ENGINEERING WORKSHOP

LAB MANUAL

I – B.TECH

Prepared by

Department of Mechanical Engineering

RISE Krishna Sai Prakasam Groups of Institutions

(Autonomous)
(Approved by AICTE, New Delhi and Affiliated to JNTUK, Kakinada)
Accredited by NAAC, NBA ( CE, EEE ,MECH, ECE & CSE) & ISO 9001-2015 Certified Institution
Near Valluru, Ongole, Tanguturu (MD) Prakasam , Andhra Pradesh -523272
Website: https://www.risekrishnasaiprakasam.edu.in/

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ENGINEERING CURRICULUM - 2023 JNTUK B.Tech. R23 Regulations

L T P C
0 0 3 1.5
ENGINEERING WORKSHOP
(Common to All branches of Engineering)

Course Objectives:

To familiarize students with wood working, sheet metal operations, fitting, electrical house
wiring skills, and basic repairs of two-wheeler vehicle.

Course Outcomes:

CO1: Identify workshop tools and their operational capabilities.

CO2: Practice on manufacturing of components using workshop trades including fitting,
carpentry, foundry and welding.
CO3: Apply fitting operations in various applications.
CO4: Apply basic electrical engineering knowledge for House Wiring Practice

SYLLABUS

1. Demonstration: Safety practices and precautions to be observed in workshop.

2. Wood Working: Familiarity with different types of woods and tools used in wood
working and make following joints.
a) Half Lap joint b) Mortise and Tenon joint c) Corner Dovetail joint or Bridle
joint
3. Sheet Metal Working: Familiarity with different types of tools used in sheet metal
working, Developments of following sheet metal job from GI sheets.
a) Tapered tray b) Conical funnel c) Elbow pipe d) Brazing
4. Fitting: Familiarity with different types of tools used in fitting and do the following
fitting exercises.
a) V-fit b) Dovetail fit c) Semi-circular fit d) Bicycle tire puncture
and change of two-wheeler tyre
5. Electrical Wiring: Familiarity with different types of basic electrical circuits and make
the following connections.
a) Parallel and series b) Two-way switch c) Godown lighting
d) Tube light e) Three phase motor f) Soldering of wires
6. Foundry Trade: Demonstration and practice on Moulding tools and processes,
Preparation of Green Sand Moulds for given Patterns.
7. Welding Shop: Demonstration and practice on Arc Welding and Gas welding.
Preparation of Lap joint and Butt joint.
8. Plumbing: Demonstration and practice of Plumbing tools, Preparation of Pipe joints
with coupling for same diameter and with reducer for different diameters.
9. Basic repairs of Two-wheeler vehicle Demonstration of working of two-wheeler
vehicle and its repairs.
 ENGINEERING WORK SHOP LAB MANUAL

RISE KRISHNA SAI PRAKASAM GROUP OF INSTITUTIONS

ONGOLE, VALLURU VILLAGE.

DEPARTMENT OF MECHANICAL ENGINEERING

Engineering Workshop Lab Manual

Name: _

Reg. No:_

Year/Semester:

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 Department of Mechanical Engineering

VISION OF DEPARTMENT

 To be a competent Mechanical Engineering Department for quality education

with global standards to serve humanity and contribute for the socio-economic
development

MISSION OF DEPARTMENT

 Impart quality education through dedicated faculty and state-of-the art facilities

 Achieve academic excellence in Mechanical Engineering through innovatives

teaching and learning methodologies
 Inculcate professional, managerial and entrepreneurial skills among stake-holders

 Promote industry institute interaction for problem solving

 Involve in life-long learning activities to cater the society needs

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 PROGRAM OUTCOMES
Engineering Graduates will be able to: (POs)
Engineering knowledge: Apply the knowledge of mathematics, science, engineering
PO_1 fundamentals, and an engineering specialization to the solution of complex engineering
problems.
Problem analysis: Identify, formulate, review research literature, and analyze complex
PO_2 engineering problems reaching substantiated conclusions using first principles of
mathematics, natural sciences, and engineering sciences.
Design/development of solutions: Design solutions for complex engineering problems
and design system components or processes that meet the specified needs with appropriate
PO_3
consideration for the public health and safety, and the cultural, societal, and environmental
considerations.
Conduct investigations of complex problems: Use research-based knowledge and
PO_4 research methods including design of experiments, analysis and interpretation of data, and
synthesis of the information to provide valid conclusions.
Modern tool usage: Create, select, and apply appropriate techniques, resources, and
PO_5 modern engineering and IT tools including prediction and modeling to complex
engineering activities with an understanding of the limitations.
The engineer and society: Apply reasoning informed by the contextual knowledge to
PO_6 assess societal, health, safety, legal and cultural issues and the consequent responsibilities
relevant to the professional engineering practice.
Environment and sustainability: Understand the impact of the professional engineering
PO_7 solutions in societal and environmental contexts, and demonstrate the knowledge of, and
need for sustainable development.
Ethics: Apply ethical principles and commit to professional ethics and responsibilities and
PO_8
norms of the engineering practice.
Individual and team work: Function effectively as an individual, and as a member or
PO_9
leader in diverse teams, and in multidisciplinary settings.
Communication: Communicate effectively on complex engineering activities with the
engineering community and with society at large, such as, being able to comprehend and
PO_10
write effective reports and design documentation, make effective presentations, and give
and receive clear instructions.
Project management and finance: Demonstrate knowledge and understanding of the
PO_11 engineering and management principles and apply these to one’s own work, as a member
and leader in a team, to manage projects and in multidisciplinary environments.
Life-long learning: Recognize the need for, and have the preparation and ability to
PO_12 engage in independent and life-long learning in the broadest context of technological
change.

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 Program Specific Outcomes (PSOs)
A Graduate of the Mechanical Engineering Program will be able to:

S. No. After graduation, the students will able to:

Apply their knowledge in the areas of Design and Thermal Engineering for the development
PSO_1
and implementation of mechanical systems .
PSO_2 Apply the principles of Manufacturing Technology and Scientific Management towards
improvements of quality and optimization of products.

Programme Educational Objectives (PEOs)

PEO-1: Pursue higher education and work in the field of Design, Manufacturing and Thermal
Engineering.

PEO-2: Identify, analyze and find a suitable Engineering solution with interdisciplinary
knowledge.

PEO-3: Exhibit professional values to seek realistic solutions of social, economical and
environmental problems with ethical values.

PEO-4: Continue to learn and develop a team and face the competencies with dynamically
changing technological environment.
Course Outcomes:

After completion of this lab the student will be able to

1. Apply wood working skills in real world applications.

2. Build different parts with metal sheets in real world applications.
3. Apply fitting operations in various applications.
4. Apply different types of basic electric circuit connections.
5. Demonstrate soldering and brazing.

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 ENGINEERING WORK SHOP LAB MANUAL

ENGINEERING WORKSHOP
(Common to all branches)

Course Objective:

To familiarize students with wood working, sheet metal operations, fitting and electrical house wiring skills
1. Demonstration: Safety practices and precautions to be observed in workshop.
2. Wood Working: Familiarity with different types of woods and tools used in wood
working and make following joints.
a) Half Lap joint b) Mortise and Tenon joint c) Corner Dovetail joint or Bridle
joint
3. Sheet Metal Working: Familiarity with different types of tools used in sheet metal
working, Developments of following sheet metal job from GI sheets.
a) Tapered tray b) Conical funnel c) Elbow pipe d) Brazing
4. Fitting: Familiarity with different types of tools used in fitting and do the following
fitting exercises.
a) V-fit b) Dovetail fit c) Semi-circular fit d) Bicycle tire puncture
and change of two-wheeler tyre
5. Electrical Wiring: Familiarity with different types of basic electrical circuits and make
the following connections.
a) Parallel and series b) Two-way switch c) Godown lighting
d) Tube light e) Three phase motor f) Soldering of wires
6. Foundry Trade: Demonstration and practice on Moulding tools and processes,
Preparation of Green Sand Moulds for given Patterns.
7. Welding Shop: Demonstration and practice on Arc Welding and Gas welding.
Preparation of Lap joint and Butt joint.
8. Plumbing: Demonstration and practice of Plumbing tools, Preparation of Pipe joints
with coupling for same diameter and with reducer for different diameters.
9. Basic repairs of Two-wheeler vehicle Demonstration of working of two-wheeler
vehicle and its repairs.

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 ENGINEERING WORK SHOP LAB MANUAL

LIST OF EXPERIMENTS
1. Demonstration: Safety practices and precautions to be observed in workshop.
2. Wood Working: Familiarity with different types of woods and tools used in wood
working and make following joints.

a) Half Lap joint b) Mortise and Tenon joint c) Corner Dovetail joint or Bridle joint

3. Sheet Metal Working: Familiarity with different types of tools used in sheet metal
working, Developments of following sheet metal job from GI sheets.
a) Tapered tray b) Conical funnel c) Elbow pipe d) Brazing
4. Fitting: Familiarity with different types of tools used in fitting and do the following
fitting exercises.
a) V-fit b) Dovetail fit c) Semi-circular fit d) Bicycle tire puncture and change of two-wheeler tyre
5. Electrical Wiring: Familiarity with different types of basic electrical circuits and make
the following connections.
a) Parallel and series b) Two-way switch c) Godown lighting

d) Tube light e) Three phase motor f) Soldering of wires

6. Foundry Trade: Demonstration and practice on Moulding tools and processes,

Preparation of Green Sand Moulds for given Patterns.

