DEPARTMENT OF MECHANICAL ENGINEERING

GE3271-ENGINEERING PRACTICES
LABORATORY
GROUP A (CIVIL & MECHANICAL)

II SEMESTER - R 2021

LABORATORY MANUAL
 GE3271-ENGINEERING PRACTICES LABORATORY
GROUP A (CIVIL & MECHANICAL)

COURSE OBJECTIVES
1. Drawing pipe line plan; laying and connecting various pipe fittings used in common
household plumbing work; Sawing; planning; making joints in wood materials used in
common household wood work.
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; Making a tray out of metal sheet using sheet metal work

SYLLABUS
I CIVIL ENGINEERING PRACTICE
PLUMBING WORK:
a) Connecting various basic pipe fittings 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 and Tenon joint and Dovetail joint. Wood Work
Study:
d) Studying joints in door panels and wooden furniture
e) Studying common industrial trusses using models.
II MECHANICAL ENGINEERING PRACTICE
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 conditioner.
SHEET METAL WORK:
a) Making of a square tray
FOUNDRY WORK:
a) Demonstrating basic foundry operations.
 COURSE OUTCOMES

1. Ability to install pipeline to distribute water to the required purpose.

2. Ability to handle the various plumping tools.

3. Ability to join wooden pieces/parts.

4. Ability to use wooden cutting and finishing tools.

5. Ability to understand working procedure of metal arc welding.

6. Ability to perform welding operations to make joints.

7. Ability to understand the functioning of the machine tool.

8. Ability to perform step turning operations.

9. Ability to develop sheet metal models with given dimension and shape.

10. Ability to handle the various sheet metal tools.

11. Ability to know about centrifugal pump, Air conditioner, Household mixer and the

operations of foundry.
 GE3271 - ENGINEERING PRACTICES
LABORATORYGROUP – A (CIVIL & MECHANICAL)
CONTENTS

SL. PAGE
NAME OF THE EXPERIMENT
NO. NO.
CYCLE 1 – EXPERIMENTS
1 Prepare a Pipe line connection for the wash basin.
Prepare a model of metallic pipe layout for water supply in a house
2
from the given service connection.
3 Make a T.lap joint from the given wood pieces
4 Make a , Mortise joint and Tenon joint from the given wood pieces
5 Make a dovetail halving joint from the given work piece.
6 Make a butt joint on the given work pieces using arc welding.
7 Make a lap joint on the given work pieces using arc welding.
8 Make a T.joint on the given work pieces using arc welding.
CYCLE 2 – EXPERIMENTS
9 Perform step turning on a cylindrical work piece.
10 Perform tapping operation on a given work piece.
Make a hole on a given work piece as per the required dimensions
11
using drilling machine.
12 Prepare a square tray from the given thick metal sheet.
13 Demonstration on Foundry operation
 Precaution
1. Never use loose clothes.
2. Full sleeve shirts should be avoided.
3. Never use neck tie while working.
4. Never mix the Measuring tools with cutting tools.
5. Keep the surroundings clean.
6. Every tool should have a proper place and it should be kept at its proper place after
use.

‘General Instructions to Students’

1. Students should come with thorough preparation for the exercise to be conducted.
2. Students will not be permitted to attend the laboratory unless they bring the
practical record fully completed in all respects pertaining to the exercise conducted
in the previous class.
3. They should obtain the signature of the staff-in-charge in the observation book after
completing exercise.
4. Theory regarding each exercise should be written in the practical record before
procedure in your own words.
5. Come prepared to the lab with relevant theory about the exercise you are
conducting.
 PLUMBING
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. Pipevice 3. Pipecutter
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.

Figure 1 Pipe wrench

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.

Figure 2 Pipe wrench

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.

Figure 3 Pipe Cutter

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

Figure 4 Hack saw

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.

Figure 5 Dies
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

Figure 6 Pipe fittings

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 beturned.

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

Figure 7 Valves
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.

Figure 8 Bell and spigot joints

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.

Figure 9 Bell and spigot joints

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

Figure 9 Threaded joints

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

Figure 10 Flexible joints

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

Figure 11 Expansion joints

 Exp No.:
Date:
PIPE LINE TO WASH BASIN

AIM:
To prepare a pipe line connection to the wash basin.

KEYWORDS:
Plumber, plumbing, wash basin, PVC, valve.

MATERIAL REQUIRED:
1. PVC pipe
2. Elbows
3. Flexible pipe
4. Valve
5. Clamps
6. Wash basin with tap
7. Tee Joint

TOOLS REQUIRED:
1. Pipe wrench
2. Hammer
3. Screw driver
4. Hack saw

THEORY:
Plumbing also refers to a system of pipes and fixtures installed in a building for the
distribution of potable water and the removal of waste water. Plumbing is the skilled trade of
working with pipes, tubing and plumbing fixtures for drinking water systems and the drainage of
waste. A plumber is someone who installs or repairs piping systems, plumbing fixtures and
equipment such as water heaters. The plumbing industry is a basic and substantial part of every
developed economy due to the need for clean water, and proper collection and transport of wastes.
In addition to the straight pipe or tubing, many fittings are required in plumbing systems, such as
valves, elbows, tees, and unions.
DIAGRAM:

Figure 1. Water line connection to wash basin

STEP BY STEP WORKING PROCEDURE:

1. Mark the location of wash basin and fix it properly.
2. Fix the tap on the wash basin in the required position properly
3. Connect the water tank and the wash basin tap using required length of pipes and pipe
fittings.
4. Fix the flow control valve near the wash basin tap and connect its outlet with the tap
using flexible pipe.
5. Fix the flexible drain pipe from the wash basin to the common drain outlet.

VIVA – VOCE
PRE LAB
1. How the pipes are specified?
2. What are the common pipe material used nowadays?
3. Name any five fittings?
4. What is B.S.P.?
5. What are the types of joints used in plumbing
POST LAB
1. Which vice used in plumbing
2. Where flexible joints are used?
3. What type of valve used in plumbing connection?
4. What is the purpose of reducer?
5. What is the purpose of coupling?

APPLICATION:
Hand wash in hotel, dining hall, rest room etc.

RESULT:
Thus the pipe line connection to the wash basin is prepared as per the given diagram.
 Exp No.:
Date:
BASIC GI PIPE CONNECTIONS WITH DIFFERENT JOINING COMPONENTS
AIM:
To prepare the pipe line connection to the tap from the main water line using GI pipes, GI
reducers, valves and clamps.

KEYWORDS:
Plumber, plumbing, Galvanized iron, PVC, valve.

MATERIAL REQUIRED:
1. GI pipe
2. Elbows
3. Reducer
4. Clamps
5. Tap
6. Valves

TOOLS REQUIRED:
1. Pipe wrench
2. Hammer
3. Screw driver
4. Hack saw

THEORY:
GI or Galvanized Iron (GI) pipe is basically the process of coating a metal with zinc, also
known as galvanization. Due to this process of coating the metal whether steel or iron becomes
more improved than traditional metal. Therefore, stainless steel or iron pipes that go through
galvanization become more productive and are usually preferred over pipes made from PVC,
plastic or ABS. Piping accessory that is fabricated through the process of galvanization is mainly
preferred for application in larger construction projects. Irrigation, sewage treatment plants and
factories are some other popular areas where such pipes find widespread application.
DIAGRAM:

Figure 1. Basic pipe connections with different joining components

STEP BY STEP WORKING PROCEDURE:

1. The required diameter pipes were picked and cut to the desired length
2. Pipe wrench is used for holding the pipes.
3. Make external threads to both pipes A and B using pipe threading dies.
4. Some hemp and white lead paint is inserted in the threads to make the joint sound.
5. Then the gate valve is connected to one end of pipe and other end connected to the
elbow.
6. Then, the elbow is connected with a pipe and other end connected to the elbow as per
the diagram.
7. Then the tap is connected with the pipe by using a reducer socket.
8. The water tank was filled with water and the gate valve was opened slowly to supply
water into the pipe line
9. The tap was opened to check its function.

