GE3271-ENGINEERING PRACTICES LABORATORY MANUAL

DEPARTMENT OF MECHANICAL ENGINEERING

Name of the Student :

University Register No. :

Course/ Specialization :

Semester :

Academic Year :
 LABORATORY MANUAL

[Link] : GE3271
[Link] : Engineering Practices Laboratory
(Civil & Mechanical)
Regulation : 2021

Prepared By, Approved By,

Dr. [Link] Dr. V. JEYA BALAJI
ASP/MECH HOD/ME
 INSTITUTE VISION
To become a center of excellence in preparing engineering professionals with excellent technical,
scientific research, and entrepreneurial abilities to contribute to the society.

INSTITUTE MISSION
Providing a comprehensive learning environment.
1
Imparting state-of-the art technology to fulfil the needs of the students and Industry.
2
Establishing Industry - Institute alliance for bilateral benefits.
3
Promoting Research and Development activities.
4
Offering student lead activities to inculcate ethics, social responsibilities, entrepreneurial,
5 and leadership skills.

DEPARTMENT VISION
To evolve as a centre of repute in Mechanical Engineering by producing quality Engineers through
technical education and scientific approach

DEPARTMENT MISSION
To provide state of art, facilities and environment for quality education in Mechanical
1 Engineering.
To train the students in problem solving skills to bridge the industrial needs.
2
To impart professional practices for societal well-being.
3

ii
 COURSE
COURSE NAME L T P C
CODE
GE3271 ENGINEERING PRACTICES LABORATORY 0 0 4 2
COURSE OBJECTIVES :
1. Drawing pipeline plan; laying and connecting various pipefittings used in common
household plumbing work; Sawing; planning; making joints in wood materials used in
common household woodwork.
2. Welding various joints in steel plates using arc welding work; Machining various simple
processes like turning, drilling, tapping in parts; Assembling simple mechanical assembly
of common household equipment’s; Making a tray out of metal sheet using sheet metal
work. LIST OF EXPERIMENTS
PART I CIVIL ENGINEERING PRACTICES 15
PLUMBING WORK:
a) Connecting various basic pipefittings like valves, taps, coupling, unions, reducers,
elbows and other components, which are commonly used in household.
b) Preparing plumbing line sketches.
c) Laying pipe connection to the suction side of a pump.
d) Laying pipe connection to the delivery side of a pump.
e) Connecting pipes of different materials: Metal, plastic and flexible pipes used in
household appliances.
WOOD WORK:
a) Sawing, b) Planning and c) Making joints like T-Joint, Mortise joint, Tenon joint, and
Dovetail joint.
WOOD WORK STUDY:
a) Studying joints in door panels and wooden furniture
b) Studying common industrial trusses using models.
PART 3 MECHANICAL ENGINEERING PRACTICES 15
WELDING WORK:
a) Welding of Butt Joints, Lap Joints, and Tee Joints using arc welding.
b) Practicing gas welding.
BASIC MACHINING WORK:
a) (Simple) Turning.
b) (Simple) Drilling.
c) (Simple) Tapping.
ASSEMBLY WORK:
a) Assembling a centrifugal pump.
b) Assembling a household mixer.
c) Assembling an air-conditioned.
SHEET METAL WORK:
a) Making of a square tray
FOUNDRY WORK:
a) Demonstrating basic foundry operations.
TOTAL: 30 Periods

iii
COURSE OUTCOMES

After the completion of course, the students will be able to

1. Draw pipeline plan; lay and connect various pipe fittings used in common household
plumbing work; Saw; plan; make joints in wood materials used in common household
woodwork. (Analyze)
2. Weld various joints in steel plates using arc-welding work; Machine various simple
processes like turning, drilling, tapping in parts; Assemble simple mechanical assembly of
common household equipment’s; Make a tray out of metal sheet using sheet metal work.
(Design)

iv
 LIST OF EXPERIMENTS

[Link] Name of the Experiment Pg. No. Marks Signature

I PLUMBING WORK

1 BASIC CONNECTION
INVOLVING PVC / GI PIPES
AND PIPE FITTINGS
2 PREPARING PLUMBING LINE
SKETCHES.
3 LAYING PIPE CONNECTION TO
THE SUCTION SIDE OF A PUMP
4 LAYING PIPE CONNECTION TO
THE DELIVERY SIDE OF A
PUMP.
II WOOD WORK

1 PLANING & SAWING

2 T-LAP JOINT

3 DOVETAIL JOINT

4 CONNECT TWO WOODEN PIECE

BY MORTISE AND TENON
III WOOD WORK STUDY

STUDYING COMMON
1 INDUSTRIAL TRUSSES USING
MODELS.

STUDYING JOINTS IN DOOR

2 PANELS AND WOODEN
FURNITURE

IV WELDING

1 BUTT JOINT

2 LAP JOINT

3 T- FILLET JOINT

V BASIC MACHINING (LATHE)

1 FACING AND TURNING

STEP TURNING AND TAPER

2
TURNING

3 DRILLING
VI SHEET METAL

SQUARE TRAY
1
MAKING

VII ASSEMBLY WORK

1 CENTRIFUGAL PUMP

2 AIR CONDITIONING

3. HOUSE-HOLD MIXER

vi
 I. PLUMBING WORK
Introduction:

Plumbing deals with the laying of a pipeline. A craftsman may be perfectly

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

Study of Plumbing Tools:

The tools used by a plumber can be classified as follows

1. Pipe wrench
2. Pipe vice
3. Pipe cutter
4. Hacksaw
5. Dies

1. Pipe wrench

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

2. Pipe vice

A pipe vice is fitted on the work bench. This has a set of jaws to grip the pipe
and prevent it from turning while cutting, threading and fitting of bends, couplings etc.
The yoke vice is commonly used in plumbing used in plumbing practice.

1
3. Pipe cutter

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

4. Hack saw

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

2
5. Dies

It is used for cutting external thread on pipes. Threads are produced in various shape
and sizes which are used for fitting inside a handle.

Pipe Fittings

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

3
1. Coupling

It is a short a cylindrical sleeve with internal threads throughout. A couplings is used

for joining two pipes in a straight and bend where at least one pipe can be turned.

2. Union

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

3. Nipple

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

4. Elbow

An elbow is to make an angle between adjacent pipes.

5. Tee

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

a single outlet branch pipe.

6. Reducer

It is used to connect two different sized of pipes

7. Plug

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

Valves

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

1. Gate valve
1. [Link] valve
2. Plug valve
3. Check valve
4. Air relief valve.

4
Types of Pipe Joints

1. Bell and spigot joints

A connection between two sections of pipe i.e. the straight spigot end of one
section is inserted into the flared out end of the adjoining section. The joint is sealed by
a sealing component.

2. Flanged joints

A flanged joint helps to connect and disconnect two pipes as per the need. A similar
example is as shown in figure.

3. Threaded joints

Threads are formed in a pipe, flange coupling to connect them with each other and
these joints are called threaded joints.

5
4. Flexible joints

The flexible joints are generally used to connect between a washbasin and an angle
valve.

5. Expansion joints

Expansions joints are specially designed in pipeline where a small extension of pipe is
required.

6
[Link]: BASIC PIPE CONNECTIONS Date

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

Materials Used:
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.
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 bend – 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 bend – 2 for further extension.
6. A horizontal pipe is connected to this bend – 2 for further extension.
7. Then tap is fitted to the end of the pipe for closing and opening water supply.

