Workshop Manual

German Jordanian University
School of Applied Technical Sciences

Industrial Engineering Department
Engineering Workshop Handout- IE121
GJU/ SATS/ IE/ Workshop 2nd Semester 2012/2013

GERMAN JORDANIAN UNIVERSITY
SCHOOL OF TECHNOLOGICAL SCIENCES
INDUSTRIAL ENGINEERING DEPARTMENT
Engineering Workshop- IE121
Course:
Technical Workshop IE121
Manual preparation:
Dr. Iyas Khader; Eng. Maysa Ammouri; Eng. Raghad Hemeimat; Eng. Ahmad
Alkousha; Eng. Lamiss Hamasha
Laboratory Objectives
To familiarize the students through brief lectures and practical training with the
following:
Safety guidelines and requirements in the workshop
Various machines and tools used in manufacturing and production processes
The following manufacturing and production processes:
Machining and other material removal operations: Turning, milling, drilling and
finishing processes
Sheet metal forming: Shearing, forging and bending
Welding and metal joining: Arc welding and resistance welding
Carpentry: Wood, wood joints and carpentry work
GJU/ SATS/ IE/ Workshop -i- 2nd Semester 2012/2013

GJU/ SATS/ IE/ Workshop - ii - 2nd Semester 2012/2013
Contents
v ___________________ Workshop Instructions A.
vi __________________________________ Report Format B.
vii _________________ Safety in the workshop C.
1 ___________ Measurement Workshop I.
6 __________________ Machining Workshop II.
Sheet Metal Forming Workshop III.

17
23 ________________________ Welding Workshop IV.
29 ____________________ Carpentry Workshop V.
37 _________________________________________ References D.
39 ____________________________________________________ Appendix A: Cover Page
GJU/ SATS/ IE/ Workshop - iii - 2nd Semester 2012/2013

GJU/ SATS/ IE/ Workshop - iv - 2nd Semester 2012/2013
A. Workshop Instructions
Rule number one: SAFETY, SAFETY, SAFETY

Attend on time
Turn off your cell phones and laptops
Prepare your experiment well
Bring all your requirements: pencil, calculator, sheets, etc
Laboratory assessment will be according to your reports' grade, quizzes and
participation
Reports should be submitted on time. Late report will not be graded
Reports are individual, cheating off of another person is not allowed. Copying any
text or graphics from another person will be viewed as plagiarism, and will be
dealt with accordingly
Reports should be typed and submitted as hardcopy at due date, unless otherwise
specified. Softcopy may be requested
GJU/ SATS/ IE/ Workshop -v- 2nd Semester 2012/2013

B. Report Format
Cover page: See Appendix A

Introduction including a brief description of the experiment
Results and Discussion:
o Document all your data in the best possible representation
o Show sample calculations whenever required showing all steps and equations
o Name and number all graphs and tables
o Comment on each graph and table
o Include a brief discussion to your results
Conclusions:
o Draw your conclusion to summarize your discussion and add your
recommendations
Use the following format:
o Font: Times New Roman
o Size: 12 for the body and 14 for headings
o Line spacing: Multiple 1.1
GJU/ SATS/ IE/ Workshop - vi - 2nd Semester 2012/2013

C. Safety in the workshop
Always listen carefully to the instructor and follow instructions

Wear proper attire: workshop apron (always: it will protect your clothes and hold
loose clothing items), protective gloves and safety goggles (following required
safety regulations). Prescription glasses do NOT protect your eyes; if the lenses
are not made of approved safety shatterproof glass, serious eye injury can still
occur
Tie back long hair, remove all pieces of jewelry (wrist watches, rings, bracelets,
necklaces, etc.) and tuck in all loose clothing items when using machine tools
Wear suitable strong shoes. Training shoes, canvas shoes or open-toed sandals
must never be worn in the workshop because they offer no protection to the feet.
Suitable shoes prevent injury caused by hot objects, slippery floor and falling
heavy items. Shoelaces must be tied properly before entering the technology room
Bags should not be brought into a workshop as people can trip over them
Do NOT run in the workshop. Be attentive; never put your hands in your trousers
lest you may be caught in a state of non-readiness. Always be patient, never rush
in the workshop
Before attempting practical work check your vicinity; ensure the floor is clean
and clear from oils, obstructions and debris
When learning how to use a machine, listen very carefully to all the instructions
given by the instructor. Ask questions, especially if you do not fully understand
Do NOT use a machine if you have not been shown how to operate it safely by the
instructor
Know where the emergency stop buttons are positioned in the workshop. If you
see an accident at the other side of the workshop you can use the emergency stop
button to turn off all electrical power to machines
When carrying sharp or pointed tools, carry them down by your side and return
them safely to the cupboard/drawer when you are finished with them
Use hand tools carefully, keeping both hands behind the cutting edge
Report any damage to machines/equipment as this could cause accidents
Keep hands away from moving/rotating machinery
Always use a guard when working on a machine
NEVER distract anyone when they are using a piece of machinery
When you are operating any machine, stand at a proper distance
Never handle machines or workpieces during operation;
STOP the machine first;
STOP any machine before leaving it;
Never leave any machine running unattended
Do NOT use hands to clear metal chips
Do NOT blow chips, dust from vises, etc. lest they may get into your eyes
The above list is not exhaustive; use common sense and always think twice
before you carry out any step
GJU/ SATS/ IE/ Workshop - vii - 2nd Semester 2012/2013

GJU/ SATS/ IE/ Workshop - viii - 2nd Semester 2012/2013
Workshop I. Measurement Workshop
1. Objectives
Getting familiar with some measuring instruments, such as the vernier caliper and
outside micrometer
Measuring sample dimensions using the vernier caliper and outside micrometer.
2. Background
2.1. Machining operations
It has been said ”whatever exists, exists in some amount”. The determination of the
amount is what measurement is all about. The measurement process is the act of
obtaining a quantitative comparison between a predefined standard and the particular
physical parameter being observed, such as the height of a cylinder, temperature, etc.
Measurement instruments could be classified based on the measured physical
parameter; they are used to measure various physical parameters, like:
• Length
• Temperature
• Voltage
• Current
• Mass
• Etc.
The main instruments used in the determination of lengths and diameters in any
workshop are vernier calipers and micrometers.
2.2. Vernier Caliper
Fig. I.1 shows the varnier caliper typically used in many workshops worldwide.
Figure I.1. Parts of a vernier caliper (Source: tbc.school.nz)
The vernier caliper consists of the following parts:

External jaws: Used to measure the external diameter or width of an object
Internal jaws: Used to measure the internal diameter or width of an object
Depth probe: Used to measure depths of an object or a hole
GJU/ SATS/ IE/ Workshop -1- 2nd Semester 2012/2013

