BSc in Mechanical Engineering

Course Details

Course Information Package

Course Unit TitleMECHANICAL WORKSHOP
Course Unit CodeAMEW101
Course Unit Details
Number of ECTS credits allocated2
Learning Outcomes of the course unitBy the end of the course, the students should be able to:
  1. Explain of the role of measurements in engineering design and manufacturing. Describe the types and sources of errors in measurements. Use metric and imperial system of length measuring units.
  2. Use instruments and apply methods for measuring angles (sine bar, sinus and tangent method, angle gauge blocks, bevel protractor, combination square)
  3. Execute form measurements using the dial indicator. Apply the appropriate method for measuring perpendicularity, flatness, roundness, parallelism, eccentricity, etc.
  4. Describe dimensional tolerances and define the notions of basic size, deviation and tolerance for a shaft and a hole according to ISO system. Calculate the allowance, clearance, interference and limit dimensions for all types of fit.
  5. Describe surface texture and properties (surface roughness, measurement, units. Symbols for surface roughness in DIN, ASA and ΒS, roughness parameters. Use instruments for roughness measurements.
  6. Describe the main features, controls, structure and cutting tools of lathes and milling machines. Define basic cutting parameters (cutting speed, depth of cut, feed rate). Operate a lathe and milling machine for cutting a representative workpiece.
  7. Describe principles of welding and typical welding processes such as arc welding with coated electrodes, TIG, MIG, induction welding, resistance welding, gas welding.
Mode of DeliveryFace-to-face
PrerequisitesNONECo-requisitesNONE
Recommended optional program componentsNONE
Course Contents

Engineering measurements: Importance of measurements in engineering design and manufacturing. Types of errors in measurements / sources of errors, units in metric and imperial system, conversions between the two systems. Measurement of linear dimensions, Line graduated instruments: Machinist’s rule, vernier caliper, micrometer (mechanic & digital), description, mode of use, accuracy, applications. Gauge blocks: Description, mode of use, accuracy, applications. Measurement of angular dimensions: Units, subdivisions, conversions, instruments and measuring methods (sine bar, sinus and tangent method, angle gauge blocks, bevel protractor, combination square). Comparative length-measuring instruments – Dial indicator: Description, mode of use, accuracy, applications. Form measurement (perpendicularity, flatness, roundness, parallelism, eccentricity, etc). Definitions, symbols, instruments and measuring methods. Dimensional tolerances: Basic size, deviation and tolerance for a shaft and a hole according to ISO system. Types of fit, features of dimensional relationships between mating parts (allowance, clearance, interference, limit dimensions etc). - Surface texture and properties: Surface roughness, measurement, units. Symbols for surface roughness in DIN, ASA and ?S. Roughness parameters, instruments.

Lathes and turning processes: Main features and controls of lathes. Lathe structure (models, typical structural parts, power raw, most significant dimensions), Cutting tools (structural material, tool geometry, tool selection method, Cutting fluids). Basic cutting parameters (cutting speed, depth of cut, feed rate). Safety precautions. Performance on face turning and cylindrical surface turning. Performance on thread cutting, hole drilling, slot cutting and non symmetrical lathe cutting. Cutting forces experimental estimation for various cutting parameters.

Milling machines and milling operations: Main features and controls of milling machines. Horizontal and vertical milling machines. Milling machine structure (models, typical structural parts, power raw, most significant dimensions), Milling tool properties (structural material, tool geometry, tool models, tool selection method). Basic milling parameters (cutting speed, depth of cut, feed rate). Performance of slab or face milling and slot milling (up milling and down milling). Gear cutting performance using a milling machine.

Welding: Principles of fusion welding (modes of metal transfer, heat flow, metalographic characteristics of welded joint). Typical welding processes (arc welding with coated electrodes, TIG, MIG, induction welding, resistance welding, gas welding), Safety precautions. Performance of arc welding using coated electrodes for various welding parameters (welding material properties and dimensions, coated electrode material and dimensions, welding current, welding polarity). Performance of gas welding method using various welding parameters. Permanent stress and strain in welding structures.

Recommended and/or required reading:
Textbooks
  • Fundamentals of Modern Manufacturing: Materials, Processes, and Systems by Mikell P. Groover, John Wiley & Sons, 3rd edition 2007
References
  • Manufacturing Processes for Engineering Materials, by Serope Kalpakjian, Steven R. Schmid, Prentice Hall, 2003.
Planned learning activities and teaching methods

Lectures to learn about specific topics such as surface roughness, dimensional tolerances, form measurements, machining principles, cutting conditions, welding principles etc.

Hands-on training on the equipment of a mechanical workshop (measurement instruments, cutting machines, welding machines, etc.)

Visits to modern workshops of the local industry.
Assessment methods and criteria
Tests60%
Laboratory work40%
Language of instructionEnglish
Work placement(s)NO

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