SRI VENKATESWARA COLLEGE OF ENGINEERING

PENNALUR, IRUNGATTUKOTTAI P.O. – 602117

DEPARTMENT OF MECHANICAL ENGINEERING

ME22161 – Basic Civil & Mechanical Engineering Lab
(Common to CE, EE, EC)

LAB MANUAL

Prepared by Approved by

Dr. V. Sridharan Dr. S. Ramesh Babu

ASP/ME HoD/ME
 SAFETY INSTRUCTIONS

CARPENTRY –
1. Pointed, sharp edged and heavy tools should be kept at the respective places only when not
used.
2. Measuring tools and cutting tools should be kept separately
3. Sharpness of the required tools should be checked on the wooden surface only. NOT WITH
THE HANDS.
WELDING –
1. All safety gears should be worn before starting the practice to protect hand, eyes and face.
2. Welding practice involves handling High voltage electric equipment.
3. No inflammable material should be present near the welding area.
BASIC MACHINING –
1. Ensure work piece is tightly held in the chuck and tool on the tool post.
2. Avoid getting closer to the rotating parts.
3. Clean the machine using brush after completion of exercise.

GENERAL INSTRUCTIONS
1. Report to the workshop on time. Know the entry and exit points in the workshop.
2. Wear only the allowed dress; Khaki trouser and half sleeve shirts for boys and khaki overcoat
for girls.
3. Leather shoes should only be worn inside the workshop
4. Always listen and follow the instructions given.
5. If you are not sure of using a tool, CONTACT faculty member or technical staff.
6. Never lend the tools given to you to your classmates and return and all the tools after usage.
7. BE RESPONSIBLE AND DO NOT BE PLAYFUL WITH THE TOOLS.
8. SAFETY IS MORE IMPORTANT THAN ANYOTHER TASK.
9. YOUR CARELESSNESS WITH TOOLS MAY PUT OTHERS ARE RISK OR
DANGER
10. INCASE OF ANY INCIDENT, IMMEDIATELY BRING IT TO THE NOTICE OF
THE FACULTY MEMBER OR TECHNICAL STAFF PRESENT.
 INDEX

Marks
Ex.
Date Name of Exercise obtained Initials
No.
(out of 10)

SAFETY INSTRUCTIONS TO BE FOLLOWED IN Mandatory reading and

0 WORKSHOP & understanding by all
GENERAL INSTRUCTIONS students

1 Carpentry – Cross Half Lap joint

Plumbing – Pipe connection with different

2
joining components

3 Welding – Butt joint and Lap joint

4 Sheet Metal Work – Cylinder and tray

5 Basic Machining – Lathe operations

6 Basic Machining – Fitting by grinding

7 Basic Machining – Drilling & Tapping

Casting - Demonstration of Mould

8
preparation and casting
Automation – Demonstration of Basic
9
Pneumatic Circuit
3D printing – Demonstration of 3D printing
10
of objects
ALL DIMENSIONS ARE IN MM
Ex. No. –
Date –
CARPENTRY
AIM – To make a cross half lap joint from the given wooden work piece for the given dimensions.
TOOLS REQUIRED: Jack plane, chisel, mallet, rip saw, clamp, try square, marking gauge and
steel rule
PROCEDURE:
1. Firmly clamp the wooden piece in the carpentry vice and cut two pieces of required size
using saw.
2. Using jack plane two adjacent sides are planned to get right angles. The accuracy of right
angles is checked by try square.
3. Based on the given dimension of the required joint, make the markings on the work pieces
using marking gauge and try square.
4. Using saw and chisel, unwanted portions are removed from the work pieces.
5. Both the pieces are assembled to check proper fitting of the joint. Unfit portions are removed
using chisel.
6. Finished part is checked for dimensional accuracy using steel rule and try square.

RESULT:
Thus a cross half lap joint was successfully made from the given wooden piece.

Note: Other widely used carpentry joints in Civil engineering are dove tail joint, corner joint, half
lap joint, cross lap joint, Mortise and Tenon joint etc.
Plumbing symbols for pipeline and fittings
Ex. No. –
Date –
PLUMBING
AIM – To study about pipeline joints, prepare plumbing line sketches and prepare a basic pipeline
connection with different joining components.
TOOLS REQUIRED: Pipe wrench, pipe vice, die, Teflon tape, measuring tape, hacksaw and
lubricant
JOINING COMPONENTS REQUIRED: Elbow, Tee, valves, coupling, union, reducer and tap
PROCEDURE:
1. Prepare a layout diagram/pipeline sketch for the required piping by listing out the
components required.
2. Based on the measurement, cut the pipe using hack saw.
3. Use the die set to make external threads on the pipes wherever necessary.
4. Wound the Teflon tape on the threads as required and fit the joining components. Ensure
proper fitting of joints to avoid any leaks.
RESULT:
Thus pipeline joints were studied, required line sketch was prepared and a basic pipeline
connection was prepared using various joining components.
Note: The function and location of various pipeline joints should be studied for making proper
pipeline connections at home, industries and high raise buildings. The requirements for preparing
pipe connections for pumps and turbines could also be studied.
Layout/pipeline sketch of the given exercise
 WELDING SYMBOLS