VIVA – VOCE
PRE LAB
1. Name any five valves used in plumbing?
2. What is the difference between pipe and tube?
3. What is the purpose of gate valve?
4. Name the tool used to make external thread on pipes.?
5. What is nipple?
POST LAB
1. What is the purpose of pipe wrench?
2. What is cap in plumbing?
3. What type of valve used in plumbing connection?
4. Name the tools used to cut the pipe?
5. What is the abbreviation for GI?
APPLICATION:
Water line, fire fighting system, refineries cross country pipe line, toilet, etc.

RESULT:
Thus the pipe line connection to the tap from the main water line using GI pipes, GI
reducers, valves and clamps is prepared as per the given diagram.
CARPENTRY
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 wood work.
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 furnitures
 STUDY OF CARPENTRY TOOLS

Carpentry tools are used to produce components to an exact size. The types of
carpentrytools are as follows.

1. Marking tools 2. Measuring tools 3.Holdingtools

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 with a steel nail to
scratch the surface of the work.

Figure 1. 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.

Figure 2. Mortise gauge

 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.

Figure 3.Try square and Scriber

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.

Figure 4. Spirit level

MEASURING TOOLS
The carpentry measuring tools are used to measure the dimensions in the wood for
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.

Figure 5. Steel Ruler

HOLDING TOOLS

The carpentry holding tools are shown in figure

Figure 6. Holding tools

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 other is 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 from moving.

3. G-clamp
G-clamp is made up of malleable iron with acme threads of high qualitysteel
.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, designed to suit
different purpose. A saw is specified by the length of its tooled edge. The following saws
are used in the carpentry section.

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 gain of
stock. 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 cut saw.

Figure 7. Cutting tools

10
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.

Firmer chisels
These are general purpose chisels and are used either by hand pressure or by a mallet.
The blade of a firmer chisel is flat and their sloping face is at an angle 15 to 52 degrees.

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 from the 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.

Figure 8 Jack plane

11
2. Rebate plane
A rebate plane is used for making a rebate. A rebate is a recess along the edge of a
piece 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.

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
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.

Figure 9 Striking tools

MISCELLANEOUS TOOLS

1. Pincers
They are made up of steel with a hinged joint and are used for pulling out small nails
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.

Figure 9 Miscellaneous tools

CARPENTRY PROCESSES

In a carpentry shop, a number of operations are performed to get the finished work
piece. The different types of process performed in a carpentry shop can be classified as
follows.

1. Marking and Measuring

It is the process of setting of dimensions on wooden pieces to obtain the required
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 vibrations during
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. This process
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 holes
and 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
piece. This 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 moulding plane tool.
 Exp No.:
Date: T-LAP JOINT

AIM:
To a make a T-lap joint from the given wood pieces

KEYWORDS:
Carpentry, Wood, Joint, Lap.
MATERIALS USED:
50 x 25mm wooden reaper 260 mm long - 1 No.

TOOLS REQUIRED:
a) Measuring and marking tools: Steel rule, Try square, Marking gauge.
b) Cutting tools: Tenon saw, Jack plane, Firmer chisel
c) Striking tools: Mallet
d) Work holding devices: Carpenters vice, C Clamp.

APPLICATIONS OF T-LAP JOINT:

Dovetail joints are most commonly used wood working. Carpenters use dovetail joints
to create frame assembly in cabinet making, temporary framing, crates, grids, ladders and
tabling. T-lap joints consist of two pieces of wood or metal joined together at right angles by
overlapping them in the middle of one or both members. In some cases, the joint is strong
enough on its own and no longer needs nails, screws, or glue.

DIAGRAM:

All dimensions are in mm.

Figure 1. T-lap joint
STEP BY STEP WORKING PROCEDURE:

1. Taken a wooden piece slightly more than given dimension.

2. Hold the work piece in carpenter’s vice in such a way that one of the best wider sides can
be planed.
3. Using the jack plane, plain the surface till the band saw mark has gone and check for the
straightness.
4. Plane one of the adjacent side and check for the right angle using try square.
5. Mark 40 mm on the wider sides with marking gauge and plain to remove the excess
material.
6. Mark 20mm on the thinner sides using marking gauge and plane to make the thickness
20 mm
7. Cut the material to two pieces each measuring 130 mm.
8. Mark the material to be removed on both the pieces to make the joint using steel rule,
marking gauge and try square.
9. Using Tenon saw, cut the material in the unwanted region leaving about 1 to 2 mm from
the marked line to the required depth.
10. Using firmer chisel, remove the unwanted portion of material and assemble the joint.

VIVA – VOCE
PRE LAB
1. Name four number of Indian timber used to manufacture furniture.
2. What type of chisels is used in carpentry work normally?
3. What is the purpose of a Mortise chisel?
4. Can you tell the two types of defects seen in the wood?
5. What is the purpose of seasoning the wood?
POST LAB
1. Name the common carpentry tools?
2. What is the use for firmer chisel?
3. What is the use of metal jack plane?
4. What is the purpose of marking gauge?
5. Name the carpentry process?

RESULT:
Thus, the desired T-lap joint is made as per the given dimensions.
 Exp No.: MORTISE AND TENON JOINT
Date:

AIM:
To make a Mortise and Tenon joint from the given work piece.

KEYWORDS:
Carpentry, Wood, Joint, lap.

MATERIALS USED:
50 x 25mm wooden reaper 260 mm long - 1 No.
TOOLS REQUIRED:
a) Measuring and marking tools: Steel rule, Try square, Marking gauge.
b) Cutting tools: Tenon saw, Jack plane, Firmer chisel
c) Striking tools: Mallet
d) Work holding devices: Carpenters vice, C Clamp.

APPLICATIONS OF MIDDLE LAP JOINT:

A mortise and tenon is a type of joint that is made up of two parts. The tenon portion of the
joint works as a peg, and the mortis is the hole or slot into which the tenon is inserted. The pieces
are then glued together during assembly. A mortise and tenon is a popular type of joint that is used
to connect two pieces of wood. The tenon is a peg, and the mortise is the slot in which the tenon is
inserted. Mortises can be created using any choice or combination of a drill or drill press, chisels,
or a router. Tenons are often cut onto the end of a rail can also be made with many hand saws,
table saws, routers or chisels. Most mortise and tenon joints are square or in shape, but round peg
shapes are also common.
DIAGRAM:

Figure 1. Mortise joint and Tenon joint

STEP BY STEP WORKING PROCEDURE:

1. Select a teak wood material and mark the size as per drawing with the help of marking
tools like steel rule, marking gauge, try square.
2. Planning of sides with the help of wooden jackplane to maintain the required dimensions.
3. Fix the work piece in carpentry vice and cut into two equal pieces of size 150mm X
30mm with the help of handsaw.
4. Mark the two work pieces for male cutting and groove cutting as per dimensions.
5. Fix the work pieces one by one on the bench with the help of ‘C’ Clamp and a groove is
made as shown in drawing with the help of chisels and adze.
6. The two work pieces are fitted to make Mortise and Tenon joint as per drawing.

VIVA – VOCE
PRE LAB
1. What is the name of center portion of the wooden trunk?
2. What is meant by ply wood?
3. How the ply wood is manufactured?
4. Name the work holding devices in the carpentry shop?
5. What are the difference between carpenter’s vice and Bench vice?
POST LAB
1. Where the band saw is used
2. What is the purpose of a trammel point?
3. Can you explain the parts of a jack plane?
4. What is the name of saw used to cut across the grain?
5. What is the name of saw used to cut along the grain?

RESULT:
Mortise and Tenon joint of required dimension is obtained.
 Exp No.:
Date:
DOVETAIL HALVING JOINT
AIM:
To make a dovetail halving joint from the given work piece.

