Department of Mechanical Engineering

Laboratory Worksheets

23MEE115 Manufacturing Practise Lab

Name of the Student:

Registration Number:
 LIST OF EXPERIMENTS

S. No. Name of the Experiment Page No.

I Additive Manufacturing Lab: 3-10

1 Demonstration of the 3D printing process of a prototype 3-6

2 3D printing of a prototype using fused deposition modelling 7-10

II Mechanical Engineering Lab: 11-22

3 Welding of a butt joint in the welding workshop 11-14

4 Welding of a Lap joint in the welding workshop 15-18

5 Soldering a Tee joint in a soldering workshop 19-22

III Automation Lab: 23-34

6 Design and simulation of pneumatic circuit for automation application 23-26

Design of Electro Pneumatics Circuits with Single Acting and Double Acting
7 28-31
Cylinders

8 Introduction to Programmable Logic Control (PLC) 32-34

IV Automobile Engineering Lab: 35-40

Demonstrate the working of various subsystems of automobiles namely the
9 Power train, Steering system, Suspension system and Braking system.
35-37

10 Demonstrate the working of (a) electric vehicles and (b) hybrid vehicles 38-40

2
 Department of Mechanical Engineering

23MEE115 Manufacturing Practice

Title of Experiment: Demonstration of the 3D printing process of a
prototype
Name of the Student

Registration Number

Due Date of Submission: Date of Submission:

Assessment Rubrics

Description Marks Marks

Allotted Secured
Machine Specifications 10
Process Flow Chart of 3D Printing 10
Slicing Process 10
Open-ended Questions 10
Viva Voce 10
Late Submission/Plagiarism Mark Deduction -
Total Marks 50

Signature of Lab in-charge

3
 Experiment 01

DEMONSTRATION OF THE 3D PRINTING PROCESS OF A PROTOTYPE

1. Objectives
- To understand the 3D Printing Technology.
- To generate G-Codes through slicing software.
- To demonstrate the 3D printing of a prototype using a 3D printing machine.

2. Machine Specifications
(Write down the machine specifications of the FDM Machine used for 3D printing)
A) Make:
B) Build Size:
C) Dimensions:
D) Nozzle Diameter:
E) Print speed:
F) Materials:
G) Slicing software used:
H) Underlying Technology/Process:

3. Process Flow Chart of 3D Printing

(Draw the process flow chart of the 3D printing process)

4
4. Slicing Process: (Write down the parameter settings carried out for printing)

5. Open-Ended/Viva Questions
a) Why part orientation is important in AM process? When support structures are needed?

b) Name a few materials used for the FDM process.

c) Name a few file formats compatible with AM machines. What does .stl stands for?

d) In FDM, if the weight of the product needs to be changed, what measures will be taken?

e) As per ASTM F42, write down the classification of AM processes?

f) What is the slicing of the CAD model in terms of AM process?

5
g) Name a few modern applications of AM process.

h) Name an AM process in which liquid material is converted into solid material.

i) As per ASTM standard, under which category of AM process does the SLA fall?

j) What is staircase error?

6
 Department of Mechanical Engineering

23MEE115 Manufacturing Practice

Title of Experiment: 3D PRINTING OF A PROTOTYPE USING
FUSED DEPOSITION MODELING

Name of the Student

Registration Number

Due Date of Submission: Date of Submission:

Assessment Rubrics

Description Marks Marks

Allotted Secured
Machine Specifications 05
CAD Model (Technical correctness, the complexity
15
of the model, commands used, etc)
Slicing Process (Parameters settings) 15
Open-ended questions 05
Viva Voce 10
Late Submission/Plagiarism Mark Deduction -
Total Marks 50

Signature of Lab in-charge

7
 Exercise – 02

3D PRINTING OF A PROTOTYPE USING FUSED DEPOSITION

MODELING
1. Objective
To print a self-designed CAD model prototype by Fused Deposition Modeling
(FDM).

2. Machine Specifications
(Write down the machine specifications of the FDM Machine used for 3D printing)
A) Make:
B) Build Size:
C) Dimensions:
D) Nozzle Diameter:
E) Print speed:
F) Materials:
G) Slicing software used:
H) Underlying Technology/Process:

3. CAD Model Details (Draw the CAD model with details of all the dimensions)

8
4. Slicing Process (Write down the parameter settings carried out for printing the model)

5. Open-ended Questions
a) A part is fabricated using the FDM process. Calculate the number of layers in a part having
a height of 72 mm built with a layer thickness of 0.04 mm.

b) What is the effect inside the built part if

(i) more hatch spacing

(ii) less hatch spacing

9
c) What will be the effect on the part made in SLA, if post-processing is not carried out?

d) Will scan pattern has an effect on part distortion in the FDM process?

e) A hollow cylinder needs to be manufactured using FDM process. What are the pre-
processing steps to be taken care before starting the fabrication?

