2029 BM-LAB MANUAL Final

LAB MANUAL
BASIC MECHANICAL
ENGINEERING LAB (2029)
DEPARTMENT OF MECHANICAL ENGINEERING

REVISION - 2015
VISION OF THE DEPARTMENT
To Develop the Mechanical Engineering Department as a center of excellence providing

value added education for industrial development, molding youth to practice engineering
profession with Confidence, Courage, Competence and Integrity, thereby gaining
international acceptance.
MISSION OF THE DEPARTMENT
To provide high-quality education in the fields of Mechanical Engineering through cutting-

edge, State of the art program at Diploma levels.
To provide numerous opportunities for the development of knowledge, skills and Professional
abilities of faculties and students with focus on the future, through value added education &
character shaping.
PROGRAM EDUCATIONAL OBJECTIVES (PEOS)
PEO 1 - Students will have utilized a foundation in engineering and science to improve lives
and livelihoods through a successful career in mechanical engineering.
PEO 2 - Students will have become effective collaborators and innovators, leading or
participating in efforts to address social, technical and business challenges.
PEO 3 - Students will have engaged in life-long learning and professional development through
self-studying, continuing education or graduate and professional studies in engineering,
business.
BASIC MECHANICAL ENGINEERING LAB (2029) Department Of Mechanical Engineering
LAB MANUAL
BASIC MECHANICAL
ENGINEERING LAB (2029)
For Diploma Mechanical Engineering

(REVISION - 2015)
DEPARTMENT OF MECHANICAL ENGINEERING

MA’DIN POLYTECHNIC COLLEGE
MELMURI. P O
MALAPPURAM
MA’DIN POLYTECHNIC COLLEGE 3

SYLABUS
COURSE TITLE : BASIC MECHANICAL ENGINEERING LABORATARY
COURSE CODE : 2029
COURSE CATEGORY :B
PERIODS/ WEEK :3
PERIODS/ SEMESTER : 45
CREDIT :2
CONTENT DETAILS
MODULE I
Understand the proper tools and equipments
Identify the required tools from a given number of tools
Select particular tool for a specified operation
Locate the functional part of equipments and tools
Explain the use of tools and equipments
Understand the use of precision equipments& its measurements.
Vernier Caliper, Micrometers, depth gauges etc
Practice measurements on Vernier Caliper, Micrometers, depth gauges etc
Comprehend the various plumbing tools & practice
Pipe vice, Pipe Wrench, chain wrench, pipe bending machine, pipe cutter etc.
Plumbing practice.
MODULE II
Understand the Brazing & soldering processes
Metal joining Processes
Study of various tools and equipments used in Brazing & soldering processes
Practice on brazing & soldering
MODULE III
Appreciate the parts of Centrifugal & Reciprocating pumps
Classification of Water Pumps
Positive Displacement – Rotodynamic – Miscellaneous
Comprehend the main components of petrol & diesel engines
Classification of IC Engines – Systems in IC Engines
Working of Petrol & Diesel Engines – Comparison - Main parts
MODULE IV
Understand the components of refrigerator and air conditioners
Introduction to refrigeration
Working of refrigeration plant – Major Components
Introduction to air conditioning
Working of air conditioning plant – Major Components
TEXT BOOKS
1. Mechanical Workshop Practice by K. C. John (PHI Learning Private Limited)
CONTENTS
TOPICS PAGE NO.

GENERAL INSTRUCTIONS 01
STUDY OF PRECISION MEASURING INSTRUMENTS 03
STUDY OF VARIOUS PLUMBING TOOLS 07
STUDY OF METAL JOINING PROCESS 11
STUDY OF CENTRIFUGAL PUMP 15
STUDY OF RECIPROCATING PUMP 19
STUDY OF INTERNAL COMBUSTION ENGINE 23
STUDY OF REFRIGERATION & AIR CONDITIONING

29
SYSTEM
CALIBRATION OF VERNIER CALIPER 31
CALIBRATION OF MICROMETER 33
CALIBRATION OF VERNIER DEPTH GAUGE 35
BRAZING PRACTICE 37
SOLDERING PRACTICE 39
PLUMBING PRACTICE 41
STAFF DETAILS
JITHESH NP HOS 9061414555;

9895771828
VIPIN. V. P LECTURER 9020055676
PRAVEEN. K. P LECTURER 9037834487
ANAND R LECTURER 9633915305
SANJAY K LECTURER 9633593219
NABEEL N WORKSHOP SUPERINTENDENT 9656844140
SUJITH. N W\I 9946012928

GENERAL INSTRUCTIONS
➢ Students are expected to maintain very good discipline inside the laboratory.
➢ Students should adhere to the dress code specified for the laboratory.
➢ Students must come prepared with the experiment.
➢ Students should get necessary apparatus issued against their names before starting the experiment.
➢ Every student must bring their own drawing instruments, calculator etc.
➢ Every students should get his observation and all laboratory work signed regularly by the staff members
in-charge before leaving the laboratory.
➢ Don’t wear loose cloths and be careful of moving machinery and hot objects.
➢ The application and removal of the load must be gradual.
➢ Any unusual behavior or noise of the machine must be immediately reported to the instructor.

