Lab manual

Digital Fabrication Lab

Code..20ME C02
(Common to all Branches)
 CHAITANYA BHARATHI INSTITUTE OF TECHNOLOGY
(AUTONOMOUS)
DEPARTMENT OF MECHANICAL ENGINEERING
INSTITUTE VISION AND MISSION
Vision:
To be centre of excellence in technical education and research
Mission:
To address the emerging needs through quality technical education and advanced research
DEPARTMENT VISION AND MISSION:
Vision:
To be the destination for aspiring young minds to become globally competitive, enlightened,
innovative, immediate contributors to the industry and successful in higher studies in the field of mechanical
engineering.
Mission:
1. To impart quality and innovative education in mechanical engineering with basic and
specialised training, internships to meet the current and emerging needs of the industry.
2. To prepare the students for successful professional career by inculcating ethical,
entrepreneurial and leadership qualities.
3. To foster Research and Development environment by disseminating knowledge and
technology by involving the students in publications, sponsored projects and consultancy.
PROGRAM EDUCATION OBJECTIVES (PEOs):
After Four years of graduation graduates will have
1. Ample technical knowledge and skills for a successful career in Mechanical Engineering and product
development, design, development and implementation of engineering systems, services and processes
2. Capability to develop competitive technologies and find solutions to industry, societal
challenges and engineering problems with ethical and professional standards
3. Ability to be entrepreneurial, innovative in the context of global scenarios of technological challenges and
environmental issues.
4. To pursue life-long learning and to adapt to the changing industry requirements.
5. To be a team player, lead and engage diverse teams through effective communication, interpersonal and
project management skills.
PROGRAM SPECIFIC OUTCOMES (PSOs):
The graduates will be able to
1. Apply their learning to design and develop basic mechanical systems and processes.
2. Select manufacturing processes and their appropriate parameters for the production of typical engineering
components.
3. Apply the concepts of mechanical engineering in power generation, aerospace, environmental, bio-
medical, automotive, sustainable energy systems and with suitable safety precautions.

Course Objectives:
1. Give a feel of Engineering Practices & develop holistic understanding of various Engineering materials and
Manufacturing processes.
2. Develop skills of manufacturing, safety, precision, quality, intelligent effort, optimization, positive &team
work attitude to get things right the first time.
3. To provide basic knowledge of Steel, Plastic, Composite and other materials for suitable applications.
4. Study of Principle and hands on practice on techniques of fabrication and 3D printing technology.
5. To advance important hard & pertinent soft skills, productivity, create skilled manpower which is cognizant
of industrial workshop components and processes and can communicate their work in a technical, clear and
effective way.

Course Outcomes: At the end of the course, the students are able to
1. Understand safety measures to be followed in Digital fabrication lab to avoid accidents.
2. Identify various tools used in carpentry, house wiring, plumbing and additive manufacturing.
3. Make a given model by using workshop trades including carpentry, plumbing and House wiring.
4. Students will demonstrate a basic technical understanding of the physical principles, materials, and
operation of the types of AM processes.
5. Students will demonstrate the ability to identify characteristics of parts that are fabricated by AM
processes.
 3D PRINTING.
Introduction
3D Printing or additive manufacturing is a process of making three dimensional solid objects adding material
layer by layer. By using 3D Printing it is possible to produce objects of almost any shape and form. Currently
many different 3D printing technologies and materials are used. Recently 3D printing tools are available for
industrial manufacturing and for home users as well. Due to the fact that instead of removing material to
create a part, the process adds material in successive patterns to create the desired shape.
3D Printing uses software that slices the 3D model into layers (0.01mm thick or less in most cases). Each layer
is then traced onto the build plate by the printer, once the pattern is completed, the build plate is lowered
and the next layer is added on top of the previous one. Typical manufacturing techniques are known as
‘Subtractive Manufacturing’ because the process is one of removing material from a preformed block.
Processes such as Milling and Cutting are subtractive manufacturing techniques. This type of process creates
a lot of waste since; the material that is cut off generally cannot be used for anything else and is simply sent
out as scrap. 3D Printing eliminates such waste since the material is placed in the location that it is needed
only, the rest will be left out as empty space
Typical manufacturing techniques are known as ‘Subtractive Manufacturing’ because the process is one of
removing material from a preformed block. Processes such as Milling and Cutting are subtractive
manufacturing techniques. This type of process creates a lot of waste since; the material that is cut off
generally cannot be used for anything else and is simply sent out as scrap. 3D Printing eliminates such waste
since the material is placed in the location that it is needed only, the rest will be left out as empty space.
3D Printing uses software that slices the 3D model into layers (0.01mm thick or less in most cases). Each layer
is then traced onto the build plate by the printer, once the pattern is completed, the build plate is lowered
and the next layer is added on top of the previous one. Typical manufacturing techniques are known as
‘Subtractive Manufacturing’ because the process is one of removing material from a preformed block.
Processes such as Milling and Cutting are subtractive manufacturing techniques. This type of process creates
a lot of waste since; the material that is cut off generally cannot be used for anything else and is simply sent
out as scrap. 3D Printing eliminates such waste since the material is placed in the location that it is needed
only, the rest will be left out as empty space.
Main areas of use:

 Prototyping

 Specialized parts – aerospace, military, biomedical engineering, dental

 Hobbies and home use

 Future applications– medical (body parts), buildings and cars

Advantages and Limitations: Layer by layer production allows for much greater flexibility and creativity in the design
process. No longer do designers have to design for manufacture, but instead they can create a part that is lighter and
stronger by means of better design. Parts can be completely re-designed so that they are stronger in the areas that
they need to be and lighter overall. 3D Printing significantly speeds up the design and prototyping process. There is no
problem with creating one part at a time, and changing the design each time it is produced. Parts can be created within
hours. Bringing the design cycle down to a matter of days or weeks compared to months. Also, since the price of 3D
printers has decreased over the years, some 3D printers are now within financial reach of the ordinary consumer or
small company. Complexity and freedom of design • 3D printing lets create complex shapes and parts – many of which
cannot be produced by conventional manufacturing methods. • Complex geometries can be created easily and it allows
a large amount of design freedom. • By using 3D Printing complex models can be produced as a single piece on the
spot, therefore there is no need to produce smaller parts and assemble them.

