DEPARTMENT OF MECHANICAL ENGINEERING

23MEL202 – Engineering Practices Laboratory

Laboratory Manual

Name

Roll No

Branch

Year / Section I/

Semester II

Academic Year 2024-2025 (EVEN)

 23MEL202 – Engineering Practices Laboratory

RECORD

Name :_________________________________

Roll No : ___________________________________

Class :___________________________________

Certified that this is the bonfiderecoed of work done by the above student of the First year B.E. (Mech)
degree during the year 2024 -2025

Head of the Department Staff incharge

Submitted for the End Semester Examination held on ________________

Examiner-1 Examiner -2
TABLE OF CONTENTS

S.No. Title Page No. Marks Sign

Demonstration and practice of

fitting tools

1 Preparation of V - Shape

Demonstration and practice of

carpentry tools

2 Preparation of Wooden Tee joint

Study of sheet metal works

3 Preparation of Rectangular Tray

Demonstration and practice of

Plumbing tools

4 Preparation of Pipe joints with

coupling for same and different
diameters
Demonstration and practice of
Welding

5 Preparation of butt joint using

welding process to the required
dimension.

Average Mark:_________
 INTRODUCTION TO THE LABORATORY

Workshop practices laboratory offered to first year students of study on all

branches, aims at hands on experience for students on various basic machining practices.

They are expected to work on models that have been decided keeping in mind the learning

objectives and the facilities available the students are expected to a study of the different

machine tools and instruments. A chapter on safety in this observation book highlights the

different safety precautions that need to be taken. All students are expected to follow all

the safety instructions.

WORKSHOP-SAFETY PRECAUTIONS

 The shop floor should be kept clean always and free from dirt of any kind.
 Always wear tight fit clothing.
 Never operate the machine which you do not fully aware of its control.
 Try to keep the oil, grease away from the shop floor sometimes unknowingly a man may
slip and may meet with accident.
 Confirm that all the safety guards and fenders (anything to defend or to protect from
injuries) are available before starting the machine.
 Tools which are not used should always be kept at their respective places.
 Working tools should not be kept at the edge of the table.
 Chisels and other sharp tools should not be kept on table with sharp edges pointing towards
the edge of the table.
 Never adjust or shift the belt while machine is functioning.
 Never carry any sharp tool in the pocket.
 Use only a very sharp tool. A dull one requires excessive pressure, which may cause
slipping of knife.
 Ex.No. :
Date :
STUDY OF FITTING WORKS

INTRODUCTION
The term fitting is used with bench work in assembling of parts by removing excess metals to
obtain the necessary fit. Various tools are used in fitting work to finish the job to the required size and
shape.

BEST PRACTICES

 Loose clothing should be avoided.

 Wear shoes while working in the shop.
 Tools should be placed in their respective places after proper cleaning.
 Always use the right tool for the job.
 Keep the cutting tools separate from the measuring tools.
 Sharp edges of the cutting tools should be covered when they are not in use.

STUDY OF TOOLS USED IN FITTING SHOP

A skilled fitter should have proper knowledge about the tools used, their handling and
maintenance. The following are the commonly used tools in the fitting shop.

Vice
It is a holding device and is sometimes called a fitter’s vice. The body of the vice is made of cast
iron and consists of two jaws, one fixed and the other movable. The movable jaw slides inside the fixed
one by a screw and box nut arrangement. The vice has two hardened steel jaws with serrated faces used
to hold the work firmly. These jaws are fixed with screws and have a maximum opening up to 180mm.
The vice size is know by the width of its jaws and is varying from 80 to 140mm.

Striking Tools
A hammer is a striking tool. It has a handle and a head. Hammers are classified into four types:

 Sledge hammer
 Straight peen hammer
 Cross peen hammer
 Ball peen hammer

Among these hammers, ball peen hammer is commonly used in fitting. It is used for chipping, forming,
riveting etc. Its peen is ball shaped and the face is flat. The peen and face are hardened, but the middle
portion is not hardened in order to absorb shocks. Its weight values from 120 to 1000 grams.
Files
File is a hand tool used to smoothen or fit metal parts. It is made of high carbon steel. Its teeth
remove fine chips of material on the forward stroke of the file. The length of file is measured from the
point to the heel; the tang is not included. The blade is very hard but the tang is tempered. The length of
file varies from 100 to 450mm.

The cuts in the file are made diagonally across the face. The single-cut file has a series of single
cuts across its face. This is used for finishing surface and sharpening edges. It is used for filling soft
metals. The double-cut file has a series of two cuts. The double-cut file can do filling faster than single-
cut file.

Grades of File teeth

 A rough cut file has very coarse spaced teeth. It is used for rough work.
It removes more material.

 A bastard cut file has less coarsely spaced teeth than rough cut file.
It is also used for rough work.

 A Second cut file has medium spaced teeth. It produces better finish than bastard cut
file.

 A smooth cut file has more closely spaced teeth. It is used to get smooth surface.

 A dead smooth file removes very less material. It produces better polish and finish
than smooth cut file.

Shapes of Files
The type of file used is identified with its shape. Files of different shapes are available. The
following are some of the commonly used file types.