KEYWORDS:
Carpentry, Wood, Joint, Dovetail

MATERIALS USED:
50 x 25mm wooden reaper 260 mm long - 1 No.
TOOLS REQUIRED:
a) Measuring and marking tools: Steel rule, Try square, Marking gauge.
b) Cutting tools: Tenon saw, Jack plane, Firmer chisel
c) Striking tools: Mallet
d) Work holding devices: Carpenters vice, C Clamp.

APPLICATIONS OF DOVETAIL JOINT:

Dovetail joints are most commonly used wood working. Carpenters use dovetail joints
to create cabinets, furniture, drawers, log buildings, carcass construction, timber framing.
Dovetail joints are known for their strength and durability. Dovetail joints don’t require
mechanical fasteners to stick together like other joinery techniques do. Rather, dovetail joints
use pins and tails to interlock together, where one side has a pin that locks into the other side’s
tail, and then glued together for a solid dovetail construction.

DIAGRAM:

All dimensions are in mm.

Figure 1. Dovetail joint
STEP BY STEP WORKING PROCEDURE:

1. Taken a wooden piece slightly more than given dimension.

2. Hold the work piece in bench vice in such a way that one of the best wider sides can be
planed.
3. Using the jack plane, plane the surface till the band saw mark has gone and check for
the straightness.
4. Plane one of the adjacent side and check for the right angle using try square.
5. Mark 44 mm on the wider sides with marking gauge and plane to remove the excess
material.
6. Mark 22mm on the thinner sides from planed wider side using marking gauge and plane
to make the thickness 22 mm
7. Cut the material to two pieces each measuring 120 mm.
8. Mark the material to be removed on both the pieces to make the joint using steel rule,
marking gauge and Try square.
9. Using Tennon saw, cut the material to be removed to the required depth very near to
the marked line in the unwanted portion.
10. Using firmer chisel, remove the unwanted material by holding with a C clamp and
assemble the joint.
VIVA – VOCE
PRE LAB
1. Can you tell the name of self-locking type of joint used in carpentry?
2. What is the advantage of plywood over solid wood?
3. What is the use of chisel?
4. What is the use of spirit level?
5. What is mortise gauge?
POST LAB
1. What is the purpose of scriber?
2. Name the planning tools used in carpentry.
3. Name the striking tools used in carpentry.
4. What is pincer?
5. What is the purpose of gouges in carpentry shop?

RESULT:

Dove tailed joint of required dimension is obtained.

 WELDING

Welding is a fabrication process that joins materials, usually metals or thermoplastics,

by causing coalescence. This is often done by melting the work pieces and adding a filler
material to form a pool of molten material (the weld puddle) that cools to become a strong
joint, with pressure sometimes used in conjunction with heat, or by itself, to produce the
weld. This is in contrast with soldering and brazing, which involve melting a lower-melting-
point material between the work pieces to form a bond between them, without melting the
work pieces.

Many different energy sources can be used for welding, including a gas flame, an
electric arc, a laser, an electron beam, friction, and ultrasound. While often an industrial
process, welding can be done in many different environments, including open air,
underwater and in space. Regardless of location, however, welding remains dangerous,
and precautions must be taken to avoid burns, electric shock, eye damage, poisonous fumes,
and overexposure to ultraviolet light.

TYPES OF WELDING

Arc Welding

Arc welding is a process utilizing the concentrated heat of an electric arc to join
metal by fusion of the parent metal and the addition of metal to joint usually provided by a
consumable electrode. Either direct or alternating current may be used for the arc, depending
upon the material to be welded and the electrode used.

Gas Welding

It is a metal joining process in which the ends of pieces to be joined are heated
at their interface by producing coalescence with one or more gas flames (such as oxygen and
acetylene), with or without the use of a filler metal.

Welding Safety

Welding hazards pose an unusual combination of safety and health risks. By its
nature, welding produces fumes and noise, gives off radiation, involves electricity or gases,
and has the potential for burns, shock, fire, and explosions.

Some hazards are common to both electric arc and oxygen-fuel gas welding. If you work
with or near a welding operation, the following general precautions should help you to
work moresafely.

 Weld only in designated areas.

 Only operate welding equipment you have been trained to use.
 Know what the substance is that’s being welded and any coating on it.
 Wear protective clothing to cover all exposed areas of the body for protection
sparks, hot spatter, and radiation.
 Protective clothing should be dry and free of holes, grease, oil, and other substances
which may burn.
 Wear flameproof gauntlet gloves, a leather or asbestos apron, and high-top shoes to
provide good protection against sparks and spatter.
 Wear specifically designed, leak-proof helmets equipped with filter plates to protect
against ultraviolet, infrared, and visible radiation.
 Never look at a flash, even for an instant.
 Keep your head away from the plume by staying back and to the side of the work.
 Use your helmet and head position to minimize fume inhalation in your breathing
zone.
 Make sure there is good local exhaust ventilation to keep the air in your breathing zone
clear.
 Don’t weld in a confined space without adequate ventilation and a NIOSH-approved
respirator.
 Don’t weld in wet areas, wear wet or damp clothing or weld with wet hands.
 Don’t weld on containers which have held combustible materials or on drums, barrels
or tanks until proper safety precautions have been taken to prevent explosions.
 If others are working in the area be sure they are warned and protected against
arcs, fumes, sparks, and other welding hazards.\
 Don’t coil the electrode cable around your body.
 Ground both the frame of the welding equipment and metal being welded.
 Check for leaks in gas hoses using an inert gas.
 Check area around you before welding to be sure no flammable material or
degreasing solvents are in the welding area.
 Keep a fire watch in the area during and after welding to be sure there are no
smoldering materials, hot slag or live sparks which could start a fire.
 Locate the nearest fire extinguisher before welding.
 Deposit all scraps and electrode butts in proper waste container to avoid fire and
toxic fumes.
TYPES OF ARC WELDING

Different types of arc welding are.

1. Carbon arc welding

2. Metal arc welding
3. Metal inert gas welding
4. Submerged arc welding
5. Plasma arc welding etc.

Electric Arc Welding,

Electric arc welding is the most widely used of the various arc welding processes.
Welding is performed with the heat of an electric arc that is maintained between the
end of a coated metal electrode and the work piece (See Figure 1). The heat produced by
the arc melts the base metal, the electrode core rod, and the coating. As the molten metal
droplets are transferred across the arc and into the molten weld puddle, they are shielded
from the atmosphere by the gases produced from the decomposition of the flux coating.
The molten slag floats to the top of the weld puddle where it protects the weld metal
from the atmosphere during solidification. Other functions of the coating are to provide arc
stability and control bead shape. More information on coating functions will be covered in
subsequent lessons.

Welding Power Sources: Shielded metal arc welding may utilize either alternating current
(AC) or direct current (DC), but in either case, the power source selected must be of the
constant current type. This type of power source will deliver relatively constant amperage
or welding current regardless of arc length variations by the operator the amperage
determines the amount of heat at the arc and since it will remain relatively constant, the weld
beads produced will be uniform in size and shape.

Whether to use an AC, DC, or AC/DC power source depends on the type of welding to be
done and the electrodes used. The following factors should be considered:

1. Electrode Selection - Using a DC power source allows the use of a greater range of
electrode types. While most of the electrodes are designed to be used on AC or DC, some
will work properly only on DC.
2. Metal Thickness - DC power sources may be used for welding both heavy sections
and light gauge work. Sheet metal is more easily welded with DC because it is easier to
strike and maintain the DC arc at low currents.

3. Distance from Work - If the distance from the work to the power source is great, AC
is the best choice since the voltage drop through the cables is lower than with DC. Even
though welding cables are made of copper or aluminum (both good conductors), the
resistance in the cables becomes greater as the cable length increases. In other words, a
voltage reading taken between the electrode and the work will be somewhat lower than a
reading taken at the output terminals of the power source. This is known as voltage drop.

4. Welding Position - Because DC may be operated at lower welding currents, it is more

suitable for overhead and vertical welding than AC. AC can successfully be used for out-of-
position work if proper electrodes are selected.

