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MAHAVEER INSTITUTE OF SCIENCE AND TECHNOLOGY
Name of the Lab

Laboratory Manual
Course: UG/PG/Diploma
Regulation:

Vyasapuri, Bandlaguda, Post: Keshavgiri,
Hyderabad- 500 005, Telangana, India.
Department of Mechanical Engineering Name of the Laboratory

INDEX
Sl No Item Page
1. About Laboratory 3
2. University Syllabus 4
3. List of Equipment 5
4. List of Experiment
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.

About Laboratory

University Syllabus

List of Experiment
Machine shop
1.Thread cutting
2.Handle making on lathe machine
3.combination of all operations
4.Eccentric turning
5.Male and female fit assembly
Foundry
1.core making
2.connecting rod
3.preparation of v-pulley
Welding shop
1.T-joint
2.H-joint
3.corner joint

List of Equipment
(Major)
Sl No Equipment Name Equipment ID
1. University Syllabus
2. About Laboratory
3. List of Equipment
4. List of Experiment
5. Laboratory Rules
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.

Expt1: Name Date:
*For Workshop & Manufacturing Laboratory
Aim: To do the Thread Cutting operation on a given work piece as per the given
dimension.
Practical Relevance:
Fig:
Material Required: : MS Rod ∅25 x77mm
Equipment and Tools Required: Spanner set, steel rule, outside caliper, chuck key, single
point cutting tool and Vernier caliper, parting tool, thread cutting tool.
Sequence of operations : 1. Checking the raw material 2. Fixing in chuck 3. Facing 4. Turning
5. Thread chasing
Theory
The experiment is to chase threads on work piece by engauging lead screw on lathe machine .
Procedure:
1. Check and clean the lathe before perform the operation.
2. Check the dimension of the work piece.
3. Hold the work piece in the lathe jaw chuck by using chuck key.
4. The single point cutting tool is held on the tool post by tool post key.
5. First the facing and plain turning is done on work piece by moving cutting tool towards
the lathe axis up to the required length.
6. Replace the turning tool by thread cutting tool.
7. The carriage should be moved longitudinally obtaining feed through the lead screw of the
lathe.
8. A definite ratio between the longitudinal feed and rotation of the headstock spindle
should be found out. Suitable gears with required number of teeth should be mounted on
the spindle and the lead screw.
9. The position of the tumbler gears are adjusted according to the type of the thread (right
hand or left hand).Suitable spindle speed is selected and it is obtained through back
gears.
10. Half nut lever is engaged at the right point as indicated by the thread chasing dial.
11. Depth of cut is set suitably to allow the tool to make a light cut on the work.
12. When the cut is made for the required length, the half nut lever is disengaged. The
carriage is brought back to its original position and the above procedure is repeated until
the required depth of the thread is achieved.
13. After the process of thread cutting is over, the thread is checked by suitable gauges.
Results & Discussion: Thus the given Thread Cutting operation is done as per the given
dimensions.
Precautions:
Viva Questions
1. Explain how the back gears operate?
2. When is the split nut or half nut used?
3. What is a centre gauge used in threading?
4. What is meant by chamfering?
5. What type of operations should be performed before thread cutting operation?
6. Why do you use coolant during thread cutting?
7. What are the precautions should take during thread cutting?
8. Explain gear calculations?
9. How do you inspect threading?

Expt1: Name Date:
Aim: To making a handle on lathe machine
Figure:
Material Required: Cylindrical work piece of 30×Ø25.4mm M.S rod.
Equipment and Tools Required:

1) Steel rule
2) Marking Block
3) Out – side calipers
4) Tool key
5) Chuck key
6) Vernier calipers
7) Single point Cutting tool
8) Radius tool
Sequence of operations :
1. Checking 2.Workpiece Setting
3. Tool Setting 4.Plainturning
5. Handle 6.Thread cutting
Theory
Procedure:
1. The given work piece is checked for its dimensions.
2. The work piece is held in the chuck and chuck key is used to tighten the job firmly
ensuring centering of the work piece
3. A single point cutting tool and radius tools are is held in the tool post and tightens the
nuts by using spanner.

