BASIC INTERNSHIP REPORT
NGUYEN NGOC THUY LINH
10523023
MEN2023
VIETNAMESE-GERMAN UNIVERSITY
MEN2023
1
TABLE OF CONTENTS
Contents
Week 1 Overview .......................................................................................................... 6
Report on the executed work in the week from 12.08.2024 till 16.08.2024 .................. 7
Industrial Safety ......................................................................................................... 7
The aim of industrial safety is to: .............................................................................. 7
Accident causes .......................................................................................................... 7
Safety rules................................................................................................................. 7
Measurement tools and techniques ............................................................................ 8
Week 2 Overview .......................................................................................................... 9
Report on the executed work in the week from 26.08.2024 till 29.08.2024:............... 10
Milling equipment .................................................................................................... 10
Operating milling machine manually....................................................................... 11
Exercise .................................................................................................................... 11
Shaping the face to required dimension ............................................................... 12
Drilling holes ....................................................................................................... 13
Groove milling: .................................................................................................. 15
Creating threads ................................................................................................... 16
Week 3 Overview ........................................................................................................ 17
Report on the executed work in the week from 03.09.2024 to 06.09.2024 ................. 18
Steps to operating the Lathe machine ...................................................................... 18
Exercise .................................................................................................................... 19
Week 4 Overview ........................................................................................................ 22
Report on the executed work in the week from 09.09.2024 till 13.09.2024 ................ 23
Welding equipment .................................................................................................. 23
Tungusten Inert Gas (TIG) welding ......................................................................... 24
TIG welding steps .................................................................................................... 24
Arc welding.............................................................................................................. 26
Arc welding steps..................................................................................................... 27
Advantages........................................................................................................... 28
Disadvantages ...................................................................................................... 28
2
Week 5 Overview ........................................................................................................ 29
Report on the executed work in the week from 16.09.2024 till 20.09.2024 ................ 30
Filling equipment ..................................................................................................... 30
Exercise .................................................................................................................... 31
LIST OF FIGURES
Figure 1: vernier caliper: ................................................................................................ 8
Figure 2: Milling machine ........................................................................................... 10
Figure 3: Drilling machine ........................................................................................... 10
Figure 4: the X handle.................................................................................................. 11
Figure 5: the Y handle.................................................................................................. 11
Figure 6: the Z handle .................................................................................................. 12
Figure 7: Required dimension drawing........................................................................ 12
Figure 8: Milling using the face cutter ......................................................................... 13
Figure 9: Facing 6th face using end cutter ................................................................... 13
Figure 10: Centre punches ........................................................................................... 14
Figure 11: Drill bottom drawing .................................................................................. 14
Figure 12: Drill ø11 holes ............................................................................................ 14
Figure 13:Top side result ............................................................................................. 15
Figure 14: Top side drawing ........................................................................................ 15
Figure 15: Bottom side drawing .................................................................................. 15
Figure 16: Bottom side result ....................................................................................... 16
Figure 17: Making threads ........................................................................................... 16
Figure 18: Lathe different cutting tools ....................................................................... 18
Figure 19: Tail stock and the dead end center tool ...................................................... 18
Figure 20: Lathe exercise drawing ............................................................................... 19
Figure 21: Trimming the billet ..................................................................................... 19
Figure 22: Work piece after knurling........................................................................... 20
Figure 23: Drilling process .......................................................................................... 20
Figure 24: Lathe result ................................................................................................. 21
Figure 25: HK416 welding machine ............................................................................ 23
Figure 26: Goggles....................................................................................................... 23
Figure 27: Welding gloves ........................................................................................... 24
Figure 28: TIG welding setup ( .................................................................................... 24
Figure 29: TIG electrodes ............................................................................................ 25
Figure 30: TIG welding torch ...................................................................................... 25
Figure 31: My TIG butt welding result ........................................................................ 26
Figure 32:Arc welding principles ................................................................................ 26
Figure 33: Arc welding operation ................................................................................ 27
Figure 34: My arc welding result ................................................................................. 28
Figure 35: Tools (hand saw, pen, ruler, brush, file)..................................................... 30
3
Figure 36: Workbench and vise ................................................................................... 30
Figure 37: Gloves......................................................................................................... 31
Figure 38: Nut drawing ................................................................................................ 31
Figure 39: The face after flatten................................................................................... 32
Figure 40: Draft the nut shape ..................................................................................... 32
Figure 41: The nut final result ..................................................................................... 32
Figure 42: Nut after cutting.......................................................................................... 32
4
Basic Internship Overview
Last name
Middle name
First name
Date of birth
Student ID
Nguyen
Ngoc Thuy
Linh
26.07.2005
10523023
Internship place
Vietnamese - German University (Binh Duong Campus)
Ring road 4, Quarter 4, Thoi Hoa Ward, Ben Cat City, Binh Duong Province
Internship period
12.08.2024 - 20.09.2024
Internship overview
Department
Modules
From
Till Weeks
No. of work reports
LH-301
Theory session
12.08.2024
16.08.2024
1
1
CL1-106
Milling
26.08.2024
30.08.2024
2
2
CL1-106
Turning
02.09.2024
06.09.2024
3
3
CL5-204
Welding
09.09.2024
13.09.2024
4
4
CL5-307
Filling
16.09.2024
20.09.2024
5
5
5
Week 1 Overview
In the beginning week of the Internship at VGU (Vietnamese – German University)
campus, some basic safety principles were provided, to avoid accidents and dangers
that may exist throughout the course. Additionally, measurement techniques as well
as some introductions to various machines also been prepared before we went to the
workshops.
For the first week from 12.08.2024 to 16.08.2024
Module: Theories.
Department of workshop: VGU campus, lecture hall, room 301
Daily
hours
Hours
of
absence
Day
Short description of executed activities
Single
hours
Monday
Introducing internship courses and the
facilities
Guided to industrial safety and workshop
regulations
Protective clothing.
3
3
3
Tuesday
Introduction to measurement tools and
techniques, and practice sessions.
3
3
0
Wednesday
Measurement technique practice
3
3
0
Thursday
Introduction to turning and milling
machine
3
3
0
12
3
Total
6
Report on the executed work in the week from 12.08.2024 till 16.08.2024
No. of work report: 01
Industrial Safety
Safety is the field that must not be ignored during the operation of a machine and must
be strictly followed, as this keeps workers free from unwanted, life-threatening
working accident. Upon entering the workplace, the thinking of “Safety’s first” shall be
born in mind of the workers.
The aim of industrial safety is to:




