9518 - National College of Engineering

NATIONAL COLLEGE OF ENGINEERING MARUTHAKULAM

GE-2116 ENGINEERING PRACTICES LABORATORY MANUAL GROUP A- CIVIL & MECHANICAL FIRST YEAR FIRST SEMESTER (MECH, EEE, ECE, CSE, IT & CIVIL)

Engineering Practices Laboratory GE 2116

9518 - National College of Engineering

Engineering Practices Laboratory GE 2116

9518 - National College of Engineering

INDEX
Sl.No . CIVIL I 1 2 3 II 4 5 I 6 7 8 9 10 II 11 12 III 13 14 III 15 Carpentry T-joint Dove tail joint Cross lap joint Plumbing Basic pipe connections for wash basin and water heater Basic pipe connections involving the fittings like valves, taps and bends MECHANICAL Welding Lap joint Parallel fillet joint T joint Butt joint Sheet metal work Rectangular tray Frustum Basic machining Stepped Shaft Drilling Fitting V- joint Name of the Experiment Page No.

Engineering Practices Laboratory GE 2116

9518 - National College of Engineering

Engineering Practices Laboratory GE 2116

9518 - National College of Engineering

1. BASIC PIPE CONNECTIONS INVOLVING THE FITTINGS LIKE VALVES, TAPS AND BENDS

Aim: To connect the pipes with pipe fittings like valves, bends and taps with main supply pipe using joints. Materials supplied; 1. Pipe wrench 3. Bend 5. Taps 6. Flange Procedure: 1. Two pipes are taken and they are held in vice and they are connected by using a flanged joint as shown in fig. 2. A gate valve is connected to the pipe for controlling the water supply. 3. Then bend is connected to the end of the pipe. Make internal threads using taps in the bend-1. So it can be screwed to the pipe. 4. One more pipe is connected to the bend for extension of the layout. 5. The pipe is then screwed to bend-2 for further extension. 6. A horizontal pipe is connected to this bend-2 as shown in fig. 7. Then tap is fitted to the end of the pipe for closing and opening the water supply.

2. Spanner 4. Valves 6. Cast iron pipes of different length 8. Bench vice

Result: Thus the basic connections of pipes with accessories are made.

Engineering Practices Laboratory GE 2116

9518 - National College of Engineering

Engineering Practices Laboratory GE 2116

9518 - National College of Engineering

2. BASIC PIPE CONNECTIONS FOR WASH BASIN AND WATER HEATER

Aim: To construct a basic pipe connections for wash basin and water heater. Materials required: 1. 2. 3. 4. 5. 6. 7. 8. Plumbing tool kit Taps Wash basin Water heater Elbow Tee Gate valve PVC 1 No. 3 Nos. 1 No. 1 No. 3 Nos. 2 Nos. 1 No. required length

Procedure: 1) 2) 3) 4) 5) 6) 7) 8) Study the given diagram. Mark the location of wash basin, water heater and taps. Fix the wash basin, water heater. Make the tee and elbow connections in the main pipeline to connect it to the wash basin, water heater and taps. Fix the gate valve, near the water tank. Connect all pipe fittings as per diagram. The water tank was filled with water and the gate valve was opened slowly to supply water into pipeline. The taps were opened to check its functions.

Result: Thus the basic connections for wash basin and water heater is made.

Engineering Practices Laboratory GE 2116

9518 - National College of Engineering

All Dimensions are in mm. Not to Scale.

Engineering Practices Laboratory GE 2116

9518 - National College of Engineering

3. T- JOINT Aim: To make a T-joint from the given wooden piece for the desired dimensions. Material supplied: A wooden piece of size 300x40x40 mm. Tools required: 1. Jack plane 4. Tenon saw 7. Firmer chisel Sequence of operations: 1. Rough planing 4. Chiselling Working steps: 1. The given job is checked to ensure its correct size. 2. The job is firmly clamped in the carpentry vice and any two surfaces are planed by jack plane to get right angle. 3. Using try square, the right angle of the workpiece is checked. 4. All the four sides of the wooden pieces are planed to get the smoother and finished surface. 5. The job is cut into two halves using rip saw then proper marking is done for T-joint on the two pieces using steel rule and marking gauge. 6. One half is taken. Using tenon saw and firmer chisel the unwanted portions are removed as per the drawing. 7. The above procedure is repeated for the other half of the workpiece. 8. Jack plane is used to plane the other two faces upto the marked portion. 9. Now the two pieces are assembled to check proper fitting. 10. The finished job is again checked for its accurate shape and size using try square and steel rule. Result: Thus the desired T-joint is obtained. 2. Marking 5. Finish planing 3. Cutting (or) sawing 2. Try square 5. Carpentry vice 8. Mallet 3. Marking gauge 6. Steel rule 9. Rip saw

Engineering Practices Laboratory GE 2116

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All Dimensions are in mm. Not to Scale.

