MALAYSIA POLYTECHNICS

MINISTRY OF EDUCATION

MODULE J3103
WORKSHOP TECHNOLOGY 3

WORKSYOP TECHNOLOGY 3

HAJI MAHMUD BIN HAJI SIDEK (POLISAS) SAIFUDDIN BIN ABDUL RAHMAN (POLISAS)
Name : Hj Mahmud b Hj Sidek Address : Mechanical Engineering Department Politeknik Sultan Haji Ahmad Shah Semambu, 25350 Kuantan, Pahang.

C 3363 MECHANICAL SERVICES 2

Telephone No. : 09-5661300 ext 320 e-mail : Qualifications : Tech. Teachers Training College, Kuala Lumpur M. Sc. Voc. Ed. B. Sc VTAE( Univ.of Wisconsin- Stout, Menomonie, U.S.) Position : Polytechnic Lecturer

WORKSYOP TECHNOLOGY 3

What Do You Think Of This Module?

Registration No. : ___________

Course: ____________________________________ Module Writers: ______________________________ Please use the following scale for your evaluation:
4 3 2 1 Strongly Agree Agree Disagree Strongly Disagree

Instruction : Please on the space provided. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 How much do you agree with the following statements? A. FORMAT The pages are organized in an interesting manner. The font size makes it easy for me to read the module. The size and types of pictures and charts used are suitable for the input. The pictures and charts are easy to read and understand. The tables used are well-organised and easy to understand. The arrangement of the Input makes it easy for me to follow. All the instructions are displayed clearly. B. CONTENTS I understand all the objectives clearly. I understand the ideas conveyed. The ideas are presented in an interesting manner. All the instructions are easy to understand. I can carry out the instructions in this module. I can answer the questions in the activities easily. I can answer the questions in the self-assessment. The feedback section can help me identify my mistakes. The language used is easy to understand. 1 SCALE 2 3 4

WORKSYOP TECHNOLOGY 3

17 18 19 20

The way the module is written makes it interesting to read. I can follow this module easily. Each unit helps me understand the topic better. I have become more interested in the subject after using this module.

WORKSYOP TECHNOLOGY 3

CURRICULUM GRID The curriculum grid of this module is based on the curriculum used by Malaysian polytechnics. No . 1 TOPIC UNIT Total Hours 4 Hours

Screw Thread

1 (4H)

Gear

2 (4H) 4 (4H )

3 (3H)

7 Hours

Surface Texture

4 Hours

Power Press Machine

4 Hours 5 (4H )

Computer Numerical Control

6 Hours 6 (6 H )

Shielded Gas Arc Welding

5 Hours 7 (3 H )

WORKSYOP TECHNOLOGY 3

UNIT 1 1.0 1.1

SCREW THREAD Introduction Elements of a thread 1.1.1. Major Diameter 1.1.2. Pitch/Mean Diameter 1.1.3. Minor Diameter 1.1.4. Thread Angle 1.1.5. Pitch 1.1.6. Root Measuring the major diameter Measuring the minor/core diameter Measuring the mean/pitch/effective diameter 1.4.1. Best Size Wires. Optical Comparator 1.5.1. To check the angle of a 60o thread using an optical comparator

1.2 1.3 1.4. 1.5.

UNIT 2 2.0 2.1

GEAR Introduction Types of gears 2.1.1. Spur gear 2.1.2. Internal gears 2.1.3. Helical gears 2.1.4. Herringbone gears 2.1.5. Bevel gears 2.1.6. Miter gears 2.1.7. Angular bevel gears 2.1.8. Hypoid gears 2.1.9. Worm and worm gear 2.1.10. Rack and pinion Gear terminology 2.2.1. Addendum 2.2.2. Dedendum 2.2.3. Pitch diameter

2.2

WORKSYOP TECHNOLOGY 3

2.2.4. Base diameter 2.2.5. Pitch circle 2.2.6. Pitch line 2.2.7. Face width 2.2.8. Tooth thickness 2.2.9. Top land 2.2.10. Base diameter 2.2.11. Root 2.2.12. 2.3. Measurement and testing of gears. 2.3.1. Gear-tooth vernier caliper 2.3.2. Plug method of checking for pitch diameter and divide of teeth

2.4

UNIT 3

GEAR 3.0 3.1. 3.2. 3.3. 3.4. Gear manufacturing Form cutting Gear generating Cutting bevel gears Gear-finishing processes 3.4.1. Shaving 3.4.2. Burnishing 3.4.3. Grinding, honing and lapping 3.5. 3.6. Metric gears and gear cutting Metric modul gear cutters

UNIT

4 4.0.

