Workshop Practice Lab

Report #01
Student Name ……………………………………...Hamza Tahir

Registration #.............................................................Bche-FA17-035

Department ………………………………………. Chemical Engineering

Table of contents
TOPICS CONTENTS PAGE #
1. LABLAYOUT 02
2. OBJECTIVE #O1 02
DESIGN CONCEPTS
02
DESIGN REQUIREMENTS
02
ENGINEERING DRAWING 02-07
3. OBJECTIVE #02 07
SELECTION OF MATERIALS 07-09
4. OBJECTIVE#03 09
Manufacturing 09-22
Manufacturing processes
Turning 11-14
Lathe Machine
Milling 14-17
Milling Machine
Drilling 17-19
Drilling machines
Sawing 19-21
Sawing machines
Welding 21-22
Welding machines
Lab Layout:

OBJECTIVE#01

DESIGN CONCEPTS
There’s nothing scarier than giving someone a blank piece of paper and saying, ‘Go, give me all
your ideas.’

What are design workshops?

Design workshops are an opportunity for a team to untangle a problem together by going through a series
of exercises designed to get to a specific outcome. Workshops are about getting stuff done, and are

DESIGN REQUIREMENTS

 Objectives to achieve Geometry, Size and finish

 Prepare for manufacturing Drawing + Material

ENGINEERING DRAWING as a Food Scientist and Technologist, you will inevitably be

required to communicate with different people for different reasons. In some situations,
 communications will be sufficiently taken care of by use of plain text. However, in other situations,

text alone may not suffice and a more specialized form of communication (technical/engineering

drawing) may prove irreplaceably useful. Drawing (just like photography) is one of the basic forms of

visual communication. Drawing is used to record objects and actions of everyday life in an easily

recognizable manner. There are two major types of drawings: artistic drawings and technical
drawings.

1. Presentation of Engineering (Technical) Drawings

1.Axonometric (Pictorial) Projections:
These are drawings in which the object is drawn in three dimensions (3-D), i.e. three sides of the object
appear in one drawing. Normally only one drawing is prepared/used.
Two standards are currently used for axonometric projections: diametric projection and isometric
projection.
Example:

Example:

2.Orthographic Projections
To present an object in a unique way, generally more views (and sometimes sections) are required. In
orthographic projection, the views are seen in directions that make right angles (i.e. 90o) with each
other. The number of views needed should be sufficient to represent the object completely and
conveniently, but it should be kept to the minimum. For most purposes, three views are usually
sufficient.

Naming of Views:
In orthographic projection, three views are normally drawn. The three chosen views may be any of the
six hypothetical faces of the object. These views are named as shown below.
The Front View (ABCD) – abbreviated as FV, is that view of utmost importance in representing the
object (normally the most complicated of all the views) as seen when the object is placed directly in
front of the viewer. This view generally serves to represent the object (e.g. a work piece) in the most
common position in which it is used. It is normally the first view to be drawn – other views following
thereafter.
The Rear View – RV (EFGH) is directly opposite the FV at the back of the object.
The Right-hand Side View – RHSV (BFGC) and the Left Hand Side View – LHSV (AEHD)
appear on the right and left sides of the object, respectively.
The Top (ABFE) and Bottom (DCGH) Views are at the top and bottom sides of the FV. As you
must have noted, these six views are at right angles to one another.

2. Some Basic Instruments and Equipment

Detail Drawings are prepared with the aid of special instruments and/or equipment. It would have been
extremely difficult for most people to prepare EDs according to the required standards/specifications
without the aid of such instruments. The following are the basic drafting tools worth understanding:
 T-Square
 Parallel Rule

 Set Square
 Drafting Machine
 Rule Scale
 Wooden Pencil
 Drawing table
 Mechanical Drawing Pencils
 Erasing Shield

 Dimensioning

EXAMPLE:
General Hints on Dimensioning
· NOTE that all “rules” on dimensioning are just guidelines. Use common sense depending on
circumstances (i.e. there are no strict rules/regulations on dimensioning)
· In metric system, all linear dimensions are considered to be in millimeters
· Show full size dimensions regardless of the scale used in the drawing
· Dimension in a manner that makes it unnecessary to calculate any required size information
· For any feature, place the dimensions where the feature appears most explicitly
 · Dimension any feature only once (i.e. no repetitions are allowed)
3.Tolerances and Fits
· Tolerance is simply defined as “the degree (extent) of acceptable inaccuracy”
· It describes dimensional accuracy/inaccuracy
· Tolerance is necessary under mass production
· Absolute size (nominal size) is only theoretical/hypothetical
· Tolerance specifies the acceptable upper and lower limits for a given nominal size

Modern aids: Auto CAD is still the most widely used engineering drawing software. Utilizing C++
code allows engineers and drafters to customize CAD objects, resulting in more accurate and flexible
drawings. For Mac and Linux, QCAD is the popular engineering drawing software I have listed our top
engineering design software,

 Autodesk Product Design Suite

 MATLAB.
 CATIA.
 ZW3

OBJECTIVE #02
Selection of Materials
Selection of engineering materials is an important aspect of materials engineering. 

