mechanical engineering_workshop practice_laboratory manual

(ME 192)

!!

LABORATORY MANUAL

WORKSHOP PRACTICE (ME192/ME392)

#$%&$

&$

! ""

!

"

!

"!!

! # $!

%&'

!

!

! &' &( &)*

!"#(

+

%+!&

# !"#$% !"#

,,$

!!*

!!

-

! !

!

+

&$./

&$./

-+"

! ! !

!

+

+"

!

*!

!

' ! ! !

'! %'0&

!!!

! !1,2345%'0&265,2

,5 ! 265 The moulding sand should posses the properties !

!-7-!!

8!!+!

!9

& :8

& "

' ;8!

(

"'(>

A!

'

(

%&

!

*

-!%&%&

7'

(!

-7

*

( B

%!,,-&

*

+!

)!

*!:!

-2!!

"!!

!

&

*

!+!

+!"

!!

!+!

&(&

* ( +

(&(&&

' '

' 'C

'4

'6

'1 '3

'D

', '

'

''()

=;'''?:

A ' 7 '

' ) =

; '

' ? :

)

'9

(9 - ! 7

-9-

-9#

!

C ' !9 = !

!+

4 (2!9

AIM:

TOOLS REQUIRED:

SEQUENCE OF OPERATIONS:

RESULT:

PRECAUTIONS:

LABORATORY EXERCISE_1

PATTERN MAKING

SEQUENCE OF OPERATIONS:

LABORATORY EXERCISE_2

MOULD MAKING

AIM:

TOOLS REQUIRED:

SEQUENCE OF OPERATIONS:

RESULT:

PRECAUTIONS:

LABORATORY EXERCISE_3

CASTING

AIM:

TOOLS REQUIRED:

SEQUENCE OF OPERATIONS:

RESULT:

PRECAUTIONS:

!" #$ % !% #

& '&&% &(

&!!(#&&('))

&! "'&(&%*"%"!"%%))

&!#$'!(#$ !+ $

'

&,#$- !&( %#" # &( &" % !" &) &% .! '

/ #$ " .! ! !& & &! ' ) #$ "% "%"%#" "% "'

)#$ " )'&&&(! )"')#"!'

0/1

+ # !') (#&% + *#

&)*#'2) ! $# % "*#

#$ " + *#' 3# & ' *#

!" "'3#& &! !%"

)'4) ("*#'

) ( & # " &% #$ !! $ ! )&& '1 $ "! .! $# 1 ")

' " ,1- !!( 566'1$# & ! ( #$

!(% !"(!&!&%&!" " "! ( 1) #1& " '" ++)")'

! #$"")$(!%#"".! '

+ *# $",- &)*#! ( # '#$"&&)'

01$ 0&

0

!& & ! "#$'

! &$"!&+ &!&$"' "

!# " #$"!"

&7!& % '

( "%# %" " ' ) # %

(#"&'

0! 0"

&!" &$"566"'%! $".!

&(($#+&!(.! ' (.! & $ ' 4 ( .! (" '

%! &$$'& & "'"("! 89

8:

'

"() "%""&89:&&9:6&&'# ! &$"#" '0(.!

0

,3(-& '! &$"& " "! 7" $ ) "$' (""!"'

( & + " $ "

&!" "' ! &$" % ("! ! % ( "

'& & & #'4

(""

0 " )

&&! #""'

! &$" %&$&)('

& " ' ! ( " & ;( 8:6-

89':&&6?! "'& !%+"! )"56?! "'! &$ '

0!

( &!"! &! &'!

#!$ ! &!&'&

& & #'2!"%!"

" ! #$% # !

# " &! # &

' (""'! %

"# %"!# '

0

!

$#! !"&( '&%# %

&( '$# ( !& &' $#

)!& "" &: 8: & ;&6?'

!

# ! &$" ' & " ' / "

$ # ! ' $ # (A

" $'$# " )

"& '

#

!

%! !" ' !!(! & 4'% & !" &" ' & " " '

#

!" ! &$" + ' & ('(+ $ " *!" "'(& "'

" # )% !" ' / "&&)&! "!'# %& " ! # "& "'

#"" "#$

8' 4 %!$ $&(

9' *! &!#$(""!('B"

& & # " &

&'

=' (! &$#!'

