EP-LAB New Manual

KONGU ENGINEERING COLLEGE

Perundurai, Erode - 638052

11ME103

ENGINEERING PRACTICES LABORATORY (Common to All Engineering and Technology Branches)

PART-A –Mechanical Engineering

(Fitting, Carpentry, Sheet metal work, Plumbing

and Welding practices)

DEPARTMENT OF MECHANICAL ENGINEERING

SCHOOL OF BUILDING AND MECHANICAL SCINENCES

Index (List of experiments)

S.

No.

Experiment

Date Name of the Experiment Page No.

Submission

Date Marks

Staff

Signature

EXERCISES IN FITTING OF METAL PLATES

1. Cutting and filing operation on MS

plates for SQUARE / V / L joint

EXERCISES IN CARPENTRY

2. Joining of wooden pieces by

T/+/Corner joint method.

3. Making a square / rectangular

wooden box from plywood

EXERCISES IN SHEETMETAL WORK

4. Making a sheet metal tray of

square or rectangle shape

EXERCISES IN PLUMBING

5. Assembly of PVC/GI pipes and

pipe fittings

6. Cutting of threads in GI/ PVC pipe

by thread cutting dies.

EXERCISES IN WELDING

7. Gas welding of MS plates by Lap /

T/Butt joint method

8 Arc Welding of MS plates by Lap /

T/Butt joint method

FITTING

Profiles of metal pieces used in joining of metal plates.

ALL DIMENSIONS ARE IN mm

EX.NO: DATE:

CUTTING AND FILING OPERATION ON MS PLATES FOR SQUARE / V / L JOINT.

AIM:

Fitting of two given MS flat plates by Square / V / L type joints as indicated in the diagram.

MATERIALS REQUIRED:

Two Mild steel plates (two no’s) with its dimensional values that is marginally higher than

the required dimensions.

GIVEN WORK PIECE DIMENSIONS: First piece:…… mm X…… mm X ….. mm and

Second piece:…… mm X…… mm and ….. mm)

TOOLS REQUIRED:

1. Bench Vice

2. Try Square, Steel rule

3. Prick punch , Ball peen hammer

4.

5. Hacksaw

6. Files

7. Surface plate

8. Surface gauge

WORKING PROCEDURE

(This fitting operation is carried out using material removal process)

1. Study the given work piece dimension and also the required dimension.

2. Plan the portion of the work piece to be removed.

3. The given work piece is clamped in between the jaws of the bench vice with the surface to

be filed remains horizontal and also at the top.

4. The height of projection of the work piece above the clamp is not to exceed 5 mm in order

to minimize/avoid vibration and noise during filing operation.

5. Use flat file (rough) for removing excessive material and flat (smooth) file for finishing

operation.

6. Carry out filing operation on this top surface of the work piece without any irregularity in

material removal and ensure a perfect flat surface. This new flat surface will be used as one

of the reference plane (say X axis) for marking the required dimensions.

7. Unclamp the work piece from the bench vice and clamp it again after tilting the work piece

to 90 degrees such that this new surface comes on top, for filing operation. This new

surface will be the reference plane in Y axis. Carry out filing operation on this new top

surface and ensure flatness.

8. Using Tri square check the two right angled surfaces that are machined for

perpendicularity. Carry out further filing on these two surfaces if required to ensure

perpendicularity of its surfaces.

9. Mark the required geometry in the work piece (middle/corner of work piece as per the

geometrical requirement) using steel rule and scriber and punch.

10. Finish carrying out filing operation of the other two unfinished surfaces. Ensure the new

surfaces are parallel to the reference X axis and Y axis respectively and to the required

dimensions.

11. Use hacksaw frame fitted with sharp blade to remove the excessive material and get a

work piece with undercut and another work piece with projection as required (Square/V/L)

12. Fix the new surfaces created by cutting operation suitably for filing operation and get

required size of the undercut and projected portion.

13. Mate the undercut and projected portion and ensure perfect fitting.

14. Measure the dimensional values of the finished work pieces and compare it with the

standard / required values for accuracy.

RESULT: (All dimensions are in mm)

Dimensional Parameter Required

Dimension

Obtained

Dimension

Conclusions:

Verification note and marks awarded

Signature of faculty with date

CARPENTRY

CARPENTRY JOINTS 1. CORNER JOINT

2.T-JOINT

3.PLUS-JOINT

ALL DIMENSIONS ARE IN mm

EX.NO:

DATE:

JOINING OF WOODEN PIECES BY T / PLUS / CORNER JOINT METHOD

AIM:

Joining of wooden pieces by T / Plus / Corner joint method and demonstrate accuracy in

fitting to the desired dimensional values.

