FACULTY OF ENGINEERING, TECHNOLOGY, APPLIED DESIGN AND

FINE ART

DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL TRAINING REPORT

BY:

AMANYA SYLUS

2020/A/KME/0065/G/F

PLACE OF TRAINING: FETADFA

FROM 17TH JAN, 2021 - 25TH FEB, 2021

A recess term training report submitted to the department of Mechanical Engineering in partial

fulfillment of the requirements for the award of a bachelor degree in mechanical engineering of

Kabale University.

ii

DECLARATION

I AMANYA SYLUS, declare that this report was prepared by me during the recess training and

it has not been submitted to any other institution for any other award before.

Signature…………………….

AMANYA SYLUS

Date ………………………….

TEL: 0774911323

EMAIL: amanyasylus@gmail.com

iii

APPROVAL

This is to certify that AMANYA SYLUS registration number 2020/A/KME/0065/G/F had a

period of one and a half a month (six weeks) of industrial training at Nyabikoni Campus and this

is a true record of the work he did under supervision and is now ready for submission to the

board of Examination and Senate of KABALE UNIVERSITY with approval.

Signature: ………………………

Mr. KANYAMUMBA LIBERTY

(Field supervisor.)

Date: ………………………

Signature: ……………………….

Ms. KIZANYE STELLA

(Academic supervisor.)

Date………………

IV

DEDICATION

I dedicate this report to my parents Mr. and Mrs. POLLY and LATISIA KYALIKUNDA who

have been supportive and encouraging and for the love and respect they have for education.

I also dedicate this report to my siblings and my fellows who have been with me while in this

due course.

ACKNOWLEDGEMENT

I would like to thank our almighty God for his might and mercy upon my industrial training as

far as his grace, love and protection are concerned. I would not have been able to write this

report. I wish to thank the government of Uganda for all its tireless efforts to provide us with

security and a conducive environment in which we study.

Special thanks also go to the administration of KABALE UNIVERSITY for all its works to

ensure that our stay at KAB. Is a memorable one. To all lecturers at FETADFA especially in the

program of MECHANICAL ENGINEERING I say well done, your work deserves special

recognition.

Finally, I would like to thank my fellow students for their might co-operation throughout the

industrial training period. May God bless you.

VI

ABSTRACT

This report is about the recess term that was undertaken from 17th Jan to 25th Feb, 2022 at the

faculty of Engineering Technology Applied Design and Fine Art KABALE UNIVERSITY

Nyabikoni Campus.
This report accounts for the workshop practice I participated in, observed and other areas of

professional practice. It consists various workshop works and practices such as the engine

overhaul, foundry, metal fabrication and electronics and electrical installation.

This has helped me to broaden my knowledge, upgrade my career and carry out practical

activities on site and in workshops. For purposes of clear illustration, relevant pictures are

included.

VII

TABLE OF CONTENTS

DEDICATION...........................................................................................................................................IV

ACKNOWLEDGEMENT......................................................................................................................... V

ABSTRACT...............................................................................................................................................VI

LIST OF TABLES ....................................................................................................................................XI

LIST OF ABBREVIATIONS ................................................................................................................ XII

1.1 Organizational structure of Kabale university. .......................................................................................1

1.2 Historical Background ..........................................................................................................................2

2.1 WORK SHOP SAFETY EQUIPMENT .................................................................................................3

2.1.2 SAFETY RULES AND PRECAUTIONS.........................................................................................6

2.2 THE ENGINE OVERHAUL..................................................................................................................7

2.2.4 DIAGNOSING OF ENGINE PARTS. ..............................................................................................10

2.2.5 Measurement of
clearance .................................................................................................................10

2.2.6 Possible causes..................................................................................................................................11

2.2.7 CLEANING AND ASSEMBLING THE ENGINE PARTS. .........................................................12

2.3.3 Disadvantages. ..................................................................................................................................14

2.3.4 Raw materials and tools

used.............................................................................................................14

2.3.5 Tools ..................................................................................................................................................14

2.3.6 Important casting terms....................................................................................................................15

2.3.7 Materials used in molding.................................................................................................................16

2.3.8 STEPS IN MAKING SAND CASTINGS .......................................................................................17

CORE AND MOULD MAKING .....................................................................................................17

Preparation of sand mold.........................................................................................................................17

2.4.2 METAL MELTING AND POURING ..............................................................................................19

2.4.3 FINISHING OPERATION................................................................................................................20

2.5: WELDING AND METAL FABRICATION...................................................................................21

2.5.1 METAL FABRICATION.................................................................................................................21

2.5.2 Welding as a workshop practice exposes us to the following hazards; ............................................21

2.5.2 welding
positions ...............................................................................................................................22

VIII

2.5.3 FABRICATION OF THE TABLE. .................................................................................................23

2.5.4 OBJECTIVES OF FABRICATING THE TABLE............................................................................24

2.5.5 TOOLS USED ...................................................................................................................................24

2.5.6 The description processes/ operations in fabricating a

table.............................................................25

2.5.9 FABRICATION OF A BRACKET ...................................................................................................27

2.6.1 Painting of the

bracket .......................................................................................................................28

2.7: ELECTRONICS AND ELECTRICAL WORKS................................................................................28

2.7.1 Electronic components and their uses...............................................................................................28

2.7.5 USING CIRCUIT BREAKERS WHILE WIRING..........................................................................36

2.7.6 TESTING FOR RESISTANCE, CAPACITANCE OF A CAPACITOR ON A PRINTED BOARD

(VERO BOARD) ........................................................................................................................................37

CHAPTER THREE: CONCLUSION, RECOMMENDATIONS AND REFERRENCES................38

3.2 GENERAL SKILLS AND KNOWLEDGE ATTAINED DURING THE TRAINING......................38

3.3 GENERAL CHALLENGES FACED DURING THE TRAINING ....................................................38

3.4 POSSIBLE SOLUTIONS.....................................................................................................................39

3.5 RECOMMENDATIONS......................................................................................................................39

IX
LIST OF FIGURES

Figure 1 helmet ..........................................................................................................3

Figure 2 safety boots..................................................................................................4