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

7
Layout of a Simple Pipe Connection

8
 [Link]: PREPARING PLUMBING LINE SKETCHES Date

Aim

 To understand and prepare plumbing line sketches for water supply and
drainage systems, incorporating standard symbols and layouts used in building
construction.

Material Required

1. Drawing sheet or graph paper

2. Pencil, ruler, and eraser
3. Compass and protractor
4. Plumbing symbols reference chart
5. Scale (Architect’s/Engineer’s scale)
6. Plumbing layout guidelines

Procedure
1. Understanding Plumbing Layouts
o Study different types of plumbing systems, including water supply lines,
drainage lines, and vent pipes.
o Familiarize yourself with standard plumbing symbols used in line sketches.
2. Selecting a Layout
o Choose a simple plumbing layout, such as a residential bathroom, kitchen, or a
complete floor plan.
o Identify the main water inlet, distribution system, and drainage points.
3. Marking the Key Components
o Use a ruler and scale to draw the outline of the area where the plumbing system
will be installed.
o Mark key components such as taps, sinks, toilets, storage tanks, water meters,
and drainage lines.
4. Drawing the Plumbing Lines
o Use a solid line to represent water supply lines and a dashed line for drainage
pipes.
o Indicate pipe diameters, valve positions, and connections clearly.
o Ensure the layout follows a logical flow, minimizing sharp bends and
unnecessary complexity.
5. Labeling and Finalizing the Sketch
o Label all components and connections, ensuring clarity in representation.
o Verify the drawing against plumbing standards and best practices.
o Neatly finish the sketch with proper dimensions and notes.
.
9
RESULT
A well-defined plumbing line sketch was successfully prepared, illustrating water supply and \
drainage systems with correct symbols and notations

VIVA Questions
1. What is the purpose of a plumbing line sketch in construction?
2. What are the standard symbols used in plumbing drawings?
3. What is the difference between water supply lines and drainage lines?
4. How do you indicate pipe diameters in a plumbing sketch?
5. What are the key factors to consider when designing a plumbing layout?

10
 [Link]: LAYING PIPE CONNECTION TO THE SUCTION SIDE OF A PUMP Date

Aim

To understand and demonstrate the correct method of laying a pipe connection to the
suction side of a pump, ensuring efficient water flow and minimal losses.

Material Required

1. Centrifugal pump or any suitable suction pump

2. Suction pipe (PVC/GI)
3. Pipe fittings (elbows, couplings, reducers)
4. Gate valve/non-return valve (NRV)
5. Rubber gaskets and sealing compounds
6. Pipe wrench and spanner
7. Measuring tape
8. Pipe support clamps
9. Pipe cutter/hacksaw

Procedure
Understanding the Suction System
 Study the working principle of a pump’s suction system.
 Identify the inlet, suction pipe, and required fittings for the connection.
Measuring and Cutting the Pipe
 Measure the required length of the suction pipe from the water source to the pump.
 Cut the pipe accurately using a pipe cutter or hacksaw.
Fitting the Pipe to the Pump Inlet
 Attach a non-return valve (NRV) at the bottom of the suction pipe to prevent backflow.
 Connect the pipe to the pump suction flange using a suitable coupling and gasket to
ensure a leak-proof joint.
Ensuring Proper Pipe Alignment
o Maintain a gradual slope (if applicable) to avoid air pockets that may affect
suction efficiency.
o Ensure minimal bends and sharp turns in the pipe layout to reduce friction losses.
Securing the Pipe Connection
o Use pipe clamps and supports to hold the suction pipe firmly in place.
o Tighten all joints and fittings to prevent leaks.
Final Inspection and Testing
o Check the entire connection for proper alignment and tightness.
o Fill the suction pipe with water and start the pump to observe the flow.
o Look for any leaks and rectify if necessary.

11
Result

The suction pipe was successfully connected to the pump, ensuring a leak-free and
efficient water intake system. The setup demonstrated proper suction principles for
smooth pump operation

VIVA QUESTIONS
1. What is the function of the suction side of a pump?
2. Why is a non-return valve (NRV) used in the suction line?
3. What factors affect the efficiency of a suction pipe connection?
4. Why should the suction pipe have minimal bends?
5. What is cavitation, and how can it be avoided in suction lines?
6. Why is a proper seal important in suction pipe connections?
7. What are the common materials used for suction pipes?
8. How does the pipe diameter affect the suction pressure?
9. What is the importance of priming in pump operation?
10. How can air pockets be prevented in a suction pipe?

12
[Link]: LAYING PIPE CONNECTION TO THE DELIVERY SIDE OF A PUMP Date
Aim:
To understand and demonstrate the correct method of laying a pipe
connection to the delivery side of a pump, ensuring efficient water flow with
minimal losses and pressure drop.
Materials Used:
1. Centrifugal pump or any suitable delivery pump
2. Delivery pipe (PVC/GI)
3. Pipe fittings (elbows, couplings, reducers, flanges)
4. Gate valve/Control valve
5. Pressure gauge (optional)
6. Rubber gaskets and sealing compounds
7. Pipe wrench and spanner
8. Measuring tape
9. Pipe support clamps
10. Pipe cutter/hacksaw

Procedure:
Understanding the Delivery System
o Study the pump’s delivery system, including the outlet and the required fittings.
o Identify the optimal pipe route to ensure smooth water flow.
Measuring and Cutting the Pipe
o Measure the required length of the delivery pipe from the pump outlet to the
discharge point.
o Cut the pipe accurately using a pipe cutter or hacksaw.
Connecting the Pipe to the Pump Outlet
o Attach a flanged or threaded joint to the pump outlet using a gasket for a leak-
proof connection.
o Ensure a proper seal by tightening the bolts with a spanner/wrench.
Installing Valves and Fittings
o Fix a gate valve or control valve near the pump outlet to regulate flow.
o If required, install a pressure gauge to monitor pressure levels.
Ensuring Proper Pipe Alignment
o Maintain a gradual slope if necessary to avoid airlocks.
o Use minimum bends to reduce friction losses.
Securing the Pipe Connection
o Use pipe clamps and supports to prevent vibration and movement.
o Ensure all joints and fittings are tightly secured.

13
 Final Inspection and Testing
o Check the entire connection for proper alignment and tightness.
o Open the valve gradually and start the pump.
o Observe the flow rate and pressure while checking for leaks.

Result:
The delivery pipe was successfully connected to the pump, ensuring leak-free
operation and efficient water delivery to the discharge point. The system
functioned smoothly with controlled flow and pressure.

VIVA QUESTIONS
1. What is the function of the delivery side of a pump?
2. Why is a gate valve used on the delivery side?
3. How does pipe diameter affect the delivery pressure?
4. What precautions should be taken while laying the delivery pipe?
5. Why is it important to minimize bends in the delivery pipe?
6. What are the effects of high friction losses in the delivery line?
7. How does a pressure gauge help in monitoring pump performance?
8. What materials are commonly used for delivery pipes?
9. Why should valves be installed near the pump outlet?
10. What is the difference between suction and delivery sides of a pump?

14
 II. WOOD WORK
INTRODUCTION

Carpentry may be defined as the process of making wooden articles and

components such as doors, windows, Furniture etc. Carpentry involves cutting,
shaping and fastening wood and other materials together to produce a finished
product. Preparation of joints is one of the important operations in woodwork.
Joinery denotes connecting the wooden parts using different points such as
lap joints, mortise and tenan joints, bridle joints, etc.

