VELAMMAL COLLEGE OF ENGINEERING & TECHNOLOGY

(AUTONOMOUS)
VIRAGANOOR, MADURAI – 625 009.

21EM101 - ENGINEERING PRACTICES LABORATORY

(Civil Engineering Practice, Mechanical Engineering Practice)
(Common to all I year B.E., /B.Tech. Degree courses)
VELAMMAL COLLEGE OF ENGINEERING & TECHNOLOGY
(AUTONOMOUS)
VIRAGANOOR, MADURAI – 625 009

21EM101 – ENGINEERING PRACTICES LABORATORY

Group A (Civil Engineering Practice, Mechanical Engineering Practice)

“Listen to advice and accept instruction, and in theend

you will be wise.”

NAME :

CLASS :

ROLL NO. :

REG. NO. :
VELAMMAL COLLEGE OF ENGINEERING &TECHNOLOGY
(AUTONOMOUS)
VIRAGANOOR, MADURAI 625 009

VCET
21EM101 -ENGINEERING PRACTICES LABORATORY
(Civil Engineering Practice, Mechanical Engineering Practice)
(Common to all I year B.E., /B.Tech. Degree courses)

Course In charge Course Coordinator Module Coordinator

HoD/MECH
 BONAFIDE CERTIFICATE

This is to certify that the bonafide record of the practical work done by
Mr./Miss………………………………………………………………Reg.No..............................................
of……………………semester B.E., /B. Tech………………………………………….………..degree
course for 21EM101 – Engineering Practices Laboratory in Velammal College
of Engineering & Technology, Madurai, during the academic Year 20…… – 20……

Faculty In charge Head of the Department

Submitted for the End Semester Practical Examinations held on....................................

at Velammal College of Engineering & Technology, Madurai.

Internal Examiner External Examiner

 ENGINEERING PRACTICES LABORATORY L T P C
21EM101
(Common to all B.E / B.Tech. Programmes) 0 0 4 2
COURSE OBJECTIVES:
 To draw 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.
 To demonstrate the basic switch board wiring, fluorescent lamp wiring and stair case wiring using
various electrical components.
 To choose various joints in steel plates using arc welding work and machining various simple
processes like turning, drilling, tapping in parts
 To build a tray out of metal sheet using sheet metal work.
 To develop electronic circuit and testing for soldering and de soldering using PCB board.

LIST OF EXPERIMENTS:
GROUP – A (CIVIL & ELECTRICAL)
PART – I
CIVIL ENGINEERING PRACTICES
PLUMBING WORK:
 Connecting various basic pipe fittings like valves, taps, coupling, unions, reducers,
elbows and other components which are commonly used in household.
 Preparing plumbing line sketches.
 Laying pipe connection to the suction side of a pump
 Laying pipe connection to the delivery side of a pump.
 Connecting pipes of different materials: Metal, plastic and flexible pipes used in household
appliances.
WOOD WORK:
 Sawing,
 Planning and Making joints like T-Joint, Cross lap and Dovetail joint.
PART – II
ELECTRICAL ENGINEERING PRACTICES
 Introduction to switches, fuses, indicators and lamps - Basic switch board wiring with lamp,
fan and three pin socket
 Staircase wiring
 Fluorescent Lamp wiring with introduction to CFL and LED types.
 Energy meter wiring and related calculations/ calibration
 Study of Iron Box wiring and assembly
 Study of Fan Regulator (Resistor type and Electronic type using Diac/Triac/quadrac)
 Measurement of resistance to earth of an electrical equipment.

GROUP – B (MECHANICAL & ELECTRONICS)

PART III
MECHANICAL ENGINEERING PRACTICES
WELDING WORK:
 Welding of Butt Joints, Lap Joints, and Tee Joints using arc welding.
 Practicing gas welding.
BASIC MACHINING WORK:
 Usage of Spanners and screw drivers
 Facing and Turning.
 Taper Turning
ASSEMBLY WORK:
 Assembling a centrifugal pump.
 Assembling a household mixer.
 Assembling an air conditioner.
SHEET METAL WORK:
 Making of a square tray
FOUNDRY WORK:
 Demonstrating basic foundry operations.
PART IV
ELECTRONIC ENGINEERING PRACTICES
SOLDERING WORK:
 Soldering simple electronic circuits and checking continuity.
ELECTRONIC ASSEMBLY AND TESTING WORK:
 Assembling and testing electronic components on a small PCB.
ELECTRONIC EQUIPMENT STUDY:
 Study elements of smart phone.
 Assembly and dismantle of computer / laptop
TOTAL: 60 PERIODS
 CO-PO-PSO MAPPING

Academic Year : 20 ____ - 20 _____ (ODD / EVEN)

Batch : 20 ____ - 20 _____

Year/ Semester : I/II

Course Code / Name : 21EM101/ENGINEERING PRACTICES LABORATORY

Course Outcomes:

Students will be able to

CO 1 - Build various plumbing joints. K3

CO 2 - Develop various carpentry joints. K3

CO 3 - Construct various wiring electrical joints in common household electrical wire work. K3

CO 4 - Construct various welded joints, sheet metal and basic machining operations K3

CO 5 - Develop the electronic circuit for soldering and testing using PCB board. K3

CO - PO - PSO Mapping

PO PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11 PO 12 PSO1 PSO2
CO
K-
K3 K4 K5 K5 K6 K2 K2 K2 K2 K2 K2 K2 K3 K4
level
CO1 K3 3 2 2 2 2 2 2 2 3 2 2 2 3 2

CO2 K3 3 2 2 2 2 2 2 2 3 2 2 2 3 2

CO3 K3 3 2 2 2 2 2 2 2 3 2 2 2 3 2

CO4 K3 3 2 2 2 2 2 2 2 3 2 2 2 3 2

CO5 K3 3 2 2 2 2 2 2 2 3 2 2 2 3 2

3 Strong Contribution
2 Moderate Contribution
1 Weak Contribution
 TABLE OF CONTENTS

Page Staff’s
S. No. Date Name of the Experiment Remarks
No. Signature

CARPENTRY

1 Study of Carpentry

2 T – Lap Joint

3 Cross Lap Joint

4 Dovetail Joint

PLUMBING

5 Study of Plumbing

6 T-Joint in PVC Pipes

7 Basic Pipe connections using Fittings

WELDING

8 Study of Welding

9 Lap Joint

10 Butt Joint

11 Tee Fillet Joint

 Page Staff’s
S. No. Date Name of the Experiment Remarks
No. Signature

SHEET METAL WORK

12 Study of Sheet metal work

13 Fabrication of Rectangular tray

BASIC MACHINING

14 Study of basic machining

15 Facing and Turning

16 Step Turning

STUDY EXPERIMENTS

17 Study of air conditioner

18
Study of centrifugal pump

CONTENT BEYOND SYLLABUS (CBS)

19 Introduction Special Machines – Milling

COURSE IN CHARGE
EX. NO: DATE:

STUDY OF CARPENTRY
Aim:
To study the basics of carpentry and carpentry tools.

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

Types of wood:
Wood is generally classified in to three types.

1. Soft Wood:
It has straight fibers and is comparatively weaker. It is easy to work on soft wood. Weight and durability
are less for soft wood. Compared to hard wood, the soft wood catches fire soon.
Example: Deodar, Kail, Silver wood
2. Hard Wood:
Hard wood has closed structure, heavy, dark in color, more durable, it is difficult to work onhard wood.
It has proper bonds inside. So, it is very strong.
Example: Teak, Shirham, Sal, Mango, Maple, Oak
3. Ply wood:
Plywood consists of three layers namely Top face ply’s layer, Core layer and Bottom face ply’s layer. The
top and bottom layers are called face ply’s layers. These two layers are bonded to the center core, which is thick and
not of good quality.
Carpentry tools:
Large numbers of tools are used in carpentry. Having a thorough knowledge of tools will help in
producing accurate wood works. Following are the types of tools in Carpentry.
i. Making and measuring tools

ii. Cutting tools

iii. Planning tools

iv. Boring tools

v. Striking tools

vi. Holding tools

Marking and measuring tools:

1. Calipers and compasses:
Calipers are used for precision measurement of curved surfaces. Inside caliper is to measure hole diameters
and outside caliper is used to measure outside diameters of rods etc.

2. Steel Rule:

Steel rule is the important tool for linear measurement. Steel rule can also be used as marking tools.
3. Divider:

Divider has both points sharpened as needle points for dividing the centers

Types of saw:

1. Rip saw:
Rip saw is the largest and coarsest and coarsest of all saws. The length of the blade is between 650 -710mm
and number of teeth per 25mm is either 4or 5. Teeth are sharpened such that it will from a square cutting effect. It
is like that of large number of chisels passing through the surface of the wood and is suitable for sawing down the
grain.

