1

PANDIAN SARASWATHI YADAV

ENGINEERING COLLEGE
Arasanoor, Tamil Nadu

DEPARTMENT OF MECHANICAL
ENGINEERING

GE3271-ENGINEERING PRACTICES
LABORATORY

(R2021)

I Year – II Semester

Group A – CIVIL ENGINEERING

&

GROUP B – MECHANICAL ENGINEERING

 2

GE3271 ENGINEERING PRACTICES LABORATORY L T P C

0 0 4 2

COURSE OBJECTIVES:
The main learning objective of this course is to provide hands on training to the students in:
1. Drawing pipe line plan; laying and connecting various pipe fittings used in common household
plumbing work; Sawing; planning; making joints in wood materials used in common household
wood work.
2. Welding various joints in steel plates using arc welding work; Machining various simple
processes like turning, drilling, tapping in parts; Assembling simple mechanical assembly
of common household equipments; Making a tray out of metal sheet using sheet metal work.

GROUP – A (CIVIL & ELECTRICAL)

PART I - CIVIL ENGINEERING PRACTICES 15
PLUMBING WORK:
a. Connecting various basic pipe fittings like valves, taps, coupling, unions, reducers, elbows
and other components which are commonly used in household.
b. Preparing plumbing line sketches.
c. Laying pipe connection to the suction side of a pump
d. Laying pipe connection to the delivery side of a pump.
e. Connecting pipes of different materials: Metal, plastic and flexible pipes used in household
appliances.

WOOD WORK:
a. Sawing,
b. Planning
c. Making joints like T-Joint, Mortise joint and Tenon joint and Dovetail joint.

WOOD WORK STUDY:

a. Studying joints in door panels and wooden furniture
b. Studying common industrial trusses using models.
 3

GROUP – B (MECHANICAL AND ELECTRONICS)

PART III - MECHANICAL ENGINEERING PRACTICES 15
WELDING WORK:
a. Welding of Butt Joints, Lap Joints, and Tee Joints using arc welding.
b. Practicing gas welding.
BASIC MACHINING WORK:
a. (simple) Turning.
b. (simple) Drilling.
c. (simple) Tapping.
ASSEMBLY WORK:
a. Assembling a centrifugal pump.
b. Assembling a household mixer.
c. Assembling an air-conditioner.

SHEET METAL WORK:

a. Making of a square tray

FOUNDRY WORK:
a. Demonstrating basic foundry operations.
TOTAL = 30 PERIODS
COURSE OUTCOMES:
Upon completion of this course, the students will be able to:
1. Draw pipe line plan; lay and connect various pipe fittings used in common household
plumbing work; Saw; plan; make joints in wood materials used in common household wood
work.
2. Weld various joints in steel plates using arc welding work; Machine various simple
processes like turning, drilling, tapping in parts; Assemble simple mechanical assembly
of common household equipments; Make a tray out of metal sheet using sheet metal work.
 GE3271-Engineering Practices Laboratory
CIVIL & MECHANICAL
EX.
DATE NAME OF THE EXPERIMENT
NO.
CYCLE-1
PLUMBING WORK
1 Basic pipe connections involving the fitting like valves, taps and bends
2 Laying pipe connection to the suction and delivery side of a pump
3 Connection pipes of different materials
WOOD WORK
4 Cross lap joint
5 Mortise and tenon joint
6 Dove-tail joint
CYCLE-2
ARC WELDING WORK
1 Single V-Butt Joint
2 Lap Joint
3 T-Fillet joint
BASIC MACHINING WORK
4 Facing, Turning, Step turning, Chamfering and Taper turning
5 Drilling & Tapping
SHEET METAL WORK
6 Making of a square tray
WOOD WORK STUDY
1 Studying joints in door panels and wooden furniture
2 Studying common industrial trusses using models.
ASSEMBLY WORK
1 Assembling a centrifugal pump
2 Assembling a house hold mixer
3 Assembling an air-conditioner
FOUNDRY WORK
1 Basic foundry operations
 5

PLUMBING WORK
 6

CYCLE - 1

PLUMBING
 7

BASIC PIPE CONNECTIONS INVOLVING THE FITTING LIKE

VALVES, TAPS AND BENDS
 8

EX.NO.1
BASIC PIPE CONNECTIONS INVOLVING THE FITTING LIKE
VALVES, TAPS AND BENDS
Aim:
To connect the pipes with pipe fittings like valves, bends and taps with main supply pipe
using joints.