4. Adjust the cutting tool parallel to the work piece axis and do the Plain turning upto 70mm
length.
5. By using of radius tool to give the feed and depth of cut at a time to produce radius on
the work piece
6. Do the plain turning on other side of the work piece up to 18 mm diameter.
7. Slow down machine and then engage the carriage to the lead screw.
8. Then cut a treads on other part of the work piece
9. Finally, the dimensions of the work pieces are again checked
Results & Discussion :

Hence the Handle was prepared successfully.
Precautions:
1. Make sure that the work piece is held rigidly in the work piece
2. Chuck key should be removed before starting the motor.
3. Person working on the machine should stay away from the moving parts
4. Appropriate feed, speed and depth of cut should be given.
5. For threading operation, reduce the rotation speed of the job.
Viva Questions

Expt1: Name Date:
Aim: To prepare the job as per the specifications provided.
Figure:
Material Required: Cylindrical work piece of 75×Ø25.4mm M.S rod
1. Checking, 2.Workpiece Setting,
3. Tool Setting, 4.Plainturning,
5. Facing, 6.Step Turning,
7. Changing Of Tool, 8.Knurling Operation
Theory
Procedure:
1. Understand the job drawing thoroughly and plan the job.
2. Cut off a 75mm long piece from 25.4mm dia. Bar.
3. Hold the work piece in the Lathe chuck and perform facing and center drill
operations. Repeat the same on the other side also.
4. Hold the job in between live and dead centers.
5. Perform plain turning (L=35mm, dia, chamfering and knurling operations on one side
and interchange the faces axially.
6. Perform plane turning by swiveling the compound rest at an angle 50.
7. After filing if required, take off the job from m/c and do oiling in the whole job for the
protection from the rust.

Results & Discussion:

The required job is obtained by facing, turning & knurling operations.
Precautions:
1. Don’t wear loose clothes while working on the machine.
2. Work piece should be held tightly between the live and dead centers.
3. Always clean machine before use.
4. Cutting tools should be held tightly in the tool holder.
5. Never let your clothes and hand come in contact with the revolving chuck, pulleys
etc.
6. Do not touch the chips when machine is removing them
7. Do not give large feed to the cutting tool.
Viva Questions
1. What is the purpose of knurling?

2. What are the various types of knurling tool?
3. Which machine used for knurling operation?
4. What is meant by Machinability index?
5. What is the purpose of grooving?
6. What are various types of grooving tool?
7. Write the tailor’s tool life equation.
8. What are the purposes of gear grinding process?
9. What is meant by gear lapping?
10. What is meant by cutting shaping process?
11. Define – Tool life
12. What are the factors affecting tool life?
13. What are the factors affecting the machinability?
14. Define – Machinability of metal
15. What are the purposes of chip breakers?


Expt1: Name Date:
Aim: To assemble two parts by using of lathe machine..
[Shaft is inserted into a circular hole]
Figure:
Material Required: Cylindrical work piece of 30×Ø25.4mm and 30×Ø12 mm M.S rod.

1. Lathe
2.Single Pont Cutting Tool
3.Vernier Calipers
4.Outside Calipers
5.Steel Rule
6.Drilling Tool
7.Boring Tool
1.Checking the dimensions of work,
2. Work piece setting,

3. Tool setting,
4.Drilling,
5. Plain turning,
6.Assemble 2 parts.
Theory

Procedure:
1. The given work piece is checked for its dimensions.
2. The work piece is held in the chuck and the chuck key is used to tighten the job firmly
ensuring centering of the work piece.
3. A single point cutting tool is held in the tool post and tighten the nuts by using spanner.
4. Drill tool is held in the tail stock.
5. Adjust the cutting tool perpendicular to the work piece axis for facing operation.
6. Then move the tool from the centre of the work piece towards or outside depending upon
the rotation of spindle.
7. Then take the carriage back and stop the machine.
8. Unlock the lock of tail stock and move the tail stock towards the head stock..
9. Touching the drill to the work piece then start the machine.
10. Next unlock the spindle lock and give the depth up to the required length by tail stock
spindle.
11. Next take the tail stock back remove the work piece from chuck.
12. Hold the other work piece in the chuck and chuck key is used tighten the job firmly
ensuring the centre of the work piece.
13. Adjust the single point cutting tool parallel to the work piece axis.
14. By moving of cutting tool from tailstock to head stock to do turning of work piece up to
the our required size.
15. Then, assemble the shaft in the hollow shaft.
Results & Discussion: Assemble of two parts completed successfully
Precautions:
1. Make sure that the work piece is held rigidly in the work piece
2. Chuck key should be removed before starting the motor.
3. Person working on the machine should stay away from the moving parts
4. Appropriate feed, speed and depth of cut should be given.