The limitations of 3D printing in general include expensive hardware and expensive materials. This leads to
expensive parts, thus making it hard if you were to compete with mass production. It also requires a CAD
designer to create what the customer has in mind, and can be expensive if the part is very intricate. 3D
Printing is not the answer to every type of production method; however its advancement is helping
accelerate design and engineering more than ever before. Through the use of 3D printers designers are able
to create one of a kind piece of art, intricate building and product designs and also make parts while in space!
 List of Experiments
1. To Study the method of Additive Manufacturing process using a 3D printer

2. To create a 3D CAD model using a modelling software

3. To Print a door bracket using an extruder type 3D Printer

4. To Design and Print an innovative component using the facilities of lab

 EXERCISE -1
To Study the Additive Manufacturing process using a 3D printer

Aim: To study the complete procedure of Additive Manufacturing process using an Extruder type 3D printer
Equipment required: A 3D printer
Material required: A spool of ABS/PLA material
Software required: CAD software for 3D modelling (Solid works), Flashprint Slicing software
Sequence of steps:

 3D CAD Modelling
 Converting the CAD Model to STL file
 Pre-processing of the model
 Printing
 Part removal and Post processing

Components of an Extruder type 3D Printer:

1. Axes Fixed Rods: The three axes that the 3D printer utilizes are on the Cartesian coordinate system. The
linear fixed rods are maintained at right angles to each other and each represents a coordinate axis.
Movement The timing belts and pulleys allow the movement of the hot end (or the print bed, depending on
the type of 3D printer) along each axes according to the g-code (generated by slicing software). The stepper
motors power this movement.
2. Extruder Extrusion: It is the feeding of filament into the hot end of the 3D printer. This movement is also
powered by a stepper motor. Retraction This mechanism is the pulling of the melted filament from the hot
end. This movement is primarily programmed through the g-code to prevent the formation of unwanted
filament creating a bridge between two areas. The bridging of unwanted filament is referred to as stringing
or the formation of cobwebs. Dual Extrusion Some models of 3D printers are equipped with dual extrusion
capabilities. This allows for mixed material objects to be printed. Dual extrusion can be used to print out
complex objects with a different colour material as the support, making it easy to differentiate between the
object and the support.
3. Hot End: The hot end is heated to temperatures ranging from 160 C to 250 C, depending on the type of
filament to be used. The hot end melts the filament and pushes the melted filament through the nozzle. The
hot end needs to be thermally insulated from the other components of the 3D printer to prevent any
damage.
4. Print Bed: Heated Print beds that are heated improve print quality of 3D printed objects. The heated bed is
heated to the glass transition temperature of the filament being used. This allows the model layers to slightly
melt and stick to the heated bed. Non-Heated Print beds that are not heated require adhesion in the form of
glue, tape, hairspray, etc. In the innovation lab, painters tape is frequently used for adhesion.
5. Filament: Filament is a consumable used by the 3D printer to print layers. Filament comes in a variety of
materials and colors. Filament can be composed of metal, wood, clay, biomaterials, carbon fiber, etc.
 i). ABS: - ABS is a thermoplastic that needs to be heated to temperatures from 210C to 250C. ABS can only
be printed on a 3D printer with a heated bed, which prevents the cracking of the object. When ABS is
heated, it emits a strong unpleasant odor. ABS requires a complete enclosure while printing.
ii). PLA: - PLA is a thermoplastic that needs to be heated to temperatures from 160C to 220C. PLA is also
biodegradable and emits slight odors. PLA is most frequently used in the Innovation Lab on all 3D printers.

Procedure for 3D printing

1. Preparing your 3D Model in CAD Software:
CAD software is used to create 3D models and designs. This software is available on our computers and the
level of difficulty varies. With the exception of Sketch up Pro and the industry standard software mentioned,
all of these programs are available on the innovation lab computers. Solid works main idea is user to create
drawing directly in 3D or solid form. From this solid user can assemble it directly on their workstation
checking clashes and functionality of it. Creating drawing is pretty easy just drag and drop the solid to
drawing block.
2. Converting the CAD file into STL file format
Nearly every 3D printer accepts the STL file format, which has become a de facto standard, and nearly every
CAD system can output of STL file format. The solid or surface model to be built is next converted into a
format dubbed the STL file format. This format originates from 3D Systems which pioneers the
Stereolithography system. The STL file format approximates the surfaces of the model using tiny triangles.
Highly curved surfaces must employ many more triangles, which mean that STL files for curved parts can be
very large. Almost all major CAD/CAM vendors supply the CAD-STL interface. Since 1990, almost all major
CAD/CAM vendors have developed and integrated this interface into their systems. This conversion step is
probably the simplest and shortest of the entire process chain. However, for a highly complex model coupled
with an extremely low performance workstation or PC, the conversion can take several hours. Otherwise, the
conversion to STL file should take only few seconds.
3. Pre-processing of the model for print in Flashprint software
Preparing building parameters for positioning and stepwise manufacturing in the light of many available
possibilities can be difficult if not accompanied by proper documentation. These possibilities include
determination of the geometrical objects, the building orientation, spatial assortments, arrangement with
other parts, necessary support structures and slice parameters. They also include the determination of
technological parameters such as cure depth, laser power and other physical parameters as in the case of
SLA. It means that user-friendly software for ease of use and handling, user support in terms of user manuals,
dialogue mode and online graphical aids will be very helpful to users of the RP system

4. Printing
For most RP systems, this step is fully automated. Thus, it is usual for operators to leave the machine on to
build a part overnight. The building process may take up to several hours to build depending on the size and
number of parts required. The number of identical parts that can be built is subject to the overall build size
constrained by the build volume of the RP system.

5. Part removal & Post processing

The final task in the process chain is the postprocessing task. At this stage, generally some manual operations
are necessary. As a result, the danger of damaging a part is particularly high. Therefore, the operator for this
last process step has a high responsibility for the successful process realization. The necessary postprocessing
tasks for some major RP systems are shown in Table 2.2. The cleaning task refers to the removal of excess
parts which may have remained on the part. Thus, for SLA parts, this refers to excess resin residing in
entrapped portion such as a blind hole of a part, as well as the removal of supports. Similarly, for SLS parts,
the excess powder has to be removed. Likewise for LOM, pieces of excess woodlike blocks of paper which
acted as supports have to be remove
Precautions
The Following precaution are while using 3D Printer
1. Do not place limbs inside the build area while the nozzle is in motion.
2. Do not touch the printer nozzle as it is heated to a high temperature in order to melt the build material.
3. Choose an area that has adequate ventilation and exhaust capability
4. always use Gloves while using 3D printer
Results:
 EXERCISE -2
To create a 3D CAD model using any modelling software
Aim: To create a 3D CAD model of a door bracket using sold works software
Equipment required: computer workstation
Material required: Nil
Software required: Solid works software package
Sequence of steps:

 Creating a sketch with given dimensions

 Extruding the sketch
 Creating the hole features
 Providing fillets and chamfers

Procedure:
Precautions
1. Save the work at regular intervals to avoid data loss during power cuts
2. Check the dimensions of the sketch properly
3. The sketch must be fully constrained before extruding
Results:
 EXERCISE -3
To Print the door bracket using an extruder type 3D Printer
Aim: To print the given 3D cad model using an Extruder type 3D printer
Equipment required: A 3D printer, post processing tools, 3D cad model in STL format
Material required: A spool of ABS/PLA material
Software required: A Slicing software required for the 3D printer

Sequence of steps:
 Converting the CAD Model to STL file
 Pre-processing of the model
 Printing
 Part removal, cleaning and Post processing

Procedure:
1. Open the Flash forge software and click on Load and Select the required STL file from the saved
location

2. Orient the loaded part in the required orientation using Move and Rotate option

3. Select the required scale to increase or decrease the print size of the model and then select the
extruder that is loaded with the required material.
4. Click on support and do the support generation. Auto support option can be used to generate the supports.
Then select back option

