Lab manual of 1st year mechanical workshop

LABORATORY MANUAL MEC 108 Engineering Workshop

Name of the Student:……………………………………………….. Registration Number/Roll No………………………………………. Section and Group…………………………………………………….. School of Mechanical Engineering

Table of contents Sr. No. 1

Title of experiments To prepare a mortise and tenon joint by using carpentry shop.

Page No. 4-7

2 3

To make a male and female V- shape joint by using fitting shop. To prepare the pipeline connections with various fitting joints.

8-11 12-16

4

To make the T-fillet joint on given metal pieces using arc welding.

17-20

5

To prepare a Lap joint using AC Arc welding.

21-24

6

To prepare a Chisel edge by forging from a given round rod.

25-28

7

To prepare a multi-operation job as per sketch using Lathe Machine.

29-33

8

To make a funnel from the given sheet metal piece.

34-37

9

To prepare the mould using different patterns by using green sand.

38-40

2

General tolerances for linear measures according to ISO 2768-1 Table 1 Permissible deviation for linear dimensions Permissible deviations for basic size range in mm

Designation

Description

from 0.5

Over 3

upto 3

upto 6

Over 6 upto30

Over 30

Over 120

upto 120

upto 400

Over 400 upto 1000

Over 1000 Upto 2000

Over 2000 upto 4000

F

Fine

±0,05

±0,05

±0,10

±0,15

±0,20

±0,30

±0,50

Nil

M

Medium

±0,10

±0,10

±0,20

±0,30

±0,50

±0,80

±1.20

±2.00

C

Coarse

±0,20

±0,30

±0,50

±0,80

±1.20

±2.00

±3.00

±4.00

V

Very coarse

Nil

±0,50

±1.00

±1.50

±2.50

±4.00

±6.00

±8.00

Table 2-Permissible deviation for broken edges (external radius and chamfer heights) Permissible deviations for basic size range in mm Designation Description From 0.5 upto 3 Over 3 upto 6 Over 6 f Fine ±0,20 ±0,50 ±1.00 m Medium c Coarse ±0,40 ±1.00 ±2.00 v Very coarse

Table 3- Permissible deviation for angular dimensions Permissible deviations for ranges of length in mm of shorter side of Designation Description the angle concerned Upto 10 f m c

Fine Medium Coarse

±1.00ᴼ

Over 10 upto 50 ±0.500ᴼ

±1.500ᴼ

±1.000ᴼ

±0.500ᴼ

±0.250ᴼ

±0.166ᴼ

v

Very coarse

±3.00ᴼ

±2.000ᴼ

±1.000ᴼ

±0.500ᴼ

±0.333ᴼ

3

Over 50 upto 120 ±0.333ᴼ

Over 120 upto 400 ±0.166ᴼ

Over 400 ±0.083ᴼ

CARPENTRY SHOP 1. OBJECTIVE To prepare a mortise and tenon joint according to the dimensions as shown in figure 1. 2. JOB Soft wood block of size 30×45×240 mm

3. MACHINE/EQUIPMENT’S/TOOLS TO BE USED a) b) c) d) e)

Scriber engineering steel scale Vernier Caliper Marking chalk Power hacksaw Hand hacksaw 4

f) g) h) i) j) k) l)

Bench vice Try square Dividers Hammer Surface plate Outside caliper Inside caliper

4. PROCEDURE (a) Hold the job securely in carpentry vice. (b) Plane the job to the dimensions as given in drawing. (c) Cut the job in two pieces of equal length using a rip saw. Mark them as ‘X’ and ‘Y’. (d) Mark the required dimensions on piece ‘X’ and ‘Y’ to identify the material to be removed. (e) Remove the unwanted material using a rip saw and chisel. (f) Smooth the remaining surfaces with file or sandpaper. (g) Make the joint. 5. RESULT The mortise and tenon joint of required dimension is obtained as shown below (Fig.2)

6. PRECAUTIONS (a) Job should be held securely in carpentry vice so that the job does not move while planning. (b) Check the squareness of sides while planning. (c) Marking should be done properly and accurately. (d) Cutting and removal of material should be done accurately. (e) Surfaces to be smoothened before making the lap joint.

5

Worksheet of the student

Aim: To prepare a Mortise and tenon joint.