2. Cross Cut Saw:

Cross cut saws are for cutting across the grain in thick wood. These are 600to 650 mm long and have 8 to
10 teeth per 25mm.

3. Back Saw:
Back saw is used for cross cutting when a fine finish is required. Then this blade is reinforced with a steel
back. Back saw is 250 to 400mm in length and has 13 teeth per 25mm
4. Compass saw:
Compass saw is used for sawing small curves in confined spaces and has a narrow tapering blade about 250
to 400mm long. The blade is fitted with an open type wooden handle.

Types of chisels:
Chisels are the tools produced from forged steel (or) tool steel blades.

1. Firmer Chisel:
Firmer chisel is the most used chisel. It is used for light and heavy work.

2. Parts of a chisel:
The parts of a firmer chisel are,
a. Tang - Tang is the portion used to locate the chisel in handle.
b. Handle - Handle is the portion made up of wood and facilitates holding.
c. Ferrule - Ferrule prevents splitting of handle.
d. Cutting edge - Cutting edge is the sharp edge used for cutting (chiseling).

3. Paring chisel:
Paring chisel has a thinner blade and used for light work. This chisel is used for shaving or paring plane
surfaces. The blade has either square or beveled edges.
4. Mortise chisel:
It is used to make mortises. Mortise chisel is used for heavy cuts. The blade thickness this blade is stronger
in comparison to other chisels of same size; therefore, it can take the heavy blows.

5. Gauge chisel:

It is used to finish curved holes, Gauge chisels are of two types i.e., inside, and outside gauge chisels.

Planning Tools:
Generally, planes are used to produce flat surfaces on wood. A plane is like a chisel fitted in a block of
metal on wood. The cutting blade is fixed in a wood or metal with same inclination.
1. Wooden Jack plane
2. Iron jack plane
3. Trying Plane
4. Smoothing Plane
5. Rasp Files
6.
Striking tools:
1. Hammer:
Hammer is one of the mostly used striking tools.
(i) Cross peen hammer: 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.
(ii) Claw Hammer: The claw hammer is effective in removing very large nails and for driving the nails using
other end of the hammer.
(iii) Mallet: Mallet is used to give light blows. The head is made up of wood and around in section. The Striking
face is flat.
Holding Tools:
During wood working, job is Shaked. So, maintaining accuracy is tough to maintain in accuracy, the wood
is to be held rigidly.

1. Bench Vice:
It is the most common working holding device. It consists of one fixed jaw and the movable jaw mounted
over the screw rod and guide pins. The gap between the jaws is adjusted by using the screw rod.

2. C-Clamps:
It is made up of malleable iron. The opening capacity varies from 50 to 350mm. It can be used for
clamping small work. The swivel shoe allows to fix angled work.

Types of joints:

1. Tee halving (or) Middle lap joint

2. Cross lap joint
3. Mortise and tenon joint
4. Dovetail joint

Result:

Thus, the study of basic carpentry and carpentry tools are carried out.
EX. NO: DATE:

T – LAP JOINT
Aim:

To make a T - Lap Joint to the required dimensions from the given workpiece.

Material Supplied:

A soft wooden piece of size: L x b x t = (250 x 50 x 35) mm.

Equipment and Tools required:

i. Carpentry Vice iv. Steel Rule di. Tenon saw div. Scriber

ii. Jack Plane v. Marking gauge dii. Firmer Chisel

iii. Try Square vi. Rip saw diii. Mallet

Sequence of Processes:

a. Rough Planing c. Sawing e. Finish planning

b. Marking d. Chiseling f. Fitting

Procedure:

1. The given workpiece is firmly clamped in the carpentry vice.

2. Any two adjacent surfaces are planned to get flatness, using Jack Plane.

3. Using Try Square, the flatness of the planned faces is checked.

4. The excess material is chiseled-out using firmer chisel and then planned to correct size to get smooth
surface.

5. Using rip saw, the workpiece is cut into two halves A and B.

6. Using steel rule and marking gauge, the mating dimensions of T - lap joint are marked on the two halves of
the workpiece, with the finished face as reference.

7. In one half A of the workpiece, the unwanted portion of wood is removed for the required dimension using
Tenon saw and firmer chisel.

8. Step 7 is repeated for the other half B of the workpiece.

9. Using Jack plane, the other two faces of the workpiece are planed to the required dimensions.

10. The finished two pieces are fitted together to form the “T – Lap Joint” to obtain a slightly tight joint.

11. Finally, the accuracy of the dimensions is checked, using Steel rule and try square.
T-LAP JOINT
FIGURE:
 DEPARTMENT OF MECHANICAL ENGINEERING
21EM101 – ENGINEERING PRACTICES LABORATORY
Assessment Sheet (Checklist & Rubrics)

Exercise No.: Date:

Checklist (5):

Marks
Criteria
Secured
Finished Workpiece Yes (3) No (0)
Completed Record & Observation Yes (2) No (0)
Total

Rubrics (15):

Marks
Criteria Excellent (5) Moderate (3) Weak (1) Secured
Understands the design Understands the Understands the
Comprehending clearly and identifies the design clearly and design obscurelyand
the Design of best technique for identifies a method predicts methods for
workpiece developing it for developing it developing it

Develops the process

Develops the process
plan to fabricate the Develops the process
plan fragmentally
Creating and workpiece and executes plan and executes
and executes
Executing the by adapting proper fabrication of
fabrication of
Process Plan tools with safety workpiece
workpiece
precautions

Fabricated Workpiece Fabricated Workpiece

Dimensional Fabricated Work
matches exactly to the resembles the design
Accuracy and piece inaccurate with
design with good with acceptable
Surface Finish the design
surface finish surfacefinish

Total

Total Marks Signature of the

Secured out of 20 Faculty with date

Result:

Thus, the T – lap joint is made to the required dimensions from given workpiece.
EX. NO: DATE:

CROSS LAP JOINT

Aim:

To make a Cross Lap Joint to the required dimensions from the given workpiece.

Material Supplied:

A soft wooden piece of size: L x b x t = (250 x 50 x 35) mm.

Equipment and Tools required:

i. Carpentry Vice iv. Steel Rule vii. Tenon saw x. Scriber

ii. Jack Plane v. Marking gauge viii. Firmer Chisel

iii. Try Square vi. Rip saw ix. Mallet

Sequence of Processes:

a. Rough Planning c. Sawing e. Finish Planning

b. Marking d. Chiseling f. Fitting

Procedure:

1. The given workpiece is firmly clamped in the carpentry vice.

2. Any two adjacent surfaces are planned to get flatness, using Jack Plane.

3. Using Try Square, the flatness of the planned faces is checked.

4. The excess material is chiseled-out using firmer chisel and then planned to correct size to get smooth
surface.

5. Using rip saw, the workpiece is cut into two halves A and B.

6. Using steel rule and marking gauge, the mating dimensions of Cross lap joint are marked on the two halves
of the workpiece, with the finished face as reference.

7. In one half A of the workpiece, a required slot is made using Tenon saw and firmer chisel.

8. Step 7 is repeated for the other half B of the workpiece.

9. Using Jack plane, the other two faces of the workpiece are planed to the required dimensions.

10. The finished two pieces are fitted together to form the “Cross Lap Joint” to obtain a slightly tightjoint.

11. Finally, the accuracy of the dimensions is checked, using Steel rule and try square.
CROSS LAP JOINT
FIGURE:
 DEPARTMENT OF MECHANICAL ENGINEERING
21 EM 101 – ENGINEERING PRACTICES LABORATORY
Assessment Sheet (Checklist & Rubrics)

Exercise No.: Date:

Checklist (5):

Marks
Criteria
Secured
Finished Workpiece Yes (3) No (0)
Completed Record & Observation Yes (2) No (0)
Total

Rubrics (15):

Marks
Criteria Excellent (5) Moderate (3) Weak (1)
Secured
Understands the design Understands the Understands the
Comprehending clearly and identifies the design clearly and design obscurelyand
the Design of best technique for identifies a method predicts methods for
workpiece developing it for developing it developing it

Creating and Develops the process plan Develops the process Develops the process
Executing the to fabricate the workpiece plan and executes plan fragmentally
Process Plan and executes by adapting fabrication of and executes
proper tools with safety workpiece fabrication of
precautions workpiece

Fabricated Workpiece Fabricated Workpiece Fabricated Work

Dimensional matches exactly to the resembles the design piece inaccurate with
Accuracy and design with good surface with acceptable the design
Surface Finish finish surfacefinish

Total

Total Marks Signature of the

Secured out of 20 Faculty with date

Result:

Thus, the Cross Lap Joint is made to the required dimensions from given workpiece.
EX. NO: DATE:
DOVETAIL JOINT
Aim:

To make a Dovetail Joint to the required dimensions from the given workpiece.

Material Supplied:

A soft wooden piece of size: L x b x t = (250 x 50 x 35) mm.

