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POLYTECHNIC OF KOTA KINABALU

MECHANICAL ENGINEERING DEPARTMENT

JJ203 - MECHANICAL WORKSHOP PRACTISE 2

WELDING WORKSHOP

NAME : ___________________________________________

STUDENT ID : ___________________________________________

PROGRAMME : ___________________________________________

SESSION : ___________________________________________

LECTURER : ___________________________________________

LECTURERS REMARKS :
TABLE OF CONTENTS

TITTLE PAGES

WORK SHEET 3

INTRODUCTION 5

SAFETY PROCEDURES 6

EQUIPMENT/MACHINES/TOOLS USED 7

WORK PROCEDURES 9

FINAL PROJECT DIAGRAM 15

CONCLUSION 16

REFERENCES 18

APPENDIX 19

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WELDING DIRECTION
BEGIN FROM CENTER

ARC WELDING WORK TOP VIEW


SHEET
TITTLE : Beading WELDING DIRECTION
CONTINUE FROM CENTER
PROGRAMME :
DKM 2, DTP 2, DEM 2
MATERIAL :
Mild steel : 2 x 35 mm x 120 mm
x 6mm
OBJECTIVES :
Continue unfinished bead
TITTLE : Padding TOP VIEW FRONT
PROGRAMME : SIDE VIEW
DKM 2, DTP 2, DEM 2
MATERIAL :
Mild steel : 2 x 35 mm x 120 mm
x 6mm
OBJECTIVES : 120 mm
Perform padding process
TITTLE : Tee fillet TOP VIEW FRONT
PROGRAMME : SIDE VIEW
DKM 2, DTP 2, DEM 2 35 mm
MATERIAL :
Mild steel : 2 x 35 mm x 120 mm 6 mm
x 6mm
OBJECTIVES : 120 mm
Weld T fillet in a flat position

GAS WELDING WORK


SHEET 45
TITTLE : Tee fillet
60 - 70
PROGRAMME :
DKM 2, DTP 2, DEM 2
MATERIAL :
Mild steel : 2 x 40 mm x 150 mm
x 3mm
Welding Direction

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OBJECTIVES :
Weld T fillet and T joint in a flat
position
TITTLE : Lap joint 60 - 70

PROGRAMME :
DKM 2, DTP 2, DEM 2
MATERIAL :
Mild steel : 2 x 40 mm x 150 mm
30
x 3mm
Cutting direction
OBJECTIVES :
Weld lap joint and lap joint 15 - 20
using brazing process
TITTLE : Cut metal plate
PROGRAMME :
DKM 2, DTP 2, DEM 2
MATERIAL :
Mild steel : 2 x 40 mm x 150 mm
x 3mm
OBJECTIVES :
Cut metal plate using oxy-
acetylene process
INTRODUCTION

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SAFETY PROCEDURES

a) Self-safety

b) Equipments/tools safety

c) Workspace safety

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EQUIPMENTS/MACHINES/TOOLS USED

EQUIPMENTS/MACHINES/
NO USAGE DIAGRAM
TOOLS NAME

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EQUIPMENTS/MACHINES/
NO USAGE DIAGRAM
TOOLS NAME

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WORK PROCEDURES

PROJECT 1 : ____________________

NO SKECTHING/DIAGRAM PROCEDURES

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NO PROCEDURES EXPLAINATION

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WORK PROCEDURES

PROJECT 2 : ____________________

NO SKECTHING/DIAGRAM PROCEDURES

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NO PROCEDURES EXPLAINATION

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WORK PROCEDURES

PROJECT 3 : ____________________

NO SKECTHING/DIAGRAM PROCEDURES

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NO PROCEDURES EXPLAINATION

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FINAL PROJECT DIAGRAM

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CONCLUSION

1. Arc welding machines utilize a high-amperage electric current which is extremely dangerous. Explain what
should you do to decrease the possibility of accidental electrical shock?

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2. Explain why there have AC and DC electricity supply in arc welding.

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3. Describe three (3) types of oxy-acetylene flames with appropriate sketches.