Main scale: It consists of imperial scale and metric scale. The imperial scale is
marked in inches and fractions, while the metric scale is marked every millimeter.
Vernier scale (sliding scale): It gives interpolated measurements in fractions of
inches and millimeters.
Locking screw: It is used to block the movable (sliding) part to allow the easy
transferring of the measurement
The vernier caliper can be used to measure (1) external dimensions, (2) internal
dimensions and (3) depth dimensions, see Fig. I.2.
Figure I.2. dimensions measured by vernier caliper (1) external, (2) internal and (3) depth
dimensions (Source: craftsmanspace.com)
Other types of calipers are dial calipers and digital calipers, see Fig. I.3.
(a) (b)
Figure I.3. calipers (a) dial caliper (Source: pohoto-dictionary.com); (b) digital caliper (Source:
aylj.com)
Accuracy: The accuracy of a device is defined as the difference between the

measured and true value. Typically, it is the maximum error that the manufacturer will
specify. For the vernier caliper, the accuracy is calculated as in Eq. I.1:
1 devision in main scale

Accuracy = (I.1)
number of devisions in vernier scale
Reading error: It refers to the error introduced when reading a number. The error
1
may be estimated as ± of the finest graduation.
2

Measurement reading: Before determining the length of an object, the accuracy of
the vernier caliper should be determined.
The following steps are followed to take a measurement shown in Fig. I.4:
Main Scale
13 14 15 16 17 18
0 1 2 3 4 5 6 7 8 9 0
Vernier Scale
Figure I.4. reading using vernier caliper scale
• Close jaws on the object to be measured. Then rotate the locking screw, to
block the sliding part. Move the vernier caliper away and start reading it.
• Considering the metric scale; the bold numbers represent centimeters (cm) and
the smaller tick marks represent millimeters (mm). The main scale (fixed
scale) is read from the leftmost tick mark (marked by 0) on the vernier scale
(sliding scale). From Fig. I.4, the leftmost tick mark (0) on the vernier scale
lies between 134 mm and 135 mm. So the main reading is 134 mm.
• The tick mark on the vernier scale that is aligned with a tick mark on the main
scale gives the reading of the former. For the example shown above, the 34th
tick mark on the vernier scale is aligned with a tick on the main scale above it.
• Each tick mark on the vernier scale represents 1 50 mm (0.02 mm). In this
example, the vernier caliper reading is 134.0 mm+0.02 mm×34, which yields:
134.68 ± 0.01 mm.

2.3. Micrometer
Fig. I.5 shows an outside micrometer.
Figure I.5. Parts of an outside micrometer (Source: technologystudent.com)
The micrometer consists of the following parts;

Frame: The C-shaped body that keeps the anvil and barrel in constant relation to each
other.
Anvil: The part on which the sample rest against and the spindle moves toward.
Spindle: The cylindrical part that moves toward the anvil as the thimble is rotated.
Thimble: The graduated cylindrical part that is rotated to measure an object.
Sleeve (barrel): It is stationary part, with linear scale graduated in halves of
millimeters.
Lock nut: It is used to block the movable part to allow the easy transferring of the
measurement
Ratchet: It limits the applied pressure by slipping at a calibrated torque.
For each dimension, specific type of micrometers should be used; outside
micrometers are used to measure external dimensions, inside micrometer measures
internal dimensions, while depth micrometer measures depth dimensions, see Fig. I.6.
(a) (b)
Figure I.6. Micrometers types; (a) inside micrometer (Source: hiwtc.com), (b) depth micrometer
(Source: bakergauges.com)
Some micrometers may be digital or dial indicator as shown in Fig. I.7.

(a) (b)
Figure I.7. calipers (a) dial micrometer (Source: componentsandparts.com); (b) digital micrometer
(Source: mitutoyo.com)
Measurement reading: Before determining the length of an object, the accuracy of

the used micrometer should be determined.
The following steps are followed to take a measurement from shown in Fig. I.8:
40
Thimble
35
30
Figure I.8. Reading using micrometer
• Rotate the thimble till the object is closed by the spindle and anvil. Use the
ratchet to close the spindle and anvil on the object to be measured. The lock
nut is used to keep the reading parts.
• Considering the sleeve, the half millimeters are read. For the example, it is
23.5 mm.
• Thimble’s tick marks represent a half millimeter fraction; each thimble
revolution will expose another tick mark in the sleeve. Thimble’s tick mark
aligned with sleeve linear scale is 34th (hence the cumulative reading till this
point is 23.5 mm+0.34)
• Each tick mark on the vernier scale represents 0 .5 50 mm (0.01 mm), so the
micrometer’s reading is 23.84 ± 0.005 mm.

Workshop IE121 Machining Workshop
Workshop II. Machining Workshop

1. Objectives
Getting familiar with machining operations
Describing the various parts of a milling machine and a lathe machine
Performing various milling and turning operations
Getting familiar with drilling
2. Background
2.1. Machining operations
Machining is a broad term used to describe removal of material from a workpiece.
All categories of material removal processes fall into the following categories:
• Cutting
• Abrasive processes
• Non-traditional machining processes (may utilize electrical, chemical or optical
sources of energy)
The three principal machining processes are classified as turning, milling and
drilling.
Turning: In turning, a workpiece is rotated about its axis as a single-point cutting
tool is fed into it shearing away unwanted material and creating the desired part (see
Fig. II.1a). Turning can be performed on both external and internal surfaces to
produce axially-symmetric contoured parts. The machines used in turning are called
lathes.
Milling: In milling material removal is accomplished through the relative motions of
a rotating, multi-edge cutter and multi-axis movement of the workpiece (see Fig.
II.1b). Milling is the most versatile of machining processes. The machines used in
milling are called milling machines.
(a) (b)
Figure II.1. (a) Turning; (b) milling (Source: CustomPartNet)
Drilling is the process of producing holes by bringing a rotating cutter with cutting
edges at the lower extremity into contact with the workpiece (Fig. II.2a). The process
may be followed by boring or reaming (Fig. II.2b) to improve accuracy and surface
finish. Drilling operations are done primarily on drill presses but sometimes on lathes
or milling machines.

(a) (b)
Figure II.2. (a) Drilling; (b) reaming (Source: CustomPartNet)
Grinding (abrasive process): Grinding is considered to be a finishing process used

to improve surface finish, abrade hard materials, and tighten the tolerance on surfaces
by removing a small amount of material. The abrasive material is typically the surface
of a wheel (grinding wheel) or belt and abrades material in a way similar to sanding
(sanding paper as an example). Grinding is primarily used when:
• The material is too hard to be machined economically (e.g., hardened surfaces)
• The tolerance specifications are beyond the capability of other machining
operations
• A preliminary surface finishing process is required (followed by polishing and
lapping)
Other miscellaneous processes differ from machining by producing no swarf (fine
metallic chips, filings or shavings removed by a cutting tool), yet these processes are
performed at a typical machine tool. Burnishing is an example of such a process; it is
performed to improve the surface finish of metallic parts by rubbing a tool on the
metal surface with sufficient force to flatten out high spots and fill in valleys.
Burnishing produces no swarf and can be performed using a lathe, milling machine, or
drill press.
While primary manufacturing processes involve casting and molding, secondary
manufacturing processes constitute the main mechanical removing techniques
involving turning, drilling and milling. Abrasive processes to super-finish a workpiece
are called tertiary manufacturing processes.
A workpiece (pre-shaped material) that requires machining will need to have some
material cut away to create a product. A product would be a workpiece that meets the
specifications set out for that workpiece by engineering drawings.
Example: a workpiece may be required to have a specific outside diameter. A lathe is
a machine tool that can be used to create that diameter by rotating a metal workpiece,
so that a cutting tool can cut metal away, creating a smooth round surface matching
the required diameter and surface finish. A drill can be used to remove metal in the
shape of a cylindrical hole. Other tools that may be used for various types of metal
removal are milling machines, saws, and grinding machines.
More recent, non-traditional machining techniques include electrical discharge
machining EDM, laser cutting or water jet cutting to shape workpieces.
Cooling lubricants (also referred to as cutting fluids) are used in most machining
processes. They can either be liquids, solids or greases. A lubricant should have good