5. Select the print option and set the parameters for printing

6. More options can be selected for setting layer height, shells, infills, speed, temperature etc. Restore
defaults option can also be chosen. After clicking ‘ok’, a new file is saved in the .gx format. This file is
given input to the 3D printer for starting the print.
Precautions
The Following precaution are while using 3D Printer
1. Do not place limbs inside the build area while the nozzle is in motion.
2. Do not touch the printer nozzle as it is heated to a high temperature in order to melt the build material.
3. Choose an area that has adequate ventilation and exhaust capability
4. always use Gloves while using 3D printer
Results:
 EXERCISE -4
To Design and Print an innovative component using the facilities of lab
Aim: To design and print an innovative component using an Extruder type 3D printer
Equipment required: A 3D printer, post processing tools, 3D cad model in STL format
Material required: A spool of ABS/PLA material
Software required: CAD software for 3D modelling (Solid works), Flashprint Slicing software
Sequence of steps:
 3D CAD Modelling
 Converting the CAD Model to STL file
 Pre-processing of the model
 Printing
 Part removal, cleaning and Post processing

Procedure:
The 3D cad modelling of any creative model can be done using the solid works software. Many sample CAD
models are also available on open source websites like Grabcad, aa3dp, free3d etc. these models can be
imported to the design software and modification can be done on these models. After designing the CAD
model of the desired component, printing is done using the extruder type 3D printer.

Precautions
The Following precaution are while using 3D Printer
1. Do not place limbs inside the build area while the nozzle is in motion.
2. Do not touch the printer nozzle as it is heated to a high temperature in order to melt the build material.
3. Choose an area that has adequate ventilation and exhaust capability
4. always use Gloves while using 3D printer
Results:
CARPENTRY
 INTRODUCTION TO CARPENTRY

Carpentry may be defined as the process of making wooden components. It starts from a marketable form of
wood and ends with finished products. It deals with the building work, furniture, cabinet making. Etc. joinery,
i.e., preparation of joints is one of the important operations in all woodworks. It deals with the specific work of
carpenter like making different types of joints to form a finished product.

Timber

Timber is the name given to the wood obtained from well grown trees. The trees are cut, sawn into
various sizes to suit building purposes.

The word, ‘grain’, as applied to wood, refers to the appearance or pattern of the wood on the cut surfaces.
The grain of the wood is a fibrous structure and to make it strong, the timber must be so cut, that the
grains run parallel to the length.
Wood suitable for construction and other engineering purposes is called timber. Wood in general is
divided into two broad categories: soft woods and hard woods.

Seasoning of Wood

A newly felled tree contains considerable moisture content. If this is not removed, the timber is likely to
wrap, shrink, crack or decay. Seasoning is the art of extracting the moisture content under controlled
conditions, at a uniform rate, from all the parts of the timber. Only seasoned wood should be used for all
carpentry works. Seasoning makes the wood resilient and lighter. Further, it ensures that the wood will
not distort after it is made into an object.

Classification of carpentry tools:

 Marking and measuring Tools
 Holding tools.
 Planning tools
 Cutting tools.
 Drilling and boring tools
 Striking tools
.

Marking and Measuring Tools:

Accurate marking and measurement are very essential in carpentry work, to produce parts to exact size.
To transfer dimensions onto the work; the following are the marking and measuring tools that are
required in a carpentry shop.

Steel Rule and Steel Tape

Steel rule is a simple measuring instrument consisting of a long, thin metal strip with a marked scale of
unit divisions. It is an important tool for linear measurement. Steel tape is used for large measurements,
such as marking on boards and checking the overall dimensions of the work.

Fig: Steel Rule and Steel Tape

Marking Gauge
It is a tool used to mark lines parallel to the edge of a wooden piece. It consists of a square wooden stem
with a sliding wooden stock (head) on it. On the stem is fitted a marking pin, made of steel. The stock is
set at any desired distance from the marking point and fixed in position by a screw. It must be ensured
that the marking pin projects through the stem, about 3 mm and the end are sharp enough to make a
very fine line.
Mortise Gauge
It consists of two pins. In this, it is possible to adjust the distance between the pins, to draw two parallel
lines on the stock.

Marking gauge Mortise gauge

Fig: Marking Gauges

 Try ‐ Square
It is used for marking and testing the squareness and straightness of planed surfaces. It consists of a
steel blade, fitted in a cast iron stock. It is also used for checking the planed surfaces for flatness. Its size
varies from 150 to 300 mm, according to the length of the blade. It is less accurate when compared to the
try‐square used in the fitting shop

Fig: Try Square

Divider and Compass
Divider and Compass, are used for marking arcs and circles on the planed surfaces of the wood

Fig. Divider and Compass

Marking Knife

It is used for marking on timber. It is made of steel having one end pointed and the other end formed
into a sharp cutting edge.

Fig – Marking knife

Meter Square: It is used for marking and testing 45⁰. It consists of a steel blade fitted in a wooden or
metal stock at an inclination of 45⁰ with horizontal.

Bevel Square
It is used for laying‐out and checking angles. The blade of the bevel is adjustable and may be held in
place by a thumb screw. After it is set to the desired angle, it can be used in much the same way as a try‐
square

Fig: Bevel Square

Holding Tools

Carpenter's Vice
It is used as a work holding device in a carpenter shop. It’s one jaw is fixed to the side of the table while
the other is movable by means of a screw and a handle. The Carpenter's vice jaws are lined with hard
wooden' faces
Bar Cramp
It is made of steel bar of T‐section, with malleable iron fittings and a steel screw. It is used for
holding works such as frames or tops.

C-Clamp
It is used for holding small work on the bench. It consists of a frame with a jaw at one end, and movable
jaw, which is operated by a screw and a thumb nut, at the other end.

BENCH VICE

BAR CLAMP
 C-CLAMP

Planing Tools

Planing is the operation used to produce flat surfaces on wood. A plane is a hand tool used for this
purpose. The cutting blade used in a plane is very similar to a chisel. The blade of a plane is fitted
in a wooden or metallic block, at an angle.

Types of Planes

Jack Plane
It is the most commonly used general purpose plane. It is about 35 cm long. The cutting iron (blade)
should have a cutting edge of slight curvature. It is used for quick removal of material on rough
work and is also used in oblique planning.

Smoothing Plane

It is used for finishing work and hence, the blade should have a straight cutting edge. It is about 20
to 25 cm long. Being short, it can follow even the slight depressions in the stock, better than the
jack plane. It is used after using the jack plane.

Rebate Plane

It is used for making a rebate. A rebate is a recess along the edge of a piece of wood, which is
generally used for positioning glass in frames and doors.

Plough Plane

It is used to cut grooves, which are used to fix panels in a door. The following figure shows the
various types of planes mentioned above.
Cutting Tools
Cutting tools are used for cutting timber to approximate size, cutting excess wood to obtain desired
shape and accuracy. They are Saws and Chisels.

Types of Saws

Cross‐Cut Saw or Hand Saw

It is used to cut across the grains of the stock. The teeth are so set that the saw kerf will be wider
than the blade thickness. This allows the blade to move freely in the cut, without sticking.

