2.

3 UNITS OF WORKSHOP TOOLS AND MACHINES

2.3.1 Workshop Measuring Tool

Measurement was a very vital part in machining process which
looks minute but very important. I was really taught how to make
use of various measuring instruments such as meter rule,
measuring tape, venire caliper, micrometer screw gauge and the
various conversions and accuracy.

i. Venire Caliper
This is the most common measuring derive used more often in the
workshop. These instruments are capable measuring of external,
internal, step and depth of a shaft etc. Measurements are available
in a range of measuring capacities form 150mm to 1000mm.

The venire calipers can be said to have a reading accuracy of

0.01cm or 0.1mm.

ii. Micrometer
This is used to measure diameters of a very thin piece of a wire
or object. It has a higher reading accuracy than the venire caliper.
The micrometer can be said to have a reading accuracy of
0.001cm or 0.01mm.

iii. Measuring Tape

It is a very vital tool used in the workshop in a situation where
works to be done are very lengthy.
 It is divided into metric and imperial reading. The meter reading
involves; the meter and millimeter measurement while the imperial
reading involves; the inch and foot measurement.

Conversion:
16 gradient = 1 inch = 25.4mm=2.54cm=0.0254m.
12inch = 304.8mm = 30.48cm = 0.3048m
Also note that 2 feet 3 inch could be represented as 21311

iv. Filler Gauge

The filler gauge is a measuring tool that is used in a compartment
where the venire caliper cannot measure. That is filler gauge goes
into such a compartment, gets the gauge of that compartment
then the venires caliper take the measurement from the gauge.

v. Thread Gauge
This is a measuring tool that has two (2) sides the metric and the
imperial side. They are used to determine the pitch thread.

2.3.2 Hand Tool

Hand tools are used for the removal of small quantity of material
usually from small areas of a work piece. This may be done
because no machine is available, the work piece is too large to go
on a machine, the shape is too intricate or simply that it would be
too expensive to set up a machine to do the work.
They include:
i. A File
Files are used to perform variety of task, from simple removal of
sharp edges, roughening down, squaring, finishing surface to
produce intricate shapes where the use of a machine is
impracticable.

Files come in various shapes and sizes for the purpose of filling
various shapes and compartment. Types of files include: flat file,
square file, round file, three square, half-round file, knife file,
dread naught file, and needle file are name according to their
shapes and functions.

ii. Knurling Tool

This is a tool used on the lathe machine. It is used to roughen the
surface of a metal cylinder in order to enhance grip of the
material. The knurling tool is a machine tool that has to two
roughed rollers on it, that actually makes in roughened surface on
the cylinder.

iii. Spanners
This is used in loosening and tightening of nuts and bolts. They
vary in sizes depending on the size of the nut or bolt, the also
have different shapes in order to be able to loosen nuts in various
compartments e.g. The socket spanner, flat spanners etc.

iv. Hammers
In the workshop we use hammers for various operations which
include:
 Centre punching a work piece, straightening of flat metal sheets,
shaping of metal sheet and even bending sheet.

v. Hack Saws
These are used in cutting metal bars, pipes and also steel metals
etc for required lengths. Their frames are made adjustable to
enable them take blade of different lengths. The blades are made
of high speed steel (HSS) and specific by length and pitch.

vi. Chisels
Chisels are used for cutting metal. They are made from high-
carbon steel, hardened and tempered at the cutting end. In the
workshop, the chisels are mostly used in shaping thin metal steels
by use of hammer on its head.

vii. Dies
Dies are used to cut external threads and are available in size up
to approximately 36mm thread diameter. The common type, for
use by hand, is the circular split die, made from high-speed steel
hardened and tempered.

viii. Tri-Square
The tri-square is a measuring device and also is derive to made
accurate lines before cutting. The tri-square is like our T-square
we use it to draws lines for making lines on our metal sheet before
cutting for accuracy.
ix. Taps
Tapping is the operation of cutting an internal thread by means of
a cutting tool known as a tap. These are made from hardened
high-speed steel and are supplied in set of three.

x. Screw Drivers
The screw driver is one of the most common tools, and is also the
one most misused. Its main purpose is for only to tighten or
loosen screws.

xi Pipe Wrench
This is used mainly for turning pipes and round bars, clamping
around them.

2.3.3 Workshop Machining Tool

Machine tools are a power driven machine for making articles of a
given shape, size and accuracy by removing metal from work piece
in the form of chips.

During my industrials training activities we made used of some

machines at the workshop, they include: the lathe machine,
Guillotine, shaping machine, folding/true fold machine, Drilling
machine, welding machine, Bench vice, steady rest.

i. The Lathe
This is a multipurpose machine tool used for performing a great
variety of machining operation on a wide range of work piece. This
is why it is called a “universe lathe” it is one of the most widely
used in the workshop in almost every thing.

