Unit0 J3103

HAJI MAHMUD BIN HAJI SIDEK (POLISAS)SAIFUDDIN BIN ABDUL RAHMAN (POLISAS)

MODULE J3103WORKSHOP TECHNOLOGY 3

MALAYSIAPOLYTECHNICS

MINISTRY OF EDUCATION

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WORKSYOP TECHNOLOGY 3 1

Name : Hj Mahmud b Hj SidekAddress : Mechanical Engineering Department

Politeknik Sultan Haji Ahmad Shah Semambu, 25350 Kuantan, Pahang.

Telephone No. : 09-5661300 ext 320e-mail :

Qualifications : Tech. Teachers Training College, KualaLumpurM. Sc. Voc. Ed. B. Sc VTAE( Univ.ofWisconsin- Stout, Menomonie, U.S.)

Position : Polytechnic Lecturer

Name : Saifuddin b Abdul RAhman Address : Mechanical Engineering Department

Politeknik Sultan Haji Ahmad Shah Semambu, 25350 Kuantan, Pahang.

Telephone No. : 09-5661300 ext 320 Qualifications : Dip Mech Eng (UTM)

B. Mech Eng. Hons (UTM) Position : Polytechnic Lecturer

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What Do You Think Of This Module?

Title of Module: _______________________ Module Code : ___________

Student’s Name: _______________________ Registration No. : ___________

Course : ____________________________________

Module Writers: ______________________________

Please use the following scale for your evaluation:

4 Strongly Agree3 Agree2 Disagree1 Strongly Disagree

Instruction : Please Ö on the space provided.

No. How much do you agree with the following statements? SCALE

A. FORMAT 1 2 3 41 The pages are organized in an interesting manner.2 The font size makes it easy for me to read the module.

3 The size and types of pictures and charts used are suitable forthe input.

4 The pictures and charts are easy to read and understand.5 The tables used are well-organised and easy to understand.6 The arrangement of the Input makes it easy for me to follow.7 All the instructions are displayed clearly.

B. CONTENTS 1 2 3 48 I understand all the objectives clearly.9 I understand the ideas conveyed.

10 The ideas are presented in an interesting manner.11 All the instructions are easy to understand.12 I can carry out the instructions in this module.13 I can answer the questions in the activities easily.14 I can answer the questions in the self-assessment.15 The feedback section can help me identify my mistakes.16 The language used is easy to understand.17 The way the module is written makes it interesting to read.18 I can follow this module easily.19 Each unit helps me understand the topic better.

20 I have become more interested in the subject after using thismodule.

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CURRICULUM GRID

The curriculum grid of this module is based on the curriculum used byMalaysian polytechnics.

No. TOPIC UNIT TotalHours

1 ScrewThread

1(4H)

4 Hours

2 Gear 2(4H)

3(3H)

7 Hours

3 SurfaceTexture 4

(4H )

4 Hours

4 Power PressMachine 5

(4H )

4 Hours

5 ComputerNumericalControl

6(6 H )

6 Hours

6 Shielded GasArc Welding 7

(3 H )

5 Hours

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UNIT 1 SCREW THREAD

1.0 Introduction1.1 Elements of a thread

1.1.1. Major Diameter1.1.2. Pitch/Mean Diameter1.1.3. Minor Diameter1.1.4. Thread Angle1.1.5. Pitch1.1.6. Root

1.2 Measuring the major diameter1.3 Measuring the minor/core diameter1.4. Measuring the mean/pitch/effective diameter

1.4.1. Best Size Wires.1.5. Optical Comparator

1.5.1. To check the angle of a 60o thread using an opticalcomparator

UNIT 2 GEAR

2.0 Introduction2.1 Types of gears

2.1.1. Spur gear2.1.2. Internal gears2.1.3. Helical gears2.1.4. Herringbone gears2.1.5. Bevel gears2.1.6. Miter gears2.1.7. Angular bevel gears2.1.8. Hypoid gears2.1.9. Worm and worm gear2.1.10. Rack and pinion

2.2 Gear terminology2.2.1. Addendum2.2.2. Dedendum2.2.3. Pitch diameter

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2.2.4. Base diameter2.2.5. Pitch circle2.2.6. Pitch line2.2.7. Face width

2.2.8. Tooth thickness2.2.9. Top land2.2.10. Base diameter2.2.11. Root2.2.12.

2.3. Measurement and testing of gears.2.3.1. Gear-tooth vernier caliper2.3.2.

2.4 Plug method of checking for pitch diameter and divide ofteeth

UNIT 3 GEAR

3.0 Gear manufacturing3.1. Form cutting3.2. Gear generating3.3. Cutting bevel gears3.4. Gear-finishing processes

3.4.1. Shaving3.4.2. Burnishing

3.4.3. Grinding, honing and lapping3.5. Metric gears and gear cutting3.6. Metric modul gear cutters

UNIT 4 SURFACE TEXTURE

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4.0. Definition4.1 Surface texture terms and definition

4.1.1. Flaws4.1.2. Lay

4.1.3. Roughness4.1.3.1. Roughness height4.1.3.2. Roughness width

4.1.4. Waviness4.1.5. Profile4.1.6. Microinch and micrometer

4.2. Standard symbols to describe surface texture/finish4.3. Symbol for surface roughness4.4. Surface roughness

4.4.1. The Arithmetic Mean Value, Ra4.4.2. The Root-Mean-Square Average, Rq.4.4.3. Maximum Roughness Height, Rt

4.5. Comparison of Ra and Rq4.6. Using a Surface Texture Comparator

4.6.1. Comparison blocks4.6.2. Commercial sets of standard finished specimens

UNIT 5 POWER PRESS MACHINE

5.0 Introduction5.1 Shearing

5.1.1. Punch5.1.2. Die5.1.3. Stripper5.1.4. Stop5.1.5. Pilot5.1.6. Sets5.1.7. Pressure Plate

5.2 Clearance between Punch and Die

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5.3 Force and Work Done required for Shearing5.4 Shear5.5 Bending

