UNIVERSITI TUN HUSSEIN ONN MALAYSIA

CENTRE FOR DIPLOMA STUDIES

LABORATORY REPORT

COURSE NAME MECHANICAL ENGINEERING WORKSHOP I

TITLE OF EXPERIMENT FITTING
COURSE CODE DAM 13701 GROUP
SECTION 5
LECTURER'S NAME
GROUP MEMBERS MATRIC ASSESSMENT
1 MUHAMMAD TAUFIQ HAKIMI BIN JAMIL AA231745 Cognitive - PLO1
2 SEAN LIM SHEN WANG AA230020 Objectives 2.5%
3 Additional
5.0%
4 Theory/ Info
5 Discussion 10.0%
DATE OF EXPERIMENT Conclusion 10.0%
DATE OF SUBMISSION References 2.5%
EXAMINER COMMENTS TOTAL (PLO 1) 30.0%

Psychomotor - PLO5
Apparatus 10.0%
Procedures 20.0%
Observations 10.0%
Workpiece 20.0%

APPROVAL STAMPS TOTAL (PLO 5) 60.0%

* Detailed components for results of
experiment. Changes are subjected to the
form of experimental results obtained.
** The assessment rating guidelines in
the TOS of report must be used together
when conducting the evaluation.
1.0 Objectives

-The objectives of this workshop is to measure and mark,file edge,file surface,file angle,hacksaw,drill
hole,tapping in and punching in the workpiece.Other than that,we should be able to operate the drilling machine
post,recognize the hand tools used in the fitting process, as well as how to use the vernier calipers for
measuring.Besides that,we should also be able to read and interpret engineering drawing,know basic workshop
process,inspect the job for specified dimensions and adopt safety procedures while working on various machines.
2.0 Additional theory

-Engineering workshop is a place where students obtain knowledge on the operation of a multitude of processes
involved in manufacturing and production.Bench work and fitting has its own significance in engineering
work.Even after machining,finishing by hand,to get an exact accuracy is called bench work.In short bench work
refers to an activity that had been carried out on a bench,but in engineering workshop benchwork means a work is
done on the bench in a workshop.Benchwork includes sawing,milling,filing and,marking.

-Fitting is the assembly of two coherent parts, they may either be tight or loose fitting. The degree of tightness or
looseness between them is termed as fit. Manufactured parts are mostly required to fit one another. They may be
designed to slide freely against one another or bound together to form a single unit.
3.0 Observations/Safety

-Throughout the whole fitting process,there were several problems encountered:

1. Cutting on the work pices were skewed/not straight

Solution: Hold hacksaw the proper way by tilting the hacksaw by 45 degrees from the workpiece when cutting.

2. Lack of accuracy on measurement

Solution: Make sure the surface of the workpiece is placed on a flat palne before marking using an angle plate
and vernier height gauge.A non flat surface would greatly impact the measurement.

3. Work pieces do not fit and are not in the required shape
Solution: The surface of the work piece is made sure to be placed on a flat plane when marking using angle
plate and vernier height gauge.The work pieces were also filed down in order to match the required dimensions.

Safety precautions

-Before carrying out any work in the workshop,permission must be obtained from the workshop supervisor or
lecturer.When using powered tools,use goggles.Work area should be cleaned after use.Be disciplined in the
workshop and refrain from playing with the tools.When using a hacksaw,make sure its teeth is sharp and faced in
the forward direction.While using a chisel,direct it away from other persons.
4.0 Apparatus

 Rough flat file

- Used to remove metal or material quickly and roughly.

 Smooth flat file

- Used to smoothly remove very tiny parts of the metal or material and can be used to polish the metal as
the finishing step.

 Rough triangle file

- Used to remove metal or material quickly and roughly at the edgy part.
 Smooth triangle file
- Used to smoothly remove very tiny parts of the metal or material at the edgy part.

 Scriber
-Used to mark and make precise line on material surface for the guidance of cutting process and
measurement.

 Engineer L square
-Used for measuring and marking right angle in various construction.
 Centre punch
-Used to create centre mark on the workpiece. This will help the drilling process to drill accurately on the
centre point.

 Cold chisel
-Use with hammer to cut or remove metal piece by striking on it.

