WORKSHOP TECHNOLOGY AND PRACTICES

Course Learning Outcome:

At the end of the course, students will be able to:

1. Provide understanding on basic engineering workshop practices.

2. Provide understanding on basic process and exposure on tools and
equipment used in engineering workshop.
3. Develop basic skill in handling tools and equipment and in carried
out fabrication and machining processes.
4. Provide understanding on basic engineering workshop safety
practices.
5. Provide understand the industry safety and regulation.
Stuck in Between
Slip Hands Crushed
 Workshop Technology
Workplace:
The workplace is the physical location where someone works.

Natural Environment:
All living and non-living things.

Hazard:
Something that can cause harm or injury to personnel, damage to
equipment or reduction of ability to perform a prescribe function.

Accident:
An accident is an incidental and unplanned event that could have been
prevented had circumstances leading up to the accident been
recognized.

Risk:
Is the chance of a injury, loss, or damage measured in terms of
Probability and Severity.
Safety Regulations

Must be known by everybody working in a workshop.

Particular safety instructions will be given during further

training (chiseling , grinding, drilling, etc). Nevertheless,
common workshop safety regulations must be known by
everybody.

Harmful or dangerous processes, contents or areas are

marked by signs(written information or symbols)

5

2 types of signs:-

i. Mandatory signs
- Prohibition
- Safety demand

ii. Warning Signs

Form and color additionally classify signs and this information is adopted in
accordance with international conventions.

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i. Mandatory signs

Round shape.

Prohibition is intended  symbol diagonally crossed.

Prohibitory symbols are black on a white

background with a red margin and diagonal.

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Mandatory signs - prohibition
Black on a white background with a red margin and diagonal

8
Mandatory signs – Safety demand

Symbols are white on a blue back ground.

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ii. Symbolic Warning signs

Triangular shape.

Colors are black for the symbol and yellow for the
background.

Sign with an exclamation mark is often provided as a

portable sign and used for early warning of temporary
hazards.

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Symbolic Warning signs

11
WORKSHOP SAFETY

Engineering workshop and hangars (processes carried out, and presence

of moving machinery)
accident risk is high and consequently, the 'Safety First’ rules
to be observed are many.

i. CLOTHING
Loose clothing, long sleeves, flowing neckties and finger rings
are a source of danger.

Many fatal accidents have been caused by loose clothing being

caught by machinery, particularly such things as revolving shafts,
pulleys and spindles or traveling belts.

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ii. FOOTWEAR

Light footwear is unsafe in the workshop.

Thick soles will prevent injury through stepping on metal

scraps or protruding nails.

A strong toe-cap and sturdy upper may save an injury,

should some object fall on your foot.

iii. OVERALLS

Overalls of DUSTCOAT type are not RECOMMENDED.

The flowing skirt of the coat is too frequently caught in

handles and projection and hampers general freedom of
movement.

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WHEN MOVING AROUND WORKSHOPS

 Don’t knock against other workers as you are passing or

'skylark‘ in any other way when moving amongst running
machines.

 Don’t indulge in practical jokes

 Don’t stand or walk under over-head loads, whether

traveling or suspended. Lifting tackle, although inspected
and tested periodically, may fail, even at the most
unexpected moments.

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  Keep away from under staging on which men are working.

 Don’t use any machine without all guards in place.

 Don’t stand on stairways or platforms without handrails.

 Don’t leave it to the other fellow to shift something lying in a position on the
floor or other place where it is an obvious source of danger.

 Don’t let things fall when working in high places

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 WORKSHOP SAFETY
SEVEN (7) general safety precautions when working in the workshop.

 Workshop can be a dangerous place if few safety precautions are

not observed.
 Maintenance personnel should only operate equipment with
which they are familiar and can operate safely.
 Maintenance personnel should know the location of the first-
aid and emergency equipment.
 Good housekeeping in workshops is essential to safe efficient
maintenance.
 No defective electrical equipment should be used. Any faulty
electrical equipment must be reported to the supervisor-in-
charge immediately.
 WORKSHOP SAFETY
• Never direct compressed air to yourself or any other person as it
can drive dust particles and dirt into the skin.

• Do not operate a machine unless you are authorized to do so.

