaning dust

Small tray Keeping screws safely

Precautions

• Shut down the computer properly.

• Unplug power cable and all peripherals.
• Press power button once to discharge residual power.
• Avoid touching circuit parts with bare hands (ESD risk).
• Handle components gently.

Main Parts inside CPU Cabinet

Component Function

SMPS (Power Supply) Supplies DC power to system

Motherboard Main circuit board connecting all parts

RAM Temporary memory

Hard disk / SSD Permanent storage

Processor (CPU chip) Performs computations

Heat sink & fan Cooling processor

Expansion cards Graphics / network functions

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Procedure

Step 1: Remove Side Cover

• Place CPU cabinet on table.

• Unscrew side panel screws.
• Slide and remove the cover.

Step 2: Observe Internal Layout

• Identify SMPS, motherboard, RAM, storage drive, and cables.

Step 3: Disconnect Power and Data Cables

• Carefully remove SATA and power connectors from HDD/SSD and motherboard.

Step 4: Remove RAM

• Press side clips of RAM slot.

• Gently pull RAM out.

Step 5: Remove Storage Drive (HDD/SSD)

• Unscrew mounting screws.

• Slide the drive out.

Step 6: Remove Expansion Cards (if present)

• Unscrew bracket screw.

• Pull card straight out of slot.

Step 7: Remove Heat Sink and Fan

• Disconnect fan wire.

• Unscrew/unjoint heat sink.
• Observe processor placement (do not remove CPU unless instructed).

Step 8: Observe SMPS Connections

• Note power connectors to motherboard and drives.

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Observations

Component Observation

Processor cooling Heat sink with fan

Memory type DDR RAM module

Storage type SATA HDD/SSD

Power distribution From SMPS to all units

Result

The CPU cabinet was successfully disassembled and internal hardware components were
identified and studied.

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Ex. No. 5. a. Date:

Practice of Basic Measurement and Sketching of a Square Rod

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Ex. No. 5. a. Date:

Practice of Basic Measurement and Sketching of a Square Rod

Aim

To measure the dimensions of a square rod using basic measuring instruments and prepare a
neat, dimensioned sketch.

Instruments Required

• Steel rule
• Vernier caliper
• Micrometer (optional)
• Try square
• Pencil, eraser, sketch sheet

Specimen

Mild steel / aluminum square rod

Procedure

1. Clean the rod to remove dust/burrs.

2. Measure the length (L) using a steel rule.
3. Measure the side of square (a) using vernier caliper.
4. Use a try square to check right angles.
5. Note all readings in mm.
6. Draw front view, top view, and side view with proper dimensions.

Observation Table

Parameter Instrument Used Measured Value (mm)

Length (L) Vernier caliper
Side (a) Vernier caliper

Calculations

• Cross-sectional Area = A2 =
• Volume = A2 × L =

Result

The square rod was measured accurately and a dimensioned sketch was prepared using standard
drawing practice.

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Ex. No. 5. b. Date:

Practice of Basic Measurement and Sketching of a Circular Rod

Aim

To measure the dimensions of a circular rod using basic measuring instruments and prepare a
freehand sketch with proper proportions.

Tools and Instruments Required

Instrument Purpose

Steel rule Measuring length

Vernier caliper Measuring diameter accurately

Pencil, eraser Sketching

Drawing sheet Freehand sketch

Try square Checking straightness

Material Required

• Mild steel circular rod (sample piece)

Theory

Measurement is the first step in manufacturing and design. Accurate measurement of simple
components like a circular rod helps in:

• Understanding use of measuring instruments

• Developing sketching skills
• Representing real objects in drawing form with correct proportions

Procedure

Step 1: Visual Inspection

• Observe the circular rod.

• Note its shape, surface finish, and ends.

Step 2: Measure the Length

• Use steel rule to measure total length of the rod.

• Record the value.

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Ex. No. 5. b. Date:

Practice of Basic Measurement and Sketching of a Circular Rod

ALL DIMENSIONS ARE IN MM

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Step 3: Measure the Diameter

• Use vernier caliper to measure the diameter at:

o One end
o Middle
o Other end
• Check for uniformity.

Step 4: Check Straightness

• Place rod along try square edge to ensure it is straight.

Step 5: Freehand Sketching

• Draw the rod in front view (rectangular shape).

• Draw the end view (circle).
• Mention measured dimensions on the sketch.

