Engineering Project

Preparation (ENGG101)

Conducted By
Technical Training Center
Kathmandu University
Engineering Project Preparation
(ENGG101)

Prepared by :
Gokarna Poudel
Technical Training Center
Kathmandu University
Date: 12/01/2018
 OBJECTIVE
• Introduce students to the conepts of project
work.
• To provide practical knowledge in basic
engineering skills.
• To work on a small constructional project to
use the skills and knowledge they have
acquired.
 About the course
• The course describes and practices the
general principles of different workshop
processes including hand working
processes. such as :
>>Safety measures.
a. Bench work and fitting.
b. Carpentry.
c. Sheet metal.
d. Metal joining methods.
e. Surface finishing and Coating.
 FERROUS METALS

• Ferrous metals are iron base metals which

include all variety of pig iron, cast iron
wrought iron and steels.
• The ferrous metals commonly used in
engineering practice are cast iron, wrought
iron, steel and alloy steels.
 Main Types of Iron

1. Pig iron
2. Cast iron
• (A) White cast iron
• (B) Gray cast iron
• (C) Malleable cast iron
• (D) Ductile cast iron
• (E) Alloy cast iron
 Main Types of Iron
• 3. Wrought iron
• 4. Steel
• (A) Plain carbon steels
• 1. Low Carbon steels
• 2. Medium Carbon steels
• 3. High Carbon steels
• (B) Alloy steels
• 1. High speed steel
• 2. Stainless steel
 Plain carbon steel
• Plain carbon steel is an alloy of iron and
carbon. It has good machine ability and
malleability.
• It is different from cast iron as regards the
percentage of carbon. It contains carbon
from 0.06
• Low carbon or mild steel — 0.15% to
0.45% carbon
• 3. Medium carbon steel — 0.45% to 0.8%
carbon
• 4. High carbon steel — 0.8% to 1.5%
carbon
 LOW CARBON OR MILD
STEEL
• Low carbon steel is sometimes known as
mild steel also. It contains 0.20 to 0.30% C
• which has tensile strength of 555 N/mm2
and hardness of 140 BHN. It possesses
bright fibrous structure. It is tough,
malleable, ductile and more elastic than
wrought iron. It can be easily forged and
welded. It can absorb shocks. It rusts
easily. Its melting point is about 1410°C. It
is used for making angle, channels, case
hardening steel, rods, tubes, valves,
 MEDIUM CARBON STEELS

