Escolar Documentos
Profissional Documentos
Cultura Documentos
Category
Profesional
Qualification Employment
Degree
Engineer
Work scope
Design, teach
Semi
Profesional
Diploma
Assistant
Engineer
Supervise skilled
worker
Skilled
Certificate
Fitter,welder
Machinist
Fitting, welding
Machining
CHAPTER 2 : SAFETY
Shifting and storage of inflammable/toxic materials
Kept in coverage container, away from source of fire, labelled, use trolly
when shifting.
Fire Extinguisher
Class
A
B
C
D
Catridge
Water
Foam
Carbon dioxide
Dry powder
Application
Paper, wood, cloth
Petrol, alcohol, varnish, paint
Electric equipment
Magnesium, sodium
CHAPTER 3 : METROLOGY
Metrology is the science of measurement
Measuring instruments
Protractor
Depth gauge
Steel rule
Combination square
i. Steel rule
ii. Square head
iii. Protractor head
iv. Centre head
Usage
Mark, transfer, measure an angle
To test and measure the depth of a hole
Measure , mark straight line.
Gauging
Definition : A measurement method used to determine that a product
meets the required standart or specification.
Importance : Save time and production cost.
Gauge type
Plug gauge
Snap gauge
Ring gauge
Taper plug gauge
Thread plug gauge
Usage
To test the diameter of a machined hole.
To test machine component
To test the concentricity of cylinder
To test tapering of machined component
To test the screw threat
Tolerance limits
Definition : a measurement range of a machine component to enable the
assmbley of two components.
Unilateral limit
Bilateral limit
Dimension
50.00
Limit
: 50.20 49.70 = 0.50 (upper-lower)
Limit type
: Bilateral
Use of tolerance limits
1. Produce product with accurate dimensions.
2. Allows the concept of interchangeability.
3. Simplifies the components assembly process
Quality Control
Definition : process of inspection and testing of products using specific
techniques and activities to achieve and control the product quality.
Improtant of quality control
1. Achieve the standarts of the product
2. Control product quality
3. Fulfil customers satisfaction
4. Reduce manufacturing cost of product.
Batch size [ N ]
Sample size taken for inspection [ n ]
Acceptence Quantity Limit [ P ]
Batch Rejected
> P units defective
2. Double sampling
Sampling used when :
a. Inspection cost for each product is too high
b. Large quantities of product to be inspection
CHAPTER 4 : WORKSHOP PRACTICE
Types of fastening
Bolts, nuts, screws, studs, washers
Function of washers prevent the surface being damage, to distribute
the force to larger surface area, to prevent nut from being loosen.
Pop riveting process
1. Mark the position of the hole
2. Hold the metal sheets close together
3. Select the correct rivet size
4. Drill the mark according to rivet size
5. Insert the rivet into the rivet gun
6. Place the rivet close to the hole until the rivet gun is
close to the surface of the component.
7. Complete the riveting work.
Soft-soldering
Principle : forming an alloy on a metal sheet surface
using a solder.
Material : Solder tip, tin, flux, brush
Brazing
Principle : forming an alloy on the surface of a base metal and a filler
Gas welding
Principle : Melting the base metal with the filler metal from the
combustion of oxygen and acetylene gas.
Equipment : Gas cylinders, pressure regulator, one-way valve, gas
hose, welding torch, special key, lighter.
Safety attire : goggles,gloves, apron
Safety measure :
1. Wear the safety equipment such as goggles, gloves, apron.
2. Ensure that the gas cylinder are in upright position.
3. Welding be done where the air circulation is good.
4. Welding away from inflammble material
Sampling
1. Single sampling
Batch Accepted
< P units defective
Arc welding
Principle : Melting of base metal using electric arc.
Equipment : Welding machine, electrode holder, electrode, earthing,
electrode cable, cleaning tools.
Safety equipment : Face shield, leather glove, leather apron, safety
shoes.
Arc welding process
1. Clean the surface to be welded.
2. Position the plates close together.
3. Select the appropriate electrode.
4. Adjust the electric current according to the electrode size.
5. Scratch or knock the electrode to strike the arc and do a tack weld.
6. Weld along the joint
7. Switch off the welding machine
8. Remove the slag from welding bead
Safety measure
1. Wear the protective equipment
2. Ensure that the welding and earth cable are in good condition.
3. Perform welding away from inflammable materials
4. Perform welding where the air circulation is good.
Cutting by division
Principle : cutting by shearing on metallic materials.
Equipment : snippers, hand lever shearing machine, square shearing
machine.
Stages of cutting process by division
1. First stage metal goes through a deformation
2. Second stage structure change to plastic deformation
3. Third stage - the inner surface go through work hardening.
4. Fourth stage the metal separate into two.
Cutting by Chipping.
Principle : removal or reducing the thickness of the work piece that
produce metal flakes known as chips.