The work to be machine is rotated (turned) and cutting tool is

moved relative to the job. That is why; the lathes are also called
as “turning machines”. The tool moves parallel to the axis of
rotation of the work piece, cylindrical surface is produced, if it
works perpendicular to the axis, it produces a flat surface. But
many other operations can also be performed on lathe, they are:
facing, parting, necking, knurling, taper turning, thread cutting,
formed, reaming and drilling, boring, milling, grinding.

Diagram of lathe machine

Parts of the lathe
The main parts of a centre lathe are: Bed, Head stock, Tail stoic,
carriage and electric drive.
1. Bed
The bed is base or foundation of the lathe. It is a massive (heavy)
and rigid casting made in one piece to resist deflection and
vibration. It holds or supports all other parts that is, head stock,
tail stock and carriage etc.
2. Head Stock
The head stock assembly is permanently fattened to the left hand
end of the lathe. It serves in support the first operation unit of the
lathe, that is, the spindle. The spindle revolves in bearing, one at
each end of the head stock.
3. Tail Stock
Tail stock is on the other end of the bed from the head stock. Its
chief function is to hold the dead centre so that long work pieces
can be supported between centers. It can be moved along the bed
and clamped to the bed at the various desired location to suit the
length of the work piece.
4. Carriage
In between the headstock and the tail stock is the carriage. It is
movable on the bed ways and its purpose to hold the cutting tool
and to impact to it’s either longitudinal or cross feed. It has fire
major parts:
(a) Saddle- the base of the carriage is the saddle which slides along
the ways of the lathe bed.
(b) Cross-side
The cross stick is mounted on the saddle.
It provides cutting tool motion which is perpendicular to the centre
line of the lathe itself. The cross-feed movement may be controlled
by manual or by power feed.
(c) Compound Rest (Top slide or compound slide)
It is mounted on top of the cross-slide. The compound rest has a
graduated base and can be swiveled around a vertical axis. The
range of compound rest is only limited and is used for obtaining
angular cuts and short tapers, as well as convenient positioning of
the tool to the work.
(d) Tool Post
The tool post is mounted on the compound rest slide in a T-shot.
Cutting tool/tool holder is firmly held in it.
(e) Apron
The apron of secured underneath the saddle and hangs over from
of the bed. It contains the gears, clutches, and levers for operating
the carriage by hand and common lathe operation.

Diagram from the text page 44g.

Common lathe operation

Lathe Operations
A large variety of operations can be performed on an engine lathe
which includes:
1. Turning (skinning operation).
 Turning is the operation to remove material from the outside
diameter of a work piece to obtain a finished surfaced. The
finished surface may be of continuous diameter, stepped, tapered
or contoured. Feed of the tool for turning operation is along the
axis of the lathe i.e. the position of the cutting boil is parallel to
the work piece (longitudinal/horizontal operation).
2. Facing
Pricing is the operation of machining the end of a work piece to
make the end square with its own axis and that of the lathe. The
tool moves perpendicular to the axis of the lathe i.e. the
positioning of the cutting is perpendicular to the work piece
(transverse operation).
3. Reaming and Drilling
Drilling is the operation of making hole in a work piece when non-
previously existed. Reaming is the operation of finishing the drilled
hole. These operations are done on lathe by holding the drills and
reamers in the tail stock quill, and the job is held in a chuck and
the tools an fed to the revolving work piece by the rotating the
tailstock handle.
4. Boring
Boring is the operation of enlarging the drilled hole. The work
piece is held in a chuck in the lathe spindle and boring bar is
mounted in the tool post. Boring is done by moving the carriage
towards the head stack.
5. Knurling
It is the operation of plastically displacing metal into a particular
pattern for the purpose of creating a hand grip or roughed surface
 on a work piece. The knurling tool is held in the tool post and is
period against surface of the work piece by cross feed.
6. Milling
For the milling operation, small milling cutters are held in the head
stock and revolved while the work is clamped in a vice mounted
over the top of the compound rest, instead of the tool post. Used
for only small work.
7. Grinding
Cylindrical and intend grinding can be done on a lathe, with a tool-
post grinder.
8. Taper Turning
It is a turning operation that involves two unequal cross sectional
diameter making use of the compound rest (compound side).
The formula:
Tan α = D-d
2l
Where:
α = Half tape angle,
D = larger diameter,
d= smaller diameter required
l = length of the taper.
After swiveling the compound rest to this angle about the vertical
axis, it is clamped in position. The paper is turned by hand wheel
by rotating the handle.

This was the method we employed in the workshop during my

course. The method can be employed for turning short internal
 and external tapers with a large angle of taper, the work piece
commonly held in a chuck.