4. Explain in brief about T-fillet and Lap joint welding.

5. Do you have any suggestions for room of improvement?

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REFERENCES

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MACHINING & WELDING WORK REPORTS RUBRIC [PLO 8]

VERY
UNSATISFACTO MARKIN
CRITERIA EXCELLENT GOO GOOD FAIR
NO RY G SCORE
D
FACTOR
(7) 5 4 3 2 1
- Overdue
- Report was submitted - Report submission
- Low quality
1 Accountability before the deadlines. on time. 4
work
- High quality work - Proper quality work
- Covers self, workplace and Cover any two of No safety
Safety
2 equipment safety. self/workplace/equip procedures 2
procedures
- Well organize ment safety stated
Equipment /
Cover any one
machinery / Complete with tools Cover any two of
of tools
3 tools used name, sketching and its tools name 2
name/sketching
(Photocopies function. /sketching/its function
/its function
are acceptable)
Explain the
- Explain the workshop
workshop
processes step by step. - Explain the workshop
processes step by
Work processes step by step.
4 step without 4
procedures - Assisted with sketching.
sketching.
- Assisted with sketching
Or
- Well organize
Sketching only
Not fulfilling the
Meet the requirement with Partially fulfilling the
5 Reports format requirement 3
excellence. requirement needed.
needed.
6 Integrity & - Report completed. - Report partially - Too much 4
Honesty completed. missing

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- Original idea - Copy totally information.
7 References > 4 references 2 References No references 1
TOTAL /100
PLO 8 : Demonstrate an understanding of professional ethics, responsibilities and norms of mechanical engineering practices
WELDING PRACTICAL TASKS RUBRIC [PLO 2]

VERY UNSATISFACTO MARKIN


CRITERIA EXCELLENT GOOD FAIR
GOOD RY G SCORE
(9) 5 4 3 2 1 FACTOR
ARC WELDING
All of the following safety No welding
Two or more of the following
practices were followed: helmet worn.
safety practices violated:
Proper welding gloves No safety glasses
No welding gloves worn.
worn. worn.
Safety Practices Incorrect shoes worn. 2
Proper shoes worn. Student will not
Incorrect clothing worn.
Proper clothing worn. be allowed to
Hot metal carried in gloved
Pliers, etc. used to carry continue the
hand(s).
hot metal. assignment.
Bead width equals the The majority of the bead is Bead
Bead Width width of two electrodes equal to the width of two unsuccessfully 3
used. electrodes used. made.
Bead
Bead has an acceptable Proper bead shape is not
Bead Shape unsuccessfully 2
shape for the entire weld. consistent for the entire length
made.
of the bead.
Bead has neither of the
Bead has one of the following
following problems:
problems: Bead
Bead is rough, narrow
Weld Start & Finish Bead is rough, narrow and unsuccessfully 1
and high.
high. made.
Weld crater is not filled
Weld crater is not filled in.
in.
Weld Defects No weld defects are Bead 2

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1 of the following defects are
present:
Excess spatter is present.
unsuccessfully
present. Bead is not uniform.
made.
Weld ripples are long and
pointed.

MARKI
GAS WELDING NG SCORE
FACTOR

Properly prepared weld Did not prepare


metal. weld metal.
Tacked weld metal in Missed one or two of the Did not tack
Metal Inspection 1
proper position. criteria. metal.
Showed to instructor Did not show to
before welding. instructor before
welding.

Less than the


Bead Width 1/8" to 3/16" wide 1/16" to 1/8" wide thickness of the 3
material

1/16" high and smooth 3/32" height and varied Less than 3/32"
Bead Height 3
bead consistence and inconsistent

Penetration of less than Penetration of less than 1/2 Penetration of


Penetration 3
3/4 of the base the base less than 1/4 the
base

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TOTAL /100

PLO 2 : Demonstrate practical skills which includes the ability to troubleshoot, repair and do maintenance work for mechanical equipment.

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Name : ______________________________________________

Student ID : ______________________________________________

Practical Task Report


PLO Marks PLO Marks
PLO 2 PLO 8
TOTAL ( /100)*70 = TOTAL ( /100)*30 =

Your Total mark is :

Lecturer signature,

.......................................

Date :

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-THE END-

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