KABALE UNIVERSITY

P.O.Box317 Tel:+256-392-84355/04864
Kabale-Uganda Mob: +256-782-860259
Emails:info@kab.ac.ug Fax: +256-4964-22903
admissions@kab.ac.ug Website: www.kab.ac.ug
kabaleuni@utlonline.co.ug

FACULTY OF ENGINEERING, TECHNOLOGY, APPLIED DESIGN AND

FINE ART

DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL TRAINING REPORT AT KABALE UNIVERSITY

WORKSHOPS

FROM 17TH JANUARY 2022 TO 25TH FEBRUARY 2022

BY

TWEBAZIBWE EDSON

REG NO. 2020/A/KME/1194/F

ACADEMIC YEAR: 2020/2021

POSITION INDUSTRIAL SUPERVISOR ACADEMIC SUPERVISOR

NAME MR.LIBERTY KANYAMUMBA MR.ISAAC NDAWULA
SIGNATURE
AND STAMP

DATE

A recess training report submitted to the department of mechanical engineering in

partial fulfilment of requirement of the award of a degree in mechanical engineerin
 DECLARATION
I TWEBAZIBWE EDSON REG.NO: 2020/A/KME/1194/F a student of Kabale
University hereby declare that this information cantained in this report is original
work and truly as a result of my own effort and it has been compiled by me and
approved by Mr. Isaac Ndawula and has never been submitted to any university or
any other institution for the ward of diploma or bachelors of mechanical engineering.
NAME:TWEBAZIBWE EDSON

REGISTRATION NUMBER:2020/A/KME/1194/F

SIGNATURE:…………………….

DATE:…………………………….

TELEPHONE NUMBER:0780186776

EMAIL:etwebazibwe@gmail.co

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 PREFACE
This report documents the activities that were carried out during the industrial training
at Kabale University mechanical engineering workshop.
It summarises the manufacturing processes such as foundry ,welding and metal
fabrication,electronics and electrical installation plus health and safety at the work
place.
The technical description and detailed pictorial illustration have been clearly dealt
with to provide the reader with minimum difficulty and boost their interest in
engineering.

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 ACKNOWLEDGEMENT
I take this opportunity to thank the University for the Support they have provided and
the passion for their students to get enough practical knowledge in relation to the
theoretical part taught in class which will be important in production of quality output
in our competitive world today.
A sincere gratitude to Mr.Liberty Kanyamumba,Mr.Bruno Balenti ,Mr.julius
Asimwe and Mr. Justus Owembabazi the laboratory technicians for their tireless
effort to provision of practical knowledge and skills which have been vital to the
success of this training.
I thank my fellow course mates for their interactive and team work towards a
successful completion of this training.
I also thank all my lecturers more so Mr. Isaac Ndawula for their provision of
necessary knowledge and advice towards this training.
Above all, I thank the almighty God who for His sustainance and
immeasurableprovision in our training without any calamity..

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 DEDICATION
I dedicate this report to my beloved mentors:Mr.Dan Akampurira and
prof.Jonathan M who provided me with all adorable support and encouragement
during the training, my brother Mr.Matson Mwije who has been there for me during
the struggle and Mr.liberty who provided me with the practical knowledge and
skills.

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 TABLE OF CONTENTS.
DECLARATION.............................................................................................................i
PREFACE......................................................................................................................ii
ACKNOWLEDGEMENT............................................................................................iii
DEDICATION...............................................................................................................iv
TABLE OF CONTENTS...............................................................................................v
LIST OF FIGURES.......................................................................................................vi
LIST OF ABBREVIATIONS:....................................................................................viii
CHAPTER ONE: INTRODUCTION............................................................................1
1.0.INTRODUCTION.............................................................................................1
1.1.BRIEF ACCOUNT OF KABALE UNIVERSITY..........................................1
1.2:ORGANISATION STRUCTURE.....................................................................2
1.3.BRIEF MOTIVATION ABOUT KAB.............................................................3
1.4.OBJECTIVES OF THE TRAINING................................................................3
CHAPTER TWO : ACTIVITIES INVOLVED.............................................................4
2.0.INTRODUCTION.............................................................................................4
2.1:HEALTH AND SAFETY..................................................................................4
2.1.1: SAFETY OF THE HUMAN BEING.....................................................4
2.1.2: SAFETY OF THE EQUIPMENT..........................................................7
2.2:GENERAL INTRODUCTION TO HAND TOOLS.........................................8
2.3 ELECTRICAL INSTALLATION AND ELECTRONICS..............................10
2.3.1:INTRODUCTION TO ELECTRONICS..............................................10
2.3.2:REGULATED POWER...............................................................................13
2.3.2.1:SOLDERING AND SOLDERING CIRCUIT............................13
2.3.3.:ELECTRICAL INSTALLATION........................................................13
2.4:INTELLIGENT MECHANICAL SYSTEMS................................................15
PROJECT BASED LEARNING IN ROBOTICS..........................................15
2.4.1:ARDUINO UNO BOARD....................................................................15
2.4.2:COMMUNICATION PROTOCOL......................................................17
2.4.3:C++ PROGRAMMING........................................................................18
2.5.FOUNDRY......................................................................................................19
2.5.1:SAND MOLDING................................................................................19
2.5.2:MELTING AND POURING.................................................................21
2.6:WELDING......................................................................................................22
2.6.1:GAS WELDING...................................................................................22
2.6.2:METAL ARC WELDING.....................................................................25
2.6.2(A):MAKING THE TABLE............................................................25
2.6.2(B):MAKING THE CAGE.............................................................27
CHAPTER THREE:CONCLUSION,CHALLENGES RECOMMENDATIONS AND
REFERENCES.............................................................................................................30
3.1.CONCLUSIONS.............................................................................................30
3.1.2.SKILLS ATTAINED....................................................................................30
3.2.GENERAL CHALLENGES FACED ............................................................30
3.3.RECOMMENDATIONS.................................................................................30
3.4.REFERENCES................................................................................................31
3.5APPENDICES..................................................................................................32

