Perform Benchwork (Complex)

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Notes Format of Learner’s Guide

Course: MACHINING NC II
Unit of competency: PERFORM BENCH WORK (complex)
PERFORMED BENCH WORK (complex)
Module: At the end of the session, learners should be able to:
Learning outcomes:

1. Chip work piece 4. Repair damage thread

2. File work piece 5. Scrape/hone holes

3. Remove damage/broken threaded fastener

Duration: 55 HRS
Situating Learning:

You are a leadman in a Machine shop. Your supervisorinstructed youto
fabricate 1 piece of a bench vice. In order to complete the assigntask, you
need a materials and equipments to use. To start the job , you need to
identify the materials needed ; the most suitable and low cost materials, the
gauge of MS plate, the diameter of CRS, the thread form of a leadscrew of a
vice and the require size of the bench. To carry out the job well, you need
to be equipped with the following skills and knowledge .

 Interpret Engineering drawing /plans
 Identify the classification and properties of Engineering materials
 List the different Hand tools and equipment
 List the tools for bench work
 State the procedures and techniques in preparing the work area
 List appropriate safety and PPE needed and good housekeeping
 Select chisel according to requirements of operation
 Chipped work piece according to drawing specifications
 Select file according to to requirements of operations
 Filed the work piece according to drawing specification
 Cleaned and stored according worksite and procedures
 Select extractors according to requirements of operations
 Remove damage thread and broken threaded fasteners according

worksite and procedures
 Select tap and die according to requirements of operation
 Repair thread according to worksite and procedures
 Conform repair thread with drawing specification
 Select scraper according to requirements of operation
 Select flushing agents according to requirements of operation
 Scrape and hone according to drawing specification

Assessment Criteria: Accomplished the above skills and knowledge, you are able to perform
excellent quality check for making any bench work operation.

1 . direct observation of bench work activities
2 . written or oral short answer questions
3 . practical exercises
4 . project work
5 . identify colleagues/clients who can be approached for the collection of

competency evidence, where appropriate

Pedagogical Training in Instructional Design & Delivery for TVET Page 1
© 2010, Institute of Technical Education, Singapore

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Notes Format of Learner’s Guide

Learning chunk Performance Criteria Learning Activities (Brief Learning documents
description of strategies, (Documents

sequence of lesson, referenced by each
evaluation) learning activity)

Sub-task 1: -Interpret drawing 1.1 Identifydifferent  Projector film clips
“Determine job engineering drawing Drawing symbols, showing
or plan
Requirements” Isometric and the 1.1.1 Interpret
a. Drawing/plan Orthographic drawing drawingsamples

“Determine job  Read Information
Requirements” Sheet
b. Shop Safety
Different
Practices components
of drawing/plans
 Answer worksheet

1.1.2 Questions

List of the requirements 1.2 Identify the different  Projector film show

needed Requirements for shop On different shop

For shop safety Safety practices Safety practices

practices

 Read Information
sheets
1.1.3 Different
shop safety
practices

 Answer worksheet
1.1.4 Questions

Pedagogical Training in Instructional Design & Delivery for TVET Page 2
© 2010, Institute of Technical Education, Singapore

DLM 03 Developing print-based Learner’s Guide including all related documents
Notes Format of Learner’s Guide

Learning chunk Performance Criteria Learning Activities (Brief Learning documents
description of strategies, (Documents

sequence of lesson, referenced by each
evaluation) learning activity)

“Determine job
Requirements”

c. Material and List of the classification 1.3 Identify the  Power point show
related science Of mechanical classification of mechanical On Material related
properties of Properties of Engineering science
engineering materials materials
 Read Information
Sheet

1.1.5 Properties of
Engineering
materials

 Answer Worksheet
1.1.6 Questions

Sub-task 2: -List appropriatetools 2.1 Identify the necessary  Power point on
and materials for Tools needed and Bench vice
“Prepare work Materials needed for
Area” bench work Bench work and  Read Information
Sheet
-State the importance Discuss procedures 2.1.1 How to pre-
of preparing a work and techniques pare work area
area before doing in preparing the
bench work operation work area.  Answer Work
Sheet
2.1.2 Question

Pedagogical Training in Instructional Design & Delivery for TVET Page 3
© 2010, Institute of Technical Education, Singapore

DLM 03 Developing print-based Learner’s Guide including all related documents
Notes Format of Learner’s Guide

Learning chunk Performance Criteria Learning Activities (Brief Learning documents
description of strategies, (Documents

sequence of lesson, referenced by each
evaluation) learning activity)

Sub-task 3

“Performed bench
work operation”

a. Chip workpiece  Select chisel 3.1 Identify different * Read Information
according to chisel used for Sheet
requirements of chipping. 3.1.1 Types of
operations chisel and its
a. Uses and operations
 Chipped the application
workpiece  Follow
according to Worksheet3.1.2
drawing Question
specification

b. File workpiece  Select file 3.2 Identify different
according to types of files
requirement of  Read Information
operation a. Uses and Sheet
applications 3.1.3 Types of
 Filed according to files and its
drawing operation
specification
 Follow Worksheet
 Cleaned and 3.1.4 Questions
stored according
worksite and
procedure

 Select extractors  Read Information
Sheet
c. Remove damage according to 3.3 Identify different 3.1.5Types of
and broken requirement of Types of extractor extractors
threaded operations a. Uses and
Application * Follow Worksheet
fastener  Remove damage 3.1.6 Question

threaded fastener

according worksite

procedures

Pedagogical Training in Instructional Design & Delivery for TVET Page 4
© 2010, Institute of Technical Education, Singapore