1
VERNIER CALIPER
OUTSIDE MICROMETER

2
STUDY O PRECISION MEASURING INSTRUMENTS

AIM:
To study the different types of precision measuring instruments.
VERNIER CALIPER
The principle of vernier is which has two scales of different sizes used to measure the dimensions in
high accuracy. The vernier caliper has two steel rules which slide each other. One of the longer scales is named
as main scale which is graduated on a solid L-shaped frame. The graduation is done for 20 parts in which one
small division is equal to 0.05 cm. The vernier caliper consists of three elements such as beam, fixed jaw and
sliding jaw or movable jaw. The movable jaw slides over the main scale according to the dimension of the
specimen to be measured. Before starting the measurement, we should ensure, the scale is checked for zero
reading when two measuring jaws are in contact with each other.
Vernier calipers have two scales namely, main scale and vernier scale. The vernier scale moves along the
main scale.Verniers are used to measure both internal and external dimensions. The caliper is placed on the
object to be measured and the fine adjustment screw is rotated until the jaws fit tightly against the work
piece. The readings from the main and vernier scales are taken
Least count (LC) is the minimum value that can be measured. It is the difference between one main scale
division and one vernier scale division.
Least count = 1 Main scale division – 1 Vernier scale division.
1 division on main scale = 1mm
No. of divisions on vernier scale = 50
50 vernier scale divisions = 49 divisions on main scale (49mm)
1 Vernier scale division = 49/50
Least count = 1- (49/50)
= 0.02mm
OUT SIDE MICROMETER

Micrometer is measuring instrument used to measure very fine and precise dimensions of length, width,
thickness, diameter, etc. it is also used for measure cylindrical component like shaft, bolt coin ball etc. This is
more accurate and precise than vernier caliper.
The micrometer has an accurate screw which rotates inside a fixed nut. The end of the screw acts as one
measuring tip and fixed anvil acts other measuring tip. The spindle moves towards the fixed anvil or away from
it by rotating the thimble. The spindle is placed inside the barrel in such a way freely slide over the barrel. But
the barrel is firmly fixed with the frame. 20 divisions per cm are made in barrel. It is lead screw for one
complete revolution. But the thimble has 25 divisions around circumference. So, each revolution is again
3
VERNIER DEPTH GAUGE

4
divided in to 25 divisions. Therefore, each division is equal to 0.002 cm it is equal to 0.02 mm. At the same
time, if the thimble has 50 divisions around circumference, each division is equal to 0.001 cm which is equal to
0.01 mm. So, this 0.01 mm is the least count of the micrometer.
While measuring dimensions, the locknut arrests the movement of the spindle to ensure correct reading. A
retchet is provided to apply uniform pressure after just touching the ends of the part to be measured.
The parts of external micrometer are,
➢ Frame: The C shaped body holds the anvil and barrel in constant relation to each other. It is thick
because it needs to minimize flexion, expansion, & contraction. It is often covered by insulating
plastic plates which further reduce heat transfer.
➢ Anvil: The projected portion out of the frame for a distance of at least 3 mm is called anvil. It is one
of the measuring faces.
➢ Spindle: The spindle acts and grips the job against the anvil. The threaded mechanism allows for
the forward and backward movement of the spindle.
➢ Barrel: The datum line and graduations are marked on this.
➢ Thimble: It is a tubular cover attached with the spindle and moves with the spindle. The thimble
has a beveled edge, and divided into 50 equal parts.
➢ Ratchet stop: This is an extension to the thimble. It ensures a uniform pressure between the
measuring surfaces.
➢ Spindle Lock Nut: It is used to lock the spindle at a desired position.
Back lash: It is the lagging in motion when the thimble rotates. It means, the thimble rotation direction is
changed.
Zero Error of a Micrometer: Move the spindle of the micrometer until it touches the anvil. If the zero mark on
the thimble is not aligned with the zero of the datum line of the sleeve, the micrometer is said to have zero
error. If the micrometer reads positive, it has a minus zero error. The error will have to be subtracted from the
actual reading.
VERNIERDEPTH GAUGE
A vernier depth gauge is precision instrument used to measure depth measurements of holes, recesses,
slots and steps within an accuracy of 0.02 mm.
It consists of the following parts
a) Base. d) Fine Adjustment Mechanism.

b) Graduated Beam. e) Vernier Scale.
c) Clamping Screws.
Precautions:
➢ Zero error of vernier depth gauge must be checked before use.

➢ It should not be mixed with other cutting tools.
➢ If not in use, it should be kept in its box.

5
PIPE WRENCH PIPE CUTTER

1. Handle
2. Jacking screw
3. Cutting wheels
4. Roller wheel (Fixed) to face
5. Moving reel base
6. Frame
PIPE BENDING MACHINE

PIPE VICE
CHAIN PIPE WRENCH

6
STUDY OF VARIOUS PLUMBING TOOLS

AIM:
To study about Plumbing and various plumbing tools.
DESCRIPTION:
PIPE WRENCH: It is used for Holding and gripping pipes. Assembling and dismantling of pipes and fittings. The
pipe wrench is designed as a heavy duty tool to withstand rough handling and heavy work. The jaws give and
immediate and positive grip. It may be used for all pipes with 15mm to 50mm diameters. Pipe wrenches are
selected according to the pipe size. While using this pipe wrench, the jaws must be placed over the work piece
to their full depth and tightened by means of the adjusting nut.
PIPE CUTTER: A tool or machine for cutting pipe specifically a hand tool comprising a grasping device and three
sharp-edged wheels forced inward by screw pressure that cut into the pipe as the tool is rotated.
PIPE VICE: A pipe vice is a plumbing tool used to hold pipe or tubing securely so that it can be cut or
threaded. Pipe vices are also useful for pipe welding. In a manufacturing environment, a pipe vice is a critical
piece of apparatus in the assembly of pipeline components.
PIPE BENDING MACHINE: A pipe bender is a tool used to bend piping of different materials, such as copper and
stainless steel, to form various angles and curves. There are four main categories of pipe benders: manual,
hydraulic, electric and mechanical.
CHAIN PIPE WRENCH: Chain pipe wrenches are used for pipes with diameters of 50mm to 150mm. They may
be used for gripping cylindrical or irregular objects. In which the head is placed on the pipe and the chain pulled
round the circumference of the pipe. The chain is then engaged with the large teeth in the center of the head.
The chain pipe wrench is a heavy gripping tool and should not be used for pipes with less than 50mm diameter.
TYPES OF PIPES
According to material used:
- Galvanized iron pipes - Brass pipes.

