INTERNAL ATTACHMENT TECHNICAL REPORT 2021

DEDAN KIMATHI UNIVERSITY OF TECHNOLOGY

SCHOOL OF ENGINEERING
DEPARTMENT:MECHANICAL
COURSE: B Sc MECHANICAL ENGINEERING
NAME: MURIIKI JOSLINE NKIROTE
REG NO: E023-01-0853/2019

JAN 4TH 2021-MARCH 2021

 SUMMARY
The internal attachment was designed to give the students a hands on skills and also a platform in which they get to see
the application of the theory taught in lecture rooms applied in the real world of engineering.
In the course of the internal attachment period we covered different technical areas in mechanical engineering. In the first
week we covered the Computer Aided Design CAD which is cornerstone in engineering. The software used was Auto-
Desk Inventor 2017. We covered different key areas such as part file assembly file etc. Thereafter we proceeded to
Computer Aided Manufacturing CAM which involved producing the already designed product. The exercise involved the
CNC machines which will be covered later in the report. Later on we proceeded to learn in the automotive area where we
covered different areas such as the Plugin Hybrid Vehicles, Manual and automatic transmission system which will also
will be covered in details. Later on we went to the mechatronics labs which we also covered areas such as motor control
and safety on overload, AC and DC circuit systems etc. We headed to the carpentry and woodwork in the maintenance
workshop which learnt the different types of joints in stool. Later on in the same week we summed up with machine
maintenance in the machine workshop in ADMATC. We also went to the electronica Lab to learn about domestic wiring
installation systems. In the last days we embarked in our final internal attachment project which was about designing and
fabricating a metal SCRAP BIN.
Throughout the process we some couples of skills that are vital in our career. Among the skills learnt including the
following; welding and joinery which is important in metalwork and joinery. We also learnt how to code and safely
operate the CNC machines in the ADMATC. The skill of designing through Inventor software was also captured. Fault
detection in vehicles was also covered learnt real life scenario. Team work and also team building skills was also
incorporated in the process.
The internal attachment serves as a mirror to the real world of industries working. It also shows how the knowledge learnt
in class can be used to solve problems on our field. It also show how the different fields of engineering are intertwined to
achieve a common goal.
Number of weeks Suction Subsection
Week 1 Computer-aided design Inventor design/files
Data and the projects
Assembly design works
Documentations
Frame generator
Week 2 Computer aided manufacturing Box ford

Benchmill

EMX

Week 3 Automotive Gasoline engine

Hybrid engine

Week 4 Mechatronic AC /DC systems

Sensors
Electrical motor control
Pneumatic and hybrid
systems
Robotics
Week 5 Carpentry Woodwork
Classification of tools
Classification
Week 6 Electrical workshop Meter box
Wiring systems
Accessories
INTRODUCTION
The main objective of the internal attachment was to apply the knowledge learnt in the classroom set in the real world of
engineering. It also provide an opportunity for the students to gain hands on skills from different areas in the ADMATC.
The attachment also paints a picture of how industries are managed and maintained. The report starts from the initial
stages of designing to the final stage of fabricating the final project of the scrap bin. In between there are several processes
and stages that complete the process from concept of an idea to the actual product.

Computer aided design

Engineering drawing and design is a cornerstone in the field of engineering especially in the mechanical engineering field.
The process starts from conceptualization of an idea to coming up with a sketch on paper. In order to actualize the idea we
need a drawing and design tool such as Autodesk-Inventor. It is therefore necessary to familiarize with this designing
software without forget to apply the engineering drawing rules and skills learnt in the EMG1102 Engineering Drawing.
Auto CAD Inventor
We launched the Autodesk-Inventor and learnt about the files found in the Inventor which included part file (.ipt) which
has a single item or part like drill bit. Assembly files (.iam) which are used to create assemblies or sub-assemblies of a
large design. Drawing files (.idw and .dwg) which create a drawing to document your design after you create the model.
Presentation file (.ipn) to create an exploded view of an assembly to use in a drawing file. We created a project file named
attachment 2021 which will be used to store or save our work. We opened .ipt file and familiarize with the main menu; the
3D section sketches view and others. We started by drawing basic sketches such as circles and hexagons. From the
sketches we proceeded to 3D section environment where we applied work features on the circles and hexagon through
extrusion. Soon after we applied edge treatment features like chamfer and fillet on the cylinder object. We saved the work.
The following morning we proceeded to learn lofting in coming up with a cylinder and a cone. We also learnt Revolving
feature to come up with a bolt. The process begun by drawing the bolt sketch in a half in which it was revolved along the
axis to form a 3D bolt. The threading feature was also applied in the bolt. The previous learnt working features in edge
treatment were also applied in the bolt. In the afternoon we were introduced in documentation of our drawing. We learnt
the different projection views and how to apply them to come up with a working drawing of the 3D bolt and dimension.
We started by enlisting the parts of the table and taking the necessary dimension. Each and every part was drawn different
and saved on .ipt file format. The generic materials were also accompanied in the parts drawing. Later on we learnt the
.iam file features and their application. After completing the whole assembly we opened .idw for the assembled table for
detailed documentation.