• Ground-support personnel in the vicinity need to wear proper eye

and ear protection.

• The person that is performing maintenance operations should be

thoroughly familiar with the procedures that apply to the type
of machine and equipments.
Safety Precaution When Working With
Electricity
– All electrical connections must be secured; loose
wires or connections may arc and lead to
overheating which can result in a fire.
– A fuse is your safeguard if a fault develops. Therefore
the one fitted must be of the correct rating.
– Never use make shift fuses such as pieces of wire.
– Any external metal parts must be correctly earthed
so that, if any fault develops, the fuse will
blow and interrupt the electrical supply.
– Never run power tools from lamp sockets.
Connection between the plug and the
equipment is to be made with the correct 3-
core flexible cable suited to the current rating of
the equipment.
– Never use braid covered cable for portable
equipment. It can fray which leads to a
fault and causes shock or fire.
– Old and threadbare cable should never be used.
Let a qualified electrician replace it
immediately.
– Do not under any circumstances interfere with
any electrical equipment or attempt to repair
it yourself.
– Equipment should always be disconnected from
the mains before making any adjustment,
even changing a bulb.
– It is essential that correctly wired plugs are used
for all portable equipment.
– Never improvise by jamming wires in sockets
with nails or matches.
– Molded rubber plugs should be preferred, rather
than the brittle plastic types, since they are
less liable to mechanical damage.
Safety Precaution When Working With Oil And Grease

• Some synthetic oils used in turbine engines contain tricresyl phosphate

or other additives which are highly toxic and should not be allowed
to come into contact with the skin. It is recommended that suitable
gloves should be worn by personnel continuously handling these
oils.
• Oil, grease and other substances spilled on hangar or workshop
floors should be immediately cleaned or covered with an
absorbent material to prevent fire or personal injury.
• Drip pans should be placed beneath engines and engine parts wherever
dripping exists.
• Waste oil and dirty cleaning fluid should be stored in containers for
future salvage.
• Under no circumstances should oil or cleaning fluid be emptied into
floor drains. Fumes from this type “disposal” may be ignited and
cause severe property damage
Safety Precautions (Fire Protection)

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Fire Protection
Fire  chemical reaction called combustion (usually oxidation resulting in
release of heat and light).

To initiate and maintain this chemical reaction, or in other words, for an

outbreak of fire to occur, the following are essential: -

1. Fuel - A combustible substance either solid, liquid or gas

2. Oxygen - Usually air, which contains approximately 21% oxygen

3. Heat - Sufficient in volume and intensity to raise the temperature of fuel to its
ignition

TAV0063 Presentation V1.0 dated 02.01.15 23

24 TAV0063 Presentation V1.0 dated 02.01.15
 All standing fire orders of the base must be fully observed at all times. The following
additional rules and considerations apply :-

 Smoking and use of fire are prohibited on aprons, in aircraft hangars, in aircraft repair
shops marked by relevant warning signs, as well as within a safety distance of 15 m
around parked aircraft and refueling installations.

 Open fire is only allowed in rooms specially equipped according to the fire protection
regulations and released for that purpose by the airport authorities.

25 TAV0063 Presentation V1.0 dated 02.01.15

 Vehicles and ground equipment with internal-combustion engines operated on the
apron, in hangars and aircraft repair shops must have commercial safety provisions,
e.g. exhaust installations comprising silencers, in order to prevent the exit of burning
gases.

 Material, equipment and waste has to be kept in such a way and location that fire
and explosion hazard is excluded.

26 TAV0063 Presentation V1.0 dated 02.01.15

  Lubricating oils used in or near aircraft hangars and repair shops have to be
stored in tanks equipped with the prescribed discharge device.

 Empty fuel high--pressure storage containers for dangerous materials are not
to be kept in hangars and repair shops.

 Inflammable waste (lubricating oil remainders, used cleaning material, etc.) has
to be collected and stored in specially marked metal containers equipped with
tight--closing covers.

27 TAV0063 Presentation V1.0 dated 02.01.15

 The containers have to be emptied as often as necessary to avoid spontaneous
ignitions of the waste. Waste oil trays and similar containers have to be emptied and
cleaned after use.

 The storage of dangerous material, especially radio-active materials, is only allowed

on special permission and under the condition that the relevant safety precautions
are observed.