Examine of all potential risks of accidents to prevent loss of life or disability of
the machine operators, damage to machine and material and other surrounding
facilities.
Eliminating the declination of work efficiency.
Reducing hazard to the lowest possible level
Increasing production and living standards.
Accident causes



Human causes:
o Operators work on unsafe or dangerous, moving equipment, machinery,
or improper tools.
o Operating machines without knowledge, without authority, without safety
precautions.
o Working with unwell mental or physical health like nervousness,
ignorance, sickness also occur in accidents. 
Environmental causes:
o Poor working area, improper temperature or illumination, and bad plant
layout may cause accidents.
Mechanical causes:
o Old, poorly maintained, or unsafe equipment or building structure may
lead to accidents.
o Lack of safety devices such as helmets, goggles, safety shoes.
Safety rules



Always wear the correct personal protective gear.
Remove personal items like jewelry, watch, coats, ... Secure long hair to avoid
accidents.
Only one person operates a machine at once.
7









Keep both the equipment and its surroundings clean and organized.
Do not operates the machine that you are approved or trained by instructors.
Always get instructions before using equipment you're unfamiliar with.
Use tools and machines only for their designed purposes.
Report any injuries, accidents, broken equipment.
Ensure that machine guards are in place and properly used.
Avoid distracting others operating equipment and never leave the machine
when it is working.
Do not work alone in the lab.
Never use compressed air for cleaning.
Measurement tools and techniques
There are many kinds of tools that have been introduced to us, but in this course,
we just use the vernier calipers most of the time to measuring distances. This is one
of the most common and accurate measuring tools that have been using for many
years.
Using the vernier caliper:
1. Zero out the calipers before you take a measurement.
2. Clamp the jaws around the outside of the object for external measurement.
Extend the jaws inside of the object to get an internal measurement.
Push the extension rod into the object for depth measurement.
3. Record the measurement going from the largest to the smallest number.
Figure 1: vernier caliper:
8
Week 2 Overview
Milling is the first module that is I have been taught. In this module, we learned how to
operate the milling machine and were taught some basic skills about it.
For the week from 26.08.2024 to 29.08.2024
Module: Milling.
Department of workshop: VGU campus, cluster 1, room 106
Day
Short description of executed activities
Single
hours
Daily
hours
Hours
of
absence
Monday
Introduction to the milling machine,
equipment, safety instructions and
regulation.
Get familiar with the milling machine
Milling faces to the width of 68 mm and
the height of 28 mm
Cleaning
1
1.5
3
0.5
6
0
Tuesday
Change the face milling cutter to the end
milling cutter
Milling two perpendicular faces to the
length 110mm
Cleaning
5.5
0.5
6
0
Wednesday
Drilling holes and make miscellaneous
details
Cleaning
5.5
0.5
6
0
Thursday
Drilling holes and milling grove
Cleaning
5.5
0.5
6
0
24
0
Total
9
Report on the executed work in the week from 26.08.2024 till 29.08.2024:
No. of work report: 02
Milling equipment

