Workshop management for

Baja buggy

Husain Kanchwala
Manufacturing Phase

 Manufacturing is derived from the Latin word manufactus, means made by hand. It is
specifically true in the context of a BAJA vehicle which is primarily made by hand.
 Manufacturing is the backbone of any project.
 Every team member must know the various manufacturing processes, materials being
processed, tools and equipments to be used for manufacturing different components using
proper precautions and specified safety rules to avoid accidents.
 The complete understanding of even basic manufacturing processes and workshop
technology is highly difficult for any one to claim expertise over it.
Safety Practices:
Precautions to be taken while working with different hand tools
 Screw Drivers:
Use only a screw driver with an approved handle.
Screws with burred heads are dangerous, burrs must be removed with file or an abrasive cloth. One should
use the correct tip of screw drivers while screwing, too narrow or wide tip will damage the work.
 Wrenches:
One should not hammer a wrench to loosen a stubborn fastener, unless the tool has been specially designed
for such treatment.
Always pull on a wrench to have more control over the tool as in pushing there is chance of injury.
It is dangerous practice to lengthen the wrench handle for, additional leverage. Use a larger wrench.
Choose a wrench that fit properly. A loose fitting wrench may slip and round off the corners of the bolt head
and nut.
 Hammers:
One should not operate the hammer unless its head is tightly fixed to the handle.
Never hold the hammer too far on the handle when striking a blow.
Safety Practices:
Precautions to be taken while working with different hand tools
 Files:
One should always use a file card to clean the file. Never use your hand.
One should not use a file without a handle.
Short burns formed in filling may cause serious cuts. Always use a piece of cloth to wipe the surface being
field.
Files are highly brittle and should never be used as a hammer otherwise the file will break
 Chiesels:
One should always hold the chisel in such a manner that the hammer blow may not miss the chisel to injure
your hand.
Flying chips are dangerous. Wear transparent plastic safety goggles and use a shield.
Mushroomed head of the chisel should be removed by grinding.
 Saws:
One should not test the sharpness of the blade by a running a finger across the teeth.
One should not be sure that the blade is properly tensioned.
Safety Practices:
Precautions to be taken while working with different hand tools
 Reamers:
One should remove all bars from the reamed holes.
One should use a piece of cotton waste to clean reamed holes.
 Abrasives/ Grinding:
Machine must be protected from the abrasive grains that fall from the polishing wheels during
polishing. They can cause rapid wear of the precision parts.
Grinding wheels badly worn or cracked should be replaced.
One should ensure that no combustible or flammable materials are nearby that could be ignited by
sparks generated by grinding wheels during grinding operations.
One should allow the grinding wheel to reach full speed before stepping it into the grinding position.
Faulty wheels usually break at the start of an operation.
One should slowly move job-pieces across the face of wheel in a uniform manner. This will keep the
wheel sound.
 Safety Practices:
Precautions to be taken while working with machines
 Lathe/ Machining:
Always clamp the work and tool properly with correct size of work and tool holding device.
Machine should be stopped before making measurements or adjustments.
One should check the face-plate or chuck by hand to be sure that there is no danger of the work striking any part of the lathe. Use
lubrication and frequently inspect the tool for Built up edges.
 Welding:
 A. Gas welding
One should not handle oxygen cylinders, valves, regulators, hoses or fittings with oily hands.
No one should transfer the gas from one cylinder to another and should inspect leakage.
Always avoid skin contact with fluxes, which contain fluorides. If they will penetrate the skin, they produce severe irritation.
Acetylene gas should not be brought in contact with the unalloyed copper directly (except in torch) which may result in a violent
explosion.
 B. Arc welding
One should use protective clothing and eye protection devices while performing arc welding operation.
Always use ear protection devices such as muffler because excessive noise caused during the process of arc welding.
One should prevent the non-insulated portion of the electrode holder from touching the welding ground or job-piece when the current is
on. Also one should check for polarity.
One should not change the polarity switch when the machine is under use. This will burn the surface of the switch and the resulting arc
can cause injury to the welder.
 Commercial material forms
 For producing products materials are needed. Generally, raw materials used in
manufacturing are extracted from ores.
 Molten metals are extracted from ores using Foundry.
 This molten metal is poured into moulds for providing commercial Castings, called ingots.
 Such ingots are then processed in Rolling mills to obtain market form of material supply in
form of bloom, billets, slabs (pipes, rods, plates).

Blooms are intermediate-stage Billet is a length of metal that has a A slab is a length of metal that is
pieces of steel produced by a first round or square cross-section, with rectangular in cross-section. It is
pass of rolling (in a blooming mill) an area less than 36 in2 (230 cm2). created directly by rolling of billets in
that works the ingots down to Billets are created directly by  a slabbing mill. Slabs are further
smaller cross-sectional area, but continuous casting or extrusion or processed using flat rolling, skelping,
still greater than 36 in2  indirectly via hot rolling of blooms and pipe rolling. Final products
include sheet metal, plates, strip metal, 
pipes, and rods
Manufacturing processes

