PRIR11 - Engineering Practice

Lab Manual

Roll No:
Name:

National Institute of Technology

Tiruchirappalli- 620015
Exercise. Number: Date:

LAP JOINT
Aim:
To join two given metal plates by a lap joint using arc welding.

Tools required:
Power supply (AC /DC), earthing clamps, welding electrode, welding torch, tongs,
bench vice, wire brush, gloves, shield, apron, safety goggles, steel rule, flat file and chipping
hammer.

Material Supplied:
Mild Steel Plate of Size _____________ mm

Sequence of Operation:
a. Edge preparation (removal of rust, scale, etc.)
b. Tacking
c. Welding
d. Cooling
e. Chipping
f. Cleaning

Working Steps:
1. The given metal plates are cleaned to remove rust and scale formation, by using a wire
brush.
2. Then edge preparation is done to the required dimensions, with the aid of bench vice.
3. Based on the thickness of the metal plates to be welded the amperage and correct
voltage is selected.
4. Two metal plates are placed as per the position and tag weld is done on the ends to
avoid the movement of the plates while welding.
5. Then welding is started from one end of the plates and is continued till the other end
by maintaining 3 mm gap between the welding rod and the plates to be welded.
6. While welding goggles, gloves and shield are used for the safety of eyes and hand.
7. The electric arc produced by the transformer melts the electrode and joins the two
metal plates.
8. Then cool the welded metal plates
9. Finally the welded portion is chipped to remove slag using chipping hammer and wire
brush.
Diagram:

Dimension:
Required

Obtained

Result:
Hence the two given metal plates are joined by lap joint using arc welding.
Exercise. Number: Date:

BUTT JOINT
Aim:
To join two given metal plates by a butt joint using arc welding.

Tools required:
Power supply (AC /DC), earthing clamps, welding electrode, welding torch, tongs,
bench vice, wire brush, gloves, shield, apron, safety goggles, steel rule, flat file and chipping
hammer.

Material Supplied:
Mild Steel Plate of Size _____________ mm

Sequence of Operation:
a. Edge preparation (removal of rust, scale, etc.)
b. Tacking
c. Welding
d. Cooling
e. Chipping
f. Cleaning

Working Steps:
1. The given metal plates are cleaned to remove rust and scale formation, by using a wire
brush.
2. Then edge preparation is done to the required dimensions, with the aid of bench vice.
3. Based on the thickness of the metal plates to be welded the amperage and correct
voltage is selected.
4. Two metal plates are placed as per the position and tag weld is done on the ends to
avoid the movement of the plates while welding.
5. Then welding is started from one end of the plates and is continued till the other end
by maintaining 3 mm gap between the welding rod and the plates to be welded.
6. While welding goggles, gloves and shield are used for the safety of eyes and hand.
7. The electric arc produced by the transformer melts the electrode and joins the two
metal plates.
8. Then cool the welded metal plates
9. Finally the welded portion is chipped to remove slag using chipping hammer and wire
brush.
Diagram:

Dimension:
Required

Obtained

Result:
Hence the two given metal plates are joined by butt joint using arc welding.
Exercise. Number: Date:

STEPPED FLANGE

Aim:
To make the mould using stepped flange.

Material Required:
Moulding sand, Parting sand, Facing sand, stepped Flange pattern and
MouldingBoxes.

Tools Required:
Shovel, Sieve, Trowel, Rammers, Sprue pin, Strike off bar, Lifter, Gate cutter, Runner,
Riser, Vent rod, Draw spike, Bellow.

Sequence of Operation:
a) Sand Preparation
b) Core preparation
c) Placing the pattern on the moulding board
d) Ramming of drag
e) Placing runner and riser
f) Ramming of cope
g) Removal of pattern, runner, riser
h) Gate cutting

Working Steps:
1. The stepped flange pattern is placed on the moulding board.
2. A suitable core is prepared and placed in the hole of the flange pattern.
3. Clay washing is done inside the drag surface.
4. Parting sand is applied over the pattern.
5. Box is filled with smooth moulding sand and proper ramming is done using flat and
peen rammers.
6. Excess sand is removed using the strike off bar.
7. The drag is turned upside down.
8. The cope is placed on the drag after doing clay wash.
9. The runner and riser is placed over the pattern.
10. After applying parting sand, moulding sand is filled over the pattern.
11. Ramming is done to get a rigid mould.
12. Using strike off bar excess sand is removed.
13. Vent holes are made using vent rod.
14. Runner and riser are removed and a funnel shape is moved on the runner hole.
15. Cope is kept aside and the pattern is removed using draw pin.
16. Gate is prepared using gate cutter.
17. The cope is placed on the drag.
Diagram:

Result:
Hence the stepped flange mould is prepared.
Exercise. Number: Date:

HAND WHEEL

Aim:
To make the mould using Hand Wheel.