• Medium carbon steel contains carbon from

0.30 to 0.8%.
• It possesses having brightfibrous structure
when fractured. It is tough and more
elastic in comparison to wrought iron.
• It can be easily forged, welded, elongated
due to ductility and beaten into sheets due
to its good malleability. It can easily
absorb sudden shocks.
Stress strain behaviour of
various steels:
Stress strain Diagram :
 Mechanical properties
Properties of metal
• Strength
• Elasticity
• Stiffness
• Plasticity
• Ductility and malleability
• Resilience
• Toughness
• Hardness and brittleness
• Machinability
• Creep
 Mechanical properties of metal
• Mechanical Properties
• Under the action of various kinds of forces,
the behavior of the material is studied that
measures the strength and lasting
characteristic of a material in service.
• The mechanical properties of materials are of
great industrial importance in the design of
tools, machines and Porperties and
• structures.
 Mechanical properties of metal
1. Elasticity
•It is defined as the property of a material to
regain its original shape after deformation
when the external forces are removed. It can
also be referred as the power of material to
come back to its original position after
deformation when the stress or load is
removed. It is also called as the tensile
property of the material.
Mechanical properties of metal
2. Proportional limit
•It is defined as the maximum stress under
which a material will maintain a perfectly
uniform rate of strain to stress. Though its
value is difficult to measure, yet it can be
used as the important applications for
building precision instruments, springs, etc.
Mechanical properties of metal
3. Elastic limit
•Many metals can be put under stress
slightly above the proportional limit without
taking a permanent set.
•The greatest stress that a material can
endure without taking up some permanent
deformation is called elastic limit. Beyond
this limit, the metal does not regain its
original form and permanent set will occurs.
 Mechanical properties of metal
4. Yield point
•At a specific stress, ductile metals
particularly ceases, offering resistance to
tensile forces. This means, the metals flow
and a relatively large permanent set takes
place without a noticeable increase in load.
This point is called yield point. Certain metals
such as mild steel exhibit a definite yield
point, in which case the yield stress is simply
the stress at this point.
Mechanical properties of metal
5. Strength
•Strength is defined as the ability of a
material to resist the externally applied
forces with breakdown or yielding.
•The capacity of bearing load by metal and
to withstand destruction under the action of
external loads is known as strength. The
stronger the material the greater the load it
can withstand.
Mechanical properties of metal
6. Stiffness:
•It is defined as the ability of a material to
resist deformation under stress.
•The resistance of a material to elastic
deformation or deflection is called stiffness
or rigidity.
•A material that suffers slight or very less
deformation under load has a high degree
of stiffness.
Mechanical properties of metal
7. Plasticity
•Plasticity is defined the mechanical property
of a material which retains the deformation
produced under load permanently.
•This property of the material is required in
forging, in stamping images on coins and in
ornamental work.
• It is the ability or tendency of material to
undergo some degree of permanent
deformation without its rupture or its failure.
Mechanical properties of metal
8. Ductility
•Ductility is termed as the property of a
material enabling it to be drawn into wire
with the application of tensile load.
•The materials those possess more than
5% elongation are called as ductile
materials. The ductile material commonly
used in engineering practice in order of
diminishing ductility are mild steel, copper,
aluminum, nickel, zinc, tin and lead.
Mechanical properties of metal
9. Malleability
•Malleability is the ability of the material to
be flattened into thin sheets under
applications of heavy compressive forces.
•The malleable materials commonly used
in engineering practice in order of
diminishing malleability are lead, soft steel,
wrought iron, copper and aluminum.
Aluminum, copper, tin, lead, steel, etc. are
recognized as highly malleable metals.
Mechanical properties of metal
10. Hardness :
•Hardness is defined as the ability of a
metal to cut another metal. A harder metal
can always cut or put impression to the
softer metals by virtue of its hardness. It is
a very important property of the metals and
has a wide variety of meanings. It
embraces many different properties such as
resistance to wear, scratching, deformation
and machinability etc.
Mechanical properties of metal
11. Brittleness:
•Brittleness is the property of a material
opposite to ductility.
•It is the property of breaking of a material
with little permanent distortion.
•Brittle materials when subjected to tensile
loads, snap off without giving any sensible
elongation. Glass, cast iron, brass and
ceramics are considered as brittle material.
Mechanical properties of metal
12. Creep
•When a metal part when is subjected to a
high constant stress at high temperature for
a longer period of time, it will undergo a
slow and permanent deformation (in form of
a crack which may further propagate further
towards creep failure) called creep.
Mechanical properties of metal :
13. Formability :
•It is the property of metals which denotes
the ease in its forming in to various shapes
and sizes.
•The different factors that affect the
formability are crystal structure of metal,
grain size of metal hot and cold working,
alloying element present in the parent metal.
 Mechanical properties of
metal
14. Cast ability :
Cast ability is defined as the property of
metal, which indicates the ease with it can
be casted into different shapes and sizes.
Cast iron, aluminum and brass are
possessing good cast ability.
 Mechanical properties of
15. Weldability
metal
•Weldability is defined as the property of a
metal which indicates the two similar or
dissimilar metals are joined by fusion with or
without the application of pressure and with
or without the use of filler metal (welding)
efficiently.
•Metals having weldability in the descending
order are iron, steel, cast steels and
stainless steels.
 COURSE CONTENT
• Introduction
• Workshop Skills
• Mini Project
 EVALUATION
• Quality of the job : 60
• Report : 20
• Attendance and behavior : 5
• Final viva : 15
 The Course Involves
• Bench work and fitting
• Carpenty
• Sheet metal
 Bench work and fitting
• Work done primarily at a bench with hand
tools. occasionally supplemented by small
power-driven tools.
• A bench fitting is a mechanical job work
done using a bench vice to hold the job
and the operation with normal manual
tools.
 Bench work importance
• Useful for completing and finishing a
job.
• Performing minor operation and
preparing complex geometry.
• Assembling of parts together and
removing metals to secure the
necessary fit.
 Tools used
1. Marking tools
2. Measuring tools
3. Supporting tools
4. Holding tools
5. Striking tools
6. Cutting tools
7. Tightening tools, and
8. Miscellaneous tools
 Tools….
1. Measuring tools : steel scale ,vernier,
measuring tape.
2.Holding tools: Bench vice
3. Striking tools : Hammer
Steel Scale
 Tools….
4. Cutting tools : Ripsaw, chisels, drills,snip,
hacksaws and files.
• Files. There are different types of files
such as flat, square, round, triangular,
knife , needle.
5. Tightening tools : plier, wrenches.
6. Miscellaneous tools : centre punch (60 °)
Pliers :
Centre punch and files
 Bench vice
• Bench vice commonly used in fitting shop
for holding a variety of jobs.
• Parts:
>Fixed Jaw, Jaw, Plate, the vice
>Movable Jaw, Collar, Handle
>Base, Spindle.
Parallel Bench vice
 Cutting Tools

