V-GAUGE FITTING

AIM
To prepare a V-Gauge fitting as per given dimensions.
MATERIAL REQUIRED
Mild Steel (MS) flat, size 50 mm X 6 m m , length 70 mm.
TOOLS REQUIRED
Bench vice, Steel rule, Try square, Hacksaw, Flat file, Triangular file,
V-Block, Surface plate, Vernier height gauge, Angle plate, Scriber,
Hammer, Dot punch, Vernier caliper, etc.
PROCEDURE
1. Work piece is fixed firmly in a bench vice keeping its one face just
above the jaw piece and the stain is removed by filing. The other face
is also filed to remove the stain.
2. Its one long edge 90° to the face is then filed, whose flatness and
squareness are checked with a try square.
3. The short edge 90° to the filed long edge is filed. Its flatness and
squareness to the former edge is checked. The same is repeated for
the other short edge.
4. Chalk paste (Chalk powder + water) is applied on the filed two faces
and dried.
5. All dimensions on the male and female parts are marked on both the
faces with the help of Vernier height gauge, Surface plate and Angle
plate.
6. The guide lines are punched with a dot punch and a ball peen
hammer.
7. Cut the material on the waste side with a clearance of 1 mm from the
punch mark.
8. Male and female parts are separated by sawing.
9. File out all the unwanted material by leaving half punch mark on the
work piece.
10. Check all dimensions, the male and female parts are brought
together and joined to get a V-Gauge Fitting.
RESULT
A V-Gauge fitting is prepared from the given metal piece with the
required dimensions.
 FIGURE
SIDE GIVEN DIMENSION OBTAINED DIMENSION DIFFERENCE1
A
B
C
__
--

COST ANALYSIS
Cost of production = Material cost + Labour cost + Overhead charges
MATERIAL COST
Material cost = (Mass in kg) X (Rate / kg)
= (Volume X density) X (Rate / kg)
= (L X W X T X density of Mild Steel) X (Rate / kg)
= (0.07 m X 0.05 m X 0.006 m X 7860 kg / m 3 ) X (Rs. 37.50)
= Rs. 6.19
LABOUR COST
Labour cost = (Total time) X (Hourly Rate)
Total time = 6 Hours
Rate of skilled labour = Rs. 240 / day (8 Hours)
Rate for student = Rs. 120 / day (8 Hours)
Hourly rate = Rs. 120 / 8 Hours
= Rs. 15 / Hour
Hence Labour cost = (6 Hours) X (Rs. 15 / Hour)
= Rs. 90
OVERHEAD CHARGES
Overhead charges = (Amount spending for cotton waste, grease, oil, etc.)
+ (Amount spending for electricity, telephone, e-mail, advertisement,
salaries to officials, etc.) = R s . 1 2 0

Hence Total Cost of Production = R s . 6 . 1 9 + R s . 9 0 + R s . 1 2 0

= Rs. 216.19
 CROSS JOINT
AIM
To Prepare a Cross Joint of required dimensions.
MATERIAL REQUIRED
Soft wood (Pine wood or Vangana wood) with dimensions of
50 mm X 25 mm, length 310 mm.
TOOLS REQUIRED
Carpenter's bench vice, Wooden Jack plane, Metal jack plane, Steel
rule, Try square, Hand saw, Tenon saw, Marking knife, Marking gauge,
G-Cramp, Chisels, Mallet, etc.
PROCEDURE
1. A defect free reaper of size 50 mm X 25 mm, length 310 mm is taken
and fixed in a carpenter's vice.
2. One of its faces (Face side) is planed with a wooden jack plane and is
followed by a metal jack plane. The flatness (straightness) of the face
side is checked with a try square.
3. The adjacent side of the planed face side (Face edge) is then planed
and its flatness and squareness with the face side is checked with a
try square.
4. Marking gauge is set and lines are marked at 40 mm & 20 mm to
mark the width & thickness of the model respectively.
5. The excess material is first chiselled with firmer chisel and then
planed to a size of 40 mm X 20 mm, length 310 mm,
6. The piece is cut into two equal parts of 155 mm length.
7. On the first piece, mark width of the slot 40 mm middle of the face
side. Mark the thickness of the slot 10 mm on the face edge of both
sides using a Marking gauge.
8. Using Tenon saw, Firmer chisel and Mallet the slot is then removed.
Corners of the trenches are finished and made square with a bevelled
edge chisel.
9. The excess material on the edge is removed by sawing & chiselling.
10. The same procedure is repeated for the second piece.
1 1 . The two pieces are joined together. Checked the squareness of Cross
Joint using Try square.