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 LIST OF FIGURES

Figure 1 Organisational structure.....................................................................................2

Figure 2 :Safety shoes........................................................................................................4
Figure 3 :Safety helmet......................................................................................................5
Figure 4 :Insulated gloves..................................................................................................5
Figure 5 :Overall................................................................................................................6
Figure 6 :Dust mask...........................................................................................................6
Figure 7 :Fire extinguisher................................................................................................7
Figure 8 :Hammer and angle grinder in use......................................................................8
Figure 9 :Multimetre........................................................................................................10
Figure 10 :Resistor...........................................................................................................11
Figure 11 :Bread board....................................................................................................11
Figure 12 :DC power supplysupply.................................................................................12
Figure 13 :Circuit analysis...............................................................................................12
Figure 14 :Monitoring wave forms..................................................................................13
Figure 15 :Electrical installation test...............................................................................14
Figure 16 :Arduino uno board.........................................................................................15
Figure 17 :Digital oscilloscope for displaying wave forms.............................................16
Figure 18 :Mobile robots1...............................................................................................17
Figure 19 :Mobile robots2...............................................................................................18
Figure 20 :Pipe bender former.........................................................................................20
Figure 21 :Cope containing riser and sprue cavities........................................................20
Figure 22 :Furnace and crucible during melting..............................................................21
Figure 23 :Powering of molten metal..............................................................................21
Figure 24 :Finished product.............................................................................................22
Figure 25 :Gas welding equipment..................................................................................23
Figure 26 ;Carburising flame...........................................................................................23
Figure 27 :Neutral flame..................................................................................................23
Figure 28 :Oxidising flame..............................................................................................24
Figure 29 :Metal bars.......................................................................................................26
Figure 30 :Finished products...........................................................................................26
Figure 31 :Table sketch....................................................................................................26
Figure 32 :Cage sketch....................................................................................................28
Figure 33 :Unfinished cage..............................................................................................28

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 LIST OF ABBREVIATIONS:
FETADFA:Faculty of Engineering,Technology,Applied Design and Fine Art

KAB:Kabale University

BME:Bachelor of Mechanical Engineering

DME:Diploma in Mechanical Engineering

BCE:Bachelor of Civil Engineering

BEE:Bachelor of Electrical Engineering

DEE:Diploma in Electrical Engineering

DCE:Diploma in Civil Engineering

IDE: Integrated Development Environment

vii
 CHAPTER ONE: INTRODUCTION
1.0.INTRODUCTION
At the end of first year, all students are subjected to the industrial training course
during the recess period.
This course is intended to introduce the Learners to the basic knowledge of applied
mechanical and production engineering. The students are introduced to the
engineering applications in five different mechanical engineering modules, namely:
hand tools, machines in the workshop, welding and fabrication,foundry, motor vehicle
maintenance and repair and project-based learning in robotics and artificial
intelligence.
The Learners are introduced to the proper working methods, techniques and tools
used in the industry.
The training was conducted at Kabale University Mechanical workshop at the Faculty
of Engineering, Technology, Applied design and Fine Art.
Kabale University/Faculty of E ngineering,Technology,Applied Design and Fine Art
is located at: KK 3 AVE 38B ,RW-01,Kigali,Rwanda.
FETADFA is made up of four departments namely: Mechanical, Electrical, Civil and
Applied design and Fine Art.
It is steered by a very well dedicated staff consisting of well qualified and experienced
Lecturers and Support staff.