Figure 3 an overall .....................................................................................................4

Figure 4 nose mask ....................................................................................................5

Figure 5 gloves...........................................................................................................5

Figure 6 eye goggles ..................................................................................................6

Figure 7 cylinder of an engine ...................................................................................7

Figure 8 piston of an engine......................................................................................8

Figure 9 fuel pump of an engine.............................................................................9

Figure 10 dismantling of an engine ...........................................................................9

Figure 11 analysis and cleaning f engine parts ........................................................12

Figure 13 fixing back of engine accessories............................................................12

Figure 14 sieving of clay and sand ..........................................................................18

Figure 15 finished mold ...........................................................................................18

Figure 16 preparation of mold .................................................................................19

Figure 17 firing of molds .........................................................................................19

Figure 18 firing of molds .........................................................................................20

Figure 19 produced product after firing and cooling of molds................................20

Figure 20 flat position of welding............................................................................22

Figure 21 illustration of horizontal welding position ..............................................22

Figure 22 over head welding position......................................................................23

Figure 23 a gas welding equipment .........................................................................23

Figure 24 a 3-D solid work of table to be produced ................................................24

Figure 25 a semi finished table to be finished .........................................................26

Figure 26 painting of the table.................................................................................26

Figure 27 a 3-D figure of a bracket to be produced.................................................27

Figure 28 capacitor types .........................................................................................29

Figure 29 resistor types............................................................................................29

Figure 30 diode ........................................................................................................31

Figure 31 transistor ..................................................................................................32

Figure 32 bread board ..............................................................................................32

Figure 33 vero board................................................................................................33

Figure 34 lighting a single bulb ...............................................................................34

Figure 35 lighting two bulbs with one switch..........................................................35

Figure 36 three bulbs lighting after wiring ..............................................................36

Figure 37 figure of a circuit breaker ........................................................................36

XI

LIST OF TABLES

Table 1 showing bearing clearance..........................................................................11

Table 2 showing colour codes, value,multiplying factor and tolerances of resistors

..................................................................................................................................31

Table 3 showing values of resistances and capacitances obtained..........................37

XII

LIST OF ABBREVIATIONS

FETADFA -Faculty of Engineering Technology Applied Design and Fine Art.

PPEs: Personal Protective Equipments

KAB: Kabale University

IC engine: internal combustion engine.

CHAPTER 1: GENERAL INTRODUCTION

This chapter consists of the organization of KABALE UNIVERSITY, back ground history of the University,

the vision and motto of the University. It explains clearly about the historical background of the
University,

progress of the university and the administration structure.

Industrial training covered a wide range of industrial work related to the academic work which I did
during the
course from the lecture room, I was able to acquire theoretical and practical knowledge which enabled
me to

finally come with a report of what I covered in this training. The training started at KABALE UNIVERSITY –

Nyabikoni Compass-Southern Division-Kabale Municipality- Kabale District

1.1 LOCATION

Kabale University Faculty of Engineering, Technology, applied design and Fine art is located in

Nyabikoni, Kabale municipality, Kabale district in south western Uganda.

1.2 PROBLEM STATEMENT

The unending developments in technology have led to insatiable demand for technocrats and experts.

This has increased the demand for well-trained engineers because they play the biggest role in

technological advancement and maintaining them.

1.1 Organizational structure of Kabale university.

The chancellor of Kabale university is the titular head of the university. The chancellor confers degrees,
diploma,

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 university is
professor

George Mondo Kagonyoera.

The university council is the policy- making organ of the academic, financial, human resource and social
health

of the university. The Vice Chancellor, professor Joy C. Kwesiga, is the chairperson of the university
senate

The management is responsible for the day today running of the university. The cadre comprises top

administrative and academic staff.

The team is led by the vice Chancellor 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)

VISION
A sustainable vibrant Centre of excellence in teaching, learning, research and community services in the
great

region and beyond

MISSION

To be a people centered, efficient university that excels in the generation and dissemination of relevant
quality

knowledge. It aims at kills development attitudinal change for life long learning

MOTTO

Knowledge is future

1.2 Historical Background

Kabale University Institute of Engineering and Technology started in 2008 with diploma and certificate
courses.

After the university became a public university in 2015, programs at bachelor degree level in civil and
building

engineering, electrical and electronic engineering, mechanical engineering and Applied design and fine
art were

added to the curriculum. It now has four departments consisting of highly qualified and dedicated staff
and that

is Kabale University Faculty of Engineering, Technology, Applied design and Fine art.

As part of the academic requirements for the award of Bachelor’s degree in Mechanical Engineering at

KABALE UNIVERSITY, every student is required to perform a practical training known as industrial
training

in any company or institution relevant to the student’s discipline. The purpose of industrial training is to
enable

the student practically apply the knowledge obtained the course and gain hands-on experience of works

preformed in the industry.

It is in this context that I carried out industrial training at Nyabikoni campus which is a Faculty of
Engineering

Technology Applied Design and Fine Art at KABALE UNIVERSITY situated at Southern Division Kabale

Municipality, Kabale District. This report details the works carried out and is a partial fulfillment of the
award

of a bachelor’s degree in Mechanical Engineering.

3

CHAPTER TWO: HEALTHY AND SAFETY AND VARIOUS WORKS CARRIED OUT

DURING THE RECESS TRAINING.

This chapter consists of various recess training activities carried out from 17th.Jan.2022 to
25th.Feb.2022 at

FETADFA. It also covers various health and safety precautions and Equipments that aided us in making
the

recess training a successful one.

2.1 WORK SHOP SAFETY EQUIPMENT

2.1.1 Safety at work place was an important thing in order for my recess to be successful. In order to be

safe, I had to have safety equipment before going to the mechanical workshop at FETADFA. The
following

were the safety equipment I used;

Helmet

This is basically worn on the head to safe guard the engineer from any falling object. I had to put on the
helmet

at all times to protect my head from any danger and accident.

Workshop safety shoes

Figure 1 helmet

Figure 2 safety boots

Due to a dangerous working environment with nails and other sharp instruments everywhere, it is not
advisable

to move around bare footed or with normal shoes. Safety shoes were recommended because they have
a strong

sole and are leather made to protect the feet.