Rip Saw

It is used for cutting the stock along the grains. The cutting edge of this saw makes a steeper
angle, i.e., about 60° whereas that of crosscut saw makes an angle of 45° with the surface of the
stock.

Tenon Saw
It is used for cutting the stock either along or across the grains. It is used for cutting tenons and in
fine cabinet work. However, it is used for small and thin cuts. The blade of this saw is very thin
and so it is stiffened with a thick back steel strip. Hence, this is sometimes called as back‐saw. In
this, the teeth are shaped like those of cross‐cut saw.

Compass Saw
It has a narrow, longer and stronger tapering blade, which is used for heavy works . It is mostly
used in radius cutting. The blade of this saw is fitted with an open type wooden handle.

CROSS CUT SAW TENON SAW

CROSS CUT TEETH RIP SAW TEETH

Fig: Types of Saws.

 Chisels
Chisels are used for cutting and shaping wood accurately. Wood chisels are made in various blade
widths, ranging from 3 to 50 mm. They are also made in different blade lengths. Most of the wood
chisels are made into tang type, having a steel shank which fits inside the handle. These are made
of forged steel or tool steel blades.

Types of Chisels

Firmer Chisel
The word 'firmer' means 'stronger' and hence firmer chisel is stronger than other chisels. It is a
general-purpose chisel and is used either by hand pressure or by a mallet. The blade of a firmer
chisel is flat, as shown in figure.

Dovetail Chisel
It has a blade with a bevelled back, as shown in Figure, due to which it can enter sharp comers
for finishing, as in dovetail joints.

Mortise Chisel

It is used for cutting mortises and chipping inside holes, etc. The cross‐section of the mortise chisel
is proportioned to withstand heavy blows during mortising. Further, the cross‐section is made
stronger near the shank.
 Fig- Types of Chisels.

Drilling & Boring tools

These tools are used for drilling and making holes in wooden jobs.
Gimlet

It is hand operated tool used for making small holes for screws. It has a spiral flute with
screw like point.
Hand drills

It is used for drilling small holes. A straight shank drill is used with this tool. It is small, light
in weight. The bit is clamped in the chuck at its end.
Auger
It is used for producing long deep holes.
It is a steel bar with an eye at the top in which a handle is fitted. The bottom end is provided
with a screw point.
 Fig- Hand Drill, Auger bit.

Fig- Gimlet

Striking tools:
Striking tools are used to drive in nails and to operate chisels.
Warrington Hammer:

It is mostly used for bench work and light work. It is made of cast steel with tempered face
and peen. The wooden handle fits in the eye and steel wedge are driven in to form a rigid
joint.

Claw Hammer:
It is dual purpose hammer. It has a hammer face which is used to drive in nails, and claw at
the other end for pulling out nails from the wood. It is designed by its weight and it varies
from 375 to 675gms.
Mallet:
It is used for operating the chisels and gauges. It is made of hard wood and is provided with
 handle. The striking faces are made flat, and may be in square or rectangular cross-section.

Fig- Warrington hammer (peen Hammer)

Fig- Claw Hammer. Fig- Mallet.

 EXERCISE -1
TO PLANE THE GIVEN WOODEN PIECE TO REQUIRED SIZE

AIM: To plane the given wooden piece to required size and obtain groove cutting.
MATERIALS REQUIRED: Teak block of dimensions 155 mm × 46 mm ×28 mm.
TOOLS REQUIRED
 Metal jack plane
 Try Square
 Marking Gauge
 Steel Rule
 Hand Saw
 Firmer Chisel
 Mortise Chisel
 Plastic Mallet
 Carpentry Vice
OPERATIONS TO BE CARRIED OUT
 Planning
 Marking
 Cutting
 Chiseling
 Finishing
 Fig- 1- Groove cutting and chiselling.
All dimensions are in mm.
PROCEDURE
The given wooden piece was fixed to carpenter’s vice and planning operation was done with the help of a
Metal jack plane.
The adjacent faces were made perpendicular and was tested with the help of a Try square.
Dimensions were marked carefully with a marking gauge and the wooden block was brought to the required
dimensions of 155 mm × 46 mm ×28 mm by planning and sawing.
As per the given fig 1, required marks were placed on the block with a pencil and depth was marked using a
marking gauge.
Sawing was done with the help of a hand saw to provide the depth of cut and to remove the block of dimension
of 25 mm× 21 mm as shown in figure.
Groove cutting was done with the help of mortise and firmer chisel, followed by finishing of the job.
PRECAUTIONS
Marking must be done accurately
Care must be taken in chiselling so that the required material is not removed.
 EXERCISE -2
TO MAKE A LAP JOINT ON THE GIVEN WOODEN PIECE ACCORDING TO THE
GIVEN DIMENSIONS.

AIM: To make a lap joint on the given wooden piece (155 mm × 46 mm ×28 mm.)
according to the figure.

TOOLS REQUIRED
 Metal jack plane
 Try Square
 Marking Gauge
 Steel Rule
 Hand Saw
 Firmer Chisel
 Mortise Chisel
 Plastic Mallet
 Carpentry Vice
OPERATIONS TO BE CARRIED OUT
 Planning
 Marking
 Cutting
 Chiseling
 Finishing
 Fig- 2-Half lap joint. All dimensions are in mm.
PROCEDURE
Given wood piece was fixed to the carpenter’s vice followed by planning by a metal jack plane and the
adjacent two faces were made perpendicular.
These faces were checked by try square and parallel lines of 46 mm and 28 mm was marked from the required
edge with a marking gauge.
These marks represented the width and thickness of the model respectively.
Length of the workpiece was marked as 155 mm.
The required dimensions were achieved by planning with the help of a metal jack plane.
Now marking of 46mm,29 mm,17mm,46mm and 17 mm were made respectively with a pencil on the 155 mm
side.14mm depth was marked at the required edge with a marking gauge.
With the help of a hand saw depth of cut was provided and sawing of the 46mm×46 mm part as shown in
figure 2 (extreme left) was carried out.
The second part in the figure 2(extreme right) is removed off with the help of a mortise chisel.
The wooden block was divided into two parts at a distance of 75 mm from the left-hand side with the help of a
hand saw. Then finishing was done for the job.
PRECAUTIONS
• Marking must be done accurately.
• Care must be taken in chiseling so that the excess material is not removed.
 EXERCISE 3
TO OBTAIN DOVE TAIL JOINT WITH THE GIVEN WOODEN PIECE

AIM: To obtain dove tail joint with the given wooden piece of dimensions
155 mm × 46 mm ×28 mm
TOOLS REQUIRED
 Metal jack plane
 Try Square
 Marking Gauge
 Steel Rule
 Hand Saw
 Firmer Chisel
 Mortise Chisel
 Plastic Mallet
 Carpentry Vice

