GE2152 Basic Civil & Mechanical Engineering

7/30/2019 GE2152 Basic Civil & Mechanical Engineering

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. ALAGARRASU,BE.,

UNIVERSITY COLLEGE OF

ENGINEERING

VILLUPURAM

GE2152 Basic civil &

MEchanical EnGinEErinGLAB MANUAL

For Second Semester B.E / B.Tech. Students

(For Non - Circuit Branches)

Compiled by

M. ALAGAR RASU, B.E.,Professional Assistant - I Department

ofMechanical Engineering University

College ofEngineering


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INDEX

S.NO NAME OF THE EXPERIMENT PAG

E

SIGNATURE

CIVIL

1 Basic Pipe Connection Using Valves, Taps, Elbows, T InHouse Hold Fittings

2

2 Preparation Of Mixed Pipe Material Connection For HouseHold Appliances.

3

CORPENTARY

3 Planning 4

4 TEE joint or middle LAP joint 5

5 MORTISE and TENON joint 6

6 HALF LAP joint 7

7 BUTT joint 88 LAP joint 9

9 TEE joint 10

SHEET METAL

10 TRAY 11

11 FUNNEL 12LATHE

12 FACING AND PLAIN TURNING 13

13 STEP TURNING 14

14 TAPPER TURNING 15MOULDING

15 STEPPED CONE PULLEY 16

16 GEAR WHEEL 17

FITTING

17 Square fitting 18

18 V fitting 19

19 Square filing 20WELDING

20 Butt Joint And Lab Joint 21


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GE 2152 BASIC CIVIL & MECHANICAL ENGINEERING LAB MA

M. ALAGARRASU,BE.,

B A S IC PI P E C O NN E C T I O N U S I NG VA L V E S , T A P S , EL B O W S , T IN

HO U S E H O L D F I T T I N G S

AIM:

To prepare a pipe line connection with all fittings.

TOOLS REQUIRED:

1. Pipe wrench2. Adjustable spanner

3. Measuring tape4. Plumbing vice

FITTINGS REQUIRED:1. Bend

2. Coupling3. Elbow

4. T5. Tap

6. Valve7. End cap

8. Reducer

PROCEDURE:

1. First draw the plumbing lines sketches for the basic pipe connection.2. Take the plumbing fittings and tools.

3. Then connect the pipe line with the plumbing fittings as per the diagram.

4. Then tighten each connection properly by fitting them in plumbing vice.

RESULT

: Thus the basic pipe connection using valve tap T, elbow, etc., is done.


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P R E P ARA T ION O F M I X E D P I PE M A TE R I A L C O NN E C T I O N F O R HO U S

HO L D A P P L I ANC E S

AIM

: To draw and construct mixed pipe materials connection for washing machine and water heat

TOOLS REQUIRED:1. Pipe wrench2. Adjustable spanner

3. Measuring tape4. Plumbing vice

5. Hacksaw

MATERIALS REQUIRED:1. Bend2. Coupling

3. Flexible pipes and hoses4. T

5. Tap6. Valve

7. End cap8. Reducer

9.GI and PVC pipes

10. Union

PROCEDURE:1. First draw the plumbing line sketches.

2. Mark the location for washing machine, water heater and pipe lines.3. Now connect the pipes line to the fitting as per the plumbing line sketch.

4. The water tank was filled with water and gate valve was opened slowly to supply water into pipe line.

5. Then properly tighten the connections.

RESULT

: Thus the pipe line connection to a washing machine and water heater is done.


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M. ALAGARRASU,BE.,

PL ANNING

AIM:

To plan the given work piece according to the size given.

MATERIALS REQUIRED:

A wooden piece of size mm.

TOOLS REQUIRED:

1. Jack plane

2. Steel rule3. Try square

4. Marking gauge5. Bench vice

OPERATIONS:

1. Planning

2. Marking3. Finishing

PROCEDURE:

1. The given job is clamped in a carpentry vice and any two surfaces are planned to get right angle.

2. The right angle required is to be checked by try square..3. Required size is marked on the work piece by means of using steel rule and marking gauge.