SURFACE TEXTURE Definition

WORKSYOP TECHNOLOGY 3

4.1

Surface texture terms and definition 4.1.1. Flaws 4.1.2. Lay 4.1.3. Roughness 4.1.3.1. Roughness height 4.1.3.2. Roughness width 4.1.4. Waviness 4.1.5. Profile 4.1.6. Microinch and micrometer

4.2. 4.3. 4.4.

Standard symbols to describe surface texture/finish Symbol for surface roughness Surface roughness 4.4.1. The Arithmetic Mean Value, Ra 4.4.2. The Root-Mean-Square Average, Rq. 4.4.3. Maximum Roughness Height, Rt Comparison of Ra and Rq Using a Surface Texture Comparator 4.6.1. Comparison blocks 4.6.2. Commercial sets of standard finished specimens

4.5. 4.6.

UNIT 5 5.0 5.1

POWER PRESS MACHINE Introduction Shearing 5.1.1. Punch 5.1.2. Die 5.1.3. Stripper 5.1.4. Stop 5.1.5. Pilot 5.1.6. Sets 5.1.7. Pressure Plate Clearance between Punch and Die Force and Work Done required for Shearing

5.2 5.3

WORKSYOP TECHNOLOGY 3

5.4 5.5

Shear Bending 5.5.1. Force Required for Bending 5.5.2. Planishing 5.5.3. Allowance for Bending 5.5.4. Drawing 5.6.1. Blank Size 5.6.2. Force Required for Drawing Combination tools Progression tool

5.6

5.7. 5.8.

UNIT 6

COMPUTER NUMERICAL CONTROL 6.0 6.1 6.2 Introduction NC operation Industrial Application 6.2.1. Metal Machining 6.2.2. Metal Forming 6.2.3. Finishing 6.2.4. Assembly Joining 6.2.5. CNC axis conventions NC machine sub-unit 6.4.1. The Machine Tool 6.4.2. The Control Unit 6.4.3. Control System 6.5 . Program input 6.5.1. Punched Tape 6.5.2. Computers 6.5.3. Direct Input

6.3 6.4.

WORKSYOP TECHNOLOGY 3

10

6.5.4. By Manual Data Input (M.D.I.) 6.5.5. Interactive Programming. 6.5.6. External Devices 6.6 NC programming 6.6.1. Job Planning 6.6.2. Incremental 6.6.3. Absolute 6.6.4. Linear Interpolation 6.6.5. Circular Interpolation 6.7. Program definition 6.7.1. Program 6.7.2. Program preparation 6.7.3. Operation of program 6.8. 6.9. Types of control system Programming codes 6.9.1. G codes (preparatory codes) 6.9.2. M codes 6.10. Writing a Program 6.11. Advantages of computer numerical control

UNIT 7 7.0 7.1

SHIELDED GAS ARC WELDING

Introduction Tungsten Inert Gas (TIG) 7.1.1. Preparation of Metal 7.1.2. Joint Fit. 7.1.3. Welding Machine 7.1.4. Welding Torch 7.1.5. Shielding Gas. 7.2 7.3 7.1.6. Filler Metal TIG Welding Techniques Metal Inert Gas (MIG)

WORKSYOP TECHNOLOGY 3

11

7.3.2.

7.3.1. Power Requirements Selection of Gas.

7.3.3. Filler Metal 7.4 Job Procedures 7.4.1. Current 7.4.2. Voltage. 7.4.3. Travel Speed 7.4.4. Electrode Extension 7.6. MIG Welding Techniques 7.7. Direct current straight polarity 7.8. Direct current reverse polarity arc welding

MODULE GUIDELINES

WORKSYOP TECHNOLOGY 3

12

To achieve maximum benefits in using this module, students must follow the instructions carefully and complete all the activities. 1. 2. This module is divided into 6 units. Each page is numbered according to the subject code, unit and page number. J3103 / UNIT 1 / 5

Subject Unit 1 3. 4.

Page Number 5

The general and specific objectives are given at the beginning of each unit. The activities in each unit are arranged in a sequential order and the following symbols are given:

OBJECTIVES The general and specific objectives for each learning topic are stated in this section.INPUT This section introduces the subject matter that you are going to learn. ACTIVITIES The activities in this section test your understanding of the subject matter. You have to complete this section by following the instructions carefully.

FEEDBACK Answers to the questions in the activity section are given here

WORKSYOP TECHNOLOGY 3

13

SELF-ASSESSMENT Self-assessment evaluates your understanding of each unit.

