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J1003 WORKSHOP TECHNOLOGY 1
1.0 ACCIDENT PREVENTION
Understanding the importance of safety procedures and applications in machining, welding,
fitting and foundry work in the engineering workshop.
§ State the precautionary step in common accidents for personal safety while operating
machines, equipment, materials and fire prevention equipment.
§ Explain the importance of wearing goggles, safety glasses, fixing grinding wheel guard
and maintenance of workshop cleanliness.
§ Explain the danger of misusing gloves, rags, grinding wheel without guard and wearing
inappropriate uniform.
§ Differentiate between self safety, safety of equipment, machine, machine tools, arc
welding machine and oxy acetylene gas welding equipment.
2.0 HAND TOOL
Understand the importance of using hand tools in fitting.
§ Mark off the layout.
§ Define the meaning of layout.
§ State the procedures of making off the layout including the preparation of the work
piece
§ Explain the advantages of using various types of marking tool or liquid mediums.
§ Explain the uses of marking tools such as scriber, center punch, divider. Surface plate
and others.
§ Explain way of using marking tools to achieve accurate finishing, drawing a circle,
curve, center line and finding the center of a block using a scriber.
Testing tool
§ Name the types of testing tools.
§ Use testing tools such as L Square and straight edge.
Hack Saw
§ Sketch and label the part of a hack saw
§ State the purpose and techniques of handling hack saw, cutting stroke and the type of
hack saw handle.
§ State the material used for the hack saw blade, teeth per inch (t.p.i). the distance
between the tooth and tooth set of a hack saw blade.
§ Explain the procedures in replacing the blade.
§ State the cause of blade breakage.
§ State the safety measures and accidents prevention while handling hack saw.
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Files
§ Sketch and label parts of a file.
§ Define the terminology on the types of cut, the degree of coarseness and the safety edge
§ Explain the various type and shapes of file and the uses.
§ State the cutting stroke, methods of holding the file, method of filing, cross and draw
filing and its advantages.
§ State the terminology of pinning and the disadvantages of file pinning and also ways of
preventing pinning.
§ State the safety procedures to be adhered while filing.
Hammer
§ Explain the types of hammer and their uses.
§ Sketch and name the part of ball pein hammer
§ Explain the safety steps to be adhered while using a hammer.
Tap and Dies
§ Sketch and name the parts of a tap.
§ Differentiate the types of tap and understand the procedures of using three types of taps.
§ Explain the basic terminologies of screw thread, specifications of screw thread and the
V shaped thread.
§ Explain the terminology on drill size for internal threading and the importance of
internal threading process.
§ Calculate the size of drill for internal threading for a given screw.
§ Explain the reasons for the breakage of taps and prevention including threading blind
holes.
§ Sketch and name different types of dies.
§ Explain the step for external threading with a die.
3.0 MEASUREMENT
Use basic measurement tools and equipment correctly to obtain accurate reading.
§ Name the basic measurement tools such as steel rule, tape, external calipers and internal
calipers.
§ State the different types and sizes of micrometers
§ Sketch and name the part of an external micrometer.
§ State the basic principles of a micrometer.
§ Able to read and sketch the micrometer reading (metric and imperial).
§ Explain the method of using micrometers.
§ Sketch and name the part of a vernier caliper.
§ State the basic principles of a vernier caliper.
§ Explain the methods of using a vernier caliper.
§ Read and sketch the vernier caliper reading (metric and imperial)
§ State the various types of measuring equipment using the vernier principles such as
vernier protractor and vernier height gauge.
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4.0 DRILLS
Drill bit and drilling machine.
Know the type of drill bit and able to operate a drilling machine.
§ Read Sketch and name the main part and function of a twist drill
§ Explain how drill sizes are stated and determined.
§ State and material used to make drill bit.
§ Explain the step to mark before drilling
§ Explain the method of fixing a drill bit and work piece before drilling.
§ Differentiate the various types of drill bits such as center drill, straight slot drill, blind
hole drill and flat tipped drill.
§ Explain the method of grinding and sharpening twist drill.
§ Explain the effects to a drilled hole if the angle of the drill bit tip is not accurate.
§ Explain and name the part of a drilling machine.
§ Calculate the speed of the spindle in rpm, the feeding rate and the factors that influence
the selection of the cutting speed.
§ State the types of coolants, function and their uses.
§ State the steps taken to protect drill bits and drilling machine.
§ State the safety step to be taken while drilling
Method of holding work piece and drilling.
§ Explain the reason for holding the work piece tightly while drilling
§ Explain the types work piece holders commonly used in a drilling machine such as
machine vice, machinist vice, v block and others.
§ Explain the procedure taken to drill a large hole.
§ Explain the importance of drilling center and guided drilling.
§ Provide example of jigs.
§ Explain the uses of jigs in a drilling machine.
§ State the safety procedures to be followed while drilling.
5.0 LATHE MACHINE
Explain the types of lathe machine
§ Explain the functions of various parts of center lathe machine.
§ Explain and sketch to show how a work piece is held in a lathe machine.
§ State and sketch to show the various shape of tool bits and their function.
§ Explain and sketch to show the various angles of tool bit tip.
§ Explain the materials used and uses of tool bits.
§ Elaborate the operation in relation to lathe work such as boring, drilling, knurling, to
turn pointed, cut screw thread and turn off center.
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6.0 GAS WELDING
Introduction
§ Define gas welding.
§ Explain high pressure gas welding and low pressure gas welding.
§ State the uses of gas welding in industry.
Gas
§ Explain the types of gases used in gas welding.
§ Explain the characteristics, production and oxygen gas cylinder.
§ Explain the characteristics, production and acetylene gas cylinder.
§ Explain the availability of other gas fuel besides acetylene.
Oxy acetylene gas welding equipment
§ Explain the oxy-acetylene welding equipment including their operation.
§ Explain the working principle of regulators.
§ State the types of oxy-acetylene hoses.
§ State the types, working principles, uses and function of the welding torch.
§ Explain the oxy-acetylene welding tip.
§ Explain the oxy-acetylene welding manifold system and single station system
Assembling oxy-acetylene equipment.
§ Explain the steps to be followed to assemble oxy-acetylene welding equipment.
§ Explain the method for testing gas leakage at the oxy-acetylene welding equipment.
Oxy-acetylene flame
§ Recognize the types and uses of oxy-acetylene flame.
§ Explain the method of adjusting the flame.
§ Explain the characteristics and temperature of the flame.
§ Explain and demonstrate the step taken to ignite and turn off the flame.
§ State the reasons for back fire, flash back and rectification.
Oxy-acetylene welding technique.
§ Explain the oxy-acetylene welding technique
§ Explain the method and uses of forward and backward welding technique.
§ Explain and demonstrate the movement, speed, angle and distance of the flame while
welding.
Joints and edge preparation.
§ Explain the types of basic joints such as corner, fillet, lap, butt and flange.
§ Explain and demonstrate edge preparation, root gap and root face.
§ Explain the method of making edge preparation.
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7.0 ARC WELDING
Arc welding machine
§ Explain the function of the amperage adjustment control.
§ Recognize and explain the basic components of an arc welding machine.
§ Name five types of arc welding machine and explain the working principles,
advantages and disadvantages such as:
i. Direct current Arc welding machine
ii. Alternating current arc welding machine
iii. Integrated AC/DC arc welding machine.
iv. Power driven direct current petrol/ diesel arc welding generator
v. Electric motor driven direct current arc welding generator
§ Draw basic Arc welding machine circuits.
Polarity of arc welding machine
§ Define the terminology polarity. Straight polarity and reverse polarity.
§ Explain the characteristics of polarity.
§ Explain the procedures to choose the correct type of polarity.
Techniques of arc welding
§ Sketch and label the arc welding process.
§ Explain the effects of arc gap, electrode angle and the speed of travel on a welding
product.
§ Explain the method of starting the arc.
§ Explain the method of starting the arc.
Electrode
§ Explain how electrode is produced.
§ Explain different type of metal composition found in the electrode core wire.
§ Explain the function of the electrode coating.
§ Explain the type, class, colour code and number code of electrodes.
§ Explain the function of the electrode core wire.
Mokhtar Padeli 5