UNIVERSITI TEKNIKAL MALAYSIA MELAKA

FAKULTI KEJURUTERAAN MEKANIKAL

WORKSHOP REPORT

DMCU 1912 – TECHNOLOGI AND SEMESTER I SESSION 2021/2022

ENGINEERING WORKSHOP
PRACTICE 1

ARC & MIG WELDING / FABRICATION / FITTING

No. Name Matrix No. Section

1. Muhammad Muaz Zakwan D042110219 1
Bin Zamri Group 7
2. Rabiatul Adawiyah Binti D042110245 1
Mohamad Shafiee
3. Mohamad Nurshabani Bin D042110157 1
Ma’arop
4. Muhammad Afiq Aiman Bin D042110114 1
Mohd Zahar
Submission 5/12/2021
date
Prepared for : IR. Dr. Abdul Rafeq Bin Saleman

LECTURER REMARKS EVALUATION

1.0 Title & Objectives

2.0 Introduction & Theory

3.0 Work Procedures & Apparatus

4.0 Suggestion for improvement

5.0 Conclusion

6.0 References

TOTAL
1.0 Tittle & Objectives

Tittle: Lab Report For Fabrication

Objectives:

1. Understand the safety measures that should be emphasized while in the workshop.
2. Proper handling of equipment involved in the rushing process.
3. Able to recognize the type of equipment involved in the rushing process.
4.Fully understand the processes involved during the rushing process.

2.0 Introduction & Theory

2.1 Introduction

Metal fabrication involves cutting, folding and assembling metal structures. It's a value-added
process that involves making machines, components, and structures out of a variety of basic materials.

Sheet metal forming is a method of forming work on thin metal sheets or mild steel in various ways
according to the desired work movement. The fabrication process usually involves the work of drawing a
spreadsheet, measuring, marking, cutting and shaping the workpiece to get the desired shape. Common
materials used in fabrication include galvanized iron, tin, aluminum, copper and stainless steel.

Both human labour and automation are routinely utilized in manufacturing operations, as they are in other
industries. A fabrication is a fabricated product, and fab shops are firms that specialize in this sort of
labour. Other popular methods of metalworking, such as machining, metal stamping, forging, and casting,
produce comparable end products in terms of shape and function, but they are not categorized as
fabrication. (Funkhouser et al. 2004)

2.2 Theory of Fabrication

Fabrication involves a few processes which is cutting, bending, and assembling. Cutting is done by
sawing, shearing or chiseling with manual and motorized torch versions with portable torches such as
oxy-fuel torches or plasma torches.

Other than that is bending. Bending is done by hammering manually or powered or via press breaks,
tube benders and similar tools. Modern metal fabricators use press breaks to coin or air bend metal sheet
into form.

The pieces are then assembled by welding, adhesive binding, riveting, threaded fasteners, or further
bending in the form of crimped seams. The most common materials for fabrication are structural steel and
sheet metal, with welding wire, flux, and fasteners used to join the cut pieces.(Shaurya Prakash , Marie
Pinti , Bharat Bhushan , May 2012)
a) Safety measures in the workshop:
1. Be sure to wear appropriate clothing such as safety boots and a lab coat.
2. Be sure to be guided by the workshop staff during the workshop.
3. Use all machines correctly and carefully.
4. If there is damage to the machine, stop all work and report it to the workshop staff. Do not start
work until the damage to the machine has been repaired.
b) Procedures before starting workshop work:
1. Provide all the equipment to be used during the workshop.
2. Carefully read all existing machine instruction descriptions and warning notes before starting
work.
3. Inspect and ensure all equipment and machinery are in good condition and report to staff if there
is any damage.
4. Keep the work area tidy.

Figure 2.1 Main Body

Figure 2.2 Figure 2.3 Holder

Figure 2.4 Isometric View

c) Procedures during the workshop:
1. Understand the drawing of a spreadsheet that has been given in the lab sheet.
2. Perform the process of measuring and marking according to the measurements given in figure 2.1
of the main body.
3. Draw the shape of the main body based on figure 2.1 on the iron surface according to the
measurements on the measurement process using a steel ruler, L-square, protractor ruler to
measure the angle as in figure 2.2 and mark using a scriber.
4. Mark the place to be drilled using a scriber.
5. Perform the cutting process on the iron sheet according to the mark that has been made using
scissors to produce the shape as shown in figure 2.1.
6. Fold the iron sheets using a folding machine to form the main body as shown in figure 2.4.
7. Repeat steps 2 to 6 guided by figure 2.3 to form the holder as shown in figure 2.4.
8. Punch a hole in the part that has been marked based on figures 2.1 and 2.3 using a drill press.
9. Join the main body part and the handle to produce the desired shape as figure 2.4 isometric view.
join the part using rivets.
d) Procedures after the workshop are conducted:
1. Make sure the work area has been cleaned.
2. Put used tools back in their proper place.
3. Make sure excess unused iron sheets are disposed of in the trash.
4. Turn off all machines after use.

Apparatus
1. Iron sheet
2. Steel ruler
3. L-square
4. Protractor ruler
5. Scriber
6. Scissors
7. Folding Machine
8. Drill press
9. Rivet

4.0 Suggestion for Improvement

1) PROJECT MATERIALS FOLDING

During the folding procedure, our crew made a few blunders. The error is that we fold the project materials
using the folding machine rather than following the line we have already drawn. So, the next change we
need to do is to carefully place the project in the folding machine and follow the line that we have
produced. To ensure that no errors occur during the procedure, our eye must be perpendicular to the line
that has already been drawn. The error is depicted shown in Figure 4.1.
 Figure 4.1

2) MEASURE THE PROJECT PROCESS

In this procedure, our group made a mistake in that we did not precisely measure the materials project and
follow the lab sheet. This is due to the fact that we take the measurement once and then proceed to draw
the line on the project. As a result, our project extends by 10 mm beyond the measured origin. To guarantee
that this error does not occur again in the future, we must measure three times to verify that the
measurement is precise. After that, if the measurement is validated, we may draw a line on the project and
proceed with the cutting procedure. The error is depicted shown in Figure 4.2.

Figure 4.2
5.0 Conclusion

The objective of this laboratory work to Learners and fully understand the safety measures that need to
be emphasized while in the workshop. We can also learn about the cooperative spirit among members of
each group during practice to solve the problem together. After that, we can complete the project
according to the design and measures provided in the sheet lab to achieve the project goals and according
to our requirements. Thus, we were able to learn how to handle the related equipment during the proper
implementation of manufacturing projects, for example Drill Press, Folding Machine, etc. Not only that,
we also gained much of the appropriate knowledge and techniques that were indicated by the lab. Finally,
we can enhance our skills in machine operation to produce quality products so that we can use this
technique in industrial training in the future.

6.0 References

1. Funkhouser et al , 2004 ,https://modernmobile.cs.washington.edu/docs/fabbyexample.pdf

2. May 2012, Shaurya Prakash , Marie Pinti , Bharat Bhushan ,
https://www.researchgate.net/publication/224052959_Theory_Fabrication_and_Applications_of
_Microfluidic_and_Nanofluidic_Biosensors
3. 2017 , Marcelo Martins . M . Werneck , Regina C.S.B Allil ,Fabio V. B de Nazare , Fiber
Bragg Gratings: Theory, Fabrication, and Applications (spiedigitallibrary.org)