[Sample] - Final EIT Report 1

International Islamic University

Malaysia

Engineering industrial training

(Eit 4004)

OMNI OIL TECHNOLOGIES (ASIA)

SDN BHD

Name: Mohd Affizul Ariff Bin Salim

Matric No: (0710841)

Discipline: Bachelor of Mechanical Automotive Engineering

Department: Mechanical

Visiting Lecturer: Dr Mirghani

Training Period: 12th April 2010 – 2

nd July 2010

Year: 2010

MOHD AFFIZUL ARIFF BIN SALIM 0710841

OMNI OIL TECHNOLOGIES (ASIA) SDN BHD

COMPANY VERIFICATION STATEMENT

I hereby declared that, MOHD AFFIZUL ARIFF BIN SALIM (Matric No: 0710841) student of

DEPARTMENT OF MECHANICAL ENGINEERING, International Islamic University Malaysia (IIUM)

has successfully completed his Engineering Industrial Training from 12th April 2010 till 2nd July

2010 at OMNI OIL TECHNOLOGIES (ASIA) SDN BHD under Quality Control Department and

Engineering Department.

This report is prepared by above-mentioned student as a partial fulfillment of this training. All

information given in this report is true and does not contain any confidential information or

classified data that might in a way or another abuse the company’s policies

Approved by,

Mr. Zulkiflee Samsi

Manufacturing Engineer act as Plant Manager


(i)



ACKNOWLEDGEMENT

In the name of ALLAH, the Most Gracious and Most Merciful, I thank ALLAH SWT for

bestowing me with health, knowledge, patience and determination to complete the

Engineering Industrial Training at OMNI OIL TECHNOLOGIES (ASIA) SDN BHD.

Therefore, I acknowledge with great gratitude to Engineering Department and Quality

Control department of OMNI OIL TECHNOLOGIES (ASIA) SDN BHD, which supervised by Mr.

Zulkiflee Samsi and Mr. Hanafi Mamat for willingness to train me, giving advices, sharing

experiences, and giving encouragement to me. Biggest appreciation to Quality Control

Inspector, Mr. Md Shah and Mr. Yazid Sabarani for continuously supporting and providing me

with all great lessons and valuable experiences during the time I was in the company.

Acknowledgement also to Mr. Hisham Serry act as Production Engineer for his kindness

and for treating me nicely and equally like other permanent staffs in OMNI OIL TECHNOLOGIES

(ASIA) SDN BHD. Millions appreciation goes to all staffs, engineers, senior technicians and

technicians for sharing their knowledge and for welcoming me to be part of OMNI OIL

TENOLOGIES member.

Also I would like to express my greatest appreciation to my visiting lecturer Dr MIrghani

for his consultation and advice to complete my final presentation and report and also for the

assessment throughout this engineering industrial training. Special thank goes to my

colleagues, Bro Khairul Muhaimin who always helped and support to solve all engineering work

throughout the training process. Finally, my highest appreciation goes to my beloved parents

for the moral support and encouragement to fulfill successfully this engineering industrial

training.

(ii)



SUMMARY

This Engineering Industrial Training report is prepared for the purpose of fulfilling the

final requirement upon completion of the EIT program which had been underwent during

semester 3, 2009/2010 session. This report contains all the relevant information and

description regarding the training program which has been successfully completed at OMNI OIL

TECHNOLOGIES (ASIA) SDN BHD. It also discusses the activities and contribution towards the

company throughout the training program period.

There were no specific projects assigned to the students, instead the students were

placed to various section within the company such as Quality Control Department section

Assembly Department section and Engineering Department section. Any tasks given are

subjected to the supervision of personnel of each section.

This Engineering Industrial Training is beneficial for the students since it will enhance

their knowledge regarding engineering work throughout the practical training. During the

training, it helps the student to build up their level of confidence as well as how to respect

other peoples such as technician or engineer. It is a platform for the students to be more

adaptable to real working environment and to develop as well as to enhance their interpersonal

skills. More over it can develop the skills, ability, and competency of the students throughout

this industrial training.

(iii)



BACKGROUND OF OMNI OIL TECHNOLOGIES

Omni Oil Technologies is the first leading edge integrated technology development and

manufacturing center that was set up in the Middle East early 2004 for drilling tools for the Oil

and Gas industry. It is conveniently based in Dubai prominent Free Zone, Jebel Ali, United Arab

Emirates. Omni oil is capable of developing, modifying and producing customized tools to deal

with even the most extreme down holes challenges.

Omni currently operates throughout the Middle East and North Africa in major oilfield

centers such as Saudi Arabia, U.A.E., Oman, Kuwait, Egypt and Sudan. A larger manufacturing

facility for OMNI is currently under construction in Jebel Ali Free Zone in order to face up to the

increased demand for OMNI products. In addition, another manufacturing center is under

establishment in Malaysia to cover the Asia Pacific market needs.

“We are committed to excellence in standards and quality control and providing unmatched

local support,” says Mr. Mohammad Makhlouf, the President/CEO of the company.

All OMNI products adhere to API standards and are assured through a quality

management system in accordance with ISO-9001 2000. All OMNI tools are designed and

analyzed using leading edge technologies in design and stress analysis using Finite Element

Analysis (FEA) computer simulation packages. The manufacturing facility is equipped with

Computer Numerically Controlled (CNC) production lines, delivering precisions manufacturing

to the highest worldwide standards.