MATERIALS REQUIRED:

Two wooden reapers of size and material suitable to get the required joint.

GIVEN WORK PIECE DIMENSIONS: First piece: …… mm X…… mm X ….. mm and

Second piece: …… mm X…… mm X ….. mm)

TOOLS REQUIRED:

1. Jack plane

2. Try square

3. Marking gauge

4. Tenon saw

5. Carpentry vice

6. Steel rule

7. Firmer chisel

8. Mallet

9. Rip saw

WORK INSTRUCTIONS:

1. Check the given wooden work pieces for its dimensional values and quality.

2. Analyze the given drawing for the required specifications and ensure the suitability of

the given material to make the required joint.

3. Identify the type of wooden joint to be made.

4. Carry out planning operation using Jack Plane on all the surfaces of the work piece

along its axis by holding the work piece firmly in the clamp.

5. Ensure proper cross sectional area and surface finish.

6. Mark the portion to be removed on each work piece in order to facilitate making part

and counterpart for the required wooden joint.

7. Clamp one of the work pieces firmly in the vice such that the portion to be removed

may be chiseled /operated.

8. Remove the marked portion from the work piece by chiseling or cutting. Use mallet and

firmer chisel to remove the excess wood by chiseling or use tennon saw to cut and

remove the excess wood.

9. Complete the counterpart also in the same manner as per the specification.

10. Press fit the two parts to make joint as per specification.

11. Check the obtained joint against specification using try square and steel rule.

12. Carryout small corrections in work pieces if required.

13. Record the obtained dimensional values and compare it with desired values.

RESULT: (All dimensions are in mm)

Dimensional Parameter Required

Dimension

Obtained

Dimension

Conclusions:

Verification note and marks awarded

Signature of faculty with date

Plywood box

THICKNESS OF PLYWOOD = mm

ALL DIMENSIONS ARE IN mm

EX.NO:

DATE:

MAKING A SQUARE / RECTANGULAR WOODEN BOX FROM PLYWOOD

AIM:

Making a square / rectangular wooden box using plywood and nail to the desired

dimensional values

MATERIALS REQUIRED:

Ply wood sheet of sufficient area and thickness to make the box as per specification.

GIVEN WORK PIECE DIMENSIONS: Ply wood size: …… mm X…… mm X ….. mm and

Second piece: …… mm X…… mm X .... mm)

TOOLS REQUIRED:

1. Try square

2. Marking gauge

3. Tenon saw

4. Carpentry vice

5. Steel rule

6. Firmer chisel

7. Mallet

8. Rip saw

WORK INSTRUCTIONS:

1. Check the given ply wood for its dimensional values and quality.

2. Analyze the given drawing for the required specifications and ensure the suitability of

the given material to make the required joint.

3. Study the base area and wall area of the wooden box to be made.

4. Mark the outer edge dimensions of the base portion on the given ply wood and Carry

out cutting operation using ……….

5. Similarly mark all the side walls of the box based on the height and width of the box

required and the Carryout cutting operation using …………. And get the pieces

6. Ensure proper cross sectional area and surface finish.

7. Mark the portion to be removed on each work piece in order to facilitate making part

and counterpart for the required wooden joint.

8. Clamp one of the work pieces firmly in the vice such that the portion to be removed

may be chiseled /operated.

9. Remove the marked portion from the work piece by chiseling or cutting. Use mallet and

firmer chisel to remove the excess wood by chiseling or use tennon saw to cut and

remove the excess wood.

10. Complete the counterpart also in the same manner as per the specification.

11. Press fit the two parts to make joint as per specification.

12. Check the obtained joint against specification using try square and steel rule.

13. Carryout small corrections in work pieces if required.

14. Record the obtained dimensional values and compare it with desired values.

RESULT: (All dimensions are in mm)

Dimensional Parameter Required

Dimension

Obtained

Dimension

Conclusions:

Verification note and marks awarded

Signature of faculty with date

SHEET METAL

SHEET METAL BOX

THICKNESS OF SHEET METAL = mm

ALL DIMENSIONS ARE IN mm

EX.NO:

DATE:

MAKING A SHEET METAL TRAY OF SQUARE OR RECTANGULAR SHAPE

AIM:

To make a metal tray of square or rectangle shape from given sheet metal.

MATERIALS SUPPLIED:

Galvanized Iron (G.I) sheet of thickness ranging from 18-28 gauge and cut to an area

sufficient for making the box.

