1

Dr.K.V.S.R.I.T
(Autonomous)

ENGINEERING WORKSHOP
LABORATORY MANUAL

DEPARTMENT OF MECHANICAL ENGINEERING

Common For All Branches
YEAR: B. Tech I/I- I/II (R23)

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SAFETY RULES & UNSAFE PRACTICES

Remember that “accidents do not occur, they are caused”. With this in mind, strictly follow the general
safety rules given below and safe practices indicated in brief under each section.

1. Safety first, work next.

2. Know your job and follow instructions.
3. Avoid wearing clothing that might catch, moving or rotating parts. Long sleeves of
shirts, long hair, neck tie and jewelers are definite hazards in the shop.
4. Wear safety shoes. Do not wear canvas shoes; they give no resistance to hard
objects dropped on the feet.
5. Keep the area around machine or work clean.
6. Keep away from revolving work.
7. Be sure that all guards are in place.
8. One person only should operate the machine controls.
9. Use tools correctly and do not use them if they are not in proper working condition.
10. Wear safety goggles when working in areas, where sparks or chips of metal are
flying.
11. Get to know who in-charge of first aid is and where boxes are placed and where the
first aid can be found in case of emergency.

Instructions for Laboratory

1. The objective of the laboratory is learning. The experiments are designed to illustrate
phenomena in different areas of Workshop and to expose you to uses of instruments.
Conduct the job with interest and an attitude of learning.
2. You need to come well prepared for the job.
3. Work quietly and carefully (the whole purpose of experimentation is to make reliable
measurements!) and equally share the work with your partners.
4. All presentations of job and diagram should be neatly and carefully done.
5. Diagrams should be neatly drawn with pencil. Always display units.
6. Come equipped with scales, pencils etc.
7. Do not fiddle idly with apparatus. Handle instruments with care. Report any breakage
to the instructor. Return all the equipment you have signed out for the purpose of your
experiment.

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ENGINEERING WORKSHOP

An Engineering Workshop has become important field in the industrial atmosphere to produce products for
the service of mankind. The knowledge of converting a raw material into a use full product is highly
essential for all engineers for familiarizing with concepts. The basic need of Engineering Workshop is to
provide theoretical and practical knowledge of manufacturing environment to all the engineering students.
Therefore, an attempt has been made through this laboratory subject to learn both the theoretical and
practical knowledge of shaping a product. Considering the general needs of engineering students in the
country and the fact that they hardly get any exposure to hand tools, equipment’s, machines and
manufacturing setups, a basic course in Engineering Workshop remains a core subject for all the branches
of engineering. This Engineering Workshop laboratory classes covers most of the basic skill that an
engineering student needs to familiarize themselves.
The Engineering Workshop laboratory in has six major sections such as Machine shop, Carpentry shop,
Fitting Shop, Welding shop, Sheet metal shop and Moulding shop. The utility of each shop in shaping
engineering students in the manufacturing environment are discussed as:
Machine shop: In a machine shop, metals are cut to different shapes as per the requirement of the
manufacturer. Major machines that are available in the lathe, shaper, milling, drilling and grinding
machine.
Carpentry shop: Carpentry shop deals with making joints for a variety of applications like door frames,
cabinet making furniture, packing etc.
Fitting Shop: The fitting shop is related to assembly of parts, after bringing the dimension or shape to the
required size or form, in order to secure the necessary fit.
Welding shop: In welding shop, an engineering student learns the art of joining similar metals by the
application of heat, with or without application of pressure or filler metal.
Sheet metal shop: In sheet metal shop an engineering student learns the art of making various house hold
articles such as boxes, cans, funnels, ducts etc., which are made from a flat sheet of metals.
Moulding shop: Moulding shop is the platform where an engineering student learns the art of making of
manufacturing by shaping liquid or pliable raw material using a rigid frame called a moulid or matrix.

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LIST OF EXPERIMENTS

I. Carpentry
1. Introduction
2. Half Lap T-Joint
3. Mortise And Tenon Joint
4. Corner Dovetail Joint or Bridle Joint
5. Practice Figures
II. Sheet Metal
1. Introduction
2. Preparation of A Tapered Tray
3. Preparation of Conical Funnel
4. Preparation of Elbow Piece
5. Study of Brazing
III. Fitting
1. Introduction
2. V- Fitting Joint
3. Dovetail Fit
4. V Semi-Circular Fit
5. Bicycle Tire Puncture and Change of Two-Wheeler Tyre
IV. House Wiring
1. Introduction
2. Parallel and Series
3. One Light Controlled By 2 Two – Way Switches
4. Godown Lighting
5. Tube Light
6. Three Phase Motor
7. Soldering of Wires
V. Foundry
1. Demonstration and Practice on Moulding Tools and Processes
2. Preparation of Green Sand Moulds for Given Patterns.
VI. Welding
1. Demonstration and Practice on Arc Welding and Gas Welding.
2. Preparation of Lap Joint and Butt Joint.

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VII. Plumbing:
1. Demonstration and Practice of Plumbing Tools
2. Preparation of Pipe Joints with Coupling for Same Diameter and With Reducer for Different Diameters.

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I. CARPENTRY

INTRODUCTION

It is the art and science of manufacturing items out of wood with the help of tools is known as carpentry.

Tools used in carpentry are classified as:

1. Marking and measuring tools: These tools are used for measuring, then marking the required
dimensions on the work. Some of these tools are rules, try square, straight edge, mitre square, scriber,
marking gauge, mortise gauge, divider, calipers, leveler etc.

2. Cutting tools: These tools are used for cutting excess of material to obtain desired shape and accuracy.
Some of these tools are rip saw, cross cut saw, tenon saw, firmer chisel, parting chisel, mortise chisel, etc.

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3. Planning tools: These are hand tools used for smoothing the wood surfaces and for finishing, some of
planning tool are Jack plane, trying plane, smoothing plane etc.

4. Boring tools: These tools are used for making holes on the wooden work piece. Tools like Bradawl,
gimlet, brace, and bit are used for this purpose...

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5. Striking tools: Various wood working tools like chisels and nails need striking from the top to drive
them into the wood, they are called striking tools such as Hammers, mallet.

6. Holding tools: These are used for holding work rigidly during operations. Some of holding tools are
work bench, carpentry vice, G- cramp etc.

7. Miscellaneous tools: Rasp and file, pincer, screw driver etc are some of the miscellaneous tools.

Safety Precautions:

1. Wear appropriate safety shoe, apron and other necessary items for body protection.
2. Be careful when using the thumb as a guide in cross cutting and ripping.
3. Test the sharpness of edge cutting tools on wood, not on the hand.
4. The chisel is the hand tool which causes most injuries in wood working. Use it carefully.

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GENERAL SAFETY PRECAUTIONS OF CARPENTRY:

1. Do not operate any machine without permission of the instructor.

2. Be sure that the machine is active and properly working and guard are always in the right place.
3. Always wear tight and appropriate clothing with apron
4. Do not wear loose, torn or such kind of clothing.
5. Concentrate at the work and do not talk unnecessarily while operating the machine
6. Do not lean against the machine.
7. Always wear safety glasses and goggles designed the work.
8. Shoes must be laced tight at the working time.
9. Rings and wrist watches must be removed while working at the machine
10. Keep the floor clean from metal, wood and other chips, curls or waste pieces, if any. Put them in the
container provided in the laboratory.
11. Get First Aid Immediately If Necessary.
12. Different Safety Rules for Each Individual Machine Could Be Known from The Concerned Instructor
13. Do Not Leave the Machine Until the Power Is Off and The Machine Has Stopped.

