jj103 mechanical workshop practice 1

RESTRICTED JJ103 Mechanical Workshop Practice 1

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Version : 080510_1.2_Effective:1June 2011 RESTRICTED

POLYTECHNICS MINISTRY OF HIGHER EDUCATION MALAYSIA

DEPARTMENT OF MECHANICAL ENGINEERING COURSE : JJ103 MECHANICAL WORKSHOP PRACTICE 1 INSTRUCTIONAL DURATION : 15 WEEKS CREDIT (S) : 2 PREREQUISITE (S) : NONE

SYNOPSIS MECHANICAL WORKSHOP PRACTICE 1 exposes the students to welding, machining

and fitting which involves the use of arc and gas welding machine, lathe machine, drilling

machine, grinding machine, hand tools, marking out tools, measuring and testing tools.

Students are also taught to emphasize on safety procedures and cleanliness in the

workshop.

LEARNING OUTCOMES

Upon completion of this course, students should be able to:- 1. practice correctly safety procedures in the workshop.

2. carry out fitting works with various hand tools, marking out, measuring tools,

testing tools and drilling machine.

3. perform grinding works and various types of lathe work according to prescribed

procedures

4. carry out correctly basic gas and arc welding works involving various processes

of welding and types of joining metals according to S.O.P


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SUMMARY ( 00 LECTURE : 60 PRACTICAL) RTA

1.0 FITTING (00:20) The topic exposes the students to fitting works involving the use of various hand tools, measuring tools, marking out, testing tools and drilling machine.

2. . 0 MACHINING (00:20) The topic exposes the students to tool bits grinding (off hand grinding),

operate the lathe machine for various machining processes and practice measuring skills.

3 . 0 BASIC WELDING (00:20)

The topic exposes the students to basic gas and arc welding processes involving various types of joining metals.

RTA : Recommended Time Allocation


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SYLLABUS 1.0 FITTING

1.1 Perform fitting works 1.1.1 Flat file , square and form surfaces using various types of files 1.1.2 Mark out parallel, vertical and different angular lines on a

workpiece. 1.1.3 Chisel off metal using various types of chisels 1.1.4 Cut mild steel plates using a hack saw 1.1.5 Mark out and drill holes on a bench drilling machine 1.1.6 Cut internal and external Metric V thread using :

a. taps b. dies

1.1.7 Measure workpiece using: a. steel ruler b. external micrometer c. vernier caliper d. vernier height gauge 1.1.8 Test finished workpieces using gauges, templates, profile projector and surface testing machine

1.1.9 Keep the workshop clean and safe

2..0 MACHINING WORK

2.1 Perform machining work 2.1.1 Practice safety procedures while operating the lathe and grinding machine 2.1.2 Grind tool bits (off hand grinding) according to the required geometric angles for general purposes machining using pedestal grinder.

2.1.3 Operate the lathe machine, select spindle speeds and feeds 2.1.4 Operate lathe machine for a. parallel turning b. stepped turning c. facing d. taper turning e. centre drilling f. knurling 2.1.5 Measure workpiece by using the following instruments: a. micrometer b. vernier caliper

c. steel ruler 2.1.6 Keep the workshop clean and safe.

3.0 BASIC WELDING.

3 . 1 Practice Oxy acetylene welding. 3.1.1 Ignite and adjust flame for different types of welding job 3.1.2 Select proper filler rods and use it to get a neat and correct bead flow. 3.1.3 Weld an open square butt joint with full penetration throughout the point.


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3.1.4 Weld open corner joint with full penetration throughout the joint 3.1.5 Keep the workshop clean and safe.

3 . 2 Practice Arc welding 3.2.1 Deposit stringer beads using correct electrode size and amperage

selection for different types of recommended metal thickness. 3.2.2 Weld a close square butt joint with straight, smooth and convex bead throughout the joint. 3.2.3 Weld an open corner joint with straight convex bead surface.

3.2.4 Keep the workshop clean and safe.


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ASSESSMENT TYPES OF ASSESSMENT

The course is assessed through 100% Continuous Assessment

CONTINUOUS ASSESSMENT (CA): Continuous assessment is carried out throughout the semester and comprises the followings:

a. Practical Task ( minimum 3 ) 60% b. Project ( minimum 1) 20% c. Other Assessment Task i. Report ( minimum 3 ) 20%

[ Assessment Task above ( a-b ) to be executed during Lecture / Practical / Tutorial hour ]

Note : 1. Refer to Assessment Specification Table for the details. 2. The percentage of Continuous Assessment may vary depending in courses.


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ASSESSMENT SPECIFICATIONS TABLE ( AST) LEARNING OUTCOMES

1. practice correctly safety procedures in the workshop.

2. carry out fitting works with various hand tools, marking out, measuring tools, testing tools and drilling machine.

