Electrical Engineering

Drill Gauge

Work in date: 21/08/2012                                                                                                                      
List tools used and describe:

Center Punch: It is a hand tool used to produce a dimple in a workpiece (for example, a piece of metal).

Vice: A tail vice is mostly used in design technology, it holds your work-piece firmly.

Bastard File: A bastard file or a mill bastard file is a file whose teeth configuration is in between a rough or coarse file and a 'second cut' file.

Second Cut File: A second cut file is a grade or pitch finer than a bastard file and is used for cutting hard metals.

Pillar Drill: A pillar drill is a stationary style of drilling machine that can be mounted on a stand or bolted to the floor or workbench.

               

Scriber: A scriber is a hand tool used in metalworking to mark lines on workpieces, prior to machining. 

Engineer Protractor: Engineer's protractor is a general purpose tool used for the measuring / checking of angles.

Steel Rule: A ruler, sometimes called a rule or line gauge, is an instrument used in geometry, technical drawing, printing and engineering

Ball Pein Hammer: The type most commonly used is the ball pein hammer, which has a flat striking face and a ball-shaped end (call the pein). Hammer heads are made from medium carbon steel. The two ends must be hardened and tempered, the centre of the head with the eye being left soft. It is specified according to its weight.

Engineers try-square: It is composed of two parts, the stock and the blade. They are usually made from bright mild steel with the blade being hardened and tempered so that it resists damage.

Engineer's blue: It is a highly pigmented paste used to assist in the mating of two or more components.

Jenny Caliper: A jenny caliper, which features a pair of arms connected by a circular hinge at one end.

Hacksaw: It is a fine-tooth saw with a blade held under tension in a frame, used for cutting materials such as metal or plastics.

Abrasive paper: It is used to remove small surfaces from materials.

Describe the process used in completing the task:

• Select a steel metal as exercise target, then clean this material and check size;
• One side use engineers blue ink to brush for marking;
• Square bottom and top edge using engineers protractor;
• Stamp bench number on back face;
• Mark out holes, lightly center punch using scriber;
• There are five holes on the metal, and each one has different size: 4, 6, 8, 10, and 12mm, 
• Check top and bottom size length if correct.

Work in date: 22/08/2012  

Describe the process used in completing the task:

• Using hacksaw cut unnecessary parts, then use rough and smooth files to polish the corners of the steels.
• File to shape ensuring: Point X is sharp not rounded, point Y is clear not undercut, 24mm width is parallel with max variation of ±0.05mm,
• Keep top corner is 45 degree.
• Number stamp hole 4, 6, 8, 10, and 12mm.
• Using pillar drill to drill six different size holes.
• Using abrasive paper polish the steel.

Potential hazards and injuries:
Metal splinter, Dust particles,Hot Metal, Sparks, Noise, Sharp edges and burrs, Hands and eye injuries

List some photos from workshop:

Workshop Tools

1. What is the name of the hammer most commonly used in Automotive engineering?

The most common hammer in an automotive workshop is the ball pein or engineer's hammer. The soft-face & deadblow hammers are also used.

2. What would you typically use one for?

The ball pein hammer is also used for hitting chisels and punches, but sometimes you need just to tap a component, to position it. A steel hammer might mark or damage it, especially if it's made of a softer metal like aluminum. In such cases a soft-face hammer should normally be used for the job. Some are very soft with rubber or plastic heads through to those using brass or copper. 

3. Why would you use a soft faced hammer?

Soft material made to protect surface of components or parts by damaged hit. 

4. What type of hammer would you use to give a really strong blow to a chisel?

When a large chisel needs a really strong blow, it's time to use the lump hammer.

5. What would you use a mallet for in Automotive Engineering?

It's a special purpose tool, and is often used for moving things into place where it is important not to damage the item being moved.

6. When would you use a dead blow hammer?

In auto repair they are commonly used for chassis work, dislodging stuck parts and sometimes used for hubcap installation and removal (e.g. knock-off hubs). They can be used to pop out small dents as well.

7. What can cause a hacksaw blade to clog?

The hacksaw is not be of right pitch, or number of teeth in an inch of blade. If a blade cutting through a thick section of metal has too many teeth, in other words the pitch is too fine, they can clog up and stop cutting.

8. What can happen if the blade is too coarse for the job it is intended for?

If the blade is too coarse the saw teeth could be stripped off of the blade at it try's to cut.

