DJJ3032 : MECHANICAL WORKSHOP PRACTICAL 3

LAB REPORT 1 (MIG WELDING)

CHUNG CHEANG PING

NAME

20DKM18F2032
MATRIX.NO

DKM3A
CLASS

MOHAMAD SYAHIDULLAH BIN

LECTURER
AHMAD ANUAR
 CONTENTS

TOPICS

1. INTRODUCTION

2. OBJECTIVE

3. SAFETY

4. TOOLS & EQUIPMENT

5. PROCEDURES

6. CONCLUSION
INTODUCTION
MIG welding is a gas shielded metal arc welding process usig the heat of an electric arc
between a continuously fed, consumable electrode wire and the material to be welded.
Metal is transferred through a protected arc column of inert gas to the work. A wire of
copper coated mild steel is fed continuously from a reel through a gun with a melting rate
up to 5m/min.

OBJECTIVE
 To know main function of welding.
 To know the part of arc welding.
 To know what is a step when doing a welding.
 To ensure student prevent from accident.
 To ensure student know the skills of welding.
 To ensure student follow the instruction and safety given.

SAFETY
 Do not touch the electrode or the work circuit, and do not access the internal circuits
while the unit is live.
 Always wear according PPE rule and instructions given.
 Never weld on or near anything that's been cleaned with a chlorinated hydrocarbon
like brake-cleaner. When combined with UV light, chlorinated hydrocarbons can
create phosgene gas, which can cause serious injury or death. Ventilation will not
prevent poisoning.
TOOLS & EQUIPMENT
 Arc welding machine
 Heat shield
 Leather gloves
 Safety boots
 Chipping hammer
 Brush
 Mild steel plate
 Chisel
 Wire feeder
 Welding gun
 Gas cylinder (CO2/ Argon)

PROCEDURES
1. Prepare a piece of mild steel plate.
2. Carving or cutting the edge of sharped on the mild steel plate by using chisel.
3. After that, turn on the power supply of arc welding. Set the power ranges from100A
– 400A depend upon the diameter of the wire.
4. CO2 is principally used apart from argon or argon helium mixture as shielding gas.
5. Hold the electrode 60 degrees work angle 2mm – 3mm above the steel plate.
6. Hold that position over a spot just inside the left edge of the steel plate until a
molten pool is established.
7. Welding then proceeds from left to right.
8. The correct technique is hold an electrode at the start position for 1s or 2s and
continue until the end of process.
9. Stop the process at the end of the work piece.

CONCLUSION
To conclude, GMAW is the most common industrial welding process, preferred for its
versatility, speed and the relative ease of adapting the process to robotic automation. It is
used extensively by the sheet metal industry and, by extension, the automobile industry.
DJJ3032 : MECHANICAL WORKSHOP PRACTICAL 3

LAB REPORT 2 (TIG WELDING)

CHUNG CHEANG PING

NAME

20DKM18F2032
MATRIX.NO

DKM3A
CLASS

WAN JAMALILAIL BIN WAN MOHD

LECTURER ZEN
 CONTENTS

TOPICS

1. INTRODUCTION

2. OBJECTIVE

3. SAFETY

4. TOOLS & EQUIPMENT

5. PROCEDURES

6. CONCLUSION
INTODUCTION
TIG Welding, also known as Gas Tungsten Arc Welding (GTAW), is a process that joins
metals by heating them with an arc between a tungsten electrode (non-consumable) and
the work piece. The process is used with a shielding gas and may also be used with or
without the addition of filler metal. The primary variables in TIG Welding are arc voltage
(arc length), welding current, travel speed and shielding gas composition. The amount of
energy the arc produces is proportional to the current and the voltage. The amount of
energy transferred per unit length of weld is inversely proportional to the travel speed.
Shielding gases are typically inert to protect the electrode from contamination. The use of
helium shielding provides more penetration than argon. The arc, established between the
tip of the electrode and the work, generates heat to melt the base metal. Once the arc and
weld pool are established, the torch is moved along the joint, and the arc progressively
melts the surfaces to be joined. If used, filler wire is usually added to the leading edge of
the weld pool to fill the joint. The tungsten electrode can be alloyed with small amounts of
active elements to increase emissivity of the electrode; this provides quicker arc starting,
greater arc stability, and longer electrode life.

OBJECTIVE
 To know main function of welding.
 To know the part of gas welding.
 To know what is a step when doing a welding.
 To ensure student prevent from accident.
 To ensure student know the skills of welding.
 To ensure student follow the instruction and safety given.

SAFETY
 Do not touch the electrode or the work circuit, and do not access the internal circuits
while the unit is live.
 Always wear according PPE rule and instructions given.
 Never weld on or near anything that's been cleaned with a chlorinated hydrocarbon
like brake-cleaner. When combined with UV light, chlorinated hydrocarbons can
create phosgene gas, which can cause serious injury or death. Ventilation will not
prevent poisoning.
TOOLS & EQUIPMENT
 Tungsten Inert Gas welding machine
 Heat shield
 Leather gloves
 Safety boots
 Chipping hammer
 Brush
 Mild steel plate
 Chisel
 Torch or electrode holder
 Tungsten electrode
 Argon gas

PROCEDURES
1. Prepare a piece of mild steel plate.
2. Carving or cutting the edge of sharped on the mild steel plate by using chisel.
3. Next, grind the electrode until it sharp look alike cone shaped.
4. After that, unscrew the back of the electrode holder, insert the rod, replace back. The
tip of the electrode should be about ¼ away from the protective sheath.
5. Turn on the power supply and the gas.
6. Hold the electrode about an inch away from the metal. When the pool is formed, the
the rod in.
7. Jam down the foot pedal if the process is done.