1.1.BRIEF ACCOUNT OF KABALE UNIVERSITY

Kabale University is located on plot 364 Block 3 Kikungiri Hill,in kabale
municipality.
Kabale University began lectures on 21st October, 2002, with 42 students. The plan to
establish the University had been conceived six years before in 1996.
A Steering Committee headed by Hon Avitus Tibarimbasa was selected and started
laying ground for the purpose. The Committee drafted the Kabale University
Constitution which was officially adopted on, 13th December, 1998. The idea of
launching a University in Kabale was well-received and supported by many people.
On 5th September, 1997, the Kabale District Council passed a resolution over-
whelmingly donating land for the Kabale University. This decision was subsequently
followed by the signing and sealing of a commitment deed by the Kabale District
Local Government, confirming its donation of 52 acres of land and any structures and
properties on that land. The donation of land and other structures and properties to
Kabale University inspired the Steering Committee to open an Administration Office
at Kikungiri on 5th October, 2001.
An application to operate Kabale University had been officially submitted to the
Ministry of Education and Sports on 3rd August, 1999. After operating for about three
years, Kabale University was granted a licence on 29th March, 2005, to operate as a
private university (Licence No. UI.PL.003) by the National Council for Higher
Education (NCHE). The University was, thereafter, gazetted by the government of
Uganda on 6th May, 2005, as a private university with a legal notice Number 5 of
2005. July 2015, Statutory Instruments 2015 No.3, establishing Kabale University as
Public University was gazetted.

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1.2.ORGANISATION STRUCTURE
The Chancellor of Kabale University is the titular head of the University. The
Chancellor confers degrees, diplomas, certificates and other awards of the University
may cause a visitation to the University when necessary and is often called upon for
guidance on the development of the University. The current Chancellor of Kabale
University is Professor George Mondo Kagonyera.
The University Council is the policy-making organ of the university. The University
Council is responsible for the academic, financial, human resource and social health
of the university. The current Chairperson is Mr. Manzi Tumubweinee. The University
Senate is the supreme academic authority of the University and organizes, controls
and directs the academic work of the university, both in teaching and research and has
control and direction of the standards of education, assessment and research within
the University. The Vice-Chancellor, Professor Joy C. Kwesiga, is the Chairperson
of the University Senate.

The University Management is responsible for the day to day running of the
University. The cadre comprises top administrative and academic staff. The team is
led by the Vice Chancellor. The current ViceChancellor of Kabale University is
Professor Joy.C. Kwesiga. Various institutions and individuals have played a big role
in laying the foundation for the development of Kabale University. The Foundation
Bodies consist of Kabale District Local Government, Bank of Uganda (through the
annual funding of the Chair of Economics)

Figure 1 Organisational structure

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1.3.BRIEF MOTIVATION ABOUT KAB

VISION
A sustainable vibrant centre of excellence in teaching,learning,research and
community services in the great lakes region and beyond.

MISSION
To be a people centered,efficient university that excels in generation and
dissemination of relevant quality knowledge .It aims at skills development attitudinal
change for life long learning.

MOTTO
Knowledge is the future.

1.4.OBJECTIVES OF THE TRAINING

 To enable students, appreciate the use of hand tools in the workshop in
mechanical and in production engineering.
 To teach students how to operate and maintain workshop machines for
production.
 To train students how to select materials, design and fabricate products in work.
 To introduce students to basic maintenance and repair of automotive systems.
 To introduce students to basic robotic systems.
 To enable students acquire the necessary skills for job creation rather than being
job seekers.
 To conserve the environment , maintain public health and appreciate the social
issues in engineering application.

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 CHAPTER TWO : ACTIVITIES INVOLVED
2.0.INTRODUCTION
This chapter provides a satisfactory description of equipment and machines used for
each task ,objectives to be achieved after completing the task,detailed procedure
followed during task execution ,results attained and general challenges encountered
during the process.Relevant pictures have been included to make the work enjoyable
and to deliver more emphasis on activities done.

2.1.HEALTH AND SAFETY

2.1.1. SAFETY OF THE HUMAN BEING

The following are some of the equipment that were used for human safety during the
training:
 Workshop safety shoes
The work environment was dangerous with nails and other sharp instruments. So
safety shoes were worn in order to protect the feet from being harmed by the sharp
objects.
This is because safety shoes are stronger than ordinary shoes and gum boots and sharp
objects cannot easily penetrate through them.

Figure 2:Safety shoes

 Safety helmet
The helmet was worn on the head for safety against falling debris especially when
lifting the tools from the shelves.

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Figure 3:Safety helmet

 Insulated gloves
These were worn on both hands to safeguard them from harm by sharp held material
and tools.
They were also worn to safeguard the hands from being burnt when holding material
during welding.

Figure 4:Insulated gloves

 Overall
This was worn all over the body for protection from dirt.
It was also worn to protect the clothes from oil spills while working in the workshop.
The overall also prevented the body from direct contact with the machine parts.

