Subject Overview

A practice-centered study of mechanical workshop methods, laboratory measurement, manufacturing processes, machine tools, digital production, quality, safety and professional engineering practice. The subject integrates traditional workshop skills with CAD/CAM, CNC, automation, data analytics, AI-assisted manufacturing and sustainable production.

Learning Goal

Students will safely plan, execute, measure and evaluate mechanical workshop and laboratory work; select materials, processes, tools and parameters; manufacture and inspect components; analyze experimental data; and document decisions according to engineering standards, ethics and current industry practice.

Syllabus

1. Workshop Organization, Safety and Professional Practice

Learning Objective: Apply workshop rules, hazard identification, risk assessment, PPE, machine guarding, lockout–tagout, emergency response, housekeeping, ergonomics, permits and ethical responsibilities under relevant safety standards.

Category: foundation

2. Engineering Drawings, Standards and Process Planning

Learning Objective: Interpret orthographic and sectional drawings, dimensions, tolerances, fits, surface-finish symbols and GD&T; prepare operation sequences, route sheets, bills of materials and job estimates.

Category: foundation

3. Measurement, Metrology and Experimental Data

Learning Objective: Use rules, calipers, micrometers, gauges, comparators and surface-measurement instruments; evaluate calibration, traceability, uncertainty, error, repeatability and basic statistical results.

Category: core

4. Engineering Materials and Workshop Testing

Learning Objective: Relate the structure and properties of metals, polymers and composites to manufacturability; perform hardness, tensile, impact and non-destructive tests and select materials using technical, economic and sustainability criteria.

Category: core

5. Bench Work, Fitting and Assembly

Learning Objective: Perform marking, cutting, filing, drilling, tapping, reaming, scraping and fastening; produce fitted assemblies while controlling accuracy, surface finish and safe tool use.

Category: core

6. Machine Tools and Machining Fundamentals

Learning Objective: Explain machine-tool motions, cutting-tool geometry, chip formation, cutting forces, tool wear, coolants and machinability; calculate speeds, feeds, depth of cut, machining time and material-removal rate.

Category: core

7. Turning, Milling, Drilling and Grinding Practice

Learning Objective: Set up and operate lathes, milling machines, drills and grinders; select workholding, tooling and cutting parameters; manufacture components and diagnose dimensional, vibration and finish defects.

Category: application

8. Casting and Foundry Practice

Learning Objective: Design patterns, cores, moulds, gating and risers; conduct basic sand-casting work; explain solidification, shrinkage, casting defects, inspection and process-selection considerations.

Category: application

9. Forming, Sheet-Metal and Fabrication Processes

Learning Objective: Perform bending, shearing, drawing, rolling and basic forging operations; calculate allowances and forming forces; select tooling and assess springback, defects and manufacturability.

Category: application

10. Welding, Brazing, Soldering and Joining

Learning Objective: Select and perform appropriate fusion, resistance and solid-state joining processes; specify joints and parameters; inspect welds, recognize defects, manage distortion and follow welding safety and codes.

Category: application

11. CNC, CAD/CAM and Additive Manufacturing

Learning Objective: Develop CAD models, process plans, toolpaths and basic G-code; set up CNC operations and compare subtractive and additive processes in terms of capability, accuracy, cost and production volume.

Category: contemporary

12. Quality Control and Manufacturing Analytics

Learning Objective: Apply inspection planning, tolerance analysis, process capability, control charts, sampling and root-cause tools; use measured data to improve quality, productivity and process decisions.

Category: advanced

13. Maintenance, Automation and Smart Manufacturing

Learning Objective: Practice preventive and predictive maintenance, lubrication, alignment and condition monitoring; explain sensors, PLCs, robotics, industrial IoT, digital twins and responsible AI applications in workshop operations.

Category: contemporary

14. Integrated Manufacturing Project and Laboratory Governance

Learning Objective: Plan, manufacture, inspect and present a functional component or assembly while managing cost, schedule, resources, waste, energy, documentation, teamwork, data integrity, intellectual property and environmental responsibility.

Category: strategic