 Drill press machine

-Provide precise and controlled drilling operation for the accurate hole creation on the metal.
 Bench vice
-It can hold the workpiece securely in place during various manual operation such as cutting and shaping.

 Thread tap
-Used to create a pathway for screw or bolt.

 Hacksaw
-Used to cut the materials, especially metal.
5.0 Procedure

1. Choose 3 suitable metal piece base on the measurement of the part A,B and C. Choose
50 x 46 cm for part A and B . Choose 50 x 59 cm for part C.
2. Scrape the metal using flat file if the metal has mismeasurement. Scrape until it follow the actual size
base on this manual:

3. Measure the frame and use scriber to make the lines on the metal piece base on manual.
4. Make holes on the drill parts with a hammer and centre punch . Punch it at the intersection point.
5. Use drill press machine to make the hole, adjust the position of the metal. For part A, use drill bit size ∅7
for centre big hole and use size ∅4 for relief hole and make 4 small hole at the unused part to ease the
cutting process. Do the same for part B base on manual.
6. For part C, make 2 hole with drill bit size ∅5.
7. Use thread tap size M6 x 1.0 at the hole that has been made on part C. Tap until the pathway clearly
visible.
8. Remove the unused metal of part A and B. Cut the unused metal with hacksaw depend on the line.
9. Strike the unused piece of part A and B until it break with hammer and cold chisel to remove the part.
10. Scrape the remaining metal on part A and B with file until it follow it shape and measurement. Use flat
file on the flat surface and use triangle file on edgy part.
11. Polish the metal of part A, B, and C with smooth flat file until the rust disappear.
12. Fit and assemble the metal base on instructions below.
6.0 Workpiece

Part A

Part B

Part C
Assembled part A, B and C
7.0 DISCUSSION

1. Based on the results of the workpiece that has been produced, make a comparison between dimensions of
the final result of the workpiece with the dimensions of the drawing of the workpiece.

Part A

Drawing Final result

10 10

50 50

13 13.2

10 10

10 10.5

46 46

40 40

Ø relief hole x 4 Ø relief hole x 4

Ø7 Ø7

Part B
Drawing Final result
15 15
30 30
10 10.5
10 9.5
46 46
13 13.5
40 40
50 50
Ø7 Ø7
Part C

Drawing Final result

10 10
25 25
50 50
23 23
59 59
M6 x 1.0 M6 x 1.0
 The difference in the two workpieces compared to the drawing of the workpiece is because of the
tolerances that use to ensure that the final product is readily usable. If tolerances did not involve in this works,
there will be a problem to our final product such as component can’t fit because there is no tolerance in
measuring. Not setting a tolerance in a critical area may render the part unusable according to the design intent, as
each fabrication method comes with a certain level of inaccuracy.
After that, works from unexperienced person also plays an important role to make the measuring is
perfect. This is because they not familiar with the equipment that used in this work. In addition, the equipment
that used in this work is a real machines that used in factory so it is rarely to use it. However, it would not be a
problem because they have gain experienced by doing this work.
8.0 Conclusion

At the end of workshop, based on the result, the metal has been turn into different shape and can fit each
other. To turn this piece of metal into different things, it require the skills of drilling, cutting, scraping and
skill of using all hardware equipment that involve in this workshop. The metal will fit orderly if we use the
equipment correctly especially on the usage of drill and hacksaw. But, if we use it without knowing the skills,
the metal piece may be inaccurate. The measurement too need to be proper. Whenever in marking process,
the mark should be measured accurately depend on the measuring from the manual. If the first step is wrong,
the entire process will be wrong and the metal piece will be fail to assemble. That’s why it’s important to
measure it properly. And the most important thing in workshop which is safety. It is important to obey the
workshop rules like wearing personal protective equipment before work to ensure the safety of workshop
user.
9.0 References

1. https://issuu.com/damamhardware/docs/what_are_the_types_of_hardware_tools_and_how_are_

2. https://en.m.wikipedia.org/wiki/File_(tool)

3. https://www.protoolreviews.com/types-of-drills-know-what-drill-to-use-when/

4. https://mechanicalenotes.com/fitting-workshop/

5. https://www.gfpmachines.com/10-general-workshop-safety-tips-rules/