 All manufacturing processes are concerned about changing the ingots into usable
products. They are broadly classified into six major groups as:
 Primary shaping processes
 Secondary machining processes
 Metal forming processes
 Joining processes
 Surface finishing processes and
 Processes effecting change in material or job properties.
Primary shaping
 Primary shaping processes are manufacturing of a product from an amorphous material.
 Some processes produces finish products (POWDER METALLURGY) whereas others do
not (CASTING).
 Typical examples of the products that are produced by casting process are machine beds,
automobile engines, cranks, carburetors, flywheels, etc.
 Some of the important primary shaping processes are:
 (1) Casting, (2) Powder metallurgy, (3) Plastic technology, (4) Gas cutting, (5) Bending
and (6) Forging.
Secondary or Machining Processes
 As large number of components require further processing after the primary processes,
they are subjected to one or more machining operations.
 The process of removing undesired material from workpiece to produce a required shape
using a cutting tool is known as machining.
 The secondary processes require use of machine tools, various single or multi-point cutting
tools, job holding devices, marking and measuring instruments, testing devices and gauges
etc. for getting desired dimensional control and required surface finish.
 Some of the common secondary or machining processes are:
(1) Turning, (2) Threading, (3) Knurling, (4) Milling, (5) Drilling, (6) Boring, (7) Planning, (8)
Shaping, (9) Slotting, (10) Sawing, (11) Broaching, (12) Hobbing, (13) Grinding, (14) Gear
cutting, (15) Thread cutting and (16) Unconventional machining
Metal Forming Processes
 Forming processes encompasses a wide variety of techniques, which make use of suitable
force, pressure or stresses, like compression, tension, shear or their combination to cause a
permanent deformation of the raw material.
 These processes are also known as mechanical working processes and are mainly classified
into two major categories i.e., hot working processes and cold working processes.
 Hot working Processes:
(1) Forging, (2) Rolling, (3) Hot spinning, (4) Extrusion, (5) Hot drawing and (6) Hot spinning
 Cold working processes:
(1) Cold forging (Drop hammer type), (2) Cold rolling, (3) Cold heading, (4) Cold drawing,
(5) Wire drawing, (6) Stretch forming, (7) Sheet metal working processes such as piercing,
punching, lancing, notching, coining, squeezing, deep drawing, bending etc.
Joining Processes
 Most of the products cannot be manufactured as single unit they are manufactured as different
components using one or more of the above manufacturing processes, and are assembled to get
the desired product.
 More than 800 parts are put together to make various subassemblies and final assembly of a
car (over 2,00,000 parts for an aeroplane).
 The joining processes are carried out by fusing, pressing, riveting, screwing or any other
means of assembling.
 Temporary, semi-permanent or permanent type of fastening to make a good joint is generally
created by these processes.
 Temporary joining of components can be achieved by use of nuts, screws, bolts and adhesives,
semi-permanent by riveting and permanent by welding.
 Some of the important and common joining processes are:
(1) Welding (plastic or fusion), (2) Brazing, (3) Soldering, (4) Riveting, (5) Screwing, (6) Press
fitting, (7) Sintering, (8) Adhesive bonding, (9) Shrink fitting, (10) Explosive welding, (11)
Diffusion welding, (12) Keys and cotters joints, (13) Coupling and (14) Nut and bolt joints.
Surface Finishing Processes
 Surface finishing processes are utilized for imparting intended surface finish on the surface
of a job.
 By imparting a surface finishing process, dimension of part is not changed functionally.
 These processes should not be misunderstood as metal removing processes in any case as
they are primarily intended to provide a good surface finish or a decorative or protective
coating on to the metal surface.
 Some of the commonly used surface finishing processes are:
(1) Honing, (2) Lapping, (3) Super finishing, (4) Belt grinding, (5) Polishing, (6) Tumbling,
(7) Organic finishes, (8) Sanding, (9) De-burring, (10) Electroplating, (11) Buffing, (12) Metal
spraying, (13) Painting, (14) Inorganic coating, (15) Anodizing, (16) Sherardizing, (17)
Parkerizing, (18) Galvanizing, (19) Plastic coating, (20) Metallic coating, (21) Anodizing and
(22) Sand blasting.
Processes effecting change in properties
 Processes effecting change in properties are generally employed to provide certain specific
properties to the metal work pieces for making them suitable for particular operations.
 Some important material properties like hardening, softening and grain refinement are
needed to jobs and hence are imparted by heat treatment.
 A few such commonly used processes are given as under:
(1) Annealing, (2) Normalising, (3) Hardening, (4) Case hardening, (5) Flame hardening, (6)
Tempering, (7) Shot peeing, (8) Grain refining and (9) Age hardening.
Some handy tools to get familiar with

Steel rule (rough cut)

C clamp

Saws
Some handy tools to get familiar with

Warrington
hammer
Chisel Center bit Countersunk bit

Screw driver
Claw hammer
Some handy tools to get familiar with

Swage block Hand forging

Types of shears

Types of scribers (off

center applications)
Trammel (for marking on plates/ sheets)
 Some handy tools to get familiar with

Fillet and radius gauge

Bevel protector
Universal surface gauge

Try square

Surface plate with V block

 Some handy tools to get familiar with

Fillet and radius gauge

Bevel protector
Universal surface gauge

Try square

Surface plate with V block

 Some handy tools to get familiar with

Caliper
Outside micrometer

Depth micrometer

Vernier caliper
Vernier height gauge
 Some handy tools to get familiar with

Combination set
Wire gauge

Dial indicator

Go No-Go gauges

Hand vice Bench vice

Some handy tools to get familiar with

Tapping tools
Files (based on cuts)

Files (based on geometry)

Types of drill
Thank you