Overall

Figure 3 an overall

This is a cloth worn over the whole body to protect the person from getting dirty. I wore the overall to
protect

my clothes from oil spills while working in the workshop and also prevent body contact with some
machine
parts.

Nose masks

Figure 4 nose mask

These are basically worn over the nose to safe guard the person from inhaling contaminated air. I wore
the nose

masks every time especially during welding since during welding dangerous gases are produced which
can

affect one’s health.

Gloves:

Figure 5 gloves

these are basically worn to prevent hands and the arms from sustaining injuries during work. Gloves
further

help the worker from getting dirt into the hands and arms for example they prevent the engineer from
getting

into contact with oil spills especially when working on an engine.

Eye goggles:

Figure 6 eye goggles

these are very important to an engineer in a sense that they prevent eyes from high ultraviolet
radiations which

are always emitted during workshop operations and practices such as welding. Once eyes are not
protected,

these radiations of high intensity may damage the eye retina and other core parts of the eye and in the
future you

may be blind.

Ear muffs: these are basically worn in the ear to prevent the ears from high intensity sounds emitted
during

workshop practices. These sounds may damage the ear drum which may lead to deafness and other ear

disorders. Ear muffs also protect ears from sustaining injuries during work shop operations and practices

2.1.2 SAFETY RULES AND PRECAUTIONS

As safe working place is not always enough to control all potential hazards, I had to be very observant
and work

safely. The workshop safety rules guided and helped me to control risks of injuries from work place
hazards.

The following were the safety rules and precautions I had to follow while in the mechanical workshop at

Nyabikoni campus.

❖ Use machines and tools properly. It is always advisable to ask for help from the instructors whenever

you don’t know what to do next with the machine or tools.

❖ Personal protective equipment’s are a must. These include the overall, helmets, safety shoes among

others which prevent the engineer from sustaining injuries while in the workshop.

❖ Always attend safety meetings to get updated about new safety precautions to avoid future
accidents.

❖ Clean the workshop after working in it.

❖ Follow advice from the instructors to avoid using the machine or tool in a wrong way.

2.2 THE ENGINE OVERHAUL

This activity consists of a brief introduction about the engine such as parts of the engine, diagnosis of
engine

parts, dismantling and assembling of engine parts, setting of timing marks and among others.

It covers various disciplines about the engine and it gives a student experience and skills about engine
repair

and maintenance. As a mechanical engineer, engine analysis is very important in a sense that it exposes
him/her

to various skills and experience that can aid him in solving engine related problems.

Engine overhaul

This is the process of dismantling the engine, cleaning the internal components and assembling it. The
engine

may be dismantled on a work bench or flat floor. It is done by first removing the engine accessories and

mountings, the ignition system and its components including all sensors, distributor cap and rotor arm.

2.2.1 THE PARTS OF AN ENGINE AND THEIR FUNCTIONS

Cylinder
Figure 7 cylinder of an engine

The engine cylinder is a part or space where fuel is admitted and the reciprocating motion of the piston
is

obtained by burning it. The engine cylinder is characterized by its bore and stroke.

Crank shaft

Crank shaft is a part of the engine which has projections bent and offset from the shaft axis. This design

converts the sliding motion obtained from the piston into rotary motion via the connecting rod.

The piston

Figure 8 piston of an engine

The piston is the cylindrical part which moves up and down in the cylinder and enables compression and

expansion of the charge during the combustion cycle.

Cylinder head

The cylinder head is the part which sits on top of the cylinder block and houses the valves, rocker arms
and the

ignition elements.

Connecting rod

The connecting rod is the link connecting the piston to the crank shaft. It converts the linear motion of
the

piston into rotary motion of the crank.

Valves

Valves used in IC engines are called poppet valves. They have a long thin circular rod known as the valve
stem

at the end of which is a flat circular disk called the valve head. The valves are responsible for the intake
of fresh

charge and exhaust of waste gases.

Crankcase

This is a metallic case or housing in which the crankshaft is placed. The crank case has the main bearings
in

which the crank rotates.

Pump Oil and sump

The oil pump pumps the oil to various parts of the engine for effective lubrication, cooling and cleaning.
The oil

is pressurized to the passages machined in various components, which then lubricates and cools them.

The fuel pump

Figure 9 fuel pump of an engine

The fuel pump pressurizes the fuel to such a pressure that it atomizes and when it is sprayed in the
cylinder, it

gets ignited when it comes in contact with the air.

Other parts of the engine include, the alternator, rocker arm, fuel injectors, and among others.

2.2.2DISMANTLING OF AN ENGINE

I was instructed by Mr. Bruno on how to dismantle the engine though it was not most successful since
we had

no an assembling kit. For that matter therefore we disassembled the engine accessories as follows:

Figure 10 dismantling of an engine

✓ I started by disassembling the over flow tank and the radiator using tools such as spanner 10.

✓ In order to remove the drive belt, I first had to loosen the tensioners using spanner 12 and then I

removed the alternator, the fan and finally the belt.

✓ I removed the air cleaner using spanner 17 and from there I removed the exhaust pipe and the turbo

charger.

10

✓ Through visual inspection, I found out that the turbo charger was clogged and the connecting shaft
was

broken. Also, the impellers could not move freely.

2.2.3SETTING OF IGNITION TIMING WITH NO TIMING MARKS.

Through the guidance of the instructor Mr. Bruno, I had to set the ignition timing with no timing marks
as

follows;

I first removed the all-fuel injectors using spanner 19 to make the crank pulley easier to turn by hand.

I then removed the valve cover and rotated the crank pulley clockwise as I observed the cylinder. Then i
inserted the screw driver into the number one cylinder and rotated the crank pulley slowly back and
forth

until the screw driver was at maximum height.

This showed that the number one cylinder was at its top dead center (TDC) where as other cylinders
were at

bottom dead center (BDC).

2.2.4 DIAGNOSING OF ENGINE PARTS.

Tools used;

• Spanners

• Cleaning equipment such as petrol, oil and diesel

• Vernier caliper

• Filler gauges

• Tarpaulin etc.

