MALAWI UNIVERSITY OF BUSINESS AND

APPLIED SCIENCES
SCHOOL OF ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING

PROGRAM: MECHANICAL ENGINEERING

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SUBMITTED BY: THEODORA MAONI

MODULE NAME: ENGINEERING PRACTICE

REG NUMBER: BME/24/SS/008

MODULE CODE: MEC-ENP-111

SUBMITTED TO: L. LIKANDAWE

DUE DATE: 14/03/2025

QUESTION ONE

SAFETY ORIENTATION GUIDE FOR NEW RECRUITS

IN A MECHANICAL WORKSHOP

1. GENERAL BEHAVIOR
 Always follow workshop rules and instructions from supervisors
 No running or horseplay in the workshop
 Stay focused and avoid distractions while working
2. FIRST AID
 Know the location of first aid kits in the workshop
 In case of any kind of injury, seek first aid, no matter how trivial
3. MOVING ABOUT
 Always walk and never run in the workshop
 Always walk in the gangways and do not take shortcuts
 Look out for and obey safety signs and notices
4. HYGIENE
 Always wash your hands before and after eating, using the bathroom, and each
shift
 Never use paraffin, petrol or any kind of solvent for skin-cleaning
 Use barrier cream to protect your skin
5. HOUSEKEEPING
 If anything is spilled, wipe it immediately
 Never throw rubbish on the floor
 Keep gangways and work areas clean at all times
6. PERSONAL PROTECTIVE EQUIPMENT (PPE)
 Always wear appropriate PPE such as goggles and gloves
 Make sure PPE is in good condition before use
 Wear safety shoes to protect against falling objects
 7. HARMFUL SUBSTANCES
 Learn to recognize hazard and warning labels
 Follow all instructions given by the supervisor
 Never eat or drink near any chemicals
 Do not take home any clothes that have been contaminated with chemicals
8. MACHINERY
 Know how to stop a machine before setting it in motion
 Never leave a machine in motion unattended
 Avoid loose clothing, rings or accessories and unfastened hair when using
machines
 Always ensure safety guards are secure and in place before use
9. COMPRESSED AIR
 Only use compressed air if instructed to do so by the supervisor
 Never use compressed air to clean a machine
10. FIRE SAFETY
 Know the locations of fire extinguishers and emergency exits
 Do not store flammable materials near heat sources
 If the fire is uncontrollable, evacuate and call emergency services

QUESTION TWO

a) Precautions When Using the Following Tools

i. Files
-Keep all files in a rack, do not jumble them up or keep them with other tools,
because this can chip and damage the teeth of the file
-Never use new files on steel because this will chip the teeth and make the file
useless, rather use it on softer metal like brass or bronze
-Never file too quickly because this wears out the file and the user, instead use
slow, even strokes using the full length of the file
-Clean the files with a file card, this is a special wire brush that removes bits of
metal stuck in the teeth of the file, which slows the rate of metal removal.
 ii. Hammers
-Only use the hammer to strike other tools unless instructed to do otherwise
-Make sure to hold the hammer properly to avoid injury
-Ensure the handle shaft is not split
-Make sure the hammer head is not loose, cracked or chipped

b) Applications Of the Following Tools

i. Angle Plate
-They are used to secure workpieces at specific angles during operations like
drilling, milling, or grinding
-Angle plates are used to ensure accurate alignment in assembly processes
ii. Surface Gauge
-It is used to mark/scribe layout lines at any given distance parallel to the work
surface
-In metalworking and manufacturing, they are used to make sure components are
flat and level for use
iii. Combination Set
-The combination square can be used for simple distance measurements
-The combination set can also draw accurate parallel and perpendicular lines for
layouts.
iv. Jenny Caliper
-They are used for laying out parallel lines from an edge
-They can also be used for finding the center of round or square sections
c)
QUESTION THREE

a) Two Limitations of The Vernier Caliper

-The scales can be difficult to read accurately even with a magnifying
glass.
-Because of its size and weight, it is very difficult to get a ‘feel’ of it when taking
measurements

b)

 Of the three tools, the most accurate is the Internal Micrometer because it has a resolution

of 0.01 mm, making it ideal for precise internal measurements

 c)

 The reading on the micrometer is as follows

-16 “whole” millimeters

= 16
- 59 hundredths of a millimeter

= 0.59
Total
= 16.59 mm

QUESTION FOUR

PROCEDURE OF DRILLING AND TAPPING OF THE HOLE

The tools required are as follows:

 Bench drilling machine

 Drill bit
 Tapping tool set (taper tap, second tap, and bottom tap)
 Tap wrench
 Cutting Lubricant – Oil
 Marking out tools (odd leg caliper, metal rule, center punch, and hammer)

Procedure
1. Marking out the position of the hole
-Use an odd leg caliper and a metal rule to mark the 20 mm line horizontal parallel to the
edge.
-Then mark the vertical line 25 mm vertical parallel to the edge. Where the lines intersect
will be the center point of the hole.
-Use a hammer and a center punch to punch a hole where the lines intersect to verify the
position of the center

2. Clamping the component on the drilling machine

-Secure the component using a machine vice or clamps to prevent movement
-Ensure the workpiece is flat and stable on the drill table
-Align the drill bit with the center-punched mark before starting the drill machine.

3. Ensuring the drilling machine starts correctly

-Begin with a center drill to create a starting point
-Use a tapping drill of the correct size for a M10 × 1.5 thread, the correct drill size is 8.5
mm
-Drill at an appropriate speed, which is 30-40 m/min for mild steel
-Apply the lubricant oil to reduce heat and friction
-Drill to the required depth while frequently retracting the drill and clearing any chips

4. Types of taps and lubricant to be used

-Use a set of three taps in a sequence
 Taper tap for the initial threading
 Second Tap to deepen the thread
 Bottoming tap for the full-depth threads in blind holes

-Apply lubrication oil to reduce wear and improve thread quality

-Rotate the tap clockwise for cutting and counterclockwise slightly every few turns to
break chips

SETTING OUT THE HEXAGON AND CUTTING THE HOLE

The tools required are as follows:

 Bench drilling machine

 3mm drill bit
 Hacksaw with fine tooth blade
 Flat file
 Marking out tools (Scriber, metal rule, engineers square, odd leg caliper, divider,
center punch, and hammer)
 Angle gauge

1. Marking out the hexagon

-Find the center of the 100mm × 100mm steel plate with a metal rule and an odd leg
caliper, creating a vertical and horizontal line from the edge
-At the intersection, create a small indentation using a center punch and a hammer
-Using a divider, draw a circle with radius 25 mm because the side length of a regular
hexagon equals the radius of its circumscribed circle
-Using an angle gauge, mark six equal points around the circle, each should be 60
degrees
-Connect the points with a scriber and engineer's square to form the hexagon
-Punch holes along the lines with a center punch and hammer to verify the shape

2. Cutting the Hexagonal Hole

-Drill small holes inside each corner of the hexagon using a 3mm drill bit to allow access
for cutting tools
-For easier cutting, drill a larger hole near the center to insert a cutting tool
-Using a hacksaw with a fine-tooth blade, cut along the marked and punched lines
-Using a flat file, smooth the rough edges to ensure accurate dimensions
-Debur the piece to remove the sharp edges

QUESTION FIVE
a) First slip = 1.0075
Second slip = 1.5000
Third slip = 8. 0000
Fourth slip = 30.000
Total
- 1.0075 + 1.5000 + 8.0000 + 30.0000
= 40.5075

b) For a single prototype, this depth gauge can be made for fitting because:
-It's cost-effective. Mass production methods require expensive setups, whereas fitting is
more affordable for a one-off piece
-It's flexible in adjustments. Manual fitting allows adjustments based on trial assembly,
which is helpful for prototypes
-There's no need for specialized training. Casting requires dedicated tools and
programming, making fitting more practical
-Faster Turnaround. A prototype can be completed quickly without waiting for tool
setups
-Skilled hand finishing. A machinist can ensure precision using files, reamers, and
manual drilling techniques
c)
OPERATION SCHEDULE FOR MANUFACTURING THE DEPTH GAUGE BODY

STEP NUMBER OPERATION EQUIPMENT

REQUIRED

1 Mark out the dimensions on Scriber, odd leg caliper,

the blank divider, surface plate

2 Drill pilot holes of diameter Pillar drill, drill bits

3.2mm of 3.2 mm

3 Drill reamed holes of Pillar drill, drill bits of dia

diameter 8 mm 7.8 mm, reamer dia 8 mm

4 Cut the external Hacksaw with fine

shape Tooth blade

5 Machine 5 × 45° Milling machine,

Chamfers Chamfer cutter

6 File and debur Hand file (round file,

The edges Flat file), deburring tool

7 Inspect final Vernier Caliper,

dimensions micrometer

8 Surface finishing Surface grinder,

(If needed) Hand files