Materials supplied:
1. Pipe wrench
2. Spanner
3. Bend
4. Valves
5. Taps
6. Cast iron pipes of different length
7. Flange
8. Bench vice

Procedure:
1. Two pipes are taken and they are held in vice and they are connected by using a
flanged joint as shown in figure.
2. A gate valve is connected to the pipe for controlling the water supply.
3. Then bend-1 is connected to the end of the pipe. Make internal threads using taps in
the bent-1. So it can be screwed to the pipe.
4. One more pipe is connected to the bend for extension of the layout.
5. The pipe is then screwed to this bend-2 for further extension.
6. A horizontal pipe is connected to this bend-2 as shown in figure.
7. Then tap is fitted to the end of the pipe for closing and opening the water supply.

Result:
Thus, the basic connections of pipes with pipe accessories are made.
 9

Pump inlet and outlet connection

Suction and Delivery pipe connections

 10

Ex.No.2

LAYING PIPE CONNECTION TO THE SUCTION AND

DELIVERY SIDE OF A PUMP

Aim:
To connect the suction pipe and delivery pipe with centrifugal pump to ensure properly
aligned pipe using joints.

Materials supplied:
1. Pipe wrench
2. Spanner
3. Bend
4. Valves
5. Stainer
6. Cast iron pipes of different length
7. Foot valve
8. Bench vice

Procedure:
1. After carefully selecting the right size and materials, make sure the new pump is set up
for success with proper installation.
2. Setting the base correctly and aligning the pump, it’s also extremely important that
piping to the pump is done properly.
3. Keep suction piping as short as possible. Include a straight run pipe length equal to 5 to
10 times the pipe diameter between the pump inlet and any obstruction in the suction
line. Note: Obstructions include valves, elbows, "tees", and etc.
4. Eliminate elbows mounted on or close to the inlet nozzle of the pump.
5. Ensure the piping arrangement does not cause strain on the pump casing.
6. The delivery side of the pump requires regular pipe connection.

Result:
Thus the suction and delivery pipes are connected to a pump.
 11

Different Material fittings

 12

Ex.No.3 CONNECTION PIPES OF DIFFERENT MATERIALS

Aim:
To connect different materials pipes together by using proper joints

Material Supplied:
1. Cast iron for plumbing waste lines 7. Spanner
2. PVC (Poly Vinyl Chloride) for plumbing waste 8. Bend
lines
3. Chromed brass for plumbing waste lines 9. Bench Vice
4. Chromed copper for water supply lines 10. Threading vice
5. Galvanized iron for water supply lines 11. Connection materials like joints and flanges
6. Pipe wrench

Procedure:
1. Adapters are used when connecting two pipes of different types. For example, an adapter
could be fitted on the end of a plain pipe to allow a threaded connection at the other side of
the adapter. Bushing Fittings – Bushings, sometimes called reducer bushings, are used for
connecting two pipes of different materials.
2. Threaded joints, One component has internal threads while the connecting piece has
external threads. PVC, copper, cast iron, and GI pipes.
3. Stab-Type Fittings have a similar design that includes an elastomer seal, a gripping device
for effective pressure sealing and a self-contained stiffener.
4. Soldering are the ways to fuse by heat, with soldering being one of the first choices for
many plumbers. Solder melts using temperatures below 840 degrees C.
5. Butt Weld is the most common type of pipe joining welding method. We can use this
method to join two pipes of the same diameter. Butt fusion is used for connecting
polyethylene and high-density polyethylene pipes.
6. Saddle Fusion, We can use this method to install a saddle fitting into the line seamlessly.