- Mild steel pipes - Aluminum pipes.
- Cast iron pipes - Rubber pipes.
- C.I. soil pipes - Lead pipes
- Copper pipes - Plastic pipes
- P.V.C. pipes - Stoneware pipes

7
900 ELBOW 450 ELBOW TEE
REDUCING TEE CROSS LATERAL 450
EXPANSION JOINT UNION PLUG
DEAD END COUPLING REDUCER
LONG NIPPLE SHORT NIPPLE CLOSE NIPPLE

8
STANDARD PIPE FITTINGS:
‘Pipe fittings’ are those fittings that may be attached to pipes in order to:
- change the direction of the pipe - connect two or more pipes of different sizes
- connect a branch with a main water supply pipe - close the pipe ends.
ELBOWS: Elbows and bends provide deviations of 90° and 45° in pipe work systems. Long radius elbows have a
radius equal to 1½ times the bore of the pipe. Short radius elbows have a radius equal to the bore of the
pipe.The 45° elbows allow pipe deviation of 45°.
TEE JOINTS: A tee joint helps the pipe line to branch off at 900. The branches may be equal in diameter or there
may be one reducing branch. The dimensions of a branch are always quoted as A x B x C. Reducers are fitted
where a change in pipe diameter is required.
CROSS: Cross is also known as four-way pipe fitting. A cross has one inlet and three outlets (or vice versa).
Generally, crosses are not used in process piping to transport fluid. But forged crosses are common in the fire
water sprinkler line.
LATERAL 450: It is a type of Tee which has the branch at a 45° angle, or an angle other than 90°. Wye tee allows
one pipe to be joined to another at a 45° angle. This type of tee reduces friction and turbulence that could
hamper the flow. Wye tee is also known as a lateral.
EXPANSION JOINT: It is a connector of two pipes. It provides stress relief in a piping system due to thermal and
mechanical vibration or movements
UNION: A device used to connect pipes. Unions are inserted in a pipe-line to permit connections with little
change to the position of the pipe. When unions are used in pipe lines, it is easy to dismantle and repair.
PLUG: A plug is used for closing a pipeline which has an internal thread.
DEAD END: Used to close an ending on a pipe fitting normally used for inspection or cleanout.
COUPLING: A coupling is used to connect two pipes. Couplings have internal threads at both ends to fit the
external threads on pipes.
REDUCER: A reducer coupling is used to connect two pipes with different diameters.
PIPE NIPPLES: Pipe nipples are tubular pipe fittings used to connect two or more pipes of different sizes.

9
BRAZING
SOLDERING

10
STUDY OF METAL JOINING PROCESSES

AIM:
To study about Brazing and Soldering processes.
DESCRIPTION:
WELDING:
Welding is the process of joining two pieces of metal by application of heat. The two parts to be joined
are placed together, heated, often with the addition of filler metal, until they melt, and solidify on cooling.
Along with the application of heat, in some cases pressure is also applied in order have better action of joining.
For additional strength sometimes filler materials is also used.
.
How is brazing different from welding?
Welding is a joining process wherein metallic components are joined through fusion (melting) or
recrystallization of the base metal by applying heat, pressure or both. This process differs from brazing, where
only the filler metal melts during processing.
BRAZING AND SOLDERING:
Both brazing and soldering join metal which is melted between the two closely fitted metal surfaces.
The major difference is that in brazing the filler metal melts at a higher temperature and fuses by capillary
action, giving a stronger joint.
Soldering is a joining process wherein metals are bonded together using a non-ferrous filler metal with a
melting (liquidus) temperature lower than 450 °C (840 °F). Whenever the filler metal liquidus is greater than
450 °C (840 °F), the joining process is considered to be a brazing process rather than a soldering process.
BRAZING
It is a process of joining two pieces of metals in which a non-ferrous alloy is introduced in a liquid state
between the pieces of metal to be joined and allowed to solidify. The filler metal is distributed between the
closely filled surfaces of the joint by capillary action. The melting point of the filler metal is above 420˚c, but
lowers than the melting temperature of parent metal. During the process no forging action is present and also
the parts do not melt. The bond is produced either by the formation of solid solution or intermetallic compounds
of the parent metal. The strength of joint is provided by metallic bonding. Good brazing process involves pre
cleaning, fluxing, and proper alignment, heating and post cleaning.
Why braze?
➢ Component distortion is minimized or eliminated.

➢ Base metal dilution is low.
➢ Process thermal cycles are predictable.
➢ Joining of dissimilar materials can be achieved.
➢ Thin-to-Thin or Thin-to-Thick members can be joined.
➢ Small and wide gap sizes can be filled.
➢ Specialized labor is not required.