5. Arc Blow - When welding with DC, magnetic fields are set up throughout the
weldment. In weldments that have varying thickness and protrusions, this magnetic field
can affect the arc by making it stray or fluctuate in direction. This condition is especially
troublesome when welding in corners. AC seldom causes this problem because of the
rapidly reversing magnetic field produced.

ELECTRIC ARC WELDING

Electric arc welding is the process of joining two parts by melting their edges by an electric
arc without the application of pressure and with or without use of filler metals. Refer Figure
1.

Figure 1 Electric Arc Welding Set-up

OXY-ACETYLENE GAS WELDING

Oxyacetylene welding, commonly referred to as gas welding, is a process which

relies on combustion of oxygen and acetylene. When mixed together in correct proportions
within a hand-held torch or blowpipe, a relatively hot flame is produced with a
temperature of about 3,200˚C. The chemical action of the oxyacetylene flame can be
adjusted by changing the ratio of the volume of oxygen to acetylene.

Three distinct flame settings are used, neutral, oxidising and carburizing. Welding is
generally carried out using the neutral flame setting which has equal quantities of oxygen
and acetylene. The oxidising flame is obtained by increasing just the oxygen flow rate
while the carburising flame is achieved by increasing acetylene flow in relation to oxygen
flow. Because steel melts at a temperature above 1,500˚C, the mixture of oxygen and
acetylene is used as it is the only gas combination with enough heat to weld steel.
However, other gases such as propane, hydrogen and coal gas can be used for joining
lower melting point non-ferrous metals, and for brazing and silver soldering.

Equipment

Oxyacetylene equipment is portable and easy to use. It comprises oxygen and

acetylene gases stored under pressure in steel cylinders. The cylinders are fitted with
regulators and flexible hoses which lead to the blowpipe.
Specially designed safety devices such as flame traps are fitted between the hoses
and the cylinder regulators. The flame trap prevents flames generated by a 'flashback' from
reaching the cylinders; principal causes of flashbacks are the failure to purge the hoses and
overheating of the blowpipe nozzle.

When welding, the operator must wear protective clothing and tinted colored goggles. As
the flame is less intense than an arc and very little UV is emitted, general-purpose tinted
goggles provide sufficient protection.

Neutral Flame
As the supply of oxygen to the blowpipe is further increased; the flame contracts
and the white cone become clearly defined, assuming a definite rounded shape. At this
stage approximately equal quantities of acetylene and oxygen are being used and the
 combustion is complete, all the carbon supplied by the acetylene is being consumed and the
maximum heat given out. The flame is now neutral, and this type of flame is the one most
extensively used by the welder, who should make himself thoroughly familiar with its
appearance and characteristics.

Figure 1 Oxy-Acetylene gas welding

Neutral Flame
As the supply of oxygen to the blowpipe is further increased; the flame contracts
and the white cone become clearly defined, assuming a definite rounded shape. At this
stage approximately equal quantities of acetylene and oxygen are being used and the
combustion is complete, all the carbon supplied by the acetylene is being consumed and the
maximum heat given out. The flame is now neutral, and this type of flame is the one most
extensively used by the welder, who should make himself thoroughly familiar with its
appearance and characteristics.

Carburizing Flame

This is a flame in which an excess of acetylene is burning, i.e. combustion is

incomplete and unconsumed carbon is present. When lighting the blowpipe, the acetylene is
turned on first and ignited, giving a very smoky yellow flame of abnormal size, showing
two cones of flame in addition to an outer envelope; this is an exaggerated form of the
carburizing flame, but gives out comparatively little heat and is of little use for welding.

Oxidising Flame
 A further increase in the oxygen supply will produce an oxidizing flame in which
there is more oxygen than is required for complete combustion. The inner cone will become
shorter and sharper, the flame will turn a deeper purple color and emit a characteristic slight
"hiss", while the molten metal will be less fluid and tranquil during welding and excessive
sparking will occur. An oxidizing flame is only used for special applications, and should
never be used for welding

WELDING TOOLS AND SAFETY EQUIPMENT’S

1. Goggles

Goggles are forms of protective eyewear that usually enclose or protect the eye area
in order to prevent particulates, infectious fluids, or chemicals from striking.

2. Face Shield

Face shield is used to protect the eyes of the welder from the little sparks produced
during welding. It is normally held in hand.

3. Hand Gloves

Hand gloves are used to protect the hands from electrical shock, arc radiation and hot
spatters.

4. Tongs
Tongs are used to handle the hot metal – welding job while cleaning. They are
also used to hold the metal for hammering.

5. Chipping Hammer

Chipping hammer is a chisel shaped tool and is used to remove the slag from the weld
bead.

6. Wire brush

A wire brush is made up of stiff steel wire embedded in a wooden piece. It

removes small particles of slag from the weld bead after the chipping hammer has done its
job.
 7. Welding Helmet

Welding helmets are headgear used when performing certain types of welding to
protect the eyes, face and neck from flash burn, ultraviolet light, sparks and heat.
Welding helmets can also prevent retina burns, which can lead to a loss of vision.

8. Ground Clamp

It is connected to the end of the ground cable. It is normally clamped to the

welding table or the job itself to complete the electric circuit.

Figure 2 Welding tools and safety equipment’s

Advantages of Arc Welding

1. A big range of metals and their alloys can be welded

2. Welding equipment is portable and the cost is fairly low
3. Flux shielded manual metal arc welding is the simplest of all the arc welding
processes.
4. The applications of the arc welding are innumerable, because of the availability of
wide variety of electrodes.
5. Welding can be carried out in any position with highest weld quality.
Disadvantages of arc welding

1. Because of the limited length of each electrode and brittle flux coating on it,
mechanization is difficult.
2. In welding long joints, as one electrode finishes, the weld is to be progressed
 with the next electrode. A defect may occur at the place where welding is restarted
with the new electrode.
Applications

1. In reservoir tank, boiler and pressure vessel fabrications

2. Ship building
3. Pipes and pen stock joining
4. Building and bridge construction
5. Automotive and air craft industry

TYPES OF JOINTS

The joints used in welding are

1. Butt joint 2. Lap joint 3. Edge joint

4. T – joint 5. Corner joint

1. Butt joint
It is used to join the ends or edges of plates lying in the same plane. Plates having
thickness less than 5mm do not require edge preparation but plates having thickness more
than 5mm require edge preparation on both sides.

2. Lap joint
It is used to join two over lapping pieces so that the edges of each piece are welded to
the surface of the other. It is used on plates less than 3mm thickness. Common types are
single lap and double lap joint. Edge preparation is not required for these joints.

3. Edge joint
It is used to weld two parallel plates. This is economical for joining thin plates up to
6mm. This joint is often used in sheet metal work. It is suitable for severe loading.

4. T – joint
It is used to weld two perpendicular plates. This is economical for joining thin plates
up to 3mm. This joint is often used in structures.
 Figure 3 Basic types of weld joints

5. Corner joint
It is used to join the edges of two pieces whose surfaces are approximately at right
angles to each other. It is common in the construction of boxes, tanks, frames and other
similar items. Edge preparation is not necessary for these joints.
Exp No.:
Date:
BUTT JOINT
AIM:
To make a butt joint on the given work pieces using arc welding.

KEYWORDS:
Welding, Electrode, Joint, Butt.

MATERIALS USED:
50x6 mm M S flat bar of length 100 mm- 2 Nos.
10 SWG (3.15 mm) General purposes M S welding electrode.

TOOLS REQUIRED:
Steel rule, Try square, Welding transformer unit, Hand held welding shield, Chipping
hammer, Goggles, Steel wire brush, Gloves, and Flat tongs.

APPLICATIONS OF BUTT JOINT:

A Butt Weld is a circumferential butt welded joint, and the most common type of joint
employed in the fabrication of welded pipe systems. A butt joint is the most universally used
method of joining pipe to itself, fittings, flanges, valves, and other equipment. This welding
technique is widely applied in situations where a quality weld desired.

DIAGRAM:

All dimensions are in mm.