cooling and lubricating characteristics and it should not chemically react with the
tool, the workpiece or any machine element.
Lubricants are essential during material removal processes and should be chosen
carefully for each and every combination of process, materials and parameters. The
function of a lubricant should fulfill the following:
• Reduce friction between the workpiece and the tool
• Stabilize the temperature of the workpiece and tool
• Reduce the power consumption and the process cost accordingly
• Prevent rust on machine parts and cutters
Old, used coolants and lubricants must be properly disposed. As with used motor oil
or other chemical wastes, its impact on the environment should be mitigated.
Making good environmental lubricant choices does not have to compromise
equipment reliability or functionality. In fact, appropriate environmental decisions can
be part of a first-rate, cost-effective design.
2.2. Lathes and turning machines
Fig. II.3 shows a schematic of a lathe.
Figure II.3. Parts of a lathe (Source: CustomPartNet)
The main parts of a lathe are:

Bed: It is a large base that sits on the ground or a table and supports the other
components of the machine. It is heavily ribbed to provide rigidity. Its upper surface
carries the main guideways.
Headstock assembly: The headstock consists of a central spindle as well as the motor
and drive system, which powers the spindle. The spindle supports and rotates the
workpiece, which is secured in a workpiece holder or fixture, such as a chuck or
collet.
Carriage: The carriage is a platform that slides alongside the workpiece, allowing the
cutting tool to cut away material as it advances. The carriage rests on the guideways
(or simply ways) and is advanced by a lead screw powered by a motor or hand wheel.
Guideways: Guideways are provided along the top of the machine bed to ensure
alignment between the headstock spindle, the tailstock and the carriage.
Tailstock assembly: It is the rear section of the machine that is attached to the bed.
The purpose of this assembly is to support the other end of the workpiece and allow it
to rotate, as it is driven by the spindle. For some turning operations, the workpiece is
not supported by the tailstock so that material can be removed from the end.
Compound: The compound is attached on top of the cross slide and supports the
cutting tool. The cutting tool is secured in a tool post which is fixed to the compound.
The compound can rotate to alter the angle of the cutting tool relative to the
workpiece.
2.3. Milling machines
Milling machines are either horizontal or vertical, see Fig. II.4.
(a) (b)
Figure II.4. Milling machines (a) vertical (Source: CustomPartNet); (b) horizontal (Source:
SHIZUOKA Machine Tools)
The basic parts of a milling machine are:

Base: The base of the machine is the platform that serves as a foundation member for
all the other parts which rest upon it. It carries the column at its one end. In some
machines, the base is hollow so as to function as a reservoir for cutting fluid.
Column: The column is the main supporting frame mounted vertically on the base.
The column houses the driving mechanism for the spindle and table feed. The front
vertical face of the column is accurately machined and is provided with dovetail
guideways. The top of the column is finished to hold an overarm that extends outward
at the front of the machine.
Knee: The knee is the platform that supports the saddle and the table. It slides up and
down on the vertical guideways of the column face to move the workpiece vertically.
In some milling machines referred to as fixed bed machines the knee is fixed while
the cutter moves vertically in order to cut the workpiece. The top face of the knee
forms guideways for the saddle to provide cross travel of the table.
Saddle: The saddle is placed on the top of the knee and supports the worktable, which
slides on a set of guideways to provide horizontal motion in one direction. The saddle
provides the motion of the worktable in the other direction by sliding transversely
along the knee to apply cross feed.
Worktable: The top of the table provides T-slots and other fixtures (e.g., vise) for
clamping the workpiece. In universal machines, the table is mounted on a circular

base (gradated in degrees) which in turns is mounted on the saddle to be swiveled
horizontally.
Overarm: The overarm or over-hanging arm is mounted on the top of column and
extends beyond the column face. In a vertical milling machine the cutter is oriented
vertically. The cutter is secured inside a collet, which is attached to the vertically
oriented spindle. On the other hand, a horizontal milling machine uses a cutter that is
mounted on a horizontal shaft above the workpiece called the arbor. The arbor is
supported on one side by the overarm, which is connected to the column and on the
other side by the spindle.
The basic forms of milling are:
Peripheral or slab milling: In peripheral milling, the milled surface is generated by
teeth located on the periphery of the cutter. The axis of rotation of the cutter is
generally in a plane parallel to the workpiece surface to be machined (Fig II.5a).
Face milling: In face milling, the cutter is mounted on a spindle having an axis of
rotation perpendicular to the workpiece surface. The milled surface results from the
action of cutting edges located on the periphery and face of the cutter (Fig II.5b).
End Milling: The cutter in end milling generally rotates on an axis vertical to the
workpiece. It can be tilted to machine tapered surfaces. Cutting teeth are located on
both the end face of the cutter and the periphery of the cutter body (Fig II.5c).
(a) (b) (c)

Figure II.5. (a) Peripheral milling;(b) face milling;(c) end milling (Source: Nuttfield Engineering)
The main methods of milling are (see Fig. II.6):

Up Milling: Is also referred to as conventional milling. The direction of cutter
rotation opposes the feed motion. For example, if the cutter rotates clockwise, the
workpiece is fed to the right in up milling.
Down Milling: Is also referred to as climb milling. The direction of cutter rotation is
the same as the feed motion. For example, if the cutter rotates counterclockwise, the
workpiece is fed to the right in down milling.
GJU/ SATS/ IE/ Workshop - 10 - 2nd Semester 2012/2013

Figure II.6. Up milling and down milling
2.4. The cutting tool

A cutting tool (or cutter) has one or more sharp cutting edges. A cutter should be
made of a material that is harder than the workpiece material. Machining operations
remove material from the workpiece surface by producing chips. A chip is produced
just ahead of the tool edge by continuously shearing the material (see Fig II.7):
Figure II.7. Schematic of a two-dimensional cutting process (source: Wikipedia)
From the figure one can observe the following:

Rake face: It directs the flow of newly formed chips; it is oriented at a certain angle
called the rake angle. This angle is measured relative to the plane perpendicular to
the work surface. The rake angle can be either positive or negative.
Flank: It provides a clearance between the tool and the newly formed work surface,
thus, protecting the surface from abrasion, which may degrade the surface finish. The
angle between the work surface and the flank surface is called the relief angle.
There are two basic types of cutting tools:
Single-point tools: With one cutting edge and is used for turning, boring and planing.
During machining, the point of the tool penetrates below the original work surface of
the workpiece. The point is sometimes rounded to a specific radius, called the nose
radius.

