REFERENCE NO: E22 - MASHOP 1 1. COURSE NAME: Machine Shop 1 2.

COURSE DESCRIPTIONS: The course includes the Safe Working Practices, Hand Tools and Measuring Equipment for Dismantling, Maintenance, Repair and Re-Assembly of Shipboard Plant and Equipment and Fabrication and Repair. 3. NUMBER OF UNITS FOR LECTURE AND LABORATORY: 1 LECTURE, 2 LABORATORY = 3 UNITS 4. NUMBER OF CONTACT HOURS PER WEEK: 1 LECTURE, 6 LABORATORY = 7 HOURS 5. PREREQUISITE: Engineering materials 6. COURSE OBJECTIVES: The students shall be able: 6.1 to properly use hand, power and measuring tools to carry out normal maintenance, repairs and fabrication works onboard ships with safety as the primary concern. 6.2 to perform Benchwork and Tinsmithing and joining of metals FUNCTION: F1 - Marine Engineering at the Operational Level (Use of appropriate tools, Handtools and Measuring Equipment) 7. COURSE OUTLINE: LEARNING OBJECTIVES/OUTCOMES: The students shall be able to . . . . . . 7.1 Safe Working Practices 7.1.1. Safety list typical identifiable and non-identifiable hazards in an engineering environment describe the procedure to ensure safety when using a grinding machine demonstrate an awareness of the dangers which exist when using a lathe use the correct practice to avoid accidents when using a drilling machine describe the control necessary over the power supply to a machine tool list the processes for which the power supply to a machine must be isolated
E22 - MASHOP 1 page 1 OF 11 explain the use of a hacksaw using a hacksaw.4 skin protection 7.2.4 state when a scriber should not be used for marking out describe the care necessary for hands.2. including thin-walled pipe demonstrate the care of : 7.1 Use of Hands and Power Tools 7.2.4 select the correct hacksaw blade for a given job and fits it into a saw frame with the correct tension 7.9 describe the situations where the following should be worn scribers 7.1.1 datum faces 7.1.1 safety helmets 7.1.1. working from: Maintenance.3 explain the general relationships between tooth pitch of a hacksaw blade and the hardness and thickness of the material to be cut 7. the correct technique. name the correct file selection to be used for given situations E22 . describe the basic differences between ‘stop’ and ‘start’ buttons 7.2.2 datum lines 7.3 explain the uses of 60 degrees and 90 degrees punches 7.2 Hand Tools 7.1.6 explain the use of files 7. including that for any cuts or abrasions 7.2 identify the types of hacksaw blade available and describes their application 7.1.8 describe the purpose and sitting of ‘emergency stop’ buttons 1 page 2 OF 11 .1.2 vee blocks Repair and Re-Assembly of Shipboard Machinery and Equipment demonstrate the care of : 7.2 eye protection surface plate 7.2.2 dividers 7.1 Marking Out Use Hand Tools and Measuring Equipment for Dismantling.10 tate when hands and arms should be washed with soap and water 7.1.3 odd-leg calipers demonstrate. use the tools included in the above objectives to mark out simple exercises.2. to cut common materials. protective footwear 7.

1.17 use and sharpens a chisels listed in the above objective in a correct and safe manner 7. and safety precautions necessary when using files the following files.2.8.11 describe the uses of flat and half-round scrapers diamonds-cut 7.15.8 7.4.13 use scrapers correctly on given exercises 7.1 7. explaining their use: explain why dimensional control is necessary 7. Powered Hand Tools 7.5.2 explain what governs the diameter of the hole to be drilled prior to tapping explain the use of chisels E22 . describe the different techniques used in cutting: small-diameter threads large-diameter and fine threads 7.2.MASHOP 1 page 3 OF 11 . cuts internal threads in open-ended and blind holes and external threads on small. demonstrate the care of. state the practical maximum and minimum capacities of an electrically powered hand drill identifies the processes for which powered hand tools might be used 7. second-cut and smooth 7.15 describe the use of the following cold chisels: explain the purpose of taper’s second plug taps 7.2.4 round-nose 7.2. Measurement 7.2.1 flat 7.10 use rough and finishing files correctly on given exercises describe the safety measures necessary when using a chisel explain the difference in use of a die nut and stock and die use powered hand tools safely and correctly and care required explain the care necessary for the supply cables of powered hand tools Thread Cutting 7.1.and large-diameter rod double-cut – rough. cross-cut demonstrate how scrapers are sharpened and cared for single-cut –smooth and second cut name the types of power used in hand tools 7.1.