FEEDBACK OF SELF-ASSESSMENT This section contains answers to the activities in the self-assessment.

5. 6.

You have to follow the units in sequence. You may proceed to the next unit after successfully completing the unit and you are confident of your achievement.

GENERAL AIMS

WORKSYOP TECHNOLOGY 3

14

This module is prepared for the third semester of Certificate/Diploma students of Malaysian Polytechnics. Its aim is to expose students to the Workshop Technology concept by units and to lead them towards self-directed learning or with guidance from their lecturers.

PREREQUISITE SKILLS AND KNOWLEDGE The prerequisite for this module is at least a pass in Workshop Technology at the SPM level and a successful completion of module J2003. GENERAL OBJECTIVES At the end of this module, students should be able to: 1. 2. State the measurement and inspection methods of ISO metric screw and BSW screw. Describe the procedure of measuring major diameter, minor diameter and min diameter by using thread measuring machines. Calculate the major diameter, minor diameter and min diameter by using thread measuring machines and the of three wire method. Inspect the method thread angle with an optic projector. State the types and the functions of gear, parts and describe the method of making gears. Name the different types of gear, specifications and uses. Mention the parts of the gear including addendum, dedendum, pitch diameter and gear specifications. Measure and inspect of gears. Describe the measurement and inspection procedures of gear using vernier calipers. Describe the pitch diameter by the inspection method for gears using micrometer and stylus machine.

3.

4. 5. 6. 7. 8. 9. 10.

WORKSYOP TECHNOLOGY 3

15

11.

Describe the method of producing the gear using simple and direct index. 12. State the importance of surface textures in engineering components and identify every s the degree of roughness for each surface. 13. Define surface texture 14. Identify the important terms: roughness, lay, wave and blemished. 15. Elaborate on the effects of quality of the surface texture on any engineering component. 16. Elaborate on the method of finding centre line average index formula. 17. State the use of surface texture comparator and elaborate on how to evaluate the roughness of machined surfaces. 18. Understand the use of surface roughness symbols according to B.S 1134. 19. State the use of power press machines and identify the types. 20. Identify the important parts of the power press machine. 21. State the main factors that influence the choice of the power press machine to perform a task. 22. State the various operations of the power press machines. 23. Differentiate between combination mould, mix mould and gradual mould. 24. State the advantages of using the power press machine in fabrication work compared to other types of machines. 25. State the functions and the principle of the Computer Numerical Control. 26. Explain the point to point and the continuous run method of machining. 27. Determine the X, Y and Z work piece point coordinates using the incremental and absolute system. 28. Write a simple CNC program for a milling work. 29. State the advantages of the Computer Numerical Control compared to Numerical Control Machine.

WORKSYOP TECHNOLOGY 3

16

30.

State the principles of the Shielded Gas Arc Welding i.e, TIG and MIG welding. 31. Compare the principles of the Shielded Gas Arc Welding and manual arc welding.

32.

33.

Elaborate on the TIG and MIG welding principles, welding procedures, welding machines, gas, electrodes and the electrode wire used, types of current, polarity used and the effects of polarity on a work piece. State the weaknesses of TIG and MIG welding and how to prevent them.

TEACHING AIDS AND RESOURCES NEEDED 1. Calculator

REFERENCES
1.

Chapman, W.A.J , Martin, S.J., Worksyop Technology Part 3; 3rd ed, The English Language Book Society & Edward Arnold (Publishers) Ltd., 1978. Haslehurtst, M, Manufacturing; 2nd ed, The English Language Book Society & Hodder & Stoughton, 1975. Pritchard, R.T., T.3 Workshop Technology for Mechanical Engineering Technicians; 2nd ed, Hodder & Stoughton, 1978. Krar, Steve F. , Oswald, J. William, Technology of Machine Tools; 4th ed, Gregg Division Mc Graw-Hill Publishing Company,1990.

2.

3.

4.

WORKSYOP TECHNOLOGY 3

17

5.

Chapman, W.A.J., Senior Workshop Calculation; 3rd ed., The English Language Book Society & Edward Arnold (Publishers) Ltd., 1975. Davies, A.C., The Science and Practice of Welding; 7th ed, Cambridge University Press., 1974. Kalpakjian, Serope, Schmid, Steren R., . Manufacturing Engineering and Technology; 4th ed, Prentice Hall International., 2001.

6.

7.

8. Love, L. Carl, Welding: Procedures and Applications , Prentice Hall, Inc., 1975. 9. Abdul Rahim Darman, Teknologi Woksyop 2: IBS Buku Sdn. Bhd.,1989.

Note: All figures and tables in this module are taken from the above sources.