MECHANICAL ENGINEERING DEPARTMENT

DJJ3032 - MECHANICAL WORKSHOP PRACTICE 3

REPORT
(METAL INERT GAS (MIG))

NAME MOHD ASYRAAF BIN MOHD ALI

MATRIC 20DKM18F2037 CLASS DKM 3A

MR MOHAMMAD SYAHIDULLAH BIN AHMAD ANUAR

LECTURER

CLO1 (10%) CLO2 (10%)

ASPECT SCORE ASPECT SCORE
5 4 3 2 1 5 4 3 2 1

Introduction Result

Equipment Discussion

Procedure Conclusion

Safety Reference
precautions

1
 1.0 INTRODUCTION
Metal inert gas welding, or MIG welding, is the most widely used of the arc welding
processes. It is suitable for everything from hobbies and small fabrications or repairs,
through to large structure , shipbuilding and robotic welding. MIG can be used on broad
range materials and thickness, and the latest Super Pulse technology enables MIG to give a
finish that is similar to that obtained TIG (Tungsten inert gas) welding, yet with the speed
for which MIG is renowned
The concept underlying MIG welding is simple, with the arc being stuck between the tip of
the reel-fed wire as it emerges from the torch, and the workpiece. A shielding gas prevents
oxidation forming, or the use of some flux-cored wires avoid the need for a shielding gas.
With most MIG welding steps, the user sets the wire feed speed, which determines the
current; the user sets the voltage to suit that current.
Ease of use is clearly a major benefit if MIG in many applications, but speed is also
important. It is far quicker to lay down weld metal with MIG and TIG, MMA(manual
metal arc- or ‘stick’ welding) or gas welding.

2.0 OBJECTIVES
I. To gain experience and knowledge of the use of MIG arc-welding and materials
safe.
II. To learn how to use MIG machine and hand tool
III. To improve patience while do work piece
IV. To learn how to weld butt joint
V. To discipline students using workshop should
VI. Able to help students in the job environment

3.0 SAFETY DURING WORK

Some of measures that need to be done while in welding workshop are:
I. Well-dressed, neat and safe.
II. Wear headshield when welding. Googles protect the eyes when student operate
MIG welding.
III. Do not look at welding with the naked eye as strong arc light can cause eye pain,
glare and juicy.
IV. Put the lid onto the shirt before use MIG welding.
V. When wearing an apron workshop, always tie back not in front.
VI. Remove watches and rings as they can endanger yourself while using the welding
conditions and cause injury.
VII. Turn off welding machine before cleaning.
VIII. Always ensure MIG welding and hand tools are clean.
IX. Make sure the floor is not greasy so as to avoid injuries from occurring

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 4.0 TOOLS AND EQUIPMENT
I. Machine MIG
II. Chipping Hammer
III. Wire Brush
IV. Welding Gloves
V. Welding Helmet
VI. Engineering chalk
VII. Chisel
VIII. Welding gun
IX. Gas cylinder (CO2/Argon)
X. Wire Feeder

5.0 PROCEDURE
I. Clear the part of the metal sheet before start welding.
II. Put two metal sheet on the flat place to butt weld.
III. Connect the earth line one the iron material so that current can be discharge
IV. Setting the machine suitable current AC/DC and the spark.
V. Firstly weld a straight run of welding between two metal sheet.
VI. Next weld the nails at the side between two metal sheet.
VII. After weld the nails, then butt weld the metal sheet at the side between two metal.
VIII. After butt joints, clear the slag to make sure welding is done.

6.0 CONCLUSION
From the results of this assignment I have learned many things during this project,
especially in dealing with MIG machine. This is because there are several steps that must
be followed before conducting proper welding proper is . For example adjust the gas
pressure which is suitable for welding workpiece. I also gain experience and knowledge of
the use of MIG arc-welding and material safe. At last also know how to use MIG-machine
and hand tools in the right way

3
 MECHANICAL ENGINEERING DEPARTMENT

DJJ3032 - MECHANICAL WORKSHOP PRACTICE 3

REPORT
(TUNGSTEN INERT GAS (TIG))

NAME MOHD ASYRAAF BIN MOHD ALI

MATRIC 20DKM18F2037 CLASS DKM 3A

LECTURER MR WAN JAMALILAIL WAN MOHD ZEN

CLO1 (10%) CLO2 (10%)

ASPECT SCORE ASPECT SCORE
5 4 3 2 1 5 4 3 2 1

Introduction Result

Equipment Discussion

Procedure Conclusion

Safety Reference
precautions

4
 1.0 INTRODUCTION
Originally Inert Gas Tungsten Arc Welding (Tungsten Inert Gas) is a type of arc welding
made the atmosphere control. Tungsten electrodes were used. Electrodes only to produce
an arc only. So, for the weld when the metal Additional required to weld, trunk filler rod
should be fed to the weld area as methods done in oxy-gas welding process acetylene.
During the welding process is a shield in the form of gas inert (argon & helium) is used to
block the welded from atmospheric air. Shied works for the prevent oxidation at the
electrode tip, a puddle weld and the parent metal in the vicinity of the welded. There are
two types of commonly used welding nozzle weld TIG operation manually. For welding
use per current is low (less than 200 amperes) when welding thin is material, weld nozzles
are usually of the type that can be cooled in air conditioning. But, for welding require more
current than 200 amperes , the nozzle weld should be cooled with water so that the
electrodes do not become overheated.