9. Parting
A parting tool is deeper and narrower than a turning tool. It is
designed for making narrow groves and for cutting off parts. The
parting tool is held in the tool post while feeding is done by the
spindle on cross slide as the case may be to the rotating work
piece on the chuck..

ii. Shaping machine

We used the shaping machine for shaping internal and external
key ways, contoured surfaces, stools, groves, other recesses etc.
The cutting process in a shaping machine is intermittent, since
cutting is done in one direction (i.e. its turned stroke). Its return
stroke is idle stroke and is faster than the cutting stroke.
Diagram of shaping machine

iii. The Drilling Machine

The drilling machine is also one of the important machines used at
the workshop. The drilling machine was used to accomplish the
purpose of drilling boring or making of round hole using drill bit of
various diameters which ranges from 5mm-12mm.It accomplishes
this by the rule of rotary and axial feed motions of the cutting tool
or work, it drills in vertical axis.

I was fortunate to use this machine to perform operations like

drilling, chain drilling, reaming counter-bung and counter sinking.
 Diagram show a drilling machine.

iv. Grinding Machine

The grinding machine is an electro machine which makes use of a
rotary abrasive tool, called “grinding wheel” for cutting and for
removing and smoothing of excess material from casting forging
and weldments, filling and sometimes shaping a work piece.

The grinding wheels machine was given a fix support on a metal

steel table; that enables it to withstand vibration of slacking when
on. Its primary function is for finishing on the work piece.
Diagram of grinding machine

v. Folding / True Fold Machine

These are very heavy industrial machine used for folding galvanize
sheets, mild steels and stainless steel sheets to various shapes or
angles desired. The fold and the true fold machines shapes are
two different machines used folding metal sheet but in different
angles.

The folding machine folds sheets in an angle of 360 0; whereas, the

true fold and bends sheet metal at angle 450, 900, 1200.
 I was opportune to use the folding device to fold metals into
cylindrical shape of different diameter, folding into cuboids shape
of varying dimensions.

vi. Guillotine/Cutting Machine

The guillotine machine is a cutting machine that uses a straight
blade and is mainly used for cutting or shearing metal sheets
whose thickness must not exceed 2mm. The guillotine is a foot
operation machine, which requires enough force to pull its pedal
down wards in other for it to give a good cut; how ever the work
piece is fully supported with a clamp before cutting.

vii. The Welding Machine

The welding machine is an electrical machine with a primary and
secondary winding and has a very high wattage; it also has plate
for the adjustment of current range. In the department where I
operation, we did welding operation mainly on electric are welding
in which an electrode is brought in contact with the work at the
point when the welding is to be stated, after connecting the work
to the welding circuit.

We used the welding machine in tacking (temporary welding) and

welding (permanent joining process) During this period of my
training we were taught that, that welded structures are assemble
by five basic types of joint, bult, lap, corner, T and Edge Joints as
shown.
viii. Bench Vice
The bench vice was used in holding work piece of various sizes
and shapes, is usually fixed in a metal steel table or bench.

More also, we have a machine vice which is usually found in our

shaping machine and also a hand vice which was movable and
was used in holding work piece considered to be too small.

ix. Steady Rest

The steady rest is a vice which holds very long work piece. When
ever a very big work piece (L/D>10 or 12) or longer slender work
piece of low rigidity are machine between centers, steady rest are
used to additionally support the work piece and prevent if from
bending due to pressure of cut. Their two types of steady rest
are: fixed steady rest follower or travelling steady spent.

The followers travelling steady rest: This steady is mounted on the

saddle and moves together with the tool.
 CHAPTER THREE

PROBLEMS AND RELEVANCE OF THE SEWES PROGRAMME

3.1 PROBLEMS ENCOUNTERED DURING THE SEWES

PROGRAMME
The industrial training was quite interesting and vigorous
irrespective of the knowledge gained within the duration. In the
workshop, I encountered several setbacks/problem and some
challenges, with out the training would have been incomplete.
They include:

i. Accuracy in measurement of work piece

The ability to measure a work piece accurately before, while
machining and after machining was not an easy task, during my
first few week in the workshop. But soon after, I was able to take
accurate measurement.
ii. Setting of work piece on a machine tool
Though look simple but not as easy as it was seen. That was
another area of difficult; like in the case of holding the centre of a
work piece by using and tool maker’s buttons, which I was able to
do after my first few weeks.
iii. Operation of machine tool
The operation of some of machine like the lathe, grinding, drilling
machine required some techniques operate properly ,also posed
me some problem when I initially started my training but due to
 frequent instruction and carefully observation from my instructor I
was able operate most of the machines effectively.

