(Approved by AICTE and Affiliated to Anna University Chennai )

Department of Mechanical Engineering

GE6162 ENGINEERING PRACTICES LAB

LABORATORY RECORD

Name :. Roll No :.....

Class :. Branch :...

University Register
Number

Certified that is a bonafide record of work done by the above student during
the year 2016-2017.

Staff - in - Charge Head of the Department

Submitted for the University Practical Examination held on at

SASURIE ACADEMY of Engineering , Coimbatore - 641653

Internal Examiner External Examiner

 GE6162 ENGINEERING PRACTICES LAB
LABORATORY RECORD

CONTENTS

Sl. Page
N Date Name of the Experiment Mark Sign.
No
o.
CARPENTRY
INTRODUCTION

1 Introduction

2. Sawing and Planing

3. Half Lap Joint

4. Tee Lap Joint

5. Dovetail Halving Joint

SHEET METAL WORK

6. Introduction

7. Square Tray

8. Rectangle Tray

9. Frustum of a Cone - Funnel

WELDING

10 Introduction

11 Square Butt joint

12 Lap joint

13 Tee Fillet Joint

 PLUMBING

14 Introduction

15 Pipeline to Washbasin

16 Pipeline to a Washing Machine

17 Pipeline to Water Heater

Basic pipe connections involving

18 the fitting like valves ,taps and
bends
BASIC MACHINING

19 Introduction

Facing, Turning, Step Turning,

20
Chamfering and Taper
Turning
21 Drilling and Tapping

STUDY EXPERIMENT

22 Study Of Centrifugal Pump

23 Study of Air-Conditioner
 SAFETY PRECAUTION

1. Always wear uniform, shoes and gloves for safety

2. Never operate any machines until you have been instructed properly

3. Always wear goggles to protect your eyes from flying chips.

4. Never hold the job when the machine runs.

5. Never give heavy cut on longer job

6. Never change the gear and belt when the machine is running

7. Always use the correct size spanner and tool for fitting and removing of tool

8. Never try to clear the chips when the machine is running

9. To prevent accident, clean the spilled oil and grease immediately

10. Always clear the area around the machine and machine tool surface

11. Leather shoes or boots with steel toes are recommended.

12. No open toed shoes or sandals are allowed in the shop.

13. Do not wear loose clothing. Cotton clothes are best to wear.

14. Remove all jewelry and tie back long hair.

15. Do not operate any machine equipment unless you have been instructed on its proper use
and the safety risks involved with the machining operation.

16. Do not leave any machinery or power tools running and unattended.

17. Clean up metal shavings, oil, etc. from machine tools after use; pick up after yourself and
return tools to their proper storage area.

18. Wear closed toe shoes and appropriate clothing.

19. Dont run, push or surprise other students. No horse play will be tolerated
CARPENTRY

1
Structure of Wood

2
[Link] : 1 INTRODUCTION OF CARPENTRY
DATE:

Introduction: Carpentry is the process of working with wood for applications such as floor works,
roofs and partitions in a building. Preparation of other wood works such as windows, stairs,
cupboards, etc., is called as joinery.

Types of wood: Wood is generally classified into three types.

(a) Soft wood

(b) Hard wood

(c) Ply wood

Soft wood: It has straight fibers and is comparatively weaker. It is easy to work on the soft wood.
Weight and durability are less for soft wood. Soft wood catches fire soon. Eg. Deodar, Kail, chir.

Hard wood: Hard wood has closed structure, heavy in weight, dark in colour, more durable. It is
difficult to work on hard wood. So it is very strong. Eg. Teek, Shirham, Sal, Mango, Oak.

Ply wood: Ply wood consists of three layers

(a) Top face plys layer

(b) Core layer

(c) Bottom face ply layer

The top and bottom layers are called face ply laters. These two layers are bonded to the centre
core, which is thick and not of good quality.

Structure of wood: The following are the main parts of the wood.

(a) Medulla: Medulla or Pith is the centre part of the tree. Medulla feeds the sap from the roots to
the leaves. It is dark in colour.

(b) Heart wood: It is the portion surrounding the medulla. The percentage of moisture is less than
the central part.

3
4
(c) Sap wood: Sap wood is the portion between cambium layer and heart wood. Sap wood is
light in weight and softer and consists of high percentage of moisture.

(d) Cambium layer: Cambium layer is the rings adjacent to the bark.

(e) Bark: Bark is the outer surface of the tree. It acts as the cover for inner portion of the tree.
(f) Medullary rays: Medullary rays are radial layer starting from pith up to the cambium
layer.
(g) Annual rings: It is the concentric layer of the wood around the pith. In every year, one
such layer is added to the trees.

Carpentry tools: Large numbers of tools are used in carpentry. Following are the types of tools
used in carpentry.
(1) Marking and measuring tools.
(2) Cutting tools.
(3) Planning tools.
(4) Boring tools.
(5) Striking tools and Holding tools and Power tools.

Holding tools: During the wood working job is shacked, so marking accuracy is tough. To
maintain accuracy the wood is to be held rigidly.

(a) Bench vice: It is the most common work holding device. It consists of one fixed jaw and one

movable jaw. The fixed jaw is fastened to the work bench. The gap between the jaws are
adjusted using the screw rod.