Sr. Job specification/Dimension No. In Drawing In actual

Operations

6

Tool Used

Equipment/ Machine Used

Remarks

Drawing:

Learning Outcomes (what I have learnt):

To be filled in by Faculty S.No. Parameter (Scale from 1-10, 1 for very poor and 10 Marks obtained Max. Marks excellent Understanding of the student about the 1 20 procedure/apparatus.(process sheet) 2

Dimensional Accuracy, Finishing and Learning Outcome

20

3

Completion of experiment/Job, Discipline and Cleanliness

10

Signature of Faculty

Total marks obtained 7

FITTING SHOP 1. OBJECTIVE To make a male and female V- shape joint as per dimension given below.

2. JOB Mild steel cutting specimen of dimensions 93×48×8 mm

3. MACHINE/EQUIPMENT’S/TOOLS TO BE USED a) Hacksaw with blade b) Bastard flat file c) Second cut flat file d) Square file e) Triangular file f) Try square g) Steel foot rule h) Scriber i) Centre punch j) Ball pean hammer 8

k) Vernier caliper and micrometer l) Bench vice 4. PROCEDURE (a) Hold the job in a bench vice. (b) Perform filing operation on all sides and check that the adjacent sides are at right angles using try square. (c) Maintain the finished job after filing to the dimension of 91×45×8 mm. (d) Using hacksaw cut the job in two equal lengths. Mark them as part ‘A’ and ‘B’. (e) Mark areas using scriber, punch and hammer on parts ‘A’ and ‘B’. (f) Using hacksaw cut out the areas as marked on piece ‘A’ and ‘B’ (g) Smoothen the remaining surfaces on the pieces using a file. (h) Match parts ‘A’ and ‘B’ so that they fit fully with no light can be seen at matching line. Otherwise do more filling to ensure more matching. 5. RESULT A perfect ‘V’ – shaped male and female joint is obtained as shown in Figure 3.

6. PRECAUTIONS (a) Job should be held tightly in a vice while doing fitting operations like filing and cutting. (b) While filing by a file and cutting by a hacksaw pressure should be applied during forward stroke. (c) Cutting should be done accurately along the lines drawn after measurement.

9

Worksheet of the student

Aim: To make a male and female V- shape joint as per dimension given below.

Sr. Job specification/Dimension No. In Drawing In actual

Operations

Tool Used

10

Equipment/ Machine Used

Remarks

Drawing:

Learning Outcomes (what I have learnt):

To be filled in by Faculty S.No. Parameter (Scale from 1-10, 1 for very poor and 10 excellent about

Marks obtained

1

Understanding of the student procedure/apparatus.(process sheet)

2

Dimensional Accuracy, Finishing and Learning Outcome

20

3

Completion of experiment/Job, Discipline and Cleanliness

10

Signature of Faculty

the

Max. Marks

20

Total marks obtained

11

PLUMBING SHOP 1. OBJECTIVE To prepare the pipeline connections with various fitting joints. 2. JOB

Fig 1 All types of pipeline connections MATERIALS REQUIRED: (a) (b) (c) (d) (e) (f) (g) (h)

GI pipe of required size Teflon tape Elbow Union Socket Gate and globe valve Bibcock Tee

3. MACHINE/EQUIPMENTS/TOOLS TO BE USED (a) (b) (c) (d) (e)

Hack saw frame with blade or pipe cutter Measuring tape File Pipe vice Pipe wrench and Die set 12

OPERATIONS TO BE CARRIED OUT (a) (b) (c) (d) (e)

Measuring Marking Cutting Threading Checking and Joining

4. PROCEDURE Measuring and marking: Measure the GI pipe of required dimensions and mark them. Cutting: (a) After checking the original dimension using scale the length to be cut is marked. (b) Pipe is clamped firmly in a pipe vice and the cutting process is carried out using pipe cutter or hacksaw frame with blade. (c) If pipe cutter is used for cutting, the pipe is placed between the rollers and the handle is tightened. Then it is rotated clockwise until the pipe is cutting. Threading: (a) After checking the original dimension using scale the Pipe is clamped firmly in a pipe vice and using the die set it is threaded. (b) For this die set is fitted into pipe and it is rotated clockwise and counter clock wise direction. This process is continued until a fine thread is obtained. (c) Now the thread is checked by using any one of the pipe joint. Joining: (a) The given pipe and joints are checked for its original dimensions as per drawing and for fixing the joint, we use thread sealing over the threads by using pipe wrench. 5. RESULT Preparation of job as per sketch with detail dimensions.

13

6. PRECAUTIONS (a) (b) (c) (d) (e) (f)

Always wear shoes while performing the practical. Always wear safety goggles. Do not lean on to the machines. Do not even try to touch anything unknown. Follow the operative instructions given strictly. Do not wear loose clothes while working on machines.

14

Worksheet of the student

Aim: To prepares the pipeline connection with all fitting joint.

Sr. Job specification/Dimension No. In Drawing In actual

Operations

Tool Used

15

Equipment/ Machine Used

Remarks

Drawing:

Learning Outcomes (what I have learnt):

To be filled in by Faculty S.No. Parameter (Scale from 1-10, 1 for very poor and 10 excellent Understanding of the student about 1 procedure/apparatus.(process sheet)

Marks obtained the

Max. Marks 20

2

Dimensional Accuracy, Finishing and Learning Outcome

20

3

Completion of experiment/Job, Discipline and Cleanliness

10

Signature of Faculty

Total marks obtained

16

WELDING SHOP 1. OBJECTIVE To make a T- fillet joint on given metal pieces using arc welding. 2. JOB Two mild steel pieces of dimension 40×30×8 mm.

3. MACHINE/EQUIPMENTS/TOOLS TO BE USED (a) Arc welding machine (b) Welding electrode (c) Eye shield (d) Hand gloves and apron (e) File (f) Chipping hammer (g) Welding table (h) Bench vice (i) Wire brush

17

4. PROCEDURE (a) Clean the work pieces with file and wire brush. (b) Keep one piece horizontal on welding table and hold another piece vertical to it as shown in the figure. (c) Fix an electrode into the electrode holder of the machine. The clamp of the machine is grounded to the welding table. (d) Switch on the machine and position the electrode at the corner made by the vertical piece with the horizontal piece. Perform a spot weld so that the vertical pieces stay standing on horizontal piece without any other support. (e) Check the perpendicularity of the vertical piece. If it is correct, carry out the welding of complete length at both sides of the vertical piece. (f) Switch off the machine and lift the job to put it into water for cooling. (g) Remove excess stag by using chipping hammer and wire brush. 5. RESULT A required T- fillet joint has been obtained for joining two pieces. 6. PRECAUTIONS (a) Use welder’s eye shield while welding. (b) Wear leather gloves and apron. (c) Move the electrode gradually ensuring proper filling of weld metal at the corners.

18

Worksheet of the student

Aim: To make a T- fillet joint on given metal pieces using arc welding.

Sr. Job specification/Dimension No. In Drawing In actual

Operations

Tool Used

19

Equipment/ Machine Used

Remarks

Drawing:

Learning Outcomes (what I have learnt):

To be filled in by Faculty S.No. Parameter (Scale from 1-10, 1 for very poor and 10 excellent Understanding of the student about 1 procedure/apparatus.(process sheet)

Marks obtained the

Max. Marks 20

2

Dimensional Accuracy, Finishing and Learning Outcome

20

3

Completion of experiment/Job, Discipline and Cleanliness

10

Signature of Faculty

Total marks obtained

20

WELDING SHOP 1. OBJECTIVE To prepare a Lap joint using AC Arc welding. 2. JOB Two mild steel pieces of dimension 100×50×6 mm.

Fig.1 Lap joint 3. MACHINE/EQUIPMENT’S/TOOLS TO BE USED (a) Arc welding machine (b) Welding electrode (c) Eye shield 21

(d) Hand gloves and apron (e) File (f) Chipping hammer (g) Welding table (h) Bench vice (i) Wire brush 4. PROCEDURE (a) Clean the work pieces with file and wire brush. (b) Keep both the pieces on welding table vertically as shown in the figure. (c) Fix an electrode into the electrode holder of the machine. The clamp of the machine is grounded to the welding table. (d) Switch on the machine and position the electrode at the corner. Perform a spot weld so that both the vertical pieces stay without any other support. (e) Check the accuracy of the vertical pieces. If it is correct, carry out the welding of complete length at both sides of the vertical pieces. (f) Switch off the machine and lift the job to put it into water for cooling. (g) Remove excess stag by using chipping hammer and wire brush. 5. RESULT A required Lap joint has been obtained for joining two pieces. 6. PRECAUTIONS (a) Use welder’s eye shield while welding. (b) Wear leather gloves and apron. (c) Move the electrode gradually ensuring proper filling of weld metal at the corners.

22

Worksheet of the student

Aim: To prepare a Lap joint on given metal pieces using arc welding.

