Vehicle Technology

TTEC 3205 Internal Combustion Engines

Engine Technology - Semester 2

Engineering - Toolbox

Over the last three days I have been in the workshop fabricating a Toolbox for the final part of the Engineering module, I began with pre-cut pieces of 1.6mm mild steel sheet and with the design drawings I began to mark out the measurements for folding and cutting the material. Once the steel was all marked out and cut I began folding the required pieces to make the components of the Toolbox. I began with the base and sides of the toolbox followed by the ends of the box and the shelves for the tray, once these were folded I clamped the pieces together and spot welded them in place. After the box was together I began cutting the hinges to size to fit the lid, and then measured, marked and folded the two pieces of the lid. after the lid and hinges were spot welded in place I made the tray for inside the toolbox, once the tray was finished I used pieces of square bar which I cut at 45 degree angles to make the handle for the tray. Next came the handles for the toolbox and the saddles for the handles, once these were completed I began to MIG weld the handles onto the toolbox and tray, a latch to keep it closed, followed by welding all the joints, hinges and to reinforce the toolbox. After welding it all up I gave the welds a quick tidy up with the angle grinder. I will be painting the toolbox in the near future and will be uploading pictures once I have them.


the base and sides of the box folded up.


The end of the toolbox before folding with cuts for the folds to weld it into the box and to make room for the hinges.


The shelves of the toolbox to hold the tray in place.


Toolbox ends and shelves spot welded together and to the toolbox.


One half of the lid of the toolbox pre-folding.


Folding one side of the lid, the small piece of metal is a guide for the fold required for the lid.


The lid and hinges spot welded in place.


This photos is just to show the action of the hinge and how the lid closes.


The tray folded up.


Tray inside the Toolbox, nice fit!


handle for the tray clamped in place ready for welding.


Handles welded onto the toolbox.


Toolbox complete with latch.


Movements of the handles and latch.


Tray complete with handle inside toolbox.


The inside of the toolbox, all of the welds can be seen to show the reinforcement of the toolbox.

Electrical Engineering

Tapping

Last week in the workshop we covered tapping and removing a broken stud. We started by drilling a hole into a piece of steel, then we tapped and and screwed a bolt into it, we then cut the head of the bolt to simulate a broken stud. We began by drilling through the broken stud right the way through, then used an EZ out to remove the broken stud. After this was complete we covered repairing a thread. We drilled out the hole and re-tapped it, we then used a Heli-coil to repair the thread.


Tapping the hole that was drilled.


The bolt with its head chopped off


Drilling through the broken stud.


Using the EZ out to remove the broken stud.


Repairing the thread with the Heli-Coil.

Workshop Tools

Please answer the following questions on common work shop tools (in your E Portfolio). Copy and paste the questions in your E Portfolio and answer below. The CDX on-line text book is a good resource to use click on the link and have a look through, this e text book will have all the answers you need CDX E Text Book for the hand tools questions.

1. What is the name of the hammer most commonly used in Automotive engineering?
Ballpein Hammer

2. What would you typically use one for?
Flattening or Peining a Rivet

3. Why would you use a soft faced hammer?
To prevent damage or scratching to work surfaces

4. What type of hammer would you use to give a really strong blow to a chisel?
Lump Hammer

5. What would you use a mallet for in Automotive Engineering?
A job that requires you to use force to get a bolt/bung in without damaging the surface

6. When would you use a dead blow hammer?
In a small or enclosed environment

7. What can cause a hacksaw blade to clog?
Material is too thick to cut

8. What can happen if the blade is too coarse for the job it is intended for?
The blade will grab the material

9. What should you do before and after using a hacksaw?
Clean the blade, make sure its tight.