C' #$&()& & (&

'

:' !#%!&$ ("!# '

>' " && % ( !" ! !

"'2 "(!" "'

D' !"(%# #!&'

) " &""#$ '

E' & " !#$ !#!('

/

&"4" " %#!"

& )" !& !" "' % % 4 #

"( & 4 & & & !

"4'

&& " !%)

"# !"'$ && "

#' ( %## .!

& ##$ )' (& ")

" #$" % (( # !"%

($# #&)"'

&

"& &)"&&!&&!&

' % )" & # !" "

!'

%!!( " "'

# ' "!#)! ' #

" "( $% # ' ) # ! ! '

%"! " "#$# "'

0

"%!" " '

"!#)!( '

" !!

(

&!%! "%&&"%"" F#

'

! $)"&'

&& $" # ! ( ( !" !"%

"%&$" !"&'&& #"

4'(&&& )""

6'EA8'&&"4 0F% "&&'

/F&&& % "! & (

#"' && # ! " #$ %

!(! )"'

/&&

&&&%+'! "%)"%

" "& &&" !) ! '

&&&%!F#&& '!

#""%)" "&'

&&"!"&&

!

# ) " !#' & )

" &'" ")(&'#

)( " #' !

'# ) ("&& '

# )

#"& #$#$ "#

!

8'G # % "'( !

('

9'($'

='2 '

C'-#'

:'$#$" "'

>'#$!!& )')

""%#$" *!('

D' ( ( # ;!"

LABORATORY EXERCISE_1

FITTING

&$1F&")# " "#"!'

!" #$ % !% #

& '&&% &(

&!!(#&&('))

&! "'&(&%*"%"!"%%))

&!#$'!(#$ !+ $

'

&,#$- !&( %#

" # &( &" % !" &) &%

.! '

/ #$ " .! ! !& &

&! ' ) #$ "% "%

"%#" "% "'

/)%%(F.!%%!%/F&&%!%$#%

1%!%"%:&& %=&& %>##%

) "&'

8'!&) &$ #!'

9'$! ) ""(+" 1%! &)"

&")'

='2(.!$"" !)'

C'B"! "&$")#& #"#

! "'

:' ! # ! && $" )' ! !

"):&&"'

>'!+)(#$# '

D' ! (!".!H "!"

'

E'# &E':&& (&! "&'

5' ! # # '

E'&$ () '( %

("#&'

5'$! %# (

! '

.! 1F"! %(#""% )'

!!!!"#!$ !!!%

! !!!&! !'&

' ()!!! *!+'!)"' ()# '#

! % !!#)#',

! '! % & ! ' !

!%!)&$!%! -!

!*! ).!&*#!,

-!!*** ).!)'

!! &%

' ' )%

!'#))&!)%*'

! ''&/0123114%

!!!!$!$ !%! &'!!!

$ ! ! 5!!6% !$ &' ,!!

'!&))!%!&!*!'

! !* ! )% ! ' ! -" 78* .*

&&!!!!'! !%

!& !!! %%#

#!!%!!"'%!9:;!*

()**

***

+,,*

! )# ' ' # )! ' !

!%'! '!###!*!

$)""'! ##!*! !$)""%! !

$ !#&'#" %

,*

!)''!!#&!%!'!"!!

')%! $ $)##"

! ! $ )) '#", # '" ' % ! )#

!' '" &)# # '

)!%

*)*

!#!#))#", %!'!

)# ''"&)#

)! ' * ! ! '"% = ! !

$!!"#!%!!&&)#

'%

- *)*

! $!'!!%!)#

'!'" &)#! )!'

! ! !% ! $ ')# !

'"#" !'%=!!! $!!

"#!!%!!&&)#!'%

- *

!)# !"'% $!

)##" %

- *

! )# ! ! ' !' !"% ! !

"#!%!! !)' #&''!!'%

-

! ! ! % !!!!! ! !

#!! !)'!''!#",

*

! *!! ''!%!!!

)&$$#"!%#"! "*'

! ,)# !% ! '= !*

$)! !)%)'#"*

#!!!,#!%>*"!,"#!*#$#

'!"%

*)*

)$!!'