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4. DOVE-TAIL JOINT Aim: To make a dove-tail joint from the given wooden piece to get the desired dimensions. Material supplied: A wooden piece of size 300x40x40 mm. Tools required: 1. Jack plane 4. Tenon saw 7.Firmer chisel 2. Try square 5. Carpentry vice 8. Mallet 3. Marking gauge 6. Steel rule 9. Rip saw 3. Cutting (or) sawing

Sequence of operations: 1. Rough planning 2. Marking 4. Chiselling 5. Finish planing

Working steps: 1. The given job is checked to ensure its correct size. 2. The job is firmly clamped in the carpentry vice and any two surfaces are planed by jack plane to get right angle. 3. Using try square, the right angle of the workpiece is checked. 4. All the four sides of the wooden pieces are planed to get the smoother and finished surface. 5. The job is cut into two halves using rip saw then proper marking is done for dovetail joint on the two pieces using steel rule and marking gauge. 6. One half is taken. Using tenon saw and firmer chisel the unwanted portions are removed as per the drawing. 7. The above procedure is repeated for the other half of the workpiece. 8. Jack plane is used to plane the other two faces upto the marked portion. 9. Now the two pieces are assembled to check proper fitting. 10. The finished job is again checked for its accurate shape and size using try square and steel rule. Result: Thus the desired dove-tail joint is obtained.

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All Dimensions are in mm. Not to Scale.

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5. CROSS LAP JOINT Aim: To make a cross lap joint from the given wooden piece for the desired dimensions. Material supplied: A wooden piece of size 300x40x40 mm. Tools required: 1. Jack plane 4. Tenon saw 7. Firmer chisel Sequence of operations: 1. Rough planning 4. Chiselling 2. Marking 5. Finish planing 3. Cutting (or) sawing 2. Try square 5. Carpentry vice 8. Mallet 3. Marking gauge 6. Steel rule 9. Rip saw

Working steps: 1. The given job is checked to ensure its correct size. 2. The job is firmly clamped in the carpentry vice and any two surfaces are planed by jack plane to get right angle. 3. Using try square, the right angle of the workpiece is checked. 4. All the four sides of the wooden pieces are planed to get the smoother and finished surface. 5. The job is cut into two halves using rip saw then proper marking is done for cross lap joint on the two pieces using steel rule and marking gauge. 6. One half is taken. Using tenon saw and finner chisel the unwanted portions are removed as per the drawing. 7. The above procedure is repeated for the other half of the workpiece. 8. Jack plane is used to plane the other two faces upto the marked portion. 9. Now the two pieces are assembled to check proper fitting. 10. The finished job is again checked for its accurate shape and size using try square and steel rule. Result: Thus the desired cross lap joint is obtained.

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All Dimensions are in mm. Not to Scale.

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6. STEPPED SHAFT Aim: To obtain the required stepped shaft by turning and facing operations. Materials supplied: Cylindrical work piece of diameter 25mm and length 65mm mild steel rod. Tools required: 1. Lathe 4. Try square Sequence of operations: 1. Checking 4. Facing Working steps: 1. The given work piece is checked for its dimensions. 2. The work piece is held in the chuck. Chuck key is used to tighten the job firmly, ensuring centering of work-piece. 3. The single point cutting tool is held in the tool post and tighten the nuts using spanner. 4. Facing is done with cutting tool moving from the centre of workpiece towards outside. It is done until the required length of the job is obtained. 5. Turning is done to reduce the diameter of the job. Sufficient depth of cut is given and it is done until the required diameter of the job is obtained. 6. Finally the dimensions of workpiece are again checked. Result: Thus the required size and shape of the given work piece is obtained. 2.Workpiece setting 5. Turning 3. Tool setting 2. Cutting tool 5. Scriber 3. Vernier Caliper 6. Vernier height gauge

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All Dimensions are in mm. Not to Scale.

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9518 - National College of Engineering 7. DRILLING Aim: To drill the holes of required sizes . Material supplied: 50x50x5 nun Mild steel plate - 1 No. Tools required: 1. Bench vice 4. Standard set of filing tools 7. Vernier height gauge 10. Dri11 bit Sequence of operations: 1. Checking 4. Punching Working steps: 1. The raw material is checked for its size 50 x 50 x 5 mm using steel rule. 2. The given workpiece is clamped in a vice and any two surfaces are filed to get right angle. 3. Chalk is applied uniformly on the surfaces of the workpieces. 4. With the help of vernier height gauge, surface plate, angle plate, steel rule, and scriber the given dimensions are marked. 5. The mid point of the required holes is punched by using a dot punch. 6. The punched dots are drilled by drilling machine. 7. Finally the dimensions are again checked. 2. Machine vice 5. Try square 8. Scriber 3. Steel rule 6. Surface plate 9. Dot Punch

2. Filing 5. Drilling

3. Marking

Result: Thus the given work piece is drilled to the required dimensions.