3. perform grinding works and various types of lathe work according to prescribed procedures

4. carry out correctly basic gas and arc welding works involving various processes of welding and types of joining metals according to S.O.P

CONSTRUCT CONTEXT CLO

ASSESSMENT TASK

Practical Task Project Report

1 2 3 4 L M H L M H L M H

FITTING fitting works 8

1

1

MACHINING machining works

3 1

BASIC WELDING

gas welding 4

1

1

arc welding 3 1

TOTAL 18 2 4

RATIO RUBRIC RUBRIC RUBRIC


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REFERENCES Bawa, (2004). Manufacturing Processess1. McGraw Hill Bawa, (2004). Manufacturing Processess2. McGraw Hill Chapman, W.A.J, (1996). Workshop Technology Part 1. ELBS Chapman, W.A.J, (1996). Workshop Technology Part 2. ELBS Krar, S.F, Oswald J.W. (1976). Technology of Machine Tools. Mc Graw Hill Richard R. Kibbel,et al (2006), Machine Tool Practice (8th ed.). U.S: Pearson Prentice

Hall. Ibrahim Che Muda, R. Ramudaran, (2000), Teknologi Bengkel Mesin, Dewan

Bahasa Pustaka.


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DISTRIBUTION OF STUDENT LEARNING TIME

No. Activities CODE SLT

1 Lecture [ hour(s) x 15 week(s) ] L 0

- Lecture hours [ ]

- Theory test/quiz [ ]

2 Self Learning: Theory [ hour(s) x 15 week(s) ] I 0

- Preparation before theory class viz. review/download lesson notes. [ ]

- Preparation after theory class viz. additional references, discussion group, discussion with lecturers. [ ]

- Preparation for theory test/Preparation before work presentation [ ]

3 Practical [ 4 hour(s) x 15 week(s) ] P 60

- Lab work [ ]

Workshop safety [ ] Presentation/ Critique

- Skill/Practical test [ ]

Workshop practice [ ] [ ]

- Field work [ ]

Simulation

[ ] Practical task [ ]

- Survey/research [ ]

Outdoors

[ ]

- Project [ ]

4 Self Learning: Practical [ 1 hour(s) x 15 week(s) ] I 15

- Preparation before practical class/field work/eview notes, checklist/labsheets and/or tools and equipment. [ ]

- Preparation after practical class/field work/dditional references, discussion session and report writing. [ ]

- Preparation before work presentation/critique. [ ]

- Preparation for practical test. [ ]

5 Tutorial T 0

6 Other Assessment Task O

- Capstone Project [ ]

Portfolio

[ ] Essay Question [ ]

5

- Presentation

[ ]

Peer Assessment [ ] Observation [ ]

- Reflective Journal [ ]

Self Assessment [ ] Discussion [ ]

- Case Study [ ] End-of-Chapter [ ] Report [ ]

Total 80

L Lecture 0

P Practical 60

I Self Learning 15

T Tutorial 0

O Other Assessment Task 5

SLT (Student Learning Time) 80

Credit = SLT/40 2.00

* Note: Assignments/projects shall begin guided during practical session.


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TABLE OF LEARNING DOMAINS

NO

SPESIFIC OUTCOME (SO)

COGNITIVE PSYCHOMOTOR AFFECTIVE

C1 C2 C3 C4 C5 C6 P1 P2 P3 P4 P5 A1 A2 A3 A4 A5

1.0 FITTING

1.1 Perform fitting works

1.1.1 Flat file, square and form surfaces using various types of files

1.1.2 Mark out parallel, vertical and different angular lines on a workpiece

1.1.3 Chisel off metal using various types of chisels

1.1.4 Cut off mild steel plates by using a hacksaw

1.1.5 Mark out and drill holes on a bench drilling machine

1.1.6 Cut internal and external Metric V thread using taps and dies

1.1.7 Measure workpiece using steel ruler, external micrometer, vernier calliper, vernier height gauge

1.1.8 Test finished workpieces using gauges, templates, profile projector and surface testing machine


2.0 MACHINING WORK

2.1 Perform machining work

2.1.1 Practice safety procedures while operating the lathe and grinding machine

2.1.2 Grind tool bits (off hand grinding) according to the required geometric angles for general purposes machining using pedestal grinder

2.1.3 Operate the lathe machine, select spindle speeds and feeds


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NO

SPESIFIC OUTCOME (SO)

COGNITIVE PSYCHOMOTOR AFFECTIVE

C1 C2 C3 C4 C5 C6 P1 P2 P3 P4 P5 A1 A2 A3 A4 A5

2.1.4 Operate lathe machine: parallel turning, stepped turning, facing, taper turning, centre drilling, knurling

2.1.5 Measure workpiece by using the following instruments : micrometer, vernier calliper, steel ruler


3.0 BASIC WELDING

3.1 Practice Oxy acetylene welding

3.1.1 Ignite and adjust flame for different types of welding job

3.1.2 Select and use proper filler rods to get a neat and correct bead flow

3.1.3 Weld an open square butt joint with full penetration throughout the point.

3.1.4 Weld open corner joint with full penetration throughout the joint


3.2 Practice arc welding

3.2.1

deposit stringer beads using correct electrode size and amperage selection for different types of recommended metal thickness.