TIMBER
Timber is the material used for carpentry. It is the name given to the wood
obtained from well grown trees called exogenous trees. Timber is made suitable for
engineering purposes by sawing into various sizes.

ADVANTAGES OF TIMBER
 It is easily available
 It is lighter and stronger to use
 It responds well for polishing and painting
 Suitable for sound proof construction
 It is easy to work with tools
 It is very economic

Classification of Timber
1. SOFT WOOD
 It is obtained from trees having long needle shaped leaves
 It is light in weight
 It is easy to work
 It is relatively less durable
 It has good tensile resistance and poor shear resistance
 It has straight fibers and fine texture
 It is widely used for construction
2. HARD WOOD
 It is obtained from trees having broad leaves
 It is heavier in weight and dark in colour
 It is difficult to work
 It is highly durable
 Its fibres are quiet close and compact
 It has both tensile and shear resistance
 It widely used for doors, windows and furniture

15
STUDY OF CARPENTRY TOOLS
Carpentry tools are used to produce components to an exact size. The types of
carpentry tools are as follows.
1. Marking tools
2. Measuring tools
3. Holding tools
4. Cutting tools
5. Planning tools
6. Boring tools
7. Striking tools
8. Miscellaneous tools

MARKING TOOLS
Accurate marking is important in carpentry to produce components to exact size.
1. Marking gauge
It consists of a square wooden stem with a sliding wooden stock on it. On the stem, a
marking pin is attached which is made up of steel. This stem is provided witha steel
nail to scratch the surface of the work.

Marking gauge

2. Mortise gauge
It consists of two pins; the distance between the pins is adjustable. It is used to draw
parallel lines on the stock.

Mortise gauge

16
3. Try Square
The engineer’s try-square is composed of two parts, the stock and the blade. They are
usually made from mild steel with blade being hardened and tempered to resist
damage. The try square is pushed against a straight side of the material. An
engineer’s scriber is then used to scratch a line onto the surface of the material.

4. Scriber
A Scriber is a hand tool used to mark lines on workpieces. This is used instead of
pencil. They consist simply of a rod of high carbon steel with a sharpened point.

5. Spirit level
Spirit levels are used for testing the position of large surfaces. It is used for testing
horizontal position of the workpieces. It is having a glass tube with air bubble.

Spirit level

MEASURING TOOLS
The carpentry measuring tools are used to measure the dimensions in the woodfor
exact measurement in cutting.

1. Carpenter’s steel rule

Large measurements can be made by steel rule. It is also suitable for measuring
circumference of curved surfaces.

17
 Steel Ruler

HOLDING TOOLS
The carpentry holding tools are shown in figure

1. Carpentry vice or Bench vice

A carpentry vice is the common work holding device. It consists of one fixed jaw and
one movable jaw. It’s one jaw is fixed to the side of the table while the otheris
movable by means of a screw and a handle.

2. Bench stop
It is a simple straight flat plank of wood having two projected rectangular sections of
wood screwed on opposite side of the plank. The work is placed in such a way that it
is always butting against the projected portion so as to resist the work frommoving.

3. G-clamp
G-clamp is made up of malleable iron with acme threads of high quality
steel
.It can be used for clamping small work when gluing up.

CUTTING TOOLS
1. Saws
A saw is used to cut wood into pieces. There is different type of saws, designedto suit
different purpose. A saw is specified by the length of its tooled edge. The following
saws are used in the carpentry section.

18
Rip Saw
The blade of rip saw is either straight or skew-backed. The teeth are so set that the
0
cutting edge of this saw makes a steeper angle about 60
Cross Cut saw
This is similar in shape of a rip saw. It is used to cut across the grain of the [Link]
0
correct angle for cross cutting is 45 .The teeth are so set that the saw kerfs is
widerthan the blade thickness. This allows the blade to move freely in the cut without
sticking.

Tenon or back saw

A tenon saw is used for fine and accurate work. It consists of a very fine blade, which
is reinforced with a rigid steel back. The teeth are shaped like those of cross cutsaw.

2. Chisels
Chisels are used for cutting and shaping wood accurately. Wood chisels are made in
various blade widths, ranging from 3 to 50mm. Most of the wood chisels are made
into tang type, having a steel shank which fits inside the handle.

19
Firmer chisels
These are general purpose chisels and are used either by hand pressure or by a mallet.
0 0
The blade of a firmer chisel is flat and their sloping face is at an angle 15 to52 .
Mortise Chisels
These are general purpose chisels and are used for cutting mortises above 9mm wide.
The blade of a firmer type is in which they have a thicker section and a stronger neck.
By means of this chisel we can apply more Leverage to remove waste wood fromthe
mortise.

Bevel chisels or Dove tail chisel

A bevel chisel is similar in construction to the firmer chisel. Its edges are bevelled to
allow access to difficult corners. It has a blade with a bevelled back due to which it
can enter sharp corners for finishing in dove tail joints.

PLANNING TOOLS

In general, planes are used to produce flat surfaces on wood. The cutting blade used
in a place is very similar to a chisel. The blade of a plane is fitted in a wood or
metallic block at an angle.

1. Jack plane
Jack plane which is about 35 cm long is used for general planning. A Jack plane that
is about 20 to 25cm long is used for smoothening the stock. It can follow even the
slight depressions in the stock better than the jack plane. Smooth plane is used after
using the jack plane.

Jack plane

2. Rebate plane
A rebate plane is used for making a rebate. A rebate is a recess along the edge ofa piece

20
of wood which to generally used for positioning glass in frames and doors. A plough
plane is used to cut grooves, which are used to fix handle in a door.

BORING TOOLS
Boring tools are used to make holes in wood. Common types of boring tools are as
follows.

1. Gimlet
It has cutting edges like a twist drill. It is used for boring holes with the hand pressure.
2. Hand drill

A straight shank drill is used with this tool. It is small, light in weight and may be
conveniently used. The drill bit is clamped in the end.

3. Ratchet brace
It consists of crank made of steel, wooden handle in the middle, head at the top and
chuck at the bottom. The bit rotates when the crank is rotated by hand.

STRIKING TOOLS

1. Hammers
The cross peen hammer is mostly used for positioning small nails. The head is tightly
held in the handle with the help of iron wedges. The claw hammer is effective in
removing very large nails and also for driving the nails using the other end of the
hammer.

2. Mallet
A mallet is used to drive the chisel, when considerable force is to be applied, which

21
may be the case in making deep rough cuts. A steel hammer should not be used for
this purpose, as it may damage the chisel.

MISCELLANEOUS TOOLS

1. Pincers
They are made up of steel with a hinged joint and are used for pulling out smallnails
from wood.

2. Screwdrivers
Screwdriver is used for driving wood screws into wood or unscrewing them.
The screwdriver used in carpentry is different from the other common types.

3. Rasp file
A rasp file is a file used for finishing the surface of wood. The rasp has sharp cutting
teeth on its surface for this purpose. The file is used for removing rasp marks end
finally the scratches left by the fix are removed with the scraper and glass paper.

4. Oil stone
This is an essential flat used for providing sharp edges on cutting tools. The oil stones
may be artificial or natural stones. The carborundum is the best artificial stones
where as the Arkansas are the natural stones.

CARPENTRY PROCESSES

In a carpentry shop, a number of operations are performed to get the finished

workpiece. The different types of process performed in a carpentry shop can be

22
classified as follows.

1. Marking and Measuring

It is the process of setting of dimensions on wooden pieces to obtain therequired
shape. This is the first step for further carpentry operations. The marking operation
is done with use of marking tools. Before marking, one end is planed for reference.