7. Welding Shop: Demonstration and practice on Arc Welding and Gas welding.
Preparation of Lap joint and Butt joint.
8. Plumbing: Demonstration and practice of Plumbing tools, Preparation of Pipe joints
with coupling for same diameter and with reducer for different diameters.
9. Basic repairs of Two-wheeler vehicle Demonstration of working of two-wheeler

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 ENGINEERING WORK SHOP LAB MANUAL

INDEX
Pag Signature of
S.No NAME OF THE EXPERIMENT Date
e the faculty
No

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 ENGINEERING WORK SHOP LAB MANUAL

WOOD WORKING
INTRODUCTION

Wood work or carpentry deals with making joints for a variety of applications like door
frames, cabinet making furniture, packing etc.,

Timber:
Timber is a name obtained from well grown plants or trees. The timber must cut in such a
way that the grains run parallel to the length. The common defects in timber are knots,
wet rot, dry rotetc.,
Market sizes of timber:
-
Timber is sold in market in various standard shapes and sizes.They are:-
Log:-
The trunk of a tree, which is free from
branches.
Balk:-
The log sawn to have roughly square crosssection.
Post:-
A timber piece, round or square in cross section with more than 275 mm in width,50 to
150 mm in thickness and 2.5 to 6.5 mts
length.
Board:-
A sawn timber piece, below 175 mm in width and 30 mm to 50 mm inthickness.
Reapers:-
Sawn timber pieces of assorted and nonstandard sizes, which don’t conform tothe above
shapes.

WORK HOLDING TOOLS:

Carpentry vice:-
It is a work holding device. When handle vice is turned in a clockwise direction,the
sliding jar forces the work against the fixed sawn. The greater the force appliedto the
handle, the tighter to the work held.
Bar clamp:-
It is a rectangular (or) square block with V-groove on one or both sides oppositeto each
other. It holds cylindrical work pieces.
C-Clamp:-
This is used to hold work against an angle plate or V-block.

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 ENGINEERING WORK SHOP LAB MANUAL

MARKING AND MEASURING TOOLS:

Try square:-
It is used for marking and testing the squareness of planed surfaces. It consists of a steel
blade, fitted in a cast iron stock. It is also used for flatness. The size of a try square used
for varies from 150 mm to 300 mm, according to the length of the blade. It is less accurate
when compared to the try square used in fitting shop.
Marking gauge:-
It is a tool used to mark lines parallel to the edges of wooden pieces. It consists of a
square wooden stem with a riding wooden stock on it. A marking pin, made of steel is
fitted on the stem. A mortise gauge consists of two pins. In these it is possible to adjust the
distance between the pins, to draw two parallel lines on thestock.

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 ENGINEERING WORK SHOP LAB MANUAL

Fig : 1 steel rule fig: 2 marking

Gauge

Fig: 3 steel tape fig: 4 Try square

Fig: 5 corpenter vice Fig: 6 Bar clamp

Fig: 7 metal jack plane Fig: 8 compass and

divider

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 ENGINEERING WORK SHOP LAB MANUAL

Compass and dividers:

This is used for marking circles, arcs, laying out perpendicular lines on the planedsurface of the
wood.
CUTTING TOOLS:
Hack saw:-
It is used to cross cut the grains of the stock. The teeth are so set that the sawkerfs will be
wider than the blade thickness. Hard blades are used to cut hard metals. Flexibleblades
are having the teeth of hardened and rest of the blade is soft and flexible. Chisels:-
These are used for removing surplus wood. Chisels are annealed, hardened andtempered to
produce a tough shank and a hard cutting edge.
Rip saw:-
It is used for cutting the stock along the grains. The cutting edge of this saw makesa sleeper
angle about 60o whereas that saw makes an angle of 45o with the surface ofthe stock.
Tenon saw:
It is used for cutting tenons and in fine cabinet works. The blade of this saw is very thin
and so it is used stiffed with back strip. Hence, this is sometimes calledback saw. The
teeth shapes similar to cross cutsaw.
DRILLING AND BORING TOOLS:
Auger bit:-
It is the most common tool used for boring holes with hardpressure.
Gimlet:-
This is a hand tool used for boring holes with handpressure.
Hand drill:-
Carpenters brace is used to make relatively large size holes, whereas hand drill is used for
drilling small holes. A straight shank drill is used with these tools. It is small light in
weight and may be conveniently used than the brace. The drill is clamped in the chuck.

MISCELLANEOUS TOOLS:
Ball peen hammer:-
It has a flat face, which is used for general work and a ball end is used for riveting.Mallet:-
It is used to drive the chisel, when considerable force is to be applied, steel hammer should
not be used for these purpose, as it may damage the chisel handle. Further, for better to apply
a series of light taps with the mallet rather than a heavy single blow.
Claw hammer:-
It is a striking flat at one end and the claw at the others. The face issued to drive nails into
wood and for other striking purpose and the claw for extracting nails out of wood.
Pinches:-
It is made of steel with a hinged and is used for pulling out small nails from wood.
Wood rasp file:-
It is a finishing tool used to make the wood smooth, remove sharp edge finishing fillets
and other interior surfaces. Sharp cutting teeth are provided on its surfacefor the purpose.
This file is exclusively used in wood work.

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 ENGINEERING WORK SHOP LAB MANUAL

Fig: 9 cross cut saw Fig: 10 Tenon saw Fig: 11 compass saw

Fig: 12 Chisels Fig: 13 Carpenter’s brace Fig: 14 Auger bit

Fig: 15 Gimlet Fig: 16 wood rasp file Fig: 17 Mallet

Fig: 18 Hand drill Fig: 19 Trammel Fig: 20 Claw

hammer
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 ENGINEERING WORK SHOP LAB MANUAL

HALF-LAP JOINT

EXPERIMENT NO: DATE:

Aim: - To make a Half- lap joint.

Tools required: -

1. Carpenter’s vice

2. Steel Rule

3. Try square

4. Jack plane

5. Scriber

6. Cross cut saw

7. Marking gauge

8. Firmer chisel

9. Mallet

10. Wood rasp file and smooth file

Material required: - Wooden pieces of size 50 x 35 x 250 mm–2 Nos.

Sequence of operations: -

1. Measuring and Marking

2. Planning

3. Check for squareness

4. Removal of extra material

5. Sawing

6. Chiseling

7. Finishing

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 ENGINEERING WORK SHOP LAB MANUAL

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 ENGINEERING WORK SHOP LAB MANUAL

Procedure: -

1. The given reaper is checked for dimensions.

2. They are planed with jack plane and checked for straightness.

3. The two surfaces are checked for squareness with a try square.

4. Marking gauge is set and lines are marked at 30 and 45 mm to mark the thickness and
width of the model respectively.

5. The excess material is first chiseled with firmer and then planned tocorrect size.

6. The mating dimensions of the parts X and Y are then marked using steel rule and
marking gauge.

7. Using the crosscut saw, the portions to be removed are cut in both the pieces, followed
by chiseling.

8. The ends of both the parts are chiseled to the exact lengths.

9. The fine finishing is given to the parts, if required so that, properfitting is obtained.

10. The parts are fitted to obtain a slightly tight joint.

Safety precautions: -

1. Loose cloths are to be avoided.

2. Tools to be placed at their proper placed.

3. Hands should not be placed in front of sharp edged tools.

4. Use only sharp tools.

5. Care should be taken, when thumb is used as a guide in crosscutting

and ripping.

6. Handle while chiseling, sawing and planning with care.

Result: - Half- lap joint is made as per the required dimensions.

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 ENGINEERING WORK SHOP LAB MANUAL

CORNER BRIDLE JOINT

EXPERIMENT NO: DATE:

Aim: - To make a Corner Bridle joint.

Tools required: -

1. Carpenter’s vice

2. Steel Rule

3. Try square

4. Jack plane

5. Scriber

6. Cross cut saw

7. Marking gauge

8. Firmer chisel

9. Mallet

10. Wood rasp file and smooth file

Material required: - Wooden pieces of size 50 x 35 x 250 mm–2 Nos.

Sequence of operations: -

1. Measuring and Marking

2. Planning

3. Check for squareness

4. Removal of extra material

5. Sawing

6. Chiseling

7. Finishing

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 ENGINEERING WORK SHOP LAB MANUAL

CORNER BRIDLE JOINT

ALL DIMENSIONS ARE IN MM

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 ENGINEERING WORK SHOP LAB MANUAL

Procedure: -

1. The given reaper is checked for dimensions.

2. They are planed with jack plane and checked for straightness.

3. The two surfaces are checked for squareness with a try square.

4. Marking gauge is set and lines are marked at 30 and 45 mm to mark the
thickness and width of the model respectively.

5. The excess material is first chiseled with firmer and then planned tocorrect
size.

6. The mating dimensions of the parts X and Y are then marked using steelrule and
marking gauge.

7. Using the crosscut saw, the portions to be removed are cut in both thepieces,
followed by chiseling.

8. The ends of both the parts are chiseled to the exact lengths.

9. The fine finishing is given to the parts, if required so that, properfitting

is obtained.