Multiple-cutting-edge tools: With more than one cutting edge, these tools usually
achieve motion relative to the workpiece by rotating. Drilling and milling use rotating
multiple-cutting-edge tools. Although the shapes of these tools are different from a
single-point tool, many elements of tool geometry are similar.
Materials commonly used for cutters:
• Steel: e.g., low carbon steel, high carbon steel, high speed steel (HSS)
• Cobalt-chromium alloys
• Cemented carbides
• Ceramics
• Cermets (a composite of ceramic and metallic materials)
• Polycrystalline diamonds (PCD)

2.5. Cutting conditions
The cutting conditions are variables that are easily changed in the machine tool by the
operator and that affect the rate of material removal. The cutting conditions are
determined by the machinability rating.
The cutting speed (in units of length/time): Is the speed at the outside edge of the
cutter as it is rotating. It is also known as surface speed. The hardness of the work
material has a great deal to do with the recommended cutting speed. The harder the
work material, the slower the recommended cutting speed will be.
The depth of cut (in units of length): The distance the cutting tool projects below the
original surface of the workpiece.
The feed rate (in units of length/revolution or length/stroke): Refers to how fast the
tool moves through the material being cut. Feed Rates will decrease with dull tools, a
lack of coolant or deep cuts.
In turning, the feed motion is parallel to the axis of rotation of the workpiece. The
distinguishing characteristic of all turning machines is that the workpiece rotates past
a stationary tool that is fed essentially parallel to the axis of rotation. In a lathe the
tool does not rotate. This is exactly the opposite of milling, in which the tool rotates
over, through or past a workpiece.
In milling, the direction of the feed motion is perpendicular to the tool's axis of
rotation. The speed motion is provided by the rotating milling cutter.
Machining is an expensive process and requires attention to many details for a
workpiece to meet the specifications set out in the engineering drawings and
application. The process is only used when tight dimensional tolerances and specific
surface finish is required.
2.6. Machining defects
Machining defects might occur due to:
• Incorrect working parameters
• Dull cutter
• Unsecured workpiece
An example of poor surface finish is due to machining vibrations (referred to as
chatter), which is manifested by undulating or irregular finish and the appearance of
waves on the machined surfaces of the workpiece.
Vibration occurring during the material removal process might affect the process as
follows:
• Reducing surface quality and the dimensional accuracy of the desired product
• Increasing power consumption
• Increasing noise level
• Reducing the lifetime of the machine tool parts
2.7. Drilling, reaming and the drill press
In drilling the tool is fed in a direction parallel to its axis of rotation into the
workpiece to form the round hole. A typical drill press is shown in Fig. II.8.
The typical parts of a drill press are:
Base: Supports a column
Column: supports a table
Table: The workpiece can be supported on the table with a vise or hold-down clamps;
the table can be swiveled out of the way to allow tall work to be supported directly on
the base
Motor: Turns the spindle at a speed controlled by a variable speed control dial
Spindle: Holds a drill chuck (see Fig. II.8) to hold the cutting tools (drill bits, center
drills, etc.).
<
Figure II.8. Parts of a drill press (Source: University of Virginia); frame: drill chuck and key
Drilling involves the creation of holes that are right circular cylinders. This is
accomplished most typically by using a twist drill. The chips must exit through the
flutes to the outside of the tool. As shown in Fig. II.9, the cutting front is embedded
within the workpiece, making cooling difficult. The cutting area can be flooded,
coolant spray mist can be applied, or coolant can be delivered through the drill bit
shaft.
Figure II.9. Twist drill (Source: efunda)

Many different materials are used for drills depending on the required application:
• Steel: e.g., low carbon steel, high carbon steels, high speed steel (HSS); cobalt
steel alloys, hi-molybdenum tool steel
• Tungsten carbide
• Polycrystalline diamond (PCD)
Reaming is a process which involves enlarging a pre-existing hole to a certain
diameter; little material is removed in reaming, therefore it can be done by hand; the
reamer is similar to a mill which has several cutting edges arranged around a central
shaft.


Workshop IE121 Sheet Metal Forming Workshop
Workshop III. Sheet Metal Forming Workshop

1. Objectives
Understanding and using the basic techniques of sheet metal forming operations and
tools
2. Background
Sheet metal forming is a family of processes used in shaping thin sheets of the metal
by subjecting the metal to forces in order to produce thin parts having diverse
geometries; it is basically accomplished by processes such as blanking, bending, deep
drawing and shearing. A skilled metal worker is a specialist craftsman of the highest
order. The engineer is called upon to understand and use the most basic of these
techniques.
2.1. Shearing
In the shearing process, the metal is cut with either hand shears or bench shears. Hand
shears are available in various shapes so that both straight and curved surfaces can be
produced. The produced sheets typically have thicknesses up to 0.9 mm; although
bench shears are hand operated, the force acting on the shear blades is magnified by a
system of levers. This enables thicker sheets >0.9 mm to be cut. Fig. III.1 shows a
hand shear and a swing shear.
(a) (b)
(c)
Figure III.1. (a) Hand shear (Source: highlandwoodworking.com); (b) swing shear (Source:

craftsmanspace.com); (c) motorized shear
During the shearing process, the metal is placed between an upper blade and a lower
blade that are forced past each other with the space between them determined by a
required offset. Normally, one of the blades remains stationary as shown in Fig III.2.
Materials that are commonly sheared include aluminum, brass, bronze and steel.
2.1.1. Advantages of shearing process
• Its ability to make straight-line cuts on flat sheet stock
• Its ability to produce burred and slightly deformed metal edges
• Its ability to cut relatively small lengths of material at any time since the
shearing blades can be mounted at an angle to reduce the necessary shearing
force required
Figure III.2. Shearing process (Source: CustomPartNet) and motorized shear
2.2. Bending
Bending is one of the most common processes in sheet forming where the part can be
bent along a straight line or curved path as shown in Fig. III.3. It can be done in
various ways such as forming along the complete bend in a die, or by wiping, folding
or flanging in special machines or sliding the sheet over a radius in a die. Boxes such
as electrical enclosures and rectangular ductwork are typical products that are made
by bending process.
Figure III.3. Bending a sheet in a V-die (Source: efunda)
2.2.1. Bending mechanism

In bending, the work piece is positioned over the die block and then pressed to
produce the required shape, usually bending has to overcome both tensile stresses as
well as compressive stresses. When bending is done, the residual stresses cause the
material to spring back towards its original position, so the sheet must be over-bent to
achieve the proper bend angle (see Fig. III.4). The amount of springback is
dependent on the material.