COMPUTER- AIDED MANUFACTURING

Computer aided manufacturing is the use of software and computer-controlled machinery to automate a
manufacturing process. CAM itself stands for computer-aided manufacturing and usually works in tandem with
CAD (computer-aided design) to allow machines to create objects directly from computer designs and software
rather than engineers having to set up machines and processes manually.
The CAM system works by substituting hand-made jigs with software than defines the actions and process of a
machine directly. Computer-aided manufacturing software translates drawings and data into detailed
instructions that drive automated tools/machines. This allows designers to submit designs and specifications
directly to machines without the need to develop jigs or program machines manually. Typically, a designer will
use CAD software on their computer to create a 3D design of a model. The software talks to CAM
tools/machines to set up the processes to produce thousands of identical models automatically reducing the time
it takes to produce.

Uses of CAM
Tools path designs create computer models of new designs.
Machining equipment in manufacturing that rely on numerical controls for precision cutting, shaping and
packing.
Management of overall production process to drive efficiency.
Equipment safety. CAM is highly reliable able to reproduce identical processes without deviation.
Fabrication and engineering design which relies on the integration and synchronization of various pieces of
machinery with CAM software.
Machining equipment in the manufacturing that rely on numerical controls for precision cutting, shaping and
packaging.

Advantages of CAM
Predictable and consistent.
Ability to create prototypes quickly and without waste.
Can aid in optimizing NC programs for optimum machining productivity
Can automate the creation of performance reports.
Higher productivity

Disadvantages of CAM
Computer errors are possible
CAD and CAM software’s can be expensive
Training need more time

The difference between CAM and CAD

There is often confusion about the difference between computer-aided design (CAD) and computer-aided
manufacturing (CAM). The key is that one relates to design and to manufacturing. While in terms refer to
different process, they are closely related, making up different steps in modern manufacturing process. Product
designers use CAD software to create `Blueprints` for models. Importantly, these blueprints can be used to
directly program CAM machines to produce the models-avoiding

Automotive engineering
Engine principle of operation
The engine is the device that converts the chemical energy contained in the fuel into the mechanical energy that propels
the vehicle. The energy in the fuel is converted into heat energy by burning the fuel in a process known as Combustion
which is why vehicle engines are often referred to as internal combustion engines. Most engines in motor vehicles make
use of the piston and crank mechanism that converts linear motion into rotary motion; the piston motion to and fro in the
cylinder in a reciprocating motion. In order for the engine to function it goes through a sequence called events or strokes
The four-stroke Otto cycle strokes
A four-stroke engine has one end of the cylinder sealed called cylinder head. In the cylinder head are two valves and a
spark plug that supplies the spark that ignites the fuel. One Inlet is called the inlet Valve and it is opened when air and fuel
are required the other valve is the exhaust valve and this is opened when the spent gas is removed from the cylinder.
First stroke- Induction the Inlet valve is open and the exhaust valve is closed. The Piston is pulled down the cylinder by
the action the crank and connecting rod as the piston descends it creates a partial vacuum in the cylinder and this causes
the atmospheric air pressure to force a mixture of air and fuel that is supplied by a Carburetor or fuel injection system into
the cylinder.
Second stroke- compression both valves are now closed and the piston is pushed up the cylinder by the action of the
flywheel, crank, and connecting rod. The mixture of air and fuel in the cylinder is now compressed to a high pressure. A
high pressure is required to extract the maximum amount of energy from the fuel.
Third stroke- power both valves are closed and the spark ignites the fuel. This causes the pressure in the cylinder to rise
and the action pushes the piston down the cylinder to rotate the crankshaft and deliver power to the flywheel.
Fourth stroke-exhaust the exhaust valve is open and the inlet valve is closed, the action of the flywheel and crank pushes
the piston up the cylinder to expel the spent gas. The cycle is now complete and the engine is ready to start the next cycle.
The two stroke cycle
No valves are used because the piston covers and uncovers ports through which air and fuel enter the engine and exhaust
products are expelled. A power stroke occurs once for each revolution of the crank in theory this makes a two-stroke
engine of a given size twice as powerful as a four-stroke engine. The crankcase is sealed because it is used to hold the Air-
fuel mixture at a stage of the cycle of operations. By using both the top and underside of the piston the four phases of the
cycle (induction, compression, power, and exhaust) are completed in two strokes of the piston and one revolution of the
crankshaft.
First stroke (piston moving down the cylinder)
Events above the piston. The expanding gases that have been ignited by the spark plug force the piston down the cylinder.
About two thirds of the way down the cylinder the exhaust port is uncovered by the piston and the exhaust gases leave the
cylinder. As the piston moves further downwards the transfer port is uncovered and this allows a fresh charge of fuel and
air from the crankcase to enter the cylinder above the piston.
Events below the piston. The descending piston covers the inlet port and compresses the air and fuel mixture in the
crankcase.
Second stroke (piston moving up the cylinder)
Events above the piston Compressed fuel and air is forced into the cylinder from the crankcase, through the transfer port.
With the aid of the deflector on top of the piston the incoming charge of fuel and air helps to drive exhaust gas out. When
both the transfer port and the exhaust ports are closed the piston continues to rise and compress the fuel and air mixture.
The spark occurs at the end of this stroke and the engine begins the next power stroke.
Events below the piston As the piston moves upwards the partial vacuum in the crankcase now draws in fuel and air
through the inlet port as it is uncovered by the bottom of the piston. Because the piston is used to control the opening and
closing of the ports the power stroke is effectively shortened and this reduces the power output of the simple two-stroke
engine
The braking system
Principle of the hydraulic system
The small-diameter master cylinder is connected to the large-diameter actuating cylinder by a strong metal Pipe. The
cylinders and the pipes are filled with hydraulic fluid when force is applied to the master cylinder Piston pressure is
created that is the same at all parts of the Interior of the system. Because Pressure is the amount a force acting on each
square meter the force exerted on the large piston will be greater than the fore applied to the small piston, When the force
on the brake pedal and the master cylinder Push rod is released the return spring pushes the spring back and the hydraulic
operating pressure is removed. The action of the main Piston seal ensures that the master cylinder remains filled win fluid.
Air supply and exhaust systems and turbocharging
The purpose of the air filter is to remove dust and other particles so that the air reaching the combustion chamber is clean.
The porous paper is used as the main filtering medium. To improve engine warm up and to provide as near constant air
temperature as possible, the air cleaner may be fitted with a device that heat up the incoming air as and when required.
The air flow meter measures how much air is flowing in the combustion chambers. It measures through a voltage signal
which is conducted to the ECU. The throttle positioning sensor tells the ECU the angular position of the throttle butterfly
valve. It acts on voltage signal which determines the amount of fuel to be injected.
Idle air control sensor which provides an air supply for the idling purpose. The intake system is provided by a separate
system in order that the engine will continue to run properly. This provide fast idle speed so that the engine keeps running
even when extra load is imposed with the throttle closed. Such as by switching on the headlights.
The manifold is provided with ports that connect to the individual cylinder of the engine. The gasket between the intake
manifold and the cylinder head must be secure and advisable to check the seal. The power output of the naturally aspirated
engines is limited thus turbocharger is commonly used to boost the pressure of the incoming air. The turbine is driven by
the exhaust fumes, intake air is drawn into the compressor through the air filter. The compressor raises the pressure of the
intake air.
The exhaust gases are expelled from the piston cylinder through the exhaust valve to the exhaust manifold where they
meet the oxygen gas sensor which measures the quality of gas being released to the environment. Therefore the exhaust
gases go through a ceramic mesh of rhodium which filters most harmful gases. The gas flows through the resonator and
the muffler which reduce noise and thereafter released to the atmosphere through the exhaust pipe.