Observation Table

Parameter Measured Value

Length of rod ______ mm

Diameter at end ______ mm

Diameter at middle ______ mm

Diameter at another end ______ mm

Calculations

• Cross-sectional Area

A = (πD2) / 4 =

• Volume

V=A×L=

Result

The circular rod was measured accurately and its freehand sketch was drawn with proper
dimensions.

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Ex. No. 5. c. Date:

Practice of Basic Measurement and Sketching of a Circular Taper Rod

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Ex. No. 5. c. Date:

Practice of Basic Measurement and Sketching of a Circular Taper Rod

Aim

To measure the dimensions of a round taper rod and prepare a neat, dimensioned sketch using
basic measuring instruments.

Instruments Required

• Steel rule, Vernier caliper, Micrometer screw gauge, Bevel protractor (optional, for taper
angle), Pencil, eraser, sketch sheet

Specimen

Mild steel / aluminum round taper rod

Procedure

1. Clean the rod surface.

2. Measure the total length (L) using a steel rule.
3. Measure the larger diameter (D₁) at the big end using micrometer.
4. Measure the smaller diameter (D₂) at the small end using micrometer.
5. Measure diameter at mid-length to observe uniform taper.
6. Record all readings in mm.
7. Draw front view, top view, and side view with proper dimensions.

Observation Table

Parameter Instrument Value (mm)

Length (L) Vernier caliper
Large diameter (D₁) Vernier caliper
Small diameter (D₂) Vernier caliper

Calculations

Taper per unit length

Taper = (D1 − D2) / L = mm/mm

Taper angle (optional)

tan θ = (D1 − D2) / 2L

Result

The round taper rod dimensions were measured accurately and a proper dimensioned sketch was
prepared.

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Ex. No. 6

Introduction to CAD Modeling of Disassembled Parts

CAD Modeling of Hexagonal Head Bolt with Threaded End

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Ex. No. 6

Introduction to CAD Modeling of Disassembled Parts

CAD Modeling of Hexagonal Head Bolt with Threaded End

Aim

To create the 3D model of a hexagonal head bolt with external thread using CAD software as
per the given drawing.

Software Required

• AutoCAD / SolidWorks / Fusion 360 / Creo (3D CAD)

Given Dimensions (from drawing)

Feature Dimension

Hex head across flats 24 mm

Head thickness 19.2 mm

Shank diameter 24 mm

Total bolt length 150 mm

Threaded portion length 60 mm

Thread specification M24

Chamfer at end 30°

Chamfer at head bottom 60°

Theory

A hexagonal head bolt consists of:

• A hex head for spanner grip

• A cylindrical shank
• A threaded end for fastening
• Chamfers for easy engagement

This experiment demonstrates solid modeling, polygon creation, extrusion, thread

representation, and chamfering in CAD.

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Procedure

Step 1: Set Workspace

• Open new file → 3D Modeling

• Units: millimeters

Step 2: Create Hexagonal Head

1. Command: POLYGON
2. Number of sides: 6
3. Specify center → choose Circumscribed about circle
4. Radius = 12 mm (to get 24 mm across flats)
5. Command: EXTRUDE → Height = 19.2 mm

Step 3: Create Cylindrical Shank

1. On top face of head, draw Circle Ø24 mm

2. EXTRUDE to 130.8 mm
(150 − 19.2 = 130.8 mm)

Step 4: Create Threaded Portion

1. Mark 60 mm length from end

2. Use HELIX command (for realistic thread) or represent thread using:
o Cosmetic thread / groove lines
3. Thread size: M24

Step 5: Chamfer the Bolt End

• Command: CHAMFEREDGE
• Angle: 30°

Step 6: Chamfer Below Head

• Apply 60° chamfer at junction of head and shank.

Step 7: Union

• Use UNION to combine head and shank if created separately.

Step 8: Isometric View

• Switch to SE Isometric
• Apply Shaded visual style

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Commands Used

Command Purpose

POLYGON Create hex head

CIRCLE Create shank

EXTRUDE Convert 2D to 3D

HELIX Create threads

CHAMFEREDGE Chamfer edges

UNION Join solids

Result

The 3D model of a hexagonal head bolt with M24 threaded end was successfully created as
per the given drawing.

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Ex. No. 7 Date:

Group brainstorming sessions

1. Household Appliance Reverse Engineering

• Example: Electric kettle, table fan, or hair dryer.

