Introduction to workshop practice Lesson 1. Introduction to workshop practice, safety, care and precaution in workshop. Module 2. Bench work tools and processes Lesson 2. The bench work tools and its uses Lesson 3. The bench work tools, its uses and processes. Module 3. Smithy and forgoing tools and operation Lesson 4.
Smithy and forging tools and equipment Lesson 5. Smithy and forging operation. Module 4. Heat treatment process Lesson 6. Heat treatment processes: Hardening, tempering, annealing and normalizing Lesson 7.
Metal Cutting. Module 5. Welding Lesson 8. Electric arc welding Lesson 9. Gas Welding. Shielded Metal Arc Stick Fig. Schematic illustration of the shielded metal-arc welding process. Submerged arc welding Fig : Schematic illustration of the submerged-arc welding process and equipment.
The unfused flux is recovered and reused. Submerged arc welding Cont Fig : Simplified schematic illustration of the submerged-arc welding process Deep and narrow welds can be made by this process at high welding speeds. Welding Positions Derived Welding Joint Design Fig. Examples of welded joints and their terminology. Different types of seam welding Different types of seam welding, from left to right conventional seam welding, roll spot welding, continuous resistance seam welding.
Shipyards normally do not use it, except in modular construction. Weld Symbols Butt Joints Backing Weld Symbol Fillet Joints Weld Symbol Corner Joints General Design Guidelines Electrode Designations Weld Quality and Testing in Arc Welding Discontinuities and Defects in Fusion Welds Fig. Examples of various discontinuities in fusion welds. Schematic illustration of various defects in fusion welds.
Types of cracks Fig : Types of cracks in welded joints caused by thermal stresses that develop during solidification and contraction of the weld bead and the surrounding structure. Distortion of Parts After Welding Fig. Distortion of parts after welding. Distortion is caused by differential thermal expansion and contraction of different regions of the welded assembly. Weld Testing 2. Destructive Techniques Fig.
Destructive Techniques: a Specimen for longitudinal tension-shear testing; b specimen for transfer tension-shear testing; c wraparound bend test method; d three- point bending of welded specimens.
Part 3: Turning operations Principal Surfaces and Motions The resulting machined surface is cylindrical. These operations are generally performed manually for small thread diameters.
Drilling, Internal grooving and Boring Instead, it is a metal forming operation used to produce a regular crosshatched pattern in the work surface. Various work holding attachments such as three jaw chucks, collets, and centers can be held in the spindle. The spindle is driven by an electric motor through a system of belt drives and gear trains. Principal components of a lathe Work holding methods in lathes Cutting tools Left and Right-hand turning tool bit Shapes of Tool Bits Total views 10, On Slideshare 0.
From embeds 0. Number of embeds 2. Downloads Inflammation: This could be as a result of impact on body casing internal bleeding or rupture of blood vessels without visible cut and blood flow 7. Superficial injury: Injury occurring at the skin surface such as bruise, minor cut, or scratches and lacerations. Amputation: This is a case of fatal injury which often result from caught-in and struck-by accidents, 9.
Death: This is a situation in which life flows out of the body as a result of injury sustained. Such case is regarded as a fatal injury case. Definition of Safety Safety in its simplest form is a state of being at little or no risk of injury resulting from a harmful external impact, inhalation, or contact. It is a holistic approach to a state of wellbeing that requires people to feel they are free from being harmed in addition to actually being safe.
To be safe in any work environment, you must think about the nature of your job and plan ahead to avert hazards that could be associated with it. In the field of safety, it is generally recognized that consequences are only negative and therefore the management of safety risk is focused on prevention and mitigation of harm. Note: It takes effort to recognize, evaluate, and control hazards. If you do not recognize, evaluate, and control hazards, you may be injured or killed by machinery, electricity, electrical fires, or falls.
If you use the safety model to recognize, evaluate, and control hazards, you will be much safer. Workplace health and safety laws The aim of the Workplace Health and Safety Act is to prevent death, injury or illness caused by a workplace, relevant workplace area, work activities, plant or substances for use at a workplace. Improving health and safety in workplaces reduces human and financial cost of injury and disease. Workers, their families, employers and the community benefit from improved workplace health and safety.