Sr. Job specification/Dimension No. In Drawing In actual

Operations

Tool Used

23

Equipment/ Machine Used

Remarks

Drawing:

Learning Outcomes (what I have learnt):

To be filled in by Faculty S.No. Parameter (Scale from 1-10, 1 for very poor and 10 excellent Understanding of the student about 1 procedure/apparatus.(process sheet)

Marks obtained the

Max. Marks 20

2

Dimensional Accuracy, Finishing and Learning Outcome

20

3

Completion of experiment/Job, Discipline and Cleanliness

10

Signature of Faculty

Total marks obtained 24

SMITHY SHOP 1. OBJECTIVE To prepare a Chisel edge by forging from a given round rod 2. JOB Mild steel rod (12×100mm)

Fig.1 - Preparation of Chisel edge from round rod 3. MACHINE/EQUIPMENTS/TOOLS TO BE USED (a) (b) (c) (d) (e) (f) (g) (h)

Smith’s furnace Round tong Flat tong Sledge hammer Flatter Anvil Rake Poker

25

4. PROCEDURE (a) Heat the given round rod in the furnace until it is red hot. (b) Using the round tong, the work piece is removed and held against an anvil. (c) By using sledgehammer, the round rod is struck to get a square cross section, when the round rod tends to become a square. (d) In heated condition, the square is held using a flat tong and its sides are finished to get an even surface using a flatter. (e) Then again it is heated and converted into a square headed bolt using flatter. (f) To form hexagonal bolt head any two corners to be hammered. (g) Finally the work piece is cooled using water to avoid deformation and to attain the maximum hardness. 5. RESULT 1. Preparation of job as per sketch with detail dimensions. 6. PRECAUTIONS (a) Job should be heated up to red hotness but not beyond that as otherwise metal may melt. (b) Hammering should be done gradually along the chosen portion with repeated heating so that deformation should take place without any damage. (c) Used correct tools as required for the specific smithy operation. (d) Use protective apron and gloves.

26

Worksheet of the student

Aim: To forge a Chisel edge from a given round rod.

Sr. Job specification/Dimension No. In Drawing In actual

Operations

Tool Used

27

Equipment/ Machine Used

Remarks

Drawing:

Learning Outcomes (what I have learnt):

To be filled in by Faculty S.No. Parameter (Scale from 1-10, 1 for very poor and 10 excellent Understanding of the student about 1 procedure/apparatus.(process sheet)

Marks obtained the

Max. Marks 20

2

Dimensional Accuracy, Finishing and Learning Outcome

20

3

Completion of experiment/Job, Discipline and Cleanliness

10

Signature of Faculty

Total marks obtained

28

MACHINE SHOP 1. OBJECTIVE To prepares a multi-operation job as per sketch using Lathe Machine.

Fig. 1 Finished part (All dimensions in mm and tolerance as per ISO standard)

2. JOB A mild steel rod of size 210×40 mm ɸ ±

Fig. 2 Job

29

3. MACHINE/EQUIPMENTS/TOOLS TO BE USED (a) (b) (c) (d) (e) (f) (g) (h)

Lathe machine Single point cutting tool Grooving tool Steel rule Scriber Chuck key Tool post key Vernier calliper

4. PROCEDURE (a) Place the round bar in chuck (three jaws self – centring chuck) of the lathe machine and tighten the chuck using chuck key. (b) Mount the single point cutting tool on the tool post with the help of tool post key. (c) Now face both the ends of the round bar by facing operation so that the length is brought to 100 mm. Check the length by Vernier calliper. (d) Start turning operation to obtain the different step on the round bar, i.e. 100×25 mm ɸ. Check the diameter and length by Vernier calliper. (e) Set the cross slide to about 450 and give a small feed in longitudinal direction. Move the tool using cross slide to chamfer the ends. (f) Mount another grooving tool on the tool post with the help of tool post key. (g) Start grooving operation to obtain the desired dimensions.

Fig. 3 Lathe operation

30

5. RESULT The given round bar is (i) faced (ii) Turned (iii) Grooving, and (iv) Chamfered to the required dimensions. 6. PRECAUTIONS (a) Loose clothes should not be worn. (b) Job must be fixed tightly in the chuck using chuck key. (c) Chuck key must be removed from the chuck before starting the machine. (d) Machine should not be left in running position when operation is not being done. (e) Use brush for removing chip instead of using hand. (f) Last cut for facing and turning should be done with smallest feed to ensure smooth finish.

31

Worksheet of the student

Aim: To prepares a multi-operation job as per sketch using Lathe Machine.