In order to identify faults in an engine or engine parts, I based on measurement of clearance.

2.2.5 Measurement of clearance

This aids in identifying the wearing off of the piston and the cylinder bore.

Using a vernier caliper, the values of average bore diameter and piston diameters were determined.

11

The clearance in the main bearings was determined with nuts at a torque of 30 foot pounds and the
vanier

caliper was used to measure the average inner diameter which I found in the range 4.84mm-4.81mm.

The wearing off of the piston and the cylinder could have been caused by high temperatures, friction or
low

pressure according to the trainer’s explanation. There were also scratch lines on the piston cylinder
which I

viewed using visual inspection.

With visual aid, wearing off of the main bearings was spotted and this could have been caused by
friction, low

oil pressure and high temperatures.

I also observed brownish deposits on the gasket which signified the mixing of oil and water.

A table of values on the bearing clearances

Number of main

bearing diameter,

main journals Main bearing

diameter, A1(mm) Main journal

diameter, A2 (mm) Clearance, C (mm)

1 4.83 4.81 0.02

2 4.84 4.80 0.04

3 5.00 4.79 0.21

4 4.85 4.82 0.03

5 4.82 4.81 0.01

Total 24.34 24.03 0.31

Average 4.87 4.81 0.06

Table 1 showing bearing clearance

The average clearance was larger than the maximum standard clearance value of 0.0254mm or 0.001-
inch for

every one inch of the main journal diameter.

2.2.6 Possible causes

▪ Extreme operating conditions such as overheating

▪ Reduced oil clearance causing metal to metal contact which in turn would result into friction.

▪ Low oil pressure which failed to lubricate the parts of the engine thus increasing wearing off.

12

2.2.7 CLEANING AND ASSEMBLING THE ENGINE PARTS.

I cleaned all the disassembled parts as follows;

▪ I soaked the alternator and the turbocharger in the bucket that was containing petrol for some time
and

after I cleaned it using cotton gauze.

▪ I also cleaned all the exterior engine components with gauze soaked in petrol except the fuel injectors

that I cleaned using diesel.

Figure 11 analysis and cleaning f engine parts Figure 12 cleaning of the engine parts
▪ I then fitted the belt on the alternator and the crankshaft pulley which was followed by fixing the

alternator and the tensioners using spanner 12.

▪ I then fitted back the fan using spanner 10 and then fixed the radiator to its position and the overflow

tank as well using spanner 10.

▪ I further fitted back the turbo charger that I used the mallet to fit it before fixing it back on the engine.

▪ Finally, I fixed the turbo charger, air cleaner and the exhaust pipe on the engine using spanner

Figure 13 fixing back of engine accessories

13

2.3 FOUNDRY.

This activity covers the brief theory about casting, the procedures followed in mold making and casting
until the

final product is produced. This activity was very fundamental during the recess session because it
equipped me

with skills and experience in casting up to when the final product was produced.

2.3.1 Foundry practice consists of making sand molds and filling them with metal in a liquid form which

hardens into casting.

Sand casting is the metal casting process where metal melted in furnace is poured into cavities made in
sand.

The final shape obtained from this process is called a metal casting.

Metal casting is the process of producing metal shapes by pouring molten metal into molds. Sand
casting is

commonly used because it is less costly to produce as compared to cast steel, easily cast, readily
machinable

and suitable for a wide range of cast metal products that do not require superior strength and
malleability of

steel.

The iron foundry industries comprises of establishments that produce both rough and machined iron
castings by

melting scrap iron, pig iron and scrap steels in a traditional coke fired furnace or in electric arc furnaces.

Furnaces are used for high temperature heating and Coke fired furnaces are commonly used because
they are

readily available and cheap compared to other types of furnaces.

The castings produced are grouped in to three classes each having distinct physical properties such as;
strength,

toughness and durability.

2.3.2 Summary of advantages of sand molding casting technique.

➢ The tools used are cheap and readily available.

➢ It's possible to practically cast any material.

➢ There's no limitation to the size and weight of the casting

➢ The technique makes it easy to cast very intricate shapes since the molten metal can flow through to
all

14

interstices of the mold.

2.3.3 Disadvantages.

✓ Complete automation is almost possible

✓ It's labor intensive

✓ The process results in poor surface finish

2.3.4 Raw materials and tools used

Raw materials

✓ Sand

✓ Water

✓ Clay

✓ Lubricant

✓ Aluminum metal pieces

✓ Charcoal

2.3.5 Tools

Wheel barrow. This is used in the sand washing process and carrying of

Shovel. It consists of a steel pan fitted with a long wooden handle.

It is used in mixing, tempering and conditioning the foundry sand by hand. It is also used for moving and

transforming the molding sand to the container and molding box or flask. It should always be kept clean

Trowel. They are utilized for finishing flat surfaces and joints and partings lines of the mold. They consist
of
metal blade made of iron and are equipped with a wooden handle. The common metal blade shapes of
trowels

may be pointed or contoured or rectangular oriented. The trowels are basically employed for smoothing
or

slicking the surfaces of molds. They may also be used to cut in-gates and repair the mold surfaces

Lifter. They are utilized for finishing flat surfaces and joints and partings lines of the mold. They consist
of

metal blade made of iron and are equipped with a wooden handle. The common metal blade shapes of
trowels

may be pointed or contoured or rectangular oriented. The trowels are basically employed for smoothing
or

slicking the surfaces of molds. They may also be used to cut in-gates and repair the mold surfaces

15

Hand riddles. It consists of a screen of standard circular wire mesh equipped with circular wooden
frame. It is

generally used for cleaning the sand for removing foreign material such as nails, shot metal, splinters of
wood

etc. from it

Shovel. It consists of a steel pan fitted with a long wooden handle.

It is used in mixing, tempering and conditioning the foundry sand by hand. It is also used for moving and

transforming the molding sand to the container and molding box or flask.

Strike off bar this is a flat bar having straight edge and is made of wood or iron. It is used to strike off or

remove the excess sand from the top of a molding box after completion of ramming thereby making its
surface

plane and smooth. It’s one edge is made beveled and the other end is kept perfectly smooth and plane.