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All Dimensions are in mm. Not to Scale.

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9518 - National College of Engineering 9. BUTT JOINT Aim: To make a butt joint using gas welding on the given work pieces. Material supplied: Mild steel plate of size 100 x 50 x 4 mm 2 Nos. Tools required: 1. Oxygen cylinder 4. Tongs 7. Wire brush Sequence of operations: 1. Edge preparation 4. Cooling Working steps: 1. First of all, the workpieces must be thoroughly cleaned to remove rust, scale and other foreign material. 2. Set the neutral flame in welding torch. 3. Set the workpiece in correct position and maintain the gap 3mm and start tack welding at both ends of the workpiece. 4. Now the partially welded plate are inverted and tacked at both ends of the workpiece. 5. Again the welding is carried out throughout the length. 6. As soon as the welding process is finished close the valves of both the oxygen cylinder and acetylene cylinder. Then allow the workpiece to cool. 7. Finally using wire brush, welded portions are cleaned 2. Tacking 5. Chipping 3. Welding 6. Cleaning 2. Acetylene cylinder 5. Safety glasses 8. Gloves 3. Welding torch 6. Chipping hammer 9. Aprons

Result: Thus the desired butt joint is obtained using gas welding.

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All Dimensions are in mm. Not to Scale.

10. LAP JOINT

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Aim: To make a lap joint using arc welding on the given work pieces. Material supplied: Mild steel plate of size l00x50x4 mm - 2 Nos. Tools required: 1. Power supply (AC or DC) 3. Electrodes 5. Chipping hammer 7. Gloves 9. Shield 11. Earthing clamps Sequence of operations: 1. Edge preparation (Removal of rust, scale etc.) 2. Tacking 3. Welding 4. Cooling 5. Chipping 6. Cleaning Working steps: 1. First of all, the workpieces must be thoroughly cleaned to remove rust, scale and other foreign material. 2. Now the workpieces are placed on the table in such a way that two workpieces are overlapped one over another as shown in fig. 3. Appropriate power supply should be given to the electrode and the workpieces. 4. Now the welding current output may be adjusted. 5. When current is passed, arc is produced between electrode and the workpieces. 6. Set the two workpieces in correct position like lap joint and tack at both ends of the workpieces as shown in figure. 7. Then the welding is carried out throughout the length of the workpiece. 8. As soon as the welding process is finished switch off the current supply. 9. Then allow the workpiece to cool, after that slags are removed by chipping process with the help of chipping hammer. 10. Finally by using wire brush, welded portions (weldment) are cleaned. Result: Thus the desired lap joint is obtained using arc welding. 2. Welding Torch 4. Tongs 6. Wire brush 8. Apron 10. Safety goggles

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9518 - National College of Engineering 12. Double Parallel Fillet joint

Aim: To make a lap joint using arc welding on the given work pieces. Material supplied: Mild steel plate of size l00x50x4 mm - 2 Nos. Tools required: 1. Power supply (AC or DC) 3. Electrodes 5. Chipping hammer 7. Gloves 9. Shield 11. Earthing clamps Sequence of operations: 2. Edge preparation (Removal of rust, scale etc.) 2. Tacking 3. Welding 4. Cooling 5. Chipping 6. Cleaning Working steps: 11. First of all, the workpieces must be thoroughly cleaned to remove rust, scale and other foreign material. 12. Now the workpieces are placed on the table in such a way that two workpieces are overlapped one over another as shown in fig. 13. Appropriate power supply should be given to the electrode and the workpieces. 14. Now the welding current output may be adjusted. 15. When current is passed, arc is produced between electrode and the workpieces. 16. Set the two workpieces in correct position like lap joint and tack at both ends of the workpieces as shown in figure. 17. Then the welding is carried out throughout the length of the workpiece. 18. As soon as the welding process is finished switch off the current supply. 19. Then allow the workpiece to cool, after that slags are removed by chipping process with the help of chipping hammer. 20. Finally by using wire brush, welded portions (weldment) are cleaned. Result: Thus the desired lap joint is obtained using arc welding. 2. Welding Torch 4. Tongs 6. Wire brush 8. Apron 10. Safety goggles