 Hand file
 Pillar file
 Flat file
 Square file
 Triangular file
 Round file
 Half-round file
 Knife edge file

Filling Operation
The file handle is held in the right hand. The ball of the left-hand thumb is placed on the end of
the file blade. The file cuts only on the forward stroke. No pressure is applied on the return stroke, but
the file is allowed to remain in the work. Filling is carried out for the maximum possible length in every
stroke so that all the teeth of the file receive even wear. Filing is done on the work with slow, steady
strokes for about 40 to 50 per minute.
CUTTING TOOLS

Hacksaw
It is used for cutting rods, strips, bars and pipes into desired length. It consists of a fixed or
adjustable frame, a wing nut and blade. The hacksaw blade is made of hard, tempered alloy steel. There
are three types of blades: (a) all hard (b) semi-flex (c) flexible back.

Using a Hacksaw

 The blades fixed to the frame with its teeth facing away from the handle.

 The blade is tightened properly.

 Start the cutting slowly with steady forward stroke.

 No pressure is applied on the return stroke.

 Move for longest possible stroke and about 40 to 50 stroke per minute.

 Move the hacksaw slowly when the cutting is nearing the end so that your hand will not hit
when the blade is through.

Flat or cold chisel

This is used for metal cutting and chipping. It is made of carbon steel. Its shank is rectangular,
hexagonal or octagonal in cross-section. The length of a flat chisel varies from 100mm to 400mm and
the width of the cutting edge varies from 16mm to 32mm.

Marking tools
Marking tools are used to mark the layout on the work piece by means of scribed lines. The
following are the commonly used marking tools in fitting.

Steel rule
It is used to measure and mark dimensions. It is graduated on both sides in millimeters,
centimeters and inches. Its length varies from 15cm (6 inches) to 30cm (12 inches).

Scriber
It is used to mark or scribe lines on the work piece. Its length varies from 150mm 300mm and
has diameter which varies from 3 to 5mm.

Compass or leg-end pointer

It is used for marking lines and circles on the work piece. It has a pair of steel legs which are
hinged at the top. One of the ends is bent and the other is pointed.
Spring divider it is used to mark the dimensions from scale to the work piece. It is similar to the
compass and is used for more accurate marking. The spring divider has a screw with a knurled nut.
Calipers
These are used for measuring inside and outside diameters and linear dimensions. There are two
types of calipers.

a) Firm joint calipers

b) Spring calipers

Firm joint calipers

These are of two: (i) outside caliper (ii) inside caliper. The size taken on the calipers is measured
on the steel rule. It consists of two legs connected together at one end by means of a friction joint. The
outside caliper is used to measure outside dimension such as diameter of a rod, thickness of a plate, etc.
The inside caliper is used to measure dimensions such as diameter of a hole, width of la slot, etc.
Spring calipers
These are operated by means of a screw and a knurled nut. It also consists of two legs which are
hinged together at one end. The advantage of the knurled nut is that it can be easily operated by hand. It
is very convenient and takes less time in setting.

Centre punch
It is used to mark a centre for a hole to be drilled. It can also be used for marking points along a
line for cutting. Its tapered point end has an angle of 60 degree.

Prick punch
It has a sharp point end which is used to make punch marks along a one on the work piece. Its
tapered point end has an angle of 40 degrees.

Try-square
It is used for marking and checking right angles. It consists of a steel blade riveted at right
angles to the edge of machined stock. The stock acts as a fence and the blade as guide for marking. The
length of blade varies from 150mm to 300 mm.
Surface plate it is used to check the surface flatness or straightness of the work piece. It is made
of grey cast iron. The top surface is machined smoothly and finished accurately. It is also used as a
reference surface for marking with the scriber block. The figure demonstrates the use of surface plate for
marking on a work piece.
 SAFETY PRECAUTION FOR FITTING WORK

General

 Keep hands and tools wiped clean and free from dirt, oil and grease. Dry tools are safer to use
than slippery tools.
 Keep tools sharp and in good adjustment. Dull or poorly adjusted tools must be forced, causing
accidents.

Bench vice

 Position the work piece such that the cut to be made is close to the vice. This practice prevents
springing, saw breakage and personal injury.

 Position the work in the vice such that it does not overhang into an aisle or other area where a
person might accidentally brush against it.

Hacksaw

 Cut a small groove with sharp corner of a file. Where a saw cut is to be started. The groove
permits accurate positioning of the saw and also prevents slipping of the teeth.

 For cutting thin metal strips, clamp them between two pieces of wood. Cutting through both the
wood and the metal prevents the saw teeth from digging-in and bending the metal.

Chisel

 Wear goggles while chiseling.

 While using chisels, be careful that flying chips do not hit others in the shop.
 Watch the chisel when striking, to avoid hitting of hand.

Files

 Use the file with a properly fitted tight handle.

 Never drive a file into its handle with a hammer or other objects. It may chip or break the file or
split the handle.

Hammer

 Examine the hammer each time before it is used. The handle must be securely wedged.
 Do not strike with more force than necessary.

Result :

Thus the uses of fitting tools and process are studied.

 Ex.No. :
Date :

VEE JOINT
Aim
To make a Vee joint from the given work piece.

Tools Required

1. Bench vices 7. Steel rule

2. Try square 8. Scriber
3. Dot punch 9. Hacksaw
4. Flat file (rough & smooth) 10. Surface plate
5. Angle plate 11. Surface gauge
6. Hammer 12. Square file

Given Work piece

Mild Steel polish flat of 100 x 50 x 6 mm.

Procedure

 The given work piece is checked with the original dimensions using a steel rule.
 The given work piece is firmly fitted in the bench vice and the two adjacent sides of the work
piece are filed with the help of a flat file.
 Chalk is applied on the surface of the work piece.
 With the help of try square the two sides are corrected and set at right angles.
 By keeping the two sides as bases, the given dimensions are marked with the use of surface
plate, surface gauge, angle plate and steel rule.
 The markings are made clear by punch in dots on the marked line using dot punch.
 Two pieces are separated by sawing 1 mm in left from the punch mark.
 By using hacksaw unwanted portions are removed and corresponding surfaces are filed and
smoothened to get required dimensions.
 Accuracy is also checked with the help of try square.
 When these two pieces are fitted, they form a Vee fitting.