28 TAV0063 Presentation V1.0 dated 02.01.15

 The storage of freight, packing cases, building material, devices, etc., outside the
specially assigned places is only allowed on special permission.

 Contamination of airport installations shall be avoided. Waste oil containers shall be used
as far as necessary. Contamination has to be removed immediately by those having
produced it.

29 TAV0063 Presentation V1.0 dated 02.01.15

 Only normal waste water may be drained into the sewer system.

 If there is any doubt that the water may be contaminated, either by radioactive material
or by fuel, oil, etc., it must be stored in special containers and treated correspondingly.

 The official national safety regulations have to be observed.

30 TAV0063 Presentation V1.0 dated 02.01.15

Classification of Fires

Fires are generally classified as Class ’A’, ’B’ , ’C’ and ‘D’

1. Class ’A’

 Burning of combustible materials such as wood, paper and cloth.

 Extinguished by cooling with water.

31 TAV0063 Presentation V1.0 dated 02.01.15

2. Class ’B’

 Fires from flammable liquids such as paraffin, petrol, paint, varnishes, oil
and from greases and fats.

 Extinguished by smothering with foam or other agents which exclude (’cut

off’) the air’s oxygen.

32 TAV0063 Presentation V1.0 dated 02.01.15

3. Class ’C’

 Fires from electrical equipment and wiring.

 Extinguish these fires is to displace the oxygen by applying a gas or dry

powder into the vicinity of the fire after having switched OFF the current.

33 TAV0063 Presentation V1.0 dated 02.01.15

4. Class ‘D’

 High intensity that may occur in certain metals such as magnesium, sodium,
potassium, titanium, and zirconium.

 Greatest hazard exist when these metals are in a molten state or in finely
divided forms of dust, chips, turnings, or shavings.

 Application of dry powder which prevents oxidation and the resulting flame.

34 TAV0063 Presentation V1.0 dated 02.01.15

Types of Extinguishers

1. Water/Gas

 Operated by striking a plunger to

release a gas which pressurizes the
water and forces it out of the
nozzle.

 Only suitable for class ’A’ fires.

 Jet should be directed onto the

base of the fire and kept moving
across the area of the fire.

35 TAV0063 Presentation V1.0 dated 02.01.15

2. Chemical Foam
 Operated by inverting the extinguisher or by
releasing a plunger, allowing 2 liquids to mix
and produce foam.

 Used on class ’B’ fires.

 Jet directed in a gentle sweeping movement,

allowing the foam to drop down and lie on the
surface of the liquid.

 This smothers the fire by excluding the oxygen.

 Never aim the jet directly into the flammable liquid

as this will force the foam under the surface and
render it ineffective.

36 TAV0063 Presentation V1.0 dated 02.01.15

3. Carbon Dioxide

 Operated by pressing the CO2

discharge lever which allows the
liquid CO2 to be discharged as a gas.

 Used on class ’C’ fires.

 After the current has been switched

OFF the discharge nozzle is directed
straight at the fire.

37 TAV0063 Presentation V1.0 dated 02.01.15

4. Dry Powder

 This type contains a pressurized

gas and a dry chemical agent.

 After the operation lever has

been activated, discharge is
controlled by a nozzle at the
end of a hose.

 These extinguishers are used on

bigger class ’C’ fires in the same
manner as the CO2 types.

38 TAV0063 Presentation V1.0 dated 02.01.15

Methods of extinguishing fires

Basically, there are three ways of putting out fires:

a. Cooling the burning material to below its burning temperature

b. Starving of fuel

c. Smothering the oxygen supply

39 TAV0063 Presentation V1.0 dated 02.01.15

 5 Measuring Tools

1.Steel rule

2. Vernier calliper

3. Micrometers

4. Divider

5. Calliper
Measuring Rules
Steel rule is also called the machinist rule, is made in many thickness, width and
lengths. The most commonly used steel rule is 6 inches.

The edges of steel rules are divided by fine lines into different parts of an inch
such as 8 ths.,32 ths., and 64 ths. of an inch.