)$ ' !#! * !% ! ' #"

!)&!%

.+

!!! '*#!)!%! !'

!!! '!% !"$ #&! $

)%!!&'!%

/.,

! & ! $ !!& ' ! ! '!%

!! *##"!%

0.*,

!!! '#" %&) & !

)% !"! ! ! $ ! !

#"%!* !* !&!) ' ! * ' ' ! !!

* %

.*

!!$'%!!)&!!!'

!*!!! ! %!!!$!!!')

=! ' ! % ! $ ! ! ' ' $

!!& '# % *# !) !* ! ''

! !! ! !%!$ ! )&&

$!#%!) !$!''! !

&)&)""!)'1.

2.

! ! !%?&!#$ !!!!*! !&)

&!!%

3.*

!!*#&)(!" !%

4.*5

!!'*''*',!"!"%

!! ! $' * ' ' '

!%'! !!'%!!!

#!#!'!#!!$!

#" !#!%

.

#!"#!$%! !

!" ! $* ,!" ! %> )#!*

!$$##"#$$$!##"%

5,*&

.65,

!#"$$(#!-!',.##! #!

"! *!!#'% !!')(!"

)!*=!*%

/.)65,

' (#! " ! ' & ! ()!%

/.+

?!!!#!+!$)%#$*!)

)"%

0.)

! * ' " !' ' #" * '

=!'%!*#" &)")

=!% ' ! ' =! ' % ! !&

#!'#" %

.

!'!''#" *!!%!

= !!!'''!%!!= !!!''

- .% '! '!'*#"

% ! !&) )& !#$ @

% * ! ' )&! ' ! ' % #" !

"' )#!%

2.**

!=& & ! )& *!#!%

!*#" !"' %!"! !! %

)!'!"! &"%!"!$

$) #"%>()!*)!'#")&

!"#%

3.,*

! !!')!!! !''#" !

! "%!!!!'!'!!#

!' ' % !& !! !!

!$$#" [email protected]+! !% !'

" ! $ ''$ !' #" $ ' ! #

)&%

4.)

! ')$='#" %'! $')"*

) !! '& #" * $)! ' #"

')%

.

! ) $ #" % !& )

=&!'!%! &! *"#!*!

!'! !%! ')&$!'

* ##"$$!%

!'!#'#'!A,

)$! !'

)(

9% #&!#& , ')& [email protected]&!'&!!!# !,!!%

#'' ! * ! !) ! !# !! '' ! !'

)@+!%B"!#&&!%

7% >!!$!!*!!$!#"@"& &

B!#&%

8% >!!, ')"!!, &''! !

! ''!"!'& %

*+(78

*

()$$'*!* *! *

!" ''%

**9

9)

*

! -! ! . ! & ' ! '

!'!'!# '! $!" %

' !'& ) +* $% ' ! )

)&"[email protected]"!>#@"

!%

).! !

*)

). !'

!'! *!!# $!!!'#!A

.+

!$&!'!#! ! !'! %

/.*

! )=," ! ' ! )!% ! $

! ! $ # # #&! ' #

!%

0.

! )# !#&! $)$%!

,!!!'(!!"%

.*

!' '# ')%!!

&E! $!$$!'%

2.*

!'$ '%!!''## !!A

-. !$)$ #*

-.))$ =!'$!!!

%

3.+*

! ! ' #" % ) (! +& $& # '

! !%

5,*)

>$&!!!! *! !$!&

#" %! !' '!

!'#!"%&))"#!"'*!

$'#" %?!!"!-%%*'#)"#!"!.'

#"&'! %! +*!!#%-.% #"

! ' ! ' $& &% ' ! (! )&

$## #! #" %! $*!!#%

-).% ! ' $& #! #" ' $& &% ' !

(!)&$#" !#&!%

-. +-). F

).>" '

! * & ' $ ! $ ' )&

!!# % ! ! ! $

'#!"*#!"!!$! %

! ! ! ! ! $! $& !#

! '# !"*#! !" # $

'!! %!!!"#[email protected]"!%

).G"!

*))

! !!!'!'#!A

.&

$!*! !!!'!'#!A

' ,

" ! * " ! $ @" ! ! ! $

%"!(!)!!)&')

-!".%

:

! *!")#*#!$)&! %!& '! !