10. The parts are fitted to obtain a slightly tight joint.

Safety precautions: -

1. Loose cloths are to be avoided.

2. Tools to be placed at their proper placed.

3. Hands should not be placed in front of sharp edged tools.

4. Use only sharp tools.

5. Care should be taken, when thumb is used as a guide in crosscutting

and ripping.

6. Handle while chiseling, sawing and planning with care.

Result: - Corner Bridle joint is made as per the required dimensions.

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 ENGINEERING WORK SHOP LAB MANUAL

SHEET METAL WORKING

INTRODUCTION:

Many engineering and house hold articles such as boxes, cans, funnels, ductsetc., are
made from a flat sheet of metals. These process being known as tin smithy. For this,
the development of the article is first drawn on the sheet metal then cut and folded to
form the required shape of the article. The edge of the articles are then secured
through welding, brazing, soldering, rivetingetc.

Sheet metal materials:

A variety of metals used in a sheet metal shop such as black iron, aluminum and stainless
steel. A sheet of soft steel which is coated with molten zinc is known as galvanized iron.
The zinc coat forms a coating that resists rust, improves the appearance of the metal and
permits it to be solderised with greater care.

Hand tools:

The common hand tools used in sheet metals work are steel rule, usually of 60 cm length,
Vise gauge, dot punch, scriber, trammels, ball peen hammer, and straight peen hammer,
cross peen hammer, mallets, snips and soldering iron.

Trammels:-
Sheet metals layouts require marking of arcs and circles. This may be done by usingthe
trammels. The length of the beam decides the maximum size of the arc that canbe scribed.

Wire gauge:-
The thickness of the sheet metal is referred in numbers known as standard wiregauge
(SWG). The gaps in the circumstance of the gauge are used to check the gaugenumber.

Bench shears:

Sheet metal may be cut by shearing action. In this the force is applied through a
compound lever, making it possible to cut sheet metal up to 4mm thick. The chopping hole
can shear a mild steel rod up to 10mm diameter.

Snips:-
Snips are hand shears, varying in length from 200mm to 600mm. 200mm to 250mm
being the commonly used. The straight lines are curved snips or bent snips arefor
trimming along inside curves.

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 ENGINEERING WORK SHOP LAB MANUAL

Hammers:-
Ball peen hammer has a cylindrical slightly curved face and a ball head straight peen and
similar to the cross peen, but it is positioned paralleled to the handle which can be used
conveniently for certain operations of folding.

Stakes:
-
Stakes are nothing but anvils, which are used as supporting tools and to form seam, bend,
rivet sheet metal objects.

Fig: 1 Sheet metal joints

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 ENGINEERING WORK SHOP LAB MANUAL

Fig: 2 Stakes

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 ENGINEERING WORK SHOP LAB MANUAL

Snips:-
Snips are hand shears, varying in length from 200mm to 600mm. 200mm to 250mm
being the commonly used. The straight lines are curved snips or bent snips are for
trimming along inside curves.

Hammers:-
Ball peen hammer has a cylindrical slightly curved face and a ball head straight peen and
similar to the cross peen, but it is positioned paralleled to the handle which can be used
conveniently for certain operations of folding.

Stakes:
-
Stakes are nothing but anvils, which are used as supporting tools and to form seam, bend,
rivet sheet metal objects.

SHEET METAL JOINTS:

Various types of joints are used in sheet metal work to suit the varying requirement.
These are self-secured joints, formed by joining together two pieces of sheets metal and
using the metal itself to form the joints. These joints are to be used on sheets of less than
1.6 mm thickness.

Riveting:-
Rivets are used to fasten two of more sheets of metal together. It is the commonpractice to
use the rivets of the same material as that of the sheets having fastened.

Sheet metal
screws:-
These are used in sheet metal work to join and install duct work for ventilation air
conditioning etc. These screws are also known as self-tapping screws since theycut their
own threads.

Soldering:-
Soldering is one method of joining two pieces of metal with an alloy that melts at a lower
temperature than the metals to be joined for a good job. The metals to be joined must be
free from dirt, grease and oxide. Solder is made of tin and lead in equal proportions. It
comes either in the form of wire and bar.

Soldering iron:-
Soldering requires a source of heating. A common method of transmitting heat ofthe metal
surfaces is by using a soldering iron.

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 ENGINEERING WORK SHOP LAB MANUAL

TAPERED TRAY
EXPERIMENT NO: DATE:

AIM: - To make a tapered tray using the given G.I. Sheet.

TOOLS REQUIRED: -

1. Steel rule
2. Scriber
3. Straight snip
4. Bench vice
5. Stake
6. Cross peen hammer
7. Wooden mallet
8. Cutting pier

MATERIAL REQUIRED: - Galvanized Iron (G.I) sheet 110 x 125 mm size.

SEQUECE OF OPERATIONS:-

1. Cleaning
2. Surface leveling
3. Marking
4. Cutting
5. Folding

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 ENGINEERING WORK SHOP LAB MANUAL

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 ENGINEERING WORK SHOP LAB MANUAL

PROCEDURE: -
1. Clean the given sheet with cotton waste.
2. The size of the given sheet is checked with the steel rule.
3. Flatten the surface of the given sheet with wooden mallet.
4. Check the G.I. Sheet for dimensions and remove extra material, if any.
5. Mark all the measuring lines on the given sheet with scriber.
6. Cut the given sheet with straight snips as required.
7. Fold the given sheet by using stakes and ball peen hammer to therequired
shape.

SAFETY PRECAUTIONS: -

1. For marking purpose use scriber only. Do not use pencil or pen.
2. Sufficient care is to be taken while cutting and folding of G.I. sheet.
3. Remove the waste pieces immediately from the work place.

RESULT: Tapered tray is made as per the required dimensions.

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 ENGINEERING WORK SHOP LAB MANUAL

CONICAL FUNNEL
EXPERIMENT NO: DATE:

AIM: - To make Conical funnel using the given G.I. Sheet.

TOOLS REQUIRED: -
1. Steel rule
2. Scriber
3. Straight snip
4. Bench vice
5. Stake
6. Cross peen hammer
7. Wooden mallet
8. Cutting pier

MATERIAL REQUIRED: - Galvanized Iron (G.I) sheet 160 x 80mm size.

SEQUECE OF OPERATIONS:-

1. Cleaning
2. Surface leveling
3. Marking
4. Cutting
5. Folding

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 ENGINEERING WORK SHOP LAB MANUAL

FUNNEL DEVELOPEMENT

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 ENGINEERING WORK SHOP LAB MANUAL

PROCEDURE: -

1. Clean the given sheet with cotton waste.

2. The size of the given sheet is checked with the steel rule.
3. Flatten the surface of the given sheet with wooden mallet.
4. Check the G.I. Sheet for dimensions and remove extra material, if any.
5. Mark all the measuring lines on the given sheet with scriber.
6. Cut the given sheet with straight snips as required.
7. Fold the given sheet by using stakes and ball peen hammer to the required shape.

SAFETY PRECAUTIONS: -

1. For marking purpose use scriber only. Do not use pencil or pen.
2. Sufficient care is to be taken while cutting and folding of G.I. sheet.
3. Remove the waste pieces immediately from the work place.

RESULT: Conical funnel is made as per the required dimensions.

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 ENGINEERING WORK SHOP LAB MANUAL

FITTING
INTRODUCTION:

Machine tools are capable of producing work at a faster rate, but there are occasions when
components are processed at a bench. Sometimes it becomes necessary to replace
or repair a component that must fit accurately with one another or reassemble. This
involves a certain amount of hand fitting. The assembly machine tools, jigs, gauges etc.,
involves certain amount of bench work.

FITTING TOOLS:
Holding tools:-
Bench vice
V-block with clamp
C-clamp
Bench vice:-
It is a work holding device, when vice handle is turned in a clockwise direction the sliding
jaw forces the work against the fixed jaw, the greater the force applied to the
handle, the tighter is the work held.
V- block with clamp:-
It is a rectangular (or) square block with v-groove on one or both sides, opposite to each
other. It holds cylindrical work pieces.
C-clamp:-
This is used to hold work against an angle plate or v-block.

MARKING AND MEASURING TOOLS:

1. Surface plate
2. Try square
3. Angle plate
4. Scriber
5. Universal scribing block
6. Odd leg caliper
7. Divider
8. Calipers
9. Dot punch
10. Vernier caliper

Surface plate:-
It is used for testing flatness of work piece, for marking out small works.

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Fig: 1 Bench wise Fig: 2 V- Block

Fig: 3 C – Clamp Fig: 4 Surface plate

Fig: 5 Angle plate Fig: 6 Dot punch

Fig: 6 try square Fig: 7 scriber

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Combination cutting pliers: -

This is made of tool steel and is used for cutting as well as for ripping work.
Taps and die holders: -
Tap and wrenches are used for cutting internal threads in a drilled hole.
Dies and die holders:-
They are used for making external threads. Dies are made either solid (or) splittype.