OPERATIONS TO BE CARRIED OUT

 Planning
 Marking
 Cutting
 Chiseling
 Finishing
 Fig- 3-Dove tail joint
PROCEDURE
Given wood piece was fixed to the carpenter’s vice followed by planing by a metal jack plane and the adjacent
two faces were made perpendicular.
These faces were checked by try square and parallel lines of 46 mm and 28 mm was marked carefully from the
required edge with a marking gauge.
These marks represented the width and thickness of the model respectively.
Length of the workpiece was marked as 155 mm.
The required dimensions were achieved by planing with the help of a metal jack plane.
The dimensions of the two mating parts were marked using scale and marking gauge.
Using a hand saw the portions to be removed are cut, followed by chiselling.
Now the block was separated into two halves to obtain the mating parts.
The ends of both the parts were brought to exact dimensions.
Finishing of the two mating parts was done to get a tight joint.
PRECAUTIONS
• Marking must be done accurately
• Care must be taken during chiseling so that the required material is not removed
APPLICATIONS
This joint is used for making box and drawer joints
HOUSE WIRING
 ELECTRICAL WIRING SYSTEMS

Introduction to various types of wires:

1. V.I.R. (Vulcanized India Rubber) Wires:

These wires are used for General Electric wiring in casing capping and
conduit wiring. These wired absorb moisture quickly.

2. C.T.S./T.R.S. (Cab Tyre Sheathed/Tough Rubber Sheathed) Wires:

These wires are same what moisture proof. These are available in single core,
twine core and three cores.

3. Lead Sheathed Wires:

Such types are similar in construction with T.R.S. as per as core section is
concerned but having outer sheath of lead alloy. These wires are used for the
moisture full weather and for the snow fall area.

4. P.V.C. (Polyvinyl Chloride) Wires:

In these types of wire, conductors are insulted with P.V.C. insulations. Now a day
mostly these wires are used for better wiring e.g., Cleat wiring, Casing capping wiring
and conduit wiring. P.V.C. insulation is harder than rubber. So, cotton taping and
braiding is not required for mechanical and moisture protection. These wires should
not be used for giving connection to the heating appliances and pendent lighting etc.

5. Weather Proof Wires:

These wires are used for outdoor work as service lines. The conductors are
insulated first with rubber then braiding with cotton thread. The braiding material is
dropped in weather proof compound.

6. Flexible Wires:
These wires are used for giving connections to heating appliances. Pendent
lights, portable appliances etc.

The following are the types of flexible wires available in market:

1. T.R.S. flexible wires.
2. Workshop flexible available in 3 core and 4 core (3 phase and neutral wire).
3. P.V.C. insulated flexible wire.
 4. Other wires are:
a) Nichrome wires: It is used as heat producing resistances ex. Heater etc.
b) Hard drawn base copper conductor: It is used overhead lines and earth
connection wires.
c) Aluminium conductor: It is used in overhead lines and now a days it is used well
in V.I.R. wires. C.T.S. wires and P.V.C. wires.
d) Enamelled wires: It is used for winding all types of electric motors and
generators. It is also used for making electro magnets.
e) Eureka wire: IT is used in rheostats.

Specifications of wire: A wire is specified by type of wire, length of wire and fraction
denoting its number of strands and thickness expressed in gauge number.

Electric lamp holder: The function of lamp holder is to hold the lamp. There are two
types of lamp holders.

Batten holder: Batten holder are used for fixing the bulb at one point. There are
angle Bakelite lamp holder also.

Pendant holder: Pendant holder is used to suspend bulb from one point. Outside
material is brass for holder, inside there are two copper terminals separated by insulting
material of porcelain.

Switches: Switch is used to on or off the system. There are two types of switches.
1. SPT Switch
2. DPT Switch

SPT Switch (Single Pole Tumbler): There are two terminals in SPT switch. When the
switch is on these two terminals are connected with each other and hence current floes.
Switch is made of with plastic or Bakelite, Switch is specified by current rating like 5A, 15A
etc.

DPT Switch (Double Pole Tumbler): DPT switch is used in staircase wiring.
There are three or four terminals in DPT switch. There are piano type switches available in
the market. Tumbler switches are out date now.

Bulb: The specification of bulb is voltage and wattage. In the bulb, electrical energy is
converted into light energy. Inside the bulb, there is filament, made of tungsten. The bulb is
vacuumed or filed with inert gas to avoid combustion or oxidation of filament.

When two bulbs are connected in series. We can operate those bulbs with single
switch. If two resistances R1 and R2 are connected in series, resultant resistance
R=R1+R2
If two resistances R1 and R2 are connected in parallel, resultant resistance
R=R1R2/(R1+R2) If two capacitances C1 and C2 are connected in series, resultant
resistance R=C1C2/(C1+C2) If two capacitances C1 and C2 are connected in parallel,
resultant resistance R=C1+C2
Fluorescent Mercury Vapour Lamps: Basically, a fluorescent lamp consists of long
glass tube internally coated with a suitable fluorescent power. The tube contains a small
amount of mercury along with argon whole function is to facilitate the starting of mercury
along with argon whole function is to facilitate the staring of the are. There are two sealed
electrodes at each end of the tube.

Two basic types of electrodes used in fluorescent lamps are:

1. The coated coil tungsten wire type: This type is used standard pre-heat, rapid
start instant start lamps etc.
2. Two inside-coated metal cylinder type: It operates at a lower and more even
temperature than tungsten type and called cold cathode.
Circuits employed for the fluorescent lamps can be divided into two main groups:

1. Switch-Start circuits.
2. Start less circuits requiring no

starter. There are two types of starters:

a) Glow type which is voltage operated device and,

b) Thermal switch which is current operated device.
Choke: The function of the highly inductive choke is

(i) To supply large potential for starting the are or discharge and,
(ii) To limit the discharge current to a safe value.
Starter: During starting it opens and interrupts the current in the circuit and there by induces
high voltage source of 1000 volts in the choke to start the bulb.

Units and Measurement of Electrical Parameters

Electrical Units Measuremen

parameter t
Resistance Ohm Ohm meter
Current Ampere Ammeter
Voltage Volts Voltmeter
Capacitance Farad R.L.C. meter
Inductance Henry R.L.C. meter
The various types of wiring systems are:

1. Cleat Wiring
2. C.T.C Wiring (Batten Wiring)
3. Wood Casing Capping Wiring
4. Lead Sheathed Wiring
5. Conduit Wiring
Cleat Wiring System:

This type of wiring is not used particularly for permanent wiring and is only suitable for
temporary wiring purpose such as for marriage with advantage of saving in labour and
overall cost. The porcelain or wood cleats are very easy to erect and fixed at a distance of
5cms to 15cms apart. V.I.R wires are normally used in this system, through T.R.S. wires can
also be installed.

C.T.C. or Batten Wiring System:

These wires used are sheathed in tough rubber or P.V.C and they are arrived on wooden
batten. This wiring is suitable for damp climate, but cannot withstand much heat. So, it is not
suitable for places for very hot weather and there is also danger of mechanical damage and
fire hazard.
C.T.C wires are not suitable for outdoor use. Therefore, they should not be exposed to direct
sun light.
Wooden Casing and Capping Wiring System:

This is the most common type of wiring used for indoor and domestic installation. This
system was introduced 50years ago, when it was first considered necessary to provide some
protection of conductors. V.I.R wires are carried in two or more channel of wooden casing
and closed by wooden capping.