Viva Questions

Expt1: Name Date:
Aim: To do the Eccentric turning operation on a given work piece as per the given
dimension.
Figure:
Material Required: Mild steel Φ 9.5mm X 75 mm long
Equipment and Tools Required: Spanner set, steel rule, outside caliper, chuck key, single
point cutting tool and Vernier caliper, parting tool, thread cutting tool.
Sequence of operations
Theory
Procedure:
1. Check and clean the lathe before perform the operation.
2. Check the dimension of the work piece.
3. Hold the work piece in the lathe jaw chuck by using chuck key. The single point cutting
tool is held on the tool post by tool post key.

4. First the facing and plain turning is done on work piece by moving cutting tool towards
the lathe axis up to the required length.
5. Replace the turning tool by thread cutting tool.
6. The carriage should be moved longitudinally obtaining feed through the lead screw of the
lathe.
7. A definite ratio between the longitudinal feed and rotation of the headstock spindle
should be found out. Suitable gears with required number of teeth should be mounted on
the spindle and the lead screw.
8. The position of the tumbler gears are adjusted according to the type of the thread (right
hand or left hand).Suitable spindle speed is selected and it is obtained through back
gears.
9. Half nut lever is engaged at the right point as indicated by the thread chasing dial.
10. Depth of cut is set suitably to allow the tool to make a light cut on the work.
11. When the cut is made for the required length, the half nut lever is disengaged. The
carriage is brought back to its original position and the above procedure is repeated
until the required depth of the thread is achieved.
12. After the process of eccentric cutting is over, then the check the work piece using
suitable gauges.
Results & Discussion: Thus the given Eccentric turning operation is done as per the given
dimensions.
Precautions:
Viva Questions
1. What is meant by eccentricity?
2. What is meant by effect of back rake angle? Mention the types.
3. What is meant by side rake angle? Mention its effects.
4. What are all the conditions for using positive rake angle?
5. When will the negative rake angles be used?
6. Define – Orthogonal cutting
7. What is meant by cutting force?
8. What is meant by chip thickness ratio?
9. What are the purposes of chip breakers?
10. Define – Machinability of metal

11. Define – Oblique cutting

12. Differentiate between orthogonal and oblique cutting.
13. Which type of chuck used for eccentric turning?
14. What are the applications of eccentric components?
15. What is meant by tool signature?

Expt1: Name Date:
Aim: To make the connecting rod mould by double – box sand moulding method.
Figure:
Material Required:
Equipment and Tools Required: 1) Trowel 2) Shovel

3) Rammer 4) Runner
5) Vent rod 6) Raiser
7) Moulding boxes 8) Strike of bar
9) Draw spike
1) Sand preparation
2) Ramming
3) Leveling
4) Toweling
5) Venting
6) Cleaning
Theory

Procedure:
1. The connecting rod, pattern is placed in the drag & facing sand is poured on it, slightly
uniform ramming is done.
2. The drag is filled with the backing sand & ramming is done.
3. Excess sand is removed by strike of bar.
4. The drag is turned over and parting sand is sprinkled over the parting line.
5. Cope is placed over the drag. Runner & raiser are placed at suitable positions.
6. Facing sand is poured first and then the backing sand is removed by strike of bar.
Runner and raiser are removed and excess sand removed by strike of bar.
7. Cope is removed over the drag.
8. Pattern is removed by draw spoke and gate cutting is done and vent holes are made.
9. Cope is placed over the drag. Mould is ready for pouring.
Results & Discussion The required connecting rod mould is thus obtained.
Precautions:
1. Tempering of sand should be done carefully.
2. Ramming should be placed on suitable position.
Viva Questions
1. What is the function of connecting rod?

2. What are the applications of connecting rod?
3. What are the casting defects?
4. What is mean by blow holes?
5. Where do you locate the runner and riser?
6. What is mean by permeability?
7. What is mean by refractoriness?
8. What is the purpose of core prints?
9. What are the pattern allowances?
10. List common pattern materials?
11. What is mean by shrinkage allowance?

Expt1: Name Date:
Aim: To prepare green sand mould for the given stepped pulley pattern.
Figure:

Material Required: Green sand, Parting sand and water.
Equipment and Tools Required: Shovel, Round rammer, Peen rammer, Strike off bar, Lifter,
Riddle,Trowel, Vent rod, Swab, Runner riser, Moulding box, Pattern, Bucket, Draw spike.
Theory
Procedure
1. The mould sand has properly tempered by 6 to 8 % of water.
2. Clean the floor and place the moulding board.
3. Place the drag box on the moulding board and the given solid pattern(stepped pulley)
is placed in middle of the drag box.
4. Adequate amount of sand is filled and rammed with peen and round rammer.
5. Excess sand is removed by using strike off bar.
6. Then the drag box is tilted upside down.
7. Parting sand is sprayed on the molded surface of the drag box. The cope box is placed
above the drag box. Then place the runner and riser pin in position.
8. Similarly the box is filled with sand and properly rammed and leveled.
9. Remove the runner and riser slowly. Vent holes are properly made with equal distances.
10.Make the funnel shape Sprue holes opening for easy pouring of moulten metal.
11.Now the cope box is removed.
12.Cut the gate in drag box and remove the pattern without any damage.
13.Place the cope box over drag box. Now the mould is ready to pour molten metal.
Results & Discussion:

Thus the given Stepped pulley pattern is molded properly using moulding sand
Precautions:
Viva Questions
1. What is foundry?

2. What is meant by casting?

3. What is meant by pattern?
4. What are the materials used for making patterns?
5. Name the various types of pattern.
6. What are the types of allowances used for making pattern?
7. What is the name of the binder used to mix with moulding sand?
8. Name the different types of sand used in foundry work.
9. What are the ingredients of good moulding sand?
10. What are the types of casting used in foundry?
11. List the foundry tools?
12. What is gate?
13. What is vent rod?
14. Name the types of moulding boxes.
15. Give the application of casting.
16. What do you mean by green sand?
17. Why ramming is done?
18. What is the use of sprue pin?
19. What is the function of gate cutter?
20. What is the function of riser?

Expt1: Name Date:
Aim: To prepare green sand mould for the given Cylindrical Core.
Figure:
Material Required: Green sand, Parting sand and water.

Equipment and Tools Required: Shovel, Round rammer, Peen rammer, Strike off bar, Lifter,
Riddle, Trowel, Vent rod, Swab, Runner riser, Moulding box, Pattern ,Bucket, Draw spike.
Theory
Procedure:
1. First Mix the core sand properly.

2. This mixture must be homogeneous, so that the core will be having uniform strength
throughout. Fill the sand in the core box and ram well.
3. The sand mixture is compacted to the core box by compressed air. Remove the core
from the core box. Then place it on metal plate or core carrier.
4. Place the core carrier into the core oven and remove the moisture and also develop the
strength of binder. After baking process core are smoothen.
5. Apply a line of refractory coating or core wash to the surface and finish the core.
Results & Discussion Thus the given cylindrical core prepared by moulding sand and
inspected.
Precautions:
Viva Questions

Expt1: Name Date:
Aim: To make a T – welded joint.
Figure:
Material Required: mild steel flat of 50x 50 x 5mm thickness-two pieces

1) Electrode
2) Chipping hammer
3) Flanged tong
4) Safety goggles

5) Wire brush
6) Hand gloves
Theory
Procedure:
1. First the electrode is fixed in the electrode holder.
2. The given pieces are arranged in such a way that one is perpendicular to other.
3. The electrode is moved over the plates to be joined.
4. The flux formed is removed by using chipping hammer.
5. Using the wire brush the joint is cleaned and the same procedure is repeated on the
other side of the joint
.
Results & Discussion: The required T – welded joint is obtained as shown in the figure.
Precautions: 1. While welding the light should not be seen directly.

2. The job should be held with tongs after welding is completed.
3. The chipping of the job is done after immersing the welded job in water.
Viva Questions
1. What is the criteria to select an electrode?

2. What are the different zones of a typical weld?
3. What are the different methods to find the weld defects?
4. What do you mean by weld spatter?
5. What do you mean by inclusion defect?

Date:
Name
Expt1:
Aim: To make a H –joint by ARC welding.
Figure:
Material Required: A mild steel flat of 50x 50 x 5mm thickness-four pieces.

1) Electrode
2) Chipping hammer
3) Flanged tong
4) Safety goggles
5) Wire brush

6) Hand gloves
Theory
Procedure:
2. Arrange the 2 plates in such a way that one is perpendicular to other.
3. The electrode is moved over the plates to be joined.
4. Now place the other work piece and that should be perpendicular to the centre of the
work piece. Thus should be welded.
5. The flux formed is removed by using chipping hammer.
6. Using the wire brush the joint is cleaned and the same procedure is repeated on
the other side of the joint.
Results & Discussion: Hence the H- joint is obtained as shown in the figure.
Precautions:
1. While welding the light should not be seen directly.
Viva Questions
1. What is meant by welding?

2. Welding is used to join similar (or dissimilar metals. Say True (or) False.
3. Name the two important welding process.
4. Name the three basic types of joints, common to arc welding and gas welding.
5. What is gas welding?
6. What is flux?
7. What is the significance of filler material?