Rammers This is a flat bar having straight edge and is made of wood or iron. It is used to strike off or
remove

the excess sand from the top of a molding box after completion of ramming thereby making its surface
plane

and smooth. It’s one edge is made beveled and the other end is kept perfectly smooth and plane.

Sprue pin. It is a tapered rod of wood or iron which is placed or pushed in cope to join mold cavity while
the
molding sand in the cope is being rammed. Later its withdrawal from cope produces a vertical hole in
molding

sand, called sprue through which the molten metal is poured into the mold using gating system.

It helps to make a passage for pouring molten metal in mold through gating.

Furnace. This is a device that is aided by an electric motor which runs a fan that is used for blowing air
into the

burning charcoal to provide the necessary heat for melting aluminum.

2.3.6 Important casting terms

Flask

A metal/ wood frame, without fixed top/bottom in which the mold is formed.

Pattern.

It's the replica of the final object to be made. The mold cavity is made with the help of pattern

Parting line

This is the dividing line between the two molding flasks that makes up the mold.

Molding sand

Sand, which binds strongly without losing its permeability to air/gases

Facing sand.

The small amount of carbonaceous material sprinkled on the inner surface of the mold cavity to give a

16

better surface finish to the castings

Core

A separate part of the mold, made of sand and generally baked, which is used to create openings and

various shaped cavities in the castings

Sprue

The passage through which the molten metal, from the pouring basin, reaches the mold cavity. It
controls the

flow of metal into the mold

Runner.

The channel through which the molten metal is carried from the sprue to the gate

Riser.
A column of molten metal placed in the mold to feed the castings as it shrinks and solidifies

Vent.

Small opening in the mold to facilitate escape of air and gases.

MOLDING.

This refers to the making of molds and cores used in molds.

Sand is widely used as a major material in molding.

This is because it is readily available, cheap and easily repairable, can easily allow the escape of air and
gasses

generated by heat of the poured metal and can retain the desired shape of the pattern.

2.3.7 Materials used in molding

Materials used for making molds include; Sand (Molding and free sands), loam, facings (graphite,

charcoal, sea coal), parting dust (burnt sand, charcoal river/beach sand) and core binders (flour, rosin,
glue,

linseed oil).

Free sands.

These are sands that have little or no clay mixed with them. This sand is of two kinds: river and beach

sand.

River sand has sharp and angular grains while beach sand has round grains. Both are used core and
daubing

mixtures and for parting sand.

The river sand is better for core and daubing mixtures because the angular grains interlock with one
another and

form a strong mixture.

Core sands.

Free sand, rock sand and debris of abraded rock are used in making cores.

Parting sand.

17

This is used on a mold at the joint or where parts of a mold are to separate to prevent them from
sticking

together
2.3.8 STEPS IN MAKING SAND CASTINGS

✓ PATTERN MAKING.

A Pattern is a form around which sand is packed to give rise to a mold cavity in which molten metal is

poured; the result is the cast object.

The pattern shape resembles the shape of the object to be cast.

Wood is the common material used in making patterns. This is because it is cheap, readily available and

repairable, easily fabricated in various forms, very light and can produce highly smooth surface. The
main

varieties of wood used in pattern making are pine and jackfruit.

Other materials used in making a pattern include; metals, plastic and wax.

✓ CORE AND MOULD MAKING

Preparation of sand mold

This consists of removing foreign materials sand that is to be used in molding.

These foreign materials may include dust, stones and sticks. It was done in the following ways;

• Sand was collected into the wheel borrow using shovels

• I did not perform sand preparation since it was already washed. But it was very important since it
cleans

sand from stone, clay particles and other particles that make it unsuitable to produce a good cast.

• After drying, the sand was sieved and graded using different hand riddles of different hole sizes to

obtain different grades of the sand with varying grain size and to remove tramp material such as stones

18

Figure 14 sieving of clay and sand

• The finest of the sand was used as the parting sand

• Clay was crushed from lumps to form fine clay

• The less fine was used in mixed with fine clay in appropriate proportions while adding a small volume

of water until it was able to form clumps when squeezed in hand

Preparation of mold

Figure 15 finished mold

The following procedure were followed as far as preparing a mold is concerned;

❖ The pattern was smeared with a lubricant and then sprinkled with parting sand

❖ The pattern was placed in the Centre of the drag and then the flask was filled with molding sand while

being rammed to achieve maximum compactions

❖ After the excess was removed using strike off bar

❖ The pattern was the retrieved from the bag

❖ The sprue pin and the riser pin were then strategically located in the cope after lubrication and
sprinkling

with parting sand to ease their retrieval

❖ The cope was then filled with the molding sand while ramming until it was dilled. The excess was

removed using the strike off bar

❖ The riser and sprue pin were removed to form the riser and the sprue channels

19

❖ The pouring cup was formed at the top of the sprue on the cope

❖ The sprue bottom was the formed on the drag and the rummer was curved out at the top of the drag

❖ Vent holes were formed in the cope using vent rod

❖ The drag and cope were then clamped together and left for some time to dry.

Figure 16 preparation of mold

2.4.2 METAL MELTING AND POURING

Metal melting is done in a furnace and the type of furnace depends on the type of metal to be cast and

the volume of molten metal required.

Coke fired furnaces are always used and the commonly cast metal is iron.

The molten metal is refined by adding alloying metals in the furnace and then moved to the pouring
station for

pouring into the molds. Procedures were followed as listed below;

The furnace was prepared by connecting a dc mortar to the fan that was blowing air into the furnace
that

was being heated by charcoal. The furnace was able to generate enough heat to melt the heat

Figure 17 firing of molds

The metal pieces were reduced in Size and then melted in ladle
20

Figure 18 firing of molds

The melted metal was then lifted out from the furnace using lifters and then poured into the mould until

it was filled to its capacity

After cooling, the mold was broken to retrieve the new formed metal casting

Figure 19 produced product after firing and cooling of molds

2.4.3 FINISHING OPERATION

This is specifically on surface the cast and removal of sprue and Rammer.

I did not perform finishing of the final product due to in adequate time to but generally finishing is
important;

Because of the molten metal that freezes in the sprue and rammer. These extensions should be cut
using grinder

to obtain a final shape of the casting.