(1)



MISSION AND VISION OF OMNI OIL TECHNOLOGIES

To create a product development and manufacturing organization that serves the oil

and gas industry in the Middle East and grows profitably and independently into the global markets in an environmentally friendly manner while maximizing value to its shareholders and surrounding community and become the preferred organization of choice to its employees and customers

To provide a training and development platform for emerging regional human capital and place the region on the front end of technical innovation and development in the global oil and gas industry

To become the leading global technology development and manufacturing organization in the oil and gas industry originating from the Middle East

(2)



PRODUCT OF OMNI OIL TECHNOLOGIES

OMNI Oil Technologies is an approved supplier of Drilling Enhancement Tools for the major national oil companies through the Middle East. OMNI Drilling Enhancement Tools are deployed in many locations and in a variety of different formation lithologies around the region. Furthermore, these tools have shown outstanding performance in total operating hours. OMNI Oil Technologies Drilling Enhancement Tools are compatible with any BHA configuration thereby improving the overall drilling performance in well bores of all sizes. OMNI's current products are branded as the “Bassal” generation of products after their chief designer, Mr. Adel Bassal.

OMNI products are classified into three groups:

(3)



OBJECTIVES OF ENGINEERING INDUSTRIAL TRAINING

To provide student with industrial working environment

To provide students with job experience

To assist students to acquire knowledge related to Oil and Gas industry, and company

Administration Systems.

To assist student to gain informal learning process regarding engineering studies

(4)



ROLES DURING ENGINEERING INDUSTRIAL TRAINING

Join Quality Control Department on 12th April 2010

1st week – to be familiar with all measuring tools and equipment in QC department such as Holtest, Digital Calliper, Vernier Calliper, Rotary work plug, Rotary work ring, Block Gauge, Dial Gauge and others.

2nd week – to be able to measure threading for different bodies such as flexi joint 6.5 inches and flexi joint 8.00 inches also for roller reamer 17.5 inches. There different types of threading which are 4 ½ Internal Flush Threading, 6 5/8 Regular Threading, 7 5/8 Regular Threading. The threading measurement done by using thread height gauge, rotary work plug, rotary work ring, bore gauge, outer micrometer, thread profile 4 1/2 IF, 6 5/8 REG, 7 5/8 REG, API Gauge, Lead gauge and others. Also measure the diameter of flexi joint 8.00 inches and 6.75 inches.

3rd week – Do the quality file for flexi Joint 8.00 inches and 6.75 inches. In this quality file, it includes inspection standard, inspection test plan (bubble drawing), Inspection check sheet, Drawing A3 size and also the NCR report. Before the inspection check sheet is done, must refer to the drawing to check the tolerance for each parameter and also check the bubble drawing parameter

4th week - Check the flexi joint again with brother Shah to confirm the length dimension by using the Big Milling Centre 3 (BMC 3) machine. This due to the accuracy of measurement by using the BMC 3 is higher rather than by using measuring tape. The measurement by using BMC 3 machine is up to 3 decimal points rather than using tape measure which is up to only 2 decimal points. With BMC 3 machine also we can check the straightness and roundness of the flexi joint.

5th week – Check the dimension of RR Pin since it cannot be assembles with the RR cutter. Do the measurement for the diameter of the RR Pin and all the dimension are within the tolerance. Then, carry out the straightness check for RR Pin at the Granite table by using the Filler Gauge. Then only we can detect the straightness problem which is around 50 micron.

(5)



6th week – Do the length measurement for driver sub 10 inches and driver sub tapered 7.5 inches with brother shah. Also check the straightness and roundness of driver sub 10 inches and driver sub tapered 7.5. Also check the surface roughness at the machining site for mandrel upper and mandrel lower. Regarding the measurement of radius which is difficult to be measured, brother shah and me do the testing by using the silicon putty and put the silicon putty at the designated area so that the radius can be measured by using CMM machine.

7th week – Do the inspection check sheet of mandrel upper and mandrel lower, also the inspection standard for mandrel upper and mandrel lower, with the inspection test plan (bubble drawing) and the original drawing for mandrel upper and mandrel lower. Do the inspection check sheet of driver sub, also the inspection standard, the inspection test plan (bubble drawing) and the original drawing for mandrel upper and mandrel lower. Revise the flexi joint check sheet, inspection test plan (bubble drawing), inspection standard and the original drawing A3 size. The entire documents are in soft copy form.

8th week – Do the checking and inspection for the quality control’s equipment such as outer micrometer, rotary work plug and rotary work ring. This due to the existence of corrosion at the surface of the equipment and need to be removed from the surface. Also do the checking for all equipment’s serial numbers and do the marking of the serial number at all equipments.

9th week – Do the inspection for upper block and lower block with bro Yazid and identify the incomplete inspection for upper block and lower block. There are 2 batches which consist of 24 pieces. Also do the packing for cutter, upper block, and lower block and pin to be sent for nitriding process.

10th week – Join Assembly Process Department on 8th June 2010. Do the assembly process between tungsten carbide insert and cutter. Do the hardness test for the heat treated jig with Bro Halim. Do the assembly process for cartridge, which consist of upper block, lower block and cutter.

(6)



11th week – Do assembly process for cutter and pin with piston, spring and oil ring. Then do the assembly for cartridge, which consist of upper block, lower block and cutter. Do inspection for raw material which given from the supplier. Need to confirm the dimension such as diameter and length.

