MALAWI UNIVERSITY OF BUSINESS AND
APPLIED SCIENCES
SCHOOL OF ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING
PROGRAM: MECHANICAL ENGINEERING
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SUBMITTED BY: THEODORA MAONI
MODULE NAME: ENGINEERING PRACTICE
REG NUMBER: BME/24/SS/008
MODULE CODE: MEC-ENP-111
SUBMITTED TO: L. LIKANDAWE
DUE DATE: 14/03/2025
QUESTION ONE
SAFETY ORIENTATION GUIDE FOR NEW RECRUITS
IN A MECHANICAL WORKSHOP
1. GENERAL BEHAVIOR
Always follow workshop rules and instructions from supervisors
No running or horseplay in the workshop
Stay focused and avoid distractions while working
2. FIRST AID
Know the location of first aid kits in the workshop
In case of any kind of injury, seek first aid, no matter how trivial
3. MOVING ABOUT
Always walk and never run in the workshop
Always walk in the gangways and do not take shortcuts
Look out for and obey safety signs and notices
4. HYGIENE
Always wash your hands before and after eating, using the bathroom, and each
shift
Never use paraffin, petrol or any kind of solvent for skin-cleaning
Use barrier cream to protect your skin
5. HOUSEKEEPING
If anything is spilled, wipe it immediately
Never throw rubbish on the floor
Keep gangways and work areas clean at all times
6. PERSONAL PROTECTIVE EQUIPMENT (PPE)
Always wear appropriate PPE such as goggles and gloves
Make sure PPE is in good condition before use
Wear safety shoes to protect against falling objects
7. HARMFUL SUBSTANCES
Learn to recognize hazard and warning labels
Follow all instructions given by the supervisor
Never eat or drink near any chemicals
Do not take home any clothes that have been contaminated with chemicals
8. MACHINERY
Know how to stop a machine before setting it in motion
Never leave a machine in motion unattended
Avoid loose clothing, rings or accessories and unfastened hair when using
machines
Always ensure safety guards are secure and in place before use
9. COMPRESSED AIR
Only use compressed air if instructed to do so by the supervisor
Never use compressed air to clean a machine
10. FIRE SAFETY
Know the locations of fire extinguishers and emergency exits
Do not store flammable materials near heat sources
If the fire is uncontrollable, evacuate and call emergency services
QUESTION TWO
a) Precautions When Using the Following Tools
i. Files
-Keep all files in a rack, do not jumble them up or keep them with other tools,
because this can chip and damage the teeth of the file
-Never use new files on steel because this will chip the teeth and make the file
useless, rather use it on softer metal like brass or bronze
-Never file too quickly because this wears out the file and the user, instead use
slow, even strokes using the full length of the file
-Clean the files with a file card, this is a special wire brush that removes bits of
metal stuck in the teeth of the file, which slows the rate of metal removal.
ii. Hammers
-Only use the hammer to strike other tools unless instructed to do otherwise
-Make sure to hold the hammer properly to avoid injury
-Ensure the handle shaft is not split
-Make sure the hammer head is not loose, cracked or chipped
b) Applications Of the Following Tools
i. Angle Plate
-They are used to secure workpieces at specific angles during operations like
drilling, milling, or grinding
-Angle plates are used to ensure accurate alignment in assembly processes
ii. Surface Gauge
-It is used to mark/scribe layout lines at any given distance parallel to the work
surface
-In metalworking and manufacturing, they are used to make sure components are
flat and level for use
iii. Combination Set
-The combination square can be used for simple distance measurements
-The combination set can also draw accurate parallel and perpendicular lines for
layouts.
iv. Jenny Caliper
-They are used for laying out parallel lines from an edge
-They can also be used for finding the center of round or square sections
c)
QUESTION THREE
a) Two Limitations of The Vernier Caliper
-The scales can be difficult to read accurately even with a magnifying
glass.
-Because of its size and weight, it is very difficult to get a ‘feel’ of it when taking
measurements
b)
Of the three tools, the most accurate is the Internal Micrometer because it has a resolution
of 0.01 mm, making it ideal for precise internal measurements
c)
The reading on the micrometer is as follows
-16 “whole” millimeters
= 16
- 59 hundredths of a millimeter
= 0.59
Total
= 16.59 mm
QUESTION FOUR
PROCEDURE OF DRILLING AND TAPPING OF THE HOLE
The tools required are as follows:
Bench drilling machine
Drill bit
Tapping tool set (taper tap, second tap, and bottom tap)
Tap wrench
Cutting Lubricant – Oil
Marking out tools (odd leg caliper, metal rule, center punch, and hammer)
Procedure
1. Marking out the position of the hole
-Use an odd leg caliper and a metal rule to mark the 20 mm line horizontal parallel to the
edge.