RESULT
A Cross joint of required dimensions is obtained.
 FIGURE
SIDE GIVEN DIMENSION OBTAINED DIMENSION | DIFFERENCE
A
B
C
—
—

COST ANALYSIS
Cost of production = Material cost + Labour cost + Overhead charges
MATERIAL COST
Material cost = (Volume of wood used in Cubic feet) X (Rate / Cubic feet)
= (0.310 m X 0.050 m X 0.025 m) X (Rate / Cubic feet)
= (0.0003875 m 3 ) X (Rate / Cubic feet)
= (0.01368443 Cubic feet) X (Rs. 890)
= Rs. 12.18
LABOUR COST
Labour cost = (Total time) X (Hourly Rate)
Total time = 3 Hours
Rate of skilled labour = Rs. 160 / day (8 Hours)
Rate for student = Rs. 80 / day (8 Hours)
Hourly rate = Rs. 8 0 / 8 Hours
= Rs. 1 0 / Hour
Hence Labour cost = (3 Hours) X (Rs. 10 / Hour)
= Rs..30
OVERHEAD CHARGES
Overhead charges = (Amount spending for cotton waste, grease, oil, etc.)
+ (Amount spending for electricity, telephone, e-mail, advertisement,
salaries to officials, etc.) = R s . 60

Hence Total Cost of Production = R s . 1 2 . 1 8 + R s . 30 + R s . 60

= Rs. 102.18
 DOVE TAIL JOINT
AIM
To Prepare a Dove Tail Joint of required dimensions.
MATERIAL REQUIRED
Soft wood (Pine wood or Vangana wood) with dimensions of
50 mm X 25 mm, length 310 mm.
TOOLS REQUIRED
Carpenter's bench vice, Wooden Jack plane, Metal jack plane, Steel
rule, Try square, Hand saw, Tenon saw, Marking knife, Marking gauge,
G-Cramp, Chisels, Mallet, etc.
PROCEDURE
1. A defect free reaper of size 50 mm X 25 mm, length 310 mm is taken
and fixed in a carpenter's vice.
2. One of its faces (Face side) is planed with a wooden jack plane and is
followed by a metal jack plane. The flatness (straightness) of the face
side is checked with a try square.
3. The adjacent side of the planed face side (Face edge) is then planed
and its flatness and squareness with the face side is checked with a
try square.
4. Marking gauge is set and lines are marked at 40 mm & 20 mm to
mark the width & thickness of the model respectively.
5. The excess material is first chiselled with firmer chisel and then
planed to a size of 40 mm X 20 mm, length 310 mm.
6. The piece is cut into two equal parts of 155 mm length.
7. Set out 'Socket': Mark position of Socket on the face side of first
piece. Mark the guide lines of Socket using pencil. Use marking gauge
to mark thickness of the slot 10 mm on the face edge of both sides.
Using Tenon saw, Firmer chisel and Mallet the slot is then removed.
Corners of the trenches are finished and made square with a bevelled
edge chisel.
8. Cutting 'Dove tail pin': Rip (cut) the thickness of pin using handsaw
and chiselling is done on the waste side of gauge lines. Rip both
sloping sides of pin, sawing on waste side of guide lines. Finish
sloping groves by chiselling.
9. The excess material on the edge is removed by sawing & chiselling.
10. The two pieces are joined together.
RESULT
A Dove Tail joint of required dimensions is obtained.
 FIGURE
SIDE GIVEN DIMENSION OBTAINED DIMENSION DIFFERENCE
A
B
C
--
--

