Assignment 1 Fabricating a pair of inside calipers

1.1 Objective of the project

1. 2. To learn the proper use of the hacksaw To be able to file a workpiece to the desired dimensions

1.2 Procedures
1. File one side edges of workpiece straight and flat. -Use a try square to check for flatness and straightness Use the flat edge as a reference. Mark out the pattern for inside calipers.

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Figure 1: Description of project drawing 3. Use the hacksaw to saw the calipers according to the shape but leaving a tolerance of 2 mm for fine filling. Cross filling to be followed by draw filling the edges of caliper legs Make the top section round by carefully using the file. Remove burrs from the surface of the mild steel to prevent injuries to your hands. Drill the 6mm diameter hole on the washer and attach the calipers together by using a bolt and nut. If the bolt is too long, remove the section that is protruding from the assembled calipers. Use emery cloth to give the job smooth finish.

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Drawing of assignment 1

Assignment 2 Shielded Metal Arc Welding (SMAW)

2.1 Objective
1. To learn the proper use of the welding equipment 2. To learn welding at different angles

2.2 Introduction
1. An AC/DC burning arc is struck between the electrode and the work piece to melt the joint area. Both the electrode and work piece surface melt to form a weld pool. 2. The gases and slag from melting of the flux coating on electrode protect the weld pool from atmospheric attack on the weld. 3. The metal particles from electrode are transferred across the arc to fill the joint and welder must feed in the electrode to maintain a constant arc gap.

Figure 2.1: Features of Arc Welding

2.3 Equipment
1. Power sources, controllable AC supply between 50A and 500A, 50V to 100V for AC welding. 2. Electrode Holder. 3. Welding Cables 4. Chisel 5. Brush 6. Apron 7. Welding hand gloves 8. Welding mask.

2.4 Welding current

Welding current is determined by the size of electrode; please refer to the normal operating range and current recommended by the manufacturer.

2.5 Weld joint preparation.

The weld up to 6mm thick can be welded with one pass.

2.6 ASSIGNMENT 2.1: -STRAIGHT BEAD

1. Use 2.6mm electrode and perform few runs of welding on a piece of 150 x 75 x 6.4 mm thick mild steel flat bar. 2. Inspect the uniformity of the ripples on weld bead and its width. 3. Excessive spatter may cause by too high current or too long an arc i.e. the gap in between the electrode and the joint or the metal to be welded should between 1.6 and 3.2mm. 4. If the speed of travel is too fast a narrow and thin weld deposit and the surface of the weld bead has elongated ripples.

2.7 ASSIGNMENT 2.2: -BUTT WELD

1. Use 2.6mm electrode and perform welding on the joint of two pieces of 150 x 39.5 x 4.5mm thick mild steel flat bar as shown. Inspect the weld bead.

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Figure 2.2: Open square butt joint for parent metal over 1.5 mm and up to 3mm thick.

2.8 ASSIGNMENT 2.3: -FILLET WELD (HORIZONTAL)

1. Use 2.6mm electrode and perform welding on both sides of two pieces of 150 x 75 x 6.4 mm thick mild steel flat bar as shown. Inspect the weld bead.

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Figure 2.3: Tee fillet with equal leg (horizontal). Note: the throat thickness in a fillet weld should be a minimum of 0.7 times its leg length.

2.9 Quality of welding

Figure 2.4: Cracks

Figure 2.5: Under Cut

Figure 2.6: Lack of Penetration

Figure 2.7: Porosity Note: Porosity is the pores (bubbles) left by gas on the weld metal.

2.10 Operating
1. Strikes the end of the electrode against the work piece to produce the arc. 2. Move the holder slowly along the joint and simultaneously feed in the electrode to maintain a constant gap between the electrode and weld metal. 3. Moves the arc from side to side as shown in the weaving path below.

Figure 2.8: Weaving path

2.11 Electrode angles

Flat 700-750 Horizontal-vertical 650-750

Table 1. Electrode Angles 4 Brush and chip off the slag on weld bead after the weld run is completed or before the next weld deposited on it.

5. Do not submerge the welded work piece in the water

2.12 Safety
1. Beware of heat source from arcs and hot metal. 2. Wear protective devices while welding. i.e. apron, welding mask and gloves. 3. Proper ventilation to emit fumes and gases. 4. Proper disposal of electrodes. 5. Consult the technician if in doubts. 6. Failure to abide the safety rules may cause serious injury.

