1. GSM: 08034843286; Email: phillip.babalola@covenantuniversity.edu.ng
COURSE CODE: MCE314
COURSE TITLE: WORKSHOP PRACTICE(2 UNITS)
COURSE COORDINATOR: DR. P.O. BABALOLA
Engr. T.O Makun, Mr. Makinde Adisa, Mr. Olaniyi Kayode, Mr. Gbolahan Odewole, Mr. Siyanbola John., Mr. J.Oladotun
GSM: ;

2. OBJECTIVES
To prepare the students for various responsibilities they will bear as engineers and technologists in the industries, corporate bodies and other institutions even as individual entrepreneurs in the practice of engineering profession.

3. OBJECTIVES CONTD.
To expose the students to all aspects of engineering workshop practice and other technical activities.
To train the students to translate the project designs into physical system and how to construct and refine prototypes.

4. WORKSHOPS IN MECHANICAL ENGINEERING
*Machine shop
*Foundry Workshop
* Welding and Fabrication Workshop
Automobile Workshop
Refrigeration and Air Conditioning

5. PROGRAM OUTLINES (MECHANICAL)
FOUNDRY SHOPS AND PROCESSES
MECHANICAL WORKING OF METALS
JOINING OF ENGINEERING MATERIALS
SHEET METAL WORKS
MACHINE SHOP

6. Specific Industries
©2010 John Wiley & Sons, Inc. M P

7. Manufacturing Industries - continued
Secondary industries include manufacturing, construction, and electric power generation
Manufacturing includes several industries e.g., apparel, beverages, chemicals, and food processing
For our purposes, manufacturing means production of hardware
Nuts and bolts, forgings, cars, airplanes, digital computers, plastic parts, and ceramic products
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e

8. Manufactured Products
Final products divide into two major classes:
Consumer goods - products purchased directly by consumers
Cars, clothes, TVs, tennis rackets
Capital goods - those purchased by companies to produce goods and/or provide services
Aircraft, computers, communication equipment, medical apparatus, trucks, machine tools, construction equipment

9. Materials in Manufacturing
Most engineering materials can be classified into one of three basic categories:
Metals
Ceramics
Polymers
Their chemistries are different, and their mechanical and physical properties are different
These differences affect the manufacturing processes that can be used to produce products from them

10. In Addition: Composites
Nonhomogeneous mixtures of the other three basic types rather than a unique category
Venn diagram of three basic material types plus composites

11. 1. Metals
Usually alloys, which are composed of two or more elements, at least one of which is metallic. Two basic groups:
Ferrous metals - based on iron, comprises about 75% of metal tonnage in the world:
Steel and cast iron
Nonferrous metals - all other metallic elements and their alloys:
Aluminum, copper, nickel, silver, tin, etc.

12. Charging a basic oxygen furnace in steelmaking: molten pig iron is poured into the BOF. Temperatures are around 1650C (3000F).

13. 2. Ceramics
Compounds containing metallic (or semi- metallic) and nonmetallic elements.
Typical nonmetallic elements are oxygen, nitrogen, and carbon
For processing, ceramics divide into:
Crystalline ceramics – includes:
Traditional ceramics, such as clay, and modern ceramics, such as alumina (Al2O3)
Glasses – mostly based on silica (SiO2)

14. 3. Polymers
Compound formed of repeating structural units called mers, whose atoms share electrons to form very large molecules. Three categories:
Thermoplastic polymers - can be subjected to multiple heating and cooling cycles without altering molecular structure
Thermosetting polymers - molecules chemically transform into a rigid structure – cannot reheat
Elastomers - shows significant elastic behavior

15. 4. Composites
Material consisting of two or more phases that are processed separately and then bonded together to achieve properties superior to its constituents
Phase - homogeneous mass of material, such as grains of identical unit cell structure in a solid metal
Usual structure consists of particles or fibers of one phase mixed in a second phase
Properties depend on components, physical shapes of components, and the way they are combined to form the final material

16. Manufacturing Processes
Two basic types:
Processing operations - transform a work material from one state of completion to a more advanced state
Operations that change the geometry, properties, or appearance of the starting material
Assembly operations - join two or more components to create a new entity

18. Processing Operations
Alters a material’s shape, physical properties, or appearance in order to add value
Three categories of processing operations:
Shaping operations - alter the geometry of the starting work material
Property‑enhancing operations - improve physical properties without changing shape
Surface processing operations - clean, treat, coat, or deposit material on surface of work

19. Shaping Processes – Four Categories
Solidification processes - starting material is a heated liquid or semifluid
Particulate processing - starting material consists of powders
Deformation processes - starting material is a ductile solid (commonly metal)
Material removal processes - starting material is a ductile or brittle solid

20. Solidification Processes
Starting material is heated sufficiently to transform it into a liquid or highly plastic state
Casting process at left and casting product at right

21. Particulate Processing
(1) Starting materials are metal or ceramic powders, which are (2) pressed and (3) sintered

22. Deformation Processes
Starting workpart is shaped by application of forces that exceed the yield strength of the material
Examples: (a) forging and (b) extrusion

23. Material Removal Processes
Excess material removed from the starting piece so what remains is the desired geometry
Examples: (a) turning, (b) drilling, and (c) milling

24. MACHINING
Metal chips fly in a high speed turning operation performed on a computer numerical control turning center (photo courtesy of Cincinnati Milacron).

25. Waste in Shaping Processes
It is desirable to minimize waste in part shaping
Material removal processes are wasteful in the unit operations, but molding and particulate processing operations waste little material
Terminology for minimum waste processes:
Net shape processes - little or no waste of the starting material and no machining is required
Near net shape processes - when minimum machining is required

26. Property‑Enhancing Processes
Processes that improve mechanical or physical properties of work material
Examples:
Heat treatment of metals and glasses
Sintering of powdered metals and ceramics
Part shape is not altered, except unintentionally
Example: unintentional warping of a heat treated part

27. Surface Processing Operations
Cleaning - chemical and mechanical processes to remove dirt, oil, and other surface contaminants
Surface treatments - mechanical working such as sand blasting, and physical processes like diffusion
Coating and thin film deposition - coating exterior surface of the workpart. Examples:
Electroplating
Physical vapor deposition
Painting

28. Photomicrograph of the cross section of multiple coatings of titanium nitride and aluminum oxide on a cemented carbide substrate (photo courtesy of Kennametal Inc.).

29. Assembly Operations
Two or more separate parts are joined to form a new entity
Types of assembly operations:
Joining processes – create a permanent joint
Welding, brazing, soldering, adhesive bonding
Mechanical assembly – fastening by mechanical methods
Threaded fasteners (screws, bolts and nuts); press fitting, expansion fits

30. WELDING OPERATION
Two welders perform arc welding on a large steel pipe section (photo courtesy of Lincoln Electric Company).

31. PROGRAM OUTLINES (MARKS)
AUTOMOBILE WORKSHOP
MACHINE SHOP
WELDING AND METAL FABRICATION
FOUNDRY WORKSHOP
SAFETY 10
WORKSHOP TECHNIQUES 20
INDIVIDUAL REPORT
GROUP PROJECT 40
INDIVIDUAL ATTENDANCE

32. TEXTBOOKS
Grover M.P, Fundamentals of Modern Manufacturing, John Wiley & Sons, Inc, 2010
Introduction to Basic Manufacturing Processes and Workshop Rajender Singh
Workshop Technology Vol. I & II. Gupta & Kaushik.
Workshop Technology Vol. I & II. B. S. Raghuvanshi.
Casting, John Campbell, Butterworth-Heinemann