DLM 03 Developing print-based Learner’s Guide including all related documents
Notes Format of Learner’s Guide

Learning chunk Performance Criteria Learning Activities (Brief Learning documents
description of strategies, (Documents

sequence of lesson, referenced by each
evaluation) learning activity)

d. Repair damage  Selects tap and die 3.4 Identify different  Read Information
according to Types of Tap and sheet
thread requirements of Dies 3.1.7Types of tap
operation a. Different tools and die and its
b. Uses and uses and
 Repair thread Application and application and
according to Procedures different tools
worksite procedure used and different
procedures
 Conform repaired
thread with  Follow Worksheet
drawing 3.1.8 Question
specification

e. Scrape and hone  Selects scraper
holes
according to 3.5 Identify different  Read Information
requirement of Types of scraping Sheet
Tools 3.1.9 Types of
operation a. Uses and scrapers and hone
Application holes
 Select flushing b. Honing holes
 Follow worksheet
agent and applied 3.2.0 Question

according to

requirements of

operation

 Scrape and hone

work piece

according to

drawing

specification

End End End

End

Pedagogical Training in Instructional Design & Delivery for TVET Page 5
© 2010, Institute of Technical Education, Singapore

DLM 03 Developing print-based Learner’s Guide including all related documents
Notes Format of Learner’s Guide

Pedagogical Training in Instructional Design & Delivery for TVET Page 6
© 2010, Institute of Technical Education, Singapore

Information Sheet 1.1.1 : Components and Functions of the Starting System

1.1. 1– Information sheet

Learning Outcome :
1 “Determine Job Requirements”
Learning Activity :
1 . 1 “Interpret Drawing /Plans”
__________________________________________________________________________________________

1. Identify the Standard drawing symbols

Symbols

- are used to communicate and detail the characteristic of an engineering drawing.
Is something such as an object, picture, written word, sound, or particular mark that
represents something else by association, resemblance, or convention. For example, a red
octagon may be a symbol for "STOP". On maps, crossed sabres may indicate a battlefield.
Numerals are symbols for numbers (amounts). All language consists of symbols. Personal
names are symbols representing individuals.

Engineering Abbreviation and Symbols

Examples:

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Information Sheet 1.1.1 : Components and Functions of the Starting System

Abbreviation/symbol Definition Description
AC Across corners
commonly used when
AF Across flat measuring the corners
of a hex drive, such as
hex nut

commonly used when
Measuring the corners
Of a hex drive, such as
Hex nut

AMER American Center line of features
APPROX Approximaely
BC Bolt Circle

CL Center line

Center mark Defines the center of a circle or
Or partial circle

CHAM Chamfer

CRS Cold rolled steel

C’BORE CounterboreP

CSK Countersink

DIA Diameter Diameter of a circle

HRS Hot rolled steel

MACH Machine

MAX Maximum

MIN Minimum

NOM Nominal

8x or (8) Number of places

PHR BRZ Phosphor bronze

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Information Sheet 1.1.1 : Components and Functions of the Starting System

POI or TSC Point of interest A point that makes the layout
of the part easier. It is usually
the intersection of the tangent
lines of a curve.

R Radius Radius of an arc or circle

REF Reference

SPOT FACE Spot Facing

STD Standard

STL Steel

STK Stock A nominal dimension for stock

material

TAP Tapped hole Usually implies drilling a hole

does not exist

THRU Through

THRU ALL Through all Other features share the same
TYP Typical Characteristic

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Information Sheet 1.1.1 : Components and Functions of the Starting System

2. Orthographic/Isometric drawing

ISOMETRIC DRAWING

A pictorial representation of an object in which all three dimensions are drawn
at full scale rather than foreshortening them to the true projection. An isometric
drawing looks like anisometric projection but its all lines parallel to the three
major axes are measurable.

Isometric drawing of a cube Isometric drawing

ORTHOGRAPHIC DRAWING

Orthographic projection (or orthogonal projection) is a means of representing a
three-dimensional object in two dimensions. It is a form of parallel projection,
where the view direction is orthogonal to the projection plane,[1] resulting in
every plane of the scene appearing in affine transformation on the viewing
surface. It is further divided into multiview orthographic projections and
axonometric projections.

Code No. Servicing Starting System Date: Developed Date: Revised Page #
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Information Sheet 1.1.1 : Components and Functions of the Starting System

The term orthographic is also sometimes reserved specifically for depictions of
objects where the axis or plane of the object is also parallel with the projection
plane, as in multiview orthographic projections.

Orthographic Drawings/Orthographic Projection
A projection on a plane, using lines perpendicular to the plane
Graphic communications has many forms. Orthographics is one such form. It was developed
as a way of communicating information about physical objects. It is part of a universal
system of drawings. House plans - one well known drawing format, are a form of
othographic projection. In simple terms, orthographic drawings are views (front, side, top,
and so on) of an object. An orthographic view is only one side. It takes several views to show
all the object. Before getting to views, it is useful to look at another type of drawing. Pictorial
drawings show several sides at the same time. Many people find pictorial drawings easier to
understand. They do not provide as much information as orthographic views. The most
commonly used pictorial drawing for technical information is called isometric drawings.
Isometric drawings were developed to approximate perspective, but are much easier to
draw. For a square box, all the sides are drawn as vertical lines, or at 30 degrees to the
horizontal.

Pictorial Drawing Example 1
A simple box has 6 sides - top, bottom, 2 ends and 2 sides. An isometric drawing of a box looks like

this.