11
TOURCH BRAZING
FURNACE BRAZING
INDUCTION BRAZING DIP BRAZING

12
Typical Brazing temperature ranges for various filler metals:
VARIOUS METHODS OF BRAZING:
• Torch brazing: The base metal is heated to the required temperature by the application of the oxy-
acetylene flame.
• Furnace brazing: The parts to be brazed are aligned with the brazing material placed in the joint. The
assembly is kept in the furnace. The temperature is controlled to provide uniform heating
• Dip brazing: The parts to be brazed are submerged in a molten metal or chemical bath of brazing filler
metal
• Induction brazing: The parts to be brazed are heated to the melting point of the brazing material by
means of a high frequency electric current. This is done by encircling the joint with a water cooled
induction coil.
Applications: Fastening of pipe fittings, tanks, Carbide-tips on tools, radiators, heat exchangers,
electrical parts and the repair of castings.
SOLDERING
It is a method of joining two or more pieces of metal sheets by means of a fusible alloy or metal, called
solder, applied in the molten state. The melting point of the filler metal is below 420˚c. Generally lead and tin
alloys are used in various compositions depending upon the use of the joint.
Composition of some the solders are listed below.
a) Soft solder – lead 37% and tin 63%.
b) Medium solder – lead and tin each 50%.
c) Electrician solder – lead 58% and tin 42%.
d) Plumbers solder – lead 70% and tin 30%.
The above mentioned alloys have melting point between 150˚c and 400˚c. The strength of soldering joint
depends upon the strength of alloys and its adhesive qualities
Depending on method of heating, soldering process may be classified as dip, iron, resistance, torch, induction,
furnace, infrared and ultrasonic type.
Soldering is divided into two classes. Soft and hard soldering. Soft soldering is extensively used in sheet
metal work for joining parts that are not exposed to the action of high temperature and excessive loads or forces.
Hard soldering is employed when a stronger joint is required than that is obtainable by the soft solder. Silver
alloyed with tin is used as a hard solder, the melting point of which is 300 to 450˚c. The process of cleaning the
surfaces and applying the flux is same as an in case of welding and brazing. In soldering process, butt joints are
avoided and lap joints are preferred

13
CENTRIFUGAL PUMP

14
STUDY OF CENTRIFUGAL PUMP

AIM:
To study the constructional details and working of centrifugal pump.
DESCRIPTION:
A pump is a device used to move gases, liquids or slurries from a lower pressure to higher pressure, and
overcomes this difference in pressure at the expense of energy to the system. Hydraulic pumps convert
mechanical energy from a prime mover (engine or electric motor) into hydraulic (pressure) energy.
A centrifugal pump is generally used where a large volume of flow is required at relatively low
pressures. Centrifugal pump is hydraulic machines that converts the mechanical energy into pressure energy by
means of centrifugal force acting on the fluid are called Centrifugal pumps.
The energy changes occur by virtue of two main parts of the pump, the impeller and the volute or
diffuser. The impeller is the rotating parts that convert driver energy into kinetic energy. The volute or diffuser
is the stationary part that converts the kinetic energy into pressure energy.
PARTS &WORKING PRINCIPLE OF A CENTRIFUGAL PUMP:
The impeller is keyed on to a shaft which is mounted on bearings and is coupled to a motor which
rotates the impeller. The kinetic energy of the impeller is transmitted to the fluid and its velocity increases. The
volute casing converts the kinetic energy of the fluid to pressure energy. The pressure at the centre of the
impeller decreases as the fluid flows outward. The increase in pressure cases the fluid of the sump to
continuously flow through the section pipes.
Impeller: The impeller is the main rotating part that provides the centrifugal acceleration to the fluid. It consists
of a series of backward curved vanes. The impeller is mounted on a shaft which is connected to the shaft from
an electric motor.
Casing. It is an air tight passage surrounding the impeller and is designed in such a way that the kinetic energy
of fluid discharged at the outlet of the impeller is converted into pressure energy before the fluid leaves the
casing and enters the delivery pipe. The following are the three types of casing that are normally used.
Volute casing, Vortex casing, & Casing with guide blades.
Volute casing: - In this type, the impeller is surrounded by a spiral casing which provides a gradual
increase in the area of flow, thus decreasing the velocity of water and correspondingly increasing the pressure.
Vortex casing: - This is an improved form of volute casing. A circular chamber is introduced between
the casing and the impeller. By introducing a circular chamber, the loss of energy due to formation of eddies is
reduced to a considerable extent. Thus the efficiency is improved than that of a volute casing pump.
Casing with guide blades: - In this type of impeller is surrounded by a series of guide blades mounted
on a ring which is known as diffuser. Guide vanes are designed in such a way that fluid from the impeller enters
the guide vanes without shock. Also the area of the guide vanes increases, thus reducing the velocity of flow
through guide vanes and consequently increasing the pressure of fluid.

15
TYPES OF CASING

16
Suction pipe with a foot valve and strainer: The pipe which connects the centre or eye of the impeller to
sump from which fluid is to be lifted is known as suction pipe. In order to prevent the formation of air pockets
the pipe is laid air tight. To prevent the entry of solid particles, debris etc. into the pump, the suction pipe is
provided with a strainer at its lowest end. The lower end is also fitted with a non-return foot valve which does
not permit the liquid to drain out of the suction pipe when the pump is not working; this also helps in priming.
Delivery pipe: A pipe whose one end is connected to the out let of the pump and other end delivers fluid at a
required height is known as delivery pipe. A regulating valve is provided on the delivery pipe to regulate the
supply of water.
Priming: The process of removal of entrapped air from the suction pipe & casing by filling water is called
priming; if air is present sufficient pressure cannot be developed. Pressure developed by the impeller is directly
proportional to the density of the fluid.
Cavitation: At any pump in the flow of water of in any region of liquid, if local pressure is reduces to vapor
pressure corresponding to liquid temperature, the liquid boils and small bubbles of vapor from in large numbers.
These bubbles travel along the flow until a region of high pressure is reached. At this state, the bubbles
suddenly collapse with a tremendous shock on the adjacent walls. This phenomenon is called cavitations.
HEADS OF A CENTRIFUGAL PUMP:
Suction head: It is the vertical height between the fluid level in the sump and the centre of the pump impeller.
Delivery head: It is the vertical height between the fluid level in the discharge tank and the centre of the pump
impeller.
Static head: It is the vertical height between fluid levels in the sump and the reservoir.