(b) C-clamps: It is made up of malleable iron. The operating capacity rates from 50 to 350mm. it
can be used for clamping small work. The swivel shoe allows to fix angled work.

5
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[Link]: 2 SAWING AND PLANNING
DATE: :

Aim: To make a planning from the given wooden piece for the given dimensions.

Material supplied: A wooden piece of size 300 x 40 x 40 mm

Tools required:
1. Steel rule 2. Carpentry vice
3. Jack plane 4. Try square
5. Marking gauge 6. Rip saw
7. Tenon saw 8. Firmer chisel
9. Mallet

Sequence of operation:
1. Rough planning 2. Marking
3. Cutting (or) Sawing 4. Chiseling
5. Finish planning

Working steps:

1. The given job is checked to ensure its correct size.

2. The job is firmly clamped in the carpentry vice and two surfaces are planned by Jack plane
to get right angle.
3. Using try square, the right angle of the work piece is checked.
4 Now all the four sides of the wooden pieces are planned to get the smoother and finished
surface.
5. Now the job is cut into two halves rip saw
6. Finally, the accuracy and proper dimensions are verified by using steel rule and try square.

Result: Thus the workpiece is palnned to reuired dimensions.

7
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[Link]: 3 CROSS LAP JOINT
DATE :

Aim: To make a cross lap joint from the given wooden piece for the given dimensions.

Material supplied: A wooden piece of size 300 x 40 x 40 mm

Tools required:
1. Steel rule 2. Carpentry vice
3. Jack plane 4. Try square
5. Marking gauge 6. Rip saw
7. Tenon saw 8. Firmer chisel
9. Mallet

Sequence of operation:
1. Rough planning 2. Marking
3. Cutting (or) Sawing 4. Chiseling
5. Finish planning

Working steps:

1. The given job is checked to ensure its correct size.

2. The job is firmly clamped in the carpentry vice and two surfaces are planned by Jack plane
to get right angle.
3. Using try square, the right angle of the work piece is checked.
4. Now all the four sides of the wooden pieces are planned to get the smoother and finished
surface.
5. Now the job is cut into two halves rip saw then proper marking is done for cross lap joint on the
two pieces using steel rule and marking gauge.
6. One half is taken. Using tenon saw and firmer chisel the unwanted portions are removed as per
the drawing.
7. The above procedure is repeated for the other half of the work piece.
8. Jack plane is used to plane the other two faces up to the marked portion.
9. Now the two pieces are assembled to check proper fitting.
10. The finished job is again checked job is again checked for its accurate shape and size using
try square and steel rule.

Result: Thus the desired cross lap joint is obtained.

9
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[Link]: 4 TEE LAP JOINT
DATE: :

Aim: To make a Tee lap joint from the given wooden piece for the given dimensions.

Material supplied: A wooden piece of size 300 x 40 x 40 mm

Tools required:
1. Steel rule 2. Carpentry vice
3. Jack plane 4. Try square
5. Marking gauge 6. Rip saw
7. Tenon saw 8. Firmer chisel
9. Mallet

Sequence of operation:
1. Rough planning 2. Marking
3. Cutting (or) Sawing 4. Chiseling
5. Finish planning

Working steps:
1. The given job is checked to ensure its correct size.
2. The job is firmly clamped in the carpentry vice and two surfaces are planned by Jack plane
to get right angle.
3. Using try square, the right angle of the work piece is checked.
4. Now all the four sides of the wooden pieces are planned to get the smoother and finished
surface.
5. Now the job is cut into two halves rip saw then proper marking is done for cross lap joint on the
two pieces using steel rule and marking gauge.
6. One half is taken. Using tenon saw and firmer chisel the unwanted portions are removed as per
the drawing.
7. The above procedure is repeated for the other half of the work piece.
8. Jack plane is used to plane the other two faces up to the marked portion.
9. Now the two pieces are assembled to check proper fitting.
10. The finished job is again checked job is again checked for its accurate shape and size using
try square and steel rule.

Result: Thus the desired Tee lap joint is obtained.

11
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[Link] : 5 DOVETAIL HALVING JOINT
DATE :

Aim: To make a mortise and tenon joint from the given wooden piece for the given dimensions.

Material supplied: A wooden piece of size 300 x 40 x 40 mm

Tools required:

1. Steel rule 2. Carpentry vice

3. Jack plane 4. Try square

5. Mortise gauge 6. Rip saw

7. Tenon saw 8. Mortise chisel

9. Mallet

Sequence of operations:

1. Rough planning 2. Marking

3. Cutting (or) Sawing 4. Chiselling

5. Finish planning

Working steps:

1. The given job is checked to ensure its correct size.

2. The job is firmly clamped in the carpentry vice and any two surfaces are planed by jack
plane to get right angle.
3. Using try square, the right angle of the work piece is checked.
4. Now all the four sides of the wooden pieces are planed to get the smoother and finished
surface.
5. Now the job is cut into two halves using rip saw then proper marking is done for dovetail
halving joint on the two pieces using steel rule and marking gauge.
6. One half is cut into a tapering slot having the required dimension using tenon saw and
firmer Chisel
7. The above procedure is repeated for the other half of the work piece.
8. Jack plane is used to plane the other two faces upto the marked portion.
9. Now the two pieces are assembled to check proper fitting.
10. The finished job is again checked for its accurate shape and size using try square and steel
rule.