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Figure 5:Overall

 Dust mask
The mask was worn in such a way that it covers the nose and mouth.
This was meant to prevent dust and other small metal particles from entering both the
nose and the mouth. The mask was more useful when carrying out grinding operation.

Figure 6:Dust mask

 Goggles
These were worn in such a way that they cover the eyes. This was meant to prevent
eyes from direct contact with the sparks produced during welding.

6
Gaggles were also worn to protect eyes from entry of dust and small metal particles
during grinding operation.

2.1.2. SAFETY OF THE EQUIPMENT

There following precautions were taken to ensure safety of the equipment in the
workshop:
- Working in groups to ease the lifting of the heavy material.
- Proper handling of the equipment was ensured to prevent damage while carrying
them especially for heavy equipment.
- A fire extinguisher at the entrance of the workshop was placed to put off fire in
case of
any outbreak

Figure 7:Fire extinguisher

A large entrance which was enough for passage of large materials that were used
during the training.

Fire Precautions
Fire is a great danger in a workshop and care has to be taken not to start a fire
breakout.
The main causes of fire are;
 Careless storage of flammable materials
 Careless electrical maintenance
 People throwing away cigarettes

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2.2.GENERAL INTRODUCTION TO HAND TOOLS.
Tools/ equipment used
 Scribers
 Tri square
 Ruler
 Hacksaw
 Vice
 Taps
 Drilling machine
 Grinder
 File
 c-clamp
Objectives
 To acquire more knowledge and practical skills for operation of various hand
tools.
Technical description of work
Different operations were done such as marking, measuring, cutting, holding,
tapping, drilling, and boring.
During measuring, tools like tape measure, rulers, square, vernier callipier were
used for the straightness.

8
Figure 8:Hammer and angle grinder in use
We gained a skill of marking by using a tool like centre punch, scriber after measuring
The marked outline ensured cutting of the required work piece through using of
a hacksaw blade powered grinder.
Holding the work pieces was fully supported in the v-block, c-clamp to ease
filing, cutting, and smoothening edges of the work piece.
Drilling, boring and tapping were carried through use of taps and a drilling
machine.
Results
 At the end different practical skills for measuring, marking, tapping, holding,
drilling was obtained through use of different tools.
Challenges faced
 Fluctuating source of power
 Abrupt weather changes

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2.3. ELECTRICAL INSTALLATION AND ELECTRONICS
2.3.1.INTRODUCTION TO ELECTRONICS.

Tools used
 Resistors
 Capacitors
 Transistors
 Diodes
 Inductors
 Micro-controller
 Thyristors
 Sensors
 Transformers
 Bread board
 Printed circuit
 Vero board
Objectives
 To acquire more knowledge and practical skills
 To measure the resistance of a resistor using a multimeter.
 To learn how to test for continuity using a multimeter.
 To compare Bread board and vero board connections.
 To interprete the forward and backward biasing of a diode
Technical description of work
A diode is a device that converts alternating voltage to direct voltage. This is
called rectification process. A diode conducts current in only one direction.
The conduction of current in a diode is called forward biasing.

Therefore, forward biasing is when external DC voltage applied to the junction is in

such a direction that it cancels the potential barrier thus permitting current flow.
Multimeter
A Multimeter is an electronic instrument which can measure resistances, DC
and AC currents and voltages.
Construction
A Multimeter consists of an ordinary pivoted type of moving coil
galvanometer having a coil pivoted on jeweled bearings between the poles of a
permanent magnet. The indicating needle is fastened to the coil. When electric current
is passed through the coil, mechanical force acts and the pointer moves over the scale.

Figure 9:Multimetre

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Measuring continuity using a Multimeter
For checking the circuit continuity, a device continuity, the ohmmeter or Wi-Fi scale
is utilized and the equipment to be measured is shut off from the power mains. If the
buzzer sound is heard, then the device is continuous otherwise it is faulty.
Resistors
A resister is a device that opposes the flow of current in the circuit. The resistance of a
resistor is determined by either the color codes on it or by direct measurement using a
Multimeter.

Figure 10:Resistor
Measuring using a Multimeter
The ohmmeter scale is utilized and probe wires are tapped at both ends of the resister.
The resistance is displayed on the screen in Ω, kΩ, MΩ, etc.
Digital lab
This is a platform equipped with built-in power supply (fixed and variable), function
generator (sine, triangle, square, TTL) and universal counter as well as various
common Input/output components such as data switches, 7-segment display, LED
indicators, speaker, etc.
Breadboard
A breadboard also known as a protoboard, is a construction base for prototyping of
electronics. It has terminal strips, DIP support or the center groove, and bus strips.
The bus strips are continuous horizontally and the terminal strips are continuous
vertically. The DIP support partitions the breadboard and it runs through the middle of
the terminal strips.