Code No. Add label to the sides Date: Developed Date: Revised Page #
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Information Sheet 1.1.1 : Components and Functions of the Starting System

These labels are OK, but in the world of technical drawings, special labels are used. The label
refers to a position on the drawing. Proper labels for the sides on this box are:

Top View
Front View
Right Side View
Left Side View
Rear View
Bottom View

TOP

An
Orthographic projection

SIDE FRONT

An examples of several Orthographic

Code No. Servicing Starting System Date: Developed Date: Revised Page #
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Worksheet 1.2.3 : Measuring current, Voltage And Resistance

1. 1. 2 Worksheet

Learning outcomes:

1 “Determining Job requirements”

Learning Activity:
1.1 “Interpret drawing/Plan”

A. Multiple Choice : Select the correct answer. Write the letter of the correct answer
on the blank provided before each number.

_________ 1. What component of an engineering drawing represents something by
pictures, objects.

a. Fits
b. Symbols
c. Details
d. Assembly

__________2. A pictorial presentation of an object of which all three dimensions
are drawn in full scale is called?

a. Pictorial drawing
b. Symmetric drawing
c. Analog drawing
d. Isometric drawing

__________ 3. Engineering drawing abbreviation and symbols are used to;

a. communicate and details the characteristic of a drawing
b. limit the outline alone
c. make and how to read drawing
d. show the object appear to the eye

___________ 4. Defines as the center of the circle or a partial circle is;

Code No. a. Center line Date: Developed Date: Revised Page #
ALT723307 b. Bolt circle
c. Center mark Nov. 28, 2003 Mar 01, 2006 1

Servicing Starting System

Worksheet 1.2.3 : Measuring current, Voltage And Resistance

d. Diameter
___________ 5. A point that makes the layout of the part easier. It is usually the

Intersection of the tangent line of the curve.

a. Point of origin
b. Reference
c. Point of Interest
d. Radius

B. Identify the following abbreviation drawing symbols.
Give each meaning.

1. AC
2. AF
3. BC
4. CL
5. DIA
6. MAX
7. MIN
8. R
9. REF
10. STD

Code No. Servicing Starting System Date: Developed Date: Revised Page #
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Worksheet 1.2.3 : Measuring current, Voltage And Resistance

C. Give/Draw the three views of an Isometric drawing.

Code No. Servicing Starting System Date: Developed Date: Revised Page #
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Information Sheet 1.1.1 : Components and Functions of the Starting System

1.1.3 – Information sheet

Learning Outcome :
1 “Determine Job Requirements” (Shop Safety Practices)
Learning Activity :
1 . 2 “Identify different requirements in Shop Safety Practices”
__________________________________________________________________________________________

2. Identify different Shop Safety practices

a. Shop Working habits

Being new in the working world, I am sure you are eager to show off your newfound
skills and knowledge. However, out there in the working world some basic work
effective habits can increase your productivity. By being consistently effective at your
work increases your chances of success in your career.

The 5 effective work habits are:

1. Volunteer for Assignments

One of the best ways to signal that you are a keen learner and are not afraid of
hard work is to volunteer for assignments. Especially assignments that no one seems
interested to do. However, before that do assess your own skills and knowledge to see if
you can confidently accomplish it. If you are confident in completing the task in full and
perfection, go ahead and volunteer for it.
However, do remember one thing. Under promise and over deliver on the assignment
you volunteered. Do not be too confident that you turn a perfect opportunity into mess.
Once you start the project, see it till the end. You would be seen as someone who is
courageous enough to take on additional assignments. You would also be seen as
someone who follows through in your work. This is the first habit you need to
internalize.

2. Be Nice to People

I am sure we have all heard this often enough. Be nice to people regardless of
their rank and designation. It sounds philosophical but when you are nice to people they
go out of their way to help you. And being new in an organization you would never
know what sort of help you would need. Colleagues often like to work with nice
talented people. When you have this effective work habit you increase the chances of
people wanting you to work on their team.
Being nice to people is just common courtesy. There is nothing extra ordinary about this
particular habit that you need special skills. A smile in the morning and

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Information Sheet 1.1.1 : Components and Functions of the Starting System

a "Good Morning" is a good start. In this day and age, people working in
pressurized environments often use stress as an excuse when they blow up. Is
this necessary? Nice is often reciprocated by nice. In fact, it can lower your
stress level.

3. Prioritize Your Work

We all love to start work on things that are close to our hearts. However, often
these may not be the most urgent and important in our list of tasks in the
workplace. When you select things you are more interested in rather than work
that is more important or urgent, you lower your chances of success.
Have a list of things to do according to its strategic importance to your company.
Know your role in completing the tasks at hand in order to achieve that corporate
goal. When you prioritize your work, you are more productive and that increases
your chances of career success.

4. Stay Positive

As someone new in the working world it is very easy to feel down because you
are new. You are not used to the work system. You have new people to deal with
and people in the working world who behave very differently from school. It takes a
lot of getting used to. There will be office politics to deal with regardless of how
little.
Be above all these and stay positive in the face of challenges. When you are positive
you remain focused on your goals. You make better decisions and therefore become
more productive.

5. Highlight a Problem but Bring Solutions

The last effective work habit of the five effective work habits is to bring
solutions each time you highlight a problem to your boss or management. You need
to remember that when you bring problems and not solutions, it is often construed
as complaining.
To avoid that label, offer solutions. A range of possible solutions also indicates to
your boss that you have thought this through before approaching him/her with a
problem. Have in mind a recommended solution amongst those you suggested

b. Hazardous areas are defined by three main
criteria:

1. The type of hazard
2. The likelihood of the hazard being present in flammable

concentrations

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Information Sheet 1.1.1 : Components and Functions of the Starting System

3. The (auto) ignition temperature of the hazardous material

The type of hazard (Groups)

The hazard will be in the form of a gas, vapour, dust or fibre.