Filing of the cut offs is also important to produce a good surface finish.

Defects on the work piece

✓ Shrinkage cavity on the areas of the casting that freezes last

✓ Blow holes due to presence of gases

✓ Poor surface finish, this was due to the poor mold cavity conditions and improper lubrication.

21

2.5: WELDING AND METAL FABRICATION

This activity introduces us to various techniques in grinding, welding and finishing operations. In this
activity,

several skills were obtained such as grinding skills, welding skills and among others.

it also covers different tools used in fabrication together with their roles in engineering.

2.5.1 METAL FABRICATION

Metal fabrication is the creation of metal structures by cutting, bending and assembling processes. It is a
valueadded process involving the creation of machines, parts and structures from various raw materials.

Welding is the metal joining process where molten metal at the joint solidifies to form a strong bond.
The
metals are usually joined by a filler metal that is heated by heat that is supplied by the welding torch.

2.5.2 Welding as a workshop practice exposes us to the following hazards;

Live wire, loose terminal, short circuits

Radiation such as infrared and ultra violet

Fumes and poisonous gases caused by electrode coatings, welding oily and greasy parts and welding

containers which have been holding substances that fume on combustion in air.

The welder should therefore take up the following precautions while welding;

The welder should put on protective clothing such as overall, safety boots, hand gloves which may be

leather, helmet and face shield.

Basically, there are two types of welds namely;

Multiple path weld: In this type of weld, molds of molten metal are spotted on several spots along the

joint such that they appear like beads.

Continuous weld: In this type of weld, the molten metal is applied to the joint in a continuous line such

that there are no breaks in the joint.

Basically, multiple path weld is stronger than the continuous weld because cracks in the joint can easily
spread

in the single path type of weld unlike multiple path where each bead offers its own independent
bonding

strength.

Welding can be either in the left or right. When welding in the left, the rod should be at an angle of
between 30

degrees and 45 degrees. And 45 degrees to 60 degrees for right.

22

Normally, it is not good to weld at a right angle because it makes the welded joints weak and it is hard to
see the

gap remaining.

2.5.2 welding positions

⚫ The flat position or down hand position is one in which the welding is performed from the upper side
of the

joint and the face of the weld is approximately horizontal. This is the simplest and the most convenient
position for welding.

Figure 20 flat position of welding

⚫ Horizontal Welding Position In horizontal position, the plane of the work piece is vertical and the
deposited

weld head is horizontal. The metal deposition rate in horizontal welding is next to that achieved in flat or

down hand welding position.

Figure 21 illustration of horizontal welding position

⚫ Vertical Welding Position In vertical position, the plane of the work piece is vertical and the weld is

deposited upon a vertical surface. It is difficult to produce satisfactory welds in this position due to the

effect of the force of gravity on the molten metal. The welder must constantly control the metal so that
it

does not run or drop from the weld.

23

⚫ The overhead position is probably even more difficult to weld than the vertical position. Here the pull
of

gravity against the molten metal is much greater. The force of the flame against the weld serves to

counteract the pull of gravity. In overhead position, the plane of the work piece is horizontal.

Figure 22 over head welding position

-Gas welding is the metal joining process in which fuel gases (gasoline) and oxygen are used to weld
metals.it

is also a metal joining process in which the edge pieces of a metal that are required to be joined are
heated at

their interface by producing coalescence with one or more gas flames such as oxygen and acetylene. The

welding process can be welded with or without the application of the filler material to the joint.

Figure 23 a gas welding equipment

2.5.3 FABRICATION OF THE TABLE.

Making of a table of dimensions 126mm by 84mm by 78mm and hollow section of 40mm by 40mm by
1.5mm

thickness.

24

Figure 24 a 3-D solid work of table to be produced

2.5.4 OBJECTIVES OF FABRICATING THE TABLE.

To attain skills in measuring and marking

To learn how to measure and cut the metal using a cutting disc.

To attain practical skills in metal joining.

To learn how to grind the welded joints using a grinder

To fabricate a table to be used in offices at FETADFA

2.5.5 TOOLS USED

The following tools were used in the process of fabricating a table:

Tape measure

Scriber

Hacksaw

Cutting disc

Grinder

AC arc welder

Bench vice

Tri-square

Paint sprayer

25

2.5.6 The description processes/ operations in fabricating a table

✓ The first thing was to interpret the working drawing and the markings to be cut.

✓ This was followed by measuring and marking the legs of the table and I cut them using an angle
grinder.

I also used a file to make the legs of the table straight.

✓ Using a sand paper, I cleaned the metal surface such that it could become smooth. I also used an
angle

grinder to cut it and make it smoother.

✓ Then I used a tape measure, Scriber and an angle grinder to cut the smooth plate.

✓ This was followed by cutting of the table supports using a hacksaw and smoothed them using a file.

✓ I made the hollow section pipes at an angle of 45 to connect the pipes and diagonals taken accurately.
✓ Furtherly, did smoothing of the metal plate using a sand paper and re-dimensioned it using a tape

measure and a square.

NB. While measuring and marking of the parts of the table, an allowance of 1.2mm was accounted for in

order to produce an accurate measurement after cutting and grinding.

2.5.7 Welding and joining parts of the table

✓ It was started by welding frames of the table. This was done by spotting the hollow section with the
legs

of the table.

✓ From there I did grinding of welded joints of the table parts to make it smooth.

✓ And then welded stoppers on the metallic table at the legs/supports. This was intended to avoid
stressing

of the concrete floor.

26

Figure 25 a semi-finished table to be finished

✓ This was followed by further sand papering of the metallic table to make it more smooth and remove

ridges on its surface which rendered it ready for painting.

✓ And finally, I added filler mixed with hardener material especially at the edge of the table which also

rendered it ready for painting.

2.5.8 Painting of the table and finishing.

✓ This was done by mixing paint and added thinner liquid in order to reduce on the viscosity of the
paint

thus making it easy for the spraying works.

✓ Then I connected the air compressor to the power supply and then placed the paint in the cup that
was

covered in the painting gun.