-Then mark the vertical line 25 mm vertical parallel to the edge. Where the lines intersect
will be the center point of the hole.
-Use a hammer and a center punch to punch a hole where the lines intersect to verify the
position of the center
2. Clamping the component on the drilling machine
-Secure the component using a machine vice or clamps to prevent movement
-Ensure the workpiece is flat and stable on the drill table
-Align the drill bit with the center-punched mark before starting the drill machine.
3. Ensuring the drilling machine starts correctly
-Begin with a center drill to create a starting point
-Use a tapping drill of the correct size for a M10 × 1.5 thread, the correct drill size is 8.5
mm
-Drill at an appropriate speed, which is 30-40 m/min for mild steel
-Apply the lubricant oil to reduce heat and friction
-Drill to the required depth while frequently retracting the drill and clearing any chips
4. Types of taps and lubricant to be used
-Use a set of three taps in a sequence
Taper tap for the initial threading
Second Tap to deepen the thread
Bottoming tap for the full-depth threads in blind holes
-Apply lubrication oil to reduce wear and improve thread quality
-Rotate the tap clockwise for cutting and counterclockwise slightly every few turns to
break chips
SETTING OUT THE HEXAGON AND CUTTING THE HOLE
The tools required are as follows:
Bench drilling machine
3mm drill bit
Hacksaw with fine tooth blade
Flat file
Marking out tools (Scriber, metal rule, engineers square, odd leg caliper, divider,
center punch, and hammer)
Angle gauge
1. Marking out the hexagon
-Find the center of the 100mm × 100mm steel plate with a metal rule and an odd leg
caliper, creating a vertical and horizontal line from the edge
-At the intersection, create a small indentation using a center punch and a hammer
-Using a divider, draw a circle with radius 25 mm because the side length of a regular
hexagon equals the radius of its circumscribed circle
-Using an angle gauge, mark six equal points around the circle, each should be 60
degrees
-Connect the points with a scriber and engineer's square to form the hexagon
-Punch holes along the lines with a center punch and hammer to verify the shape
2. Cutting the Hexagonal Hole
-Drill small holes inside each corner of the hexagon using a 3mm drill bit to allow access
for cutting tools
-For easier cutting, drill a larger hole near the center to insert a cutting tool
-Using a hacksaw with a fine-tooth blade, cut along the marked and punched lines
-Using a flat file, smooth the rough edges to ensure accurate dimensions
-Debur the piece to remove the sharp edges
QUESTION FIVE
a) First slip = 1.0075
Second slip = 1.5000
Third slip = 8. 0000
Fourth slip = 30.000
Total
- 1.0075 + 1.5000 + 8.0000 + 30.0000
= 40.5075
b) For a single prototype, this depth gauge can be made for fitting because:
-It's cost-effective. Mass production methods require expensive setups, whereas fitting is
more affordable for a one-off piece
-It's flexible in adjustments. Manual fitting allows adjustments based on trial assembly,
which is helpful for prototypes
-There's no need for specialized training. Casting requires dedicated tools and
programming, making fitting more practical
-Faster Turnaround. A prototype can be completed quickly without waiting for tool
setups
-Skilled hand finishing. A machinist can ensure precision using files, reamers, and
manual drilling techniques
c)
OPERATION SCHEDULE FOR MANUFACTURING THE DEPTH GAUGE BODY
STEP NUMBER OPERATION EQUIPMENT
REQUIRED
1 Mark out the dimensions on Scriber, odd leg caliper,
the blank divider, surface plate
2 Drill pilot holes of diameter Pillar drill, drill bits
3.2mm of 3.2 mm
3 Drill reamed holes of Pillar drill, drill bits of dia
diameter 8 mm 7.8 mm, reamer dia 8 mm
4 Cut the external Hacksaw with fine
shape Tooth blade
5 Machine 5 × 45° Milling machine,
Chamfers Chamfer cutter
6 File and debur Hand file (round file,
The edges Flat file), deburring tool
7 Inspect final Vernier Caliper,
dimensions micrometer
8 Surface finishing Surface grinder,
(If needed) Hand files
