Unit 4010 Mechanical Workshop Practices Assignment Brief
| Unit Number | 4010 |
| Unit Title | Mechanical Workshop Practices |
| Unit Reference Number | M/651/0722 |
| Unit Level | 4 |
| Credits | 15 |
Introduction
The complex and sophisticated engineering manufacturing processes used to mass produce the products we see and use daily has its roots in the hand-operated lathes and milling machines still used in small engineering companies. To appreciate the fundamentals underpinning complex manufacturing processes, it is essential that engineers are able to read engineering drawings and produce simple components accurately and efficiently.
This unit introduces students to the effective use of textual, numeric and graphical information, how best to extract and interpret information from engineering drawings, and the practices of workshop-based turning and milling machining.
On successful completion of this unit students will be able to learn about the mechanical measurement and quality control processes to analyse the dimensional accuracy of a machined component; operating machining equipment to produce a range of components to specification; the importance of material selection when choosing the most appropriate machining process; and application of safe working practices throughout.
Learning Outcomes
By the end of this unit students will be able to:
LO1 Discuss the potential hazards that exist when operating machine tools and bench fitting equipment, with reference to the appropriate health and safety regulations and risk assessment criteria
LO2 Produce dimensionally accurate engineering components through operating a manual lathe and milling machine
LO3 Interpret information from engineering drawings to operate measuring tools and work-holding equipment to check dimensional accuracy of machined components
LO4 Explain mechanical measurement and quality control processes.
Essential Content
LO1 Discuss the potential hazards that exist when operating machine tools and bench fitting equipment, with reference to the appropriate health and safety regulations and risk assessment criteria
Safety compliance:
- Importance of, and responsibility for, safe working practice
- Safe working practices when operating machining equipment in the mechanical machine workshop
- Safe working practices when performing workshop fitting activities, e.g. using hand tools for marking out, sawing, filing, drilling, tapping and assembling parts
- Consider the implications of waste produced by the workshop process, relating to environmental and health and safety issues
- Workshop safety legislation and regulations, and how they are met in practice
- Risk assessment of bench fitting and machining activities
- Discuss in groups a range of industry case studies involving hazards and mitigation measures undertaken.
LO2 Produce dimensionally accurate engineering components through operating a manual lathe and milling machine
Operation:
- Factors influencing machining operations
- Set-up and use of a manual lathe and milling machine following all safety procedures
- Most appropriate cutting tools, work and tool holding methods for multiple applications
- Speeds and feeds to suit material properties (e.g., metallics, non-metallics/composites/plastics) and application
- Use of work-holding jigs and fixtures
- Removing material within dimensional tolerances.
LO3 Interpret information from engineering drawings to operate measuring tools and work-holding equipment to check dimensional accuracy of machined components
Drawings function:
- Types of engineering drawing and their use
- Developing proficiency in reading and extracting information from mechanical engineering drawings
- Types of measuring tools
- Characteristics of measurement tools for inspecting parts
- Preparing quality control and inspection reports.
LO4 Explain mechanical measurement and quality control processes
Control processes:
- Types of production quality control processes, metrology techniques
- Importance of quality checks on machined components
- Function of quality control metrology equipment, including CNC controlled coordinate measuring machines, mobile measuring arms and touch probes, contact scanning probes and non-contact sensors (optical)
- Importance of the process for data collection, analysis and product improvement.
Learning Outcomes and Assessment Criteria
| Pass | Merit | Distinction |
| LO1 Discuss the potential hazards that exist when operating machine tools and bench fitting equipment, with reference to the appropriate health and safety regulations and risk assessment criteria |
D1 Interpret the key features of relevant health and safety regulations as applied to machine tools and bench fitting equipment in a machining workshop. |
|
| P1 Discuss a range of possible hazards associated with operating machine tools and bench fitting equipment.
P2 Explain the safe working practices and procedures to be followed when preparing and using a manual lathe and milling machine. |
M1 Produce a risk assessment, identifying suitable control measures, prior to undertaking a machining activity. | |
| LO2 Produce dimensionally accurate engineering components through operating a manual lathe and milling machine |
D2 Evaluate the operating parameters of the milling machine and lathe and the function and features of the associated cutting tools, work and toolholding devices. |
|
| P3 Produce a dimensionally accurate component using a lathe and milling machine. | M2 Calculate appropriate cutting speeds and feeds to suit the material properties and application for the component. | |
| Pass | Merit | Distinction |
| LO3 Interpret information from engineering drawings to operate measuring tools and work-holding equipment to check dimensional accuracy of machined components |
D3 Evaluate, with reference to material properties and geometry, the criteria for the selection of the appropriate tooling for machining components from engineering materials including aluminium alloy, stainless steel and titanium alloy. |
|
| P4 Interpret information from an engineering drawing to plan, machine and check the accuracy of a complex component.
P5 Explain the function of precision measuring equipment used to check the dimensional accuracy of a machined component. |
M3 Analyse the function of the tooling/equipment required to machine and measure components made from aluminium
alloy, stainless steel and titanium alloy. |
|
| LO4 Explain mechanical measurement and quality control processes |
D4 Evaluate why accurate measurement and the process of machining data collection and analysis are of critical importance to a production engineering company |
|
| P6 Explain the purpose of an engineering metrology laboratory with a list of equipment found in a typical metrology laboratory | M4 Analyse the function of the metrology equipment, surface testing, profile projectors, video measuring, interferometer, SIP measuring equipment, coordinate measuring machines (CMM) and 3D scanners | |
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