DJM10012- MECHANICAL WORKSHOP PRACTICE 1

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DEPARTMENT MECHANICAL ENGINEERING DEPARTMENT
CODE DJM 10012
COURSE MECHATRONIC WORKSHOP PRACTICE 1
PROGRAM DEM
TOPIC FITTING

CLO 1 : Practice and perform correct techniques in handling fitting and machining works and
equipments (P3,PLO3)

CLO 3 : Demonstrate the understanding and awareness of safety procedure in mechanical workshops
according to the workshop safety regulation.(A3, PLO6)

PLO3: Design / development of solution :design solutions for well-defined technical problems and assist
with the design of systems, components or processes to meet specified needs with appropriate
consideration for public health and safety, cultural, societal, and environmental considerations (DK5)

PLO6: The engineer and society: demonstrate knowledge of the societal, health, safety, legal and
cultural issues and the consequent responsibilities relevant to engineering technician practice and
solutions to well-defined engineering problems (DK7)

INTRODUCTION : Fitting
TOPIC : Hand tools
OBJECTIVES : At the end of the session the students should be able to;
i) recognize the hand tools used in the fitting process
ii) learn how to use the vernier caliper for measuring
iii) read and interpret engineering drawing

TOOLS REQUIRED:
Vernier caliper, vernier height gauge, flat file, file card, hammer, centre punch, vise, micrometer,
hacksaw, L-square, tap and tap wrench,die, chisel and drills.
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THEORY:
Fitting is basis exposure that involves the usage of hand tools, drilling machines, marking tools,
measuring and testing tools, and grinding work.
A hand tool is a device for performing work on a material or a physical system by using only hands. The
hand tools can be manually used employing force, or electrically powered, using electrical current.
Virtually every type of tool can be a hand tool and many have also been adapted as power tools, which
receiver their motive power from motors or engines rather than from human mechanical action.

Students are always reminded to emphasize on safety procedures in workshop

1.0 FILING
In spite of modern machines and technology, work by hand is still necessary and one of the such
processes is filing. The purpose of filling is to shape work pieces accurately so as to achieve smooth
surfaces.
Filing is a finishing process where fine chips are removed by a multiple pointed tool called a File. Files
are used mainly for finishing metal works by hand. They are classified into five types of shapes;

Figure 2.0 (a): Flat File Figure 2.0 (b): Square File

Figure 2.0 (c): Triangle File Figure 2.0 (d): Round File
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Figure 2.0 (e): Half Round File

1.1 Holding of a File

Place the file’s handle on the right palm and grip firmly.
Hold the end of the file with the left hand and press it with the palm keeping the wrist horizontal as
shown in the figure below:

Figure 2.1 (a): Left Hand Figure 2.1 (b): Right Hand

Figure 2.1 (c): Correct way of holding a file

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1.2 File Card
Cleaning the file is necessary to remove the clogged chips from the file, which can cause poor surface
finish.
A file brush or file card is used to clean the file in the direction of the over cut. Stuck chips can be
removed with a file cleaner made of brass or copper sheet.

File Card

Figure 2.2: Clean the file

1.3 Hand Hacksaw
Hand hacksaw is use to cut the work pieces and the process is called as sawing.

Figure 2.3: Parts of Hacksaw

1.4 Vise
Spacing vices are usually used for holding or clamping the work pieces during the filing operation. The
height of the vice should be adjusted according to the correct body positioning.
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Figure 2.4: Parts of Vise

1.5 L – Square
Square are used to lay out lines at 90 o of angles to a machine edge, to test the accuracy of surface that
must be square (90o to each other) and to set up work for machining.

Figure 2.5: L-Square

1.6 Angle Plate
Angle plate (90o angle) can be used to hold or support the work in a vertical plane so that the layout will
be accurately positioned.

Figure 2.6: Angle Plate

1.7 Vernier Height Gauge
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The vernier height gauge can be used to measure or mark vertical distances to ± 0.02mm (0.001 in)
accuracy.
The main parts of vernier height gage are base, beam, vernier slide, clamp screw and scriber.

Beam

Vernier slide
Clamp Screw
Scriber

Base

Figure 2.7: Parts of Vernier Height Gauge

1.8 Center Punch

Center punch is used to mark the location of the center hole. The wider indentation permits easier and
more accurate starting of a drill point.

Figure 2.8: Center Punch

1.9 Hammer
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Many different types of hammer are used by the machinist, and one of the commonly use is ball-peen
hammer. The larger striking surface is called the face and the smaller rounded is called peen. The peen
generally used in riveting operation.

Figure2.9: Hammer
1.10 Hand Tap and dies
Taps are cutting tools used to cut internal threads. They are made from a high quality tool steel (high
speed steel – HSS), hardened and ground. Hand tap are usually made in sets of three. They are taper,
plug and bottoming. Dies are use to cut external threads.

Taper Plug Bottom Tap Square

Figure 2.10 (a): Tap wrenc
Figure 2.10 (b): Tap Wrench
h

Figure 2.11 : Dies

1.11 Drilling Machine

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Drilling is the production of cylindrical holes of specific diameters in work pieces by using drilling
machine. The drill bit has wedge-shaped edges and operates by a chip removal process.

Pulley
Drilling

Motor
Depth Stop

Hand Feed

Chuck
Column

Table
Table
Clamp

Base

Figure 2.12: Part of Drilling Machine

FITTING PROJECT
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CLO 1 : Practice and perform correct techniques in handling fitting and machining works and
equipments (P3,PLO3)

CLO 3 : Demonstrate the understanding and awareness of safety procedure in mechanical workshops
according to the workshop safety regulation.(A3, PLO6)

PLO3: Design / development of solution :design solutions for well-defined technical problems and assist
with the design of systems, components or processes to meet specified needs with appropriate
consideration for public health and safety, cultural, societal, and environmental considerations (DK5)

PLO6: The engineer and society: demonstrate knowledge of the societal, health, safety, legal and
cultural issues and the consequent responsibilities relevant to engineering technician practice and
solutions to well-defined engineering problems (DK7)

TOPIC: SHAPE A, SHAPE B, INTERNAL THREAD AND EXTERNAL THREAD.

OBJECTIVES: At the end of the session the students should be able to;
i) Measure and mark, file edge, file surface, file angle, hacksaw, drill hole, punch
the of work piece taps and dies to produce internal and external thread.
ii) Read and interpret engineering drawing
iii) Operate drilling machine post
TOOLS REQUIRED:

i) Post drilling machine.

ii) Equipment mark, to measure and tested namely vernier caliper, vernier height
gauge.
iii) Hand tools namely vice, table, flat file, handsaw, chisel, hammer, center punch,
tap wrench and taps M10 x 1.5 and dies M10 x 1.5, twist drill size 9 mm and
10.5mm

SAFETY PRECAUTION:
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The following recommendation details the standard behavior for all personnel working within in a
workshop;
i) Before any work is carried out in the workshop, permission must be obtained
from the Workshop Supervisor or Lecturer.
ii) Always wear eye protection when using power operated hand or machine tools
such as goggle.
iii) Work areas and equipment are to be thoroughly cleaned after use.
iv) Make sure all equipment are turned off before leaving the workshop.

WORKSHEET Fitting

PTF1- A shape
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PTF2-B shape