DIFFERENT TYPES OF WELDED JOINTS

GIVEN EXERCISE:
Ex. No. –
Date –
WELDING PRACTICE
AIM – To make a butt joint and lap joint by arc welding on the given work pieces.
TOOLS REQUIRED: AC/DC transformer, earth clamp, electrodes, electrode holder, hand gloves,
goggles, tongs, wire brush, chipping hammer, flat file, try square.
PROCEDURE:
1. Using wire brush the surfaces of the work pieces are cleaned to remove scale, rust and other
impurities.
2. The edges of the work pieces are filed to required dimension and right angles.
3. The ampere and voltage is selected based on the material thickness. Safety wear like goggles
and gloves are worn. The power is switched on.
4. The electrode is clamped on the holder connected to the power supply. When the electrode
is taken near the work piece, an arc is struck. Tack the pieces at the ends.
5. Now the electrode is moved along the line on which joint is required. A continuous seam of
welding is done. Continuity is ensured by uniform speed of travel of the electrode and gap
between work piece and electrode.
6. The procedure is repeated at the other of the work piece.
7. The joint specimen is held using tongs in running water from a tap. Using chipping hammer
the slag deposited on top of the weld bead is removed by gently striking on it and the cleaned
with a wire brush.
RESULT:
Thus the required butt joint and lap joints were made on the given work pieces.
DEVELOPMENT OF A RECTANGULAR TRAY

FABRICATED TRAY
Ex. No. –
Date –
SHEET METAL WORK
AIM – To make a tray and cylinder from given sheet of metal for the required dimensions.
TOOLS REQUIRED: Sheet metal, steel rule, scriber, mallet, anvil, snips, folding bar, riveting
hammer, file.
PROCEDURE:
1. Development of the surfaces of the required cylinder is marked on the sheet metal using steel
rule, protractor and scriber. Provide enough joining allowance in addition to the required
dimensions of the tray. Punch holes according to the dimensions.
2. Remove the unwanted portion of the sheet metal as per the markings and remove the burr
using flat file.
3. Single folding is done at the ends of tray along the marked line.
4. The sheet is then folded at required places according to the markings using bench vice or
folding bars with the help of a mallet.
5. All the sides are bent and the corners are folded and mechanically jointed by application of
force.
6. Rivets are inserted in the holes and closed using riveting hammer.

RESULT:
Thus a tray and cylinder were fabricated from the sheet metal for given dimensions.
GIVEN WORKPIECE

FINISHED JOB
Ex. No. –
Date –
BASIC MACHINING – LATHE OPERATIONS
AIM – To perform simple lathe operations like facing, turning and chamfering using lathe machine
tool.
TOOLS REQUIRED: Lathe, chuck key, single point cutting tool, chamfering tool, work piece,
brush
PROCEDURE:
1. Firmly clamp the work piece in self centering chuck using the chuck key. Ensure firm and
proper gripping of the work piece.
2. Mount the tool on the tool post using key.
3. Switch on the power supply to lathe. Check whether the work piece is rotating without
wobbling. If it wobbles, switch off the machine and grip it properly.
4. Bring the cutting tool closer to the rotating work piece by rotating the hand wheel.
5. Make initial contact at the end of the work piece and move the tool in the direction
perpendicular to the axis of the work piece to perform facing operation. This operation
reduces the length of the work piece.
6. Make initial contact at the end of the work piece and move the tool in the direction parallel
to the axis of the work piece and along the circumference to perform turning operation. This
operation reduces the diameter of the work piece.
7. Once the work piece has been turned and faced to required dimension, engage the
chamfering tool as explained above to perform chamfering at the end of the work piece.
RESULT:
Thus basic operations such as facing, turning and chamfering were performed using lathe
machine tool.
Different types of files used in making a fitting
Ex. No. –
Date –
Basic Machining – Fitting by Grinding

AIM: To grind the sides of the given workpiece at right angles.

Process: Fitting is a process for preparing matching parts that can fit in each other by touching or
sliding. Marking, scribing, punching, sawing, filing and finishing are the various processes involved
in fitting.

TOOLS REQUIRED: Steel rule, try square, scriber, dot punches, hammer, anvil, cutting saw, files
set, power grinder.