Result: Thus the desired dovetail halving joint is obtained.

13
14
SHEET
METAL

15
16
[Link] : 6 INTRODUCTION OF SHEET METAL
DATE :
Introduction:
Sheet metal work is working on the metal of 16 gauge to 30 gauge with hand tools and simple

machines into different forms by cutting, forming into shape and joining. Sheet metal work is one
of the major applications in the engineering industry. It has its own significance as useful
trade in engineering work.

Application of sheet metal:

Sheet metal work is used for making hoppers, funnels, various ducts, chimneys, ventilating

pipes, machine tool guards, boilers, etc., It is also used in major industries like aircraft
manufacturing, ship building, automobile body building and fabricating ducts in air conditioning
equipments etc.,

Tools used:

Cutting tools (chisels, snips or shears): Chisels:

Chisels are used for cutting sheets, rivets, bolts and clipping operations. Round nose chisel and

flat chisel are the often used ones.

Snips or shears: Snips are hard shears, varying in length from 200mm to 600mm. 200mm and
250mm length is commonly used. Straight snips are used for cutting along outside curves and
straight [Link] snips or bent snips are used for trimming along inside curves.

Striking tools: Hammer: Hammers are used in sheet metal work for hollowing, stretching,
levelling, revetting, strengthening of sheet metal joints etc., the following joints are used in sheet
[Link] peen hammer, Straight peen hammer, Rivetting hammer, Mallet

Punches: In sheet metal work, punch is used for making out work locating centers etc., the following
two types of punches are widely used. Dot punch & Centre punch.

Supporting tools: Stakes: Stakes are nothing but sheet metal workers anvils used for bending,
hemming, seaming, forming etc., using hammers and mallet.

17
18
Bending tools: Pliers: Pliers are used for bending the sheet metal to the required shape. It is also
used for holding and cutting the sheet metal. Flat nose pliers and round nose pliers are used in sheet
metal work for forming and holding work.

Layout tools: Steel rule: It is used for measuring and laying out small work it can measure with as
accuracy of up to 0.5mm.

Scriber: It is a long wire of steel with its one and sharply pointed and hardened to scratch line on
sheet metal for laying out patterns.

Dividers: Dividers are used for drawing circles or arcs on sheet metal.

Trammels: It is used for marking areas and circles. Maximum size of the arc that can be scribed
depends on the length of the beam in scriber.

Sheet metal gauge: It is used tom find the thickness of the sheet metal. The various types of gauges
are: Standard Wire Gauge (SWG), Birham Wire Gauge, Burmingham Wire Gauge and American
Wire Gauge.

Other tools: Groover: Grooving: In order to join the sheet metal joints, their ends are grooved
with the help of grooving [Link] process is called grooving. It is a most widely used tool made
up of hardened and tempered carbon steel. These are used for making locked joints in sheet metal
works such as wired edges, slots etc., These are available in different sizes.

Bench plate: A special type of plate made of carbon steel. Types of bench plate: fixed bench plate,
revolving bench plate.

Hand dolly: It is a steel block rectangular in shape and fitted with a handle in the bottom of the
block.

Sheet metal joints: Sheet metal working incorporates a wide variety of hems and seams.

Hem: A hem is an edge or border made by folding. Types of hem are Single hem, Double hem,

Wired edge.

19
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[Link] : 7 SQUARE TRAY
DATE :

Aim: To make a square tray from the given sheet metal.

Material supplied: 22 gauge Galvanized Iron (G.I) sheet.

Tools required:

1. Steel rule
2. Mallet
3. Scriber
4. Divider
5. Protractor
6. Snips
7. Stakes
8. Rivet set
9. Ball peen hammer

Sequence of operations:

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

Working steps:

1. The size of the given sheet is checked for its dimensions using a steel rule.
2. Then the sheet is leveled on the leveling plate using a mallet.
3. The development procedure is followed same as square taper tray.
4. The dimensions are marked as shown in fig.
5. The sheet is cut as per the marked dimensions by straight snips.
6. Then a single hemming is made on the four sides of the tray as shown in fig.
7. This four sides of the tray are bent to 90 using stakes anvil.
8. Finally all the corners of the tray are joined by riveting.

Result: Thus the desired Square tray is made from the given sheet metal.

21
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[Link] : 8 RECTANGULAR TRAY
DATE :

Aim: To make a rectangular tray from the given sheet metal.

Material supplied: 22 gauge Galvanized Iron (G.I) sheet.

Tools required:

1. Steel rule
2. Mallet
3. Scriber
4. Divider
5. Protractor
6. Snips
7. Stakes
8. Rivet set
9. Ball peen hammer

Sequence of operations:

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

Working steps:

1. The size of the given sheet is checked for its dimensions using a steel rule.
2. Then the sheet is leveled on the leveling plate using a mallet.
3. The development procedure is followed same as square taper tray.
4. The dimensions are marked as shown in fig.
5. The sheet is cut as per the marked dimensions by straight snips.
6. Then a single hemming is made on the four sides of the tray as shown in fig.
7. This four sides of the tray are bent to 90 using stakes anvil.
8. Finally all the corners of the tray are joined by riveting.