Result
Thus the Vee joined is made as per the given dimensions from the given work piece.
 Ex.No.:

Date :
STUDY OF CARPENTRY WORKS

INTRODUCTION

The term carpentry is used with wood working. Wood works such as making wooden
partition, roofing, flooring, etc., are carpentry works. The term joinery is used with making of door,
windows, wooden frames, etc. Teak, Mahogany, Sal, Mango, Deodar, Padak, etc. are the commonly
used woods in carpentry works.

It deals with then specific work of a carpenter like making different types of joints to form a finished
product.

WOOD :
Wood, also called timber, is the universally used material for making the above said items. The
advantages of wood are

 It is abundantly available.
 It is tough and strong and can be worked easily.
 It is lighter and comparatively cheap.
 It can be beautifully painted and polished for good aesthetics.
 It is moreover environment friendly.

TYPES OF WOOD
Wood is generally classified into three types.

Soft Wood
It is obtained from soft and quickly growing trees. Pine, redwood, deodar, chair, larch, etc.,
are all having soft wood. These are used to make furniture, light weight boats etc.

Hard Wood
It is obtained from hard trees having broad leaves. Teak, Mahogany, Oak, Rose wood,
Maple, Pabul, Neem are very hard. These are used to make furniture, doors, windows, wardrobes etc.

Plywood
Plywood consists of three layers

 Top face ply layer

 Core layer
 Bottom facer ply layer

The top and bottom layers are called face ply layers. These two layers are bonded to the center core,
which is thick and not of good quality.
 CARPENTRY TOOLS

Following are the types of tools in carpentry.

 Marking and measuring tools

 Cutting tools
 Planning tools
 Boring tools
 Striking tools
 Holding tools
 Power tools
 Miscellaneous tools

MARKING AND MEASURING TOOLS

Marking Gauge
It is used for marking lines parallel to the edges of a wooden piece. It consists of a square
wooden stem with a sliding wooden stock (head) on it.

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

Try Square
It is used for marking and checking right angles. It consists of a steel blade riveted at right
angles to the edge of machined stock. The length of blade varies from 150mm to 300mm.

Bevel Square
It is used for laying – out and checking angles. It is also called a sliding level. It is similar to the
try square but has a blade that can be swiveled to any angle from 0 to 180 degrees.

Mitre Square
Mitre square is used for marking and measuring an angle of 40. Length of blade is between 200
to 300mm. They are made up of steel blade with rose wood stock.
Compass and Divider
Compass and divider are used for marking arcs and circles on the planed surfaces of the wood.

Carpenters Folding Rule

It consists of four pieces, each 150mm long, one pair is pinned and the other two are hinged with
the pair, so that it can be folded and carried easily. It has graduation both in mm and inches.

Carpenter’s Tap
It is used to measure or mark larger lengths. It is made up of a toughened spring steel strip. It is
available in lengths of 2m to 5m, graduated both in mm and inches.

CUTTING TOOLS

SAWS
A saw is used to cut wood into pieces. There are different types of saws, designed to suit
different purposes. A saw is specified by the length of its toothed edge.

Cross-cut or Hand saw

It is used to cut across the grain of the stock.

Rip Saw
It is used for cutting the stock along the grain. The cutting edge of this saw makes a steeper
Angle, i.e., about 60, whereas that of cross cut saw makes an angle of 45 with the surface of the stock.

Tenon Saw
It is used for cutting tenons and in the fine cabinet work. The blade of this saw is very thin and
so it is stiffened with a thick back strip.

Dovetail Saw
The number of teeth varies from 12 to 18 teeth per 25mm. It is used for carpenting works such
as making dovetail joints.

Hack Saw
It is used to cut all types of work piece. The b lade used in it is made of tempered carbon steel.
It is used for cutting PVC and metal surfaces.

Firmer Chisel
It is used by hand pressure or with a mallet for cutting square recesses in wooden pieces. It has a
flat blade of 5 to 25mm width and 125mm length.
Dovetail Chisel
It is used for fine finishing of dovetails and other V shaped grooves. Its blade is beveled and has
minimum thickness at the rear face.

Mortise Chisel
It is used for cutting heavy pieces or mortises. It consists of a heavy blade with strong shoulder
and is capable of withstanding heavy strains. It has a length of 200 to 400mm and width of 8 to 16mm.

PLANING TOOLS
Wooden Jack Plane
It is used for quick removal of material on rough work and is also used in oblique planning. Its
length varies from 355 – 380mm and cutting iron width is between 50 – 62mm.

Metal Jack Plane

It helps a smoother operation and produces a better finish than a wooden jack plane. The body
of a metal jack plane is made from grey iron casting steel.

BORING TOOLS
Carpenter’s Brace
It is used for rotating auger bits, twist drills, etc., to produce holes in wood. The size or a brace is
determined by kits sweep. There are two type of braces commonly used in carpentry. They are (1)
Ratchet Brace and (2) Wheel Brace.

Gimlet
It is used for making small holes in wood. These are of two types: (a) plain gimlet and (b)
twisted gimlet. It has a flute and a wooden handle.

Auger Bit
It is used for making big holes in wood. It has a steel bar with fluted teeth and a handle. It can
bore holes of 25mm diameter.