Result:
Thus different pipe materials are joined by using suitable techniques.
13
 14

WOOD
WORK
 15

CROSS LAP JOINT

 16

Ex.No.4 CROSS LAP JOINT

Aim:
To make a cross lap joint from the given wooden piece for the given dimensions.
[[
Material supplied:
A wooden piece of size 300 x 40 x40 mm

Tools required:
1. Steel rule 6. Rip saw
2. Carpentry vice 7. Tenon saw
3. Jack plane 8. Firmer chisel
4. Try square 9. Mallet
5. Marking gauge

Sequence of operations:
1. Rough planning 4. Chiseling
2. Marking 5. Finish planning
3. Cutting or Sawing

Working steps:
1. The given job is checked to ensure its correct size.
2. The job is firmly clamped in the carpentry vice and two surfaces are planned by jack plane
to get right angle.
3. Using try square, the right angle of the work piece is checked.
4. Now all the four sides of the wooden pieces are planned to get the smoother and finished
surface.
5. Now the job is cut into two halves rip saw then proper marking is done for cross lap joint on
the two pieces using steel rule and marking gauge.
6. One half is taken, Using tenon saw and firmer chisel the unwanted portions are removed as
per the drawing.
7. The above procedure is repeated for the other half of the work piece.
8. Jack plane is used to plane the other half of the work piece.
9. Now the two pieces are assembled to check proper fitting.
10. The finished job is again checked for its accurate shape and size using try square and steel
rule.

Result:
Thus the desired cross lap joint is obtained.
 17

MORTISE AND TENON JOINT

 18

Ex.No.5 MORTISE AND TENON JOINT

Aim:

To make a mortise and tenon joint from the given wooden piece for the given dimensions.

Material supplied:
A wooden piece of size 300 x 40 x40 mm

Tools required:
1. Steel rule 6. Rip saw
2. Carpentry vice 7. Tenon saw
3. Jack plane 8. Mortise chisel
4. Try square 9. Mallet
5. Mortise gauge

Sequence of operations:
1. Rough planning 4. Chiseling
2. Marking 5. Finish planning
3. Cutting or Sawing

Working steps:
1. The given job is checked to ensure its correct size.
2. The job is firmly clamped in the carpentry vice and two surfaces are planned by jack plane
to get right angle.
3. Using try square, the right angle of the work piece is checked.
4. Now all the four sides of the wooden pieces are planned to get the smoother and finished
surface.
6. Now the job is cut into two halves rip saw then proper marking is done for cross lap joint on
the two pieces using steel rule and marking gauge.
7. One half is taken, Using tenon saw and mortise chisel the unwanted portions are removed as
per the drawing.
8. The above procedure is repeated for the other half of the work piece.
9. Jack plane is used to plane the other half of the work piece.
10. Now the two pieces are assembled to check proper fitting.
11. The finished job is again checked for its accurate shape and size using try square and steel
rule.

Result:
Thus the desired mortise and tenon joint is obtained.
 19

DOVE-TAIL JOINT
 20

Ex.No.6 DOVE-TAIL JOINT

Aim:
To make a dove-tail lap joint from the given wooden piece for the given dimensions.

Material supplied:
A wooden piece of size 300 x 40 x40 mm

Tools required:
1. Steel rule 10. Rip saw
2. Carpentry vice 11. Tenon saw
3. Jack plane 12. Frimer chisel
4. Try square 13. Mallet
5. Marking gauge

Sequence of operations:
1. Rough planning 6. Chiseling
2. Marking 7. Finish planning
3. Cutting or Sawing

Working steps:
1. The given job is checked to ensure its correct size.
2. The job is firmly clamped in the carpentry vice and two surfaces are planned by jack plane
to get right angle.
3. Using try square, the right angle of the work piece is checked.
4. Now all the four sides of the wooden pieces are planned to get the smoother and finished
surface.
5. Now the job is cut into two halves rip saw then proper marking is done for dove-tail joint on
the two pieces using steel rule and marking gauge.
6. One half is taken, Using tenon saw and firmer chisel the unwanted portions are removed as
per the drawing.
7. The above procedure is repeated for the other half of the work piece.
8. Jack plane is used to plane the other half of the work piece.
9. Now the two pieces are assembled to check proper fitting.
10. The finished job is again checked for its accurate shape and size using try square and steel
rule.
Result:
Thus the desired dove-tail joint is obtained.
 21

ARC WELDING
 22

CYCLE - 2

ARC
WELDING WORK
23
 24

Ex.No.1 Single V-Butt joint

Aim:
To make a single V-Butt joint using arc welding on the given work pieces.

