POLITEKNIK KOTA KINABALU, SABAH
JABATAN KEJURUTERAAN MEKANIKAL
SESI DISEMBER 2011
Syllabus: JJ104 – WORKSHOP TECHNOLOGY 1
1.0 ACCIDENT
PREVENTION
1.1 Understand
the importance of safety procedures and applications in machining, welding,
fitting and foundry work in the engineering workshop
1.1.1
State the general accident prevention procedures in relation
to personal safety, colleague, machine and equipments
1.1.2
Explain the importance of wearing goggles, grinding wheel
guards and maintaining workshop safety and cleanliness
1.1.3
Explain the environmental issues regarding accident,
legislation, protocol, laws and regulations in engineering workshop
2.1
Understand the importance of using hand tools in fitting
work
2.1.1
Define the marking out / lay out
2.1.2
State the procedures of marking out / lay out
2.1.3
Explain the use of marking tools such as scriber, centre
punch, divider, surface plate and procedures to draw a circle, lines, curve and
etc
2.2
Understand the use of testing tools
2.2.1
Define testing tools
2.2.2
Name the types of testing tools such as square, straight
edge,surface gauge and etc
2.2.3
Use testing tools such as L square and straight edge
2.3
Understand the use of hack saw
2.3.1
Sketch and label the parts of a hack saw
2.3.2
State the uses of hack saw and cutting stroke
2.3.3
State the characteristics of hack saw blade such as materials
used and pitch
2.3.4
Explain the procedure to replace hack saw blade
2.3.5
Discuss the causes of hack saw blades breakage
2.3.6
State the safety precaution and procedure to prevent
accidents
2.4
Understand the use of files and filing work
2.4.1
Sketch and label the parts of a file
2.4.2
Define the file terminology such as cuts and grades
2.4.3
Explain various types and shapes of files and its uses
2.4.4
Explain methods of filling such as cross and draw filing
technique
2.4.5
Explain pinning and ways to avoid pinning
2.4.6
State the safety procedures in filing
2.5
Understand the use of hammer
2.5.1
Explain types of hammers and its uses
2.5.2
Name parts of ball a peen hammer
2.5.3
Explain the safety procedures in using hammer
2.6 Understand the use of chisel
2.6.1
Differentiate
various types of chisels such as flat, horizontal tip, half round, edge round,
nose and diamond tip chisel
2.6.2
Differentiate
the various types of chisels: flat chisel, diamond tip point, cape chisel, edge
round, nose chisel
2.6.3
Name
the parts of a flat chisel
2.6.4
Explain
flat chisel on its material, size, cutting angle of the tip and uses to cut and
shear metal plate
2.6.5
Explain
the disadvantages of mushroom head chisel
2.6.6
Explain
method of using chisel
2.6.7
Explain safety
procedure to be follow while chiselling
2.7 Understand the use of taps and dies
2.7.1
Name
parts of a tap
2.7.2
State
types of taps and procedures of using three types of taps
2.7.3
Explain
basic terminology of tapping a blind hole and through hole screw thread
2.7.4
Explain
the terminology on tap drill size ‘v’
2.7.5
Calculate
the size tap drill size
2.7.6
Explain
the steps to do internal threading
2.7.7
Explain
the reasons for taps breakage of taps and its prevention
2.7.8
Name
different types of dies
2.7.9
Explain
steps for external threading using a die
3.0 MEASUREMENT
3.1 Explain the use of common measuring
tools and equipment
3.1.1
List
basic measuring tools such as steel ruler, tape, external and internal calipers
3.1.2
State
different types of micrometers
3.1.3
Sketch
and label the parts of an external micrometer
3.1.4
State
the in using a micrometer
3.1.5
Sketch and label the parts of a vernier
caliper
3.1.6
State
the basic principles of a vernier caliper
3.1.7
Explain
the methods of using a vernier caliper
3.1.8
Read
the vernier caliper reading (metric and imperial units)
3.1.9
State
the various types of measuring equipment using the vernier principle such as
vernier protractor and vernier height gauge
4.0
DRILLING
4.1
Understand the drilling machine and drill bit (twist drill)
4.1.1
Sketch and name parts of a drill bit (twist drill)
4.1.2
Explain how drill sizes are stated and determined
4.1.3
Explain steps of marking out before drilling
4.1.4
Explain method of holding a drill bit
4.1.5
Differentiate the various types of drill bits such as centre
drill, straight slot drill, blind hole drill and flat tipped drill