MASHOP 1 page 4 OF 11 . Drilling Machines 7.1.10explain the principles of the vernier caliper 7.6.2 state engineering terms used to describe geometrical surfaces and vice-versa 7.18explain briefly why and how dimensions of components are checked by comparison explain how a workpiece is held place. explain the purpose of the ratchet fitted to a mechanical micrometer demonstrate the use of a common datum when using a steel tube state the difference between functional and nonfunctional dimensions and the relative tolerance given to each 7.9 use small-scale vernier callipers to measure internal and external dimensions to an accuracy of 0.7 checks a try-square for accuracy against a master square explain how feed rates are determined E22 .1.2.7 state that accurate drilling is very difficult to achieve use inside and outside callipers to measure diameters use a bevel gauge and a plain protractor to check and mark out angles 7.2.16use micrometers correctly and accurately 7.1.14list measuring instruments which use the micrometer principle 7.6 relate the approximate limits on drill diameters and the uses of the machines listed in the above objective and adjusts the zero reading of a micrometer that the vernier principle can be applied to micrometers to give greater accuracy 7.6 use a try-square to check 90 degrees angles the accuracy of micrometer measurements 7.8 state the general relationship between drill diameter and rotational speed 7.2.20use a standard dial test indicator to compare dimensions 7.1.5 name the types of drilling machines used in engineering workshops 7.02 mm state the accuracy obtainable using a steel rule 7.3 explain briefly how drills are held in a machine emphasizing dangerous practice and the particular problem when drilling thin plate 7.2.19explain the principle of operation of a standard dial test indicator plunger-type comparator demonstrate the care of micrometer instruments 7.1 list the uses of a drilling machines 7.1.2.

1.7.3 parallel-shank long series explain the principal uses of the following drills and tools: spotfacer 7. Drills 7.3 clearance angle state the normal allowances on hole diameter for reaming stub 7.1.10lists the operation which can be carried out by using a pillar drilling machine spindle speeds to those of a sensitive machine 7.1.1 set up work 7.13describe the care necessary to avoid accidents when using automatic feed four-fluted drills 7.7.1 sketch the cutting face of a twist drill. reamers .8 sharpen twist drills safely and correctly 7.3 counterbore.2.15list the steps taken to: Morse-taper-shank series its simple term the difference between the worktables used on pillars machines the procedure for inserting and removing drills with parallel and with tapered shanks explain the purpose of four basic heat treatments E22 . reaming 7.1.7 use drilling machines to carry out all of the processes included in the above objectives correctly explain how speeds and feeds are affected with when: the land 1 page 5 OF 11 .2.2.2 explain the care necessary when using twist drills two.7.7 counter sinker 7.2 list four basic heat treatments 7. showing.1 parallel-shank jobber series 7. Heat treatment of Carbon Steel explain the purpose of heat treatment 7.1. ream or countersink 7.hand and machine 7.2 countersinking 7.17describe the care necessary when using automatic feed 7.7.11 explain how feed is provided to the drill on the pillar machine explain the care necessary when driling plastics drill rake angle 7.2. annealing state the source of early adhesives 7.4 sketch the four joint configurations 7.8.3 fire explain the principle of bonding smooth surfaces and states applications color identify a cemented joint 7.2. Adhesives and Bonding Health and Safety application conditions 7.1.1 explain the care necessary when using adhesives.9.2.7 explain the principle of bonding friction linings to steelshoes or discs 7.2.4 toxicity 7.8 test a hardened and tempered cutting edge taking the necessary safety precautions hardening 1 page 6 OF 11 .2 state the advantages and disadvantages of adhesive bonding normalizing compare the strength of parent material to that of s wellmade joint skin protection state the purpose of an activator when using an epoxy resin explain how component is tempered throughout its whole section 7.3 describe the basic principles of joining by using an adhesive 7.1.4 typical tool applications 7.9.4 describe the following processes and the types of steel to which they might be applied: carry out the heat treatments listed in the above objective 7.8.4 tempering 7.2 storage 7.8.12 state the significance of pot file E22 . to include: temperatures (230 to 320 degrees C) 7.5 describe the principle testing for shear strength and peel strength of adhesives 7.5 complete items of deleted information in a table which gives the following 7.

1 Permanent Joints 1 explain the limitations of soft-soldered joints and the reason explain how soft-soldered joints might be strengthened with the aid of a simple sketch. describe the uses of state the main hazards and precautions necessary when tin a soldering iron and makes a soft-soldered joints page 7 OF 11 .20 describe the principle of welding plastics 7.1 explain why not rivetting is sometimes used 7.6 soldering describe briefly metal-to-metal bonding and applications using: list the range of rivets commonly used including metal to metal E22 .3.9.1 liquid or paste select and uses the correct adhesive for a variety of applications for a variety and strength tests included in the above objectives soldering iron Soldering explain why brazing is used describe the basic principles of soldering Soft Soldering Rivetting list the steps necessary when bonding together: 7.1 list the different ways of making permanent joints 7.4 make a cold-rivetted joints 7.2 describe the principles of common forms of rivetted joint 7.2 beads or dry film Joining Plastics 7.15.1 two metal components state the need to use the correct adhesive for the plastic to be joined 7.2 friction material steel 7.13 explain the limitation on the service conditions of epoxy resins 7.19 describe the principle of solvent welding 7.2.3 7.2.14 state the special epoxy resins are made to meet particular service conditions 7.2.3 Fabrication and Repair 7.17 state the three methods of joining plastics