TYPES OF FILES:
Hand file:-
It is a rectangular in section tapered in thickness but parallel in width.
Flat file:-
Rectangular in section and tapered for 1/3rd length in width and thickness.
Square file:-
Square in section and tapered for 1/3rd length on all sides.
Half round file:-
It has one flat face, connecting by a curved (surface) face & tapered for 1/3rdlength.
Round file:-
Circular in cross section and tapered for 1/3rd length, it has double cut teeth.

MISCELLANEOUS TOOLS:
Ball peen hammer:-
It has a flat face, which is used for general work and a ball end is used for riveting.
Screw driver:-
It is designed to turn the screws. The blade is made of steel and is available indifferent lengths
and diameters.
Spanners:-
It is a tool for turning nuts and bolts. It is usually made of forged steel.

FITTING OPERATIONS:
Chipping:-
Removing metal with a chisel is called chipping and is normally used wheremachining is
not possible.
Fitting:-
1. Pinning of files:-
Soft metals cause this; the pins are removed with a file card.
2. Checking flatness and square ness:-
To check flatness across thickness of plate.

MARKING AND MEASURING:

Measurements are taken either from a center line, for visibility of the non-ferrous metals
and oxide coated steels are used.

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Fig: 8 odd leg clamp and divider

Fig: 9 calipers Fig: 10 Vernier caliper

Fig: 11 Parts of hand file

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Fig: 12 Types of files Fig: 13 ball peen hammer

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 ENGINEERING WORK SHOP LAB MANUAL

V-FIT

EXPERIMENT NO: DATE:

AIM: - To make a V-fit from the given two M.S pieces.

TOOLS REQUIRED: -
1. Bench vice
2. Steel rule
3. Try square
4. Ball peen hammer
5. Scriber
6. Hack saw with blade
7. Dot punch and Centre punch
8. Surface plate
9. Rough and smooth flat files
10. Flat chisel and triangular file

MATERIAL REQUIRED: - Mild steel (M.S) plate of size 48 x 34–2

Nos.SEQUECE OF OPERATIONS:-

1. Filing
2. Checking flatness and squareness
3. Marking and measuring
4. Punching
5. Sawing
6. Chipping
7. Finishing

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ALL DIMENSIONS ARE IN MM

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 ENGINEERING WORK SHOP LAB MANUAL

PROCEDURE: -
1. The burrs in the pieces are removed and the dimensions are checkedwith the
steel rule.
2. The pieces are clamped one after the other and the outer mating edgesare filed
by using rough and smooth files.
3. The flatness, straightness and squareness i.e. right angle betweenadjacent sides
are checked with help of Try-square.
4. Chalk is then applied on the surfaces of the two pieces.
5. The given dimensions of the V-fitting are marked carefully.
6. Using the dot punch, dots are punched along the above scribed lines.
7. Using the hack saw, the unwanted portions are removed.
8. Using the flat chisel, the unwanted material in the piece Y is removed.
9. The cut edges are filed by the half round file.
10. The corners of the stepped surfaces are filed by using a square ortriangular
file to get the sharp corners.
11. The pieces (X and Y) are fitted together and the mating is checked forthe
correctness of the fit.

SAFETY PRECAUTIONS: -
1. Care is taken to see that the marking dots are not crossed, which is
indicated by the half of the punch dots left on the pieces.
2. Apply pressure in forward direction during hack sawing.
3. Don’t rub steel rule on the job.
4. Fix blade in hack saw frame with correct tension.
5. During hack sawing the coolant like water or lubricating oil is to be used.
7. Files are to be cleaned properly after using.

RESULT: - The required V-fit is thus obtained as per given dimensions.

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 ENGINEERING WORK SHOP LAB MANUAL

BICYCLE TIRE PUNCTURE AND CHANGE OF TWO

WHEELER TYRE

EXPERIMENT NO: DATE:

AIM: - To repair bicycle tire puncture and change of two wheeler tyre.

TOOLS REQUIRED: -

1. Rim protector
2. Tire Irons
3. Valve core tool
4. Air compressor
5. Bead breaker
6. Silicone lubricant
7. Tire pressure gauge
8. Hand gloves
MATERIALS
REQUIRED: -
1. Bicycle tire puncture kit
BICYCLE TIRE PUNTCURE:
Procedure:
Finding the Puncture:

1. Remove the wheel from the bike.

2. Use tire levers to remove the tire.
3. Locate the hole that’s causing the leak.
4. Mark the hole in the tube.

Patching the hole:

1. Remove any foreign objects from the hole.
2. Sand around the hole if necessary.
3. Apply the patch.
4. Know when replacing the tube is a smarter choice.
Putting the Wheel back together :
1. Replace the tube in the tire.
2. Work the tire and tube back onto the wheel.

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 ENGINEERING WORK SHOP LAB MANUAL

3. Inspect the bead and pump up the tube gradually to let the tube and tire settle.
4. Replace the wheel on the bike.
5. Consider buying a new tube when you can

CHANGE OF TWO WHEELER TYRE:

Procedure:
Taking off the Wheel:
1. Put your bicycle on its side with the chain facing up.
2. Adjust your gears to the smallest ring if you are removing the back tire.
3. Open and remove the quick release lever, if your bike has one.
4. Use a wrench to loosen the nuts if you don’t have a quick release lever.
5. Detach the brake cables if necessary.
6. Lift the wheel off the frame.
Removing the tire and tube:
1. Shift down and hang the bike from a tree or workstand to work on it.
2. Disengage the brakes if they get in the way of removing the wheel.
3. Loosen the nuts that attach the wheel axle to the bike.
4. Pull the chain clear of the gear discs if you are removing the rear wheel.
5. Pull the wheel clear of the bike frame.
Pulling out the old tube:
1. Deflate the tire fully while it’s still on the removed wheel.
2. Pry out a section of the outer tire with two simple levers.
3. Pop out the rest of the tire from the wheel rim.
4. Pull the tube out from between the outer tire and wheel rim.

Installing the new tube:

1. Pump up the replacement tube just until it has a basic circular shape.
2. Feed the new tube between the outer tire and wheel rim.
3. Work the tire back onto the inner rim of the wheel frame.
4. Fill the new tube with air to the recommended tire pressure.

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 ENGINEERING WORK SHOP LAB MANUAL

Reattaching the wheel:

1. Follow the same procedure you used to remove the wheel, only in reverse.
2. Guide the wheel onto the fork on the bike frame.
3. RE-engage the brakes.
4. Tighten the nuts to secure the wheel in place.

RESULT:

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 ENGINEERING WORK SHOP LAB MANUAL

ELECTRICAL WIRING
INTRODUCTION:-
Power is supplied to domestic installations through a phase and a neutral, forming a single
phase. A.C 230V, 2- wire system for industrial establishments. Power is supplied through
three phase four wire system to give 440V. Fig. Shows the power tapping for domestic and
industrial purposes. The neutral is earthed atthe distribution sub-station of the supply.
When supplied to domestic utilizes power is fed to a kilowatt meter and then to a
distribution panel. The panel distributes power along several circuits’ breakers. The panel also
serves as a main switch.
Electrical wiring is defined as a system of electrical conductors, components and apparatus for
conveying electrical power from the source to the point of use. The wiring system must be
designed to provide a constant voltage to the load.

ELEMENTS OF HOUSE WIRING:-

Fuses & circuit Breakers:
These are the devices to provide protection to a circuit against excess current.
Open link
fuses are not in safe in operations, even though they are cheaper and reliable. Itconsists of a
thin strip of metal (or) wire.
Electric switch:
This is a device that makes and breaks or changes the course of electric circuit. It consists
of 2 or more contacts mounted on an insulating structure and arranged such that they may
be moved in to and out of contact with each other by a suitable operating mechanism.
Plug:
It is a device carrying 2 or 3 contact, designed for engagement with corresponding plugs
pins and arranged for connection to fixed wiring and arranged for attachment to
appliances such as radio, T.V, table, fan etc.,
Socket outlet:
It is a device carrying 2 or 3 contacts, designed for engagement with corresponding plug
pins and arranged for connection to fixing wiring.
Lamp holder:-
These are designed to hold lamps & connect them in the circuit. Both bay one cap and
screw lamp holders are available up to 200 watts lamps.
Ceiling rose:-
A ceiling rose consists of a circular base & cover made of Bakelite. The base has 2 or 3
terminal plates. One end of the plate is connected to supply wire connected to pendent
lamp, ceiling fan, exhaust fan, etc.
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 ENGINEERING WORK SHOP LAB MANUAL

Main switch:-
This is a switch intended to connect or cut-off the supply of electrical to the whole of an
installation. It is generally of metal clad type. The metal clad givesgreater strength and safety.
The main switch contains one or more fuses, single phase, and A.C. circuits.

Incandescent light:-
Incandescent means ‘glowing at white heat’. A lamp actually works like heating elements that
it
gives off light by becoming white hot, the amount of power it consume is stamped on the
bulb. Higher the wattage, brighter the light. The bulbs have filaments made of tungsten.