Assignment 3 The Milling Process

3.1 Objective of the project
1. To learn the proper use of the vertical and horizontal milling machine. 2. Learn the method of surface and step cut at the steel

3.2 Introduction
Milling is the most versatile of machining processes. Metal removal is accomplished the through the relative motion of a rotating, multi-edge cutter and multi-axis movement of the workpiece. Milling is a form of interrupted cutting where repeated cycles of entry and exit motions of the cutting tool accomplish the actual metal removal and discontinuous chip generation. Milling has more variations in machine types, tooling, and workpiece movement than any other machining method.

3.3 The Horizontal Milling Machine Cutting Procedure

Figure 3.1: Cutting directions

Published By: Longman Scientific & Technical ( General Engineering by R.L Timings )

3.4 The Horizontal Milling Machine

Figure 3.2: Horizontal Milling Machine

Published By: Longman Scientific & Technical ( General Engineering by R.L Timings )

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3.5 The Vertical Milling Machine

Figure 3.3: Vertical Milling Machine

Published By: Longman Scientific & Technical ( General Engineering by R.L Timings )

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3.6 Tools
Face milling cutting tools and end mill cutting tools

3.7 Material
Mild steel block of approximately 73 x 73 x 23mm

FACEMILLING

CUT STEP WITH ENDMILL

5 73 10

23

Drawing of assignment 3

3.7 Operations
3.7.1 Secure the workpiece in the table of the milling machine using the vise
1. 2. Clean milling machine vise thoroughly. Place parallel-edged blocks under workpiece to raise the surface to be Milled above the level of the vise jaws. After the workpiece is in place, tighten the vise securely.

Figure 3.4: Milling machine Control panel 12

3.7.2 Milling the top surface using facemilling

1. Before starting the machine, be sure the cutting tool is clear of the workpiece. If not, lower the workpiece using the crank. Turn the machine ON. Turn ON the spindle by pressing the button marked CCW on the control panel. (Do not touch the CW button!) Pressing the CCW button will result in the spindle turning counter clockwise when viewed from the bottom. If viewed from the top, the spindle will be turning clockwise. Note that the facemilling tool should operate only in this direction! Any attempt to use the facemilling tool in the opposite direction will result in damage to the milling cutter teeth. Turn ON the cutting fluid. Turn the coolant switch to the ON position at the control panel. This turns on the coolant fluid motor. The coolant valve can now be opened by hand to get a steady flow of coolant on the workpiece. Move the table with the cross-feed and longitudinal feed handles to position the workpiece under the cutter Lower the cutting tool or raise the table using the crank until it touches the top surface of the workpiece gently. This position is known as your zero position. Lower the table by 0.5mm Move the table longitudinally so that the cutter is clear of the workpiece at either end Raise the table at your zero position. Then crank the table pass the facemilling cutter manually. Use the conventional milling (upmilling) method. Do not use the downmilling (climb milling) method!

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Conventional milling position when viewed from above

9. 10. Raise the table by 0.2mm and make another pass with the worpiece under the facemilling cutter manually again Raise the table by 0.2mm. Engage the power feed with level. Note: Table travels in the direction of the feed engagement lever. Power feed is smoother than manual feed and therefore can produce a better finish. After workpiece has been milled on the top surface, disengage power feed and turn spindle off. Remove the workpiece from the vise.

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3.7.3 Using the endmill to cut the step

12. 13. Mount the workpiece onto the machine where the endmill is fixed. Cut a step using the endmill tool by using the conventional milling method. This is similar in process to what you have been doing in facemilling. Check that the feed direction is against the cutter rotation. You will need to make several passes until this is achieved.

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Assignment 4 The Lathe Process

4.1 Objective
1. To learn the proper use of the lathe machine. 2. To learn how to cut the round steel metal using lathe machine.

4.2 Introduction
The lathe machine is used to remove the material by turning; the lathe has rotate the workpiece and guide the tool.

Figure 4.1: Lathe Machine

Published By: Longman Scientific & Technical ( General Engineering by R.L Timings )

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4.3 Procedure
1. Mount a round bar of diameter 37mm and a length of 100mm onto the three-jaw chuck of the lathe machine. Make sure that the bar is held firmly. Use a sharp edged cutting tool. Adjust the height of the cutting tool to a correct height. If the cutting edge is higher than the center line of the bar, the tool will not cut. Turn ON the spindle and the coolant. Move the tool onto the metal and feed the tool from a right to left direction. A depth of cut of 0.5mm can be attempted without any problem. When stopping the machine, please the footbrake before disengaging the gear lever. There is a possibility of the spindle suddenly reversing in direction due to misapplication of the gear lever, so the footbrake needs to be used before the gear lever is disengaged. Leave a small allowance on the bar for finishing work. For a finer finishing cut, use a broad nose cutting tool with a very small depth of cut.

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Drawing Of Assignment 4

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