Gases and Vapours

Gases and vapours are categorized in terms of their ignition energy or the
maximum experimental safe gap (in respect of flameproof protection).

Examples: Mining and Industry

The hazard that being present in flammable
concentrations

The likelihood of the hazard being present in flammable concentrations will
vary from place to place. A location very close to an open source of hazard
will have a high likelihood of a flammable atmosphere. On the other hand,
outside a flanged pipe containing a flammable liquid, the likelihood of a
flammable atmosphere being present is much lower since it will only occur if
the flange leaks. Rather than work with an infinite range of possibilities,
three zones are defined.

The (auto) ignition temperature of the hazardous material
(Temperature Classes)

As well as considering the protection against electrical arcs and sparks
igniting a flammable atmosphere, consideration needs to be given to the
surface temperature of equipment. (Most electrical apparatus dissipates
some heat!) Flammable materials are categorized according to their
ignition temperature.
Again, rather than work with an infinite range.

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Information Sheet 1.1.1 : Components and Functions of the Starting System

Six temperature classes are defined as follows:

T –Class Hazard which will not at temperature
Below

T-1 450 degrees Celsius
T-2 300 “
T-3 200 “
T-4 135 “
T-5 100 “
T-6 85 “

Note: The bigger the T-number the lower is the
Temperature

c. Personal Protective equipment (PPE)

Personal protective equipment (PPE) refers to protective clothing, helmets,
goggles, or other garment designed to protect the wearer's body from injury by
blunt impacts, electrical hazards, heat, chemicals, and infection, for job-related
occupational safety and health purposes, and in sports, martial arts, combat, etc.
Personal armor is combat-specialized protective gear. In British legislation the term
PPE does not cover items such as armour. The terms "protective gear" and
"protective clothing" are in many cases interchangeable; "protective clothing" is
applied to traditional categories of clothing, and "gear" is a more general term and
preferably means uniquely protective categories, such as pads, guards, shields,
masks, etc.

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Information Sheet 1.1.1 : Components and Functions of the Starting System

d.Safe Handling Tools and equipment and materials

Introduction

More than a 1/3 of injuries reported to the Health and
Safety Executive are from incidents involving manual
handling procedures. These injuries are costly to the
employee and the employers.
The Manual Handling Operations Regulations 1992
(Amended 2002) apply to any process where
manual handling occurs. It offers a framework to help
reduce the number of accidents and injuries
from these procedures.

TYPES OF INJURY
The back is a series of bones with a disk separating each
vertebra. There are ligaments and muscles,
which support the spine. Pain is a protective
mechanism to warn you about potential harm to your
body.

The types of injury that occur are:
1. Strains, both immediate and those that occur over time due to repeated movements.
2. Sprains, cuts and bruising, fractures and intra-vertebral disc injuries.

Anywhere in the musculo-skeletal system can be injured.

1) Risk Assessment

The purpose of a risk assessment is to:
1. Identify hazardous practices by looking at the Task, Individual, Load, and the Environment.

Also to decide who may be harmed by the process, to look at the existing controls and to
decide if further interventions are necessary.
The person carrying out the assessment should be:
1. Familiar with The Management of Health and Safety at Work Regulations 1999, The Manual
Handling Operations Regulations 1992 (Amended 2002) and any amendments or updates.

2. Familiar with the processes being carried out.
3. Competent to carry out the task.

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Information Sheet 1.1.1 : Components and Functions of the Starting System

The assessment should be written down and the recommendations acted
upon where reasonably practicable.

LOAD

Is it an awkward shape?
Is it heavy?
Can the load shift; is it unstable or predictable?
Are there handholds or can the packaging be made to include handholds?
Is team handling required?
Is the load hazardous e.g. hot, cold, sharp or a chemical?

TASK

The whole task should be looked at from the beginning to the end. Some of these aspects
need to be considered:

Is it manageable?
Can the height of the lift be made more suitable?
Can the lifting above the head or below the knees be avoided?
Can twisting or repetitive movement be reduced?
If repetitive movements are involved the weight of the load will need to be

reduced.
Does the operator need to hold the load away from their trunk, or need to

push or pull?
Can mechanical aids be used, e.g. trolleys, hoists, roller tracks or conveyers?

ENVIRONMENT

Is there enough space?
Is it cold so that the touch sensation may be less?
Is it very hot so that the hands may be sweaty and slip?
Are there varying floor levels?
Do different surfaces have to be crossed?
Is the lighting suitable?
Could something in the environment suddenly change e.g. a sudden gust of wind?

INDIVIDUAL

Are they fit and trained to carry out the task?
Does it require unusual capability?
Does personal protective equipment need to be used with the hazard, and does this

affect the movement or grip of the operator?
Is the load a hazard to particular people e.g. pregnant workers?

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Information Sheet 1.1.1 : Components and Functions of the Starting System

2) Employers and Employees

EMPLOYERS DUTIES
Employers should:

1. Assess the likely risk of injury with all manual handling operation occurring in the
workplace.

2. Put in place a safe system of work.
3. Avoid the need for manual handling so far as reasonably practicable.
4. Reduce any remaining risk as far as reasonably practicable.
5. To provide information and training.
6. To re-assess any manual handling at regular intervals or, if anything in the risk

assessment changes.

EMPLOYEES DUTIES
Employees must:

1. Follow a safe system of work.
2. Make proper use of equipment provided by the employer for manual handling.
3. Attend any training that is provided.
4. Not put either themselves or others at risk.
5. Report any accidents or near misses in line with the local policy.

