Ratified Machineshop 2018

ZIMBABWE
MINISTRY OF HIGHER AND TERTIARY EDUCATION, SCIENCE AND

TECHNOLOGY DEVELOPMENT
HIGHER EDUCATION EXAMINATIONS COUNCIL
2018
REGULATIONS AND SYLLABUS
FOR
NATIONAL CERTIFICATE
IN
MACHINESHOP ENGINEERING
COURSE CODE: 340/18/CR/0
IMPLEMENTATION DATE: January 2019

NATIONAL CERTIFICATE IN MACHINESHOP ENGINEERING: 340/18/CR/0
1.0 PREAMBLE
The course is designed to develop an artisan with knowledge, skills and attitudes to competently
practice fitting including machining in the Mechanical industry. The total duration of the
course is 1620 notional hours spread over a period of two (2) years and one (1) year On the Job
Education and Training (OJET). The minimum entry requirements into this course are English
Language, a relevant Science subject and Mathematics passed at Ordinary Level with grade C or
better and any other two subjects or National Foundation Certificate (NFC) subjects or equivalent.
The course is offered on a full time, part time, Block release or Open Distance e-Learning (ODeL)
basis. The assessment is through continuous assessment and written examination and On the Job
Education and Training (OJET). The course will consider gender mainstreaming, sustainable
development, physical challenges, health dispositions and the intersections between race, class and
culture. It shall embrace innovative heritage-based education and training philosophy to solve
national problems and to produce goods and services for industrialization and modernization.
2.0 CONSULATATIONS YEAR

1. Bantar PL 2018
2. National Foods 2018
3. Delta Beverages 2018
4. Zimphos 2018
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PART I COURSE REGULATIONS
1.0 TITLE AND LEVEL OF AWARD

National Certificate in Machineshop Engineering.
2.0 AIM
To produce an artisan with knowledge, competences and attitudes required to work in a
Mechanical Engineering Workshop.
3.0 OBJECTIVES
By the end of the course, students should be able to:
3.1 apply the theoretical and technological principles of Machineshop engineering.
3.2 apply mathematical concepts to solve engineering problems.
3.3 apply engineering science principles to solve engineering problems.
3.4 generate engineering drawings using a drawing board.
3.5 demonstrate the practical principles of Machineshop engineering.
3.6 generate engineering drawings using CAD software.
3.7 demonstrate patriotism to national issues.
3.8 operate a sustainable business.
3.9 apply communication skills in the engineering field.
3.10 demonstrate the Machineshop Engineering practices to real world of work.
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4.0 COURSE STRUCTURE

SUBJECT CODE DURATION IN
HOURS
1 Workshop Technology 340/18/S01 280
2 Engineering Mathematics 340/18/S02 150
3 Engineering Science 340/18/S03 150
4 Engineering Drawing 340/18/S04 150
5 Workshop Practice 340/18/S05 500
6 Computer Applications in Mechanical 359/18/S05 150
Engineering
7 National Studies 401/18/S01 80
8 Entrepreneurship Skills Development 402/18/S01 80
9 Basic Communication 310/18/S02 80
10 On The Job Training 340/18/S06 1 year
TOTAL 1620+1 year
5.0 DURATION
The course duration is 1620 notional hours spread over two (2) years and one (1) year On
-the Job Education and Training (OJET).
6.0 ENTRY REQUIREMENTS

English Language, a relevant Science subject and Mathematics passed at Ordinary Level
with grade C or better and any other two Ordinary Level subjects or relevant National
Foundation Certificate.
7.0 MODE OF STUDY

Full time : 1620 notional hours
Part time : 1620 notional hours
Block Release: 1620 notional hours
ODeL : 1620notional hours
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8.0 ASSESSMENT
8.1 ASSESSMENT SCHEME
MODE OF STUDY WEIGHTING

SUBJECT TITLE AND WRITTEN CONTINUOUS
CODE EXAMINATION ASSESSMENT
40% 60%
A minimum of:
• 3 field work-based
Workshop Technology 1 x 3 hour theory paper Assignments 30%
100%
340/18/S01 1 x 3 hour theory paper (Weighted 10% each)
Skills Competency Testing
30%
A minimum of:
Engineering Mathematics Assignments 30%
3 hour paper 100%
340/18/S02 (Weighted 10% each)
30%
A minimum of:
Engineering Science Assignments 30%
3 hour paper 100%
340/18/S03 (Weighted 10% each)
• Skills Competency
Testing 30%
A minimum of:
Assignments 30%
Engineering Drawing
4 hour paper (Weighted 10% each) 100%
340/18/S04
30%
A minimum of:
Workshop Practice 32 hours practical Assignments 30%
340/18/S05 machining project (Weighted 10% each) 100%
30%
A minimum of:
Basic Communication • 3 field work-based
3 hour paper 100%
310/18/S02 Assignments 30%
(Weighted 10% each)
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30%
1x 3 hour theory paper A minimum of:
Computer Applications in 1x 3 hour practical • 3 field work-based
Mechanical Engineering paper Assignments 30%
100%
(Weighted 10% each)
359/18/S05 Skills Competency Testing
30%
A minimum of:
Assignments 30%
National Studies 3 hour paper
(Weighted 10% each) 100%
401/18/S01
30%
A minimum of:
Entrepreneurship Skills
Assignments 30%
Development 3 hour paper
(Weighted 10% each) 100%
402/18/S01
30%
On The Job Education

and Training As per log book 100%
340/18/S06
9.0 GRADING
0% to 49% - Fail
50% to 59% - Pass
60% to 79% - Credit
80% and above - Distinction
10.0 CONDITIONS OF AWARD

10.1 A candidate should attend at least 85% of learning sessions to qualify for
examinations.
10.2 The final mark should be obtained through aggregation provided the candidate
scores at least 50% in each of continuous assessment and examinations.
10.3 The pass mark shall be 50%.
10.4 Candidates should pass all subjects.
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11.0 RE-WRITE
11.1 Re-write(s) should conform to current course structure.
11.2 Candidates should pass at least two thirds of the course to qualify for a
referral.
11.3 Any candidate who fails to pass at least two thirds of the course should repeat the
whole course, including the subjects they would have passed.
11.4 There is no time limit for which to re-write a failed examination.
11.5 There is no aggregation for re-writes.
11.6 All re-writes should pass on performance in the examination.
11.7 If a candidate fails continuous assessment he/she repeats the subject
12.0 EXEMPTIONS
12.1 Exemptions are only granted in subjects already attained from a completed
accredited qualification provided an exemption certificate specifying subjects of
exemption is produced.
12.2 Exemption certificate should be applied for at enrolment and produced before
registration for examinations.
13.0 IRREGULAR PRACTICES

13.1 Cheating in examinations will result in disqualification from the whole course and
all other HEXCO courses. The candidate will be suspended for two years.
13.2 Plagiarisms in any of the assessments will result in automatic disqualification in the
course and any other HEXCO courses and the penalty as in 13.1 will apply.
14.0 RESOURCES
14.1 Lecturer’s Qualifications

A minimum of National Diploma in Mechanical Engineering or equivalent.
14.2 Tools and Equipment
LIST OF SUGGESTED TOOLS
Engineer’s Square
Precision Steel Rules
Adjustable Engineer’s Try – Square
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Centre Square
Bevel Protractor
Inside Callipers
Outside Callipers
Jenny Legs with Adjustable Scribing Point
Scribers: Double – Ended
Depth gauge: Metric
Wire Gauge Imperial
Drill gauge: Metric
Combination Set
Trammel Heads (Pairs)
Engineer’s Straight Edge
Engineer’s Level
External Micrometre set 0 – 75 mm
Vernier Callipers
Internal Micrometre set with Extensions: 25 – 200mm
Micrometre Depth Gauge
Screw Thread Gauge 1 75 – 3mm pitch
Surface Plate
Surface Gauge
Angle Plate
Vee Block Sets
Centre Punch
Parallel Pin Punch Set: 1. 6 – 95 mm diameter
Automatic Centre Punch
Letter Making Punch Set: 3mm Character Height
Number Marking Punch Set: 3mm Character Height
Hand Engraver Set: Variable Speed and Stroke
Universal Test Indicator
Dial Test Indicator with Magnetic Base
Small Hole Gauge Set: 3.2 – 12.7mm
Telescopic Gauge Set: 12.7 – 152.4mm
General Purpose Feeler Gauge Set: 0.05mm – 0.8mm
Screw Pitch Gauge Set: 0.75 – 13.0 mm
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Radius Gauge Set: 0.75mm – 13.0 mm

Engineer’s scrapper set
Allen Key Set: 6mm – 20 mm
Twist Drill Set: 6mm – 20 mm
Center Drill set: 6-10mm
Dies stock set: M3 – M24
Thread Insert Kit Metric: M6 – M14
Thread Restorer Set
Adjustable reamer set: 35mm – 50mm
Turning Tool Holder Set: 6mm – 10mm
Boring Tool Holder 10mm
Parting off tool Holder
Parting – off Blade HSS with 10% Cobalt
Toolbit square Set: 6 – 10mm
Concut drill Set: 3:30mm diameter
Drill grinding gauge
Combination spanner Set: Metric
Combination spanner set: Imperial
Pliers Set
Ball pein hammer
Plastic hammer
Rubber Mallet
Brass Punch
Cold Chisels
Engineer’s File Set
Torques Wrench (Direct Reading)
Torques wrench: 50 – 25 Nm
Torques wrench: 150 – 550Nm
Torque Multiplier: 2 000 Nm
Ring spanner set
Wire Brush
File Card Brush
Stud Remover Set
Screw Extractor Set
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Bolt Cutter
Circlip Pliers Set: Internal and External
Allen Key, Set XZN – M5 to M21
Precision Honing Tool
Chuck Tap Wrench
Hexagonal Screw Driver bit set
Impact screw driver Set
Bush Driver Set
Hydraulic Nut – splinter
Two – Arm Puller
Three – Arm puller
Bearing Puller set
Nipple Forming Tool
Bench Grinder: Double – Ended
Bench Vice
Drill Bit Sharpener
Pneumatic Wrench Set
Twist and Bending testing machine
MACHINE & CUTTING TOOLS AND GENERAL EQUIPMENT

Pedestal Grinder 200mm height
Centre Lathe: 1 000mm straight bed
Centre Lathe: Accessories including 4 – jaw chuck
Centre Lathe: 1 500mm straight Bed
Centre Lathe; 3000mm
Turret Milling Machine
Universal Milling Machine
CNC lathe Machine
CNC Milling Machine
Surface grinder
Cylinder Grinders: 75mm diameter
Tool and Cutter Grinder
Universal 3Way Angle Vice
Swivel Base Machine Vice
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Fixed Machine Vice

Milling Cutters (sets)
Drilling Machine: Floor Standing
Power Hacksaw: Two speed + 100 stroke/min
Cutting off Machine
Guillotine: Cutting Length 1 030 mm
Box and Pan Folder: Max Folding Length 2031mm
Universal Tube Bending Machine 4.
Flat Bending Machine
Fly Press
Metal Arc Welding Equipment (60 -130A)
T.I.G Welding Equipment
M.I.G Welding Equipment
Pedal Operated Spot – Welding Machine
Oxy – Acetylene Welding/Cutting Equipment
Crucible furnace
Boiler
Arbor Press + 30KN
Hydraulic Press + 50kN
Mobile Hoist
14.3 SUGGESTED REFERENCE BOOKS

1. Giesecke, F.E, Mitchell, A, and Spencer, H.C. and Hill, I. L. (2017) Technical Drawing
with Engineering Graphic.5th edition. Newness. London.
2. Morling, K. (2003) Geometric and Engineering Drawing. 2nd Edition, Butterworth-
Heinermann.
3. Rhodes, R.S. and Cook, L.B. (2002) Basic Engineering Drawing. Pitman Publishers.
4. Narayana, K.L, Kannaih, P. and Venkata Reddy K. (2006) Machine Drawing. 3rd Edition.
New Age International.
5. Collin, H. Simmons and Dennis E. Maguire (2004) Manual of Engineering Drawing. 2nd
Edition. Elsevier Newness.
6. Madsen, D. A. and Madsen, D. P. (2012) Engineering Drawing and Design. Newness.
London.
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7. Basant, A. and Agrawal, C, M. (2014) Engineering Drawing. McGrawl Hill Education