1.Files
hardened high grade steel with slanting rows of
teeth. It is used to cut, smooth, or fit metal
parts.
(A)Type of Cut
• (i) Single
• (ii) Double and
• (iii) Rasp
 Files ,Cutting Tools…
(B) Grade of Cut
• Files are cut with teeth of different grades.
• (i) Smooth, (ii) Second cut
• (iii) Bastered, (iv) Rough

• (C) Shape of File

• Common shapes of files are having
different cross sections(flat, square,
triangular, round etc).
 Cutting Tools…
2. Chisel
• used for cutting and chipping the work
piece.
• made of high carbon steel or tool
• steel.
• in the form of a rod having cutting edge at
one end, hexagonal or octagonal body
• and striking head at the other end.
 Cutting Tools…
3. Drill
• tool for making holes in a metal piece in
fitting shop.
• types of drills: (a) flat
• drill, (b) straight fluted drill and (c) twist
• drill.
• twist drills are commonly used.
• A twist drill comprises the cutting
• angle of 60° on tip and a twist screw type
groove on length
Twist Drill Details
 Drill machine

• The drill machine used on the project is

• Pillar drill
• Hand drill
Pillar or bench Drill
Manual, pneumatic, Electric
drill
 Striking tools:
• HAMMERS
• Are known as striking tools
• Categorized by the shape, weight and the
specific performance.
• Made by hardened and tempered steel.
• Some of the hammers are :
- Ball peen , cross peen , flat ..
- Mallet hammer.
- according to the weight
- Claw hammer.
Hammers
Hammer nomenclature
 Carpentry:
• The practice related with wood.
• Used for preparing basic needs up to the
luxury ones.
• Shelter , railroad tracks, furnishing, boat
building, composites, plywood.
• Wood are commonly classified into
hardwoods(oak) and softwoods(pine).
 TYPES OF COMMON
TIMBERS :
• The common types of well recognized
timbers available locally are Shisham,
Sal, salla, Teak, Deodar, Mango, oak,
pine etc.
• On our Carpentry Practice on ENGG
101 we use Shisham planks.
 SEASONING OF WOOD:
 Process of removing moisture content from
the wood log .
• Artificial seasoning:
-stacking the timber on a truck or a
chamber and blowing hot air through out.
• Natural Seasoning:
-slow and steady process on which log
are stacked and free circulation of air is
provided.
Tools used in carpentry shop:

• Marking, measuring , cutting , holding

tools, striking tools.
• Includes pencils , ripsaw, files, steel
scale , try square, drill, chisels, bench vice,
hammer.
Carpentry Tools
 Try Square
• generally utilized for measuring and
checking of squareness, perpendicularity,
• dimensions, testing of finish of planned
surfaces and drawing parallel and
perpendicular lines.
• The steel blade and metallic or wooden
handle of try square are at right angles to
each other.
• The blade of try square is made of hard
tempered steel of non rusting kind.
 Holding And Supporting
Tools
• Work Bench
• solid bench or table of rigid construction of
hard wood on which each can perform or
carry out the carpentry and fitting
operations.
• Work bench should be equipped with a
vice for holding the work and with slots
and holes for keeping the common hand
tools.
 Cutting Tools
• Cutting tools generally are rip saw, chisels,
rasp file, drill, planner for carpentry shop.
1.Saws:
• tools having handle and a thin steel blade
with small sharp teeth and we used rip saw
for the cutting operation.
• Rip Saw
• The teeth of rip saw are chisel-shaped and
are set alternately to the right and left.
Cutting tools: Rip Saw and
Hack saw
 Cutting Tools….
• Hack saw:
• Hand hacksaws are made in two types
namely a fixed frame and adjustable
frame
• The hand hacksaws are commonly used
for sawing all soft metal.
• They consist of a frame, handle, prongs,
tightening screw and nut, and blade.
 Files and Rasps
• Used for maintaining other wood
working tools and equipment.
• Made of hardened tool steel which is
tempered and they should never be
dropped as they are brittle in property.
Rasp File
COMMON WOOD JOINTS:
SHEET METAL WORK
• Sheet metal is generally considered to be
a plate with thickness less than about 5
mm. Articles made by sheet metal work
are less expensive and lighter in weight.
• Products made through the sheet metal
processing include automobile bodies,
utensils, almirah, cabinet’s appliances,
electronic components, electrical parts,
aerospace parts, refrigeration and air
conditioning parts etc.
 SHEET METAL WORK….
• For carrying out sheet metal work, the
knowledge of geometry, measurement and
properties of metal is most essential
because nearly all patterns come from the
development of the surfaces of a number of
geometrical models such as cylinder, prism,
cone, and pyramid.
• Generally metals used in sheet metal work
are black iron, galvanized iron, stainless
steel, copper, brass, zinc, aluminium, tin
plate and lead.
• Higher the gauge lowers the thickness and vice versa, we
use 21 gauge sheet metal on our sheet metal practice.
METALS USED IN SHEET
METAL WORK
1. Black Iron Sheet
•Non expensive, black in appreance, got
rusted rapidly ,coating is necessary.
2. Galvanized Iron (G.I.)
•soft steel coated with molten zinc.
Articles such as pans, furnaces, buckets,
cabinets etc. are made from GI sheets.
METALS USED IN SHEET
METAL WORK…..
3. Stainless Steel
•alloy of steel with nickel, chromium and
small percentages of other metals.
•has good corrosion resistance ,costlier
but tougher than GI sheets.
•used in kitchenware, food processing
equipments, food handling articles, tools
and instruments for surgery work in
hospitals and components of chemical
plants etc.
 SHEET METAL TOOLS
……
• Hand shears or snips
• Hammers
• (v) Measuring tools
• (vi) Miscellaneous hand tools such as
chisels, groovers, seamers, rivet sets
and hand punches.
Hand Shear or snips
 HAND SHEARS OR SNIPS

• resemble with pair of scissors

• and are used like them to cut thin soft
metal sheets of 20 gauge or thinner.
• can make straight or circular cuts.
• Various types: straight hand shear, curved
hand shear.
SHEET METAL OPERATIONS
• 1. Cleaning 2. Measuring
• 3. Marking 4. Laying out
• 5. Hand cutting 6. Hand shearing
• 7. Hand forming 8. Edge forming
• 9. Wiring 10. Joint making
• 11. Bending 12. Drawing
• 13. Soldering 14. Circle cutting
• 15. Machine shearing 16. Nibbling
• 17. Piercing 18. Blanking
MACHINES USED IN SHEET
METAL SHOP

• Shearing machine
• Bending machine
• Folding machine
• Drilling Machine
• Grooving machine
 Fastening process..