Milling machine: The milling machine is the main machine that we will use in
study and practice for the week. The one that provided for us in the internship
was the Taiwanese MC Denver Vertical Horizontal Turret Milling machine
(model MD-186 VH).
Figure 2: Milling machine

Drill machine: The Alzmetall Drilling machine was used in Lab.
Figure 3: Drilling machine
10
Operating milling machine manually

X-axis: when rotated clockwise, the table moves to the right and vice versa
Figure 4: the X handle

Y- axis: when rotated clockwise, the table moves toward the inside and vice
versa
Figure 5: the Y handle

Z-axis: when rotated clockwise, the table moves upward
Exercise
11
Figure 6: the Z handle
Shaping the face to required dimension
Figure 7: Required dimension drawing
12
After having secured the billet to the vise, we began the work by smoothen the face of
the billet for the precision later on. Then we milled the opposite face of the smoothen
one to the required dimension. The process is the same for all required dimension
Figure 8: Milling using the face cutter
For the 5th and 6th face of the billet, we change to the end cutter.
Figure 9: Facing 6th face using end
cutter
Drilling holes
In order to dill accurately, we first had to mark the position of 8 holes with a marker
After marking, we used the center punching tool to mark the holes when we drilling.
13
Figure 11: Drill bottom drawing
Figure 10: Centre punches
Then we secure the billet on the mechanical vice on our drilling machine and start
drilling.
Figure 12: Drill ø11 holes
14
Figure 14: Top side drawing
Figure 13:Top side result
Groove milling:
This process starts by setting zero for the X-Axis, Y-Axis and Z-Axis by touching the
edge of the cutter to the edge of the length, width, height of the billet gently while the
milling machine is turning on.
Figure 15: Bottom side drawing
15
Then the groove can be created. The cutter coordinates must be calculated carefully to
achieve the required result.
Creating threads
The last part is to do the threading for some holes.
Figure 17: Making threads
Figure 16: Bottom side result
Intern
Date, signature, and full name
Supervisor or Training center
Stamp
Date, signature, and full name
16
Week 3 Overview
In the third week, we learned about turning. In this module, we learned how to operate
the turning machine and were taught some basic skills about it
For the week from 03.09.2024 to 06.09.2024
Module: Turing.
Department of workshop: VGU campus, cluster 1, room 106
Day
Short description of executed activities
Single
hours
Introduction to turning machine,
equipment, safety instructions and
regulation.
Get familiar with the turning machine
1.5
Wednesday
Threading and chamfer
Cleaning
5.5
0.5
Thursday
Trimming the thread to smooth
surface
Cleaning
5.5
0.5
Friday
Drilling holes and make threads
Cleaning
5.5
0.5
Tuesday
Total
Daily
hours
Hours
of
absence
6
0
6
0
6
0
18
0
0.5
17
Report on the executed work in the week from 03.09.2024 to 06.09.2024
No. of work report: 03
Steps to operating the Lathe machine
1. Choose the suitable cutting tool and install it to the tool post. Ensure that all
screws must be tighten.
2. Calibrate the cutting tool. The position of the cutting tool must coincide with the
Figure 18: Lathe different cutting tools
Figure 19: Tail stock and the dead end center tool
dead center of the lathe.
3. Secure the work piece into the chuck. If you want to cut a length of 100mm in Y
direction, the billet must be positioned at 115mm.
4. Adjust the cutting speed before turning the machine. Calculate the cutting speed
is based on the following equation, in meters per minute: Cs = (π * D
*N))/1000. With D: work piece diameter (m); n: spindle speed (rpm)
5. Turn on the machine. Press the test button and apply the emergency brake. If the
machine fails to works normally, report to the instructor.
18
Exercise
Figure 20: Lathe exercise drawing
Step 1: First we get a round cylindrical billet. Next we have to drill the center of the
blank to make a dead centre. Then we smoothened the billet in both X and Y dimension.
After that we trimming the X dimension of the billet according to the design
requirement.
Figure 21: Trimming the billet
19
Step 2: Parting method is also applied to create a trench between the 2 knurled zones of
the work piece. Now we need to cut the billet at two different place where x is 55mm
and x is 85mm respectively, each cut will be 1mm deep and 3mm long.
Step 3: Then we started the knurling process. When the knurling tool is placed in the
tool box, it must be ensured that it is placed according to the correct height, which the
middle part of the knurling tool touches the working billet
Figure 22: Work piece after knurling
Step 4: We need to drill thought the billet so that we can cut the excess of it. When
drilling, the hand wheel of the tailstock must be rotated very gently and slowly, so as
not to break the drill as well as the work billet.
Figure 23: Drilling process
Step 5: We then chamfer the work piece, drill some holes using the drilling machine
and make the threads.
20
Figure 24: Lathe result
Intern
Date, signature, and full name
Supervisor or Training center
Stamp
Date, signature, and full name
21
Week 4 Overview
Welding is the process of fusing two or more parts using heat, with or without pressure
and with or without the use of filler metal. In this module, I was taught two types of
welding: Arc welding and TIG welding.
For the week from 09.09.2024 to 13.09.2024
Module: Welding.
Department of workshop: VGU campus, cluster 5, room 204
Day
Short description of executed activities
Single
hours
Daily
hours
Hours
of
absence
Monday
Introducing welding protective clothing
and equipment.
Theory session on TIG, MIG/MAG
welding
Welding in straight lines practice.
0.5
0.5
3
6
0
Tuesday
Welding butt joint practice
Welding butt joint test
5.5
0.5
6
0
Wednesday
Theory session on arc welding
Welding straight lines practice
Welding straight lines test
0.5
5
0.5
6
0
Thursday
Welding butt joint practice
Lap welding practice
Lap welding test
3
2.5
0.5
6
0
24
0
Total
22
Report on the executed work in the week from 09.09.2024 till 13.09.2024
No. of work report: 04
Welding equipment

