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POLYTECHNICS MINISTRY OF HIGHER EDUCATION DEPARTMENT OF MECHANICAL ENGINEERING COURSE INSTRUCTIONAL DURATION CREDIT(S) PRE REQUISITE(S)

JJ104 Workshop Technology 1

: JJ104 WORKSHOP TECHNOLOGY 1 : 15 WEEKS : 2 : NONE

SYNOPSIS WORKSHOP TECHNOLOGY 1 provides exposure to the students in using hand tools correctly and safely, technique of operating drilling machine and lathe machine. It also emphasis on ways of operating gas and arc welding equipment correctly and safely and gives emphasis on concept of tolerance in production process.

COURSE LEARNING OUTCOMES (CLO) Upon completion of this course, students should be able to: 1. explain the accident prevention, hand tools, measurement equipments and indexing in workshop technology (C2) 2. classify the types of the removal and joining process in mechanical engineering (C4) 3. justify the importance issues of workshop technology in current technology trend (A3)

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SUMMARY

JJ104 Workshop Technology 1

(30 LECTURE : 00 PRACTICAL) RTA (01 : 00)

1.0

ACCIDENT PREVENTION Safety procedures and applications in a general engineering workshop ( machining, welding, fitting and foundry work ).

2.0

HAND TOOLS The importance of using hand-tools, measuring and testing equipment, taps and dies.

(01 : 00)

3.0

MEASUREMENT The use of measuring tools and equipment such as steel rule, tape, external and internal calipers

(02: 00)

4.0

DRILLING Drill bits and drilling machine, understand the types of drill bits and able to operate a drilling machine, ways of holding a work piece and drilling.

(02 : 00)

5.0

LATHE MACHINE Explain the types of lathe machine, explain the operation in relation to lathe work such as boring, drilling, knurling, lathe work making taper, cut screw threads and off centre lathe work. MILLING MACHINE Differentiate the various types of milling machines, explain the characteristics and name the parts of universal milling machine, state the basic principles of milling machine and moving work piece (axis X,Y and Z) towards the rotating cutter.

(04 : 00)

6.0

(04 : 00)

7.0

GRINDING MACHINE The theory of grinding, machine operation, types and uses of grinding machines and state and types of grinding wheels.

(04 : 00)

8.0

OXY ACETYLENE WELDING Definition of oxy acetylene welding, high pressure uses of oxy acetylene welding in industrial sectors, oxy acetylene oxy acetylene welding equipment, assemble oxy acetylene equipment, oxy acetylene flame, oxy

(06 : 00)

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acetylene welding technique, joints and edge preparation of the work piece, cutting process, brazing welding process and weld defects. 9.0 ARC WELDING Arc welding machine, function of transformer, function of basic components of arc welding machine, arc welding electrodes and technique, weld defects, types of joints, distortion, welding terminologies and welding symbols.

JJ104 Workshop Technology 1

(06 : 00)

RTA Recommended Time Allocation

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SYLLABUS

JJ104 Workshop Technology 1

1.0

ACCIDENT PREVENTION 1.1 Understand the importance of safety procedures and applications in machining, welding, fitting and foundry work in the engineering workshop 1.1.1 State the general accident prevention procedures in relation to personal safety, colleague, machine and equipments 1.1.2 Explain the importance of wearing goggles, grinding wheel guards and maintaining workshop safety and cleanliness 1.1.3 Explain the environmental issues regarding accident, legislation, protocol, laws and regulations in engineering workshop