2. Sawing
Sawing is the process of cutting wood to the required shape and size such as straight,
inclined or curved. Sawing can be done along the grains or across the grains. In
sawing, wooden work is fixed in a vice and wood is moved up to prevent
vibrationsduring sawing.

3. Planning
Planning is an operation of obtaining, smooth, dimensionally true surface of wood by
using a planer. It is done along the grains. So, smooth surface is achieved.
Thisprocess can be also called facing or edging.

4. Chiseling
It is the process of cutting a small stock of wood to produce required
shapes.

5. Mortising and Tenoning

Mortising is the process of producing a mortise, i.e. a rectangular or square holesand
recesses in wooden pieces. A tenon is a projected piece of wood that fits into the
corresponding mortise. This process is done by using mortise chisels and a mallet.

6. Boring
Boring is the process of producing through holes or blind holes in wooden [Link]
process can be done straight or inclined according to the type of work. The small
holes are produced by using bradawl and gimlet, whereas large holes are produced by
using braces, drills.

7. Grooving
Grooving is the process of making grooves tonguing is the process of producing
corresponding projections of wood for fitting into grooves. Grooving and tonguing
operation can be seen in drawing boards, floor boards and partitions. Grooving is
done
with a plough plane tool, and tonguing is done with a molding plane tool.

23
 [Link]: PLANING & SAWING Date:
Aim
 To plane the given work piece for the required shape.
Material Required: Soft wood of size 305 mm X 55 mm X 55 mm.
Tools Required
1. Jackplane 2. Bench vice [Link] square [Link] gauge 5. Steel rule 6. Tenon
saw 7. Rip saw 8. Firmer chisel 9. Mallet
Procedure
1. The given work piece is firmly clamped in the bench vice and any two
adjacent surfaces are planed to get right angles using the jack plane.
2. Using the try square, the right angles of planed faces are checked.
3. Now the other two surfaces are planed to get smooth surface.
4. Based on the planed surfaces, the markings are made on the two sides by
usingmarking gauge.
5. After marking, the work piece is planed such that it should
haverequired dimensions.
6. Finally, the finished job is checked for required size using the steel rule and
trysquare.

Result
 Thus, the required Dimension is obtained by planing.
Sample Viva Questions
1. Describe the steps involved in planing a woodworking project from conception to
completion.
2. How do you select the appropriate type of wood for a specific project? Discuss the factors
to consider when choosing wood.
3. What safety precautions should be taken into account during the planning stage of a
woodworking project?
4. How to mitigate waste reduction when planing a woodwork?

24
 [Link]: TEE LAP - JOINT Date:

Aim
To make a Tee lap –joint from the given work piece.

Material Required: Soft wood of size 300 mm X 50 mm X 50 mm.

Tools Required
1. Jackplane
2. Bench vice
3. Try square
4. Marking gauge
5. Steel rule
6. Tenon saw
7. Rip saw
8. Firmer chisel
9. Mallet

Procedure
1. The given work piece is firmly clamped in the carpentry vice and any
two adjacent surfaces are planned to get right angles using the jack
plane.
2. Using the try square, the right angles of planed faces are checked.
3. Now the other two surfaces are planed to get smooth surface.
4. The work piece is cut into two pieces by using the rip saw.
5. Using the steel rule and marking gauge, marking is done for T-joint on the
twohalves.
6. In one-half, the unwanted portions of wood are removed by using the tenon
saw andfirmer chisel. The same procedure is done for the other half of work
piece.
7. Using the jackp l a n e , the other two faces of work piece is planed
to the required size.
8. The finished two pieces are assembled to getter to form the T-joint.
9. Finally, the finished job is checked for required size and shape using the steel
ruleand try square.

25
Result
Thus the required Tee lap -joint is obtained.

Sample Viva Questions

1. What are the advantages and disadvantages of using a tee lap joint?
2. Can you explain the steps involved in creating a tee lap joint, including marking, cutting,
and assembly?
3. How do you ensure a tight and secure fit when joining pieces using a tee lap joint?
4. What tools and equipment are typically used to create a tee lap joint?
5. How does the thickness of the wood affect the design and strength of a tee lap joint?

26
 [Link]: DOVETAIL HALVING JOINT Date

Aim
 To make a dovetail halving joint from the given work piece.

Material Required: Soft wood of size 300 mm x50 mm x50 mm.

Tools Required
1. Jackplane
2. Bench vice
3. Try square
4. Mortise gauge
5. Mallet
6. Firmer chiesel

Procedure
1. The given work piece is firmly clamped in the Bench vice and any two
adjacent surfaces are planed to get right angles using the jack plane.
2. Using the try square, the right angles of planed faces are checked.
3. Now the other two surfaces are planned to get smooth surface.
4. The work piece is cut into two pieces by using the rip saw.
5. Mark the dimensions for the dovetail joint on the two pieces using the steel rule and
marking gauge.
6. Remove the unwanted portions as per the drawing and assemble to check proper
fitting.

27
 All dimensions in ‘mm’

Result
Thus, the desired dovetail-halving joint is obtained.

Sample Viva Questions

1. When is it appropriate to use a dovetail halving joint in woodworking projects?

2. What are the advantages and disadvantages of using a dovetail halving joint?
3. Can you explain the steps involved in creating a dovetail halving joint, including marking,
cutting, and assembly?
4. Can you provide examples of woodworking projects where dovetail halving joints are
commonly utilized?

28
Ex. No: CONNECT TWO WOODEN PIECE BY MORTISE AND TENON Date

AIM
To prepare a Mortise and Tenon joint using two wooden pieces and understand its applications in
carpentry and furniture making.
MATERIALS REQUIRED
1. Two wooden pieces (softwood or hardwood)
2. Measuring tape and pencil
3. Tenon saw
4. Chisel and mallet
5. Wood glue (optional)
6. Clamps
7. Try square
8. Sandpaper
PROCEDURE
1. Marking the Joint
o Take two wooden pieces and mark the tenon on one piece and the mortise on the
other using a pencil and try square.
o Ensure accurate measurements for a snug fit.
1. Cutting the Tenon
o Use a tenon saw to cut along the marked lines on the tenon piece.
o Remove excess material with a chisel and mallet to achieve the required shape.
2. Creating the Mortise
o Secure the second wooden piece and use a chisel to carve out the mortise along the
marked lines.
o Remove excess wood carefully to achieve the proper depth and width.
3. Fitting the Joint
o Insert the tenon into the mortise and check for proper fit.
o If necessary, make minor adjustments using sandpaper or a chisel.

29
 4. Assembling the Joint
o Apply wood glue (if required) for additional strength.
o Clamp the pieces together and allow them to dry.
5. Finishing Touches
o Smoothen the joint using sandpaper for a neat finish.
o Inspect the joint for strength and alignment.
RESULT
The Mortise and Tenon joint was successfully created and assembled. The joint exhibited strong
mechanical interlocking, suitable for various woodworking applications.

1. VIVA QUESTIONS
2. What is the purpose of a Mortise and Tenon joint in woodworking?
3. What are the main tools used in making a Mortise and Tenon joint?
4. Why is accuracy important while marking and cutting the joint?
5. What are the advantages of using wood glue in this joint?
6. How can the strength of a Mortise and Tenon joint be improved?