Equipment and Tools required:

i. Carpentry Vice iv. Steel Rule vii. Tenon saw x. Scriber

ii. Jack Plane v. Marking gauge viii. Firmer Chisel

iii. Try Square vi. Rip saw ix. Mallet

Sequence of Processes:

a. Rough Planning c. Sawing e. Finish Planning

b. Marking d. Chiseling e. Fitting

Procedure:

1. The given workpiece is firmly clamped in the carpentry vice.

2. Any two adjacent surfaces are planned to get flatness, using Jack Plane.
3. Using Try Square, the flatness of the planned faces is checked.
4. The excess material is chiseled-out using firmer chisel and then planned to correct size to get smooth
surface.
5. Using rip saw, the workpiece is cut into two halves A and B.
6. Using steel rule and marking gauge, the mating dimensions of Dovetail joint are marked on the two halves
of the workpiece, with the finished face as reference.
7. In one half A of the workpiece, the unwanted portions of wood are removed by using Tenon saw and firmer
chisel.
8. Step 7 is repeated for the other half B of the workpiece.
9. Using Jack plane, the other two faces of the workpiece are planed to the required dimensions.
10. The finished two pieces are fitted together to form the “Dovetail Joint” to obtain a slightly tight joint.
11. Finally, the accuracy of the dimensions is checked, using Steel rule and try square.
DOVE TAIL JOINT
FIGURE:
 DEPARTMENT OF MECHANICAL ENGINEERING
21EM101 – ENGINEERING PRACTICES LABORATORY
Assessment Sheet (Checklist & Rubrics)

Exercise No.: Date:

Checklist (5):

Marks
Criteria
Secured
Finished Workpiece Yes (3) No (0)
Completed Record & Observation Yes (2) No (0)
Total

Rubrics (15):

Marks
Criteria Excellent (5) Moderate (3) Weak (1)
Secured
Understands the design Understands the Understands the
Comprehending the clearly and identifies the design clearly and design obscurelyand
Design of best technique for identifies a method predicts methods for
workpiece developing it for developing it developing it

Develops the process Develops the process Develops the process

plan to fabricate the plan and executes plan fragmentally
Creating and workpiece and executes fabrication of and executes
Executing the by adapting proper tools workpiece fabrication of
Process Plan with safetyprecautions workpiece

Fabricated Work piece Fabricated Workpiece Fabricated Work

Dimensional matches exactly to the resembles the design piece inaccurate with
Accuracy and design with good surface with acceptable the design
Surface Finish finish surfacefinish

Total

Total Marks Signature of the

Secured out of 20 Faculty with date

Result:

Thus, the Dovetail Joint is made to the required dimensions from given workpiece.
EX NO: DATE:
STUDY OF PLUMBING

Aim:

To study the basics of plumbing and plumbing tools.

Introduction:

Plumbing is the art of design, installation and maintenance of pipes, pipe fittings, water tank, etc.,
laying-out pipe line requires several joints to be made. Plumbing deals with the laying of a pipeline.
Materials of pipes and pipe fittings:
Pipes and pipe fittings are made of metals, plastics, PVC, Reinforced Cement Concrete, and flexiblematerial
such as rubber
1. Galvanized Iron G.I. Pipes - G.I. Pipes is wrought iron pipe, coated with zinc by the process of galvanizing.
Galvanizing protects ferrous metal from rust and corrosion. Therefore, G.I. Pipes and fittings are used to carry
water at low pressure from storage tanks for domestic purposes.
2. Plastic Pipes - Plastic refers to thermoplastic materials, namely, Polyethylene and polypropylene and poly vinyl
chloride. Nowadays, plastic pipes have substituted metallic pipes due to low cost and resistance to corrosion.
3. Rubber pipes - Rubber is used in pipes as hard or soft rubber to carry liquids to which it is corrosion resistant.
Soft rubber is flexible and is used in house for gardening, etc,

Plumbing tools:

The tools used by a plumber can be classified as follows

i. Pipe wrench iii. Pipe cutter v. Dies vii. Plumb bob

ii. Pipe vice iv. Hacksaw vi. Files and Rasps

1. Pipe wrench - A pipe wrench is used for holding and turning the pipes, rods and machine parts. Wrenches
areclassified as follows.

 Fixed wrenches

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

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 fig.

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

5. Threading dies and taps - 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.
6. Files and rasps - The file surface is covered with sharp edged teeth and its used for removing metal by rubbing.
Arasp is used for finishing the surface of the work piece.
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 fig.
1. Coupling - It is a short a cylindrical sleeve with internal threads throughout. A coupling is used for joining two
pipesin a straight and bend where at least one pipe can be turned.

2. Union - A union is used for joining two pieces of pipes, where either can be turned. It consists of three parts, two
parts joints can be screwed, in to two pipe ends, and the third on for tightening called center 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
lengthof 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
i. Gate valve
ii. Globe valve
iii. Plug valve
iv. Check valve
v. Air relief valve.

RESULT:

Thus, the plumbing equipment and basic plumbing techniques are studied.
EX NO: DATE:

PVC PIPES T-JOINT

Aim:

To join the three given PVC pipes of same diameter using TEE.

Tools and Materials required:

a. Hacksaw

b. PVC Pipes – 3 Nos.

c. Fine emery paper

d. PVC Tee

e. Glue Solution

f. Brush

g. Steel rule

h. Plumber’s tool kit

Figure:
Procedure:

1. The given three PVC pipes 1, 2 & 3 are to be connected by a PVC Tee

2. Using Hacksaw, all the three pipes are cut as square as possible.

3. Using fine emery paper, the corner end of three pipes is rubbed and cleaned to get a perfect joint.

4. A thick coat of glue solution is applied on the outer end of surface of the three pipes and inner surface of
the PVC Tee.

5. The PVC are inserted into the PVC Tee by force one-by-one and the T-joint is obtained.

6. The T-Joint is kept undisturbed for two minutes and allowed to dry.

7. The T-Joint is ready for use after 24 hours.

 DEPARTMENT OF MECHANICAL ENGINEERING
21 EM 101 – ENGINEERING PRACTICES LABORATORY
Assessment Sheet (Checklist & Rubrics)

Exercise No.: Date:

Checklist (5):

Marks
Criteria
Secured
Finished Workpiece Yes (3) No (0)
Completed Record & Observation Yes (2) No (0)
Total

Rubrics (15):

Marks
Criteria Excellent (5) Moderate (3) Weak (1)
Secured
Understands the design Understands the Understands the
Comprehending the clearly and identifies the design clearly and design obscurelyand
Design of best technique for identifies a method predicts methods for
workpiece developing it for developing it developing it

Develops the process Develops the process Develops the process

plan to fabricate the plan and executes plan fragmentally
Creating and workpiece and executes fabrication of and executes
Executing the by adapting proper tools workpiece fabrication of
Process Plan with safetyprecautions workpiece

Fabricated Work piece Fabricated Workpiece Fabricated Work

Dimensional matches exactly to the resembles the design piece inaccurate with
Accuracy and design with good surface with acceptable the design
Surface Finish finish surfacefinish

Total

Total Marks Signature of the

Secured out of 20 Faculty with date
FIGURE:

Result:

Thus, the given three PVC pipes of same diameter are connected to make a T-Joint.
EX. NO: DATE:

BASIC PIPE CONNECTIONS USING FITTINGS LIKE GATE VALVE, ELBOW, TEE, REDUCER,
COUPLING AND TAP

Aim:

To make the basic pipe connections using fittings like gate valve, elbow, Tee, reducer, coupling and a tap
with a main supply line.

Tools and Materials required:

 Pipe wrench  Measuring tape  Pipe Die  Plumber’s tool kit

 Adjustable spanner  Bench vice  Die stock  Steel rule

Fittings supplied:

 G.I. pipes – 6 Nos.  Tap  Gate valve  Tees – 2 Nos.

