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Part III Part IV.

Answer the following questions in Answer the following Questions in
about a page 5 Marks detail. 10 Marks
21. What are the advantages of the good 27. List out the importance to be
plant location? considered in selecting a plant
location?
22. What are the functions of
PPC(Production Planning and 28. What are the factors for increasing
Control)? Productivity?
29. Explain about productivity of men
23. Explain about quality control?
and machine?
24. How many groups are there in
30. Draw a simple organization method
industrial undertakings categorized
and functional organization chart?
by Henry Fayol?
31. Define Lean manufacturing and
25. Write “types of organizations”? explain seven wastes in Lean
26. What are the points should be taken Manufacturing.
into account for “Cost estimation”? 32. Write and Explain the
“Administrative Expenditure”?

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Model Question Paper

12th-Basic Mechanical Engineering-Theory

TIME: 2.30 HOURS MARKS: 90

PART –A
Choose the correct option 15 x 1 = 15

1. The inventor of lathe is

a. Henry maudslay b. Eli whitney
c. James nasmith d. Michael faraday

2. A part used for taper turning

a. Cross – slide b. Compound rest c. Saddle d. Apron

3. The lip clearance angle of a drill is

a. 590 b. 1180 c. 120 to 150 d. 1350

4. The groove in the body of the drill is

a. V-shape groove b. U-shape groove
c. Flute d. Straight shape groove

5. The operation mainly done in a shaping machine is

a. Turning b. Drilling
c. Machining a flat surface d. Thread cutting

6. The part involved in reciprocation by quick return is

a. Table b. Ram c. Saddle d. Crossrail

7. The heat generated during dry grinding process will be

a. 200 c b. 10000 c c. 20000 c d. 12000 c

8. The hardest natural abrasive is

a. Sand stone b. Emery c. Diamond d. Corundum

9. In a milling machine, cutters are mounted on

a. Column b. Spindle c. Overhanging arm d. Arbor

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10. In a milling machine, travelling of work table is controlled by

a. Saddle b. Trip dogs
c. Cross – slide d. Elevating screw

11. Maintenance done once a year is known as

a. Routine maintenance b. Preventive maintenance
c. Breakdown maintenance d. Corrective maintenance

12. Plastic welding is

a. Pressure welding b. Resistance welding
c. Fusion welding d. Arc welding

13. IC refers to
a. Information control b. Instruction control
c. Internal control d. Integrated circuit

14. “The brains of Robot” is

a. Sensor b. Control system
c. Piston d. Gears

15. Father of scientific management is

a. Henry Feyol b. Pierre Vernier
c. F.W. Taylor d. Michel Faraday

PART – B
Answer any ten of the following
Questions in one (or) two lines 10 x 3 = 20

16. Define “swing diameter” in lathe.

17. What is the use of “back gear” in lathe?

18. What are the special features of radial drilling machine?

19. Define “cutting speed” in drilling machine

20. What is the use of “clapper box” in shaping machine?

21. Mention any three types of Bonds used in grinding wheel.

22. What is meant by “milling”?

23. Write diffrent types of Arbor.

24. What are the different types of maintenance?

25. Mention three types of flames in gas welding.

26. What are the functions of input unit?

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27. What are the types of automation based on application?

28. Define cost estimation

PART C
Answer any five of the following Questions for a Page 5 x 5 = 25

29. Mention the differences between turret and capstan lathe.

30. How do you specify the drilling machine?

31. List-out the types of shaping machine.

32. Explain with sketch the “truing of grinding wheel”

33. What are the differences between plain milling machine and universal milling
machine.
34. Explain with sketch of “Greese Lubrication”.

35. Explain any two parts of gas welding with neat sketch

PART D

Answer the following Questions in detail. 2 x 10 = 20

36. Draw the diagram of a Lathe and mention the parts

(or)
Explain the construction of a “Radial” in drilling machine with neat sketch

37. Explain any two types of work holding devices in shaping machine with neat
sketches
(or)
Explain Arc welding with neat sketch.