Lubrication system
Main components in the lubrication system
The lubrication system is mostly pressurized and consists of the following main components: Oil pump-draws the oil from
the sump and delivers it under pressure to the engine lubrication system. Relief valve-limits the maximum pressure of the
oil supplied by the pump to the system. Sump-serves as a reservoir for the oil. Oil galleries-are channels or drillings
through which the oil passes to the different lubrication points in the engine. Oil pressure indicator-shows whether the oil
pressure is being kept within the manufacturers’ limits. Oil filter-filters the oil, removing impurities to keep it clean. A
typical lubrication system works in the following way: Oil is drawn from the sump by the oil pump. The pump pressurizes
the oil and passes it through the oil filter into the oil galleries and passages that lead to the crankshaft and camshaft
bearings and, in some engines, the rocker shaft and rocker arms. The oil splashed from the crankshaft lubricates the
pistons and other internal parts of the engine. After lubricating the moving components, the oil drips back down into the
sump.
Tie level of the oil in the sump is checked by means of a dipstick on which the maximum and minimum oil levels are
indicated. The oil pump is immersed in the oil reservoir in the sump. It has a strainer that prevent large particles from
being sucked into the lubrication system. As engine speed Increases the oil pump produces a higher pressure than is
required by the engine lubrication system. A pressure relief value is therefore fitted in the system to take away the excess
pressure and maintain it at a level appropriate for the bearings and seals used. There are two types a cooler where the heat
is removed from the oil; is the oil to air where the heat passed directly to the air, the other is the oil –water where heat
from the oil is passed to the water cooling system
Cooling system
There are two main types a cooling systems in common use air and water. Both radiate heat removed from the cylinder
into the surrounding.

