Fitting Report G-27 - For sharing purposes to students who are in need PDF

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For sharing purposes to students who are in need...

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FACULTY OF MECHANICAL AND MANUFACTURING ENGINEERING

PRACTICAL REPORT

COURSE CODE

: BDA 18201

COURSE NAME

: Mechanical Engineering Workshop I

SEMESTER

: 1-2021/2022

No. 1. Leader 2. 3.

Section

Group Number

19

G-27

Name of Group Members ARWIN A/L M.SUNDRARAJ MALEK HAMID ALI NAGI AL-JAMAL MUHAMMAD ZAID BIN AHMAD SAPIAN

-To be filled by lecturerSubmitted Date

Contact Number 0122134519

Matric Number AD210153

0182910957

AD210008

0126938104

AD210038

TABLE OF CONTENT

1.0 INTRODUCTION

2.0 SAFETY PRECAUTION

3.0 STANDARD OF PROCEDURE

4.0 RESULTS AND ANALYSIS

5.0 DISCUSSION

6.0 CONCLUSION

7.0 REFERENCE

8.0 MINUTE OF MEETING

1.0 INTRODUCTION Fitting is process to produce product that was make from the mild steel. Fitting involves, measuring, cutting, drilling, and finishing process. Fitting process totally done manually. Objective of fitting process is to expose student to the way how some product has been done. In fitting process student also need to measure with accurate measuring. Need to know how to use the vernier callipers. Fitting is the process to make the mid steel become a shape with accurate measuring. Other than that, the objectives are to measure and mark file edge, file surface, file angle, hacksaw, drill hole, tapping in, punch the of work piece, operate a drilling machine post. Hence to recognize the hand tools used in the fitting process, learn how to use the Vernier height gauge for measuring, read and interpret engineering drawings, know the basic workshop process, inspect the job for specified dimensions, and adopt safety practices while working on various machines

Machine tools are capable of producing work at a faster rate, but there are occasions when components are processed at the bench. Sometimes, it becomes necessary to replace or repair component which must be fit accurately with another component on reassembly. This involves a certain amount of hand fitting. The assembly of machine tools, jigs, gauges, etc, involves certain amount of bench work. The accuracy of work done depends upon the experience and skill of the fitter. The term ‘bench work’ refers to the production of components by hand on the bench, whereas fitting deals which the assembly of mating parts, through removal of metal, to obtain the required fit. Both the bench work and fitting require the use of number of simple hand tools and considerable manual efforts. The operations in the above works consist of filing, chipping, scraping, sawing drilling, and tapping. There are three general categories of fits: 1) Clearance fits for when it may be desirable for the shaft to rotate or slide freely within the hole this is usually referred to as a "sliding fit." 2) Interference fits for when it is desirable for the shaft to be securely held within the hole, this is usually referred to as an interference fit and 3) Transition fits for when it is desirable that the shaft to be held securely, yet not so securely that it cannot be disassembled, this is usually referred to as a Location or Transition fit.

Within each category of fit there are several classes ranging from high precision and narrow tolerance (allowance) to lower precision and wider tolerance. The choice of fit is dictated first by the use and secondly by the manufacturability of the parts. Fitting applications are pipe and pipe fittings go hand-in hand. Just as pipes are used for a variety of residential, public and industrial applications, so also the pipe fittings. No pipes can be connected without the use of proper fittings and flanges. Pipe fittings allow pipes to be installed and connected or joined where necessary and terminated in the right place. There is no end to applications of pipe fittings so long there is no end to the applications of pipes. While the list of piping applications continues to expand, its strength, flexibility, very good flow rates and high chemical resistance are qualities which are uniquely suited for the movement or transfer of liquids, steam, solids and air from one point to another.

2.0 Safety Procedure and Rules in Working Area The following are some of the safe and correct work practices in bench work and fitting shop, with respect to the tools used. Why is safety important? Safety working will protect yourself, other lab member, visitor to the lab and your work. As student, you should know the general rules in the lab. 1. Listen and/or read instructions carefully before entering the workshop. -Follow general rules in lab

-Read SOP before using the machine

2. Wear appropriate and safe clothes -such as goggle, lab coat and safety shoes.

3. Know and learn how to use equipment of fabrication and machine like the drilling machine as an example for one of the machine in the workshop

4. Use and wear personal protective equipment like goggle while working with the drilling machine to prevent from injury

5. Inform the instructor immediately if injury occurs to make sure the injury did not get any worse. 6. Clean the table and store the tools where they belong. -store the tools in this provided box

7. Turn off all the switches and equipment before leaving the lab to prevent overloading the equipment.

SOP DURING PANDEMIC COVID 1. Always wear mask

2. Follow the provided arrows when entering and leaving the lab

3. Stand within the yellow box

4. Must be physically one meter distance away from other people

3.0 STANDARD OF PROCEDURE. Part A: specimen preparations and cutting process. 1. Measure the square mild steel dimension using vernier calliper.

2.The unnecessary part of the specimen is cut according to the required dimension using hacksaw.

3.The height of the specimen is adjusted using the vernier height gauge, then it is screwed.

4.The specimen is then placed at the block and by using the vernier edge the specimen is marked.

5.The specimen is clamped at the bench vice for cutting preparation.

6. The hand saw is adjusted near the marking line, then the unnecessary part is cut. 7. The cut edge specimen surface is smoothen using the file and the final dimension is 75 × 46 𝑚𝑚.

8. Before proceeding to the next stage, the intersection position line is marked to avoid overcutting. The specimen is placed on an anvil and the centre punch and hammer is used to make the centre point.