Interior wiring:-
Wires & wire sizes:- A wire is defined as a bare or insulated conductor consisting of one (or)
several strands. An insulating wire consists of a conductor with insulating material made of
Vulcanized Indian Rubber (VIR) (or) Poly Vinyl Chloride (PVC). The wire may consist of 1
or several twisted strands. A multi sore conductor consists of several cores insulated from one
another and enclosed in a common seating. Wire sizes are specified by the diameter of the
wire, using a standard wire gauge (SWG), which also gives an idea of the current carrying
capacity. The specification consists of the both the number of strands and the diameter of the
each wire in it

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 ENGINEERING WORK SHOP LAB MANUAL

PARALLEL AND SERIES

(WIRING FOR TWO LAMPS CONTROL BY ONE SWITCH)

EXPERIMENT NO: DATE:

Two Lamps Connected in Series or Parallel by a One Way Switch: Two lamps may be
connected by a one way switch in parallel for bright glow or in series for dull glow. This is
recommended when the intensity in the room as to be controlled.
SERIES

AIM: - To give connection to two lamps, controlled With Independent SwitchControls

with or Without Looping.
TOOLS REQUIRED: -
1. Screw driver
2. Cutting pliers
3. Ball peen hammer
4. Insulation remover
5. Tester
MATERIAL REQUIRED: -
1. Wooden wiring board
2. Silk wire
3. Electrical bulbs - 2 No
4. One-way switch - 1No
5. Wooden round blocks - 1 No
6. Batten lamp holders - 1 No
7. Wire clips
8. Nails
9. Screws

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 ENGINEERING WORK SHOP LAB MANUAL

PROCEDURE: -

1. The outline of the wiring diagram is marked on the wooden wiringboard.

2. Clips are nailed to the board, following the wiring diagram.
3. Wires are stretched and clamped with the clips.
4. Round blocks are screwed on to the board, as per the diagram.
5. Wires are connected to the holders and the switch, which are thenscrewed
on to the round blocks.
6. Bulb is fitted to the holder.
7. The wiring connections are tested, by giving power supply.

SAFETY PRECAUTIONS: -

1. Electricity has no respect for ignorance. Do not apply voltage or turn-on any
device until it has been properly checked.
2. Care should be taken from electrical shocks.
3. Don’t touch the connection points.
4. Avoid loose connection.
5. Don’t work at damped areas and with wet clothing.
6. Handle the lamp carefully.

Result: - The electrical circuit, for two lights controlled by one switch in paralleland
series is thus made.

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 ENGINEERING WORK SHOP LAB MANUAL

TWO -WAY SWITCH

EXPERIMENT NO: DATE:

AIM: - To give connections to one light controlled by 2 two-way switches.TOOLS

REQUIRED: -
1. Screw driver
2. Cutting pliers
3. Ball peen hammer
4. Insulation remover
5. Tester
6. 2 two-way switches

MATERIAL REQUIRED: -

1. Wooden wiring board

2. Silk wire
3. Electrical bulb - 1 No
4. Two -way switches - 2Nos
5. Wooden round block - 3 Nos
6. Batten lamp holder - 1 No
7. Wire clips
8. Nails
9. Screws

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 ENGINEERING WORK SHOP LAB MANUAL

Fig:1 One lamp controlled by 2 two – way switches

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 ENGINEERING WORK SHOP LAB MANUAL

PROCEDURE: -
1. The outline of the wiring diagram is marked on the wooden wiring board.
2. Clips are nailed to the board, following the wiring diagram.
3. Wires are stretched and clamped with the clips.
4. Round blocks are screwed on to the board, as per the diagram.
5. Wires are connected to the holders and the switch, which are thenscrewed
on to the round blocks.
6. Bulb is fitted to the holder.
7. The wiring connections are tested, by giving power supply.

SAFETY PRECAUTIONS: -
1. Electricity has no respect for ignorance. Do not apply voltage or turn-on anydevice
until it has been properly checked.
2. Care should be taken from electrical shocks.
3. Don’t touch the connection points.
4. Avoid loose connection.
5. Don’t work at damped areas and with wet clothing.
6. Handle the lamp carefully.

RESULT: -

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 ENGINEERING WORK SHOP LAB MANUAL

TUBELIGHT

EXPERIMENT NO: DATE:

Tube light: Tube lights are the commonly used light sources for illumination in the houses,
industries, commercial organizations etc. A tube light is a low pressure mercury discharge lamp with
internal surface coated with suitable fluorescent material.

AIM: - To give connections to tube light.

TOOLS REQUIRED: -
1. Screw driver
2. Cutting pliers
3. Ball peen hammer
4. Insulation remover
5. Tester
6. 2 two-way switches

MATERIAL REQUIRED: -

1. Wooden wiring board

2. Silk wire
3. Electrical bulb - 1 No
4. Two -way switches - 2Nos
5. Wooden round block - 3 Nos
6. Batten lamp holder - 1 No
7. Wire clips
8. Nails
9. Screws
10.Starter
11. Ballast

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 ENGINEERING WORK SHOP LAB MANUAL

PROCEDURE: -
1. The outline of the wiring diagram is marked on the wooden wiring board.
2. Clips are nailed to the board, following the wiring diagram.
3. Wires are stretched and clamped with the clips.
4. Round blocks are screwed on to the board, as per the diagram.
5. Wires are connected to the holders and the switch, which are thenscrewed
on to the round blocks.
6. Bulb is fitted to the holder.
7. The wiring connections are tested, by giving power supply.

SAFETY PRECAUTIONS: -
1. Electricity has no respect for ignorance. Do not apply voltage or turn-on anydevice
until it has been properly checked.
2. Care should be taken from electrical shocks.
3. Don’t touch the connection points.
4. Avoid loose connection.
5. Don’t work at damped areas and with wet clothing.
6. Handle the lamp carefully.

RESULT: -

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 MOULDING TOOLS AND EQUIPMENTS

Slick

Lifter

Strike off bar

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 FOUNDRY: SAND MOULDING

SLICK:

It is a small double-ended tool having a flat on one end and a spoon shape on the
other end as shown in the figure. This tool is also made ode of a variety of shapes. The
type most commonly obtained is the oval spoon. Slicks are commonly used for repairing
and finishing small surfaces of the mould.

LIFTER:
Lifter are made of thin sections of steel of various widths and lengths with one
end bent at right angles as shown in the adjacent fig. They are used to clean and finish the
bottom and sides of deep, narrow openings in moulds.

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 STRIKE OFF BAR:
The strike off bar is a piece of metal or wood with a straight edge as shown in the
fig. It is used to stickle or strike off excess sand from the mould after ramming to provide
a level surface

SHOVEL:
A shovel is used for mixing and tempering the moulding sand and for moving the
moulding sand from the pit to the flask.

Sprue pin

Mallet

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 Riddle

SPRUE PIN:
A sprue pin is a tapered peg pushed through the cope the joint of the mould. As
the peg is withdrawn it removes the sand, leaving an opening for the metal. This opening
is called the sprue through which the metal is poured. The sprue pin forms the riser pin as
shown in the fig.

MALLET:
A mallet is used to loosen the pattern in the mould so that it can be withdrawn
without damaging the mould.

HAND RAMMER:
A hand rammer is a wooden tool for packing or ramming the sand into the mould.
One end is called the peen, is wedge shaped and the opposite side is called as the butt,
and has a flat surface as shown in the figure. Floor rammers are similar in construction
but have long handles.
Pneumatic rammers are used in large moulds saving considerable time and labour.

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 Gaggers
Vent rod Draw Spike

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 TROWEL:
A trowel consists of a metal blade fitted with a wooden handle as shown in figure.
Trowels are employed in order to smooth or sleek over the surfaces of the moulds. A
moulder also uses them in repairing the damaged portions of the mould. The usual trowel
is rectangular in shape and has either a round or square end.

STRIKE OFF BAR:

The strike off bar is a piece of metal or wood with a straight edge as shown in the
fig. It is used to stickle or strike off excess sand from the mould after ramming to provide
a level surface.

VENT ROD:
A vent rod or wire used makes a series of small holes to permit the gases to
escape while the molten metal is being poured.

DRAW SPIKE:
The draw spike is a pointed steel rod, with a loop and end as shown in fig 11.1. It
is used to rap and draw patterns from the sand. The draw spike is used to thread on end to
engage metal parts.

GAGGERS:
Gaggers sometimes know as lifters are iron rods bent at one end or both the ends
as shown in fig 11.2. They are used for reinforcement of sand in the top part of a
moulding box, and to support the hanging bodies of sand.

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SOLID PIECE PATTERN

Step by step procedure of preparing mould cavity

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 Model I

PREPARATION OF A SAND MOULD USING SOLID PATTERN

Aim: To prepare a mould cavity by using a solid / single piece pattern.

Apparatus Used: Moulding Flasks, Solid / Single piece pattern, Sand Rammers, Trowel,
Leveler, Vent Road, and Moulding Sand Mixture.