Pvt (Ltd).
8. Bird, J.O. (2003) Engineering Mathematics. 4th edition. Newness. London.
9. Page, M. G. (2008) Mathematics for Mechanical Engineering Technicians. London.
10. Stroud, K, A. (2013) Engineering Mathematics. 7th Edition. Industrial Press. New York.
11. Kalpakjian, S. and Schmid,S.R. (2015) Manufacturing Engineering and Technology. 6th
Edition.
12. Krar, S.F. and Oswald, J.W. (2000) Turning Technology. Engine and Turret lathes.
Delmar Publishers.
13. Jain, R. K. (1995) Production Technology. Kharmar Publishers. India.
14. Kazanas, H.C, Glenn, E. and Gregor,T. (1991) Manufacturing processes. McGrawl Hill
Education Pvt (Ltd).
15. Krar, S.F. and Oswald, J.W. (1997). Technology of machine tools. 5th Edition. McGrawl
Hill Education Pvt (Ltd).
16. Wynter, E.J. (2012) Metalcraft. Longman. London.
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SUBJECT: WORKSHOP TECHNOLOGY

CODE: 340/18/S01
DURATION: 280 HOURS
1.0 AIM
The aim of the subject is to provide the student with knowledge, competencies and
attitudes required in Machineshop Engineering environment.
2.0 OBJECTIVES
By the end of covering the subject content, the student should be able to:
2.1 select hand, marking and measuring tools for a given task.
2.2 use Machineshop Engineering machines and equipment.
2.3 apply engineering standards of accuracy and principles to operations carried out in
a Machineshop Engineering environment.
2.4 explain heat treatment procedures carried out in a Machineshop.
2.5 relate maintenance procedures in a Machineshop.
2.6 implement safety procedures stipulated in Machineshop Engineering
environment.
3.0 TOPICS
SAFETY PRECAUTIONS
HAND AND BENCH TOOLS
POWERED HAND TOOLS
MEASURING TOOLS
MARKING OUT TOOLS
DRILLING AND OPERATIONS
ENGINEERING MATERIALS
GAUGING
HEAT TREATMENT
GRINDING
POWERSAWS
LATHE MACHINE
SLOTTING AND BROACHING
STANDARDS OF ACCURACY
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JIGS AND FIXTURES

MILLING
OPERATIONAL PLANNING
FABRICATION
LUBRICATION OILS & CUTTING FLUIDS
HYDRAULICS
PNEUMATICS
FITTING
BOILERS
4.0 CONTENT
4.1 SAFETY PRECAUTIONS
4.1.1 Identify and implement all basic safety precautions relevant to fitting and machine
shop.
- Personal grooming
- Housekeeping
- Securing of work pieces
- Metal removal operations
- Fitting equipment and lifting procedures
4.1.2 FACTORIES ACT REGULATIONS
- use of current Occupational Health and Safety literature.
4.1.3 FIRST AID
Demonstrate and implement appropriate remedial action in emergencies involving the
following: -
-Electric shock
-Fire burns
-Oil burns
-Toxic gas
-Chemical poisoning
4.1.4 FIRE FIGHTING EQUIPMENT AND PROCEDURES
Select and correctly operate fire-fighting equipment for effective use on the
following classes of fire.
4.1.4.1 Class A
- wood, cloth, paper
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4.1.4.2 Class B
- flammable liquids – petrol, oil, grease, fats
4.1.4.3 Class C
4.1.4.4 Class D
4.1.5 WORKSHOP SAFETY
4.1.5.1 Identify and operate all emergency switches in the workshop.
4.1.5.2 Demonstrate proper sanitation in all workshop activities.
4.1.5.3 Demonstrate the proper use and/storage of the following: -
- chemicals
- oil
- toxic gases
- electricity
flammable gases
4.1.5.4 Identify and implement the procedures involved in the use of machine safety
guards /screens, warning notices and signals.
4.1.5.5 Demonstrate the correct procedures involved in the lifting and moving of heavy
materials and workshop equipment.
4.1.5.6 Identify and implement all safety precautions relating to machines and machine
tools.
4.2 HAND TOOLS AND BENCH WORK

4.2.1 Demonstrate an awareness of the safety precautions which should be observed to
ensure safe working conditions when performing bench work.
4.2.2 Identify the range of hand tools and powered hand tools available and the reasons
for selection for a specific use.
4.2.3 State the uses of hand operated machines in basic mechanical engineering work.
4.2.4 Identify common hand tools
4.2.5 State the care necessary to maintain hand tools in good condition
4.2.6 Select and use the correct hand tool to perform various basic tasks efficiently and
safely.
4.2.7 Select appropriate equipment for holding the work while performing basic tasks.
4.2.8 Select appropriate powered hand tools to perform basic tasks.
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4.2.9 List the relative merits and limitations of both powered and non-powered hand
tools in terms of speed of production, cost, accuracy and fatigue caused to the
operator.
4.2.10 Select appropriate powered and non- powered hand tools to produce basic shapes
4.2.11 Identify common hand tools and perform the necessary bench work operations
efficiently and safely to include types of:
- vices e.g. bench, pipe, pin, hand etc their care and uses.
- files e.g. hand flat round etc. Their care and uses.
- hammers e.g. ball pein, straight pein, etc their care and uses.
- chisels e.g. cross cut, round nose, diamond point flat – their care and uses.
- scrapers e.g. flat, curved, disc (Hollow, scrappers) etc – their care and uses.
- punches e.g. centre, dot, drift, pin etc – their care and uses.
- saws e.g. centre, dot, drift, pin etc - their care and uses.
- Reamers e.g. standard, collapsible etc - their care and uses.
- tape wrenches, tap, stocks and dies – their care and uses.
- broaches e.g. pull or push, solid or inserted – their care and uses.
- laps e.g. internal and external laps - their care and uses.
- assembling tools e.g. spanners, pliers, screw drivers, Allen keys- care and
uses.
4.3 POWERED HAND TOOLS

4.3.1 State and use the following electrical hand tools
- types of hand grinders
- types of hammers hand drills (plus impact combination)
- care and uses
4.3.2 Pneumatics
- types of hand grinders
- types of hand drills
- types of wrenches (Pneumatic)
- types of hammers (Pneumatics)
- care and uses.
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4.4 MEASURING TOOLS

4.4.1 Explain the use and care of the following measuring tools:
- rules and tapes
- verniers (callipers, height gauge, Depth Gauges)
- micrometers (outside, inside, depth)
- combination set
- bevel protractor
- dial test indicator
- sine bar
- balls and rollers
- slip gauges
- gear tooth vernier
- thread micrometer
4.4.2 Describe the degree of accuracy of the tools in 4.4.1.
4.4.3 Sketch measurement scales and show correct readings for the measuring tools
discussed in 4.4.1.
4.4.4 Describe the importance, proper care, handling and storage of measuring tools.
4.5 MARKING OUT

4.5.1 Explain the need for and importance of marking out.
4.5.2State and describe the use of the following marking out tools: -
(a) rules and tapes
(b) engineer’s squares
(c) dividers and trammels
(d) callipers – (outside, inside)
(e) scribers
(f) vernier height gauges
(g) centre and prick punches
(h) parallels, angle plates and ‘V’ blocks.
(i) Surface block and surface gauge
(j) surface table and surface plate
(k) marking out dyes
4.5.3 Describe marking out preparations.
4.5.4 Explain the importance and use of datum surfaces with reference to marking out.
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4.5.5 Describe the correct procedures in the care and maintenance of marking out tools.
4.6 GAUGING
4.6.1 Explain the need and importance of gauging
4.6.2 Describe the principle of gauging with reference to limits and fits.
4.6.3 List gauge types used and explain their applications.
4.6.4 Explain the procedures required to maintain gauges in safe and operational
conditions.
4.7 DRILLING MACHINES AND OPERATIONS

4.7.1 Describe the following different types of drilling machines:
bench, pillar, column and radial arm drilling machines.
4.7.2 Describe the following drilling operations:
- drilling
- reaming
- boring
- counterboring
- countersinking
- spot facing
- trepanning
- tapping
4.7.3 State and describe the following work holding and supporting devices commonly
used on a drilling machine.
- hand vice, machine vice and universal machine vice
- angle plate
- parallels
- ‘V’ blocks and clamps
- budge clamps, ‘T’ bolts, step blocks.
4.7.4 Calculate spindle speeds and feeds relative to the type of work material and drill
diameter.
4.8 ENGINEERING MATERIALS

4.8.1 Describe the main properties of non-metallic, ferrous and non- ferrous, pure metals
and alloys.
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4.8.2 List the following engineering materials and categorise these materials in their
respective classes.
4.8.2.1 Non – Metallic
(a) plastics
-Distinguish between thermosetting and thermoplastic
(b) wood
(c) rubber
(d) ceramics
4.8.2.2 Metallic
- ferrous
(a) cast iron
- Plain carbon steels
-Wrought iron
-Dead mild steel
-Mild steel
-Medium steel
-High carbon
-High speed steel
4.8.2.3 Non-Ferrous
-Aluminium
-Copper
-Zinc
- Lead
-Tin
4.8.2.4 Alloys
-brass
-bronze
-babitt
4.8.3 Alloying elements and their effects on steel (nickel, chromium, cobalt, carbon,
vanadium, sulphur, lead)
4.8.4 State and describe the following mechanical properties of engineering materials.
- Hardness
- Ductility
- Malleability
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- Toughness
- Brittles
- Elasticity
- Plasticity
4.9 HEAT TREATMENT

4.9.1 Explain the listed heat treatment processes.
- hardening
- annealing
- tempering
- normalising
- case hardening (including carburising methods)
(a) carburising
(b) nitriding
(c) cyaniding
- induction and flame hardening
4.10 GRINDING
4.10.1 List and describe grinding operations, considerations being given to safety,
wheel mounting and work holding devices.
4.10.2 Name the major parts of each grinding machine and describe their
functions:
(a) off – hand grinder
(b) surface grinder
(c) cylindrical grinder
(d) centreless grinder
4.10.3 Identify the work holding devices in surface and cylindrical grinders.
4.10.4 List the types of abrasives and their applications under the following
classes:
- natural (diamond, quartz)
- artificial (silicon carbide, aluminium oxide)
4.10.5 List the types of bonds and state their applications.
4.10.6 Describe the mounting and balancing of grinding wheels
4.10.7 Identify grinding faults and their remedies when grinding.
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4.10.8 Explain importance of wheel truing and dressing.

4.10.9 State factors considered in grinding wheel selection.
4.10.10 Describe the following methods of grinding
- surface grinding
- cylindrical grinding
- crush grinding
- thread grinding
- form grinding
- centreless grinding
4.10.11 State and explain the meanings of grinding wheel markings:
- abrasive
- grit size
- grade
- structure
- bond
4.10.12 List and describe the types of coolants, their functions and applications
when grinding.
4.11 POWER SAWS AND BAND SAWS

4.11.1 Determine the requirements of work involving the use of power saws and band
saws.
4.11.2 Identify and implement safety precautions related to the power saws and
band saws.
4.11.3 List and identify different parts of a power saw and a band saw.
4.11.4 State and explain the functions of the different parts in 4.11.1 above.
4.11.5 Describe the correct procedure in the following operations.
(i) loading of work pieces
(ii) unloading of work pieces
(iii) work holding devices
(iv) mounting of blades – to include direction of blade teeth
(v) proper tensioning of the blade
(vi)removal of blades
4.11.6 Explain all the cutting operations performed on power saws
and the band saws.
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4.11.7 Select blades for each specified operation