10
 Department of Mechanical Engineering

23MEE115 Manufacturing Practice Lab

Title of Experiment: Welding of a butt joint in the welding workshop

Name of the Student

Registration Number

Due Date of Submission: Date of Submission:

Assessment Rubrics
Description Mark Allotted Mark Secured
Objectives, Apparatus required, Procedure 5
Final product (Based on final finish/ completion of
work, use of appropriate tools/equipment, following 35
safety precautions)
Answers to Open Ended/Viva Questions 5
Viva voce 5
Late Submission / Plagiarism Mark Deduction -
Total Marks 50

Signature of Lab in-charge

11
 EXERCISE – 03

Welding of a butt joint in the welding workshop

1. Objectives
To do a butt joint by welding as given in the drawing.
Butt Joint

2. Apparatus Used (List out the tools required to finish the product)

3. Procedure followed (Write in your own words the sequence of operations involved)

12
4. Result

5. Open-Ended/Viva Questions

1. List the different types of arc welding process?

2. What is the minimum Arc-gap should be maintained between electrode and work piece
for existence of arc?

13
3. Differentiate between gas welding and arc welding.

4. Is welding a permanent or temporary fastening method. Mention different types of

welding process.

5. What is the minimum amount of current and voltage required for arc welding circuit?

6. What type of Transformer used in AC arc welding process? What is the main function
of that transformer?

14
 Department of Mechanical Engineering

23MEE115 Manufacturing Practice Lab

Title of Experiment: Welding of a Lap joint in the welding workshop

Name of the Student

Registration Number

Due Date of Submission: Date of Submission:

Assessment Rubrics
Description Mark Allotted Mark Secured
Objectives, Apparatus required, Procedure 5
Final product (Based on final finish/ completion of
work, use of appropriate tools/equipment, following 35
safety precautions)
Answers to Open-Ended/Viva Questions 5
Viva voce 5
Late Submission / Plagiarism Mark Deduction -
Total Marks 50

Signature of Lab in-charge

15
 EXERCISE – 04

Welding of a Lap joint in the welding workshop

1. Objectives
To do Lap joint by welding as given in the drawing.

2. Apparatus Used (List out the tools required to finish the product)

3. Procedure followed (Write in your own words the sequence of operations involved)

16
4. Result

5. Open-Ended/Viva Questions

1. What is oxidation and how it can be prevented?

2. What is the difference between electrode and filler metal?

3. Define Temporary joining process and give example.

17
4. Differentiate between consumable electrode and non-consumable electrode.

5. What are the defects that will result if flux is not used in welding?

6. Amount of arc length required between electrode work pieces.

18
 Department of Mechanical Engineering

23MEE115 Manufacturing Practice Lab

Title of Experiment: Soldering a Tee joint in soldering workshop

Name of the Student

Registration Number

Due Date of Submission: Date of Submission:

Assessment Rubrics
Description Mark Allotted Mark Secured
Objectives, Apparatus required, Procedure 5
Final product (Based on final finish/ completion of
work, use of appropriate tools/equipment, following 35
safety precautions)
Answers to Open Ended/Viva Questions 5
Viva voce 5
Late Submission / Plagiarism Mark Deduction -
Total Marks 50

Signature of Lab in-charge

19
 EXERCISE – 05

Soldering a Tee joint in a soldering workshop

1. Objectives
Solder a Tee joint with the given copper windings

2. Apparatus Used (List out the tools required to finish the product)

3. Procedure followed (Write in your own words the sequence of operations involved)

20
4. Result

5. Open-Ended/Viva Questions

1. What is soldering? State some of its advantages.

2. How hot should a soldering iron be in order to solder leaded solder (temperature
range)?

3. Name the three types of solder and which type of solder is mainly preferred for
electronics?
21
4. State the reasons for using soldering flux in soldering technique.

5. Differentiate between soldering and brazing.

6. What are the common applications of soldering?

22
 Department of Mechanical Engineering

23MEE115 Manufacturing Practice Lab

Title of the Experiment: Design and simulation of pneumatic circuit for

automation application

Name of the Student

Registration Number

Due Date of Submission: Date of Submission:

Assessment Rubrics
Mark
Description Mark Allotted
Secured
Diagram, Tabulation 10
Lab conduction & adherence to the safety practices 15
Calculations, Graphs, Results 15
Answers to Open-Ended Questions & Viva-voce 10
Late Submission/Plagiarism Mark Deduction -
Total Marks 50

Signature of Lab in-charge

23
 Exercise – 06
Design and simulation of pneumatic circuit for automation application
1. Objectives
For the given pneumatic circuit for automation application:
(i) Identify the main pneumatic components and their function
(ii) Demonstrate the working of the circuit using the pneumatic kit

Double-acting cylinder for automation application

2. Components/Tools Required
(List out the various pneumatic component and tools required for this exercise)

3. Symbols of the Pneumatic Components

24
 (List out various pneumatic components used in this circuit. Draw their symbols and mention
their functions)
Sl. No. Name of the Symbol Function
pneumatic component

25
4. Demonstrate the working of the above-mentioned pneumatic circuit
(Using the pneumatic circuit assemble the component and demonstrate the above-mentioned
circuit)

5. Open-Ended/Viva Questions
1. Which system (hydraulic or pneumatic) has been used for opening/closing the door
for the MTC bus?