GIVEN WORK PIECE DIMENSIONS: …… mm X…… mm and thickness ….. ….gauge /mm)

TOOLS REQUIRED:

1. Steel rule, Scriber, Divider

2. Mallets

3. Protractor

4. Standard wire gauge/ Sheet thickness measuring gauge

5. Snips/Tin cutter

6. Stakes

7. Rivet set

8. Ball peen Hammer

WORKING PROCEDURE

1. Check the dimensions of the given sheet using steel rule and thickness measuring gauge.

2. Draw the development of the tray on a white paper and obtain various dimensions. Provide

allowances for edge folding and also for flap. Mark the obtained dimensions on the given

work sheet surface using scriber.

3. Cut and remove the unwanted / excess materials using tin cutter.

4. Hold the work piece suitably in a bench vice and bend the sheet along the edges of the box

using Stakes and Mallet.

5. Complete bending process of the work piece.

6. Fold the flaps to the inner surface of the wall for riveting / soldering if required for leak

proof joints.

7. Complete edge folding along the open edges of the box to avoid sharp edges.

8. Complete trimming and finishing operations to ensure accuracy and safety.

RESULT: (All dimensions are in mm)

Dimensional Parameter Required

Dimension

Obtained

Dimension

Conclusions:

Verification note and marks awarded

Signature of faculty with date

PLUMBING

PIPE JOINTS INVOLVING THE FITTINGS LIKE VALVES, TAPS AND BENDS

EX. NO:

DATE:

ASSEMBLY OF PVC / GI PIPES AND PIPE FITTINGS

AIM:

To connect the given pipes and pipe fittings resembling water lines used in households.

FACILITIES/TOOLS REQUIRED:

1. Pipe vice fitted on a work table

2. Pipe wrench

3. Thread cutting dyes of suitable size.

4. Spanner

MATERIALS REQUIRED:

1. PVC / GI Pipes.

2. Gate valves

3. Water Taps

4. Flanges, Bolts, nuts

5. Couplings

6. Elbow, Tee fittings

7. L bends

8. Union etc.,

PROCEDURE:

1. Study the pipe circuit for its constraints and the requirements.

2. Fix/identify a reference element in the circuit based on which the entire circuit will be built.

3. Identify the suitable joints for connecting pipes Use flanges or couplings for connecting

pipes.

4. Ensure threads on the external surface of the pipe and internal surface of the coupling to

make leak proof joint.

5. Use elbow, L bends to make suitable bends in the pipe circuit.

6. Use Tee or 4 way joint for distribution or collection of fluid in the circuit.

7. Fit gate valves to control the flow of liquid and taps to open or shut the flow in the place of

requirement.

8. Prefer threaded joint if the joint is temporary or GI pipe joint.

9. PVC materials may be preferred.

10. Metal pipes may be preferred if large pressure exists in the flow circuit.

11. Check the line diagram against the specification/requirement.

Conclusions:

Verification note and marks awarded

Signature of faculty with date

FORMING OF THREADS USING THREAD CUTTING DYES IN G/ PVC PIPE

No of Threads :

Type of Thread :

ALL DIMENSIONS ARE IN mm

EX.NO:

DATE: CUTTING OF THREADS IN GI / PVC PIPE BY THREAD CUTTING DIES

AIM:

To form external threads on a given PVC/ GI pipe for standard specification using dies.

FACILITIES/TOOLS REQUIRED:

1. Pipe vice fitted on a work table

2. Pipe wrench

3. Thread cutting dies of suitable size.

4. Spanners

MATERIALS REQUIRED:

1. PVC / GI Pipe

2. Gate valves

3. Water Taps

4. Flanges, Bolts, nuts

5. Couplings

6. Elbow, Tee fittings

7. L bends

8. Union etc.,

PROCEDURE:

1. Identify the given pipe material and measure the diameter of the given pipe.

2. Study the specification of thread (Length, diameter, pitch and type of thread) to be made

and select suitable thread forming die.

3. Tightly fix the given PVC/GI pipe in the pipe vice. Ensure sufficient projection to

accommodate the die rotation for the required length.

4. Select suitable die and fix it in the die set.

5. Align the axis of the die set to the axis of the pipe without any error.

6. Rotate the die set clock wise for making right hand thread.

7. Periodically rotate the die set anti clock wise and ensure removal of chips from die.

8. Continue the thread formation process (and antilock wise) by rotating in the die set in

clockwise direction until the required length of thread is achieved.

9. Apply lubricant to remove the heat generated by the thread forming process if the pipe is

made of GI

10. Remove the die set and clean the chips if any.

11. Cut the threaded portion of the pipe and check the threads for form and dimensional

accuracy.