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Basic Mechanical
Engineering
PRACTICAL

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CONTENTS

Basic Mechanical Engineering

Practical

Ex. No. Title of the exercise Page No Month

1. Hacksaw Cutting 153 JUNE

2. FITTING L-Cutting 156 JUNE

3. V- Cutting 159 JULY

4. Facing & Plain Turning 162 JULY

LATHE
5. Step Turning and Chamfering 166 AUGUST

6. Drilling and Counter Sinking 170 AUGUST

DRILLING
7. Tapping and Dieing 176 SEPTEMBER

8. Lap Joint 182 OCTOBER

9. WELDING Butt Joint 185 NOVEMBER

10. T-Joint 188 DECEMBER

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PRACTICAL 01

HACKSAW CUTTING

OBJECTIVE
To perform the hacksaw cutting on the given M.S plate according to the given design

Operations /exercises covered under the project

Given raw material and Drawing

Read the drawing

Tools required

To file the two adjacent sides into

right angle shape

Marking and Punching

File the required square shape

Hacksaw cutting

Finished job

Material Specification
Mild Steel plate 50mm X 50mm X 6mm

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Tools and equipments required :

Section / SI Name of the tools / Specification Quantity
Activity Tittle No Equipments
1 Bench Vice No.4 1
2 Try square ½ Feet Scale 1
3 Surface Plate 300x300 mm 1
4 Vernier Height Guage 12” 1
Filing 5 Steel rule 12” (One feet) 1
6 Angle Plate Size (1) 125 x 75 x 100 mm 1
7 Flat File (Rough/ 12” 3 Nos
Medium/ Smooth )
8 Vernier Caliper 12” 1
9 Hacksaw Frame 12” 1

Marking & 10 Hacksaw blade 10-12” 1

punching 11 Dot punch Head Weight 8x100 mm 1
12 Scriber 6” 1
13 Hammer Face diameter 15/8” 1
Hacksaw cutting
14 Chalk Length 6” 1

Drawings

(i) Given Material (ii) Marking & Punching

12 12 12
25
48
50

50 6 48

(iii) Finished Job

25
48

All Dimensions are in mm

Scale: Not to Scale
48

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Procedure
„ The design of the given model is studied completely to understand the features like its
size and shape
„ The given raw material is checked for size whether it is sufficient for the design.
„ Hand Tools and measuring instruments are selected suitability to perform the required
Operations.
„ The raw material (mild steel) is held on the bench vice and two adjacent sides are filed
for right angles (900) using a flat files. The two sides are considered prime sides.
„ The remaining two sides are also filed for right angle(900) by using flat file at required
dimension of 48x48 mm2.
„ The work piece is checked for 900 on all four sides with help of a try square
„ A thin layer of chalk is applied on the workpiece and allowed to dry.
„ Given dimension of the Hacksaw Cutting are marked with help of Vernier height
gauge carefully.
„ Using dot punch , dots are punched along the above marked lines by using hammer.
„ Punch marks are made by keeping the dot punch inclined at 600 and they are filed off
later. The spacing between the adjacent punch marks should be at least 6 mm.
„ Hacksaw cut are made on the workpiece at marked locations at a medium speed .

Conclusion:
Hacksaw Cutting is made as per the required dimensions .

Simple Assessment :
1. The vice with ‘ V ‘ shaped jaw is …………………………………….
2. The punch used for making holes on sheet materials like leather, rubber and soft
materials is …………
3. The angle of scriber is ………………….
4. Grade of a file with 20-25 teeth per inch ………………..
5. The least count of a vernier caliper ………………………..

Answer
1. Pipe vice   2) Hollow punch   3) 120  4) Flat file  5) 0.02mm

Video Suggestions:
S.No Tittle Link
1 Hacksaw https://youtu.be/8G9sc2mKoig

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PRACTICAL 02

L- CUTTING

OBJECTIVE
To perform the L cutting on the given M.S plate according to the given design

Operations /exercises covered under the project

Given raw material and Drawing

Read the drawing

Tools required

To file the two adjacent sides into

right angle shape

Marking and Punching

File the required square shape

Hacksaw cutting

Finished job

Material Specification
Mild Steel plate 50mm X 50mm X 6mm

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Tools and equipments required :

Section / Activity S. Name of the tools /
Tittle No Equipments Specification Quantity
1 Bench Vice No.4 1
2 Try square ½’ Feet Scale 1
Filing
3 Surface Plate 300x300 mm 1
4 Vernier Height gauge 12” 1
5 Steel rule 12” One feet 1
6 Angle Plate Size (1) 125 x 75 x 100 mm 1
7 Flat File ( Rough/ 12” 3 Nos
Medium / Smooth )

8 Vernier Caliper 12” 1

9 Dot punch Head Weight 8x100 mm 1

Marking and 10 Scriber 150 mm 1

Punching 11 Hammer Face diameter 15/8 inch 1
12 Chalk Length 150mm 1
13 Hacksaw Frame 12”(300 mm) 1
L-cutting 14 Hacksaw blade 10-12” 1
15 Triangular file 12” 1

Drawings

(i) Given Material (ii) Marking & Punching (iii) Finished Job
16 16
50

48

48
32

32

50 6 48 48

All Dimensions are in mm

Scale: Not to Scale

Procedure
„ The design of the given model is studied completely to understand the features like its
size and shape
„ The given raw materials is checked for sizes whether it is sufficient for the design.