STRIKING TOOLS

Claw Hammer
It is used for heavy works. It is made of steel and has head at one end and a claw at the other
end. The head is used to drive nails and the claw is used to pull out nails from wood.

Cross Peen Hammer

It is used for general works and light hammering. It is made of forged carbon steel. The cross
peen is used for pressing small inlays and veneers into correct position.

Mallet
It is used to give light blows. The head is made up of wood and round in section.
HOLDING TOOLS

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

C-Clamp or G-Clamp
It is used to hold smaller work pieces. It consists of an iron frame and a screw with a handle rod
or thumbscrew. It is made up of malleable iron.

Nose Plier
By nose plier we can tighten up bolts, nuts land can hold thin jobs.

POWER TOOLS

Wood Turning Lathe

It is used for producing cylindrical, spherical and tapered shape products. In wood working
lathes, the work piece is held in between two centers. The tool is held in the tool post.

Circular Saw
Circular saw is used for ripping, cross cutting, leveling, grooving and rebating. It consists of a
cast iron table, a circular cutting blade, guide ways, saw guide and main motor.

Band saw
Band saw is used for ripping, cross cutting, leveling, grooving and rebating. It consists of two
wheel having equal diameter, saw guider, frame table and steel blade having teeth on it.

Mitre Saw
A mitre saw is a tool used to make accurate cross cuts and mitres in a work piece. A mitre saw
will crosscut long stock, cut picture frame moulding, fit crown moulding and quickly cut multiple
boards to the same length. They are fast and cut angles with repeatable accuracy.

Jointer
A jointer is a woodworking machine used in woodworking to produce a flat surface on a board.
The jointer derives its name from its primary function of producing flat edges on boards prior to joining
them edge-to edge to produce wider boards.

Thickness Planer
A thickness planer is a woodworking machine which is used to create boards that are of an even
thickness throughout their length and flat on the upper surface.
MISCELLANEOUS TOOLS JAW

Pincer
It is made of steel with a hinged joint and is used for pulling- out small nails from wood.

Screw Driver
It is used for driving wood screws into wood or unscrewing them.

Wood Rasp File

It is a finishing tool used to make the wood surface smooth, remove sharp edges, and finish
fillets and other interior surfaces.

CARPENTRY PROCESSES

The carpentry work involves variety of operation to finish the work piece to get required shape and size.
The carpentry operations are,

(i) Marking and measuring (vi) Boring

(ii) Planning (vii) Grooving and Tonguing
(iii) Chiseling (viii) Rebating
(iv) Sawing (ix) Moulding
(v) Mortising and tenoning (x) Recessing

Marking and Measuring:

Marking is the process of setting out dimensions on a wooden piece to produce the required
shape.

Planning:
The operation of smoothing a wooden surface with the help of a suitable plane is called planning.
This operation can be also called as ‘facing’ or edging’.

Chiseling:
It is the operation of cutting a small stock of wood from the given work piece to get the required
shapes by using chisel.

Sawing:
It is the basic operation carried out in the carpentry shop for cutting wood to the required size
and shapes like straight, inclined or curved surfaces.

Mortising and Tenoning:

Mortising is the operation of producing a rectangular or square hole land tenoning is the
operation of making a corresponding projection so that it fits into the mortise to form and assembly.

Boring:
It is the process of producing through or blind hole is wood.
Grooving:
Grooving is making grooves and tongues to join the wood.

Rebating:
It is the process of making a process (also called as rebate) taken out not the edge of a piece of
wood.

Moulding:
It is the process of cutting concave, convex and other curved surfaces.

Recessing:
It is the process of making slot in wooden pieces.
 Ex.No. :
Date :
PLANNING PRACTICE & MAKING TEE JOINT
Aim
To plane the given work piece for the given dimensions and to make a Tee joint as per the given
drawing.

Materials Required
Soft wood-Silver Oak wood
Tools Required
 Metal Jackplane Firmer chisel
 Try square Marking gauge
 Mallet Calipers.
 Circular saw
Procedure
The given work piece is ‘clamped in the carpentry vice and two adjacent faces are planed to get
right angles, using machine planer.

 The right angle of the work piece is then checked by using try square.

 With the finished face as reference the required size is marked on the work piece by means of
steel rule land marking gauge.

 The other two faces of the work piece are planed to the marked dimensions by sing thickness
planer.

 Finally, the accuracy and proper dimensions are verified by using steel rule and try square.

 The given work piece is ‘clamped in the carpentry vice and two adjacent faces are planed to get
right angles, using machine planer.

 The work piece is cut into two halves using circular saw.

 With the finished face as reference the required size is marked on the work piece by means of
steel rule land marking gauge.

 In one half, the unnecessary portions are also removed using mitre saw and finner chisel.

 Similarly the unwanted portions are also removed in the other half of the work piece using
circular saw and finner chisel.

 Now the two pieces are assembled to check proper fitting.

 Finally, the accuracy and proper dimensions are verified by using steel rule and try square.
Result
Thus the work piece is planned to the required dimensions and the Tee joint is made as per the
given drawing.
 Ex.No. :
Date :
STUDY OF SHEET METAL WORKS
Aim:
To study about the sheet metal tools and sheet metal operations.