RESULT:

Verification note and marks awarded

Signature of faculty with date

WELDING

GAS WELDING JOINTS

BUTT JOINT

LAP JOINT T JOINT

ALL DIMENSIONS ARE IN mm

GAS WELDING OF MS PLATES BY LAP / T / BUTT JOINT METHOD

EX.NO:

DATE:

AIM:

Joining of metal plates by gas welding method.

MATERIALS REQUIRED:

Two Mild steel plates cut to standard size that is to be joined by welding.

GIVEN WORK PIECE DIMENSIONS: First piece: …… mm X…… mm X ….. mm and

Second piece: …… mm X…… mm X ….. mm)

TOOLS REQUIRED:

1. Welding Torch

2. Filler rod (copper coated mild steel)

3. Tongs

4. Chipping Hammer

5. Wire brush

6. Gloves

7. Apron

8. Safety goggles

PROCEDURE:

1. Study the given work piece dimension and also the type of welding joint to be adopted

2. Prepare the edge/surface (at least one edge on each plate that is to be joined) of the work

piece by means of filing operation if required. (For procedures refer “Cutting and filing

operation on MS flat plates for square / V / L shaped joint” experiment).

3. For preparing a Butt joint welding, Place the two work pieces on a flat surface and bring

the two surfaces close to each other whose edges are to be joined by welding

If it is Lap joint welding then places the work pieces one over the other overlapped as per

the specification given in the drawing.

If it is T joint welding then places one of the work piece on a flat surface and other work

piece may be held suitably (perpendicular to the first plate and the edges closer.) by tongs.

4. Light the welding torch and regulate the supply of gases to the required proportion by

adjusting the knob in welding torch.

5. Maintain 3 mm gap between core of the flame and the portion to be welded.

6. Place a filler rod in the flame to melt and fill the gap between the two welding edges.

7. Ensure uniform welding speed and sufficient filler material fills the gap between two

plates.

8. Complete the welding throughout the required length (single side or double side).

9. Switch OFF the gas supply after the weld.

10. Hold the work piece using tongs and quench it in water for 2minutes.

11. Remove the slag by chipping and clean the burrs using the wire brush.

RESULT:

Verification note and marks awarded

Signature of faculty with date

ARC WELDING JOINTS

BUTT JOINT

LAP JOINT T JOINT

ALL DIMENSIONS ARE IN mm

ARC WELDING OF MS PLATES BY LAP / T/ BUTT JOINT METHOD

EX.NO: DATE:

AIM:

Joining of metal plates by arc welding method.

MATERIALS REQUIRED:

Two Mild steel plates cut to standard size that is to be joined by welding.

GIVEN WORK PIECE DIMENSIONS: First piece: …… mm X…… mm X ….. mm and

Second piece:…… mm X…… mm X ….. mm)

TOOLS REQUIRED:

1. MS Electrodes(3.15 mm X 350 mm)

2. Tongs

3. Chipping Hammer

4. Wire brush

5. Gloves

6. Apron

7. Shield

8. Electrode holder with cable

PROCEDURE:

1. Study the given work piece dimension and also the type of welding joint to be adopted

2. Prepare the edge/surface (at least one edge on each plate that is to be joined) of the work

piece by means of filing operation if required. (For procedures refer “Cutting and filing

operation on MS flat plates for square / v / l shaped joint” experiment).

3. For preparing a Butt joint welding, place the two work pieces on a flat surface and bring

the two surfaces close to each other whose edges are to be joined by welding

a. If it is Lap joint welding, then place the work pieces one over the other overlapped

as per the specification given in the drawing.

b. If it is T joint welding, then place one of the work piece on a flat surface and other

work piece may be held suitably (perpendicular to the first plate and the edges

closer.) by tongs.

4. Select suitable electrode and power source based work piece material and thickness.

5. Select suitable current (Amps) for sufficient melting of electrode and work piece.

6. Fix the electrode in the electrode holder at the specified inclination (45 or 90 or 120

degrees) based in application.

7. Strike the electrode on the work piece at an angle of 60 degrees and ensure arc.

8. Maintain an air gap (maximum of 3 mm) between electrode and work piece for continuous

welding.

9. Ensure uniform welding speed during the welding process for uniformity of weld.

10. Complete the welding throughout the required length (single side or double side).

11. Remove the slag and spatter by chipping hammer and wire brush.

12. Allow the welded pieces for natural cooling or quench it in water for 2minutes.

13. Clean the burrs using the wire brush and check for quality of weld, welding defect and

dimensional accuracy.

RESULT:

Verification note and marks awarded

Signature of faculty with date