College of Electrical and Mechanical Engineering

Department of Mechanical Engineering

Workshop Practices II (MEng4191)

Chapter 1: Manufacturing of Products

ByTolina T.

March, 2020
 TOPICS
 What is Manufacturing?
 Materials for Manufacturing
 Manufacturing Processes
 Selection of Manufacturing Processes
 Projects(e.g. lock, parallel or toolmaker’s
clamp or wheel puller, gear-shaft assembly,
etc.)
What is Manufacturing?
• Process of converting raw materials into products
• It includes:
 Design of The product
 Selection of the raw materials
 The sequence of processes through which the product will
be manufactured
Materials in Manufacturing
• Most engineering materials can be classified into one of three
basic categories:
1.Metals
2.Ceramics
3.Polymers
• Their chemistries are different
• Their mechanical and physical properties are dissimilar
• These differences affect the manufacturing processes that can be
used to produce products from them
Manufacturing Processes
 Manufacturing processes are the steps through which raw
materials are transformed into a finished product.
Manufacturing Processes
Solidification processes

Particulate processing
Shaping processes
Deformation processes

Processing Material removal

operations
Property
enhancing Heat treatment
processes
Cleaning and surface
Manufacturing treatments
Surface processing
processes operations Coating and deposition
processes

Welding

Permanent joining Brazing and soldering

processes
Assembly Adhesive bonding
operations
Threaded fasteners

Mechanical Permanent
fastening fastening methods
 Projects: (e.g. lock, parallel clamp or wheel puller,
gear-shaft assembly, etc.)
College of Electrical and Mechanical Engineering
Department of Mechanical Engineering

Workshop Practices II (MEng4191)

Chapter 2: Gear Cutting

ByTolina T.

April, 2020
• Gears are widely used in various mechanisms and devices to
transmit power and motion positively (without slip) between
parallel, intersecting ( axis) or non-intersecting non parallel
shafts
• Gears of various type, size and material are widely used in
several machines and systems requiring positive and stepped
drive.
• The major applications are:
 Speed gear box, feed gear box and some other kinematic units of
machine tools
 Speed drives in textile, jute and similar machineries
 Gear boxes of automobiles
 Speed and / or feed drives of several metal forming machines
 Machineries for mining, tea processing etc.
 Large and heavy duty gear boxes used in cement industries, sugar
industries, cranes, conveyors etc.
 Precision equipments, clocks and watches
 Industrial robots and toys.
• The dimensional features that are used to express or specify
the gears are;
• For spur gears and worm wheels
⎯ number of teeth, Z
⎯ module, m
⎯ helix angle, if any (θ)
⎯ width (b)

• Some geometrical features also need to be mentioned while

specifying gears, such as:
- Pressure angle

- Addendum and dedendum

College of Electrical and Mechanical Engineering
Department of Mechanical Engineering

Workshop Practices II (MEng4191)

Chapter 3: Measurement and Testing

ByTolina T.

May, 2020
Measurement
• Measurement is the process of determining or
finding the size, quantity or degree of something .

• The principle dimensional measurement is length;

secondary measurement is angle and curvature.
You can describe shape without describing size,
but not the reverse.

• Measurement science is vital for trade

&commerce ,&the basis of modern science&
technology.
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 Means of measurement
The means of measurement could be classified as
follows:
I. Standards (reference masters or setting standards)-
these are used to reproduce one or several definite
values of a given quantity.

II. Fixed gauges-these are used to check the dimensions,

form, and position of product features.

III. Measuring instrument-these are used to determine the

values of the measured quantity
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 Measurement Methods
Classification of methods of measurement:
1. Direct method:- compare the quantity directly with the primary or secondary
standard. It involves no mathematics calculations to arrive the results.
e.g. Measurement of length by a graduated scale.

2. Indirect method;-Several parameters are measured directly &then the value is

determined by mathematical calculation.
e.g. Measurements of density by measuring mass & geometrical dimension.

3. Comparison method: -the comparison of an unknown quantity to a known quantity ,

for example a standard using Dial Indicator.
4. Coincidence method :- the differential method of measurement very small the
difference b/n the given quantity and the reference is determined by the
observation of the coincidence of the scale marks. For example measurement on
vernier scale 24
 Measuring Instruments
 Measuring instruments are measuring devices that transform the
measured quantity into an information, either analog or digital.
 The functions of the measuring instruments are:
1. Indicating function
2. Recording function
3. Controlling function
 The applications of the measuring instruments are:
1. Monitoring of processes and operations
2. Control of process
3. Experimental engineering analysis
According to the accuracy of measurements , Measuring
instruments are classified as follows
1. most accurate instruments eg. light interference instruments
2. Less accurate instruments such as tool room micro scopes,
comparators, optimeters
3. Less accurate instruments e.g. vernier caliper, dial indicators..
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 LINEAR MEASUREMENTS
• Linear metrology is defined as the science of linear
measurement, for the determination of the distance
b/n two points in a straight line. linear measurement
is applicable to all external and internal measurement
such as distance, length and height difference,
diameter, thickness and wall thickness.
e.g. Ruler, Caliper, Vernier Calipers, micrometer

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Rule: A rule is a tool consisting of a straight-edged strip of
metal, wood, or some other material, graduated in some units
of measurement
• Lengths can be measured by using the following
• metre/half-metre rule
• accuracy = 1 mm 0r 0.1 cm or 0.001 m

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• Caliper: Calipers are simple measuring instrument used
to transfer measurement from steel rule to objects and
vice versa. They are made from tools steel or high carbon
steel.