12th week – Visit to Umetoko Company in Kota Kemuning Shah Alam to see the nitriding process. Preparation of final presentation slide and also final report on Engineering Industrial Training

(7)



MANUFACTURING PROCESS

The word manufacturing is derived from the Latin manu factus, meaning made by hand.

The word manufacture first appeared in 1567 and the word “manufacturing” appeared in 1683.

The word product and production first appeared sometime during the 15th century. The word

“manufacturing” and “production” often are used interchangeably.

For any manufacturing company such as OMNI OIL TECHNOLOGIES (ASIA) SDN BHD,

manufacturing is generally a complex activity involving a wide variety of resources such as:

- Product design

- Machinery and tooling

- Process planning

- Materials

- Purchasing

- Manufacturing

- Production control

- Support services

- Marketing

- Sales

- Shipping

- Customer service

(8)



MANUFACTURING PROCESS AT OMNI OIL TECHNOLOGIES

(9)

Raw material



(10)

Tools (Steady rest)

Equipment

(CNC BIG MILLING

CENTER)

Equipment

(CNC BIG TURNING

CENTER)



(11)

Labor / Workforce

Waste (chips)

Finished Product Rejected Product



It is essential that manufacturing activities be responsive to several demands and trends:

1. Product must fully meet design requirement, product specification and standard

2. A product must be manufactured by the most economical and environmentally friendly

methods

3. Quality must be build into the product at each stage, from design to assembly rather

than relying on quality testing after the product is manufactured

4. In the highly competitive environment of today, production methods must be

sufficiently flexible to respond changing market demands, types of products, production

rates, production quantities, and provide on time delivery to customer.

5. Continuous developments in materials, production methods, and computer integration

of both technological and managerial activities in a manufacturing organization must be

evaluated constantly with a view to their appropriate, timely, and economical

implementation

6. Manufacturing activities must be reviewed as a large system, all parts of which are

interrelated to varying degrees. Such systems can now be modeled in order to study the

effect of factors such as changes in market demands, product design, materials, and

production methods on product quality and cost.

7. The manufacturer must work with customer for timely feedback for continuous product

improvement.

8. A manufacturing organization constantly must strive for higher levels of productivity,

defined as the optimum use of all its resources such as materials, machines, energy,

capital, labor, and technology; output per employee per hour in phase must be

maximized.

(12)



SELECTION OF MATERIAL

(13)

Selection of material

Properties of material Cost and availability Appearance, service life and

recycling

The appearance of materials,

after they have been

manufactured into products,

influences their appeal to the

consumer. Color, feel and surface

texture are characteristics that we

all consider when marking a

decision about purchasing a

particular product.

The economic aspects of material

selection are also important as

technological consideration of the

properties and characteristic of

material. If raw materials or

manufactured component are not

available in desired shapes,

dimension, and quantities, hence

additional processing will be

required and this situation will

lead to increase in the production

cost.

The first consideration is the

mechanical properties of the

material such as strength,

toughness, ductility, hardness,

elasticity, fatigue and creep.

The next consideration is the

physical properties of the material

such as density, specific heat,

thermal expansion, thermal

conductivity, melting points, and

electrical and magnetic properties.

A combination of mechanical and

physical properties is the strength

to weight and stiffness to weight

ratios of the material, particularly

important aerospace, automotive

and petroleum industry.

Chemical properties play an

important part such as oxidation,

corrosion, general degradation,

toxicity and flammability.

Manufacturing properties of

material whether it can be cast,

formed, machined, joined, and

heat treated, with relative ease.



BEHAVIOUR AND MANUFACTURING

PROPERTIES OF MATERIAL

(14)

-Heat Treatment

-Precipitation Hardening

-Annealing

-Tempering

-Surface Treatment

-Alloying

-Reinforcement

-Composites

-Laminations

-Fillers

-Density

-Melting Point

-Specific Heat

-Thermal Conductivity

-Thermal Expansion

-Electrical Conductivity

-Magnetic Property

-Oxidation

-Corrosion

-Atomic bond:

Metallic, covalent and ionic

-Crystalline

-Amorphous

-Partly Crystalline

-Polymer Chains

-Strength

-Ductility

-Elasticity

-Hardness

-Fatigue

-Creep

-Toughness

-Fracture

Structure of

materials

Mechanical properties Physical and Chemical

properties

Property modification

Behavior and manufacturing

properties of materials



HEAT TREATMENT PROCESS

The properties and behavior of metal and alloy during manufacturing and performance

during their service life depend on their composition, structure, processing history and as well

as heat treatment process to which they have been subjected. The important properties such

as strength, hardness, ductility, toughness and resistance to wear are influenced greatly by

alloying elements and heat treatment process. By doing heat treatment processes it can

modifies the microstructures and change the mechanical properties such as formability,

machinability, hardness, toughness and strength.

As for OMNI OIL TECHNOLOGIES (ASIA), the implementation of heat treatment process

is done for the purpose of hardening the jigs which is used for machining process and quality

inspection process.

As shown in the picture, it is during the heating process of the jig. The required

temperature is about 800 °C and the increment of the temperature is measured by using the

temperature sensor.