17
SINGLE ACTING RECIPROCATING PUMP

18
STUDY OF RECIPROCATING PUMP

AIM:
To study the constructional details and working of reciprocating pump.
DESCRIPTION:
The reciprocating pump is a positive displacement pump. It operates on the principle of actual
displacement or pushing of liquid by a piston or plunger that reciprocates in a closely fitting cylinder.The
reciprocating pumps are generally employed for light oil pumping, feeding small boiler condensate return and
pneumatic pressure systems.
Classification of reciprocating pump:
1. According to the fluid being in contact with piston or plunger

➢ Single acting pump
➢ Double acting pump.
2. According to the number of cylinders
➢ Single cylinder pump.
➢ Multi cylinder pump.
3. According to position of cylinders
➢ Horizontal pump
➢ Vertical pump
WORKING OF SINGLE ACTING RECIPROCATING PUMP:
This pump is said to be single acting since liquid acting on one side of the piston. A single acting pump has one
suction pipe and one delivery pipe. When the crank rotates the piston moves backward and forward inside the
cylinder. The pump operation can be described by two strokes, namely suction stroke and delivery stroke as
follows,
Suction stroke: Let us suppose that initially crank is at the inner dead centre (IDC) and crank rotates in
the clockwise direction. As the crank rotates, the piston move towards right and vacuum is created on the left
side of the piston. This vacuum causes suction valve to open and the liquid is drawn from the sump into the left
side of the piston. When the crank is at the outer dead centre (ODC), the suction stroke is completed and the left
side of the cylinder is full of fluid.
Delivery stroke: When the crank further moves from O.D.C to I.D.C, the piston moves inward to the
left and the high pressure is built up in the cylinder. The delivery valve is now opened and the liquid is forced
into the delivery pipe. At the end of delivery stroke, the crank comes to the I.D.C. and the piston is at the
extreme left position.

19
DOUBLE ACTING RECIPROCATING PUMP

20
WORKING OF DOUBLE ACTING RECIPROCATING PUMP:
In double acting pump fluid acts on both side of the piston. It has two suction pipes and two delivery
pipes. Each suction and delivery pipe has one corresponding valve. Here suction and delivery occurs
simultaneously. When the crank rotates from I.D.C. in clockwise direction, a vacuum is created on the left side
of the piston and the liquid is sucked from the pump through the suction valve open. At the same time, the
liquid in the right side of the piston is pressed and a high pressure causes the delivery valve to open and the
liquid is passed on to the discharge side. This operation continues till the crank reaches O.D.C.
With further rotation of the crank, the liquid is sucked from the sump through the suction valve open and
on the left side liquid is forced through the delivery valve opens. When the crank reaches I.D.C. the piston is in
the extreme left position. Thus one cycle is completed and as the crank further rotates, cycle is repeated.

21
PARTS OF IC ENGINE

22
STUDY OF INTERNAL COMBUSTION ENGINE

AIM:
To study the constructional details and working of internal combustion engine.
DESCRIPTION:
Internal combustion engine (IC engine) is a heat engine which converts the chemical energy of fuel into
mechanical energy. The chemical energy of fuel is first converted into thermal energy by means of combustion
or oxidation with air inside the engine. This thermal energy is again converted into useful work through
mechanical mechanism of the engine.
CONSTRUCTION DETAILS
• Cylinder: - It is a cylindrical vessel or space in which the piston makes a Reciprocating produces.
• Piston: - It is a cylindrical component fitted into the cylinder forming the moving boundary of combustion
system. It fits in cylinder perfectly.
• Combustion Chamber: - It is the space enclosed in the upper part of cylinder, by the cylinder head & the
piston top during combustion process.
• Inlet Manifold: - The pipe which connects the intake system to the inlet valve of engine.
• Exhaust Manifold: - The pipe which connects the exhaust system to the exhaust valve of engine.
• Inlet / Exhaust Valves: - They are provided on the cylinder head to head to regulate the charge coming into or
going out of the chamber.
• Spark Plug: - It is used to initiate the combustion process in S.I engines.
• Connected Rod: - It connects piston & the crank shaft.
• Crank Shaft: - It converts the reciprocating motion of the piston into useful rotary motion of output shaft.
• Gudgeon Pins: - It forms a link between connection rod and the piston.
• Cam Shaft: - It controls the opening & closing of the valves.
• Cam: - They open the valves at the correct tunes.
• Carburetor: - Used in S.I engine for atomizing & vaporizing and mixture it with air in varying proportion.
FOUR STROKE (S.I) ENGINE (Petrol)

In a four stroke engine, the cycles of operations is completed in 4 strokes of piston or 2 revolution of
crank shaft. Each stroke consists of 180° & hence the fuel cycle consists of 720° of crank rotation. The 4-
Strokes are:
• SUCTION OR INTAKE STROKE: - In starts at, when the piston is at top dead center &about to move
downwards. The inlet valve is open at that time and exhaust valve is closed due to suction created by the motion
of the piston, towards the bottom dead center, the charge containing air fuel mixture is drawn into the cylinder.
When the piston reaches BDC the suction stroke ends and inlet valve is closed.
• COMPRESSION STROKE: - The charge taken into the cylinder during suction stroke is compressed by
return stroke of piston. During this stroke both the valves are closed. The mixture which fills the entire cylinder
volume is now compressed into the clearance volume. At the end, the mixture is ignited with the help of
electrode of spark plug. During the burning process the chemical energy of fuel is converted to heat energy. The
pressure is increased in the end due to heat release.
• EXPANSION STROKE: The burnt gases escape out and the exhaust valve opens but inlet valve remaining
closed the piston moves from BDC to TDC and sweeps the burnt gases out at almost atmospheric pressure. The
exhaust valve gets closed at the end of this stroke.
• EXHAUST STROKE: - During the upward motion of the piston, the exhaust valve is open and inlet valve is
closed. The piston moves up in cylinder pushing out the burnt gases through the exhaust valve. As the piston
reaches the TDC, again the inlet valve opens and fresh charge is taken in during next downward movement of
the piston and the cycle is repeated.