When sheet metal is bent, it stretches in length due to deformation. As this happens, a
small amount is gained of the total length of the original part. The following terms are
important to understand sheet metal forming:
Figure III.4. Bending terminology (CustomPartNet)

Neutral axis: The location in the sheet that is neither stretched nor compressed, and
therefore remains at a constant length.
K-factor: The location of the neutral axis in the material, calculated as the ratio of the
distance of the neutral axis (measured from the inside bend surface) to the material
thickness. The K-factor is dependent upon several factors (material, bending
operation, bend angle, etc.) and is typically greater than 0.25 but cannot exceed 0.50.

Bend allowance: The length of the neutral axis between the bend lines, or in other
words, the arc length of the bend. The bend allowance (BA) added to the flange
lengths (a+b) is equal to the total flat length (Lf).
Bend deduction: Also called the bend compensation, the amount a piece of material
has been stretched by bending. Its value equals the difference between the mold line
lengths (Lm,a+Lm,b) and the total flat length (Lf). This deduction should be made to
calculate a flat length from the desired part (bent part).
Bend radius (R): The radius measured to the inner surface of the bend. The formed
bend radius is dependent upon the dies used, material properties, and the material
thickness.
Bending is a cost effective process when used for low to medium quantities,
because it does not require significant amounts of tooling.
2.2.2. Types of bending
Air bending: Air bending is performed with the punch touching the workpiece and
the workpiece, not bottoming in the lower cavity. As the punch is released, the
workpiece springs back a little and ends up with less bend than that on the punch. The
amount of spring back depends on the process parameters, material and thickness. In
air bending, there is no need to change any equipment or dies to obtain different
bending angles because the bend angles are determined by the punch stroke. The
forces required to form the parts are relatively small, but accurate control of the punch
stroke is necessary to obtain the desired bend angle (Fig. III.5).
Bottoming: Is the bending process where the punch and the workpiece bottom on the
die. The sheet is forced against the V-opening in the bottom tool. U-shaped openings
cannot be used. Space is left between the sheet and the bottom of the V opening. The
force required on this type of press is more than in air bending. The inner radius of the
workpiece should have a minimum value of T (where T stands for the sheet
thickness). A disadvantage of this process in the need for a different tool set for each
bend angle, sheet thickness, and material (Fig. III.5).
Figure III.5. Schematic drawing of air bending and bottoming (Source: CustomPartNet)
Folding: In folding, clamping beams hold the longer side of the sheet. The beam rises
and folds the sheet around a bend profile (see Fig. III.6). The bend beam can move the
sheet up or down. Large sheets can be handled in this process, making the operation
easily automated.

Figure III.6. Multipurpose machine used for folding (Source: Knuth.de)
Wiping: In wiping (wipe bending), a sheet is held between a wipe die and pressure
pad and a punch presses against the edge of the sheet. The sheet will bend against the
radius of the edge of the wipe die. Though faster than folding, wiping has a higher
risk of producing scratches or otherwise damaging the sheet because the tool is
moving over the sheet surface (Fig. III.7a).
Roll bending: Roll bending is usually performed on machines that use two to four
rolls to rotate and bend a sheet as it passes between them. It shapes the sheet into
cylinders or cylindrical segments, flattened and elliptical cylinders and cones. The roll
bender machine is shown in Fig. III.7b).
(a) (b)
Figure III.7. (a) Wipe bending (Source: CustomPartNet); (b) roll bending (Source: Wikipedia)
Metal spinning: Metal spinning, is a metalworking process, by which a disc or tube

of metal is rotated at high speed and formed into an axially symmetric part. Spinning
can be performed by hand or by a CNC lathe.
The spinning process can be performed by mounting a block in the drive section of a
lathe. A pre-sized metal disk is then clamped against the block by a pressure pad,
which is attached to the tailstock. The block and workpiece are then rotated together
at high speeds. A localized force is then applied to the workpiece to cause it to flow
over the block. The force is usually applied via various levered tools. Simple
workpieces are just removed from the block, but more complex shapes may require a
multi-piece block. Spinning tools can be made of hardened steel for using with
aluminum or solid brass for spinning stainless steel or mild steel. Common products
are cylinders, cones, flanged and dished heads and fan panels (see Fig. III.8).
Figure III.8. Sample of parts produced by spinning (Source: MetalSpinners Inc.)

Workshop IE121 Welding Workshop
Workshop IV. Welding Workshop

1. Objectives
Describing welding, and knowing the tools used in the welding workshop
Describing various types of welding processes
Performing several different types of welding joints
2. Background
Welding is the process of joining two or more materials, usually metals (also
thermoplastics) permanently, to form a continuous material. The ends of the two
metals (base metals) that are to be united are subjected to heat, pressure or a
combination of both and are brought to a molten state. A filler (i.e., material used to
produce a weld) is placed between the two molten metal parts to form a molten pool
or weld puddle. Upon cooling, a strong permanent bond is formed between the two
metals, thereby forming a joint. Various energy sources can be used for carrying out
welding such as gas flame, electric arc, laser, electron beam, ultra sound, friction, etc.
2.1. Types of welding
Welding processes can be classified into different types depending on the combination
of pressure and temperature used for joining the materials. The different types of
welding processes are listed in Table IV.1.
Table IV.1. Types of welding*

Welding Type Subgroups
Air acetylene welding
Oxy-acetylene welding
Gas welding
Oxy-hydrogen welding
Pressure gas welding
Carbon arc welding
TIG welding
MIG welding
Submerged arc welding
Arc Welding Shielded metal arc welding
Plasma arc welding
Flux cored arc welding
Stud arc welding
Electro slag welding
Spot welding
Seam welding
Percussion welding
Resistance welding High frequency welding
Projection welding
Resistance butt welding
Flash butt welding
Friction welding
Cold welding
Solid state welding Ultrasonic welding
Hot pressure welding
Diffusion welding
Laser beam welding
Radiant energy welding
Electron beam welding
Thermite welding
Thermo-chemical welding
Atomic welding
* Items in boldface are treated in some detail in the text

2.1.1. Arc welding
In arc welding the heat required is obtained through electrical energy - either direct
current (DC) or alternating current (AC) is used. Consumable or non-consumable
electrodes are used to produce an arc between the tip of the electrode and the
workpiece to be welded. The electrode may be consumed or not consumed during
welding based on the process that is used.
The welding region is usually protected by some type of shielding gas, vapor, and/or
slag. Arc welding is one of the most economical and simple welding processes (see Fig.
IV.1).
Figure IV.1. Diagram of arc and weld area in shielded metal arc welding (Source: S. Kalpakjian
and S. Schmid, 2009)
Shielded metal arc welding: It is one of the oldest and cheapest methods for
welding. It is known as stick welding, because of the stick shaped electrode. In
shielded metal arc welding process the electrode used is consumable. The electric
current (usually in the range 50-300 A) will strike an arc between the consumable
electrode and the base metal that is being used. Too low current causes incomplete
fusion, while too high current may cause damage to the electrode coating. In most
cases, the workpiece is positive and the electrode in negative.
The consumable electrode is also known as a welding stick. The stick should be made
of a material that is compatible with the base material. The electrode is often coated
with a flux (substance used to promote fusion). As the electrode melts, the flux
covering disintegrates, giving off shielding gases that shields the weld area from
oxygen and other atmospheric gases, which contaminate or corrode the welding zone.
The coating has the following basic functions:
• Stabilizes the arc
• Generates gases to act as a shield against the surrounding atmosphere
• Controls the rate at which the electrode melts
• Act as a flux to protect the weld against formation of oxides, nitrides, and other
inclusions, and with the resulting slag, protect the molten weld pool.
• Add alloying elements to the weld zone to enhance the properties of the weld.
This is the simplest of the processes available which requires very little technical
training. However this process of welding is limited to welding ferrous materials
only. Electrodes are identified by numbers and letters (e.g., E60xx).
Gas metal arc welding (GMAW): Gas metal arc welding (GMAW) is sometimes
referred to by its types: metal inert gas (MIG) welding or metal active gas (MAG)
welding.