PREVENTING BACK PAIN
As well as the processes above there are actions that you can take to

help prevent back pain these are:

1. Keep your weight within normal limits for your height.
2. Try to maintain a good posture during all activities e.g. standing, sitting, and

driving.
3. Stretch and warm up before activity.
4. Gentle stretching and exercise program can assist in building a strong back

and a strong stomach to support it.
5. If you get back pain, stop the activity immediately and seek further advice from

your medical practitioner. If the pain occurred during a work activity report the
incident according to local policy.

3) Handling Techniques

Code No. Think – PLAN Date: Developed Date: Revised Page #
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Where am I going? Mar 01, 2006 7
What am I lifting?
What are the options?

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Information Sheet 1.1.1 : Components and Functions of the Starting System

Are there any aids available?
Do I need help?
Do I need to remove any obstructions?

Think – FEET

Am I wearing suitable footwear for the task?
Place your feet apart to give you a good balanced posture.
Place the leading foot so it is positioned slightly forward in the

direction of travel.

Think – POSTURE

Keep the spine in its normal alignment.
Bend from the knees but do not over flex them.
Keep shoulders and knees in normal alignment.
Keep the shoulders level.

Think – GRIP

Ensure the grip is secure.
Are there suitable handholds?
Is the load likely to slip?
Keep arms within the boundary of the body.

Think – LIFT

Keep relaxed.
The upward movement starts with the head.
Make the movement as smooth and progressive as possible.
Use the power of the legs.
Keep the load close to the body.
Keep the heaviest part towards you.
If you need to turn, move the feet, don’t twist the body.
Put the load down.

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Information Sheet 1.1.1 : Components and Functions of the Starting System

e. HOUSEKEEPING

INTRODUCTION:

Good Housekeeping practices at the workplace have proven to raise the level of
productivity for many organizations. Using this relation between housekeeping and
productivity as a basis, organizations should take steps on a regular basis to reduce
its costs through the elimination or reduction of wastage. To achieve this, employees
should be trained to carry out 5S Good Housekeeping to identify and eliminate
waste in their organization. 5S Good Housekeeping is a simple, systematic and
successful way to an improved workplace. An organized workplace is a safer place.
It also leads to a cleaner and neater environment and happy workers

5S or Good Housekeeping

5S or good housekeeping involves the principle of waste elimination through
workplace organization. 5S was derived from the Japanese words seiri, seiton, seiso,
seiketsu, and shitsuke.

In English, they can be roughly translated as sort, set in orderstandardize, and

sustain. The cornerstone of 5S is that untidy, cluttered work areas are not

productive. As well as the physical

implications of junk getting in

everybody's way and dirt

compromising quality, we all are

happier in a clean and tidy

environment and hence more

inclined to work hard with due

care and attention.

Thus, 5S and good housekeeping

are core elements of "lean

thinking" and a

"visual workplace" and are a

fundamental platform for world-

class manufacturing. Good Housekeeping

5S provides the foundation for all quality improvement programs. Thus, it is
often said that the road to productivity starts with 5S and through 5S you can
create a highly productive company with highly productive people. 5S is not only
a matter of good housekeeping.
It is a process to create more productive people and more productive companies

Code No. Servicing Starting System Date: Developed Date: Revised Page #
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Information Sheet 1.1.1 : Components and Functions of the Starting System

through motivation, education, and the practice of 5S. It involves the creation of a
strong corporate culture filled with the spirit filled with the spirit of high

productivity.

Seiri -Sorting/Putting things in order (remove/discard what is not needed so that there
are fewer hazards and less clutter to interfere with work. Only keep what is needed.)

Seiton Orderliness/Proper Arrangement (Place things in such a way that they can be
Easily reached whenever they are needed. "There must be a place for verything,
and everything must be in its place.")

Seiso Clean/cleanliness. (Keep workplace and things clean and polished; no trash or dirt
in the workplace)

Seiketsu Standardize/Purity (Maintain cleanliness after cleaning, consistently- perpetual
cleaning. Such cleaning is part of every one's work.)
Shitsuke Sustaining/discipline/commitment (Maintaining standards and keeping the

facility in safe and efficient order day after day, year after.

e. First Aid

First aid - is the provision of initial care for an
illness or injury. It is usually performed
by a non-expert person to a sick or
injured casualty until definitive
medical treatment can be
accessed. Certain self-limiting illnesses
or minor injuries may not require
further medical care past the first aid
intervention. It generally consists of a
series of simple and in some cases,
potentially life-saving techniques that
an individual can be trained to
perform with minimal equipment.
While first aid can also be performed
on animals, the term generally refers
to care of human patients.

First Aid Symbol

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Information Sheet 1.1.1 : Components and Functions of the Starting System

First Aid Kits

First aid kits can be assembled in almost any type of container, and this will depend on
whether they are commercially produced or assembled by an individual. Standard kits
often come in durable plastic boxes, fabric pouches or in wall mounted cabinets. The
type of container will vary depending on purpose, and they range in size from wallet
sized through to large rucksacks.

It is recommended that all kits are in a clean,waterproof container to keep the
contents safe and aseptic.[2 Kits should also be checked regularly and restocked if any
items are damaged or out of date.

