UNIVERSITI KUALA LUMPUR

MALAYSIAN INSTITUTE OF CHEMICAL AND BIOENGINEERING TECHNOLOGY

CLD 20502
BASIC ENGINEERING WORKSHOP

LAB MANUAL JULY 2012

Name

: _______________________________

Section

:_______________________________

Group

:_______________________________

CLD 20502 BASIC ENGINEERING WORKSHOP

Title

Labwork 1: Metal Fitting

Objective

1. To familiarize with the hand tools.

2. To familiarize with the measurement tools.

3. To understand the usage of tools in fitting work.

Machine

Drilling machine

Tools

Hand hacksaw, Files, Hammer, Center punch, Scriber, Engineers square, Ruler,
Vernier caliper.

Material

Mild steel plate thickness 2

Task :
Fabricate the metal fitting for two parts that can be fit to each other as shown in Figure 1.
1. Measure and draw the plan of Figure 1 on the mild steel plate given by using a suitable
hand and measurement tools.
2. Cut the plate by using a hand hacksaw and drilling machine (if necessary).
3. Finish and smooth the fitting shape with suitable files.

Figure 1:

B
A

A = C = R20
B = D = R40
C

All units is in mm

CLD 20502 BASIC ENGINEERING WORKSHOP

Title

Labwork 2: Sheet Metal Fabrication

Objective

1. To familiarize with the hand tools.

2. To familiarize with the measurement tools.
3. To familiarize with bending and shearing machine
4. To familiarize with joining process.
5. To understand the usage of tools in fabrication work

Machine

Bending machine, shearing machine, drilling machine

Tools

Measurement tools, engineers square, scriber, hand snips, mallet, center punch,
hammer, rivet gun

Material

Galvanized iron sheet metal

Task:
4. Measure and draw the plan of Figure 2 on the galvanized iron plate given by using a
suitable hand and measurement tools.
5. Cut the plate by using a hand snips.
6. Bend the plate with a bending machine and mallet.
7. Join together the plate using a rivet. Mark a center point of the hole before you drill with
a drilling machine.
Figure 2:

(will be given later)

CLD 20502 BASIC ENGINEERING WORKSHOP

Title

Labwork 3 Machining Process Milling Machine

Objective

1. To familiarize with the milling machine.

2. To familiarize with milling processes.
3. To understand the usage of milling machine in fabrication work.

Machine

Vertical Milling machine

Tools

End mill cutter 10, Vernier caliper

Material

Aluminum block

Task:
1. Measure the dimension of the workpiece given;
Length = ________ mm. Width = ______ mm. Thickness = ________ mm.
2. Set your machine with suitable cutting properties.
3. Use an end mill with a diameter of 10 mm as your cutting tool.
4. Milling on the side of your workpiece until you get 120 mm x 120 mm dimension.
5. Do various milling processes on your workpiece by following the coordinate given.
6. Identify the shape of your final piece.

Figure 3: End milling

Coordinate:
Slot
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

0, 30, -1
110, 30, -1
110, 40, -1
0, 40, -1
0, 50, -1
110, 50, -1
110, 60, -1
0, 60, -1
0, 70, -1
110, 70, -1
110, 80, -1
0, 80, -1

Pocket
1. 30, 40, -3
2. 80, 40, -3
3. 80, 50, -3
4. 30, 50, -3
5. 30, 60, -3
6. 80, 60, -3
7. 80, 70, -3
8. 30, 70, -3
Holes
1.
2.
3.
4.

25, 25, -5
85, 25, -5
85, 85, -5
25, 85, -5

CLD 20502 BASIC ENGINEERING WORKSHOP

Title

Labwork 4 Machining Process - Lathe Machine

Objective

1. To familiarize with the lathe machine.

2. To familiarize with the measurement tools.
3. To familiarize with turning, facing, drilling and tapering processes.
4. To understand the usage of lathe machine in fabrication work.

Machine

Lathe machine

Tools

Single point tool with carbide insert, Vernier caliper

Material

Aluminium rod

Task:
1. Measure the dimension of the workpiece given;
Length = ________ mm. Diameter = ______ mm.
2. Refer figure 4.
3. Start the process with facing. Machine each end of the rod until you get the length of rod
is 120 mm.
4. Do turning process until you get a diameter of rod is 55 mm.
5. Next, make a hole of 10 mm and its depth is 20 mm using drilling process at the end of
point A.
6. Finish the shape by using facing and turning process.
7. Lastly, do taper turning with an angle of 30 at the end of point H.

Figure 4:

120

55

50

40

45

20
30

60

40

20

All units are in millimeter (mm)

CLD 20502 BASIC ENGINEERING WORKSHOP

Title

Labwork 5a: Shielded Metal Arc Welding (SMAW)

Objective

1. To familiarize with SMAW welding process.

2. To identify factors that affects the welding process.
3. To apply safety in welding process.

Machine

SMAW Machine

Tools

Long nose plier, Chipping hammer, Chisel

Material

Mild steel plate thickness 4, Electrode

Task:
1. Take tools in the drawer and place on your workstation.
2. Make sure you wear your PPE before you start welding.
3. Make sure the equipment and material are in a good condition. Switch on the machine. Set
the machine current between 70-80 amp.
4. Start welding when you are ready.
5. You are required to weld a straight line on you metal.
6. After finished, clean your workpiece by using a chipping hammer and chisel (if necessary).
7. Submit your work and write your name and ID no. on your workpiece.
Figure 5: SMAW welding process

CLD 20502 BASIC ENGINEERING WORKSHOP

Title

Labwork 5b: Metal Inert Gas Welding (MIG)

Objective

1. To familiarize with MIG welding process.

2. To identify factors that affects MIG welding process.
3. To apply safety in welding process.

Machine

MIG welding machine

Tools

Long nose plier, Chisel

Material

Mild steel plate thickness 4, CO2 gas, Copper electrode

Task:
1. Take tools in the drawer and place on your workstation.
2. Make sure you wear your PPE before you start welding.
3. Make sure the equipment and material are in a good condition. Open CO2 gas source.
Switch on the machine.
4. Start welding when you are ready.
5. You are required to weld a straight line on you metal.
6. After finished, clean your workpiece by using a chisel (if necessary).
7. Submit your work and write your name and ID no. on your workpiece.
Figure 6: MIG welding process

CLD 20502 BASIC ENGINEERING WORKSHOP

Title

Labwork 5c: Tungsten Inert Gas Welding (TIG)

Objective

1. To familiarize with TIG welding process.

2. To identify factors that affects TIG welding process.
3. To apply safety in welding process.

Machine

TIG welding machine

Tools

Long nose plier

Material

Aluminum plate thickness 4, Tungsten electrode, Aluminum rod, Argon gas.

Task:
1. Take tools in the drawer and place on your workstation.
2. Make sure you wear your PPE before you start welding.
3. Make sure the equipment and material are in a good condition. Open argon gas source.
Switch on the machine. Set the machine current between 90-95 amp.
4. Start welding when you are ready.
5. You are required to weld a straight line on you metal.
6. After finished, clean your workpiece by using a chisel (if necessary).
7. Submit your work and write your name and ID no. on your workpiece.
Figure 7: TIG welding process