Result: Thus the desired rectangular tray is made from the given sheet metal.

23
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[Link] : 9 FRUSTUM OF CONE - FUNNEL
DATE :

Aim: To make a funnel from the given sheet metal.

Material supplied: 22 gauge Galvanized Iron (G.I) sheet.

Tools required:
1. Steel rule
2. Mallet
3. Ball peen hammer
4. Scriber
5. White paper
6. Straight snips
7. Groover
8. Solder

Sequence of operations:
1. Checking
2. Levelling
3. Marking on paper
4. Marking on sheet metal
5. Cutting
6. Folding
7. Hemming
8. Soldering

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

Result: Thus the Frustum of a cone - funnel of the required dimensions is made from the
given sheet metal.

25
26
WELDING

27
 Welding

Plastic Welding (non- Fusion Welding (no

Fusion)(Under pressure, pressure is required, but
Without addition of with the addition of
filler material filler material

Forge Resistance Gas Electric arc Thermit

Welding Welding Welding Welding welding

(a) Lap Welding (a) Spot (a) Oxy- (a) Metal Arc Welding
(b) Butt Welding Welding Acetylene (b) Arc Welding
(c) V Welding (b) Projection Welding (c) Tungsten Welding
(d) T - Welding Welding (b) Air- (d) Argon Welding
(c) Seam Acetylene (e) Submerged Arc
Welding Welding Welding
(d) Butt (c) Oxy- (f) Atomic Hydrogen
Welding hydrogen Welding
(e) Percussion Welding
Welding

28
[Link] : 10 INTRODUTION TO WELDING
DATE :

Introduction:

Welding is a metal joining process wherein localized coalescence is produced either by

heating the metal to a suitable temperature, with or without the use of filler metal, with or without
application of pressure. The filler material has similar compositional melting point temperature as
that of the base metal. It is used to fill gap between the join surfaces.

Types of welding:

Welding process is mainly divided into the subdivisions as follows:

1. Plastic welding: The pieces of the metal to be joined are heated to the plastic state and then
forced together by external pressure without the addition of filler material. Plastic welding is further
classified as:

(a) Forge welding

(b) Resistance welding

2. Fusion welding: In fusion welding, metal parts to be joined are melted and then allowed to
solidify pressure is not applied and filler metals may be used for this type of welding.

Fusion welding is further classified as:

(a) Gas welding

(b) Electric arc welding

(c) Thermit welding

3. Oxy-Acetylene welding: Here, oxygen and acetylene are the two gases are used for producing
flame. Oxygen is mainly used for supporting the combustion intensity. A typical oxy-acetylene
gas welding setup is used.

Chemical reactions in gas welding:

C2H2 + O2 2CO + H2 + Heat

2CO + O2 2CO2

2H2 + O2 2H2O

29
30
Types of flames:

[Link] flame ( oxygen, acetylene in equal proportions )

[Link] flame ( excess of oxygen )

3. Reducing flame (excess of acetylene )

Limitations:

In this method, only those metals whose combustion temperature is below their melting point
can be cut. So iron and steel can be cut flame cutting.

Principle:

The heat required for joining the metal is obtained from an electric arc. The electric motor
generator or transformer sets are used to supply high electric current and the electrodes are used to
produce the necessary are. The electrode saves as the filler rod and are melts the surfaces so that
the metals to be joined are fused together.

Welding bed cleaning accessories:

1. Wire bush: A wire bush made up of stiff steel wire.

2. Chipping hammer: A chipping hammer is chisel shaped one and it is used to remove the slag
from the weld bed.

3. Hand screen: It is a protective device used in arc welding. A hand shield is held in the hand of
the welder and it is fitted with a suitable fitter lens.

4. Helmet: It is used for sheiding and protecting the face and neck of the welder and it is fitted
with a suitable fitter lens.

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

6. Goggles: Chipple joggle are used to protect the eyes while chipping the slay. They are fitted
with a plain glass to see the area to be cleaned.

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

31
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[Link]: 11 SINGLE V-BUTT JOINT
DATE :

Aim: To make a Single V-Butt joint using arc welding on the given work pieces.

Material supplied:

Mild steel plate of size 100 x 50 x 6mm - 2 Nos.

Tools required:

1. Power supply (AC or DC)

2. Welding Torch
3. Electrodes
4. Tongs
5. Chipping hammer
6. Wire brush
7. Gloves
8. Apron
9. Shield
10. Safety goggles
11. Earthing clamps
Sequence of operations:

1. Edge preparation (Removal of rust, scale etc.,)

2. Tacking
3. Welding
4. Cooling
5. Chipping
6. Cleaning
Working steps:
1. First of all, the work pieces must be thoroughly cleaned to remove rust, scale and other foreign
materials.
2. Then the given work pieces are placed on the table in such a way that two work pieces are
brought close to each other so that it forms a V-Shape when the plates butt each other.
3. Appropriate power supply should be given to the electrode and work pieces.
4. Now the welding current output may be existed.
5. When current is passed, arc is produced between the electrode and work pieces.
6. Now set the two work pieces in correct position and maintain the gap 3mm and drack at both
ends of the work pieces as shown in the figure.
7. Then the welding is carried out throughout the length.
8. As soon as the welding process is finished, switched off the current supply and allow the work
piece to cool.
9. Slags are removed by chipping process with the help of chipping hammer.
10. Finally using wire brush, welded portions are cleaned.