End

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Information Sheet 1.1.1 : Components and Functions of the Starting System

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Worksheet 1.2.3 : Measuring current, Voltage And Resistance

1. 1. 6 Worksheet

Learning outcomes:

1 “Determining Job requirements” (Material and related science)

Learning Activity:
1.3 “Identify the classification of Mechanical properties and engineering materials”

A. MULTIPLE CHOICE. Select the correct answer. Write the letter of the correct
on the blank provided before each number.

_______ 1. Is a mechanical property used to describe the extent to which

the material can be deformed plastically without fracture.
a. Ductility
b. Compressive strength
c. Fatigue Limit
d. Flexural modulus

___________ 2. Expression used to described a property of materials, the
amplitude of cyclic stress that can be applied to the material
without causing fatigue failure.

a. Ductility
b. Compressive strength
c. Fatigue limit
d. Flexural modulus

____________ 3. Is the capacity of a material to withstand axially directed pushing
forces, and when the limit of compressive strength is reached
material are crushed.

a. Ductility
b. Compressive strength
c. Fatigue limit
d. Flexural modulus

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Worksheet 1.2.3 : Measuring current, Voltage And Resistance

____________ 4. Is the ratio of stress to strain in flexural deformation, or the
tendency for the material to bend.

a. Flexural modulus
b. Fatigue limit
c. Compressive strength
d. Ductility

____________ 5. Is the ratio when a sample ject is stretched, of the
contraction or transverse strain, to the extension or axial
strain.
a. Hardness
b. Poisson’s ratio
c. Fracture toughness
d. Flexural strength

____________ 6. Measure of how resistant solid matter is to various kinds
of permanent shape change when a force is applied.

a. Hardness
b. Poisson’s ratio
c. Fracture toughness
d. Flexural strength

_____________ 7. A mechanical for brittle materials that has ability to resist
deformation under load.

a. Flexural strength
b. Fracture toughness
c. Poisson’s ratio
d. Hardness

_____________ 8. Is a property which describes the ability of a material
containing a crack to resist fractures.

a. Flexural strength
b. Fracture toughness
c. Poisson’s ratio
d. Hardness

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Worksheet 1.2.3 : Measuring current, Voltage And Resistance

_______ 9. Is a term used to describe the strength of a material

or components against the type of yield or structural
failure where the material or components fail in shear.
a. Softness
b. Shear strength
c. Specific modulus
d. Specific weight

____________ 10. A material property consisting of the elastic modulus per
Mass density of a material. It is also known as the
Stiffness to weight ratio or specific stiffness.

a. Specific modulus
b. Softness
c. Specific weight
d. Shear strength

**** END ****

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Information Sheet 1.1.1 : Components and Functions of the Starting System

1.1.5 – Information sheet

Learning Outcome :
1 “Determine Job Requirements” (Material and related science)
Learning Activity :
1 . 3 “ Identify classification of Mechanical properties of Engineering materials”
__________________________________________________________________________________________

3. Material and related science

Mechanical Properties

The mechanical properties of a material describe how it will
react to physical forces. Mechanical properties occur as a result
of the physical properties inherent to each material, and are
determined through a series of standardized mechanical tests.

Properties:

 Compressive strength
 Ductility
 Fatigue limit
 Flexural modulus
 Flexural strength
 Fracture toughness
 Hardness
 Poisson ratio
 Shear modulus
 Shear strength
 Softness
 Specific modulus
 Specific weight
 Tensile strength
 Yield strength
 Young modulus

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Information Sheet 1.1.1 : Components and Functions of the Starting System

1. Compressive strength

- is the capacity of a material to withstand axially directed pushing
forces. when the limit of compressive strength is reached, materials are
crushed.
Concrete can be made to have high compressive strength, e.g. many
concrete structures have compressive strengths in excess of 50 MPa,
whereas a material such as soft sandstone may have a compressive
strength as low as 5 or 10 MPa. Compare tensile strength

2. Ductility

- is a mechanical property used to describe
the extent to which materials can
be deformed plastically without fracture.

Tensile test low ductility

3. Fatigue Limit

Fatigue limit, endurance limit, and
fatigue strength are all expressions
used to describe a property of
materials: the amplitude (or range) of
cyclic stress that can be applied to the
material without causing
fatigue failure.

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4. Flexural Modulus

In mechanics, the flexural modulus is the ratio
of stress to strain in flexural
deformation, or the tendency for a material to
bend. It is determined from
the slope of a stress-strain curve produced by a
flexural test (such as the ASTM D 790), and
uses units of force per area.[1] It is an
intensive property.

Flexural modulus

5. Flexural strength

Flexural strength, also known as modulus of

rupture, bend strength, or fracture

strength, a mechanical parameter for brittle

material, is defined as a material's

ability to resist deformation under load. The

transverse bending test is most

frequently employed, in which a rod specimen

having either a circular or

rectangular across section is bent until fracture Bonded porcelain restoration

using a three point flexural test

technique. The flexural strength represents the highest stress experienced

within the material at its moment of rupture. It is measured in terms of stress.

6. Fracture toughness

In materials science, fracture toughness is a property which describes the
ability of a material containing a crack to resist fracture, and is one of the
most important properties of any material for virtually all design applications.

It is denoted KIc and has the units of .

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Information Sheet 1.1.1 : Components and Functions of the Starting System

7. Hardness

Hardness is the measure of how resistant solid
matter is to various kinds of permanent shape
change when a force is applied. Macroscopic
hardness is generally characterized by strong
intermolecular bonds, however the behavior
of solid materials under force is complex,
therefore there are different measurements
of hardness: scratch hardness, indentation
hardness, and rebound hardness. Hardness is
dependent on ductility, elasticity, plasticity,
strain, strength, toughness, viscoelasticity, and
viscosity.

Vickers hardness tester

8. Poisson’s ratio

Poisson's ratio (ν), named after Siméon Poisson, is the ratio,
when a sample reject is stretched, of the contraction or transverse
strain (perpendicular to the applied load), to the extension or axial
strain (in the direction of the applied load).

