Introduction to Engineering

Ust. Mhadi
 Introduction to Engineering
• Course Outlines:
• Introduction to work shop technology ,
• Industrial Safety
• Chip & chip lees generating operations,
• Sand casting operations,
• Permanent and temporary joints of metal,
• Measurement and measuring devices,
• Scientific classification of maintenance, preventive and
corrective maintenance,
• Energy: Definition, sources and utilization, Impact of
Engineers in Society, Power, Health, Safety and Care.
 Introduction to Engineering

• What is engineering?

• What do Engineers do?

• The basic engineering process

 What is an Engineer?
All kinds of the future engineers must know the
basic requirements of workshop activities in
term of man, machine, material, methods,
money and other infrastructure facilities needed
to be positioned properly for optimal shop
layouts or plant layout and other support
services effectively adjusted or located in the
industry or plant within a well planned
manufacturing organization.
 What Engineers Do ?

• Build a Bridge?
• Make a Robot?
• Work on a Computer?
• Drive a Train?
• Repair Car Engines?
Is This Guy an Engineer ?
Engineering Job Descriptions
• Analytical engineer
• Design engineer
• Test engineer
• Manufacturing engineer
• Development engineer
• Research engineer
• Sales engineer
• Engineering manager
• Consulting engineer
Why Be An Engineer?

• Money ??
• Fame ??
• Fortune ??
Why might YOU want to be an Engineer?
• You have high goals in life and want to get a strong
college education!
• You like math and sciences, and would like to apply
them to real world problems!
• You enjoy hands-on work and tinkering with things!
• You were told that engineers make a lot of money!
• You were told that you can get a good job with an
engineering degree!
• You want to help humanity!
What is Mechanical Engineering?
• Mechanical engineering is the second largest
and one of the oldest disciplines; broadest of all
engineering disciplines.
• Mechanical engineers apply the principles of
mechanics and energy to the design of
machines and devices:

ENERGY and MOTION

 What is Civil Engineering?
• Civil engineering is a professional
engineering discipline that deals with the
design, construction, and maintenance of the
physical and naturally built environment,
including works like roads, bridges, canals,
dams, and buildings.
 What is an Electrical
Engineering?

Electrical engineering is a field of engineering

that generally deals with the study and
application of electricity, electronics, and
electromagnetism.
 What is an Agricultural
Engineering?
Agricultural engineering is the engineering
discipline that applies engineering science and
technology to agricultural production and
processing. Agricultural engineering combines
the disciplines of animal biology, plant biology,
and mechanical, civil, electrical andchemical engi
neering principles with a knowledge of
agricultural principles.
 The Engineering Design Process:
(Core of Engineering)
• Problem Identification: Get with Customer.
• Conceptual Design: Ideas, Sketches and Solution Lists.
• Refinement: Computer Modeling, Data Base Development.
• Testing: Analysis and Simulation of All Design Aspects.
• Prototyping: Visualizing and Improving the Design.
• Communication: Engineering Drawings, Specifications.
• Production: Final Design, Manufacturing, Distribution.
 Design Graphics

Sketching 3-D Modeling Analysis

Prototyping 2-D Drawing Team Work

 Manufacturing processes and
workshop technology
• Manufacturing is the backbone of any industrialized
nation.
• Manufacturing and technical staff in industry must know
the various manufacturing processes, materials being
processed, tools and equipment's for manufacturing
different components or products with optimal process
plan and specified safety rules to avoid accidents.
• All kinds of the future engineers must know the basic requirements of
workshop activities in term of man, machine, material, methods,
money and other infrastructure facilities needed to be positioned
properly for optimal shop layouts or plant layout and other support
services effectively adjusted or located in the industry or plant within a
well planned manufacturing organization.
Manufacturing processes and
workshop technology
 CLASSIFICATION OF MANUFACTURING
PROCESSES