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Exp: - 1

Fig: Half Lap T-joint

All dimensions are in mm

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1. HALF LAP T-JOINT

Exp: - 1

Aim: To prepare the Half lap T-joint from the given wooden work for the required dimensions.

Material supplied: Wooden Piece

Tools required: Steel Rule, marking gauge, carpentry vice, jack plane, rip saw, try square, firmer chisel,
wooden mallet, rasp file

Operations performed:
 Measuring
 Planning
 Marking
 Sawing
 Chiseling
 Finishing
 Joining

Procedure:
1. Measure the dimensions of a given wooden work piece and clamp the work piece on the vice then reduce
the length for the required measure using rip saw
2. Plane the surfaces of the work using jack plane and check the surface flatness using try square.
3. Unclamp the wood from the vice and mark the given dimensions on the work piece.
4. Clamp the work to the vice and cut the edges to the required depth using rip saw.
5. Chip out unwanted wood using firmer chisel and finish it by using rasp.
6. Repeat the above steps to prepare half lap T-joint and check the fitness of the joint.

Precautions:

1. Job is clamped properly.

2. Pressure is applied on the plane only during forward stroke.
3. Concentration should be on the cutting edge of chisel, but not on the handle during chiseling.

Result: Thus, the Half lap T-joint is obtained as per the given dimensions.

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Exp: - 2

MORTISE AND TENON JOINT

Fig: Mortise and Tenon Joint

All dimensions are in mm

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2.MORTISE AND TENON JOINT

Exp: - 2

Aim: To prepare the mortise and Tenon joint from the given wooden work for the required dimensions.

Material supplied: Wooden Piece

Tools required: Steel Rule, marking gauge, carpentry vice, jack plane, rip saw, try square, firmer chisel,
wooden mallet, rasp file

Operations performed:
 Measuring
 Planning
 Marking
 Sawing
 Chiseling
 Finishing
 Joining

Procedure:
1. Measure the dimensions of a given wooden work piece and clamp the work piece on the vice then
reduce the length for the required measure using rip saw to make mortise
2. Plane the surfaces of the work using jack plane and check the surface flatness using try square.
3. Unclamp the wood from the vice and mark the given dimensions on the work piece.
4. Clamp the work to the vice and cut the edges to the required depth using rip saw.
5. Chip out unwanted wood using firmer chisel and finish it by using rasp.
6. Repeat the above steps to prepare tenon and check the fitness of the joint.

Precautions:

1. Job is clamped properly.

2. Pressure is applied on the plane only during forward stroke.
3. Concentration is on the cutting edge of chisel but not on the handle during chiseling

Result: Thus, the mortise and tenon joint is obtained as per the given dimensions.

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Exp: - 3

MITRED CORNER DOVETAIL JOINT

Fig: Mitered corner dovetail joint

All dimensions are in mm

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3.PREPARATION OF MITRED CORNER DOVETAIL JOINT

Exp: - 3

Aim: To prepare the dovetail joint from the given wooden work for the required dimensions.

Material supplied: Wooden Piece

Tools required: Steel Rule, marking gauge, carpentry vice, jack plane, rip saw, try square, firmer chisel,
wooden mallet, rasp file

Operations performed:
 Measuring
 Planning
 Marking
 Sawing
 Chiseling
 Finishing
 Joining

Procedure:
1. Measure dimensions of given wooden work piece and clamp the work piece on the vice then reduce the
length for the required measure using rip saw.
2. Plane the surfaces of the work using jack plane and check the surface flatness using try square.
3. Unclamp the wood from the vice and mark the given dimensions on the work piece.
4. Clamp the work to the vice and cut the edges to the required depth using rip saw.
5. Chip out unwanted wood using firmer chisel and finish it by using rasp.
6. Repeat the above steps for another piece and check the fitness of the joint.

Precautions:

1. Job is clamped properly.

2. Pressure is applied on the plane only during forward stroke.
3. Concentration is on the cutting edge of chisel but not on the handle during chiseling

Result: Thus, the dovetail joint is obtained as per the given dimensions.

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PRACTICE FIGURES

BRIDLE JOINT

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II. SHEET METAL

INTRODUCTION

Sheet metal work is working on the metal of 16 gauges to 30 gauges, with hand tool and simple machines into
different forms by cutting, forming into shape and joining

Sheet metal work is one of the major applications in engineering industry. It has its own significance as
useful trade in engineering work

APPLICATION OF SHEET METAL:

Sheet metal work is used for making hoppers, funnels, various ducts, chimneys, ventilating pipe, boiler etc.

It is also extensively used in major industries like air craft manufacturing, ship building,
automobile body building and fabrication of ducts in air conditioning equipment’s etc.

TOOLS USED IN SHEET METAL WORK:

1. Cutting tools:
a) Chisels
Chisels are used in sheet metal work for sheets, rivets, and bolt and chipping operations. Though there are
many types of chisels available round nose chisel and flat chisel are mostly used for sheet metal work

b) Snips
Snips are hand shears, varying in length from 200 mm to 600 mm. 200mm and 250 mm length is most
commonly used. In sheet metal work straight and curved snips are mostly used. Straight snips are used for
cutting along outside curves and straight lines
Curved or bent snips are used for trimming along onside curves

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2. Striking tools:
a) Hammers
Hammers are used in sheet metal for hollowing, stretching, leveling, riveting etc
The following hammers are mostly used in sheet metal work
(i) Ball peen hammer
(ii) Straight peen hammer
(iii) Riveting hammer
(iv) Mallet

b) Punches: in sheet metal work punch is used for marking out work locating center etc. dot punch and
center punch are the types of punches

3. Supporting tools:
Stakes; stakes are nothing but sheet metal workers anvils and used for bending, hemming, seaming, forming
etc using hammers or mallets

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Bending tools:

Pliers are mainly used fir bending the sheet metal to the required shape. It is also used for holding and cutting
the sheet metal

4. Layout tools:
a) The steel rule used for measuring and laying out small work

b) Scriber is a long wire of steel where its one end sharply pointed and hardened to scratch line on sheet
metal for laying out patterns

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c) Dividers are used for drawing circles or arcs on sheet metal.

d) Trammels are used for drawing circles or arcs on sheet metal. Maximum size of the arcs that can be
scribed depends on the length of the beam of scriber

e) Sheet metal gauge: it is used to find the thickness of the sheet metal

f) Protractor used for drawing angle lines on the sheet metal.

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Safety precautions for sheet metal work:

1. Heavy sheets must be handled by using gloves

2. Check whether the head portion of the mallet and hammer should be tightly fixed to the handle.
3. Respective snips should be selected according to the sheet metal thickness
4. While cutting operation, blade should be perpendicular to the job and along the marking line
5. Adequate care should be taken while folding, hammering, seaming operations
6. Waste materials should be cleaned by using wire brush
7. High force should not be applied while leveling the sheet because that leads to malleability state of sheet
metal

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Exp: - 1 TAPERED TRAY

Fig: Tapered Tray

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1.PREPARATION OF A TAPERED TRAY

Exp: - 1

Aim: To prepare a tapered type tray from given sheet

Tools: Steel rule, scriber, straight snip, stake, wooden mallet.