ESPI measurements on bone beams
(could measure concurrently tension and compression in the same specimen)

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Information Sheet 1.1.1 : Components and Functions of the Starting System

9. Shear Modulus

In materials science, shear modulus or
modulus of rigidity, denoted
by G, or sometimes S or μ, is defined
as the ratio of shear stress to the
shear strain.

Shear modulus Shear stain
Expressed in (SI unit):
Commonly used symbols: gigapascal
Expressed in other quantities: G
G=τ/γ

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Information Sheet 1.1.1 : Components and Functions of the Starting System

10. Shear strength

Shear strength in engineering is a term used
to describe the strength of a
material or component against the type of
yield or structural failure where
the material or component fails in shear.
In structural and mechanical engineering the
shear strength of a component
is important for designing the dimensions
and materials to be used for the
manufacture/construction of the component
(e.g. beams, plates, or bolts)
In a reinforced concrete beam, the main purpose of stirrups is to increase the
shear strength.

11. Softness

Softness may refer to:
The opposite of one of the many types of hardness.
A texture which is the opposite of roughness.

12. Specific Modulus

Specific modulus is a materials property consisting of the elastic modulus per
mass density of a material. It is also known as the stiffness to weight ratio or
specific stiffness. High specific modulus materials find wide application in
aerospace applications where minimum structural weight is required.
The dimensional analysis yields units of distance squared per time squared.
The utility of specific modulus is to find materials which will produce structures
with minimum weight, when the primary design limitation is deflection or
physical deformation, rather than load at breaking—this is also known as a
"stiffness-driven" structure. Many common structures are stiffness-driven
over much of their use, such as airplane wings, bridges, masts, and bicycle
frames.

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Information Sheet 1.1.1 : Components and Functions of the Starting System

13. Specific Weight

The specific weight (also known as the unit weight) is the weight per unit
volume of a material. The symbol of specific weight is γ (the Greek letter Gamma).
A commonly used value is the specific weight of water on Earth at 5°C which
is 62.43 lbf/ft3 or 9807 N/m3. [1]
The terms specific gravity, and less often specific weight, are also used for
relative density.

14. Tensile Strenght

Tensile strength (σUTS or SU ) is indicated by the maxima of a stress-strain curve and,
in general, indicates when necking will occur. As it is an intensive property, its value
does not depend on the size of the test specimen. It is, however, dependent on the
preparation of the specimen and the temperature of the test environment and
material. The standard way to measure tensile strength is to use a small bar with
uniform width (apart from at the edges where the thickness increases) and to 'pull'
at each end until the bar fails. In the process, other mechanical properties may be
obtained. Other testing methods also exist, such as the
plane strain compression test.

Tensile strength, along with elastic modulus and corrosion resistance, is an
importantparameter of engineering materials used in structures and
mechanicaldevices. It is specified for materials such as alloys, composite
materials,ceramics, plastics and wood.

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Information Sheet 1.1.1 : Components and Functions of the Starting System

15. Yield strength

The yield strength or yield point of a material is defined in engineering
and materials science as the stress at which a material begins to deform plastically.
Prior to the yield point the material will deform elastically and will return to its
original shape when the applied stress is removed. Once the yield point is passed
some fraction of the deformation will be permanent and non-reversible.

Typical yield behavior for non-ferrous alloys.
1: True elastic limit
2: Proportionality limit
3: Elastic limit
4: Offset yield strength

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Information Sheet 1.1.1 : Components and Functions of the Starting System

16. Young modulus

In solid mechanics, Young's modulus, also known as the tensile modulus,
is a measure of the stiffness of an isotropic elastic material. It is defined
as the ratio of the uniaxial stress over the uniaxial strain in the range of
stress in which Hooke's Law holds.[1] This can be experimentally determined
from the slope of a stress-strain curve created during tensile tests
conducted on a sample of the material.
It is also commonly, but incorrectly, called the elastic modulus or modulus of
elasticity, because Young's modulus is the most common elastic modulus
used, however there are other elastic moduli, such as the bulk modulus and
the shear modulus.

------- E N D -----

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Information Sheet 1.1.1 : Components and Functions of the Starting System

2.1.1 – Information sheet

Learning Outcome :
2 “Prepare Work area”
Learning Activity :
2.1 “Identify necessary tools and materials needed for bench work and its procedures ”
__________________________________________________________________________________________

2. Prepare Work Area

a. Identify necessary tools and materials for Bench Work

Necessary Tools Necessary Materials

Chisels CRS (cold rolled steel)
Files Stainless steel
Extractors Mild Steel
Tap and Die CRS shafting
Scrapers SS shafting
Ball hammer Cast iron
Portable drill Aluminum

Calipers Bronze

Rulers Tin plate

Scribers

Bench grinder

Gauges

Drill Press

Note: “ Preparation of necessary tools and materials depends upon
on job requirements”

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Information Sheet 1.1.1 : Components and Functions of the Starting System

In the preparation of the work station the machinist will
have to consider actions to be taken

● before the work starts
● during the work processes
● after completion of the immediate work
● before leaving the premises – The actions will include

The removal and replacement of components.
The responsibility attached to these actions is important
as damage can be easily caused to the object or
the operator.

b. In Preparation of Work area you must:

1. Work safely at all times,
complying with health and safety
and other relevant regulations
and guidelines

2. Ensure that the work environment
is suitable for the work activities to
be under taken

3. Ensure that all necessary service
supplies are connected and ready
for use

4. Prepare the work areas so that
they are ready for the engineering
activities to be carried of out.

Example of a work area

5. Make sure that required safety
arrangements are in place to protect other workers from activities
likely to disrupt normal working

6. Report completion of preparations in line with organisational
procedures

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Information Sheet 1.1.1 : Components and Functions of the Starting System

7. Deal promptly and effectively with problems within your control
and report those that cannot be solved

c. Safety in work Area

1. Make sure that your work area will keep clean and neat
2. When you done in using tools, make sure that you place it back in

an appropriate location
3. It is good to have a mop or brooms and clean the floor theoretically

where you working.
4. Lighting is another important aspect of a safe workshop. Make sure

You have plenty of lights that you always see clearly of what you are
working on.
5. Always good to have an identify safety zone, a yellow box area
where the safety zone works. The purpose of this, is to avoid
distraction of work, or avoid anybody watching the way you work
that might cause the stock coming through or the blade might
cutting through.