2. When you prefer a pneumatic system over a hydraulic system. Write your opinion.

3. Which pneumatic element is more suitable for reducing the noise generated during
the exhaust of air from the cylinder?

26
4. For the given applications, which system (hydraulic or pneumatic) is being used?

27
 Department of Mechanical Engineering

23MEE115 Manufacturing Practice Lab

Title of the Experiment: Design of Electro Pneumatics Circuits with Single

Acting and Double Acting Cylinders

Name of the Student

Registration Number

Due Date of Submission: Date of Submission:

Assessment Rubrics
Mark
Description Mark Allotted
Secured
Diagram, Tabulation 10
Lab conduction & adherence to the safety practices 15
Calculations, Graphs, Results 15
Answers to Open-Ended Questions & Viva-voce 10
Late Submission/Plagiarism Mark Deduction -
Total Marks 50

Signature of Lab in-charge

28
 EXERCISE – 07

Design of electro pneumatics circuits with single-acting and double-acting

cylinders

1. Objectives
(i) A single-acting cylinder is to be moved forward when a push button valve is pressed. On
releasing this push button valve the cylinder retracts to the home position.

(ii) A large diameter double-acting cylinder is to move downward when a push switch is
pressed and released. When another push switch is pressed and released the cylinder must
retract home position immediately.

2. Apparatus Used
(Note down the list of apparatus used in the experiment)

29
3. Circuit diagram

30
1. Result

5. Open-Ended Questions
1. You are operating an automation circuit in the industry, suddenly you noticed the pressure
inside has been increased what will be the action you will take

2. How it is possible to improve the control system of the stand for the study of the
pneumatic apparatus sowing process?

3. Summarize the main difference between an open-loop and closed-loop fluid power
system.

31
 Department of Mechanical Engineering

23MEE115 Manufacturing Practice Lab

Title of the Experiment: Introduction to Programmable Logic Control

(PLC)

Name of the Student

Registration Number

Due Date of Submission: Date of Submission:

Assessment Rubrics
Mark
Description Mark Allotted
Secured
Diagram, Tabulation 10
Lab conduction & adherence to the safety practices 15
Calculations, Graphs, Results 15
Answers to Open-Ended Questions & Viva-voce 10
Late Submission/Plagiarism Mark Deduction -
Total Marks 50

Signature of Lab in-charge

32
 EXERCISE – 08

Introduction to Programmable Logic Control (PLC)

1. Objectives

2. Apparatus Used
(Note down the list of apparatus used in the experiment)

3. Ladder diagram:

33
2. Result

5. Open-Ended Questions
1. What are the types of PLC?

2. What are the different parts of automation?

3. How can we implement PLC automation in different industries?

34
 Department of Mechanical Engineering

23MEE115 Manufacturing Practice Lab

Title of the Experiment: Demonstrate the working of various subsystems of

automobiles namely Power train, Steering system, Suspension system and
Braking system.

Name of the Student

Registration Number

Due Date of Submission: Date of Submission:

Assessment Rubrics
Mark
Description Mark Allotted
Secured
Diagram, Tabulation 10
Lab conduction & adherence to the safety practices 15
Calculations, Graphs, Results 15
Answers to Open-Ended Questions & Viva-voce 10
Late Submission/Plagiarism Mark Deduction -
Total Marks 50

Signature of Lab in-charge

35
 EXERCISE – 09

Demonstrate the working of various subsystems of automobiles namely

Power train, Steering system, Suspension system and Braking system.

1. Identify the parts and component groups.

2. Fill in the table with the correct part and its function.
Component group name Part name Function
Wheel Assembly
Suspension System
Steering System
Lighting & Infotainment
System
Braking System

36
3. Identify the numbered drivetrain subsystems in the table and fill in their functions.

Number Labels Subsystem Function

1
2
3
4
5
6
7
8

4. In the picture, fill in the vehicle material flow for air, fuel and exhaust and the energy flow.

37
 Department of Mechanical Engineering

23MEE115 Manufacturing Practice Lab

Title of the Experiment: Demonstrate the working of (a) electric vehicles and
(b) hybrid vehicles

Name of the Student

Registration Number

Due Date of Submission: Date of Submission:

Assessment Rubrics
Mark
Description Mark Allotted
Secured
Diagram, Tabulation 10
Lab conduction & adherence to the safety practices 15
Calculations, Graphs, Results 15
Answers to Open-Ended Questions & Viva-voce 10
Late Submission/Plagiarism Mark Deduction -
Total Marks 50

Signature of Lab in-charge

38
 EXERCISE – 10

Demonstrate the working of (a) electric vehicles and (b) hybrid vehicles.

1. Identify the parts of the EV and fill in the below table based on the given image:

Part Number Part Name Function

1
2
3
4
5
6
7
8
9

39
2. Fill the table based on the given hybrid vehicle layouts.

Image number Type of Hybrid Description

A
B
C
D

40