Figure 1. Butt weld joint
STEP BY STEP WORKING PROCEDURE:

1. Collect the work piece and check the size.

2. Mark the portion to be welded.
3. Clean the portion to be welded by using steel wire brush.
4. Place the work pieces on the welding table and held it with suitable clamp.
5. Check the earth connection to the welding table.
6. Grip the welding electrode on the electrode holder and adjust the output current nearly
110A and switch on the welding transformer. Check for the arc on a waste piece.
7. Do the welding on the marked space and remove the slag from the welding bead after
cooling by using a chipping hammer. Final cleaning to be done by using a steel wire
brush.

VIVA – VOCE
PRE LAB
1. Name the types of welding.
2. Name different joints commonly used in welding.
3. What is welding?
4. What are the welding defects?
5. Why is coating done on electrode surface?

POST LAB
1. What is the use of welding holder?
2. What is the use of hand shield?
3. What is the use of hand gloves?
4. What is butt joint?
5. What is corner joint?

RESULT:

Butt joint of required dimension is obtained.

 Exp No.:
Date:
LAP JOINT
AIM:
To make a lap joint on the given work pieces using arc welding.

KEYWORDS:
Welding, Electrode, Joint, Lap.

MATERIALS USED:
50x6 mm M S flat bar of length 100 mm- 2 Nos.
10 SWG (3.15 mm) General purposes M S welding electrode.

TOOLS REQUIRED:
Steel rule, Try square, Welding transformer unit, Hand held welding shield, Chipping
hammer, Goggles, Steel wire brush, Gloves, and Flat tongs.

APPLICATIONS OF BUTT JOINT:

Lap welding joints are used most often to joint two pieces with differing thicknesses
together. Also considered a fillet type, the weld can be made on one or both sides. A Lap Joint
is formed when 2 pieces are placed in an over lapping pattern on top of each other. Lap welds
are commonly used in automation involving processes. They are also used in tabling, temporary
framing and frame assembly in cabinet making.

DIAGRAM:

All dimensions are in mm.

Figure 1. Lap weld joint
STEP BY STEP WORKING PROCEDURE:

1. Collect the work piece and check the size.

2. Mark the portion to be welded.
3. Clean the portion to be welded by using steel wire brush.
4. Place the work pieces on the welding table and held it with suitable clamp.
5. Check the earth connection to the welding table.
6. Grip the welding electrode on the electrode holder and adjust the output current nearly
110A and switch on the welding transformer. Check for the arc on a waste piece.
7. Do the welding on the marked space and remove the slag from the welding bead after
cooling by using a chipping hammer. Final cleaning to be done by using a steel wire
brush.

VIVA – VOCE
PRE LAB
1. Which welding process uses non-consumable electrodes?
2. What is gas welding?
3. What is flux?
4. What are the advantages of using LPG over acetylene for cutting?
5. Which equipment is used to supply power for welding?

POST LAB
1. What is the use of chipping hammer?
2. What is the use of wire brush?
3. What is filler material?
4. What is electrode?
5. What are the types of resistance welding?

RESULT:

Lap joint of required dimension is obtained.

 Exp No.:
Date:
T-JOINT
AIM:
To make a T-joint on the given work pieces using arc welding.

KEYWORDS:
Welding, Electrode, Joint.

MATERIALS USED:
50x6 mm M S flat bar of length 100 mm- 2 Nos.
10 SWG (3.15 mm) General purposes M S welding electrode.

TOOLS REQUIRED:
Steel rule, Try square, Welding transformer unit, Hand held welding shield, Chipping
hammer, Goggles, Steel wire brush, Gloves, and Flat tongs.

APPLICATIONS OF T JOINT:
The joint in which the two parts intersect each other at right angle i.e. 90 degrees & one
part is above the other at the center is called as T joint. The metal surface that is being joined
is never on the same plane. T welded joints are used when a metal piece is attached to some
sort of a base and also is is used in structural and machine applications

DIAGRAM:

All dimensions are in mm.

Figure 1. Lap weld joint
STEP BY STEP WORKING PROCEDURE:

1. Collect the work piece and check the size.

2. Mark the portion to be welded.
3. Clean the portion to be welded by using steel wire brush.
4. Edges are prepared suitably to the given dimension and positioned at right angles for
the T joint.
5. Place the work pieces on the welding table and held it with suitable clamp.
6. Check the earth connection to the welding table.
7. Grip the welding electrode on the electrode holder and adjust the output current nearly
110A and switch on the welding transformer. Check for the arc on a waste piece.
8. Do the welding on the marked space and remove the slag from the welding bead after
cooling by using a chipping hammer. Final cleaning to be done by using a steel wire
brush.

VIVA – VOCE

PRE LAB

1. What will happen if the arc length is reduced while welding?

2. What is auto genous welding?
3. What is flux change in welding?
4. What are the advantages of using electric arc welding?
5. What is arc welding?
POST LAB

1. Name the materials used for coating on electrodes.

2. What is T- joint?
3. What is the other name of lap joint?
4. Distinguish between electrode and filler rod
5. What is open source voltage?

RESULT:

T joint of required dimension is obtained.

 LATHE

The lathe is used for producing cylindrical work. The work piece is rotated while
the cutting tool movement is controlled by the machine. The lathe is primarily used for
cylindrical work. The lathe may also be used for: Boring, drilling, tapping, turning, facing,
threading, polishing, grooving, knurling etc.

The purpose of a lathe is to rotate a part against a tool whose position it controls. It
is useful for fabricating parts and/or features that have a circular cross section. The spindle
is the part of the lathe that rotates. Various work holding attachments such as three jaw
chucks, collets, and centers can be held in the spindle. The spindle is driven by an electric
motor through a system of belt drives and/or gear trains. Spindle speed is controlled by
varying the geometry of the drive train.

The tailstock can be used to support the end of the work piece with a center, or to
hold tools for drilling, reaming, threading, or cutting tapers. It can be adjusted in position
along the ways to accommodate different length work pieces. The ram can be fed along
the axis of rotation with the tailstock hand wheel.

The carriage controls and supports the cutting tool. It consists of: A saddle that mates
with and slides along the ways, an apron that controls the feed mechanisms, a cross slide
that controls transverse motion of the tool (toward or away from the operator), a tool
compound that adjusts to permit angular tool movement and a tool post T-slot that holds
the tool post.

Feed, Speed, And Depth of Cut

Cutting speed is defined as the speed at which the work moves with respect to the
tool. Feed rate is defined as the distance the tool travels during one revolution of the part.
Cutting speed and feed determines the surface finish, power requirements, and material
removal rate. The primary factor in choosing feed and speed is the material to be cut.
However, one should also consider material of the tool, rigidity of the work piece, size
and condition of the lathe, and depth of cut. To calculate the proper spindle speed, divide
the desired cutting speed by the circumference of the work.
 Figure 1 Lathe

Head Stock

The headstock houses the main spindle , speed change mechanism , and change gears
The headstock is required to be made as robust as possible due to the cutting forces
involved, which can distort a lightly built housing, and induce harmonic vibrations that
will transfer through to the work piece, reducing the quality of the finished work piece

Bed

The bed is a robust base that connects to the headstock and permits the carriage and
tailstock to be aligned parallel with the axis of the spindle. This is facilitated by hardened
and ground ways which restrain the carriage and tailstock in a set track. The carriage
travels by means of a rack and pinion system, leads crew of accurate pitch, or feed screw.

The feed screw is a long driveshaft that allows a series of gears to drive the carriage
mechanisms. These gears are located in the apron of the carriage. Both the feed screw and
lead screw are driven by either the change gears or an intermediate gearbox known as a quick
change gearbox or Norton gearbox. These intermediate gears allow the correct ratio and
direction to be set for cutting threads or worm gears. Tumbler gears are provided between
the spindle and gear train that enables the gear train of the correct ratio and direction to
be introduced. This provides a constant relationship between the number of turns the
spindle makes, to the number of turns the lead screw makes. This ratio allows screw
threads to be cut on the work piece without the aid of a die.

