DEPARTMENT OF

MECHANICAL ENGINEERING

MANIPAL UNIVERSITY JAIPUR

JAIPUR

1ST YEAR ENGINEERING

BASIC WORKSHOP PRACTICE

LABORATORY RECORD

NAME: ___________________

BATCH: __________________

ROLL NO: _______________

REGISTER NUMBER: ______________________

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 BASIC WORKSHOP PRACTICE ME1130
INDEX PAGE

BATCH NO: ________ ROLL NO: ________

1. Introduction: Basic workshop experiments, tools, machines and applications of

processes.

2. Machine shop (A): Study of parts of lathe machine and lathe operations.

3. Machine shop (B): Facing, Turning, Taper Turning and knurling on MS cylindrical
work piece.

4. Foundry shop (A): Study different types of moulding processes and various tools use
for foundry processes.

5. Foundry shop (B): Prepare a green sand mould and demonstration of casting with
molten aluminum.

6. Welding shop (A): Study of types of welding process and applications of welding
process.

7. Welding shop (B): Welding of different types of joint on MS plate with arc welding
process.

8. Carpentry shop (A): Cut and prepare “T halving joint part A” *.

9. Carpentry shop (B): Cut and prepare “T halving joint part B” *.

10. Fitting shop (A): Cut and prepare mild steel square part and make all the edges at 90
degree*.

11. Fitting shop (B): Cut a 10x10 mm Notch on the mild steel Piece and make all the
edges of notch at 90 degree *.

12. Soldering shop (A): Cut and Prepare part A of the funnel *.

13. Soldering shop (B): Cut and Prepare part B of the funnel *.

14. Plumbing shop: Cut PVC pipe ‘work piece’ and prepare thread on it.

*Find all drawings of parts A and B on the workshop board.

Extended- Advanced Experiments

1. To cut and prepare a T-halving joint using power jigsaw, power wood planer and
power hand held circular saw.

2. To perform a PVC pipe cutting operation using power metal off grinder tool.

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 Lathe Machine Shop
Experiment no: 1 Date:

AIM:

To prepare a job on lathe involving facing, outside turning, taper turning, step turning,
knurling and parting off on given mild steel piece.

Tools required: Single point cutting tool, parting tool, knurling tool.

Material required: Mild steel rod (Diameter 32mm)

Instruments required: Steel rule, vernier caliper, outside caliper.

Procedure:

1. Job is fixed in three jaw chuck for proper alignment.

2. Single point cutting tool is fixed in the tool post and facing operation is completed.
3. A rough cut is used to turn the outer periphery.
4. Final turning and step turning operation are completed in sequence.
5. The compound slide is set at the taper angle as per calculation with the center line
and tapering operation is completed through different cuts.
6. Knurling tool is fixed in tool post for knurling operation.
7. For maintaining the proper length of the job parting off tool is used and parting
operation is completed.

Precautions:

1. Work piece should be firmly gripped in the three jaw chuck.

2. Coolant is to be used.
3. Hand gloves and apron must be used while working.
4. Proper rpm should be selected before the operation.

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 Drawing:

Φ 27
Φ 15

Φ 20 Φ 30

20 5 10 15 10

Dimensions are in mm

Conclusion:

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 Foundry Shop
Experiment no: 2 Date:

AIM:
To prepare green sand mould for split pattern and perform casting process.

Tools required: Gate cutter, swab, trowel, vent rod, draw spike, strike off bar, wooden
pattern T joint, sprue and runner, cope and drag moulding box.
Material required: Green Sand, baking sand, parting sand
Machine required: Induction furnace
Procedure:

1. Initially a suitable size of molding box for creating suitable wall thickness is
selected for a two piece pattern. Sufficient care should also be taken in such that
sense that the molding box must adjust mold cavity, riser and the gating system
(sprue, runner and gates etc.).
2. Next, place the drag portion of the pattern with the parting surface down on the
bottom (ram-up) board as shown in following figures.
3. The facing sand is then sprinkled carefully all around the pattern so that the pattern
does not stick with molding sand during withdrawn of the pattern.
4. The drag is then filled with loose prepared molding sand and ramming of the
molding sand is done uniformly in the molding box around the pattern. Fill the
molding sand once again and then perform ramming. Repeat the process three four
times,
5. The excess amount of sand is then removed using strike off bar to bring molding
sand at the same level of the molding flask height to completes the drag.
6. The drag is then rolled over and the parting sand is sprinkled over on the top of the
drag.
7. Now the cope pattern is placed on the drag pattern and alignment is done using
dowel pins.
8. Then cope (flask) is placed over the rammed drag and the parting sand is sprinkled
all around the cope pattern.

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9. Sprue and riser pins are placed in vertically position at suitable locations using
support of molding sand. It will help to form suitable sized cavities for pouring
molten metal etc.
10. The gaggers in the cope are set at suitable locations if necessary. They should not be
located too close to the pattern or mold cavity otherwise they may chill the casting
and fill the cope with molding sand and ram uniformly.
11. Strike off the excess sand from the top of the cope.
12. Remove sprue and riser pins and create vent holes in the cope with a vent wire. The
basic purpose of vent creating vent holes in cope is to permit the escape of gases
generated during pouring and solidification of the casting.
13. Sprinkle parting sand over the top of the cope surface and roll over the cope on the
bottom board.
14. Rap and remove both the cope and drag patterns and repair the mold suitably if
needed and dressing is applied
15. The gate is then cut connecting the lower base of sprue basin with runner and then
the mold cavity.
16. Apply mold coating with a swab and bake the mold in case of a dry sand mold.
17. Set the cores in the mold, if needed and close the mold by inverting cope over drag.
18. The cope is then clamped with drag and the mold is ready for pouring.

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Precautions:

1. Care should be taken while ramming sand in cope and drag boxes.
2. Molten aluminum should be poured with extra care with proper ladle and tong.

Conclusion:

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 Arc Welding Shop-1
Experiment no: 3 Date:

AIM:
To prepare a Butt joint on given MS plate piece with the help of arc welding process.

Tools required:
1. Rough and smooth files.
2. Protractor
3. Arc welding machine (transformer type)
4. Mild steel electrode and electrode holder
5. Ground clamp
6. Tongs
7. Face shield
8. Apron
9. Chipping hammer.
Material required: Mild steel plate of size 30X50X6 mm – 2 No’s, M.S electrodes 3.1
mm X350 mm
Welding Equipment: Air cooled transformer Voltage-80 to 600 V 3 phase supply, amps up
to 350
Sequence of operations:
1. Marking
2. Cutting
3. Edge preparation (Removal of rust, scale etc.) by filling
4. Try square leveling
5. Tacking
6. Welding
7. Cooling 8. Chipping
8. Cleaning
Procedure:

1. The given M.S pieces are thoroughly cleaned of rust and scale.
2. One edge of each piece is believed, to an angle of 300 , leaving nearly ¼ th of the
flat thickness, at one end.
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 3. The two pieces are positioned on the welding table such that, they are separated
slightly for better penetration of the weld.
4. The electrode is fitted in the electrode holder and the welding current is ser to be a
proper value.
5. The ground clamp is fastened to the welding table.
6. Wearing the apron and using the face shield, the arc is struck and holding the two
pieces together; first run of the weld is done to fill the root gap.
7. Second run of the weld is done with proper weaving and with uniform movement.
During the process of welding, the electrode is kept at 150 to 250 from vertical and
in the direction of welding.
8. The scale formation on the welds is removed by using the chipping hammer.
9. Filling is done to remove any spanner around the weld.
Precautions:

1. Wear welding goggle while doing welding operation.

2. Wear apron and remove all the rings and watches while performing welding
operation.
Drawing:

30 mm

6 mm

Conclusion:

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 Arc Welding Shop-2
Experiment no: 4 Date:

AIM:
To prepare a Lap joint on given MS plate piece with the help of arc welding process.