The Workplace Health and Safety Act sets out the laws about health and safety guidelines for all relevant workplace areas, work procedures or activities by machinery or substances for use at workplaces as well as safeguarding workers.
All health and safety laws place specific duties of care or legal obligations on various parties in the chain of machinery design, supply and use. Workers, their families, employers and the community benefit from these obligations. Improving workplace health and safety in workplaces reduces the human and financial cost of workplace injury and disease.
Workplace partners and responsibilities The following human elements have been recognized as the workplace partners in any such organization. Employee: An employee is in the payroll of an employer.
Self-employed: He is a job provider the employer as well as the employee. Supervisors: This is an employee with special skills and mastery in his field required to offer specialized or expert advice or direction on efficient job delivery. Duties of supervisors: A supervisor shall take such measures as are practicable to ensure that the workplace, or the means of access to or egress from the workplace, as the case may be, are such that persons who are at the workplace or use the means of access to and egress from the workplace are not exposed to hazards.
Safety obligations Every workplace partners has an obligation to ensure safety at every stages of their involvement. You can have more than one set of obligations stipulated under the Safety Act. For example, if you are an employer and a principal contractor a sole proprietor at the same time within the same workplace. In this case, you would have two sets of obligations - those of an employer on one hand and an employee on the other. You must meet all the obligations under the Acts.
This can be done through the following ways: 1. Issue regulations that either prohibit exposure to a risk or prescribe ways to prevent or minimize exposure to such risks and you must comply with such regulations. Codes of practice: Code of practice is a document which gives practical advice about ways to manage exposure to risks identified as typical in workplace.
This document states ways to manage exposure to risks within workplace and job practices. To meet your obligations under the Act, you must follow codes of practice or adopt another way that offers at least the same.
Examples of such codes include Tractor Code, Where there is no regulation or code of practice about exposure to a risk, you can meet your obligations by choosing any appropriate way to minimize exposure to a risk and you must take reasonable precautions and exercise proper diligence in making sure the risk is managed.
To properly manage exposure to risks, the risk management process must be undertaken to identify hazards and determine appropriate control measures. Such processes are set out in a document called the risk management code of practice 4. Safety planning. Plan your work and plan for safety. Take time to plan your work, not alone, but with others. Safety planning is an important part of any task. It is hard to take the time to plan for safety.
But, you must plan. Plan to be safe! Health and safety policy A written health and safety policy is an important documentary part of safety rules for managing health and safety in your workplace and an important step in demonstrating management commitment. A health and safety policy explains: 1. The overall goals and objectives for health and safety 3. The responsibilities of management, workers, as well as visitors and contractors where applicable Work ergonomics Ergonomics is the human factors involvement in satisfactory work or job delivery and systems to maximize safety, comfort, and efficiency of the people who use them.
Ergonomics is not limited to human comfort in manual handling operations, but also in automated tool and machine handling. Ergonomics in manual handling: Manual handling of task includes any activity which requires a person to lift, lower, push, pull, hold or carries any object, animal or person. These considerations are assessed by the following factors: 1.
Moderating the extent of weight being lifted. Match up weight to be lifted with body weight; 2. Study the nature of body posture and improve on body layout when carrying load; 3. Regulate work frequency and duration of operation under long time and short time operations ; 4. Study object physical and material characteristics to know the best approach in handling it; 5.
Individual characteristics physical, physiological, psychological and mental fitness should be considered and 6. The physical and operating environment should be favourable to human effectiveness in job handling. Guidelines for hand work The following guidelines have been scientifically proved to influence effectiveness of hand work handling operation. Avoid placing needed tools or other items above shoulder height. Position items that are used often within 17 inches mm of the worker.
For standing work, use the proper work station height Figure Figure Proper workstation height for light and heavy work. Optimal working height OWH of worker is based on body dimensions. Figure Working Heights 5. Sitting down while working reduces the strain on the lower back and legs. Standing causes legs to swell more than walking does. The best jobs are ones that allow workers to do different types of work, changing from sitting to standing to walking and back again.
For example, a worker who performs a high repetition weeding task should be given other tasks that do not require repetitive hand motions, like carrying the finished boxes to the loading area. Allow foot and knee clearances for both standing and sitting workers, so they can get close to the work.
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