COST ANALYSIS
Cost of production = Material cost + Labour cost + Overhead charges
MATERIAL COST
Material cost = (Volume of wood used in Cubic feet) X (Rate /Cubic feet)
= (0.310 m X 0.050 m X 0.025 m) X (Rate / Cubic feet)
= (0.0003875 m3) X (Rate / Cubic feet)
= (0.01368443 Cubic feet) X (Rs. 890)
= RS. 12.18
LABOUR COST
Labour cost = (Total time) X (Hourly Rate)
Total time = 4 Hours
Rate of skilled labour = Rs. 160 / day (8 Hours)
Rate for student = Rs. 80 / day (8 Hours)
Hourly rate = Rs. 8 0 / 8 Hours
= Rs. 10 / Hour
Hence Labour cost = (4 Hours) X (Rs. 10 / Hour)
= Rs. 4 0
OVERHEAD CHARGES
Overhead charges = (Amount spending for cotton waste, grease, oil, etc.)
+ (Amount spending for electricity, telephone, e-mail, advertisement,
salaries to officials, etc.) = R s . 60

Hence Total Cost of Production = R s . 1 2 . 1 8 + R s . 40 + R s . 60

= Rs. 112.18

• '
 RECTANGULAR TRAY
AIM
To Prepare a Rectangular tray of dimensions of 80 mm length, 50
mm width & height 25 mm.
MATERIAL REQUIRED
24 / 22 SWG Galvanised Iron (G.I.) sheet with dimensions of
150 mm X 120 mm.
TOOLS REQUIRED
Bench shear, Bench vice, Stakes, Anvil, Steel square, steel rule, try
square, scriber, Divider spring type, Wing divider, Punches, Flat cold
chisel, groover or seam set, Standard wire gauge, snips, mallet, files,
hammer, etc.
PROCEDURE
1. Draw the plan and elevation of the object.
2. Draw the developed view in original from the plan and elevation.
3. From the developed view it is seen that a G.I. sheet of 140 mm X
110 mm is needed, taking also into account 5 mm hemming. So cut
150 mm X 120 mm G.I. sheet using bench shear for making the tray.
4. Mark 140 mm & 110 mm lines in the sheet using steel rule, scriber &
try square.
5. Cut along the guide lines using bench shear.
6. Place the sheet above anvil & hammer lightly in the edges using
mallet to level it.
7. Copy the dimensions in original, directly, to the sheet metal using
steel square, scriber, try square, steel rule, etc.
8. Slits, notches wherever necessary are cut using snips.
9. Single hem is made at 1-1', 4-4', 5-5' and 6-6'.
10. Bend 2-3, 3-3', 2'-3' and 2-2' at 90°.
11. Bend 1-2, l'-2', 3-4 and 3'-4' at 90° and brought over the vertical
side.
12. Riveting or soldering is done over the folded vertical side.

RESULT
A Rectangular tray of required dimensions is obtained.
 FIGURE
SIDE GIVEN DIMENSION OBTAINED DIMENSION DIFFERENCE
A
B
C
—
--

COST ANALYSIS
Cost of production = Material cost + Labour cost + Overhead charges
MATERIAL COST
Cost of 8' X 4' G.I. Sheet = Rs. 800/-
Cost of 32 square feet G.I. Sheet = Rs. 800/-
Cost of 1 square feet G.I. Sheet = Rs. 25/-
Cost of 1 metre square G.I. Sheet = Rs. 269.10/-
Area of the Sheet used = 150 mm X 120 mm
= 0.150 m X 0.120 m
= 0.018 square metre
Hence Material Cost = (Area in m 2 ) X (Rate / Area in m2)
= 0.018 m 2 X Rs. 269.10 .
= Rs. 4.84
LABOUR COST
Labour cost = (Total time) X (Hourly Rate)
Total time = 3 Hours
Rate of skilled labour = Rs. 160 / day (8 Hours)
Rate for student = Rs. 80 / day (8 Hours)
Hourly rate = Rs. 8 0 / 8 Hours
= Rs. 10 / Hour
Hence Labour cost = (3 Hours) X (Rs. 10 / Hour)
= Rs, 30
OVERHEAD CHARGES
Overhead charges = (Amount spending for cotton waste, grease, oil, etc.)
+ (Amount spending for electricity, telephone, e-mail, advertisement,
salaries to officials, etc.) = R s . 60

