LABORATORY

MANUAL
Course: Engineering Workshop
Course Code: 23BEX06

B.Tech. (Common to All Branches)

1st Year :: 1st / 2nd Semester

Name of the Lab-in charge:

Dr. V.R.S. Shanmukha Sundaram (Sr. Assistant Professor)

Department of Mechanical Engineering

GMR Institute of Technology (Autonomous)
GMR Nagar, Rajam, Vizianagaram, Andhra Pradesh - 532 127
 Name of the Course: Engineering Workshop
Course Code: 23BEX06
❖ COURSE OBJECTIVES:
The course is mainly intended to
• familiarize students with wood working, sheet metal operation, fitting operation, electrical house
wiring, foundry and welding operation skills.
• make the students correctly use of different measuring, marking and hand tools.
• apply safe workshop practices when performing wood working, sheet metal operation, fitting
operation, electrical house wiring, foundry operation and welding operation.
• read and interpret the component drawings and assemble components as per drawing specifications.
• develop the fabrication skills among the students.
• gain practical skills to apply student’s knowledge of theory concepts in real time practice.

❖ COURSE OUTCOMES:
At the end of this course a student will be able to
1. develop simple wooden joints
2. develop simple objects using sheet metal
3. create V- Fit, Square fit, Dovetail fit using mild steel
4. demonstrate simple house wiring circuits
5. create green sand moulds
6. construct the metal joints using arc welding

❖ LIST OF EXPERIMENTS:
Wood Working: Electrical Wiring:
1. Cross Lap joint, 10. Parallel/Series connection of three
2. T-Lap joint, bulbs,
3. Dovetail Joint 11. Stair Case Wiring,
Sheet Metal Working: 12. Godown Wiring
4. Taper Tray, Foundry Trade:
5. Square box, 13. Mould cavity for rectangular shape
6. Open Scoop 14. Mould cavity for a straight pipe
Fitting: Welding Shop:
7. V- Fit, 15. Lap joint
8. Square fit, 16. Butt joint.
9. Dovetail fit
# Any two jobs from each trade must be performed by the student.

❖ AUGMENTED EXPERIMENT / MINI PROJECT: An innovative and creative useful

house hold product/model should be prepared by the group of 6-10 students using the knowledge
gathered from all the shops in the workshop.
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TABLE OF CONTENTS

Exp. No. Experiment Page No.

Introduction to Carpentry Shop 1
1 Cross Lap Joint 6
2 T – Lap Joint 8
3 Dove Tail Joint 10
Introduction to Sheet Metal Shop 12
4 Square Box without lid 14
5 Taper Tray 16
6 Open Scoop 18
Introduction to Fitting Shop 20
7 Square Fitting 24
8 V- Fitting 26
9 Dovetail fitting 28
Introduction to Electrical Shop 30
10 Parallel / Series Connections of three bulbs 34
11 Staircase Wiring 35
12 Godown Wiring 37
Introduction to Foundry Trade 40
13 Mould cavity for rectangular shape 42
14 Mould cavity for a straight pipe 44
Introduction to Welding Shop 46
15 Lap joint 48
16 Butt joint 49

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INTRODUCTION TO CARPENTRY SHOP

Carpentry may be defined as the process of making wooden components. It starts from a marketable
form of wood and ends with a finished product. It deals with the building work, furniture, cabinet
making, etc. Joiner, i.e., preparation of joints is one of the important operations in all wood-works. It
deals with the specific work of a carpenter like making different types of joints to form a finished
product.
CARPENTARY TOOLS
The efficiency of the workman depends upon the tools used in the workshop. Good quality tools
always make the work easy. In the carpentry trade the tools are classified as under:
I. Measuring tools
II. Marking Tools
III. Cutting Tools
IV. Planning Tools
V. Holding Devices
VI. Striking Tools
(I) MEASURING TOOLS:
Steel Rule: It is made up of stainless steel and is marked with scales. In this scale also thereis
graduation in both inches and centimeters and inches and centimeters are also further divided into
smaller divisions.

Fig.: Steel Rule

Steel Tape: It is made up of a flexible thin steel strip. It is folded around a centre pin attached with a
small handle. It is graduated.

Fig.: Steel Tape

(ii)MARKING TOOLS
Pencil: Lead pencil is generally used for marking purposes.

Fig.: Pencil
Scriber: Scriber has a sharp conical edge used to mark on even hard surfaces. The front edge is
hardened so as to resist wear and tear. It is made up of carbon steel. It is used for measuring and
marking the points and lines on the wooden stock before processing.

Fig.: Scriber
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Try Square: It is used to draw lines at right angle, parallel or to check the trueness of planed surfaces.
It is made up of a steel blade with heavy base

Fig.: Try Square

(III) CUTTING TOOLS:
Rip Saw: It is hand saw from 30 cm. to 75 cm. long, containing one to one and half teeth per cm. It
should not be called a hand saw but a rip saw only. Cutting of the wood is done along the grains,
nearly the entire length of the saw blade is used for cutting. Cutting takes place in the forward stroke
backward stroke is ideal.

Fig.: Rip saw

Tenon Saw: It drives its name from the tenon form of joint. It is a thin saw ranging from 20 cm. to
40 cm. in length, and is-supported by back of wrought iron or brass; hence it is also called a back
saw. It contains about 4 teeth to a cm. It is used primarily for short cuts such as for tenons. So the
blade is provided with a reinforcing strip or back at the top so that blade is prevented from bending
during operation.

Fig.: Tenon saw

Coping Saw: It is used for cutting quick or sharp curves either internal or external. For cutting the
internal surfaces first-drilling is done and then the saw blade is inserted in the hole for cutting. It
consists of approximately 10 teeth per cm.

Fig.: Coping saw

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CHIESELS:
There are three types of chisels commonly used in Carpentry shop :

Firmer Chiesel: It is a general purpose chiesel used to finish inside grooves. It has various sizes of
cutting edge depending upon the work to be done. Width varies from 5 mm to 35 mm. The cross
section of the blade is rectangular in shape the wider portion of the rectangle shows the width and the
smaller side the thickness.