Tools required:
1. Rough and smooth files.
2. Protractor
3. Arc welding machine (transformer type)
4. Mild steel electrode and electrode holder
5. Ground clamp
6. Tongs
7. Face shield
8. Apron
9. Chipping hammer.
Material required: Mild steel plate of size 50X50X6 mm – 2 No’s, M.S electrodes 3.1
mm X350 mm
Welding Equipment: Air cooled transformer Voltage-80 to 600 V 3 phase supply, amps up
to 350
Sequence of operations:
1. Marking
2. Cutting
3. Edge preparation (Removal of rust, scale etc.) by filling
4. Try square leveling
5. Tacking
6. Welding
7. Cooling
8. Chipping
9. Cleaning
Procedure:
1. The given M.S pieces are thoroughly cleaned of rust and scale.
2. The two pieces are positioned on the welding table such that, the two pieces
overlapped one over the other as shown in drawing.
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 3. The electrode is fitted in the electrode holder and the welding current is set to be a
proper value.
4. The ground clamp is fastened to the welding table.
5. Wearing the apron and using the face shield, the arc is struck and the work pieces
are tack-welded at both the ends and at the centre of the joint.
6. The alignment of the lap joint is checked and the tack-welded pieces are required.
7. The scale formation on the welds is removed by using the chipping hammer.
8. Filling is done to remove any spanner around the weld.
Precautions:

1. Wear welding goggle while doing welding operation.

2. Wear apron and remove all the rings and watches while performing welding
operation.

Drawing:

6 mm

Conclusion:

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 Carpentry Shop
Experiment no: 5 Date:

AIM:
To prepare a Tee Halving joint in carpentry shop

Tools required:
1. Steel rule
2. Try square
3. Marking guage
4. Rip saw
5. Tenon saw
6. Mortise chisel
7. Mallet
8. Jack plane
9. Wood rasp file
Material required: Pine wood Pieces 2 nos
Operations to be carried-out:
1. Planning
2. Marking
3. Sawing
4. Chiseling
5. Finishing
Procedure:

1. The wooden pieces are made into two halves and are checked for dimensions.
2. One side of pieces is planned with jack plane and for straightness.
3. An adjacent side is planned and checked for perpendicularity with a try square.
4. Marking gauge is set and lines are marked at 30-40 mm to make the thickness and
width according to given figure.
5. The excess material is planned to correct size.
6. Using tenon saw, the portions to be removed and cut in both the pieces
7. The excess material in part-A is chiseled with mortise chisel.
8. The excess material in part-B is chiseled to fix in part-A.
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 9. The end of both the pieces is chiseled to exact lengths.
Precautions:

1. Wood should be free from moisture

2. Marking is done without parallax error
3. Care should be taken while chiseling
Drawings:

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Conclusion:

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 Fitting Shop
Experiment no: 6 Date:

AIM:
To prepare a job with a square cut on mild steel plate (46x33 mm2) and make all the edges
perpendicular to each other.

Tools required:
1. 6”try square
2. 6”sriber
3. vernier height
4. 12”hack saw Frame
5. Blades (12 TPI)
6. 10”rough file
7. 10”smooth file
8. 10”triangle file
9. Knife Edge file
10. Dot punch
11. Ball peen hammer (0.5 Ib)
12. Steel Rule
Material required: Mild steel flat (35*50*6mm)
Sequence of Operations:
1. Filling
2. Marking
3. Punching
4. Sawing
5. Filling
6. Finishing

Procedure:
1. The given mild steel flat piece is checked for given dimensions.
2. One edge of given is filled with rough and smooth files and checked with try square
for straightness.

