Technical and Vocational Institute

Centre No.: 91043

BTEC
RQF - Assignment Brief (16)

Qualification: BTEC Level 5 HND in Mechanical /Electrical and Electronic

Engineering

Student Name /ID Adham Ashraf Mahmoud Ahmed

Number
Unit Number and Title 10- Mechanical Workshop Practices

Unit Learning Outcome LO1:LO3

Academic Year 2020/2021

Unit Assessor Yassin Shaalan

Assignment Title Machining and Dimension Inspection

Issue Date 17-Mar-2021

Completion Date 23-May-2021

IV Name Yassin Shaalan

22/3/2021
Date

Student Declaration

Declaration
“I certify that the assignment submission is entirely my own work, and I fully understand the consequences of
plagiarism. I understand that making a false declaration is a form of malpractice.”

Student Name: Adham Ashraf Mahmoud Student Signature: Adham Ashraf Mahmoud
Ahmed Ahmed

Submission Format:

-CD including an image for the part and images for you working on both the milling
and lathe machine.
- The final part you worked on the lathe machine.
- A printed word report including images and references for the M and D tasks.
Assignment Brief and Guidance:

Ver.4
Assignment 1/2
Scenario:
During a summer training period in the manufacturing workshop inside the AAST, you
will learn how to operate and use the conventional centre lathe and milling machine.
By the end of the training period, you will be asked to cut apart on the centre lathe.
Tasks
Task 1: Produce a dimensionally accurate component
1.1 In case that practice session continues during the Covid-19 Pandemic, you will
have to use the centre lathe available in the workshop to produce an
aluminium model shown in Figure 1, which represents a standard arbour that
holds a milling cutter in a milling machine. All dimensions in mm and the
tolerance are equal to ± 0.5mm as
shown in Figure 2. (10 marks). ( if Workshops are closed go to task 3)

Figure 1.3D view of the milling arbour

 Figure 2. 2D view of the standard
arbour
1.2 Calculate the suitable spindle speed (RPM) and the suitable feed rate of
the centre lathe to cut the part of the final diameter (D)if the part is made
of the material
(X), and the original diameter of raw material is (D0) and the cutting tool
material is (Y), lookup Table 1, for values of D, D0, X, Y. (3 marks)
1.3 Determine the angle needed to rotate the top slide to cut the tapered
part in Figure 2. (2 marks).

ANS:

D = 30 Tan(θ/2 ¿ = (D-d)/2L ∴ (30-20)/2*30 = 1/6

d = 20 ∴ Tan (θ/2 ¿ = 1/6
L = 30 ∴ shift tan (1/6) ≅9°
Tan(θ/2 ¿=??

1.4 If you use the horizontal milling machine to produce a spur gear that has an
external diameter (da) and the number of teeth (z). lookup Table 1, for values
of da
and z. (5 marks)
 Determine the following:
a) The module of the gear.
b) The pitch of the gear teeth
c) The depth of the gear tooth.
d) The cutter number required to cut the gear.
e) The suitable configuration of the dividing head plates if the following plates
are available
Plate 1 – 15, 16, 17, 18, 19 and 20 holes.
Plate 2 – 21, 23, 27, 29, 31 and 33 holes.
Plate 3 – 37, 39, 41, 43, 47 and 49 holes.

1.5 Determine the function of each of the following: (6 marks)

a) Three Jaw Chuck (centre lathe).

Ans:

It Lathe chuck found on the stationary crane is an important part of rotating

and anchoring the workpiece and controls the spinning speed, in addition to it
is an essential piece in protecting the workpiece. The three jaw secures the
workpiece, allowing the cutting tool to cut and sculpt the workpiece with
extreme precision.

b) Faceplate (centre lathe).

c) Mandrel (centre lathe).
d) Three-point steady(turning)
e) Gauge blocks.
f) Dividing head.
Task 2: Interpret information from engineering drawings and operate measuring tools.
2.1 Prepare a machining process plan including the sequence and names
of all machining steps needed to manufacture the part shown in Fig
3. (3 marks)

Ds
 Fig 3. Engineering Drawing of a part

2.2 Calculate the minor diameter of the tapered part in Fig3. (2 marks).

Ans:

D = 28.03 Tan (θ/2 ¿ = (D - d) / 2L

d =?? ∴ √ 3/3 = (28.03 – d) / 2*16.05
L = 16.05 ∴ √ 3/3 = (28.03 - d) / 32.1
θ= 60° ∴ 3*(28.03 - d) = √ 3 *32.1
∴Tan (θ/2 ¿= 60/2 ∴ 84.09 - (3d) = 55.59883092
∴ tan ( 30 ° )=¿ √ 3/3 ∴ -3d = -29.30116908
∴ d = -29.30116908 / -3 = 9.76705636
∴ d ≅ 9.8

2.3 Determine the upper and lower limit of 4 dimensions according to the
tolerances shown on the drawing in Fig 3. (4 marks)
2.4 Determine the suitable measuring tool (name, range, scale value) used to
check all the dimensions shown in Fig 3 (5 marks).
 2.5 If a shaft of diameter Ds with the tolerance shown in table1 is required to fit
into the hole of Φ18 in Fig 3. Determine the type of fit. (3 marks)
2.6 Determine the meaning of symbols of 3 geometric tolerances in Fig 4. (3 marks)

Fig 4. Engineering Drawing of a part

2.7 Determine the function of each of the following metrology equipment to

inspect the dimension and features of the part in Figure 4. (4 marks)
a) Form Talysurf
b) Profile projector.
c) Dial Gauge Indicator.
d) Coordinate measuring machine (CMM).

Task 3: Group Presentation (10 marks) (in case of closure of workshops)

According to your registration number prepare a PowerPoint presentation on one of the
topics shown in table 1. Your presentation should include the following:
 Definition and introduction to the topic. (2 marks)
 Images to describe the theory of the topic and its types. (2 marks)
 Advantages and disadvantages (if any). (2 marks)
 Applications in real life. (2 marks)
 Time management (no more than 10 minutes) (1 mark)
 Reply to audience questions. (1 marks)
Guiding table to solve problems according to your registration number

Table 1. Parameters of Question 1.2, 1.3, and Task 3

Example:
 If your registration number is 20100013
 The last digit is 3
 You will go to number 3 in table, (Steel, HSS, D0=55mm, D= Ø20, da =58 mm, z = 27
teeth, Oxy-Acetylene Welding)
 RQF - Summative Assignment Feedback Form

Qualification: BTEC Level 5 HND in Mechanical/ Electrical and Electronic

Engineering

Student Name/ID Adham Ashraf Mahmoud Ahmed 20200520

Unit Title Mechanical Workshop Practices

Assignment Number 1 Assessor Yassin Shaalan
30 Mar-14 Apr-5 May-19 May
Formative Dates
23-May-2021
Submission Date

Assessor Feedback:

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