9. What should you do before and after using a hacksaw?

Before using a hacksaw should be determine the correct blade (and number of teeth) by laying the blade across the section being cut. Normally, at least 3 teeth should touch the metal at that point. This will ensure that the blade can do its job. After the job is done, the tension on the blade should be loosened, to prevent the frame from distorting over time.

Engineering Technology

Engine Strip Down

What is the petrol four stroke engine?

A four-stroke engine, also known as four-cycle, is an internal combustion engine in which the piston completes four separate strokes—intake, compression, power, and exhaust—during two separate revolutions of the engine's crankshaft, and one single thermodynamic cycle. (From Google Engine)

Describe what you have done to date and mention the health and safety.

Note: Turn off the engine and keep it cold, and shut off the power. PPE equipments(overall and safety boot)  must be wear any time when working.

Work in date: 07/08/2012

Petrol four stroke engine all parts of name and photo

Take some parts off and describe what it is for

Cylinder block: 

Cylinder block is a rigid frame that holds the cylinders in proper alignment. If the engine is liquid cooled, the block is jacketed, so that it can be surrounded by the liquid, or has passages for the liquid around each cylinder. In automotive engines, the cylinder block and crankcase form a single unit. Most cylinder blocks are made of cast iron or aluminium.

Cylinders 

Cylinders are rigid tubes that serve as a bearing for the pistons that move up and down inside them. They have highly polished surfaces. This permits a close fit between piston and cylinder and prevents gases from leaking past the piston. The cylinders in most car engines are part of the block. Some engines have a cylinder sleeve made of specially hardened steel or cast iron pressed into the cylinder block.

Cylinder head:

Cylinder head is a casting bolted to the top of the cylinder block. The cylinder head, together with the upper end of the cylinder and the top of the piston, form the combustion chamber where the fuel-air mixture burns. A cylinder head and block may be one unit.

Piston and Connecting rods

There is a piston fitted in the cylinder. This piston is connected to a connecting rod which in turn is connected to the crank shaft. When the fuel-air mixture burns, the expanding gases exert a force on the piston. This force is then transmitted through a connecting rod to the crankshaft. The piston has two to six rings to prevent the gases from escaping and to keep lubricating oil from getting into the combustion chamber. 

Work in 08/08/2012

Take some parts off and describe what it is for

Crankcase

Crankcase is a rigid frame that holds the crankshaft and the crankshaft bearings. In small engines, all or part of the crankcase may be a part of the cylinder block.

Crank shaft

Crankshaft changes the reciprocating motion of the pistons into rotary motion. The crankshaft has a number of cranks, or throws. These cranks are displaced at angles to each other. For example, in a six-cylinder, in-line, four-stroke cycle engine, the cranks are displaced at 120° angles to each other. As a result, the engine delivers three equally spaced power strokes in each revolution of the crankshaft to assure smooth operation.

Flywheel

Flywheel stores energy during a piston's power stroke and releases it during other strokes. This helps to keep the crankshaft turning at a constant speed.

Valves

In a four-stroke cycle engine, each cylinder has one or two intake valves, to let the air-fuel mixture into the combustion chamber, and one or two exhaust valves, to let the burned gases escape. These are called poppet valves, because they pop up and down as they open and close. The opening in the cylinder block or head uncovered by the valve is called the port. In many two-stroke cycle engines, the movement of the piston takes the place of separate valves. As the piston moves, it covers and uncovers the ports.

Camshaft

Camshaft opens and closes the valves at the proper point in the engine cycle. It runs the length of the engine and has one cam (lobe) at each intake and exhaust valve. In a four-stroke cycle engine, the camshaft is geared to the crankshaft so that it runs at half the crankshaft's speed. The camshaft may be located in the head of an overhead valve engine, or in the crankcase.

Micrometer

METRIC MICROMETER READING EXERCISES

Jacking up a vehicle in the workshop

Tools List as below:

1. Trolley Jack

2. Axle stands

3. Wheel brace

4. Torque wrench

Jacking up a vehicle processing video from YouTube



Tips & Warnings

• Use a trolley jack designed to support the weight of your vehicle. Trolley jacks are not "one size fits all."
• Long-handled trolley jacks allow for more leverage and may be more effective when lifting vehicles that are lower to the ground, as a short handle will only allow for smaller strokes when lifting.
• Consult the owner's manual for your vehicle prior to using a trolley jack.
• Do not use the oil pan or areas of the car unsupported by the frame as a lift point when using a trolley jack.
• Do not work underneath a car supported by a trolley jack alone. Always use jack stands.

(From Google How to Lift a Car Using a Trolley Jack)