4. The sizes marked on the wooden pieces are to be planned by means of wooden jack plane.5. the planned surfaces are again checked for its accurate size and shape and angle.

RESULT:Thus the given job is planned and the correct dimensions size and shapes are

obtained.


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T EE J OINT OR MIDDLE L AP J OINT

AIM:

To make a Tee or middle lap joint on the work piece according to the given dimensions.

MATERIALS REQUIRED:


TOOLS REQUIRED:

1. Jack plane

2. Steel rule

3. Try square4. Marking gauge5. Bench vice

6. Rip saw7. Firmer chisel

8. Mallet

OPERATIONS:

1. Planning2. Marking

3. Cutting4. Chiseling

5. Finishing

PROCEDURE:

1. The given job is clamped in carpentry vice and any two surfaces are planned to get right angle.

2. The right angle required is to be checked by try square.3. Now all the four surfaces of the wooden pieces are planned to get the smoother and finished surface.

4. Then the job is cut into two halves.5. The different markings required for making Tee Halving joints are to be marked on the work piece by mean

ofusing steel rule and marking gauges.7. One half of the work piece is taken using saw and chisel to remove the unwanted portion as per the dimensi

8. The other half of the work piece is also produced by means of repeating the above procedure.9. The two pieces are to be assembled to get a proper joint.

10. The job is again checked for its accurate shape and size using try square and steel rule.


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M. ALAGARRASU,BE.,

RESULT

: Thus the Tee or middle lap joint is made on the work piece according to the given dimensions.


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MORT ISE AND TE NON J OINT

AIM:

To make a mortise and tenon joint on the work piece according to the given dimensions.

MATERIALS REQUIRED:


TOOLS REQUIRED:

1. Jack plane

2. Steel rule



8. Mallet

OPERATIONS:



5. Finishing

PROCEDURE:








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M. ALAGARRASU,BE.,

RESULT

: Thus the mortise and tenon joint is made on the work piece according to the given dimensions.


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HAL F L AP J OINT

AIM:

To make a half lap joint on the work piece according to the given dimensions.

MATERIALS REQUIRED:


TOOLS REQUIRED:

1. Jack plane

2. Steel rule



8. Mallet

OPERATIONS:



5. Finishing

PROCEDURE:







RESULT :


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M. ALAGARRASU,BE.,

Thus the half lap joint is made on the work piece according to the given dimensions.


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B UT T JOINT

AIM:

To make a butt joint on the given mild steel plate by arc welding.

MATERIALS REQUIRED:

Two mild steel plates size mm

TOOLS REQUIRED:

1. Try square

2. File3. Steel rule

4. Electrode

5. Tongs6. wire brush7. Chipping hammer

8. Gloves

PROCEDURE:

1. Two mild steel plates ofsize

is taken.

2. The metal plates are cleaned by wire brush and are wiped thoroughly.

3. One edge of each metal plate are filed smoothly.

4. The metal plates are placed to required position.5. Suitable electrodes and the current required for welding are selected. The electrode is held in the holder.

6. The hand shield must be used during arc welding.7. The electrode is brought near the work piece with an air gap of about 3mm.

8. The ends are welded first then slowly welding is done between the two ends.9. After welding process is over by using chipping hammer, the slag over the welded portion is removed then

cleaned with the help of wire brush.10. Now the joint is finished.

RESULT:


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M. ALAGARRASU,BE.,

GE 2152 BASIC CIVIL & MECHANICAL ENGINEERING LAB MAThus the two mild two plates are welded to get a butt joint


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L AP J OINT

AIM:

To make a lap joint on the given mild steel plate by arc welding.

MATERIALS REQUIRED:

Two mild steel plates size mm

TOOLS REQUIRED:

1. Try square


4. Electrode


8. Gloves

PROCEDURE:


is taken.

2. The metal plates is cleaned by wire brush and are wiped thoroughly.

3. One edge of each metal plate is filed smoothly.

4. The metal plates are placed to required position.5. Suitable electrodes and the current required for welding are selected. The electrode is held in the holder.



cleaned with the help of wire brush.10. Now the joint is finished.

RESULT:

Thus the two mild two plates are welded to get a lap


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M. ALAGARRASU,BE.,

joint


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M. ALAGARRASU,BE.,

T EE J OINT

A I M :

To make a Tee joint on the given mild steel plate by arc welding.

M ATER I AL S RE Q U I RED:

Two mild steel plates mm

T OOL S RE QUI RED:

1. Try square


4. Electrode


8. Gloves

P R OCEDURE :


is taken.

2. The metal plates are cleaned by wire brush and are wiped thoroughly.

3. One edge of each metal plate is filed smoothly.

4. The metal plates are placed in Tee required position.5. Suitable electrodes and the current required for welding are selected. The electrode is held in the holder.



cleaned with the help of wire brush.

10. Now the joint is finished.

RE SULT:

Thus the two mild two plates are welded to get a Tee joint


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M. ALAGARRASU,BE.,

T RAY

A I M

To make a tray out of the given sheet with specified dimensions.

T OO LS RE Q U I RED1.Bench vice

2.Try square3.Steel rule

4.Divider5.Snap

6.Mallet7.Hand shearing

8.Dot punch9.Scriber

MATERIALS REQUIRED

G.I. Sheet of suitable size

P R OCEDURE :

1.Draw the lay out of the bottom and body of the tray

2.The edges are marked clearly on the sheet metal using pencil3.The given sheet is cut to the required shape and size using hand shears

4.The marked lines are folded with the help of mallet and required stakes5.After folding on the all sides it resembles a tray

6.The folds are made with dot punch on the marked portions for riveting

RE S UL T :

Thus the required tray is finished from the given sheet


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M. ALAGARRASU,BE.,

FUNNE L

A I M

To make a Funnel out of the given sheet with specified dimensions.

T OO LS REQUIRED1.Bench vice2.Try square

3.Steel rule4.Divider

5.Snap6.Mallet

7.Hand shearing

8.Dot punch9.Scriber

M ATERI ALS RE QU I RE D

G.I. Sheet of suitable size

P R O CEDURE ;

1.Draw the lay out of the funnel on the given sheet metal (Part I and Part II)2.The angle subtended by the cone when opened for lay out is calculated by using

The relationAngle =3.14xDiameter of the base

Slant height3The edges are marked clearly on the sheet metal using pencil

4.The given sheet is cut to the required shape and size using hand shears4.The marked lines are folded with the help of mallet and required stakes5.After folding on the all sides it resembles a funnel

6.The folds are made with dot punch on the marked portions for riveting

RE S UL TThus the funnel is finished from the given sheet


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M. ALAGARRASU,BE.,

FACING AND PL AIN T URNING

A I M

To get a required shape and size of a given work piece by Facing and plain Turning operations done

in lathe.

T OO LS RE Q U I RED:

1.Single point cutting tool

2.Vernier Caliper3.Tool post key

4.Steel rule5.Scriber

MATERIALS REQUIRED

Mild steel rod ofdiameter

and length

P R OCEDURE

1 First the given work piece is checked for its dimensions

2 The work piece is fitted in the chuck properly and tighten by the chuck key3 Ensure the center of work piece.

4 Hold the cutting tool in the Tool post ,check the tool tip whether it is coincide

With tail stock spindle tip for centering and then tighten the nuts using toolpost Key.

5 Facing operation is done with cutting tool by many it perpendicular to lathe axis.

6 It is done on both sides of workpiece up to the required length.7 Then turning operation is done with cutting tool which removes the upper part of

The workpiece to reduce the diameter up to the dimensions required.8 Then remove the work piece from the chuck

9 Atlast the dimensions of workpiece are checked.

RE S UL T

Thus the required shape and size of a given work piece is done on lathe by Facing and


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M. ALAGARRASU,BE.,

Plain Turning Operation.


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M. ALAGARRASU,BE.,

STE P TURN I NG

A I M

To get a required shape and size of a given work piece by Step Turning operations done in lathe.

T O O L S REQUIRED:

1.Single point cutting tool2.Vernier Caliper

3.Tool post key4.Steel rule

5.Scriber


Mild steel rod of

diameter

and length

P R O CEDURE

1 First the given work piece is checked for its dimensions

2 The work piece is fitted in the chuck properly and tighten by the chuck key3 Ensure the center of work piece.

4 Hold the cutting tool in the Tool post ,check the tool tip whether it is coincide

With tail stock spindle tip for centering and then tighten the nuts using toolpost Key.

5 Facing operation is done with cutting tool by many it perpendicular to lathe axis.

6 It is done on both sides of workpiece up to the required length.7 Then turning operation is done with cutting tool which removes the upper part of

The workpiece to reduce the diameter up to the dimensions required.8 Then remove the work piece from the chuck

9 Atlast the dimensions of workpiece are checked.

RE SULT

Thus the required shape and size of a given work piece is done on lathe by Step

Turning Operation.


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M. ALAGARRASU,BE.,

T APPE R T URNING

A I M

To get a required shape and size of a given work piece byTaper Turning

operations done in lathe.

T O O L S REQUIRED:

1.Single point cutting tool2.Vernier Caliper

3.Tool post key4.Steel rule

5.Scriber


Mild steel rod ofdiameter

and length

F OR M ULA:Taper angle=tan

-1D - d

2L

D=Diameter of big endd=Diameter of small end

L=Length between two ends

P R OCEDURE

1. First the given work piece is checked for its dimensions2. The work piece is fitted in the chuck properly and tighten by the chuck key

3. Ensure the center of work piece.4. Hold the cutting tool in the Tool post , check the tool tip whether it is coincide

with tail stock spindle tip for centering and then tighten the nuts using tool post

key.5. Facing operation is done with cutting tool by many it perpendicular to lathe axis.6. It is done on both sides of work piece up to the required length.

7. Then turning operation is done with cutting tool which removes the upper part of8. The work piece to reduce the diameter up to the dimensions required.

9. Next the Taper turning is done on the work piece according to the taper angle Calculated10. The compound rest base is swiveled and set at calculated taper angle

11. Cutting tool is move towards at an angle to the lathe axis12. Tool is removed by compound rest hand wheel up to required angle.

13. Then remove the work piece from the chuck14. At last the dimensions of work piece are checked.

RE S UL T


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M. ALAGARRASU,BE.,

Thus the required shape and size of a given work piece is done on lathe by Taper

Turning Operation.


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M. ALAGARRASU,BE.,

STE PPED CONE PUL LEY

A I M :

To prepare the green sand mould for the given stepped cone pulley

T OO LS RE Q U I RED :Moulding boxes, Moulding board, Shovel, Peen and round rammer, Strike off bar,

Trowel, Slick, Sprue pins, Vent wire, Brush, Lifter, Swab, Cleaner and gate cutter.

P R O CEDURE :1. Select a suitable moulding box.

2 Here a single piece pattern is used so place one half of the pattern on a mouldingBoard.

3. Place the drag box around the pattern and keep 20mm layer of facing sand around the pattern.4. Fill the track with loose sanding sand.

5. Ram the sand by rammer around the pattern uniformly.6. Fill the sand up to the top of box. Strike off the excess sand by using strike off bar and bring it at thesame

level of the flask height. This completes the drag.7. Make vent hole in the sand.

8. Now the drag is tilted upside down.9. Sprinkle parting sand over the top of the drag.

10. Place copes over the rammed drag.11. Place sprue pin and riser pin in position then fill the cope with the moulding sand and ram it uniform

using a rammer.12. Strike off the excess sand from the cope.

13. Make vent holes in the cope using vent wire.14. Remove sprue pin and raiser pin and cut pouring basin at the top to pour the molten metal.

15. Separate the cope and drag.16. Finish and smooth the top surfaces of cope and drag with trowel.

17. With draw the pattern from the mould by using drawspike.18. Cut the gate connecting the sprue basin with mould cavity.

19. Carry out the repair work in the mould if necessary.20. Apply mould cavity coating with swab.

21. Now assemble the two mould boxes in correct positions and place the pouring the weight.22. Now the mould is ready for pouring.

RE S U L T:Thus the mould for step cone pulley is made.


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M. ALAGARRASU,BE.,

GE AR WHE EL

A I M

: To prepare the green sand mould for the given gear wheel.

T OO L S RE Q U I RED:Moulding boxes, Moulding board, Shovel, Peen and round rammer, Strike off bar,

Trowel, Slick, Sprue pins, Vent wire, Brush, Lifter, Swab, Cleaner and gate cutter.

P R O CEDURE :1. Select a suitable moulding box.2 Here a single piece pattern is used so place one half of the pattern on a moulding

board.3. Place the drag box around the pattern and keep 20mm layer of facing sand around the pattern.

4. Fill the track with loose sanding sand.5. Ram the sand by rammer around the pattern uniformly.

6. Fill the sand up to the top of box. Strike off the excess sand by using strike off bar and bring it at thesame

level of the flask height. This completes the drag.7. Make vent hole in the sand.

8. Now the drag is tilted upside down.9. Sprinkle parting sand over the top of the drag.

10. Place copes over the rammed drag.11. Place sprue pin and riser pin in position then fill the cope with the moulding sand and ram it uniform

using a rammer.12. Strike off the excess sand from the cope.

13. Make vent holes in the cope using vent wire.

14. Remove sprue pin and raiser pin and cut pouring basin at the top to pour the molten metal.15. Separate the cope and drag.16. Finish and smooth the top surfaces of cope and drag with trowel.

17. With draw the pattern from the mould by using drawspike.18. Cut the gate connecting the sprue basin with mould cavity.

19. Carry out the repair work in the mould if necessary.20. Apply mould cavity coating with swab.

21. Now assemble the two mould boxes in correct positions and place the pouring the weight.22. Now the mould is ready for pouring.

RE S ULT:Thus the mould for gear wheel is made.


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M. ALAGARRASU,BE.,

SQUARE FITT ING

A I M :To make a square fitting on the given work piece with proper dimension.

M ATER I AL S RE Q U I RED:Mild steel, plates of

T OOL S RE QUI RED:

1. Bench vice2. Try square

3. Steel rule4. Surface plate

5. Surface gauge6. Hacksaw

7. Angle plate8. Dot punch

9. Scriber

O P ERAT I O N S :1. Right angle the given work piece.2. Darken the face of work by chalk.

3. Marking4. Punching

5. Cutting6. Filing to finish.

PROCEDURE:1. After checking the dimensions using steel rule the job is fixed on a vice and the sides are filed using

flat file so that they are at right angles.2. Chalk is applied on the work piece.

3. With the help of caliper surface plate and steel rule the given dimensions are marked on the workpiece and punching is done using dot punch.

4. By using the hacksaw the unwanted portions are removed and the corresponding surfaces are filedand smoothened to get require dimension and the accuracy is checked by a try square.

5. Finally when these two pieces are fitted they form a square fitting.

RE S ULT:Thus the square fitting is obtained on the given work piece.


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M. ALAGARRASU,BE.,

V FITT ING

A I M :To make a V fitting on the given work piece with proper dimension.