Many materials, when in service, are subjected to forces or loads; examples include the aluminum alloy
from which an airplane wing is constructed and the steel in an automobile axle. In such situations it is
necessary to know the characteristics of the material and to design the member from which it is made
such that any resulting deformation will not be excessive and fracture will not occur.
The mechanical behavior of a material reflects the relationship between its response or deformation to an
applied load or force.

Thus the reasons for selecting the materials in the above examples can be summarized as:
 Commercial factors such as:
Cost, availability, ease of manufacture.
 Engineering properties of materials such as:
 Electrical conductivity,
 strength,
 toughness,
 ease of forming by extrusion,
 forging and casting,
 machinability and corrosion.
 resistance.

3. Classification of Engineering Materials

 There are thousands of materials available for use in engineering
applications.
 Most materials fall into one of three classes that are based on the atomic
bonding forces of a particular material.
 These three classifications are metallic, ceramic and polymeric.
Additionally, different materials can be combined to create a composite
material.
 Within each of these classifications, materials are often further organized into
groups based on their chemical composition or certain physical or mechanical
properties.
 Composite materials are often grouped by the types of materials combined
or the way the materials are arranged together.
 Materials used in the design and manufacture of products.
• Plastics
• Wood
• Composites
• Ceramics
• Metals
• Fabrics

4. Material Selection Ensures the Integrity at Design

The integrity of a design can be ensured only after a systematic material selection procedure.
Otherwise, the result it is highly susceptible for failures. In the selection process, materials will be
assessed for tensile strength and modulus, flexural strength and modulus, impact strength,
compressive strength, fatigue endurance, creep, and stress-relaxation properties depending on the
 application. This will ensure that the design will have a better probability of succeeding. It will also
assure that the design is technically fit to obtain desired properties.

OBJECTIVE#03
Manufacturing
Manufacturing is the backbone of any industrialized nation. Manufacturing and technical staff in industry
must know the various manufacturing processes, materials being processed, tools and equipment’s for
manufacturing different components or products with optimal process plan using proper precautions and
specified safety rules to avoid accidents. Beside above, all kinds of the future engineers must know the
basic requirements of workshop activities in term of man, machine, material, methods, money and other
infrastructure facilities needed to be positioned properly for optimal shop layouts or plant layout and other
support services effectively adjusted or located in the industry or plant within a well-planned
manufacturing organization.

It also describes and demonstrates the use of different hand tools (measuring, marking, holding and
supporting tools, cutting etc.), equipment, machinery and various methods of manufacturing that facilitate
shaping or forming the different existing raw materials into suitable usable forms. It deals with the study
of industrial environment which involves the practical knowledge in the area of ferrous and nonferrous
materials, their properties and uses.

It should provide the knowledge of basic workshop processes namely

 bench work and fitting, sheet metal, carpentry, pattern making, mold making, foundry, smithy,
forging, metal working and heat treatment, welding, fastening, machine shop, surface finishing and
coatings, assembling inspection and quality control.
 It emphasizes on basic knowledge regarding composition, properties and uses of different raw
materials, various production processes, replacement of or improvement over a large number of old
processes, new and compact designs, better accuracy in dimensions, quicker methods of production,
better surface finishes, more alternatives to the existing materials and tooling systems, automatic and
numerical control systems, higher mechanization and greater output.
5. MANUFACTURING PROCESSES
a. Molding in Manufacturing If the products you’re creating start out as liquid, chances are the
manufacturer uses molding. One popular type of molding is casting, which involves heating plastic
 until it becomes liquid, then pouring it into a mold. Once the plastic cools, the mold is removed,
giving you the desired shape. You can also use casting to make plastic sheeting, which has a wide
variety of applications.

There are four other types of molding:

 injection molding, which melts plastic to create 3-D materials such as butter tubs and toys
 blow molding, used to make piping and milk bottles;
 compression molding, used for large-scale products like car tires; and
 rotational molding, used for furniture and shipping drums.