Result: Thus the desired Single V-Butt joint is obtained using arc welding.
33
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[Link] :12 LAP JOINT
DATE :

Aim: To make a lap joint using arc welding on the given workpieces.

Material supplied: Mild steel plate of size 102 x 51 x 6mm - 2 Nos.

Tools required:

1. Power supply (AC or DC)

2. Welding Torch
3. Electrodes
4. Tongs
5. Chipping hammer
6. Wire brush
7. Gloves
8. Apron
9. Shield
10. Safety goggles
11. Earthing clamps

Sequence of operations:
1. Edge preparation (Removal of rust, scale etc.,)
2. Tacking
3. Welding
4. Cooling
5. Chipping
6. Cleaning
Working steps:

1. First of all, the work pieces must be thoroughly cleaned to remove rust, scale and other foreign
materials.
2. Then the given work pieces are placed on the table in such a way that two work pieces are
overlapped one over another as shown in fig.
3. Appropriate power supply should be given to the electrode and work pieces.
4. Now the welding current output may be existed.
5. When current is passed, arc is produced between the electrode and work pieces.
6. Set the two work pieces in correct position like lap joint and tack at both ends of the work
pieces as shown in the figure.
7. Then the welding is carried out throughout the length of the work piece.
8. As soon as the welding process is finished, switch off the current supply and allow the work
piece to cool.
9. Slags are removed by chipping process with the help of chipping hammer.
10. Finally using wire brush, welded portions are cleaned.

Result: Thus the desired lap joint is obtained using arc welding.

35
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[Link] :13 T-FILLET JOINT
DATE :

Aim: To make a T-Fillet joint using arc welding on the given workpieces.

Material supplied: Mild steel plate of size 100 x 50 x 6mm - 2 Nos.

Tools required:

1. Power supply (AC or DC)

2. Welding Torch
3. Electrodes
4. Tongs
5. Chipping hammer
6. Wire brush
7. Gloves
8. Apron
9. Shield
10. Safety goggles
11. Earthing clamps
Sequence of operations:

1. Edge preparation (Removal of rust, scale etc.,)

2. Tacking
3. Welding
4. Cooling
5. Chipping
6. Cleaning
Working steps:

1. First of all, the work pieces must be thoroughly cleaned to remove rust, scale and other foreign
materials.
2. Then the given work pieces are placed on the table in such a way that two work pieces are
brought close to each other so that it forms a T shape is shown in the fig.
3. Appropriate power supply should be given to the electrode and work pieces.
4. Now the welding current output may be existed.
5. When current is passed, arc is produced between the electrode and work pieces.
6. Set the two work pieces in correct position like T-Fillet joint and tack at both ends of the work
pieces as shown in the figure.
7. The joint is placed on a welding table in a flat position by keeping the tack side down.
8. Then the welding is carried out throughout the length.
9. As soon as the welding process is finished, switched off the current supply and allow the work
piece to cool.
10. Slags are removed by chipping process with the help of chipping hammer.
11. Finally using wire brush, welded portions are cleaned.

Result: Thus the desired T-Fillet joint is obtained using arc welding.
37
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PLUMBING

39
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[Link] :14 INTRODUCTION TO PLUMBING
DATE :

Introduction:

Plumbing is the art of design, installation and maintenance of pipe, pipe

fittings and other accessories in a building. It plays a major role in the construction
of every building. Plumbing includes the pipes, fixtures and accessories which
carry water from the main source of supply to the building. It also conveys the
used fluids from a building to other place of local [Link] distribution
system consists of a supply pipe leading to a fixture and a drain pipe taking the
used water away.

Purpose of plumbing:

Plumbing is installed in a building for the comfort and convenience of the

inhabitants as well as sanitation and health. Water is brought by supply pipes and
used water is carried off by drainage pipes. Good plumbing is necessary in houses,
apartments, commercial and other public buildings.

Tools used by plumber: The tools used by plumber can be classified as follows.

TOOLS EXAMPLE

1. Guiding & testing tools Straight edge, Level, Plumb bob

2. Marking tools Pencil, Chalk liner, punches, scriber

3. Measuring tools Rule, Tape

4. Holding tools Pliers, Clamps, Wrenches, Vices

5. Cutting tools Saws, Files, Chisels

6. Scraping & Grinding tools Scraper, Grinders

7. Boring & Threading tools Drills, Taps, Pipe vice, Pipe cutter

8. Striking & Fastening tools Hammers, Screwdrivers

Pipe threading dies:

(a) It is also called stocks and dies.

(b) Two types of dies are available viz., solid and adjustable.
41
42
(c) There are fitted into the centre of the frame. Dies are held in position by a block
which is adjustable by means of a tommy bar.

(d) This stock cuts parallel threads.

(e) Separate set of dies are required for each pipe size.

Pipe fittings: A lot of fittings are used for joining pipes. Cast iron pipes of larger size are joined
with flanges while small size pipes are joined by sockets. Some of the accessories used in pipe
fitting are

1. Socket:

(a) Its outside diameter is somewhat larger than the diameter of the pipe.