2.0 OBJECTIVES
I. To gain experience and knowledge of the use of TIG arc welding and materials
safe.
II. To learn how to use TIG machine and hand tool in the right way
III. To improve patience while do work piece
IV. To learn how to weld butt joint

3.0 Safety During Work

Some of measures that need to be done while in welding workshop are:
I. Well-dressed, neat and safe.
II. Wear headshield when welding. Googles protect the eyes when student operate
TIG welding.
III. Do not look at welding with the naked eye as strong arc light can cause eye pain,
glare and juicy.
IV. Put the lid onto the shirt before use TIG welding.
V. When wearing an apron workshop, always tie back not in front.
VI. Remove watches and rings as they can endanger yourself while using the welding
conditions and cause injury.
VII. Turn off welding machine before cleaning.
VIII. Always ensure TIG welding and hand tools are clean.
IX. Make sure the floor is not greasy so as to avoid injuries from occurring

5
 4.0 TOOLS AND EQUIPMENT
I. Machine TIG
II. Wire Brush
III. Welding Shield
IV. Safety Gloves
V. Apron
VI. Two metal sheet
VII. Chipping Hammer
VIII. Engineering Chalk
IX. Argon gas
X. Electrode holder
XI. Tungsten Electrode

5.0 PROCEDURE
I. Firstly choose the Electrode.
II. Grind the electrode if the rod is a brand-new cylinder and doesn’t have a pointed or
rounded tip yet
III. Insert the electrode into its collet.
IV. Choose the settings.
V. Turn on the gas.
VI. Prepare workpiece and welding table
VII. Clean the workpiece to be in welding.
VIII. Firstly weld a straight run at two sheet of workpiece
IX. Next put the two workpiece to locate the ends of the material and do weld the nail
on the connection of the workpiece.
X. Perform TIG weld finish filling the space with use of the rod.
XI. Switch TIG weld and cover gas pressure when finished welding steel connections
and cool the workpiece.
XII. Clean the slag on the workpiece by using an air purifier to get the results updates.

6.0 Conclusion
From the results of this assignment I have learned many things during this project,
especially in dealing with TIG machine. This is because there are several steps that must be
followed before conducting proper welding.

6
 MECHANICAL ENGINEERING DEPARTMENT

DJJ3032 - MECHANICAL WORKSHOP PRACTICE 3

REPORT
( LATHE MACHINE)

NAME MOHD ASYRAAF BIN MOHD ALI

MATRIC 20DKM18F2037 CLASS DKM 3A

LECTURER MR ALFAN SERAIL

CLO1 (10%) CLO2 (10%)

ASPECT SCORE ASPECT SCORE
5 4 3 2 1 5 4 3 2 1

Introduction Result

Equipment Discussion

Procedure Conclusion

Safety Reference
precautions

7
1.0 INTRODUCTION
Lathe machine is one of the most versatile used machine tools over the world. The main
function of lathe is to remove metal from a workpiece to give it require size and shape. The
workpiece is securely and rigidly held in the chuck or in between centres on lathe machine
and then turn it against a single point cutting tool which will remove metal form the work
piece in the form of piece.
A lathe machine is generally used in metalworking, metal spinning ,woodturning, and glass
working. The various operation that it can perform include the following: sanding, cutting,
knurling, drilling, and deforming of tools that are employed in creating objects which have
symmetry about the axis of of rotation. Some of the most common products of the lathe
machine are crankshaft, camshafts, table legs, bowls, and candlestick holder
There are many lathe accessories provided by the lathe manufacturer along with the lathe,
which support the lathe operations. The important lathe accessories include centres, catch
plate and carriers, chuck, collets, face plates, angle plates, mandrels and rests.

2.0 OBJECTIVE
I. To identify type of lathe machine and their function in the process of designing the
objects you want to create.
II. To operate lathe machine more confidently
III. To use the measuring tool more confidently
IV. To learn how to use lathe machine well.

3.0 SAFETY DURING WORK

I. Always use google when operating the machine
II. Remove the watch, rings and bracelet as they can endanger yourself while using the
lath machine and cause injury.
III. Make sure the machine is in good condition before using it.
IV. Make sure to turn off lathe machine before cleaning.

4.0 TOOLS AND EQUIPMENT

I. Safety glasses
II. Vernier Calliper
III. Tipped tool bit
IV. Lubricant oil
V. Turret tool post
VI. Allen Key
VII. Brush

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 5.0 PROCEDURE
I. Read the project instructions submitted by the instructor/ lecturer
II. Make sure the size of the workpiece is in accordance with the machining process to
be handled
III. The size to be cut should be sharpened so that the workpiece is safe to use during
the machining process.
IV. Make sure the machine in good condition and safe to use before using the machine
V. Mount the tipped tool bit and position the tipped tool bit correctly on the back gear
to make it accurate.
VI. Adjust the gearbox according to the appropriate feed size and ON the engine
mount.
VII. Follow the precautions using the lathe machine to prevent accident.
VIII. Start the process with the easy part first and then follow by more difficult step until
the work is aligned.
IX. Turn off the machine after finish using the machine.
X. Clean the lathe machine every time you finish using the machine.