30
 III. WOOD WORK STUDY

STUDYING COMMON INDUSTRIAL TRUSSES USING MODEL

31
STUDYING JOINTS IN DOOR PANELS AND WOODEN FURNITURE

32
 Sample Viva Questions
1. Name the work piece material?
2. In how many ways you can classify fitting tools?
3. What is hacksaw blade material?
4. What is the purpose of Triangular file?
5. Name different types of files?
6. What is difference between chipping and Filing?
7. Name different types of Chisels?
8. What is C-clamp?
9. What is the importance of Try – square?
10. Mention the difference between dot punch and centre punch?
11. What is the difference between inside and outside calliper?
12. What is the purpose of Round file?
13. What is difference between single and double cut files?
14. Why dot punching is necessary?
15. What is the purpose of using scriber?
16. Compare Hand saw & Hack saw?
17. Where we can use half round file?
18. Material removal takes place while moving the hack saw in (forward / backward)
19. which direction?
20. When & where smooth and rough files are used?
21. Name the tools used to perform chipping & Filing operations?
22. In how many ways you can classify files?
23. Name the sequence of operations in fitting?
24. What are the tools used to perform above operations?
25. Classification of Timber?
26. What are the applications of wood?
27. What are the defects in wood?
28. Which tool is used to check squareness?
29. What is the difference between marking and mortise gauge?
30. Which type of saw is used for small and mortise gauge?
31. Which is C-clamp? What are the applications of C-clamp?
32. Give the name of Chisel for making Dove – tail joints?
33. What type of hammer is used for removing nails?
34. What issued for making small holes?

33
 IV. WELDING
Introduction:

Welding is 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 applicationof pressure.
The filler material has similar composition and melting point temperature as that of the
base metal. It is used to fill gap between the joint surfaces.
Types of welding:
The welding process is divided into two main sub divisions.
Plastic welding:
The pieces of metal to be joined are heated to the plastic state and then forced together by
external pressure without the addition of filler material.
Forge welding:
The work piece are placed in a forge or other appropriate furnace and heated within the
area tobe joined to the plastic condition. Then parts are quickly superimposed and worked
into a complete union by hand or power ham mering or by pressing together.
Resistance welding:
In resistance welding, a heavy electric current is passed through the metals to be joined
over limited area, causing them to be locally heated to plastic state and the welding is
completed by the application of pressure for the prescribed period of time.
Fusion welding:
In fusion welding, the metal parts to be joined are melted and then allowed to solidify
pressureis not applied and filler metals may be used for this type of welding.
Gas welding:
Gas welding is a process in which the required heat to melt the surfaces is supplied by a
high temperature flame obtained by a mixture of two gases. Usually the mixture of
oxygen and acetylene isused for welding purpose.
Electric Arc welding:

Electric arc welding is the process of joining two parts by melting their edges by an
electricarc with or without the application of pressure and with or without use of filler
metals.
Thermit welding:
Thermit welding is a fusion process in which weld is effected by pouring super heated
liquid thermit steel, around the parts to be united with or without the application of
pressure. 34
Oxy-acetylene welding:
In oxy-acetylene welding oxygen and acetylene are the two gases used for producing
flame. Oxygen is mainly used for supporting the combustion intensity.

The oxygen and acetylene under high pressure in cylinders which are fitted with pressure
regulator. Each cylinder is connected to the blowpipe by flexible hoses. The oxygen
cylinders are painted block and acetylene cylinders are painted maroon.
When acetylene is mixed with oxygen in correct proportions in the welding torch, ignition
is takes place. The flame resulting at the tip of the torch is sufficient enough to melt and
the parent material .The fla me temperature is about 3200º[Link] filler metal rod is
generally added to the moltenmetal pool to built up the seam for greater strength.
Types of flames:
Neutral Flame (Oxygen, Acetylene in equal proportions)
Oxidizing Fla me (excess of Oxygen)
Reducing Flame (excess of Acetylene)

35
Neutral Flame:
A neutral flame is produced when approximately equal volumes of oxygen and acetylene
aremixed in the welding torch and burnt at the torch tip.
The temperature of the neutral flame is of the order of about 3260ºC
The flame has inner cone which is light blue in color.

Oxidizing Flame:
If the volume of the oxygen supplied to the neutral flame is increased, then resulting
flamewill be oxidizing flame.
The temperature of oxidizing flame is of the order of about 3482ºC.
Normally the outer flame envelope is much shorter. It has very small white inner cone.
This flame is used to weld copper-base metals, zinc-base metals.

Reducing Flame (Carburizing Flame):

If the volume of the oxygen supplied to the neutral flame is reduced, the resulting flame
willbe a reducing flame.
In this case, flame is recognized by acetylene feather which exists between the inner cone
andouter envelope.
The outer flame envelope is longer than that of the neutral flame and is usually much
brighterin color.
It has an appropriate temperature of 3038ºC.
In this type, flames are used to weld the high-carbon steel, non-ferrous alloys, zinc-
bearingalloys.

Filler Metal:
It is the material that is added to the weld pool to assist in filling the gap. Filler metal
forms anintegral part of the weld. The filler metal is usually available in rod form. The
rods are called filler rods.
Fluxes:
During the welding, if the metal is heated in the air, oxygen in the air combines with the
metal5to form oxides which result in poor quality, low strength welds or in some cases
may even make welding impossible. In order to avoid this problem, a flux is added during
the welding. The flux prevents oxidation by preventing oxygen from contacting the weld
zone. Arc welding:
In the arc welding process, the source of heat is electricity. In arc welding process,
coalescence is produced by heating the work piece with an electric arc struck between
electrode and the work [Link] may be carried out in air or in an inert atm. Filler
material may or may not be used. The temperature of the arc is of the order of 3600ºC.
Principle of Arc Welding:
The heat required for joining the metals 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 arc. The electrode serves as the filler rod and arc melts
the surfaces so that the metals to be joined are fused together. The transformer type
welding machine produces AC [Link] takes power directly.
36
Electrodes:
Filler rods are used in arc welding are called as electrodes. The Electrodes are made of
metallicwire called core wire. It is uniformly with a protective coating called flux while
fluxing an electrode about 20 mm of length is left bare at one end for holding it using
electrode holder. It is used to transmitfull current from electrode holder to the front end of
the electrode coating.
Electrode Holder:
It is a device used for mechanically holing the electrode and conducting current to it.
Electrode holder should be light, to minimize fatigue incurred by the welder.
Jaws are made to hold the bare end of the electrode in either at vertical or at an angular
position.

Welding Cables:
Two cables are needed for welding purpose. One is used to connect the power
source toelectrode; another cable is connected to ground.
The cables are well isolated with rubber.
Welding Bead Cleaning Accessories:

37
Chipping Hammer:
A chipping hammer is chisel-shaped one and it is used to remove the slag from the weld
bead.
Wire Brush:
A wire brush made up of stiff steel wire, embedded in wood, removes small particles of
slagfrom the weld bead after the chipping ham mer is used.
Hand Screen:
It is a protective device used in arc welding. A hand shield is held in the hand of the
welderand it is fitted with a suitable fitter lens.
Helmet:
It is used for shielding and protecting the face and neck of the welder and it is fitted
with asuitable fitter lens.
Tongs:
Tongs are used to handle the hot metal-welding job while cleaning; they are also used to
holdthe metal for hammering.
Goggles:
Chipping goggle is used to protect the eyes while chipping the slag. They are fitted
while aplain glass to see the area to be cleaned.
Hand Gloves:
Hand gloves are used to protect the hands from electrical shock, arc radiation and
hot spatters.
Advantages of Arc Welding:
Flux shielded manual metal arc welding is the simplest of all the arc welding process.
The equipment can be portable and the cost is fairly low.
This process finds innumerable applications, because of the availability of a wide variety
ofelectrodes.
A big range of metals and their alloys can be welded.
Disadvantages of Arc Welding:
 Because of the limited length of each electrode and brittle flux coating on it,
Mechanization isdifficult.
 In welding long joints, as one electrode finishes, the weld is to be progressed with the
next electrode. Unless properly cared, a defect may occur at the place where welding is
restarted with the new electrode.
 It cannot be used to weld metal thickness less than