In this type of welding, a consumable electrode is used and the weld area is shielded
by an external gas source, such as argon, carbon dioxide, helium, or various other gas
mixtures. Both, the electrode and gas are fed automatically through the welding gun.
The welding gun is either air cooled or water cooled for heavy operations.
The function of the shielding gas is to isolate the welding zone from atmospheric
gases. The selection of the gas depends upon the materials combination being used
and the process, so that no reaction will take place with the metals being welded.
The selection of electrode is based on the metals that are being welded, the joint
design and the process that is being used. Electrode selection, as in any arc welding, is
a key factor to the material strength and other mechanical properties of the weld. After
solidification, the welded metal should have the same properties of the base materials,
in other words there should not be any discontinuities and other welding defects.
The GMAW process was developed in the mid 20th century. It is widely used in metal
fabrication industries as it is easily automated and used with robotics.
Health risks associated with arc welding
Welding can be a dangerous and unhealthy practice without the proper precautions;
however, with the use of proper protection the risks of injury or death associated with
welding can be greatly reduced. Precautions should be taken to avoid the following
risks:
Heat and sparks: Welders wear protective clothing in the form of heavy leather
gloves and protective long sleeve jackets to avoid exposure to extreme heat, flames,
and sparks.
Eye damage: Exposure to the brightness of the weld area leads to a condition called
arc eye in which ultraviolet light causes inflammation of the cornea and can burn the
retinas of the eyes. Welding goggles and helmets with dark face plates - much darker
than those in sunglasses or oxy-fuel goggles - are worn to prevent this exposure. To
protect bystanders, transparent welding curtains often surround the welding area.
These curtains, made of a polyvinyl chloride plastic film, shield nearby workers from
exposure to the UV light from the electric arc.
Inhaled matter: Welders are also often exposed to dangerous gases and particulate
matter. Processes like flux-cored arc welding and shielded metal arc welding produce
smoke containing particles of various types of oxides. The size of the particles in
question tends to influence the toxicity of the fumes, with smaller particles presenting
a greater danger. Additionally, many processes produce various gases (most
commonly carbon dioxide and ozone, but others as well) that can prove dangerous if
ventilation is inadequate. Furthermore, the use of compressed gases and flames in
many welding processes pose an explosion and fire risk; some common precautions
include limiting the amount of oxygen in the air and keeping combustible materials
away from the workplace.
2.1.2. Spot welding
Spot Welding is a resistance welding (RW) process, in which two or more overlapped
metal sheets are joined by spot welds. In RW the workpieces are welded due to a
combination of a pressure applied to them and a localized heat generated by a high
electric current flowing through the contact area of the weld.
Spot welding is one of the most important types of welding. It is primarily intended
for joining parts that are normally up to 3 mm (usual range 0.5-3.0 mm) thickness.
The workpieces are brought in contact and held together under pressure exerted by
electrodes (see Fig. IV.2).

Figure IV.2. Schematic of the spot welding process (Source: Substances and Technologies) and
spot welding machines (Source: CEA)
The method uses pointed copper electrodes providing passage of electric current. The
electrodes also transmit pressure required for formation of strong weld. Forcing
suitably high current through will melt the metal surfaces and form the weld. The
process requires a well determined combination of pressure, current intensity and
duration.
The attractive feature of spot welding is the high energy density that can be delivered
to the spot in an extremely small time (ten to one hundred milliseconds). This permits
the welding to happen without overheating the rest of the workpiece.
Applications of spot welding
The most common application of spot welding is in the automobile car manufacturing
industry, where it is used to weld the sheet metal to form a car body and other parts.
It is frequently used in the place of riveting.
Another application is in dental prosthesis (orthodontics), where small scale spot
welding equipment is used.
Spot welding can be entirely automated, and many of the spot welding industrial
robots found on assembly lines are “spot welders”.
2.2. Common welding joints types
Fig. IV.3 shows the five common types of join designs used for welding.
Figure IV.3. Schematic of the spot welding process (Source: weldingteacher.com)
2.3. Welding defects

A welding defect is any flaw that compromises the usefulness of the finished weld.
According to the American Society of Mechanical Engineers (ASME) the causes for
welding defect are broken down into the following: 41% poor process conditions,
32% operator error, 12% wrong technique, 10% incorrect consumables, and 5% bad
weld grooves. The main types of welding defects are:
Gas inclusion (porosity): Caused by trapped gas released during melting of the weld
area and trapped during solidification (Fig. IV.4a).
Inclusions (slag inclusions): Such as oxides trapped in the weld zone (Fig. IV.4b).
Undercut, underfill and overlap: Undercuts are generated from melting away the
base metal. Underfills are caused when the joint is not filled with the proper amount
of weld metal. Overlaps are generally due to poor welding practice (Fig. IV.4c and d).
Incomplete fusion and incomplete penetration: Produce poor weld beads, and
results in insufficient depth of weld (Fig. IV.4e).
Lamellar tearing: Caused by shrinkage of restrained members of the structure during
cooling.
Cracks: Weld cracks could be transverse, longitudinal, under bead or toe cracks (Fig.
IV.4f).

