Course Objectives: To provide instruction and practical workshop experience in
basic machine shop metal-working operations.
1.0Bench Tools and Basic Hand Operations: (8 hours)
1.1. Familiarization with tools and their use
1.2. Machinist’s hammers
1.3. Types of screw drivers
1.4. Use and sharpening of punches, chisels, chippers and scrapers, scribers
1.5. Classification of files
1.6. Types of pliers and cutters
1.7. Types of wrenches: open end, box end, combination, adjustable, socket, offset, twelve point ratchet, strap wrench, pipe wrench, spanner wrenches, Allen wrenches
1.8. Hacksaws
1.9. Bench vises
1.10. Hand drills
1.11. Taps and dies
1.12. Hand shears
1.13. Rules, tapes and squares
1.14. Soldering and brazing equipment
1.15. Rivet types
2.0Hand Working Operations:(8 hours)
2.1 Choice of blades and sawing techniques
2.2 Filling to obtain flat and parallel surfaces, square corners, roughing and finishing operations
2.3 Tapping holes and threading rods
2.4 Scribing layout patterns
2.5 Shearing and cutting sheet metal
2.6 Soldering
2.7 Safety
2.8 Riveting
3.0 Power Tools: (4 hours)
3.1 Power hacksaw
3.2 Horizontal cutoff band saw
3.3 Vertical band saw and cutting operations
3.4 Bench and hand-held grinders
3.5 Belt and disk sanders
3.6 Hand-held power drills
3.7 Safety aspects
4.0Measuring and Gagging: (4 hours)
4.1 Semi-precision tools such as rules, scales, try squares, inside/outside clippers, depth gages, feeler gages
4.2 Precision tools such as micrometers, vernier calipers, vernier height gages, telescoping gages, hole gages, bevel protractors, dial indicators, gage blocks and surface plates
5.0Drills and Drilling Processes: (4 hours)
5.1 Types of drill presses
5.2 Work holding attachments and accessories
5.3 Cutting tools
5.4 Geometry and grinding of drill bits
5.5 Drilling, countersinking, reaming, lapping
5.6 Cutting speeds
5.7 Safety
6.0Machine Tools: (12 hours)
6.1 General safety considerations
6.2 Physical construction and types of engine lathes
6.3 Facing and straight turning operations
6.4 Threading
6.5 Tool selection and feed rates
6.5 Horizontal and vertical shapers
6.6 Applications of shapers
6.7 Types and construction of milling machines
6.8 Selection of milling machine cutters and accessories, operations
6.9 Grinding machines
6.10 Horizontal surface grinding
6.11 Plain cylindrical grinding
7.0Material Properties: (8 hours)
7.1 Tool materials such as low, medium and high carbon steels, hot and cold rolled steels, alloy steels, carbide and ceramic materials
7.2 Heat treating methods for steels: hardening, tempering, annealing, normalizing, quenching
7.3 Non-ferrous materials such as brass, bronze, aluminium: comparative properties and machinability
8.0Sheet Metal Work: (4 hours)
8.1 Tools
8.2 Marking and layout
8.3 Bending and rolling operations
8.4 Cutting operations
9.0Metal Joining: (8 hours)
9.1 Safety considerations
9.2 Soldering methods and practices
9.3 Brazing methods and materials
9.4 Practice of torch brazing
9.5 Oxygen-acetylene welding methods and practices
9.6 Selection of welding rods
9.7 Arc welding methods and practices
9.8 Resistance welding
9.9 Electric arc welding
Textbooks and Reference Books:
1.0 J.Anderson and E.E. Tatro, “Shop Theory”, Mcgraw-Hill, 5th Edition, 1942.
2.0 O.D.Lascoe, C.A.Nelson andH.W.Porter, “Machine shop operations and setups”, American Technical society, 1973.
3.0 “Machine shop practice – volume I”, Industrial press, New York, 1971.
4.0 “Machine shop practice volume II”, Industrial press, New York, 1971.
5.0 K.Oswald, “Technology of Machine Tools”, McGraw Hill-Ryerson, 3rd Edition.
6.0 Oberg, Jones and Horton, “Machinery’s Handbook”, 23rd Edition, Industrial press, New York.
Workshop Practice: 3 hours per week for 12 weeks
1.0 Bench tools and hand operations: measuring, marking, layout, cutting, filling, drilling, tapping, assembly.
2.0 Bench tools and hand operations continued.
3.0 Power tools and drilling machines.
4.0 Measuring and gagging
5.0 Engine lathe: basic operations such as facing, cutoff, plain turning, knurling.
6.0 Lathe work continuation: taper turning, drilling and boring.
7.0 Basic shaper operations.
8.0 Milling machine and/or surface grinder.
9.0 Sheet metal working.
10.0 Soldering and brazing.
11.0 Gas welding.
12.0 Electric arc welding.