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„ Hand Tools and measuring instruments are selected suitabily to perform the required
Operations.
„ The raw material (Mild Steel) is held in the bench vice and two adjacent sides are filed
for right angles (900) using a flat files. The two sides are considered prime sides.
„ The remaining two sides are also filed for right angle(900) by using flat file at required
dimension of 48x48 mm2.
„ The work piece is checked for 900 on all four sides with help of a try square
„ A thin layer of chalk is applied on the workpiece and allowed to dry.
„ Given dimension of the ’L’ Cutting are marked with help of Vernier height gauge
carefully.
„ Using dot punch , dots are punched along the above marked lines by using hammer.
„ Punch marks are made by keeping the dot punch inclined at 600 and they are filed off
later. The spacing between the adjacent punch marks should be at least 6 mm.
„ ‘L’ cut are made on the workpiece at marked locations at a medium speed .
„ The rough surface resulting from hacksaw cutting is filed for required dimensions for
right angles(90°) with the help of flat files. (Rough, Medium and smooth)
„ Drawing the filing operation, half of the punch mark is retained on the work piece.
„ The sharp corner of the ‘L’ shape is filed with the help of triangular file.
„ While filing, the edge surface of the work piece are checked frequently for perpendicular
and parallelism with the help of a try square.

Conclusion:
‘L’ Cutting is made as per the required dimensions.

Simple Assessment:
Questions and answer
1. Name the file used of general filing works …………………………
2. The point angle of centre punch is …………
3. The point angle of Scriber is ………………….
4. The jaw-plates of a bench vice are made of ………………..
5. The scriber is made of ………………………..

Answer
1) Flat file   2) 900  3) 120 to 150   4) Tool steel    5) High carbon steel

Video suggestions:
Tittle Link
L Cutting https://youtu.be/KgQyuCrOKoU

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PRACTICAL 03

V- CUTTING

OBJECTIVE
To perform the ‘V’ cutting on the given M.S plate according to the given design

Operations /exercises covered under the project

Given raw material and Drawing

Read the drawing

Tools required

To file the two adjacent sides into

right angle shape

Marking and Punching

File the required square shape

Hacksaw cutting

Finished job

Material Specification
Mild Steel plate 50mm X 50mm X 6mm

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Tools and equipments required:

Section / SI Name of the tools /
Specification Quantity
Activity Tittle No Equipments
Filing 1 Bench Vice No.4 1
2 Try square ½’ Feet Scale 1
3 Surface Plate 300x300 mm 1
4 Vernier Height 12” 1
Gauge
5 Steel rule 12” One feet 1
6 Angle Plate Size (1) 125 x 75 x 100 1
L xB xH
7 Flat File ( Rough/ 12” 3 Nos
Medium / Smooth )

8 Vernier Caliper 12” 1

Marking and 9 Chalk Length 150mm 1
Punching 10 Scriber 150 mm 1
11 Dot punch Head Weight 8x100 mm 1
12 Hammer Face diameter 15/8 inch 1
V- cutting 13 Hacksaw Frame 12”(300 mm) 1
14 Hacksaw blade 10-12” 1
15 Triangular file 12” 1

Drawings
(i) Given Material (ii) Marking & Punching (iii) Finished Job
12 12 12 12
15

48
50

50 6 48 48

All Dimensions are in mm

Scale: Not to Scale

Procedure
„ The design of the given model is studied completely to understand the features like its
size and shape
„ The given raw materials is checked for sizes whether it is sufficient for the design.