3bronze welding 7.2 make self-secured joints 7. when: 7.2active 7.3.3bronze welding sketch the stages of making self-secured joints 7.2brazing 7.6 describe the dangers of fume on welding and how this should be dealt with state the protective clothing to be worn when welding at the bench 7.4. its application and its removal know the differences between the uses of the following solder 7.11 explain the differences between (including the approximate melting temperature) and the uses of: 7.13.12 7.3.5 explain the effect of radiation from welding on the eyes and skin 7.14 tate the processes to be followed stating the approximate melting point. Self-secured joints explain the principles of precautions to be taken when welding or when a similar heating process is to be performed in tanks which have contained combustibles fluxes: describe the process of sweating joints explain the need for a flux.13 tate the reasons for hard soldering identify the metals which can be joined by: tinman’s solder Hard Soldering plumber’s solder state the precautions related specifically to gas welding 7.8 state the additional protection necessary when welding in more difficult situations 7.14.MASHOP 1 .3.3 state the measures necessary to protect other personnel when welding soldering 7.8 state the precautions to be taken when working in confined spaces page 8 OF 11 E22 .5 Safety and Health when Welding ake soft –and hard-soldering joints identify the common engineering metals which can and cannot be cut using an oxygen-fuels gas mixture 7.4 cut sheet steel by mechanical means Forming 1 page 9 OF 11 .3.8 state the basic principles of plasma-arc cutting state the care and precautions necessary when handling and storing compressed gas cylinders with particular reference to acetylene and oxygen 7.1 use correctly: 7.1.5 large dividers a nibbler 7.2.9 use oxygen-fuel gas cutting torch to cut straight lines and curves in mild steel plate up to 10mm thick to crop mild steel sections Mechanical Cutting 7.3 a shear machine E22 .3 describe the conditions necessary in order to cut when using an oxygen-fuel gas mixtures a flat square 7.8.2 explain the principles upon which oxygen is used to cut iron 7.8.1 describe the principle upon which mechanical cutting is based Thermal Cutting 7.1 hand shears 7.2.3 a trammel bar Plate-Work – Marking Out state the maximum thickness of mild steel plate that can normally be cut by bench shears explain the basic differences between: 7.6.5 list the gases commonly used as fuels 7.7 explain the factors which can affect the quality of cutting 7.4 surface colouring 7.1.6 identify the controls a gas cutting blowpipe and demonstrates their purpose odd-leg calipers 7.1 a chalk line state that applications of flame and plasma-arc cutting 7.2 guillotine or bench shears 7.

3.1 bend describe the principle of: macroscopic 7.3 7.1 describe the principle of bending plastics 7.3.3 nick-break explain the care and safeguards necessary when heating plastics 7.11.2 7.2 construct a list of the points to check visually after welding is completed 7.11 Inspection 1 page 10 OF 11 .5 electric welding Bonding Plates 7.2 state the range of softening temperature of plastics ultrasonic inspection 7.4 describe the principles of basic methods of plate forming including: pyramid roll initial-pinch bending rolls press brake hand operated folding machine state the maximum thickness of mild steel which can be bent using a hand operated machine describe the effect of varying the width of the vee when bending plate relate the width of the vee to the inside radius of the bent plate illustrate by means of sketch what is meant by development of a sheet metal component estimate lengths of plate. explain the limitations of visual inspection 7.3.6 microscopic inspection 7.11.12 Pipework E22 .3.6.1 construct a checklist for visual inspection during: 7.8 7.3.9 7.5 carry out penetrant tests on welded joints gas welding to include bending allowances list equipment required to bend thin steel plate without a bending machine explain the dangers encountered in sheet-metal work and the precautions to be taken design and constructs simple container from thin plate carry out the following destructive tests on welded joints: 7.4.7 list common weld defects and their caused

materials. “Machine tool operation” part i Anderson.4 9.12. et. Felicito.3. “Machine Shop Practice”.1 and ii.3. thinning and other defects 7. 1986. TEACHING AIDS: The equipment. teaching aids needed in this course is listed in the attached APPENDIX 1. MATERIALS.12.12.2 9.6 Burghard. normalizes or stress-relieves as necessary 8. Dalaguete.3. Axelred and Anderson.6 check for ovality. Nelson. 9.2 select pipe filter 7.3.7 material and process to be used 7. “Machine Shop 1”. chemicals. using both cold and hot techniques 7. Felicito.12.3.4 bend pipes. 1999.3 9. Lascoe. thickness.7.3 observe safety precautions 7. CHEMICALS. “Fundamentals of Tool Design”.1 determine minimum bend radius with regard to pipe diameter. “Shop theory”. 9.12. EQUIPMENT. E22 .MASHOP 1 page 11 OF 11 .12.5 remove bulk filter and residue 7.”Machine Shop Operation and Set Up”.3.3. Dalaguete. REFERENCES: 9.5 9.12.