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 3. An adjacent edge is also filled such that it is square to first edge and checked with
try square.
4. Wet chalk is applied on one side of the flat and dried for marking.
5. Lines are marked according to given figure, using odd leg caliper and steel rule.
6. Using the dot punch, punches are made along the marked lines.
7. The excess materials removed from the remaining two edges with try square level
up to half of the marked dots.
8. Finally buts are removed by the filling on the surface of the fitted job.
Precautions:
1. The perpendicularity of face ends edges is checked perfectly by using try square.
2. Finishing is given by using only with smooth files.
3. Marking is done without parallax error.

Drawings:
10 mm
33 mm

10 mm

46 mm

Conclusion:

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 Soldering Shop-1
Experiment no: 7 Date:

AIM:
To make a rectangular tray of base 50x50 mm area from GI sheet using soldering iron.

Tools required:
1. Steel rule
2. Flat file
3. Scriber
4. Try square
5. Snips
6. Dot punch
7. Stakes
8. Mallet

Material required: Galvanized Iron sheet of 33 SWG.

Sequence of Operations:
1. Planning
2. Marking
3. Cutting
4. Bending
5. Seaming
6. Soldering
Procedure:
1. The size of the given sheet is checked with steel rule.
2. Mark the measurement and make the development surface sketch diagram.
3. The layout of the tray is marked on given sheet.
4. The layout of the tray is cut by using the straight snips.
5. The sheet is bent to the required shape using stakes and mallet.
6. Now the bent edges are made to overlap each other and stuck with a mallet to get the
required joint.
7. The joint is soldered.

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Precautions:
1. Care should be taken while cutting with snip.
2. Care should be taken while bending and jumping.

Drawings:

Prepare a graph for above drawing and paste here.

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Conclusion:

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 Soldering Shop-2
Experiment no: 8 Date:

AIM:
To make a Funnel of length 70 mm from GI sheet using soldering iron.
Tools required:
1. Steel rule
2. Flat file
3. Scriber
4. Try square
5. Snips
6. Dot punch
7. Stakes
8. Mallet

Material required: Galvanized Iron sheet of 33 SWG.

Sequence of Operations:
1. Planning
2. Marking
3. Cutting
4. Bending
5. Seaming
6. Soldering
Procedure:
1. The size of the given sheet is checked with steel rule.
2. Mark the measurement and make the development surface sketch diagram.
3. The layout of the conical shape is marked on the given sheet.
4. The layout of the cylindrical shape pipe is marked on the given sheet.
5. The sheet is bent to the required shape using stakes and mallet.
6. Now the edges are slightly bent to one is one side and the other is opposite side,
using stakes and mallet.
7. Join both the ends with in a cylindrical shape and conical shape.

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Precautions:
1. Care should be taken while cutting with snip.
2. Care should be taken while bending and jumping.

Drawings:

Prepare above drawing on graph paper and paste that graph paper here.

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Conclusion:

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 Plumbing Shop
Experiment no: 9 Date:

AIM:
To study plumbing fittings and prepare a job of PVC pipe with external threading.
Introduction:
Plumbing deals with the laying of pipe lines. Pipe line provides the means of transporting
the fluid/gas. It is obvious that, laying out the pipe line , requires a number of joints to be
made and a number of valves to be incorporated, while connecting different length of pipes.
Plumbing work requires tools like pipe wrenches, hack saw, pipe cutter, threading
equipment and a pipe vice.
Different types of pipe fittings:
The size of the pipe is designated by inside diameter. The size of the pipe fitting is
designated by the size of the pipe on which it fits. There are different types of pipe fitting
available in market. They should be selected keeping in mind the desired piping layout. The
most common pipe fittings are coupling, union, elbow, nipple, tee, plug, cap, flange,gate
valve, globe valve, non return(check) valve, common tap etc.
Tools required: Pipe Wrench, Die Block and ½ “die set
Material required: PVC pipe (blue) ½ “size, ½ “coupler
Procedure:
1. Fix pvc pipe on plumbing vice.
2. Adjust the die stock and prepare to cut thread.
3. Rotate die stock in clock wise and anti-clockwise direction to cut thread.
4. Smooth the pipe with flat file and remove burrs from the surface.
Drawing:

Conclusion:

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