Lead Sheathed Wiring:

In lead sheathed wiring system, the conductor either of twin core, each being separately
insulated and covered with the common lead sheath is used. The lead sheathed wires are
easily fixed by means of metal clips on wooden batten and forms a good surface system.
Wherever the wires must be broken for connection to switch or light point. A junction boxes
are usually metal a provided with some means of earthing, so that continuity of the sheath
is obtained.
Conduct Wiring System:

In this system P.V.C wires are carried through steel or iron for P.V.C pipes giving good
protection from mechanical injury or fire risks.

EARTHING:
A wire coming from the ground 2.5-3 meters deep from an electrode is called earthing. The
earthing potential is always taken as zero for all practical purposes. The electrical
appliances or machines when connected with earth attain zero potential and are said to be
earthed.
HAND TOOLS:

1. Screw Driver
2. Combination Pliers
3. Pocket Knife
4. Poker
5. Hammers
6. Ball Peen Hammer
7. Cross Peen Hammer
8. Claw Hammer
9. Firmer Chisel
10. Cold Chisel
11. Hand Drilling Machine With ¼” bit
12. Wooden Saw
13. Hack Saw
14. Try Square
15. Blow Lamp
16. Files
17. Wrenches
18. Raw Plug Tool
19. Mallet
20. Bradawl
21. Standard Wire Gauge
22. Tester
23. 3-pin socket with switch

Screw Drivers: It is most important tool and is used more often than any other tool. The
screw driver are available in different sizes and they can used to mean different types of
jobs. They are used for taking out or driving in slotted head screw by turning them.
Precautions to be used while using screw drivers.

1. The edge should not be too sharp.

2. It must fit in the slot of screw head.
3. Do not use it as a hammer chisel.

HANDL
E
SHANK

NI
P

SCREW DRIVER
Combination plier: This type of plier is commonly used by an electrician. It is used for
cutting and twisting the wires only insulated pliers are used for electric work. These are
available in different sizes.

COMBINATION PLIERS

Pocket Knife: It is also one of the most important tools. It is generally used for removing
insulation from the wires. It should be made of high-grade cutting steel. Do not use it for cutting
wires in open shape. It should not be kept in the pocket.

POCKET KNIFE
Poker: It is generally difficult to insert a wooden screw into job. Unless there is small guide
hole with the poker an impression is made into the wood. It is a pointed tool and made from
forged tool, steel. Much care should be taken to handle such tool, it should never be taken
into pocket.

HANDLE

NIP

POKER
Hammers: There are many types of hammers but mostly following types are used by
an electrician.

Ball peen Hammers: It is used for riveting purposes.

BALL PEEN HAMMER

Cross peen Hammer: It is used for riveting purpose in awl award places.

CROSS PEEN HAMMER

Claw Hammer: It is use for driving nails into or pulling nails from some other object.

CLAW HAMMER
Firmer Chisel: It is used for chipping scraping and grooving in the wood. The size varies
and is taken from the width of the blade.

FIRMER CHISEL

Cold Chisel: It is used for plaster cutting or brick cutting. It is made from forded alloy
steel. Before use these chisels are tempered. The cold chisels are generally available in
different sizes.

COLD CHISEL

Hand Drill: This used for drilling holes in wooden blocks and wooden boards to facilitate
the passage of insulted wires while doing wiring.

HAND DRILL
Wooden Saw: Most of the wiring done with wooden casing and capping or batten. So it
is necessary to make use of a carpenters saw for making joints or for cutting the casing and
capping and batten reaper.

WOODEN SAW

Hacksaw: It is used for cutting metals such as conduits, cables etc. The hacksaw frame is
adjustable and blade of tool steel is used. The blade is usually 30cms long with 24 or 38
teeth in 25cms. The less numbered blades are used for coarse jobs while more numbered
once are used for fine cuts.

HACKSAW

Blow Lamp: It is used for soldering and cable jointing.

BLOW LAMP
Hand Drilling Machine: It is a small portable drilling machine resembling a breast drill
but designed to be held and operated by hand. A primitive drill consisting of a shaft carrying
a point of stone, bone, shell, or metal and revolved usually by the palms of the hand.

HAND DRILLING MACHINE

Try Square: It is used check and mark right angles in constructional work. It is a
wooden working tool used for marking and checking 900 angle on pieces of wood. Though
wood workers use many different types of square, the try square is considered one of the
essential tool for woodworking.

TRY SQUARE

Files: It is a tool used to remove fine amount of material from a work piece. It is common in
woodworking, metal working, and other similar trade and hobby tasks.

FILE
Wrenches: It is also called spanner, toll, usually operated by hand, for tightening bolts
and nuts. Some wrenches have end with straight sided slots that fit over the part being
tightened, these tools are known as open end wrenches and are made in various sizes to fit
specific bolt nut sizes.

WRENCHES

Rawl plug Tool: It is an electrical socket usually located in a wall that is connected to
and used as a source of electric power.

RAWL PLUG

Bradawl: It is a small, sharp tool used for making holes. It is a wood working hand tool with
a blade similar to that of a straight screw driver and handle made from wood or plastic.

BRADAWL
Tester: A test light, test lamp, voltage tester, or mains tester is a piece of electronic
test equipment used to determine the presence of electricity in piece of equipment
under test.

TESTER

Mallet: It is a kind of hammer, often made of rubber or sometimes wood, that is smaller
than a maul or beetle, and usually has a relatively large head. Wooden mallets are
usually used for hitting percussion instruments.

MALLET

Standard Wire Gauge: It is also known as imperial wire gauge or British standard
gauge. Use of SWG sizes has fallen greatly in popularity, but is still used as a measure
of thickness in guitar string and some electrical wire.

STANDARD WIRE GAUGE

CONDUCTORS AND INSULATORS:

Conductors: Through which electricity can flow easily or through metals which offer a
small resistance to the flow of electricity. Generally copper and aluminium are the materials
used as a conductor for the wires.

Insulators: Insulators are those substances, which offer a very high resistance to the
flow of electricity. The type of the wire depends upon the type of insulation used.
Generally, rubber and polyvinyl are used as insulation on wire.
 EXERCISE NO-1
Wiring of one light point controlled by one single pole switch, a three-pin socket
controlled by a single pole switch, and wiring of one buzzer controlled by a bell push

PART-A
AIM: Wiring of one light point controlled by one single pole switch (5A); a 3-pin socket
controlled by a single pole switch.