Liquid cooling
In this arrangement the outer surfaces of the cylinder and head are enclosed in a jacket, leaving a space between the
cylinder and the jacket through which a suitable liquid is circulated. The liquid generally used is water, which is in many
ways the most suitable for this purpose, even though it has a number of drawbacks. Whilst passing through the jacket the
water absorbs heat from the cylinder and head, and it is cooled by being passed through a radiator before being returned to
the jacket. Most modern engines use a pump to provide a positive circulation of the coolant.
The purpose of the radiator is to provide a cooling area for the water and to expose it to the air stream. A reservoir for the
water is included in the construction of the radiator. This is known as the header tank and is made of thin steel or brass
sheet and is connected to the bottom tank by brass or copper tubes; these are surrounded by ‘fins’. This assembly is
known as the matrix, core, block, or stack. The more modern radiator uses plastic for the tanks and aluminum for the
matrix.
A reservoir for the water is included in the construction of the radiator known as the header tank. Thermostat This is a
temperature-sensitive valve that controls the water flow to the radiator. Wax type this is used in the pressurized system as
it is not sensitive to pressure like the bellows type. A special wax is used, contained in a strong steel cylinder. The reaction
pin is surrounded by a rubber sleeve and is positioned inside the cylinder. As the temperature increases the wax begins to
melt, changing from a solid to a liquid, and at the same time it expands. This forces the rubber against the fixed reaction
pin, opening the valve against spring pressure, thus allowing the water to circulate through the radiator. There is a small
hole in the valve disc to assist in bleeding the system as filling takes place. The ‘jiggle pin’ closes the hole during engine
warm-up.

The steering system

The steering system steering mechanism has two main purpose enable the drives to easily maintain the straight ahead
direction of the vehicle even when bumps are encountered at high speeds and change the direction as the vehicle with the
minimum effort at the steering wheels. The types steering system include the warm and roller, cam and peg Recirculating
ball, Rack and pinion which were discussed in detailed during the lab session.

Ignition system
The Sole Purpose is to provide spark to ignite compressed air-fuel mixture in the combustion chamber. The current from
the battery flows through the primary windings via the ignition Switch and the close contact between points, to earth The
current about 3A in the primary winding causes a strong magnetic field which is concentrated by the soft Iron laminations
at the coil center which induces the high voltage in the secondary circuit the capacitor store charges so that when in the
case of the coil ignition system the contact points begin to open. The self-induced current from the across the gap. Direct
ignition system are those where each cylinder has a separate ignition coil placed directly on the sparking plug.

Suspension system
The suspension of a vehicle is present to prevent the variations in the road surface encountered by the wheels from being
transmitted to the vehicle body. Independent suspension has each wheel moving up and down without affecting the wheel
on the opposite side of the vehicle. The non-independent systems movement of one wheel will affect the wheel of the
opposite side. Leaf springs is a type of the independent suspension. The coil spring gives a smoother ride than the multi
leaf due to the absence of interleaf friction. The torsion bar is a bar that can either be round or square section and fixed at
one end to the rubber suspension can be used as the suspension medium as well as for mountings and pivot.
Plugin hybrid vehicles
This is vehicle that runs through combustion of fuel and also through the motor generator motion. They have a high
voltage battery that act as source for the motor power and also store power during the charging session by the motor
generator connected to the engine. It has also the inverter converter device which either convert AC to DC or vice versa
when needed by the motor generator until a certain speed is achieved when the engine kicks in to provide power boost.
Motors There are three types of motors in hybrid engine that are the AC, DC and special motors. They are mainly used to
convert electrical energy to mechanical energy. Battery The batteries are the source of power to the motors and store
charge. Some of the factors that determine the type of battery to be used are the load requirements of the vehicle, power
energy density, efficiency, range and cost of the battery. Some of the batteries used in hybrid engine include the lithium-
ion battery, Nickle-metal hybrid battery and the lead-acid battery. Hybrid engine. There two type of hybrid engine that is
the parallel and the series. In series hybrids have a separate generator which is connected to the engine while the parallel
hybrid the electrical motor acts as a generator. In series hybrid the gasoline engine is not coupled directly to the wheels,
while it is in a parallel hybrid. In series type motors are connected in series. The MG1 acts as a starter. It also cranks the
engine. It charges the battery and powers the MG2. There is also the MG2 which run the wheels of the vehicle. Other
components in the hybrid engine are the invertor convertor that converts DC currents from the batteries to AC current to
the MG1 and converts AC current from the MG1 to DC current to the battery. A diode is used in converting or
electrifying the current in the invertor convertor.

Mechatronics
We were firstly introduced briefly on some of the practical that we were to undertake for the whole week in mechatronics
lab the practical that we did include the following: AC/DC system, sensors, electrical motor control and pneumatic/
hydraulic system

AC and DC circuit
We also learnt the ac/dc systems. We noticed that when a current flow through a resistor it gives off heat. This concept is
applied for application where heat is the most desired output. This is the same basic operation in turning on and off of a
heater. A buzzer module sounds when connected to current and does not sound when disconnected. This is applied in
doorbell button where the pushbutton switch is the doorbell button. When the armature is connected to current the
armature is pulled into the solenoid because the magnetic field created in the solenoid leads to electromagnetic effect
which thereby pulls the armature inside. When the selector switch is rotated to the right the fan blow and when rotated
back to the left the fan is not blowing. The selector switch completes the circuits thereby electric circuit is supplied to the
fan and is able to blow. We then tested a capacitor with the digital millimeter (DMM). We found out that both the
capacitors were good since the value of the resistance on the DMM goes to a low value then climbs to overload. Then we
charged one of the capacitors and measured its voltage. The value was close to the source voltage and then it starts to drop
off

Hydraulic and pneumatic system

We also undertook the pneumatic system which is comprised of the following components: gauge pressure, pump,
delivery system, valves, compressor, reservoir, cooler, actuator and filter. In pneumatic system we use air while in
hydraulic system we use a liquid. We learnt and used the 4-way cylinder, 3-piston directional control valve. This method
helps one not to be switching hoses connection. There are two types of actuator that are the hydraulic cylinder and the
hydraulic motor. The hydraulic cylinder consists of single acting cylinder and double acting cylinder and a rotary actuator.
The hydraulic motor consists of the gear motor, valve motor and piston motor.