38
Ex. No: BUTT JOINT Date:

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

Materials Used:
Mild Steel plate of size 100 × 50 × 6 mm – 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. Earthling Clamps
Sequence of Operations:
1. Edge Preparation
2. Tacking
3. Welding
4. Cooling
5. Chipping
6. Cleaning

Procedure:
1. First of all, the work pieces must be thoroughly cleaned to remove rust, scale
and otherforeign materials.
2. Then the given work piece are placed on the table in such a way that two
work piece 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 the work piece.
4. Now the welding current output may be adjusted.
5. When current is passed, arc is produced between the electrode and work piece.
6. Now set the two work piece in correct position and maintain the gap 3mm and
tack at bothends of the work piece as shown in the figure.
7. Then the welding is carried out throughout the length.
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.

39
 BUTT JOINT

Result:
Thus the desired Butt Joint is obtained using arc welding.

40
Ex. No: LAP JOINT Date
Aim:
 To make a Lap Joint using arc welding on the given work piece.

Materials
Used:
Mild Steel plate of size 100 × 50 × 6 mm – 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
2. Tacking
3. Welding
4. Cooling
5. Chipping
6. Cleaning
Procedure:
1. First of all, the work pieces must be thoroughly cleaned to remove
rust, scale and otherforeign materials.
2. Then the given work piece are placed on the table in such a way that
two work piece areoverlapped on over another as shown in the figure.
3. Appropriate power supply should be given to the electrode and the work piece.
4. Now the welding current output may be adjusted.
5. When current is passed, arc is produced between the electrode and work piece.
6. Now set the two work piece in correct position like lap joint and tack
at both ends of the work piece as shown in the figure.
7. Then the welding is carried out throughout the length.
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.

41
 LAP JOINT
Result:
Thus, the desired Lap Joint is obtained using arc welding.

42
Ex. No: T – FILLET JOINT Date:
Aim:
To make a T – Fillet Joint using arc welding on the given work piece.

Materials Used:
Mild Steel plate of size 100 × 50 × 6 mm – 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
2. Tacking
3. Welding
4. Cooling
5. Chipping
6. Cleaning
Procedure:
1. First of all, the work pieces must be thoroughly cleaned to remove rust, scale
and otherforeign materials.
2. Then the given work piece are placed on the table in such a way that two
work piece arebrought close to each other so that it forms a ‘T-Shape’ as
shown in
the figure.
3. Appropriate power supply should be given to the electrode and the work piece.
4. Now the welding current output may be adjusted.
5. When current is passed, arc is produced between the electrode and work piece.
6. Now set the two work piece in correct position like T – Fillet joint and tack at both
ends of thework piece 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 of the work piece.
9. As soon as the welding process is finished, switch off the current supply and
allow thework 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.
43
 T – FILLET JOINT

Result:
Thus the desired T – Fillet Joint is obtained using arc welding.

44
 Sample Viva Questions
1. What is meant by welding?
Welding is the process of joining metals or nonmetals (plastics) together using filler metal
or without filler metals/materials
2. What is the name of item coated over a welding rod?
Flux (Flux consists of cellulose, mineral silicates, iron powder, Rutile, Potassium
aluminum silicate)
3. What is the purpose of it?
In order to reduce the atmospheric action on molten metal pool
4. What is the name of tool to remove the slag from welded portion?
Chipping hammer
5. Can you tell the approximate temperature while welding Mild steel item?
Above 2000 degree Celsius
6. What is meant by straight line welding?
Welding on a straight line over a metal (only for the study purpose)
7. What is meant by Butt welding?
Butt welding is the process by which metals are joined together to the edges.
8. What is the advantage of 'V' Butt joint?
V butt welding is done to avoid projection over the surface
9. What is the difference between welding and soldering?
Welding is the process of joining the metals together usually the same parent metals, but in
The case of soldering the filler material is usually a compound of lead, tin and small
amount of zinc. The soldering is done below 400 degree Celsius whereas the welding is
done above
800 degree Celsius the joining process in between 400 and 800 degree Celsius is called
brazing.
10. What is the approximate voltage for welding in AC welding set?
20 to 80 V
11. What are the accessories used in the welding shop?
Hand gloves, Face shield, apron, goggles
12. Name the main tools used in the welding shop?
Chipping hammer, clamps, tongs, wire brush, grinder, punches measuring tools, etc
13. What type of transformer is used in welding shop?
(Step down or step up)- Step down transformer
14. What are the safety precautions to be followed in welding shop?
15. Tell how to weld a petrol tank to prevent the leak?

45
 V. BASIC MACHINING (LATHE)
Introduction:
Machining is a process of converting the given work piece into the required shape
and size withthe help of a machine tool. The most widely used machine tool is lathe.
There are different types of tools used in lathe. Several types of operations can be carried
out in the work piece with the help of lathe. In simple words, machining is a process of
removing certain material from the work piece.
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”.
Working principle of lathe:
In a lathe, the work piece is held in chuck and rotates about its axis by means of
power. A single point cutting tool is mounted in tool post. When the chuck rotated the
work piece also rotated. The tool moves parallel to the axis of rotation of work piece to
produce a cylindrical surface, where asthe tool moves perpendicular to the work piece to
produce a flat surface. The tool moves at an angle to the axis of work piece to produce a
turn surface. ---The material is removed in the form of chip from the work piece by giving
proper feed and depth of cut. So, there quire size and shape of the work is 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
Main parts of Lathe:
The lathe consists of various parts. Their parts and function are discussed below.
Bed:
Bed is the base of the lathe. The headstock is mounted on the left end; the carriage
is in the middle and the tailstock at the right end of bed. The bed is made up of cast iron,
alloyed with nickel, chromium. The bed is made up of cast iron to observe shock and
vibration created during [Link] guide ways of the bed may be flatter inverted ‘V’
shape.
Headstock:
It is mounted on the left end of the bed. It carries a hollow spindle. The live center
can be attached in the spindle. The spindle nose is threaded. In chuck faceplates can be
attached to the [Link] headstock may be back threaded type. The headstock has two
types of driving mechanism
 Back geared mechanism
 Belt driven mechanism

46
47
Tailstock:
It is located on the bed at the right end. It is used for supports right end of work and also
for holding drills, reamer tools for drilling, reaming and such other operations. The tailstock
can be movedalong the bed and clamped at any position, to support the different length work.

Carriage:
Carriage is used for giving various feed to the tool by hand or by power. The
carriage isattached with the saddle.

Saddle:
It is a H shaped casting fitted on the bed and moves along the guide ways. It carries the
crossslide, compound rest and a tool post.

Cross slide:
It is attached to the upper side of saddle and carries compound slide and tool post. The
cross slide can be moved cross wise by hand or power. The micro meter dial is mounted on
the cross slide hand wheel, with an accuracy of 0.05mm.

Compound Rest:
It is attached over the cross slide. It is used during the taper turning opening operations
to setthe tool for angular cuts. Here the micro meter dial is mounted to show the depth of
cut.