(a) (b)
(c) (d)
(e)
(f)
Figure IV.4. Common welding defects (a) porosity; (b) slag inclusion; (c) underfill; (d) undercut
and overlap; (e) incomplete fusion; (f) weld cracks (Source: a and b NPTEL, Manufacturing
processes; c isadikin technical blog 2006; d and e L. Baughurs, G. Voznaks. 2009; f Wikipedia)

Workshop IE121 Carpentry Workshop
Workshop V. Carpentry Workshop

1. Objectives
Getting familiar with wood types, wood joints and carpentry tools
Understanding the principles of carpentry work
2. Background
Carpentry is the process of converting timber into wooden articles and components
such as furniture, casting patterns, roofs, doors and windows.
2.1. Wood types
Wood is available for many products in various forms, naturally from trees as
softwood or hardwood; other types are manufactured panels such as plywood. The
selection of wood type depends on the desired strength, hardness, weight, durability,
availability and cost.
Natural woods (solid wood)
As the name indicates, natural wood is available in nature as trees. Trees are cut, then
seasoned (treated to reduce moisture) to form timber. Timber is used in the production
of different wooden products.
Softwood: Softwood is taken from fast growing evergreen or coniferous (cone-
bearing) trees. It is characterized by being soft, easy to work with, and cheap.
Examples on softwood are pine, fir, cypress, hemlock, spruce, cedar and redwood.
Cedar and redwood are excellent choices for outdoor projects.
Hardwood: Hardwood is taken from slow growing deciduous trees that shed their
leaves annually. It is dense, hard and expensive. Cutting hardwood requires extremely
sharp cutting tools. On the other hand, it is beautiful and usually knot-free. It is used
to manufacture furniture, musical instruments, window frames and boats. Examples
on hardwood are oak, maple, cherry, birch, walnut, ash, mahogany, teak, beech,
rosewood and poplar.
Manufactured panels (man-made)
Plywood (the original engineered wood product): Plywood is manufactured from
sheets of cross-laminated veneer and bonded, forming three layers with crossing
fibers, under heat and pressure with durable, moisture-resistant adhesives. It is very
strong board. It is cheap and available with flexible sizes. It has many uses such as;
wall and roof sheathing, furniture, and exterior works (Fig. V.1a).
MDF: MDF has a smooth, even surface. It is easily machined and painted or stained,
and can be available in water and fire resistant forms. It is widely used in furniture
and interior works (Fig. V.1b).
Chipboard: Chipboard is made from chips of wood glued and pressed together. It is
used for bedroom, and kitchen, sometimes it is covered within plastic laminate (Fig.
V.1c).
Blockboard: Blockboard is like plywood, it combines two types of wood. The central
layer is made from strips of timber. It is used with heavy duty applications, such as
shelves and worktops (Fig. V.1d).
Hardboard: It is very cheap particle board, produced by mixing and pressing wood
to form sheet. It used in low stress application, like furniture backs, and covering
curved structures (Fig. V.1e).

Oriented strand board (OSB): It is manufactured from rectangular-shaped strands
of wood that are oriented lengthwise and then arranged in layers, laid up into mats,
and bonded together with moisture-resistant, heat-cured adhesives (Fig. V.1f).
(a) (b)
(c) (d)
(e) (f)
Figure V.1. (a) Plywood; (b) MDF; (c) chipboard; (d) blockboard; (e) hardboard; (f) oriented
strand board (Source: a,b,c,e: Winwood)
2.2. Carpentry tools

Carpentry tools are used to produce components as per the required dimensions and
shapes. They can be either hand tools or power driven ones. The needed hand tools
could be classified to the following categories:
Marking tools: Mortise gauge (Fig. V.2) is a main marking tool. It consists of a
sliding wooden stock which moves on a square stem. Marking pen is fitted on the
stem. By positioning sliding block on the stem, it is possible to mark a line parallel to
any side of the wooden specimen.

Figure V.2. Mortise gauge (Source: Technologystudent)
Measuring tools: Measuring tool could be steel tape, carpenter's rule, try square
(Fig. V.3a), bevel square, and calipers to measure cylindrical shapes.
Holding tools: The most common holding device is carpentry vise (Fig. V.3b). In
addition, these tools include carpentry cramps, and clamps, such as G-clamp
(Fig. V.3c).
Cutting tools: Cutting include saws, and chisels, they are used for cutting and
shaping wood piece. Saw could be a hand saw, back saw, which is stiffened by metal
reinforcement along the upper edge, coping saw, which has a thin blade used for
cutting small curves, or any other hand operated saw for wood cutting and shaping.
On the other hand, chisel is a metal tool with a sharp beveled edge, used to cut and
shape stone, wood, or metal.
Planing tools: Planing tools are used to produce flat surfaces on wood. They consist
mainly, of a cutting blade which is fitted in a wood or metallic block at an angle. They
include; jack plane (Fig. V.3d), which is used for rough surfaces, jointer plane, which
is used to shape the edges of boards to make them fit together, and block plane, which
is used on end grains of wood.
Boring tools: Boring tools are used to make holes in the wooden piece. They include
gimlet, bradawl (Fig. V.3e), wheel brace and drill.
Striking tools: Striking tools includes hammers and mallets. They are used to strike
nails, drive a chisel (Fig. V.3f) or wedge. Hammers have a metal head with various
shapes, while mallets have a large head used to strike a surface without damaging it,
such as in assembling.
Miscellaneous tools: They include various tools like screwdriver, nail-punch,
reamers, files, etc.
Electrical Tools: Electrical tools could be classified as previously stated, the main
carpentry electrical tool found in a carpentry workshop are:
• Band saw (Fig. V.4a): Band saw is named after its saw blade, which is a
continuous steel loop with teeth along one edge. Various blade thicknesses are
available. Thin blades are used to cut curves, while thick blades are used to cut
straight lines. This electrical driven saw is capable of performing a whole range
of cuts, such as ripping, bevel and curves.
• Table saw (Fig. V.4b): A table saws has a cabinet-type base with a circular
blade. It is used to make long, straight and accurate cuts quickly on large pieces
wood. It could be used in angle cuts using miter gauge.
• Circular saw: It is a portable, power-driven saw, in which a circular disc with a
toothed edge is rotated at high speed. It is favored for quick cuts when accuracy
is not an issue. More accurate cuts can be done using guides or fence.

(a) (b)
(c) (d)
(e) (f)
Figure V.3. (a) Try square; (b) carpentry vise; (c) G-clamp; (d) jack plane; (e); bradawl; (f) chisel
• Compound miter saw (Fig. V.4c): Compound miter saw is bench top saw,
equipped with bevel and miter gauge for miter and bevel cutting. It is used in
mainly in decoration cutting.
• Power drill: Power drills are used in boring processes. Two main types of drills
are available; corded drill and cordless drill. Cordless drills are power driven by
rechargeable batteries; therefore, they are less powerful than corded drills.
• Random orbit sander (Fig. V.4d): Random orbit sander is a portable, power-
driven tool, with a circular pad used in finishing processes, sanding and
smoothing.

(a) (b)
(c) (d)
Figure V.4. (a) Band saw; (b) table saw; (c) compound miter saw; (d) random orbit sander
2.3. Joints
Butt joint: A very simple joint but it is also very weak. Butt joints tend to be used for
making picture frames, corner pieces and nails are often used to strengthen the joint
(Fig. V.4a).
Miter joint: It is one of the easiest and simplest joining methods. Both wood pieces
are prepared by cut at an angle of 45°, and butted against the other one (Fig. V.4b).
Halving joint: Used to join two wood parts by removing half of the wood from each
piece. Glue or nails should be used to join the parts together. (Fig. V.4c).
Mortise Tenon joint: It is a classical and fundamental joint type. It consists of a T-
shaped tenon part (named after the tenon saw) that is inserted in a “mortised” slot
(named after the mortise chisel). Such joints are milled using a milling machine (Fig.
V.4d).
Dowel joint: It is one of the easiest and cheapest methods of fastening. A small rod is
used to joint two pieces; the rod is glued and inserted in a drilled hole in both wood
parts (Fig. V.4e).
Lap joint: This joint is only slightly stronger than the butt joint. There is however a
bigger surface area for gluing. This joint is often strengthened with nails (Fig. V.4f).