Material Required:
Moulding sand, Parting sand, Facing sand, Hand wheel pattern and MouldingBoxes.

Tools Required:
Shovel, Sieve, Trowel, Rammers, Sprue pin, Strike off bar, Lifter, Gate cutter, Runner,
Riser, Vent rod, Draw spike, Bellow.

Sequence of Operation:
a. Sand Preparation
b. Core preparation
c. Placing the pattern on the moulding board
d. Ramming of drag
e. Placing runner and riser
f. Ramming of cope
g. Removal of pattern, runner, riser
h. Gate cutting

Working Steps:
1. The Hand Wheel pattern is placed on the moulding board.
2. A suitable core is prepared and placed in the hole of the flange pattern.
3. Clay washing is done inside the drag surface.
4. Parting sand is applied over the pattern.
5. Box is filled with smooth moulding sand and proper ramming is done using flat and
peen rammers.
6. Excess sand is removed using the strike off bar.
7. The drag is turned upside down.
8. The cope is placed on the drag after doing clay wash.
9. The runner and riser is placed over the pattern.
10. After applying parting sand, moulding sand is filled over the pattern.
11. Ramming is done to get a rigid mould.
12. Using strike off bar excess sand is removed.
13. Vent holes are made using vent rod.
14. Runner and riser are removed and a funnel shape is moved on the runner hole.
15. Cope is kept aside and the pattern is removed using draw pin.
16. Gate is prepared using gate cutter.
17. The cope is placed on the drag.
Diagram:

Result:
Hence the Hand wheel mould is prepared.
Exercise. Number: Date:

T-JOINT

Aim:
To make tee-lap joint from the given work piece to the required shape and dimension.

Material Supplied:
Wooden piece of size _________________ mm

Tools Required:
Steel rule, Marking Gauge, Try-Square, Carpentry Vice, Jack Plane, Tenon Saw, Rib
Saw, Mallet and Chisels.

Sequence of Operation:
a. Rough Planning
b. Marking
c. Cutting (or) Sawing
d. Chiselling
e. Finish planning

Working Steps:

1. The given job is checked to ensure its correct size.

2. The job is clamped rigidly in the carpentry vice and any two adjacent surfaces are
planned using jack plane to the given specifications.
3. Using try square the right angle of the work piece is checked.
4. All the four sides are planned to get smoother and finished surfaces at right angles to
each other.
5. The job is cut into two halves using the Rib saw. Then proper marking is done for T
Lap joint on the two pieces using steel rule and marking gauge.
6. Using Tenon saw and firmer chisel the unwanted portions are removed as per the
drawing in both the pieces.
7. The two pieces are assembled to check proper fitting.
8. The finished job is checked for its accuracy using try square and steel rule.
Diagram:

Dimension:
Required

Obtained

Result:
Hence the required T through Half lap Halving joint is obtained from the given work
piece.
Exercise. Number : Date :
SCARF TENON JOINT

Aim:
To make Scarf Tenon joint from the given work piece to the required shape and
dimension.

Material Supplied:
Wooden piece of size ________________ mm

Tools Required:
Steel rule, Marking Gauge, Try-Square, Carpentry Vice, Jack Plane, Tennon Saw, Rib
Saw, Mallet and Chisels

Sequence of Operation:

a. Rough Planning
b. Marking
c. Cutting (or) Sawing
d. Chiseling
e. Finish planning

Working Steps:

1. The given job is checked to ensure its correct size.

2. The job is clamped rigidly in the carpentry vice and any two adjacent surfaces are
planned using jack plane to the given specifications.
3. Using try square the right angle of the work piece is checked.
4. All the four sides are planned to get smoother and finished surfaces at right angles to
each other.
5. The job is cut into two halves using the Rib saw. Then proper marking is done for
Scarf Tenon joint on the two pieces using steel rule and marking gauge.
6. Using Tenon saw and firmer chisel the unwanted portions are removed as per the
drawing in both the pieces.
7. The two pieces are assembled to check proper fitting.
8. The finished job is checked for its accuracy using try square and steel rule.
Diagram:

Dimension:
Required

Obtained

Result:
Hence the required Scarf Tenon joint is obtained from the given work piece.
Exercise. Number: Date:

L FITTING

Aim:

To make L- fitting from the given work pieces.

Material Required:
Two pieces of M.S. plate of the size __________________ mm.

Tools Required:
Bench vice, Steel rule, Files, Vernier Height gauge, Try square, Dot punch.

Sequence of Operation:
1. Checking
2. Rough Filing
3. Marking
4. Punching
5. Sawing
6. Rough Filing
7. Finish Filing

Working Steps:
1. The dimensions of the given work piece is checked using steel rule.
2. The work piece is fixed on a bench vice separately and the all sides are filed using a
flat file so that they are at right angles.
3. Then chalk is applied uniformly on the surfaces of the work piece.
4. The given dimensions are marked by using surface plate and Vernier height gaugewith
reference to the datum.
5. Then using dot punch, dots are punched along the marked line.
6. Then using fixed hack saw the unwanted portions are removed.
7. Cutting edges are filed using triangular files.
8. Checking is done to ensure squareness and flatness of the work piece surfaces using
try square.
9. Finally the assembly is checked for the required best fit.
Diagram:

Dimension:
Required

Obtained

Result:
Hence the required L- fitting is done from given work pieces.
Exercise. Number: Date:

RECTANGLE FITTING

Aim:

To make rectangle fitting from the given work pieces.

Material Required:
Two pieces of M.S. plate of the size __________________ mm.

Tools Required:
Bench vice, Steel rule, Files, Vernier Height gauge, Try square, Dot punch.

Sequence of Operation:
1. Checking
2. Rough Filing
3. Marking
4. Punching
5. Sawing
6. Rough Filing
7. Finish Filing

Working Steps:
1. The dimensions of the given work piece is checked using steel rule.
2. The work piece is fixed on a bench vice separately and the all sides are filed using a
flat file so that they are at right angles.
3. Then chalk is applied uniformly on the surfaces of the work piece.
4. The given dimensions are marked by using surface plate and Vernier height gauge
with reference to the datum.
5. Then using dot punch, dots are punched along the marked line.
6. Then using fixed hack saw the unwanted portions are removed.
7. Cutting edges are filed using triangular files.
8. Checking is done to ensure squareness and flatness of the work piece surfaces
using try square.
9. Finally the assembly is checked for the required best fit.
Diagram:

Dimension:
Required

Obtained

Result:
Hence the required Rectangle- fitting is done from given work pieces.
Exercise. Number : Date :

LOCKED GROOVE JOINT

Aim:
To make the locked groove joint from the given sheet metal.

Material Required:
26 gauge Galvanized Iron (G.I) Sheet

Tools required:
Steel Rule, Scriber, Try-Square, Ball Peen Hammer, Mallet, Stacks, Straight Snip,
Groover and Pliers

Sequence of Operation:
a. Marking
b. Cutting
c. Hemming
d. Bending
e. Finishing

Working Steps:
1. The given GI sheet is marked as per the given dimensions shown in the drawing.
2. The unwanted portion of the sheet is cut by using the straight snip along the marked
lines.
3. Then the sheet is levelled for the perfect flatness using the mallet.
4. The position of the hemming operation is marked at the edges with the help of the
steel rule and a scriber.
5. The ends of the sheets are bent along the marking as per the given sketch by using the
required stacks, anvil and mallet.
6. Finally the corners of the sheets are joined by riveting and finishing operations.
Diagram:

Dimension:
Required

Obtained

Result:
Hence the locked joint is made on the given GI sheet to the required size.
Exercise. Number : Date :

DUST PAN

Aim:
To make the dust pan from the given sheet metal.

Material Required:
26 gauge Galvanized Iron (G.I) Sheet

Tools required:
Steel Rule, Scriber, Try-Square, Ball Peen Hammer, Mallet, Stacks, Straight Snip,
Groover and Pliers

Sequence of Operation:
a. Marking
b. Cutting
c. Hemming
d. Bending
e. Finishing

Working Steps:
1. The given GI sheet is marked as per the given dimensions shown in the drawing.
2. The unwanted portion of the sheet is cut by using the straight snip along the marked
lines.
3. Then the sheet is levelled for the perfect flatness using the mallet.
4. The position of the hemming operation is marked at the edges with the help of the
steel rule and a scriber.
5. The ends of the sheets are bent along the marking as per the given sketch by using the
required stacks, anvil and mallet.
6. Finally the corners of the sheets are joined by riveting and finishing operations.
Diagram:

Dimension:
Required

Obtained

Result:
Hence the Dust Pan joint is made on the given GI sheet to the required size.