LESSON LEARNING OUTCOMES

After the lesson, the student must be able to:

1. Recognize and discuss the theories, concepts in workshop practices
2. Develop futuristic perspective and imagination of the students in handling shop practices
3. Understand machine shop practices as a collaboration of mechanical engineering theory and
design to form certain specimen and workshop outputs
WHAT IS A MACHINE SHOP
A place where hand tools and power-driven tools are used for making, finishing, or repairing
machines or machine parts or in other words a facility that has machines, machine tools for
working with metal other relatively hard materials such as some ferrous and nonferrous,
composites, polymers, etc,. Various kinds of machine shops
make and repair all types of metal objects from machine tools, dies and molds etc
MACHINE DESIGN
Machine design is an area of study in which one learns to design machine parts by utilizing its
whole knowledge and experience in field of mechanical engineering.
May include the following studies:
1. Materials Engineering and Sciences
2. Deformation of Rigid Bodies
3. Finite Element Analysis
4. Computer Aided Drafting and Technical Drafting
FINITE ELEMENT ANALYSIS
The Finite Element Analysis (FEA) is the simulation of any given physical phenomenon using
the numerical technique called Finite Element Method (FEM). Engineers use FEA software to
reduce the number of physical prototypes and experiments and optimize components in their
design phase to develop better products, faster while saving on expenses. It is necessary to use
mathematics to comprehensively understand and quantify any physical phenomena such as
structural or fluid behavior, thermal transport, wave propagation, the growth of biological cells,
etc
MACHINE DESIGN
OBJECTIVES OF DESIGN

1. DESIGN FOR STRENGTH- safety is first so part to be designed should strong enough to
withstand forces in its service. It also required to be resist some probable happening during
service due to increased load by some reason.