Slotted Tenon joint (Housing joint): This is just a simple slot cut into one piece of
wood to increase the glue area. This is often done with a router and works very well in
MDF (Fig. V.4g).
Dovetail joint: Dovetail joint is one of the strongest wood joints used in joining wood
parts at right angle. It is used in the fabrication of drawers for example. Dovetails are
cut at an end of one part, and tails are cut at the end of the other part to be joined.
Dovetails and tails should be matched and have a trapezoidal shape (Fig. V.4h).
Finger joints are based on the same concept but with a straight shaped cut.
2.4. Storage
Softwood, like pine, will absorb and lose moisture more than hardwoods so they are
not as stable. They should be purchased before being used at least two weeks, and
stored in a dry place with place stickers, small pieces of scrap wood, between the
boards to permit good air circulation around each piece of stock, and to allow the
wood to reach equilibrium with the indoor environment which reduces the likelihood
of dramatic wood movement after a woodworking is completed.

(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
Figure V.5. (a) Butt joint; (b) Miter joint; (c) Halving joint(d) Mortise Tenon joint; (e) Dowel
join; (f) Lap joint; (g) Housing joints; (h) Dovetail joint (Source: a-g K. Cooper 2006; h
diydata.com)


Workshop IE121 References
D. References
A guide to engineered wood products, APA

C.N. Matthews, ASME engineer's data book, ASME Press, 2001
G.S. Sawhney, Mechanical Experiments and Workshop Practice, I K International
Publishing House Pvt. Ltd, 2010
H.B Cary, S.C. Helzer, Modern Welding Technology, Pearson/Prentice-Hall, 2005
L. Baughurs, G. Voznaks, Welding defects, Australian Bulk Handling Review,
2009
Lathes and turning machines, Free Online Library
Machine Shop, Fox Valley Technical College
Marc Madou, Advanced Manufacturing Choices, University of California, Irvine
MIT OpenCourseWare, Introduction to Machine Tools
National Programme on Technology Enhanced Learning (NPTEL),
Manufacturing processes
S. Kalpakjian, S. Schmid, Manufacturing Processes of Engineering Materials,
Prentice Hall, 2009
University of Virginia, Workshop Technologies
Wikipedia, the free encyclopedia
http://www.efunda.com
http://www.lathes.co.uk
http://www.technologystudent.com
http://www.CustomPartNet.com
http://www.inthewoodshop.org
http://www.mr-dt.com
http://www.technologystudent.com
http://sawdustmaking.com
http://www.ehow.com
http://www.mr-dt.com/manufacturing/woodjoints.htm

Workshop IE121 References

Workshop IE121 Appendix A: Cover Page
Appendix Appendix A: Cover Page
See next page

Workshop IE121 Appendix A: Cover Page

German Jordanian University
School of Applied Technical Sciences
Industrial Engineering Department
Engineering Workshop- IE121
Workshop Number:
Workshop Name:
Workshop Date:
Section Number:
Group Number:
Submitting Date:
Student Number:
Student Name:

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German Jordanian University

School of Applied Technical Sciences

Engineering Workshop Handout- IE121

GJU/ SATS/ IE/ Workshop 2nd Semester 2012/2013

GJU/ SATS/ IE/ Workshop -i- 2nd Semester 2012/2013

v ___________________ Workshop Instructions A.

vi __________________________________ Report Format B.

vii _________________ Safety in the workshop C.

1 ___________ Measurement Workshop I.

6 __________________ Machining Workshop II.

Sheet Metal Forming Workshop III.

23 ________________________ Welding Workshop IV.

29 ____________________ Carpentry Workshop V.

39 ____________________________________________________ Appendix A: Cover Page

GJU/ SATS/ IE/ Workshop - iii - 2nd Semester 2012/2013

Rule number one: SAFETY, SAFETY, SAFETY

GJU/ SATS/ IE/ Workshop -v- 2nd Semester 2012/2013

Cover page: See Appendix A

GJU/ SATS/ IE/ Workshop - vi - 2nd Semester 2012/2013

Always listen carefully to the instructor and follow instructions

GJU/ SATS/ IE/ Workshop - vii - 2nd Semester 2012/2013

Figure I.1. Parts of a vernier caliper (Source: tbc.school.nz)

The vernier caliper consists of the following parts:

GJU/ SATS/ IE/ Workshop -1- 2nd Semester 2012/2013

Accuracy: The accuracy of a device is defined as the difference between the

1 devision in main scale

GJU/ SATS/ IE/ Workshop -2- 2nd Semester 2012/2013

Figure I.4. reading using vernier caliper scale

GJU/ SATS/ IE/ Workshop -3- 2nd Semester 2012/2013

Figure I.5. Parts of an outside micrometer (Source: technologystudent.com)

The micrometer consists of the following parts;

Some micrometers may be digital or dial indicator as shown in Fig. I.7.

GJU/ SATS/ IE/ Workshop -4- 2nd Semester 2012/2013

Measurement reading: Before determining the length of an object, the accuracy of

GJU/ SATS/ IE/ Workshop -5- 2nd Semester 2012/2013

Workshop II. Machining Workshop

GJU/ SATS/ IE/ Workshop -6- 2nd Semester 2012/2013

Grinding (abrasive process): Grinding is considered to be a finishing process used

GJU/ SATS/ IE/ Workshop -7- 2nd Semester 2012/2013

Figure II.3. Parts of a lathe (Source: CustomPartNet)

The main parts of a lathe are:

The basic parts of a milling machine are:

GJU/ SATS/ IE/ Workshop -9- 2nd Semester 2012/2013

(a) (b) (c)

The main methods of milling are (see Fig. II.6):

GJU/ SATS/ IE/ Workshop - 10 - 2nd Semester 2012/2013

Figure II.6. Up milling and down milling

2.4. The cutting tool

Figure II.7. Schematic of a two-dimensional cutting process (source: Wikipedia)

From the figure one can observe the following:

GJU/ SATS/ IE/ Workshop - 11 - 2nd Semester 2012/2013

GJU/ SATS/ IE/ Workshop - 12 - 2nd Semester 2012/2013

Figure II.9. Twist drill (Source: efunda)

GJU/ SATS/ IE/ Workshop - 15 - 2nd Semester 2012/2013

GJU/ SATS/ IE/ Workshop - 16 - 2nd Semester 2012/2013

Workshop III. Sheet Metal Forming Workshop

GJU/ SATS/ IE/ Workshop - 17 - 2nd Semester 2012/2013

Figure III.2. Shearing process (Source: CustomPartNet) and motorized shear

Figure III.3. Bending a sheet in a V-die (Source: efunda)