Introduction:
Sheet metal work is regarded as working of thin metallic sheets with hand tools and simple
machines. Many important engineering articles made up of sheet metal find their application in houses,
agriculture machinery, decorative articles etc.,

Types of sheet metal:

Sheets

Steel (ferrous) sheets Non-ferrous sheets

Coated sheets uncoated sheets

(Galvanized) (Plain)

Galvanized Iron (GI) Sheets:

It is soft steel sheet coated with zinc. Sheets have corrosion resistance due to zinc coating
welding is not easy. If these are used for making a.c. ducts roof flashing boxes, buckets, coolers etc.,

Tools Used In Sheet Metal:

1. Steel rule
2. Steel square
3. Scriber
4. Divider
5. Punches
i. Prick punch
ii. Centre punch
6. Straight snip
7. Bent snip
8. Hollow punch
9. Chisels
10. Hammers
i. Ball peen hammer
ii. Square face hammer
iii. Raising hammer
iv. Riveting hammer
11. Mallet
Stakes

i. Hand Stake
ii. Half round stake
iii. Tapper stake
iv. Grooving Stake
v. Horse stake

Steel rule:
These are available in variety of sizes. The rule could be steel foot rule, folding rule or tape rule.

Steel square:
It is an L-shaped piece of hardened steel. It is used to make square corners. It is also used for
checking and making right angles.

Scriber:
It is steel wire of 200-mm length with one end sharp and hardened to mark lines on metallic
sheet.

Divider:
It is used to scribe arcs and circles on metallic sheets.

Punches:
The following punches of tool steel are used in sheet metal shop.

1. Prick punch:

Used for making indentation marks for locating the Centre position for dividers, having
included angle of 30.

2. Centre Punch :
Used for marking the location of points and the centre of holes to be drilled. Its tapered point is
grounded to 90 included angle.

Straight Snips :
For cutting along straight line, straight snip is used whose blades are straight. It is used to cut 22
S.W.G. or lighter. To cut sheets of greater thickness lever shearing machine is used.

Bent Snip:
Blades are curved back from the cutting edge, which allows the metal to slide over trop blades.

Hollow Punch:
When circular holes are to be cut in the sheet then hollow punch is used for thin sheets. The
sheet should be placed over the wood or thick block of lead to avoid chipping of edges of the punch.
Chisels:
These are generally used in sheet metal shop for cutting sheets, rivets and bolt.

Hammers:
The rammers are used for riveting work, bending of sheets, smoothening of sheets, locking of
joints etc., for these operations the following hammers are generally used.
There are two square holes for holding two stakes at a time for carrying out different operations.

Sheet Metal Operations:

 Measuring and marking
 Laying out
 Hand cutting and shearing
 Hand forming
 Nibbling
 Circle cutting
 Piercing and blanking
 Edge forming and wiring
 Joint making
 Bending
 Drawing

Measuring and Marking

The standard market sizes of metal sheets are quite large. But the required sheet size for making
a component may be much smaller. So, a standard size sheet may have to be cut into several smaller
pieces, each piece being sufficient for making one such component. These smaller sizes are first
decided and then these sizes are marked on the larger sheet to cut the latter into small pieces along the
marked lines. A little allowance for cutting is always added to the required overall sizes so that the cut
pieces are not undersize.

Laying out :
Laying out means the operation of scribing the development of the surface of the component on
the sheet/sheet blank, together with the added allowances or overlapping, bending, hammering, etc.,
which when cut out of the blank and folded and jointed will give the required component.

Cutting and shearing:

The word cutting is normally used when the sheet metal is cut by means of a chisel and a
hammer manually. The term, shearing stands for cutting of sheet metal by two parallel cutting edges
moving in opposite directions. This can be done either manually by using hand shears or snips or by
means of machines called shears. The operation is then known as machine shearing or mechanical
shearing.

Hand forming:
The term metal forming stands for shaping and bending of sheet metal in three dimensions in
order to give it the desired shape and size of the final product. For this the metal is either required to be
stretched or sprung in all directions or may need a combination of both.
Nibbing:
Nibbing is a process of continuous cutting along a contour, which may be a straight line or an
irregular profile. The machines used in this operation are known as nibblers, which are portable type
shearing machines.

Circle cutting:
It is the operation of cutting circular blanks or cured contours with the help of a circle-cutting
machine. It is also a continuous cutting operation.

Piercing and blanking:

Piercing is basically a hole punching operation while blanking is an operation of cutting out a
blank. In both the cases blanks will be produced, but in the former case obtaining a bank is not the
objective. It is the hole of desired size that is he objective and the blank produced may not be used
further. In the latter operation the production of a blank of the desired size is the main objective, which
is a useful part for further processing.

Edge forming and wiring:

The edges of sheet metal products are formed to ensure safety of hands, while handling these
products and to provide stiffness to the products in order that they will retain their shape during handling
i.e., will not get buckled or compressed by simple hand or finger pressure during handling.

Joint making:
Several means are used for joining sheet metal parts together or securing them to other metallic
or non-metallic bodies. In case of very large size parts, especially when they are to be fastened to other
metallic or large non-metallic bodies, screwed fastening can be used. Riveting, welding brazing, and
adhesives can also join sheet metal parts. Self-tapping screws are more popular screwed fasteners in
sheet metal work. However, still the most commonly used methods are joining the sheet metal parts by
means of folded joints or self securing joints, followed by soldering and adhesive joining.

Bending :
Sheet metal is required to be bent at different angles to shape it into the required form. The
bending operation involves stretching of metal on the outer surface and compressing it on the inner
surface along a neutral align which remains unchanged in length. Hammering over a base by hand or by
means of bending or rolling machines can bend sheet metal.

Drawing:
Thin walled hollow shapes are produced in sheet metal through the drawing operation. The
operation is carried out with the help of die and a punch on a suitable press. If the drawn length of the
component is less than its width or diameter it is called box drawing or shallow drawing. When the
drawn length is more than the width, the operation is known as deep drawing.
Development of Surfaces
Development of surfaces is the first step in sheet metal workshop. The objects that are going to
be fabricated are developed by the use of front view and top view of the object. The techniques used for
development are parallel line develop0ment and radial line development method. From the development
the true dimensions of the sheets required are known. Then these sheets are properly made to cut and
fold by the use of various tools the required object is made.

Process
The surfaces to be joined are cleaned and are placed on each other. A flux is employed to
prevent oxidation. Zinc chloride is commonly used for this purpose. The soldering iron is heated either
electrically or by some external heat. Then the hot end is dipped into the flux and solder is pressed
against the surfaces to be joined. Melting the solder forms a joint.

SAFEFTY PRECAUTION FOR SHEET METAL

 Loose clothing should be avoided.

 Wear shoes while working in the lab.

 Tools should always be kept in good condition.

 Tools not used must be kept in their proper places.

 Always use the right tool for the right job.

 Keep the cutting tools separate from the measuring tools.

 During the sheet metal development, cutting lines are scribed by thick lines and folding lines
are scribed by thin lines in order to avoid mistakes while cutting the material.

 Heavy metal can be cut by clamping the sheet between two pieces of angle cross and
shearing it with a cold chisel.

Result:

Thus the various sheet metal tools and sheet metal operations are studied.
 Ex.No. :
Date :
RECTANGULAR TRAY

Aim

To make a rectangular tray, using the given sheet metal

Tools required

 Steel Rule
 Try-square
 Divider
 Scriber
 Straight snip
 Mallet
 Ball peen hammer
 Hatchet stake

Procedure

 The size of the given sheet is checked with the steel rule.

 The layout of the tray is marked on the given sheet.

 The layout of the tray is cut by using the straight snip.

 Single hemming is made on the four sides of the tray.

 The four sides of the tray.

Result

The rectangular tray is thus made, from the given sheet metal.
 Ex.No. :
Date :
STUDY OF PLUMBING WORKS
INTRODUCTION

Plumbing refers to installation of pipelines. Water tanks and other pipe fittings to distribute
water in a building.

PLUMBING TOOLS:
Plumbing tools are many. The following tools are commonly used to install 25mm size
pipelines. PVC (Poly Vinyl Chloride) pipes and GI (Galvanized Iron) pipes are commonly used in
plumbing.

A pipe wrench is used to hold and rotate the pipes to tight them. It consists of la fixed jaw, a
movable jaw with adjusting screw.

Pipe vice
A pipe vice in used to hold the pipe during cutting, making threads at the ends of the pipe, fitting
of couplings, etc. It also consists of a fixed jaw, a movable jaw and a screw with handle for adjustment.

A PVC connection uses fittings like elbow bend, coupling, tee reducer, etc. Fittings like
couplings, elbow, bend, union, nipple, tee reducer, plug, cap, flange, etc. with V-threads are commonly
used in GI pipe connections.

Valves and taps

A gate valve or globe valve is commonly used in the main pipeline to control/regulate the flow
of water through it. Valves are usually made of cast iron or brass.

A domestic tap is commonly used to collect or tap water at desired points in the pipelines. Taps
are made of brass, steel or plastic.

Flow Control Angle Valve

Flow control angle valve is used along with the appliances to regulate the flow of water. The
outlet of the valve and the control knob are at 90 degrees which is convenient to operate it.

A hacksaw is used to cut pipes. It has a frame where the blade is tightened by means of a wing
nut.

Screw Drivers
Screw drivers are used to tighten screws in the appliances. Screw drivers of various sizes are
used.
Hammers
Ball peen hammer is commonly used in plumbing work where greater power is required in
striking.

A measuring tape is used to measure the length of the pipe and also to mark the location of the
fittings, valves and appliances.

Different types of Pipes:

Pipes:

These are circular conduits, in which water flows under pressure. Nowadays pressure pipes are
mostly used at every place and they have eliminated the use of channels, aqueducts and tunnels to a
large extent. These are made of various materials as cast iron wrought iron, steel, cement concrete,
asbestos, cement, timber etc. in the towns, pipes are also used for distribution system. In distribution
system pipes of various diameters, having many connections and branches are used. To prevent the
bursting of pipes due to water hammer, surge tanks or standpipes are provided at the end of the pipes.

The selection of material for the pipe is done on the following points:

 Carrying capacity of the pipe

 Durability and life of the pipe
 Type of water to be conveyed and its possible corrosive effect on the pipe material
 Availability of funds
 Maintenance cost, repair etc.

The pipe material, which will give the smallest annual cost or capitalized cost will be selected,
because it will be most economical.

1. Cast iron pipes 7. Wrought iron pipes

2. Steel pipes 8. Concrete pipes
3. Cement lined cast iron pipes 9. Asbestos cement pipes
4. Copper and lead pipes 10. Wooden pipes
5. Vitrified clay pipes 11. Poly Vinyl Chloride (PVC)
6. Galvanized Iron pipes (GI)
PREPARATION OF PLUMBING LINE SKETCHES

Water Supply and Sewage Lines

The purpose of plumbing line sketches is to show the size and location of pipes, fittings and
valves. Since these items may be purchased, la set of symbols has been used on drawing. The size of
the symbol is left to discretion of the draftsman. There are two types of piping drawings - single-line
and double line drawings.