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„ Hand Tools and measuring instruments are selected suitability to perform the required
Operations.
„ The raw material (mild steel) is held in the bench vice and two adjacent sides are filed
for right angles (900) using a flat files. The two sides are considered prime sides.
„ The remaining two sides are also filed for right angle (900) by using flat file according
to required dimension of 48x48 mm2.
„ The work piece is checked for 900 on all four sides with help of a try square
„ A thin layer of chalk is applied on the workpiece and allowed to dry.
„ Given dimension of the ’V’ Cutting are marked with help of Vernier height gauge
carefully.
„ Using dot punch, dots are punched along the above marked lines by using hammer.
„ Punch marks are made by keeping the dot punch inclined at 600 and they are filed off
later. The spacing between the adjusant punch marks should be at least 6 mm.
„ ‘V’cut are made on the workpiece at marked locations at a medium speed
„ The rough surface resulting from hacksaw cutting is filed for required dimensions for
right angles(90°) with the help of flat files. (Rough, Medium and smooth)
„ When filing, care is taken that half of the punch mark is retained on the work piece.
„ The sharp corner of the ‘V’ shape is filed with the help of triangular file.
„ While filing, the edge surface of the work piece are checked frequently for perpendicular
and parallelism with the help of a try square.

Conclusion:
‘V’ Cutting is made as per the required dimensions.

Video Suggestions:
Tittle Link
V Cutting https://youtu.be/hhOIRbEd9D8

Simple Assessment:
Questions and answer
1. Steel rule is a ……………… measuring tool.
2. The caliper used for measuring the width of a slot is …………
3. Surface plate is made up of ………………….
4. Micrometer works on the principles of ………………..
5. Try square is used to check up an angle of………………………..

Answer
1) Direct 2) Inside caliper 3) Cast iron 4) Nut &Bolt 5) 900

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PRACTICAL 04

FACING & PLAIN TURNING

OBJECTIVE
To machine a flat surface on the face of the given round rod (Facing) and to perform
plain turning operation to produce a cylindrical part of given dimensions by using a
lathe.

OPERATIONS/EXERCISES COVERED UNDER THE PROJECT

Read the given drawing

Selection of Job

Holding the Job

Selection of tools

Tool setting

Facing operation

Marking

plain turning operation

Finished Job

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TOOLS AND EQUIPMENT REQUIRED

Section/Activity Name of the tools/
S.No Specification Quantity
title equipment
Selectionn of 1 Facing tool 10mm-12mm 1No.
cutting tools 2 Plain turning tool 10mm-12mm 1No.
Setting tools 3 Surface gauge Based on usage 1No.
4 Chuck key Based on chuck 1No.
5 Tool holder Based on lathe 1No.
Measuring Tools 6 Steel rule 300mm 1No.
7 Inside caliper 150mm 1No.
8 Outside caliper 150mm 1No.
9 Vernier caliper 150mm 1No.
Finishing tool 10 Smooth file 300mm 1No.

Drawings:
(i) Given Material
∅20

80

(ii) Facing
∅20

78

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(iii) Plain Turning

78

30
∅18

All Dimensions are in mm

Scale: Not to Scale

Tool setting
A facing tool and a plain turning are mounted on the toolpost and their cutting edges
are set exactly aligned to the axis of the lathe spindle. The compound rest is set at 00
mark.

Holding of the work

The metal piece to be machined is held in the chuck of the lathe. Surface gauge is used
to check whether the work is held aligning with the lathe axis.

Facing operation
The facing tool is mounted on the toolpost. The lathe is switched on the feed is given
by the cross -slide perpendicular to the lathe axis. A flat surface on the face of the
workpiece is generated.

Marking
Marking is done on the workpiece as per the given diagram.

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Procedure
„ The plain turning tool mounted on the tool post. The cross-slide is adjusted for
required depth of cut and the lathe is switched on. The feed is given by to move the
carriage parallel to the required lathe axis.
„ The above process is repeated until the required diameter is obtained. This is done by
gradually moving the cross-slide after each cut.
„ During the process, the diameter of the work is checked with the help of outside
caliper.
„ Finishing tool is used to obtain accurate dimensions of length and diameter.

Conclusion
The finished piece of work is sent for inspection after the machining is over.

Assessment
1. Four way tool post is known as ----------------
2. For facing operation the tool moves --------------------to the axis of the lathe
3. For straight turning the tool moves -------------------- to the axis of the lathe
4. ------------ is used for centring the cylindrical work piece in a lathe chuck.
5. ----------- is used to obtain accurate dimensions of length and diameter.