Material supplied: G.I. Sheet

Sequence of Operations:

1. Checking
2. Marking
3. Cutting
4. Folding

Procedure:

1. The given sheet is checked for its dimensions using a steel rule.
2. The sheet is leveled using mallet
3. The dimensions are marked on the sheet by using scriber
4. The sheet is cut as per the marked dimensions by using straight snip.
5. Then a single hemming is made on the four sides of the tray as shown in figure.
6. These four sides of the tray are bent to 900 using stakes and anvil
7. Finally, all the corners of the tray are joined by riveting.

Precautions:

1. Care is to be taken in avoiding wastage of sheet metal

2. Proper pressure is to be applied with mallet.
1. Properly bend the sheet.

Result: Thus, the tapered tray made from the given G.I. Sheet

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Exp: - 2 CONICAL FUNNEL

Fig: Conical Funnel

All dimensions are in mm

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2.PREPARATION OF FUNNEL

Exp: - 2

Aim: To prepare a Funnel from given sheet

Tools: Steel rule, scriber, straight snip, stake, wooden mallet.

Material supplied: G.I. Sheet

Sequence of Operations:

1. Checking
2. Marking
3. Cutting
4. Folding
5. Joining

Procedure:

a) Top conical part

1. The given sheet is checked for its dimensions using a steel rule.
2. The sheet is leveled using mallet
3. The dimensions are marked on the sheet by using scriber
4. The sheet is cut as per the marked dimensions by using suitable snip.
5. Forming the sheet into designed conical shape by using suitable stakes and mallet.
b) Bottom conical part: similarly follow the same above procedure for preparing bottom conical part.

Assemble both the Top & Bottom conical part to obtain the funnel

Precautions:

1. Care is to be taken in avoiding wastage of sheet metal

2. Snips are properly used for cutting
3. Bending is doing carefully with the help of stake.

Result: Thus, the Funnel is made from the given G.I. Sheet.

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Exp: - 3 ELBOW PIPE

Fig: Elbow Pipe

All dimensions are in mm

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3.PREPARATION OF ELBOW PIPE

EXP: - 3

Aim: To prepare a hollow elbow pipe from given sheet

Tools: Steel rule, scriber, straight snip, stake, wooden mallet.

Material supplied: G.I. Sheet of 200X112 mm

Sequence of Operations:

1. Checking
2. Marking
3. Cutting
4. Folding

Procedure:

1. Cutting the required sheet from the stock with the help of snips
2. Marking the development of cylinder on the sheet by using scriber
3. The allowance for folding and bending is provided
4. Using straight snips to cut the straight edges and remove unwanted portion
5. The hemming is done using mallet and it is joined.

Precautions:

2. Care is to be taken in avoiding wastage of sheet metal

3. Proper pressure is to be applied with mallet.

Result: Thus, the hollow elbow pipe made from the given G.I. Sheet

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III. FITTING

INTRODUCTION
Fitting is the process of assembling various parts manufactured in the machine shop.

Tools used in fitting are:

1. Holding tools: These are used for holding work rigidly during operations. Some of holding tools are
bench vice, C-clamp, V-Block with Clamp etc.

2. Striking tools: Hammers are used as striking tools, to strike a job or a tool. They are made of forged steel
of various sizes and shapes to suit various purposes.

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3. Cutting tools: These tools are used for cutting excess of material to obtain desired shape and accuracy.
Various cutting tools used in fitting are:
 Chisels: Cold chisels are important cutting tools used in fitting for cutting and chipping away pieces of
metal. They are made by forging of carbon steel. Some of the chisels used are flat chisel, cross-cut chisel,
half-round chisel etc.

 Files: File is a cutting tool having number of cutting points and is directly moved by hand. A file is a
hardened piece of high-grade steel with slanting rows of teeth. It is used to cut, smooth or fit metal parts.
Files like flat file, hand file, square file, round file, triangular

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 Scrapers: Scraper is a tool by means of which very small amount of metal can be removed. It is employed
for obtaining a fine surface finish on the work. Types of scrapers are flat scraper, triangular scraper and half-
round scraper.

 Hack saw: Hack saw is the chief tool used in fitting for cutting rods, bars and pipes into desired lengths.

 Drill bits: Drill bit is a tool used for making hole in a metal. It consists of two cutting edges, set at an angle
with the axis. Types of drill bits are flat drill, straight fluted drill and twist drill.

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 Reamer: It is a tool used get accurate hole after drilling. Hand reamer and machine reamer are types used.

 Taps: These are the tools used for cutting internal treads of a cylindrical hole or for cleaning damaged
threads. The upper part of a tap consists of a shank ending in a square for holding the tap by a tap wrench.

 Dies and die stock: Tool used for cutting external threads on bars or tubes are called die and tool used for
holding to turn the threading die is called die stock.

4. Marking tools: These are the tools used to mark the required dimension on the job, surface plate, v-
block, try square, scriber, punches etc are used for this purpose.

5. Checking and measuring tools: These are used for inspecting and measuring the dimensions of the
components during manufacture to have accurate size and shape. Such as steel rule, calipers, dividers, radius
gauge, screw pitch gauge etc. are used.

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6. Miscellaneous tools: Miscellaneous tools like Screw driver, spanner, thread cleaner, pliers etc. are used.

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Safety Precautions:

1. The job should be held tightly in the vice, during various fitting operations.
2. Wear safety goggles or protective shield, when chipping.
3. Chipping should be done towards the fixed jaw of the vice.
4. Use a file with a properly fitted tight handle.
5. Apply force only on the forward stroke; relive the force on the return stroke.
6. Does not use file as hammer. Examine the hammer each time before it is used.
7. Cut a small groove with a file in sharp corners, where a saw cut is to be started

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Exp: - 1 V-FITTING

Fig: V- Fitting

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1. V-FITTING

Exp: - 1

Aim: Assembling of two pieces with fitting operations.

Material supplied: Mild steel plate of 50X50X5 mm – 2 No

Tools required: Bench vice, surface plate, steel rule, try square, scriber, flat file, cold chisel, hacksaw, dot
punch, Anvil.

Operations performed:

 Measuring
 Marking
 Punching
 Cutting
 Filing
Procedure:

1. Measure the dimensions of a given work piece and clamp the work piece in the bench vice.
2. Filing the work piece to size by using flat file, try square.
3. Mark the required dimensions on the work piece by using scriber, steel rule.
4. Mark dot punches along the marked lines by using anvil, ball peen hammer, and dot punch.
5. Cutting the work piece according to dot punches with hacksaw.
6. Remove the unwanted portion & filing the ends.
7. Assembling the two pieces
Precautions:
1. Surface plate is checked for cleanliness.
2. Ensure that hack saw blade is properly fitted in the frame.
Result:
Thus, the assembling of two pieces with fitting operations is obtained.

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Exp: - 2 DOVETAIL JOINT

All dimensions are in mm

Fig: Dovetail Joint

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2.DOVETAIL JOINT

Exp: - 2

AIM: Assembling of two pieces with fitting operations.

Material supplied: Mild steel plate of 50X50X5 mm – 2 No

Tools required: Bench vice, surface plate, steel rule, try square, scriber, flat file, cold chisel, hacksaw, dot
punch, Anvil.