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9518 - National College of Engineering 13. T joint Aim: To make a T joint using arc welding on the given work pieces. Material supplied: Mild steel plate of size l00x50x4 mm - 2 Nos. Tools required: 1. Power supply (AC or DC) 3. Electrodes 5. Chipping hammer 7. Gloves 9. Shield 11. Earthing clamps Sequence of operations: 3. Edge preparation (Removal of rust, scale etc.) 2. Tacking 3. Welding 4. Cooling 5. Chipping 6. Cleaning Working steps: 21. First of all, the workpieces must be thoroughly cleaned to remove rust, scale and other foreign material. 22. Now the workpieces are placed on the table in such a way that two workpieces are overlapped one over another in the form of a T-shape as shown in fig. 23. Appropriate power supply should be given to the electrode and the workpieces. 24. Now the welding current output may be adjusted. 25. When current is passed, arc is produced between electrode and the workpieces. 26. Set the two workpieces in correct position like tjoint and tack at both ends of the workpieces as shown in figure. 27. Then the welding is carried out throughout the length of the workpiece. 28. As soon as the welding process is finished switch off the current supply. 29. Then allow the workpiece to cool, after that slags are removed by chipping process with the help of chipping hammer. 30. Finally by using wire brush, welded portions (weldment) are cleaned. Result: Thus the desired T joint is obtained using arc welding. 2. Welding Torch 4. Tongs 6. Wire brush 8. Apron 10. Safety goggles

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9518 - National College of Engineering

All Dimensions are in mm. Not to Scale.

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14. RECTANGULAR TRAY Aim: To make a rectangular tray from the given sheet metal. Material supplied: 22 gauge Galvanized Iron (G. I) sheet. Tools required: 1. Steel rule 4. Divider 7. Stakes Sequence of operations: 1. Checking 4. Cutting 6. Rivetting Working steps: 1. The size of the given sheet is checked for its dimensions Using a steel rule. 2. Then the sheet is levelled on the levelling plate using a mallet. 3. The development procedure is followed same as square taper tray. 4. The dimensions are marked as shown in fig. 5. The sheet is cut as per the marked dimensions by straight snips. 6. Then a single hemming is made on the four sides of the tray as shown In fig. 7. The four sides of the tray are bent to 90 using stakes anvil. 8. Finally all the corners of the tray are joined by riveting. Result: Thus the desired rectangular tray is made from the given sheet metal. 2. Levelling 5. Bending 3. Levelling 6. Hemming 2. Mallet 5. Protractor 8. Rivet set 3. Scriber 6. Snips 9. Ball peen hammer

MAKING OF A CONE FUNNEL

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Aim To make a funnel from the given sheet metal. Tools required Steel rule Mallet Scriber Divider Protractor Snips Stakes Ball peen hammer Solder Procedure 1. The size of the given sheet is checked for its dimension using steel rule. 2. The required development of surface is being made on the white paper which is overlapped on the sheet metal. 3. The marking is done on the sheet metal as per the development being done on the paper. 4. Now using straight snips, unwanted material are removed. 5. Now fold and bend the workpiece to make the funnel shape and joint is made on the workpieces. 6. Then using a groove, a locked grooved joint is made for about 5mm. also; hemming is done in the bottom of the funnel. 7. In between top face and bottom face, a butt joint is made using a solder. 8. Finally, trimming and finishing operations are carried out.

Result Thus desired cone funnel is made from the given sheet metal.

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All Dimensions are in mm. Not to Scale.

17. V- JOINT Engineering Practices Laboratory GE 2116 29

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Aim: To make a v-joint on the given work piece. Material supplied: 50 x 50 x.5 mm Mild steel plate - 2 Nos. Tools required: 1. Bench vice 3. Standard set of filing tools 5. Scriber 7. Surface plate 9. Dot punch Sequence of operations : 1. Checking 3. Marking 5. Sawing 7. Finish Filing Working steps: 1. The given material is checked for its size 50 x 50 x 5mm after deburring. 2. The given pieces are fixed rigidly on the vice separately and all edges are filed using flat file so that they are at right angles. 3. Then chalk is applied uniformly on the surfaces of the workpieces. 4. The workpiece is marked to given dimensions as per drawing with reference to the datum using surface plate and vernier height gauge. 5. Now using dot punch, dots are punched along the marked line. 6. Using Hacksaw frame, the unwanted portions are removed. 7. Cutting edges are filed by using half round and triangular files. 8. Finally, the assembly is checked for the required class of fit. Result: Thus the required V- joint is obtained from the given work piece. 2. Rough Filing 4. Punching 6. Rough Filing 2. Steel rule 4. Try square 6. Vernier Height gauge 8. Angle Plate 10. Fixed Hacksaw

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