Answer
1) Turret tool post.   2) perpendicular   3) parallel  
4) Surface gauge   5) Finishing tool

Video Suggestion
Tittle Link
Facing and plain turing https://youtu.be/LeTjT8WGI-w

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PRACTICAL 05

STEP TURNING AND CHAMFERING

OBJECTIVE
To perform step turning and chamfering operations to produce a cylindrical part of
given dimensions.

OPERATIONS/EXERCISES COVERED UNDER THE PROJECT

Read the given drawing

Selection of Job

Holding the Job

Selection of tools

Tool setting

Facing operation

Marking

plain turning operation

Chamfering

Finished Job

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TOOLS AND EQUIPMENT REQUIRED

Section/Activity Name of the tools/
S.No Specification Quantity
title equipment
Selectionn of 1 Facing tool 10mm-12mm 1No.
cutting tools
2 Plain turning tool 10mm-12mm 1No.
Setting tools 3 Surface gauge Based on usage 1No.
4 Chuck key Based on chuck 1No.
5 Tool holder Based on lathe 1No.
Measuring Tools 6 Steel rule 300mm 1No.
7 Inside caliper 150mm 1No.
8 Outside caliper 150mm 1No.
9 Vernier caliper 150mm 1No.
Finishing tool 10 Smooth file 300mm 1No.

Drawings :
Given Dimensions

Æ20 Æ18 Æ16

3x45°
15

30

Given Material

∅20

50

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Step I

30

∅18

Step II
15 15

∅16

Step III

Tool setting
A facing tool and a plain turning are mounted on the toolpost and their cutting edges
are set exactly aligned to the axis of the lathe spindle. The compound rest is set at 0°
mark.
Holding of the work
The metal piece to be machined is held in the chuck of the lathe. Surface gauge is used
to check whether the work is held aligning with the lathe axis.

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Facing operation
The facing tool is mounted on the toolpost. The lathe is switched on the feed is given
by the cross -slide perpendicular to the lathe axis. A flat surface on the face of the
workpiece is generated.

Marking
Marking is done on the workpiece as per the given diagram.

Procedure
„ The plain turning tool mounted on the tool post. The cross-slide is adjusted for
required depth of cut and the lathe is switched on. The feed is given by to move the
carriage parallel to the required lathe axis.
„ The above process is repeated until the given larger diameter is obtained. The length
should be equal to the sum of the lengths of larger and smaller diameter.
„ When the larger step of given diameter is obtained, the tool is again fed parallel to the
lathe axis to the given length of smaller step. Depth of cut is gradually given by the
cross-slide to get the smaller step of required length and diameter.
„ During this process, the dimensions of the work are checked with the help of outside
caliper and inside calipers.
„ Finishing tool is used to obtain accurate dimensions of length and diameter.

Chamfering
The chamfering tool (form tool) is set at the work at the required angle. Feed is given
to the tool by operating the cross-slide to perform chamfering.

Conclusion
The finished piece of work is sent for inspection after the machining is over.

Assessment
1. --------is the dimension of chamfering in the given drawing
2. Carriage moves ----------------to the lathe axis
3. ----------------- tool is used for chamfering
4. For straight or plain turning compound rest is set at --------degree
5. Depth of cut is given by operating the----------------

Answer
1) 3×45° 2) parallel 3) Form tool 4) 0° 5) cross slide

Video suggestion
Tittle Link
Facing and plain turing https://youtu.be/LeTjT8WGI-w

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PRACTICAL 06

DRILLING AND COUNTER SINKING

Objective:
To drill hole and make counter – sinking by using the counter – sink drill bit given
workpiece

Operations Covered under the Practical

Preparation

Filing Operation

Marking Process

Punching

Drilling

Counter – Sinking

Finishing

Given Material Specification:

Name of the Material Dimension
Mild Steel plate 50mm X 50mm X 6mm
or
50mm X 50mm X 8mm

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Tools and Materials Required:

Section / S. Name of the tools/
Specification Quantity
Activity Title No Equipment’s
Preparation 1. Steel Rule One feet 1
2. Try – Square ½ Feet Scale 1
3. Flat file - (Rough) 12 Inch 1
4. Flat file - (Smooth) 12 Inch 1
5. Bench vise No. 4 1
6. Jenny calliper 6” 1
Marking and 7. Ball – Peen Hammer Face diameter 15/8 Inch Head 1
Punching wt: 32 oz