Operations performed:

 Measuring
 Marking
 Punching
 Cutting
 Filing

Procedure:

1. Measure the dimensions of a given work piece and clamp the work piece in the bench vice.
2. Filing the work piece to size by using flat file, try square.
3. Mark the required dimensions on the work piece by using scriber, steel rule.
4. Mark dot punches along the marked lines by using anvil, ball peen hammer, and dot punch.
5. Cutting the work piece according to dot punches with hacksaw.
6. Remove the unwanted portion & filing the ends.
7. Assembling the two pieces.

Precautions:
1. Surface plate is checked for cleanliness.
2. Ensure that hack saw blade is properly fitted in the frame.

Result:
Thus, the assembling of two pieces with fitting operations is obtained.

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Exp: - 3 SEMI CIRCULAR JOINT/ HALF ROUND JOINT

All dimensions are in mm

Fig: Semi Circular Joint/ Half Round Joint

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3.SEMI CIRCULAR JOINT/ HALF ROUND JOINT

Exp: - 3

AIM: Assembling of two pieces with fitting operations.

Material supplied: Mild steel plate of 50X50X5 mm – 2 No

Tools required: Bench vice, surface plate, steel rule, try square, scriber, flat file, cold chisel, hacksaw, dot
punch, Anvil.

Operations performed:
 Measuring
 Marking
 Punching
 Cutting
 Filing

Procedure:

1. Measure the dimensions of a given work piece and clamp the work piece in the bench vice.
2. Filing the work piece to size by using flat file, try square.
3. Mark the required dimensions on the work piece by using scriber, steel rule.
4. Mark dot punches along the marked lines by using anvil, ball peen hammer, and dot punch.
5. Cutting the work piece according to dot punches with hacksaw.
6. Remove the unwanted portion & filing the ends.
7. Assembling the two pieces
Precautions:
1. Surface plate is checked for cleanliness.
2. Ensure that hack saw blade is properly fitted in the frame.
Result:
Thus, the assembling of two pieces with fitting operations is obtained.

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IV.HOUSE WIRING

INTROUCTION

Power is supplied to the domestic installations through, the phase and a neutral, forming a single
phase A.C. 230V, two wire system. For industrial establishments, power is supplied through three-phase
four-wire system to give 440V. Figure shows the power tapping for domestic and industrial purposes. The
neutral is earthed at the sub-station of the supply. As a safe practice all single-phase devices such as
switches, fuses etc., are connected to the live conductor. All electrical conductors and cables are colored
coded and must be correctly connected up. Electrical wiring is defined as a system of electrical conductors,
components and apparatus for conveying electrical power from the source to the point of use. The wiring
system must be designed to provide a constant voltage to the load.

Elements of House wiring:

1. Fuses and circuit breakers

2. Electrical switch

3. Plug

4. Socket outlet

5. Lamp holder

6. Ceiling rose

7. Main switch

8. Incandescent light

Wires and wire sizes:

A wire is defined as a bare or insulated conductor consisting of one or several strands. An insulated wire
consists of a conductor (Silver/Copper/Aluminium) with insulating material made of vulcanized Indian
Rubber (VIR) or Poly Vinyl Chloride (PVC). Wire sizes are specified by the diameter of the wire, using a
standard wire gauge (SWG), which also gives an idea of the current carrying capacity. The specification
consists of both the number of strands and diameter of each wire in it. For Example, the specification 3/18
PVC consists of 3 strands of 18 gauge each.

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Various systems of wiring:

1. Cleat wiring

2. C.T.S. / T.R.S. Wiring (Cap tyer sheathed/ Tough rubber sheathed wiring)

3. Wooden casing & capping wiring

4. Lead sheathed wiring

5. Conduit wiring

6. PVC casing & capping

Wiring methods:

1. Series circuit 2. Parallel circuit

Fundamentals of Electricity:

Electricity: Electricity is a form of energy, which cannot be seen. But can be felt and effects like magnetic
effect, heating effect and Chemical effect.

Voltage: It is a pressure which makes the electricity to flow. The unit of measure is Volt. The symbol used is
‘V’. The instrument used to measure is Voltmeter.

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Current:

The free flow of electrons is called as current. The unit to measure current is ‘Ampere’. The symbol is ‘A’.
The instrument used to measure the current is Ammeter.

Resistance:

It is opposition to current. The unit of resistance is ‘Ohm’. The symbol of ohm is Ω. The resistance is
measured by Ohmmeter. Watt: It is the rate of doing work, when potential difference across the current is of
volt and current flowing is ampere per second. The energy consumed is of Watt.

1000 Watts = 1 Unit

746 Watts = 1 H.P.

The following are the formulae for calculation.

Voltage V or E = W / I = ÖWR = IR

Current I = E / R = W / E = ÖW / R

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Resistance R = E2 / W = E / I = W / I2

Wattage W = I2 R = EI = E2 / R

House Wiring Tools:

Combination Pliers: Used for holding, twisting or cutting of wires.

Side cutting Plier: Used for Cutting at narrow places or ordinary places for removing insulation.

Round Nose Plier or Flat Nose Plier: Used for holding, twisting or joining the wire at narrow places.
Firmer

Chisel: Used for chipping, scrapping and grooving the wood.

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Cold chisel: Used for chipping, Boring and channeling in walls.

Tenon saw or back Saw: Used for cutting wooden boards, Block casting etc.

Hack saw: Used for cutting conduit GI pipes or mild steel.

Mallet: Used as a hammer and made of wood

Double Blade Electric knife: It has two blades, one for removing insulation of wires and another for
cleaning the wires

Soldering Iron: Used to solder small joint terminals

Poker: Used for making pilot holes for fixing wood screws.

Line Tester: Used for testing the current.

Royal Plug Tool: It is made of steel and is used for making holes in the stone wall or concrete wall for fiber
made Royal plugs.

Screw driver: Used for loosening, tightening and to keep the screws in position.

Ball Peen Hammer: Used for fitting nails in the walls or wooden boards.

Instructions:

1. When closing the electric switch, always grasp the switch by the insulated handle.

2. Do not run too many electrical items from one point.

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3. Use fuses and circuit breakers of proper capacity, so as to interrupt the current before it becomes
dangerous. 4. Disconnect the units to be repaired free from power supply and make sure that they might not
be energized while the repair work continues

5. Do not pour water to put-off fires in electric wires and electric equipment. You will be subjected to electric
shock or you will be electrocuted. Use sand to put-off fires in electric items.

6. Whenever there is power failure, put-off the power supply to all equipment, in order to prevent
spontaneous recovery.

7. Never remove a plug from an outlet by pulling cord. Always pull by holding the plug.

8. While testing always keep one hand in your packet. If the hands are in contact with a circuit, current will
flow across your body and is more dangerous.

9. Electricity has no respect for ignorance. Do not apply voltage or turn-on any device until it has been
properly checked. Check earth connection before switching on portable equipment.

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Safety Precautions:

1. First we should be insulated

2. Care should be taken while fixing the fuse

3. All the switches should be off before power supply.

4. When power is on, the terminal wires should not be touched

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Exp: - 1 PARALLEL AND SERIES CONNECTIONS

Fig: Parallel and Series Connections

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Exp: - 1 PARALLEL AND SERIES CONNECTIONS

Exp: - 1
Aim: - To give connection to two lamps, controlled With Independent Switch Controlswith
or Without Looping.