Carriage

In its simplest form the carriage holds the tool bit and moves it longitudinally
(turning) or perpendicularly (facing) under the control of the operator. The operator moves
the carriage manually via the hand wheel or automatically by engaging the feed screw with
the carriage feed mechanism, this provides some relief for the operator as the movement
of the carriage becomes power assisted. The hand wheels on the carriage and its related
slides are usually calibrated both for ease of use and to assist in making reproducible cuts.

Cross-slide

The cross-slide stands atop the carriage and has a lead screw that travels
perpendicular to the main spindle axis, this permit facing operations to be performed. This
lead screw can be engaged with the feed screw (mentioned previously) to provide
automated movement to the cross-slide; only one direction can be engaged at a time as an
interlock mechanism will shut out the second gear train.

Compound rest

The compound rest is the part of the machine where the tool post is mounted. It
provides a smaller amount of movement along its axis via another lead screw. The
compound rest axis can be adjusted independently of the carriage or cross-slide. It is
utilized when turning tapers, when screw cutting or to obtain finer feeds than the lead screw
normally permits.

Tool post

The tool bit is mounted in the tool post which may be of the American lantern style,
traditional 4 sided square styles, or in a quick change style. The advantage of a quick change
set-up is to allow an unlimited number of tools to be used (up to the number of holders
available) rather than being limited to 1 tool with the lantern style, or 3 to 4 tools with the 4
 sided type.

Tail Stock

The tailstock is a tool holder directly mounted on the spindle axis, opposite the
headstock. The spindle does not rotate but does travel longitudinally under the action of a
lead screw and hand wheel. The spindle includes a taper to hold drill bits, centers and other
tooling. The tailstock can be positioned along the bed and clamped in position as required.
There is also provision to offset the tailstock from the spindles axis; this is useful for turning
small tapers.

LATHE OPERATIONS

Turning
Turning is the machining operation that produces cylindrical parts. In its basic form,
it can be defined as the machining of an external surface:

 with the work piece rotating,

 with a single-point cutting tool, and
 with the cutting tool feeding parallel to the axis of the work piece and at a
distance that will remove the outer surface of the work.

Taper turning is practically the same, except that the cutter path is at an angle to the
work axis. Similarly, in contour turning, the distance of the cutter from the work axis is
varied to produce the desired shape

Facing

Facing is the producing of a flat surface as the result of a tool's being fed across the
end of the rotating work piece. Unless the work is held on a mandrel, if both ends of the
work are to be faced, it must be turned end for end after the first end is completed and
the facing operation repeated. The cutting speed should be determined from the largest
diameter of the surface to be faced. Facing may be

done either from the outside inward or from the center outward. In either case, the point
of the tool must be set exactly at the height of the center of rotation.
Parting

Parting is the operation by which one section of a work piece is severed from the
remainder by means of a cutoff tool. Because cutting tools are quite thin and must have
considerable overhang, this process is less accurate and more difficult. The tool should be
set exactly at the height of the axis of rotation, be kept sharp, have proper clearance angles,
and be fed into the work piece at a proper and uniform feed rate.
Drilling

A lathe can also be used to drill holes accurately concentric with the centerline of a
cylindrical part. First, install a drill chuck into the tail stock. Make certain that the tang on
the back of the drill chuck seats properly in the tail stock. Withdraw the jaws of the chuck
and tap the chuck in place with a soft hammer.

Figure 2 Lathe operations

Move the saddle forward to make room for the tailstock. Move the tailstock into
position, and lock the bit in place. Before starting the machine, turn the spindle by hand. Just
move the saddle forward, so it could interfere with the rotation of the lathe chuck. Always
use a center drill to start the hole.
Boring

Boring is an operation in which a hole is enlarged with a single point cutting tool. A
boring bar is used to support the cutting tool as it extends into the hole. Because of the
extension of the boring bar, the tool is supported less rigidly and is more likely to chatter.
This can be corrected by using slower spindle speeds or by grinding a smaller radius on the
nose of the tool.
Single Point Thread Turning

External threads can be cut with a die and internal threads can be cut with a tap. But
for some diameters, no die or tap is available. In these cases, threads can be cut on a lathe. A
special cutting tool should be used, typically with a 60 degree nose angle. To form threads
with a specified number of threads per inch, the spindle is mechanically coupled to the
carriage lead screw. Procedures vary for different machines
 Drilling Machine
The machine which performs the drilling operation is known as drilling machine.
There are two types of machine drill, the bench drill and the pillar drill. The bench drill is
used for drilling holes through materials including a range of woods, plastics and metals. It
is normally bolted to a bench so that it cannot be pushed over and that larger pieces of
material can be drilled safely.

The larger version of the machine drill is called the pillar drill. This has a long
column which stands on the floor. This can do exactly the same work as the bench drill but
because of its larger s i z e it is capable of being used to drill larger pieces of materials and
produce larger holes.

Figure 1 Drilling Machine

SAFETY MEASURES

1. Always use the guard.

2. Wear goggles when drilling materials.
3. Clamp the materials down or use a machine vice.
4. Never hold materials by hand while drilling.
5. Always allow the ‘chippings’ to clear the drill by drilling a small amount at a time.
6. Follow all teacher instructions carefully.

TYPES OF DRILLING MACHINE

1. Portable drilling machine

2. Sensitive drilling machine
3. Upright drilling machine
4. Radial drilling machine
5. Gang drilling machine
6. Multi spindle drilling machine

DRILLING OPERATIONS

1. Drilling
It is the operation by which circular holes can be produced by rotating a tool called drill
bit against the work piece. Using centre punch the centre of the hole is marked before
drilling. The hole produced by drilling will be rough and of less accuracy.

2. Reaming
It is the operation of finishing and sizing the already drilled hole. The tool used is
called reamer. It removes very little amount of metal to finish the hole.

3. Boring
The operation to enlarge the drilled hole is called boring. For boring, the cutter is held
in a boring bar and is fixed to the spindle. It gives good surface finish.

4. Counter boring
To seat the heads of socket, screw and studs, a drilled hole is enlarged to a given
depth. This operation is called counter boring.

5. Counter sinking
The operation of machining a conical enlargement at the top of a drilled hole is called
counter sinking.
 Exp No.:
Date:
PERFORM STEP TURNING ON A CYLINDRICAL WORK PIECE
AIM:
To perform step turning on a cylindrical work piece.

KEYWORDS:
Lathe, turning, feed, machining.

MATERIALS USED:
Mild steel bar: Ф 32 mm x 100 mm long - 1 No.

TOOLS REQUIRED:
Lathe with all its accessories, single point cutting tool, Vernier caliper, steel scale,
outside caliper, spanner.

THEORY:
Lathe removes undesired material from a rotating work piece in the form of chips with
the help of a tool which is traversed across the work and can be fed deep in work. The tool
material should be harder than the work piece and the later help securely and rigidly on the
machine. The tool may be given linear motion in any direction. A lathe is used principally to
produce cylindrical surfaces and plane surfaces, at right angles to the axis of rotation. It can
also produce tapers and bellows etc. Turning is a form of machining, a material removal
process, which is used to create rotational parts by cutting away unwanted material. Turning is
used to produce rotational, typically axi-symmetric, parts that have many features, such as
holes, grooves, threads, tapers, various diameter steps, and even contoured surfaces. Parts that
are fabricated completely through turning often include components that are used in limited
quantities, perhaps for prototypes, such as custom designed shafts and fasteners. Turning is
also commonly used as a secondary process to add or refine features on parts that were
manufactured using a different process.
DIAGRAM:

All dimensions are in mm.

Figure 1. Step turning

STEP BY STEP WORKING PROCEDURE:

1. Loosen the jaws in the chuck using chuck key to position the work piece and then
tighten the jaws.
2. Fix the single point cutting tool in the tool post

3. Switch on the lathe, move the carriage near the work piece and perform the rough
turning operation up to desired length with a small depth of cut.
4. Perform the further operation to required diameter.
5. Do step turning up to desired length to required diameter.
6. Continue machining till final diameter being achieved.

