Department of Electrical Engineering

B.P.PODDAR INSTITUTE OF MANAGEMENT AND

TECHNOLOGY
137, V.I.P. Road, Kolkata

Laboratory report on
Workshop/Manufacturing Practices
(ES-ME-292)

Name: __________________________________________

Roll No.: _____________Year:___________________

Semester:____________ Section: ________________

Group:_______________Session : _________________
 General Information
Course Name B.Tech Semester 1st/2nd

Session 2019-20 Year with stream

Course Credit 3 Class hour 4 (P)+1(L)

Faculty 2 Technical 4
Instructor/s assistants

Mechanical Laboratory Block-C

Department Engineering
Room no-004

SL NO Course Objective
1 To know the use of Fitting Tools.
2 To know the use of Carpentry Tools.
3 Students get knowledge in machining operation(e.g- Making surface finish good)
4 Students get basic knowledge in Welding operation.
5 Students get knowledge on Casting and the use of the tools e.g.-Sprue
Pin,Mallet,Rammer etc.
6 Students get knowledge on function of electrical components like
MCB,Fuse,Switches,LT Switchgear etc

CO Course Outcome Statement

Utilise the conception of fitting shop and make typical jobs.
CO1
Utilise the conception of carpentry shop and make typical jobs.
CO2
Develop the conception of machining, make use of Lathe, Milling and Shaping
machine and construct typical jobs.
CO3
Make use the conception of joining process and join two MS plate using arc welding
and gas welding process.
CO4
Construct typical jobs in Smithy, plastic moulding, green sand moulding and glass
CO5 cutting and build the conception of casting.
Demonstrate few common electrical and electronic elements like LT switchgear,
Kitkat fuse, Glass cartridge fuse, Plastic fuse holders (optional), Iron clad isolators,
MCB style isolators, Single phase MCB, Single-phase wire, wiring cable, MCB,
LED lamp, illustrate simple soldering exercises and fabricate a single-phase full
CO6 wave rectifier.

1
CO-PO-PSO Mapping:

CO PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11 PO12 PSO1 PSO2
CO1
2 2 1 2
CO2
2 2 1 2
CO3
2 2 1 2
CO4
2 2 1 2
CO5
2 2 1 2
CO6 2 2 1 2

Course 2 2 1 2

Safety Norms and precautions

1. Do not run in the workshop, you could ‘bump’
into another pupil and cause an accident.

2. Do not use a machine if you have not been

shown how to operate it safely by the teacher.
Donot
3. Do not make noise inside the workshop.

1. Always listen carefully to the teacher and follow

instructions.

2. Always wear an apron as it will protect your

clothes and avoid loose clothing such as ties.

3 Always be patient, never rush in the workshop.

4. Use hand tools carefully, keeping both hands

Do behind the cutting edge.

5. When learning how to use a machine, listen

very carefully to all the instructions given by the
teacher. Ask questions, especially if you do not
understand fully.

6. Must wear cover shoes during the work shop

classes.

2
 Course policies
1. Attendance

Attendance is compulsory. Please be respectful to your classmates by being on time. Cell

phones should be turned off and kept out of sight.

2. Calculator policy

You may need a calculator device

3. Plagiarism

Collaboration on performing the experiments and taking measurements is strongly

encouraged; however, the lab report you carry must be solely your own. Sharing written work
beforehand is considered as academic dishonesty.
4. Disability Support
If you have a disabling condition which may interfere with your ability to complete this
modulesuccessfully, please contact Faculty in charge.
5. Make-up Job
Make-up for a missing Job will not be offered, normally. The only exceptions to that are illness
or emergency (e.g., death in family, a traffic accident, etc.), in which case you may contact
your faculty in charge.
6. Innovative Experiments: As per policy you should perform at least two innovative
experiments from the list of innovative experiments to be provided.

7. As per policy you should perform at least two virtual experiments. You may select your
virtual experiments from: www.iitkgp.vlab.co.in

3
 Course assessment process
Continuous assessment (40)

Performance [50] :Experiment number, Objective, theory, procedure, discussion and conclusion

Lab Record [15]: Performance on method of working and attendance etc.

Viva at the end of each job[15] :There is a 5 –minute viva-voce at the end of job.

Internal Examination [20] : A 10-minutesViva-voce is taken based on the experiments completed.