Material supplied:
Mild steel plate of size 100 x 50 x 6 mm – 2 Nos.

Tools required:
1. Power supply (AC or DC) 7. Gloves
2. Welding torch 8. Apron
3. Electrodes 9. Shield
4. Tongs 10. Safety goggles
5. Chipping hammer 11. Earthing clamps
6. Wire brush
Sequence of operations:
1. Edge preparation (Removal of rust, scale etc., 4. Cooling
2. Tacking 5. Chipping
3. Welding 6. Cleaning

Working steps:
1. First of all, the work pieces must be thoroughly cleaned to remove rust, scale and other
foreign materials.
2. Then the given work pieces are placed on the table such a way that two work pieces are
brought close to each other so that it forms a ‘V-shape’ when the planes butt each other.
3. Appropriate power supply should be given to the electrode and work pieces.
4. Now the welding current output may be existed.
5. When current is passed, arc is produced between the electrode and work pieces.
6. Now set the two work pieces in correct position and maintain the gap 3 mm and drack at
both ends of the work pieces as shown in the figure.
7. Then the welding is carried out throughout the length.
8. As soon as the welding process is finished, switch off the current supply and allow the work
process to cool.
9. Slags are removed by chipping process with the help of chipping hammer.
10. Finally using wire brush, welded portions are cleaned.
Result:
Thus the desired single V-Butt joint is obtained using arc welding.
 25

LAP JOINT
 26

Ex.No.2 Lap joint

Aim:
To make a lap joint using arc welding on the given work pieces.

Material supplied:
Mild steel plate of size 102 x 51 x 6 mm – 2 Nos.

Tools required:
1. Power supply (AC or DC) 7. Gloves
2. Welding torch 8. Apron
3. Electrodes 9. Shield
4. Tongs 10. Safety goggles
5. Chipping hammer 11. Earthing clamps
6. Wire brush

Sequence of operations:
1. Edge preparation (Removal of rust, scale etc., 4. Cooling
2. Tacking 5. Chipping
3. Welding 6. Cleaning

Working steps:
1. First of all, the work pieces must be thoroughly cleaned to remove rust, scale and other
foreign materials.
2. Then the given work pieces are placed on the table such a way that two work pieces are
overlapped one over another as shown in figure.
3. Appropriate power supply should be given to the electrode and work pieces.
4. Now the welding current output may be existed.
5. When current is passed, arc is produced between the electrode and work pieces.
6. Now set the two work pieces in correct position like lap joint and tack at both ends of the
work pieces as shown in the figure.
7. Then the welding is carried out throughout the length.
8. As soon as the welding process is finished, switch off the current supply and allow the work
piece to cool.
9. Slags are removed by chipping process with the help of chipping hammer.
10. Finally using wire brush, welded portions are cleaned.
Result:
Thus the desired lap joint is obtained using arc welding.
 27

T-FILLET JOINT
 28

Ex.No.3 T-Fillet joint

Aim:
To make a T-Fillet joint using arc welding on the given work pieces.

Material supplied:
Mild steel plate of size 100 x 50 x 6 mm – 2 Nos.

Tools required:
1. Power supply (AC or DC) 7. Gloves
2. Welding torch 8. Apron
3. Electrodes 9. Shield
4. Tongs 10. Safety goggles
5. Chipping hammer 11. Earthing clamps
6. Wire brush

Sequence of operations:
1. Edge preparation (Removal of rust, scale etc., 4. Cooling
2. Tacking 5. Chipping
3. Welding 6. Cleaning