23
FOUR STROKE CI ENGINES (Diesel)

24
FOUR STROKE CI ENGINES (Diesel)
In four strokes C.I. Engine compression ratio is from 16 to 20. During suction stroke air is inducted. In
C.I. engines high pressure. Fuel pump and injectors are provided to inject the fuel into combustion chamber and
ignition chamber system is not necessary.
➢ SUCTION: - During suction stroke, air is inducted through inlet valve.
➢ COMPRESSION: - The air inducted is compressed into the clearance volume.
➢ EXPANSION: - Fuel injection starts nearly at the end of the compression stroke. The rate of injection is
such that the combustion maintains the pressure constant inspired of piston movement on its expansion
stroke increasing the volume. After injection of fuel, the products of combustion chamber expand.
➢ EXHAUST: - The piston traveling from BDC to TDC pushes out the products of combustion out of
cylinder.

25
BASIC REFRIGERATION CYCLE

26
STUDY OF REFRIGERATION AND AIRCONDITIONING SYSTEM

AIM:
To study about Refrigeration and Air conditioning system.
DESCRIPTION:
Refrigeration is the process of maintaining a system at a temperature below the temperature of its
surroundings. It can be accomplished by removing heat from the system. For example the household
refrigerator absorbs heat from the food products and releases this heat into the room where it is kept and thus a
constant temperature is maintained inside the refrigerator cabinet. The working fluid used in a refrigerating
system is known as refrigerant. The application of refrigeration can be broadly classified into three groups as,
I. Industrial processes which includes processing of food stuffs, farm crops, photographic materials,
petroleum and other chemical products etc.
II. Preservation of perishable goods which includes storage and transportation of food stuffs.
III. Providing confortable environment which includes comfort air conditioning of residences, hospitals,
theatres, offices etc.
VAPOUR COMPRESSION SYSTEM:

In Vapour compression refrigerator the working fluid is a Vapour which readily evaporates and
condenses. During the evaporation process it absorbs heat gets converted from liquid to Vapour. During the
condensing process it rejects heat and gets converted from Vapour to liquid. A simple Vapour compression
system of refrigeration consists of the following basic components.
1. Compressor. 2. Condenser.
3. Expansion valve. 4. Evaporator.
DOMESTIC REFRIGERATOR:
A domestic refrigerator consists of the following four basic components,
1) Evaporator.
2) Compressor.
3) Condenser and
4) Expansion device (Capillary tube).
Evaporator: - It is the equipment in which liquid refrigerant evaporates. In a typical refrigerator it is located in
the freezer compartment of the refrigerator. The latent heat of vaporization is absorbed from the refrigerator
cabinet. Thus the liquid refrigerant entering the evaporator leaves the evaporator as a Vapour.
Compressor: - The low pressure Vapour leaving the evaporator enters the compressor where the pressure
Vapour is increased. The pressure is increased to enable the refrigerant to condense and to release the heat in the
condenser. This high pressure Vapour enters the condenser.

27
AIR CONDITIONER

28
Condenser: - The equipment used to convert the refrigerant Vapour to liquid is called condenser. It is usually a
wire and tube type mounted at the back of the refrigerator. The refrigerant Vapour is condensed by releasing
latent heat of condensation to the surrounding air. The heat absorbed by the refrigerant while passing through
the Vapour is released in the condenser. This liquid refrigerant leaving the condenser enters the expansion
device.
Expansion device: -The high pressure of liquid refrigerant is reduced to the low pressure of evaporator by
passing through a pressure reducing device is called expansion device. The low pressure refrigerant leaving the
capillary tube is used as the expansion device. The low pressure refrigerant leaving the capillary tube enters the
evaporator and thus one cycle of operation is completed.
AIR CONDITIONING:
The science of air conditioning deals with supplying and maintaining a desired internal atmospheric
condition irrespective of external conditions. This involves the simultaneous control of air purity, air motion,
temperature and humidity of the air inside an enclosed space. The condition to be maintained is dictated by the
need for which the conditioned space is intended.
Air conditioning applications are two types: comfort and industrial. Any air conditioning application
having the primary intention of human health and comfort is called comfort air conditioning. Any air
conditioning which is not primarily meant for human comfort is industrial air conditioning. Basically, the
equipment and process involved in both types of air conditioning is the same. The difference lies in the required
inside conditions.
WINDOW AIR CONDITIONING:

A window air conditioner consists of a case divided into two parts, outdoor and indoor parts, by a
partition. The outdoor part consists of compressor, condenser, and a fan. The indoor part consists of evaporator
and a fan. Capillary tube is provided in between the condenser and evaporator. The outdoor portion remains
outside the window sill. Dampers are provided at the front of indoor portion for changing the direction of air
flow. Low pressure Vapour drawn from the evaporator is compressed to a high pressure and is delivered to the
condenser. In the condenser the refrigerant Vapour is condensed by releasing latent heat oil condensation to the
surrounding air. This hot air is driven out using a fan. The high pressure liquid refrigerant enters the capillary
tube where the pressure is reduced. This low pressure liquid Vapour enters the evaporator. This liquid
refrigerant evaporators by absorbing latent heat of vaporization from the surrounding air. This cold air is
delivered to the room using a fan. The direction of air flow can be changed using a damper. The low pressure
refrigerant Vapour leaving the evaporator is sucked into the compressor and is compressed to very high
pressure. This high pressure Vapour is condensed in the condenser. Thus one cycle of operation is completed.