Sensors
We then proceeded to sensors. Sensors provide reliable low-cost input and monitoring for electrical control systems. We
used several sensors such as the inductive proximity sensor, capacitive proximity sensor, photoelectric sensor and the Hall
Effect sensor. We used all the sensor to detect different targets that were provided such as wood, glass, aluminum etc. the
Hall Effect sensor did not detect any of the targets provided. Wood glass and plastic were not detected by the inductive
proximity sensor. Capacitive proximity sensor and photoelectric sensor detected all the targets. We also used the pressure
sensor which comprised of the differential pressure sensor, gauge pressure sensor and the absolute pressure sensor. When
slowly applying pressure to the sensor by actuating the manual pump the sensor output voltage increases with increase in
the pressure. We also did the aluminum thermistor and RTD where the increase in temperature results in increase in
voltage.

Motor power control

We began with the electrical motor control circuits which basically are designed to perform functions such as starting,
stopping, reversing and speed control. Several different control devices are used in electrical motor control. We learnt on
the components required to satisfy the most basic safety requirements for the motor control circuits and also, we covered
the manual control and overload protection. Manual starters are applied in some sump pump, refrigeration systems, fans
and blowers because of the automatic restart which automatically restarts upon the return of power

CARPENTRY

Carpentry is a skilled trade and a craft in which the primary work performed is the cutting, shaping and
installation of building materials during the construction of buildings, timber and concrete formwork it also
includes cabinet making, wood curving, joinery, carpentry and wood cutting.
Safety procedures should be followed when using woodworking machines for example safety glasses or
goggles, overall or dust coat and safety boots. Joint woodworking comes from the word joinery, which involves
jointing together pieces of wood or lumber to produce more complex items. Some wood joints employ
fasteners, bindings or adhesives while others use only wood elements. The features off wooden joints include
strength, flexibility, toughness and appearance. Types of wood joinery include basic butt, mitered butt, mortise
and tenon rabbet joint and half-blind dovetail.
Classification of tools for example measuring tools (steel tape, four fold race), marking out tools ( try square,
marking gauge, mortise cutting, cutting tools, cross cut saw, ripping saw, tenon saw) and holding or clamping
tools (bench vice, G-clamp, sash clamp). Classification of woodcutting joints this include angle joints or
framing joints (mortise joint), widening or edge joints and leghthning joint or end joint. Surface finishes such as
shellac and varnish dry on tap of the wood to create a protective coating. Surface finishes are applied with
brushes rather than rags, and a variety of brushes are available each with different attributes.

Different types of carpentry

Read the plans
Familiarize yourself with the plans and procedures before you buy or cut any wood. Make sure the project is
something you can handle.
Check and double-check the materials list
Organize the list so that you can efficiently get the supplies you need before you cut the board.
Plan your cut list
Go through all your wood and lay out where each cut is going to go. Choose the most appropriate part of the
board for each part of the board for each part of the project. For instance, choose matching tabletop pieces for
grain patterns and color consistency. Also, plan your cuts so that you do the minimum of saw adjustments (do
all the crosscut first and then all the rip cuts).
Pre-mill all the boards to get straight and flat pieces
This goes-hand in hand with the cut list planning procedure
Mill the boards to their final dimensions
This involves planning and jointing the boards.
Cut the joints
Dry fit the assemblies to make sure everything fits properly
Make sure that your assemblies and subassemblies fit together properly before you add any glue. You also want
to use this step to practice the assembly procedure. Repeat the procedure until you can do it smoothly and
efficiently.
Glue the assembly and clamp it
Work quickly and pull each joint fully together before moving on. This minimizes the possibility of joint freeze
up. When clamping, be careful not to use too much pressure. Use just enough force to pull the joints together.
You don`t want to squeeze all the glue out.
Square the parts
Tabletops should be perfectly flat and other assemblies should be perfectly square. Use a straightedge to check
for flatness and the tape measure (measuring diagonally across the assembly) to check for square.
Clean up
Put the assembly aside where it would not get bumped and clean up all the glue seepage before it dries.