4.11.8 Select and set appropriate speeds and feeds for each operation specified in
4.11.6
4.11.9 Specify and apply the correct type of coolant during the performance of
each type of operation specified in 4.11.6
4.12 LATHE
4.12.1 List the main parts of a centre lathe and their functions:
- headstock
- bed
- quick change gearbox
- tailstock
- carriage (cross slide, compound slide, tool post, saddle and apron)
4.12.2 State the criteria used to designate the size and capacity of a centre lathe.
4.12.3 State and describe the uses of the following lathe accessories:
- chucks (3 jaw, 4 jaw and collet)
- faceplates
- centres
- driving dogs
- Mandrels
- steadies
- drive plate
4.12.4 Describe lathe tool geometry.
- rake angles
- clearance angles
- approach angles
4.12.5 State and explain the advantages of cutting tool materials:
- carbon steel
- high speed steel
- tipped tools (tungsten carbides)
- insert tool
- ceramics
- diamond tools
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4.12.6 Calculate the appropriate speeds and feeds relative to size and material of
the work pieces and the tool material.
4.12.7 Describe correct tool mounting and setting procedure on a centre lathe.
4.12.8 State the benefits in the use of cutting fluids on centre lathe operations.
4.12.9 Describe the following centre lathe operations:
- facing
- turning
- boring
- knurling
- form turning
- taper turning
- parting off
- parallel turning
- thread cutting
4.12.10 List and identify the operations of the listed production lathes.
- turret lathe
- capstan lathe
- automatic lathe
- Computer Numerically Controlled lathe (CNC)
- copy lathe
4.12.11 Describe the different methods for eccentric turning for two or more
throws.
4.12.12 Describe the methods of cutting the following thread forms in
both left and right hand and both single and multi – start thread
- Vee threads (ISO, UNC, UNF, Whitworth)
- Square
- Acme
- Buttress
4.12.13 State and describe the application of the thread forms listed in
4.12.12.
4.12.14 Calculate change gears for thread cutting (both imperial and
metric)
4.12.15 Describe the purpose and operations of the thread chasing dial.
4.12.16 Explain with the aid of sketches, the following thread terminology.
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- pitch
- pitch circle diameter
- major diameter
- minor diameter
- thread angle
- helix angle
- lead
- root
- crest
- flank
4.12.17 State the relationship between pitch, lead and number of starts.
4.12.18 Describe limit gauges, thread angle gauge, thread file, thread pitch gauge and
thread chasers (internal and external) as methods of measuring and checking
threads.
4.13 SLOTTING AND BROACHING

4.13.1 Describe the setting up of slotting and broaching operations.
4.13.2 Identify the parts of the slotting machine and their operation.
4.13.3 Explain the table and tool movement on the slotting machine.
4.13.4 Explain the set – up and machining operation on the slotting machine.
4.13.5 Describe the broaching process and its applications.
4.13.6 Identify the types of broaching machines and describe their operation.
4.14 STANDARD OF ACCURACY

4.14.1 Identify and describe the system of limits and fits to BS 4500A
- basic hole system
- basic shaft system
4.14.2 State and describe the types of fits and their applications.
- clearance fit
- interference fit
- transition fit
4.14.3 List and explain the reasons for adopting a system of limits and fits:
- interchangeability
- uniform quality
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- economic manufacture
4.14.4 Define the terminology related to limits and fits:
- nominal size
- actual size
- upper limit
- lower limit
- unilateral tolerance
- bilateral tolerance
- allowance
4.14.5 Relate the system of limits and fits to the use of limit gauges in the workshop:
- plain plug and ring gauge
- thread plug and ring gauge
- snap or gap gauge
- taper plug and ring
4.15 JIGS AND FIXTURES

4.15.1 Describe the various types of jigs and fixtures.
4.15.2 Explain uses of jigs and fixtures.
4.15.3 Differentiate between jigs and fixtures.
4.15.4 State advantages of using jigs and fixtures
4.15.5 Describe the operating principle of jigs and fixtures
4.15.6 Describe the process of designing a simple jig or fixture.
4.15.7 Explain correct uses of jigs and fixtures.
4.16 MILLING
4.16.1 State safety precautions related to milling machines.
4.16.2 Identify different types of milling machines (horizontal, vertical, universal)
4.16.3 State how the sizes of milling machines are designated.
4.16.4 Identify main parts of milling machines and their functions.
4.16.5 Describe and explain the concept of speeds and feeds when applied to
milling.
(a) Define speed and feed
(b) Determine the correct cutting speeds and feeds for various materials and
operations.
25
(c) Calculate and correctly set feed and speed controls basing on:
- type of material
- type of cutter
- rigidity of work piece
- condition of machine
(d) Calculate time taken and material removal rate when using milling
machines.
4.16.6 Explain the effects of depth of cut on:
- cutter
- machine
- material
- rigidity of work piece
4.16.7 Select the proper work holding devices e.g. machine vices; tee-bolts and clamps.
4.16.8 Select and mount cutter and cutter holding devices e.g. collets
4.16.9 Describe cutting tools and explain their geometry.
(a) Give the advantages and limitations of different cutting tool materials.
(b) List and explain the principles of multi – point cutting tools when milling.
(c) Perform calculations involving material removal rate.
(d) Compare the advantages and limitation of solid tool constructions, tipped
tools and inserts.
(i) Sketch and describe the following types of solid milling cutters and
their applications
- End mill
- Slot drill
- Face mill
- Side cutter and fall cutter (barrel) mill
- Angle cutter
- Tee slot cutter
- Dovetail cutter
4.16.10 Define gang and straddle milling and state when to apply each of them.
4.16.11 Define and explain up- cut and down-cut milling stating merits and
limitations of each process.
4.16.12 Describe all the basic milling processes such as:
(a) key way cutting
26
(b) gear cutting

(c) angular surface
(d) flat surface
(e) form milling
4.16.13 Describe and perform calculations involving the following methods of
indexing
- direct
- simple
- angular
- differential indexing
4.17 OPERATIONAL PLANNING

4.17.1 Describe and explain the basic format of an operational plan and understand the
need for operational planning.
4.17.2 Explain the importance of a well-prepared operation plan.
4.17.3 List the information required on an operation plan to include:
- Sequence
- Operational description
- Tools and equipment required.
4.17.4 Prepare an operational plan for a given task.
4.18 FABRICATION
Describe and explain the following:
- arc welding
- gas welding
- brazing
- soldering
- sheet metal work joints
- riveting
4.19 LUBRICATION AND CUTTING FLUIDS

4.19.1 List and describe the types and uses of lubrication oils and cutting fluids.
4.19.2 State the different types of lubricants and cutting fluids to include:
(a) Lubricants
27
- oil
- grease
(b) Cutting Fluids
- chemicals
- mineral water
- fat oil
- cutting paste
- Compounds
- Soluble oil
- pressure additives
- gases
4.19.3 State the engineering applications of the lubricants and cutting fluids in 4.19.2
above.
4.19.3 State reasons for selecting oil or grease as lubricants.
4.19.4 Explain the characteristics of lubricants and cutting fluids.
4.19.5 Describe the methods of application of lubricants and cutting fluids.
4.20 HYDRAULICS
4.20.1 Define the following terms as they relate to hydraulic systems:
- hydrostatic
- hydrodynamics
4.20.2 State the components of a hydraulic circuit to include:
- reservoir
- filters and strainers
- actuators (linear, rotary and semi rotary)
- valves – directional and pressure
- pumps – (vane, gear, screw and piston types)
- Pipes, hoses and joints
4.20.3 Illustrate the symbols used in hydraulic circuits.
4.20.4 Give examples of the use of components in 4.20.2 in hydraulics.
4.20.5 State and describe the characteristics/properties of hydraulic fluids.
4.20.6 List hydraulic operated equipment found in an Engineering workshop.
4.20.7 State the functions of a hydraulic fluid.
- power transmission
28
- lubrication
- dissipation of heat
- protection against corrosion
- internal sealing
4.20.8 Define the following terminology related to hydraulics
- obliteration
- silt sensitivity
- stick – slip
- cavitation
- viscosity
- viscosity index
- setting point
- “oil – in – water” emulsion
- aqueous solutions
- “water – in – oil” emulsion
4.21 PNEUMATICS
4.21.1 State and describe the properties of compressed air.
4.21.2 State the advantages and limitations of hydraulic and pneumatic systems.
4.21.3 Illustrate the symbols used on pneumatic diagrams.
4.21.4 List some relevant examples of pneumatic operated equipment often found in the
workshop to include hammers, presses, saws, drills and guns.
4.21.5 Draw symbol pneumatic circuits using standard symbols and explain how they
work.
4.22 FITTING
4.22.1 Describe and explain various fitting processes.
4.22.2 Describe the procedure of caring out installation, maintenance and overhaul of
machinery and equipment.
4.22.3 Explain the procedures involved in the installation, maintenance and overhaul of
machines, machinery and equipment.
4.22.4 Describe the use of the following fasteners and locators:
(a) keys
- woodruff
29
- flat
- gib head
- feather
(b) fasteners
- bolts
- nuts
- studs
- screws
- washers
(c) locking and retaining devices
- locking plates
- locknuts
- spring washers
- peening
- fibre insert bolts and nuts
- circlips
- washers
4.22.5 State applications of the following types of extractors
(a) pullers
(b) stud extractors
(c) tap extractors
4.22.6 Explain the usage of the following types of presses and jacks:
- arbour press
- fly press
- hydraulic press and jack
- screw jacks.
4.22.7 State types of bearings, their materials of manufacture and applications:
(a) Frictional Bearings
- flat or regular – solid or split angle.
- linear: materials – Babbitt, brass, bronze, aluminium, non –
metallic.
(b) Anti – frictional Bearings
- ball (thrust and radial)
- roller (thrust and radial)
30
- spherical
4.22.8 State and explain the use of the following types of couplings:
(a) Rigid Couplings
- flanged
- compression
- clamp
(b) Flexible Couplings
- slider
- roller chain
- Falk chain
- gear
- rubber
4.22.9 Describe the coupling alignment methods:
(a) Simple
- straightedge
- taper gauge
- feeler gauge
- callipers inside/outside
(b) Precision
-dial test indicator
-inside micrometer
-paper and pencil
-suitable stands
4.22.10 State the application of various seals and gaskets including:
(a) Gaskets and gasket materials
(b) Seals
- piston
- lip seals
- O – rings
- V – rings
- Packing – “V” and cup packing
4.22.11 State the application of the following belt and pulley arrangements:
(a) Drive Belts
- “V” – belts
31
- Flat belts
- Toothed belts
(b) Pulleys
- V – pulley
- crowned pulleys
- idler pulleys
- flanged pulleys
4.22.12 State the types of pumps, valves and gear boxes, their application.
(a) Pumps
- Centrifugal
- Mono
- Gear
- Screw
- Piston/reciprocating
- Vane
- Diaphragm
(b) Valves
- gate
- ball
- needle/throttle
- rotary
- butterfly
(c) Gear Boxes
- Worm and worm wheel (reduction gear boxes)
- Quick change gear boxes.
4.23 BOILERS
4.23.1 Identify types of boilers.
4.23.2 Describe how the stated types of boilers in 4.23.1 operate.
4.23.3 Describe how to carry out routine checks on the following:
- tube connections
- pipe connections
- valves
- water level regulators
32
- gauges to include (temperature and pressure)

- linkages
- chains
- conveyors
5.0 ASSESSMENT
5.1 ASSESSMENT GRID
WORKSHOP TECHNOLOGY PAPER 1 340/18/S01A
NO. OF
WEIGHTING
TOPIC CONTACT MARKS
%
HOURS
SAFETY PRECAUTIONS 10 1.9 3
HAND AND BENCH TOOLS 10 3.8 6
POWERED HAND TOOLS 6 3.1 5
MEASURING 10 3.1 5
MARKING OUT 6 3.8 6
GAUGING 6 1.9 3
ENGINEERING MATERIALS 10 12.5 20
HEAT TREATMENT 14 12.5 20
STANDARDS OF ACCURACY 6 12.5 20
FABRICATION 4 3.8 6
FITTING 16 12.5 20
LUBRICATION AND CUTTING 10 12.5 20
FLUIDS
HYDRAULICS 6 6.25 10
PNEUMATICS 6 6.25 10
BOILER 10 3.8 6
TOTAL 130 100 160
33
WORKSHOP TECHNOLOGY PAPER 2, 340/18/S01B
NO. OF
WEIGHTING
TOPIC CONTACT MARKS
%
HOURS
Drilling operations 15 10 12
Grinding 25 12 14
Powersaws and bandsaws 16 8 10
Lathe machine 25 13 15
Operational planning 12 25 30
Slotting and broaching 16 8 10
Milling 25 14 17
Jigs and Fixtures 16 10 12
TOTAL 150 100% 120

1. Kalpakjian, S. and Schmid, S.R. (2015) Manufacturing Engineering and Technology. 6th
Edition.
Delmar Publishers.
4. Kazanas, H. C, Glenn, E. and Gregor, T. (1991) Manufacturing processes. McGrawl Hill
6. Wynter, E.J. (2012) Metalcraft. Longman. London.
34
7.0 WRITTEN PAPER STRUCTURES FOR THE WORKSHOP TECHNOLOGY