Assessment during end semester examination (60)

Lab examination [20]:Jobs are allotted to the students randomly on lottery basis during
examination time which they have to complete within stipulated time.

Answer Scripts[20] :After completion of the job, students have to write the answers of the theory
questions.

Viva [20]: There is a 10-minute viva-voce during examination time.

Grading Scale
Grade Marks(15) Percent score

O 14-15 90-100

E 13 80-89

A 11-12 70-79

B 10 60-69

C 8-9 50-59

D 6-7 40-49

F 0-5 Below 40

I Incomplete

Recommended books 1.Workshop Technology by

HazraChowdhury(vol-1 and vol-2)

2. Manufacturing Technology by P.N. Rao.

3. Manufacturing Practices(Workshop
Practice) by Dr.R.K.Singal

4
 List of Jobs:
Date of Sr Job Name of Job Page Signature Grade
Job No. No. No. awarde
d
1 1 Introduction to Workshop
2 J1 Making a gauge from M.S plate.
3 J2 Making a Wooden Joints (Cross-Halving
Joint) or a Pattern or like.
4 J3 Making a Round Headed Peen from M.S.
round bar.
5 J4 Making a key slot /V-slot on M.S. plate by
Milling machine/ Shaping Machine.
6 J5 Making a butt joint of two M.S plates by
arc welding.
7(a) J6 Making a green sand mould of given
pattern and demonstration of casting
7(b) J6 Making a simple plastic component by
Plastic Moulding
7(c) J6 Cutting of three rectangular glass pieces

8(a) J7 Electrical: Demonstration of Electrical

Components

8(b) J7 Electronics: Fabrication of a Single-Phase

Full Wave Rectifier

5
Date:

INTRODUCTION TO WORKSHOP

1.Satisfies ____________________________________of bloom’s Taxonomy

2. Achieve po1,po2,po3,po5,po6,po8,po9,po10,po11 of program outcome

Introduction:

6
7
Application:

Safety Rules:

8
Questions :

a. What is the importance of workshop?

b. Name the various shops which are there in our Workshop.

Grade awarded:

Teacher’s signature with date …………………..

9
 1. Job No: Date:
MAKING A GAUGE FROM MS PLATE.

1. Satisfies “Applying”of bloom’s Taxonomy

2. Achieve po1, po3, po9, po12 of program outcome

A. Theory:
The present job focuses on the operation of measuring, filing, marking, sawing and
tapping. A sample of mild steel is proportionately shaped according to given
dimensions. In the present work,a Gauge is made as per the following drawing.

B. Diagram: (All dimensions are in mm.)

x t

Top View Side View

Work piece Material Diagram

x ØD x L Ød

b b t

Top View Side View

Diagram of the job

10
 C. Tools Required:

i. Steel rule 1'

ii. Try square 6”
iii. Flat file 12”
iv. Odd leg caliper 6”
v. Bevel protector 180
vi. Centre punch.
vii. Ball peen hammer
viii. Hack saw 12”
ix. Scriber
x. Half round file 10”
xi. Tap and tap wrench 8x1.25
xii. Fitting vice 6”
xiii. Drilling machine (Pillar type bench drill)
xiv. Surface plate

D. Procedure:

i. Squaring and finishing of the blank by filing.

ii. Marking
iii. Drilling
iv. Sawing
v. Filling the vee portion
vi. Tapping manually.
vii. Finishing and checking.

Filing Operation Drilling operation Cutting

operation

11
1. Job Title:

2. Objective:

3. Diagram for the Job(including exact dimensions):

12
4. Short Description of the following Tools:

i) Try square

ii) Half round file

iii) Center punch

iv) Scriber

13
v) Drilling machine

vi) Twist drill tool

vii) Tap & tap wrench

14
5. Procedure:

15
6. Precautions related to Job (If any):

7. Conclusion:

Questions:

 Name of any five measuring instruments?

 What is tapping and how many taps are there?

16
  Write down the formula for tapping drill size calculation.

 What do you mean by internal thread dimension of “Ø8 x 1.25”

Grade awarded:

Teacher’s signature with date …………………..