(15)

JIG

COOLANT

FLAME



After about 3 hours heating the jig, thus the temperature reaches 800 °C. So after that we

need to immediately immerse the jig inside the coolant. This is rapid cooling process since we

desired the properties of the jig to be very hard as compared to initial properties of the jig. This

process is known as quenching process.

There are 7 different cooling processes which are:

Quenching

This is the process in which the heated material is being rapidly cooled by using water, oil,

coolant or other cooling liquid as a medium of cooling. By doing quenching process, it has

great rate of cooling and instantaneously the heated material will be in the normal

temperature again. The property of the material differ from the untreated material such as

increase in hardness value, become brittle, increase in strength and toughness value and

not uniform grain structure (Formation of martensite microstructure)

Normalizing

This is the process in which the heated material is cooled down in the open air in the room

temperature. By doing normalizing process, it has better rate of cooling as compared to

annealing process and the will be in the normal temperature again for about 4 to 5 hours.

The property of the material will be different than the untreated material such as slightly

increase in hardness value, increase in ductility, and slightly increase in strength and

toughness value, and also slightly uniform grain structure (Formation of partly martensite

and partly pearlite microstructure). The normalizing process also is done to refine the grain

boundaries.

(16)



Annealing

This is the process in which the heated material is cooled down very slowly inside the

heating furnace. By doing annealing process, it has the lowest cooling rate as compared to

the normalizing process and quenching process. The material will be in the normal

temperature again for about 1 day after the heating process is done. The property of the

material will differ than the untreated material in term of the hardness since annealing

process will have the lowest hardness value than quenching and normalizing process. The

other property which differs is the ductility in which the annealed material will be very

ductile. Furthermore, the annealed material will have less strength and toughness value.

The annealed material also will have very fine and uniform grain structure. (Formation of

pearlite microstructure)

Tampering

In tempering process the material is heated to a specific temperature (depend on the

composition of the material) and it is cooled down under prescribed rate of cooling.

Tempering process is used to reduce brittleness, increase ductility and toughness and

reduce the residual stress.

Austempering

In austempering process, the heated material is quenched rapidly from the austenitizing

temperature to avoid formation of ferrite and pearlite microstructure. It is then held at a

certain temperature until isothermal transformation from austenite to bainite

microstructure is complete. It is then cooled down to room temperature. Austempering

process is used to substitute the conventional quenching and tempering in which to reduce

the tendency toward cracking, and distortion during quenching, to improve ductility and

toughness while maintaining hardness value.

Martempering

In martempering process, the heated material is first quenched from austenitizing

temperature in a hot fluid medium such as hot oil or molten salt. Then it is held at that

temperature until the temperature is uniform throughout the material, and being cooled at

moderate rate such as in air. Martempered material has fewer tendencies to crack, distort,

or develop residual stress during heat treatment process.

(17)



Ausforming

In ausforming process the material is formed into desired shapes within controlled ranges

of temperature and time to avoid formation of nonmartensitic transformation product. The

part is then cooled at various rates to obtain the desired microstructures. Ausformed

material has superior mechanical properties.

To clearly see the different microstructures such as pearlite, bainite, ferrite and

martensite, it can be visualize through microscope and electron microscope.

(18)



SURFACE TREATMENTS AND COATINGS

After the part is manufactured, some of its surfaces may have to be processed further in

order to ensure certain properties and characteristics. It may be necessary to perform surface

treatments in order to:

Improve resistance to wear, erosion, and indentation

Control friction (sliding surfaces of tools, dies, bearings, and machine ways)

Reduce adhesion (electrical contact)

Improve lubrication

Improve resistance to corrosion and oxidation

Improve fatigue resistance

Rebuild surfaces

Modify surface textures

Impart decorative features

(19)



(1) Mechanical Surface Treatment Shot Peening Process

In shot peening the workpiece surface is impacted repeatedly with a large number of

cast steel, glass, or ceramic shot (small ball), which make overlapping indentation on the

surface. This action causes plastic surface deformation at depths up to 1.25 mm using shot sizes

that ranges from 0.125 to 5 mm in diameter. Because of the plastic deformation is not uniform,

throughout the part’s thickness, shot peening causes compressive residual stresses on the

surface, thus improving the fatigue life of the component by delaying fatigue crack initiation.

Unless the process parameters are controlled properly, the plastic deformation of the surface

can be so severe that it can damage the surface. However it should be noted that (if these parts

are subjected to high temperature) the residual stress will begin to relax (thermal relaxation)

and their beneficial effects will be diminished greatly.

(20)

Shot peening surface



(2) Case Hardening Nitriding Process

Methods of case hardening are such as carburizing, carbonitriding, cyaniding, nitriding,

flame hardening, and induction hardening. Case hardening as well as some of other surface

treatment processes induces residual stresses on the surface of the material. The formation of

martensite microstructure during case hardening causes compressive residual stresses on

surface. Such stresses are desirable since it will improve the fatigue life of the component by

delaying the initiation of fatigue crack.

As the engineering industrial training (EIT) conducted at OMNI OIL TECHNOOGIES (ASIA)

SDN BHD, the case hardening process also already implemented to improve the fatigue life of

the material such as roller reamer. The case hardening process that being used is nitriding.