EXAMINATION
7.1 WORKSHOP TECHNOLOGY PAPER 1: WORKSHOP PROCESSES

The following topics will be covered in this theory paper:
- SAFETY PRECAUTIONS
- HAND TOOLS & BENCH TOOLS
- POWERED HAND TOOLS
- MEASURING
- MARKING OUT
- GAUGING
- ENGINEEERING MATERIALS
- BOILER
- FABRICATION
- FITTING
- LUBRICATION OILS AND CUTTING FLUIDS
- HYDRAULICS AND PNEUMATICS
- HEAT TREATMENT
- STANDARDS OF ACCURACY
7.2 PAPER FORMAT FOR WORKSHOP TECHNOLOGY PAPER 1

This paper consists of two sections as follows:
SECTION A (40 marks)
Answer all questions from the following topics: Safety precautions, Hand tools
and bench tools, Powered hand tools, Measuring, Marking out tools, Gauging,
Fabrication and Boiler.
SECTION B (80marks)
Answer any 4 questions out of 6 from the following topics: Fitting, Lubrication
oils and cutting fluids, Engineering Materials, Hydraulics and Pneumatics, Heat
treatment, Standards of accuracy one question each.
35
7.3 WORKSHOP TECHNOLOGY PAPER 2: MACHINING PROCESSES

The following topics will be covered in this theory paper:
- Power saws and band saws
- Drilling operations
- Lathe machine
- Milling machine
- Grinding
- Slotting and broaching
- Jigs and fixtures
- Operational planning
PAPER FORMAT FOR WORKSHOP TECHNOLOGY PAPER 2

This paper consists of three sections as follows:
Section A (30 marks)
Answer all 10 questions.
Section B (60 marks)
Answer four (4) questions out of six (6)
Section C (30 marks)
Compulsory question on operation planning
36
SUBJECT: ENGINEERING MATHEMATICS

CODE: 340/18/S02
DURATION: 150 HOURS
1.0 AIM
By the end of the course, students should be able to apply Mathematical principles in
solving Mechanical Engineering problems.
2.0 OBJECTIVES
By the end of the course, students should be able to:
2.1 perform basic arithmetic and algebra calculations.
2.2 illustrate the relationship of algebraic equations and associated graphs.
2.3 apply trigonometric functions and describe their properties
2.4 define the base of a number and perform basic calculations in various number
systems.
2.5 apply various methods to simplify simultaneous equations.
2.6 explain a function and its derivative
2.7 use derivatives to find extremes and rates of change, applying the techniques to
problems in Mechanical Engineering.
3.0 TOPICS
THEORY OF INDICES AND LOGARITHMS
TRANSPOSITION OF FORMULAE
SIMPLE, SIMULTANEOUS AND QUADRATIC EQUATIONS
GRAPHS
COORDINATE GEOMETRY
RADIAN MEASURE
TRIGONOMETRY
MATRICES
BINOMIAL EXPANSIONS
DIFFERENTIATION
INTEGRATION
37
4.0 CONTENT
4.1 THEORY OF INDICES AND LOGARITHMS
4.1.1 State the laws of indices
4.1.2 Apply rules of indices to problems with negative and positive powers of roots.
4.1.3 Solve problems on indices and indicial equations.
4.1.4 Definition of a logarithm and use of the laws of logarithms.
4.1.5 Apply indices as an aid to logarithms
4.1.6 Solve problems on logarithms involving the arithmetic operations of subtraction
addition, multiplication and division.
4.1.7 Solve equations using logarithms.
4.2 TRANSPOSITION OF FORMULAE

4.2.1 Define transposition of formula
4.2.2 Transpose general formulae.
4.2.3 Solve problems by substituting values for symbols in a formula.
4.3 SIMPLE, SIMULTANEOUS AND QUADRATIC EQUATIONS

4.3.1 Solve simple and simultaneous linear equations.
4.3.2 Solve quadratic equations by factorisation, completing the square or using the
quadratic formula.
4.3.3 Use equations to solve practical problems.
4.4 GRAPHS
4.4.1 Plot graphs of the form;
- 𝑦 = 𝑚𝑥 + 𝑐
- 𝑦 = 𝑎𝑥 2 + 𝑏𝑥 + 𝑐
4.4.2 Solve graphically problems on the following: simple, linear simultaneous and
quadratic equations.
4.4.3 Plot logarithm graphs of the form
𝑦 = 𝑎𝑥 𝑛 (𝑡𝑟𝑎𝑛𝑠𝑓𝑜𝑟𝑚𝑒𝑑𝑡𝑜 log 𝑦 = log 𝑎 + 𝑛 log 𝑥)
𝑦 = 𝑎𝑏 𝑥 (𝑡𝑟𝑎𝑛𝑠𝑓𝑜𝑟𝑚𝑒𝑑𝑡𝑜 log 𝑦 = log 𝑎 + 𝑥 log 𝑏)
Excluding graphs of the form 𝑦 = 𝑘𝑒 𝑛𝑥
4.4.4 Deduce the law in 4.4.3.
38
4.5 TRIGONOMETRY
4.5.1 State the six trig ratios.
4.5.2 Solve problems using the six ratios (excluding solving trig equations).
4.5.3 State the following identities:
𝑠𝑖𝑛2 𝜃 + 𝑐𝑜𝑠 2 𝜃 ≡ 1 …………………………..(1)
1 + 𝑡𝑎𝑛2 𝜃 ≡ 𝑠𝑒𝑐 2 𝜃 …………………………(2)
1 + 𝑐𝑜𝑡 2 𝜃 ≡ 𝑐𝑜𝑠𝑒𝑐 2 𝜃 ………………………(3)
4.5.4 Prove identities using identities in 4.5.3
4.5.5 Simplify trigonometry expressions (excluding solving trig equations)
4.5.5 Apply angle properties of triangles and regular polygons.
4.5.6 Solve practical problems from practical situations on similar triangle, tangents
and chords.
4.5.7 Apply the sine and cosine rule problems on non- right-angled triangles.
4.5.8 Calculate length of open and crossed belts using trigonometric ratios.
4.5.9 Calculate area of a triangle using the following methods.
1
𝐴= 𝑏𝑎𝑠𝑒 × ℎ𝑒𝑖𝑔ℎ𝑡
2
1
𝐴= 𝑎𝑏 sin 𝜃
2
1
𝐴 = √𝑠(𝑠 − 𝑎)(𝑠 − 𝑏)(𝑠 − 𝑐) where 𝑠 = 2 (𝑎 + 𝑏 + 𝑐)
4.5.10 Solve problems on height and distances including the use of angle of elevation
and angle of depression.
4.5.11 Calculate taper diameter, length and taper angles.
4.5.12 Calculate the taper ratio.
4.5.13 Calculate bending allowance and bending radius.
4.6 COORDINATE GEOMETRY

4.6.1 Determine length, gradient and midpoint of a straight line.
4.6.2 Determine equation of a straight line in the form 𝑦 = 𝑚𝑥 + 𝑐
4.6.3 Use properties of parallel and perpendicular lines that is for:
parallel lines, 𝑚1 = 𝑚2
perpendicular lines, 𝑚1 𝑚2 = −1
4.6.4 Find equation of straight lines in 4.6.3.
39
4.7 RADIAN MEASURE

4.7.1 Define a radian
4.7.2 Convert degrees and minutes to radians and vice versa
4.7.3 Calculate arc length, area of a sector and segment.
4.8 MENSURATION (AREAS AND VOLUMES)

4.8.1 Calculate areas and perimeters of the following plane figures of quadrilateral and
polygons:
- parallelogram
- rhombus
- trapezium
- hexagon
- ellipse
- square
- pentagon
- octagon
- nonagon
- decagon
4.8.2 Calculate the surface areas and the volume for the following:
- cylinders
- prisms
- cones
- pyramids
- spheres
- frustum of a cone and pyramid
- composite figures
4.8.3 Estimate areas of irregular figures using the following approximate methods.
(a) Mid – ordinate rule
(b) Trapezoidal rule
(c) Simpson’s rule
4.8.4 Estimate volume of irregular solids using Simpson’s rule
40
4.9 BINOMIAL EXPANSION

4.9.1 Expand using Pascal’s triangle method.
4.9.2 State the binomial theorem
4.9.3 Expand using binomial theorem.
4.10 DIFFERENTIATION
4.10.1 Differentiate polynomial functions 𝑦 = 𝑎𝑥 𝑛
4.10.2 Find the derivative of composite polynomial functions and a sum.
4.10.3 Determine gradient of a line using differentiation.
4.10.4 Differentiate polynomial functions using first principles.
4.10.5 Determine nature of stationary points of curves (maximum and minimum).
4.10.6 Apply rate of change in kinematics
4.10.7 Solve practical problems using differentiation (maximum and minimum if
𝑑2 𝑦 𝑑2 𝑦
< 0 and 𝑑𝑥 2 > 0 respectively).
𝑑𝑥 2
4.11 INTEGRATION
4.11.1 Define integration.
4.11.2 Obtain indefinite and definite integrals of polynomial functions
𝑎𝑥 𝑛 (𝑛 ≠ −1)
4.11.3 Apply integral calculus in the following:
- areas and volumes of solids of revolution
- kinematics
4.12 MATRICES
4.12.1 Define a matrix
4.12.2 State the order of a matrix
4.12.3 Add, subtract and multiply(2 × 2) matrices.
4.12.4 Perform scalar multiplication.
4.12.5 Determine determinant of a (2 × 2) matrix
4.12.6 Calculate inverse of a (2 × 2) matrix.
4.12.7 Solve linear simultaneous equations having two unknowns using:
(i) the determinant method (Cramer’s rule)
(ii) inverse method
41
5.0 ASSESSMENT
5.1 ASSESSMENT GRID
QUESTION TOPIC WEIGHT% MARKS
1.1 THEORY OF INDICES AND LOGARITHMS 3.8 5
1.2 TRANSPOSITION OF FORMULA 3.8 5
1.3 TRIGONOMETRIC IDENTITIES/EXPRESSIONS 3.8 5
1.4 RADIAN MEASURE 3.8 5
1.5 DIFFERENTIATION FROM FIRST PRINCIPLES 3.8 5
1.6 COORDINATE GEOMETRY 3.8 5
1.7 MATRICES 3.8 5
1.8 BINOMIAL EXPANSIONS 3.8 5
SOLVING EQUATIONS, PRACTICAL
2 APPLICATIONS OF SIMPLE, SIMULTANEOUS 11.5 15
AND QUADRATIC EQUATIONS
PRACTICAL APPLICATION OF
3 11.5 15
TRIGONOMETRY
MENSURATION (AREAS AND VOLUMES)
4 11.5 15
INCLUDING IRREGULAR SHAPES
PRACTICAL APPLICATION OF 11.5 15
5
DIFFERENTIATION
SIMPLE INTEGRATION AND APPLICATION
6 11.5 15
OF INTEGRATION
7 GRAPHS 11.5 15
1. Bird, J.O. (2003) Engineering Mathematics. 4th edition. Newness. London.