17
Job No: Date:
MAKING A CROSS-HALVING JOINT

1. Satisfies “Applying”of bloom’s Taxonomy

2. Achieve po1, po3, po9, po12 of program outcome

A. Theory:
A halving joint is a useful woodworking joint best suited to frameworks; this joint joins
two pieces of timber by cutting the full width of each part by half the depth and then
overlapping.
B. Diagram:

40 44 40

22

22

44

18
 40

44

40

40 44 40

22

22

N.B :All dimensions are in mm.

19
C. Tools Required:

 Steel rule
 Pencil
 Try Square
 Farmer Chisel / Mortise Chisel
 Mallet
 Marking gauge
 Rip Saw
 Carpentry Vice
 Metal Jack Plane
 Rasp File
 Sand paper

D. Procedure:

1. Plaining: by Metal Jack Plane, try square

2. Marking: by Steel Rule, Marking Gauge, Pencil, Try Square.
3. Sawing: by Rip Saw.
4. Chiseling: by farmer chisel (removal of material in groove portion)
5. Finishing: by Rasp file and sand paper.

20
1. Job Title:.

2. Objective:

3. Diagram for the Job:

21
 Short Description for the Tools:
 Metal Jack Plan

 Rasp File

 Chisel

22
 Rip Saw

 Procedure:

23
 Precautions related to Job (If any):

 Conclusion:

 Questions:

a. What is the difference between Fitting Vice and Carpentry Vice?

b. State the function of Matel Jack Plane and Chiesel.

Grade awarded:

Teacher’s signature with date …………………..

24
Job No: Date:

MAKING A ROUND HEADED PEEN FROM A MS ROUND BAR BY LATHE

MACHINE

1. Satisfies ____________________________________of bloom’s Taxonomy

2. Achieve po1,po2,po3,po5,po6,po8,po9,po10, po11 of program outcome

A. Theory:
The present job focuses on the operation of measuring, facing, turning, grooving and
chamfering. A sample of mild steel bar is proportionately shaped according to given
dimensions. In the present work, a round headed peen is made as per the following
drawing.

B. Diagram: (All dimensions are in mm.)

Raw Material Diagram:

Φ20
75

DIAGRAM FOR THE REQUIRED JOB:

Φ8

Φ12
25 20 5 20
Φ18

25
C. Tools required:

a. Steel rule1’
b. Outside caliper
c. Ball peen hammer
d. Scriber
e. Turning tool
f. Grooving tool
g. Tool holder
h. Lathe machine

D. Block Diagram:

Block diagramof Lathe Machine

E. Procedure:

i. Facing
ii. Marking
iii. Turning
iv. Grooving
v. Turning
vi. Facing
vii. Finishing and checking.

26
1. Job Title:

2. Objective:

3. Diagram for the job:

4. Short description of Tools:

 Turning Tool

27
  Grooving Tool

5. Short Description of the Important parts of the Lathe Machine:

28
29
6. Procedure:

30
7. Precautions (If any) related to job:

8. Conclusion:

9. Questions:
a. What is machining process?

31
b. Describe Facing and Turning Operation.

c. State the application of Lathe Machine.

Grade awarded:

Teacher’s signature with date …………………..

32
Job No: Date:

MAKING A VEE SLOT / KEY SLOT IN A MS BLOCK BY SHAPING

MACHINE/MILLING MACHINE

1 Satisfies ____________________________________of bloom’s Taxonomy

2 Achieve po1, po2, po3, po5, po7, po8, po9, po10, po12 of program outcome

A. Theory:
The present job focuses on the operation of measuring, shaping, cutting and how to
make a flat surface, how to make a rectangular / vee slot. A sample of mild steel is
proportionately shaped according to given dimensions. In the present work a Vee Slot
is made following the drawing provided below.

B. Diagram:

24

48
6

12 6 12
48

33
C. Tools Required:

i. Steel rule 1’
ii. Ball peen hammer
iii. Scriber
iv. Shaping tool
 RH Shaping Tool / Left Hand Shaping Tool
 V-cut tool
 Square nose tool(in case of milling machine: milling cutter-1/4” thick)
v. Shaping Machine
vi. Parallel bar.
vii. Odd leg caliper 6”
viii. Marking gauge 12”
ix. Center punch
x. Coolant or Cutting fluid and brush etc.
xi. Side milling cutter, HSS 4”X1”X1/4”

D. Procedure:

i. Measuring the block

ii. Shaping the surfaces
iii. Marking the block as per requirement or drawing
iv. Slot cutting
v. V-cutting operation
vi. Finishing
vii. Inspection and checking

E. Block Diagram of Shaping Machine:

Block diagram of Milling Machine

34
35
1. Job Title:

2. Objective:

3. Diagram for the job:

36
4. Short description of Tools:

Shaping Tool:

Or

Milling Cutter:

37
5. Short Description of the Important parts of the Shaping Machine/Milling Machine:

38
6. Procedure

39
7. Precautions (If any) related to job:

8. Conclusion:

9. Questions:
a. Operation wise what are the differences in between Lathe Machine and
Shaping / Milling Machine.

b. State Qucik Return Mechanism.