• Activity:
o Disassemble in groups.
o Identify components: motor, heating element, switches, blades.
o Discuss the function of each part and how they interact.
• Learning Outcome: Understanding mechanical and electrical assemblies.

2. Mechanical Toy Reverse Engineering

• Example: Wind-up toy, toy car, or Lego mechanism.

• Activity:
o Analyze gears, levers, and linkages.
o Draw a simple schematic of how motion is transmitted.
• Learning Outcome: Comprehension of mechanical motion and gear systems.

3. Simple Electronics Reverse Engineering

• Example: LED torch, basic calculator, or remote control.

• Activity:
o Identify circuits, batteries, resistors, switches, and LEDs.
o Trace the flow of electricity and explain the working principle.
• Learning Outcome: Basic electronics understanding and circuit tracing.

4. Furniture / Fixture Reverse Engineering

• Example: Chair, drawer, or folding table.

• Activity:
o Disassemble, note joints, fasteners, and material usage.
o Suggest improvements or alternative designs.
• Learning Outcome: Design thinking and material application.

5. Packaging Reverse Engineering

• Example: Plastic bottle, box, or carton.

• Activity:
o Identify material type, structural design, and usability.
o Brainstorm ways to optimize cost or reduce waste.
• Learning Outcome: Product design and sustainability considerations.

6. Everyday Tools Reverse Engineering

• Example: Scissors, screwdriver, stapler.

• Activity:
o Examine moving parts, ergonomics, and leverage principles.
o Sketch parts and explain their interaction.
• Learning Outcome: Understanding mechanical advantage and simple machines.

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Ex. No. 8. a. Date:

Manufacture of Prototype Parts Using 3D Printing

Aim

To manufacture a prototype part using FDM-based 3D printing technology from a CAD model.

Objectives

• To prepare a 3D printable CAD model

• To fabricate a prototype using additive manufacturing
• To study the working of an FDM 3D printer

Apparatus / Equipment

3D printer (FDM), computer system, CAD software, slicing software, PLA filament, vernier
caliper.

Theory

3D printing is an additive manufacturing process in which parts are built layer by layer from a
digital model. In FDM technology, a thermoplastic filament is melted in a heated nozzle and
deposited on a build platform following the tool path generated from slicing software. It is widely
used for rapid prototyping in reverse engineering and product development.

Procedure

Create the CAD model of the prototype part.

1. Export the model in STL format.

2. Slice the STL file and generate G-code.
3. Load filament and set printer parameters.
4. Print the prototype layer by layer.
5. Remove and inspect the printed part.

Example

Prototype Part: Ergonomic Handle

Material: PLA
Printing Method: FDM
Purpose: Design validation in reverse engineering

Diagrams

Fig.1 Block Diagram of FDM 3D Printer

Labels: Filament spool, extruder motor, drive gear, heated nozzle, X–Y gantry, Z-axis, build
platform, controller.

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Fig.2 Working Principle of FDM 3D Printing

Labels: Filament, heated nozzle, molten material, printed layer, previous layer, build platform,
movement direction.

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Ex. No. 8. b. Date:

Manufacture of simple mechanical parts using 3D Printing

Aim

To model simple mechanical parts in CAD from measured data and assemble them virtually.

Example Parts Chosen

• Rectangular plate
• Cylindrical rod

Step 1 – Observation & Measurement

1. Measure the part using vernier/scale.

2. Draw rough hand sketches with dimensions.

Neat sketch to draw

Rectangular plate

Length = 20 mm
Height = 10 mm
Thickness = 2 mm

Cylindrical Rod
Length = 20 mm
Diameter = 5 mm

Step 2 – Start CAD → Create New Part (Chassis)

1. Open CAD → New Part.

2. Select Top Plane → Sketch.

Rectangular plate

3. Draw rectangle 20 × 10 mm.

4. Use Extrude → thickness 2 mm.

Cylindrical Rod

3. Draw circle – diameter 5 mm.

Objectives

• To convert CAD models into printable files.

• To understand slicing and printing parameters.
• To fabricate simple mechanical parts using 3D printing.