9. Adjust the hand saw near to the marking line then the specimen is cut.

Part B: Drilling Process 1.The hole of the specimen is drilled using bench drill. 2.The line is measured and marked. The drill centre is punched by using centre punch. 3.Drill bit size 3mm is installed carefully at the spindle. 4.The specimen is placed at the vice clamp and tighten. 5.The specimen is adjusted using a hammer. 6.The small hole is drilled on the marked point.

7.After the small hole is done the drill process is continued using a driven drill to drill bigger holes.

8.Install the drill bit size 8mm. 9.Tight the drill bit at the spindle. 10.The drilling process is started and drill it manually by a given force to the handle. 11.Then the drill bit is changed to size 15mm and the previous step 8,9 and 10 is repeated.

4.0 RESULTS AND ANALYSIS 1.1 Schematic drawing

1.2 Actual Parts Picture (isometric view)

From the results the dimension that was taken for the fitting is 76mm and 46mm. The diameter of the hole was drilled for 15mm for the fitting. From the results the analysis are, the dimension was perfectly calculated and the final result does not have problem during the cutting and drilling.

5.0 DISCUSSION In this project, a steel workpiece with dimension 75 mm x 46 mm (Raw material) will be used for the fitting process and the other tools. The fitting and bench work plays an important role in engineering workshop. The work carried out at the fitting bench or bench vice is called bench work. The following safety precautions should be taken when using hand tools and equipment. The problems encountered also should be taken. The differences between the product and the sample are the measuring of the sample is more accurate than the product. because there is some error and precaution during doing the cutting and finishing. The measuring of product not same as the sample because error happen during do the filling. Wrong technique in using the hacksaw will make our cutting not accurate and also the measuring is not accurate. So, it will ruin the shape. Not only that error can happen when doing the measuring, the precaution is to know how to read the vernier callipers. Problems encountered: 1. Cutting on the work pieces not straight Solution: hold hack saw on proper way. Tilt the hack saw 45 ° from the work piece when cutting. 2. Lack of accuracy on measurement Solution: Make sure the surface of work piece is flat when marking using angle plate and vernier height gauge, non-flat surface will affect the measurement and also the shape. 3. Work pieces not in required shape or not fit each other. Solution: Make sure the surface of work piece flat when marking using angle plate and vernier height gauge, non-flat surface will affect the measurement and the shape.

6.0 CONCLUSION To conclude our report, the objective planned, practically process the steel workpiece according to the dimension given can be achieved. Students must first correctly use the hands-on apparatus and machines. Other than that, students must also have the correct knowledge of the techniques and steps such as measurements, looking for errors, the type of material dealt with and the work surroundings. Most importantly, proper safety measures are essential to follow while demonstrating the fitting process. After following all the objectives stated above, the practical task is finished. To reduce time, energy and cost required to complete the fitting process as much as possible, using the right way and proper tools is very significant. Therefore, several recommendations for each process had been made. When the measuring part to get an accurate measurement without any error its better to use digital vernier callipers or digital measuring devices so that mistakes can be narrowed down. On the other hand, when cutting its better to cut the metal with hacksaw under a running water so that the cutting process is smooth. For the marking rather than using the vernier edge to mark the specimen its better to use the marking knife scriber where it can give flawless markings. To avoid damage, happen to the specimen when clamped to the bench vice for cutting, its better to use wood and keep the specimen in between the wood when cutting. For the smoothing of the specimen surface, its better to use a new file because usually the old file might be too much used up and will affect the smoothing process. During the drilling process, its better the put oil on the hole when using a bigger drill bit for a smooth hole in the specimen.

7.0 REFERENCES 1.) From internet: All downloaded on October 24, 2021 a).https://www.scribd.com/document_downloads/direct/248101938?extension=pdf&ft=1635 052008<=1635055618&user_id=572757831&uahk=sKglodk1ItflnrQDmB76Tot3F3M b).https://pdf-to-word.acey.info/download/pdftodocx c).https://www.docsity.com/payments/index/paypoints/?content_type=document&content_id=2605562&point_type=blue d).https://www.scribd.com/document_downloads/direct/157139963?extension=docx&ft=163 5051540<=1635055150&user_id=572757831&uahk=mGn4HZWMB86QFSa-67jfNxHnHo e).https://www.scribd.com/document_downloads/direct/305818947?extension=docx&ft=163 5051572<=1635055182&user_id=572757831&uahk=3CpdxinlwunaRBw9H_eBQdMA8A f). https://d1wqtxts1xzle7.cloudfront.net/60712020/bengkel_fitting20190926-1002281w3viw8.doc?1569507938=&response-contentdisposition=attachment%3B+filename%3DPoliteknik_Sultan_Salahuddin_Abdul_Aziz.doc& Expires=1634909156&Signature=e6ZeX5YFVghtoItHmZnIcP~7Sf7Wd59SAVqGC4ZtYXaLOpznI3IdcZBY1Cy6StJCMFQEhSMS3Xrj1NUX3Va8mBuW2hwnej~KHYeZQotwucAfdWzUspDhX88cGZSfYk3j8YgWzyZo5HKh z6LMouVu4YB2FXMlUz~7iNjMU6Ud5F2VSfiwqtc68YySoRBrlP2VbtfLekST1FbltV6b7SCbqsAeNAf7T64zBOXWjhU477eNgivmIuJwxd6lxidE 7dhNxvc4Rj6NTSVTThwcGnKgu8GQ79EzXfw~mr9Io4fQGlMdrOkrNaV2C~02C3FeuUxj Ln5kPoVBYPPGru4Cj8A__&Key-Pair-Id=APKAJLOHF5GGSLRBV4ZA

8.0 Minutes of meeting

1st discussion: 21 October 2021 2nd discussion: 22 October 2021 3rd discussion: 24 October 2021 4th discussion: 25 October 2021 5th discussion: 31 October 2021...