(b) Its inside diameter is equal to that of pipes diameter.

(c) It is used to bring two pipes in a straight direction.

2. Elbow: It is similar to the socket. It is used for fitting two pipes at right [Link]
threads are cut in the elbows.

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

Threads are cuts on both its ends and it is joined to the sockets and pipes.

4. It is used for giving connection from the main pipe line to the branch line. By using it,
two or more lines can be made from the supply line.

5. Four way cross: Its shape is like (+) signs. It is used for fitting a pipe in all four directions.
Threads are cut in all its four ends.

6. Valves: Pipes can be joined with valves and according to our needs; we can stop or open the

flow of water through the pipes. Types of valves are: Safety valve, Check valve, Ball valve,
Air release valve, Silence valve, Non-return valve, Globe valve, Gate valve, Wheel valve.

7. Cock: (a) It serves the purpose of putting off or on the flowing water through the pipes.

(b) It is made up of copper, plastics, gun metal. Types of cock are: Bib cock, Stop cock,

Push cock, Plug stop cock, Plug bib cock, Surgeon cock, Pillar cock, Peot cock,
Locking cock, Combination cock

8. Pipe union: It connects two pipes. Water meter is fitted with union so that they can be
removed easily.

43
44
[Link] :15 PIPELINE TO A WASH BASINN
DATE :

Aim: To prepare a pipeline connection to a washbasin.

Tools Required:

1. Screwdriver
2. Hammer
3. Hacksaw
4. measuring tape
5. Pipe wrench.

Components Required :

1. Washbasin
2. Flow Control Angle Valve
3. Hacksaw
4. Tee
5. Elbow
6. Flexible pipe and
7. Flexible Drainpipe

Procedure:

1. Mark location of the washbasin and fix it.

2. Fix the washbasin tap in the required position.
3. Make a tee connection in the existing pipeline to connect it to the washbasin.
4. Fix the flow control angle valve near the washbasin.
5. Connection the flow control valve to the washbasin taps using a flexible pipe.
6. Fix the flexible drainpipe from washbasin to the common drain outlet.

Result: The pipeline connection to a washbasin is made

45
46
[Link] :16 PIPELINE TO A WASHING MACHINE
DATE :

Aim: To prepare a pipeline connection to a washing machine.

Tools Required:

1. Screwdriver
2. Hammer
3. Hacksaw
4. measuring tape
5. Pipe wrench.

Components Required :

1. Washing machine
2. Flow Control Angle Valve
3. Hacksaw
4. Tee
5. Elbow
6. Flexible pipe and
7. Flexible Drainpipe

Procedure:

1. Mark location of the washing machinet.

2. Make a tee connection in the existing pipeline to connect it to the washing machine.
3. Fix the flow control angle valve near the washbasin.
4. Connection the flow control valve to the washbasin taps using a flexible pipe.
5. Fix the flexible drainpipe from washbasin to the common drain outlet.

Result: The pipeline connection to a washing machine is made

47
48
[Link] : 17 PIPELINE TO A WATER HEATER OR GEYSER
DATE :
Aim: To prepare a pipeline connection to a washing machine.

Tools Required:

1. Screwdriver
2. Hammer
3. Hacksaw
4. measuring tape
5. Pipe wrench.

Components Required :

1. Water heater
2. Flow Control Angle Valve
3. Hacksaw
4. Tee
5. Elbow
6. Flexible pipe and
7. Flexible Drainpipe
8. Shower

Procedure:

1. Mark location of the water heater and draw the pipeline.

2. Fix the washbasin tap in the required position.
3. Make a tee connection in the existing pipeline to connect it to the water heater.
4. Fix the flow control angle valve near the washbasin.
5. Connection the flow control valve to the inlet of the water heater using a flexible
pipe.
6. Fix the outlet of the water heater to domestic tap and showert.

Result: The pipeline to a water heater, Shower and tap is made

49
Pipe Connections Involving The Fitting Like Valves, Taps And Bends

50
 [Link] BASIC PIPE CONNECTIONS INVOLVING THE FITTING
DATE : LIKE VALVES, TAPS AND BENDS

Aim:
To connect the pipes with pipe fittings like valves, bends and taps with main supply pipe
.

Materials supplied:

1. Pipe wrench
2. Spanner
3. Bend
4. Valves
5. Taps
6. Cast iron pipes of different length
7. Flange
8. Bench vice.

Procedure:

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

Result: Thus the basic connections of pipes with pipe accessories are made.

51
52
 BASIC
MACHINING

53
54
[Link] : 19 BASIC MACHINING
DATE :

Introduction:

Machining is a process of converting the given workpiece into the required shape and size
with

the help of a machine tool. The most widely used machine tool is lathe. There are
different types of tools used in lathe. Several operations can be carried out in the
workpiece with the help of lathe. In simple words, machining is a process of removing
certain material from the workpiece.

Lathe: Lathe is a machine tool which is used to perform several operations on the work piece.

Lathe is useful in making several parts which is further assembled to make new machine.

Hence lathe is known as mother of machines.