✓ Firstly, I applied the red oxide on the table surface which acted as a coat and then finally applied the

Grey paint/colour which I obtained by mixing white paint thoroughly with red paint.

Figure 26 painting of the table

✓ Careful attention was paid when spraying by applying paint on the exposed metallic parts of the table
to
avoid rusting.

✓ Finally, the table was allowed to dry and a good surface quality finish was produced.

27

NB, I used a nose mask while spraying avoid in inhalations of gases from paints which are very harmful

to the respiratory system. Also, other PPEs were very as well.

2.5.9 FABRICATION OF A BRACKET

Figure 27 a 3-D figure of a bracket to be produced

Objectives of fabricating a bracket.

To attain skills in measuring and cutting

To attain skills in drilling

To attain skills in grinding and filling

To attain skills in using various workshop tools and Equipments

2.6.0 Description of the processes/operations involved in fabricating a bracket

⚫ This was done by measuring and marking 60mm by 60mm dimensions on the sheet plate that was to
be cut.

This was done by use of a tape measure and a Scriber.

⚫ Then I used a grinder with a cutting disc to cut the measured dimensioned piece.

⚫ After cutting, I used a grinder to weaken the Centre point by applying a cutting grinder.

⚫ This was followed by using a file to smoothen and flatten the cut piece. This removed the ridges and
waste

pieces on the cut sheet.

⚫ From there, I used a scriber, center punch and a tape measure to mark out points on cut sheet where
holes of

5mm diameter were to be drilled using a drilling machine.

⚫ Using a drilling machine, six holes of 5mm diameter equally distanced apart were drilled.

28

⚫ I then used a bench vice and bent the cut sheet from its mid-point which I had weakened it before
using a

grinder.

⚫ Finally, I used a file to clean the drilled holes and they became smoother.
2.6.1 Painting of the bracket

◼ I mixed paint with red oxide and thinner in a bucket. And then used a wire brush to paint the made
bracket.

◼ After painting, I allowed it dry and it was ready.

◼ Finally, I was able to fabricate a bracket with six holes that the technician had instructed me to
fabricate.

2.7: ELECTRONICS AND ELECTRICAL WORKS

This activity covers the brief introduction about electronics and their electronics, domestic installation
and the

various tools used in electrical works. It was through this activity that I was able to know the various
uses of

electronic components such as resistors. I was also able to attain skills in domestic installation.

2.7.1 Electronic components and their uses.

These are components that are used in designing and construction of electronic circuits that can be used
to solve

practical problems. These electronic components cannot by themselves generate voltage or current. The

following are the electronic components that I was able to learn during my recess period;

CAPACITORS:

29

Figure 28 capacitor types

These are electronic components used for storing electric charge. It is a reservoir into which charge is
deposited

and then later extracted. A capacitor consists of nothing more than two parallel metal plates.

There are two types of capacitors namely;

➢ Fixed capacitors which include the polarized capacitors that have charge and non-polarized capacitors

which do not have charge.

➢ Variable capacitors which include turning capacitors for turning radio receivers and changing the

frequency or channels and presets for varying capacitance in circuits.

Uses of capacitors

❖ They are used in smoothing or filtering in power supplies.

❖ They are used as coupling devices to couple alternating current signals from one amplifier to another
and as well as decoupling supply rails by effectively grounding the supply rails as far as alternating

current signals are connected.

RESISTORS:

Figure 29 resistor types

These are electronic components that oppose the flow of current. Resistors obey a straight line law

when voltage is plotted against current, thus being used as a means of converting current to the

corresponding voltage drop.

30

There are two types of resistors namely; fixed resistors which have power ratings of 1/4W, 1/2W, 1W,

2W among others and variable resistors which include potentiometers for varying voltage and rheostat

that varies current.

Resistors are marked to show their estimated resistance either using number coding or colour coding

depending on the type of the resistor.

✓ Coding for variable resistors

Variable resistors are marked using number coding of three digits. The first two digits represent the first

two digits of resistance and the last digit represents the number of zeros to be added on the first two

digits.

✓ Coding for fixed resistors

Fixed resistors are marked using color coding to indicate the value and tolerance. Color coding can be of

four-color code, five color code or chip color code, though chip color code is not common and is rarely

used.

For four color code, the first two colors represent the value, the third color represent the multiplying

factor and the fourth color represent the tolerance.

For a five-color code, the first three colors represent the value, the fourth color represent the
multiplying

factor and the fifth color represents the tolerance.

2.7.2 A TABLE SHOWING COLOUR CODES, COLOUR VALUE,

MULTIPLYING FACTOR AND TOLERANCE.

COLOUR CODE COLOUR VALUE MULTIPLYING

FACTORTOLERANCE

Black 0 1 -

Brown 1 10 +-1%

Red 2 100 +-2%

31

Orange 3 1000 -

Yellow 4 10000 -

Green 5 100000 +-0.5%

Blue 6 1000000 +-0.25%

Violet 7 10000000 +-0.1%

Grey 8 100000000 -

White 9 1000000000 -

Gold - 0.1 +-5%

Silver - 0.01 +-10%

Table 2 showing colour codes, value, multiplying factor and tolerances of resistors

Functions of resistors

To reduce voltage applied to other currents

To be used as a fuse in power circuits

To limit the current in particular circuits

To vary current and voltage applied in the circuit.

DIODES

Figure 30 diode

These are devices formed when a junction is formed between N-type and P-type semiconductor

materials. These electronic components offer an extremely low resistance to current flow in one

direction and an extremely high resistance to current flow in the other.

Diodes are mainly divided into two groups namely; power diodes and zener diodes. The power

diodes are formed by joining a doped N-type to a doped P- type semi-conductor.

32
TRANSISTORS

Figure 31 transistor

This is a semiconductor device used to amplify or switch electrical signals and power.

BREAD BOARD

Figure 32 bread board

This is used to make quick electrical connections between components like resistors, capacitors among

others.

VERO BOARD

33

Figure 33 Vero board

This is a sand witch structure of conductive and insulative layers. It provides reliable electrical

connections between component terminals.

2.7.3 SOLDERING

This is a low temperature joining process which involves joining of two metal plates together and it is

only the filler metal that undergoes melting and the work piece does not experience any form of
melting.