Fig.: Firmer Chiesel

Mortise Chiesel: It is used to make mortises. Mortise chiesel is used for heavy cuts. The blade
thickness varies from 5 mm. to 12 mm. Because of wider thickness this blade is stronger in
comparison to other chisels of same size, therefore, it is capable of taking the heavy blows.

Fig.: Mortise Chiesel

(IV) PLANING TOOLS
Wooden Jack Plane: Its length is 20" - 30" and used for general purpose. It consists of a wooden
body called as stock, bottom face is called as sole. The blade is fixed in the stock at an angle 450 with
respect to sole and material of the blade is high carbon steel. The projection of the blade from the sole
is controlled by a tapered wooden wedge.

Fig.: Wooden jack plane

Iron Jack Plane: This plane is used for better finish. It is made of cast Iron with a wooden handle at
the back and a wooden knob at the front, so that it can be held by both the hands during operation.
This plane have a rigid and stronger body in comparision to wooden Jack Plane, but it is costlier.

Fig.: Iron Jack Plane

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Rasp: It is also known as a rasp file. It is a finishing tool used to make the wood surface smooth,
remove sharp edge, finishing fillets and other interior surfaces. Sharp cutting teethare provided on
its surface for this purpose. This file is used in wood-work only.

Fig.: Rasp

(V) HOLDING TOOLS

Work Bench: It is a table which is made of Sal or She sour wood. Size of the table is6' x 3'.
Two to four carpenter's vice are fixed at the four corners of the table. This table acts as a base for ail
the carpentry or wood working operations.

Fig.: Work Bench

(VI ) STRIKING TOOLS
Striking tools are used to force the nails or chiesels into the wood. Main striking tools are as under:
(i) Cross pean Hammer (ii) Claw Hammer (iii) Mallet
Cross Pean Hammer: It has a cast steel body and a wooden handle. Body has two parts face and
pean. In cross pean hammer, the pean is in the form of a narrow-round edge ridge placedat right angle
to the axis of the handle.

Fig.: Cross Pean Hammer

Claw Hammer: It is used for striking as well as for pulling the nails from the wood. The material of
the wood is case steel. One end is made striking and the second is claw face. Its weight varies from
0.25 kg to 0.75 kg.

Fig.: Claw Hammer

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Mallet: It is used to strike the chiesels which have wooden handles. It is made up of a hard wood and
is round or rectangular in shape.

Fig.: Mallet

SAFETY PRECAUTIONS IN CARPENTARY TRADE

Following precautions must be kept in mind while working in carpentary trade:
1. Tool should be placed properly on work bench.
2. Wooden pieces with projected nails should not be allowed to remain lying on theshop floor.
3. Never stand in front of the blade while working on a circular saw,
4. Blunt tools should not be used.
5. The wooden pieces should not be fed to the sawing machines faster than the cuttingspeed of
the machine.
6. Do not try to operate the machine or tools without having proper knowledge.

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Experiment 1
CROSS-LAP JOINT

Aim: To make a Cross–lap joint from a given piece of wood.

Tools Used: Steel rule, Metal Jack Plane, Try square, Marking gauge, Tenon saw, Hand saw,
Firmer Chisel, Mallet and Bench vice.

Sequence of Operations:
1. Planning
2. Marking
3. Cutting (Sawing)
4. Chiseling
5. Finishing

Procedure:
1. A wooden piece is taken and fixed to a Bench vice
2. It is leveled on all sides using a jackplane and a Try square.
3. Required markings are made on the given piece using a marking gauge.
4. The given piece is cuts into two halves using Hand saw.
5. The required dimensions are marked on each half piece.
6. The two pieces are cut up to the mark using a hand saw.
7. Excess material is removed using a chisel and mallet.
8. Leveling, cutting and chiseling are done and the two pieces are joined to obtain therequired
shape.

Safety Precautions:
1. The instruments must be handled with care.
2. The workpiece should be clamped tightly to the bench vice care should be taken thatmetal
jack plane doesn’t fall.
3. The firmer chisel shouldn’t be hit hardly with the mallet. Otherwise the workpiece maybe
damaged.
4. While using a chisel care should be taken that extra material is removed from theworkpiece.

Result: The Cross-lap joint is thus made by following the above sequence of operations.

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All dimensions are in mm

Fig.: Cross-Lap Joint

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Experiment 2
T - LAP JOINT

Aim: To make a T - Lap joint from a given piece of wood.

Tools Used: Steel rule, Metal Jack Plane, Try square, Marking gauge, Tenon saw, Hand saw,
Firmer Chisel, Mallet and Bench vice.

Sequence of Operations:
1. Planning
2. Marking
3. Cutting (Sawing)
4. Chiseling
5. Finishing

Procedure:
1. A wooden piece is taken and fixed to a Bench vice
2. It is leveled on all sides using a jackplane and a Try square.
3. Required markings are made on the given piece using a marking gauge.
4. The given piece is cuts into two halves using Hand saw.
5. The required dimensions are marked on each half piece.
6. The two pieces are cut up to the mark using a hand saw.
7. Excess material is removed using a chisel and mallet.
8. Leveling, cutting and chiseling are done and the two pieces are joined to obtain the
required shape.

Safety Precautions:
1. The instruments must be handled with care.
2. The workpiece should be clamped tightly to the bench vice care should be taken that
metal jack plane doesn’t fall.
3. The firmer chisel shouldn’t be hit hardly with the mallet. Otherwise the workpiece may
be damaged.
4. While using a chisel care should be taken that extra material is removed from the
workpiece.

Result: The required T - Lap joint is thus made by following the above sequence of
operations.

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All dimensions are in mm

Fig. T-Lap Joint

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Experiment 3
DOVE TAIL JOINT

Aim: To make a Dove tail joint from a given piece of wood.

Tools Used: Steel rule, Metal Jack Plane, Try square, Marking gauge, Tenon saw, Hand saw,
Firmer Chisel, Mallet, Wood rasp file and Bench vice.

Sequence of Operations:
1. Planning
2. Marking
3. Cutting (Sawing)
4. Chiseling
5. Finishing

Procedure:
1. A wooden piece is taken and fixed to a Bench vice
2. It is leveled on all sides using a jackplane and a Try square.
3. Required markings are made on the given piece using a marking gauge.
4. The given piece is cuts into two halves using Hand saw.
5. The required dimensions are marked on each half piece.
6. The two pieces are cut up to the mark using a hand saw.
7. Excess material is removed using a chisel and mallet.
8. Leveling, cutting and chiseling are done and the two pieces are joined to obtain the
required shape.