CONCLUSION
To conclude, GTAW is uses a non consumable tungsten electrode during the welding
process. It is easy applied to thin materials and produces very high quality. Welds can be
made with or without filler metal. The welding yields are low distortion, and also leaves no
slag or splatter.
DJJ3032 : MECHANICAL WORKSHOP PRACTICAL 3

LAB REPORT 3 ( LATHE PROCESS)

CHUNG CHEANG PING

NAME

20DKM18F2032
MATRIX.NO

DKM3A
CLASS

ALFAN BIN SERAIL

LECTURER

CONTENTS
 TOPICS

1. INTRODUCTION

2. OBJECTIVE

3. SAFETY

4. TOOLS & EQUIPMENT

5. PROCEDURES

6. CONCLUSION

INTODUCTION
Turning is one of the machining process which involves cutting and trimming a workpiece to
their desirable final dimension. A cutting tool typically a non-rotating tool bit, defines a
helix tool path by travelling almost a linear line of motion while the workpiece is rotating
around its axes. The motion of the workpiece may be defined as a straight line or in some
set of curvature of angle specified according to the needs of the final product. although
however, it is essentially linear in all the turning process.

OBJECTIVE
 To learn how to operate the lathe machine which require a turning process.
 To understand and undergo the turning process.
 To calculate the tolerances of the product by using the Vernier caliper.
 To produce the pre-shaped materials to a workpiece which rational, typically axis-
symmetric, parts that have many features such as holes, grooves, threads, tapers,
various diameter steps and even contoured surfaces.

SAFETY
 Always wear PPE in workshop.
 Always stop the lathe before making adjustments.
 Do not change spindle speeds until the lathe comes to a complete stop.
 Handle sharp cutters, centers, and drills with care.
 Remove chuck keys and wrenches before operating.
 Know where the emergency button to stop before operating the lathe.
 Use pliers or a brush to remove chips and swarf.
 Never lean on the lathe.
 Never attempt to measure work while it is running.
 Protect the lathe ways when grinding or filing.

TOOLS & EQUIPMENT

 Work piece
 Tool bit
 Brush
 Lathe machine
 Vernier caliper
 Goggle

PROCEDURES
 1. First, the workpiece will be cutting by using power hacksaw machine and given to
students.
2. Brief explanation by assistant engineer on how to operate the lathe machine.
3. Take a dimension of the workpiece and compare with given dimension and drawing.
4. Apply all equipment before starting.
5. Start operating the lathe machine.
6. Design the workpiece according to the given drawing and given measurement
including turning, miling and turning by angle .
7. Take a final measurement.
8. Turn off the power after finish operating on lathe machine.
9. Keep tools in safety place.
10.Clean the metal pieces among the machine with brush and broom.
11.Brief explanation about report by lecturer.

CONCLUSION
In conclusion, the project has provided us the knowledge regarding the turning process
which is a form of machining and removing several parts of a material by cutting away
unwanted parts in a rotational motion way. This process involved a machine called turning
machine or lathe machine. we learnt that turning process including the cutting parameters
of the process. These parameters are listed as the cutting feed, cutting speed, spindle
speed, feed rate, axial depth of cut and the radial depth of cut. These specification aspects
are highly essential as it will determine the value of the end product of out work piece.
DJJ3032 : MECHANICAL WORKSHOP PRACTICAL 3

LAB REPORT 4 ( MILLING PROCESS)

CHUNG CHEANG PING

NAME

20DKM18F2032
MATRIX.NO

DKM3A
CLASS

REDZA IZWAN BIN ABDUL RRAHMAN

LECTURER
 CONTENTS
TOPICS

1. INTRODUCTION

2. OBJECTIVE

3. SAFETY

4. TOOLS & EQUIPMENT

5. PROCEDURES

6. CONCLUSION
INTRODUCTION
Milling is the most common form of machining, a material removal process, which can
create a variety of features on a part by cutting away the unwanted material. The milling
process requires a milling machine, workpiece, fixture, and cutter. The workpiece is a piece
of pre-shaped material that is secured to the fixture, which itself is attached to a platform
inside the milling machine. The cutter is a cutting tool with sharp teeth that is also secured
in the milling machine and rotates at high speeds. By feeding the workpiece into the
rotating cutter, material is cut away from this workpiece in the form of small chips to ceate
the desired shape.

OBJECTIVE
 To familiarize with the milling machine.
 To familiarize with milling process.
 To understand the usage of milling machine in fabrication work.

SAFETY
 Always wear PPE in workshop.
 Know where the emergency button to stop before operating the lathe.
 Use pliers or a brush to remove chips and swarf.
 Never attempt to measure work while it is running.

TOOLS & EQUIPMENT

 Workpiece
 Vernier caliper
 Milling machine
 Goggle
 Coolant medium (oil)
 Collets
PROCEDURES
1. Measured the dimension of workpiece given in the drawing by using vernier capliper.
2. Set the equipment in milling machine.
3. Turn on the power supply and set up the speed that given by instructor.
4. Start the process by rotating crossfeed handle to move either horizontal axis or
vertical axis.
5. After that, stop the process if finish and turn off the power supply.
6. Clean the metal pieces among the machine with brush and broom.
7. Brief explanation about report by lecturer.

CONCLUSION
To conclude, we have learned how to organize the milling machine and understand the
operation involved. Besides that, we also know the purpose of the main parts of this
machine. We also realize that the cutter diameter should be choosen in such a manner that
it will not interfere with fixtures and other components in the setup.