Surface coatings are clear, built-up, highly durable finishes hat are virtually maintenance-free. Examples of
surface coatings are varnish, shellac and lacquer. Surface coating finishes will add depth and warmth to the
appearance of the woodwork, while enhancing the color and grain. One of the easiest and cheapest ways to give
your apartment or home a renewed look is with finishing. Upon the first touch of a rag or brush, furniture comes
alive and the true character of any wood grain is emphasized. Finishing also adds protection. It is designed to
inhibit the transfer of moisture and to prevent the surface from being contaminated by dirt and stains, adding to
the life of your furniture.
To pick a suitable finish, you will have to shop through a multitude of products with varying characteristics.
The most common finishes are shellac, lacquer, oil-based products, so make sure to take precautions. Wear
protective gloves, goggles and a respirator with organic vapor cartridges when using these materials.
One of the biggest difference among the four traditional finishes is how they function on wood. Shellac, lacquer
and varnish are all surface finishes. This means that they do not penetrate, to any great extent, past the surface
of the wood. The first coat goes in the farthest, but subsequent coats merely build on the first to form a smooth,
usually glossy, surface oil, on the other hand, is considered a penetrating finish because it reaches much deeper
into the wood and leaves only a microscopic layer of finish on the surface.
Lacquer is also quick-drying and is the preferred finish of many professionals. It is usually sprayed on and
yields a clear, hard finish that stands up well to practically any abuse. It is however flammable. Varnishes, both
the traditional types and the newer poly-urethane versions, are steamily durable and some impart a warm amber
tone, not unlike shellac. Unfortunately, varnish can be difficult to dry. Because of this, airborne shop dust
becomes a real problem. Then it has to be rubbed out before another coat is applied. For a beginner, an oil finish
is the best choice. It is easy to apply, driers fairly quickly and is not difficult to repair. It’s easy to apply, dries
fairly quickly and is not difficult to repair. It also imparts silkiness to the surface and develops a beautiful patina
over time.

STEP 1: SURFACE PREP

Proper surface preparation is key to good finishing. This requires a bit of sanding. For the best results, you
should work through a sequence of abrasives, starting at 120-grit and moving to 150, then to 180 and 2220-grit,
finishing up with 320-grit. Ease all the edges on your project with sandpaper and a sanding block. Work across
the grain for the best results. Always dust off the piece thoroughly before moving to the next grit and ease any
sharp edges by hand sanding.
STEP 2: RUB WITH OIL
When you are done sanding the entire piece, brush off all the dust with a tack cloth or a rag that is been slightly
dampened with linseed oil. Rub the oil into the wood and let it dry for one hour then wipe off any excess.
STEP 3: TEST THE FINISH
Once you have chosen your coloring method, be sure to test it out on some scrap pieces of stock before turning
to your project. Taking the time to get it right is much easier than removing a stain or dye that you do not like.
When you are ready to apply your oil finish, begin by rubbing a liberal amount of oil into the surface of the
wood using a lint-free rag.
STEP 4: LET IT DRY AND RUB WITH STEEL WOOL
Allow the oil to absorb for about an hour, then wipe off the excess.
STEP 5: WAX IT
Once the last oil coat is dry, apply a light coat of paste wax to your project. Be sure to cover all the surfaces.
STEP 6: BUFF IT
Let the wax dry until the surface it takes on a dull appearance. Then buff the entire piece to a high luster with a
clean dry cloth.
 Carpentry and joinery and machine maintenance
Joints
They comprise of the following: angle joint, widening joint, lengthening out/ end joint. The angle joint includes the
following joints: butt joint, cross halving joint, mortise and Tenon joint and dovetail joint. Butt joint is a technique in
which two pieces of materials are joined by simply placing their ends together without any special shaping. Cross halving
joint is a joint in which the two members are joined by removing materials from the each at the point of intersection so
that they overlap.
A mortise and Tenon joint connect two pieces of wood or materials. We have the male and female in mortise and Tenon
joint that join together to form a strong and stable joint. The dovetail joint is simply a joinery technique most commonly
used in woodworking joinery, commonly used to join the sides of a draw to the front.
Widening joint are used to make wider boards by joining narrower one’s edge to edge. Commonly used when making
table tops, shelving, seats, timber door panels. Lengthening joints is used to increase the length of timber to the required
length. Mainly used to connect two beams lengthwise. They comprise of a halved joint, lapped joint and scatted joint.
.We then saw the machines used in the carpentry and joinery workshop like the circular saw. We finally did machine
maintenance which included cleaning, greasing, replacing the won out parts and also repairing the repairable parts

Marking out
We learnt doing measure on the workpiece before proceeding to the next stage. We also learnt how use the marking out
tools such the protractor and many more.

Machine and tools type

We were introduced to various carpentry tools and their functions. We saw that there were marking out tools, cutting
tools, measuring tools among others. The marking out tools included the carpenter’s pencil. Cutting out tools included the
cross-cut saw while the measuring tools included the steal tape.
We were introduced to different types of hand tools that used in carpentry work. Some of the types of hand tools we learnt
and used them include the following: measuring tools, marking tools, cutting tools, planning tools and holding/ clamping
tools.
Measuring tools are basically used to take measurement during marking out. They comprise of the tape measure. Speed
square, protractor. Marking out tools are important when creating a template or transferring a pattern or design into a
specific workpiece. They include carpenters’ pencil, gauge, and scriber. Cutting tools are used to cut timber. They include
the cross-cut saw which cuts across the grain, Tenon saw which cuts across the grain, ripping saw that cuts along the grain
and chisels. Planning tools are used to reduce the thickness level of all kinds of wood surface. They include the jack plane
and the smoothing plane. Holding tools comprise of the sash clamp and the G-clamp. They are basically used to hold a
wood in carpentry.