Hence Total Cost of Production = R s . 4 . 8 4 + R s . 30 + R s . 60

= Rs. 9 4 . 8 4
 HOLLOW CYLINDER
AIM
To prepare the lateral surface of a hollow cylinder of dimensions of
50 mm diameter & 110 mm height.
MATERIAL REQUIRED
24 / 22 SWG Galvanised Iron (G.I.) sheet with dimensions of
170 mm X 120 mm.
TOOLS REQUIRED
Bench shear, Bench vice, Stakes, Anvil, Steel square, steel rule, try
square, scriber, Divider spring type, Wing divider, Punches, Flat cold
chisel, groover or seam set, Standard wire gauge, snips, mallet, files,
hammer, etc.
PROCEDURE
1. Draw the plan and elevation of the object.
2. Draw the developed view in original from the plan and elevation.
3. From the developed view it is seen that a G.I. sheet of 167 mm X
110 mm is needed, taking also into account 5 mm grooved joint. So
cut 175 mm X 120 mm G.I. sheet using bench shear for making the
lateral surface of hollow cylinder.
4. Copy the dimensions in original, directly, to the sheet metal using
steel square, scriber, try square, steel rule, etc.
5. Also give 5 mm at the edges of the sheet to make grooved joint.
6. Cut along the guide lines using bench shear.
7. Place the sheet above anvil & hammer lightly in the edges using
mallet to level it.
8. Join edges after folding to the correct shape using stakes.

RESULT
The lateral surface of a hollow cylinder of required dimensions is
obtained.
 FIGURE
SIDE GIVEN DIMENSION OBTAINED DIMENSION DIFFERENCE
A
B
C
__
--

COST ANALYSIS
Cost of production = Material cost + Labour cost + Overhead charges
MATERIAL COST
Cost of 8 ' X 4 ' G . I . Sheet = Rs. 800/-
Cost of 32 square feet G.I. Sheet = Rs. 800/-
Cost of 1 square feet G.I. Sheet = Rs. 25/-
Cost of 1 metre square G.I. Sheet = Rs. 269.10/-
Area of the Sheet used = 175 mm X 120 mm
= 0.175 m X 0.120 m
= 0.021 square metre
Hence Material Cost = (Area in m2) X (Rate / Area in m 2 )
= 0.021 m 2 X Rs. 269.10
= Rs. 5.65
LABOUR COST
Labour cost = (Total time) X (Hourly Rate)
Total time = 3 Hours
Rate of skilled labour = Rs. 160 / day (8 Hours)
Rate for student = Rs. 80 / day (8 Hours)
Hourly rate = Rs. 8 0 / 8 Hours
= Rs. 10 / Hour
Hence Labour cost = (3 Hours) X (Rs. 10 / Hour)
= Rs. 30
OVERHEAD CHARGES
Overhead charges = (Amount spending for cotton waste, grease, oil, etc.)
+ (Amount spending for electricity, telephone, e-mail, advertisement,
salaries to officials, etc.) = R s . 60

Hence Total Cost of Production = R s . 5 . 6 5 + RS. 30 + R s . 60

= Rs, 95.65
 EXTERNAL THREADED PIPE
AIM
To prepare an external threaded pipe of given dimensions.
MATERIAL REQUIRED
A PVC pipe of size 1" diameter and sufficient length.
TOOLS REQUIRED
Pipe vice, Pipe die set, Steel rule, Scriber, Dot punch, hammer,
Hacksaw, Flat file, chalk piece, cotton waste, etc.
PROCEDURE
1. Cutting
Take the pipe and apply chalk paste on the pipe. Hold the pipe in a
pipe vice. From one end of the pipe mark 200 mm to be cut using steel
rule and scriber. Punch on that marked line with dot punch and ball peen
hammer. Then cut the pipe with a hacksaw through the punched line. File
the cut edges to finish it.
2. Threading
Hold the pipe in a pipe vice. File the pipe, if the shape is irregular.
Select the die set of the size of the pipe. Insert the die set to the pipe
with the non-cutting edge side to the fore. Rotate the die set in clockwise
direction and tight the die pieces with the help of key. After 2 or 3
rotations, make a small reverse rotation to remove chips, Finish the
thread to the required length of 25 mm. Repeat the same procedure on
the other end of the pipe. Take a coupling of same size and rotate in the
prepared thread to check it.

RESULT
Cutting & Threading is done on a PVC pipe and an external threaded
pipe is made with given dimensions.