Nitriding is a heat treating process that alloys nitrogen into the surface of a metal to

create a case hardened surface. It is predominantly used on steel but also titanium, aluminum

and molybdenum. The processes are named after the medium used to donate nitrogen. The

three main methods used are:

Gas nitriding

Salt bath nitriding

Plasma nitriding

(21)

After nitriding process

(surface are slightly darker)

Before nitriding process

(surface are shining)



Gas Nitriding

In gas nitriding the donor is nitrogen rich gas usually ammonia (NH3), which is why it

is sometimes known as ammonia nitriding. When ammonia comes into contact with the

heated work piece it disassociates into nitrogen and hydrogen. The nitrogen then

diffuses from the surface into the core of the material.

The advantages of gas nitriding are:

All round nitriding effect

Large batch sizes possible

With modern computer control of the atmosphere the nitriding result can be

tightly controlled

Relative cheap equipment cost

The disadvantages of gas nitriding are:

Reaction kinetics heavily influenced by surface condition

Surface activation is sometimes required to successfully treat with a high

chromium content

Ammonia as nitriding medium (toxicity which is harmful when inhaled in large

quantities and when there is presence of oxygen there is risk of explosion)

(22)



Salt Bath Nitriding

In salt bath nitriding the nitrogen donating medium is a nitrogen containing salt such as

cyanide salt. The salt used also donates carbon to the workpiece surface making salt bath a

nitrocarburizing process. The temperature used is typical of all nitrocarburizing processes 550-

590 °C

The advantages of salt bath nitriding are:

Quick processing time

Simple operation

The disadvantages of gas nitriding are:

The salt used are highly toxic

Only one process possible with a particular salt type

Plasma Nitriding

Plasma nitriding also known as ion nitriding, plasma ion nitriding, or glow discharge is an

industrial surface hardening treatment for metallic materials. There is hot plasma, typified by

plasma jets used for metal cutting, welding, cladding or spraying. There is also cold plasma

usually generated inside vacuum chambers at low pressure regimes. Here high temperature

characteristics of the ionized gases are not used, but the electronic properties become useful.

Thus an ionized gas like nitrogen in such a low pressure regime becomes much more reactive.

The advantages of plasma nitriding are:

Close control of the nitride microstructure

Allowing nitriding with or without compound layer formation

Performance of metal parts get enhance

Working lifespan gets boosted

Strain limit and fatigue strength are being treated

(23)



(3) Conversion coatings Phosphate conversion coating

Conversion coating is the process of producing a coating that forms on metal surfaces

as a result of chemical or electrochemical reactions. Various metals can be conversion coated

such as steel, aluminum, and zinc. Oxides that naturally form on their surfaces are a form of

conversion coating.

Usually phosphate coatings are used on steel part for corrosion resistance, lubricity or as

a foundation for subsequent coating or painting.

The application of phosphate coating make use of phosphoric acid and takes advantages

of the low solubility of phosphates in medium or high pH solution. Iron, zinc, or manganese

phosphate salt are dissolved into solution of phosphoric acid. When steel are placed in the

phosphoric acid metal reaction takes place which locally depletes the hydroxonium ions, raising

the pH and causing the dissolved salt to fall out of the solution and be precipitated on the

surface. The acid and metal reaction also creates iron phosphate locally which may also be

deposited. In the case of depositing zinc phosphate or manganese phosphate the additional

iron phosphate is frequently an undesirable addition to the coating.

(24)

Semi finish area at OMNI OIL

TECHNOLOGIES (ASIA) SDN BHD

Phosphate coating at the 12.25

inches Roller Reamer body



Typical phosphate procedures:

(1) Cleaning the surface

(2) Rinsing

(3) Surface activation

(4) Phosphating

(5) Rinsing

(6) Neutralizing rinse

(7) Drying

(8) Application of supplement coating

(25)

Surface of material after

phospating

Surface of material before

phospating



(4) Hard Facing

In this process a relatively thick layer, edge, or point of wear resistance hard metal is

deposited on the workpiece surface using the fusion welding techniques. Numerous layers

can be deposited to repair worn part. Hard facing enhances wear resistance of the material,

hence such material are used in the manufacture of tools, dies and various industrial

components. Worn part also can be hard faces for extended use.

(26)

The picture before hard facing

process is done.

This is the surface whereby the hard

facing process is conducted

During hard facing process

The picture after hard facing

process is done.

Stress concentration initiated



STRESS CONCENTRATION

The torsion formula (shear stress) τmax = Tc / J, whereby T is torsion, c is the outer radius

and J is the polar moment of inertia. This formula can be applied to regions of a shaft having

circular cross section that is constant or tapers slightly. When sudden changes arise in the cross

section, both the shear stress and shear strain distribution in the shaft become complex and

can be obtained only by using experimental methods or possibly by a mathematical analysis

based on the theory of elasticity.

In order to eliminate the necessity for the engineer to perform a complex stress

analysis, the maximum shear stress can be determined for a specified geometry using a

torsional stress concentration factor, K. As in the case of axially loaded members, K is usually

taken from the value of graph. To use this graph, first we must determine the geometric ratio

D/d to define the appropriate curve and then once the abscissa r/d is calculated, the value of K

is found along the ordinate. The maximum shear stress is then determined from the equation:

It can be noted from the graph that an increase in fillet radius, r causes a decrease in K.

Hence the maximum shear stress can be reduced by increasing the fillet radius. Also if the

diameter of the material is reduced, the ratio D/d will be lower and so the value of K and

therefore τmax will be lower.