Machine maintenance
Later in the week we did machine maintenance in the machine workshop. Which comprises of cleaning the lathe and
milling machines using paraffin as the cleaning agent.
 Electrical workshop
Sources of power
The three Major Categories of energy for electricity generation are fossil fuels (coals, natural gas and petroleum) nuclear
energy and renewal energy sources most electricity is generated with thermal energy steam turbines using fossil fuels,
nuclear biomass geothermal and solar other technologies include gas turbines, hydro turbines, wind turbines and solar
photovoltaics. Natural gas combustion alone, or as Part of a furnace (boiler system propels turbines to create energy most
power plants we coal-fired Steam turbine to generate power. with nuclear power, nuclear fission Produces the energy
generating steam necessary to spin turbines and generate electricity. Energy from the sun current is captured in
Photovoltaic solar cells which generate electrical energy through current

Electricity transmission and distribution

After electrical power is generated it is transmitted over distance using transmission. Lines transmission lines are
constructed between transmission substation located at electric generating station transmission lines may be supported on
towers or maybe Underground. They are operated at high voltages they carry out power and extend over considerable
distances. when electricity come out of a generating station the transmission substation located there step up the voltage to
the within range of 138000 to 7 6 000 volt within the operating area transmission substation reduce the transmitted
voltage to 34000-138000 volts this power is transmitted to the distribution system located in the local service territory.
The distribution system connect the transmission system to the customer’s equipment. The distribution substation reduces
the transmitted electrical voltage to 24000-19920 a distribution transformer further reduces the voltage transmissions and
distribution substations are installed where the voltage phase or other characteristics of the electrical energy are changed
as part of the final distribution process.

Domestic wiring
From the distribution line outside the consumer power Is connected in the following order up to the final accessories and
appliances A two-phase connection as a the red blue or yellow live wire and a neutral black wire While a three-phase has
all the three live wire is the neutral and earth from the line the power is connected to your meter box then to the main
switch and a letter in the consumer control unit found inside the house the consumer control unit distributes power to the
Entire house it has the live and neutral bars and the earth bar connected to the copper plate in the ground on the life we
have the circuit breaker which supply power in different current values for the lighting cooking showering systems in the
house

Wiring system
There are three types of wiring system including the following surface wiring in closed wiring which uses conduit and
franklin and lastly the special case wearing which includes overhead catenary and heated wiring system Surface wiring is
done when the cables are not enclosed in walls or pipes laid just on the surface of the wiring area in flat building erasing
main and molded case circuit breaker are used in power distribution in between floors
Accessories are the things or devices during the used during the wiring system Such as junction boxes socket etc.

Domestic wiring system 1

A series circuit has all its components wired in the same loop in a series circuit the current flows through one continuous
pathway so the current is the same in all the parts of a series circuit in a series circuit the voltage supplied by the source is
shared by their components so they're some of the potential difference across the components equal the battery voltage as
more bulbs are added each bag has less potential difference and saw the bag become dimmer as seen in the lab experiment
Potential difference across all the components in a series circuit must add up to the potential difference across the power
supply this is because the work done by the force on the charge Must always equal the work done on the components
otherwise energy would be lost the component with the highest resistance would have the largest potential difference
because the higher the resistance the more work is done by the charge passing through it a change in the resistance of one
component will change the potential difference across the components
A parallel circuit contains junctions and so there is more than one path of the current in a parallel circuit the current divide
at the point where the circuit branches and then and then the commands to complete the circular saw the current is not the
same in all the parts of a parallel circuit if the potential difference across the ball is the same as the potential difference
across the power supplied this means that all the bulbs have the same brightness and they are brighter than the same
number of bones in a series circuit however this also means that they bought the battery will run down faster than in a
parallel circuit
The cables used in connecting the bulbs and the socket were different in thickness the cables for the socket were bigger
than those in the bulb since wide cross-section area is used to small amount of resistance therefore more current will flow
in them Which is needed for heavy appliances more current is needed in the socket and alarms was the use of the thinner
cables in lamps
The sockets were connected in radial connection one live terminal is successfully connected to the next terminal in the
next socket by a wire the connection tends to borrow from the series connection upon one socket blowing up in the circuit
the remaining socket switch draw power from the malfunctioning socket also stop working this problem is solved by the
ring method of connecting sockets where the last socket is looped the live and neutral terminal by why is however this
method is the expensive since more cables are required raising the wiring cost
The parallel method of connecting bob is the best the bulbs connected in parallel light brighter than those in series the
radial method of connecting socket is cost-effective than the ring method

Domestic electrical wiring system 2

Multiway switch is the connection of two or more electrical switches to control and electrical load in more than one
location A 3-way 4-way switch enables control of light from multiple-location this witches look like single pole
externally but have extra connection which enables a circuit to be control from different locations In contrast to a simple
light switch which is a single pole single throw switch multiple switch users switches with one or more additional
contracts and two or more wires around between the switches
Intermediate switch
It is the most versatile switch that can be used for most situation they are used where there's two or more switches
controlling one light the connection of to switch with an intermediate switch it allows the control of lumps from multiple
locations for example in a whole way stay away or a large rooms the main switch it allow operation for the others which is
when it is on it on it allows the other switch to operate but when it is switch off the other switches cannot operate

FINAL INTERNAL ATTACHMENT PROJECT

After the completion of the electrical workshop practical we embarked in our final internal attachment project which was
about designing and fabricating a metal SCRAP BIN. We took a maximum of two weeks to complete the project .