END

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Worksheet 1.2.3 : Measuring current, Voltage And Resistance

3. 1. 2 Worksheet

Learning outcomes:

3 “Performed Bench work” (Chip work piece)

Learning Activity:
3.1 “ Identify different chisel used and its application“

A. MULTIPLE CHOICE. Select the correct answer. Write the letter of the correct
answer on the blank provided before each number.

__________ 1. The removal of metal with a hammer and chisel.
a. Filing
b. Chipping
c. Extracting
d. Sawing

___________ 2. It has a semi-circular shape at the back of the 30degrees
wedge.

a. Flat cold chisel
b. Cape chisel
c. Round nose chisel
d. Diamond point chisel

___________ 3. It has a flattened and tapered at the front side of wedge.
a. Flat cold chisel
b. Cape chisel
c. Round nose chisel
d. Diamond point chisel

____________ 4. It is used for finishing internal square corner and for cutting
square holes.
a. Diamond point chisel
b. Round nose chisel
c. Cape chisel
d. Flat cold chisel

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Worksheet 1.2.3 : Measuring current, Voltage And Resistance

___________ 5. It is used generally for all types of chipping works.

a. Flat cold chisel
b. Cape chisel
c. Round nose chisel
d. Diamond point chisel

B. ESSAY TYPE:

1. Describe a chisel.

a. Draw a chisel and label the different parts.
b. State the different types of chisel.
c. State the usage of each type of chisel
d. Give the method of Heat treatment.
e. State the different cutting angle required

2. Why chisel must be sharpened?
3. Explain why should a chisel having a “mushroom head” is not

advisable to use?

******* END *****

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Information Sheet 1.1.1 : Components and Functions of the Starting System

3.1.1 Information Sheet
Learning Outcome:
3 “ Performed Bench work” (Chip work piece)
Learning Activity:
3.1 “Identify different chisel used for chipping its uses and application”

Different Bench work operation:

1. Chipping work piece:

haCmhimppeinr gan- discthheisreelmoval of metal with a hammer and chisel. Hand chipping has been replaced

to a great extent by certain operations on power machines. There are however times
when a machinist and toolmaker must use their hand-chipping skills.

CHISEL

2.1.2 - InforTmyaptioensSohfeCethisel

1. Flat cold chisel FLAT COLD CHISEL
2. Cape chisel
3 Diamond-point
4. Round nose chisel

 Made of alloy steel
 100mm to 250mm in length
 Has a slightly convex cutting edge
 Used for general work

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Information Sheet 1.1.1 : Components and Functions of the Starting System

Usage

* to cut down the side of slots and
cotter ways

* to true up square corner
* for sharpening surfaces close to each other

Ex. Armature grinding

PARTS OF A CHISEL

* Head
* Body or stock
* Cutting angle
* Cutting edge
* Bevel or facet

CAPE CHISEL AND ROUND NOSE

 has a semi-circular shape at the
back of the 30 degrees wedge

 flattened and tapered at the front
side of wedge

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Information Sheet 1.1.1 : Components and Functions of the Starting System

USAGE

* To cut square or rectangular grooves
* To true up key ways
* To cut a starting grooves on wide flat square for a flat chisel

DIAMOND POINT CHISEL

Usage

* for finishing internal square corner
* for cutting square holes
* for cutting vee grooves along cracks
* for chipping out faulty welds
* for cutting sharp vee grooves for easy breaking off

USAGE OF CHISEL

a. Bringing a job to approximate size and shape quick removal of waste

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Information Sheet 1.1.1 : Components and Functions of the Starting System

materials.
b. Dressing casting
c. Cutting up light stock and sheet metal
d. Preparing edges for welding
e. Cutting out rivets and seized nuts

MATERIALS USED

a. Carbon Tool Steel (0.8% to 1% carbon)
b. Alloy Steel

METHOD OF HEAT TREATMENT

a. Oil quenched as from 900 degrees

CUTTING ACTION

* a combined wedging and shearing action

Cutting angle

* suit the hardness of metal being cut
* for hard materials, 70 degrees or more
* for soft materials, 30 degrees or less

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Information Sheet 1.1.1 : Components and Functions of the Starting System

Sharpening a chisel:

To perform the operation of
chipping, it is necessary to keep
the chisel sharp. Since the
cutting edge is tempered, care
must be used so that temper will
not be removed when chisel is
sharpened.

Ways of sharpening chisel

1. Alloy steel chisels – smooth filing
2. Carbon steel chisels - grinding

Safety precautions:

“ Do not use a chisel with ‘mushroom’ head”

Reasons:
* cause mishit
* overlapping burrs may fly off
* hand may hurt in the case that the chisel is driven down
from the grip

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Information Sheet 1.1.1 : Components and Functions of the Starting System

Performed chipping work piece operation:

Chipping

***************** end *****************

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