Workshop Technology
 
 
Subject Code: EME3016
Aim of Subject: To introduce workshop technology and metrology, and also provide students with workshop experience.
Learning Outcome of Subject: At the completion of the subject, students should be able to :
  • Know workshop safety, bench work and marking techniques, handling machine tools, joining, hot & cold working processes.
  • Have some understanding of metrology including standard of length, comparators, angle measurement, limits & fits and gauge design.
  • Undertake, under supervision, workshop practice with hands-on in turning, welding, milling and metrology.
Programme Outcomes:
  • Ability to acquire and apply fundamental principles of science and engineering(60%)
  • Capability to communicate effectively(10%)
  • Acquisition of technical competence in specialised areas of engineering discipline(10%)
  • Understanding of the importance of sustainability and cost-effectiveness in design and development of engineering solutions(10%)
  • Ability to work independently as well as with others in a team(10%)
Assessment Scheme:
  • Lab Experiments - work in groups, lab report writing, oral assessment at the end of lab (10%)
  • Tutorial / Assignment - group assignment,focus group discussion at tutorial,to enhance understanding of basic concepts in lecture(10%)
  • Test Quiz - written exam (20%)
  • Final Exam - written exam (60%)
Teaching and Learning Activities: 63 hours (lectures,tutorials and laboratory experiment)
Credit Hours: 3
Pre-Requisite: None
References:
  • S. Kalpakjian, "Manufacturing Engineering and Technology", Prentice Hall, 2001.
  • T. Busch, "Dimensional Metrology", Delmar, 1998.

Subject Contents

  • Workshop Safety, Bench Work and Marking

    • Clothing, shoes, belts, gloves. Hair, nails, eye protection. Use of machines: lathe, drill, planer, shaper, grinder, saw. Use of chemicals and welding equipment. Bench work. Cleanliness of working area.
      
  • Use of Machine Tools

    • Introduction to the processes of metal cutting. Cutting tools and cutting tool materials. Nomenclature of cutting tools. Basic mechanism of machines. Use of machines: lathe, drilling, milling, grinding and shaping machines, planer and power saw.
     
  • Joining Processes

    • Welding processes: Introduction and function of processes. Types of processes. Processes using pressure and heat: brazing and soldering, advantages and disadvantages. Unconventional processes. Temporary fasteners: screw, stud, bolt and nut, locking devices. Permanent fasteners: rivets and dimensions of rivets, types of riveted joints.
     
  • Hot and Cold Working Processes

    • Hot:     Rolling, forging, press forging, drawing, extrusion, spinning .
    Cold:   Squeezing, bending, shearing, drawing processes. Sheet metal work.
     
  • Casting

    • Introduction to casting processes. Sand casting: castability, quality of sand for casting. Casting process. Other processes: permanent mould die casting, precision investment casting, shell and plaster moulds.
     
  • Standards of Length

    • International prototype meter, wavelength of light (krypton 86), slip gauges and end bars, airy points.
     
  • Workshop Measuring Instruments and Comparators

    • Micrometers and verniers, principles of operation, usage. Construction and principles of operation of electrical, air, mechanical and optical comparators.
     
  • Angle Measurement

    • Angular standards, divided circles, protractors, sine bars, levels, operation of autocollimators.
     
  • Limits and Fits

    • Significance of specifying and working to limits, stating tolerances - unilateral, bilateral terminology, types of fits, hole and shaft basis systems, Newall System, BS 1916 and BS 4500 system, selection of limits and fits, maximum and minimum metal conditions.
     
  • Gauge Design

    • Limit gauges, GO and NOT GO tolerances on gauges. Taylor’s principle.
     

Laboratory

1. Turning
2. Welding
3. Milling
4. Metrology