4.1.6
Explain the effects to a drilled hole if the angle of the
drill bit tip is not accurate
4.1.7
Calculate the spindle speed revolution (rpm) and the feed
rate including factors that influence
the selection of the cutting speed
4.1.8
State the types of coolants, function and advantages
4.1.9
State the safety procedures to be taken while drilling
4.2
Understand methods of holding work piece and drilling
4.2.1
Give the reason for holding the work piece securely while
drilling
4.2.2
Explain the types work holding devices commonly used in a
drilling machine such as machine vice, machinist vice, V block and others
4.2.3
Explain the procedures taken to drill a large hole
4.2.4
Explain the importance of centre drilling and guided
drilling
4.2.5
Explain the uses of jigs in a drilling machine
4.2.6
Provide examples of jigs
4.2.7
State safety procedures to be followed while drilling using
jigs
5.0
LATHE MACHINE
5.1
Understand lathe machines
5.1.1
Explain functions of various parts of centre lathe machine
5.1.2
Explain with sketch of work piece held to the lathe machine
5.1.3
State with sketch the various shapes of tool bits and their
function or usage
5.1.4
Sketch to explain the various angles of a tool bit tip
5.1.5
Explain the materials used in a tool bit
5.1.6
Elaborate the operation in relation to lathe work such as,
turning boring, facing, drilling, knurling, tread cutting and off-centre
turning
6.0
MILLING MACHINE
6.1
Understand lathe machines
6.1.1
Differentiate types of milling machines
6.1.2
Explain the characteristics and parts of universal milling
machine
6.1.3
State the basic principles of milling machines ( X,Y and Z
axis)
6.1.4
Explain two methods of up cut and down cut milling
6.1.5
List the usage of various types of milling cutter
6.1.6
Explain the uses of various types of milling cutter
6.1.7
State methods of holding cutting tools
6.1.8
State methods of holding a work piece
6.1.9
Calculate the revolution per minute (rpm), feed rate and
cutting time
6.1.10
State the safety procedures while using the milling machine
6.2
Understand indexing
6.2.1
Name parts of index head
6.2.2
Explain the operation of index head
6.2.3
State the various types of indexing
6.2.4
Calculate direct, simple and angular indexing
7.0
GRINDING MACHINE
7.1
grinding machine
7.1.1
Name types of grinding machines and their uses
7.1.2
State the different types of grinding wheels
7.1.3
Explain the following grinding wheel specifications:
7.1.3.1
types of abrasive
7.1.3.2
Size of particles
7.1.3.3
Wheel grade
7.1.3.4
Wheel structure
7.1.3.5
Bonding material
7.1.4
Explain defects and maintenance of grinding wheels
7.1.5
Explain steps to carry out assembling and balancing of
grinding wheels
7.1.6
Explain the safety procedures to be followed using a
grinding machine
8.0
OXY ACETYLENE WELDING
8.1
Understand oxy acetylene welding
8.1.1
Define oxy acetylene welding
8.1.2
Explain high pressure and low pressure oxy acetylene welding
8.1.3 State the uses of oxy acetylene welding in industrial sector
8.2
Understand Welding gases
8.2.1
Explain the types of gases used in oxy acetylene welding
8.2.2
Explain the characteristics, production and oxygen gas
cylinder
8.2.3
Explain the characteristics, production and acetylene gas
cylinder
8.2.4
Explain the availability of other gas fuel besides acetylene
8.3
Explain oxy acetylene welding equipment
8.3.1
Explain oxy acetylene welding equipment
8.3.2
Explain the working principles of regulators
8.3.3
State types of oxy acetylene hoses
8.3.4
State types, working principles, uses and function of the
welding torch
8.3.5
Explain the oxy acetylene welding tip
8.3.6
Explain the oxy acetylene welding manifold system and single
station system
8.4
Understand Brazing and Braze Welding Process
8.4.1
Define brazing and braze welding process
8.4.2
Explain the application of brazing and braze welding process
8.4.3
Explain the function of flux, filler rod and types of flames
used
8.4.4
Explain brazing and braze welding technique
8.5
Understanding oxy acetylene weld defects and its prevention
8.5.1
Explain a completed welding joint based on penetration, bead
shape and joints accuracy
8.5.2
Explain the types weld defects and its prevention
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