29
OBSERVATIONS:
Value of 1 main scale division = 1mm
Number of divisions on vernier scale = 50
Value of 1 main scale division
LEAST COUNT = Number of divisions on vernier scale
= 1/50
= 0.02mm
TABULATION:
TR
MSR VSR AVERAGE
SL.NO ITEM MSR+(VSR x LC)
(mm) (div) (mm)
(mm)
1
External
2
diameter (D)
3
1
Internal
2
Diameter (d)
3
2 Height (h)
External radius (R) = D/2 =
Internal radius (r) = d/2 =
Height (h) =
Volume of hollow cylinder (V) = 𝜋ℎ(𝑅2 - r2)

=

30
Expt. No: 01
Date:
CALIBRATION OF VERNIER CALIPER
AIM:
To study and calibrate the Vernier caliper.
APPARATUS REQUIRED:
Vernier caliper, Steel rule.
PRINCIPLE:
Value of 1 main scale division

Least count =
Number of divisions on vernier scale
Total reading = MSR + (VSR x LC)

Volume of hollow cylinder (V) = 𝜋ℎ(𝑅2 - r2)
PROCEDURE:
➢ The least count of the apparatus is determined.
➢ The apparatus is then checked to find the zero correction, if any.
➢ The two jaws are kept in correct. If the zero of the main scale coincides with the zero of the vernier,
there is no zero error.
➢ If the zero of the vernier is on to the right of main scale zero, it is a case of positive zero error and the
zero correction is negative, if zero of vernier is on to the left of main scale zero, zero error is negative
and zero correction is positive.
➢ Now the work piece is gently gripped in between the jaws, and finds the various dimensions.
➢ The reading of the main scale just before the zero of the vernier is noted as the MSR. The vernier scale
division coinciding with any division on the main scale is noted as the VSR.
➢ Now the total reading is calculated using the formula.
➢ Repeated the same procedure to measure the various parameters like length, outside diameter, inside
diameter and depth etc.
➢ All the readings are tabulated correctly.
RESULT:
The precision measuring instruments are studied and calibrated.

31
OBSERVATIONS:
Pitch = distance moved for 1 rotation
Number of division on the head scale = 50
pitch
LEAST COUNT =
Number of division on the head scale
= 1/50 = 0.02mm
Zero correction =
TABULATION:
Observed Corrected TR
PSR AVERAGE
SL.NO HSR HSR PSR + (HSRCR x LC)
(mm) (mm) (mm)
(div) (div)
1
Length of the specimen (L) =
Width of the specimen (W) =
Thickness of the specimen (T) =
Volume of the specimen (V) = LxWxT =

32
Expt. No: 02
Date:
CALIBRATION OF MICROMETER
AIM:
To study and calibrate the Micro meter.
APPARATUS REQUIRED:
Micrometer, Steel rule.
PRINCIPLE:
Pitch = distance moved for 1 rotation
Number of division on the head scale = 50
pitch
LEAST COUNT =
Number of division on the head scale
= 1/50 = 0.02mm
Total reading = PSR + (HSRCR x LC)
Volume of the specimen (V) = LxWxT
PROCEDURE:
➢ The apparatus is first all checked to find the zero correction if any.
➢ The screw is tightened without keeping any object in between the screw tip and stud.
➢ If the zero of the head scale coincides with the reference line, there is no zero error. No correction is
needed in such case. But if the zero of the head scale is above the index line, zero correction is positive.
If the zero of the head scale is below the reference line the zero correction is negative.
➢ The pitch of the screw is then found out. For this, the screw is rotated 4 times and the distance moved by
the screw due to one rotation is calculated. Now, the number of division on the vernier is noted and the
least count is calculated.
➢ The work piece is gently gripped in between the screw tip and the stud.
➢ The last fully visible reading on the pitch scale is noted as the pitch scale reading.
➢ The reading of the head scale against the reference line is noted as the HSR. The zero correction is
accounted with this HSR and correct HSR is calculated. Now the total reading is calculated using the
formula.
➢ Repeated the same procedure to measure the various parameters like length, outside diameter, inside
diameter and depth etc.
RESULT:

33
TABULATION:
MSR VSR TR ERROR

SL.NO WORK PIECE
(mm) (div) (mm) (mm)

34
Expt. No: 03
Date:
CALIBRATION OF VERNIER DEPTH GAUGE
AIM:
To study and calibrate the Vernier depth gauge.
APPARATUS REQUIRED:
Surface plate, Vernier depth gauge, Steel rule.
MATERIAL REQUIRED:
PRINCIPLE:
Least count = 1 Main scale division – 1 Vernier scale division.

= 1 – 9 / 10 = 0.1mm
In 0.02 mm L.C vernier caliper, 49 m.s.d is divided into 50 v.s.d
LC = 1 – 49 / 50 = 0.02 mm
In 0.05 mm L.C vernier caliper, 19 m.s.d is divided is divided into 20 v.s.d.
LC = 1 – 19 / 20 = 0.05mm
PROCEDURE:
➢ The least count of the apparatus is determined.

➢ The apparatus is then checked to find the zero correction, if any.
➢ Select the plane which is measure.
➢ Tighten the clamping screw and check the fine adjustment mechanism.
➢ Find the various dimensions and note the VSR & MSR readings.
➢ Now the total readings are calculated using the formula.
➢ Repeated the same procedure to measure the various parameters like holes, slots, etc.
RESULT:

35
BRAZING

36
Expt. No: 04
Date:
BRAZING PRACTICE
AIM:
Joint the given copper rod use brazing.
APPARATUS REQUIRED:
Swaging tool set, Ball peen hammer, Blow lamp, Tongs, Steel rule, Combination player.
MATERIAL REQUIRED:
Copper tube of diameter 10 mm.
PROCEDURE:
➢ Swage the copper rod at required dimension as given.

➢ Clean the outer and inner surfaces and the joint using sand paper and wire brush.
➢ Apply the thin coat of flux to outside of the joint as required.
➢ Insert one piece of tube into the swaged tube and make a joint properly.
➢ Keep the joint vertically on the sand bricks and clamp the joint if required.
➢ Light the blow lamp properly for brazing before starting the job.
➢ Heat up the joint properly; keep the safe distance by blow lamp.
➢ After making at fine layer of solder on the joint then allowed to cool.
➢ After cooling the assembly and heat the connector to 10.5 kg/cm2 pressure.
➢ Submit for inspection.
RESULT:
Jointed the given copper pipe using Brazing.