Safety Precautions:
1. The instruments must be handled with care.
2. The workpiece should be clamped tightly to the bench vice care should be taken that
metal jack plane doesn’t fall.
3. The firmer chisel shouldn’t be hit hardly with the mallet. Otherwise the workpiece maybe
damaged.
4. While using a chisel care should be taken that extra material is removed from the
workpiece.

Result: The required Dove tail joint is thus made by following the above sequence of
operations.

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All dimensions are in mm

Fig.: Dove Tail Joint

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INTRODUCTION TO SHEET METAL SHOP

The metal plank having less than 2mm thick is called sheet metal. Sheet metal work deals with the
production of components is a wide variety of shapes and sizes from sheet metalwith aid of hand
tools and machines.

TOOLS USED IN SHEET METAL SHOP

Various hand tools are used in sheet metal are described as below:
Steel Rule: These are available in variety of sizes. The rule could be steel foot rule,folding rule
or tape rule.

Fig.: Steel Rule

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

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

Fig.: Divider
Punches: The following punches of tool steel are used in sheet metal shop.
Centre Punch: Used for marking the location of points and the centre of holes tobe drilled. Its
tapered point is grounded to 900 included angle.

Fig: Centre Punch

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 m/c is used.

Fig.: Snips
Bent Snip: Blades are curved back from the cutting edge which allows the metal to slide over top
blades.

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Fig.: Bent Snip

Supporting Tools:
Hand Stake: It is a handy with a flat face, two straight edges one concave edge and otherconvex
edge and is used for pressing the inner sides of straight joint

Fig.: Hand Stake

Taper Stake: It is used for rounding of tapering jobs such as conical jobs.

Fig.: Taper Stake

SAFETY PRECATION IN SHEET METL SHOP:

1. Never carry tools in pockets.
2. Do not try to hold the sheets with bare hands.
3. Do not remove any guards on squaring sheer.
4. Care should be exercised when working on squaring shears. Be sure that the fingersare away
from the shearing handle.
5. Never use a soldering iron with a loose blade.
6. Never touch a soldering iron to are its hotness. The safest methods is to touch theiron to
solder. The melting of solder indicates the correct temperature.
7. Be careful when cutting of sheet metal, remove extra sheet metal to avoid injuries.

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Experiment 4
TAPER TRAY
Aim: To make a taper tray from a given piece of galvanized iron sheet.

Tools Used: Steel rule, Try square, Scriber, Straight snip, Wooden mallet, Flat stake.

Sequence of Operations:
1. Planning
2. Leveling
3. Marking
4. Cutting
5. Hemming
6. Bending
7. Finishing

Procedure:
1. A galvanized Iron sheet of 150 x 150 mm is taken and is made flat using a mallet on aflat stake.
2. The required markings are made on the sheet (as shown in fig.) with the help of a scriberand a
steel rule.
3. The excess sheet is cut of using a straight snip.
4. As per the given measurements. Hemming is done on the edges of the metal sheet, using a
mallet on the flat stake.
5. The necessary cuttings are made on the sheet using a straight snip as per the given
measurements.
6. The sides of the sheet is bent inwards (with the hemming coming outwards) using amallet
placing the sheet on the flat stake, to obtain the required shape of the tray.

Safety Precautions:
1. Never carry tools in pockets.
2. Do not try to hold the sheet bare hands.
3. Do not remove any guards on squaring shears.
4. Be sure that the fingers are away from the shearing handle.

Result: The Required taper tray is thus made from the given sheet metal.

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All dimensions are in mm.

Fig.: Taper Tray

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Experiment 5
SQUARE BOX WITHOUT LID
Aim: To make a square box without lid from a given piece of galvanized iron sheet.

Tools Used: Steel rule, Try square, Scriber, Straight snip, Wooden mallet, Flat stake.

Sequence of Operations:
1. Planning
2. Leveling
3. Marking
4. Cutting
5. Hemming
6. Bending
7. Finishing

Procedure:
1. A galvanized Iron sheet of 150 x 150 mm is taken and is made flat using a mallet on aflat
stake.
2. The required markings are made on the sheet (as shown in fig.) with the help of a scriber
and a steel rule.
3. The excess sheet is cut of using a straight snip.
4. As per the given measurements. Hemming is done on the edges of the metal sheet, using a
mallet on the flat stake.
5. The necessary cuttings are made on the sheet using a straight snip as per the given
measurements.
6. The sides of the sheet is bent inwards (with the hemming coming outwards) using a
mallet placing the sheet on the flat stake, to obtain the required shape of the square box.

Safety Precautions:
1. Never carry tools in pockets.
2. Do not try to hold the sheet bare hands.
3. Do not remove any guards on squaring shears.
4. Be sure that the fingers are away from the shearing handle.

Result: The Required square box without lid is thus made from the given sheet metal.

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All dimensions are in mm.

Fig.: Square Box with Out Lid

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Experiment 6
OPEN SCOOP
Aim: To make Open scoop from a given piece of galvanized iron sheet.

Tools Used: Steel rule, Try square, Scriber, Straight snip, Wooden mallet, hatchet stake.

Sequence of Operations:
1. Planning
2. Leveling
3. Marking
4. Cutting
5. Hemming
6. Bending
7. Finishing

Procedure:
1. A galvanized Iron sheet of 150 x 150 mm is taken and is made flat using a mallet on aflat
stake.
2. The required markings are made on the sheet (as shown in fig.) with the help of a scriberand
a steel rule.
3. The excess sheet is cut of using a straight snip.
4. As per the given measurements. Hemming is done on the edges of the metal sheet, using a
mallet on the flat stake.
5. The necessary cuttings are made on the sheet using a straight snip as per the given
measurements.
6. The sides of the sheet is bent inwards (with the hemming coming outwards) using amallet
placing the sheet on the flat stake, to obtain the required shape of the tray.

Safety Precautions:
1. Never carry tools in pockets.
2. Do not try to hold the sheet bare hands.
3. Do not remove any guards on squaring shears.
4. Be sure that the fingers are away from the shearing handle.