Working steps:
1. First of all, the work pieces must be thoroughly cleaned to remove rust, scale and other
foreign materials.
2. Then the given work pieces are placed on the table such a way that two work pieces are
brought close to each other so that it forms a ‘T-shape’ as shown in figure..
3. Appropriate power supply should be given to the electrode and work pieces.
4. Now the welding current output may be existed.
5. When current is passed, arc is produced between the electrode and work pieces.
6. Now set the two work pieces in correct position like T-Fillet joint and tack at both ends of
the work pieces as shown in the figure.
7. The joint is placed on a welding table in flat position by keeping the tack side down.
8. Then the welding is carried out throughout the length.
9. As soon as the welding process is finished, switch off the current supply and allow the work
piece to cool.
10. Slags are removed by chipping process with the help of chipping hammer.
11. Finally using wire brush, welded portions are cleaned.
Result:
Thus the desired single T-Fillet joint is obtained using arc welding.
 29

LATHE

DRILLING MACHINE
 30

BASIC
MACHINING
WORK
 31

Facing, Turning, Step turning, Chamfering and Taper turning

 32

Ex.No.4 Facing, Turning, Step turning, Chamfering and Taper turning

Aim:
To obtain the required shape and size of the work piece by turning and facing operation.
Materials supplied;
Cylindrical work piece of diameter 35mm and length 112mm mild steel rod.
Tools required:
1. Lathe 4. Try Square
2. Cutting tool 5. Scriber
3. Vernier Caliper 6. Vernier height Gauge

Sequence of operations:
1. Checking 5. Turning
2. Work piece setting 6. Taper turning
3. Tool setting 7. Chamfering
4. Facing
Working steps:
1. The given work piece is checked for its dimensions.
2. The work piece is held in the chuck. Chuck key is used to tighten the job firmly.
3. The single point cutting tool is held in the tool post and tighten the nuts using spanner.
4. Facing is done with cutting tool moving from the centre of the work piece towards outside.
It is done until the required length of the job is obtained.
5. Turning is done to reduce the diameter of the job. Sufficient depth of cut is given and it is
done until the required diameter of the job is obtained.
6. Next the taper turning is done on the work piece, as per the taper angle already calculated.
8. Then the compound rest base is swiveled and set at half taper angle. Cutting tool moved at
an angle to the lathe axis. Tool is moved by the compound rest hand wheel.
7. For chamfering to be done at the end of work piece, the tool is held at 45˚ to the lathe axis
and it is fed against the rotating work piece.
8. Finally, the dimensions of the work piece are again checked.

Result:
Thus the required size and shape of the given work piece is obtained.
 33

BEFORE DRILLING

AFTER DRILLING AND TAPPING

 34

Ex.No.5 DRILLING AND TAPPING

Aim:
To drill the holes of required size and tap the drilled holes.

Materials supplied:
50 x 50 x 5mm Mild steel plate – 1 No.

Tools required:
1. Bench vice 7. Vernier height gauge
2. Machine vice 8. Scriber
3. Steel rule 9. Dot punch
4. Standard set of filling tools 10. Drill bit
5. Try square 11. Drilling machine
6. Surface plate 12. Tap set with die holder

Sequence of operations:
1. Checking 5. Drilling
2. Filling 6. Tapping
3. Marking 7. Cleaning
4. Punching

Working steps:
1. The given work piece is checked for its dimensions using steel rule
2. The work piece is held in the vice and any two surfaces are filled to get right angle.
3. Chalk is applied uniformly on the surfaces of the work piece.
4. With the help of the vernier height gauge, surface plate, angle plate, steel rule and scriber
the given dimensions are marked.
5. The mid-point of the required hole is punched by using dot punch.
6. The punched dots are drilled by drilling machine,
7. After drilling the holes, they are tapped by using tap set.
8. Finally, the dimensions of the work piece are again checked.

Result:
Thus the required work piece is drilled and tapped to the required dimensions.
 35

SQUARE TRAY
 36

SHEET
METAL
WORK
 37

SQUARE TRAY
 38

Ex.No.6 SQUARE TRAY

Aim:
To make a square tray from the given sheet metal.

Materials supplied:
22 gauge Galvanized Iron (G.I) sheet.