2. Page, M. G. (2008) Mathematics for Mechanical Engineering Technicians. London.
3. Stroud, K, A. (2013) Engineering Mathematics. 7th Edition. Industrial Press. New York.
4. Bostock and Chanlder (1990) The core course for A level Mathematics.
5. Backhouse 1(1988) Pure Mathematics.
42
7.0 PAPER STRUCTURE

SECTION A [40marks]
Consists of one compulsory question.
SECTION B [60marks]
This section consists of seven questions. Candidates are required to choose 4 questions. Each
question carries 15 marks.
43
SUBJECT: ENGINEERING SCIENCE

CODE: 340/18/S03
DURATION: 150 HOURS
1.0 AIM
By the end of the subject content, students should be able to apply Science principles in
solving Mechanical Engineering problems.
2.0 OBJECTIVES
By the end of covering the subject content, students should be able to:
3.1 demonstrate knowledge of the science fundamentals.
3.2 apply statics fundamentals.
3.3 state and perform calculations on friction.
3.4 calculate the strength of different materials.
3.5 perform calculations in kinematics.
3.6 perform calculations on work, energy and power.
3.7 perform calculations on machines.
3.8 identify different sources of heat and perform calculations.
3.0 TOPICS
INTRODUCTION TO FUNDAMENTALS
STATICS
FRICTION
STRENGTH OF MATERIALS
KINEMATICS
WORK, ENERGY AND POWER
MACHINES
HEAT
4.0 CONTENT
4.1 INTRODUCTION TO FUNDAMENTALS
4.1.1 List the seven Engineering fundamental quantities and their S.I units
4.1.2 State the S.I units of the following:
- energy
44
- force
- power
- pressure
- heat
- stress
- weight
- work
- velocity
- acceleration
4.1.3 Define the following prefixes and relate each prefix to any other: -
(a) atto
(b) femto
(c) pico
(d) nano
(e) micro
(f) milli
(g) centi
(h) deci
(i) Deca
(j) Hecta
(k) Kilo
(l) Mega
(m) Mega
(n) Giga
(o) Tera
(p) Peta
(q) Exa
4.1.4 Convert from one unit to the other.
4.1.5 Define the following terms:
- mass
- weight
- acceleration due to gravity
- density
- relative density/specific gravity
- specific weight
4.1.6 Solve problems in 4.1.4
4.1.7 Describe the following pressures:
-atmospheric pressure
-gauge pressure
-absolute pressure
45
4.1.8 Describe the following pressure measuring instruments and their applications.
-manometer
-barometer
-bourdon gauge
4.2 STATICS
4.2.1 Define statics
4.2.2 Define vector and scalar quantities, giving examples of each.
4.2.3 Express a force as a vector and perform additions and subtraction of vectors.
4.2.4 Define resultant of two or more forces.
4.2.5 Define and state condition of equilibrium
4.2.6 Explain equilibrant, coplanar and concurrent forces.
4.2.7 Produce free body diagrams of multiple force systems.
4.2.8 Resolve forces into parallel and perpendicular components.
4.2.9 Determine the resultant force of a system of forces using:
(i) analytical method
(ii) graphical method
4.2.10 Solve problems on multi – force systems using.
- parallelogram of forces theorem
- triangle of forces theorem
- polygon of forces theorem
4.2.11 Define a moment.
4.2.12 Describe the conditions for equilibrium under the action of forces about a pivot.
4.2.13 Solve problems involving simply supported beams and consists of:
- concentrated/point loads
- weight of the beam
- uniformly distributed loads
4.2.14 Define and solve problems on torque and couple.
4.2.15 Define the following:
- centre of gravity
- centroids
4.2.16 State centroids of lamina shapes
- square
- rectangle
46
- circle
- semi- circle
- right angled triangle
4.2.17 Describe how to find position of centroids by using an:
-experiment
-analytical method
4.2.18 Obtain centroids for composite figures.
4.2.19 Define the following stability terms:
- unstable equilibrium
- neutral equilibrium
- stable equilibrium
4.3 FRICTION
- static and dynamic friction
- co-efficient of friction
-angle of repose/friction
- dry friction
4.3.2 state laws of friction
4.3.3 State and explain common engineering applications where the presence of friction
is:
- an advantage e.g. brakes, clutch, machine vice.
- a disadvantage e.g. bearings, gear devices etc.
4.3.4 State and explain the methods of reducing or overcoming friction for example:
- lubrication
- smooth surface finish
- rollers
4.3.5 Solve problems of dry friction:
- on a horizontal plane
- on an inclined plane with the applied force parallel to the plane.
- on an inclined plane with the applied force at an angle to the plane.
4.4 STRENGTH OF MATERIALS
4.4.1 Define the listed properties:
- strength
47
- elasticity
- plasticity
- ductility
- toughness
- malleability
- rigidity
- hardness
4.4.2 Define the following
-tension
- compression
- shear
4.4.3 Define and solve simple problems on:
- stress (1Pascal = 1N/m2)
- strain
4.4.4 Describe the process of tensile testing of materials.
4.4.5 Draw typical load – extension graphs for brittle and ductile materials such as
aluminium, mild steel, high tensile steel and cast iron and indicate the following:
- region of proportionality
- elastic limit
- yield point
- U.T.S
- breaking point
4.4.6 Define:
- Hooke’s law
- Young’s modulus of elasticity
- Modulus of rigidity
-Factor of safety
4.4.7 Solve simple problems involving the terms covered in 4.4.5 and 4.4.6 excluding
the modulus of rigidity.
4.5 KINEMATICS
4.5.1 Define the following terms in linear motion
(a) displacement
(b) distance
48
(c) velocity
(d) speed
(e) acceleration
4.5.2 Produce the following:
- displacement – time graphs
- velocity- time graphs
4.5.3 Define the following as:
- velocity as the slope of the displacement -time graph.
- acceleration as the slope of the velocity-time graph.
- displacement as area under the velocity-time graph.
4.5.4 State the four equations of linear motion.
4.5.5 Solve problems using equations in 4.5.4.
4.5.6 Define the following terms in angular motion:
(a) angular displacement
(b) angular velocity
(c) angular acceleration
4.5.7 Produce and solve problems using:
(a) angular displacement- time graphs
(b) angular velocity-time graphs
4.5.8 Define the following as:
- angular velocity as the slope of the angular displacement – time graph.
- angular acceleration as the slope of the angular velocity - time graph.
- angular displacement as the area under the angular velocity -time graph
4.5.9 State the four equations of angular motion.
4.5.10 Solve problems using equations in 4.5.9.
4.5.11 State the relationship between angular velocity and linear velocity (𝑣 = 𝑤𝑟)
4.5.12 State relationship between angular acceleration and linear acceleration (𝑎 = 𝛼𝑟)
4.5.13 Solve problems using equations in 4.5.11 and 4.5.12
4.6 WORK, ENERGY AND POWER

4.6.1 Define work and state its unit as the Joule
4.6.2 Calculate work done using the formulae:
(i) 𝑊 =𝐹×𝐷
49
(ii) 𝑊 = 𝑇𝜃
4.6.3 Calculate work done:
- on a horizontal plane
- on an inclined plane
- in tightening a nut
4.6.4 Define energy as the ability to do work.
- potential energy
- kinetic energy
- strain energy
4.6.6 State and explain the principle of conservation of energy.
4.6.7 Solve problems in 4.6.5 and 4.6.6 above applying the conservation of energy
principle.
4.6.8 Define power as the rate of doing work
4.6.9 Determine power transmitted by a force
4.6.10 Determine power required in belt transmission.
4.6.11 Calculate efficiency in 4.6.9 and 4.6.10
4.6.12 State Newton’s three laws of motion.
4.6.13 Define momentum and solve problems
4.6.14 Solve problems on Newton’s second law of motion.
4.6.15 State principle of conservation of momentum.
4.7 MACHINES
4.7.1 Define a simple machine with examples.
4.7.2 Define and calculate the following:
- Force ratio (MA), limiting MA.
- Movement ratio
- Efficiency, limiting efficiency.
- Reversibility/irreversibility of a machine
4.7.3 State the three types/orders of levers and give examples.
4.7.4 Solve problems for equilibrium of a lever.
4.7.5 Describe with the aid of diagrams
- Pulley systems
- Rope pulley system
50
- Wheel and axle lifting

- Differential pulley block
- Screw jack
- Worm and worm wheel
- Gear systems
4.7.6 Determine the following in 4.7.5:
- movement ratio
- force ratio
- efficiency
4.7.7 Define the law E=𝑎𝑊 + 𝑏 of the machine.
4.7.8 Determine the law of a machine.
4.7.9 Calculate belt speed using the formula for simple and compound belt drives.
𝑃𝑜𝑤𝑒𝑟 = (𝑇2 − 𝑇1 )𝑉
4.7.10 Solve problems on the following gear calculation for simple and compound gear
trains.
- number of teeth on the gears
- speed of gears
- pitch of leadscrew
- Power transmitted by gears.
4.8 HEAT
4.8.1 Define heat and temperature.
4.8.2 State and explain modes of heat transfer.
- conduction
-convection
-radiation
4.8.3 Distinguish temperature scales.
4.8.4 Briefly describe the following temperature measuring devices.
- alcohol/mercury thermometers
- thermocouples
- pyrometers
- fusible cones
4.8.5 Illustrate the change of state of a substance on heat energy – temperature graph.
51
- sensible heat
- latent heat
4.8.7 Define specific heat capacity.
4.8.8 Solve problems in 4.8.5
4.8.9 Solve relevant problems involving heat transfer in mixtures.
4.8.10 Define the calorific value of a fuel.
4.8.11 Define thermal expansion:
- linear expansion
- area/superficial expansion
- volumetric/cubical expansion
4.8.12 State equations in thermal expansion.
4.7.13 Solve simple problems using equations in 4.8.12
5.0 ASSESSMENT
5.1 ASSESSMENT GRID
QUESTION
TOPIC WEIGHT% MARKS
NO.
1.1 CONVERSIONS 3.4 5
1.2 INTRODUCTION TO FUNDAMENTALS 3.4 5
1.3 STATICS 3.4 5
1.4 FRICTION 3.4 5
1.5 LINEAR MOTION 3.4 5
1.6 ANGULAR MOTION 3.4 5
1.7 WORK, ENERGY AND POWER 3.4 5
1.8 HEAT 3.4 5
2 STATICS 10.3 15
3 FRICTION 10.3 15
4 STRENGTH OF MATERIALS 10.3 15
5 KINEMATICS 10.3 15
6 WORK, ENERGY AND POWER 10.3 15
7 MACHINES 10.3 15
8 HEAT 10.3 15
TOTALS 100 145
52
6.0 SUGGESTED REFEERENCE BOOKS
1. Houpt (1993) Mechanical Engineering Science.

2. Page, M.G (2012) Science for Mechanical Engineering Technicians.
3. Hanner and Hillier, (2002) Mechanical Engineering Science.
4. Titcomb, K. (1994) Mechanical Engineering Science.
7.0 PAPER STRUCTURE

SECTION A [40marks]
This section consists of one compulsory question.
SECTION B [60marks]
This section consists of seven questions. Candidates are required to choose 4 questions. Each
question carries 15 marks.
53
SUBJECT: ENGINEERING DRAWING

CODE: 340/18/S04
DURATION: 150 HOURS
1.0 AIM
The aim of subject is to provide the student with knowledge, competencies and attitudes
required in an Engineering Drawing office.
2.0 OBJECTIVES
By the end of the subject content, students should be able to:
3.1 produce required Engineering drawings for given tasks.
3.2 interpret a given drawing.
3.3 relate use of drawing equipment and accessories.
3.4 apply principles of limits and fits to given tasks.
3.5 draw the assembled item.
3.0 TOPICS
INTRODUCTION
GEOMETRICAL CONSTRUCTION
ORTHOGRAPHIC PROJECTION
PICTORIAL
DEVELOPMENTS
FASTENERS AND LOCKING DEVICES
ASSEMBLY DRAWING AND DETAIL DRAWING
4.0 CONTENT
4.1 INTRODUCTION
4.1.1 State and explain the advantages of using drawings as a means of communication.
4.1.2 Identify and select standard paper sizes and pencil grades.
4.1.3 Explain the use of scales.
4.1.4 Copy to a given scale.
54
4.1.5 Identify and produce engineering components from given working drawings as
well as interpret and produce working drawings in accordance with PD 7308, BS
4500 BS 499 PD 7306 and current British Standards.
4.1.6 Identify and select the following drawing instruments and equipment:
- types of drawing boards
- tee-square
- pens and pencils
- scale rules
- stencils
4.1.7 Demonstrate how to take care of drawing boards, tee, square and drawing
instruments.
4.1.8 Prepare drawing board and tee square for use.
4.1.9 Draw boarder lines.
4.1.10 Draw title bock and print required information (minimum information as follows:
name, group, title, date and scale).
4.1.11 Correctly position views on paper.
4.1.12 Identify the types of lines.
4.1.13 State uses of different types of lines.
4.1.14 Draw the different types of lines.
4.1.15 Apply the types of lines.
- Produce clear, uniform freehand letter and numerals.
4.1.16 Identify abbreviations and symbols for the engineering terms listed in PD 7308.
4.1.17 Identify machining symbols
4.1.18 Identify, state and correctly use the following welding symbols.
(a) fillet weld
(b) butt weld
(c) Vee groove
(d) square groove
(e) bevel groove
4.1.19 Identify geometrical tolerance symbols
4.1.20 Identify and sketch the following conventional representations in accordance with
BS 308/PD7308.
- threads
- interrupted views
55
- repeated parts
- splined and serrated shafts
- knurling
- square or flat on a shaft
- holes on linear or circular pitch
- bearing
- spur gears
4.2 GEOMETRICAL CONSTRUCTION