7. Stop the operation, clean the machine and return the cutting tools and measuring tools
after the measurements.

8. Finally measure the dimensions (length and diameter) of the job.

VIVA –VOCE

PRE LAB

1. State the various feed mechanisms used for obtaining automatic feed.
2. List any four holding devices.
3. What are the different operations performed on the lathe?
4. What is the use of chuck?
5. What is the use of tail stock?
POST LAB

1. Where is the motor located in lathe?

2. What is the use of knurling?
3. What is the difference between pitch and lead?
4. what is the necessity of doing chamfering?

5. What is least count of vernier caliper?

RESULT:
Turning operation are carried out on the given work piece as per the given
dimensions.
 Exp No.:
Date:
PERFORM TAPER TURNING ON A CYLINDRICAL WORK PIECE
AIM:
To perform taper turning operation on a cylindrical work piece.

KEYWORDS:
Lathe, turning, feed, machining.

MATERIALS USED:
Mild steel bar: Ф 32 mm x 100 mm long - 1 No.

TOOLS REQUIRED:
Lathe with all its accessories, single point cutting tool, Vernier caliper, steel scale,
outside caliper, spanner.

THEORY:
Taper turning means, to produce a conical surface by gradual reduction or increase in
diameter from a cylindrical work piece. This tapering operation has wide range of use in
construction of machines. Almost all machine spindles have taper holes which receive taper
shank of various tools and work holding devices.

DIAGRAM:

All dimensions are in mm.

Figure 1. Taper turning

STEP BY STEP WORKING PROCEDURE:

1. Loosen the jaws in the chuck using chuck key to position the work piece and then
tighten the jaws.
 2. Fix the single point cutting tool in the tool post
3. Switch on the lathe, move the carriage near the work piece and perform the rough
turning operation up to desired length with a small depth of cut.
4. Perform the further operation to required diameter.

5. Do step turning up to desired length to required diameter.

6. Continue machining till final diameter being achieved.

7. To produce a taper, rotate and set the cross slide to the required angle.
8. Give a small feed and then move the tool using the cross slide. Repeat the steps to
complete the taper.
9. Stop the operation, clean the machine and return the cutting tools and measuring tools
after the measurements.
10. Finally measure the dimensions (length and diameter) of the job.

VIVA –VOCE
PRE LAB

1. What are the types of chuck based on numbering?

2. What do you meant by coolant and what is the necessity of using coolant?
3. What is the difference between iron and steel?

4. What is the difference between ferrous and non-ferrous metal?

5. What is taper turning?

POST LAB
1. Define the term ‘Conicity’.
2. What is truing?

3. What is turning?
4. What is the nature of chip in cast iron and mild steel?

5. Explain the different types of taper turning method?

RESULT:
Taper turning operation are carried out on the given work piece as per the given
dimensions.
 Exp No.:
Date:
DRILLING AND TAPPING
AIM:
To make a hole on a given work piece as per the required dimensions using drilling
machine and also making tapping using tapping tool.

KEYWORDS:
Drill bit, hole, punching, tapping tool.

MATERIALS USED:
MS Plate: 50 mm x 50mm - 1 No.

TOOLS REQUIRED:
Drilling machine with all its accessories, Machine vice, Drill bit, Dot punch, tapping
tool, HammerSteel scale.

THEORY:
Drilling is a cutting process that uses a drill bit to cut a hole of circular cross-section in
solid materials. The drill bit is usually a rotary cutting tool, often multi-point. The bit is pressed
against the work-piece and rotated at rates from hundreds to thousands of revolutions per
minute. This forces the cutting edge against the work-piece, cutting off chips from the hole as
it is drilled. Drilling allows a person to make holes through boards, metals, and other materials.

DIAGRAM:

All dimensions are in mm.

Figure 1. Drilling
STEP BY STEP WORKING PROCEDURE:

1. The dimensions of the given work piece is checked as per the requirement.
2. The work piece is clamped in the vice and any two surfaces are filed to get right
angle.
3. Drill bit of required size is fitted in the drill chuck of the drilling machine.
4. The mid-point of the required hole is punched by using dot punch and hammer.
5. The punched dot is drilled by drilling machine.
6. After drilling the hole, the dimensions are checked.
7. Finally, the tapping operations are carried out in the drilled holes.

VIVA –VOCE
PRE LAB
1. What are the drilling operations?
2. What is tapping?
3. What is Boring?
4. What is counter sinking?
5. What is the use of drilling machine?

POST LAB
1. What is the use of a guard?
2. What is counter boring?
3. What is radial drilling machine?
4. Why is boring operation preferred?
5. Mention few applications of drilling.

RESULT:
Thus the given work piece is drilled and tapped to the required dimensions.
 SHEET METAL

INTRODUCTION

Sheet metal is simply metal formed into thin and flat pieces. It is one of the fundamental
forms used in metalworking, and can be cut and bent into a variety of different shapes.
Countless everyday objects are constructed of the material. Thicknesses can vary
significantly, although extremely thin thicknesses are considered foil or leaf, and pieces
thicker than 6 mm (0.25 in) are considered plate.

Sheet metal is available as flat pieces or as a coiled strip. The coils are formed by running a
continuous sheet of metal through a roll slitter.

The thickness of the sheet metal is called its gauge. The gauge of sheet metal ranges from 30
gauge to about 8 gauge. The higher the gauge, the thinner the metal is.

There are many different metals that can be made into sheet metal, such as aluminum,
brass, copper, steel, tin, nickel and titanium. For decorative uses, important sheet metals
include silver, gold, and platinum (platinum sheet metal is also utilized as a catalyst.)

Sheet metal has applications in car bodies, airplane wings, medical tables, roofs for building
and many other things. Sheet metal of iron and other materiales with high magnetic
permeability, also known as laminated steel cores, has applications in transformers and
electric machines. Historically, an important use of sheet metal was in plate armor worn
by cavalry, and sheet metal continues to have many decorative uses, including in horse tack.

SHEET METAL PROCESSING

The raw material for sheet metal manufacturing processes is the output of the rolling
process. Typically, sheets of metal are sold as flat, rectangular sheets of standard size. If the
sheets are thin and very long, they may be in the form of rolls. Therefore the first step in any
sheet metal process is to cut the correct shape and sized ‘blank’ from larger sheet.

Sheet metal processes

Sheet metal processes can be broken down into two major classifications and one minor
classification
  Shearing processes - processes which apply shearing forces to cut, fracture, or
separate the material.

 Forming processes - processes which cause the metal to undergo desired shape
changes without failure, excessive thinning, or cracking. This includes bending and
stretching.

 Finishing processes - processes which are used to improve the final surface
characteristics.

Shearing Process
1. Punching: shearing process using a die and punch where the interior portion of the
sheared sheet is to be discarded.
2. Blanking: shearing process using a die and punch where the exterior portion of the
shearing operation is to be discarded.
3. Perforating: punching a number of holes in a sheet
4. Parting: shearing the sheet into two or more pieces
5. Notching: removing pieces from the edges
6. Lancing: leaving a tab without removing any material

Forming Processes

 Bending: forming process causes the sheet metal to undergo the desired shape
change by bending without failure. Ref fig.
 Stretching: forming process causes the sheet metal to undergo the desired shape
change by stretching without failure.
 Drawing: forming process causes the sheet metal to undergo the desired shape
change by drawing without failure.
 Roll forming: Roll forming is a process by which a metal strip is progressively
bent as it passes through a series of forming rolls.
 Figure 1. Common Die – Bending operations

Finishing processes

Material properties, geometry of the starting material, and the geometry of the desired
final product play important roles in determining the best process

Equipments

Basic sheet forming operations involve a press, punch, or ram and a set of dies

Presses

 Mechanical Press - The ram is actuated using a flywheel. Stroke motion is not
uniform.