Design
We began by designing the scrap bin that we wanted. We took measurements from scrap bin that had been fabricated the
previously. We used this measurement to design our scrap bin using the Autodesk inventor software. We firstly design the
individual parts and finally we assembled the parts using the knowledge and skills we obtained when doing Computer
Aided Design.

Material selection
After completing designing the scrap bin, we proceeded to ADMATC in the sheet metal workshop for material selection.
We selected the materials depending on the available materials, thereby we used mild steel. We specifically used the angle
lines and flat bars which were the only materials available.

Marking out and cutting

After material selection we proceeded to marking out and cutting of the materials. We used tools such scriber, set square
and steel rule to mark out. After marking out the appropriate measurements we cut using the hack saw. We managed to
cut all the parts required.

Pre-assembling
We did pre-assembling immediately after cutting all the parts to see whether this measurement parts will fit to each other.
All the parts cut were fitting appropriately and thereby we proceeded to welding.

Welding
We joined the assembled parts together by welding the joints using the welding machine. Firstly, we joined the joints by
spot welding and after confirming that everything was right, we proceeded to weld continuously. All the parts were
welded together we were able to assembly and come up with scrap bin.

Surface preparation
We then did surface finish by grinding. We used the grinder to grind the welded joints to make them smooth and remove
the excess weld.

Painting
After completing fabricating the scrap bin we proceeded to painting. We began by filling some of the welded joints using
the filler material. Thereafter we painted the scrap bin with the first coat and after sometime we painted the second coat

CONCLUSION
The objectives of this internal attachment are for the trainees to learn and acquire knowledge and skills that is required in
the industry. The other objective is to be able to apply the theoretical part learnt in class into practice and be able to solve
problems in field. To also show the trainees how the different field of engineering intertwined to achieve a similar goal.
The objectives of this internal attachment were able to be achieved to some extent. We acquired a lot of skills such as the
skill of joinery and welding. We also gained the skill on how to come up with code program used in the CNC machines.
We also gained the skill on how to do different types of domestic wiring installation. We also gained the skills on how to
operate the CNC machines. The significance of this internal attachment is to impact the trainees with knowledge and skills
that is demanded while in the industry. It is also to prepare and familiarize the student with what they should expect in
their external attachments.
The other objective of the internal attachment was to acquire practical skills in the various places and labs that we went. In
this period of the internal attachment, we learnt various skills that we only knew the theory bit of them. It was in this
session that we practically did what we learnt in class but got no chance to practice it. The Computer Aided Design
(CAD) gave us the foundation of starting any manufacturing as one must have the design and simulate in in the software.
The Computer Aided Manufacturing (CAM) also made it easy to manufacture through automation and one could generate
codes from the software making it even simpler. In automotive, we came to see the real model of a car engine and knew
how various systems in it work. In the mechatronics, we saw how sensors work and also the motor control. We then
acquired some skills on carpentry and machine maintain ace. We were also at the electrical installation workshop we
learnt on production, transmission and distribution of electricity. We finally had to finish with a project that required the
skills we learnt from the above.
In a nutshell, we were able to do what we hoped to and met our achievements. The skills gained were numerous and
useful. The evidence of the skill gained were seen in the final project where it started from designing it up to coming with
a finished product. It is very clear that the skills were useful to us. The internal attachment is very important as it prepares
us to the external attachment and even more, prepares us to the job and to the market.

RECOMMENDATION
In the electrical workshop: The experiment should have included the 32A circuit breaker in order to include heavy
appliances. The circuit should also include an intermediate switch for switch variety. The lab should have included heavy
appliances in order to test the circuit breaker how it is safety gadget in case of an overload.
In the carpentry workshop: they should have come up with more experiments in order to gain more hands on skills on
woodwork.

REFERENCE
1. Barger, V. and Olsson, M., Classical Mechanics, A Modern Perspective, McGraw-Hill, 1973
2. Eastlake, Charles N., "An Aerodynamicist's View of Lift, Bernoulli, and Newton", The Physics Teacher 40, 166
(March 2002).V.K Menta, Rohit
3. Jearl Walker- Fundamentals of physics 10th edition (2014)
4. John Bird-Electrical Circuit Theory and Technology.
5. V.K Menta, Rohit Mehta- Basic Electrical Engineering-S Chand (2017)

APPENDICES
Figure a.f.1

Figure a.f.2
Figure a.f.3
Figure a.f.4

Figure a.f.5
Figure a.f.6