Like the case of axially loaded member, torsional stress concentration factors should

always be used when designing part or material that will be subjected to fatigue or cyclic

torsional loadings. These conditions give rise to the formation of cracks at the stress

concentration, and this often lead to sudden failure of the part or material. Thus it is necessary

to strengthen the region which has stress concentration though hardening process such as hard

facing.

(27)

τmax = KTc / J



Stress concentration in material occurs at point of sudden cross sectional change, such

as couplings, keyways and at shoulder fillets. The more severe change the larger the stress

concentration. As for the design analysis it is not necessary to know the exact shear stress

distribution on the cross section. Instead it is possible to obtain the maximum shear stress

concentration factor, K which is determined through experiment and is only a function of the

geometry of the material. Normally the stress concentration in a ductile material subjected to a

static torque will not have to be considered in design. However if the material is brittle or

subjected to fatigue loadings, thus stress concentration become important parameter.

(28)

D d

r

Ratio: D/d Ratio: r/d

Stress concentration

section



HARDNESS TEST

The hardness test is conducted to test the hardness of the material after the material

undergoes the heat treatment process. As for the heat treatment process, it can alter the

microstructure of the material as well as it can change the properties of the material. Thus

hardness is one of the characteristics or properties that also changed after the heat treatment

process is conducted.

(29)

Portable Brinell hardness

Tester

Specimen

Pressure Lever

Proper way to use the


Tester



(30)

The impact diameter after

hardness test is conducted

The impact diameter at the

surface of the specimen is

observe through the King

Brinell Microscope

King Brinell Microscope



(31)


table

Impact Diameter

Brinell hardness value

Rockwell hardness value

Tensile strength value



PROCEDURE FOR USING BRINELL HARDNESS TESTER

After the hardness test is conducted then only we can compare the hardness value of

untreated material with the heat treated material. The result shows that the hardness value

increased as the material undergoes heat treatment process.

(32)

1. Put the specimen at the Brinell hardness tester.

2. Assemble the Pressure Lever at the Portable Brinell hardness Tester.

3. Slowly apply force at the Pressure Lever until the indicator reach the value of 3000 kg.

4. Remove the specimen and observe the impact diameter at the surface of the specimen.

5. Observe the impact diameter through King Brinell Microscope

6. Compare the value of impact diameter with the portable Brinell hardness table.



ENGINEERING METROLOGY AND INSTRUMENTATION

Engineering Metrology is defined as the measurement dimensions such as length,

thickness, diameter, taper, angle, flatness, profile, and others. Traditionally, measurement has

been after the part has been produce (known as post-process inspection). The term inspection

means checking the dimension of what has been produced or is being produced and

determining whether it complies with the specified dimensional tolerances and other

specification. However, for current situation, measurement is being made while the part is

being produced on the machine known as in-process or on-line or real-time inspection.

An important aspect of metrology in manufacturing processes is the dimensional

tolerance. Tolerance is the permissible variation in the dimension of a part. Tolerance is

important because of their impact on the proper functioning of a product, part

interchangeability and manufacturing cost. Generally, the smaller the tolerance the higher are

production costs.

Numerous measuring instrument and devices are used in engineering metrology each of

which has its own application, resolution, precision and other features. Two terms that

commonly are used to describe the type and quality of an instrument are:-

Resolution- It is the smallest difference in dimension that the measuring instrument can detect

or distinguish.

Precision- It is the degree to which the instrument gives repeated measurements of the same

standard.

In Engineering Metrology, the word instrument and gage are used interchangeably. The

temperature control is very important, particularly for making measurement with precision

instruments. The standard measuring temperature is 20 °C, and all gages are calibrated at this

temperature. In the interest of accuracy, measurement should be taken in controlled

environments which have the tolerance ±0.3 °C.

(33)



GEOMETRIC FEATURE OF PART AND PRODUCT

The most common quantities and geometric features that typically are measured in engineering

practice and products made by the manufacturing processes as described:-

Length – including all linear dimension part

Diameter – outside and inside, including part with different outside and inside diameter

(steps)

Roundness – including out-of-roundness, concentricity, and eccentricity

Depth – such as drilled or bored holes and cavities in dies and molds

Straightness – such as shafts, bars and tubing

Flatness – such as machined and ground surfaces

Parallelism – such as two shafts and slide ways in machine

Perpendicularity – such as threaded bar inserted into a flat plate

Angle – including internal and external angles

Profile – such as curvatures in castings, forgings, and car bodies

(34)



GENERAL CHARACTERISTICS AND SELECTION OF MEASURING

INSTRUMENTS

The characteristics and quality of measuring instruments generally are described by various

specific terms such as:-

Accuracy – The degree of agreement of the measured dimension with true value

Amplification – See magnification

Calibration – Setting of instrument to give reading that are accurate according reference

standard

Drift – See stability

Linearity – The accuracy of reading of instrument over its full working range

Magnification – The ratio of instrument output to the input dimension

Precision – Degree to which instrument gives repeated measurement of same standard

Repeat accuracy – The same as accuracy but repeat many times

Resolution – Smallest dimension that can be read on instrument

Rule of 10 – An instrument or gage should be 10 times more accurate than the

dimensional tolerances of the part being measured

Sensitivity – Smallest difference in dimension that an instrument can distinguish or

detect

Speed of response – How rapidly an instrument indicates the measurement

Stability – An instrument’s capability to maintain its calibration over period of time