Primary Shaping Processes

 Primary shaping processes are manufacturing of a product
from an amorphous material.
Secondary or Machining Processes
 As large number of components require further processing
after the primary processes. These components are
subjected to one or more number of machining operations
in machine shops, to obtain the desired shape and
dimensional accuracy on flat and cylindrical jobs
 CLASSIFICATION OF MANUFACTURING
PROCESSES

Metal Forming Processes

• Forming processes encompasses a wide variety of
techniques, which make use of suitable force, pressure or
stresses, like compression, tension and shear or their
combination to cause a permanent deformation of the raw
material to impart required shape. Classified into two
major categories:
1. hot working processes
2. cold working processes.
Joining Processes
Most of the products cannot be manufactured as single unit
they are manufactured as different components using one or
more of the above manufacturing processes, and these
components are assembled to get the desired product
 There are two basic types of joints
1. temporary joints and
2. permanent joints
Some of the important and common joining processes are:
(1) Welding (plastic or fusion), (2) Brazing, (3) Soldering,
(4) Riveting, (5) Screwing, (6) Press fitting, (7) Sintering,
(8) Adhesive bonding, (9) Shrink fitting, (10) Explosive
welding, (11) Diffusion welding, (12) Keys and cotters joints,
(13) Coupling and (14) Nut and bolt joints.

 Surface Finishing Processes

 Processes Effecting Change in Properties

 Industrial Safety
• With the advancement of scientific and technological
development in various areas of design and manufacturing,
the danger of life human being is increasing day by day.
• SAFETY CONCEPTS
 In all kinds of industries, each shop supervisor is generally
assigned the responsibility of safety in his shop regarding
the men, machines and materials.
 Every supervisor in each shop ensures to the top
executives in respect of all kinds of the safety matters. He
is supposed to incorporate all new safety measures needed
in the shop from time to time.
 A safety programme should always include engineering
safety at the design and equipment installation stage,
education of employees in safe practices, concerns the
attitude of employees and management. It should motivate
all the industrial employees in accident prevention and
safety consciousness.
 An industrial worker will usually accept the use of a safety
measure if he is convinced of its necessity. Therefore,
suitable measures must be adopted to increase the
awareness of a need for safety in the environment of work
 PLANNING FOR INDUSTRIAL SAFETY

 Mis-happening of a large number of fire hazards,

accidents, industrial disasters can be reduced to the
minimum possible extent through careful safety planning
within an industrial organization.
 Safety consideration includes proper layout of buildings
and equipment, such as providing adequate ventilation,
sufficient working area to the operator, clear pathways for
movement of materials and parts, provision for adequate
personnel facilities- viz., canteens, lunch rooms,
dispensary, fire fighting services.
 Material handling and its storage are very common
functions in a plant. Material handling when performed
manually the chances of injuries are greater. Therefore the
following points should be taken care for carrying out such
tasks.
 The workers should be properly trained to adopt safe
working habits and proper supervision should be done
while these operations are being carried out manually.
Industrial personnel and unskilled workers should be
adequately trained for adopting safe working habits in the
proper ways of lifting and setting down the objects.
 Objectives of Industrial Safety
1. Industrial safety is needed to check all the possible chances
of accidents for preventing loss of life and permanent
disability of any industrial employee, any damage to machine
and material as it leads to the loss to the whole establishment.
2. It is needed to eliminate accidents causing work stoppage
and production loss.
3. It is needed to prevent accidents in industry by reducing
any hazard to minimum.
4. It is needed to reduce workman’s compensation, insurance
rate and all the cost of accidents.
5. It is required to educate all members regarding the safety
principles to avoid accidents in industry.
6. It is needed to achieve better morale of the industrial
employees.
7. It is required to have better human relations within the
industry.
8. It is needed to increase production means to a higher
standard of living.
 COMMON SAFTY METHODS

The common methods of safety are as follows:

1. Safety by construction or design.
2. Safety by position.
3. Safety by using fixed guards.
4. Safety by using interlock guards.
5. Safety by using automatic guards.
6. Safety by using trip guards.
7. Safety by using distance guards.
8. Safety by workplace layout and proper working conditions.
9. Safety by proper material handling.
10. Safety by using personal protective devices.
 TYPES OF SAFETY
 The fo1lowing general types of safety are considered in the
workshop:
1. Safety of self.
2. Safety of job.
3. Safety of machines tools.
General Safety Precautions while Working in a Workshop
One should not leave the machine ON even after the power is OFF and
until it has stopped running completely.
Operator should not talk to other industrial persons when he is operating a
machine.
3. One should not oil, clean, adjust or repair any machine while it running.
Stop the machine and lock the power switch in the OFF position.
4. One should not operate any machine unless authorized to do so by the
authorize
person in the shop.
5. Always check that work and cutting tools on any machine are
clamped securely before starting.
6. The floor should be kept clean and clear of metal chips or curls
and waste pieces.
6. Stop the machine before making measurements or adjustments.
Safety Precautions while Working in Casting shop
1. One should use mask to avoid excessive inhalation of the dust,
which may cause serious problem to health.
2. Always wear protective clothes to keep safe from the heat
radiating from the melting process.
3. All foundry men should wear protective clothes, glasses, shoes,
and gloves while handling molten metal for casting process.
4. Always use proper ventilation to protect from molten metal
fumes and gases that evolve from the mould during pouring.
5. One should not touch hot moulds and castings.
6. One should always keep clean the work area.
 Sand Casting Operation

• Casting process is one of the earliest metal

shaping techniques known to human being. It
means pouring molten metal into a refractory
mold cavity and allows it to solidify.
• The solidified object is taken out from the mold
either by breaking or taking the mold apart. The
solidified object is called casting and the technique
followed in method is known as casting process.
 Sand Casting Operation
• Sand casting is the most widely used metal
casting process in manufacturing. Almost
all casting metals can be sand cast.
 Types Of Sand Used In Sand Casting
There are two general types of sand used in the
manufacturing process of sand casting.
Naturally Bonded:
Naturally bonded sand is less expensive but it includes
organic impurities that reduce the fusion temperature of the
sand mixture for the casting, lower the binding strength, and
require a higher moisture content.
Synthetic Sand:
Synthetic sand is mixed in a manufacturing lab starting with a
pure (SiO2) sand base. In this case, the composition can be
controlled more accurately, which imparts the casting sand
mixture with higher green strength, more permeability, and
greater refractory strength. For these reasons, synthetic sand
is mostly preferred in sand casting manufacture.
 Properties Of A Sand Casting Mixture:

• Moisture Content:
Moisture content affects the other properties of the mixture such as
strength and permeability. Too much moisture can cause steam bubbles to
be entrapped in the metal casting.
• Grain Size:
This property represents the size of the individual particles of sand.
• Shape of Grains:
This property evaluates the shape of the individual grains of sand based on
how round they are. Less round grains are said to be more irregular.
• Strength:
The explanation of strength is, the ability of the sand casting mixture to
hold its geometric shape under the conditions of mechanical stress
imposed during the sand casting process.
 Sand Conditioning For A Metal Casting
Operation:

• If the sand is being reused from a previous sand casting

manufacturing process, lumps should be crushed and then
all particles and metal granules removed, (a magnetic field
may be used to assist in this). All sand and constituents
should be screened. In industrial practice shakers, rotary
screens, or vibrating screens, are used in this process. Then
continuous screw-mixers or mulling machines are used to
mix the sand uniformly.
 Types Of Molds Used In Sand Casting:
 Green Sand Molds:
• A green sand mold is very typical in sand casting manufacture, it is
simple and easy to make, a mixture of sand, clay and water.
 Manufacturing Considerations And Properties Of
Green Sand Molds:
1. Has sufficient strength for most sand casting applications
2. Good collapsibility
3. Good permeability
4. Good reusability
5. Least expensive of the molds used in sand casting manufacturing
processes
6. Moisture in sand can cause defects in some castings, dependent upon
the type of metal used in the sand casting and the geometry of the part
to be cast.
•
 Dry Sand Molds:
Dry sand molds are baked in an oven, (at 300F - 650F for 8-48 hours),
prior to the sand casting operation, in order to dry the mold. This drying
strengthens the mold, and hardens its internal surfaces.
Dry sand molds are manufactured using organic binders rather than clay.
Manufacturing Considerations And Properties Of Dry Sand Molds:
1. Better dimensional accuracy of sand cast part than green sand molds
2. Better surface finish of sand cast part than green sand molds
3. More expensive manufacturing process than green sand production
4. Manufacturing production rate of castings are reduced due to drying
time
5. Distortion of the mold is greater, (during mold manufacture)
6. The metal casting is more susceptible to hot tearing because of the
lower collapsibility of the mold
7. Dry sand casting is generally limited to the manufacture of medium
and large castings
 The Pattern
A few different types of patterns may be used in the sand casting process.