Figure 11:Bread board

DC power supply
A DC power supply is a type of power supply that gives DC voltage to power a
device. It has two major power inputs: AC input that can be rectified and filtered to
produce a DC voltage; and DC input with typical values, 5V, 12V, 24V, 48V, etc.

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Figure 12:DC power supplysupply
LED
A light emitting diode is a diode that gives off visible light when forward
biased. It has two legs, the longer leg is positive and the shorter is negative. Or the
negative has a bigger end inside the vacuum valve whereas the positive has a small
end.
Analysis and observation of the circuit
.

Figure 13:Circuit analysis

Outcomes
 The forward biasing of the diode was successfully achieved.
 Circuit arrangement
 Circuit diagnosis

Challenges
 Unstable power delayed the experiment as it was off and on
 Inadequate tools in the workshop which also delayed the practical.

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2.3.2.REGULATED POWER

2.3.2.1.SOLDERING AND SOLDERING CIRCUIT

Tools used
 Soldering gun
 Vero board
 Soldering wire
 Bread board
 Transformers
 resistors
 Capacitors
Objectives
 To produce a wire mesh and solder wire across.
 To step down the voltage of 240vac or 230vac to 5vdc.
Technical description of work
Transformer steps down the current that is 240vac or 230vac to 5vdc.
Rectifier changes alternating current to direct current.
Filter removes the remaining alternating current.
Regulator output regulates amount of current.

Figure 14:Monitoring wave forms

Transformer rectifier filter regulator output

240vac transformer rectifier smoothing regulation

12vac 12vdc 12vdc 5vdc
230vac
Results
More knowledge and practical skills of connecting transformer, rectifier, filter and
regulator were obtained.
Challenges faced
Excessive smoke

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2.3.3.ELECTRICAL INSTALLATION

Tools used
 Pencil
 A ruler
 Sheet of a paper
 Priers
 Hammer
 Creeps
 Screws
 Wire
 Lamps
 Junction box
 Sockets
 Lamp holders
 Cutter
Objectives
 To acquire more knowledge and practical skills on how electrical work is done
using different types of electrical accessories components and different type of
cables.
Technical description of work
One gang one way switch were connected controlling one lamp
Two way switches were controlling two lamps where one lamp would light after
switching on and another would light after switching off the switch.

Figure 15:Electrical installation test

Second two switches were controlling three lamps where two lamps would light at
ago when switched on and another lamp would light after switching off where other
two lamps would get off.
Results
 At the end different practical skills and knowledge were obtained such as wiring
using one gang one way switch and one gang two ways for lighting two lamps at
once.
Challenges
 Abrupt weather changes
 Lack of enough supervision

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2.4.INTELLIGENT MECHANICAL SYSTEMS

PROJECT BASED LEARNING IN ROBOTICS

Tools
 Power source
 USB cable
 Bread board
 Actuators
 Effectors
 Sensors
 microcontrollers
 Computer
 Wireless connection
 Camera
 Integrated circuits
 Printed circuit boards
Objectives
 To introduce students to arduino board and software
 To introduce students to C/C++ coding language
Technical description

2.4.1.ARDUINO UNO BOARD

Arduino is a microcontroller based open source electronic prototyping board which

can be programmed with an easy to use Arduino IDE.
Features
 USB connector
 Power port
 Microcontroller
 Analog input pins
 Digital pins
 Reset switch
 Crystal oscillator
 USB interface chip

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Figure 16:Arduino uno board
 Power port:
The board can be powered through AC to CD adapter or battery.The plug used is a
centre positive plug 2.1 mm which is fixed into the power jack of a board.The board
operates at a voltage of 5V but can withstand up to 20V .I n case the board is supplied
with a higher voltage,the voltage regulator btn USB and power port is used to prevent
the board from burning out.
 USB connector:
This loads a program from arduino IDE to arduino board.
It also powers the board
 Microcontroller:
This is normally refered to as the brains of a computer.The microcontroller used here
was Atmega 328P.Its a black rectangular chip with 28 pins.
It is comprised of the following:
1. Flash memory of 32kB. The program loaded from arduino IDE is loaded here.
2. RAM of 2kB. This is a run time memory.
3. CPU. This controls everything that goes on within the device.It also fetches
program instructions from flash memory and runs them by the help of RAM.
4. EEPROM of 1kB.This is a non volatile memory and keeps the data even after the
device is at rest or reset.\\

Figure 17:Digital oscilloscope for displaying wave forms

Analog input pins:

They are six in number and lebelled 0-5 analog.These pins can read sygnal from
analog sensor eg temperature sensor and convert it into digital value that the system
understands.These pins only measure voltage and not current because they have a
very high internal resistance hence a negligible amount of current flows through them.
NB: A lthough these pins are lebelled analog and are analog input by default,they can
also be uesd for digital input.
 Digital pins:
These are lebelled 0-13 digital. They can be used as either input or output.When used
as input,they read signals from components connected to them.When used as
output,they supply power to components connected to them.
When used as output, they supply they supply 40mA 5V which is more enough to
light an LED.
 Reset switch:
When the switch is clicked,it sends a logical pulse to the reset pin of the

16
microcontroller.and now runs the program again from the start.This can be useful
incase your code doesnt repeat but you want to test it multiple times.
 Crystal oscillator:
This is made up of quartz crystal.This oscillator ticks 16 million times a second.On
each tick,the micro controller performs one operation eg addition,subtraction.
 USB interface chip:
This is a signal translator.It converts signals in the USB level to the level the arduino
board understands.
 TX-RX LED:
These are indicator LED(transmit and receive) which blink whenever the arduino
board is transmitting or receiving data.

Figure 18:Mobile robots1

2.4.2.COMMUNICATION PROTOCOL

A. UART(Universal Asynchronous Reception and Transmission)

This allows the arduino to communicate with serial devices connected to it.eg
computer etc It communicates using digital pins RX and TX.
B. I2C(Integrated Circuit)
This communication protocol is specially designed for microcontrollers.It is popular
with modules and sensors.
When connecting 2 circuits to one another,think of the main device as the master and
other devices as slaves(sensors,driver pins,and pin expansions)
It makes it possible to connect multiple masters to master slaves.
C. SPI(Serial Peripheral Interface)
This is a protol that allows microcontrollers to talk to each other.It is almost similar to
i2c but differs from it in a way that SPI allows a single master device with a maximum
of 4 slave devices.

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Figure 19:Mobile robots2

2.4.3.C++ PROGRAMMING

This is a general purpose programming language.It contains both high and low level
languages.
It has the following features.:
 Data types

 Character ie characters and symbols

 Boolean ie true or false condition
 Integer ie integer values both positive and negative
 Float ie decimals and formal values
 Arrays
Collection of similar kind of elements stored at contageous memory location.
 Strings
These are used to represent text in the program and manipulate it.There are two ways
to create a string ie IC style strings and creating string objects.
 If-else
This is a conditional statement used to run the code on condition
 Loops
These are used to repeat execution of a code instead of repeating the code again and

18
again.It has three parts ie initialisation,conditionalisation and updation.
 Functions
These are designed to perform a specific task.
Learning outcomes
 Understood various hardware features of the arduino board.
 Learnt various features of Integrated Development Environment used for
development of software.
 Understood how to download and use the Arduino IDE for the development of
software.
 Was able to understand pin configuration and features of ATmega 328p
microcontroller,which is the Arduino UNO board’s main brain.
 Understood Serial Peripheral Interface(SPI) and Integrated Circuit (I 2C) serial
communication protocols.
 Understood how to download and use the C/C++ IDE for the development of
software.
 Understood the value and importance of learning a coding language.
 Was ale to write a simple program in C/C++ with GNU compiler.

Challenges
 Limited access to wireless connection.
 The lecturer was too busy to provide adequate attention to students
 Limited tools to use for programming

2.5.FOUNDRY
2.5.1.SAND MOLDING

Tools
 cope
 drag
 Sprue pin and riser
 Strike off bar
 Vent rod
 Rammer
 Flat board
 Wheel barrow
 Pattern
Objectives
 To compare and learn how to make different sand molds
 To determine different propotions sand mold making
Technical desription
Making a sand mold required a mixture of sand ,clay and water in
appropriate propotions ie 62%,30%and 8% respectively.Only fine sand and clay are
required which calls for pounding and sieving.
The drag was placed on a flat board,inverted and an oiled pattern ,sprinkled
with parting sand placed in the drag.It was then covered by moulding sand and
rammed by use of a rammer.

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Figure 20:Pipe bender former
The drag was then inverted and a cape placed on top of it.The oiled
sprue pin and riser were positioned on top of the drag to allow easy flow of molten
metal.Molding sand was rammed around them and levelled by use of a strike off bar.

Figure 21:Cope containing riser and sprue cavities

The riser and sprue pin were removed and a small gating made.
The pattern was also pulled off by use of screws,.the cope then placed on top of
the drag and then kept indoors for sand to dry on its own
Results
 Learnt how to make different sand molds.
 Udertood the step by step procedure in making the sand mold cavity.
Challenges
 Inadequate tools
 Failure to remove the pattern well

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2.5.2.MELTING AND POURING

Tools
 Crucible
 charcoal
 furnace
 electric motor
 blower
 Pair of tongs
 aluminium scrap
 match box
 Power source

Objectives
 To analyse melting point of different metals
 To learn different pouring techniques
 To observe the different casting defects
 To learn the ways of cooling the final product
Technical description
To melt the metal ,heating was required.This called for placing a crucible
containing aluminium scrap in a furnace , putting charcoal around it and fire
ignited.The furnace is made up of fine clay and fire bricks that withstand very high
temperatures,having fusion greater than 16000c.