Tools required:

1. Steel rule 6. Snips

2. Mallet 7. Stakes
3. Scriber 8. Rivet set
4. Divider 9. Ball peen hammer
5. Potractor

Sequence of operations:
1. Checking 5. Bending
2. Levelling 6. Hemming
3. Marking 7. Riveting
4. Cutting

Working steps:
1. The size of the given sheet is checked for its dimensions using a steel rule.
2. Then the sheet is leveled on the leveling plate using a mallet.
3. The development procedure is followed to form a square tray.
4. The dimensions are marked as shown in the figure.
5. The sheet is cut as per the marked dimensions by straight snips.
6. Then a single hemming is made on the four sides of the tray as shown in figure.
7. This four sides of the tray are bent to 90˚ using stakes anvil.
8. Finally all the corners of the tray are joined by riveting.

Result:
Thus the desired square tray is made from the given sheet metal.
 39

WOOD
WORK
STUDY
 40

Joints in door panels and wooden furniture

 41

Ex.No.1 Studying joints in door panels and wooden furniture

Wood working joints come in a variety of configurations that join together two pieces of wood.
Some joints involve carving channels into two different wood pieces so that they lock together, while
others use fasteners like nails or screws to hold them in place.
Because wood joints are essential to wood working, many joint types have been used for
centuries and even millennia. Carpenters and craftsmen of ancient chine and Egypt helped perfect
joinery methods that contractors and wood workers still use today
Wood joinery is one of the most basic concepts in woodworking. If we didn't have the ability to
join two pieces of wood together in a solid fashion, all woodworking pieces would be sculptures,
carved out of a single piece of wood. However, with the many varied types of wood joinery, a
woodworker has a number of different joints in his arsenal from which to choose, based on the
project. If you master these wood joinery concepts, you'll be well on your way to becoming a very
accomplished woodworker.
There is no more basic wood joinery than the butt joint. A butt joint is nothing more than when
one piece of wood butts into another (most often at a right angle, or square to the other board) and is
fastened using mechanical fasteners. This type of joint is often used in wall framing on construction
sites. Learn tips for using a butt joint, as well as when to choose another wood joinery type.
The mortise and tenon is a classic wood joinery method. These joints have been used since the
early times of woodworking, and are still among the strongest and most elegant methods for joining
wood. Learn methods for creating tight, beautiful mortise and tenon joints.
Another method for joining boards along the edges (like the tongue and groove joint) is to cut
slots and use beech wood wafers (known as a biscuit) to hold the boards in place. This is a very useful
modern woodworking joint, particularly for creating table tops, relying on glue and the swelling of
the beech wood biscuit to hold the boards in place. Learn how to cut consistent slots and get reliable
results from biscuit joinery.
Of all wood joinery methods, the through dovetail may be the most revered. A classic through
dovetail is beautiful and very strong and adds a touch of class to any piece. There are a few methods
for creating through dovetails, from hand cutting to machining with a jig. Learn the keys to a quality
through dovetail joint and how to create them.
Miter joints are commonly used at the visible, outside corners of door, window, and picture
frames. They are stronger than butt joints because there is a greater surface area where the two
wood pieces meet, but they still require both glue and mechanical fasteners to stay in place.
 42