 Solid Pattern:
This is a one piece pattern representing the geometry of the casting. It is
an easy pattern to manufacture, but determining the parting line between
cope and drag is more difficult for the foundry worker.
Split Pattern:
The split pattern is comprised of two separate parts that when put
together will represent the geometry of the casting. When placed in
the mold properly the plane at which the two parts are assembled
should coincide with the parting line of the mold. This makes it
easier to manufacture a pattern with more complicated geometry.
Also mold setup is easier since the patterns placement relative to
the parting line of the mold is predetermined.
 The Sand Casting Operation:
The sand casting operation involves the pouring of the molten
metal into the sand mold, the solidification of the casting
within the mold, and the removal of the casting.
the effect and dissipation of heat through the particular sand
mold mixture during the casting's solidification, the effect of
the flow of liquid metal on the integrity of the mold, (mold
sand mixture properties and binder issues), and the escape of
gases through the mixture. Sand usually has the ability to
withstand extremely high temperature levels, and generally
allows the escape of gases quite well.
Manufacturing with sand casting allows the creation of
castings with complex geometry.
• After the sand casting is removed from the sand mold it
is shaken out, all the sand is otherwise removed from the
casting, and the gating system is cut off the part. The part
may then undergo further manufacturing processes such as
heat treatment, machining, and/or metal forming.
Inspection is always carried out on the finished part to
evaluate the effectiveness and satisfaction of its
manufacture.
WORKSHOP PRACTICE

Measuring Tools
Ust. Mhadi
Today’s LAB
 Measuring Tools
 Vernier Caliper
 Micrometer
 SWG
Measurement

 Measurement means to compare something

with standard.
 E.g. measuring length of a wire, diameter of a
cylinder, depth of any object.
 The SI unit of length is meter (base unit).
 Its multiples and sub-multiples are given in
the table.
Meter and its sub-multiples

Relationship with
Prefix Symbol
Meter (base unit)

meter m 1m = 1 m

deci dm 1dm = 10-1 m

centi cm 1cm = 10-2 m

milli mm 1mm = 10-3 m

micro µm 1 µm = 10-6 m

nano nm 1nm = 10-9 m

pico pm 1pm = 10-12 m

Meter and its multiples

Relationship with
Prefix Symbol
meter

deca da 1 dam = 101 m

hecto h 1 hm = 102 m

kilo k 1 km = 103 m

mega M 1 Mm = 106 m

giga G 1 Gm = 109 m
Measuring Tools

 Vernier caliper
 Vernier caliper is a measuring device used to measure
precise increments between two points.

 Micrometer
 Micrometer is a measuring device used for precisely
measuring thickness, inner and outer diameter, depth of
slots.

 SWG
 A gauge for measuring the diameter of wire, usually
consisting of a long graduated plate with similar slots
along its edge.
Vernier caliper

 Function
 To measure smaller distances
 Can measure up to .001 inch or .01mm.
 Features
 Larger, lower jaws are designed to measure outer points
e.g. diameter of a rod.
 Top jaws are designed to measure inside points e.g. size
of a hole.
 A rod extends from the rear of the caliper and can be used
to measure the depth.
Structure of Vernier caliper
Structure of the Vernier caliper

 Main Scale
 Main scale is graduated in cm and mm.