List of tools:
1. Screw driver large 6” -1No
2. Screw driver small 3” -1No
3. Connector screw driver -1No
4. Tester -1No
5. Insulation remover -1No
6. Cutting pliers -1No
7. Ball peen hammer -1No
8. Hand drilling machine -1No

List of accessories:

1. Single pole switch 5A -2Nos

2. 3-pin socket 5A -1No
3. Ceiling rose 5A -1No
4. Pendent holder -1No
5. Bulb 60watts -1no
6. Connecting wires -4mts
Wiring of one light point controlled by one single pole switch, a three-pin socket controlled by a single
pole switch

PROCEDURE
Neutral wire from D.P. Switch was connected to the neutral terminal of ceiling rose.
Live wire from D.P. switch was connected to fuse input.
Phase wire from fuse output was connected to switch input.
Phase wire from 3 pin socket was connected to switch
output.
Off wire from switch output was joined to the line input terminal of ceiling rose.
Neutral wire from 3 pin socket was connected to neutral input terminal of ceiling rose.
The pendant holder with bulb was connected to line and neutral output of the ceiling rose.
RESULT

The bulb glowed when D.P. switch and single pole switch was Switched ON.

PRECAUTIONS

Avoid contact with energized electrical circuits.

Switch off all appliances at the mains at the end of your work.

Do not wear loose clothing near electrical equipment.

Keep electrical equipment or outlets away from water.

 EXERCISE NO-1
PART-B
AIM: Wiring of one buzzer controlled by a bell push (5A) and a 3-pin socket (5A) controlled
by a single pole switch.
List of tools:

1. Screw driver large 6” -1No

2. Screw driver small 3” -1No
3. Connector screw driver -1No
4. Tester -1No
5. Insulation remover -1No
6. Cutting pliers -1No
7. Ball peen hammer -1No
8. Hand drilling machine -1No

List of accessories:

1. Single pole switch 5A -1No

2. 3-pin socket 5A -1No
3. Ceiling rose 5A -1No
4. Buzzer -1No
5. Push -1no
6. Connecting wires -4mts
Wiring of one buzzer controlled by a bell push (5A) and a 3-pin socket (5A) controlled by a single
pole switch.
 PROCEDURE
Neutral wire from D.P. Switch was connected to the neutral terminal of ceiling rose.
Live wire from D.P. switch was connected to fuse input.
Phase wire from fuse output was connected to inputs of bell push and
switch. Phase wire from 3 pin socket was connected to switch output.
Off wire from bell push output was joined to the line input terminal of ceiling rose.
Neutral wire from 3 pin socket was connected to neutral input terminal of ceiling rose.
The buzzer was connected to line and neutral output of the ceiling rose.

RESULT

The buzzer made a buzzing noise when D.P. switch and single pole switch were
switched ON.

PRECAUTIONS

Avoid contact with energized electrical circuits.

Switch off all appliances at the mains at the end of your work.

Do not wear loose clothing near electrical equipment.

Keep electrical equipment or outlets away from water.

 EXERCISE NO-2
AIM: Wiring of two light points connected in series and controlled by single pole switch.
Verify the above circuit with different bulbs. Wiring of two light points connected in parallel
from single pole switches and a three-pin socket
.

List of tools:
1. Screw driver large 6” -1No
2. Screw driver small 3” -1No
3. Connector screw driver -1No
4. Tester -1No
5. Insulation remover -1No
6. Cutting pliers -1No
7. Ball peen hammer -1No
8. Hand drilling machine -1No

List of accessories:

1. Two-way switches -2Nos

2. Batten holder -1No
3. Bulb 60watts -2Nos
4. Connecting wires -4mts
Wiring of two light points connected in series and controlled by single pole switch.

24
PROCEDURE

Neutral wire from D.P. Switch was connected to the neutral terminal of batten holder 1.
Phase wire from D.P. switch was connected to fuse input.
Phase wire from fuse output was connected to inputs of the single pole
switches. Live wire from 3 pin socket was connected to switch output.
Off wire from single pole switch output was joined to the phase terminal of batten
holder 2.
Neutral wire from 3 pin socket was connected to neutral terminal of batten holder 1.
The two batten holders were connected using off wire.

RESULT

The two bulbs connected in series glowed when the D.P switch and single pole switch
were turned ON.

PRECAUTIONS

Avoid contact with energized electrical circuits.

Switch off all appliances at the mains at the end of your work.

Do not wear loose clothing near electrical equipment.

Keep electrical equipment or outlets away from water.

Wiring of two light points connected in parallel from single pole switches and a three-pin
socket
PROCEDURE (PARALLEL CIRCUIT)

Neutral wire from D.P. Switch was connected to the neutral terminal of batten holder of both
the batten holders.
Phase wire from D.P. switch was connected to fuse input.
Phase wire from fuse output was connected to inputs of the single pole
switches. Live wire from 3 pin socket was connected to switch output.
Off wire from single pole switch output was joined to the phase terminal of both the batten
holders.
Neutral wire from 3 pin socket was connected to neutral terminal of batten holder 1.
The two batten holders were connected using off wire.
RESULT

The two bulbs connected in parallel glowed when the D.P switch and single pole switch were
turned ON.

PRECAUTIONS

Avoid contact with energized electrical circuits.

Switch off all appliances at the mains at the end of your work.

Do not wear loose clothing near electrical equipment.

Keep electrical equipment or outlets away from water.

 EXERCISE NO-3
AIM: Stair case wiring-wiring of one light point controlled from two different places
independently using two 2-way switches.
List of tools:

9. Screw driver large 6” -1No

10. Screw driver small 3” -1No
11. Connector screw driver -1No
12. Tester -1No
13. Insulation remover -1No
14. Cutting pliers -1No
15. Ball peen hammer -1No
16. Hand drilling machine -1No

List of accessories:

5. Two-way switches -2Nos

6. Batten holder -1No
7. Bulb 60watts -2Nos
8. Connecting wires -4mts
Stair case wiring-wiring of one light point controlled from two different places
independently using two 2-way switches

29
 PROCEDURE
Neutral wire from main supply was connected to the neutral
terminal of batten holder. Live wire from D.P. switch was connected
to fuse input.
The first pole and second pole of switch 1 were connected to the corresponding first
and
second pole of switch 2 with the help of off wires. i.e., similar poles of
both switches were connected to each other.
The phase of the supply line was connected to the common pole of switch 1.
An off wire (i.e., phase line to the load) was taken from the common pole
of switch 2, to the phase terminal of the batten holder.
To achieve a closed circuit, the common poles of the switches must be in contact.

RESULT

Stair case wiring of one light point controlled from two different places
independently using two 2-way switches was accomplished.

PRECAUTIONS

Avoid contact with energized electrical circuits.

Switch off all appliances at the mains at the
end of your work. Do not wear loose

clothing near electrical equipment.

Keep electrical equipment or outlets away from water.

 PLUMBING

1. 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.

2. PLUMBING TOOLS
2.1 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

2.2 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 pipe vice is fitted on the work bench. It holds the pipes
in position during cutting, threading and fitting of bends, couplings, etc. Figure 2 shows a
pipe vice. It consists of two jaws for holding the work, which are serrated to ensure firm grip.
 Fig. 2 Pipe Vice

2.3 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. Figure 3 shows a pipe cutter.

Fig. 3 Pipe Cutter

2.4 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.
2.5 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
hardened steel nut, having flutes cut along its inside surface. These flutes 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.

Fig. 4 Pipe Threading

3. 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
3.1 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.
 3.2 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
pipes together tightly.
3.3 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.