Tools Required: -
1. Screw driver
2. Cutting pliers
3. Ball peen hammer
4. Insulation remover
5. Tester
Material Required:
1. Wooden wiring board
2. Silk wire
3. Electrical bulbs - 2
4. One-way switch - 1
5. Wooden round blocks - 1
6. Batten lamp holders -1
7. Wire clips
8. Nails
9. Screws

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

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

Safety Precautions:

1. Electricity has no respect for ignorance. Do not apply voltage or turn-on anydevice
until it has been properly checked.
2. Care should be taken from electrical shocks.
3. Don’t touch the connection points.

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4. Avoid loose connection.

5. Don’t work at damped areas and with wet clothing.
6. Handle the lamp carefully.

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

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Exp: - 2 ONE LIGHT CONTROLLED BY 2 TWO-WAY SWITCHES

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

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2.ONE LIGHT CONTROLLED BY 2 TWO-WAY SWITCHES

EXP: -2

AIM: To give connection to two lights controlled by 2 two-way switches

Tools Require: Wooden wiring board, 2 two-way switches, wooden round blocks, batten lamp holders,
connector screw driver, wires, wire clips, nails, wooden screws, poker and bulbs

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

Safety Precautions:

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

Result: The electric circuit, for one light controlled by 2 two-way switches is thus made.

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Exp: - 3. GODOWN WIRING

Fig:1 Godown Wiring

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3.GODOWN WIRING

Exp: -3

Aim: To prepare a Godown wiring circuit with PVC conduit wiring system.
Materials required:
1PVCwireofsufficientlength5-no
2. Two-way switches
3. Bulb holders
4. Ceiling rose and bulb
Tools and equipment used:
a. 6’’ cutting pliers,
b. 6’’screwdrivers,
c. Wire stripper
d. 12mmhanddrillingmachine
e. Tester
Operations to be carried out:
1. Fitting the wires
2. Connection of the bulb holder
3. Connection of switches
4. Circuit-connection
5. Power from mains
6. Operating the lam
Procedure:
A phase wire is taken and its one end is connected to the middle point of two – way switch, S1. While the
other end is connected to the phase point of main supply. Another phase wire (second wire) is taken and
used for connecting the upper points of the two switches S1 with middle point of switch S2The third phase
wire piece is taken and is connected between the upper point of S2 and one of the points of the bulb holder.
A neutral wire piece is taken and its one end is connected to the remaining points of bulb holders, while the
other end is connected to main supply. Now the glowing of the bulb is controlled by two-way switches.

1. The outline of the wiring diagram is marked on the wooden wiring board.
2. Clips are nailed to the board, following the wiring diagram.
3. Wires are stretched and clamped with the clips.
4. Round blocks are screwed on to the board, as per the diagram.

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5. Wires are connected to the holders and the switch, which are then screwedon to the
round blocks.
6. Bulb is fitted to the holder.
7. The wiring connections are tested, by giving power supply.

Precautions:
1. All wire connections to the switches and bulb holders should be right.
2. Always red wire should be used for phase and black for neutral.
3. Too many load connections from a single junction are avoided
4. Switch should be connected in phase only.
Result and conclusion: GD wiring is done.

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V. FOUNDRY

Introduction to Foundry:

A foundry is a factory that produces metal castings from either ferrous or non-ferrous alloys. Metals are
turned into parts by melting them into a liquid, pouring the metal in a mould, and removing the Mold
material or casting after the metal has solidified as it cools. The most common metal processed are
aluminium and cast iron. However, other metals, such as steel, magnesium, copper, tin,
and zinc, are also used to produce castings in foundries.

Process

In the casting process a pattern is made in the shape of the desired part. This pattern is made out of wax,
wood, plastic or metal. Simple designs can be made in a single piece or solid pattern. More complex designs
are made in two parts, called split patterns. A split pattern has a top or upper section, called a cope, and a
bottom or lower section called a drag. Both solid and split patterns can have cores inserted to complete the
final part shape. Where the cope and drag separates is called the parting line. When making a pattern it is
best to taper the edges so that the pattern can be removed without breaking the mould. The patterns are then
packed in sand with a binder, which helps to harden the sand into a semi-permanent shape. Once the sand
mould is cured, the pattern is removed leaving a hollow space in the sand in the shape of the desired part.
The pattern is intentionally made larger than the cast part to allow for shrinkage during cooling. Sand cores
can then be inserted in the mould to create holes and improve the casting's net shape. Simple patterns are
normally open on top and melted metal poured into them. Two-piece moulds are clamped together and
melted metal is then poured in to an opening, called a gate. If necessary, vent holes will be created to allow
hot gases to escape during the pour. The pouring temperature of the metal
should be a few hundred degrees higher than the melting point to assure good fluidity, thereby avoiding
prematurely cooling, which will cause voids and porosity. When the metal cools, the sand mould is removed
and the metal part is ready for secondary operations, such as machining and plating.
Moulding Material and Properties:
A large variety of moulding materials is used in foundries for manufacturing moulds and cores. They include
moulding sand, system sand or backing sand, facing sand, parting sand, and core sand. The choice of
moulding materials is based on their processing properties. The properties that are generally required in
moulding materials are:

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Permeability:
During pouring and subsequent solidification of a casting, a large number of gases and steam is generated.
These gases are those that have been absorbed by the metal during melting, air absorbed from the
atmosphere and the steam generated by the moulding and core sand. If these gases are not allowed to escape
from the mould, they would be entrapped inside the casting and cause casting defects. To overcome this
problem the moulding material must be porous. Proper venting of the mould also helps in escaping the gases
that are generated inside the mould cavity.
Refractoriness:
It is the ability of the moulding material to resist the temperature of the liquid metal to be poured so
that it does not get fused with the metal. The refractoriness of the silica sand is highest.
Green Strength:
The moulding sand that contains moisture is termed as green sand. The green sand particles must have the
ability to cling to each other to impart sufficient strength to the mould. The green sand must have enough
strength so that the constructed mould retains its shape.
Dry Strength:
When the molten metal is poured in the mould, the sand around the mould cavity is quickly converted into
dry sand as the moisture in the sand evaporates due to the heat of the molten metal. At this stage the
moulding sand must possess the sufficient strength to retain the exact shape of the mould cavity and at the
same time it must be able to withstand the met allostatic pressure of the liquid material.
Hot Strength:
As soon as the moisture is eliminated, the sand would reach at a high temperature when the metal in the
mould is still in liquid state. The strength the sand that is required to hold the shape of the cavity is called
hot strength.
Collapsibility:
The moulding sand should also have collapsibility so that during the contraction of the solidified casting it
does not provide any resistance, which may result in cracks in the castings. Besides these specific properties
the moulding material should be cheap, reusable and should have good thermal conductivity
Patterns:
Used to mould the sand mixture into the shape of the casting.
Patterns Materials:
Wood – for small production (white pine, mahogany, cherry etc.)
Metal – for high quality production: Brass, Cast iron, Aluminium, Plastics
Advantage of metal or plastic pattern:

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Do not absorb moisture,

Strong and dimensionally stable
Smooth surface finish.
Pattern material selection depends on:
The size and shape of the casting
The dimensional accuracy
The quantity of castings required
The moulding process to be used.
Strength and durability of the material selected for patterns must reflect the number of castings that the mould
will produce. Sometimes combination of materials is used to reduce wear in critical regions. Patterns are
usually coated with a partings agent to facilitate their removal from the moulds.
Types of patterns
Solid or single piece pattern: generally used for simpler shapes and low quantity production. They
are generally made of wood and are inexpensive.
Split pattern: many patterns cannot be made of a single piece because of the difficulty in moulding.
To eliminate the difficulty the patterns are made split, half rests in lower part and half in upper part.