Single-line piping drawings use a single line to show the arrangement of the pipe and fittings.
The single-line piping drawing is prepared in orthographic or pictorial projections. Orthographic
projection is used for the representation of single pipes either straight or bent in one plane. Pictorial
projection is used for pipes bent in more than one plane, because the finished drawing is easier to
understand.

Double-line drawing take more time to draw and therefore not commonly used. They are used for
sewage line sketches, catalogs land other applications where the visual appearance is more important.

PIPE CONNECTIONS ON THE SUCTION AND DELIVERY LINES FOR PUMPS AND
TURBINES

Introduction
A pump is used to handle water or any other fluid. Water enters the suction side and discharged
at the delivery side of the pump. Centrifugal pump, Positive displacement pump or Reciprocating pump,
Jet pump, Submersible pump etc are commonly used for water pumping in domestic irrigation purpose.
The connection on the suction and delivery sides of these pump connections are almost similar. The
suction and delivery line with centrifugal pump is discussed below.

Pipe connection on delivery line

The delivery line consists of pipes and valve to deliver the water to the tank or field. The
delivery line can be longer to deliver water at the required place. Depending on the kind of pump used,
there is a limit to the height to which a pump must be started with delivery valve open.

PUMPS
The pump which raises water or liquids from a lower to a higher level by means of centrifugal
force is known as centrifugal pump. The action of a centrifugal pump is the reverse of that of a reaction
turbine, A turbine converts hydraulic energy into mechanical energy, whereas, a pump converts
mechanical energy into hydraulic energy.
Centrifugal pump

 Mono Block pump

 Jet pump
 Submerged

Can suck water from deer wells, and deliver to a shorter distance only. In jet pump 4 to 6 stage
pumps are available to suck and deliver to a higher head.

Submerged Pump
These pump sinks inside water and deliver fluid or water outside. It is used in fresh water lifting
purpose only, submerge pumps deliver fluid up to 80 to 100 feet and 160 to 180 feet respectively
depending upon the number of stage in pump. These are used in bore wells. Its cost is higher than that
of jet pump.

SAFETY PRECAUTINS IN PLUMBING

 Make sure that there is no leakage after connecting the pipes and other pipe layout.

 Close the gate valve to prevent the water supply from the main tank and carry on plumbing
work.

 Never strike with hammer on the handle of screw driver.

 Handle the plumbing tools with care since they are hard tools.

 Use goggles, shoes while working.

 Don’t hold the work in your hand while using screw driver.

Result :

Thus the Plumbing of pipes, pipe fittings, pipe line joints, its locations and functions are studied.
 Ex.No. :

Date :
PIPE CONNECTIONS WITH DIFFERENT JOINING COMPONENTS
(MIXED PIPE MATERISLS)

Aim:

To make a Plumbing layout using mixed Pipes.

Tools required:

 Hacksaw
 Pipe cutter
 Pipe vice
 Threading dies
 Pipe wrench
 Set of common spanners

Procedure:

 The given GI & PVC (3/4”, 1/2”) pipes are cut into suitable size using hacksaw or pipe cutter.
 The pipes are threaded using threading die.
 The pipes of same size are joined by using coupling, union, elbows, tee, reducer, bend, taps,
plug, gate valve, ball valve, etc are joined as per the layout.
 The pipes that are joined and tightened using pipe wrench.
 The required layout is obtained as per the given layout.

Result:

Thus the plumbing layout is made as per the given layout.

 Ex.No. :
Date :

STUDY OF WELDING TOOLS AND WELDING PROCESSES

Aim:
To make a detailed study about the welding tools and the processes.

Welding:
Welding is a process of joining similar metals by application of heat with or without application
of pressure and addition of filler material.

Welding tools:
 Hand tools
 Safety tools

Hand tools:
The following are the hand tools, which are normally used in welding operations, a) Steel wire
brush, b) Chipping hammer.

Steel wire brush:

Steel wire brush is used to clean the welded area.

Chipping hammer:
Chipping hammer is used to clean the welded area and to remove the lag from the welded area.

Hand shield:
Hand shield is fitted with an insulating handle. It is used to protect the welder’s hand, and as
well as the welder from radiation and hot slag.

Leather hand gloves:

These are used to protect the welder from electric shock and heat.

Apron:
Aprons are made up of leather wool. It is used to protect the welders body from hot metal
sparks.

Goggles:
Gas flames produce high intensity light & heat rays, which are harmful to naked eye. To protect
the eyes from these rays, goggles are used. Goggles also protect the eyes from flying sparks.
Shoes:
Rubber or leather shoes should be worn to protect the welder’s legs from the falling hot slugs
and electrical shocks.

Welding Types:

1. Gas welding:
a) Oxy-acetylene
b) Air-acetylene
c) Oxy-hydrogen

2. Arc welding:
a) Carbon arc f) Plasma arc
b) Metal arc g) Submerged arc
c) Electro-slag h) Flux-cored arc

3. Resistance welding:
a) Butt
b) Projection
c) Spot
d) Percussion
e) Seam

4. Thermit welding

5. Solid state welding

a) Friction
b) Explosive
c) Ultrasonic
d) Diffusion

6. Newer welding
a) Electron-beam
b) Laser

Gas Welding:
Gas welding is the process in which a gas flame is used to raise the temperature of the
metals to be joined. The metals are heated up to melting. The metal flows and on cooling it solidifies.
A filler metal may be added to the flowing molten metal to fill up cavity made during the end
preparation. Many combinations of gases are used in gas welding. But the most common of these is
oxygen and acetylene.
Principles of oxy-acetylene welding:

Burning of the gases coming through the torch tip produces a very hot flame. The edges
to be welded are heated up to melting. A filler metal is also added to complete the welding. This
molten metal mixture when solidifies on cooling forms a welded joint. The oxy-acetylene welding is
consists of,
a) Oxygen cylinder
b) Acetylene cylinder
c) Pressure gauges
d) Valves
e) Hose pipes
f) Torch

Oxygen cylinder and acetylene cylinders are filled with gases. Both the cylinders are attached
with pressure gauges, regulators and cylinder valves

The cylinder containing oxygen is painted black where as the acetylene cylinder is painted
maroon. Hospices are provided with each cylinder. These pipes are connected to welding torch.