Result: The Required Open scoop is thus made from the given sheet metal.

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All dimensions are in mm.

Fig.: Open Scoop

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INTRODUCTION TO FITTING SHOP

Fitting work is a very important work in engineering. In fitting shop unwanted material is removed
with the help of hand tools. It is done for mating, repair and manufacturing purposes. The person
working in fitting shop is called fitter.

FITTING TOOLS:
Holding Tools:
Bench vice: It is a common tool used for holding jobs. It consists of a cast iron jaws. Twojaw
plates are fitted on both the jaws. Jaw plates are made up of high carbon steel and are wear resistant.

Fig.: Bench Vice

Marking and Measuring Tools

Surface plate: The surface plate is machined to fine limits and is used for testing the flatness of the
work piece. It is also used for marking out small works and is more precise than the marking table.
The degree of fineness of the finish depends upon whether it is designed for bench work in a fitting
shop or for using in an inspection room.

Fig.: Surface plate

Try-square: It is a measuring and marking tool for 90° angle. In practice, it is used for checking the
squareness of many types of small works, when extreme accuracy is notrequired. The blade of the
try-square is made of hardened steel and the beam, of cast iron or steel. The size of the try-square is
specified by the length of the blade

Fig.: Try Square

Scriber: A scriber is a slender steel tool, used to scribe or mark lines on metal work pieces. Itis made
of hardened and tempered high carbon steel. The tip of the scriber is generally ground at 12° to 15°.
It is generally available in lengths, ranging from 125 mm to 250 mm. It has two pointed ends. The
bent end is used for marking lines where the straight end can not reach.

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Fig.: Scriber
Dot punch: This is used to lightly indent along the layout lines, to locate centre of holes and to
provide a small centre mark for divider point, etc. for this purpose, the punch is ground to aconical
point having 60° included angle.

Fig.: Dot Punch

Centre punch: This is similar to the dot punch, except that it is ground to a conical point having 90°
included angle (Fig. 8.12b). It is used to mark the location of the holes to be drilled.

Fig.: Center Punch

CUTTING TOOLS
Hacksaw: The hacksaw is used for cutting metal by hand. It consists of a frame, which holds a thin
blade, firmly in position. Hacksaw blade is specified by the number of teeth per centimeter. Hacksaw
blades have a number of teeth ranging from 5 to 15 per centimeter (cm).Blades having lesser number
of teeth per cm are used for cutting soft materials like aluminum, brass and bronze. Blades having
larger number of teeth per centimeter are used forcutting hard materials like steel and cast iron.

Fig.: Hacksaw frame with blade

Types of files: Files are classified according to their shape, cutting teeth and pitch or grade of the
teeth. The following figures shows the various types of files based on their shape. Table gives types
of files and their description and uses.
Flat file: Rectangular in section and tapered for 1/3rd length in width and thickness. The faces have
double cut teeth and the edges, single cut. Used for general purpose filing.

Fig.: Flat file

Square file: Square in section and tapered for 1/3rd length on all faces. All the faces have double cut
teeth. Used for filing comers and slots and also to cut keyways.

Fig.: Square file

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Triangular file: Equilateral triangular in section and tapered for 1/3rd 1engthon all faces. Allthe
faces have double cut teeth. Used for filing internal comers.

Fig.: Triangular file

Half round file: It has one flat face, connected by a curved face and tapered for 1/3rd length. The
curved face is not exactly semi-circular but only a part of circle. The flat face has double cut teeth
and the curved face, single cut. Used for filing concave surfaces and internal corners.

Fig.: Half-round file

Round file: Circular cross-section and tapered for 1/3rd length. It as double cut teeth. Usedfor
filing concave surfaces and circular openings.

Fig.: Round file

FITTING OPERATIONS
Chipping: Removing the metal with a chisel is called chipping and is normally used where
machining is not possible. While chipping, safety goggles must be put on, to protect eyes from the
flying chips. To ensure safety of others, a chip guard is placed in position. Care should be taken to
see that the chisel is free from mushroom head.

Fig.: Chipping
Filing: There are several methods of filing, each with a specific purpose. With reference to
thefigure, the following may be noted:
Holding the file: For heavy work and to remove more metal, a higher pressure isused. For
light and fine work, a light pressure is applied.

Fig.: Holding the file

Filing internal curves: A part of half round file only makes contact as shown, duringfiling

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operation. Movement of the file is indicated by arrows.

Fig.: Filing internal curves

Cross filing: Cross filing is carried out across two diagonals, to produce mediumsurface finish.

Fig.: Cross filing

Draw filing: A smooth file with a flat face is used for this purpose and to producefine grained
structure.

Fig.: Draw filing

SAFE AND CORRECT PRACTICES

1. Keep hands and tools wiped clean and free of dirt, oil and grease. Dry tools are saferto use
than slippery tools.
2. Keep tools sharp and in good adjustment. Dull or poorly adjusted tools must beforced,
causing accidents. .
3. Do not carry sharp tools in pockets.
4. Hold the pointed tool away from the body, to avoid injury, in case the tool slips.
5. Wear leather shoes not chappals.
6. Don't wear loose clothes.
7. Remember that a slippery floor is always dangerous.
8. Do not keep working tools at the edge of the table.
9. Put the sharp tool in its proper place, immediately after completion of work with it.
10. Never work in a place where there is no sufficient light.
11. Avoid talking and unnecessary discussions during working time and concentrate onlyon the
Work.

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Experiment 7
V- FITTING
Aim: To make a V- fitting of the given dimensions.

Tools Used: Steel rule, Scriber, Dot punch, Jenny caliper, Ball peen hammer,
Try square, Hack saw, Rough & Smooth Flat files and Rough & Smooth Square files.

Sequence of Operations:
1. Filing
2. Marking
3. Sawing (cutting)
4. Finishing

Procedure:
1. The given metal piece is fixed in the bench vice and one edge is made flat with help ofrough
flat file and smooth flat file later on.
2. The adjacent side is also made flat checking with a try square.
3. The sides are made perfectly perpendicular using smooth flat file land checking with a try
square. Then chalk can be applied on the piece to obtain visibility of markings.
4. Drawing the necessary measurements with a jenny caliper and a steel rule.
5. The piece is marked with a dot punch using a ball peen hammer.
6. Marked piece is initially cut at the middle into two haves equally.
7. To cut at a little distance from the markings as necessary to facilitate the filing processwith a
hack saw,
8. The excess material is filed off to the cutting pieces and checking the measurements in
between.
9. The pieces should be filled in such a way that the two pieces exactly fit in each other,with no
gaps in between.

Safety Precautions:
1. The work-piece should not be placed too much above the bench vice.
2. The piece should be cut at some distance from the marking.
3. The filing should be done carefully with the exact measurements.
4. All the tools should be used carefully and should not be allowed to fall.

Result: The Required V-fitting is thus made by following the above sequence of operations

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All dimensions are in mm.

Fig.: V- Fitting

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Experiment 8
SQUARE- FITTING
Aim: To make a Square-fitting of the given dimensions.

Tools Used: Steel rule, Scriber, Dot punch, Jenny caliper, Ball peen hammer,Try square, Hack
saw, Rough and Smooth Flat files and Rough and Smooth Square files.

Sequence Of Operations:
1. Filing
2. Marking
3. Sawing (cutting)
4. Finishing

Procedure:
1. The given metal piece is fixed in the bench vice and one edge is made flat with help ofrough
flat file and smooth flat file later on.
2. The adjacent side is also made flat checking with a try square.
3. The sides are made perfectly perpendicular using smooth flat file and checking with a try
square. Then chalk can be applied on the piece to obtain visibility of markings.
4. Drawing the necessary measurements with a jenny caliper and a steel rule.
5. The piece is marked with a dot punch using a ball peen hammer.
6. Marked piece is initially cut at the middle into two haves equally.
7. To cut at a little distance from the markings as necessary to facilitate the filing processwith a
hack saw.
8. The excess material is filed off to the cutting pieces and checking the measurements in
between.
9. The pieces should be filed in such a way that the two pieces exactly fit in each other, withno
gaps in between.

Safety Precautions:
1. The work-piece should not be placed too much above the bench vice.
2. The piece should be cut at some distance from the marking.
3. The filing should be done carefully with the exact measurements.
4. All the tools should be used carefully and should not be allowed to fall.

Result: The Required Square-fitting is thus made by following the above sequence ofoperations.

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All dimensions are in mm.

Fig: Square- Fitting

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Experiment 9
DOVE TAIL FITTING
Aim: To make a Dove tail fitting of the given dimensions.

Tools Used: Steel rule, Scriber, Dot punch, Jenny caliper, Ball peen hammer, Trysquare, Hack saw,
Rough & Smooth Flat files and Rough & Smooth Square files.

Sequence of Operations:
1. Filing Marking
2. Sawing (cutting)Finishing
Procedure:
1. The given metal piece is fixed in the bench vice and one edge is made flat with help of rough
flat file and smooth flat file later on.
2. The adjacent side is also made flat checking with a try square.
3. The sides are made perfectly perpendicular using smooth flat file land checking with a try
square. Then chalk can be applied on the piece to obtain visibility of markings.
4. Drawing the necessary measurements with a jenny caliper and a steel rule.The piece is
marked with a dot punch using a ball peen hammer.
5. Marked piece is initially cut at the middle into two haves equally.
6. To cut at a little distance from the markings as necessary to facilitate the filing process with a
hack saw,
7. The excess material is filed off to the cutting pieces and checking the measurements in
between.
8. The pieces should be filled in such a way that the two pieces exactly fit in each other, with no
gaps in between.

Safety Precautions:
1. The work-piece should not be placed too much above the bench vice.The piece should be
cut at some distance from the marking.
2. The filing should be done carefully with the exact measurements.
3. All the tools should be used carefully and should not be allowed to fall.

Result: The Required Dove tail fitting is thus made by following the above sequence of
operations

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All dimensions are in mm.

Fig.: Dove Tail Fit

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INTRODUCTION TO ELECTRICAL SHOP

Electricity is an essential need of our daily life. It is widely used for domestic as well as industrial
purposes. So, it is necessary for the engineering students to know about electrical work. In electric
shop knowledge is given about the electricity, field of its application, electrical instruments domestic
and industrial wiring, electrical goods used, symbols and precautions to be kept in mind.

TOOLS USED IN ELECTRIC SHOP

Common tolls used in electric shop are as given below:
Plier: Plier is used to perform the following functions: Cutting of wires, Twisting pairs of wires,
Loosening or tightening small nuts, Holding purposes, Removing the insulation of wires.
Three types of pliers are commonly used in electric shop:

Flat nose plier: Flat plier has two jaws. It is used (or holding, tightening or loosening ofnuts.

Fig.: Flat nose Plier

Long nose plier: Long nose plier has two long jaws. It is used for radio work.

Fig.: Long nose piler

Side cutting plier: Side cutting plier is used to cut the wire or strips. It has two cuttingedges.

Fig.: Side cutting Plier

Test pen: Test pen has the following functions:
(i) To check the supply, (ii) Loosening or tightening small screws.
It is a very common tool used in electrical shop. A small bulb is fitted inside a transparent handle.
When checking the supply the blade is touched to the point and the finger tip isplaced on the backside
of the handle. If the bulb glows, it shows that electric current is flowing through the wire.

Fig.: Test Pen

ACCESSORIES:
Switches: Switch is used to connect or disconnect the electric circuit. It is connected in phasewire
line. Various types of switches are as under:
Single way switch : This switch is provided with a single pole to control one light point at atime.
Two way switch: These are used for wiring circuits which are to be controlled from twopoints
independently.

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Fig.: Single way switch Fig.: Two-way switch

Lamp holders:
Lamp holders are used to support the bulbs and to connect them to the supply terminal insidethe
holders. The holders are made up of a bakelite base fitted with a copper top. Two pins are provided
in the base.

Fig.: Lamp holder

Socket: Electrical devices such as table lamp, table fan, electric iron etc., are connected tothe
electric supply through socket outlets. These are of two types:
1. Two pin socket, 2. Three pin socket.
In two pin socket, two holes are made for phase and neutral connections whereas in three pinsocket
an extra hole is made for earth connections.

Fig.: Three pin socket Fig.: Three pin socket outlet

Fuse: A device in which fusible wire is used to connect electric circuit. When there is over loading
of current, it melts and the circuit is broken. Generally thin copper wires are used as fuse wire. Other
materials that can be used as fuse wire are tin and aluminium.

Fig.: Fuse
Main switches: The main switches are used to control the hole supply.The following are the
different types of main switches: Iron clad double pole (I.C.D.P), Iron clad triple pole (I.C.T.P)

Fig.: Iron clad triple pole

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ELECTRIC SHOCK
When a person touches a naked electric wire containing current, a shock is felt due to thepassing of
electric current through his body.
Following are the effects of an electric shock:
1. Mental balance is lost
2. Heart beat decreases.

ELECTRICAL MATERIALS
Various electrical materials used for domestic and industrial purposes are described below:
Cables and Wires: Cables and wires are used to carry electricity from one place to anotherplace.
These are available in different sizes and shapes depending upon the current andvoltage flowing
through these wires and cables. Wires are made up of some conductive material drawn into
specific sizes and Cables are insulated wires. Insulation has the following functions
1. It prevents the leakage of the current.
2. It avoids the electric shock.

Various types of electric wires:

Electrical wires and cables which are commonly used are: P.V.C. wires, C.T.S. wires / T.R.S wires,
Lead sheathed wires, Weather proof wires, V.I.R wires
POWER SUPPLY SYSTEMS
There are three types of power supply systems, which are commonly used for domestic and
industrial purposes.
Single phase supply system: In this system only one phase wire and a neutral wire is used.The
current flows from phase to neutral. This system is generally used for domestic wiring and the
voltage used is 220/230 volts.
Two phase supply system: In this system two phase wires are used. The voltage is keptsame and
the phase difference is 90°.
When a neutral wire is also used along with the two phase wires, the system is known as twophase
three wire system.

Fig.: Single Phase Supply Fig.: Two Phase Supply

Three phase supply system: There are two types of three phase systems:
1. Three phase three wire system
2. Three phase four wire system

Fig.: Three Phase supply

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In the first system three phase wires are used. The voltage is constant in all phase wires but a phase
difference of 120° is kept.
When a neutral wire is used along with the three phase wires, the system is known as three phase four
wire system.

EARTHING:
Earthing is to connect the all-electrical appliances, machines and circuits with the earth. The potential
of earth is taken as zero. In case of any leakage, the current directly goes to earth. Earthing has the
following advantages:
1. To maintain line voltage constant.
2. To save human life in case of shock.
3. To protect from atmospheric lighting.

Fig: Earthling

SAFETY PRECAUTIONS IN ELECTRICAL SHOP

To avoid electric shock in electrical shop the following precautions must be observed:
1. Always wear a rubber sole closed shoe inside electrical shop.
2. Wooden board should be kept under the feet while working.
3. Proper earthing must be provided.
4. Never touch any bare conductors in the electrical shop.
5. While repairing electrical appliances, it should be disconnected from power supply.
6. Never disconnect a plug point by pulling the flexible wire.
7. Plugs should be covered with caps.
8. Never give supply to any line unless you know that no body is working on the line.
9. Safety belt should be used while working on poles.
10. Electrical appliances should be insulated properly.
11. While charging the batteries, good ventilation should be provided.
12. In case of any fire, supply should be disconnected immediately.
13. Never use water to extinguish fire, sand should be used for this purpose.
14. Before replacing burnt fuse, main switch should be off.

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Experiment 10
Parallel/Series Connections of Three Bulbs
Aim: To make connections to three bulbs, controlled by one switch in parallel / series.

Tools Used: Tester, Cutting pliers, Screw driver, Insulation remover (or) Wire cutter, Hacksaw,
Firmer chisel, Hammer, Poker, Hand drilling machine

Accessories Used: One way switches, Batten holders, Bulbs, I.C.D.P Main switch.

Materials Used: Wire, P.V.C Pipes, Junction boxes, Ceiling plates, Elbows, T-bows, Screws.

Procedure:
1. The outline of the wiring diagram is marked on the wooden wiring board.
2. Clips are nailed to the board, fol lowing the wiring diagram.
3. Wires are stretched and clamped with the clips.
4. Round blocks (3No's) are screwed onto the board, as per the diagram.
5. Wires are connected to the holders and switch, which are then screwed onto the roundblocks.
6. Bulbs are fitted to the holders.
7. The wiring connections are then tested, by giving power supply.

Precautions:
1. Phase is always connected through the switch.
2. Connect the wires correctly as per the given circuit.
3. Do not run too many electrical items from point.
4. Never work on electric wires when the power is on.
5. Never work with bare feet. It is better to wear rubber shoes while working.

Result: The required parallel/series electrical circuits for three bulbs controlled by
oneswitch in parallel / series is thus made.

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Experiment 11
STAIRCASE WIRING
Aim: To make stair case wiring to control one lamp by two switches from two differentplaces.

Accessories Used: Two way switches, Batten holders, Bulb, I.C.D.P Main switch.

Materials Used: Wire, P.V.C Pipes, Junction boxes, Ceiling plates, Elbows, T-bows, Screws.

Tools Used: Tester, Cutting pliers, Screw driver, Insulation remover (or) Wire cutter, Hacksaw,
Firmer chisel, Hammer, Poker, Hand drilling machine.

Procedure:
1. Phase is taken from the main switch and is connected to the middle terminal of Two way
switch S1.
2. From S1 upper terminal is connected to the S2 upper terminal.
3. From S1 lower terminal is connected to S2 lower terminal.
4. Again S2 middle terminal (control terminal) is connected to the lamp holder.
5. Neutral wire is taken from the main switch and is directly connected to the lamp holder.
6. All the accessories are connected as per the circuit diagram.
7. After verifying the connections and testing the supply is given.
8. The bulb glows, when the two switches are in the same position i.e., either in position 1or
position 2.
9. The bulb can be controlled by activating the switch from any switch i.e., S1 and S2.

Safety Precautions:
1. Phase is always connected through the switch.
2. Use correct rating of fuse wire.
3. Do not use leaky insulated tools.

Result: The required stair case wiring i.e., to control one lamp by two switches from two
different places is obtained.

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Fig.: Wiring diagram

Fig.: Stage 1 Lamp Off Position

Fig.: Stage 2 Lamp Glowing Position

Fig.: Stage 3 Lamp Glowing Position

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Experiment 12
GODOWN WIRING
Aim: To make Godown wiring to control the lamps in serial order.

Accessories Used: One way switch, Two way switches, Batten holders, Bulbs, I.C.D.P Main
switch.

Materials Used: Wire, P.V.C Pipes, Junction boxes, Ceiling plates, Elbows, T-bows, Screws.

Tools Used: Tester, Cutting pliers, Screw driver, Insulation remover (or) Wire cutter, Hacksaw,
Firmer chisel, Hammer, Poker, Hand drilling machine.

Procedure:
1. Phase is taken from the main switch and is connected to the incoming terminal of Oneway
switch S1.
2. Out going terminal of S1 is connected to the middle terminal of S2.
3. Upper terminal of S2 is connected to the lamp holder.
4. Lower terminal of S2 is connected to the middle terminal of S3.
5. Upper terminal of S3 is connected to the lamp holder 2
6. Lower terminal of S3 is connected to the lamp holder 3.
7. Neutral is taken from the main switch and connected to the lamp holder 1
8. Neutral is taken from the lamp holder 1 and connected to the lamp holder 2.
9. Again neutral wire taken from the lamp holder 2 is connected to the lamp holder3.
10. Now fixing and connecting all the accessories and materials after that ON the mainswitch
and check the wiring.

Safety Precautions:
1. Phase is always connected through the switch.
2. Use correct rating of fuse wire.
3. Do not use leaky insulated tools.

Result: The required Godown wiring i.e., to control the lamps in serial order is performed.

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Fig.: Wiring diagram

Fig.: Stage 1 Lamps OFF Position

Fig.: Stage 2 Lamp 1 Glowing Position

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Fig.: Stage 3 Lamp 2 Glowing Position

Fig.: Stage 4 Lamp 3 Glowing Position

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INTRODUCTION TO FOUNDRY TRADE

Foundry is a process of shaping the metal components in their molten stage. It is the also called as
metal casting. The shape and size of the metal casting is obtained depends on the shape and size of
the cavity produced in sand mould by using wooden/ metal pattern.

APPLICATION
1. Casting is the cheapest and most direct way of producing the shape of the component.
2. Casting is best suited to work where components required is in low quantity.
3. Complicated shapes having internal openings and complex section variation can be produced
quickly and cheaply by casting since liquid metal can flow into any form/ shape.
Example: Outer casing of all automobile engines, Electric motor housing, Bench vice, Irrigation
pumps etc.
4. Heavy equipment such as machine beds of lathe, milling machine, shaping, drilling plaining
machine etc. can be cast/easily
5. Casting is best suited for composite components

STEPS IN FOUNDRY PROCESS

The Foundry process involves three steps.
(a) Making the required pattern
(b) Moulding process to produce the cavity in sand using pattern.
(c) Pouring the molten metal into the cavity to get casting.

FOUNDRY TOOLS
A few commonly used manual tools and equipment are discussed briefly below.
Shovel
A shovel as shown in figure is used to transfer the sand from pile to the place of use. It is also used
to mix and temper the moulding sand.

Fig: Shovel
Hand riddle
Hand riddle consists of a wire mesh fitted into a circular wooden frame as shown in figure. It is used
for cleaning or removing unwanted material like lumps, stones, splinters, nails, etc., from the
moulding sand.

Fig: Hand riddle

Mould box
A mould box or flask as shown in figure is a container which holds the moulding sand during ramming
and until the molten metal has been solidified. A mould box may be 2 or 3 in numbers. The top box
is called cope, the bottom drag, and the middle box cheek.

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Fig: Mould box

Rammer
A rammer is used for ramming or packing the sand into the mould box. The different types of rammer
are shown in figure. The wedge or peen shaped part of the rammer is used for ramming sand in
pockets and comers where there is space restriction for a round shaped rammer.

Fig: Rammer
Trowel
A trowel consists of a metal blade of different shapes with a wooden handle as shown in figure. It is
used for smoothing and finishing the mould surface, and also for repairing the damaged portions of
the mould.

Fig: Trowel

SAFETY PRECAUTIONS IN FOUNDRY TRADE

Following precautions must be kept in mind while working in foundry trade:
1. Wear Proper Safety Equipment and Clothing
2. Comply with Environmental Regulations
3. Be Mindful of Heat Stress
4. Keep Moisture Out
5. Inspect Machinery Before Use
6. Provide Ongoing Training
7. Prevent and Minimize Harmful Vibration
8. Reduce the Risk of Dust Exposure

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Experiment 13
MOULD CAVITY FOR RECTANGULAR PATTERN

Aim: To prepare green sand mould for rectangular pattern.

Tools Used: Shovel, mould box, rammer, strike-off bar, trowel, lifter, gate cutter, vent rod, etc.
Materials Used: green sand.
Procedure:
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.
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.

Safety Precautions:
1. There should be enough clearance between the pattern and the walls of the flask.
2. The ramming of sand should be done properly so as not to compact it too hard, which makes
the escape of gases difficult.
3. Pattern should have good surface finish because finish of the casting depends on the finish of
the pattern.

Result: The green sand mould for rectangular pattern is prepared and made ready for pouring.