1. Permanent fastening
-welding
-Riveting
2.Temporary fastening
-Screw
 Welding
• Welding is a process of joining two similar or
dissimilar metals by fusion,
– with or with out the application of pressure,
– and with or with out use of filler metal.
• The fusion of metal take place by heat.
• The heat may be obtained from:
– electric arc,
– electric resistance,
– chemical reaction,
– friction
– or radiant energy
 Arc welding..
• Heat Source is Electric Arc (Plasma)
• Without application of Pressure
• With or without filler rod
• AC Or DC Current supply can be
used
 AC / DC Machines
• Step down transformers are used for
AC Machines to change the supply to
80-100 volts, 50-100 Amps.
• DC machines are used for heavy
works and for the sites where AC
source is not available.
• Straight and reverse polarity in DC
Machines (67% in +ve terminal)
Arc welding
Arc welding ..
 Riveting
• Generally done on sheet metal operation.
• It is a permanent fixture.
• Rivet are generally made by malleable
metal which can deform by certain blow.
• Generally aluminum rivets are used in
sheet metal operation, steel rivets are
used on construction of skyscrapers truss.
• Now a days gun riveting is replacing
traditional riveting process.
Rivet Type and nomenclature
 Threading
• A fixture prepare by making helical groves
on a cylinder is threading .
• It is a temporary fixture.
• We use die and taps for making threads,
die and taps are made by hardened steels
so can create a uniform recess on mild
steel.
• We learn preparing V type (60o) helical
thread.
Threads
External threading DIE and
STOCK
 Surface Coating

• The various operation of adding an extra

layer on the finished product which helps
on improvising appreance, resist rusting
and corrosion, and various other out
comes is surface coating .
• There are various types of coating such as
electroplating , enamel painting ,
galvanizing etc.
 Report :
• The report must be submitted with the
following content in standard A4
(210*297sqmm)size paper one sided and hand
written.
• introduction of the practice with
application.
• list of tools used with their sketch and
use.
• Material used.
• Sequence of operation.
 Report contd…
• Safety precaution.
• Process involved
• Machine, material and tools
description.
• Quality control report with comment.
• Cost estimation of the job.
• Ghannt chart
• Drawing.
• Title page is enclose herewith
TOP SHEET FORMAT
 INSPECTION AND QUALITY
CONTROL
• Inspection or checking of components is
related with quality control.
• To determine the quality of the product and
the deviation in terms of standard one
quality control is done.
• It shows whether the product is acceptable
or not.
• It can measure the tolerance with the
standard one.
• Inspection may be visual or by the
measurement.
 QUALITY CONTROL
• A product can be referred to be of good
quality if it works very well and perform
good function in a particular situation for
which it is meant or designed
• The object can be said as of quality when it
lies within the tolerance and meets the
standard.
• Inspection and quality control is the factor
that administers a product and its
manufacturing process to be in good line
and produce quality produce.
Quality inspection chart
(sample):
S. Dimensions Standard obtained Remarks
N.

1. Length 3 2.75 Good

2. Breadth 4 3 satisfactory

3. Height 5 4.9 Good

 Cost Estimation :
• Overall estimation of your product .
• Calculation of labor cost (hour), material
cost, miscellaneous cost (electricity…).
• Adding up a certain profit margin and
calculating the total price of the project.
• It helps us to figure out the exact time,
money and material and finally profit from
a object that we are producing .
 Cost estimation…
• Cost of the material purchased:
• Wooden plank (130*80*80 cubic mm):
Rs.50/pcs
• M.S. Flat :Rs. 120/kg
• M.S. rod(6mm dia): 110/kg
• G.I. Sheet(4ft* 8ft* 20 g): 1900/ pcs
• Paint : 190/ltr
• Aluminum Rivet: Rs. 3/ pcs
• Electricity : Rs 10/unit.
• Labour Charge : Rs. 50 per hour
• Profit margin : 5%
Drawing carpentry practice…
Drawing (fitting Practice)…
Drawing (Sheet metal
Practice)…
Drawing (Sheet metal
Practice)…
Drawing (Sheet metal
Practice)…
Drawing (Sheet metal
Practice)…
 Gantt chart:
• Overall schedule of a project which shows
the time line Vs activity of yours for the
project.
Gantt chart sample..
Process involved on the job
preparation
Welding, painting

Marking ,Cutting chipping

Bending

Cutting , filling

Drilling ,
threading
Process involved on the job
preparation
cutting

Riveting , drilling
Bending folding, marking
Process involved on the job
preparation
Any queries…
Thank you
…