2. DESIGN FOR FUNCTION- every part in a machine has its own function for which it is
applied in machine. designer should ensure that the part to be designed should fulfill its function
satisfactory.
3. DESIGN FOR MANUFACTURING PROCESS- Designer have to modify its product in
the light of available manufacturing processes and their limitations and strengths. Design of
machined part is generally different from that of casting etc.
4. DESIGN FOR SAFETY- designer should ensure that the part he is designing should safe in
use. And any life or health hazard will not produce from its working.
5. DESIGN FOR LOOK AND COMFORT- It is a secondary priority of designer to make a part
with high level of comfort for user and also looks good
MACHINE SHOP SAFETY RULES, REGULATIONS and
GUIDELINES
GENERAL SAFETY TIPS
1. Safety glasses with side shields must be worn at all times.
2. Do not wear loose clothing, loose neckwear or exposed jewelry while operating machinery.
3. Do not work alone. The buddy system is mandatory!
4. Pull back and secure long hair.
5. Do not wear thin fabric shoes, sandals, open-toed shoes, and high-heeled shoes.
6. A machinist's apron tied in a quick release manner should be worn ideally.
7. Always keep hands and other body parts a safe distance away from moving machine parts,
8. work pieces, and cutters.
9. Use hand tools for their designed purposes only.
10. Report defective machinery, equipment or hand tools to the lab manager
MACHINE SHOP SAFETY RULES, REGULATIONS and
GUIDELINES
SAFETY GUIDELINES:
1. If guards or safety mechanisms are present do not remove or disable them.
2. Do not attempt to oil, clean, adjust, or repair any machine while it is running. Stop the
machine and lock the power switch in the "OFF" position.
3. Do not operate any machine unless authorized to do so by the policy and procedures currently
in place.
4. Do not set up or operate machinery if you are not trained and familiar with that setup.
5. Even after the power is off, do not leave the machine until it has stopped running. Someone
else may not notice that it is still in motion and be injured. Do not leave a machine until it has
come to a complete stop.
6. Do not try to stop the machine with your hands or body.
7. Check tools and machines before use to assure they are safe to use.
8. Always see that work and cutting tools on any machine are clamped securely before starting to
work
9. All setscrews should be of the flush or recessed type. If they are not, move with caution when
near them. Projecting setscrews are very dangerous because they may catch on sleeves or
clothing. The same goes for chuck jaws on a lathe, they are very dangerous especially when
extended near the outer limits.
10. Only one person should operate a given machine and its switches.
11. Do not lean against a machine.
12. Concentrate on the work and do not talk unnecessarily while operating the machine.
13. Do not talk to others when they are operating a machine. A distraction may lead to an injury.
14. Do not walk behind people operating a machine; you may bump them by accident or startle
them and cause an accident.
15. Always remove gloves before turning on or operating any machine. If material is rough or
sharp and gloves must be worn, place or handle material with the machine turned off.
16. Do not leave tools or work on the table of a machine even if the machine is not running. Tools
or work may fall off and cause toe or foot injury
17. Use a brush to remove short, discontinuous types of chips--not hands, fingers, or rags.
18. Use a pair of pliers to remove chips, especially the long, stringy type.
19. Never handle chips with your bare hands or fingers. Chips are extremely sharp and can
easily cause cuts.
20. Never use compressed air to clean any machine.
21. Never use compressed air to clean your clothes or yourself. If using compressed air to clean a
part, point the air hose down and away from yourself and other persons. Never wear gloves or
use rags to clean the work piece or any part of a machine that is running. Rotating tools or parts
can grab gloves and rags and pull you into the machine.
22. Stop the machine tool to make speed and feed changes that require the shifting of a gear
lever.
23. Always use correct speeds and feeds. A broken tool becomes a hazard and can cause great
personal injury.
WHAT ARE DESIGN CODES AND STANDARDS THAT ARE BEING USED IN MECHANICAL
ENGINEERING?
CODES and STANDARDS
In mechanical engineering, there are various standards that is being utilized all throughout the
globe. These standards may vary upon the designer’s discretion on his design or what is being
required in a given scenario. These standards may be of local standards or imposed by
international associations and organizations. The standards are often backed up by research and
studies on materials upon varying factors such as reaction to foreign material and environment.
CODES AND STANDARDS USED BY MECHANICAL ENGINEERS
* SAE- Society of Automotive Engineers
* ASME- American Society of Mechanical Engineers
* ASHRAE- American Society of Heating, Refrigerating and Airconditioning Engineers
* PSME- Philippine Society of Mechanical Engineers
*ANSI- American National Standard Institute
*API- American Petroleum Institute
WHAT IS HOUSEKEEPING?
Housekeeping means performing all the duties towards cleaning, maintaining orderliness, and
running a house, business property or occupational facility. In case of workshops and industrial
machine shops, the housekeeping duties involve maintaining the facility, tools and equipment to
the best possible state in terms of cleanliness, and keeping it at highly desirable ambience.
OBJECTIVES OF GOOD HOUSEKEEPING
• The main objectives of shop and facility housekeeping are:
➢To maintain overall cleanliness of the entire machine shop and fabrication area at all times.
➢To perform cleanliness duties most efficiently and effectively.
➢To use good quality, safe cleaning equipment and chemicals.
➢To manage and maintain machine shop tools and equipment.
➢To control pests.
➢To take care of the working areas, workshop furniture, and equipment within the premises of
the machine shop facility
BENEFIT FROM GOOD HOUSE KEEPING
• Maintaining a good housekeeping will not only help the facility retain its
cleanliness and orderliness. But it will also keep the people away from certain
accidents and other near misses. Some of the benefits of maintaining good
housekeeping are the following:
a. Prevents trips, falls and slips
b. Get rid of fire hazards
c. Controls dust
d. Clutter-free areas
WHAT IS THE 5S OF HOUSEKEEPING?
5S is defined as a methodology that results in a workplace that is clean, uncluttered, safe, and
well organized to help reduce waste and optimize productivity.
WHAT IS THE 5S OF HOUSEKEEPING?
• The 5S quality tool is derived from five Japanese terms beginning with the letter "S" used to
create a workplace suited for visual control and lean production. The pillars of 5S are simple to
learn and important to implement:
✓Seiri: To separate needed tools, parts, and instructions from unneeded materials and to remove
the unneeded ones.
✓Seiton: To neatly arrange and identify parts and tools for ease of use.
✓Seiso: To conduct a cleanup campaign.
✓Seiketsu: To conduct seiri, seiton, and seiso daily to maintain a workplace in perfect condition.
✓Shitsuke: To form the habit of always following the first four S’s.
BENEFITS OF FOLLOWING A LEAN 5S PROGRAM
Benefits to be derived from implementing a lean 5S
program include:
✓Improved safety
✓Higher equipment availability
✓Lower defect rates
✓Reduced costs
✓Increased production agility and flexibility
✓Improved employee morale
✓Better asset utilization
✓Enhanced enterprise image to customers, suppliers, employees, and
management.