Tool post:
The tool is clamped over the tool post. It is fixed over the compound rest. There are
fourtypes of tool post
a. Single screw tool post
b. Open side tool post
c. Four bolt tool post
d. Four way tool post

Apron:
Apron is attached to the saddle and hangs in front of the bed. It has gears, levers, clutches
for moving the carriage automatically. A split nut is attached for engaging and disengaging
the carriage from the lead screw. It is used in thread cutting work.

Lead Screw:
It is a longer screw with standard AC ME square threads and used for transmitting power
forautomatic feed for thread cutting operation.

Feed rod:
The feed rod is the long shaft used for the movement of carriage along the axis of bed.
Itisused for operations like facing, turning and boring.

48
Ex. No: FACING AND TURNING Date
Aim:
To obtain the required shape and size of the work piece by turning and facing operations.
Materials Used:
Cylindrical work piece of diameter 30mm and length 107mm 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:
a. Checking
b. Facing
c. Work piece setting
d. Turning
e. Tool setting

Procedure:
1) The given work piece is checked for its dimensions.
2) The work piece is help in the chuck. Chuck key is used to tighten the job
firmly, ensuring center of work piece.
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 center of work piece towards
outside. It isdone 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 isdone until the required diameter of the job is obtained.
6) Finally, the dimensions of work piece are again checked.

49
 FACING AND TURNING

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

50
Ex. No: STEP TURNING AND TAPER TURNING Date:
Aim:
To obtain the required shape and size of the work piece by turning, facing and taper turning
Operations.

Materials Used:
Cylindrical work piece of diameter 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. Work piece setting 3. Tool setting
4. Facing 5. Turning 6. Taper Turning

Procedure:
1. The given work piece is checked for its dimensions.
2. The work piece is help in the chuck. Chuck key is used to tighten the job firmly,
ensuring center 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 center of 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 doneuntil 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.
Thenthe compound rest base is swiveled and set to half tape angle. Cutting tool is moved
at an angleto the lathe axis. Tool is moved by the compound rest hand wheel.
7. Finally, the dimensions of workpiece are again checked.

51
 STEP TURNING AND TAPER TURNING

Result:
Thus, the required size and shape of the given workpiece is obtained.

52
Ex. No: DRILLING Date:
Aim:
To obtain the required holes on the workpiece by drilling operations.

Materials Used:
50 × 50 × 5 mm Mild Steel plate – 1No.

Tools Required:
1. Bench Vice 2. Machine Vice 3. Steel Rule
4. Standard set of filing tools 5. Try Square
6. Surface plate 7. Vernier height gauge 8. Scriber
9. Dot punch 10. Drill Bit 11. Drilling Machine

Sequence of Operations:
1. Checking 2. Filing 3. Marking
4. Punching 5. Drilling

Procedure:
1. The raw material is checked for its size 50 × 50 × 5 mm using steel rule.
2. The given work piece is clamped in a vice and any two surfaces are filed to get right
angle.
3. Chalk is applied uniformly on the surfaces of the work piece.
4. With the help of Vernier height gauge, surfaces plate, angle plate, steel rule, and
scriber, thegiven dimensions are marked.
5. The midpoint of the required holes is punched by using a dot punch.
6. The punched dots are drilled by drilling machine.
7. After drilling the holes, they are tapped by using tap set.
8. Finally, the dimensions are again checked.

53
 DRILLING

Result:
Thus, the given work piece is drilled and tapped to the required dimensions.

54
 VI. SHEET METAL
Introduction:
Sheet metal work is working on the metal of 16 gauge to 30 gauge, with hand tools
andsimple machines into different forms by cutting, forming into shape and joining.
Sheet metal work is one of the major applications in engineering industry. It has its
ownsignificance as useful trade in engineering work.

Application of Sheet Metal:

Sheet metal work is used for making hoppers, funnels, various ducts, chimneys,
ventilatingpipes, machine tool guards, boilers, etc.
It is also extensively used in major industries like aircraft manufacturing, ship
building, automobile body building and fabrication of ducts in air conditioning
equipment, etc.

Principle Involved in Sheet Metal Work:

Generally, all the sheet metal work patterns are based on the development of the surfaces
of a number of geometrical models like prism, cylinder, pyramid and cone. Besides
development of surfaces, geometrical projections are also used for sheet metal work.

General Procedure for Sheet Metal Work:

The exact size and shape of the sheet to be cut is given by the development of the
concernedobject.
The development is drawn on a flat sheet of metal and then the sheet is cut.
The cut sheet is folded or rolled to the required shape before the joints are made by
weldingor any other form of fastening.

Tools used in Sheet Metal Work:

The various types of tools used in sheet metal work are explained below.

Cutting Tools:

Chisels: Chisels are used in sheet metal work for cutting sheets, rivets, bolts and
chipping operations. Though there are many types of chisels available, round nose
chisel and flat chisel are mostly used for sheet metal work.

Ships (or) Shears: Snips are hand shears, varying in length from 200mm to 600mm.
200mm and 250mm length is most commonly used. In sheet metal work, straight and
curved snips aremostly used. Straight snips are used for cutting along outside curves
and straight lines. Curved snipsor bent snips are used for trimming along inside
curves.

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1. Striking Tools:

a) Hammers: hammers are used in sheet metal work for hollowing, stretching,
levelling, riveting, strengthening of sheet metal joints, etc. The following hammers are
mostly used in sheet metalwork.
i. Ball peen hammer
ii. Straight peen hammer
iii. Riveting hammer
iv. Mallet

b) Punches:In sheet metal work, punch is used for making out work locating centres
etc. thefollowing two types of punches are widely used.
i. Dot Punch ii. Centre Punch

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Supporting Tools:
Stakes: Stakes are nothing but sheet metal work anvils used for bending, hemming,
seaming, forming, etc. using hammers or mallet. The following figure shows different
shapes and size of stakes.

Bending Tools:
Pliers: Pliers are mainly used for bending the sheet metal to the required shape. It is also
usedfor 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 an
accuracyof upto 0.5mm.

Scriber: It is a long wire of sheet with its one end sharply pointed and hardened to scratch
lineon sheet metal for laying our patterns.
Dividers: Dividers are used for drawing circles or arcs on sheet metal. They are used to
marka desired distance between two points and to divide lines into equal parts.

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Ex. No: SQUARE TRAY Date:
Aim:
 To make a rectangular tray from the given sheet metal.

Materials Used:
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
Riveting

Procedure:
1. The size of the given sheet is checked for its dimensions using a steel rule.
2. Then the sheet is levelled on the levelling plate using a mallet.
3. The development procedure is followed same as square taper tray.
4. The dimensions are marked as shown in the figure.
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 the figure.
7. These four sides of the tray are bent to 90° using stakes anvil.
8. Finally, all the corners of the tray are joined by riveting.

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 SQUARE TRAY

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

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 VII. ASSEMBLY WORK
STUDY OF CENTRIFUGAL PUMP
Introduction:
The pump is a hydraulic machine which converts the mechanical energy into
hydraulic energy in the form of pressure energy. The centrifugal pump is a hydraulic
machine which converts the mechanical energy into pressure energy by means of
centrifugal force.

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 in pressure
head of the rotating liquid takes place.
The rise in pressure head at any point of the rotating liquid is proportional to the
square of tangential velocity of the liquid at that point of the rotating liquid is proportional
to the square of tangential velocity of the liquid at that point (i.e., Rise in pressure head).
Thus at the outlet of the impeller, where radius is more , the rise in pressure head will be
more and the liquid will be dischargedat the outlet with a high pressure head. Due to this
high pressure head, the liquid can be lifted to a highlevel.

