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JJ103 Mechanical Workshop Practice 1

POLYTECHNICS
MINISTRY OF HIGHER EDUCATION MALAYSIA
DEPARTMENT OF MECHANICAL ENGINEERING

COURSE

: JJ103 MECHANICAL WORKSHOP PRACTICE 1

INSTRUCTIONAL DURATION

: 15 WEEKS

CREDIT (S)

: 2

PREREQUISITE (S)

: NONE

SYNOPSIS
MECHANICAL WORKSHOP PRACTICE 1 exposes the students to welding, machining
and fitting which involves the use of arc and gas welding machine, lathe machine, drilling
machine, grinding machine, hand tools, marking out tools, measuring and testing tools.
Students are also taught to emphasize on safety procedures and cleanliness in the
workshop.

LEARNING OUTCOMES
Upon completion of this course, students should be able to:1.

practice correctly safety procedures in the workshop.

2.

carry out fitting works with various hand tools, marking out, measuring tools,
testing tools and drilling machine.

3.

perform grinding works and various types of lathe work according to prescribed
procedures

4.

carry out correctly basic gas and arc welding works involving various processes
of welding and types of joining metals according to S.O.P

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JJ103 Mechanical Workshop Practice 1

SUMMARY

( 00 LECTURE : 60 PRACTICAL)

RTA
(00:20)

1.0

FITTING
The topic exposes the students to fitting works involving the use of
various hand tools, measuring tools, marking out, testing tools
and drilling machine.

2..0

MACHINING
(00:20)
The topic exposes the students to tool bits grinding (off hand grinding),
operate the lathe machine for various machining processes and
practice measuring skills.

3. 0

BASIC WELDING
The topic exposes the students to basic gas and arc welding processes
involving various types of joining metals.

RTA

(00:20)

Recommended Time Allocation

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JJ103 Mechanical Workshop Practice 1

SYLLABUS

1.0

FITTING
1.1 Perform fitting works
1.1.1
Flat file , square and form surfaces using various types of files
1.1.2
Mark out parallel, vertical and different angular lines on a
workpiece.
1.1.3
Chisel off metal using various types of chisels
1.1.4
Cut mild steel plates using a hack saw
1.1.5
Mark out and drill holes on a bench drilling machine
1.1.6
Cut internal and external Metric V thread using :
a. taps
b. dies
1.1.7
Measure workpiece using:
a. steel ruler
b. external micrometer
c. vernier caliper
d. vernier height gauge
1.1.8
Test finished workpieces using gauges, templates, profile
projector and surface testing machine
1.1.9
Keep the workshop clean and safe

2..0

MACHINING WORK
2.1 Perform machining work
2.1.1 Practice safety procedures while operating the lathe and grinding
machine
2.1.2 Grind tool bits (off hand grinding) according to the required
geometric angles for
2.1.3 Operate the lathe machine, select spindle speeds and feeds
2.1.4 Operate lathe machine for
a. parallel turning
b. stepped turning
c. facing
d. taper turning
e. centre drilling
f. knurling
2.1.5 Measure workpiece by using the following instruments:
a. micrometer
b. vernier caliper
c. steel ruler
2.1.6 Keep the workshop clean and safe.

3.0

BASIC WELDING.
3 .1

Practice Oxy acetylene welding.

3.1.1 Ignite and adjust flame for different types of welding job
3.1.2 Select proper filler rods and use it to get a neat and correct bead
flow.
3.1.3 Weld an open square butt joint with full penetration throughout
the point.
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JJ103 Mechanical Workshop Practice 1

3.1.4 Weld open corner joint with full penetration throughout the joint
3.1.5 Keep the workshop clean and safe.

3 .2

Practice Arc welding

3.2.1 Deposit stringer beads using correct electrode size and amperage
selection for different types of recommended metal thickness.
3.2.2 Weld a close square butt joint with straight, smooth and convex
bead throughout the joint.
3.2.3 Weld an open corner joint with straight convex bead surface.
3.2.4 Keep the workshop clean and safe.

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JJ103 Mechanical Workshop Practice 1

ASSESSMENT

TYPES OF ASSESSMENT

The course is assessed through 100% Continuous Assessment

CONTINUOUS ASSESSMENT (CA):

Continuous assessment is carried out throughout the semester and

comprises the followings:
a.
Practical Task ( minimum 3 )
b.
Project
( minimum 1)
c.
Other Assessment Task
i. Report
( minimum 3 )

60%
20%
20%

[ Assessment Task above ( a-b ) to be executed during Lecture / Practical /

Tutorial hour ]

Note : 1. Refer to Assessment Specification Table for the details.