3.2.2 Weld a close square butt joint with straight, smooth and convex bead throughout the joint

3.2.3 Weld an open corner joint with straight convex bead surface


TOTAL 5 12 7 0 0 0 0 5 0 0


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Legend : Cognitive Domain Psychomotor Domain Affective domain C1 Knowledge P1 Imitate A1 Receiving Phenomena C2 Comprehensive P1 Manipulate A2 Responding to Phenomena C3 Application P3 Precision A3 Valuing C4 Analysis P4 Articulation A4 Organizing Values C5 Synthesis P5 Naturalization A5 Internalizing Values C6 Evaluation


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MATRIX OF SPECIFIC OUTCOMES Vs CLO, GSA AND LEARNING DOMAINS

No SPECIFIC OUTCOME (SO) *Recommended

Teaching & Learning Strategy

CLO GSA & LD

CL

O 1

CL

O 2

CL

O 3

CL

O 4

LD

1

LD

2

LD

3 G

SA

4

LD

4 G

SA

3

LD

5 G

SA

1

LD

6 G

SA

2

LD

7 G

SA

6

LD

8 G

SA

7

GS

A 5

1.0 FITTING

Discussion, Demonstration and

Practical Work

1.1 Perform fitting works

1.1.1 Flat file, square and form surfaces using various types of files

1.1.2 Mark out parallel, vertical and different angular lines on a workpiece

1.1.3 Chisel off metal using various types of chisels

1.1.4 Cut off mild steel plates by using a hacksaw

1.1.5 Mark out and drill holes on a bench drilling machine

1.1.6 Cut internal and external Metric V thread using taps and dies

1.1.7 Measure workpiece using steel ruler, external micrometer, vernier calliper, vernier height gauge

1.1.8 Test finished workpieces using gauges, templates, profile projector and surface testing machine


2.0 MACHINING WORK Discussion,

Demonstration and Practical Work

2.1 Perform machining work

2.1.1 Practice safety procedures while operating the


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CLO GSA & LD

CL

O 1

CL

O 2

CL

O 3

CL

O 4

LD

1

LD

2

LD

3 G

SA

4

LD

4 G

SA

3

LD

5 G

SA

1

LD

6 G

SA

2

LD

7 G

SA

6

LD

8 G

SA

7

GS

A 5

lathe and grinding machine

2.1.2

Grind tool bits (off hand grinding) according to the required geometric angles for general purposes machining using pedestal grinder

2.1.3 Operate the lathe machine, select spindle speeds and feeds

2.1.4

Operate lathe machine: parallel turning, stepped turning, facing, taper turning, centre drilling, knurling

2.1.5

Measure workpiece by using the following instruments : micrometer, vernier calliper, steel ruler


3.0 BASIC WELDING Discussion,

Demonstration and Practical Work

3.1 Practice Oxy acetylene welding

3.1.1 Ignite and adjust flame for different types of welding job

3.1.2 Select and use proper filler rods to get a neat and correct bead flow

3.1.3 Weld an open square butt joint with full penetration throughout the point.

3.1.4 Weld open corner joint with full penetration throughout the joint


3.2 Practice arc welding

3.2.1 Deposit stringer beads using correct electrode size and amperage selection for different types of


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CLO GSA & LD

CL

O 1

CL

O 2

CL

O 3

CL

O 4

LD

1

LD

2

LD

3 G

SA

4

LD

4 G

SA

3

LD

5 G

SA

1

LD

6 G

SA

2

LD

7 G

SA

6

LD

8 G

SA

7

GS

A 5

recommended metal thickness.

3.2.2 Weld a close square butt joint with straight, smooth and convex bead throughout the joint

3.2.3 Weld an open corner joint with straight convex bead surface


Note: *Lecturers may use other teaching & learning strategies in order to achieve the learning outcomes. Generic Student Attributes (GSA) Learning Domain (LD) GSA 1 Communications Skills LD 1 Knowledge GSA 2 Critical Thinking and Problem Solving Skills LD 2 Technical Skills GSA 3 Teamwork Skills LD 3 Professionalism & Ethics GSA 4 Moral & Professional Ethics LD 4 Social Skills GSA 5 Leadership Skills LD 5 Communication Skills GSA 6 Information Management Skills and Continuous Learning LD 6 Critical Thinking GSA 7 Entrepreneurship Skills LD 7 Life Long Learning LD 8 Entrepreneurial Skills

jj103 mechanical workshop practice 1

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