37
SOLDERING

38
Expt. No: 05
Date:
SOLDERING PRACTICE
AIM:
Joint the given sheet use brazing.
APPARATUS REQUIRED:
Soldering iron of 230V, Steel rule, combination player

.
MATERIAL REQUIRED:
Wires, sand paper, cotton cloth, solder (lead & paste).
PROCEDURE:
➢ Select a 60W, 230V AC 50Hz soldering iron and ensure that that the iron has no physical damage, the
body is well insulated from the elements and is of the correct voltage and power rating.
➢ Check the bit to see whether the surface is smooth and clean.
➢ If found corroded, file the tip with flat file, so that the surface is clean and smooth.
➢ Connect the soldering iron to the supply and switch ON
➢ When the bit becomes sufficiently hot, apply a small quantity of rosin-cored solder and tin the bit.
➢ Wipe the bit gently on the cleaning pad to remove excess solder.
➢ Clean the joint to be soldered with the help of sand paper and wipe the dust with wire brush.
➢ Keep the soldering iron bit on the joint and heat it for soldering.
➢ When the joint is heated keep the rosin-cored solder on the joint and allow it to melt.
➢ Yet the solder with the heat of the bit and make sure the solder flows freely and evenly on the joint.
➢ Remove the soldering iron use cotton cloth on wipe off the excess solder from the surface of the joint
when it is still hot.
➢ Allow all joint to cool naturally.
➢ Clean and submit the work for inspection.
RESULT:
Jointed the given wire by using soldering.

39

40
Expt. No: 06
Date:
PLUMBING PRACTICE
AIM:
To prepare a structure using various types of pipes and pipe fittings.
TOOLS &APPARATUS REQUIRED:
Various pipe fittings, different sizes of pipes, Pipe wrench, Pipe cutter.
PROCEDURE:
➢ To study the given drawing carefully.

➢ To arrange all the tools for the given work.
➢ To collect all suitable pipes and pipefittings as per the drawing.
➢ To mark and measure the given pipe as per the drawing.
➢ Cut the pipes to the required length.
➢ To fit the pipes with suitable fittings by using proper tools and equipment’s with the drawing.
➢ To finish the neatly and correctly.
➢ Submit the work for inspection.
RESULT:
The structure is prepared as per the given drawing.

41
VISION OF THE INSTITUTE
To create new ideas and innovators in engineering technology and train the
students professionally for the new challenging industry.
MISSION OF THE INSTITUTE
To Generate New Engineering knowledge in community and promote academic

self-growth for the students and society.

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LAB MANUAL

DEPARTMENT OF MECHANICAL ENGINEERING

To Develop the Mechanical Engineering Department as a center of excellence providing

MISSION OF THE DEPARTMENT

To provide high-quality education in the fields of Mechanical Engineering through cutting-

PROGRAM EDUCATIONAL OBJECTIVES (PEOS)

For Diploma Mechanical Engineering

DEPARTMENT OF MECHANICAL ENGINEERING

MA’DIN POLYTECHNIC COLLEGE 3

TOPICS PAGE NO.

STUDY OF PRECISION MEASURING INSTRUMENTS 03

STUDY OF VARIOUS PLUMBING TOOLS 07

STUDY OF METAL JOINING PROCESS 11

STUDY OF CENTRIFUGAL PUMP 15

STUDY OF RECIPROCATING PUMP 19

STUDY OF INTERNAL COMBUSTION ENGINE 23

STUDY OF REFRIGERATION & AIR CONDITIONING

CALIBRATION OF VERNIER CALIPER 31

CALIBRATION OF VERNIER DEPTH GAUGE 35

JITHESH NP HOS 9061414555;

VIPIN. V. P LECTURER 9020055676

PRAVEEN. K. P LECTURER 9037834487

ANAND R LECTURER 9633915305

SANJAY K LECTURER 9633593219

NABEEL N WORKSHOP SUPERINTENDENT 9656844140

SUJITH. N W\I 9946012928

➢ Students must come prepared with the experiment.

in-charge before leaving the laboratory.

➢ The application and removal of the load must be gradual.

MA’DIN POLYTECHNIC COLLEGE

MA’DIN POLYTECHNIC COLLEGE

STUDY O PRECISION MEASURING INSTRUMENTS

Least count = 1 Main scale division – 1 Vernier scale division.

1 division on main scale = 1mm

No. of divisions on vernier scale = 50

50 vernier scale divisions = 49 divisions on main scale (49mm)

1 Vernier scale division = 49/50

Least count = 1- (49/50)

OUT SIDE MICROMETER

VERNIER DEPTH GAUGE

MA’DIN POLYTECHNIC COLLEGE

The parts of external micrometer are,

It consists of the following parts

a) Base. d) Fine Adjustment Mechanism.

➢ Zero error of vernier depth gauge must be checked before use.

MA’DIN POLYTECHNIC COLLEGE

PIPE WRENCH PIPE CUTTER

PIPE BENDING MACHINE

CHAIN PIPE WRENCH

STUDY OF VARIOUS PLUMBING TOOLS

According to material used:

- Galvanized iron pipes - Brass pipes.

MA’DIN POLYTECHNIC COLLEGE

900 ELBOW 450 ELBOW TEE

REDUCING TEE CROSS LATERAL 450

EXPANSION JOINT UNION PLUG

DEAD END COUPLING REDUCER

LONG NIPPLE SHORT NIPPLE CLOSE NIPPLE

MA’DIN POLYTECHNIC COLLEGE