LESSON 2: REPUBLIC ACT 8495 AND ITS CONNECTION TO WORKSHOP AND MACHINE
SHOP PRACTICES
THE MECHANICAL ENGINEER
A Mechanical Engineer is a person who successfully accomplish the Mechanical Engineering
Course.
A Mechanical Engineer may either have a Bachelor of Engineering Degree (B.Eng) or a Bachelor
of Science Degree (BS)
MECHANICAL ENGINEERING PROFESSION
• Mechanical engineers generally work in offices. They may occasionally visit worksites where a
problem or piece of equipment needs their personal attention. Mechanical engineers work mostly
in engineering services, research and development, and manufacturing.
• Mechanical engineers make a difference. That's because mechanical engineering careers center
on creating
technologies to meet human needs. Virtually every product or service in modern life has probably
been touched in some way by a mechanical engineer to help humankind.
DISCIPLINES WITHIN MECHANICAL ENGINEERING INCLUDE BUT ARE NOT LIMITED
TO:
• Acoustics
• Aerospace
• Automation
• Automotive
• Autonomous Systems
• Biotechnology
• Composites
• Computer Aided Design (CAD)
• Control Systems
• Cyber security
• Design
• Energy
• Ergonomics
• Human health
• Manufacturing and additive manufacturing
• Mechanics
• Nanotechnology
• Production planning
• Robotics
• Structural analysis
CAREERS IN MECHANICAL ENGINEERING CALL FOR A VARIETY OF TASKS:
• Conceptual design
• Analysis
• Presentations and report writing
• Multidisciplinary teamwork
• Concurrent engineering
• Benchmarking the competition
• Project management
• Prototyping
• Testing
• Measurements
• Data Interpretation
• Developmental design
• Research
• Analysis (FEA and CFD)
• Working with suppliers
• Sales
• Consulting
• Customer service
REPUBLIC ACT 8495
The Mechanical Engineering Law of the Philippined
1. Title, Statement of policies and definition of terms
2. The Board of Mechanical Engineers
3. Examination, Registration and License
4. Practice of Profession
5. Penal and Concluding Provisions
 Personal Protective Equipment
As we discussed before, aside from the safety guidelines that we need to be aware of in our
laboratory activities. We also need the proper PPE or Personal Protective Equipment.
What is personal protective equipment?
Personal protective equipment, commonly referred to as "PPE", is equipment worn to minimize
exposure to hazards that cause serious workplace injuries and illnesses. These injuries and
illnesses may result from contact with chemical, radiological, physical, electrical, mechanical, or
other workplace hazards. Personal protective equipment may include items such as gloves,
safety glasses and shoes, earplugs or muffs, hard hats, respirators, or coveralls, vests and full
body suits.

All personal protective equipment should be safely designed and constructed, and should be
maintained in a clean and reliable fashion. It should fit comfortably, encouraging worker use. If
the personal protective equipment does not fit properly, it can make the difference between being
safely covered or dangerously exposed. However, if we ever take PPEs into mind, we should only
use what is needed for a specific actviity or a certain work. That is why sometimes, the following
is taken into account when using PPEs.
 When it is necessary
 What kind is necessary
 How to properly put it on, adjust, wear and take it off
 The limitations of the equipment
 Proper care, maintenance, useful life, and disposal of the equipment
 WHAT IS A HAND TOOL?
A hand tool is any tool that is powered by hand rather than a motor. Categories of hand tools
include wrenches, pliers, cutters, files, striking tools, struck or hammered
tools, screwdrivers, vises, clamps, snips, hacksaws, drills, and knives. Hand tools have been used
by humans since the Stone Age when stones were used for hammering and cutting. During
the Bronze Age tools were made by casting the copper and tin alloys. Bronze tools were sharper
and harder than those made of stone. During the Iron Age, iron replaced bronze, and tools
became even stronger and more durable. The Romans developed tools during this period which
are similar to those being produced today. In the period since the industrial revolution, the
manufacture of tools has transitioned from being craftsman made to being factory produced
Like what we had describe a machine shop. Hand tools are also different and unique for reason
that these tools are dverse and each of them has their purpose. They can belong to any of the
following tool categories:
 Cutting
 Measuring
 Gripping
 Joining
 Hammering
 Fitting
 Flaring
And many other category depending on the usage.

And each work shop may have different hand tools present for the fact that they only have tools
that is only necessary for their activity. To know more about hand tools, You may refer to the
following videos embedded below.
Power Tools and Power Tool Safety
After hand tools, we will now be focusing on Power Tools. Power tools are different from hand
tools due to that fact that we can call them an automated tool. With a push of a button, the work
that takes a couple of minutes using a hand tool can now be accomplished almost instantly.