 Hydraulic Press - Longer strokes than mechanical presses, and develop full force
throughout the stroke. Stroke motion is of uniform speed, especially adapted to
deep drawing operations.

Dies and Punches

 Simple- single operation with a single stroke

 Compound- two operations with a single stroke

 Combination- two operations at two stations

 Progressive- two or more operations at two or more stations with each press
stroke, creates what is called a strip development
Tools and Accessories

The various operations such as cutting, shearing, bending, folding etc. are performed by these
tools.

Marking and measuring tools

 Steel Rule - It is used to set out dimensions.

 Try Square - Try square is used for making and testing angles of 90degree

 Scriber – It used to scribe or mark lines on metal work pieces.

 Divider - This is used for marking circles, arcs, laying out perpendicular lines,
bisecting lines, etc

Cutting Tools

 Straight snip - They have straight jaws and used for straight line cutting. Ref fig.

 Curved snip - They have curved blades for making circular cuts. Ref fig.

Figure 2 Snip
Striking Tools

Mallet - It is wooden-headed hammer of round or rectangular cross section. The striking face
is made flat to the work. A mallet is used to give light blows to the Sheet metal in bending

44
 and finishing. Ref fig.

Hammers – Hammers are also used in sheet metal work for forming shapes. Commonly
used hammers are rubber / nylon hammers and creasing hammer.

Figure 3 Striking tools

Merits
 High strength
 Good dimensional accuracy and surface finish Relatively low cost

Demerits

 Wrinkling and tearing are typical limits to drawing operations.

o Different techniques can be used to overcome these limitations

o Draw beads

o Vertical projections and matching grooves in the die and blank holder

Trimming may be used to reach final dimensions.

45
Exp No.:
Date:
RECTANGULAR TRAY
AIM:
To make a rectangular tray using sheet metal as per required dimensions.

KEYWORDS:
Sheet metal, forming, bending.

MATERIALS REQUIRED:
Galvanized Iron sheet: 150 mm x 110 mm x 26 gauge- 1 No.

TOOLS REQUIRED:
Steel Rule, Flat file, Scriber, Try square, Snips, Dot punch, Mallet, Stakes.

APPLICATIONS OF SHEET METALS:

Sheet metal works are widely used in automobile and truck (lorry) bodies, airplane
fuselages and wings, lockers/tool boxes, electrical enclosures, medical tables,
refrigerators/freezers and roofs for buildings.

DIAGRAM:

All dimensions are in mm.

Figure 1. Rectangular tray

46
STEP BY STEP WORKING PROCEDURE:

1. Collect and check the raw material for shape and dimensions.
2. Collect tools required for the job.
3. Acquaint with the working knowledge of the sheet metal working process.
4. Acquaint with the knowledge of safety precaution about the process.
5. Flatten the metal sheet by mallet.
6. Marking should be done on the sheet as per given dimension with the help of steel
rule, scriber, dot punch.
7. Cut the sheet as per the lay out with the help of snip.
8. Fold and bend different portion as per requirement using mallet by placing the job
on the anvil.

VIVA –VOCE

PRE LAB

1. Which are the materials used for sheet metals?

2. What is Curved snip?
3. What is parting?
4. What is Perforating?
5. What is sheet metal work?

POST LAB

1. Name the sheet metal hand tools.

2. Name the different files?
3. What are the cutting tools?
4. What is shearing?
5. What is G.I.?

RESULT:
Thus the desired rectangular tray is developed from the given sheet metal.

47
Exp No.:
Date:
FUNNEL
AIM:
To make a funnel using sheet metal as per required dimensions.

KEYWORDS:
Sheet metal, forming, bending.

MATERIALS REQUIRED:
Galvanized Iron sheet: 150 mm x 110 mm x 26 gauge- 1 No.

TOOLS REQUIRED:
Steel Rule, Flat file, Scriber, Try square, Snips, Dot punch, Mallet, Stakes,
Groover.

APPLICATIONS OF SHEET METALS:

Sheet metal works are widely used in automobile and truck (lorry) bodies, airplane
fuselages and wings, lockers/tool boxes, electrical enclosures, medical tables,
refrigerators/freezers and roofs for buildings.

DIAGRAM:

All dimensions are in mm.

Figure 1. Funnel

48
Formula used:
Angle, φ = (R/ L) × 360º
Where, R = radius of the top circle of the funnel, L = Slanting length

STEP BY STEP WORKING PROCEDURE:

1. Check the size of the given sheet metal is checked for its dimensions using steel rule.
2. Mark the required development of surface on the white paper which is over lapped
on the sheet
3. metal.
4. Mark on the sheet metal as per the development being done on the paper.
5. Now using straight snips, remove unwanted materials.
6. Now fold and bend the work piece to make the funnel shape and joint is made on the
work pieces.
7. Then using groover, make locked grooved joint for about 5 mm. Also, do hemming
in the bottom of the funnel.

VIVA –VOCE
PRE LAB

1. What are all the various methods of jointing the sheet metal?
2. Why we call it sheet?
3. How to determine size of galvanized sheet?
4. What is the use of a try square?
5. What is Blanking?
POST LAB

1. What is a Mallet?
2. What is punching?
3. What are the hammers commonly used for sheet metal operations?
4. What is the use of straight snip?
5. What is a Scriber?

RESULT:
Thus the desired funnel is developed from the given sheet metal.
 FOUNDRY

A foundry is a factory which produces metal castings from either ferrous or non-
ferrous alloys. Metals are turned into parts by melting the metal into a liquid, pouring the
metal in a mold, and then removing the mold material or casting. The most common metal
alloys produced are aluminum and cast iron. However, other metals, such as steel,
magnesium, copper, tin, and zinc, can be processed.

A sand casting or a sand molded casting is a cast part produced by forming a mold
from a sand mixture and pouring molten liquid metal into the cavity in the mold. The mold
is then cooled until the metal has solidified. In the last stage the casting is separated from the
mold. There are six steps in this process:

1. Place a pattern in sand to create a mold.

2. Incorporate a gating system.
3. Remove the pattern.
4. Fill the mold cavity with molten metal.
5. Allow the metal to cool.
6. Break away the sand mold and remove the casting.

Figure 1 Metal casting poured in sand mold

54
 There are two main types of sand used for molding. "Green sand" is a mixture of
silica sand, clay, moisture and other additives. The "air set" method uses dry sand bonded
to materials other than clay, using a fast curing adhesive. When these are used, they are
collectively called "air set" sand castings to distinguish these from "green sand" castings.
Two types of molding sand are natural bonded (bank sand) and synthetic (lake sand),
which is generally preferred due to its more consistent composition.

Foundry hand tools

The hand tools commonly used in foundry are as follows.

1. Shovel
It is used for mixing molding sand and for filling molding sand into the flask.
A shovel is shown in fig. (a)

2. Riddle
Riddle is used for removing foreign materials from the moulding sand. It is shown
in fig. (b)

3. Rammer
This is used for packing or ramming the sand into the mould. Hand rammers are
shown in fig. (c) For large moulds, machine rammers are used.

4. Trowel
A trowel is used for smoothening the surfaces of the mould. It is shown in fig.(d)

5. Sprue pin

It is a conical wooden pin, which is used while making the mould, for making an
opening to pour the molten material into the cavity. A sprue pin is shown in fig. (e).

6. Vent rod
Vent rod is used for making small holes to permit gases to escape while the molten
material is being poured. Fig. (f) shows a vent rod.

7. Draw spike
This is used for drawing patterns from the sand. It has a loop at one end for
pulling up the pattern from the mould. Draw spike is shown in fig. (g)

55
8. Moulding boxes
These are also known as moulding flasks. Moulding boxes are rigid frames made
of iron or wood to hold the sand. The purpose of the flask is to impart necessary rigidity
and strength to the rammed sand. Complete process of moulding is done in the moulding
boxes. They are usually made in two parts, which are assembled with each other by pins on
either side of the flasks. The top flask is called cope and the bottom flask is called drag.
If the boxes are made in three sections then the middle one is called as cheek.