The smallest division is 1/64" the next larger is 1/32" the next is 1/16" then 1/8",
1/4" and 1/2“

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42
Precision Measuring Instruments

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 RATCHET SCREW
Types of micrometers: - RATCHET THIMBLE
RATCHET SPRING
RATCHET PLUNGGER
1. Outside micrometer CAP WITH RATCHET
CAP ONLY
THIMBLE
COMPRESSION NUT
SCREW NUT

HUB
LOCK NUT
CLAMP RING

CLAMP RING ROLLER

SPINDLE
ANVIL

FRAME

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Principle of the Micrometer

Micrometer uses the principle of the screw to control the movement of

the spindle. The screw has 40 threads to the inch. Forty turns of the
spindle moves it 1 inch.

One complete turn of the spindle moves it 1/40th. of an inch, i.e. 0.025”

Four complete turns of the spindle moves it 4/40th. of an inch i.e. 0.100”
or 100 thousandth of an inch. Each fourth graduation is numbered 1,2,3
etc. meaning 0.1” 0.2” 0.3” etc. These are known as barrel scale. The
bevel edge of the thimble is divided into 25 equal parts and each fifth
part being numbered. This known as the thimble scale or sleeve scale.
Each graduation on the thimble scale is 0.001” or one thousandth of an
inch.

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 0.600”
0.050”
+0.023”
0”-1” mic -----------
0.673”

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Vernier Scale Micrometer

Some micrometer have a vernier scale. It can be read to ten – thousandth of

an inch. (0.0001”). The vernier scale consists of ten equal divisions whose
total length equal to nine – tenths of a thimble division, a difference of 0.0001
inch. To find the fourth decimal placing, find the line on the vernier that
coincides with a line on the thimble.

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 VERNIER SCALE

0.000”
0.300”
0.000”
0.010”
+0.0003”
-----------
0.3103”

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Vernier Scale Micrometer Reading
The reading on a 0 -1 inch vernier scale micrometer is as shown: -

1. To read the vernier scale micrometer, your first read the barrel and
thimble as with a standard micrometer.

2. The 3rd graduation on the vernier scale coincides with the 17th
division on the thimble. Add 0.0003” to your previous reading.

3. Therefore the reading of the measurement shown on the vernier

scale micrometer is 0.3103 inch.

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Vernier Calipers
A vernier calliper can make both external, internal and depth
measurements. The vernier calliper consists of a fixed scale and a vernier
scale.

The largest number represents inches. The smaller number is tenths of

an inch. Each tenth is divided into four parts, or 0.025" per graduation.

The vernier scale has 25 divisions and thus will divide each graduation
on the main scale in 0.001".

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 Internal Measurement
Locking Screw
Cursor
The adjustment Clipper

Moving
Main Scale
Jaw Vernier
Fixed Jaw
Scale
Fine Adjustment Screw

External Measurement

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Types of verniers: -

1. Vernier Calliper

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 CALIPER

DIVIDER
 MARKING TOOLS

FIVE (5) marking tools available in the workshop.

•Scriber

•Pencil

•Centre punch

•Divider

•Caliper
Centre punch scriber
Turning Machine (Lathes machine)
What is turning?
Turning is the machining operation that produces cylindrical
parts. In its basic form, it can be defined as the machining of
an external surface:
with the work piece rotating, with a single-point cutting tool,
and
with the cutting tool feeding parallel to the axis of the work
piece and at a distance that will remove the outer surface of
the work.
Lathe Machine

Is the basic turning machine. Apart from turning, several

other operations can also be performed on a lathe.

Boring. Boring always involves the enlarging of an existing

hole, which may have been made by a drill or may be the
result of a core in a casting.

Facing. Facing is the producing of a flat surface as the result

of a tool's being fed across the end of the rotating
workpiece.

Parting. Parting is the operation by which one section of a

workpiece is severed from the remainder by means of a
cutoff tool.
Milling Machine
 Milling Machine
Function:
A mill machinist operates equipment such as milling machines,
end mills, revolving lathe tools, and drill presses, to produce
manufacturing parts out of metal, aluminum, steel, or plastic,
often for the aerospace industry.

Mill machinists use measuring tools such as gauges, calipers,

indicators, and micrometers to perform tool changes and radius
offsets.

In addition to setting up, loading, and programming equipment,

they’re responsible for its smooth operation.
STAND DRILLING MACHINE
 DRILL MOTION
Identify the types of motion of the stand drilling
machine (bench-mounted) and explained each type of
motion.