3.4 Elbow
It is used to make an angle between adjacent pipes. The angle is always 90°, unless
another angle is stated.
 3.5 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.

3.6 Reducer Coupling

It is used to connect two different sized pipes.

3.7 Bush
It is a short sleeve-like 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.
 3.8 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.

3.9 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.

3.10 Gate Valve

Pipe valves are fitted in the pipe line to control the fluid flow through it. Gate valve
offers less resistance to the flow of water through it. It is used 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 gate towards its seat (Fig. 6a).
 3.11 Globe Valve
This controls the fluid flow in a pipe line; however, the passage of flow is restricted
(Fig. 6b).

3.12 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)

3.13 Common Tap

This is used for tapping the fluid flow at required points in the pipe line (Fig. 6d).

4. PIPE LAYOUT

For better pipe work, it is advisable to sketch first, the pipe layout (Fig. 7), showing
dimensions
 Fig. 6 Valves
and types of fittings to be used. Careful planning makes it possible to complete the work with
fewer joints and fittings. In cutting pipe to length, the portion of the pipe that will screw into
the fittings must be taken into account.

Fig. 7 Pipe Layout

10.4.1 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 thread. 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.

10.4.2 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.

Questions

1. With what kind of work, ‘Plumbing’, deals with?

2. List the various plumbing tools.
3. The jaws of a pipe wrench are inside, to enable a
over the pipes.
4. When pipe cutter is used, instead of hacksaw?
5. In a pipe cutter, cut the pipe.
6. A pipe-die is used for cutting threads on pipes.
7. What are the forms in which the pipes are available?
8. The size of a pipe is designated by its diameter.
9. The size of a pipe fitting is designated by the size of the on which it fits.
10. A coupling will have external threads throughout. (True/False)
11.When a union is used in a pipe layout?
12.List out the commonly used pipe fittings.
13.A nipple will have external threads at both ends. (True/False)
14.A reducer coupling is used to couple two same sized pipes. (True/False)
15.A plug will have threads at one end and square end at the other.
16.Name the various pipe valves used in a pipe line to control the fluid flow.

Answers
3. Serrated, firm, grip 5. Cutter wheels 6. External 8. Inside
9. Pipe 10. False 13. True 14. False 15. External

CHAITANYA BHARATHI INSTITUTE OF TECHNOLOGY

MECHANICAL ENGINEERING DEPARTMENT

PLUMBING

EXERCISE NO. 01

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 ½” 6) Nipple ½” x 4”L

2) Gate valve (Gun metal) ½” 7) Water tap ½” Plastic / Brass / CI
3) GI TEE ½” 8) Cotton thread or thread sealing tape
4) GI Elbow 90° - ½” 9) Dummy plug ½”
5) GI Coupling ½”
TOOLS REQUIRED:
1) Pipe vice 4) Oil can
2) Pipe cutter or Hacksaw 5) Pipe wrench
3) Pipe die with die stock and handle 6) Steel rule or measuring tape

SEQUENCE OF OPERATIONS:
1) Length marking
2) Cutting to required lengths of pipes
3) Threading with pipe die and checking thread quality for 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 length required with pipe cutter or
hacksaw.
4) Hold the pipes one by one in pipe vice in position, adjust die set screw to form half the
thread depth, cut external threads on one end using pipe die.
5) Increase the depth of cut by adjusting die set screw and finish cut threads till one thread
projects through the die.
6) Test the quality of threads for proper fit by assembling with the mating components.
7) Reverse hold the pipes one by one in pipe vice in position, follow the above procedure
cut thread on the second end for all pieces.
8) Wind cotton thread or Teflon thread seal or jute and lappam over the threads for leak
proof joints. Assemble pipes, with pipe fittings and gate valve to the inlet supply pipe as
per the layout. Fix water tap.

PRECAUTIONS:
1) Clamp the pipe securely in the pipe vice.
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 / remove
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.
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.
 CHAITANYA BHARATHI INSTITUTE OF TECHNOLOGY
MECHANICAL ENGINEERING DEPARTMENT

PLUMBING

EXERCISE NO. 02

AIM: Plumbing of bath room water shower and line water tap as per layout using GI / PVC
pipe and relevant pipe fitting.

MATERIAL REQUIRED:

1) PVC / GI pipe size ½” 7) Water tap ½” Plastic / Brass / CI

2) Gate valve (Gun metal) ½” 8) Cotton thread or thread sealing tape
3) GI TEE ½” 9) Dummy plug ½”
4) GI Elbow 90° - ½” 10) Control cock (or gate valve)
5) GI Coupling ½” 11) Shower fitting
6) Nipple ½” x 4”L
TOOLS REQUIRED:
1) Pipe vice 4) Oil can
2) Pipe cutter or Hacksaw 5) Pipe wrench
3) Pipe die with die stock and handle 6) Steel rule or measuring tape

SEQUENCE OF OPERATIONS:
1) Length marking
2) Cutting to required lengths of pipes
3) Threading with pipe die and checking thread quality for 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 length required with pipe cutter or
hacksaw.
4) Hold the pipes one by one in pipe vice in position, adjust die set screw to form half the
thread depth, cut external threads on one end using pipe die.
5) Increase the depth of cut by adjusting die set screw and finish cut threads till one thread
projects through the die.
6) Test the quality of threads for proper fit by assembling with the mating components.
7) Reverse hold the pipes one by one in pipe vice in position, follow the above procedure
cut, thread on the second end for all pieces.
8) Wind cotton thread or thread seal around the threads for leak proof joints. Assemble
pipes with pipe fittings and Gate valve as per layout.
9) Finally fix water tap and shower fitting.

PRECAUTIONS:
1) Clamp the pipe securely in the pipe vice.
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 / remove
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.
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.
 CHAITANYA BHARATHI INSTITUTE OF TECHNOLOGY
MECHANICAL ENGINEERING DEPARTMENT

PLUMBING
EXERCISE NO. 03

AIM: To Test the Plumbing connections of water shower and water tap of a bath room as per
layout by giving water connection.

MATERIAL REQUIRED:

1) PVC / GI pipe size ½” 7) Water tap ½” Plastic / Brass / CI

2) Gate valve (Gun metal) ½” 8) Cotton thread or sealing tape
3) GI TEE ½” 9) Dummy plug ½”
4) GI Elbow 90° - ½” 10) Control cock (or gate valve)
5) GI Coupling ½” 11) Shower fitting
6) Nipple ½” x 4”L 12) Union

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 length required with pipe cutter or
hacksaw.
4) Hold the pipes one by one in pipe vice in position, adjust die set screw to form half the
thread depth, cut external threads on one end using pipe die.
5) Increase the depth of cut by adjusting die set screw and finish cut threads till one thread
projects through the die.
6) Test the quality of threads for proper fit by assembling with the mating components.
7) Reverse hold the pipes one by one in pipe vice in position, follow the above procedure
cut, thread on the second end for all pieces.
8) Wind cotton thread or thread seal around the threads for leak proof joints. Assemble
pipes with pipe fittings and Gate valve as per layout.
9) Finally fix water tap and shower fitting.
10) Water supply is given and tested for leakage of water.