2.0

HAND TOOL 2.1 Understand the importance of using hand tools in fitting work 2.1.1 Define the marking out / lay out 2.1.2 State the procedures of marking out / lay out 2.1.3 Explain the use of marking tools such as scriber, centre punch, divider, surface plate and procedures to draw a circle, lines, curve and etc 2.2 Understand the use of testing tools 2.2.1 Define testing tools 2.2.2 Name the types of testing tools such as square, straight edge, surface gauge and etc 2.2.3 Use testing tools such as L square and straight edge 2.3 Understand the use of hack saw 2.3.1 Sketch and label the parts of a hack saw 2.3.2 State the uses of hack saw and cutting stroke 2.3.3 State the characteristics of hack saw blade such as materials used and pitch 2.3.4 Explain the procedure to replace hack saw blade 2.3.5 Discuss the causes of hack saw blades breakage 2.3.6 State the safety precaution and procedure to prevent accidents 2.4 Understand the use of files and filing work 2.4.1 Sketch and label the parts of a file 2.4.2 Define the file terminology such as cuts and grades 2.4.3 Explain various types and shapes of files and its uses 2.4.4 Explain methods of filling such as cross and draw filing technique 2.4.5 Explain pinning and ways to avoid pinning 2.4.6 State the safety procedures in filing 2.5 Understand the use of hammer 2.5.1 Explain types of hammers and its uses 2.5.2 Name parts of ball a peen hammer 2.5.3 Explain the safety procedures in using hammer

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2.6

JJ104 Workshop Technology 1

Understand the use of chisel 2.6.1 Differentiate various types of chisels such as flat, horizontal tip, half round, edge round, nose and diamond tip chisel 2.6.2 Differentiate the various types of chisels: flat chisel, diamond tip point, cape chisel, edge round, nose chisel 2.6.3 Name the parts of a flat chisel 2.6.4 Explain flat chisel on its material, size, cutting angle of the tip and uses to cut and shear metal plate 2.6.5 Explain the disadvantages of mushroom head chisel 2.6.6 Explain method of using chisel 2.6.7 Explain safety procedure to be follow while chiseling Understand the use of taps and dies 2.7.1 Name parts of a tap 2.7.2 State types of taps and procedures of using three types of taps 2.7.3 Explain basic terminology of tapping a blind hole and through hole screw thread 2.7.4 Explain the terminology on tap drill size v 2.7.5 Calculate the size tap drill size 2.7.6 Explain the steps to do internal threading 2.7.7 Explain the reasons for taps breakage of taps and its prevention 2.7.8 Name different types of dies 2.7.9 Explain steps for external threading using a die

2.7

3.0

MEASUREMENT 3.1 Explain the use of common measuring tools and equipment 3.1.1 List basic measuring tools such as steel ruler, tape, external and internal calipers 3.1.2 State different types of micrometers 3.1.3 Sketch and label the parts of an external micrometer 3.1 4 State the in using a micrometer 3.1 .5 Sketch and label the parts of a vernier caliper 3.1 .6 State the basic principles of a vernier caliper 3.1 .7 Explain the methods of using a vernier caliper 3.1 .8 Read the vernier caliper reading (metric and imperial units) 3.1 .9 State the various types of measuring equipment using the vernier principle such as vernier protractor and vernier height gauge

4.0

DRILLING 4.1 Understand the drilling machine and drill bit (twist drill) 4.1.1 Sketch and name parts of a drill bit (twist drill) 4.1.2 Explain how drill sizes are stated and determined 4.1.3 Explain steps of marking out before drilling 4.1.4 Explain method of holding a drill bit 4.1.5 Differentiate the various types of drill bits such as centre drill, straight slot drill, blind hole drill and flat tipped drill 4.1.6 Explain the effects to a drilled hole if the angle of the drill bit tip is not accurate 4.1.7 Calculate the spindle speed revolution (rpm) and the feed rate including factors that influence the selection of the cutting speed
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JJ104 Workshop Technology 1

4.1.8 State the types of coolants, function and advantages 4.1.9 State the safety procedures to be taken while drilling 4.2 Understand methods of holding work piece and drilling 4.2.1 Give the reason for holding the work piece securely while drilling 4.2.2 Explain the types work holding devices commonly used in a drilling machine such as machine vice, machinist vice, V block and others 4.2.3 Explain the procedures taken to drill a large hole 4.2.4 Explain the importance of centre drilling and guided drilling 4.2.5 Explain the uses of jigs in a drilling machine 4.2.6 Provide examples of jigs 4.2.7 State safety procedures to be followed while drilling using jigs