PROCEDURE:
 The dimensions of the given work piece is measured using steel rule and the edges of the work
pieces are filed for flatness and right-angles.
 Using scriber, markings are made on the work piece based on the fit required.
 Dots are made on the markings wherever necessary using punch and hammer.
 The unwanted portions are removed by saw cutting, power grinding and filing.
 The fit is finished using soft files by checking manually. The work pieces are then smoothened
and polished.
 Square fitting, Vee fitting, triangular fitting and circular fitting are most widely made fittings.

RESULT:
Thus the sides of the given workpiece are grinded and checked for right angles.
Drilling and Tapping
Ex. No. –
Date –
BASIC MACHINING – DRILLING & TAPPING
AIM – To perform drilling and tapping operations on the given work piece using different machine
tools.
TOOLS REQUIRED: Drilling machine, drill tool, tapping tool, work piece, try square, steel rule,
scriber, ball peen hammer, dot and centre punches, surface plate, and anvil.
PROCEDURE:
1. The edges of the work piece are filed and checked for dimension using steel rule, right angles
using try square and burr free edges using flat file.
2. Wet chalk is applied on one surface of the work piece for marking purposes.
3. Based on the given dimensions, markings are made using scriber.
4. Using dot punch the edges are marked by dots and excess material is removed by filing.
5. Using centre punch, the centre of the holes to be drilled are marked by punching.
6. The work piece is mounted on the table of the drilling machine, which is fitted with the drill
tool of required diameter.
7. Bring the drill tool as close as possible to work piece and align the centres of the drill tool
and hole centre.
8. Initial drilling is done by giving small feed and the proper alignment of centres is ensured.
Required adjustments are made, if necessary. Secondly, required feed is given and the work
piece is firmly drilled.
9. The work piece is removed from the drill table and taken to a surface plate.
10. Using tap wrench, the drilled holes were tapped to required dimensions and finally deburred
using appropriate files for getting smooth edges and ends of the hole.
RESULT:
Thus drilling and tapping operations were performed on the given work piece.
Steps involved in preparing a green sand mould using split pattern
Ex. No. –
Date –
CASTING
AIM: To prepare a mould using given pattern and perform casting

Processes: Mould making, Melting, degassing, pouring, shakeout, degating, surface cleaning and
finishing are various processes carried out in foundry shops.

TOOLS REQUIRED: shovel, sieve, mould box, rammer, trowel, strike off bar, lifter, gate cutter,
runner, riser, sprue pin, vent wire, draw spike and swap.

PROCEDURE:
 Green sand is sieved and tempered with right amount of water and mixed thoroughly. Mould
box, pattern, tools and working table are cleaned.
 The drag is filled with green sand after positioning the lower part of the pattern on the table.
The green sand is rammed carefully and excess sand is struck off.
 The drag is flipped and river sand is sprinkled on top of it. The cope is placed in its position
and the upper part of the pattern is carefully placed.
 Sprue pin and riser pin are positioned correctly. Green sand is filled and rammed. The sprue
and rise pins are removed.
 The pattern is carefully removed from the mould box using draw spike and the mould is
finished carefully.
 Vent wire is used to make vent holes and an opening and gate is made to pour the molten
metal, which was prepared in a furnace.

RESULT:
Thus green sand mould was prepared using the given pattern and casting was performed.
Basic pneumatic circuit
Ex. No. –
Date –
Basic Pneumatic Circuit using Single and Double Acting Cylinder
AIM: To learn about low cost automation using Pneumatic power and study the operation of single
& double acting cylinder.

COMPONENTS REQUIRED:
Compressor, FRL Unit, 3/2 Push button valve, AND Valve, OR Valve, Single and double acting
cylinder, Connecting tubes

PROCEDURE:
1. Design and draw the circuit as per requirement.
2. Select suitable components and assemble them on the profile table top.
3. Connect the components using tubes as per the circuit.
4. Connect the air supply and adjust the pressure value as per the requirements
5. Test the circuit and observe the working.

RESULT:
Thus basics of low cost automation and operation of single and double acting cylinders were studied.
3D printing by FDM process

3D printed Gears
Ex. No. –
Date –
3D Printing of Simple objects
AIM: To learn the basics of 3D printing technique and manufacture simple components using 3D
printer.

PROCESS: Fused Deposition Moulding (FDM) is a filament-based process in which filament made
from various materials (mainly thermoplastic polymer and its composites) is melted, which forms
paste. The paste is deposited line wise to make a layer and subsequently many layers are made to
form a product. FDM requires a filament to be formed.

COMPONENTS REQUIRED:
3D printer with all the accessories.

PROCEDURE:
1. Model the required object.
2. Obtain the codes (.stf file) for feeding in the 3D printer.
3. Ensure the 3D printing machine has all the accessories connected.
4. Execute the programme and complete the printing of required objects.

RESULT:
Thus the basics of 3D printing was studied and a sample object was 3D printed and observed.