Sr. Job specification/Dimension No. In Drawing In actual

Operations

Tool Used

32

Equipment/ Machine Used

Remarks

Drawing:

Learning Outcomes (what I have learnt):

To be filled in by Faculty S.No. Parameter (Scale from 1-10, 1 for very poor and 10 excellent Understanding of the student about 1 procedure/apparatus.(process sheet)

Marks obtained the

Max. Marks 20

2

Dimensional Accuracy, Finishing and Learning Outcome

20

3

Completion of experiment/Job, Discipline and Cleanliness

10

Signature of Faculty

Total marks obtained

33

SHEET METAL SHOP 1. OBJECTIVE To makes a funnel from the given sheet metal piece.

Fig 1 Procedure of making a conical funnel from sheet metal 2. JOB 22 gauge galvanized iron (GI) sheet 3. MACHINE/EQUIPMENTS/TOOLS TO BE USED (a) (b) (c) (d) (e) (f) (g) (h) (i) (j)

Steel rule Mallet Scriber Divider Protractor White paper Snips Stakes Groover Ball peen hammer

SEQUENCE OF OPERATION (a) Checking (b) Levelling (c) Marking on paper 34

(d) Marking on sheet metal (e) Cutting (f) Folding (g) Hemming (h) Soldering 4. PROCEDURE (a) The size of the given sheet metal is checked for its dimensions using a steel rule. (b) The required development of surface is being made on the white paper which is overlapped on the sheet metal. (c) The marking is done on the sheet metal as per the development being done on the paper. (d) Now using straight snips, unwanted materials are removed. (e) Now fold and bend the work piece to make the funnel shape and joint is made on the work pieces. (f) Then using a groover, a locked grooved joint is made for about 5 mm. Also, hemming is done in the bottom of the funnel. (g) In between top face and bottom face, a butt joint is made using a solder. (h) Finally, trimming and finishing operations are carried out. 5. RESULT Thus, the funnel of the required dimensions is made from the given sheet metal.

6. PRECAUTIONS (a) Always wear shoes while performing the practical. (b) Always wear safety goggles. (c) Do not lean on to the machines. (d) Do not even try to touch anything unknown. (e) Follow the operative instructions given strictly. (f) Do not wear loose clothes while working on machines.

35

Worksheet of the student

Aim: To makes a funnel from the given sheet metal piece.

Sr. Job specification/Dimension No. In Drawing In actual

Operations

Tool Used

36

Equipment/ Machine Used

Remarks

Drawing:

Learning Outcomes (what I have learnt):

To be filled in by Faculty S.No. Parameter (Scale from 1-10, 1 for very poor and 10 excellent Understanding of the student about 1 procedure/apparatus.(process sheet)

Marks obtained the

Max. Marks 20

2

Dimensional Accuracy, Finishing and Learning Outcome

20

3

Completion of experiment/Job, Discipline and Cleanliness

10

Signature of Faculty

Total marks obtained

37

FOUNDARY SHOP 1. OBJECTIVE To prepare the mould using different patterns by using green sand. 2. MACHINES/EQUIPMENT/TOOLS TO BE USED: (a) Shovels (b) Trowels (c) Hand sieve riddle (d) Sprue pipe (e) Sprue cutter (f) Rammers (g) Vent 3. PROCEDURE Prepare a mixture of green sand by adding 92% of sand, 4-5% Bentonite powder and 3-4% of water in a sand muller and prepare moulds. Pour the molten metal and decore the casting produced. 4. RESULT Thus, the mould of single piece pattern is made from the given green sand. 5. PRECAUTIONS (a) Always wear shoes while performing the practical. (b) Always wear safety goggles. (c) Do not even try to touch anything unknown. (d) Do not lean on the machines.

38

Worksheet of the student

Aim: To prepares the mould of single piece pattern by using green sand.

Sr. Job specification/Dimension No. In Drawing In actual

Operations

Tool Used

39

Equipment/ Machine Used

Remarks

Drawing:

Learning Outcomes (what I have learnt):

To be filled in by Faculty S.No. Parameter (Scale from 1-10, 1 for very poor and 10 excellent Understanding of the student about 1 procedure/apparatus.(process sheet)

Marks obtained the

Max. Marks 20

2

Dimensional Accuracy, Finishing and Learning Outcome

20

3

Completion of experiment/Job, Discipline and Cleanliness

10

Signature of Faculty

Total marks obtained

40