Basic working principle of lathe:

In lathe, the workpiece is held in the chuck, a work holding device. The cutting tool is
mounted

in the tool post. The chuck is rotated by means of power. When the chuck rotates, the
workpiece also rotates. The tool is moved against the rotating workpiece by giving small
amount of depth of cut. The material is removed in the form of chips. Continuous feed
and appropriate depth of cut is given until the required dimensions of the workpiece are
obtained.

Types of lathe machines:

There are different types of lathe machines. They are

1. Centre lathe

2. Tool room lathe

3. Bench lathe

4. Capstan lathe

5. Turret lathe

6. Automatic lathe

55
56
Work holding devices:

1. Lathe centre

They are used to support work. It has two categories of centre.

(a) Live centre is one which is fitted in the headstock spindle. (b) Dead
centre is one which is fitted in the tailstock.

2. Chuck

(a) It is a device used to hold a job. It is easily fitted on the thread cut on the end of
headstock spindle.

(b) Various types of chuck are i. Two jaw chuck

ii. Three jaw chuck

iii. Four jaw chuck

iv. Collet chuck

v. Magnetic chuck

3. Face plate

(a) It is a circular plate and it is screwed to lathe spindle.

(b) It is used for mounting the type of jobs which cannot be held by chucks.

(c) There are number of holes and slots on the face of the face plate.

4. Catch plate

(a) It is a plain disc of steel or cast iron.

(b) It is screwed to the nose of the headstock spindle.

(c) It is used to drive the workpiece through a carrier or dog when it is held between the centres.

5. Lathe carriers or Dogs

(a) It is used for transferring the motion from the rotating driving plate to the work held
between the centres.

(b) It is used for connecting end of workpiece to the driving plate.

The types of Dogs are i. Bent Tail

ii. Straight Tail

iii. Clamp Tail

57
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 6. Steady Rest

(a) It supports long workpiece when machined between the centres or by a chuck.

(b) It is used for cylindrically long jobs.

Two types of steady rest are i. Fixed teady rest ii. Travelling steady rest

7. Mandrel

(a) It is used for holding hollow jobs.

(b) It is a hardened piece of round bar for holding bored or reamed jobs. It has drill
holes at both the ends.

(c) Workpiece is mounted over the mandrel and the mandrel is rotated between centres.

8. Follower rest

(a) It is made of cast iron and is used for supporting long slender workpieces, against
the cutting tool forces.

(b) It can be clamped to the carriage of the lathe, to make it travel along with the
cutting tool.

(c) It has two adjustable jaws to support the workpiece.

Cutting tools used: For making a finished job on lathe machine, various types of
cutting tools are used.

1. Facing tool (a) It is used for facing the longitudinal ends of the job. Its shape is like
a knife.

2. Rough turning tool

(a) It is used to remove excess material from the workpiece in quick time.

(b) It can be used to give large depth of cut and works at coarse feed.

Lathe operations:
1. Plain turning
(a) It is done for reducing the diameter of the workpiece.
(b) A cutting tool with 700 setting angle is used for roughing operation.
(c) More feed is given for rough turning while less feed is given for finishing.
(d) Workpiece is held in chuck and tool is set to the centre height of the workpiece.

2. Taper turning
(a) Taper turning is different from the turning operation.
(b) Taper is defined as the uniform change in the diameter of a workpiece measured along its
length.

59
 After Machining

Taper = (D-d) / L
Where,
D is large diameter d is small diameter
L is length of tapper.

60
[Link] :20 FACING, TURNING, STEP TURNING, CHAMFERING AND
DATE : TAPER TURNING
Aim:

To obtain the required shape and size of the workpiece by turning and facing operations.

Material supplied:

Cylindrical work piece of dia 35mm and length 112mm mild steel rod.

Tools required:

1. Lathe
2. Cutting tool
3. Vernier caliper
4. Try square
5. Scriber
6. Vernier height gauge

Sequence of operations:

1. Checking
2. Workpiece setting
3. Tool setting
4. Facing
5. Turning
6. Taper turning
7. Chamfering

Working steps:

1. The given workpiece is checked for its dimensions.

2. The workpiece is held in the chuck. Chuck key is used to tighten the job firmly, ensuring
centering of workpiece.
3. The single point cutting tool is held in the tool post and tighten the nuts using spanner.
4. Facing is done with cutting tool moving from the centre of the workpiece towards outside. It is
done until the required length of the job is obtained.
5. Turning is done to reduce the diameter of the job. Sufficient depth of cut is given and it is done
until the required diameter of the job is obtained.
6. Next the taper turning is done on the workpiece, as per the taper angle already calculated. Then
the compound rest base is swivelled and set at half taper angle. Cutting tool is moved at an angle
to the lathe axis. Tool is moved by the compound rest hand wheel.
7. For chamfering to be done at the end of workpiece, the tool is held at 45 to the lathe axis and
it is fed against the rotating workpiece.
8. Finally, the dimensions of the workpiece are again checked.

Result: Thus the required size and shape of the given work piece is obtained.

61
Before Machining

After Machining

62
[Link].21 DRILLING AND TAPPING
DATE :
Aim:
To drill the holes of required size and tap the drilled hole.

Material supplied:
50 x 50 x 5mm Mild steel plate 1 No.