Casting processes
Sand Casting

Description: Tempered sand is packed into wood or metal pattern halves, removed form the pattern, and
assembled with or without cores,and metal is poured into resultant cavities. Various core materials can be

used. Molds are broken to remove castings. Specialized binders now in use can improve tolerances and
surface finish.

Metals: Most castable metals

Investment Casting The investment-casting process, also called the lost-wax process, was
first used during the period 4000-3500 B.C. The pattern is made of wax or a plastic such as
polystyrene. The sequences involved in investment casting are shown in Figure 11.18. The pattern is
made by injecting molten wax or plastic into metal die in the shape of the object.
 Die Casting
Description: Molten metal is injected, under pressure, into hardened steel dies, often water cooled.
Dies are opened, and castings are ejected.
Metals: Aluminum, Zinc, Magnesium, and limited Brass.

b. Machining in Manufacturing

It would be difficult to make products like metal parts without the use of some type of machine.
Manufacturers use tools like saws, sheers and rotating wheels to achieve the desired result. There are also
tools that use heat to shape items. Laser machines can cut a piece of metal using a high-energy light
beam, and plasma torches can turn gas into plasma using electricity. Erosion machines apply a similar
principle using water or electricity, and computer numerical control machines introduce computer
programming into the manufacturing mix.

 Machining Processes

1. Turning

Turning is a form of machining, a material removal process, which is used to create rotational parts by
cutting away unwanted material. The turning process requires turning machine or lathe, work piece,
fixture, and cutting tool. Step turning is an operation performed on lathe machine where the excess
material is removed from the work piece to obtain various steps of different diameters.

 Lathe Machine

A lathe is a tool that rotates the work piece on its axis to perform various operations such as cutting,
sanding, knurling, drilling, or deformation, facing, turning, with tools that are applied to the work piece to
create an object with symmetry about an axis of rotation.
Parts of Lathe Machine:

The lathe consists following parts.

1. Bed It is the main body of the machine. All main components are bolted on it. It is usually made by
cast iron due to its high compressive strength and high lubrication quality. It is made by casting
process and bolted on floor space.

2. Tool post It is bolted on the carriage. It is used to hold the tool at correct position. Tool holder
mounted on it.

3. Chuck is used to hold the workspace. It is bolted on the spindle which rotates the chuck and work
piece. It is four jaw and three jaw according to the requirement of machine.

4. Head stock Head stock is the main body parts which are placed at left side of bed. It is serve as
holding device for the gear chain, spindle, driving pulley etc. It is also made by cast iron.

5. Tail stock Tail stock situated on bed. It is placed at right hand side of the bed. The main function of tail
stock to support the job when required. It is also used to perform drilling operation.

6. Lead screw Lead screw is situated at the bottom side of bed which is used to move the carriage
automatically during thread cutting.

7. Legs are used to carry all the loads of the machine. They are bolted on the floor which prevents
vibration.
 8. Carriage It is situated between the head stock and tail stock. It is used to hold and move the tool post
on the bed vertically and horizontally. It slides on the guide ways. Carriage is made by cast iron.

9. Apron It is situated on the carriage. It consists all controlling and moving mechanism of carriage.

10. Chips pan Chips pan is placed lower side of bed. The main function of it to carries all chips removed
by the work piece.

11. Guide ways Guide ways take care of movement of tail stock and carriage on bed.

12. Speed controller Speed controller switch is situated on head stock which controls the speed of
spindle.

13. Spindle It is the main part of lathe which holds and rotates the chuck.

Lathe Machine Operation & Working:

Lathe Machine Operation

1. A cylindrical work piece fixed to the chuck. A chuck may have three jaw or for jaw according to the
requirement. The work piece is at the center or some eccentric according to the process perform.

2. The spindle starts to rotate and set it at desire speed. The spindle speed plays a huge role during cutting.
The spindle rotates the chuck and work piece.

3. Now check the work piece is turning properly. If it not set the work piece using dial gauge.

4. Now set the tool at desire feed by moving the tool post and carriage. The feed also play main role
during cutting. Large feed may cause unwanted temperature increase.
5. After it tool is introduce between moving work piece at desire feed rate. It cut the metal from work
piece. The feed rate is set at the cutting condition.

6. Now all unwanted metal is removed by moving the carriage form horizontally and vertically as desire
according to the job requirement. After complete all process we got a well finished job.

7. Lathe can perform turning, boring, chamfering, shaping, facing, drilling knurling, grooving as shown in
figure.

What is a CNC Machine?

CNC: (Computer+ Numerical Control)

•Numerical control is a programmable automation in which process is controlled by Numbers, Letters,

and symbols.