5.5.1. Force Required for Bending5.5.2. Planishing5.5.3. Allowance for Bending5.5.4.

5.6 Drawing5.6.1. Blank Size5.6.2. Force Required for Drawing

5.7. Combination tools

5.8. Progression tool

UNIT 6 COMPUTER NUMERICAL CONTROL

6.0 Introduction6.1 NC operation6.2 Industrial Application

6.2.1. Metal Machining6.2.2. Metal Forming6.2.3. Finishing6.2.4. Assembly Joining6.2.5.

6.3 CNC axis conventions6.4. NC machine sub-unit

6.4.1. The Machine Tool6.4.2. The Control Unit6.4.3. Control System

6.5 . Program input6.5.1. Punched Tape

6.5.2. Computers

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6.5.3. Direct Input6.5.4. By Manual Data Input (M.D.I.)6.5.5. Interactive Programming.6.5.6. External Devices

6.6 NC programming6.6.1. Job Planning6.6.2. Incremental6.6.3. Absolute6.6.4. Linear Interpolation6.6.5. Circular Interpolation

6.7. Program definition6.7.1. Program6.7.2. Program preparation6.7.3. Operation of program

6.8. Types of control system6.9. Programming codes

6.9.1. G codes (preparatory codes)

6.9.2. M codes6.10. Writing a Program6.11. Advantages of computer numerical control

UNIT 7 SHIELDED GAS ARC WELDING

7.0 Introduction7.1 Tungsten Inert Gas (TIG)

7.1.1. Preparation of Metal7.1.2. Joint Fit.7.1.3. Welding Machine7.1.4. Welding Torch7.1.5. Shielding Gas.

7.1.6. Filler Metal

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7.2 TIG Welding Techniques7.3 Metal Inert Gas (MIG)

7.3.1. Power Requirements7.3.2. Selection of Gas.

7.3.3. Filler Metal7.4 Job Procedures

7.4.1. Current7.4.2. Voltage.7.4.3. Travel Speed7.4.4. Electrode Extension

7.6. MIG Welding Techniques7.7. Direct current straight polarity7.8. Direct current reverse polarity arc welding

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MODULE GUIDELINES

To achieve maximum benefits in using this module, students must followthe instructions carefully and complete all the activities.

1. This module is divided into 6 units.2. Each page is numbered according to the subject code, unit and page

number.

J3103 / UNIT 1 / 5

Subject Unit 1 Page Number 5

3. The general and specific objectives are given at the beginning ofeach unit.

4. The activities in each unit are arranged in a sequential order andthe following symbols are given:

OBJECTIVESThe general and specific objectives for each learning topic arestated in this section.

INPUTThis section introduces the subject matter that you are going tolearn.

ACTIVITIESThe activities in this section test your understanding of thesubject matter. You have to complete this section by followingthe instructions carefully.

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FEEDBACKAnswers to the questions in the activity section are givenhere

5. You have to follow the units in sequence.6. You may proceed to the next unit after successfully completing the

unit and you are confident of your achievement.

SELF-ASSESSMENTSelf-assessment evaluates your understanding of each unit.

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

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GENERAL AIMS

This module is prepared for the third semester of Certificate/Diplomastudents of Malaysian Polytechnics. Its aim is to expose students to theWorkshop 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 WorkshopTechnology 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. State the measurement and inspection methods of ISO metric screwand BSW screw.

2. Describe the procedure of measuring major diameter, minordiameter and min diameter by using thread measuring machines.

3. Calculate the major diameter, minor diameter and min diameter byusing thread measuring machines and the of three wire method.

4. Inspect the method thread angle with an optic projector.5. State the types and the functions of gear, parts and describe the

method of making gears.6. Name the different types of gear, specifications and uses.7. Mention the parts of the gear including addendum, dedendum,

pitch diameter and gear specifications.8. Measure and inspect of gears.9. Describe the measurement and inspection procedures of gear using

vernier calipers.10. Describe the pitch diameter by the inspection method for gears

using micrometer and stylus machine.11. Describe the method of producing the gear using simple and direct

index.

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12. State the importance of surface textures in engineering componentsand 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.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.

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32. Elaborate on the TIG and MIG welding principles, weldingprocedures, welding machines, gas, electrodes and the electrodewire used, types of current, polarity used and the effects of polarityon a work piece.

33. State the weaknesses of TIG and MIG welding and how to preventthem.

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.

2. Haslehurtst, M, “ Manufacturing”; 2nd ed, The English LanguageBook Society & Hodder & Stoughton, 1975.

3. Pritchard, R.T., “T.3 Workshop Technology for MechanicalEngineering Technicians”; 2nd ed, Hodder & Stoughton, 1978.

4. Krar, Steve F. , Oswald, J. William, “Technology of Machine Tools”;4th ed, Gregg Division Mc Graw-Hill Publishing Company,1990.

5. Chapman, W.A.J., “Senior Workshop Calculation”; 3rd ed., TheEnglish Language Book Society & Edward Arnold (Publishers) Ltd.,1975.

6. Davies, A.C., “The Science and Practice of Welding”; 7th ed,Cambridge University Press., 1974.

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7. Kalpakjian, Serope, Schmid, Steren R., . “ManufacturingEngineering and Technology”; 4th ed, Prentice Hall International.,2001.

8. Love, L. Carl, “ Welding: Procedures and Applications ”, PrenticeHall, 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 abovesources.

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Unit0 J3103

Technology

Transcript of Unit0 J3103