40
 c. State the differences between Horizontal Milling Machine and Vertical Milling
Machine.

d. State the differences between Up Milling and Down Milling.

Grade awarded:

Teacher’s signature with date …………………..

41
Job No: Date:

MAKING A BUTT JOINT USING TWO MS PLATES BY ARC WELDING

1 Satisfies ____________________________________of bloom’s Taxonomy

2 Achieve po1,po2,po3,po5,po6,po8,po9,po10,po11, of program outcome

A. Theory:
The present job focuses on the operation of joining. A couple of sample of mild steel is
joined according to given dimensions. In the present work, a Butt joint of similar metals
is made following the drawing provided below.

B. Diagram:

y y

x x t
Raw Material (plate-1) Raw Material (plate-2) Side View
(x,y,t are the length, width and thickness of the plates to be joined)

x x

Diagram for finished Job and Top view

42
 C. Tools required:

i. Step down welding transformer.

ii. Welding table & fixtures
iii. Tongs with long handle.
iv. Chipping hammer.
v. Wire brush.
vi. Gloves & Apron.
vii. Face shield.
viii. Electrode Holder.

D. Procedure:

i. Cleaning the raw material.

ii. Holding.
iii. Welding.
iv. Chipping.
v. Cleaning.
vi. Finishing & checking.

E. Block Diagram:

Block diagram of welding

43
1. Job Title:

2. Objective:

3. Diagram:

4. Short description of Tools:

44
45
5. Procedure:

46
6. Precautions (If any) related to job:

7. Conclusion:

47
8. Questions:
a. What is Welding?

b. What is M.M.A.W / S.M.A.W?

c. What is Butt Joint?

d. State difference between Welding and Brazing operations.

Grade awarded:

Teacher’s signature with date …………………..

48
Job No: Date:

MAKING OF A GREEN SAND MOULD OF A GIVEN PATTERN

1 Satisfies ____________________________________of bloom’s Taxonomy

2 Achieve po1, po2, po3, po5, po6, po8, po9, po10, po11, of program outcome

A. Theory:
The present job focuses on the different procedure –how to prepare the green sand, all
the steps to prepare the green sand mould. In the present work a green sand mould is
made following the drawing provided below.

B. Diagram:

T1

T2
øD

ød

Given Pattern

C. Tools Required:

i. Hand rammer (wooden)

ii. Sieve
iii. Trowel
iv. Sprue pin
v. Plainer
vi. Gate cutter
vii. Sleek
viii. Draw spike

49
 ix. Vent rod
x. Swab
xi. Blower
xii. Cope & Drag box

D. Procedure:

i. Mixing the sand by water

ii. Ramming with pattern
iii. Making the surface plain.
iv. Putting the cope and drag box with sprue pins
v. Sand filling and Ramming
vi. Removing of sprue pins, and the Drag box
vii. Removing of Pattern
viii. Cutting the gates
ix. Checking and finishing.

E. Block Diagram of Molding:

Block diagram of Moulding

50
1. Job Title:

2. Objective:

3. Diagram:

51
4. Short description of Tools:
 Rammer

 Mallet

 Sprue Pin

 Gate Cutter

52
  Swab

5. Procedure:

53
6. Precautions (If any) related to job:

7. Conclusion:

8. Questions:
a. What is Casting?

54
 b. State some applications of Casting.

c. What is mould?

d. State the function of Riser and Runner.

Grade awarded:

Teacher’s signature with date …………………..