However, for a more, precise definition of a power tool, A power tool is a tool that is actuated by
an additional power source and mechanism other than the solely manual labor used with hand
tools. The most common types of power tools use electric motors. Internal combustion
engines and compressed air are also commonly used. Power tools are used in industry,
in construction, in the garden, for housework tasks such as cooking, cleaning, and around the
house for purposes of driving (fasteners), drilling, cutting, shaping, sanding, grinding, routing,
polishing, painting, heating and more.
Power tools are classified as either stationary or portable, where portable means hand-held.
Portable power tools have obvious advantages in mobility. Stationary power tools, however, often
have advantages in speed and precision.
LESSON 3: SHEET METAL SEAM LOCK AND COLD METAL WORKING PROCESSES
WHAT IS SHEET METAL?
Sheet metal is a type of metal that is formed into thin, flat pieces by an industrial process.
It can be made from different metals, such as aluminum, steel, copper, or tin. Sheet metal is used
for many purposes, such as making car bodies, airplane wings, roofs, or armor. Sheet metal has
different thicknesses, measured in different units depending on the metal and the country. For
example, in the United States, sheet metal thickness is often given by a gauge number, where a
higher number means a thinner sheet.
INTRODUCTION
Folding sheet metal to form edges and seams of various kinds is one of the most important
operations in sheet metal work.
The edges and seams have several purposes:
-to improve the appearance of finished products
-to strengthen the work piece
-to fasten piece of the metal together
Folding Edges
There are two types of machine commonly used in bending or folding metal to form edges
or locks for seams:
- bar folders
- folding brakes
Bar folder
The machine is adapted for bending edges of 22 gage (o.74mm) metal of lighter. There are six
important steps that must be remembered when using the bar folder:
1. Allowance for thickness of the metal
2. Sharpeners of the lock edges
3. Width of the lock edge
4. Adjustment for the thickness of metal
5. Angle of fold
6. Types of metal
Folding Brakes
 There are many types of bending brakes used by sheet metal workers. The most widely
used machine in the cornice brake.
 The average cornice brake has a capacity of 16 gage (1.588mm) and can also bend the
lightest sheet metal.
Edges
 Whenever a sheet metal object is made, some type of edges must also be formed. In
addition to providing a finish, an edge eliminates the raw edge of the metal that is likely
to cut someone and provides additional strength for the edge.
Single Hem
 The single hem is a folded edge on the metal made in order to increase its strength and to
make a smooth finished edge.
 It is one of the most common of all edges since it is the simplest to form
 The hem is folded over in the brake and smashed flat
  The allowance is generally 6mm. however on metal heavier than 22 gage, it is common
practice to increase the hem to 8mm to 10mm.
Double Hem
 The double is a simple single hem done twice. It provides much greater strength than the
single hem
 The allowance for a double hem is twice the hem size less 1.5mm, so that the outside
allowance is short and does not cover up the second bend line.
Seaming
In sheet metal construction, there are a variety of methods for joining the edges of the sheet
metal. The choice of joint, or seam, is determined primarily by:
a. Thickness of the metal
b. The type of metal
c. The cost of fabrication
d. The equipment
Types of seams
In planning the fabrication of sheet metal articles, the workers should be able to visualize the
type of seam that is best fitted for the specific job
Various type of seams are diagrammatically
-over lap -lap seam -pittsburgh lock
-single lock -riveted or soldered seam -corner double seam
-double lock -grooved seam -elbow seam
-snap on with cup -cap strip seam -reversible elbow seam
- snap on batten with cup -standing seam -flange dovetail seam
-tee -lap bottom seam -plain dovetail seam
-snap lock -insert bottom seam -beaded dovetail seam
-batten -single bottom seam -slip s hooks for cross seam
-trapezoidal -bottom double seam

What are cold metal working process?

Cold metal working processes shape metal below its recrystallization temperature, usually
at room temperature. These processes can improve the strength, hardness, and surface finish of
the metal, as well as reduce waste and machining time. However, they require more force,
harder tools and dies, and heavier equipment than hot working processes. • SQUEEZING
• BENDING
• SHEARING
• DRAWING
Squeezing: This involves applying compressive force to the metal to change its shape or size.
Examples are rolling, swaging, extrusion, forging, sizing, riveting, staking, coining, peening,
burnishing, heading, hubbing, and thread rolling.
Bending: This involves deforming the metal along a curved axis without changing its thickness.
Examples are angle bending, roll bending, draw and compression bending, roll forming, seaming,
and flanging. Shearing: This involves cutting the metal with a sharp tool or die to separate it
into two or more pieces. Examples are sheet metal shear cutting, slitting, blanking, piercing,
lancing, perforating, notching, nibbling, shaving, trimming, cutoff, dinking, and drawing.
Drawing: This involves pulling the metal through a die or around a mandrel to reduce its cross-
section and increase its length. Examples are wire drawing, tube drawing, metal spinning,
embossing, stretch forming, sheet metal drawing, and ironing.