8. Centre punch 8X100mm Point angle 60o 1

9. Scriber Point angle 12o (or) 15 o Length 1

150 mm

10. Coloured chalk blue colour 2

Drilling 11. Sensitive drilling Machine Bench type 1

12. Drill Chuck and key Tapered Mount type, size: 13mm 1

13. Drill bits dia 6 mm, dia 8mm, dia 10mm 1

14. Drift key Reduced shank type size 2.4 mm 1

Counter 15. Counter – sink drill bit 60o or 82o (or) 90o 1
sinking (engagement angle)

Finishing 16. Gauges (for checking Di-angle gauge 1

counter – sink process)

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VI. Figures
1. Given Material 2. Filing two adjacent sides at 90o

3. Marking and punching 4. Finished Job

All Dimensions are in mm

Scale: NTS

3D Drawings
Drilling

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Counter sinking

Finished Job

All Dimensions are in mm

Scale: Not to Scale

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Procedure
1. Preparation
a. Check the initial dimensions of the given work piece using a steel ruler
B. Fix the job on a bench vise and file the two adjacent sides using a flat file (rough
and smooth) to form right angle. Again, file remaining two sides at right angle.
c. C
 heck for the perpendicularity with try – square

Marking and punching:

a. Apply chalk on the worksurface.
b. Measure 8 mm and 10 mm using a jenny calliper from the steel rule
c. Transfer the measured dimensions to the workpiece with an edge 16mm
d. Draw lines along the dimensions on the work piece with scriber
e. Make dots inner centre point using centre punch

Drilling:
a. Place the work piece on the drilling machine platform or vise.
b. U
 sing a drilling machine, selected drill bits fitted into the drill spindle and make
two holes on the dotted place made by centre punch
c. P
 our some oil for smooth drill and drill the work piece properly by adjusting
the pilot.
d. R
 epeat the steps twice for better finishing.

Counter – sinking.
a. R
 emove the drill bit and fix the selected counter – sink tool (60o or 82o) in the
drill chuck and fit into the spindle
b. T
 he feed is given to the spindle and fed to the work piece with a speed of 25%
less than drilling process
c. T
 he counter – sink tool form a conical surface on the top of the hole

Finishing:
a. F
 inally, the conical surface is checked with di-angle gauge and check the taper
angle.

Conclusion:
The required hole and counter – sink on the hole with proper measurements have been
obtained using drilling and counter – sinking techniques

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Applications:
i) Fitting industries
ii) Fasteners industries
iii) Automobile industries

Simple Assessments:
1. The groove formed in a drill bit is called _______________

2. Drills are made of _______________

3. Drill chuck is used to hold _____________ drills

4. Mention any two types of drilling machines.

5. Which Machine is used to drill holes and form internal threads in a work piece.

Answer:
1. Flute 4. P
 ortable drilling machine, Sensitive
2. High Speed steel drilling machine

3. Straight shank 5. Radial drilling machine

Video Suggestions
S.No Title / Purpose Link
1. Drilling process https://en.m.wikipedia.org
https://youtu.be/k964-Ci_Qxs
2. Drill bit types https://civiconcepts.com
3. Counter sinking operation https://engineering.myindialist.com
https://youtu.be/WXqJ-0oXt2k
4. Counter sink drill specifications https://www.globalspec.com

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PRACTICAL 07

TAPPING AND DIEING

OBJECTIVE
To make Internal threads on the given mild steel plate and make External threads on
the given cylindrical mild steel round rod.

Operations covered under the practical process:

Preparation

Filing Operation

Marking and Punching process

Drilling

Tapping

Dieing

Finishing

Given Material Specification:

Name of the Material Dimension
Mind Steel Plate 50 mm x 50 mm x 8 mm
Mind steel round rod Dia 8 mm x 50 mm Length

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Tools and Equipment’s Required

Section/ S. Name of the tools/
Specification Quality
Activity Title No Equipment’s
Preparation 1. Bench wise 4” Size, Jaw width 100 mm 1
2. Steel rule Length 300 mm 1
3. Try – square 70x50x8.5 mm 1
4. Flat file (Rough) 12” Length Double cut file 1
5. Flat file (Smooth) 12” Length Double cut file 1
Marking and 6. Colour chalk 8x10 mm Persian blue 2
punching 7. Jenny calliper 6” stainless-steel 1
8. Scriber tip diameter 4 mm 1
length = 150 mm

9. Ball - Peen Hammer Head Weight = 32oz 1

Face dia 15/8”
10. Centre punch Dia 8mm x 100 mm length 1
Drilling 11. Sensitive drilling Bench type max Drill size 15mm 1
machine

12. Drill chuck and key Tapered mount type size = 13 1

13. Drill bits mm
1
14. Drift Key Dia 6mm, Ø8.5mm
1
Reduced shank type.
Size 2 to 4 mm
Tapping process 15. Tap set 10 mm x 1.5 mm 1
16. Tap wrench size – 2 Length 280 mm 1
Adjustable
Dieing 17. Die set ½” – HSS set 1
operation
Finishing 18. Thread pitch gauge Length x width x height = 9.7 x 1 set
2.5x2 cm

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Tapping Process
i) Given Material ii) Filing two adjacent sides at 90o

iii) Marking and punching and tapping iv) D

 rilling and Tapping process
(Finished product)

and tapping

All Dimensions are in mm

Scale: NTS

Dieing Process

All Dimensions are in mm

Scale: Not to Scale

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3D Drawings
Tapping

Dieing

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Calculation for Tapping and e. M

 ake dots inter centre point using
dieing: centre punch.
Tap Drill size ‘D’ = Tap size – pitch size 3. Drilling:
(or) = T- 2d [T- Diameter of the TAP d a. P
 lace the workpiece on the drilling
– depth of thread] machine vise (or) platform
For practical purpose: Tap drill size D = b. U
 sing a drilling machine, selected
0.8 T [T is the diameter of the tap] drill bits fitted into the drill
Example: D = 10 – 1.5 = 8.5 mm spindle (or) drill chuck and make
(or) holes on the dotted place made
by centre punch
Drill size = 0.8 x 10 = 8 mm
c. P
 our some oil for smooth drill
and drill the work piece properly
Die set: by adjusting the pilot
½” Die set used for making thread 10 –
d. R
 epeat the steps twice for better
15 mm diameter of the cylindrical rods
finishing.
(or) pipes.
4. Tapping Process:
Procedure for tapping a. F
 ix the work piece in the bench
operation: vise in such way that it should not
1. Preparation
move
a. C
 heck the initial dimensions of b. If necessary, add chamber to the
the given work piece using a steel hole before tapping
ruler c. P
 eck tap using the tap when First
b. F
 ix the job on a bench vise and tap is placed on the hole at 90o.
file the two adjacent sides using Then apply gentle pressure while
flat file (Rough and smooth) turning the wrench a complete
to form right angle. Again, file turn in then a half turn out. Peck
the remaining two sides at right tap to the desired depth and pour
angle. the coolant oil.
c. C
 heck for perpendicularity with d. R
 epeat the procedure. Then take
try square. the tapping tool second and third
and use it carefully by rotating
2. Marking and punching:
clockwise and anti clockwise.
a. A
 pply chalk on the work piece.
b. M
 easure 8 mm and 8.5 mm using Procedure for dieing
a jenny calliper from the steel rule process:
c. T
 ransfer the measured dimensions a. W
 ear personal protective equipment
to the work piece with an edge of [ex: eye wear, Leather gloves]
16 mm b. F
 ind the diameter of the rod. The rod
d. D
 raw lines along the dimensions diameter should be roughly the same
on the work piece with scriber. for the entire length.

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c. F
 ind the thread court the corresponds Applications:
to rod diameter. i. Fitting Industries
d. S elect die from the kit that corresponds ii. Fasteners Industries
to the initial diameter of the rod.
iii Automobile industries
e. A
 ssess the rod to ensure the end is
suitable for threads.
Simple Assessments:
f. C
 reate a chamber on the end of the rod 1. The tool used for cutting internal
that will receive threads. thread is _______________
g. S ecure the rod in a bench vice with 2. The tool used for cutting external
the end that will have threads pointing thread is ______________
towards the ceiling. 3. The formula used for calculating
h. I nsert the die into the stock Tap drill size is _______
i. S et die stock on the end of rod and 4. The two types of shank of the drill
twist in direction of the desired threads bits are _______
to start threading the die into the rod. 5. Taps and dies are made off
j. E
 nsure the die is perpendicular to the __________ material
rod and force is applied downward
while rotating the die Answer.
k. T
 urn stock in direction to desired 1) Tap
thread. 2) Die
l. T
 urn stock and full turn, then back of 3) D = T- 2d
Half turn to break off chips.
4) S traight Shank drill bit, taper shank
m. R
 emove the die once desired thread drill bit
length is achieved down the rod.
5) High speed steel
n. W
 ipe the threads and die using a cloth
and test newly created threads by Video suggestions
trying a nut that matches the thread.
Tittle Link
Finishing: Tapping https://youtu.be/vmSLjwuiXac
Using 10 mm screw (or) bolt and nut Dieing https://youtu.be/SpN7N_
check the accuracy of the tapping and yZRU4
dieing operation

Conclusion:
The required hole, tapping and dieing on
the hole with proper measurements have
been obtained using drilling, tapping and
dieing techniques.