INDUSTRIAL TRUSSES
 43

Ex.No.2
STUDYING COMMON INDUSTRIAL TRUSSES USING MODELS

Man has been building with timber trusses for over 2,000 years. The Romans were the first to
perfect the art of spanning wide spaces with timber trusses. During the Medieval age, European
cathedral builders used timber trusses to span over their vaulted stone ceilings to support the
cathedral roofs above. In a few rare instances, such as Westminster Hall, the trusses were
embellished with ornate carvings and left exposed. In North America, early meetinghouses and
churches were built with timber roof trusses in the European tradition. The design of all pre-
industrial timber trusses was based on tradition, trial and error, and the carpenter’s intuition. There
were no engineers or engineering principles to guide the design. Often, the carpenter’s intuition was
flawed, leading to irrational or mongrel trusses, some of which have managed to survive. With the
industrial revolution and the expansion of the railroads in the second half of the nineteenth century,
engineers began to play a role in the design of major structures. Many of the early engineers were
West Point trained Civil War veterans. Trusses used for railroad bridges were at first based on
patented designs. Every Inventor or amateur engineer raced to patent his own unique truss design in
hopes of making his fortune off of the railroads.
Naturally, each one of them named their truss design after themselves to add fame to their
anticipated fortune. Some of the patented truss shapes proved to be structurally efficient, smart
truss designs that actually worked. Those are the ones with names that we recognize and still use
today – Howe, Pratt, Town, Warren, and Fink. Other patented truss bridge designs were not so
lucky and ended in catastrophic train wrecks. The industrial revolution also brought mill towns
with large factories that manufactured textiles and everything else that a person could desire. The
mill buildings had robust timber structures supported on thick brick or stone masonry bearing
walls. The roofs of the mills often featured timber trusses that emulated patented bridge trusses.
While timber trusses from centuries past were built for function, today, timber trusses are just as
likely to be designed as architectural elements as they are to be created for their structural
advantages. In many cases, their form is not driven by structural efficiency, but by architectural
fancy. This can present some challenges for the timber engineer. This document is intended to
provide guidance to engineers designing, evaluating, and repairing timber roof trusses.
Trusses are structural assemblies that respond to applied loads with pure axial compression or
tension in their members. The top and bottom truss members are called chords and the members
between the chords are called web members. Web members that are in axial compression are called
struts. Web members that are in axial tension are called ties. In an ideal truss, members meet at
nodes or joints (also called panel points) that are idealized as hinges or pins that are incapable of
 44

transmitting bending moments. Loads are applied to an ideal truss only at its nodes. Applying loads
(and supports) only at nodes keeps the truss members shear-free. It helps, too, that ideal truss
analysis tended to neglect member self-weight. The centroidal axes of all truss members meeting at
a node converge to a discrete point. Classical methods of analyzing trusses are only valid for ideal
trusses, and real-world timber trusses are not very idealistic. Real trusses respond to applied loads
with a combination of axial stress, bending moments, and shear in their members. Real trusses
often have continuous chords that are not pinned at the joints and loads are often applied along the
length of the chords. It is also common to intentionally introduce eccentricities into truss joints for
more efficient joinery.
 45

ASSEMBLY
WORK
 46

CENTRIFUGAL PUMP
 47

Ex.No.1 ASSEMBLING A CENTRIFUGAL PUMP

Assembling the pump:

Assembling to be done in reverse order of dismantling.

1. Fast the bearing housing through the shaft and then fit the bearing in housing.
2. Fix retaining cir clip forbearing and apply required grease for the bearing.
3. Fit the bearing housing cover.
4. Renew the top and bottom o-rings for casing cover.
5. Fix mechanical seals stationary part with the casing cover.
6. Fit the shaft sleeve and pass the casing cover through the shaft.
7. Fix mechanical seals rotary part on the shaft sleeve and tighten the lock screw.
8. Insert distance ring.
9. Fix shaft key and secure Impeller.
10. Tighten impeller by shaft not and lock plate.
11. Now Impeller assembly is ready for lowering into pump casing.
12. Lower the impeller assembly and tighten the pump cover with Volute casing.
13. Tighten the bearing housing with casing top cover
14. Connect the cooling pipes for mechanical seal.
15. Opened liquid to casing, purge the casing and confirm mechanical seal is intact
without any leaks.
16. On confirming pump is free to turn and mechanical seal not leaking, distance piece for
connecting pump and motor coupling can be fitted with coupling discs.
17. Operate the pump and shake the performance, by monitoring its parameters.
 48

HOUSE HOLD MIXER

 49

Ex.No.2 ASSEMBLING A HOUSE HOLD MIXER

To assemble and adjust the tilt-head mixer:
When you first unpack your KitchenAid tilt-head mixer, it's time to set it up. Find out how to
assemble and adjust it ready to create. See the steps...
Your stand mixer is designed to be straightforward to use, so you will quickly become familiar with
it and enjoy getting creative. Here are the instructions for setting it up.

To secure the bowl:

1. Turn OFF (speed '0')
2. Unplug the mixer or disconnect power.
3. Tilt the motor head back.
4. Place bowl on silver metal bowl clamping plate.
5. Turn the bowl gently in a clockwise direction, making sure handle or spout of glass bowls
does not touch the back of the mixer base.