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Gated patterns: in production work where many castings are required, patterns are made of metal
to give them strengths and to eliminate any warping tendency. The gates or runners for the molten
metal is formed by connecting parts between the individual patterns.
Loose piece pattern: consists of loose pieces, which are necessary to facilitate withdrawing it from
the mould.
Match plates: provide a substantial mounting for patterns. It consists of a flat metal or wooden
plate to which the patterns and gate are permanently fastened.
Sweep pattern: they are used where the shape to be moulded can be formed by the rotation of a
curved line element about an axis:
Cores:
Cores are utilized for castings with internal cavities or passages. A core is a body, usually made of sand, used
to produce a cavity in or on a casting.
Examples: forming the water jacket in a water-cooled engine block and forming the air space between the
cooling fins of an air-cooled engine. Cores are placed in the mould cavity before casting to

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form the interior surfaces of the casting.

Tools and equipment’s:
Miscellaneous Moulding Tools:
Moulding Board: It’s a wooden board with smooth surface, it supports the flasks and pattern, while
the mould is being made
Shovel: It is used for mixing and tempering moulding Sand and transferring the sand into flask. It is
made of broad steel blade with a wooden handle.
Riddles: A riddle is used to sift the sand as it is put into the flask around the pattern. I made some
using a piece of window screen nailed on a square frame. I also bought a kitchen flour sifter which
works the best.
Rammer: It is used for packing or ramming the sand around the pattern. One of its ends called peen
end, is wedge shaped and used for packing sand in spaces, pockets and corners, the early state of
ramming. The other end called the Butt End, has a flat surface and is used for compact the sand
towards the end of moulding.
Strike Edge or Strike Off Bar: It is apiece or wood with straight edge. It is used to remove excess
sand from the mould after ramming, to provide a level surface.
Sprue Pin (Runner): It is a tapered wooden pin, used to make hole in the cope through which the
molten metal is poured into the mould.
Riser Pin: It is a straight wooden pin used to make a hole in the cope, over the mould cavity for the
molten metal to rise-in and feed the casting to compensate the shrinkage that may take place during
solidification.
Slick: It is a small double ended tool having a flat on one end and a spoon on the other. It is used
for mending and finishing small surfaces of the mould.
Shaping Tools and Gate Cutters:
Various tools can be made to use when the sand has to be shaped or cut from the flask such as when making
gates and sprues. Old spoons bent to the desired shape and sharpened work well. I have a set of kitchens
measuring spoons that I use for a lot of cutting. Shapers can also be made of old hacksaw blades. Grind off
the teeth first.
Vent Rod: It is a thin rod used for making vents or holes in the sand mould to allow the escape of
mould gases generated during the poring of molten metal.
Bellows: It is a hand tool, used to blow air, to remove loose sand particles from the mould cavity.

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1.MOULD FOR A SPLIT PIECE PATTERNS

Fig: Mould For a Split Piece Patterns

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1.MOULD FOR A SPLIT PIECE PATTERN

Exp: -1

Aim: To prepare a sand mould using the given split pattern for Stepped pulley.

Tools Required: Moulding board, cope and drag boxes, Rammer, strike-off bar, bellows, riser, sprue, pin,
slick, draw spike, vent rod and gate cutter.

Materials Required: Moulding sand, parting sand, brick powder and pattern

Sequence Of Operations:
1.Preparation of moulding sand
2.Patteren placing in moulding box
3.Filling&Ramming of moulding sand
4.Placing of Runner &Riser
5.Pattern Removal
6.Sprue base & Gate cutting
7.Finishing.

Procedure:
1. The pattern is placed on the moulding 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 moulding board.
4. Foundry sand is placed over the pattern until it is covered to a depth of 20- 30 mm.
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 butt end.
7. The excess sand from the top 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 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 pattern.
11.The sprue pin is placed at about 50-60 mm from the pattern, but on the opposite side of the riser pin.
12. Parting sand is sprinkled on the upper surface.
13.Steps 4 to 7 are repeated, appropriately.

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14.Using a vent rod, holes are made to about 10 mm from the pattern.
15. The sprue and the riser pins are removed, by carefully drawing them out. A funnel shape hole is made at
the top of the sprue hole, called pouring sin/cup.
16. The cope is lifted and placed aside on its edge.
17. 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.
18. The mould is repaired by adding bits of sand, whenever the mould is found defective.
19. Using a gate cutter, a gate is cut in the drag, from the sprue to the mould.
20. The loose sand particles that are present in the mould are blown-off.
21. The mould is finally closed by replacing the cope on the drag and placing weights on it.

Precautions:
1. Do not let the sand too wet. Water is an enemy of molten metals.
2. Provide adequate ventilation to remove smoke and fumes

Applications: Production of complicated machine components.

Result: The required mould cavity is prepared using the given Split Pattern.

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2.MOULD FOR A SINGLE PIECE PATTERNS

Fig. Mould For a Single Piece Patterns

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2.MOULD FOR A SINGLE PIECE PATTERN

Exp: -2

Aim: To prepare a sand mold, using the given single piece pattern.
Raw Material Required:
Moulding sand, parting sand, facing sand, baking sand, single piece solid pattern, bottom board,
moulding boxes etc.
Tools Required:
1. Molding board
2. Drag and cope boxes
3. Molding sand
4. Parting sand
5. Rammer
6. Strike-off bar
7. Bellows
8. Riser and sprue pins
9. Gate cutter
10. Vent rod
11. Draw spike
12. Wire Brush
Sequence of operations:

1. Sand preparation
2. Placing the mould flask(drag) on the moulding board/ moulding platform
3. Placing the pattern at the centre of the moulding flask
4. Ramming the drag
5. Placing runner and riser
6. Ramming the cope
7. Removal of the pattern, runner, riser
8. Gate cutting
Procedure:

1. First a bottom board is placed either on the molding platform or on the floor,
making the surface even.
2. The drag molding flask is kept upside down on the bottom board along with the drag part of the

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pattern at the centre of the flask on the board.

3. Dry facing sand is sprinkled over the board and pattern to provide a non-sticky layer.
4. Freshly prepared molding sand of requisite quality is now poured into the drag and on the
patternto a thickness of 30 to 50 mm.
5. Rest of the drag flask is completely filled with the backup sand and uniformly
rammed to compact the sand.
6. After the ramming is over, the excess sand in the flask is completely scraped using a flat
bar to the level of the flask edges.
7. Now with a vent wire which is a wire of 1 to 2 mm diameter with a pointed end, vent holes
are inthe drag to the full depth of the flask as well as to the pattern to facilitate the removal
of gases during casting solidification. This completes the preparation of the drag.
8. Now finished drag flask is rolled over to the bottom board exposing the pattern.
9. Using a slick, the edges of sand around the pattern is repaired
10. The cope flask on the top of the drag is located aligning again with the help of the pins of the
drag box.
11. Sprue of the gating system for making the sprue passage is located at a small distance of
about 50 mm from the pattern. The sprue base, runners and in-gates are also located as
shown risers are also placed. Freshly prepared facing sand is poured around the pattern.
12. The moulding sand is then poured in the cope box. The sand is adequately rammed, excess
sand is scraped and vent holes are made all over in the cope as in the drag.
13. The sprue and the riser are carefully withdrawn from the flask
14. Later the pouring basin is cut near the top of the sprue.
15. The cope is separated from the drag any loose sand on the cope and drag interface is
blown offwith the help of the bellows.
16. Now the cope and the drag pattern halves are withdrawn by using the draw spikes and
rapping the pattern all around to slightly enlarge the mould cavity so that the walls are not
spoiled by the withdrawing pattern.
17. The runners and gates are to be removed or to be cut in the mould carefully without
spoiling the mould.
18. Any excess or loose sand is applied in the runners and mould cavity is blown away
using the bellows.
19. Now the facing paste is applied all over the mould cavity and the runners which would
give the finished casting a good surface finish.