Hand tools : chisels, files, hacksaws
Machine : drilling, lathe, milling, grinding
Drilling procedure
1. Mark the centre of the hole.
2. Grip the work piece to the vice tightly
3. Adjust the drilling speed accordingly
Marking tools
1. Scriber
2. Centre punch
drilling
chiselling
sawing
A
B
Parts of Drilling machine
1. Head stock
2. Driving Motor
3. Column
4. Worktable
5. Base
4. Hardness
5. Elasticity
6. Toughness
7. Plasticity
3. Bending Process
Definition : a process by forming sheet metal into a shapes..
Bending process flow
1. Sheet metal is fed into punch and die set.
2. Punch is lowered and press to the metal sheet
3. The metal is bent into the die shape.
4. Punch moves back into original position.
4. Drawing process
Definition : a process of forming a container from metal sheet.
Bending process flow
1. Sheet metal is fed into punch and die set.
2. Punch is lowered and press to the metal sheet
3. The metal is pressed down to take die shape.
4. Punch moves back into original position.
Blast Furnace
Pig Iron
Open Hearth Furnace
Bessemer Converter
Heat Treatment
Definition : a process of controlled heating and cooling product to ahieve
the right properties.
Non-uniform microstructures
heated
cooled
uniform microstructures.
Microstructure : ferrite, pearlite, cementite, austenite, martensite
Temperature
Upper critical temperature line
Austenite
940 C
723 C
Austenite + Cementite
F+A
Ferrite
Ferrite + Pearlite
Pearlite + Cementite
0.2
0.4
0.8
Percentage of carbon content
1. Annealing
To relieve the internal stress, rearrange microstructures, enchange
mechanical properties.
Annealing process :
product heated to annealing temperature.
- kept in the furnace for certain peroid of time.
- cooled in the furnace.
2. Normalizing
To transform the coarse and non uniform microstructure into finer,
uniform grains and without internal stress.
Normalizing process :
- product heated to normalizing temperature.
- Kept in the furnace for certain period of time
- cooled outside the furnace.
Pearlite
austenite during heating
3. Hardening
To improve hardness, strength and scratch resistance of steel.
Hardening process :
- product heated to hardening temperature.
- Kept in the furnace for certain period of time
- cooled in water or oil
Tranformed microstructure for 0.9 % Carbon.
i. Heated under critical temperature line pearlite+ cementite
ii. Heated above critical temperature line austenite + cementite
iii. Cooled in water - martensite
Hardening process produces hard but brittle martensite.
4. Tempering
To reduced brittleness in steel after hardening process.
Tempering process :
- martensite steel heated to tempering temperature.
- Kept in the furnace for certain period of time
- cooled outside the furnace.
Tempering produces uniform and fine martensite microstructure
tempered martensite.
f = R
mg
Fy = 0
R mg = 0
R = mg
Fx = 0
Ff=0
F - R = 0
F = (mg)
The Law of Friction
1. The direction of friction force is opposite to the direction of a body
movement.
2. The surface area of two surfaces in contact does not contribute to the
friction force.
3. A friction force is a function of the normal reaction force.
4. The magnitude of a friction force depends on the shapes, type and
condition of the surface in contact.
Coefficient of Friction () is defined as the ratio between the friction force
(F) and the normal body reacting force (R)
f = R
Application of friction.
1. Belt and pulley system
2. Brake system
Stress
Definition : intensity of force distributed over a unit area.
= F N/m-2
A
Strain
Definition : the ratio of the changes in length compared to original
length.
= x
L
Modulus of Elasticity
Definition : the ratio of stress to strain within material elastic range.
E = stress =
strain
Stress
D
B
CHAPTER 6 : MECHANICS
Moment
Definition : the product of the magnitude of force acting on the
perpendicular distance from the force action( M = Fd)
Principle : when the body is in equilibrium, the sum of clockwise moment
is equal to the sum of anti-clockwise moment.
Friction
Principle :
C
E
Strain
Point
O-A
Proportional limit
A-B
Elastic limit
B Upper yield point
C Lower yield point
D Tensile strength
E Fracture point
Explanation
5. As a lubricant
Pulley
Functions :
1. lift load
2. to change the ratational direction
3. transmit power
NADA = NBDB
N = rotational speed (rpm)
D = pulleys diameter (mm)
Gears
Functions :
1. transmit power
2. change the direction
3. increase or decrease speed of shaft.