4.2.1 Perform the following:
- bisect a line.
- construct a perpendicular from a given point to a line.
- divide a line into proportional parts.
- construct a perpendicular from any point to a line.
4.2.2 Identify the types of angles
4.2.3 Bisect an angle
4.2.4 Construct various angles without a protractor
4.2.5 Copy an angle.
4.2.6 Define a circle
4.2.7 Identify parts of a circle
4.2.8 Find the centre of a given arc or circle.
4.2.9 Draw a circle through:
i. from a center point and a given radius/diameter
ii. any two points
iii. any three points.
4.2.10 Join straight lines to two or more arcs and circles.
4.2.11 Identify types of triangles.
4.2.12 Construct a triangle given the following:
(a) the sides
(b) two angles and length of one side
(c) perpendicular height and the base.
4.2.13 Construct the following triangles:
(a) inscribed
(b) circumscribed
56
(c) E-scribed
4.2.14 Define a tangent.
4.2.15 Construct internal and external tangents to any two circles.
4.2.16 Identify regular polygons up to 8 sides
4.2.17Construct the polygons in 4.2.16 using common and particular
methods given.
- the length of the sides
- outside a given circle
- inside a given circle
4.3 ORTHOGRAPHIC PROJECTION

4.3.1 Define orthographic projection.
4.3.2 Demonstrate the ability to interpret and produce single component working
drawings.
4.3.3 Describe how to obtain views in orthographic projection.
4.3.4 Name the two types of orthographic projection.
4.3.5 Select the side most suitable to be the front view.
4.3.6 Appreciate the possibilities of various numbers of views to completely describe
objects.
4.3.7 Illustrate the positioning (layout) of the views on paper.
4.3.8 Differentiate between first and third angle projection, including symbols of
projection.
4.3.9 Draw projection symbols in 4.3.8
4.3.10 Differentiate between sketching and drawing.
4.3.11 Demonstrate sketching and drawing techniques using simple objects.
4.3.12 State the importance of dimensioning.
4.3.13 State the methods of dimensioning
4.3.14 State the basic rules of dimensioning and types of dimensions.
4.3.15 Illustrate the dimensioning of special features.
4.3.16 Demonstrate acceptable layout of dimensions.
4.3.17 Apply dimensioning to working drawings.
4.3.18 Apply conventional methods of dimensioning on a working drawing to
include machining symbols, stating the surface texture value (P.D. 7306)
4.3.19 Use the principles of limits and fits in accordance with BS 4500 A.
57
4.3.20 State and describe clearance, interference and transition fits.

4.3.21 Explain the importance for clearance and interference fits in equipment
and machinery.
4.3.22 Select and apply appropriate tolerances to shafts and holes using BS4500
a data sheet.
4.3.23 State the reasons for sectioning.
4.3.24 State the general rules to be observed when sectioning, types of sections, parts
and features of parts not normally sectioned.
4.3.25 Sketch and draw sectional views of single engineering components.
4.3.26 Interpret working drawings.
4.3.27 Calculate dimensions.
4.3.28 Interpret features and symbols.
4.4 PICTORIAL
4.4.1 Produce pictorial drawings and sketches
4.4.2 Identify oblique and isometric drawings.
4.4.3 State advantages/disadvantages of pictorial drawings.
4.4.4 Sketch and draw simple engineering components in oblique and isometric
projections without using isometric scale.
4.4.5 Sketch freehand the following in isometric projection:
- hand tools
- machine tools
- measuring equipment and general engineering components.
4.5 DEVELOPMENTS
4.5.1 Sketch and draw parallel line developments.
4.5.2 Identify the end products of radial line development.
4.5.3 Match objects to their developments.
4.5.4 Sketch and draw developments of cone and pyramid related objects.
4.5.5 Identify the end products of triangulation development.
4.5.6 Match products to their developments.
4.5.7 Sketch and draw development of transition pieces i.e.
- square
- round to square
58
- square to round
4.6 FASTENERS AND LOCKING DEVICES

4.6.1 Identify and sketch the following types of fasteners and locking devices.
4.6.1.1 Keys
- Woodruff
- Flat/rectangular
- Gib head
- Feather
4.6.1.2 Fasteners
- bolts and nuts
- studs
- screws
- rivets
- washers
4.6.1.4 Locking and Returning Devices
- castle nuts
- nylon inserted nuts
- split pins
- cotter pins
- locking plates
- locknuts
- spring washers
- tab washers
- spigot and register
- circlips (internal and external)
4.7 ASSEMBLY DRAWING AND DETAIL DRAWING

4.7.1 Produce general assembly drawings from detailed component drawings.
4.7.2 Produce detailed component working drawings from given assembly drawings.
59
5.0 ASSESSMENT
5.1 ASSESSMENT GRID
TOPIC NO. TOPIC WEIGHT%

1 INTRODUCTION 10
2 GEOMETRICAL CONSTRUCTION 10
3 ORTHOGRAPHIC PROJECTION 20
4 DEVELOPMENTS 15
5 FASTENERS AND LOCKING DEVICES 10
6 ASSEMBLY DRAWING AND DETAIL DRAWING 25
7 PICTORIAL 10
TOTAL 100
6.0 SUGGESTED REFERENCES

1. Giesecke, F.E, Mitchell, A, and Spencer, H.C. and Hill, I. L. (2017) Technical Drawing
with Engineering Graphic.5th edition.
2. Morling, K. (2003) Geometric and Engineering Drawing. 2nd Edition, Butterworth-
Heinermann.
3. Rhodes, R.S. and Cook, L.B. (2002) Basic Engineering Drawing. Pitman Publishers.
4. Narayana, K.L, Kannaih, P. and Venkata Reddy K. (2006) Machine Drawing. 3rd Edition.
New Age International.
5. Collin, H. Simmons and Dennis E. Maguire (2004) Manual of Engineering Drawing. 2nd
Edition. Elsevier Newness.
60
SUBJECT: WORKSHOP PRACTICE

CODE: 340/18/S05
DURATION: 500 HOURS
1.0 AIM
The aim of the subject is to provide the student with the practical knowledge,
competencies and attitudes required in the Machineshop Engineering environment.
2.0 OBJECTIVES
By the end of the subject content, students should be able to:
2.1 use Machineshop hand tools for given tasks.
2.2 carry out maintenance on workshop equipment.
2.3 carry out heat treatment processes in the workshop.
2.4 implement safety procedures in the workshop.
2.5 operate machine tools.
3.0 TOPICS
WORKSHOP HEALTH AND SAFETY
HAND TOOLS AND BENCH WORK
MEASURING AND GAUGING
MARKING OUT TOOLS
ENGINEERING MATERIALS
HEAT TREATMENT
JOINING METALS
POWERED HAND TOOLS
DRILLING
PEDESTAL GRINDING
TURNING
SLOTTING AND BROACHING
MILLING
GRINDING
PLANNED AND GENERAL MAINTENANCE OF MACHINE AND
EQUIPMENT
61
4.0 CONTENT
4.1 WORKSHOP HEALTH AND SAFETY

4.1.1 Demonstrate safety, health and behavioural standards appropriate to fitting and
machining.
4.1.2 Identify and implement all basic safety precautions relevant to fitting and
machining.
- personal grooming hygiene.
- house keeping
- securing of work pieces
- metal removal operations.
- personal protective equipment
4.1.3 Demonstrate proper sanitation in all workshop activities.
4.1.4 Implement all relevant existing legislation on workshop health and safety.
4.1.5 Locate, identify, select and operate all fire-fighting equipment.
4.1.6 Identify and operate all emergency electrical switches.
4.1.7 Implement appropriate remedial action in emergencies involving electricity,
inflammable gas, oil, toxic gases and chemicals.
4.1.8 Demonstrate the proper, safe use and storage of the following:
- inflammable gasses
- toxic gases
- oil
- electricity
- chemicals
4.1.9 Identify and implement the procedure involved in the use of:
- machines
- safety guards
- screens
- warning notices
4.1.10 Demonstrate the correct procedures in the lifting and moving of heavy materials
and equipment.
4.1.11 Identify and implement all safety precautions relating to machines and machine
tools.
62
4.2 HAND TOOLS AND BENCH WORK

4.2.1 Identify, select and use the following hand tools to perform specific operations.
-bench vice, pipe vice, machine vice, hand vice
-hammers – ball pein, soft hammers
-chisels – flat, cross cut, round nose, diamond
-punches – centre, dot, pin
-handsaw -hacksaw
-pliers
-allen keys (Metric and Imperial)
-hand taps and threading dies (Metric and Imperial)
-files
-hand reamers
-screw drivers – flat, Phillips, offset.
-vice grips.
4.2.2 Demonstrate the correct procedures in the care, maintenance and storage of the
tools in 4.2.1above.
4.2.3 Demonstrate the effective selection and use of the hand tools to perform various
bench work, fitting and assembly tasks to blueprint specifications.
4.2.4 Perform metal removal operation to specifications using scrapers.
4.2.5 Demonstrate safety precautions which must be observed when using scrapers.
4.2.6 Select the appropriate types of scrapers for specified operations.
4.2.7 Use scrapers to perform specified operations.
(a) finishing of bearings surfaces – flat and curved.
(b) finishing of flat surfaces on cast iron surfaces plates etc.
(c) finishing of surface to enable the fitting of brass and Babbitt bearings to
shafts.
4.2.8 Demonstrate the proper care and storage of scrappers.
4.2.9 Perform hand broaching operations to specifications.
4.2.10 Identify and select appropriate broach sets for specified broaching operations.
4.2.11 Perform the following broaching operations.
(a) cutting internal keyways using an arbour press.
(b) cutting internal splines and other odd internal shapes.
(c) broaching of exterior surfaces.
4.2.12 Demonstrate the proper care and storage of broaching sets.
63
4.3 MEASURING AND GAUGING

4.3.1 Identify the following precision measuring and gauging instruments and their
accessories.
-steel rule
-tape measure
-combination set
-dividers
-vernier callipers (imperial and metric)
-vernier height gauge
-callipers (outside and inside)
-vernier micrometer (imperial and metric)
-indicating micrometer
-bevel and vernier protractors
-surface gauge
-Dial Test Indicator (D.T.I)
-gear tooth vernier callipers
-inside micrometer callipers
-micrometer depth gauge
-vernier depth gauge
-screw thread comparator micrometer
-telescopic gauges
-vernier protractor
-thread gauges
-sine bar
-sine plate
-gauge blocks
- cylindrical plug gauges
-plain ring gauges
- taper plug and taper ring gauges
- snap gauges
- thread ring and thread plug gauges
64
4.3.2 Demonstrate the effective selection and use of the measuring and gauging
instruments.
4.3.3 Demonstrate the proper procedures in the care, maintenance and storage of the
measuring and gauging instruments.
4.3.4 Apply the principles of limits and fits in all machining and fitting exercises.
4.3.5 Identify fitted components with the following types of fit.
- clearance fit
- transition fit
- interference fit
4.3.6 Undertake the disassembly of fitted components with the types of fit in 4.3.5
above and recognise the difference in types of fit.
4.3.7 Machine and fit components according to the three classes of fit in 4.3.5 above.
4.3.8 Use the gauges in machining and fitting exercises.
4.4 MARKING OUT TOOLS

4.4.1 Identify, select and demonstrate the correct use of the following marking out
tools:
- outside and inside callipers.
- odd leg callipers
- centre punch
- squares – bevelled edge squares
- straightedges
- dividers
- trammels
- V – blocks
- scribers
- centre head
- scribing block
- combination set
- vernier height gauge
- surface gauge
- angle plate
- surface plate
- layout table
65
- clamps
4.4.2 Demonstrate the correct procedures in the care, maintenance and storage of the
tools in 4.4.1.
4.5 ENGINEERING MATERIALS
4.5.1 Identify ferrous and non – ferrous and non- metallic materials by the following
methods, appearance, colour, mass, spark testing, filing, machining,
bending.
- low carbon steel
- medium carbon steel
- high carbon steel
- cast iron
- alloy steels
- copper
- bronze
- brass
- lead
- zinc
- tin
- aluminium
- plastics
- rubber
4.5.2 Identify the properties and engineering application of the materials in 4.5.1 above.
4.6 HEAT TREATMENT

4.6.1 Heat metal specimen to temperatures associated with hardening, tempering,
normalising, annealing using temperature-controlled furnaces.
4.6.2 Quench using suitable media to achieve the heat treatment conditions specified in
4.6.1 above.
4.6.3 Carry out heat treatment processes using simple workshop tests.
4.6.4 Carry out normalising and case hardening processes.
66
4.7 JOINING OF METALS