FIGURE
 ASSEMBLY OF PIPE FITTINGS
AIM
To assemble the pipe fittings & valves using PVC pipes as required
in the isometric layout after converting into symbolic diagram.
MATERIALS REQUIRED
A PVC pipe of sufficient length, Pipe fittings & Valves.
TOOLS REQUIRED
Pipe vice, Pipe wrench, Pliers, Spanners, Pipe die set, Steel rule,
Scriber, Dot punch, hammer, Hacksaw, Flat file, solvent cement solution,
chalk piece, cotton waste, etc.
PROCEDURE
1. Convert the isometric layout into symbolic diagram.
2. Select defect free and clean PVC pipes. It is cut to suit the lengths
700 mm, 700 mm, 700 mm, 500 mm, 400 mm, 300 mm and 300
mm respectively. Additional pipe pieces to connect to the elbows are
also cut to suitable length.
3. Pipe of 700 mm is taken and is connected to elbow so that the length
of the pipe horizontally, is adjusted to 700 mm when its other end is
connected to Gate valve.
4. From Gate valve to Tee the length of the pipe is adjusted horizontally
to 700 mm.
5. From Tee, a pipe is connected horizontally to elbow to adjust to a
length of 500 mm and from this elbow a vertical pipe is connected to
another elbow to adjust to a length of 300 mm.
6. From Tee, a pipe is connected vertically to elbow to adjust to a length
of 400 mm.
7. From elbow to gate valve the length of the pipe is adjusted to 700
mm.
8. From Gate valve to elbow the length of the pipe is adjusted to 300
mm.
9. Additional pipe pieces are connected to the three elbows as per the
diagram.
10. Threads are cut externally on pipes when it is fitted to valves,
metallic bends, elbow and Tee etc.
1 1 . For checking horizontally and verticality of the pipe line, plumber's
spirit level is used.
Note:
1. When PVC pipe is fitted into the pipes of same materials solvent
cement solution may be used as adhesive.
2. When PVC pipe is fitted into GI fittings or valves, Teflon tape or
shellac may be used as adhesive.
3. When a pipe is fitted into other objects (Valve, Tape, Bend, etc.) its
mouth should be trimmed and cleaned.
RESULT
The symbolic diagram is prepared from isometric layout. The pipe
fittings & valves are connected as per the given diagram.
 FLAT PULLEY
AIM
To prepare the mould of a Flat pulley.
MATERIALS REQUIRED
Sieved Silica sand or river sand, Clay or Bentonite, Parting sand,
Water.
TOOLS REQUIRED
Moulding box, Moulding board, Flat pulley pattern, Trowels,
Rammers, Mallet, Shovel, Riddle, Slick, Gate cutter, Sprue pin, Lifter,
Vent wire, Swab (Brush), Draw spike, Draw screw, Strike-off bar, water
sprinkler, spirit level, etc.
PROCEDURE
1. Select a suitable moulding box to accommodate the flat pulley
pattern.
2. After applying loose clay on the inside wall, place the drag (lower
part) of the box upside down on a clean moulding board and one part
of the pattern is kept inside the box (Fig a).
3. Parting sand is sprinkled over the pattern.
4. Fill the drag fully with moulding sand and rammed carefully.
5. With a strike-off bar the excess sand is clearly wiped out. Several
vent holes are made deeply on the rammed sand without touching
the pattern, to escape hot gases. The position of the box is reversed.
6. The pattern and its surroundings are cleaned and sprinkled with
parting sand. The cope (upper part) and mating part of the pattern is
then fitted in position with the drag and the first half of the pattern
(Fig b).
7. The runner and riser pins are held vertically in which the runner pin is
a little away from the pattern and the riser pin on the top edge of the
pattern. The moulding sand is filled as in drag and several vent holes
are made (fig c).
8. After removing the runner and riser pins, separate the drag and cope
and are placed side by side. At the top off the runner hole a funnel
shape is cut (Fig d).
9. By moistening the edges and around the pattern, the pattern is
withdrawn by loosening it with a draw spike or a draw screw.
10. A gate way is cut from the sprue way (runner) to the mould cavity
and sand particles, if any, is removed (Fig e).
1 1 . The mould cavity is brushed with suitable coatings.
• 12. The sand core is placed vertically in the depression made by the drag
pattern.
13. The core is clamped with the drag in position, under a weight.
RESULT
The mould of flat pulley is obtained.
 S
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FOUNDRY