Main Parts of a Centrifugal Pump:

The following are the main parts of a Centrifugal Pump.
1. Suction pipe
2. Impeller
3. Casing
4. Delivery pipe
All the main parts of the centrifugal pump are shown in the following figure.

Suction Pipe:
A pipe whose one end is connected to the inlet of the pump and other end dips into
water in a 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. The foot valve opens
only in the upward direction. A straineris also fitted at the lower end of the suction pipe
for filtering purpose.
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Impeller:
The rotating part of a centrifugal pump is called ‘impeller’. It consists of a series of
backwardcurved vanes. The impeller is mounted on a shaft which is connected to the
shaft of an electric motor which runs the pump.

Casing:
Casing is an air tight passage surrounding the impeller and is designed in such a
way that the kinetic energy of the water discharged at the outlet of the impeller and is
converted into pressure energybefore the water leaves the discharged at the outlet of the
impeller is converted into pressure energy before the water leaves the casing and enters
the delivery pipe.
The following three types of the casing are commonly adopted:
i. Volute Casing ii.
Vortex Casing iii.
Diffuser Casing

Volute Casing:

Figure shows the volute casing, which surrounds the impeller. It is of spiral type in which
areaof flow increases gradually. The increase in area of flow decreases the velocity of
flow. The decreasein velocity increases the pressure of the water flowing through the
casing. It has been observed that incase of volute casing, the efficiency of the pump
increases slightly

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as a large amount of energy is lostdue to the formation of eddies in this type of casing.

Vortex Casing:
If a circular chamber is introduced between the casing and the impeller as shown in
figure, thecasing is known as Vortex Casing. By introducing the circular chamber, the
loss of energy due to the formation of eddies is reduced to a considerable extent. Thus
the efficiency of the pump is morethan the efficiency when only volute casing is
provided.

Diffuser Casing:-

This casing is shown in figure in which the impeller is surrounded by a series of

guide blades mounted on a ring which is known as diffuser. The guide vanes are designed
in which a way that the water from the impeller enters the guide vanes without stock.
Also the area of the guide vanes increases, thus reducing the velocity of flow through
guide vanes and consequently increasing the pressure of water. The water from the guide
vanes then passes through the surrounding casing which is in most of the cases
concentric with the impeller as shown in figure.

Delivery Pipe:
A pipe whose one end is connected to the outlet of the pump and other end delivers
the water at a required height is known as delivery pipe.

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 STUDY OF AIR CONDITIONER
Introduction:
An Air-Conditioner is defined as an assembly of different parts of the system used to
producea specified condition of air within a required space or building below that of the
atmosphere or surroundings.
An ideal air-conditioner should maintain correct temperature, humidity and air movement
[Link] a small domestic 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 vapor compression cycle. This cycle works

infollowing four phases.
1. Compression
2. Condensation
3. Expansion
4. Evaporation

Compression:
Compression takes place at the compressor. The low pressure, low temperature dry
refrigerantor coolant vapour is drawn from the evaporator into the 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.

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Condensation:
In the condenser, the high pressure and high temperature refrigerant vapour
rejects heat tocooling medium thus allowing the vaporised refrigerant to return to
liquid state.

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 is reduced very much to allow the vaporisation of liquid at a
very low temperature of about –10°C.

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 heatfrom the surrounding, the liquid refrigerant changes to
vapour state. Then the refrigerant vapour again moves into the compressor through the
suction line. Again the vapour compression cycle is repeated.

Main parts of an Air-Conditioner:

The following are the main parts of an air-conditioner.
1. Compressor
2. Condenser
3. Expansion device
4. Evaporator
5. Fan

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Compressor:
The most important part of the air-conditioner is hermatic compressor (also called
searled compressor). In this hermatic compressor, the rotary compressor and motor are
assembled together and suspended inside a metal casing called “Dome”. The motor located
above the compressoroperates horizontally.

RSIR (Resistant Start Induction Run) or CSIR (Capacitor Start Induction Run) type motor
is used to operate the compressor. Function of the compressor is to provide the necessary
pumping action to the refrigerant. It draws cold refrigerant vapour and to raise its
temperature and pressure to such a point so that it may be easily condensed with normally
available condensing medium. It also maintainsa continuous flow of the refrigerant
through the system.

Condenser:
Function of the condenser is to provide hear transfer surface through which heat
passes from the refrigerant to the condensing medium. Normally the condenser is made
by copper aluminium or iron pipe. Here the high pressure high temperature vapour
refrigerant becomes to liquid state by losingheat because of the cooling medium.

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Expansion Devise:
An expansion valve is used as an expansion device. Its function is to supply proper
amount ofrefrigerant to the evaporator after reducing its pressure considerably.

Evaporator:

Its function is to provide a heat transfer surface through which heat can pass from
the air- conditioned space into the vaporizing refrigerant. The pressure inside the
evaporator is low and the liquid refrigerant vaporizes by absorbing heat from the air
surrounding the evaporator. The low pressure low temperature vapor thus formed moves
into the compressor through the suction line. Theevaporator also made of copper
aluminium or iron pipe.

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 STUDY ON HOUSEHOLD MIXER

Mixer grinders are an important part of Indian kitchens, indispensable and necessary.
Cooking without a mixer grinder can become very difficult and time-consuming. They
play an important role in grinding masalas, which were earlier done on a grinding stone,
also called a sil-batta in India. They are used for pureeing, mixing, grinding, and some
mincing. Mixer grinders are designed for multiple tasks. In general, a mixer grinder has
separate jars – Liquidizer jar, Grinder Jar, and Chutney Jar. Over the years, mixer
grinders have become sleeker, lighter, and easy to use with aesthetically designed looks.

1. POWER

Power or Wattage decides how much and how well can the mixer grinder do its work.
Higher power is useful for grinding tougher ingredients and at a faster speed. The Indian
market has power/wattage options starting from 450W. Usually, for Indian kitchens,
anything from 450 W to 750 W is sufficient.

2. SPEED

The speed or RPM of a mixer grinder tells you how fast the blades rotate in a minute.
Indian kitchens and their mixing-grinding needs necessitate the speed to be more than
18000 RPM. Usually, the upper limit of the speed at 23000 RPM is good. It is however
important for the mixer grinders to have a speed control knob or a switch to change the
settings as per mixing or grinding requirement.

3. JARS

The next important element is the Jar. As is the case with most things in life, the more
the merrier. Standard mixer grinders provide 2 – 3 jars, one for liquidizing, one for
grinding, and one for chutney making. The jars must be of stainless steel, must have a
good break-resistant lid and a good handle.

4. BLADES

The blades do the real work, of grinding and mixing. In that sense, they become a
critical part of the product. The blade is usually made of high-grade steel. It should be
of grade
304, which is resistant to oxidation and corrosion. Such blades also retain their sharpness
for a longer time.

Mixer Grinder Keeps Tripping

There is a reset button placed under the mixer grinder, which trips when you
continuously use the appliance for longer hours or grind hot food items. The next time
you experience this problem, avoid using the appliance for too long and allow the food to
cool down before you grind it. If the mixer grinder trips due to excessive heat, unplug
the appliance, remove the jar and look under the appliance. At the bottom of the unit you
will see a red switch. Press the switch to reset the appliance, plug it back in, switch it on
and this should solve the problem.
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