6.0 CONCLUSION
From the result of this assignment I have learned many thing about lathe machine
especially about the function of lathe machine, how it used, safety measured, the accuracy
of the measurement and how it is measured as well as the time distribution.

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 MECHANICAL ENGINEERING DEPARTMENT

DJJ3032 - MECHANICAL WORKSHOP PRACTICE 3

REPORT
(MILLING MACHINE )

NAME MOHD ASYRAAF BIN MOHD ALI

MATRIC 20DKM18F2037 CLASS DKM 3A

LECTURER MR REDZA IZWAN BIN ABDUL RAHMAN

CLO1 (10%) CLO2 (10%)

ASPECT SCORE ASPECT SCORE
5 4 3 2 1 5 4 3 2 1

Introduction Result

Equipment Discussion

Procedure Conclusion

Safety Reference
precautions

10
 1.0 INTRODUCTION
Milling machine is one of the important machining operations. In this operation the
workpiece is fed against a rotating cylindrical tool. The rotating tool consists of multiple
cutting edges (multipoint cutting tool). Normally axis of the rotation of feed given to the
workpiece. Milling operation is distinguished from other machining operation on the basis
of the orientation between the tool axis and the feed direction, however, in other operations
like drilling, turning etc. the tool is fed in the direction parallel to axis of rotation.
The cutting tool used in milling operation is called milling cutter, which consists of
multiple edges called teeth. The machine tool that perform the milling operation by
producing require relative motion between workpiece and tool is called milling machine. It
provides the require relative motion under very controlled conditions. These condition will
be discussed later in in this unit as milling speed, feed rate and depth of cut.
Normally, the milling operation creates the plan surfaces. Other geometries can also be
created by milling machine. Milling operation is considered an interrupted cutting
operation teeth of milling cutter operation teeth of milling cutter enter and exit the work
during each revolution. This interrupted cutting action subject the teeth to a cycle of impact
force and thermal shock on every rotation. The tool material and cutter geometry must be
designed to bear the above stated conditions. Depending upon the positioning of the tool
and workpiece the milling operation can be classified into different types.

2.0 OBJECTIVE
I. To identify type of milling machine and their function.
II. To operate milling machine more confidently.
III. To use the measuring tool more confidently.
IV. To learn how to use lathe machine well.

3.0 SAFETY DURING WORK

I. Do not make contact with the revolving cutter.
II. Place a wooden pad or suitable cover over the table surface to protect it from
possible damage.
III. Use the buddy system when moving heavy attachments.
IV. Do not attempt to tighten arbor nuts using machine power.
V. When installing and removing milling cutter, always hold them with a rag to
prevent cutting your hands.
VI. While setting up work, install the cutter last to avoid being cut
VII. Never adjust the workpiece or work mounting device when the machine is
operating.
VIII. Chips should be removed from the workpiece with an appropriate rake and brush.
IX. Shut the machine off before making any adjustment or measurement.

11
 4.0 TOOL AND EQUIPMENT
I. Milling chuck
II. Face milling cutter size 20mm
III. Rubber mallet
IV. Y type spanner
V. Milling collect
VI. Water Coolant
VII. Vernier calliper
VIII. Spinner
IX. Work piece
X. Dividing Head (indexing heat)

5.0 PROCEDURES
I. Face mill cutter size 20mm installed at the spindle and hold the workpiece in
chuck.
II. Set the cutting speed and feed according to the requirements by reference to the
instructions or codes provided on the machine
III. Tighten the 15mm length of work piece edges with a face mill cutter so that it
touches slightly and set it fed to 0.00mm. Make sure that the part of the workpiece
that we want to perform facing is located in the centre of the cutter and that all the
edges can be cut into the cutter.
IV. Then turn it machine and water coolant and start feeding by moving the table
forward and backward so the edges of cylinder of 15mm workpiece become flat.
V. Then rotate the workpiece by 60 degree and repeat step IV to complete 360 degree
turn.
VI. Repeat step IV and V by adding every 0.5 feed for full round 0f 360 degree up to
1.5 to form a hexagon with distance between the side of 32mm and distance
between the corners is 35mm
VII. Low the machine table and turn off the machine.
VIII. Clean the machine after the work is done.

6.0 CONCLUSION
From this activity I have learned how to organize the milling machine and understand the
operation involved. Beside that, we also know the purpose of the main parts of this
machine. The laboratory activities also provide us the information about the various type of
milling machine and cutter available for different milling process in manufacturing world
process. In addition, we had gained the knowledge of understanding their usage and
function where it can be produce different shapes of work piece with different types of
surfaces. All safety precautions are also taken seriously with the clear explanation from the
instructor.

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