To remove the bowl:

1. Turn OFF (speed '0')
2. Unplug the mixer or disconnect power.
3. Tilt motor head back.
4. Turn bowl counterclockwise

To attach the accessories (dough hook, paddle or wire whisk):

1. Turn OFF (speed '0')
2. Unplug the mixer or disconnect power.
3. Tilt the motor head back.
4. Slip accessory onto beater shaft and press upward as far as possible.
5. Turn accessory to the right, hooking beater over the pin on the shaft.

To remove the accessories (dough hook, paddle or wire whisk):

1. Turn OFF (speed '0')
2. Unplug the mixer or disconnect power.
3. Tilt motor head back.
4. Press beater upward as far as possible and turn left.
5. Pull beater from beater shaft.
 50

To check the bowl clearance (height):

Your mixer is adjusted at the factory for optimum mixing, with the paddle (flat beater) just clearing
the bottom of the bowl. If, for any reason, this hits the bottom of the bowl or is too far away from
the bowl, you can correct it quickly.
1. Turn OFF (speed '0')
2. Unplug the mixer or disconnect power.
3. Tilt motor head back.
4. Turn the screw slightly counter-clockwise (left) to raise the paddle or clockwise (right) to
lower the paddle.
5. Adjust so that the paddle just clears the surface of the bowl. If you over adjust the screw,
you may not be able to lock the motor head when it is lowered.
 51

Ex.No.3 ASSEMBLING AN AIR-CONDITIONER

1. Face Plate Assembly 13. Compressor

2. Guide Water Channel 14. Motor Support
3. Evaporator Assembly 15. Base
4. Fan Front Frame 16. Fan Frame
5. Knob 17. Axial Flow Fan
6. Fresh Air Door 18. Condenser Assembly
7. Electric Box 19. Enclosure
8. Electric Box Cover 20. Condenser Top Plate
9. Centrifugal Fan 21. Short Connecting Plate
10. Windtunnel Volute 22. Long Connecting Plate
11. Fan Cap 23. Evaporator Top Plate
12. Motor 24. Filtering Net
 52

FOUNDRY
WORK
 53

BASIC FOUNDRY OPERATIONS

 54

Ex.No.1 BASIC FOUNDRY OPERATIONS

Foundry processes can be divided into two types: ferrous industries and non-ferrous
industries. Foundry processes involve making the mold and the core, melting and pouring the metal
into the mold and finally removing the mold and core and finishing the product. Although different
processes differ in the number of steps required to make the final product.
Metal casting process starts with creation of mold. Metal that can be molted will be poured
into this mold and cooled. The form of metal being used and shape of final product required would
decide the material, which will be used to make the cast. A commonly used molding material is
sand. Investment materials, metals, etc. can also be used.
Different types of metals are used for melting different metals. Various Furnaces types are
cupolas, electric arc, induction, hearth or reverberatory and crucible. Due to the different nature of
metals, varying inputs are required and different toxic wastes are released from each type.
After the metal has been melted, it is poured into the cast already made previously and made
to cool and set. Silica sand, moisture, oils and green sand are mixed together to form a mould
cavity. Metal is then poured in this cavity. When the metal is cooled, it is easily separated from the
mould. This type of sand should b capable of handling high temperatures and pressure, allow gases
to escape, have a constantly small grain size and be non-reactive with metals.
The wastes produced by foundries depend on the type of metal, foundry types.gaseous wastes
are usually the largest pollutants. They contain metal, semi-volatile and volatile organic
compounds. Emission control systems can be installed to capture these gases.
Liquid wastes in foundry results from water used to chill metal. Water used for cleaning the floor &
other maintenance can also formulate liquid waste. A water treatment plant can be installed for
water waste.
Solid wastes come from slag, sand, spent refractories, and emissions control dust. For this
various process like sand reclamation, attrition sand reclamation, dry sand reclamation, wet sand
reclamation, etc is used. Sand may also be recycled for outside processes.
Slag and emission are also a waste produced by a foundry. These can be fed back to furnace
to recover any metal, which can possibly be recovered.
Other special foundry processes are thermal galvanization and electro less nickel plating.