1. Main motion is rotary motion

 This motion produces cutting force at the drill point.

2. Secondary motion is feeding motion

 This motion produces feeding force and enables tool
to penetrate into material.
 Stand Drilling Machine Procedures and Sequence

Sequence For a Stand Drilling Machine.

Select the correct speed and adjust it on the control panel.

Select the correct drill and install it in the chuck, start with the smallest
twist drill.

Clamp the work on the pillar drill table.

Wear safety glasses, goggles or face shield.

Start
Start pillar drill motor.

Press down drill using the feed lever. Use the recommended feed range.

Curling chips (swarf) are formed and to be removed.

Material will have been cut away by the drill and a hole produced.

Oil is to be used as the cooling method.

Stop motor and remove drill and work piece.

Check workpiece for correct drilling and repeat the drilling process by
using drill bit in steps until the desired drill hole size.
Hand Tools
Laying out is the transferring of information from a working drawing to
metal surfaces to show the worker the amount of metal to be cut away.

Surface Plate
Accurately machined to give a true flat surface.
Made of closed grain cast iron and are strongly ribbed on the underside
for rigidity.

66
 HAND TOOL
Hammers
Hammers are classified according to their weight and shape.
Hammers used by maintenance personnel are:

a. Ball Pein
- The ball pein is a semi-sphere and is a general use hammer, the
face being used for chipping and any general driving use. The ball
is mainly used for riveting, spreading the metal evenly in all
directions.

BALL PEIN

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Bench Vice

Classified by the width of the jaws, which are made of hardened

steel. Thus, a 3 inches vice is one whose jaws measure 3 inches in
width.

Handle of the vice acts as a lever, thus, the screw and lever help to
make a powerful clamp.

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69
 CUTTING TOOLS
1. Hacksaw

Construction consists of: -

a. Frame
b. Handle
c. Prongs
d. Tightening screw and wing nut
e. Hacksaw Blade
FRAME
HANDLE

BLADE SCREW

70
2. Chisels
Types and uses of Cold Chisels: -

a. Flat Chisel
- The flat chisel has a wide cutting edge. It is used for chipping flat
surfaces, cutting off sheet metal, cutting bars and rivets.

71
 3. Reamers Cutting Tools

4.Scraper

5. Tap

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6. Files
A hardened piece of high-grade steel with slanting rows of teeth. The length
of file is the distance from the point to the heel.

The common sizes of files are 6", 8”, 10" and 12" lengths.

73
 Type of cuts of files: -

a. Single Cut
- This pattern of teeth is used on softer metals such as copper and
aluminium alloys.

b. Double Cut
- This pattern in which two single sets of teeth cross each other.
Double cut files are normally used to cut iron and steel.

74
 c. Dreadnought
- A curved pattern of teeth, which is ideal for heavy cutting on board,
soft metal surface.

d. Rasp-Cut
- A cut used on very soft materials such as wood and plastic.

75
Grades of files:
a. Bastard
- This is a coarse fast-cutting grade for rough preliminary filing.

b. Second Cut
- This is an intermediary grade, which gives a better finish than a bastard
file.

c. Smooth
- This is a slow cutter, which produces a very good finish.

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 CUTTING TOOL
7 Drill

Description of parts of a twist drill: -

a. Tang
- Only applicable to taper shank drills
and engages with the drill socket for
location purposes.

b. Shank
- The plain part of the twist drill and
can be parallel or tapered and is the
part that fits into the drilling machine.

77
c. Body
- The fluted part of the twist drill.

d. Land
- The leading edge of the body.
Provides clearance for the
remainder of the body thus
reducing friction and prevent the
twist drill bending in the hole.

f. Flutes
- The spiral grooves twisted in the
body of the drill to give the swarf
passage from the cutting edge of
the drill, and to allow the cooling
lubricant down to the tip.

TAV0063 Presentation V1.0

78
dated 02.01.15
c. Body
- The fluted part of the twist drill.

d. Land
- The leading edge of the body.
Provides clearance for the
remainder of the body thus
reducing friction and prevent the
twist drill bending in the hole.

f. Flutes
- The spiral grooves twisted in the
body of the drill to give the swarf
passage from the cutting edge of
the drill, and to allow the cooling
lubricant down to the tip.