iv. Restriction to the use working tool

Tools in the Science and Engineering Workshop were owned by
individuals. There were no working tools available at our disposal.
We only touch and use tool if our instructor was present and also
permit it.
v. Inadequate/out dated (Epileptic) machine tool
In the work shop we had no enough machine tool and the
machine tools available are so old and thus are not effective in
doing works.
vi. Personal protective Equipments
With regards the nature of the operations in the workshop and it ’s
equipment, it is vital for the staff/ and industrial trainees to be
equipped with their personal protective equipments such as safety
boot, ear muffs, nose makes eye goggles, hand gloves, cover-all
etc for proper handling of works, which was not provided for staffs
or industrial trainees in the work shop, hence led to some
accidents. In fact safety measures were never part of the
workshop.
vii. Erratic power supply
In the workshop, we also experience incessant power out break
which slowed the completion time of most works undertaken.
Viii. Poor management
The management was not concerned about the welfare of the
students under its supervision. A day a friend had a cut by a work
piece, which was on a drilling process; there were no thing in the
firs aid box of the workshop to stop the bleeding.
Also in the part of spoilt or damaged equipment or machine or
machinery was abandoned. It would require sometime before the
machine would be fixed, this was due to the power financial
situation we had the work shop.
ix. No provision of allowance
It looks minor but posed so many distresses to me, as we were
not given any stipend to enable us transport to the workshop, or
make lunch for our selves during the day’s activity.

3.2 RELEVANCE OF SIWES PROGRAMME

Honestly I would say that the industrial training programme
(SIWES) has exposed me to some aspect of Mcchanical
Engineering.

During my six months training, I served in the machining/welding

de department, where knowledge acquired in courses like
mechanical engineering material was displayed in practical.The
programme has provided students an opportunity to apply
theoretical knowledge in real work situations, thereby bridging
the gab between academic work and the practical work experience
demanded for the graduate engineer.
 This programme provided the student opportunity of acquiring
industrial skills and experience/ practical knowledge in /her area of
specialization.

It avails the student the opportunity of acquiring knowledge on the

recent technology and innovations in the industry. This
programme helped develop a more conscious attitude in the
student.

Most of all, the scheme has exposed me as a student to the

challenges faced in industry, in the area of policy implementation
and development of their technological know how. It made me
realize the expectations of the industry from the engineer and the
responsibilities that would be on the students as a future
engineer, in a country like ours.

Other contributions of SIWES are follows:

 Exposure to a practical aspect of study
 Some abilities are harnessed and develop like creating,
punctuality and initial and responsibility.
 Prepare students for the work situation they are likely to meet
after graduation.
 CHAPTER FOUR

CONCLUSION AND ADVICE

4.1 CONCLUSION
Due to importance and delicate nature of machining/welding
process, so vital to the mechanical engineers, therefore
mechanical engineers should liaise in knowledge of the principles
and techniques involved in machining/welding process to make
proper and effective work; to avoid disaster and loss of life and
properties.

Having an industrial training component in a degreed programme

can add enhance the employability skills of graduate.

In order to ensure that industrial training become a natural part of

university training efforts must be collaboratively and not
individually undertaking by institution , industry and government
so that issues and challenges students face can be addressed.

SIWES should help out in securing placement for students, which

will help tremendously, as this is a major problem student ’s face.

Finally, I advice younger collogues to put knowledge and

experience above money and all that will not make them device
the gain of the SIWES programme.
4.2 ADVICE FOR FUTURE PARTICIPANT
 Intending indust.rial trainees should try to attend institution SIWES
orientation Programme before going on attachment.
 To be obedient to constituted authorities and adhere strictly to all
rules and regulations of the organization where the students is
attached. Intending industrial training should always ensure they
get their forms ready on time from the SIWES Unit and make
duplicates of the application forms in order to apply to companies,
firms etc. with in their field of study.
 Students on training should make sure they engage fully and carry
 out all duties and assignment given to them. This will in turn give
good recommendation in case of future employment.
 It pays to work hard; therefore students should be serious and
take proper records of training activities, and other assignment in
the log book.
 Also students should be punctual, diligent, honest, conscientious
take pride in protection of employers property throughout

It is important that future industrial training participants are properly

equipped with that is involved in the training. The following advice will
prove excellent for future participants.
4.3 ADVICE FOR SIWES MANAGERS
 SIWES managers should endeavour that students’ IT allowance is
paid during the course of the training to enable them support
themselves financially.
 SIWES managers should assist students in identifying placement
opportunities.
 SIWES managers should be lass harsh on students and always be
ready to accommodate their problems, as well as prepare
orientation to students.
 REFERENCES

P.O. Shama (2000): Production Technology (Manufacturing Process)

Seventh Edition.

Prof. U.J. Okoli (2010): Manufacturing Technology and Workshop

Practice Manual.