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Equipment / Software Required

• CAD software (SolidWorks / Fusion 360 / Creo)

• Slicing software (Cura / PrusaSlicer)
• FDM 3D Printer
• PLA filament
• SD card / USB
• Vernier caliper (for checking dimensions)

Prototype Parts Chosen

1. Rectangular plate (60 × 40 × 6 mm)

2. Cylindrical bush (Ø20 × 30 mm, hole Ø10 mm)
3. Simple spur gear (Ø40 × 8 mm)

Procedure

Step 1 – Create CAD Model

• Draw parts in CAD with given dimensions.

• Save each part as .STL file.

Step 2 – Import into Slicer

• Open STL file in Cura/PrusaSlicer.

• Place model on build plate.

Step 3 – Set Printing Parameters

Parameter Value

Layer height 0.2 mm

Infill 20%

Nozzle temperature 200°C

Bed temperature 60°C

Print speed 50 mm/s

Material PLA

Step 4 – Slicing

• Click Slice to generate G-code.

• Save G-code to SD card.

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Step 5 – Printing

• Insert SD card into printer.

• Load PLA filament.
• Start print and observe first layer adhesion.

Step 6 – Post Processing

• Remove part after cooling.

• Remove supports (if any).
• Measure dimensions using vernier caliper.

Result

Simple prototype parts were successfully manufactured using a 3D printer with acceptable
dimensional accuracy.

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Ex. No.: 9. a. Date:

Manufacture of Prototype Parts Using workshop tools Rectangular Tray

DEVELOPED VIEW

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Ex. No.: 9. a. Date:

Manufacture of Prototype Parts Using workshop tools Rectangular Tray

Aim

To make a tray out of the given sheet with specified dimensions.

Tools Required

1. Bench vice
2. Try square
3. Steel rule
4. Divider
5. Snap
6. Mallet
7. Hand shearing
8. Dot punch
9. Scriber

Materials Required

G.I. Sheet of suitable size

Procedure
1. Draw the layout of the bottom and body of the tray.
2. The edges are marked clearly on the sheet metal using pencil.
3. The given sheet is cut to the required shape and size using hand shears.
4. The marked lines are folded with the help of mallet and required stakes.
5. After folding on the all sides it resembles a tray.
6. The folds are made with dot punch on the marked portions for riveting.

Result

Thus the required tray is finished from the given sheet.

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Ex. No.: 9. b. Date:

Manufacture of Prototype Parts Using workshop tools

Simple Bracket, Stepped Pin, Flat Plate with Drilled Holes

ALL DIMENSIONS ARE IN MM

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Ex. No.: 9. b. Date:

Manufacture of Prototype Parts Using workshop tools

Simple Bracket, Stepped Pin, Flat Plate with Drilled Holes

Aim

To fabricate simple mechanical prototype parts using common workshop tools and understand
basic manufacturing operations.

Tools & Equipment Required

• Bench vice
• Hacksaw
• Files (flat, round, half-round)
• Ball peen hammer
• Try square
• Steel rule
• Scriber
• Center punch
• Hand drill / drilling machine
• Vernier caliper
• Emery sheet

Materials Required

• Mild steel flat plate

• Mild steel rod
• Marking blue / chalk

Safety Precautions

1. Wear apron and safety goggles.

2. Clamp the workpiece firmly in the vice.
3. Use proper file handle while filing.
4. Do not touch sharp edges with bare hands.
5. Keep tools in proper place after use.

Prototype Parts to be Manufactured

1. Simple Bracket
2. Stepped Pin
3. Flat Plate with Drilled Holes

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Procedure

Part 1: Simple Bracket

1. Mark dimensions on MS flat using steel rule and scriber.

2. Cut the piece using hacksaw.
3. File edges to obtain smooth finish and right angles.
4. Mark bending line and bend using hammer and vice.
5. Drill holes at marked locations.

Part 2: Stepped Pin

1. Cut MS rod to required length.

2. File to create step reduction in diameter.
3. Smooth finish using emery sheet.
4. Check dimensions using vernier caliper.

Part 3: Flat Plate with Holes

1. Mark hole positions using scriber and punch.

2. Drill holes using drilling machine.
3. Deburr edges using file.

Observations

Part Operations Used Tools Used

Bracket Marking, Cutting, Bending, Drilling, Filing Scriber, Hacksaw, Hammer, Drill, File
Stepped Pin Cutting, Filing, Finishing Hacksaw, File, Emery
Flat Plate Marking, Punching, Drilling, Filing Punch, Drill, File

Result

The simple mechanical prototype parts were successfully fabricated using basic workshop tools
with acceptable dimensional accuracy.

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