#&!%

; (*

&! *&!&!!!$%!& '! !''

"! %

/.&*)

!$'*! !!!'!'#!A

'

.)+*

!')*! !!!'!A

' *

! ! *)!$!%%*+$*$

'%)!#$%

: &*

$! ! * )$ #$!* ) ) !#$ )

+ =! ' ) ) )

+=! '!=!%!& '! !!&!#"%

))

! !! '!'#!A

9%='!"!!*

7%+')*%%**# ')*

8%=$+$')*

*+(78/

+!'H$!'H!!F,$!! %

**9

9)

*

**

! #$''#" "!

-.# #" ! ' ! % ! !

!$&'!%"#!IJ!

$! '!$# &

)%$$!! )#" ! )

)&)$!(#"=&)%

!! ! & ' ' !'!* ' "

$!*!%

5,*)**

?# ' !! #" & $

%()#" !& )'"=

$$!! )%()! '!#&

!%#")'$*!!%>$'

#" *$'()'' ! !

! %

).>" '

**

#!!'!!'!'#!A

.#%"!;"%-%"%'#%, ,$*!$

''! !)&!'$'#" %

/."=%#%"!;#:#%,#!!"#!)%!*

!$)&!'''#" %

). ' ,

). '#,

()**

!$) '' ! ! !+!% !!&) !!'!

'#!A

*,(**

! !!$#!!$*""

!%"#!$!$!

$! ! ' #" ! ) #" )% $!

$'#")! $)&)!#!

"%)#!!$!!!%#"

! ! )% +* $ " &

!!)#A

'

).+ C&

: &***

$"& !* !' ! !$% !

!)$!! *! !#$&))'

!!#$& %!!!)'' !%

).F C&

; (**

& !* ! ''

! ) !#$ (# ! ' % $

'#)"# !$%!'!)

! =! $ +* $ % ! &

! ) ' !!' !* -. & -.

%

/ +(**

? & ! $& $ " &

!%!!*)!$'=) '"%!

!!!$!')% )'! !

$!!*&)5!! =* = =!%

& !&)!!'!+$*)!'! =!%

' ))7+(**

(!'!! !!*&'

' ' ) ' ! $ $ $ & ' #"% !

'&' ) !!* * '* $!

=()*@"! %!! &!)' #"%

:

' +***

! , ! $ ) # ! ) $ =!%

! ! ' $ % & ) !

' ' !'! )& ! ' !% ! #

$! !*'''!#"%!!$#

! !% ! ) ! '' ! $#&! '

# ! !! !& #"

!%

: (**

! ' ' # '! ' #"

!!&!&%#!+=!!!'

#" !%'!)'+! !

$!'#'!'#" % !'! '

%

; ****

! =! !"$!*!*!*%*)&! '

! % ! ! #" ! )& !&+

$!'%! $!'

'%!&!!! !'

#!! #" ! !%

**

!!!'!#!%! )&!

$)'!&$!%!

$!#')'!#!!'! !%

,(5(**

"&,#&!! ' ! @ "&,#&! '&%

!!!) %!!&"&,#&

#!+$'#")*''*!$!$'

*%

1 ,**

! ' ) ! ! !)! % 5!

6* #" ! !& ! $ ' '

!%)$! *!"6!!!'

!!##" !)#!$ !$$

!%!&$+$ ! =!%!!!&

!'!!%

*(**

! ! ! )! ' & -. ' !

%#"!!$!#!!'

)& $$ ! '! !! ! '

%! & !')+$!!$)% &

!!')=!!'!%

7

=! '$ &' '#"&)'@ !%

! @ ! ' )" ! ' )& =% = !

!)&!! "#!$=!!#

)#,

**

!) ')&!!'!'#!A

-9. -7. -8. -

***

! ! ' ' !'! %

#!) ! #& !'!* !

)&)!%F,)"!'&!+))&! %

**

!& !'!#&$!#$

!=!%!!!' !!%

)**

!& !'!!! '#" %!)

!$=*$*#" %

**

!& !'!$'!'%&!' '*

' !%

!'!#'#'!A,

).F!& !' !

*+(780

**

()$$!'%

**9

9)

*

!