4.7.1 Select and apply mechanical fastening methods using relevant devices to include
the following:
-bolts and nuts
-screws
-cotter and dowel pins
-solid and tubular rivets
4.7.2 Perform soldering and brazing operations.
- identify and implement all safety precautions relevant to soldering and
brazing.
4.7.3 Perform oxy – acetylene welding
4.7.4 Identify and implement all safety precautions related to oxy – acetylene welding
with particular reference to the following considerations:
- general precautions regarding to the identification, storage and handling of
all gas cylinders.
- protective clothing
- adequate ventilation and screening of welding area.
4.7.5 Perform electric arc welding
4.7.6 Identify the hazards associated with electric arc welding and the relevant safety
precautions to be observed with particular reference to the following:
- electrode holders
- cables
- working area
- fire extinguisher
- protective clothing
4.8 POWERED HAND TOOLS

4.8.1 Identify and implement safety precautions related to the power hand tools.
4.8.2 Identify portable electrical and pneumatic powered hand tools to include the
following.
-hand grinders – angle grinders
-hand drilling machines
4.8.3 Implement safety precautions relevant to powered hand tools and their operations
e.g. eye protection, protection of hands.
67
4.8.4 Demonstrate the correct procedures in the mounting and dismounting of the
cutting tools of different powered hand tools.
4.8.5 Demonstrate the effective selection and use of pneumatic and electrically powered
hand tools in metal removal operations.
4.9 DRILLING
4.9.1 Identify and implement safety precautions related to drilling machines and
drilling machine operations.
4.9.2 Identify the different types of drilling machines and their functions.
4.9.3 Recognise the standard sizes and drilling capacities of different types of
drilling machines.
4.9.4 Identify the different parts of the different types of drilling machines and
their functions.
4.9.5 Identify and operate all switches and controls on various drilling machines
4.9.6 Select and mount the appropriate workholding devices and their
accessories.
4.9.7 Clamp and support workpieces on drilling machine table.
4.9.8 Select and mount the appropriate drill holding devices and their
accessories.
4.9.9 Select and mount the appropriate cutting tools for specified operations.
4.9.10 Select and set the appropriate speeds and feeds.
4.9.11 Perform the following standard drilling machines operations, to blueprint
specifications, on a variety of materials using the appropriate cutting tools
and applying the correct coolant or lubricant: -
- drilling using twist drills (small and large holes)
- countersinking
- counter boring
- spot facing
- reaming
4.9.12 Demonstrate the correct and safe use, care and storage of drilling machine
tools for performing operations listed under 4.9.11 above.
4.9.13 Recognise inaccurately drilled holes and remedy the drill faults by
accurately grinding the cutting edges of the drill.
68
4.9.14 Check the drill point and cutting edges for accuracy using the relevant
gauges.
4.10 PEDESTAL GRINDING

4.10.1 Identify and implement safety precautions relevant to pedestal grinding
machines and offhand grinding operations.
4.10.2 Identify and select the appropriate type of wheels for specific operations
relevant to the materials to be ground.
4.10.3 Grind accurately the cutting edges of the following listed tools: -
- Hand – tools – chisels, scrapers, scribers, centre punches, screw
drivers.
- lathe tools
- shaping tools
4.10.4 Identify grinding faults and their causes and take remedial action for the
following:
- wheel glazing
- loading
- defects on grinding wheels e.g. cracks, groves etc
4.10.5 Demonstrate the correct wheel dressing and truing procedure.
4.11 TURNING
4.11.1 - Perform turning operations to blueprint specifications, consideration
being given to safety, tool selection and mounting, work support, speeds, feeds and
lubrication.
- Identify and implement all safety precautions related to the
centre lathe and its operations.
- Identify the main parts of the centre lathe and their functions.
- Identify and operate all switches and controls.
4.11.2. Select, mount and dismount appropriate work – holding and work –
supporting devices and their accessories for specified operation to include:
-
- three jaw chuck + four jaw chuck
- drive plate
69
- face plate
- mandrels
- steadies – moving and stationary
- lathe centre
- tailstock
- lathe dog
4.11.3. Correctly mount and support the work piece.
4.11.4. Select the appropriate tool holding and supporting devices to include tool
holders.
4.11.5. Mount appropriate cutting tools and set them to centre height.
4.11.6. Determine and select the appropriate speeds and feeds for specified
operations.
4.11.7. Demonstrate the correct methods of offsetting the compound slide and
tailstock for specified taper turning operations.
4.11.8. Demonstrate the correct methods of machine and threading tool set – up
for specified single start internal and external V – thread cutting
operations (Whitworth and Metric).
4.11.9. Perform the following turning operations to given specifications
consideration being given to safety precautions and the correct application
of coolant.
- facing to length
- parallel turning to shoulder i.e. square shoulder, filleted corner,
angular/tapered shoulder
- turning between centres
- parting off
- drilling operations using the tailstock i.e. centre drilling, through
holes, drilling to given depth, counter boring countersinking,
reaming.
- knurling
- step turning
- boring
- grooving
- one throw eccentric turning
70
- basic taper turning using compound slide, tailstock offset method

and form tool.
- screw cutting – single start external and internal V – threads
(Whitworth and metric) course and fine.
4.11.10 Perform external and internal taper turning operations to blueprint
specifications using plain /telescopic taper attachments.
- mount the plain / telescopic taper attachments on the lathe.
- set the plain /telescopic taper attachment to the required amount of
taper in millimetres, degrees or taper per foot by offsetting the
correct end of the guide bar.
4.11.11 Carry out two or more throw eccentric turning.
- Mark out and centres of the workpieces for the number of throws
required.
- mount and support workpieces between centred on the lathe
relevant to the diameter to be machined.
4.11.12 Carry out screw – cutting operations
- Grind the relevant external and internal thread cutting tools to the
appropriate thread forms using the appropriate tool bits, pedestal
grinder and the relevant thread gauges.
- Mount and support the workpiece on the lathe.
- Mount the relevant threading tool and set it on centre height.
- Select and set the appropriate pitches and speeds relevant to the
type of threads to be machined.
4.11.13 Perform multi-start screw cutting operations.
4.12 SLOTTING AND BROACHING

4.12.1 Identify and implement all safety precautions related to slotting machines
and slotting operations.
4.12.2 Identify the main parts of a slotting machine and their
functions.
4.12.3 Identify and operate all switches and controls on the slotting machine.
4.12.4 Identify and recognise the constructional and operational differences and
similarities between slotters and horizontal shapers.
4.12.5 Select appropriate workholding and supporting devices to include: -
71
- rotary table
- clamps and supports
- machine vice
4.12.6 Demonstrate the correct procedure in fastening workpieces to the rotary
table.
N.B - smaller work should be held in a vice.
- there must be sufficient clearance for cutting tool
4.12.7 Select appropriate cutting tools for specified slotting operations.
4.12.8 Carry out correct tool mounting and setting procedure.
4.12.9 Determine and select appropriate speeds and feeds.
4.12.10 Adjust the length of the ram stroke to suit work piece being machined.
4.12.11 Demonstrate the correct procedure in adjusting the ram for the cutting of
angular surfaces, slots, and keyways.
4.12.12 Perform slotting operations to blueprint specifications to include
machining of: -
-internal vertical surfaces – straight, angular, or contoured slots and
keyways.
4.13 MILLING
4.13.1 Identify and implement all safety precautions related to milling machines.
4.13.2 Identify the different types of vertical milling machines and recognise
their operational scope.
4.13.3 Identify the main parts of vertical milling machine, their location and
functions.
4.13.4 Identify and operate all machine switches and controls
4.13.5 Read and interpret feed and speed tables on the milling machine.
4.13.6 Set controls for spindle speeds and automatic feed rates.
4.13.7 Perform adjustments to limit spindle and table motions by use of limit
stops.
4.13.8 Select, mount and dismount, appropriate work – holding and supporting
devices and their accessories for specific operations to include the
following: -
- machine vice
- clamps and support
72
- footstock
- dividing head
- rotary table
4.13.9 Demonstrate the correct procedure in securing and supporting different
sizes and shapes to workpieces on the machine table.
4.13.10 Align the machine vice and workpieces to the machine spindle using the
D.T.I.
4.13.11 Identify the different types of milling cutters and select appropriate milling
cutters for specific operations to include: -
- end mills
- slot drills
- shell end mills
- capstan cutters (carbide cutters)
- face mills
- woodruff cutters
- tee – slot cutters
4.13.12 Identify and select appropriate tool holding devices for specific operations.
4.13.13 Demonstrate the correct procedure in the mounting and dismounting of:
- tool holding devices
- milling cutters
4.13.14 Determine and select the appropriate speeds and feeds for specified
operations.
4.13.15 Perform vertical milling operations to blueprint specification consideration
being given to safety precautions and the correct application of coolant:
- surfacing
- facing surfaces square
- slots, grooves (straight and vee grooves)
- angular surfaces
- step milling
- keyway cutting
4.13.16 Identify and rectify the negative effects of: -
- vibrations during machining operations
- Over and under – tightening of workpieces
73
- incorrect tool positioning and/or direction of rotation of milling

cutter.
4.13.17 Perform horizontal milling operation to blueprint specification.
(a) Identify the different types of horizontal milling machines and
their functions.
(b) Identify the main parts of horizontal milling machines and their
functions.
(c) Select, mount, and dismount appropriate work-holding and supporting
devices and their accessories for specified operations to include the
following: -
- machine vice
- clamps and supports
- dividing head
- footstock
- rotary table
4.13.18. Perform the following milling operations on the horizontal milling
machine to blueprint specifications.
- plain milling and side milling
- slotting and slitting
- keyway cutting
- cutting of steps
- form milling
4.13.19. Perform straddle milling operations.
- identify and implement all relevant safety precautions.
- select and mount the appropriate arbour.
- select the appropriate spacers.
4.13.20. State the appropriate sizes of side milling cutters (2 for each straddle
milling operation) for specified straddle milling operations.
4.13.21. Mounting and correctly space the milling cutter on the door.
N. B The side milling cutters must be separated on the arbour by a
spacer or spacers of the required length so that the distance between the
inside face of the cutters is equal to the desired size.
4.13.22. Perform straddle milling operations to include the milling of square and
hexagonal heads on bolts.
74
4.13. 23 Perform gang milling operations.

- identify and implement all relevant safety precautions.
- select and mount the appropriate arbor.
- select the appropriate spacers.
- select the appropriate milling cutters for specified gang milling
operations.
- mount and correctly space the milling cutters on the arbor.
- determine and select the appropriate speeds and feeds.
- perform gang milling operations to blueprint specifications.
4.13.24 Perform milling operations using the dividing head.
4.13.25 Check the gears for accuracy using the correct instruments and methods.
4.13.26 Perform helical milling operations.
4.14 PRECISION GRINDING

4.14.1 Identify and implement all safety precautions related to surface grinding machines
and surface grinding operations.
4.14.2 Identify the different types of surface grinders: -
- horizontal spindle grinder with reciprocating table.
- horizontal spindle grinder with rotary table
- vertical spindle grinder with reciprocating table
4.14.3 Identify the parts of a hydraulic surface grinder and their functions.
4.14.4 Demonstrate the ability to operate all switches and controls on the grinder.
4.14.5 Demonstrate the ability to:
- properly store grinding wheels.
- test wheels for cracks prior to use.
- select the proper type of wheels for specific operations.
- properly mount and dismount grinding wheels on grinding spindle
- true and dress grinding wheel using a diamond dresser.
4.14.6 Identify and select the appropriate work holding and supporting devices
for specified operation to include the following: -
- vices
- V – blocks
- clamps
- magnetic chucks
75
- sine bar clamped to angle plate