Figure 22:Furnace and crucible during melting

The crucible is made up of carbon graphite that is resistant to high temperatures
of about 27600c compared to melting point of aluminium of 6000c-6600c.
The furnace has limited supply of oxygen and supplementary supply was obtained by
connecting it to the blower run by the electric motor.

Figure 23:Powering of molten metal

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 The aluminium scrap added to the crucible was heated to melting point and more
scrap was added by use of a pair of tongs.Skimmers and ladles were used to to skim
the slag off the molten aluminium prior to pouring in the cavity through the runner.

Figure 24:Finished product

The brouse tongs were used for handling the crucible while lifting and
pouring.Pouring was done successfully and after the metal cooling,the mold was
broken to remove the final casting.The final casting was cooled in air to maintain the
grain size.
Results
 Learnt the melting point of different metals.
 Understood different pouring techniques.
 Observed different casting defects such as blow holes.
Challenges
 Some casting defects could not be avoided.
 Rain disrupted the cooling of the casting.

2.6.WELDING

Welding formula
 Current setting
 Length of the arc
 Angle of electrode
 Manipulation ofvelectrode holder
 Speed of travel

2.6.1.GAS WELDING

Tools
 Spark igniter
 Key
 Gloves mask
 Metal plates
 Oxy-acetylene equipment.
Objectives
 To learn the components of gas welding equipment.
 To learn how to balance different flames
 To learn the application of various flames
Technical description
The trainer explained at length the safety precautions expected in handling the
oxy-acetylene equipment.
The preliminary tests,main components and material composition were also well

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ellaborated.We were also guided on how to balance the flames.

Figure 25:Gas welding equipment

When usin the fuel-gas equipment,a specific flame is needed for

each particular purpose for example welding, cutting and hardening.The different
flames included neutral(ratio mof 1:1),carburising which contains excess acetylene
and oxidising which contains more of oxygen.

Figure 26;Carburising flame

Figure 27:Neutral flame

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Figure 28:Oxidising flame
Results
 I got more confidence in gas welding since I was given various plates of different
thickness to join which was successful.
 I learnt how to balance the flames and manipulate the welding torch.
Challenges
The oxygen horse pipe was loose which disrupted our work and led to losses.
The plates to join were very thin which made it difficult to join and every time I tried
to join,I was making holes instead of welding.

2.6.2.METAL ARC WELDING.

2.6.2(A).MAKING THE TABLE.

Tools
 Angle grinder
 Tape measure
 Welding machine
 Steel rule
 Scriber
 Tri-square
 Filler
 Hardener
 Paint
 Spray gun
 Compressor
 power source

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 1 Tape measure For measuring all linear dimensions
2 Try square For measuring all angular dimensions
3 Scriber For marking the exact measured dimensions on the material
4 Hand hacksaw For cutting thin and not very hard material
5 Cutting disc For cutting thick and very hard material
6 Bench vice For holding small work piece when cutting or bending
7 Working table It is where the components are placed
8 Anvil It where the sheet metal was bent from
9 AC arc welder Used in joining metal pieces
10 Hammer For pounding the sheet metal to the required shape
For adjusting welded joints to the correct position

11 Grinding disc For smoothening welded joints

12 Filer For removing sharp tiny edges from the product
13 Filler cards Used in applying filler material to the joints
14 Sand paper Smoothening surfaces
15 Painting brush Applying paint onto surfaces

Objectives
 To acquire the arc welding skills.
 To learn the accurate marking techniques and fabrication designs.
 To gain skills in cutting,sawing,grinding and smoothening.
 To learn different ways of obtaining a better surface finish.
Technical description
To make the required table,we needed the sheet metal for the top,the
legs,reinforcement bars and the supports.To make these materials ready we needed to
carry out operations such as cutting,leveling the legs using the hacksaw,file and tape
measure.
With the help of a tri-square and spot welding,the legs were fitted on the
made top flame to position them at rigt angles.The measured supports were also
machined and fitted very well.

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Figure 29:Metal bars

The sheet metal plate was fitted on the frame but some edge was out of
angle which called for further grinding.Full welding was then done on frames,table
tops and supports.Every after each welding,the chissel would be used to chip off the
slag to make a clean and fine joint.This was folowed by grinding and smoothening
the workpiece before further welding was applied to achieve a better surface finish.

Then the filler was used to level the remaining gaps.the mixture of filler and
hardener was done in the ratio of 50:1.The function of the hardener was to boost
resilience on the surface.
Too little hardener might cause rapid gelling while too much filler increases cure time.