(35)



MEASURING TOOLS AND INSTRUMENTS

(36)

API External Taper Gauge

API Lead Gauge

API Internal Taper Gauge



(37)

API Thread Height Gauge

Setting

API Thread Profile Gauge

API Thread Height Gauge



(38)

Rotary Pin Work Plug

API Thread Lead Gauge

Setting

Rotary Ring Work Plug



(39)

Ring Gauge

Torque Wrench

Portable Brinell Hardness

Tester



(40)

3 Point Holtest

Outer Micrometer

Steel Ruler



(41)

Angle Protractor

Feeler Gauge

Bore Gauge



(42)

Depth Caliper

Vernier Caliper

Digital Caliper



(43)

Tape Measures

Surface Roughness Tester

Height Gauge



(44)

Master Gauges

Silicon Putty



QUALITY CONTROL, QUALITY ASSURANCE AND INSPECTION

As the product is manufactured, there are 2 characteristic which can observe at the

product or part. The 2 characteristics are external characteristic and internal characteristic.

External characteristic most commonly involve dimensions, size, and surface finish and also

integrity issues such as surface damage from cutting tools or friction during the processing of

the workpiece. Internal characteristics include defects, such as porosity, impurities, inclusion,

phase transformation, embrittlement, cracks, debonding of laminations and residual stress.

Some of these defects may exist in the original stocks, and some are introduced or

induced during machining or other manufacturing process operation. Before the manufactured

products are marketed, the products need to be inspected for several characteristics. This is

very important since to:-

Ensure dimensional accuracy so that the parts properly fits into other components

during assembly process

Identify the products whose failure or malfunction has potentially serious implications,

such as bodily injury or fatality.

The prevention of defects in products and on-line inspection of part are the major goals in

all manufacturing activities. Product quality always has been one of the most important aspects

of manufacturing operation. If the product has poor quality, thus it will result toward:-

Difficulties in assembling process and maintaining component

Result in the need for in-field repair

Have significant build-in-cost of customer dissatisfaction

(45)



QUALITY CONTROL'S JOB SCOPE

To do inspection process of the manufactured product at Omni Oil Technologies

To prepare the check sheet all manufactured product at Omni Oil Technologies

To prepare inspection standard of all manufactured product at Omni Oil Technologies

To prepare inspection test plan (bubble drawing) of all manufactured product at Omni

Oil Technologies

QUALITY MANAGEMENT SYSTEM (QMS)

Original drawing A-3 size

Inspection test plan

Inspection standard

Inspection check sheet

Out sourcing

Need conformation report (NCR)

(46)



INSPECTION PROCESS

(47)

Post-process

inspection

The quality control

inspectors do the

post process

inspection for the

manufactured

product

In-process

inspection

The quality control

inspectors need to

inspect the semi

finish manufactured

product at the CNC

milling machine



(48)

The length inspection by

using height gauge

The total length inspection by

using tape measure

The outer diameter

inspection by using outer

micrometer



(49)

The angle inspection by using

angle protractor

The inner diameter

inspection by using holtest



ASSEMBLY PROCESS

Assembly process is the process whereby the individual parts and components produced

by manufacturing processes are assembled into finished products by various methods. In OMNI

OIL TECHNOLOGIES (ASIA) SDN BHD, the manual assembly process is used to assemble the

manufactured product.

Manual assembly use simple tools and generally is economical for small lot. Because of

dexterity of the human hand and fingers and their capability of feedback through various

senses, worker can manually assemble even complex part without much difficulty. Human hand

is capable of doing this simple operation with relative ease.

(50)

The assembly process between Cutter and

Tungsten Carbide Insert (TCI)

TCI

Cutter



(51)

Cutter

Block

Pin

Complete assembled Cartridge

Block, Pin and

Cutter are

assembled

together

After the Cartridge

is completely

assembled, it is

then to be

assembled with

Roller Reamer

body



(52)

Roller Reamer

Body

The Pocket at

the Roller

Reamer Body

After the

assembly

process between

the Cartridge

and Roller

Reamer Body

The complete

assembled

Roller Reamer

Body

The assembly

process is done

by using Torque

wrench

There are 3

Pockets for each

Roller Reamer

Body



DESIGNING PROCESS

Before any product is manufactured, firstly we need to design the product. To design a

product, we can use computer-aided design (CAD) which involves the use of computer to create

design drawings and products models. In OMNI OIL TECHNOLOGIES (ASIA) SDN BHD, the

implementation of SOLID WORKS is very useful to design any product. Once we receive the

drawing from customer, then we need to make it in 3-D representation by using SOLID WORKS.

There is other software such as CATIA (computer aided three dimensional interactive

application). The design can be subjected to engineering analysis and can identify potential

problem such as excessive load, deflection or interference at mating surface during assembly.

Information such as list of material, specification and manufacturing instruction also included in

CAD database. Thus the designer can analyze the manufacturing economics of alternative

designs.

