Workshop theory and_practice

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Workshop theory and_practice

  1. 1. Mechanical Engineering DepartmentCourse Information and Outline .Course Title Workshop Theory and PracticeCourse Code ME 302Description The course deals with the basic principles of machine shop practices. It includes workshop safety and organization; simple workshop measuring instruments, hand tools, fitting bench work, bench drill and bench grinder; sheet metal working; principles of welding processes; welding metallurgy; joining processes; testing and inspection of welds.Course Objective At the end of the course, the students are expected to 1. Identify common shop hand tools, drill press, lathe machine, and welding machine. 2. Read Vernier Calipers and other measuring instruments 3. Design and fabricate project using various machines stated above. 4. Work harmoniously with team members playing different rolesRequirements Project Fabrication. Individual projects will be fabricated by the students for them to apply the procedures and operations discussed during lectures. The project will allow students to develop and acquire skills and proper work ethics in the work shop. Group or Individual Exercise. Group or individual exercises will be given after every lecture for the students to apply the basic theories discussed. The student will be encouraged to work in teams in different activities as a preparation for the project fabrication. Preliminary and Final Exam. The regular end-of-term exam to evaluate student on how much they have learned in course. Class Standing. Class standing includes group exercises to be submitted during every meeting and assignments.Resources [1] Steve F. Krar, Mario Rapisarda, Albert F. Check, Machine Tool and Manufacturing Technology [2] Paul De Garmo, Ronald Kohser, J.T. Blank, Material and Processes in Manufacturing [3] Gower A. Kennedy, Welding TechnologyGrading System Group Project : 40% Lecture Examinations 30% Class standing: 30% 2011
  2. 2. Mechanical Engineering DepartmentSchedule Wk Topics/Activities 1 Orientation, discuss the rules and guidelines for the machine shop laboratory Safety orientation The class will be divided into groups of 4-5 members per group. Read hand-outs 001: Rules and Guidelines for the Machine Shop Laboratory Assignment #1: Submit 3 posters in a cardboard size 17” x 11” showing or illustrating Safety in the Machine shop terms of (1) Personal grooming (2) Safe work practices (3) General Housekeeping The poster must be manually drawn and painted with any painting material and submitted with plastic cover. Prepare to discuss your poster next meeting. 2 Topic: Bench and Hand Tools and Steel Rules Read hand-outs #002: Bench and Hand Tools Exercise #1: (Individual) (1) Part 1: Fabricate a 22mm x 22mm x 60mm part fully polished with 45 degree chamfer in each side. Use mild steel. (2) Part 2: Fabricate a 25mm x 50mm x 10mm part fully polished with 45 degree chamfer in each side. This part must also have one 45 degree (5mm on each side) cut on one edge. Use mild steel. Read hand-outs #003: Drilling Machines 3 Submission of Exercise #1 Exercise #1 will be evaluated in terms of the following criteria: Accuracy: 50% Surface Finish: 40% Packaging: 10% Read hand-outs #004: Hand Taps Read hand-outs #005: Metals and their Properties 4 Topic: Hand Taps and Drill Press 2011
  3. 3. Mechanical Engineering Department Exercise #2: Assemble Part 1 and Part 2 of Exercise #1. Drill Part 1 at a depth of 40mm with a diameter in which a pencil can be placed in it. Also drill Part 1 and Part 2 with proper diameter and depth so that a tap can be placed in Part 1 and attached to Part 2 by a use of screw. A counter drill should also be placed in Part 2. The output of the assembly is a Ball pen stand. 5 Submission of Exercise #2 Exercise #2 will be evaluated in terms of the following criteria: Accuracy: 50% Final Appearance: 40% Packaging: 10% Read hand-outs #006: Lay-out and Accessories Read hand-outs #007: Sheet Metal Machines and Hand Tools Assignment: Bring a cardboard folder and scissors 6 Topic: Lay-out tools and accessories, Sheet Metals, and Bending Machine. Exercise #3: (Individual) (1) Using cardboard folder, design 4” x 2” x 1.5” box using your cardboard folder. (2) The box made in cardboard folder will be fabricated using a sheet metal. Read hand-outs #008: Shielded Metal Arc Welding (SMAW) 7 Submission of Exercise #3 (3hrs) Exercise #3 will be evaluated in terms of the following criteria: Accuracy: 50% Final Appearance: 40% Packaging: 10% Discussion and demonstration of welding machine and process. (3 hrs) Read hand-outs #009: Joining of Metals 2011
  4. 4. Mechanical Engineering Department 8 Exercise #4: (Group) (1) Each group will be scheduled to practice and strike SMAW Arc and must submit an individual electrode motions as shown in the handouts. The electrode motion will be placed in a mild steel plate. Exercise #4 will be evaluated in terms of the following criteria: Accuracy of motion: 50% Final Appearance: 40% Packaging: 10% 9 PRELIMINARY EXAMINATION (Exam 1) 10 Topic: Introduction, Design and Fabrication of Group Project #1: Tool Box 11 Project Fabrication 1: Read hand-outs #010: Vernier Calipers and Gages Read hand-outs #011:Lathe Machine 12 Project Submission: Group Project #1: will be evaluated in terms of the following criteria: Functionality: 50% Final Appearance: 40% Packaging: 10% Read hand-outs #012: Operations done on a Lathe Read hand-outs #013: Machining Processes Topic: Introduction, Design and Fabrication of Group Project #2: Wheel Borrow Wheel. The Wheel must a hub and 5 spokes. 13 Topic: Lathe Machine and Type of Joints part 1 Groups will be scheduled to attend two different sessions: (1-hour) Lathe Machine session: Basic Lathe Machine Operation (1-hour) Types of Joints Activity: Each group will perform and submit (a) Butt Joint, Lap Joint and T-Joint. 2011
  5. 5. Mechanical Engineering Department 14 Topic: Lathe Machine and Type of Joints part 2 15 Project Fabrication 1: 16 Project Fabrication 2: 17 Project Submission: Group Project #1: will be evaluated in terms of the following criteria: Functionality: 50% Final Appearance: 40% Packaging: 10% 18 Final Examination 2011

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