Soldering employs flux materials to clean the surface to be soldered and improve metallurgical bonding.

I carried out soldering during my recess and the following illustrates the procedures i performed;

❖ I heated the soldering gun

❖ Heated the joint

❖ Applied the solder

I was therefore able to produce strong soldered joints.

Uses of soldering

❖ Used for electrical connections

❖ Used for sealing in automotive radiators and tin cans

❖ Used for joining dissimilar metals

❖ Used for joining thermally sensitive components.

34

2.7.4 DOMESTIC INSTALLATION

MATERIALS AND TOOLS USED

❖ Junction box

❖ Bulb

❖ Switch

❖ PVC twin cable

❖ Power supply

Aim: To light a single bulb using a single junction box

To light two bulbs using a single junction box

Steps taken

I started by wiring the circuit which consisted of a junction box, a lamp, a switch and a power source.

This was done by first connecting the bulb to the junction box, then to the power source and then to the

junction box to the switch. This was done by connecting live and neutral wires to their corresponding

counterparts. This experiment was successful

Figure 34 lighting a single bulb

I then did the second experiment which consisted of a single switch, a single junction box, cables and

two bulbs. This was done by wiring the junction box to the two bulbs and then to the power source. This

35

was followed by then connecting to the switch by connecting the live and neutral wires to their

respective counterparts. This experiment was also successful

Figure 35 lighting two bulbs with one switch

Aim: To light a single bulb using an intermediate switch and three junction boxes.

Steps taken

I started by wiring a circuit that consisted of switches, a single bulb, three junction boxes and a power

source. This was done by connecting the power source, the three junction boxes in series and then the

bulbs and the switches in parallel but opposite to each other.

This was letting the bulb to light and rendering control to all other three switches with middle one being

an intermediate switch.

This experiment was also successful

Aim: To light three bulbs using two junction boxes and two switches
Steps taken

I started by wiring the circuit which consisted of two junction boxes, lamps, switches and a power

source. This was done by first wiring lamps in the corresponding junction boxes and then wires from the

junction box to the switches. All the junction boxes were connected in parallel.

36

The third lamp was sharing the same junction box with the second lamp. This was done by ensuring that

live wires were connected to their corresponding counterparts as well as neutral wires,

This experiment was successful.

Figure 36 three bulbs lighting after wiring

2.7.5 USING CIRCUIT BREAKERS WHILE WIRING

Circuit breakers are very important in an electric circuit since they regulate the amount of current and
voltage

flowing in the circuit beyond which they automatically switch off.

Each circuit breaker has maximum voltage beyond which it automatically puts off the switch.

Circuit breakers have buttons(nodes) labeled with its corresponding current with which it only allows to
pass

through the circuit i.e., 10A, 15A, 20A among others

Figure 37 figure of a circuit breaker

37

2.7.6 TESTING FOR RESISTANCE, CAPACITANCE OF A CAPACITOR ON A

PRINTED BOARD (VERO BOARD)

• I first did soldering using a soldering wire, soldering gun and power supply. By soldering, I was able to

connect the resistors, capacitors and diodes on the Vero board.

• I then used a multimeter to measure the resistances of resistors and capacitances of capacitors.

The following values of resistances and capacitances were obtained for the corresponding

Number Resistances (ohms) Capacitances (C)

1 50 0.96

2 0.1 1

3 0.005 2.5
4 12 10.4

5 5 4.4

Table 3 showing values of resistances and capacitances obtained

38

CHAPTER THREE: CONCLUSION, RECOMMENDATIONS AND REFERRENCES

This chapter consists of the conclusion of this report, the general skills attained out of recess, the
challenges

faced and the recommendations to both the University and the students as well.

As it is believed that every challenge has a solution, this chapter suggests suitable solutions to the
various

challenges faced during the recess training. It also gives different references where some important
information

was obtained.

3.1 CONCLUSION

It was a resourceful and a practical hands-on training that enabled me to acquire hands on skills and
experience

in various fields like metal fabrication, sand casting, electrical installation and among others. It also
helped me

to use the theory work that we studied in lecture room and use it in practical works.

3.2 GENERAL SKILLS AND KNOWLEDGE ATTAINED DURING THE TRAINING

✓ A skill in 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.

✓ About all, most of my theory was converted to practical.

3.3 GENERAL CHALLENGES FACED DURING THE TRAINING

❖ Un stable electric power supply during the training.

39

❖ Limited time for the training.

❖ Inadequate tools for example grinders, pliers and arc welders.

❖ Learning from a very old equipment for example a very old engine.

❖ Limited access to some machines in the workshop such as a lathe, milling machine and a sowing

machine. The university had not procured enough oil to use while running the machines which limited

my practice.

3.4 POSSIBLE SOLUTIONS

• The university should put in place a standby generator in order to ensure that power supply is stable
all

the time during the training.

• The duration for the training should be increased so that students get enough time to do as many

practical as possible during the training.

• The university should buy vehicles to learn from during practical and include driving on the training

program.

• The university should encourage strict supervision of students while during training such that students

can attain skills to the maximum.

3.5 RECOMMENDATIONS

TO KABALE UNIVERSITY

◆ The training duration should be increased from one month to two and a half months (10weeks) for
better

acquisition of skills, new technologies and practical knowledge by students.

◆ Machines should be bought in order for students to acquire all the required practical skills during their

course of study at KAB.

◆ Supervisors should always visit the training places to advise or credit the work being done during the

training.

◆ Information about the training program should always be delivered early to students so that they
prepare

early.

TO THE STUDENTS

40
They should respond quickly and regularly attend to their practical work as these are meant to prepare
them for

their future career.

Students should also have extra vigor and morale (willingness) to learn if at all they are to gain skills and

training out of the recess. In so doing, they will go an extra mile in learning which will help them gain
more

skills and experience.

3.6 REFERENCES

1. Introduction to Basic Manufacturing Processes and Workshop Technology by Raj Ender

Singh.

2. Whitten KW, Davis RE, Peck LM & Stanley GG 2014, Chemistry, 10th Edition.

41

42

43