Tools required:
1. Bench vice
2. Machine vice
3. Steel rule
4. Standard set of filling tools
5. Try square
6. Surface plate
7. Vernier height gauge
8. Scriber
9. Dot punch
10. Drill bit
11. Drilling machine
[Link] set with Die holder.

Sequence of operations:

[Link]
[Link]
[Link]
[Link]
[Link]
[Link]

Working steps:
[Link] raw material is checked for its size 50 x 50 x 5mm using steel rule.
[Link] given workpiece is clamped in a vise and any two surfaces are filled to get right angle .
[Link] is applied uniformly on the surfaces of the workpieces.
[Link] the help of vernier height gauge, surface plate, angle plate steel rule and scriber the
given dimensions are marked.
[Link] midpoint of the required holes is punched by using a dot punch.
[Link] punched dots are drilled by drilling machine.
[Link] drilling the holes, they are tapped by using tap set.
[Link], the dimensions of the workpiece are again checked.

Result:
Thus the given workpiece is drilled and tapped to the required dimensions.

63
64
 STUDY
EXERCISES

65
CENTRIFUGAL PUMP

66
[Link] : 22 STUDY OF CENTRIFUGAL PUMP
DATE :

Introduction:

The pump is a hydraulic machine which converts the mechanical energy into hydraulic
energy in the form of pressure. The Centrifugal pump is a hydraulic machine which convert the
mechanical energy into pressure energy by means of centrifugal force.

Working principle:

The centrifugal pump works on the principle of Forced Vortex Flow which means that
when a certain mass of liquid is rotated by an external torque, the rise I pressure head of the
rotating liquid take place. The rise in the pressure head at any point of the rotating liquid is
proportional to the square of tangential velocity of the liquid at that point.

Main parts of Centrifugal pump:

The followings are the main parts of a centrifugal pump,

1. Sunction pipe
2. Impeller
3. Casing
4. Delivery pipe.
All the main parts of the centrifugal pump are shown in the following figure.

1. Suction pipe
A pipe whose one end is connected to inlet of the pump and other end dips into the
water sump is known as suction pipe. A foot valve which is a non- return valve or one- way type
of valve is fitted at the lower end of the suction pipe. A strainer is also fitted at the lower end of
the suction pipe for filtering purpose.

2. Impeller
The rotating part of a centrifugal pump is known as Impeller. It contains series of
curved vanes. The Impeller is mounted on a shaft which is connected to the shaft of an electric
motor which runs the pump.

3. Casing
Casing is an air- tight passage surrounding the impeller and is designed such a way that the kinetic
energy of the water discharge at outlet of the impeller is converted into pressure energy before the
water leaves the casing and enter into delivery pipe. Three common types of casings are,
4. Delivery pipe:

i. Volute casing ii. Vortex casing iii. Diffuser casing

A pipe whose end is connected to outlet of the pump and the other end delivers the water at
required level is known as Delivery pipe.

67
Working of Air conditioner

68
[Link].2 3 STUDY OF AIRCONDITIONER
DATE :

Introduction:
An air conditioner is defined as an assembly of different parts of the system used to produce a
specified condition of air within required space or building below that of atmosphere or
surroundings.
An ideal air- conditioner should maintain correct temperature, humidity and air- movement etc.
Generally a small distance air- conditioning plant having the capacity of 0.5 ton. In a window
air- conditioner all the components are located in a box.

Mechanism:
An air- conditioning system works on vapour compression cycle. This cycle works
in following four phases.
1. Compression
2. Condensation
3. Expansion and
4. Evaporation
1. Compression
Compression takes place at the compressor. The low pressure, low temperature dry
refrigerant or coolant vapour is drawn from the evaporator into compressor cylinder during
suction stroke of the compressor. During compression stroke pressure and temperature of the
vapour increases until the vapour temperature is greater than the temperature of condenser cooling
medium (Air or water). This high pressure and high temperature vapour passes out to the
condenser through discharge line.
2. Condensation
In the condenser high pressure and high temperature refrigerant vapour rejects heat to
cooling medium thus allowing the vapourised refrigerant to return to liquid state.

3. Expansion
After condenser, the liquid refrigerant is stored in the liquid receiver until needed. Then
it is passes through an expansion device (i.e. Expansion valve). Due to the expansion the high
pressure reduce very much to allow the vaporization of liquid at very low temperature of about -
100 C.
4. Evaporation
Then the low pressure low temperature refrigerant vapour enters into the evaporator.
Where a considerable amount of heat is absorbed from the surrounding by the refrigerant. After
absorbing heat from the surrounding, the liquid refrigerant changes to vapour state. Then the
refrigerant vapour again move into compressor through the suction line. Again the vapour
compression cycle is repeated.

Boiling point of a refrigerant is very low. The refrigerant absorbs heat from one place and
release it to the other place. Generally Freon 12 is used as a refrigerant in domestic air -
conditioner. It is observed that all the chloro fluro carbons (CFC) including Freon affects the
ozone layer causing global warming. Since now-a-days the newly invented refrigerant Hydro
Fluoro Carbon (HFC) is used as refrigerant.

Main parts of an air- conditioner

The followings are the main parts of an air- conditioner
Compressor Condensor Expansion
device Evaporator and Fan

69
70