Types of Gears
1. Spur gears
2. Bevel gears
3. Helical gears
4. Rack and pinion gears
Gear chain
Simple gear chain
consists of two gears
Compound gear chain consists of more than two gears
Simple gear formula
NBTB = NATA
Compound gear chain
ND = TA X TC
NA
TB
TD
N = rotational speed of gear (rpm)
T = number of teeth of gear
c. Pipe leaks
a. hose leaks
b. hose connection to
component is not
proper
c. component leaks
Failed to achieve
the required
pressure
a. relief valve is
adjusted low
b. pump failure
Piston move in
wrong direction
a. wrong connection
Remedy
a. repair pump
b. check valve is
correctly installed
to its direction of
flow.
c. repair leak
a. replace with new
hose
b. tighten the
connection
c. repair/replace faulty
component
a. readjust the relief
valve.
b. repair pump
a. check hose is
correctly connection
CHAPTER 7 : SYSTEMS
1. Hydraulic System
Definition : the control and transfer of power by using high-pressure fluid
2. Pneumatic System
Definition : the control and transfer of power by using compressed air.
Dryer
Air filter
Pressure regulator
Pressure gauge
Lubricator
Directional control
valve
Flow control valve
Cylinder
Silencer
System cleaness
Clean
Dirty
3. Robotic System
Definition : a mechanical unit that is designed to perform task through
programmeed instructions.
Used in manufacturing industries welding, spray painting, assembling
components.
Elements of robotic system
a. Power element
b. Control element
c. Movement element
d. Sensor element
a. components
blockage
b. hose leakage
a. wrong connection
between components
Frequent damage of
components.
a. no lubricant
b. leakage or blockage
of filter
c. moisture presents in
the system
a. faulty silencer
System is noisy
Remedy
a. select suitable
compressor
b. repair the
compressor
a. tighten the joints of
components
b. change hose
a.make sure
connection to
suitable port.
a. add lubricant
b. replace with new
filter
c. install dryer to the
system.
a. replace with new
silencer
a. Power element
- to produce robot movement
- electrical, pneumatic, hydraulic power.
b. Control element
i. Remote teaching programme
- control panel used to operate the movement of robotic arm to the
position or location required.
- the movement sequences are recorded in memory unit of robot.
- the recorded movement will used by robot to move and perform
its work process.
ii. Lead through programme
- operator moves a devices manually to recorded the movement
- the recorded path will used by robot during the work operation
iii. Programmable Logic Control (PLC)
- robotic programmer enter the programme into PLC unit using
logical command.
- the command translated into input and output command.
- robot will perform its task according to input programme.
c. Movement element
i. Cylinderical movement
ii. Polar movement
iii. SCARA movement
iv. Rectangular movement
v. Revolute movement
d. Sensor element
i. Electronic feedback sensor
- electronic device uses infra-red light to detect objects
- object passes through or blocked the infra-red light
- the light will reflected back to the emitter.
- the signal sent to robotic control unit
- robot perform movement to required task.
ii. Touch sensor
- object that come into contact with touch sensor will send an
electric signal to the control unit.
- control unit will sending command to robot
Problem solving
Function
Construct a part of a curve and chamfer an angle of object
To make cuts on drawn objects
To copy the same object in large number
To duplicate drawing entity at different location
To shift an entity from one position to new position
To construct new entity at new position parallel to initial
To have mirror image
To lengthen entity to target entity.
To show cross sectional area
Mod OSNAP
MIDpoint
ENDpoint
CENter
INTersection
TANgent
QUADrant
PERpendicular
Description
Lines, curves, polylines midpoint
Lines, curves, polylines endpoint
Circles, curves or ellipse centre point
Linion pointes, circles curves intersect
Point or lines or circle that tangentially meet
Quadrant points on circles or curves
Lines that lies perpendicular to the referred point
Design Elements
1. Design process
2. The application of technology
3. Structure
4. Economics of design
5. Material selection
6. Design compatibility
1. Design process
a. Problem identification
b. Investigation
c. Preliminary idea
d. Idea analysis
e. Refining
f . Decision making
g. Implementation
2. The application of technology
a. Gear
- heavy duty work
- transmits constant motion
- speed without slippage
- minimum space area movement
b. Belts and pulleys
c. Joint
- to transmit force and change motion
d. Wheels
- easy the movement of object.
3. Structure
a. Sturdiness of designed product
- focus on structural strengths to withstand force such
as tension, compression, shear, bending , twist.
b. Size of design product
c. Assembly and maintenance
- product easy to assembly and dismantle
d. Safety
- stability of product
- Avoid all sharp corners and edges
- Select non- flammable and non- toxic materials
e. Construction Process
- Cutting and joining process
4. Economics of design
a. Materials
- ability to withstand force
- easy to obtain
- easy to form or shape
b. Construction process
- consider for cost, time and energy saving.
5. Material selection
Appropriate and able to withstand any condition
Easy to process
Easily obtained and cost saving.
6. Design compatibility
a. Aesthetic refers to characteristics such as beauty,
tradition, art and finishing
- colour, texture, finishing, pattern, shape
b. Ergonomics scientific study related to physical and
psychological characteristics of consumers