Procedure (Refer Figure 11)

1. Prepare the moulding sand mixture by adding adequate amounts of clay and water to it.
2. Keep the drag on the bottom board in the inverted position.
3. Locate the centre of the drag half by drawing two diagonals.
4. Place the pattern in the center.
5. Fill the drag half of the mould flask by green sand prepared as in step 1.
6. Ram the sand by using a sand rammer to form a hard mass.
7. Strike off the excess sand a level with a leveler (Strike off bar).
8. Sprinkle parting sand on the top surface of the drag half of the mould.
9. Place the cope on the drag half of the mould.
10. Place the riser pin on the pattern centre and place the sprue pin on the drag at a
convenient distance from the pattern.
11. Now by holding the sprue and the sprue and the riser pins fill the cope with the moulding
sand and ram it properly.
12. By using a vent rod pierce the holes on the top surface of the cope half.
13. Loosen the sprue pins and remove them from the rammed portion carefully.
14. Remove the cope and place it inverted.
15. By using sand lifters remove the drag and cut in gates and sprue base.
16. Shake the pattern by using a mallet without disturbing the mould cavity.
17. Remove the pattern carefully.
18. Clean the pattern carefully.
19. Place the cope on the drag and close the mould cavity.
Result: The mould cavity similar to the drawing specifications shown is obtained.

RISE Krishna Sai Prakasam Groups of Institutions, Department of Mechanical Engineering 77

 MODEL II

PREPARATION OF A SAND MOULD USING SPLIT PIECE PATTERN

SPLIT PIECE PATTERN

Aim: To prepare a mould cavity by using a Split piece pattern as shown in the fig.

Apparatus Used: Moulding Flasks, Solid/ Split piece pattern, Sand Rammers, Trowel, Leveler,
Vent Rod, and Moulding Sand Mixture, bottom board.

Procedure:
1. Prepare the moulding sand mixture by adding adequate amount of clay and water to it.
2. Keep the drag on the bottom board in the inverted position.
3. Locate the centre of the drag half by drawing two diagonals.
4. Place one half of the split pattern in the centre.
5. Fill the drag half of the mould flask by green sand prepared as in step 1.
6. Ram the sand by using a sand rammer to from a hard mass.
7. Strike of the excess sand a level with a leveler (Strike off bar)
8. Sprinkle parting sand on the top surface of the drag half of the mould.
9. Place the cope on the drag half of the mould.
10. Place the cope half of the pattern on the drag half in proper alignment of the dowel pins.

RISE Krishna Sai Prakasam Groups of Institutions, Department of Mechanical Engineering 78

 11. Place the riser pin the pattern centre and place the sprue pin on the drag at a convenient
distance from the pattern.
12. Now by holding the sprue and the sprue and the riser pins fill the cope with the moulding
sand and ram it properly.
13. By using a vent rod pierce the holes on the top surface of the cope half.
14. Loosen the sprue pins and remove them from the rammed portion carefully.
15. Remove the cope and place it inverted.
16. By using sand lifters remove the drag and cut in gates and sprue base.
17. Shake the patterns in both the halves by using a mallet without disturbing the mould
cavity.
18. Remove the patterns carefully.
19. Clean the cavities for any loose sand.
20. Place the cope on the drag and close the mould cavity.

Result: The mould cavity similar to the drawing specifications shown is obtained.

RISE Krishna Sai Prakasam Groups of Institutions, Department of Mechanical Engineering 79

 WELDING
1. INTRODUCTION

Welding is a process by which metals are joined by heating them to a suitable temperature
with or without the application of pressure and addition of filler materials. Welding processes are
employed in most of the modern fabrication works and industries.

2. CLASSIFICATION OF WELDING PROCESSES

Welding processes are broadly classified under two main headings:-

i) Pressure welding or Plastic welding processes
ii) Non Pressure welding or Fusion welding processes

i) Pressure welding or Plastic welding : - In this process, the ends of metal pieces to be joined are
heated to plastic state and are joined together by applying pressure on them. No additional
filler material is used.
eg: Blacksmith welding, Resistance welding, Cold pressure welding etc.

ii) Non Pressure welding or Fusion welding:- here the material at the joint is heated to molten
state (fusion state) and allowed to solidify. Thus the two parts are joined together without the
application of any pressure. It uses a filler material such as an electrode.
eg: Gas welding, Arc welding, Thermit welding etc.

3. ARC WELDING

Arc welding is a fusion welding process in which welding is done by producing heat from an
electric arc between the work and electrode. Both D.C. and A.C. electric supply are used for this.
The arc between the two terminals produces heat to melt the metal. If two pieces of metal that are to
be joined are placed so that they touch or almost touch one another and the arc from the electrode is
directed at this junction, the heat generated by the arc (approx. 3500oC) causes a small section of the
edges of both pieces to melt. These molten portions along with the molten portions of the electrode
flow together. As the arc column is moved, the molten puddle solidifies joining the two pieces of
metal with a combinmation of electrode and base metal.

There are different methods of arc welding in practice as listed below:

i) Metal Arc Welding

ii) Carbon Arc Welding
iii) Atomic Hydrogen Arc Welding
iv) Tungsten inert gas Arc Welding (TIG)
v) Metal inert gas Arc Welding (MIG)
vi) Submerged Arc Welding
vii) Plasma Arc Welding

RISE Krishna Sai Prakasam Groups of Institutions, Department of Mechanical Engineering 82

3.1 Metal Arc Welding

The commonly used arc welding method is metal arc welding. In this process a metal
electrode is used. The metal electrode itself melts and acts as a filler material.

An arc welding circuit consists of the following essential items:

a) The power source ie the Welding machine

b) Welding lead cable and electrode holder
c) Welding return cable and clamp
d) Welding earth

3.2 Arc Welding Machines

There are three types of welding machines in use:

i) Welding transformer
ii) Welding generator
iii) Welding rectifier

i) Welding transformer
It is used to change the voltage and current to the desired range suitable for welding.
Normally low voltage high current (high amperage) supply is preferred for welding. The welding
transformer operates on A .C. supply only and it has no rotating parts. It is a step down transformer
which reduces the main supply voltage (220 or 440 V) to the welding supply open circuit voltage
between 40 and 100 V.

ii) Welding generator

It is used to generate D.C supply for arc welding. It may be driven by an A.C. motor or
driven by a petrol or diesel engine. It can be used anywhere in the field work, away from the electric
lines.

iii) Welding rectifier

It is used to convert A.C. into D.C welding supply and does not have any rotating parts. It is
basically a transformer, but the output of which is connected with a rectifier to change the A.C in to
D.C

3.3 Welding Electrode

Electrode is a conductor from which an arc struck. The arc melts electrode and parent metal.
They join together to form a good weld when solidifies. The electrode is a core, coated with a solid
flux acts as a filler material and is consumed during welding by keeping a constant arc length. The
flux when melts produces a slag which floats on the metal pool, protects the weld from oxidation.
The flux of electrode mainly contains cellulose (burns and produces a gaseous shield around the
arc), calcium carbonate and calcium fluoride (impart fluidity to the slag), Iron powder (for higher
penetration and deposition), Titania (for stabilising the arc), asbestos etc.

RISE Krishna Sai Prakasam Groups of Institutions, Department of Mechanical Engineering 83

 Electrodes are available in different standard lengths of 450, 350, 300and 200 mm. A core
length of 25mm from one end is left uncoated for holding in the electrode holder. It is mainly
specified by its core diameter.

Electrode size in mm Gauge No.(SWG) Current range in ampere (A)

1.6 16 40-60
2.5 12 50-80
3.2 10 90-130
4.0 8 120-170
5.0 6 130-270
6.0 4 300-400

4. GAS WELDING

Oxy-fuel welding, commonly referred to as oxy welding or gas welding is a process of

joining metals by application of heat created by gas flame. The fuel gas commonly acetylene, when
mixed with proper proportion of oxygen in a mixing chamber of welding torch, produces a very hot
flame of about 3150 - 3300 oC .

Different gases suitable for welding and cutting are Acetylene, hydrogen, LPG, Methane etc.

4.1 Oxy- Acetylene Gas Welding

The oxy-acetylene welding process uses a combination of oxygen and acetylene gas to
provide a high temperature flame. The high temperature flame melts the metal faces of the work-
pieces to be joined, causing them to flow together. A filler metal alloy is normally added and
sometimes used to prevent oxidation and to facilitate the metal union.

OXY-ACETYLENE GAS WELDING APPARATUS

Oxy-fuel apparatus consists of two cylinders (one oxygen and one acetylene) equipped with
two regulators, pressure gauges, two lengths of hose, and a blow torch. The regulators are attached
to cylinders and are used to reduce and maintain a uniform pressure of gases at the torch. The gases
at reduced pressure are conveyed to the torch by the hoses. The regulators include high pressure and
low pressure gauges to indicate the contents of the cylinder and the working-pressure on each hose.
When the gases reach the torch they are there mixed and combustion takes place at the welding tip
fitted to the torch.

RISE Krishna Sai Prakasam Groups of Institutions, Department of Mechanical Engineering 84

 The basic equipments used to carry out gas welding are:
1. Oxygen gas cylinder (coloured in black) with valve made of brass having right hand threads
2. Acetylene gas cylinder (coloured in maroon/red) with valve having left hand threads
3. Oxygen pressure regulator
4. Acetylene pressure regulator
5. Oxygen gas hose(Black)
6. Acetylene gas hose(Red/maroon)
7. Welding torch or blow pipe with a set of nozzles and gas lighter
8. Trolleys for the transportation of oxygen and acetylene cylinders
9. Set of keys and spanners
10. Filler rods and fluxes
11. Protective clothing for the welder (e.g., asbestos apron, gloves, goggles, etc.)