Figure 30:Finished products

The table was then smoothened by using sand paper to remove the excess
filler and to rub off the rust and any dirt.The table was balanced on the ground to test
its stability.In cases where it was not balancing ,some small metal was welded below
the legs to bring balance.

Figure 31:Table sketch

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 The finished tables were painted using a mixture of red oxide and
thinner.The spray gun used to paint was connected to a compressor run by elecric
power which eased the work and increased smoothness.The tables were then exposed
to sunshine to dry.
Results

 More grinding and cutting skills were gained as differnt techniques were
illustrated.
 Gained more welding skillsand learnt how to control the current setting.Each
material thickness requires different plate preparations and current setting.
Challenges
 There was power fluctuation and yet the generator co uld not support the welding
operations except grinding machine.
 There were inadequate tools suc angle grinder scriber,tri-square which caused
delays in finishing the work

2.6.2(B).MAKING THE CAGE.

Tools
 Angle grinder
 Tape measure
 Welding machine
 Steel rule
 Scriber
 Tri-square
 Vice
 Hack saw
 Filler
Objectives
 .To practice and get more exposed to welding works.
 To boost confidence in measuring fabrication and accuracy awareness.
 To eliminate the defects made on the previous works.

Technical description

The cage with two shelves was required where each shelf had a hinged door
and completely enclosed on the other sides.This required us to cut enough plates and
grind them smoothly.The legs,the supports and reinforcements were also adequately
prepared

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Figure 32:Cage sketch
.The angle joining the upper flame and the supports was 450.
the frame was first obtained by spot welding and unclearenesses were corrected by re-
grinding,measuring and spot welding.the plates fitting at different positioned were
tried, smoothened and welded to their appropriate positions.complete welding was
done and slag removed to obtain a better joint.grinding was also done to smoothen the
surfaces

Figure 33:Unfinished cage

The application of the filler mixed with hardener was done and sand paper
was used to remove excess filler.the finished cage was then painted with red oxide
mixed with thinner.
All the finished products were then displayed and painted with grey paint

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which was mixture iof many paints(black,yellow,white).they were also exposed to the
sun to dry and be ready for use.
Results
 Gained more confidence in measuring,fabrication and accuracy awareness.
 We reduced the defects obtained in making the table.

Challenges

 Failure to achieve the required accuracy due to disrespect to clearence during

cutting and sawing.

 Rain drops fell on the already just painted productsand prevented a better surface
finish in the product

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 CHAPTER THREE:CONCLUSION,CHALLENGES
RECOMMENDATIONS AND REFERENCES
3.1.CONCLUSIONS
It has been a resourceful and interesting training to me and it has really helped me to
transform the theory that was learnt in class into practical. It has also been
fundamental in boosting my confidence in handling machines such as
grinders,welding torches and many other machines.
More skills and capabilities have been identified which when put together will help
this world to move.

3.1.2.SKILLS ATTAINED
A skill in welding and metal fabrication was attained.
A skill in identifying and fixing problems resulting from engine failure was attained.
Exposure and preparation to the working environment was also another benefit
attained during the training.
A skill in planning and designing different products was also another benefit.
Knowledge in relating electrical and mechanical systems for better performance of
machines was also obtained.
Exposure to mechanical intelligent systems and project based learning in robotics and
artificial inteligent systems was obtained.
Skills in electronics and electrical installation have been greatly achieved.

3.2.GENERAL CHALLENGES FACED .

* Un stable electric power supply during the training.
* Limited time for the training.
*Lack of accessories for some required machines for example lathe machines and
milling machines in the workshop.
* Inadequate tools for example grinders, pliers and arc welders.
* Learning from very old equipment for example a very old engine.

3.3.RECOMMENDATIONS
To kabale university
a) - The training duration should be increased from one month to two months for
better acquisition of skills, new technologies and practical knowledge by
students.
b) .Adequate tools ,materials and equipment should be bought to enable students
venture into different productions. And designs.
c) - Machines should be bought in order for students to acquire all the required
practical skills during their course of study at KAB.
d) - Supervisors should always visit the training places in time to advise or credit the
work being done during the training.
e) - Information about the training program should always be delivered early to
students so that they prepare early.
f) - The university should put in place a standby generator in order to ensure that
power supply is stable all the time during the training.
g) - The university should buy vehicles to learn from during practical and include
driving on the training program..

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3.4.REFERENCES

[1] Tom Denton, Advanced Automotive Fault Diagnosis, New York: Routledge,
2017.

[2] Allan Bonnick and Derek Newbold, A Practical Approach to Motor Vehicle
Engineering and Maintenance, UK: Arnold, 2011.

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3.5APPENDICES

Programming
practice

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Electrical installation practice

33
Gas welding practice

34
Display of finished products

35