Welding process:
To start welding, the acetylene control valve is turned first when acetylene comes out of the
nozzle, it should be ignited with spark lighter it will give a yellow-colored smoke flame. After it oxygen
cylinder valve is opened and supply is increased until a best suitable flame is obtained.
Then the flame is focused on the edges to be welded. Flux and filler metal are also added with
the heat of flame, the edges and filler metal melts and a joint is formed after cooling of the molten metal.
The joint may be formed with or without using filler metal.

Applications:
All the metals can be welded with proper filler metals. Same equipment may be used for cutting
purposes. Oxyacetylene welding is particularly used for sheet metal work.

Advantages of oxy-acetylene welding:

 Equipment is cheap.
 It can be used for welding all metals.
 Maintenance of equipment is very less.
 It is a portable process.
 It can be used for cutting of metals.
 It is specially used for sheet metal work.

Disadvantages:
 It takes long time for heating the job as compared to the arc welding.
 Heat affected area is more.
 Gases are expensive and difficult to store.
Types of Gas Flames:
There are three types of gas flames are,
 Oxidizing flame
 Carburizing flame
 Neutral flame

1. Oxidizing flame:
Here the volume of oxygen gas is more than the volume of acetylene mixed into the torch. This
flame is used for welding brass and is also used for cutting the metals.

2. Carburising flame:
When the volume of acetylene mixed is more than oxygen, carburizing flame is formed. This
flame is used for welding nickel.

3. Neutral flame:
It is known as balanced flame. Oxygen and acetylene gases are mixed in equal volumes.
Neutral flame is used for normal welding of steel, cast iron etc.

Equipment Used For Arc Welding:

Various equipment used for arc welding are,

1. D.C.Welding Equipment
 AC motor-generator set
 Diesel engine-generator set
 Transformer-rectifier welding set

2. Welding Transformer Set

Arc Welding:
The welding in which the electric arc is produced to give heat for the purpose of joining
two surfaces is called electric arc welding.

Power supply is given to electrode and the work. A suitable gap is kept between the
work and electrode. A high current is passed through the circuit. An arc is produced around the area to
be welded. The electric energy is converted into heat energy, producing a temperature of 3000 C to
4000  C. This heat melts the edges to be welded and molten pool is formed. On solidification the
welding joint is obtained.

Welding Transformer Set

It is used to step down the voltage supply. It consists of a primary and secondary circuit.
The input is given to primary winding. By electromagnetic induction the current flows through the
secondary coil. The output can be controlled as per requirement.
SAFETY PRECATIONS FOR WELDING

General

 Always weld in a well ventilated place.

 Do not weld around combustible or inflammable materials, where sparks may cause a fire.
 Never weld containers which have been used for storing gasoline, oil or similar materials,
without first having them thoroughly cleaned.

Arc Welding

 Check the ground connection and insulation of all the wires.

 The arc should be observed only through a shield or goggles.
 Always wear the safety hand gloves, apron and leather shoes.
 Prevent welding cables from coming in contact with hot metal, water, oil or grease. Avoid
dragging the cables around sharp corners.
 Always turn-off the machine when leaving the work.
 Remove the slag by chipping hammer only.
 Apply eye drops after welding is over for the day, to relieve the strain on the eyes.

Gas Welding

 Always wear welding goggles while doing gas welding.

 Always use the spark lighter to light the torch, never use a match.
 Do not allow blow pipe to heat cylinders, hoses or any other equipment.
 Do not allow the hose to become excessively warm.
 Secure cylinders in use, against falling, which may knock-off the valve.
 Goggles face shields and gloves must be used while welding.
 Any repairable parts of the welding equipment should be sent to the manufacturer for
necessary repairs.

Result

Thus the welding tools and welding processes are studied.

 Ex.No. :
Date :

BUTT JOINT
Aim:

To weld the given raw M.S metal pieces as butt joint by using A.C Electric arc welding as per
the given drawing.

Tools required:

 AC Electric Arc Welding unit.

 MS Electrode of 3.15 x 350 mm
 Leather Apron
 Leather hand gloves
 Goggles
 Chipping hammer
 Steel wire brush
 Rough file

Procedure:

 Given raw M.S work piece material is clamped in the bench vice and cuts to the size of
100x32x6 mm by hand using a hacksaw.
 The cutting edge is filled to right angle using rough file.
 The work pieces are set in the form of butt joint with a root gap of the 2mm as per the given
drawing.
 Using 3.15-mm diameter M.S electrode carries out tack weld.
 Using 3.15-mm dia M.S electrode carries out welding work.
 A one sided single run weld is deposited.
 An angle of 80 degree is maintained to the line of the weld and 45 degree between the weld face.
 A short arc is maintained to get uniform fusion and root penetration.
 Slag is removed with a chipping hammer and the welded area is cleaned with a steel wire brush.

Result
The given M.S metal work pieces are welded as butt using A.C electric arc as per the given
drawing.