2. The percentage of Continuous Assessment may vary depending in
courses.

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JJ103 Mechanical Workshop Practice 1

ASSESSMENT SPECIFICATIONS TABLE ( AST)

LEARNING OUTCOMES
1.
2.
3.
4.

practice correctly safety procedures in the workshop.

carry out fitting works with various hand tools, marking out, measuring tools, testing tools and drilling machine.
perform grinding works and various types of lathe work according to prescribed procedures
carry out correctly basic gas and arc welding works involving various processes of welding and types of joining metals according to S.O.P
CONSTRUCT

ASSESSMENT TASK
CLO

CONTEXT

FITTING

fitting works

Practical Task
3

Project
H

Report
H

1
1

MACHINING

machining works

gas welding

BASIC WELDING

arc welding

TOTAL

18

RATIO

RUBRIC

RUBRIC

RUBRIC

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JJ103 Mechanical Workshop Practice 1

REFERENCES

Bawa, (2004). Manufacturing Processess1. McGraw Hill

Bawa, (2004). Manufacturing Processess2. McGraw Hill
Chapman, W.A.J, (1996). Workshop Technology Part 1. ELBS
Chapman, W.A.J, (1996). Workshop Technology Part 2. ELBS
Krar, S.F, Oswald J.W. (1976). Technology of Machine Tools. Mc Graw Hill
Richard R. Kibbel,et al (2006), Machine Tool Practice (8th ed.). U.S: Pearson Prentice
Hall.
Ibrahim Che Muda, R. Ramudaran, (2000), Teknologi Bengkel Mesin, Dewan
Bahasa Pustaka.

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JJ103 Mechanical Workshop Practice 1

DISTRIBUTION OF STUDENT LEARNING TIME

No.
1

Activities
hour(s) x

15

week(s)

[
hour(s) x
Self Learning: Theory
Preparation before theory class viz. review/download lesson notes.

15

week(s)

Lecture hours

[ ]

Theory test/quiz

[ ]

Lecture

Preparation after theory class viz. additional references, discussion group, discussion
with lecturers.

Preparation for theory test/Preparation before work presentation

Practical

hour(s) x

Lab work

Workshop safety

Skill/Practical test

Workshop practice

Field work

Simulation

Survey/research

Outdoors

Project

[ ]

15

week(s)

Presentation/
Critique

Practical task

[]

[
1
hour(s) x
15
week(s)
Self Learning: Practical
Preparation before practical class/field work/eview notes, checklist/labsheets and/or
tools and equipment.
Preparation after practical class/field work/dditional references, discussion session and
report writing.
-

[ ]

Other Assessment Task

60

15

[ ]
[ ]

[]

Preparation for practical test.

Tutorial

SLT

Preparation before work presentation/critique.

CODE

Capstone Project

Portfolio

Essay
Question

Presentation

Peer Assessment

Observation

Reflective Journal

Self Assessment

Discussion

Case Study

End-of-Chapter

Report

[ ]

Total

80

Lecture

P
I

Practical
Self Learning

60

T
O

Tutorial
Other Assessment Task

0
5

15

SLT (Student Learning Time)

80

Credit = SLT/40

2.00

* Note: Assignments/projects shall begin guided during practical session.

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JJ103 Mechanical Workshop Practice 1

TABLE OF LEARNING DOMAINS

NO

COGNITIVE

SPESIFIC OUTCOME (SO)

C1

1.0

FITTING

1.1

Perform fitting works

Flat file, square and form surfaces using
various types of files
Mark out parallel, vertical and different
angular lines on a workpiece
Chisel off metal using various types of
chisels

1.1.1
1.1.2
1.1.3
1.1.4
1.1.5
1.1.6
1.1.7

1.1.8
1.1.9

C5

C6

P1

P2

P4

P5

A1

A2

A3

A4

A5

Perform machining work

P3

AFFECTIVE

Mark out and drill holes on a bench drilling

machine
Cut internal and external Metric V thread
using taps and dies
Measure workpiece using steel ruler,
external micrometer, vernier calliper, vernier
height gauge
Test finished workpieces using gauges,
templates, profile projector and surface
testing machine
Keep the workshop clean and safe

2.1

2.1.3

C4

MACHINING WORK

2.1.2

C3

Cut off mild steel plates by using a hacksaw

2.0

2.1.1

C2

PSYCHOMOTOR

Practice safety procedures while operating

the lathe and grinding machine
Grind tool bits (off hand grinding) according
to the required geometric angles for general
purposes machining using pedestal grinder
Operate the lathe machine, select spindle
speeds and feeds

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NO

JJ103 Mechanical Workshop Practice 1

COGNITIVE

SPESIFIC OUTCOME (SO)

C1

2.1.4

2.1.5
2.1.6

3.1

Practice Oxy acetylene welding

Ignite and adjust flame for different types of
welding job
Select and use proper filler rods to get a neat
and correct bead flow

3.1.3
3.1.4
3.1.5
3.2
3.2.1

C4

C5

C6

P1

P2

P3

P4

AFFECTIVE
P5

A1

A2

A3

A4

A5

Keep the workshop clean and safe

BASIC WELDING

3.1.2

C3

Operate lathe machine: parallel turning,

stepped turning, facing, taper turning, centre
drilling, knurling
Measure workpiece by using the following
instruments : micrometer, vernier calliper,
steel ruler

3.0

3.1.1

C2

PSYCHOMOTOR

Weld an open square butt joint with full

penetration throughout the point.

Weld open corner joint with full penetration

throughout the joint
Keep the workshop clean and safe

Practice arc welding

deposit stringer beads using correct
electrode size and amperage selection for
different types of recommended metal
thickness.