5.0 LATHE MACHINE 5.1 Understand lathe machines 5.1.1 Explain functions of various parts of centre lathe machine 5.1.2 Explain with sketch of work piece held to the lathe machine 5.1.3 State with sketch the various shapes of tool bits and their function or usage 5.1.4 Sketch to explain the various angles of a tool bit tip 5.1.5 Explain the materials used in a tool bit 5.1.6 Elaborate the operation in relation to lathe work such as, turning boring, facing, drilling, knurling, tread cutting and offcentre turning

6.0 MILLING MACHINE 6.1 Understand lathe machines 6.1.1 Differentiate types of milling machines 6.1.2 Explain the characteristics and parts of universal milling machine 6.1.3 State the basic principles of milling machines ( X,Y and Z axis) 6.1.4 Explain two methods of up cut and down cut milling 6.1.5 List the usage of various types of milling cutter 6.1.6 Explain the uses of various types of milling cutter 6.1.7 State methods of holding cutting tools 6.1.8 State methods of holding a work piece 6.1.9 Calculate the revolution per minute (rpm), feed rate and cutting time 6.1.10 State the safety procedures while using the milling machine Understand indexing 6.2.1 Name parts of index head 6.2.2 Explain the operation of index head 6.2.3 State the various types of indexing 6.2.4 Calculate direct, simple and angular indexing

6.2

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7.0 GRINDING MACHINE 7.1

JJ104 Workshop Technology 1

Understand grinding machine 7.1.1 Name types of grinding machines and their uses 7.1.2 State the different types of grinding wheels 7.1.3 Explain the following grinding wheel specifications: a. types of abrasive b. Size of particles c. Wheel grade d. Wheel structure e. B o n d i n g m a t er i a l 7.1.4 7.1.5 7.1.6 Explain defects and maintenance of grinding wheels Explain steps to carry out assembling and balancing of grinding wheels Explain the safety procedures to be followed using a grinding machine

8.0 OXY ACETYLENE WELDING 8.1 Understand oxy acetylene welding 8.1.1 Define oxy acetylene welding 8.1.2 Explain high pressure and low pressure oxy acetylene welding 8.1.3 State the uses of oxy acetylene welding in industrial sector Understand Welding gases 8.2.1 Explain the types of gases used in oxy acetylene welding 8.2.2 Explain the characteristics, production and oxygen gas cylinder 8.2.3 Explain the characteristics, production and acetylene gas cylinder 8.2.4 Explain the availability of other gas fuel besides acetylene Explain oxy acetylene welding equipment 8.3.1 Explain oxy acetylene welding equipment 8.3.2 Explain the working principles of regulators 8.3.3 State types of oxy acetylene hoses 8.3.4 State types, working principles, uses and function of the welding torch 8.3.5 Explain the oxy acetylene welding tip 8.3.6 Explain the oxy acetylene welding manifold system and single station system Understand Brazing and Braze Welding Process 8.4.1 Define brazing and braze welding process 8.4.2 Explain the application of brazing and braze welding process 8.4.3 Explain the function of flux, filler rod and types of flames used 8.4.4 Explain brazing and braze welding technique Understanding oxy acetylene weld defects and its prevention 8.5.1 Explain a completed welding joint based on penetration, bead shape and joints accuracy 8.5.2 Explain the types weld defects and its prevention

8.2

8.3

8.4

8.5

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9.0 ARC WELDING 9.1

JJ104 Workshop Technology 1

Understand Arc welding machine 9.1.1 Explain the function of the ampere adjustment control 9.1.2 Recognize the basic components of an arc welding machine 9.1.3 Name five types of arc welding machines and explain the working principles, advantages and disadvantages of a. Direct current arc welding machine b. Alternating current arc welding machine c. Integrated AU/UT arc welding machine d. Power driven direct current petrol/diesel arc welding generator e. Electric motor driven direct current arc welding generator 9.1.4 Draw basic schematic arc welding machine circuits Describe Polarity 9.2.1 Define the terminology of Straight polarity and reverse polarity 9.2.2 Explain the characteristics of polarity 9.2.3 Explain the procedures to choose the type of polarity Understand techniques of arc welding 9.3.1 Sketch with label the arc welding process 9.3.2 Explain the effects of arc length, electrode angle and the speed of travel on a welding product 9.3.3 Explain method in starting an arc welding Explain Electrode 9.4.1 Explain the process to produce an electrode 9.4.2 Explain the types of metal composition found in electrode core 9.4.3 Explain function of the electrode coatings 9.4.4 Explain types, classification, colour code and number code of electrodes 9.4.5 Describe the function of the electrode core and slag Understand weld defects 9.5.1 Sketch with labels the types welding defect 9.5.2 Explain weld defects in the arc welding process and its prevention Explain basic types of welding joints 9.6.1 Sketch with labels five types arc welding basic joints 9.6.2 Explain steps to be taken before starting weld 9.6.3 Explain the advantages and the uses of every joint Understand distortion 9.7.1 Name types of distortion 9.7.2 Explain the reasons for distortion and its preventive methods Identify welding terminologies 9.8.1 Explain the welding terminologies such as: bead, throat, leg size, penetration, root face and root gap Identify welding symbols 9.9.1 State the importance of welding symbols 9.9.2 Explain types of welding symbols a. Simple symbols b. additional symbols 9.9.3 Explain the welding symbol characters such as arrow, reference line, tail end, other side and arrow side 9.9.4 Interpret welding symbols

9.2

9.3

9.4

9.5

9.6

9.7

9.8

9.9

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ASSESSMENT

JJ104 Workshop Technology 1

The course assessment is carried out in two sections: i. Coursework (CA) Coursework is continuous assessment that measures knowledge, technical skills and soft skills. Final Examination (FE) Final examination is carried out at the end of the semester.

ii.

The percentage ratio of FE to CA shall follow the guideline stated in the ArahanArahan Peperiksaan dan Kaedah Penilaian which is approved by the Lembaga Peperiksaan dan Penganugerahan Sijil/ Diploma Politeknik. ASSESSMENT SPECIFICATION TABLE (AST)
CLO CONTEXT ASSESSMENT METHODS FOR COURSEWORK (CA) Report and presentation *(1) 30%

CLO 3

CLO 1

CLO 2

Test *(1) 20%

Quiz *(1) 10%

End of Chapter *(2) 40%

Accident Prevention Hand Tools Measurement Drill Lathe Machine Milling Machine Grinding Machine Oxy Acetylene Welding Arc Welding

Remark: CLO1 : explain the accident prevention, hand tools, measurement equipments and indexing in workshop technology CLO2 : classify types of the removal and joining process in mechanical engineering CLO3 : justify the importance issues of workshop technology in current technology trend *(x) refers to the quantity of assessment

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REFERENCES

JJ104 Workshop Technology 1

Bruce J.Black, C.Eng, MIEE. (2004). Workshop Process, Practices and Material, Elsevier.

Ibrahim Che Muda . N. Ramudaram . (2000) . Teknologi Bengkel Mesin, Dewan Bahasa dan Pustaka.

Rajender Singh. (2006). Introduction to Basic Manufacturing Process and Workshop Technology, New Age international (P) Limited, Publisher.

R.K. Rajput . (2005). Workshop Practice, LAXMI PUBLICATIONS (P)

Serope Kalpakjian. Steven Schmid. (2006). Manufacturing Engineering and Technology, PEARSON Prentice Hall.

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JJ104 Workshop Technology 1

MATRIX OF COURSE LEARNING OUTCOMES (CLO) VS PROGRAMME LEARNING OUTCOMES (PLO)

Compliance to PLO
Course Learning Outcome (CLO) PLO1 LD1 Quiz, Test and End of Chapter C2 PLO2 LD2 PLO3 LD3 PLO4 LD4 PLO5 LD5 PLO6 LD6 PLO7 LD7 PLO8 LD8 PLO9 LD9

Recommended Delivery Methods

Assessment

Explain the accident prevention, hand tools, measurement equipments and indexing in workshop technology (C2)

Classify types of the removal and joining process in mechanical engineering (C4)
C4

Interactive Lecture, PBL

Tests and End of Chapter

Justify the importance issues of workshop technology in current technology Trend (A3)

Report and presentation A3

Total

L D2

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JJ104 Workshop Technology 1

DISTRIBUTION OF STUDENT LEARNING TIME ACCORDING TO COURSE LEARNING - TEACHING ACTIVITY

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