79
 TWIST DRILL AND LABLE

80
•Drilling is a chip removing material treatment process to
produce holes of a specified diameter. The drilled
holes is then either smoothen by reamers or internally
thread with taps.
There are the types of motion of the stand drilling
machine (bench-mounted) .

•Main motion is rotary motion

 This motion produces cutting force at the drill
point.

•Secondary motion is feeding motion

This motion produces feeding force and enables
tool to penetrate into material.
The sequence of operation for a stand drilling machine.

1. Select the correct speed and adjust it on the control panel.

2. Select the correct drill and install it in the chuck, start with
the smallest twist drill.
3. Clamp the work on the pillar drill table.
4. Wear safety glasses, goggles or face shield.
5. Start pillar drill motor.
6. Press down drill using the feed lever. Use the recommended
7. Curling chips (swarf) are formed and to be removed.
8. Oil is to be used as the cooling method.
9. Stop motor and remove drill and work piece.
10. Check workpiece for correct drilling and repeat the drilling
process by using drill bit in steps until the desired drill hole
STAND DRILLING MACHINE
Drill Sizes

Three sizes of standard drill sizes are in common use: -

a. The Fractional Drills

- Range from 1/64" to 4" in diameter. The sizes increases by 64th of an
inch in the smaller sizes and 32nd of an inch and in the larger sizes.

b. The Number Sizes

- Consists of drills numbered from 1 to 80. The number 1 drill is the
largest (0.228") and number 80 is the smallest (0.0135"). To find the
decimal equivalent consult a drill size chart or handbook.

c. The Letter Sizes

- Consists of drills from A to Z. The letter A is the smallest (0.234") and
letter Z is the largest (0.413").

84
Welding

Gas fusion welding is a method of joining

materials which are usually similar in liquid or
semi-liquid state, using heat, pressure or both.

The weld is the best form of a non-detachable

joint. A correctly executed weld is both strong and
tight.. The materials are joined by fusion.
JOINING PROCESS

•SIX (6) types of joining process normally used

in the industry.
1.Screws

2.Rivets

3.Soldering

4.Brazing

5.Glueing

6. Welding
 Typical Welding Application

Slide No. 87
BRAZEING WELDING
1. Gas Welding /Cylinders
The gases mostly used in welding, i.e. oxygen and
acetylene, are sold in steel cylinders (often referred to
as 'bottles').

Oxygen cylinders contain the pure gas at a pressure

of 150 bar, and are painted black for identification.
Acetylene cylinders are painted maroon.

The colors are used for avoiding accidentally

interchanging the pressure reducer and the flexible
hose.
1. Acetylene Gas

• Acetylene (gas) mixed

with oxygen/hydrogen
produce flame at temp
around 6300oF (3482oC)
Welding torch used
Two pieces heated to
temp that produces
shared pool of molten
metal.
 Molten pool supplied
with filler rod
Welding Equipment:
Oxygen and Acetylene

Slide No. 91
 2. Metal Inert Gas (MIG)
Electric arc forms between consumable wire electrode
& workpiece (metal), heats metal, melt and join
Uncoated wire electrode fed into torch and inert gas
(argon, helium / CO2) flows around wire to protect
puddle from oxygen.
The electrode used is Copper wire
Metal Inert Gas (MIG)
 3. Tungsten Inert Gas (TIG) / Gas Tungsten
Arc Welding (GTAW)
• Uses non-consumable tungsten electrode to
produce weld
• Stream of inert gas (argon/ helium) flows out
of torch and envelopes
• The arc, prevent formation of oxides in puddle
• Filler metal normally used weld thin sections
of stainless Steel & non-ferrous metals (Al, Mg
and Cu)
GTAW Arc Welding
• Tungsten Inert Gas (TIG) /
Gas Tungsten Arc Welding
(GTAW)
• Uses non-consumable
tungsten electrode to
produce weld
• Stream of inert gas (argon/
helium) flows out of torch
and envelopes the arc,
prevent formation of oxides
in puddle
• Filler metal normally used
• Weld thin sections of
stainless steel & non-
ferrous metals (Al,
• Mg, Cu)
End Product