" #

$ %&'

( )*&

+ %

, -

.

/0

'

/

/*'

/1/

234%5

//

&

4&..$....".

6

6&&&

'&

7&&

4&&&&&

8

7&

6

#/

*

790

7''&/

/

:

!

:

" -

$ 4

( ;

+ -

, /

7&

7 &

)'&0/

0 & 0&

' 7

(

LABORATORY EXERCISE_1

SHEET METAL FORMING

AIM: To make a rectangular tray from a given metal sheet.

TOOLS REQUIRED: Mallet, Snip, Stake, Steel Rule, Ball peen hammer, Straight edge, Rivets, Scriber, etc.

PROCEDURES:

1. The given metal sheet is smoothed using mallet.

2. The development of rectangular tray is drawn on the sheet with given dimensions using the

scriber.

3. The unmarked and excess portions in the sheet are removed using snip.

4. Folding is done as per the given order using mallet and stake.

5. Bending is done as per the given dimension using the stake and mallet.

6. The tray is riveting using the given rivets and hammer.

RESULT:

PRECAUTIONS:

!"#

!" $

%

%

&

'

'

(

)

!*

$

+*

%*

+*

#

,

)

)

,-

)

(

(

))

.

/

0

!

!*

1

#(

+*

%

2*

!"#

+*

3+

.

4 '

%

"

567

%

%*95786

. " "

+*"

3+*

.

+

4 '

%-

567

%*5: 86 +

.")$

"

3

$

+*

*

-

56786

+* 5 86

3

) *

%

*

. *

*

;

" &&

,

8 *

* 4

484

8-- 4

%

% 3

--*

5 (" %%*

3

*%

3

6 ) %%+*4*

3 --

"

.+

41($

'%((

%*

%

79=

69> ( ;9 8?

5>99( 679 8?

% ;699 @&

;[email protected]&[email protected]:;[email protected]%B

%

4 ;; 859

% !

+ " 3

BB

BB

CC

BBB*B+

4

CC CC 65999 ( ;999 8? D 699

3 4 0

3

-

E;=

-

*

%

3;6999

/

3

+-

2;F999

/-

+ .

&-;9999

*"

(

'58>

--

--

%573

(

%

%

65'(;9998?D699

.

+

+6699

+"*

%0& %&

*

!

!

(

$

&

$

"

4

!

4

4

"

" "

$ ,,-

./

.

0&

%& 0&

)

>9*E9G79*A9

G 2

,

H&

H&

&

4

0

"

0

7!

3

!599=79=

4"

*"*

' ''%

3

.

* 0*1 *

' '3$

-

-

.&%

& 3

4

0

0 599

7!59%

3 7

!599=79=%%599=

*"*

' ''% )'%

3

.

* 0*1 * 0*1

' '3$

-

-

.&% '3$

.

3

599

59%

7

%%599=

)'%

0*1

$'%

'3$ $'%'3$

*

."))'%

.")''3$

3$ 3$$ %$ %

.

.") 3$ 3$

3$ 3

-

%

3$

#

%

2-

(

"

%23

%

I% 6 56

.

;9:9

. 4

-

%+" '

, 4,

, !

) )-

!G-G

( !- !

5: 5: F9*:9

67 67 79*A9

F9 ;6 E9*5;9

:9 F9 569*5>9

A9 79 5A9*6>9

679 :9 ;99*F99+ !" *

' )-

. )*

1 '%

3

1 "%%

3 434 '

%57J67J

)

."&% 2

)

(

."

% % 4%4&,& 3 1 G %0

& 3

& %3

&5& &5 6 !4; %

&

5 '-6 ; %

LABORATORY EXERCISE_1

ARC WELDING

AIM: To prepare a butt joint with mild steel strip using Arc welding technique.

EQUIPMENT & MATERIALS REQUIRED:

SEQUENCE OF OPERATIONS:

RESULT:

PRECAUTIONS:

LABORATORY EXERCISE_2

GAS WELDING

AIM: To prepare a butt joint with mild steel strip using Gas welding technique.

EQUIPMENT & MATERIALS REQUIRED:

SEQUENCE OF OPERATIONS:

RESULT:

PRECAUTIONS: