Workshop Practice

B.E. I/IV Yr.
(Common to all branches) Year wise

ME 131
WORKSHOP PRACTICE
List of Experiments Prescribed by Osmania University

Compulsory trades:
1. Fitting
2. House wiring
3. Carpentry
Elective Trades:
Two of the following trades shall be offered in additions to the above
1. Plumbing
2. Welding
3. Smithy
4. Sheet metal shop
List of innovative experiments (if any)
WORKSHOP PRACTICE
CONTENTS
S.
No.
Name of the Experiment
Page
No.
Sheet Metal (Tin smithy)

1.
Introduction to Tin smithy
2.
To make a rectangular scoop from a given metal sheet
3.
To prepare a rectangular box having base and top open from a given
metal sheet
4.
To prepare a pamphlet box from a given metal sheet
5.
To make a square tin having separate base and top open
10
Smithy
1.
Introduction to Smithy
12
2.
To make a round to square section of the given rod.
15
3.
To make a S shape
17
4.
To make a U clamp
19
5.
To make a O shape
22
1.
Introduction to Fitting
24
2.
To make a square
27
3.
To make a Template Fitting
29
4.
To make Drilling and Tapping in the given plate.
31
5.
To make a T Fitting as per given dimensions
33
Fitting
Plumbing
1.
Introduction to Plumbing
35
2.
Cutting of external pipe threads using hand die on the given G.I. pipe
for plumbing purpose
42
3.
Plumbing of water tap connection as per the layout using PVC / GI

pipe and relevant pipe fitting
44
4.
Plumbing of bath room water shower and line water tap as per layout
using GI / PVC pipe and relevant fitting
46
Welding
1.
Introduction to Welding
48
2.
To make a straight line bead on MS plates
51
3.
To make a Butt joint on MS plates
53
4.
To make a Lap joint on MS plates
55
5.
To make a T joint on MS plates
57
6.
To make a Corner joint on MS plates
59
Carpentry Shop
1.
Introduction to Carpentry
61
2.
To make a planning sawing and chiseling operations
64
3.
To make half Lap joint
66
4.
To make a Dove Tail joint
68
5.
To make a Mortise and Tenon joint
70
House wiring
1.
Introduction to House wiring
72
2.
To connect two lamps in series connection
77
3.
To connect two lamps in parallel connection with controlling one

way switch
78
4.
To connect a stair case wiring
79
Introduction to Tin Smithy

INTRODUCTION:
The sheet metal work section deals with working with metallic sheets using hand
tools. Sheet metal works such as making a tray, box, funnel, chimney, air duct,
fabricate boiler shells and pipe joints from thin or thick plates, etc. are few examples
of its application and the process being known as Tin Smithy. To make any object
from sheet metal, knowledge in engineering drawing and development of surfaces is
required. As per drawing the sheet is cut and folded to form the required shape of the
article. The edge of the article are then secured through welding, brazing, soldering,
rivetting etc.
Allowance should be given in the drawing stage for folding and
bending. This allowance depends on the radius of the bend and thickness of the sheet
metal.
Metal sheets:
Metal sheets of ferrous and non-ferrous metals are used in sheet metal work.
Stainless steel or aluminium sheets are used to make household utensils.
Galvanized iron (GI sheets) are used to make air ducts in central air conditioning
plant and to make steel table, chair etc.
Wire Gauge and Sheet Gauge:
The thickness of sheet metal is referred in numbers known as standard wire gauge
(SWG). The gaps in the circumference of the gauge are used to check the gauge
number as shown in figure. Some of the standard wire gauge numbers with
corresponding thicknesses are shown in figure.
Marking and Measuring Tools:
Marking and measuring tools are used to produce objects to an exact shape and size.
The commonly used tools are given below:
Steel rule:
It is used to measure and mark dimensions.
It is graduated on both sides in
millimeters and centimeters or inches. Its length varies from 15 cm (6 inches) to 30

cm (12 inches).
Scriber:
It is used to mark or scribe lines on the metal sheet. Its length varies from 150 mm to
300 mm and has diameter which varies from 3 to 5 mm.
Divider:
It is used to mark the dimensions from scale to the work piece. It is also used to
scribe arcs and circles on the sheets. It is similar to the compass and is used for more
accurate marking.
Centre punch:
It is used to mark a centre for a hole to be drilled. It can also be used for marking
points along a line for cutting. Its tapered point end has an angle of 60 degrees.
Try-square:
It is used for marking and checking right angles. It consists of a steel blade riveted at
right angles. It is used to mark square corners.
Trammel points:
It is used to draw large circles and arcs. The trammel has two removable pointed legs
and mounted on separate holders. The holders slide on a beam which can be easily
adjusted for the required length.
CUTTING TOOLS:
Snips are used to shear or cut the metal sheets to the required size and shape. Snips
are used to cut thin sheet metals. The following snips are used in sheet metal work.
Straight snip:
It is used to cut or trim along a straight line. The blades in this snip are straight.
Bent snip:
It is used to trim or cut along inside curves. The blades in this snip are curved back
from the cutting edge, which permits the sheet to slide over the top blades while
cutting.
Shearing machine:
The simple shearing machine is used to shear the sheet metal using a compound lever.
The shearing machine has a fixed bottom blade and a top shearing blade which is
operated by a lever. It is used to shear metal plates which cant be cut or trim by
snips.
STRIKING TOOLS:
Hammers: The hammer is a striking tool. It has a handle and a head. Hammers are
classified into four types.
1. Ball peen hammer
2. Cross pen hammer
3. Straight peen hammer
2
4. Rivetting hammer
The ball peen hammer is a general purpose hammer which has a slightly curved face
and a round head. The cross peen and straight peen hammers are used for folding the
sheet and to work in the corners of the object.
Mallet: It has a striking face which is used to give light blows to sheets. It is used to
smoothen/ flatten the surface of the sheet without spoiling it. Mallet is made of hard
wood and is round or rectangular in cross-section.
SUPPORTING TOOLS:
Stakes: The stakes are the supporting tools in sheet metal work to form of shapes. It
supports the sheet while bending, rivetting, punching, etc. There are many types of
stakes to carryout different operations. Following stakes are commonly used in sheet
metal work.
Rectangular Stake: It is used to form / bend the sheet metal to 90 0 and the face of the
stake can be used to form square shape.
Hand stake: It is used for pressing the inner sides of straight joint in the sheet. It has
a flat surface with two straight edges, a concave edge and a convex edge.
Half moon or Half round stake: It is used to form a round seam joint on the inner
side of the job.
Horse stake: It has two square holes for holding one or two stakes to carry out
different operations on the job.
Taper stake: It is used to form a conical or tapering job.
EXERCISE -01
1.
Rectangular Scoop
AIM: To make a rectangular scoop from a given metal sheet

TOOLS REQUIRED:
1.Steel rule
2. Scriber
3. Straight Head Shear
4. Wooden Hammer
5. Plastic Hammer
6. Ball peen hammer
7. Folding Machine
8. Spot Welding Machine
9. Hand Rivet
10. C- Clamp
11. Drilling Machine
MATERIAL REQUIRED WITH DIMENSIONS:
G.I. Sheet 30 gauge 250 mm x 190 mm.
SEQUENCE OF OPERATION:
1) Measuring
2) Marking
3) Cutting
4) Folding
5) Bending
6) Hammering
7) Welding/ Riveting
PROCEDURE:
1.
The given metal sheet is smoothened using wooden hammer.
2.
Draw the development of surface of the rectangular scoop of dimensions 250

mm x190 mm.
4
3.
On this sheet marking has to be done as per dimensions with the help of steel
rule and scriber.
4.
After completion of marking unwanted materials are removed with the help of
straight hand shear.
5.
Now bending has to be done by placing the sheet on the stake or by using
folding machine to get required shape.
6.
Finally welding is performed on the edges of the sheet metal by using Spot
welding machine. Alternatively a hand rivet can be used for riveting the edges
after drilling holes.
PRECAUTIONS:
1. Wear apron, shoes and hand gloves while doing the job for safety.
2. Dimensions have to be measured carefully.
3. Dimensions are to be marked carefully.
4. The cut portion must not be touched by hand while cutting with hand shear.
5. Cutting has to be done carefully without hurting the fingers.
RESULT:
Rectangular scoop shape of required dimensions is obtained.
SKETCH
RECTANGULAR SCOOP
Material: GI sheet 30 gauge

All dimensions in mm
Note: Sketches should be drawn with pencil neatly

6
EXERCISE-02
2.
SQUARE BOX
AIM: To prepare a square box having top open from a given metal sheet.
TOOLS REQUIRED :
1.Steel rule
2. Scriber
3. Straight Head Shear
4. Wooden Hammer
5. Plastic Hammer
6. Ball peen hammer
7. Folding Machine
8. Spot Welding Machine
9. Hand Rivet
10. C- Clamp
11. Drilling Machine
MATERIALS REQUIRED WITH DIMENSIONS:
GI sheet, 30Gauge250 mm x 250 mm
SEQUENCE OF OPERATION:
1) Measuring
2) Marking
3) Cutting
4) Folding
5) Bending
6) Hammering
7) Welding/ Riveting
PROCEDURE:
1.
The given metal sheet is smoothened using wooden hammer.
2.
Draw the development of surface of required square box with top open.
3.
Take 250 mm x 250 mm dimensional sheet and markings are made.
4.
The unwanted material is removed using a straight hand shear.
5.
Now bending is to be done by placing the sheet on stakes with the help of a
wooden hammer.
6. Finally welding is performed on the edges of the sheet metal by using Spot
welding machine. Alternatively a hand rivet can be used for riveting the edges
after drilling holes.
PRECAUTIONS:
1.
Wear apron and shoes while doing the job.
2.
Dimensions have to be marked carefully.
3.
Dimensions are to be measured carefully.
4.
The cut portion must not be felt by hand while cutting with snip.
5.
Cutting has to be done carefully without hurting the fingers.
6.
Do not let sheet metal slip through your hands.
RESULT:
Rectangular box of required dimensions and shape is obtained.
SKETCH
SQUARE BOX
35
60
35
30
60
30

3.
Pamphlet Box
AIM: To prepare a pamphlet box from a given metal sheet

TOOLS REQUIRED & EQUIPMENT:
Steel rule, Straight Snip, Mallet, Scriber, Stakes, Try square, Ball peen hammer lb
G.I sheet, 30-Gauge215mm x 95 mm
OPERATIONS TO BE CARRIED OUT:
1) Measuring 2) Marking 3) Cutting 4) Folding 5) Bending 6) Hammering.
PROCEDURE:
1.
The given metal sheet is smoothened using mallet
2.
The development of the surface of the required work piece is drawn.
3.
A metal sheet of dimensions 215 mm x 95 mm is taken. Marking is done as

per dimensions in the development of surface.
4.
Now bending is to be done by plotting sheet on stakes. After bending, the

required pamphlet box is obtained.
PRECAUTIONS:
1.
2.
3.
4.
5.
6.
Do not let sheet metal slip through your hands. Most cuts from sheet metal
result from allowing it to slide through the hands.
RESULT:
Pamphlet box of required dimensions and shape is obtained.
10
SKETCH
PUMPHLET BOX

11
4.
Square Tin
AIM: To make a square tin having separate base and top open.
Steel rule, Straight Snip, Mallet, Scriber, Stakes, Try square, Ball peen hammer lb.
G.I sheet, 30-Gauge-215mm x 70 mm, 70 mm x 70 mm
OPERATIONS TO BE CARRIED OUT:
1) Measuring 2) Marking 3) Cutting 4)Folding 5) Bending 6) Hammering.
PROCEDURE:
1.
The given metal sheet is smoothened using mallet.
2.
Draw the development of surface of square tin of required dimensions.
3.
(i) 215 mm x 70 mm (ii) 70 mm x 70 mm and mark required dimensions with

the help of steel rule and scriber.
4.
After marking, unwanted material is removed with the help of steel rule and
straight snip.
5.
Now bending is to be done by placing sheet on stakes. After bending as per

requirement, two pieces are assembled and joined with the help of stakes and
mallet. Thus the required square tin is obtained
PRECAUTIONS:
1.
2.
3.
4.
5.
6.
Do not let sheet metal slip through your hands. Most cuts from sheet metal
result from allowing it to slide through the hands.
RESULT:
Square tin of required size is obtained.
12
SKETCH
SQUARE TIN

13
Introduction to Smithy
INTRODUCTION:
The smithing is a process of heating the metal to a plastic stage and then shaping it
with a hand hammer.
SMITHS HEARTHS:
The heating of metal is done in a Smiths hearth. It consists of a hallow dish or tray
made of heavy gauge mild steel or cast iron sheets.
The air is supplied through a motorised fan blower.
The fuel used in a hearth is coal or char coal.
ANVIL:
It is used for supporting the work while it is strikes with hammer, the body of anvil is
made of mild steel to which a piece of high carbon steel about 2.5 mm thickness is
welded on the top to give a hard top face. The beak is soft like the anvil body and its
shape makes it useful for bending round section to different diameters. The ledge
between the beak and the anvil face is also soft.
In the top of the anvil, is a square and a round holes. The square hole is used for
holding square shank shaping tools like bottom fullers. Swages and hardie etc. The
round hole is used for admitting the ends of the punches or drifts. This hole is also
used for bending round bars of different curves. The anvil has a weight of about 75
kg. cast iron stand weight of about 50 kg.
SWAGE BLOCK:
The Swage block is made of cast iron. It is useful for holding bars while bending and
knocking up heads.
HAMMERS:
The hammers are four types.
1. Ball peen Hammer, 2. Cross peen Hammer, 3. Straight peen hammer
and 4. Sledge hammer.
They usually have a slightly Convex Striking face and of 2 lb in weight. The hammer
heads should be made of cast steel.
The weight of the sledge hammer varies from 4 to 6 kg. for ordinary work and 8 to 10
kg. for heavy work.
14
TONGS:
These are made of mild steel used in hand forging.
1.
Flat tong
2.
Hollow Bit tong
: It is used for holding thin sections.

: It is used for holding round, hexagonal, and
octagonal sections.
3.
Open mouth tong : It is used for holding small diameter cylindrical rod.
4.
Chisel of Bolt tong : It is used for holding square, hexagonal and octagonal
work.
FLATTER:
The flatter is used for finishing flat surfaces and or made with a perfectly flat face. It
gives smoothness and accuracy to articles which have already been finished by
Swages and fullers. It is made of tool steel.
SET HAMMER:
The set hammer is set similar to flatter but is smaller tool. It is made up of forged
steel. It is used to set down shoulders or smooth out fuller marks.
FULLERS:
It is mainly used to reduce the metal while necking shoulders. They are made of tool
steel.
SWAGES:
The swages are used for work which has to be reduced and finished to round made
with half grooves. The swage may be in separate top and bottom hallows.
COLD CHISEL:
It is made of tool steel with a cutting angle of about 60O.
HOT CHISEL:
It is made of low carbon steel and has a cutting angle of 30O.
STEEL RULE:
The steel rule is made of tempered steel.
It can be used for tacking lenear
measurements of the work piece to an accuracy of 1 mm to 0.5 mm.

FOLDING RULE:
It is made up of Brass. It is used to taking longer measurements upto 600 mm or 24
inches.
15
OUTSIDE CALIPER:
These are used for checking or measuring outside dimensions or plate thickness.
INSIDE CALIPER:
These are used for checking or measuring the internal dimensions.
WING COMPASS:
These are used for measuring and diameters marking purpose.
NUMBER PUNCH:
It is a punch that is used to Mark the numbers on finished job for identification
purpose.
16
1.
Changing Round Cross Section to Square
AIM: To make a round to square section of the given rod.

Open mouth tong. 18, Ball peen Hammer. 2 Lb, Flatter, 18, steel rule 12, In side &
out side caliper. 6 , Number punch, Anvil, smiths Hearths, with air blower.
MATERIAL REQUIRED:
Mild steel round rod of length 200 mm & Diameter 12 mm. 200 mm x 12 M.S.R.
Rod.
Volume=r2h1= 22 x 6x6x
200=9x9xh2
7
: h2 = 226 mm
226
200
Finished Job Dimensions: 226 mm x 9.mm cross section.
9
12
Note: The views are not drawn as per actual dimensions of the job.
PROCEDURE:
Step 1. Given circular rod end is held in all open mouth tong and other end is heated
in a smithy furnace for about 5mins. Heated end of the job is placed on the
anvil and start hammering by using ball peen hammer their by forming flat
surfaces to a certain width. The job should rest on the face of the anvil.
Step 2. It in repeated till sufficient width of the flat surface is formed on either side,
turn the job after heating to red hot, repeat the procedure so as to produce
approximately square cross section.
Step 3. The square surface formed is uneven so in order to make the surfaces of the
job flat Reheat the entire job to red hot state and place on the face of the
17
anvil by holding one of the ends of the job with tong and place flatter one
the square surfaces and hit on the top of the flatter with hammer.
Step 4. The process is continued till the entire surfaces becomes evenly flat. Turn
the job and repeat the above procedure to flatter other two faces of the job so
as to make all the faces of the job smooth and flat and perpendicular to each
other to produce uniform square cross section through out the length of the
job.
Step 5. The length is measured by steel rule and cross section width is by out side
caliper after marking the student number on finished job for identification
purpose.
PRECAUTIONS:
The metal rod should not be over heated since melting of metal takes place on
overheating.
RESULT:
Rod of the required dimensions i.e. square shaped is obtained.
18
2.
S Shape
AIM: To make a S shape.

Open mouth tong . 18, Ball peen Hammer. 2 Lb, Flatter, 18, steel rule 12 , In side
& out side caliper. 6 , Number punch , Anvil , smiths Hearths, with air blower.
MATERIAL REQUIRED:
Rod.
Volume=r2h1= 22 x 6x6x 200=9x9xh2
7
: h2 = 226 mm
12
9
All Dimension are in mm

Note: The views are not drawn per actual dimensions of the job.
PROCEDURE:
Step 1. Given circular rod end is held in an open mouth tong and other end is heated
in a smithy furnace for about 5mins. Heated end of the job is placed on the
anvil and start hammering by using ball peen hammer their by forming flat
surfaces to a certain width. The job should rest on the face of the anvil.
Step 2. It is repeated till sufficient width of the flat surface is formed on either side,
the job is turned and heated to red hot, repeat the procedure so as to produce
19
job flat, reheat the entire job to red hot state and place on the face of the anvil
by holding one of the ends of the job with tong and place flatter one the square
surfaces and hit on the top of the flatter with hammer.
Step 4. The process is continued till the entire surface becomes evenly flat. Turn the
job and repeat the above procedure to flatter other two faces of the job so as to
make all the faces of the job smooth and flat and perpendicular to each other
to produce uniform square cross section throughout the length of the job.
Step 5. The length is measured by steel rule which should be 226 mm and cross
section width is by out side caliper i.e. 9 mm.
Step 6. From both the ends using a steel rule 100 mm is measured marked on the rod
(job).
Step 7. Then heat the rod from one side and place it on the face of the beak and bend
the rod on another side repeat the procedure as explained above.
Step 8. Placing on the face of the anvil after reheating the job. Which results in
producing S shape then reheat the S shape the internal diameter of the S
shape in measured by using an inside caliper and should be approximately 40
mm on the top place the anvil top of the flatter on the job and surface with a
hammer on the hammering surface of the flatter. Submit the job after marking
the student number on the finisher job for identification purpose.
PRECAUTIONS:
1.
2.
Hold the job firmly while hammering.
3.
overheating.
4.
While hammering, check whether hammer head is firmly fixed to the handle
or not.
RESULT:
The round job given is formed into an S shaped square job with the required
dimension.
20
3.
U Clamp
AIM: To make a U clamp.

Open mouth tong . 18, Ball peen Hammer. 2 Lb, Flatter, 18, steel rule 12 , In side
& out side caliper. 6 , Number punch , Anvil , smiths Hearths, with air blower.
MATERIAL REQUIRED:
Rod.
Volume=r2h1= 22 x 6x6x
200=9x9xh2
7
: h2 = 226 mm
20
0
88
15
22
6
10
40
10
12
15
9
All Dimensions are in
mm
58
PROCEDURE:
in a smithy furnace for about 5mins.
Step 2. Place the heated end of the job on the anvil and start hammering by using
ball peen hammer their by forming flat surfaces to a certain width. The job
should rest on the face of the anvil.
turn the job after heating to red hot, repeat the procedure so as to produce
21
job flat reheat the entire job to red hot state and place on the face of the anvil
by holding one of the ends of the job with tong and place flatter on the
square surfaces and hit on the top of the flatter with hammer.
Step 5. The process is continued till the entire surfaces becomes evenly flat. Turn
the job and repeat the above procedure to flatter other two faces of the job
so as to make all the faces of the job smooth and flat and perpendicular to
each other to produce uniform square cross section throughout the length of
the job.
Step 6. The length is measured by steel rule which should be approximately 226 mm
and cross section width is measured by an out side caliper and should be 9
mm.
Step 7. From both the ends using a steel rule 10 MM is marked on the rod (job).
Step 8. Hold the job at one end and other end is heated to red hot stage and place on
the face of the anvil at in 45 o and hammer the edge in contact with face of
the anvil number of times by reheating in between so as to form tapered
cross section of 15 mm both sides. So that all the inclined faces of the job
meet to form a sharp point. Same sharp edge has to be formed on the other
end also.
Step 9. Then mark the center point of the job, mark distance equal to 20 mm on
either side of the center and bend the 40 mm center portion of the rod in red
hot stage and bending of the center portion by the keeping on the face of the
beak.
Step 10. Make both ends of the job straight and parallel to each other by placing on
the face of the anvil after reheating the job. Which results in producing U
shape and the length is measured by a steel rule and inside caliper is used to
measure internal Diameter which should be 40 mm. Then reheat the U
shape and place on the top of the Anvil top of the and flatter with hammering
surfaces of the flatter. Submit the job after marking the student number on
the finished job for identification purpose.
PRECAUTIONS:
1.
2.
22
3.
overheating.
4.
or not.
RESULT:
The round job given is formed into an U shaped square job with the required
dimension.
23
4.
O Shape
AIM: To make a 0 shape.

Open mouth tong. 18, Ball peen Hammer. 2 Lb, Flatter, 18, steel rule 12, In side &
out side caliper. 6, Number punch, Anvil, smiths Hearths, with air blower.
MATERIAL REQUIRED:
Rod.
80
40
80
200
226
80
40
Volume=r2h1= 22 x 6x6x 200=9x9xh2

7
: h2 = 226 mm
9
9
12
40
All Dimension are in mm

PROCEDURE:
in a smithy furnace for about 5mins.
Step 2. Heated end of the job is placed on the anvil and start hammering by using
ball peen hammer their by forming flat surfaces to a certain width. The job
should rest on the face of the anvil.
24
the job is turned and heated to red hot, repeat the procedure so as to produce
job flat, reheat the entire job to red hot state and place on the face of the
anvil by holding one of the ends of the job with tong and place flatter one
the square surfaces and hit on the top of the flatter with hammer.
Step 5. The process is continued till the entire surface becomes evenly flat. Turn the
job and repeat the above procedure to flatter other two faces of the job so
as to make all the faces of the job smooth and flat and perpendicular to each
other to produce uniform square cross section throughout the length of the
job.
Step 6. The length is measured by steel rule which should be 226 mm and cross
section width is by out side caliper i.e. 9 mm.
Step 7. Using a steel rule mark 40 mm and 80 mm from one of the ends. Its
repeated on the other end also. And the rod (starting from 40 mm to 80 mm)
is bent to
form. Its repeated on the other side also.
Step 8. Placing on the face of the anvil after reheating the job. Which results in
producing 0 shape then reheat the 0 shape the internal diameter 40x80
mm of the 0 shape in measured by using an inside caliper and should be
approximately 40x80 mm on the top place the anvil top of the flatter on the
job and surface with a hammer on the hammering surface of the flatter.
Submit the job after marking the student number on the finisher job for
identification purpose.
PRECAUTIONS:
1.
2.
3.
overheating.
4.
or not.
RESULT:
The round job given is formed into an 0 shaped square job with the required
dimension.
25
Introduction to Fitting
MEASURING TOOLS:
Steel rule:
It is a direct reading measuring instrument to read an accuracy of 0.5 mm metric and
1/64 of an inch in British. Steel rules are made from high carbon steel and stainless
steel.
Try square:
It is make and checking instrument of right angle of the job as well as levelness of the
flat surfaces.
Inside callipers:
It is a tool used to checkup the internal dimensions of any job. It is an indirect
measuring instrument.
Outside callipers:
It is a tool used to checkup the outer dimensions of any job.
Jenny caliper or bent leg calipers:
It is a tool used in layout work for locating and testing the center of cylindrical job. It
is used scribed parallel lines on flat surfaces.
Spring type divided:
It is a tool used to measure, mark and divide the given straight lines. It is used to draw
the circles and radius on the flat surfaces.
MARKING TOOLS:
Universal surface gauge:
It is an instrument having a base, and a scriber. It is a tool used for marking lines on
flat surfaces. It is an indirect marking instrument.
V-block:
It is a rectangular or square block having V-shape grooves as such it is called V-block.
It is classified by its length, breath and height. It is used to support the job and to mark
the round rod center.
Angle plate:
It is made from closed grain cast iron. It is used for marking purpose as well as to
checkup the right angles of the job.
26
Punch:
Punch is a cylindrical steel piece. It is a tool used for punching on the marked lines.
This operation is called punching. There are three types of punches: 1) Center Punch
(90),
2) Dot Punch (60), 3) Prick Punch (30).
CUTTING TOOLS:
Chisel:
Chisel is a cutting tool made from High Carbon Steel of hexagonal or octagonal bars.
It is a tool used for chipping on the flat surfaces. This operation is called chiseling.
Types of chisels:
1) Flat chisel, 2) Cross cut chisel, 3) Round Nose chisel, 4) Diamond point chisel
Hacksaw:
It is a tool which consists of a frame and a blade. It is a tool used for cutting the
surplus metal on the marked lines. This operation is called sawing.
File:
File is a cutting used to remove small quantity of surplus metal. Files having cutting
points incorporated in the body at equal distance usually on all four faces over the
length from tip to shoulder. Files are classified according to their length, grade,
section and cuts.
Types of files:
1) Flat file, 2) Round file, 3) Half round file, 4) Triangular file, 5) Square file, 6) Safe
edge file, 7) Knife edge file
Drill bit:
Drill is cutting tool used to originate round holes on fiat surfaces. It is made from high
speed steel. This operation is called drilling.
HAND TOOLS:
Hammer:
It is a simple striking tool used to make the job to a required shape either in cold or
hot conditions beating directly on the job. There are three types of hammers.
1) Ball peen hammer, 2) Cross peen hammer, 3) Straight peen hammer
Bench-vice:
A device is used to hold the job firmly fixed on a bench is called Bench-vice.
It is available according to their length of the jaw plates.
27
Types of vices:
1) Bench-vice, 2) Machine vice, 3) Carpentry vice, 4) Leg vice, 5) Pin vice, 6) Pipe
vice, 7) Toll makers vice
Parts of the vice:
1) Fixed Jaw, 2) Moveable Jaw, 3) Jaw plates, 4) Spindle, 5) Handle, 6) Box nut, 7)
Split pin, 8) Washer
Gauge:
It is an instrument used to checkup the manufacture job to know whether it is fit or
not. It is made from tool steel hardened and tempered. Gauges are classified according
to their nature or work.
Types of gauges:
1) Feeler gauge or Gap gauge, 2) Fillet gauge or Radius gauge, 3) Wire gauge or
Sheet gauge, 4) Depth gauge
28
1.
To Make a Square
AIM: To make a square as per the given dimensions.

12 Flat rough file
10 Flat rough file
4 Try square
12 Steel rule
6 Outside caliper
12
Universal
surface
gauge
4 Angle plate
2 V-Block
1/2 Lb Ball peen Hammer
4 Dot punch
12 Hacksaw
MATERIAL REQUIRED:
50 x 50 x 50 mm MS Piece
Plan OR Top view
Tolerance
+ 0.5 mm
48
Elevation or Front view
4
Side view
SEQUENCE OF OPERATIONS:
1) Filling, 2) Marking, 3) Punching, 4) Sawing, 5) Filling, 6) Finishing
PROCEDURE:
1)
The given MS piece is fixed in the Bench vice and filed one
surfaces and two adjacent sides with the help of 12 flat rough file.
2)
Checkup the flat ness with the help of Try Square.
3)
Apply wet chalk only on filed surface.
4)
Marking should be done with the help of marking tools as

per the given dimensions.
29
After marking, punching should be done as per required
5)
shape with the help of Dot punch & Ball peen hammer.
6)
Sawing the excess material with the help of Hacksaw.
7)
File the sides up to the marked level and measure the sides
with the help of outside caliper.
File another surface as per required thickness, with the help
8)
of flat rough file.

Finishing should be done with the help of flat smooth file.
9)
PRECAUTIONS:
1.
Dont use a file without handle.
2.
While sawing use coolant properly.
3.
While doing filing file should move parallel to the jaw plates.
30
2.
Template Fitting
AIM: To make a Template as per the given dimensions.

10 Flat rough file
6 Safe edge file
4 Try square
6 Vernier Calipers
12 Vernier height gauge
4 Angle plate
2 V-Block
12 Hacksaw
4 Dot punch
Feeler Gauge
MATERIAL REQUIRED:
80 x 40 x 4 mm MS Piece
Plan OR Top view
18
Tolerance
A
0.02 mm
18
18
18
18
18
3
Side view
1) Filling, 2) Marking, 3) Punching, 4) Sawing, 5) Filling to the given dimensions,
6) Finishing
PROCEDURE:
1)
The given MS piece is fixed in the Bench vice and one of

the two surfaces is filed with a 10 flat rough file and checkup the flat ness with
the help of Try Square. File two adjacent sides and make it right angle.
2)
Apply marking media only on field surface.
3)
Marking should be done with the help of a vernier height

gauge as per the given dimensions.
31
After marking, punching should be done with the help of
4)
Dot punch & Ball peen hammer as per given dimensions.

Sawing the excess material with the help of Hacksaw, filing
5)
should be done as per given dimensions with the help of a Flat smooth file &
safe edge file.
Checkup the dimensions with the help of the vernier caliper
6)
as per the given dimensions.

File another surface as per required thickness with the help
7)
of the flat smooth file.

8)
PRECAUTIONS:
1.
While sawing use coolant properly.
2.
While doing in step filing use safe edge file.
3.
While swing, Hacksaw should move perpendicular to the job pieces.
32
3.
Drilling and Tappling
AIM: To make a drilling and tapping.

10 Flat rough file
10 Flat smooth file
4 Try square
6 Vernier caliper
2 V-Block
4 Dot punch
8.5 mm Drill bit
MATERIAL REQUIRED:
40 x 40 x 12 mm Mild Steel Piece
Plan
M10 TAP
OR Top view
D = T x 0.8
10 x 0.8 = 8 mm
D = Drill Size
T = Tap size
Tolerance
+ 0.02 mm
38
9
Side view
All dimensions are in mm

1) Filling, 2) Marking, 3) Punching, 4) Drilling, 5) Tapping, 6) Finishing
PROCEDURE:
1)
of the surfaces and two adjacent sides with the help of 10 flat rough file.
2)
3)
Apply the marking media only on filed surface.
4)

5)

33
Drilling operation should be done with the help of drilling
6)
machine as per given dimension.

Tapping operation should be done with the help of Tapset &
7)
Wrench.
8)
PRECAUTIONS:
1.
While drilling and tapping use coolant properly.
2.
While doing tapping tap should rotate clock and anti-clock wise direction.
3.
While doing tapping tap should move perpendicular to the job.
34
4.
T Fitting
AIM: To make T fitting as per given dimensions.

10 Flat rough file
6 Safe edge file
4 Try square
6 Vernier Calipers
4 Angle plate
2 V-Block
12 Hacksaw
4 Dot punch
Feeler Gauge
MATERIAL REQUIRED:
80 x 40 x 4 mm Mild Steel Piece
15
Shaft
20
Hole
Tolerance
+0.02
15
3
20
20
20
20

1) Filling, 2) Marking, 3) Punching, 4) Drilling, 5) Tapping, 6) Finishing
PROCEDURE:
1)
of the surfaces and two adjacent sides with the help of 10 flat rough file.
2)
3)
Apply the marking media only on filed surface.
4)

35
5)
Drilling operation should be done with the help of drilling
6)
machine as per given dimension.

Tapping operation should be done with the help of Tapset &
7)
Wrench.
8)
PRECAUTIONS:
1.
While drilling and tapping use coolant properly.
2.
While doing tapping tap should rotate clock and anti-clock wise direction.
3.
While doing tapping tap should move perpendicular to the job.
36
Introduction to Plumbing
INTRODUCTION:
Plumbing deals with the laying of pipe lines. Pipe line provides the means of
transporting the fluid. It is obvious that laying-out the pipe line, requires a number of
joints to be made and a number of valves incorporated, while connecting different
lengths of pipes.
Plumbing work does not require many tools except pipe wrenches, hacksaw, pipe
cutter, threading equipment and a pipe vice.
PLUMBING TOOLS:
1. Pipe Wrench:
Pipe wrenches are used for holding and turning the pipes. Rods and machine parts.
Wrenches of size 300 mm and 450 mm are more useful. The adjustable wrench
shown in Fig. 1 consists of a fixed jaw and a movable jaw. The movable jaw
facilitates the adjustment of the opening between the jaws. The jaws are serrated
inside, to enable a firm grip over the pipes.
Fig. 1: Pipe Wrench

2. Pipe Vice:
The use of a regular pipe vice is advisable, though ordinary bench vice can serve the
purpose in most of the occasions. The pie vice is fitted on the work bench. It holds the
pipes in position during cutting, threading and fitting of bends, couplings, etc. Fig. 2
shows a pipe vice. It consists of jaws for holding the work, which are serrated to
ensure firm grip.
Fig. 2: Pipe Vice
37
3. Pipe Cutter:
For an occasional pipe work, a hacksaw is quite satisfactory. Pipe cutters are also used
where considerable amount of pipe work is involved. The pipe cutter mainly consists
of three wheels which are hardened and with sharp cutting edges along their
periphery. Of these three wheels, one can be adjusted to any desired distance from the
other two fixed wheels, to accommodate different sizes of pipes. After adjusting the
cutter on a pipe, it is turned around the pipe so that the cutter wheels cut the pipe
along a circle Fig. 3 shows a pipe cutter.
Fig. 3: Pipe Cutter

4. Pipe Bending Machine:
While laying the pipe line, sometimes a part of a pipe may have to be bent to the
required curvature. For this, a pipe bending machine is used. It is mounted on a tripod
stand and can swivel about a vertical axis to any desired angle, to cover the required
range for the operation. The unit consists of a number of bending blocks and dolly
blocks to obtain any desired curvature at the bend.
5. Dies:
A pipe-die is used for cutting external threads on pipes (Fig. 4). One or two piece dies
are used in the die stock. It is a hand operated tool, which may be considered as a
hardended steel nut, having flutes cut along its inside surface. These flutes are serve
the same purpose as in a twist drill. In case of two piece die, the two pieces are set at a
desired distance and secured in position by means of a set screw.
38
Fig. 4: Pipe threading

PIPES AND PIPE FITTINGS:
Pipes are available in either black or galvanized form. Black pipes are used for oil,
gas or air. Galvanized pipes are used for water supply system as they resist rusting and
corrosion. Pipe fittings are made of wrought iron. These fittings are available either in
black or galvanized finish.
The size of a pipe is designated by its inside diameter. The size of a pipe fitting is
designated by the size of the pipe on which it fits. There are different types of pipe
fittings available in the market. These should be selected, keeping in mind the desired
pipe layout. The most common pipe fittings are shown in Fig. 5.
Fig. 5: Common pipe fittings
39
1. Coupling:
It is a short cylindrical sleeve with internal threads throughout. It is used for joining
two pipes in a straight line and where atleast one pipe can be turned.
2. Union:
It is used for joining two pipes, where neither can be turned. It consists of three parts;
two parts will be screwed on to the two pipe ends and the third one, which is a nut,
draws the pipe together tightly.
3. Nipple:
It is a short piece of pipe (less than 300 mm in length) with external threads at both
ends. Nipples are available in standard short lengths. It is used to make up the
required length of the pipe line.
4. Elbow:
It is used to make an angle between adjacent pipes. The angle is always 90 O, unless
another angle is stated.
5. Tee:
It is a fitting that has one side outlet at right angles to the run. It is used for a single
outlet branch pipe.
6. Reducer coupling:
It is used to connect two different sized pipes.
7. Bush:
It is a short sleeve-lie piece, used to reduce the size of a threaded opening. It is
threaded fully on the inside and at one end on the outside. The other outer end is
hexagon shaped.
8. Plug:
It is used to screw onto a threaded opening, for closing it temporarily. It is a short
piece with external threads at one end and square end on the other, to receive the
spanner for operation. A cap may be used for closing external threaded openings
temporarily.
9. Flange:
Flanges are available either in oval or in circular shapes. These contain internal
threads in the hub and holes in the body to receive bolts. Two pipes may be joined
together in line, using flanges and bolts.
40
10. Gated valve:

Pipe valves are fitted in the pipe line to control the fluid flow through it. Gated valve
offers less resistance to the flow of water through it. It is used to where it is important,
not to obstruct the flow and where the valve is closed only rarely. In this valve, the
flow is reduced by lowering the wedge shaped gage towards its seat (Fig. 6a)
11. Globe valve:
This controls the fluid flow in a pipe line; however, the passage of flow is restricted
(fig. 6b).
12. Check valve:
It is used to prevent reverse flow in a pipe line. The swing type valve is more
commonly used in this category (Fig. 6c)
13. Common tap:
This is used for tapping the fluid flow at required points in the pipe line (Fig. 6d)
Fig. 6: Valves
PIPE LAYOUT:
For better pipe work, it is advisable to sketch first, the pipe layout (Fig. 7), showing
dimensions and types of fittings. In cutting pipe to length, the portion of the pipe that
will screw into the fittings, must be taken into account.
41
Fig. 7: Pipe Layout

1. Pipe threading:
after pipes are cut to lengths, to suit the layout, they must be threaded before the
assembly. The following are the steps involved while threading a pipe by means of a
pipe die:
1. Clamp the pipe securely in a pipe vice.
2. Select proper size of the die and insert into the stock.
3. Place the die on the end of the pipe and apply pressure, while the die is slowly
turned.
4. Once the threading is started, apply cutting oil and continue to turn the die into
the pipe, till one thread projects through the die.
Note: i) Pipe die produces tapered threads. The tapered pipe threads tighten securely
into the pipe fittings. ii) While threading, turn the die stock handle back and forth
frequency, to loosen the chips.
42
2. Assembly:
Pipe layout should be made so as to avoid strains and bending at the joints. To ensure
tight joints in pipe work, the threads are applied with some kind of thread compound,
before screwing them together. While screwing the pipe in its fitting, it is advised to
use two pipe wrenches, making one to fit the pipe and the other to fit the pipe fitting.
To avoid damaging a valve or a tap with wrench marks, it is advised to use a monkey
wrench with smooth jaws.
Some fittings like unions and flanges require gaskets to make tight joints. When
fittings are dis-assembled, gaskets are usually damaged and must be replaced. Gaskets
are made from materials such as rubber or leather.
43
1.
AIM:
External Thread Cutting
Cutting of external pipe threads using hand die on the given G.I. pipe for
plumbing purpose.
MATERIAL REQUIRED:
G.I. pipe size x 12 (or a given length of pipe)
TOOLS REQUIRED:
1) Pipe vice
2) Pipe cutter or Hacksaw
3) Pipe die with die stock and handle
4) Oil can
5) Pipe wrench
6) Steel rule or measuring tape
20 mm
Galvanised Iron pipe
20 mm
L
Pipe threads
1)
Length marking.
2)
Cutting to required lengths of pipes.
3)
Threading with pipe die and checking thread quality for

proper fit.
Assembly and quality testing with mating components
4)
(coupling / elbow) to ensure proper fit.

PROCEDURE :
1) Measure the length of given G.I. Pipe.
2) Mark to the required length
3) Hold the pipe in pipe vice; cut the pipe to length with pipe cutter or hacksaw
4) Hold the pipe in the pipe vice, adjust die set screw to half or 1/3 of the thread
depth and cut external threads on one end using pipe die (apply cutting oil, once
the threading is started) (applicable for G.I. only)
5) Increase the depth of cut by adjusting die set screw and finish cut threads till one
thread projects through the die.
44
6) Assemble coupling / elbow and test the quality of threads for proper fitting and
remove.
7) Hold the G.I. Pipe in the vice in position for the other side and follow the above
procedure cut threads on the second end.
PRECAUTIONS:
1)
Clamp the pipe securely in the pipe vice
2)
For G.I. Pipes once the threading is started, apply cutting

oil.
While threading, turn the die stock handle back and forth
3)
frequently to loosen/ remove the chips.

For PVC pipes application of cutting oil is not necessary
4)
while threading.
5)
In cutting pipe to length, the portion of the pipe that will

screw into the fittings, must be taken in to account.
6)
While screwing the pipe in its fittings, it is advised to use

two pipe wrenches, making one to fit the pipe and the other to fit the pipe fitting.
7)
To avoid damaging a valve or a tap with wrench marks, it is

advised to use a monkey wrench with smooth jaws.
45
2.
Plumbing of Water Tap Connection
AIM: Plumbing of water tap connection as per the layout using PVC / GI pipe and
relevant pipe fitting.
MATERIAL REQUIRED:
1)
PVC / GI pipe size
2) Gate valve (Gum metal)
3)
GI TEE
4) GI Elbow 900
5)
GI Coupling
6) Nipple
7)
Water tap plastic / Brass / CI
8) Cotton thread or thread sealing tap
9)
Dummy plug
TOOLS REQUIRED
1) Pipe vice
3) Pipe die with die stock and handle
4) Oil can
5) Pipe wrench
46
1)
Length marking.
2)
3)

proper fit.
4)
Assembly of pipes and pipe fitting as per layout.
5)
Fix water tap.
PROCEDURE:
1)
Measure the length of given pipe
2)
Mark to the required lengths of pipe
3)
Hold the pipe in pipe vice cut the pipe to different lengths
required with pipe cutter or hacksaw
Hold the pipes one by one in pipe vice in position, adjust
4)
die set screw to form half the thread depth, cut external threads on once end
using pipe die.
Increase the depth of cut by adjusting die set screw and
5)
finish cut threads till one thread projects through the die.
Test the quality of threads for proper fit by assembling with
6)
the mating components.

Reverse hold the pipes one by one in pipe vice in position,
7)
follow the above procedure cut threads on the second end for all pieces.
Wind cotton thread or Teflon thread seal or jute and lappam
8)
over the threads for leak proof joints. Assemble pipes, with pipe fittings and
gate valve to the in let supply pipe as per the layout. Fix water tap.
PRECAUTIONS:
1)
2)
For G.I. Pipes once the threading is started, apply cutting

oil.
While threading, turn the die stock handle back and forth
3)
frequently to loosen the chips.

For PVC pipes application of cutting oil is not necessary
4)
while threading.
5)
In cutting pipe to length, the portion of the pipe that will

screw into the fittings, must be taken in to account.
47
6)
While screwing the pipe in its fittings, it is advised to use

two pipe wrenches, making one to fit the pipe and the other to fit the pipe fitting.
7)
To avoid damaging a valve or a tap with wrench marks, it is

advised to use a monkey wrench with smooth jaws.
48
3.
Plumbing of Bathroom Water Shower
AIM: Plumbing of bathroom water shower and line water tap as per layout using
GI / PVC pipe and relevant pipe fitting.
MATERIAL REQUIRED:
1) PVC / GI pipe size
2) Gate valve (Gum metal)
3) GI TEE
4) GI Elbow 900
5) GI Coupling
6) Nipple x 4L
7) Water tap plastic / Brass / CI8) Cotton thread or sealing tape

9) Dummy plug
10) Control cock (or gate valve)
11) Shower fitting

TOOLS REQUIRED:
1)
Pipe vice
3)
Pipe die with die stock and handle
4) Oil can
5)
Pipe wrench
49
1)
Length marking.
2)
3)

proper fit.
4)
Assembly of pipes and pipe fitting as per layout.
5)
Fix water tap.
PROCEDURE:
1)
Measure the length of given pipe
2)
Mark to the required lengths of pipe
3)
Hold the pipe in pipe vice, cut the pipe to different

lengths required with pipe cutter or hacksaw
Hold the pipes one by one in pipe vice in position,
4)
adjust die set screw to form half the thread depth, cut external threads on one
end using pipe die.
Increase the depth of cut by adjusting die set screw
5)
and finish cut threads till one thread projects through the die.
Test the quality of threads for proper fit by
6)
assembling with the mating components.

Reverse hold the pipes one by one in pipe vice in
7)
position, follow the above procedure cut, threads on the second end for all
pieces.
Wind cotton thread or thread seal around the threads
8)
for leak proof joints. Assemble pipes with pipe fittings and Gate valve as per
layout.
Finally fix water tap and shower fitting.
9)
PRECAUTIONS :
1)
2)
For G.I. Pipes once the threading is started, apply cutting oil.
3)
While threading, turn the die stock handle back and forth frequently to
loosen the chips.
4)
For PVC pipes application of cutting oil is not necessary while threading.
5)
In cutting pipe to length, the portion of the pipe that will screw into the
fittings, must be taken in to account.
50
6)
While screwing the pipe in its fittings, it is advised to use two pipe
wrenches, making one to fit the pipe and the other to fit the pipe fitting.
7)
To avoid damaging a valve or a tap with wrench marks, it is advised to use

a monkey wrench with smooth jaws.
Introduction to Welding
INTRODUCTION:
Welding is a process of joining two or more parts of material(s) by heating them to
above melting point of the base metal.
Welding processes are classified as (i) Autogeneous welding and (ii) Heterogeneous
(i)
Autogeneous Welding: In this process the two pieces are fused together
without using a filler rod (or an electrode)
(ii)
Heterogeneous Welding: In this process the two parts are joined together
with the help of a filler rod (or an electrode)
The arc welding processes are again classified as follows:

1. Carbon Arc Welding (CAW)
2. Shielded Metal Arc Welding or (SMAW) Manual metal arc welding (MMAW)
3. Gas Tungsten Arc Welding (GTAW)
4. Gas metal Arc Welding (GMAW)
5. Plasma Arc Welding (PAW)
6. Atomic Hydrogen Arc Welding (AHAW)
7. Electro-gas Welding (EGW)
However, SMAW and Oxy-Acetylene Welding processes are the general purpose
processes with a wide range of applications.
Some of the typical applications of welding include the fabrication of ships, pressure
vessels automobile bodies, off-shore plat forms, storage tanks, bridges, welded pipes,
sealing of nuclear fuel and explosives etc.
Shielded Metal Arc Welding (SMAW)
51
Electric arc
In SMAW an emf is applied between the electrode and the work piece and suitable
current proportional to the diameter of the electrode is passed through the circuit. An
arc is struck between the electrode and the plate and the heat produced is utilized for
melting both the work piece and the electrode. The flux around the electrode melts
and forms a shielding gas to protect the molten weld pool from the ill effects of
atmospheric gases. The temperature in the core of the arc ranges between 60007000C. The radiations originating from the welding arc can damage the eye thus
necessitating the use of protective shield.
Oxy-Acetylene Welding (Gas Welding)
52
In this process acetylene (C2H2) is mixed with oxygen in the welding torch and is then
burnt at the torch tip to give a flame with a temperature of about 3300C which can
melt most of the ferrous and non-ferrous metals in common use.
Oxygen and Acetylene are easily available in cylinders at pressures of 1500 N/cm 2 or
150 bars and 170 N/cm2 or 17 bars respectively.
These are connected to the welding torch through hoses and are mixed and burnt to
get different types of flames viz., neutral, oxidizing and corburising. The nature of
the flame depends upon the ratio of the two gases. The neutral flame is most often
used for the welding of most of the materials like low carbon steels, cast steel, cast
iron etc.
It is quite common to use filler material with gas welding though if need be, the
process can be used without filler as well.
Tools and equipment used in gas and arc welding process
1.
Welding machine. (AC transformer, DC generator or AC, DC Rectifier.
2.
Welding cables (Copper or Aluminium)
3.
Electrode Holder (400 mps or 600 Amps) and Earth clamp
4.
Types of Electrodes and Filler rod.
5.
Welding Helmet or Hand Screen.

53
6.
Ball peen hammer and Chisel
7.
Chipping Hammer and Steel Wire Brush.
8.
Tong
9.
Steel Rule (12)
10.
Leather Hand Gloves and Leather Apron.
11.
Oxygen Cylinder and Regulator with hose pipe.
12.
Acetylene Cylinder and Regulator with hose pipe.
13.
Welding Blow pipe and Nozzle.
14.
Cutting Blow pipe and Nozzle.
15.
Spindle Key and Adjustable spanner.
16.
Spark Lighter and Goggles.
54
Laying Bead on Plate by Shielded Metal Arc Welding
1.
AIM: To make a straight line bead on MS plates

MATERIAL REQUIRED:
Ms plate 300 mm x 100 mm x 5 mm (thickness) (2 Nos)
TOOLS REQUIRED:
1. Welding machine (AC Transformer, DC generator or AC/ DC Rectifier)
2. Welding Cables
3. Electrode holder and Earth clamp
4. Metallic work table
5. MS electrodes
7. Leather apron and Leather hand gloves
8. Chipping hammer
9. Steel wire Brush
10.Tong
11. Ball peen Hammer
12. Chisel
13. Bench grinding machine.
300 mm
6. Hand Screen
100 mm
5 mm
PROCEDURE:
1.
Take the given MS plate ie 300 mm x 100 mm x 5 mm thick plate all edges
should be ground carefully.
2.
After grinding the plates remove the rust and dust particles with the help of
steel wire brush.
3.
After cleaning keep these plates on the worktable and mark straight lines on
the plate with chalk piece.
4.
Take 3.15 mm (dia) or 10 gauge electrode to do welding and fix the electrode
in to the electrode holder and slightly bend the electrode in the tip side.
55
5.
Set current rating i.e. 100 Amperes and volts 66 volts. i.e. open circuit voltage
(O.C. V.) in the welding transformer.
6.
Firstly, strike the electrode on the waste plate (touch & draw method) for 2, 3
times and straight line beads are laid on the markings made on the plates. 2
straight beads can be laid.
7.
After the plates are cooled slag is removed by the chipping hammer.
8.
After chipping, clean the bead with the steel wire brush.
PRECAUTIONS:
1.
Always use welding hand screen while doing welding.
2.
While doing welding wear protective items i.e. leather apron, leather hand
gloves.
3.
While doing welding, short arc i.e. (1mm) gap should be maintained.
56
2.
Laying Joint on Plate by Shielded Metal Arc Welding
AIM: To make a butt joint on MS plates

MATERIAL REQUIRED:
Ms plate on MS flat (80 mm x 50 mm x 5 mm thickness (2 Nos))
TOOLS REQUIRED:
1. Welding transformer (AC Transformer, DC generator or AC / DC Rectifier)
2. Welding Cables

5. MS electrodes
6. Hand Screen
8. Chipping hammer
9. Steel wire Brush
10.Tong
12. Chisel
13. Bench grinding machine
PROCEDURE:
1.
Take the given MS plate (80 mm x 50 mm x 5 mm thick) and clean the

surfaces from rust and dust particles with the help of steel wire brush.
2.
After cleaning the plates grind all sides lightly and one of the edges of both
the plates should be ground more like as V grove using the bench grinding
machine.
3.
After grinding, set the plates on the work table and set parallel to each other
and 1 mm gap should be maintained between the two plates.
4.
Take 3.15 mm (dia) or 10 gauge electrode fix into the electrode holder and
slightly bend the electrode in the tip side.
5.
Set current of the transformer rating to 66 volts. i.e. open circuit voltage and
57
100 Amps i.e. welding current.

6.
Firstly, strike the electrode on the scrap plate for 2, 3 times and do tack
welding of 2 plates on 4 sides and do full welding carefully.
7.
After completing full welding cool the job with water and remove the slag and
clean it. The job is over.
PRECAUTIONS:
1.
2.
gloves.
3.
58
3.
Making Joint on Plate by Shielded Metal Arc Welding
AIM: To make a lap joint on MS plates

MATERIAL REQUIRED:
TOOLS REQUIRED:
1. Welding Transformer (AC Transformer, DC generator or AC / DC Rectifier)
2. Welding Cables

5. MS electrodes
6. Hand Screen
8. Chipping hammer
9. Steel wire Brush
10.Tong
12. Chisel
PROCEDURE:
1.

2.
machine.
3.
After grinding, set the plates overlap (overlap length is 25 mm) to each other
on the work table.
4.
5.
Set current of the transformer rating to 66 volts i.e. open circuit voltage and
6.
Firstly, strike the electrode on the scrap plate for 2, 3 times and do tack
59

7.
PRECAUTIONS:
1.
2.
gloves.
3.
60
4.
AIM: To make a T joint on MS plates

MATERIAL REQUIRED:
TOOLS REQUIRED:
2. Welding Cables
5. MS electrodes
6. Hand Screen
8. Chipping hammer
9. Steel wire Brush
10.Tong
12. Chisel
PROCEDURE:
1.

2.
machine.
3.
After grinding, set the plates like as T joint. (Take plate is kept at 25 mm
from the edge of the other plate).
61
4.
5.
6.
Firstly, strike the electrode on the scrap plate for 2 or 3 times and do tack
7.
PRECAUTIONS:
1.
2.
gloves.
3.
62
5.
AIM: To make a corner joint on MS plates

MATERIAL REQUIRED:
TOOLS REQUIRED:
2. Welding Cables
5. MS electrodes
6. Hand Screen
8. Chipping hammer
9. Steel wire Brush
10.Tong
12. Chisel
PROCEDURE:
1.

2.
machine.
3.
After grinding, set the plates like as Corner joint. (The plate is kept at 45 O
from the edge of the other plate).
4.
5.
63

6.
Firstly, strike the electrode on the scrap plate for 2 or 3 times and do tack
7.
PRECAUTIONS:
1.
2.
gloves.
3.
64
Introduction to Carpentry
INTRODUCTION:
Carpentry is the process of any class of work with wood. Carpentry deals with all
works of a carpentry such as making of furnitures, Doors, windows, roofs, floors,
partitions and interior decorations etc. Timber is the basic material used for any class
of wood working.
The term 'Timber' is applied to the trees which provide us with wood.
Types of wood most commonly used for various wood are as follows.
Types of Timber (Name of the wood):
1.
Teak wood
2.
Assam Teak wood
3.
Rubber teak wood
4.
Mango wood
5.
Sal wood
6.
Babul wood
Types of the Carpentry tools:

1.
Iron jack plate 14
2.
Steel Rule 24
3.
Try square 6
4.
Rip saw 18
5.
Had saw 12
6.
Tenom saw 12
7.
Firmer Chisel 25, 18, 12, 6 mm
8.
Bevel edge chisel 18, 12 mm
9.
Mortise chisel 12 mm
10.
Aluminium marking gauge and Mortise gauge 2

x 2
11.
Marking gauge 2 x 2
12.
Mortage gauge 2 x 2
13.
Pincer 2 x 2
14.
Clw Hammer
15.
Wooden mallet 4 x 4
16.
Carpentry vice 8 x 6
65
17.
Wood Rasp Half round smooth file
TOOLS:
1. Wooden jack plan: A wooden jackplane is the commostest and is used for the
first truing of a piece of wood it consists of a block of wood into which the blade
is fixed by a wooden wedge.
2. Iron jack plan: A iron jack plan serve the same purpose as the wooden planes but
facilitate a smoother operation and better finish. The body of a metal plane is
made from a Grey Iron Casting.
3. Try Square: Try Square is used for marking and testing angles of 90 0. It consists
of a steel blade riveted into a hard wood stock, which has a protective brass plat.
4. Bevel Square: The bevel square is similar to the try square but has a blade that
may be swiveled to any angle 0 to 180 0. This tool is edjucted, by releasing with a
turn screw.
5. Marking Gauge: The marking gauge has one marking point. It gives an accurate
cut line parallel to the true edge. Usually with the grain.
6. Mortise Gauge: Mortise Gauge has two marking points one fixed near to the end
of the steam and the another attached to the brass sliding bar these two teeth cut
two parallel lines called mortise lines.
7. Rip Saw: Rip Saw are used for cutting along the grain in thick wood. The blade
is made of high grade tool steel and may be either straight or skew backed. It is
fitted in a wooden handle. Made of hard wood by meant of rivets or screws.
8. Cross cut saw: Cross cut saws, or hand saws as they are some times called are
used for cutting across the grain in thick wood.
9. Tenon Saw: Tenon Saw is mostly used for cross cutting when a finer and more
accurate finish is required the blade, being very thin.
10. Firmer Chisel: Firmer Chisel is most useful for general purposes and may be
used by hand pressure or mallet.
11. Bevel Edge Chisel: the beveled edge firmer chisel illustrated is used for more
delicate or fine work. They are useful for getting into corners.
12. Mortise Chisel: The mortise chisel is used for chopping out mortises. This
chisels are designed to with stand heavy work.
13. Pincer: Pincer is mainly used for pulling out nails, tacks etc. It consists of two
arms one are has a ball end and the other arm has end for levering out small
tacks.
66
14. Wood Rasp File: these are useful for cleaning up some curved surfaces for
instance. Certain con cave shapes.
15. Claw Hammer: Claw Hammer it serves the dual purpose of a hammer and a pair
of puicer. The claw is used for pulling out any nails.
16. Mallet: The mallet is woodenheaded hammer of round or rectangular cross
section the striking face is made flat to the work.
17. Bench Vice: The Bench Vice is most commonly used. Its one Jaw is fixed to the
side of the table while the other is kept movable by means of a screew and a
handle.
67
1.
Planning Sawing and Chiseling Operations
AIM: To make a planning sawing and Chiseling operations

MATERIAL REQUIRED:
Wood given size 185 x 50 x 25 mm
Finishing size 175 x 45 x 20 mm
TOOLS REQUIRED:
1. Iron Jack Plane 14
2. Steel Rule 24
3. Hand saw 12
4. Firmer chisel ,
5. Marking gauge 2 x 2
6. Try square 6
7. Wooden Mallet 4 x4
8. Wood Rasp smooth file
20
20
15
20
25
20
15
20
20
20
Elevation
25
Side
View
20
25
Plan
68
20
PROCEDURE:
Step 1. Take a wooden block of size more than the final dimensions of the job.
Step 2. Fix the job in the carpentry vice such one of the faces lies on the top and in
horizontal position.
Step 3. Planning is done on the face with Iron jackplane so as to get smooth surface
over the entire face of the block.
Step 4. Check the straightness of the planned surface at different positions along the
length of the job with try square.
Step 5. Repeat the operation from step 2 to step 4 selecting one of the adjacent sites
of the plane surface and check the perpendicularity between plane and the
plane side with the help of try square. If the planned surface and the side are
not perpendicular to each other than preplanning has to be done either on the
face or on the sides surface till they are perpendicular to each other.
Step 6. With the help of marking gauge mark on the planned face with reference to
planned side equal to the final width of the job. Similarly mark the required
thickness with reference to planned face with marking gauge.
Step 7. Fix the job in the vice remove the wood up to marked lines on the face and
side by following procedures from step 2 to step 5.
Step 8. Select anyone of the edge and remove small portion of wood by cutting with
tennon Saws so as to generate perpendicular edge surface respect to length
of the job.
Step 9. Measure the length equal to the actual final length from the edge cut as per
step.8.
Step 10. Now the block is as per the dimensions required and all the faces and sides
of the wooden block smooth and perpendicular to each other.
PRECAUTIONS:
1.
Don not use a Chisel without handle
2.
Dimensions are to be marked carefully.
69
2.
Half Lap Joint
AIM: To make a half lap joint

MATERIAL REQUIRED:
Wood given size 280 x 50 x 25 mm
TOOLS REQUIRED:
2. Steel Rule 24
3. Hand saw 12
4. Firmer chisel ,
6. Try square 6
7. Wooden Mallet 4 x4
9. Bevel Edge Chisel 6
10. Carpentry vice c
45
45
45
Elevation
Side
View
22.5
PLAN
70
PROCEDURE:
Step 1. Make two wooden blocks to the required dimensions (refer part A)
Step 2. Select any one of the blocks and mark to perpendicular lines on the face in
the center of the job equal to the width of the rectangular groove and make
the groove as per the experiment.
Step 3. Take other wooden block and make similar rectangular groove.
Step 4. Joint he two wooden blocks along the rectangular grooves.
PRECAUTIONS:
1. Don not use a Chisel without handle
2. Dimensions are to be marked carefully.
71
3.
Dove Tail Joint
AIM: To make a dove tail joint

MATERIAL REQUIRED:
Teak Wood given size 280 x 50 x 25 mm
TOOLS REQUIRED:
2. Try square
3. Tenon saw 12
4. Firmer chisel ,
7. Wooden Mallet
8. Bench Hook
90
20
25
20
Elevation
135
Plan45
22.5
22.5
25
S.V.
22.5
22.5
20
20
20
S.V.
Front View
45
45
25
45
Top View
72
PROCEDURE:
Step 1. Make two wooden blocks to the required dimensions (refer part A)
Step 2. Select any one of the block and mark as per the required dimensions of dove
tail located centrally from one of the sides of the job (as per the figure).
Draw a line passing through the bottom of the dove tail on the either side on
the face of the job.
Step 3. Cut along the side of the dove tail on both the blocks.
Step 4. In one of the blocks remove the material to form dove tail groove on one of
the wooden block, dove tail projection in the other block.
Step 5. Assemble them perpendicular to each other.
PRECAUTIONS:
1.
Always use chisel of smaller size than the trench

it has to cut.
2.
While sawing, keep the key of the saw close up

on the lines on the waste wood side. Further when the saw is kept deep
enough, it should be leveled with the line at the front and the back edge.
73
4.
Mortise and Tenon Joint
AIM: To make a Mortise and Tenon joint

MATERIAL REQUIRED:
Teak Wood given size 290 x 50 x 25 mm
TOOLS REQUIRED:
2. Try square 6
3. Steel rule 24
4. Mortise Chisel
5. Firmer chisel ,
6. Hand saw
9. Wooden Mallet
10. Bench Hook
Top view
7
21
7
7
95
45
Side view
Front
view
Top view
7
21
7
7
95
45
Side view
Front
view
74
PROCEDURE:
Step 1. Take two wooden blocks and make them to the required dimensions (refer
part A)
Step 2. Select any one of the block and then select one the sides of the job and mark
a rectangle exactly in the centre portion as per the required dimensions of
the rectangular groove to be made.
Step 3. Similarly mark rectangle exactly on the other side of the job.
Step 4. Fix the job in the carpentry vise such that the marked side is on the top and
in horizontal position.
PRECAUTIONS:
1. Always use chisel of smaller size than the trench it has to cut.
2. While sawing, keep the key of the saw close up on the lines on the waste
wood side. Further when the saw is kept deep enough, it should be leveled
with the line at the front and the back edge.
75
Introduction to House Wiring

SAFETY PRECAUTIONS:
1. Always be careful.
2. Dont tamper unnecessarily with any live electrical gear.
3. Dont disconnect any plug by pulling the flexible cable.
4. Before replacing a blown fuse, always remember to put the main switch off.
5. Safety demands good earthing. Here always keep earthing connections in good
conditions.
6. While handling on electrical appliance like Table Fan, Iron heaters etc., be sure
that they are disconnected from the supply. Switches off is not enough. Leaky
insulation may give serious shock.
7. Live wires should always be connected through the switch.
8. Do not put a share edge tool in your pocket.
9. In case of electric wire, do not throw water on line conductor and equipment as it
is dangerous. The best remedy is to disconnect the electrical supply immediately
and then throw sand (or) dust on fire.
10. Do not tie wire with the electric pole on which clothes are dried (or) hanged.
SIGNS AND SYMBOLS:
1. Alternate current
2. Direct current
3. Lamp
4. Fuse
5. Earthing
6. One way switch
7. Two way switch
8. Double pole iron clad switch
9. Triple pole iron clad switch
76
CONNECTION OF RESISTANCE:
1. Series connections
2. Parallel connections
3. Combined connections
Series Connections:
The R1 ending is connected to R2 starting and R2 ending is connected to R3 starting
like 50 is known as series connections. The characteristics of the series connection
the total voltage divided into number of lamps.
supply V
= 250/5 = 50 numbers of lamps.
lamp V
This connection is generally used for decoration purpose.
Parallel connections:
All the resistance starting terminals are connected at one end and all the ending
terminals are connected at another end is known as parallel connections.
The
characteristics of the parallel connection is voltage same and current will divide. The
number of lamps time which is depend upon supply system. This connection can be
used for domestic purpose. i.e., House, Factories, Street lights etc.
Combined connections:
The combined of series and parallel connection is known as combined connection. It
can be used when we have functions.
R1
R2
R3
1. Series connections
77
R1
R2
R3
R4
2. Parallel connections
R1
R2
R3
R4
3. Combined connections
78
CIRCUITS:
There are three types of circuits.
1) Open circuit
2) Short circuit
3) Closed circuit
Open Circuit:
When we put on the switch the lamp does not glow due to the loose connections of
conductors (or) damage of the conductor is known as open circuit.
Short Circuit:
When phase and neutral conductors are touching together before the high resistance,
the short circuit is occurred when the short circuit is occurred immediately the fuse
will blow off when we provide rating of fuse wire i.e., 5A, 10A, 15A etc.
Closed Circuit:
When we put on the switch the lamp glow is known as closed circuit. Our circuits are
closed circuit and connections are all parallel.
Consumption of power: No. of lamps x watts x hours x days
1 x 100 x 5 x 30 = 15000 wh = 15 kwh
One unit cost Rs. 1.50
= 15 x 1.50 = Rs. 22.50 p
R1 x
1. Open circuit
HR
N
2. Short circuit
79
R1
3. Closed circuit
TOOLS AND USES:
Cutting plier:
Cutting is a tool used for cutting & nipping purpose. It is used for cutting both
insulator and conductor at once. It is available 8 and 6
Long nose plier:
It is a tool used for cutting the conductors and insulators at very narrow places. Whole
cutting plier cannot be used because of its width.
Screw driver:
Screw driver of different way this and of different sizes of screws. It is used for
loosing and fitting the screw. It is available 12, 8, 6 & 4 etc.
Side cutter:
It is used for cutting the conductor.
Pocker:
It is used to make pilot holes on wooden boards.
Wire stripper:
It is used to remove the insulation.
Hammer (1/2 lb):
It is used for revetting purpose. The iron part of this hammer weigh lb.
80
1.
Connection of Two Lamps in Series
AIM: To connect two lamps in series connection.

MATERIAL REQUIRED:
1. Two lamps 250 volts 5 amp
2. Two lamp holders 250 volts 5 amp
3. PVC Pipe
4. One way Switch 1 No. 250 volts 5 amp
5. One Square block
6. Two Round blocks Wooden
7. PVC Wire 1/18
TOOLS REQUIRED:
1.
Screw Driver 12" 1 No.
2.
Screw driver 8" 1 No.
3.
4.
Cutting plier 8" 1 No.
5.
Pocker 8" 1 No.
6.
Hammer Ib 1 No.
7.
Wire Stripper 6" 1 No.
INDEX:
1 &2 Lamp Holders
3 One-Way Switch
PROCEDURE:
Step 1. Make T frame with the help of 3-way junction box and fix with help of
saddles.
Step 2. Connection such that a phase wire connected incoming of one-way switch
and another wire connected to outgoing one-way switch to the one end of L1
bottom lamp holder. Neutral wire is connected to another end of L2 lamp
holder. Finally L1 L2 top of ends points are connected with a wire.
Step 3. Fix one-way switch square block.
Step 4. Fix round blocks and the top of the round blocks are connected to lamp
holders
PRECAUTIONS:
1. Avoid loose connections.
2. Avoid short circuit
81
2.
Connection of Two Lamps in Parallel
AIM: To connect two lamps in parallel connection with controlling one-way switch.
MATERIAL REQUIRED:
1.
3 way junction box 3/4
2.
Sanddle
3.
Square block
4.
Round block wooden
5.
PVC wire 1/18
6.
Screws 12 mm &60 mm
7.
PVC pipe
8.
Lamp holder 250 V 5A 2 Nos.
TOOLS REQUIRED:
1.
2.
3.
4.
5.
Pocker 8" 1 No.
6.
Hammer Ib 1 No.
7.
Wire Stripper 6" 1 No.
INDEX:
1 &2 Lamp Holders
3 One-Way Switch
PROCEDURE:
Step 1. Make T frame with the help of 3-way junction box and fix with help of
saddles.
Step 2. Take PVC wire and give connection as per circuit diagram such that a phase
wire connected incoming of one-way switch and another wire connected
outgoing of one-way switch to the bottom wire which were connected to
bottom of L1 and L2 ends. Neutral wire is connected L1 and L2 which two
ends of lamp holders are connected with a wire.
Step 3. Fix one-way switch square block.
Step 4. Fix round blocks and the top of the round blocks are connected to lamp
holders.
PRECAUTIONS:
2. Avoid short circuit.
82
3.
Stair Case Wiring
AIM: To connect a strain case wiring.

MATERIAL REQUIRED:
1.
PVC wire 1/18 or Multistrand
2.
Sanddle
3.
PVC pipe
4.
Two way switch 250 V 5A 2 Nos.
5.
Lamp holder 250 VSA 1 No.
6.
Wooden round block 1 No.
7.
Square block 4 x 4 1 No.
8.
Screws 12 mm & 15 mm
9.
Three way junction box (PVC)
TOOLS REQUIRED:
1.
2.
3.
4.
5.
Pocker 8" 1 No.
6.
Hammer Ib 1 No.
7.
Electrician knife 4" 1 No.
INDEX:
1 & 2 Two way switch
3 Lamp
PROCEDURE:
Step 1. Make a frame with three way junction box.
Step 2. Fix the PVC pipe frame with the help of saddle.
Step 3. Take PVC wire and give the connection as per circuit diagram.
Step 4. The connection is made in such a way that neutral wire directly connected to
lamp starting. A phase in coming wire connected to 1st 2-way switch middle
point and connect 1st 2-way switch top to 2nd 2-way switch top and 1st 2-way
switch bottom to 2nd 2-way switch bottom with PYC wire. And another wire
connected 2nd 2-way switch middle point to lamp ending.
Step 5. Fix the square block.
Step 6. Takeout the two wires i.e. phase and neutral from PVC pipe and round block
and fix the round block.
Step 7. Fix the lamp holder on the round block.
83
PRECAUTIONS:
2. Avoid short circuit.
84

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B.E. I/IV Yr.

(Common to all branches) Year wise

List of Experiments Prescribed by Osmania University

List of innovative experiments (if any)

Name of the Experiment

Sheet Metal (Tin smithy)

Introduction to Tin smithy

To make a rectangular scoop from a given metal sheet

To prepare a pamphlet box from a given metal sheet

To make a square tin having separate base and top open

To make a round to square section of the given rod.

To make a Template Fitting

To make Drilling and Tapping in the given plate.

To make a T Fitting as per given dimensions

Plumbing of water tap connection as per the layout using PVC / GI

To make a straight line bead on MS plates

To make a Butt joint on MS plates

To make a Lap joint on MS plates

To make a T joint on MS plates

To make a Corner joint on MS plates

To make a planning sawing and chiseling operations

To make half Lap joint

To make a Dove Tail joint

To make a Mortise and Tenon joint

Introduction to House wiring

To connect two lamps in series connection

To connect two lamps in parallel connection with controlling one

To connect a stair case wiring

Introduction to Tin Smithy

Allowance should be given in the drawing stage for folding and

It is graduated on both sides in

millimeters and centimeters or inches. Its length varies from 15 cm (6 inches) to 30

AIM: To make a rectangular scoop from a given metal sheet

The given metal sheet is smoothened using wooden hammer.

Draw the development of surface of the rectangular scoop of dimensions 250

Material: GI sheet 30 gauge

Note: Sketches should be drawn with pencil neatly

The given metal sheet is smoothened using wooden hammer.

Take 250 mm x 250 mm dimensional sheet and markings are made.

The unwanted material is removed using a straight hand shear.

Wear apron and shoes while doing the job.

Dimensions have to be marked carefully.

Dimensions are to be measured carefully.

Cutting has to be done carefully without hurting the fingers.

Do not let sheet metal slip through your hands.

Material: GI sheet 30 gauge

Note: Sketches should be drawn with pencil neatly

AIM: To prepare a pamphlet box from a given metal sheet

The given metal sheet is smoothened using mallet

The development of the surface of the required work piece is drawn.

A metal sheet of dimensions 215 mm x 95 mm is taken. Marking is done as

Now bending is to be done by plotting sheet on stakes. After bending, the

Wear apron and shoes while doing the job.

Dimensions have to be marked carefully.

Dimensions are to be measured carefully.

Cutting has to be done carefully without hurting the fingers.

Material: GI sheet 30 gauge

Note: Sketches should be drawn with pencil neatly

The given metal sheet is smoothened using mallet.

Draw the development of surface of square tin of required dimensions.

(i) 215 mm x 70 mm (ii) 70 mm x 70 mm and mark required dimensions with

Now bending is to be done by placing sheet on stakes. After bending as per

Wear apron and shoes while doing the job.