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20. A dry sand core is prepared using a core box. After suitable baking, it is placed in
the mould cavity.
21. The cope is placed back on the drag taking care of the alignment of the two by means of the pins.
22. The mould is ready for pouring molten metal. The liquid metal is allowed to cool and
become solid which is the casting desired.

Result: The required mould cavity is prepared using the given Single /solid Pattern.

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VI. WELDING
Introduction:
Welding is the process of joining similar metals by application of heat, with or without application of pressure
or filler metal, in such a way that the joint is equivalent in composition and characteristics of the metal
joined. The various welding process are:
1) Electric Arc welding 2) Gas welding 3) Thermit welding 4) Resistance welding 5) Friction welding.
However, only electric arc welding and Gas welding are discussed here. In either process, the work
pieces are melted along a common edge, to their melting point and then a filler metal is introduced to
form the joint on solidification. The materials to be welded must be free from rust, scale, oil or other
impurities, so as to obtain a sound weld.
Arc Welding:
In Arc welding, heat required for joining the metals is obtained from an electric arc. Transformers or motor
generator sets are used as arc welding machines. These Machines supply high electric currents at low
voltages and an electrode is used to produce necessary arc. The electrode serves as the filler rod and the arc
melts the surfaces so that, the metals to be joined are actually fused together. the principle of arc welding,
using a transformer.
In addition to the welding machine, certain accessories are needed for carrying out the welding work.
1) Welding Cables:
Two welding cables are required, one from the machine to the electrode and holder and other, from the
machine to the ground clamp. Flexible cables are usually preferred because of the ease of usage and coiling
the cables. Cables are specified by their current carrying, capacity, say 300A, 400A etc.
2) Electrodes:
Filler rods used in arc welding are called electrodes. These are made of metallic wire called core wire, having
approximately the same composition as the metal to be welded. These are coated uniformly
with a protective coating called flux.
Electrode Holder:
The Electrode holder is connected to the end of the welding cable and holds the electrode. It should be light,
strong and easy to handle and should not become hot while in operation. The jaws of the holder are
insulated, offering protection from electric shock.
4) Ground Clamp:
It is connected to the end of the ground cable and is clamped to the work or welding table to complete the
electric circuit. It should be strong and durable and give a low resistance connection.
5) Chipping Hammer and Wire Brush:

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A wire brush is used for cleaning and prepared the work for welding. A chipping hammer is used for
removing slag formation on welds. One end of the head is sharpened like a chisel and the other, to be blunt,
and round point.

6) Face Shield:
A face shield is used to protect the eyes and face from the race of the arc and from spatter and flying particles
of hot metal. It is available either in hand or helmet type . The hand type is convenient to use where ever the
work can be done with one hand. The helmet type is through not comfortable to wear, leaves both hands free

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for the work. Shields are made of light weight non-reflecting fiber and fitted with dark glass to filter out the
harmful rays of the arc. A cover glass is fitted in front of the dark lens to protect it from spatter.
7) Hand Gloves:
These are used to protect the hands from electrical shock and hot spatters.
Preparation of work
Before welding, the work pieces must be thoroughly cleaned of rust, scale and other foreign material. Thin
pieces of metal are generally welded without believing the edges. However, thick work pieces should be
bevelled or vied out to ensure adequate penetration and fusion of all parts of the weld. But, in either case,
the parts to be welded must be separated slightly to allow better penetration of the weld.
Welding Position
Depending on the position of the welding joint, appropriate position of the electrode and hand movement are
selected. Figure shows different welding positions.
Arc Welding Machines:
Both Direct current (DC) and alternate current (AC) are used for electric arc welding, each having its
particular applications. DC welding supply is generally obtained from generators driven by electric motors
or if no electricity is available by internal combustion engines.
Transformers are predominately used for almost all welding works. They have to step down the usual supply
voltage of 200V-400Volts to the open circuit voltage of 50-90 volts. A 100A to 200A small and portable
and available in single phase also. A 300A to 400A size is suitable for manual welding of average work.
Automatic welding requires 800A to 3000A. The two popular manufacturers are
I) Indian Oxygen’s INDARC and
II) Advani Oerlikon makes.
The transformer may be air cooled or oil cooled with transformer oil.
Arc Welding Currents and Voltages
The range of currents and voltages applied are changed according to the electrode selected for the job. The
details are given in the table below.

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Gas Welding:
Oxy acetylene flame is commonly used for gas welding. It consists of the supply of oxygen and acetylene
under pressure in cylinder and pressure regulators, a torch, hoses and accessories like goggles and a lighter.
The oxygen and acetylene cylinders are connected to the torch through pressure regulators and hoses. The
regulator consists of two pressure gauges, one for indicating the pressure indicating the cylinder and other

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shows the pressure of the gas fed in to the torch, which may be regulated. The torch mixes the two gases and
the flame may be controlled by adjusting the oxygen and acetylene supply.
Note: Oxygen regulators have “Right hand” threads with plain nuts and acetylene regulators have
“Left hand” threads with notched hexagon nuts. So that they can’t be confused. The regulator is
closed by unscrewing the regulating screw.
Goggles with coloured glasses are used to protect the eyes from glare and flying bits of hot metal. A
welding table with a top of fire bricks is recommended for acetylene welding.
Types of Flames
The correct adjustment of flame is important for efficient welding. When oxygen and acetylene are supplied
to the torch nearly in equal volumes, a neutral flame is produced having a maximum temperature of 32000
C. The neutral flame is widely used for welding steel, cast iron, copper, aluminum etc. Carburising flame is
produced with an excess of acetylene, is needed for welding led, Oxidising flame with excess of oxygen is
used for welding brass.
Depending on the thickness of the job, different torch nozzle sizes are used. The pressure of the gases and the
flame size vary depending on the size of the nozzle tip.
Safe and Correct Practices:
1) Arc welding:
1) Never look at the arc with naked eye. The arc can burn your eyes severely.
Always use a shield while welding.
2) Always use gloves, apron and leather shoes.
3) Ensure proper insulation of cable and check for openings.
4) Apply eye drops after arc welding is over for the day to relive strain on the eyes.

2) Gas Welding:
1) Always wear welding goggles while doing gas welding.
2) Never play or get careless when using the gas welding equipment. Combustible Gas must be
handling carefully.
3) Always use spark lighter to light the torch, never use match.
4) Strictly follow the instructions and procedures laid-out in handling the Cylinders, regulators and
torches.