WELDING TORCH ( BLOW PIPE)

A welding torch mixes oxygen and acetylene in the desired proportions, burns the mixture at
the end of the tip, and provides a means for moving and directing the flame.

Fig : Welding Torch

RISE Krishna Sai Prakasam Groups of Institutions, Department of Mechanical Engineering 85

There are two types of welding torches, namely:
a) High pressure (or equal pressure) type
b) Low pressure (or injector) type

High pressure blowpipes or torches are used with (dissolved) acetylene stored in cylinders at a
pressure of 117 psi. Low pressure blowpipes are used with acetylene obtained from an acetylene
generator at a pressure of 8 inch - head of water (approximately 0.3 psi).
To change the power of the welding torch, it is only necessary to change the nozzle tip (size) and
increase or decrease the gas pressures appropriately.

4.2 Types of Gas Welding Flames

In oxyacetylene welding, flame is the most important tool. All the welding equipment simply serves
to maintain and control the flame. The flame must be of the proper size, shape and condition in order
to operate with maximum efficiency. Three distinct types of flames are possible on adjusting the
proportions of acetylene and oxygen:
1. Neutral Flame (Acetylene oxygen in equal proportions)
2. Oxidizing Flame (Excess of oxygen)
3. Reducing Flame (Excess of acetylene)

Fig : Types of Welding Flames

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86
 5. TOOLS AND ACCESSORIES USED IN WELDING SHOP

i) Flat file

A file is a hardened piece of high grade steel with slanting rows of teeth and is used for
removing excess material to smooth or fit metal parts. Files are generally forged out of high carbon
steel or tungsten steel followed by cutting of teeth, hardening and tempering.

iii) Hack saw

The hack saw is used to cut metals of different sections. The main parts are frame, handle
and a replaceable blade. The blades are available in standard lengths 225, 250 and 300mm.

iv) Try square

Try square is mainly used for checking the squarness of surfaces or edges which are
adjacent, flatness of a filed surface and for marking out lines on workpieces. It consists of a blade
and stock which are made of steel fixed rigidly at 90o to each other.

v) Steel rule/ Brass rule

The steel rule consists of a hardened steel strip having line graduations etched or engraved in
it. They are usually 150mm or 300mm long and is used to take linear measurements to an accuracy
of 1mm or 0.5mm. The brass rule is similar to steel rule, but it is made of brass. Since the brass
possess low coefficient of linear expansion, its dimensional accuracy will be more reliable in heated
regions.

vi) Ball peen hammer

Hammer is a hand tool made of tool steel, largely used for striking on the metals. A hammer is
named by its peen. The ball shaped peen hammer is known as ball peen hammer. The peen and face
are hardened.

vii) Punches

Punches are percussion tools and are manufactured from tool steel. They are used on any scribed
lines by indentations. Tips are tapered, hardened and tempered. The shanks are knurled for easier
handling and gripping. The punch whose tip is tapered at an angle of 90o is known as centre punch
used to mark centres to be drilled or to mark centre of an edge. A dot punch with tip tapered at 60o
is used to punch a chain of dots on a scribed line.

viii) Chipping hammer

It is a welding tool used to remove slag from the weldment
ix) Electrode holder
It is used to hold the electrode properly. Its mouth grips the electrode and passes current to
the electrode through the welding cable connected at the other end of the holder. It should be well
insulated.

RISE Krishna Sai Prakasam Groups of Institutions, Department of Mechanical Engineering 87

 x) Tongs
They are used to handle the hot metal (welding job) for positioning or while cleaning.
xi) Wire brush
It is used for cleaning the surface of the metal as well as for the slag from the welds. The
wire brush is made of steel wires fitted on a wooden piece.

xii) Apron
It protects the welder’s body and clothes from heat and sparks. Usually leather apron is
employed.
xiii) Face shield / eye shield ( Welding screen)
It is used to prevent direct rays of arc, weld spatter and slag and protects the operator’s eyes
and face. It consists of a cover slag and a dark filter glass. The filter glass absorbs the ultra violet
rays radiated by the arc.

xiv) Hand gloves

Mainly leather gloves are used to protect arm from welding spark and heat.
xv) Earth clamp
It is used to connect the return lead firmly to the work piece or to the welding table.

6. POSITIONS OF WELDING

All welding can be classified according to the position of the workpiece or the position of the
welded joint on the plates or sections being welded.

There are four basic welding positions, which are illustrated in figure below

Fig : Positions of welding

Reference:
1. P.Kannaiah and K.L.Narayana Workshop Manual. Scitech Publications, 1996
2. D. Venugopal Basic Engineering Workshops: Pheory and Practice. Arathy Publications, 2006
3. G.Sukumaran Basic Engineering Workshops. Link Books, 2003
4. A. Bhatiya Fundamentals of Gas Cutting and Welding. Course No: D06-002
Continuing Education and Development, Inc. 9 Greyridge Farm Court Stony Point, NY

RISE Krishna Sai Prakasam Groups of Institutions, Department of Mechanical Engineering 88

 PREPARATION OF BUTT JOINT USING ARC WELDING

AIM: To prepare double V-butt welding using electric arc welding process.
TOOL REQUIRED:
1. Steel rule,
2. Scriber,
3. Hand hack saw,
4. Flat file,
5. Shield, gloves,
6. Wire brush,
7. Chipping hammer,

EQUIPMENT REQUIRED: Welding machine (Transformer)

MATERIAL REQUIRED: Mild steel plate of 50 x50x5 thickness, Welding Electrodes.

THEORY:
Electrical arc welding is the procedure used to join two metal parts, taking advantage
of the heat developed by the electric arc that forms between an electrode (metal filler) and the
material to be welded. The welding arc may be powered by an alternating current generator
machine (welder). This welding machine is basically a single-phase static transformer
suitable for melting Rutile (sliding) acid electrodes. Alkaline electrodes may also be melted
by alternating current if the secondary open-circuit voltage is greater than 70 V. The welding
current is continuously regulated (magnetic dispersion) by turning the hand wheel on the
outside of the machine, which makes it possible to select the current value, indicated on a
special graded scale, with the utmost precision. To prevent the service capacities from being
exceeded, all of our machines are fitted with an automatic overload protection which cuts of
the power supply (intermittent use) in the event of an overload. The operator must then wait
for a few minutes before returning to work. This welding machine must be used only for the
purpose described in this manual. Read the entire contents of this manual before installing,
using or servicing the equipment, paying special attention to the chapter on safety
precautions. Contact your distributor if you do not fully understand these instructions

89

RISE Krishna Sai Prakasam Groups of Institutions, Department of Mechanical Engineering

 Experiment diagram for v butt joint
PROCEDURE:
1. Given 2 M.S. plates are filled at an angle of 450 at 2 surfaces to be joined (V groove is
formed)
2. Electrode is fixed to electrode holder.
3. Connections to be given such that electrode
electrode- negative and work piece positive.
4. Welding is to be done carefully for the half-length
half of the plates.
5. The work piece is to be cut into two halves by power hacksaw.
6. The beads are polished, etched with two percent natal solution and studied under the
microscope whose magnification fact
factors 10X for the heat effected zone.
7. By gripping the beads b/w the jaws pf Tensile testing machine and load is applied until the
work piece breaks and the readings is to be noted.

90
 8. The same procedure is repeated for the remaining half which is welded by reverse polarity
and th results are to be compared.

RESULT : Prepared double V- butt joint using electric arc welding Process.

Viva Questions:
1. What are the basic requirements of welding?
2. What is ARC welding. Explain in detail?
3. Explain the classification of welding processes?
4. What are the different types of welded joints?
5. Write about design of welded joints?
6. What is ARC blow in arc welding?
7. Write about arc welding and its application?
8. Define arc welding?
9. what is the phenomena of weld decay occurs in?
10. List the classification of welding?
11. Define weld joints?
12. Sketch different types of weld joints?
13. Explain the factors affecting the heat affected zone?
14. Define ARC welding. Explain in detail?
15. State the classification of welding?
16. Describe the basic requirements of welding?
17. Define ARC in arc welding?
18. Explain about arc welding and its application?
19. Explain the working of a welding process?
20. Define welding? What are the basic requirements of welding?
21. Explain any two methods of welding?
22. Explain about arc welding?
23. Explain any two methods of welding?
24. Purpose of flux is used in welding?
25. Why preheating is essential in welding of which material?
26. Upto what thickness of plate, edge preparation for welding is not required?
27. Define welding?
28. Give classification of welding process?

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 29. Define Arc welding?
30. What is effect of polarity on weld strength?
31. How much gap should maintain between weld electrodes and work piece?
32. What type of flux used on weld rods?
33. What is the minimum voltage for arc initiation?
34. What is the effect of current on weld strength?
35. What are different arc welding processes?
36. What is difference between arc welding and gas welding?
37. What do you mean by backward welding and forward welding?
38. The temperature of arc in case of arc welding is?
39. In arc welding, arc initiation voltage is of the order ?
40. A gap of is maintained for producing sound weld ?