- sine chuck
4.14.7 Demonstrate the correct procedure in the mounting and setting of:
- flat work or plates
- thin workpieces
- short workpieces
4.14.8 Correctly position, support and hold workpieces on the machine using the
relevant work – holding supporting devices.
4.14.9 Set the appropriate table traverse.
4.14.10 Select the appropriate speed and feed rate.
4.14.11 Perform the following surface grinding operations to blueprint
specifications.
- machining flat (horizontal) surfaces.
- grinding edges of workpieces (square)
- grinding edges of workpieces (parallel)
- grinding vertical surfaces.
- grinding angular surfaces.
- angular surfaces
- convex radii
- concave radii
4.14.12 demonstrate the ability to dress grinding wheels for specified form
grinding operations.
4.14.13 Demonstrate the ability to operate cylindrical grinding machines.
- identify and implement all safety precautions related to cylindrical
grinding operations.
- identify the different types of centre type cylindrical grinding
machines.
(a) centre type
(b) centreless type
4.14.14 Identify the different types of centre cylindrical grinding machines:
- plain
- universal
4.14.15 Identify the parts of a universal cylindrical grinder and their functions.
76
4.14.16 Demonstrate the ability to operate all switches and controls on a

cylindrical grinder.
4.14.17 Demonstrate the proper mounting of grinding wheels.
4.14.18 Parallel grind an outside diameter on a universal cylindrical grinding
machine.
4.14.19 Lubricate the machine as required.
4.14.20 Start the grinding wheel to warm up the spindle bearings.
4.14.21 True and dress the grinding wheel.
4.14.22 Clean the machine centres and the centre holes of the work.
N.B On hardened steel workpieces, the centre holes should be honed or
lapped to ensure the utmost accuracy.
4.14.23 align the headstock and footstock centres with a test bar and indicator.
4.14.24 Lubricate the centre holes with a suitable lubricant.
4.14.25 Set the headstock and footstock for the proper length of the work so that
the centre of the work will be over the centre of the table.
4.14.26 Mount the work between centres.
N.B If grinder is to be done up to a shoulder, the table traverse must be
carefully set so that it reverses just before the wheel touches the
shoulder.
4.14.27 Set the grinder to the proper speed for the wheel being used.
4.14.28 Set the work speed for the diameter and type of materials being used.
4.14.29 Set the head spindle to rotate the work in an opposite direction to that
of the grinding wheel.
4.14.30 If the machine is so equipped, set the automatic “IN” feed for each table
reversal.
4.14.31 Set the dwell which permits the wheel to clear itself at each end of the
stroke.
4.14.32 Select and set the desired table traverse or speed.
4.14.33 Perform external parallel cylindrical grinding operations to blueprint
specifications with consideration to the correct application of coolant.
N.B Short work piece may be plunge ground.
4.14.34 Check work for accuracy.
4.14.35 Grind tapered workpieces (external)
- mount pieces
77
- swivel the table to half the included angle of the taper

N.B For short steep tapers the wheel head is swivelled to the desired
angle.
- Grind tapered workpieces (external)
N.B For short steep tapers where the wheel hand is swivelled to the
desired angle, the tapered surface is plunge ground with the
face of the wheel.
4.14.36 Grind a parallel internal diameter on a universal cylindrical grinder.
- mount the workpiece in a universal chuck, a collect chuck, or on a
faceplate.
- swing the internal grinding attachment into place and mount the
proper spin.
- select and mount the proper grinding wheel for the job.
- Adjust the spindle height until its centre is in the line with the
centre axis of the hole in the workpieces.
- true and dress the grinding wheel.
- set the appropriate wheel speed and workpiece speed.
- Adjust the table dogs so that only one-third of the wheel width
overlaps the ends of the work at each end of the stroke.
- start the wheel and the work.
- turn on and direct the coolant.
- grind internal diameter to blueprint specifications
- check the internal diameters for accuracy.
4.15 PLANNED AND GENERAL MAINTENANCE OF MACHINES AND

EQUIPMENT
4.15.1 Identify the different types of bearings and their applications: -
- plain bearings
- ball race bearings
- needle roller bearings
- taper roller bearings
- pre – loaded bearings
- self – aligned bearings
78
4.15.2 Remove bearings from bearing house and shafts using the recommended
methods that is press, puller etc.
4.15.3 Clean the dismantled bearings, shafts and bearing housing using the
proper solvents.
4.15.4 Examine the bearing for wear, pit and score marks.
4.15.5 Identify the bearings which do not require lubrication.
4.15.6 Lubricate the bearing using the proper type of grease.
4.15.7 Install bearings on shafts and housings.
4.15.8 Carry out a regular lubrication schedule
- lubrication points
- frequency of lubrication
- type of lubricant
- quantity of lubricant
4.15.9 Carry out regular lubrication schedules of machines tools following the
recommendations of the prepared scheme in 4.15.8 above.
4.15.10 Remove and fit locking and assembly devices for various engineering
applications.
(a) using the appropriate tools and equipment, undertake the removal
and fitting of locking and assembly devices to include the
following
- keys
- studs
- pulleys with keys, taper locks etc
- fibre insert nuts
- slotted nuts and cotter pins
- double locking nuts
- double locking nuts
- internal and external circlips
- wire locking plates
4.15.11 Undertake the assembly, disassembly, repair and maintenance of
machinery and other engineering equipment with special emphasis on
safety and the use of the correct tools.
(a) trouble shoot faults on machinery and equipment to include the
following
79
- gear boxes
- pumps
- valves
- coupling
- gears
- pulleys and belts
- packing and seals
4.15.12 Demonstrate the correct procedures in the disassembly of the equipment in
4.15.11 using the correct tools and equipment.
4.15.13 Rectify all faults and replace worn components.
4.15.14 Demonstrate the correct procedure in the assembly and installation of the
machinery and equipment in 4.15.11 with regard to correct alignment and
positioning.
4.15.15 Carry out planned maintenance of workshop machines and equipment to
include boilers.
5.0 ASSESSMENT
5.1 ASSESSMENT SCHEME
TOPIC NO. TOPIC WEIGHT%

1 WORKSHOP HEALTH AND SAFETY 4
2 HAND TOOLS AND BENCH WORK 8

3 MEASURING AND GAUGING 6
4 MARKING OUT TOOLS 5
6 ENGINEERING MATERIALS 5
7 HEAT TREATMENT 6
9 JOINING METALS 8
10 POWERED HAND TOOLS 5

11 DRILLING 6
12 PEDESTAL GRINDING 5
13 TURNING 12
15 SLOTTING AND BROACHING 5
80
16 MILLING 10
17 PRECISION GRINDING 5
PLANNED AND GENERAL MAINTENANCE OF
18 MACHINES AND EQUIPMENT 10
TOTAL 100

1. Kalpakjian, S. and Schmid, S.R. (2015) Manufacturing Engineering and Technology. 6th
Edition.
Delmar Publishers.
4. Kazanas, H. C, Glenn, E. and Gregor, T. (1991) Manufacturing processes. McGrawl Hill
6. Wynter, E.J. (2012) Metalcraft. London. Longman.
81
SUGGESTED PROJECTS AND PRACTICAL ACTIVITIES
FIRST HALF OF COURSE

1. Drill Point Gauge
- mark out
- hacksawing (hand)
- drilling
- filing
2. Double open spanner or closed hexagon
- mark out
- hacksawing (hand)
- drilling
- filing
- chiselling
3. Tap Wrench
- hacksawing
- marking out
- drilling
- filing
- hand tapping
- parallel turning
4. Filing, drilling, tapping exercise (rectangular block)
- marking out
- hacksawing
- drilling
- filing
5. Centre punch and pin punch
- turning
- grooving
- knurling
- taper turning (compound slide)
- point hardening
6. Taper shaft
- parallel turning between centres
82
- taper turning between centres

7. Turning and fitting exercise (Precision)
- Parallel turning (between centres)
- grooving
- boring
- drilling on the lathe, form turning
8. Eccentric turning (cam shaft)
- marking out (eccentric marking out)
- parallel turning
- screw cutting
- eccentric turning (one throw)
- internal screw thread to match using boring tool.
9. Tack Hammer
- parallel turning
- radius turning
- taper turning
- knurling
- shaping
- drilling
- counter sinking
- chamfering
- radius filing
10. Precision filing and fitting test
- marking out
- hand hacksawing
- drilling
- chiselling
- filing
11. Precision Fitting and Turning Exercise
- marking out
- hand hacksawing
- drilling
- chiselling
- filing
83
- boring
12. Trammel points
- parallel turning
- concave and convex radii turning
- drilling and reaming
- screw cutting (internal and external)
- taper turning
- knurling
- milling (flat)
13. Vee block
- marking out
- flat surface shaping and milling
- angular shaping
- slot shaping and milling
14. Lathe toolholder
- flat surface milling
- marking out
- slot milling
- drilling
- tapping
- step milling
15. Actual Projects
- screw jack
- G Clamp
- Hand vice
- toolmaker’s clamp
- gear puller
- pipe vice
- crank slide mechanism
SECOND HALF OF COURSE

1. Tapered Screw Plug
- parallel turning
- taper turning
84
- recessing
- screw cutting (multi start left hand vee)
- internal screw cutting
- boring
- knurling
- milling
- indexing
2. Screw jack
- parallel turning
- drilling
- boring
- internal square thread
- cutting
- tapping
- knurling
- milling
- square thread
- slot milling
- taper turning
3. Adjustable Parallel Packing
- plain milling
- angular milling surfaces
- slot milling
- shaping
- dovetail milling
- thread taping
- surface grinding
4. Basic Fabrication Exercises
- gas welding
- arc welding
- oxy – fuel cutting
5 Scribing Block
- parallel form turning
- knurling
85
- drilling
- boring
- form grooving
- slot cutting
- bending
- hardening
6. Arbor Press
- Rack and pinion
7. Clutch Extractor
- indexing
8. Sine bar
-surface and cylindrical grinding
9. Paper Punch
10. Impact Hammer
11. Ratchet Press
PAPER FORMAT FOR WORKSHOP PRACTICE EXAMINATION

• Candidates to sit for a standard 32-hour common practical examination machining project
• Regions to avail all necessary materials for the exam.
• HEXCO rules and regulations for conducting practical examinations to be adhered to.
• Advance information is required for this practical paper. The information should reach
regions 4 weeks before the date for the practical examination.
86

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ZIMBABWE

MINISTRY OF HIGHER AND TERTIARY EDUCATION, SCIENCE AND

HIGHER EDUCATION EXAMINATIONS COUNCIL

REGULATIONS AND SYLLABUS

COURSE CODE: 340/18/CR/0

IMPLEMENTATION DATE: January 2019

2.0 CONSULATATIONS YEAR

PART I COURSE REGULATIONS

1.0 TITLE AND LEVEL OF AWARD

4.0 COURSE STRUCTURE

6.0 ENTRY REQUIREMENTS

7.0 MODE OF STUDY

8.1 ASSESSMENT SCHEME

MODE OF STUDY WEIGHTING

Skills Competency Testing

On The Job Education

10.0 CONDITIONS OF AWARD

13.0 IRREGULAR PRACTICES

14.1 Lecturer’s Qualifications

Radius Gauge Set: 0.75mm – 13.0 mm

MACHINE & CUTTING TOOLS AND GENERAL EQUIPMENT

Fixed Machine Vice

14.3 SUGGESTED REFERENCE BOOKS

7. Basant, A. and Agrawal, C, M. (2014) Engineering Drawing. McGrawl Hill Education

SUBJECT: WORKSHOP TECHNOLOGY

JIGS AND FIXTURES

4.2 HAND TOOLS AND BENCH WORK

4.3 POWERED HAND TOOLS

4.4 MEASURING TOOLS

4.5 MARKING OUT

4.7 DRILLING MACHINES AND OPERATIONS

4.8 ENGINEERING MATERIALS

4.9 HEAT TREATMENT

4.10.8 Explain importance of wheel truing and dressing.

4.11 POWER SAWS AND BAND SAWS

4.11.7 Select blades for each specified operation

4.13 SLOTTING AND BROACHING

4.14 STANDARD OF ACCURACY

4.15 JIGS AND FIXTURES

(b) gear cutting

4.17 OPERATIONAL PLANNING

4.19 LUBRICATION AND CUTTING FLUIDS

- gauges to include (temperature and pressure)

WORKSHOP TECHNOLOGY PAPER 2, 340/18/S01B

6.0 SUGGESTED REFERENCE BOOKS

7.0 WRITTEN PAPER STRUCTURES FOR THE WORKSHOP TECHNOLOGY

7.1 WORKSHOP TECHNOLOGY PAPER 1: WORKSHOP PROCESSES

7.2 PAPER FORMAT FOR WORKSHOP TECHNOLOGY PAPER 1

7.3 WORKSHOP TECHNOLOGY PAPER 2: MACHINING PROCESSES

PAPER FORMAT FOR WORKSHOP TECHNOLOGY PAPER 2

SUBJECT: ENGINEERING MATHEMATICS

4.2 TRANSPOSITION OF FORMULAE

4.3 SIMPLE, SIMULTANEOUS AND QUADRATIC EQUATIONS

4.6 COORDINATE GEOMETRY

4.7 RADIAN MEASURE

4.8 MENSURATION (AREAS AND VOLUMES)

4.9 BINOMIAL EXPANSION

6.0 SUGGESTED REFERENCE BOOKS

1. Bird, J.O. (2003) Engineering Mathematics. 4th edition. Newness. London.

7.0 PAPER STRUCTURE

SUBJECT: ENGINEERING SCIENCE

4.6 WORK, ENERGY AND POWER

- Wheel and axle lifting