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Fig: Design of a rectangular pattern

All dimensions are in mm

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Experiment 14
PREPARATION OF A MOULD CAVITY FOR A STRAIGHT PIPE

Aim: To prepare a sand mould using the given double piece pattern for straight pipe.
Material And Equipment Required: Moulding sand, Facing sand, Backing sand, Parting sand,
Pattern, Cope box, Drag box, Bottom board.
Tools Required: Rammer, Sprue, Riser, Gate cutter, Trowel, Vent rod, Sleek, Bellow.
Procedure:
1. One half of the pattern is placed on the molding board with its flat side on the board.
2. The drag box is placed over the board, after giving it a clay wash inside.
3. Parting sand is sprinkled over the pattern and the molding board.
4. Foundry sand is placed over the pattern, until it is covered to depth of 20 to 30mm.
5. Using fingers sand is packed around the pattern and into the corners of the box.
6. Some more sand is then placed in the box and packed with the rammer, using first the peen end
and then with the Tee end.
7. The excess sand from the surface of the drag is removed by striking-off with the strike- off bar.
8. The drag is turned upside down.
9. The loose sand particles are blown-off with the bellows and the surface is smoothened.
10. The second half of the pattern is located over the first half, using the dowel pins.
11. The cope box is placed in position on top of the drag box, after giving it a clay wash inside. The
riser pin is then located on the surface of the surface of the pattern.
12. The sprue pin is placed at about 50 to 60 mm from the pattern, but on the opposite side of the
riser pin.
13. Parting sand is sprinkled on the upper surface.
14. Steps 4 to 7 are repeated.
15. Using a vent rod, holes are made to about 10mm from the pattern.
16. The sprue and riser pins are removed by carefully drawing them out. A funnel shaped hole is
made at the top of the sprue hole, called pouring basin/cup.
17. The cope is lifted and placed aside on its edge.
18. A draw spike is inserted into the pattern and the edges around the pattern are wetted. Then the
pattern is loosened by tapping, and then drawn straight up.
19. The mould is repaired by adding bits if sand, wherever the mould is found defective.
20. Using a gate cutter, a gate is cut in the drag, from the sprue to the mould.
21. The loose sand particles that are present in the mould are blown-off.
22. The mould is finally closed by replacing the cope on the drag and placing weights on it.

Safety Precautions:
1. There should be enough clearance between the pattern and the walls of the flask.
2. The ramming of sand should be done properly so as not to compact it too hard, which makes
the escape of gases difficult.
3. Pattern should have good surface finish because finish of the casting depends on the finish of
the pattern.

Result: The sand mould for a straight pipe is thus made, which is ready for pouring the molten
metal.

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Fig: Preparation of a Straight pipe

Fig: Straight pipe

All dimensions are in mm

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INTRODUCTION TO WELDING SHOP

Welding is the metal joining method wherein localized coalescence is produced either by heating the
metal to suitable temperatures, with or without use of filler metal or by application of pressure. The
filler material has similar composition and melting point temperatures as the base metal. It is used to
fill gap between the joint surfaces.

Welding can be applied to both ferrous (iron based) and non-ferrous (non-iron based) metals
and their alloys e.g. wrought iron, cast iron, carbon steels, cast steels, alloy steels, stainless steels,
aluminium, copper, magnesium, nickel and zinc. Over the years welding has emerged as a successful
fabrication process owing to its several merits, though it has its demerits also.

ADVANTAGES OF WELDING
1. A good weld is as strong as the base metal.
2. General welding equipment is inexpensive and now also available in portable form.
3. It facilitates considerable freedom in design.
4. Many metals/ alloys both similar and dissimilar can be joined by welding.

DISADVANTAGES OF WELDING
1. Welding gives out harmful radiations and fumes.
2. It results in residual stresses and distortion in work pieces.
3. Edge preparation of work-pieces is required before welding.
4. Structure of welded joint isn’t the same as that of parent metal.

JOINTS TYPES:

WORK PIECE PREPARATION

1. Edges of the workpieces to be welded are prepared and cleaned to make them free of any
foreign matter like rust, grease, dust, paint etc.
2. The workpieces to be welded are positioned and spaced relative to each other
3. Welding leads are connected to the power supply and the workpiece. Power is switched on and
an optimum current is set. Electrode is gripped in the holder.
4. Before welding the actual joint, it is advised to first try on a scrap piece, to ensure optimum
current.

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WELDING EQUIPMENT’S
AC or DC welding supply, Welding electrodes, Electrode holder, Welding leads, Ground connection,
Hand and face shields

Fig: Schematic Diagram of ARC Welding

Fig: Arc Welding Equipment

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Experiment 15
PREPARATION OF A LAP JOINT USING ARC WELDING SET UP

Aim: To make a Lap Joint in downward direction.

Equipment & Material Required: Arc welding machine, M.S.plates (2 No.s), Electrode holder,
Electrodes.

Hand Tools Required: Hack saw, chipping hammer, wire brush, safety goggles, hand gloves, face
shield and files.

Procedure:
1. The electrode is held in the electrode holder.
2. The two pieces to be welded are field first and placed on over the other as shown in fig, such that
the lap joint is formed.
3. The extreme corners of the lapping portion of the weld pieces are tagged.
4. Then the welding is performed by the number of parallel passes by the electrode on the edge of
the two weld pieces and then the lapped weld piece is reversed and the same operation is
performed, and chipping the extra weld portion by chipping hammer and cooling the lap joint.
Thus the lap joint operation is performed.

Safety Precautions:
1. The process is maintained at a current of 90-130 amperes.
2. Parallel passes are a must.
3. The electrode must be at 2-3 mm from work piece.
4. During the process the electrode is held at 60˚ to 70˚ to the horizontal.
5. Keeping the cloths safely the welding operation should be done.

Result: Hence the required lap joint is prepared.

Fig: Lap joint

All dimensions are in mm

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Experiment 16
PREPARATION OF A BUTT JOINT USING ARC WELDING SET UP

Aim: To make a Butt Joint in downward direction.

Equipment & Material Required: Arc welding machine, M.S.plates (2 No.s), Electrode holder,
Electrodes.

Hand Tools Required: Hack saw, chipping hammer, wire brush, safety goggles, hand gloves, face
shield and files.

Procedure:
1. The edges of the work pieces will be prepared in V-shape as shown in fig.
2. The electrode is held in the electrode holder.
3. The two pieces to be welded are placed side by side as shown in fig, such that the butt joint is
formed.
4. The extreme corners of the work-pieces will be tagged.
5. Then the welding is performed by the number of parallel passes by the electrode on the edge
of the two weld pieces and chipping the extra weld portion by chipping hammer and cooling
the lap joint. Thus, the butt joint operation is performed.

Safety Precautions:
1. The process is maintained at a current of 90-130 amperes.
2. Parallel passes are a must.
3. The electrode must be at 2-3 mm from work piece.
4. During the process the electrode is held at 60˚ to 70˚ to the horizontal.
5. Keeping the cloths safely the welding operation should be done.

Result: Hence the required Butt joint is prepared.

Fig: Single V-Butt joint

All dimensions are in mm

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