55
Job No: Date:

MAKING OF A PLASTIC COMPONENT BY PLASTIC MOULDING

Satisfies ____________________________________of bloom’s Taxonomy

Achieve po1, po2, po3, po5, po6, po8, po9, po10, po11, of program outcome

a. Theory:
The present job focuses on the procedure of Plastic Moulding. In the present work a
plastic component is made.

b. Tools Required:

c. Block Diagram of Molding:

d. Short Description of Tools:

56
 e. Procedure:

f. Precautions (If any) related to job:

g. Conclusion:

57
h. Questions:

1. What Are The Advantages Of Plastics Over Metals?

2. Explain The Disadvantages Of Plastics?

3. Explain About Injection Molding?

4. What Is Compression Molding?

Grade awarded:

Teacher’s signature with date …………………..

58
Job No: Date:

MAKING A KALEIDOSCOPE BY USING GLASS

Satisfies ____________________________________of bloom’s Taxonomy

Achieve po1,po2,po3,po5,po6,po8,po9,po10,po11, of program outcome

Theory: The present job focuses on the procedure of Glass Cutting. In the present work a
Kaleidoscope is made.

Tools Required:
(i) Wooden scale
(ii) Glass
(iii) Diamond cutter
(iv) Coolant
Block Diagram:

59
Procedure:

60
Questions:
(i) Write down the working principle of Keleidescope.

Grade awarded:

Teacher’s signature with date …………………..

61
 ELECTRICAL
DEMONSTRATION OF ELECTRICAL COMPONENTS

3 Satisfies ____________________________________of bloom’s Taxonomy

4 Achieve po1,po2,po3,po5,po6,po8,po9,po10,po11, of program outcome

a. Theory:
The present job focuseson electrical shop knowledge which covers the basic function of
electrical components used in domestic and industrial wiring. In the present work,
demonstration of the electrical instruments and components has been delivered.

b. Diagram:

House Wiring Diagram

62
c. Electrical components:

i. Switch
ii. Fuse
iii. Coil
iv. Transformer
v. Capacitor
vi. Circuit breakers
vii. Relays
viii. Wiring
ix. Socket
x. Battery
vii. Motor
viii. Generator

d. LT Switchgear Elements:

i. Fuse
ii. Fuse holders
iii. Isolators
iv. MCB
v. Wire
vi. Cable

63
1. Job Title:

2. Objective:

3. Wiring Diagram:

64
4. Execution Procedure for Domestic Wiring

65
66
67
 Questions:

1. What is LT Switchgear ?

2. Short Description of following Electrical Instruments and Components:

(i) Fuse

(ii) Fuse holders

(iii) Isolators

(iv) MCB

(v) Wire

(vi) Cable

68
3. Short Description on the following Electrical equipment :
(i) Relay

(ii) Transformer

iii)Capacitor :

69
5. Why is earthing done?

Grade awarded:

Teacher’s signature with date …………………..

70
Job No: Date:

ELECTRONICS
FABRICATION OF A SINGLE-PHASE FULL WAVE RECTIFIER

Satisfies ____________________________________of bloom’s Taxonomy

Achieve po1,po2,po3,po5,po6,po8,po9,po10,po11, of program outcome

a. Theory:
The present job focuses on basic electronic circuit which covers the basic function of
electronic components like Diodes, Transistors etc. In the present work, Fabrication of
a single phase full wave rectifier has been worked out.

b. Diagram:

c. Electronic Components:

i. Diode

71
ii. Transistors
iii. Integrated Circuits
iv. Resistors
v. Capacitors
vi. Inductors
vii. Switches
viii. Wires and cables
ix. Plugs and sockets
x. Protection devices

d. Procedure:
(i) Connect the diode to create a bridge
(ii) Connect the bridge with Transformer
(iii) Attach the capacitor with the circuit
(iv) Supply the AC power
(v) Study the outputs

72
1. Job Title:

2. Diagram of the Rectifier:

3. Short Description of the following Tools:

(i) Vero board

(ii) Diode

73
 iii) Transistor

iv)Resistor

4. Procedure:

74
5. Precaution (If any):

6. Conclusion:

7. Questions:

i. Write short note on “Soldering Iron”.

75
ii. Describe Soldering process in detail.

iii. What is the function of capacitor in a full wave bridge rectifier circuit?

iv. Draw and explain I vs. T (Current Vs Time) diagram for half wave and full wave
output.

76
 v. Draw and explain I vs. T (Current Vs Time) diagram for full wave output without
capacitor.

Grade awarded:

Teacher’s signature with date …………………..

77