T OOL S RE QUI RED:

1. Bench vice2. Try square

3. Steel rule4. Surface plate

5. Surface gauge6. Hacksaw

7. Angle plate8. Dot punch

9. Scriber

O P ERAT I O N S :1. Right angle the given work piece.2. Darken the face of work by chalk.

3. Marking4. Punching

5. Cutting6. Filing to finish.


a flat file so that they are at right angles.

2. Chalk is applied on the work piece.3. With the help of caliper surface plate and steel rule the given dimensions are marked on the work

piece and punching is done using dot punch.

4. By using the hacksaw the unwanted portions are removed and the corresponding surfaces are filedand smoothened to get require dimension and the accuracy is checked by a try square.

5. Finally when these two pieces are fitted they form a square fitting.

RE S ULT:Thus the V fitting is obtained on the given work piece.


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M. ALAGARRASU,BE.,

SQUARE FIL ING

A I M :To make a square filing on the given work piece with proper dimension.


T OO L S RE Q U I RED:1. Bench vice

2. Try square3. Steel rule

4. Surface plate5. Surface gauge

6. Hacksaw7. Angle plate

8. Dot punch9. Scriber

O P ERAT I O N S :1. Right angle the given work piece.

2. Darken the face of work by chalk.3. Marking

4. Punching5. Cutting

6. Filing to finish.


flat file so that they are at right angles.2. Chalk is applied on the work piece.

3. With the help of caliper surface plate and steel rule the given dimensions are marked on the workpiece and punching is done using dot punch.

4. By using the hacksaw the unwanted portions are removed and the corresponding surfaces are filed a

smoothened to get require dimension and the accuracy is checked by a try square.5. Finally when these two pieces are fitted they form a square fitting.

RE S ULT:Thus the square filing is obtained on the given work piece.


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M. ALAGARRASU,BE.,

BUTT- WELDING AND LAP WELDING.

AIM:

- To prepare Joints for welding suitable for butt- welding and lap welding.

TOOL REQUIRED: -Scale, scriber, hand hack saw, flat file, swing scale protector, welding machine, eye shield, gloveswire

brush, chipping hammer, welding rod.

MATERIAL REQUIRED: - Mild steel plate of 8mm thickness.

PROCEDURE FOR BUTT JOINT:-

1. Two pieces are cut to size and surfaces are cleaned.2. One edge of both the pieces is prepared at 45 degree angler for making V- groove

using file.3. Electrode is held in electrode holder and earth clamp is clamped to the work piece.

4. Pieces are positioned properly butting each other and tack weld in done at twoend points.

5. 2-3 mm spark gap is maintained and continuous welding is done slowly.6. Slag is removed using chipping hammer and the weld is cleaned using wire brush.

PROCEDURE FOR LAP JOINT:-

1. Two pieces are cut to size and surfaces to be welded are cleaned properly.

2. Electrode is held in electrode holder and earth clamp is clamped to be work piece.

3. The pieces are positioned overlapping each other for lap joint and tack weld is done attwo end points.

4. 2-3 mm spark gap is maintained and welding is done smoothly.

5. Slag is removed using chipping hammer and weld is cleaned using wire brush.

PRECAUTIONS:- Wear apron, shoes, nose mask, gloves and tight fitted clothes.

Be careful and attentive while working on welding job. During welding dont see the welding light rage directly without the goggles / face shield.

Do not cool the welding piece in water. Do not keep electrode holder on the welding machine.

No inflammable material should be present in welding shop.

RESULT:
http://labmanual.blogspot.in/2011/12/to-prepare-joints-for-welding-suitable.htmlhttp://labmanual.blogspot.in/2011/12/to-prepare-joints-for-welding-suitable.html


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work

piece.Thus the Joints for welding suitable for butt- welding and lap welding is obtained on the give

Documents

GE2152 Basic Civil & Mechanical Engineering