 Coupling  Elbow  End  Concentric

cap reducer

Figure:
Procedure:

1. First, double line piping diagram is drawn for the basic pipe connection.

2. A branching line is taken out from the main supply line using a Tee joint.

3. External thread is cut on the pipes 1, 2, 3…. & 6 using pipe die and die stock.

4. A gate valve is fitted to pipe 1 in the branching line to control the water supply.

5. Pipe 2 is fitted at another end of the gate valve.

6. A vertical pipe 3 is connected to the other end of the elbow. Tee is screwed to it.

7. A horizontal pipe 4 is connected in the left side of the Tee joint using an end cap.

8. At the right side of Tee, pipe 5 is connected.

9. A concentric reducer is joined to the pipe 5 on its right side.

10. A coupling is fitted to the above the reducer using pipe 6 as shown.

11. A tap is fitted to the other end of the coupling for closing and opening the water supply.
 DEPARTMENT OF MECHANICAL ENGINEERING
21EM101 – ENGINEERING PRACTICES LABORATORY
Assessment Sheet (Checklist & Rubrics)

Exercise No.: Date:

Checklist (5):

Marks
Criteria
Secured
Finished Workpiece Yes (3) No (0)
Completed Record & Observation Yes (2) No (0)
Total

Rubrics (15):

Marks
Criteria Excellent (5) Moderate (3) Weak (1)
Secured
Understands the design Understands the Understands the
Comprehending the clearly and identifies the design clearly and design obscurelyand
Design of best technique for identifies a method predicts methods for
workpiece developing it for developing it developing it

Develops the process Develops the process Develops the process

plan to fabricate the plan and executes plan fragmentally
Creating and workpiece and executes fabrication of and executes
Executing the by adapting proper tools workpiece fabrication of
Process Plan with safetyprecautions workpiece

Fabricated Work piece Fabricated Workpiece Fabricated Work

Dimensional matches exactly to the resembles the design piece inaccurate with
Accuracy and design with good surface with acceptable the design
Surface Finish finish surfacefinish

Total

Total Marks Signature of the

Secured out of 20 Faculty with date
FIGURE:

Result:

Thus, the basic connections of the pipes with the pipe fittings are made as shown.
EX. NO: DATE:

STUDY OF WELDING

Aim:

To study the basics of welding and to study about the tools required for welding.

Introduction:

Welding is one of the metal joining processes. In welding, metals are used by the application of heat with
or without the application of pressure. During welding the edges of the metal pieces are heated to a high temperature
so that they either melt or brought to a plastic condition and then allowed to cool. Welding can be classified into
two types. Plastic welding and Fusion welding

Plastic welding:
The piece of metal to be joined are heated to the plastic state and then forced together by external force
without the filler material. Plastic welding further categorized by the following.

1. Forge welding:
The work pieces are placed in a forge or other appropriate furnace and heated with in the area to be joined
to the plastic condition. Then parts are quickly superimposed and worked into a complete union by hand or power
hammering or by pressing together. Example: Lap welding, Butt welding, “V” welding.

2. Resistance welding:
In resistance welding, a heavy electric current is passed through the metals to be joined over limited area
causing them to locally heated to plastic state and the welding is completed by the application of pressure for
prescribed period time. Example: Spot welding, Projection welding, Seam welding and Butt welding.

3. Thermit welding:
Thermit welding is a fusion process in which weld is affected by pouring super-heated liquid thermit steel,
around the parts to be united with or without the pressure.
FUSION WELDING

The fusion welding is categorized as follows

1. Gas welding

2. Electric welding

3. Thermit welding (without pressure)

Gas welding

 Gas welding is the process in which the required heat to melt the surface is supplied by a high temperature
flame obtained by mixture of two gases.

 Usually, the mixture of oxygen and acetylene is used for welding purpose.

Oxy-acetylene Welding

 In oxy-acetylene gas welding process, a flame is produced by burning mixture of oxygen and acetylene to
get a flame temperature up to 3500°C in two stages.

Types of flames

The ratio of oxygen and acetylene in the mixture leads to any one of the following flames.

a) Neutral flame

b) Oxidizing flame

c) Carburizing flame

Neutral flame:

 This flame has equal volumes of oxygen and acetylene.

 According to the application this flame is used to weld steel, stainless steel and cast iron.

Oxidizing flame

 It has more volumes of oxygen than acetylene.

 This flame is used to weld copper and copper alloys.

Carburizing flame

 It has more volumes of acetylene than oxygen.

 This flame is used to weld Monel metal, low carbon steel and alloy steel.
FILLER MATERIAL

It is the metal that is added to the metal that is added to the weld pool to assist in filling the gap. Filler
material forms an integral part of the weld. The filler metal is usually available in the rod form.

ARC WELDING

 In arc welding process, the source of heat is electricity

 In arc welding process, coalescence is produced by heating the work piece. With an electric arc stick
between an electrode and the work piece.

 Welding may be carried out in air or in an inert atmosphere.

Principle of Arc welding:

 The electricity is important thing in arc welding.

 The electricity motor generator or transformer sets are used to supply high electric current and the electrodes
are used to produce the necessary arc. The electrode serves as the filler rod and the arc melts the metals to
be joined are fused together.
  The electrodes are used in arc welding as a filler rod.

 The electrodes are made of metallic wire called core wire.

 It is coated uniformly with a protective coating called flux while fluxing an electrode about 20 mm of length
is left bare at one end for holding it using electric holder.

 It is used to transmit full current from electrode holder to the front end of the electrode coating.

 The size or diameter of the core wire will depend upon the amount of weld metal to be deposited and on the
type of joint.

TOOLS USED IN ARC WELDING:

1. Electric holder 4. Hand screen 7. Goggles

2. Chipping hammer 5. Helmet 8. Hand gloves

3. Wire brush 6. Tongs

1. Electrode holder

It is the device used for mechanical holding the electrode and conducting the current to it. Electrode holder
should be light to minimize fatigue in cured by the welder.
Jams are made to hold the bare of the electrode in either a vertical or an angular position.

2. Chipping hammer

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

3. Wire brush

A wire brush made up of shift steel wire, embedded in wood, removes small particulars of slag from the
weld after the chipping hammer has done its job.
 4. Hand screen

It is protective device used in arc welding, a hand shield is held in the hand of the welder and it is fitted with
a suitable fitter lens.

5. Helmet

It is used for shielding and protecting the face and neck of the welder and it fitted with fitter lens.

6. Tongs

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

7. Goggles

Chipping goggles are used to protect the eyes while chipping the slag. They are fitted while a plain glass to
see the area to be cleaned.

8. Hand gloves

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

RESULT:

Thus, the welding equipment and basic welding techniques are studied.
EX. NO: DATE:
LAP JOINT

Aim:

To arc weld two metal piece of mild steel to get the Horizontal Welding.

Materials required:

Two Mild steel plates

Tools required:

1. Electrode
2. Welding transformer
3. Gloves
4. Tong
5. Chipping hammer
6. Wire brush
7. Welding shield
8. Electrode holder

Figure:
Procedure:

1. The given workpieces are thoroughly cleaned, i.e. rust, scales are removed and the edges are filed.
2. The electrode is held in an electrode holder and ground clamp is clamped to the welding plates and the
power is supplied.
3. The workpieces are positioned on the table to form a “Lap joint”.
4. The tag weld is done on the both the ends of joining plates to avoid the movement of workpieces during
welding.
5. The welding is carried throughout the length of the workpieces on both sides by maintaining 3mm gap
between plates and the welding rod.
6. The welded plates are allowed for air cooling after the slag is removed.
7. The weld joint portions are cleaned by wire brush.
 DEPARTMENT OF MECHANICAL ENGINEERING
21EM101 – ENGINEERING PRACTICES LABORATORY
Assessment Sheet (Checklist & Rubrics)

Exercise No.: Date:

Checklist (5):

Marks
Criteria
Secured
Finished Workpiece Yes (3) No (0)
Completed Record & Observation Yes (2) No (0)
Total

Rubrics (15):

Marks
Criteria Excellent (5) Moderate (3) Weak (1)
Secured
Understands the design Understands the Understands the
Comprehending the clearly and identifies the design clearly and design obscurelyand
Design of best technique for identifies a method predicts methods for
workpiece developing it for developing it developing it

Develops the process Develops the process Develops the process

plan to fabricate the plan and executes plan fragmentally
Creating and workpiece and executes fabrication of and executes
Executing the by adapting proper tools workpiece fabrication of
Process Plan with safetyprecautions workpiece

Fabricated Work piece Fabricated Workpiece Fabricated Work

Dimensional matches exactly to the resembles the design piece inaccurate with
Accuracy and design with good surface with acceptable the design
Surface Finish finish surfacefinish

Total

Total Marks Signature of the

Secured out of 20 Faculty with date
FIGURE

RESULT:

Thus, the required Lap joint is made by arc welding process.

EX. NO: DATE:

BUTT JOINT

Aim:

To arc weld two metal piece of mild steel to get the Horizontal Welding.

Materials required:

Two Mild steel plates

Tools required:

1. Electrode
2. Welding transformer
3. Gloves
4. Tong
5. Chipping hammer
6. Wire brush
7. Welding shield
8. Electrode holder

Figure:
Procedure:

1. The given workpieces are thoroughly cleaned, i.e., rust, scales are removed and the edges are filed.
2. The electrode is held in an electrode holder and ground clamp is clamped to the welding plates and the
power is supplied.
3. The workpieces are positioned on the table form a “square butt joint”.
4. The tag weld is done on the both the ends of joining plates to avoid the movement of workpieces during
welding.
5. The welding is carried throughout the length of the workpieces on both sides by maintaining 3mm gap
between plates and the welding rod.
6. The welded plates are allowed for air cooling after the slags are removed.
7. The weld joint portions are cleaned by wire brush.
 DEPARTMENT OF MECHANICAL ENGINEERING
21EM101 – ENGINEERING PRACTICES LABORATORY
Assessment Sheet (Checklist & Rubrics)

Exercise No.: Date:

Checklist (5):

Marks
Criteria
Secured
Finished Workpiece Yes (3) No (0)
Completed Record & Observation Yes (2) No (0)
Total

Rubrics (15):

Marks
Criteria Excellent (5) Moderate (3) Weak (1)
Secured
Understands the design Understands the Understands the
Comprehending the clearly and identifies the design clearly and design obscurelyand
Design of best technique for identifies a method predicts methods for
workpiece developing it for developing it developing it

Develops the process Develops the process Develops the process

plan to fabricate the plan and executes plan fragmentally
Creating and workpiece and executes fabrication of and executes
Executing the by adapting proper tools workpiece fabrication of
Process Plan with safetyprecautions workpiece

Fabricated Work piece Fabricated Workpiece Fabricated Work

Dimensional matches exactly to the resembles the design piece inaccurate with
Accuracy and design with good surface with acceptable the design
Surface Finish finish surfacefinish

Total

Total Marks Signature of the

Secured out of 20 Faculty with date
FIGURE

Result:

Thus, the required butt joint is made by arc welding process.

EX. NO: DATE:

TEE FILLET JOINT

Aim:

To arc weld two metal piece of mild steel to get the Horizontal Welding.

Materials required:

Two Mild steel plates

Tools required:

1. Electrode
2. Welding transformer
3. Gloves
4. Tong
5. Chipping hammer
6. Wire brush
7. Welding shield
8. Electrode holder

Figure:
Procedure:

1. The given workpieces are thoroughly cleaned i.e. rust, scales are removed and the edges are filed.
2. The electrode is held in an electrode holder and ground clamp is clamped to the welding plates and the
power is supplied.
3. The workpieces are positioned on the table to form a “Tee fillet joint”.
4. The tag weld is done on the both the ends of joining plates to avoid the movement of workpieces during
welding.
5. The welding is carried throughout the length of the workpieces on both sides by maintaining 3mm gap
between plates and the welding rod.
6. The welded joint portions are allowed for air cooling after the slag is removed.
7. The weld joint portions are cleaned by wire brush.
 DEPARTMENT OF MECHANICAL ENGINEERING
21EM101 – ENGINEERING PRACTICES LABORATORY
Assessment Sheet (Checklist & Rubrics)

Exercise No.: Date:

Checklist (5):

Marks
Criteria
Secured
Finished Workpiece Yes (3) No (0)
Completed Record & Observation Yes (2) No (0)
Total

Rubrics (15):

Marks
Criteria Excellent (5) Moderate (3) Weak (1)
Secured
Understands the design Understands the Understands the
Comprehending the clearly and identifies the design clearly and design obscurelyand
Design of best technique for identifies a method predicts methods for
workpiece developing it for developing it developing it

Develops the process Develops the process Develops the process

plan to fabricate the plan and executes plan fragmentally
Creating and workpiece and executes fabrication of and executes
Executing the by adapting proper tools workpiece fabrication of
Process Plan with safetyprecautions workpiece

Fabricated Work piece Fabricated Workpiece Fabricated Work

Dimensional matches exactly to the resembles the design piece inaccurate with
Accuracy and design with good surface with acceptable the design
Surface Finish finish surfacefinish

Total

Total Marks Signature of the

Secured out of 20 Faculty with date
FIGURE:

Result:

Thus, the required Tee fillet joint is made by arc welding process.
EX. NO: DATE:

STUDY ON SHEET METAL

Introduction:

Sheet metal work is the working on the metal of 16 gauge to 30 gauge with hand tools and simple machines
into different forms by cutting, forming into shapes, and joining.

Application of sheet metal:

It is used for making hoppers, funnels, various ducts chimneys, ventilating pipes, machine tool guards, boilers
etc. It is extensively used in major industries like air craft manufacturing, ship building, automobile body building
and fabrication of ducts in air conditioning equipment.

Principle involved:

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

General procedure for sheet metal work:

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

Specification of sheet metal:

The sheets are specified by standard gauge numbers. Each gauge designates a definite thickness. The gauge number
can be identified by standard wire gauge or SWG.

SWG 10 12 14 16 18 20 22 24 26 30

Thickness (mm) 3.2 2.6 2.0 1.6 1.2 0.9 0.7 0.6 0.4 0.3

METALS USED IN SHEET METAL WORK:

The most used sheet metals are

i. Black iron – used for making tanks, pans, and stove pipes etc.

ii. Galvanized iron – used for making pans, buckets, furnaces, heating ducts, cabinets etc.

iii. Stainless steel – domestic appliances such as vessels since it is anticorrosive, it is well suited for handling
of liquid helium, hydrogen, nitrogen, and oxygen that exists at cryogenic state.
 iv. Copper – used for making cutters, expansion joints, roof flashing and hoods.

v. Aluminium – used for making house hold appliances, refrigerator trays, vessels used in chemical and food
industries, electrical industries, structural applications etc.

vi. Tin plate – used for making roofs, food containers, dairy equipment, furnace fittings, cans, and pans etc.

vii. Lead – used for lining in tank, flooring in chemical plants and in battery plates.

TOOLS USED IN SHEET METAL WORK:

Cutting tools:

1. Chisels - They are used for cutting sheets, rivets, bolts, and chipping operations. Though there are many types
ofchisels available, round nose chisel and flat nose chisel are used for sheet metal work.

2. Snips or Shears - Snips are hand shears; varying in length from 200mm to 600mm. 200mm to 250 mm length is
most used. Straight end and curved snips are mostly used for cutting along outside curves and straight lines,
trimming along inside curves respectively.

Striking tools:

1. Hammers - They are used for hollowing, stretching, leveling, riveting, strengthening of sheet metal joints etc.
themostly used hammers are ball peen hammer, straight peen hammer, riveting hammer, mallet etc.
2. Punches - It is used for marking out work locating centers etc. the widely used punches are dot punch, hollow
punch, and center punch.

Supporting tools:

1. Stakes - They are the sheet metal worker’s anvil used for bending, hemming, seaming, forming etc.,
usinghammers or mallet.

Bending tools:

1. Pliers - They are used for bending the sheet metal to the required shape. It also used for holding and cutting
thesheet metal. Flat nose pliers and round nose pliers are used in the sheet metal work for forming and holding.

Layout tools:

1. Steel rule - It is used for measuring and laying out small work. It can measure with an accuracy of up to 0.5mm.
2. Scriber - It is long wire steel with its one end sharply pointed and hardened to scratch line sheet metal for laying
out patterns.
3. Divider - It is used for drawing circles or arcs on sheet metal. They are used to mark a desired distance between
two points and to divide lines into equal parts.
4. Sheet Metal gauge - It is used to find the thickness of the sheet metal. The various gauges are standard
wiregauge, Birham wire gauge and American wire gauge.

Other Tools:

1. Groover - The process of joining two sheet metal jobs, their ends are grooved with the help of grooving tools
andthis is known as grooving.
2. Hand dolly - It is a steel bock rectangular in shape and fitted with a handle in the bottom of the block.

SHEET METAL OPERATIONS:

Shearing:

Shearing, also known as die cutting, is a process which cuts stock without the formation of chips or the use
of burning or melting
Bending:

It means that the metal is stressed beyond the elastic limit. So that the metal is bent into right angle and
forming occurs when complete items or parts are shaped. It incorporates angle bending, roll bending, and roll
forming and seaming.

Drawing:

It is the operation of producing cup shaped components from the sheet metal by many number of punching
strokes. It is performed by placing a metal blank over a stationary die and exerting a calculated pressure from a
punch against the blank.

Squeezing:

It is the one of the methods of forming ductile material. Riveting, cold heading and rotary swaging are very
common process of squeezing. Rivets are used to join two or more sheets of metal together.
SHEET METAL JOINTS:

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

HEM: A hem is an edge or border made by folding.

Types of Hems: 1. single hem, 2. double hem, 3. wired edge.

Double Hem

SEAM: A seam is a joining made by fastening two edges together.

Types of seam: 1. Single Seam, 2. Double Seam, 3. Grooved Seam.

RESULT:

Thus, the sheet metal equipment and basic sheet metal forming methods are studied.
EX NO: DATE:

RECTANGULAR TRAY

Aim:

To make a rectangular tray from the given sheet metal.

Material supplied:

26-gauge Galvanized Iron (G.I) sheet.

Tools required:

1. Steel Rule
2. Mallet
3. Scriber
4. Divider
5. Snips
6. Ball Peen Hammer
7. Stakes

Figure:
 Procedure:
1. First the work pieces must be thoroughly cleaned to remove rust, scale, and other foreign material.
2. The size of the given sheet is checked for its dimensions using a steel rule.
3. Then the sheet is leveled on the leveling plate using a mallet.
4. The dimensions are marked as shown in figure.
5. The sheet is cut as per the marked dimensions by straight snips.
6. A single hemming is made on the four sides of the tray as shown in fig.
7. These four sides of the tray are bent to 90 degrees using stakes anvil.
8. Finally, all the corners of the tray are joined.
 DEPARTMENT OF MECHANICAL ENGINEERING
21EM101 – ENGINEERING PRACTICES LABORATORY
Assessment Sheet (Checklist & Rubrics)

Exercise No.: Date:

Checklist (5):

Marks
Criteria
Secured
Finished Workpiece Yes (3) No (0)
Completed Record & Observation Yes (2) No (0)
Total

Rubrics (15):

Marks
Criteria Excellent (5) Moderate (3) Weak (1)
Secured
Understands the design Understands the Understands the
Comprehending the clearly and identifies the design clearly and design obscurelyand
Design of best technique for identifies a method predicts methods for
workpiece developing it for developing it developing it

Develops the process Develops the process Develops the process

plan to fabricate the plan and executes plan fragmentally
Creating and workpiece and executes fabrication of and executes
Executing the by adapting proper tools workpiece fabrication of
Process Plan with safetyprecautions workpiece

Fabricated Work piece Fabricated Workpiece Fabricated Work

Dimensional matches exactly to the resembles the design piece inaccurate with
Accuracy and design with good surface with acceptable the design
Surface Finish finish surfacefinish

Total

Total Marks Signature of the

Secured out of 20 Faculty with date
FIGURE:

Result:

Thus, the rectangular tray is made from the given sheet metal.
EX. NO: DATE:

STUDY OF MACHINING

Aim:

To study the basics of machining and to study the working of a center lathe.

Introduction:

Machining is the process of converting the given work piece into the required shape and size with help of a
machine tool. The most widely used machine tool is lathe. In simple words machining is the process of removing
certain material from the work piece.

Lathe:

Lathe is the machine tool which is used to perform several operations on the work piece. Lathe is useful in
making several parts which is further assembled to make new machine. Hence lathe is known as “mother of
machines”.

Types of Lathes:

 Centre Lathe

 Turret and Capstan Lathes

 Automatic Lathe / CNC Lathe

Basic working principle of lathe:

In lathe, the work piece is held in the chuck, a work holding device. The cutting tool is mounted in the tool
post. The chuck is rotated by means of power. When the chuck rotates, the work piece also rotates. The tool is
moved against the rotating work piece by giving small amount of depth of cut. The material is removed in the form
of chips. Continuous feed and depth of cut is given until the required dimensions are obtained in the workpiece.

Description of lathe:

Lathe is a machine which has several parts in it. They are

1. Bed: It is the base of the machine. On its left side, the head stock is mounted and, o n i t s r i g h t , it has
movable casting known as tailstock. Its legs have holes to bolt down on the ground.

2. Head stock: It consists of spindles, gears and speed changing levers. It is used to transmit the motion to the job.
Ithas two types one is the headstock driven by belt and the other one is the gear driven.

3. Carriage: Carriage is used to carry a tool to bring in contact with the rotating work piece or to with draw
fromsuch a contact. It operates on bed ways between the headstock and tail stock.

4. Saddle: It is a ‘H’ shaped part fitted on the lathe bed. There is a hand wheel to move it on the bed way.
Crossslide, compound rest and tool post are fitted on this saddle.

5. Cross slide: It is on the upper slide of saddle in the form of dove tail. A hand wheel is provided to drive the
crossslide. It permits the cross wise movement of the tool (i.e.) movement of tool towards or away from the
operator

6. Compound rest: It is fitted over the cross slide on a turn table. It permits both parallel and angular
movements tocutting tool.

7. Tool post: It is fitted on the top most part of the compound rest. Tool is mounted on this tool post. Cutting tool
isfixed in it with the help of screws.
8. Apron: It is the hanging part in front of the carriage. It accommodates the mechanism of hand and power feed
tothe cutting tool for carrying out different operations.

9. Lead screw: It is a long screw with ACME threads. It is used for transmitting power for automatic feed or feed
forthread cutting operation.

10. Tail stock: It is located at the right end of the lathe bed and it can be positioned anywhere in the bed. It is used
forsupporting lengthy jobs and carries tool to carry out operations such as tapping, drilling, reaming.

Work holding devices:

1. Lathe centers - They are used to support work. It has two categories of centers. Live center is one which is
fittedin the headstock spindle. Dead is another one which is fitted in the tail stock.

2. Chuck - It is a device used to hold a job. It is easily fitted on the thread cut on the end of head stock
spindle.Various types of chuck are
 Two jaw chuck  Four jaw chuck  Magnetic chuck
 Three jaw chuck  Collet chuck

Three Jaw Universal self-centering chuck Four Jaw Independent chuck

Cutting tools used:

For making a finished job on lathe machine, various types of cutting tools are used. One of them is single
point cutting tool which is used to perform several operations on the work piece. Various types of cutting tools
are

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

2. Rough turning tool: It is used to remove excess material from the work piece in quick time. It can be used to
givelarge depth of cut and work at coarse feed.

3. Finishing tool: It is used for getting smooth finish on the work piece. Its point is a little rounder.

4. Radius tool: Jobs which need round cutting are done with this tool. Two types of radius tool are convex
radiustool and concave radius tool.

5. Parting tools: It is used to cut the jobs into two parts. It is also used for grooving.

6. Form turning tool: It is used for jobs which require both convex and concave turning.

7. Thread cutting tool: It is used for making internal or external threads on the work piece. The tool nose is
designedwith a definite profile for taking threads.

8. Drill tool: It is used for making holes of various diameters on the job. Drill bit of various sizes of diameter
areavailable.

9. Boring tool: It used for enlarging the drill hole.

10. Knurling tool: It is used for making better grip on the surface of a job. Drawing slanting or square projecting
lineson the surface of a job is known as knurling.
Tool materials:

 The single point cutting tools are made of high-speed steel. (H. S. S)
 The main alloying elements in 18 – 4 – 1 HSS tools are 18% tungsten, 4% chromium and 1% Vanadium.
 5-10 % cobalt is also added to improve the heat resisting properties of the tool.
 General purpose hand cutting tools are usually made from carbon steel or tool steel.
 Carbide tipped tools fixed in tool holders, are mostly used in production shops.

Nomenclature of single point cutting tool:

Cutting tool angles:

1. Top rake angle (back rake angle): If the slope is given to the face or surface of the tool and if this slope is
alongthe tool’s length, then it is called top rake angle. It is usually 15 to 20.

2. Side rake angle: If the slope is given to the face or top of the tool along the tools width then it is called side
rakeangle. It lies between 6 and 15.

3. Clearance angle (relief angle): They are provided to keep surface of the tool clear of the work piece. The
twotypes of relief angle are
1. Side clearance angle.
2. End clearance angle.

4. Cutting edge angle:

a. Side cutting edge angle – (generally 15) it is an angle, the side cutting edge makes with the axis of the tool
b. End cutting edge angle – (from 7 to 15) it is an angle, the end cutting edge makes with the width
of thetool.

5. Lip angle (cutting angle): It is the angle between the face and the end surface of the tool.

6. Nose angle: It is the angle between the side cutting edge and end cutting edge.

Lathe operations:

1. Plain turning: It is done for reducing the diameter of the work piece. A cutting tool with 70 setting angle is
used for roughing operation. More feed is given for rough turning while less feed is given for finishing. Work
piece is held in chuck and tool is set to center height of the work piece.

2. Facing: It is done for getting fine finish (good surface finish) on the face of the job. Facing tool is set at an
angle to the work piece. The tool is fed from the center of work piece towards the outer surface against the
rotatingwork piece. Depth of cut is low for the facing operation.

3. Step turning: It is like the process of turning but in this case different diameter in step of various sizes is taken
on the work piece.

4. Knurling: It is process of making serrations on the work piece. Knurling tools of different shape and size are
usedto make grip on the work piece. It has two hardened steel rollers. The tool is held in tool post and pressed
against the rotating work piece. Work piece is rotated at lower speed and small amount of feed is given.

5. Drilling: It is a process of making a hole on the work piece. Job is held in chuck while the drill is held in the
tail stock sleeve. Feed is given by rotating the hand wheel in the tail stock which pushes the tailstock sleeve.
Cutting speed:

It is the peripheral speed of the work past the cutting tool. It is the speed at which metal is removed by the
tool from the work piece. It is expressed in meter / minute.

D – Diameter in mm

N – Spindle speed in rpm

Feed:

It is defined as the rate of tool travel across a surface cutting it. It is the distance of the tool advances for
eachrevolution of the work piece. It is expressed in mm/revolution.
Depth of cut:

It is the perpendicular distance measured from the machined surface to the uncut surface of work. It is
expressedin mm.

d1 = diameter of work before machining

d2 = diameter of work after machining

SAFETY PRECAUTIONS

Job should be tightly held in the chuck.

If the job is held in between the centers, then apply grease on the nose of dead center, otherwise it will
burnt out due to excess heat.
Do not measure the job while it is rotating.
Do not leave the chuck key in the chuck.
Do not try to stop the lathe chuck or job with hands
Do not handle metal chips by hand.
Do not give more depth of cut while the job is rotating at high speed.
Tighten the tool I n the tool post.
Do not stand close to the rotating job or bring your face to it. Do
not reduce or increase the speed during the lathe operations.

RESULT:

Thus, the basics of machining and working of a center lathe are studied.
EX. NO: DATE:
FACING AND PLAIN TURNING

Aim:
To perform turning and facing on a cylindrical work piece.

Material used:
Mild steel rod. (L = ,D= )

Tools required:
1. Lathe
2. Three-jaw chuck
3. Chuck key
4. Vernier caliper
5. Single-point cutting tool

Figure:
Procedure:
1. First loosen the jaw in the chuck key to position the work piece, and then tighten the Jaws.
2. Fix the cutting tool in the tool post.
3. Switch on the lathe and move the carriage near to the work piece. Give it a small cross feed, and then
movecarriage longitudinally to the required length slowly.
4. Bring the carriage to the original position, give a small cross feed and move carriage longitudinally.
Repeatthis step until required diameter is obtained.
5. To get smooth surface give a very small feed when the diameter is nearing the required value.
6. To face the end surface of the work piece, move the carriage to make the tool touch the end surface of
thework piece.
7. Give a small feed in longitudinal direction, and then move the tool towards the axis of
8. The work piece using the cross slide to complete the work piece.
 DEPARTMENT OF MECHANICAL ENGINEERING
21EM101 – ENGINEERING PRACTICES LABORATORY
Assessment Sheet (Checklist & Rubrics)

Exercise No.: Date:

Checklist (5):

Marks
Criteria
Secured
Finished Workpiece Yes (3) No (0)
Completed Record & Observation Yes (2) No (0)
Total

Rubrics (15):

Marks
Criteria Excellent (5) Moderate (3) Weak (1)
Secured
Understands the design Understands the Understands the
Comprehending the clearly and identifies the design clearly and design obscurelyand
Design of best technique for identifies a method predicts methods for
workpiece developing it for developing it developing it

Develops the process Develops the process Develops the process

plan to fabricate the plan and executes plan fragmentally
Creating and workpiece and executes fabrication of and executes
Executing the by adapting proper tools workpiece fabrication of
Process Plan with safetyprecautions workpiece

Fabricated Work piece Fabricated Workpiece Fabricated Work

Dimensional matches exactly to the resembles the design piece inaccurate with
Accuracy and design with good surface with acceptable the design
Surface Finish finish surfacefinish

Total

Total Marks Signature of the

Secured out of 20 Faculty with date
FIGURE:

Result:

Thus, the required shape and size is obtained by facing and plain turning.
EX. NO: DATE:

STEP TURNING AND TAPER TURNING

Aim:
To perform taper turning on a cylindrical work piece.

Material used:
Mild steel rod. (L = ,D= )

Tools required:
1. Lathe
2. Three-jaw chuck
3. Chuck key
4. Vernier caliper
5. Single-point cutting tool

Figure:
Procedure:
1. First loosen the jaw in the chuck key to position the work piece, and then tighten the Jaws. Fix the cutting
tool in the tool post.
2. Switch on the lathe and move the carriage near to the work piece. Give it a small cross feed, and then
move carriage longitudinally to the required length slowly.
3. Bring the carriage to the original position, give a small cross feed and move carriage longitudinally.
Repeat this step until required diameter is obtained.
4. To get smooth surface give a very small feed when the diameter is nearing the required value.
5. To face the end surface of the work piece, move the carriage to make the tool touch the end surface of the
work piece.
6. Give a small feed in longitudinal direction, and then move the tool towards the axis of the work piece
using the cross slide to complete the work piece.
7. The turning operation is done with cutting tool to reduce the diameter up to the required dimension for the
two steps of various diameters.
8. The work piece is removed from the chuck and the dimensions of work piece are checked for the
requirements.
 DEPARTMENT OF MECHANICAL ENGINEERING
21EM101 – ENGINEERING PRACTICES LABORATORY
Assessment Sheet (Checklist & Rubrics)

Exercise No.: Date:

Checklist (5):

Marks
Criteria
Secured
Finished Workpiece Yes (3) No (0)
Completed Record & Observation Yes (2) No (0)
Total

Rubrics (15):

Marks
Criteria Excellent (5) Moderate (3) Weak (1)
Secured
Understands the design Understands the Understands the
Comprehending clearly and identifies the design clearly and design obscurelyand
the Design of best technique for identifies a method predicts methods for
workpiece developing it for developing it developing it

Develops the process Develops the process Develops the process

plan to fabricate the plan and executes plan fragmentally
Creating and workpiece and executes fabrication of and executes
Executing the by adapting proper tools workpiece fabrication of
Process Plan with safetyprecautions workpiece

Fabricated Work piece Fabricated Workpiece Fabricated Work

Dimensional matches exactly to the resembles the design piece inaccurate with
Accuracy and design with good surface with acceptable the design
Surface Finish finish surfacefinish

Total

Total Marks Signature of the

Secured out of 20 Faculty with date
FIGURE:

Result:
Thus, the required shape and size is obtained by taper turning.
 EX. NO: DATE:

STUDY OF AIR CONDITIONER

Aim:

To study the basics of air conditioner.

Introduction:

Air Conditioning is the process of conditioning the air according to the human comfort,
irrespective of external conditions.

Applications of Air Conditioning

1. Used in offices, hotels, buses, cars.,etc

2. Used in industries having tool room machines.
3. Used in textile industries to control moisture.
4. Used in printing press.
5. Used in Food industries, Chemical plants.

Classification of Air Conditioning:

Air conditioning systems are classified as

1) According to the purpose

1. Comfort Air conditioning.
2. Industrial Airconditioning.

2) According to Season of the year

1. Summer Air conditioning.
2. Winter Air conditioning.
3. Year round Air conditioning.

3) Types of Air conditioners

1. Room Air conditioners
2. Winter Air conditioners
3. Central Air conditioners
Functions of Air conditioners
1. Cleaning air.
2. Controlling the temp of air.
3. Controlling the moisture content.
4. Circulating the air.

Basic Concepts:
1) Dry air: The atmospheric air which no water vapour is called dry air.
2) Psychometry: Psychometry is the study of the properties of atmospheric air.
3) Temperature: The degree of hotness (or) Coldness is called the temperature.
4) Moisture: Moisture is the water vapour present in the air.
5) Relative humidity: Relative humidity is the ratio of actual mass of water vapour in each volume to
the mass of water vapour.
6) Dry bulb temperature: The temperature of air measured by the ordinary thermometer is called dry
bulb temperature:
7) Wet bulb Temperature: The temperature of air measured by the thermometer when it is covered
by the wet cloth is known as wet bulb Temperature.
8) Dew point Temperature: The temperature at which the water vapour starts condensing is called dew
point Temperature

Window Type Air Conditioner:

Construction:

This unit consists of the following.

1. A cooling system to cool and dehumidify the air involves a condenser, a compressor, and a
refrigerant coil.
2. A filter to any impurities in the air. The filter is made of mesh, glass wool or fiber.
3. A fan and adjustable grills to circulate the air.
4. Controls to regulate the equipment operation.
5. The low-pressure refrigerant vapour is drawn from the evaporator to the hermetic
compressor through suction pipe.
6. It is compressed from low pressure to the high pressure and supplied to the condenser.
7. It is condensed in the condenser by passing the outdoor air over the condenser coil bya fan.
8. The liquid refrigerant is passed through the capillary into the evaporator.
9. . In the evaporator the liquid refrigerant picks up the heat from the refrigerator surface and gets
vaporized.
10. A motor driven fan draws air from the room through the air filter and this air is cooled by losing its
heat to the low temperature refrigerant and cold air is circulated back into the room.
11. The vapour refrigerant from the evaporator goes to the compressor from evaporator and
the cycle is repeated.
12. Thus, the room is air conditioned
13. . The quantity of air circulated can be controlled by the dampers.
14. The moisture in the air passing over the evaporator coil is dehumidified and drips into the trays.
15. This water evaporator to certain extent and thus helps in cooling the compressor and condenser.
16. The unit automatically stops when the required temperature is reached in the room. This is
accomplished by the thermostat and control panel.
Merits and Demerits of Window type air conditioner:
Merits:
1. A separate temperature control is provided in each room.
2. Ducts are not required for distribution.
3. Cost is less.
4. Skilled technician is required for installation.
Demerits:
1. It makes noise.
2. Large hole is made in the external wall or a large opening to be created in the window panel. This
leads to insecurity to inmates.

Split Type Air Conditioner – Layout:

1. In split air type air conditioner noise making components like compressor and condenser
are mounted outside or away from room.
2. Split type air conditioning system has two main components.
(i) Outdoor Unit (ii) Indoor unit.
3. The outdoor unit consists of compressor and condenser.
4. The indoor unit consists of power cables, refrigerant tube and an evaporator mounted inside the room.
Working:
1. Compressor is used to compress the refrigerant.
2. The refrigerant moves between the evaporator and condenser through the circuit of tubing and
fins in the coils.
3. The evaporator and condenser are usually made of coil of copper tubes and surrounded by aluminum
fins.
4. The liquid refrigerant coming from the condenser evaporates in the indoor evaporator coil.
5. During this process the heat is removed from the indoor unit air and thus, the roomis cooled.
6. Air return grid takes in the indoor air.
7. Water is dehumidified out of air is drained through the drain pipe.
8. The hot refrigerant vapour is passed to the compressor and then to the condenser where
it becomes liquid.
9. Thus, the cycle is repeated.
10. A thermostat is used to keep the room at a constant, comfortable temperature avoiding the
frequent turning on off.

Merits and Demerits of Split type air conditioner:

Merits:
1. It is compact
2. Up to four indoor AHU’s may be connected to one outdoor unit.
3. It is energy and money saving.
4. Duct is not used.
5. Easier to install.
6. It is noiseless, because rotary air compressor used is, kept outside.
7. It is more efficient and powerful.
8. It has the flexibility for zoning.

Demerits:
1. Initial cost is higher than window air conditioner
2. Skilled technician is required for installation.
3. Each zone or room requires thermostat to control the air cooling.

Applications of air conditioning:

1. Used in houses, hospitals, offices, computer centers, theatres, departmental stores etc.,
2. Air-conditioning of transport media such as buses, cars trains, aero planes, and ships.
3. Wide application in food processing, printing, chemical, pharmaceutical and machine tool, etc.,

Result:
Thus, the study was made on Air Conditioning systems.
EX. NO: DATE:

STUDY OF CENTRIFUGAL PUMP

Aim:

To study the basics of centrifugal pump.

Introduction:

It is a pump that uses an impeller to move water or other fluids by using the centrifugal force.

Components of Centrifugal pump:

 A rotating component comprising of an impeller and a shaft.
 A stationery component comprising a volute (casing), suction and delivery pipe.

Working Principle of Centrifugal pump:

Principle: When a certain mass of fluid is rotated by an external source, it is thrown away from the central
axis of rotation and a centrifugal head is impressed which enables it to rise to a higher level.
Working:

 The delivery valve is closed and the pump is primed, so that no air pocket is left.

 Keeping the delivery valve still closed the electric motor is started to rotatethe impeller.

 The rotation of the impeller is gradually increased till the impeller rotates at its normal speed.

 After the impeller attains the normal speed the delivery valve is opened when the liquid is sucked
continuously upto the suction pipe.

 It passes through the eye of the casing and enters the impeller at its centre.

 The liquid is impelled out by the rotating vanes and it comes out at the outlet tips of the vanes into
the casing.

 Due to the impeller action the pressure head as well as the velocity heads are increased.

 From the casing the liquid passes into the pipe and lifted to the required height.

 When pump is to be stopped the delivery valve is to be first closed, otherwise theremay be some
backflow of water into the reservoir.

Types of casing

1. Volute and Vortex Casing

 Volute and Diffuser casing

Volute Casing: In this type of casing the area of flow gradually increases from the impeller outlet
to the delivery pipe.
 Vortex Casing: If a circular chamber is provided between the impeller and volute chamber the
casing is known as Vortex Chamber.

Diffuser Casing:
1. The impeller is surrounded by a diffuser.
2. The guide vanes are designed in such a way that the water from the impeller enters the guide
vanes without shock.
3. It reduces the vibration of the pump.
4. Diffuser casing, the diffuser and the outer casing are stationery parts.

Priming of a centrifugal Pump:

1. The operation of filling the suction pipe, casing, and a portion of delivery pipe with the
liquid to be raised, before starting the pump is known as Priming

2. It is done to remove any air, gas, or vapour from these parts of pump.

3. If a Centrifugal pump is not primed before starting air pockets inside impeller may give rise to
vortices and causes discontinuity of flow

Losses in Centrifugal pump:

Hydraulic Losses:
1. Shock or eddy losses at the entrance to and exit from the impeller

2. Losses due to friction in the impeller

3. Friction and eddy losses in the guide vanes/diffuser and casing

Mechanical Losses:
1. Losses due to disc friction between the impeller and the liquid which fills the clearance spaces
between the impeller and casing

2. Losses pertaining to friction of the main bearing and glands.

Specific speed of Centrifugal Pump:

• It is the speed in revolutions per minute at which a geometrically similar impeller would
deliverone cubic meter of liquid per second against a delivery head of one meter.
EX. NO: DATE:
INTRODUCTION SPECIAL MACHINES – MILLING

MILLING INTRODUCTION:
Milling machine is one of the most versatile conventional machine tools with a wide range of metal cutting
capability.
Many complicated operations such as indexing, gang milling, and straddle milling etc. can be carried out
on a milling machine.
This training module is intended to give you a good appreciation on the type of milling machines and the
various types of milling processes.
Emphasis is placed on its industrial applications, operations, and the selection of appropriate cutting tools.
On completion of this module, you will acquire some of these techniques from the training exercises as illustrated
in figure 1.
However, to gain maximum benefit, you are strongly advised to make yourself familiar with the following
notes before undertaking the training activities, and to have a good interaction between yourself and the staff in
charge of your training.
Assessment of your training will be based on a combination of your skill and attitude in getting the work
done.

Types of Milling Machine:

Most of the milling machine are constructed of column and knee structure and they are classified into two
main types namely Horizontal Milling Machine and Vertical Milling Machine.

The name Horizontal or Vertical is given to the machine by virtue of its spindle axis. Horizontal machines
can be further classified into Plain Horizontal and Universal Milling Machine.

The main difference between the two is that the table of an Universal Milling Machine can be set at an
angle for helical milling while the table of a Plain Horizontal Milling Machine is not.
Horizontal Milling Machine:
Figure shows the main features of a Plain
Horizontal Milling Machine.

Column
The column houses the spindle, the
bearings, the gear box, the clutches, the shafts, the
pumps, and the shifting mechanisms for
transmitting power from the electric motor to the
spindle at a selected speed.

Knee
The knee mounted in front of the column is
for supporting the table and to provide an up or
down motion along the Z axis.

Saddle
The saddle consists of two slideways, one
onthe top and one at the bottom located at 90º to
each other, for providing motions in the X or Y
axes by means of lead screws.

Table
The table is mounted on top of the saddle
and can be moved along the X axis. On top of the
table are some T-slots for the mounting of
workpiece or clamping fixtures.

1. Arbor
The arbor is an extension of the spindle for mounting cutters. Usually, the thread end of an arbor is of
left hand helix.

2. Base
The base of the milling machine, along with the column, are the major structural components. They hold,
align, and support the rest of the machine.

3. Spindle
The spindle holds the tool and provides the actual tool rotation.

4. Spindle Reverse Lever

The position of this lever determines the spindle direction. The three positions of the handle are; In,
Middle, and Out. The middle position is the neutral position. Never move the spindle reverse lever when the
spindle is turning.
5. Spindle Speed Selection Lever

The spindle speed selection lever is used to change the spindle R.P.M. setting. This type of machine
has a geared head so the spindle speed can only be changed when the spindle is stopped.

6. Spindle Clutch Lever

The spindle clutch lever engages the spindle clutch to the motor. By manipulating the spindle clutch
lever theoperator can start and stop the spindle.

7. Feed Rate Selection Lever

The feed rate selection lever is used to change the feed rate setting. The feed rate settings are
expressed ininches per minute.

8. Motor Start and Stop Buttons

The Motor start and stop buttons control the power to the main motor for the machine

Vertical Milling Machine:

Figure 3 shows a vertical milling machine which is of similar
construction to a horizontal milling machine except that the
spindle is mounted in the vertical position. Its additional
features are :-

a. Milling head

The milling head consisting the spindle, the motor, and the
feed control unit is mounted on a swivel base such that it can
be set at any angle to the table.

b. Ram

The ram on which the milling head is attached can be

positioned forward and backward along the slideway on the top
of the column.

Result:
Thus, the Introduction Special Machines – Milling was given.