Outside caliper Inside caliper

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 • Telescopic guage: used for measuring inside holes that are too small
for an inside micrometer or when an inside micrometer is not
available.
-

• Small hole gages: used to measure holes, slots, grooves and

recesses which are too small for inside caliper & telescopic gages

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Half Ball Small Hole Gages Full Ball Small Hole Gages
Vernier caliper
• Function
– To measure smaller distances (inside & outside parts)
– Can measure up to .001 inch or .01mm.
– To measure depth of the hole
• Features
– Larger, lower jaws are designed to measure outer
points e.g. diameter of a rod.
– Top jaws are designed to measure inside points e.g.
size of a hole.
– A rod extends from the rear of the caliper and can be
used to measure the depth.
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 Parts of the Vernier caliper
Main Scale
• Main scale is graduated in
cm and mm.
Vernier Scale
• It slides on the main scale.
• On Vernier scale 0.9cm is
divided into 10 equal parts.
Jaws
• Two inside jaws (Upper)
• Two outside jaws (Lower)
• Reading of the instrument = Main Scale divisions + (coinciding Vernier Scale
division x L.C)

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Digital Calipers
• Latest advancement.
• Measurement converted to digital readout.
• Similar to conventional calipers.
• Scale can be calibrated in both inches and centimeters.

Work shop practiceII 32

Vernier Height Gauge
• A Vernier height gauge is used for measuring
height of an object or for marking lines onto an
object of given distance from a datum base.

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Micrometer
• The distance moved by the spindle during one rotation of the
thimble is 0.5mm.
• List count
• Movement of one division the thimble = 0.5 x 1/50= 0.01 is the list
count
Ranges of outside micrometer
• Outside micrometers are available in the ranges of o to 25mm, 25
to 50mm,50 to 75mm,75 to 100mm,100 to 125mm and 125 to
150mm.

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Work shop practiceII 36
 Depth Micrometer
• A depth micrometer is similar to a
conventional micrometer except that
it is designed to measure the depth
from a flat surface.

FIGURE A depth micrometer being used

to measure the height of the rotor of an oil
pump from the surface of the housing.

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Work shop practiceII 38
Dial Test Indicator (DTI)
• Dial indicators are instruments used to accurately measure a small
distance.
• They may also be known as a Dial gauge, Dial Test Indicator (DTI), or
as a "clock".
• They are named so because the measurement results are displayed in
a magnified way by means of a dial.
• Dial indicators may be used to check the variation in tolerance during
the inspection process of a machined part, measure the deflection of a
beam or ring under laboratory conditions, as well as many other
situations where a small measurement needs to be registered or
indicated.
• The definition of small depends on the observer however a range
between 1 mm and 50 mm may be thought of as typical with a travel
of 10 mm being perhaps the most common.

Work shop practiceII 39

 Feeler Gauge
• A feeler gauge (also known as a thickness gauge) is an accurately
manufactured strip of metal that is used to determine the gap or
clearance between two components.
• A feeler gauge can be used to check the following:
– Piston ring gap
– Piston ring side clearance
– Connecting rod side clearance

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 Straight Edge
• A straightedge is a precision
ground metal measuring gauge
that is used to check the flatness
of engine components when used
with a feeler gauge.
• A straightedge is used to check
the flatness of the following:
– Cylinder heads
– Cylinder block deck
– Straightness of the main
bearing bores (saddles)

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Work shop practiceII 42
 Angular Measuring Tools
The most common tools
Simple Protractor
Multi-Use Gage
Angle gauge blocks
Combination Set
Universal bevel
protractor
Sine bar
Sine centre

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College of Electrical and Mechanical Engineering
Department of Mechanical Engineering

Workshop Practices II (MEng4191)

Chapter 4: Assembly of Units

ByTolina T.

June, 2020
Assembly of Units
• Creating a finished product requires more than just metal
fabrication – it also needs to determine its finishes, choose
packaging and put them together.
• Almost all products are assemblies of a large number of
components.
• Some of the components or subassemblies can move with
respect to each other, others are physically fixed together, with
no relative motion possible.
• The process and methods used for joining depend on the type of
joint, the required strength, the materials of the components
being joint, the geometry of the components, and cost issues.
Need of Assembly
a.To restrict some degrees of freedom of motion for
components.
b.A complex shaped component may be
impossible/expensive to manufacture, but it may be
possible/cheaper to make it in several parts and then
join them.
c. Some products are better made as assemblies, since
they can be disassembled for maintenance.
d.Transporting a disassembled product is sometimes
easier/feasible compared to transporting the entire
product.
Types of Assembly Methods