•CNC Machining is a process used in the manufacturing sector that involves the use of computers to
control machine tools like lathes, mills and grinders.

2.Milling

Milling and Milling Operations. Milling is the process of machining flat, curved, or irregular surfaces by
feeding the work piece against a rotating cutter containing a number of cutting edges.

 Milling Machine: Milling is a mechanical machine which is used to machined unsymmetrical job.
It is widely used in tool and die making industries. It is a versatile machine. It can perform all
operations like turning, facing, drilling, shaping, grooving, etc.
 Milling Machine Parts: There are mostly two types of milling machine used
in mechanical industries. First one is horizontal milling machine and other one is vertical milling
machine. The basic parts of these machine described as follow.

 Base: It is the foundation part of a milling machine. All other parts are jointed on it. It carries the
entire load so it should have high compressive strength so it is made by cast iron. It also works as
reservoir of cutting fluid.
 Column: Column is another foundation part of milling machine. It is mountain vertically on the
base. It supports the knee, table etc.  Work as housing for the all the other driving member.it is a
hollow member which contains driving gears and sometimes motor for spindle and the table.
 Knee: Knee is the first moving part of milling machine. If is mounted on the column and moves
along the sideways situated over the column. It is made by cast iron and moves vertically on
slideways It moves up and down on sideways which change the distance between tool and
workpiece It is driven by mechanically or hydraulically.
 Saddle: It is placed between table and the knee and work as intermediate part between them. It can
move transversally to the column face. It slides over the guide ways provided situated on the knee
 which is perpendicular to the column face. The main function of it is to provide motion in horizontal
direction to work piece. It is also made by cast iron.
 Table: Table is situated over the knee. It is the part of machine which holds the work piece while
machining.  It is made by cast iron and have T slot cut over it. The work piece clamp over it by using
clamping bolts. The one end of clamping bolt fix into this slot and other is fix to work piece which
hold the work piece. It can provide three degree of freedom to work piece.
 It provides vertical motion by moving the knee up and down.
 It provides horizontal motion by the feed screw.
 It provides horizontal (transverse) motion by moving the saddle.
 Overhanging arm: It is situated over the column on horizontal milling machine. It is overhang
over the column surface and other end supports the arbor. It is made by cast iron.
 Spindle: Spindle is the main part of the machine which hold tool at right place in vertical milling
machine and hold arbor in horizontal milling machine. It is a moving part which is in rotary motion. It
is motor driven and drives the tool. It has a slot on the front end of it. The cutting tool fix in that slot.
 Arbor: It is a mechanical part on which is used as extension part of the spindle in horizontal milling
machine. It is fitted on the spindle whenever required. It holds the tool and moves it in correct
direction.

 Arbor Supports: This are used to support arbor at right place. One end of this support is jointed at
the overhanging arm and another is jointed with arbor.
 Milling head: It is upper section of vertical milling machine. It consist spindle, driving motor and
other controlling mechanism.
 Ram: Ram is work as overhanging arm in vertical milling machine. One end of the arm is attached
to the column and other end to the milling head.
 Working of Milling Machine:

A milling is a versatile machine which is used to form different shapes by metal cutting. The working of
milling machine is as follow.

1. First the cutting tool is set at the arbor which is connected to the spindle.

2. The knee is moved downward.

3. Now the work piece is clamped on the table by using clamping screw.
4. All the controlling points are set to zero like knee position, saddle position etc.

5. Now the spindle starts to rotate which further rotates the cutting tool.

6. As the tool is moving, we move the work piece as required by moving the knee, saddle and table.

7. The controlling axis move the work piece and cut the desire shape on it. The tool remains stationary
and only in rotary motion.

 Tools used in Milling Machine:

 CNC MILLING MACHINE:

CNC milling is a specific form of computer numerical controlled (CNC) machining. Milling itself is
a machining process similar to both drilling and cutting, and able to achieve many of the operations
performed by cutting and drilling machines. Like drilling, milling uses a rotating cylindrical cutting
tool.

3.Drilling

Drilling is a cutting process that uses a drill bit to cut a hole of circular cross-section in solid materials.
The drill bit is usually a rotary cutting tool, often multi-point.
Basic purposes of use of drilling machines : Drilling machines are generally or mainly used to
originate through or blind straight cylindrical holes in solid rigid bodies and/or enlarge (coaxially)
existing (premachined) holes:

 of different diameter ranging from about 1 mm to 40 mm

 of varying length depending upon the requirement and the diameter of the drill
 in different materials excepting very hard or very soft materials like rubber, polythene etc.