3.2.2

Weld a close square butt joint with straight,

smooth and convex bead throughout the joint

3.2.3

Weld an open corner joint with straight

convex bead surface

3.2.4

Keep the workshop clean and safe

TOTAL

12

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Legend :
Cognitive Domain
C1 Knowledge
C2 Comprehensive
C3 Application
C4 Analysis
C5 Synthesis
C6 Evaluation

JJ103 Mechanical Workshop Practice 1

Psychomotor Domain
P1 Imitate
P1 Manipulate
P3 Precision
P4 Articulation
P5 Naturalization

Affective domain
A1 Receiving Phenomena
A2 Responding to Phenomena
A3 Valuing
A4 Organizing Values
A5 Internalizing Values

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JJ103 Mechanical Workshop Practice 1

MATRIX OF SPECIFIC OUTCOMES Vs CLO, GSA AND LEARNING DOMAINS

1.1.2
1.1.3

Chisel off metal using various types of chisels

1.1.4

Cut off mild steel plates by using a hacksaw

1.1.5

Mark out and drill holes on a bench drilling machine

Cut internal and external Metric V thread using

taps and dies
Measure workpiece using steel ruler, external
micrometer, vernier calliper, vernier height gauge
Test finished workpieces using gauges, templates,
profile projector and surface testing machine
Keep the workshop clean and safe

1.1.7
1.1.8
1.1.10
2.0

MACHINING WORK

2.1

Perform machining work

2.1.1

GSA 5

1.1.6

LD 8 GSA 7

LD 7 GSA 6

LD 6 GSA 2

LD 5 GSA 1

LD 4 GSA 3

LD 3 GSA 4

CLO 4

CLO 3

Discussion,
Demonstration and
Practical Work

Perform fitting works

Flat file, square and form surfaces using various
types of files
Mark out parallel, vertical and different angular
lines on a workpiece

1.1.1

LD 2

1.1

FITTING

*Recommended
Teaching &
Learning Strategy

GSA & LD

LD 1

1.0

SPECIFIC OUTCOME (SO)

CLO 2

No

CLO 1

CLO

Discussion,
Demonstration and
Practical Work

Practice safety procedures while operating the

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JJ103 Mechanical Workshop Practice 1

2.1.4

2.1.5
2.1.6

lathe and grinding machine

Grind tool bits (off hand grinding) according to the
required geometric angles for general purposes
machining using pedestal grinder
Operate the lathe machine, select spindle speeds
and feeds
Operate lathe machine: parallel turning, stepped
turning, facing, taper turning, centre drilling,
knurling
Measure workpiece by using the following
instruments : micrometer, vernier calliper, steel
ruler

BASIC WELDING

3.1

Practice Oxy acetylene welding

3.1.2
3.1.3
3.1.4
3.1.5
3.2
3.2.1

GSA 5

LD 8 GSA 7

LD 7 GSA 6

LD 6 GSA 2

LD 5 GSA 1

LD 4 GSA 3

LD 3 GSA 4

CLO 4

CLO 3

Keep the workshop clean and safe

3.0

3.1.1

LD 2

2.1.3

*Recommended
Teaching &
Learning Strategy

GSA & LD

LD 1

2.1.2

SPECIFIC OUTCOME (SO)

CLO 2

No

CLO 1

CLO

Discussion,
Demonstration and
Practical Work

Ignite and adjust flame for different types of welding

job
Select and use proper filler rods to get a neat and
correct bead flow
Weld an open square butt joint with full
penetration throughout the point.
Weld open corner joint with full penetration
throughout the joint
Keep the workshop clean and safe
Practice arc welding
Deposit stringer beads using correct electrode size
and amperage selection for different types of

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JJ103 Mechanical Workshop Practice 1

3.2.4

recommended metal thickness.

Weld a close square butt joint with straight, smooth
and convex bead throughout the joint
Weld an open corner joint with straight convex bead
surface
Keep the workshop clean and safe

GSA 5

LD 8 GSA 7

LD 7 GSA 6

LD 6 GSA 2

LD 5 GSA 1

LD 4 GSA 3

LD 3 GSA 4

CLO 4

CLO 3

LD 2

3.2.3

*Recommended
Teaching &
Learning Strategy

GSA & LD

LD 1

3.2.2

SPECIFIC OUTCOME (SO)

CLO 2

No

CLO 1

CLO

Note:
*Lecturers may use other teaching & learning strategies in order to achieve the learning outcomes.
Generic Student Attributes (GSA)
Learning Domain (LD)
GSA 1 Communications Skills
LD 1
Knowledge
GSA 2 Critical Thinking and Problem Solving Skills
LD 2
Technical Skills
GSA 3 Teamwork Skills
LD 3
Professionalism & Ethics
GSA 4 Moral & Professional Ethics
LD 4
Social Skills
GSA 5 Leadership Skills
LD 5
Communication Skills
GSA 6 Information Management Skills and Continuous Learning LD 6
Critical Thinking
GSA 7 Entrepreneurship Skills
LD 7
Life Long Learning
LD 8
Entrepreneurial Skills

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