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RISE Krishna Sai Prakasam Groups of Institutions, Department of Mechanical Engineering

 PREPARATION OF LAP JOINT USING ARC WELDING

AIM: To prepare the lap joint using electric arc welding process.

TOOL REQUIRED:
Steel rule,
Scriber,
Hand hack saw,
Flat file,
Shield, gloves,
Wire brush,
Chipping hammer,
EQUIPMENT REQUIRED: Welding machine (Transformer)
MATERIAL REQUIRED: Mild steel plate of 50x50x5 thickness, Welding Electrodes.
THEORY:
Electrical arc welding is the procedure used to join two metal parts, taking advantage
of the heat developed by the electric arc that forms between an electrode (metal filler) and the
material to be welded. The welding arc may be powered by an alternating current generator
machine (welder). This welding machine is basically a single-phase static transformer
suitable for melting Rutile (sliding) acid electrodes. Alkaline electrodes may also be melted
by alternating current if the secondary open-circuit voltage is greater than 70 V. The welding
current is continuously regulated (magnetic dispersion) by turning the hand wheel on the
outside of the machine, which makes it possible to select the current value, indicated on a
special graded scale, with the utmost precision. To prevent the service capacities from being
exceeded, all of our machines are fitted with an automatic overload protection which cuts of
the power supply (intermittent use) in the event of an overload. The operator must then wait
for a few minutes before returning to work. This welding machine must be used only for the
purpose described in this manual. Read the entire contents of this manual before installing,
using or servicing the equipment, paying special attention to the chapter on safety
precautions. Contact your distributor if you do not fully understand these instruction

93

RISE Krishna Sai Prakasam Groups of Institutions, Department of Mechanical Engineering

 EXPERIMENT DIAGRAM FOR LAP JOINT:

PROCEDURE FOR LAP JOINT:

1. Two pieces are cut to size and surfaces to be welded are cleaned properly.
2. Electrode is held in electrode
rode holder and earth clamp is clamped to be work piece.
3. The pieces are positioned overlapping each other for lap joint and tack weld is done
at two end points.
4. 2-33 mm spark gap is maintained and welding is done smoothly.
5. Slag is removed using chipping hammer and weld is cleaned using wire brush.

PRECAUTIONS:
1. Wear apron, shoes, nose mask, gloves and
tight fitted clothes. Be careful and attentive
while working on welding job.
2. During welding don’t see the welding light rrage directly without the
gaggle face shield.
3. Do not cool the welding piece in water.
4. Do not keep electrode holder on the welding machine.
5. No inflammable material should be present in welding shop.

RISE Krishna Sai Prakasam Groups of Institutions, Department of Mechanical Engineering 94

 RESULT: To prepared Joints for welding suitable for lap welding .

Experiments different from JNTUK syllabus:

1. Prepare T-Joint from the given MS material 50 x 50 x 5mm.

2. Prepare L-Joint from the given MS material 50 x 50 x 5mm.

3. Prepare H-Joint from the given MS material 50 x 50 x 5mm.

VIVA QUESTIONS:
1. What are the basic requirements of welding?
2. What is ARC welding? Explain in detail?
3. Explain the classification of welding processes?
4. What are the different types of welded joints?
5. Write about design of welded joints?
6. What is ARC blow in arc welding?
7. Write about arc welding and its application?

RISE Krishna Sai Prakasam Groups of Institutions, Department of Mechanical Engineering 95

 8. Define arc welding?
9. what is the phenomena of weld decay occurs in?
10. List the classification of welding?
11. Define weld joints?
12. Sketch different types of weld joints?
13. Explain the factors affecting the heat affected zone?
14. Define ARC welding. Explain in detail?
15. State the classification of welding?
16. Describe the basic requirements of welding?
17. Define ARC in arc welding?
18. Explain about arc welding and its application?
19. Explain the working of a welding process?
20. Define welding? What are the basic requirements of welding?
21. Explain any two methods of welding?
22. Explain about arc welding?
23. Explain any two methods of welding?
24. Purpose of flux is used in welding?
25. Why preheating is essential in welding of which material?
26. Up to what thickness of plate, edge preparation for welding is not required?
27. Define welding?
28. Give classification of welding process?
29. Define Arc welding?
30. What is effect of polarity on weld strength?
31. How much gap should maintain between weld electrodes and work piece?
32. What type of flux used on weld rods?
33. What is the minimum voltage for arc initiation?
34. What is the effect of current on weld strength?
35. What are different arc welding processes?
36. What is difference between arc welding and gas welding?
37. What do you mean by backward welding and forward welding?
38. The temperature of arc in case of arc welding is?
39. In arc welding, arc initiation voltage is of the order?
40. A gap of is maintained for producing sound weld?

RISE Krishna Sai Prakasam Groups of Institutions, Department of Mechanical Engineering 96

 Plumbing Shop
5.1 Introduction
Plumbing deals with the
l a yi n g o f a p i p e l i n e . A c r a f t s m a n m a y b e p e r f e c t l y p r o fi c i e n t w i t h the
hammer, saw and other tools, but the faces difficulties with leaking pipes and over
flowing toilets. Many people rush to a plumber on seeking a tripping pipe, but a
person with a little knowledge of the sanitary system can control this problem
easily, saving time and, one with help of few tools.
5.2 Plumbing tools
The tools used by a plumber can be classified as follows1. Pipe wrench2. Hacksaw3 .
P l u m b b o b 4 . P i p e v i c e 5 . D i e s 6. Pipe cutter7. Files and Rasps
5.2.1 Pipe wrench
A pipe wrench is used for holding and turning the pipes, rods and machine
parts. Wrenches are classified as (1)Fixed wrenches and (2) Adjustable wrenches.

Figure 5.1: Pipe Wrench

5.2.2 Pipe vice

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

Figure 5.2: Pipe Vice

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 5.2.3 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 Figure 5.3.

Figure 5.3: Pipe cutter

5.2.4 Hack saw

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

Figure 5.4: Hacksaw

5.2.5 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.

RISE Krishna Sai Prakasam Groups of Institutions, Department of Mechanical Engineering 107
 Figure 5.5: Threading dies and taps
5.2.6 Files and rasps
The file surface is covered with sharp edged teeth and its used for removing metal
by rubbing. A rasp is used for finishing the surface of the work piece.
5.2.7 Plumb bob
It is used for check the vertical line and made up of steel or brass.

Figure 5.6: Plumb bob

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

Figure 5.7: Pipe fittings

RISE Krishna Sai Prakasam Groups of Institutions, Department of Mechanical Engineering 108
 5.2.9 Coupling
It is a short a cylindrical sleeve with internal threads throughout. A couplings is used for joining
two pipes in a straight and bend where at least one pipe can be turned.
5.2.10 Union
A union is used for joining two pieces of pipes, where either can be turned. It
consists of three parts, two parts joint can be screwed, in to two pipe ends, and the third on for
tightening called centre part.
5.2.11 Nipple
A nipple is a short piece of pipe with external threads at both ends. It is used to
make up the required length of a pipe line.
5.2.12 Elbow
An elbow is to make an angle between adjacent pipes.
5.2.13 Tee
A tee is a fittin g that has one side outlet at a right angl e to the run. It
i s u s e d f o r a s i n g l e outlet branch pipe.
5.2.14 Reducer
It is used to connect two different sized of pipes
5.2.15 Plug
It is used to screw on to a threaded opening, for closing it temporarily.
5.2.16 Valves
Valves are used for regulating the flow of fluid through a pipe. The commonly
used valves in plumbing’s are:1. Gate valve2. Globe valve3. Check valve4. Common Tap

Figure 5.8: Types of valves

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

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 Figure 5.9: Bell and spigot joints
Flanged joints
A flanged joint helps to connect and disconnect two pipes as per the need. A similar
examples as shown in Figure 5.10.
Bolted joints
The use of bolted joint is advantageous in the following circumstances:1. The
component that cannot be serviced in line.2. The components being joined that are
not capable of being welded.3. Quick field assembly is required.4. The component
or pipe section that needs to be frequently removed for surface

Figure 5.10: Flanged joints, Figure 5.11: Bolted joints

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RISE Krishna Sai Prakasam Groups of Institutions, Department of Mechanical Engineering
 Threaded joints

Figure 5.12: Threaded joints

Threads are cutted in a pipe, flange coupling to connect them with each
o t h e r a n d t h e s e joints are called threaded joints.

Flexible joints

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

RISE Krishna Sai Prakasam Groups of Institutions, Department of Mechanical Engineering 111
 M ake a p ipe str ucture

Aim:
To make a Piping structure with different plumbing components.

Tools required:
A tank, Elbows, Gate valve, Bands, Reducer, Tee joint, Coupling, Nipple, Taps.
Sequence of operations:
1. Take a piece of pipe of given size. Then cut it in different parts.2. Take all the
given components and make the plumbing structure as shown in diagram.

Result:
The pipe structure is thus made by following the above sequence of operations.

Figure 5.14: Line diagram of pipe structure

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RISE Krishna Sai Prakasam Groups of Institutions, Department of Mechanical Engineering