Different types of Drilling Machines:

Pillar Drilling machine Table top sensitive drilling machine

Radial drilling machine Column drilling machine

4.Shaping / Planning.
The main difference between these two processes is that inshaping the tool reciprocates across the
stationary workpiece. Planing motion is the opposite of shaping. Both planing and shaping are rapidly
being replaced by milling. The mechanism used for this process is known as a planer

 Simple shaper machine:

5.Sawing

The machining process primarily used to part material such as rough-cutting excess material away before
machining or cutting curved patterns in sheet metal. Sawing machines substitute mechanical or hydraulic
powered motion for arm motion to achieve the speed necessary for production operations. The cutoff
operation is usually one of the first requirements in any production process before any machining,
welding, or forging is done.

The saw blade has individual teeth that "track" through the workpiece, each tooth deepening the cut made
by the preceding tooth in the direction of feed. The saw or work may be fed and by controlling the
direction of feed, either straight or curved cuts can be made. 

 Sawing Machines:

Band saw hack saw

6.Grinding A grinding machine, often shortened to grinder, is any of various power tools
or machine tools used for grinding, which is a type of machining using an abrasive wheel as the cutting
tool. Each grain of abrasive on the wheel's surface cuts a small chip from the workpiece via shear
deformation.

 Grinding machines

Wheel Grinder Centerless Grinder

7.Welding Welding is a fabrication or sculptural process that joins materials, usually metals or
thermoplastics, by using high heat to melt the parts together and allowing them to cool causing
fusion.

MIG (Metal Inert Gas) Welding or GMAW (Gas Metal Arc Welding):

The concept of combining two pieces of metal together with a wire that is connected to an electrode
current, is referred to as Metal Inert Gas (MIG) welding. In this type of welding process, a shielded gas is
used along the wire electrode, which heats up the two metals to be joined. A constant voltage and direct
current power source is required for this method, and this is the most common industrial welding process.
The MIG or GMAW process is suitable for fusing mild steel, stainless-steel as well as aluminium.

Arc Welding or SMAW (Shielded Metal Arc Welding):

Arc welding is also called as Shielded Metal Arc welding, or simply referred to as ‘Stick’. This is the
most basic of all welding types. The welding stick uses electric current to form an electric arc between the
stick and the metals to be joined. To weld iron and steel, this type of welding is often used in
the construction of steel structures and in industrial fabrication. Stick welding can be used for
manufacturing, construction and repair work.
TIG (Tungsten Inert Gas) or GTAW (Gas Tungsten Arc Welding):

A non-consumable tungsten electrode is used in this type of welding process. This tungsten electrode is
made use of to heat the base metal and create a molten weld puddle. By melting two pieces of metal
together, an autogenous weld can be created. For this type of welding, the welder needs to have a lot of
expertise as it’s a very complex process. This welding process is employed to carry out high-quality work
when a superior standard finish is required, without making use of excessive clean up by sanding or
grinding.

FCAW (Flux-Cored Arc Welding):

As an alternative to shield welding, Flux-cored Arc Welding was developed. This welding process is
quite similar to MIG or GMAW process, except for the fact that in FCAW a special tubular wire filled
with flux is used and shielding gas is not always needed, depending on the filler. This type of welding is
well-known for being extremely inexpensive and easy to learn. However, there are several limitations in
its applications and the results are not often aesthetically pleasing as some of the other welding methods.
The semi-automatic arc is often used in construction projects, thanks to its high welding speed and
portability.

C. joining in Manufacturing

You can only get so far with molds and machines. At some point you need to be able to put multiple parts
together to make one piece. Otherwise, just about all you can create is IKEA-like furniture that needs to
be assembled, part by part. Joining uses processes like welding and soldering to apply heat to combine
materials. Pieces can also be joined using adhesive bonding or fasteners.

D.Shearing and Forming in Manufacturing

 When dealing with sheet metal, shearing comes into play. Shearing uses cutting blades to make straight
cuts into a piece of metal. Also known as die cutting, you’ll often see shearing used on aluminum, brass,
bronze and stainless steel. Another metal-shaping process is forming, which uses compression or another
type of stress to move materials into a desired shape. Although forming is often used with metal, it also
can be used on other materials, including plastic.

 Sheet Metal Forming
 Sheet metal forming processes are those in which force is applied to a piece of sheet metal to modify its
geometry rather than remove any material. ...
 Bending is a metal forming process in which a force is applied to a piece of sheet metal, causing it to
bend at an angle and form the desired shape.