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1.BUTT JOINT

All dimensions are in mm

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1.PREPARATION OF V-BUTT JOINT

Exp: -1

Aim: Prepare a V-Butt joint as shown in figure by using shield metal arc welding process.
Tools &Equipment Required
Steel rule, Welding Table, connecting cables, electrode holder, Earthing clamp, chipping hammer, welding
shield, Apron, Goggles, Welding Transformer etc
Materials Required
2 M.S Flat pieces of size50X30X6mm, Mild steel flux coated electrodes.
Sequence Of Operations
1) Measuring 2) Marking 3) Filing 4) Bevelling of Edges 5) Welding 6) Chipping 7) Finishing
Procedure:
1. Check the material for size.
2. The given metallic pieces are filed to the desired sizes
3. Bevel the edges of the pieces in order to have V-grove.
4. The metallic piece is thoroughly cleaned from rust, grease, oil etc.
5. Place the work pieces on the welding table.
6. The connecting cables are connected to terminals of transformer.
7. Select electrode diameter is based on thickness of work piece and hold it on the
electrode holder. Set the welding machine for proper amperage of current.
8. Switch on the power supply and initiate the arc by either striking arc method or
touch and drag method.
9. Hold the electrode at an angle of about 70 to 90 degrees and draw it slowly
along the line of weld, travelling from left to right thus depositing a small
smooth bead of the weld metal uniformly.
10. Control the beading until the gap is filled to a slightly convex form.
11. Slag is removed from the weld bead with the wire
12. Brush and chipping hammer.
Precautions 1. Protect devices like apron, hand screen and gum boots are to be used.
Applications Fabricating the Boilers, reactors etc.
Result: The single V-butt joint is thus made, using the tools and equipment as mentioned above.

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2.LAP JOINT

All dimensions are in mm

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2.LAP JOINT
Exp: -2

Aim: To Prepare a Lap joint as shown in figure using shield metal arc welding process.

Tools & Equipment Required:

Steel rule, Dot punch, Welding Table, Connecting cables, electrode holder, Earthing, clamp, chipping
hammer, welding shield, Apron, Goggles, Welding Transformer etc.

Materials Required:
Two M.S Flat pieces of size 50X30X6mm, Mild steel flux coated electrodes.

Sequence of operations:
1) Measuring 2) Marking 3) Filing 4) Welding 5) Chipping 6) Finishing

Procedure:
1. Check the material for size.
2. The given metallic pieces are filed to the desired sizes.
3. The metallic pieces are thoroughly cleaned from rust, grease, oil etc.
4. Place the work pieces on the welding table with appropriate overlap.
5. The connecting cables are connected to terminals of transformer.
6. Select electrode diameter is based on thickness of work piece and hold it on the electrode holder. Set the
welding machine for proper amperage of current.
7. Switch on the power supply and initiate the arc by either striking arc method or touch and drag method.
8. Hold the electrode at an angle of about 70 to 90 degrees and draw it slowly along
the line of weld, travelling from left to right thus depositing a small smooth bead of the weld metal uniformly.
9. Control the beading and repeat the above procedure for another side of work pieces.
10. Slag is removed from the weld bead with the wire brush and chipping hammer.

Precautions:
1. Eyes are to be protected by using proper welding shield.
2. Don’t touch the welding equipment when the power is on.
3. Gloves are to be used while handling the job.

Applications: Fabricating the Boilers, reactors etc.

Result: The Lap joint is thus made, using the tools and equipment as mentioned above

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VII. PLUMBING
INTRODUCTION:
Plumbing deals with the laying of pipe lines. Pipe line provides the means of transporting the fluid. Pipes are
used for carrying fluids such as water, steam, gas, oil etc from one place to another. It is obvious that laying
out the pipe line requires number of joints to be made and a number of valves incorporated, while
connecting different lengths of pipes. Generally, pipes are made of cast iron, wrought iron, steel, brass or
copper. The material selection is based on the nature of the fluid to be conveyed, viz; pressure, temperature,
chemical properties etc. Now a days PVC pipes are extensively used with ease for various purposes.
Plumbing tools:
Pipe wrench, pipe vice, pipe cutter, pipe bending machine, dies.

Pipes and pipe fittings: Pipe fittings, also known as pipe connectors, attach one pipe to another in order to
lengthen the run or change the flow direction in a plumbing system.

Cast iron pipe fittings:

Couplings, bends, elbows, tees, crosses, reducer.

GI pipe fittings:
Coupling, union, nipple, elbows, tees, reducer coupling, bush, plug, flange, gate valve, chuck valve, common
tape
Applications:
1. Agricultural and lift irrigation schemes.
2. Rural and urban drinking water supply Schemes.
Types of pipe joints:
According to the pipe material, size and application, different methods are used to join pipes. The most
common types of pipe joints are:
1. Screwed pipe joint – For GI Pipes
2. Welded pipe joint – for steel, copper, aluminium and lead pipes
3. Flanged pipe joint – for cast iron and steel pipes
4. Soldered pipe joint – for brass and copper tubes
5. Glued or cemented pipe joint – for PVC pipes

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Fig: Couplings

Fig: Reducers

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1.PREPARE AND CONNECT THE COUPLING FOR THE GIVEN PIPE

Fig: Coupling

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1.PREPARE AND CONNECT THE COUPLING FOR THE GIVEN PIPE

Exp: -1

Aim: To connect the PVC / GI pipe with pipe fittings like coupling
Fittings and Components Required:
1. Pipes of different length
2. Pipes of different diameter
3. Coupling
4. Teflon tape
5. PVC Solution
6.Hammer
Tools required:
Measuring tape, Pipe range, Hack saw, die set, Hammer, Screw driver.
Sequence of Operation:
a) Selection of pipes.
b) Fitting of pipes.
c) Connection of the pipes with the pipe fittings
Procedure:
1. The required pipe connection layout is drawn.
2. Two pipes of required lengths with equal diameter are taken.
3. Connect the PVC pipe at one end of the coupling and another PVC pipe for another end of the coupling.
4. After checking all the connections apply the PVC solution on pipes and coupling.
5. The coupling is mainly used for joints are increasing the length of the pipe.
6. The connections are ready with PVC pipe and coupling.
Result: Hence the required connection is obtained using required pipe length and coupling.

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2.PREPARE AND CONNECT A REDUCER JOINT USING PVCPIPE

Fig: Reducer

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2.PREPARE AND CONNECT A REDUCER JOINT USING PVCPIPE

Exp: -2

Aim: To connect the PVC / GI pipe with reducer for pipe fitting
Fittings and Components Required:
1. Pipes of different length
2. Pipes of different diameter (1 inch and half inch)
3. Reducer (1 inch and half inch)
4. Teflon tape
5. PVC Solution
6.Hammer
Tools required:
Measuring tape, Pipe range, Hack saw, die set, Hammer, Screw driver.
Sequence of Operation:
a) Selection of pipes.
b) Fitting of pipes.
c) Connection of the pipes with reducer.
Procedure:
1. The required pipe connection layout is drawn.
2. Two pipes of required lengths and diameter are taken.
3.The reducer is attached with the pipe for both the ends of reducer.
4. After checking the diameter of the pipe the PVC solution is put on the pipe and reducer.
5. Then the connections are ready for the reducer and pipes.
6. The reducer is mainly used for reducing the flow of the pipes.
Result: Hence the required connection is obtained using required pipes and reducer.

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