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PRACTICAL 08

LAP JOINT

OBJECTIVE
To make Lap-joint using the two given same metal workpieces in arc welding

OPERATIONS/EXERCISES COVERED UNDER THE PROJECT

Checking

Edge preparation

Wearing safety equipments

Workpiece positioning

Electrode positioning

Welding

Finishing

Material Required
Mild Steel Plate 100 x 60 x 8 mm – 02 Nos

Tools and Equipment required

Section/ Name of the tools/
S.No Specification Quantity
Activity Title Equipment
1 AC Transformer Input supply 220v 1
Current 43.5 amp
Lap welding 2 Electrode holder Open type 1
3 Electrode Dia 6 to 12 mm 1
Length 450mm

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4 Hand shield 83X108 mm 1

5 Goggles L X W X H : 11x9x4 cm 1
6 Apron L X W X T : 900x600x3 mm 1
Safety
7 Gloves Length 11-15 inches 1 pair
Width @ opening 5 ½ - 6 ½
inches
8 Chipping hammer Weight 8.5 kg handle type 1
9 Wire brush L X W X H : 290x30x15 1
Finishing
10 Flat file Length 12 inch double cut rough 1
file

Drawings
GivenMaterial size (Two pieces)
100

60 8

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Finished Job
60

0
10
All Dimensions are in mm
60 Scale: Not to Scale

Procedure Conclusion
1. The given workpieces are thoroughly Thus the required “Lap-Joint” is made by
cleaned and the edges are filed Arc welding process.
2. The electrode is held in an electrode
holder and ground clamp is clamped Simple Assesment
to the welding plates and the power 1. The pressure of oxygen in
is supplied. the cylinder of gas welding
3. The workpieces are positioned on is………………………………….
the table to form a “Lap-Joint” 2. The pressure of acetylene in
4. The tag weld is done on the both the cylinder of gas welding
ends of joining plates to avoid the is………………………………….
movement of workpieces during 3. The working pressure of
welding oxygen in gas welding
5. The welding is carried throughout is………………………………
the length of the workpieces on 4. The working pressure of
both sides by maintaining 3 mm gap acetylene in gas welding
between plates and the welding rod is……………………………………
6. The welded joint portions are
allowed for air cooling after the slag Answers
is removed 1) 125 kg/cm 2  2) 16kg/cm 2  3)
7. The welded joint portions are cleared 1kg/cm2   4) 0.15 kg/ cm2
by wire brush

Video suggestions:
S.No Tittle Link
1 Lap joint https://youtu.be/6A35U8zW0Pg

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PRACTICAL 09

BUTT-JOINT

OBJECTIVE
To make Butt-joint using the two given same metal workpieces in arc welding

OPERATIONS/EXERCISES COVERED UNDER THE PROJECT

Checking

Edge preparation

Wearing safety equipments

Workpiece positioning

Electrode positioning

Welding

Finishing

Material Required
Mild Steel Plate 80 x 40 x 8 mm – 02 Nos

Tools and Equipment required

Section/ Name of the tools/
S.No Specification Quantity
Activity Title Equipment
Butt welding 1 AC Transformer Input supply 220v Current 1
43.5 amp
2 Electrode holder Open type 1
3 Electrode Dia 6 to 12 mm 1
Length 450mm

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Safety 4 Hand shield 83X108 mm 1

5 Goggles L X W X H : 11x9x4 cm 1
6 Apron L X W X T : 900x600x3 1
mm
7 Gloves Length 11-15 inches 1 pair
Width @ opening 5 ½ - 6 ½
inches
Finishing 8 Chipping hammer Weight 8.5 kg handle type 1
9 Wire brush L X W X H : 290x30x15 1
10 Flat file Length 12 inch double cut 1
rough file

Drawings
GivenMaterial size (Two pieces)
80

40 6

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