 Vernier Scale
 It slides on the main scale.
 On Vernier scale 0.9cm is divided into 10 equal parts.

 Jaws
 Two inside jaws (Upper)
 Two outside jaws (Lower)
Least Count

 Least count (L.C) is the smallest reading we can

measure with the instrument.
 L.C = one main scale division – one
vernier scale division
L.C = 1mm – 0.09mm
L.C = 0.1mm = 0.01cm
 Least Count = Value of the smallest division on MS/
Total number of division on VS
L.C = 1mm / 10 = 0.1 cm / 10 = 0.01cm
 How to use Vernier caliper?
• Close the jaws
• Calculate the least count
• Place the object between
the two jaws
• Record the position of zero
of Vernier scale on the Main
scale (3.2cm)
• Notice the reading of VS
which coincides with MS
reading (3rd division in this
case)
Reading of the Instrument

 Reading of the instrument = MS div +

(coinciding VS div x L.C)
 = 3.2 + (3 x 0.01)
 = 3.2 + 0.03
 = 3.23 cm
Sample Picture
To measure the depth

 A rod extends from the rear of the caliper and

can be used to measure the depth.
 Open the jaws of caliper and place the rod
inside hole of the object, such as the rod
reaches the inner most portion of the object.
 Read the Vernier caliper. (same procedure as
described in previous slides)
Micrometer

 Function
 Micrometer allows the measurement of the size of the body
i.e. thickness, depth, inner/outer diameter.
 Features
 Two jaws (one fixed, one movable)
 Spring loaded twisting handle
 Easy to use and more précised
 Can measure up to .001cm
Structure of the Micrometer
Structure of Micrometer

 Jaws
 2 jaws (one fixed, one movable)
 Circular Scale
 Movable jaw is attached to a screw, scale on this screw is
called Circular scale.
 Either 50 or 100 divisions
 Linear Scale
 Horizontal Scale
Structure of Micrometer
 Frame
 The C-shaped body that holds the anvil and sleeve in constant relation to
each other.
 Anvil
 The jaw which remains stationary.
 Spindle
 The jaw which moves towards the anvil.
 Lock Nut
 A lever, one can tighten to hold the spindle stationary.
 Sleeve
 The stationary round part with the linear scale on it. (Main Scale)
 Thimble
 Thimble rotates around the sleeve.
 Ratchet Stop
 Device on end of handle that limits applied pressure by slipping at a
calibrated torque.
Pitch of Micrometer

 When the head of the micrometer rotate

through one rotation, called pitch of the
micrometer.
 The screw moves forward or backward 1mm
on the linear scale.
 Pitch of Micrometer = distance on linear
scale / one rotation
Pitch of Micrometer = 1/1 = 1mm
Least Count

 Least Count = Pitch of the Micrometer / Total

number of circular scale division
 Least Count = 1 / 100 = 0.01mm
= 0.001cm
 How to use Micrometer?
• Thimble
– The thimble rotates around a
cylinder which is marked in
millimeters.
– The left-hand side of the
thimble has markings all
around it.
– The line labeled 0 is the
primary pointer.
• Close the jaws
• Calculate the least count
• Place the object between the
two jaws
• Record the position of main
scale where the two measuring
rods met.
• Note the position of the circular
scale which coincides with
main scale
Reading of the Instrument

 Reading of the instrument = MS div +

(coinciding CS div x L.C)
 = 8+ (12 x 0.01)
 = 8 + 0.120mm
 = 8.120 mm = 8120 µm
Standard Wire Gauge (SWG)

 A gauge for measuring the diameter of wire, usually

consisting of a disk having variously sized slots in its
periphery or a long graduated plate with similar slots
along its edge.
 A standardized system of wire sizes.
 Wires are manufactured to standard sizes and
labeled with their SWG.
 As the SWG increases the diameter decreases.
SWG

SWG No. Diameter (inches) Diameter (mm)

0 0.324 8.230
1 0.300 7.620
2 0.276 7.010
3 0.252 6.401
4 0.232 5.893
5 0.212 5.385