8. What is arc welding?
9. What is an electrode?
10. What are the types of electrodes used in practice?
11. What are the types of welding?
12. What is the temperature obtained in gas and arc welding?
13. List the equipments needed to carry out welding operation.
14. Which type of welding (Gas / Arc) you prefer?
15. What are the necessary precautions you have to take while welding?
16. Why you should not see the flame during the welding operation?
17. What are the two gases used in gas welding?
18. What are the different types of joints, you make in the lab?
19. What is the difference between riveting and welding?
20. How do welding is different from machining?

Expt1: Name Date:
Aim: To make a Corner welded joint.
Figure:
Material Required: A mild steel flat of 50 x 50 x 6mm thickness-two pieces.

1) Electrode
2) Chipping hammer
3) Flanged tong
4) Safety goggles
5) Wire brush
6) Hand gloves
Theory
Procedure:
2. Electrode is moved carefully by maintaining a gap of 3mm while welding.
3. The given two pieces are placed in such a way that one should rest on the edge of the
other and represent at right angles to each other and the electrode is held in the
electrode holder and moved over the plates which are to be joined.
4. The flux formed on the welding of the joint is removed by chipping the joint with the help
of chipping hammer.
5. Using the wire brush the joint is cleaned and the procedure is repeated on the other side
of the plate.
Results & Discussion: Hence the corner welded joint is obtained as shown in the figure.
Precautions:
1. While welding the light should not be seen directly.
Viva Questions
1. What do you mean by weld bead?
2. What are different types of butt joints?
3. What are different types of lap joints?
4. What is the difference between leftward welding and right ward welding?
5. What is the general range of angles for leftward and right ward welding?
6. What do you mean by weld penetration?
7. Where do weld penetration defect occurs?

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MAHAVEER INSTITUTE OF SCIENCE AND TECHNOLOGY

Name of the Lab

MAHAVEER INSTITUTE OF SCIENCE AND TECHNOLOGY

Department of Mechanical Engineering Name of the Laboratory

Department of Mechanical Engineering Name of the Laboratory

Department of Mechanical Engineering Name of the Laboratory

Department of Mechanical Engineering Name of the Laboratory

Department of Mechanical Engineering Name of the Laboratory

Department of Mechanical Engineering Name of the Laboratory

Expt1: Name Date:

*For Workshop & Manufacturing Laboratory

Material Required: : MS Rod ∅25 x77mm

Department of Mechanical Engineering Name of the Laboratory

Expt1: Name Date:

*For Workshop & Manufacturing Laboratory

Aim: To making a handle on lathe machine

Material Required: Cylindrical work piece of 30×Ø25.4mm M.S rod.

Equipment and Tools Required:

3. Tool Setting 4.Plainturning

5. Handle 6.Thread cutting

Department of Mechanical Engineering Name of the Laboratory

6. Do the plain turning on other side of the work piece up to 18 mm diameter.

8. Then cut a treads on other part of the work piece

9. Finally, the dimensions of the work pieces are again checked

Results & Discussion :

2. Chuck key should be removed before starting the motor.

4. Appropriate feed, speed and depth of cut should be given.

5. For threading operation, reduce the rotation speed of the job.

Department of Mechanical Engineering Name of the Laboratory

Expt1: Name Date:

*For Workshop & Manufacturing Laboratory

Aim: To prepare the job as per the specifications provided.

Material Required: Cylindrical work piece of 75×Ø25.4mm M.S rod

Equipment and Tools Required:

3. Tool Setting, 4.Plainturning,

5. Facing, 6.Step Turning,

7. Changing Of Tool, 8.Knurling Operation

Department of Mechanical Engineering Name of the Laboratory

Results & Discussion:

1. What is the purpose of knurling?

Department of Mechanical Engineering Name of the Laboratory

Department of Mechanical Engineering Name of the Laboratory

Expt1: Name Date:

*For Workshop & Manufacturing Laboratory

Aim: To assemble two parts by using of lathe machine..

[Shaft is inserted into a circular hole]

Equipment and Tools Required:

2. Work piece setting,

Department of Mechanical Engineering Name of the Laboratory

4. Drill tool is held in the tail stock.

7. Then take the carriage back and stop the machine.

15. Then, assemble the shaft in the hollow shaft.

Results & Discussion: Assemble of two parts completed successfully

2. Chuck key should be removed before starting the motor.

4. Appropriate feed, speed and depth of cut should be given.

Department of Mechanical Engineering Name of the Laboratory

Expt1: Name Date:

*For Workshop & Manufacturing Laboratory