(53)

The design of

the product in

three

dimensional

representations

After the

product is

manufactured

The

product of

Halliburton

Company

(Flexi Joint)



DESIGNS OF PRODUCT

(54)

Flexi Joint Design

AGS Mandrel Lower

Design

Driver Sub Design

AGS Mandrel Upper

Design



DESIGNS OF JIGS

(55)

Design of the jig to be

used during assembly

process between cutter

and tungsten carbide

insert

Design of the jig for

inner diameter

inspection

Design of the jig for

outer diameter

inspection



PROBLEMS AND DIFFICULTIES

ASSEMBLY DIFFICULTIES:-

Before the assembly process is done, the inspection process need to be done first to ensure all

the parameters are within the tolerance

Even if all parameters are within test plan (bubble drawing) tolerance but the part cannot be

assembled properly due to:-

Straightness problem

Roundness problem

(56)

Straightness

Roundness



MEASUREMENT DIFFICULTIES:-

1. Difficulties to measure the radius value

Measured by using silicon putty and coordinate measuring machine

(CMM)

2. Difficulties to measure total length of the body

Measured by using big milling centre 3 (BMC-3) rather than using tape

measure since the machine coordinate is more accurate and more

precise

3. Difficulties to measure the inner diameter of the body

Measured by using jig

(57)



LESSON AND EXPERIENCED LEARNED

Engineering Industrial Training is very essential to all students since it will provide the

student with knowledge and experience regarding engineering discipline. Throughout 12 weeks

Engineering Industrial Training, it help me a lot in term of discipline, time management, the

ethics at work, practicing health and safety procedures, and most importantly how to adapt

with the real working environment as well as how to tackle the problems.

Furthermore, this Engineering Industrial Training enhances my communication skills

effectively since the interaction between different kinds of people in various situations. It

teaches me the proper way to mingle with my supervisor and senior technicians. In fact, all the

staffs at OMNI OIL TECHNOLOGIES are very friendly and they give me a full cooperation in order

to accomplish the job assigned to me.

For me, the main objectives of Engineering Industrial Training which is to expose the

students to the real working environment, to learn how to handle and working with various

engineering equipments, getting familiar with the ethics at work, and how to deal with difficult

situation regarding engineering discipline, has been achieved. The students were given the

opportunity to deals with hands-on-experience and a place to apply related engineering theory

which already learned in university. Lastly, OMNI OIL TECHNOLOGIES is a good place to have

industrial training since it can provide student with related engineering studies as well as it can

build up the engineering attitude for the student benefits.

(58)



SUGGESTION AND RECOMMENDATION

During Engineering Industrial Training, it is brilliant way for the students to gain

knowledge and industrial experience. The Engineering Industrial Training is essential since it will

enable the students to face challenge in real working environment and yet can provide

exposure to the students.

As for university future implantation of Engineering Industrial Training program, it is

suggested that the duration should be more than 12 weeks. Instead of 3 months or 12 weeks

Engineering Industrial Training, the Kuliyyah of Engineering should conduct the industrial

training to be for about at least for 4 to 6 months. As far as this matter is concern, most of the

companies require the industrial training to be for about 4 to 6 months. This is because during

the Engineering Industrial Training, most of the companies assigned the students with certain

project which need to be complete at the end of the industrial training. Hence, if the student

only have short period of time, the students cannot completely solve the projects within the

time provided.

Furthermore, for the industrial company, it is wise and suggested to have proper plan

for the practical students. This is due to students can learn more on the things that had to be

done during the practical training. It is also recommended for the company to send the

industrial trainee to various departments accordingly in order to familiarize the students with

whole working process.

(59)



CONCLUSION

As conclusion, Engineering Industrial Training has provided the student with real

exposure of industrial environment. After 12 weeks of industrial training, there are so many

experiences that have been gained such as what is quality control job description, how the

company manages their worker, how to deal with difficult task and how to solve it and many

others.

During Engineering Industrial Training, it can help the student to get clear view about

real life engineering situation whereby all the workers are dedicated to solve any task related to

engineering discipline. Some of the knowledge may not be learned from the books or in lecture

but it can be learned through Engineering Industrial Training. Analytical and critical thinking

skills are very important to make a good decision. Book may tell the facts and the truth but may

not teach the way to solve every problem in real life situation.

Besides the technical skills, trainees will also learn to improve their communication skills

and how to develop good character. This is because to build up a good relationship, one must

have a good attitude and characteristic. An engineer may be the superior of the technician but

if the characteristic and attitude showed by the engineer is bad, the technician or the people

who work with the engineer may not respect the engineer as their superior. So that is why the

proper attitude and characteristics need to be developed.

Lastly, the students is eventually turned to be more mature and independent as they

complete the Engineering Industrial Training since the projects or activities conducted require

the student to be more proactive. As the result, the students will be equipped more in term of

technical part as well as attitude and characteristics part to be future engineer. Insyallah.

(60)



REFERENCES

Wikipedia – hardening process

Mechanics of Materials (seventh edition) by R. C. Hibbeler

Manufacturing Engineering Technology (fifth edition in SI unit) by Serope Kalpakjian and

Steven Schmid

Umetoko (Malaysia) Sdn Bhd – pamphlet

Omni Oil Technologies (Asia) Sdn Bhd – Omni sealed bearing roller reamer inspection

and maintenance manual

Mr. Zulkiflee Samsi (Manufacturing Engineer act as Plant manager Omni Oil

Technologies) – 06-799 6203

Mr. Hanafi Mamat (Quality Control Supervisor Omni Oil Technologies) – 06-799 6203

(61)



APPENDIX A

[Sample] - Final EIT Report 1

Documents

Transcript of [Sample] - Final EIT Report 1