Welding machine: In welding section, we use the HK 416 welding machine
produced by Hong Ky for both arc welding and TIG welding.
Figure 25: HK416 welding machine

Goggles: These are fitted with colored lenses and are used to protect the eyes
from harmful heat and ultraviolet and infrared rays.
Figure 26: Goggles
23

Welding gloves: These are required to protect the hands from getting burned
caused by the heat of welding process.
Figure 27: Welding gloves
Tungusten Inert Gas (TIG) welding
TIG welding is an arc welding process whose weld is produced by a non-digestible
tungsten electrode with a surrounding inert gas shielding layer. The gas protects the
electrode and the welding bead from oxidization process of the environment. In the
lab, Argon is used as shielding gas.
Figure 28: TIG welding setup (
Source: Rajender Singh, (2006), Introduction to basic manufacturing processes and
workshop technology, p. 324)
TIG welding steps
First, prepare TIG welding torch with a tungsten electrode and supply Argon to the
machine. Before any TIG welding process is conducted, the Tungsten electrode must
be kept sharp to prevent sticking. If the electrode is not in shape, it must be grinded by
a grinder. TIG welding procedure includes the use of protective gas (in our lab:
Argon). Therefore, before the process is conducted, the welder must make sure that
24
the gas valve is turned on and supplies the air. If not, a quirky sound is heard and
during the welding process, the weld pool is not protected and exposed into air, which
oxidates immediately thus making the weld ugly with low endurance. The distance
between the electrodes and plane is at around 2 to 2.5mm above and at an angle of 70
to 75 degree to the plane for straight line or butt welding; 45 degree applies to tee
welding joint.
Figure 29: TIG electrodes
Figure 30: TIG welding torch
25
Figure 31: My TIG butt welding result
Arc welding
Arc welding is a process that uses an electric arc to join metals together. The arc is
created between an electrode and the base material or between two electrodes,
producing intense heat that melts the metals at the weld point. When the metals cool,
they fuse together, forming a solid joint.
Figure 32:Arc welding principles
(Source: Rajender Singh, (2006), Introduction to basic
manufacturing processes and workshop technology, p. 318)
26
Arc welding steps
First, hold the electrode holder and creates the arc by swiping the electrode like a
match or tapping the electrodes onto a metal piece. At this stage check again the
applied current and sparks from the electrode, ensure that it is not too large (very big
spark and splashing arc) nor too small (very small arc and unclear arc). Once the arc
is established, move the electrode towards the joint needed to be welded. The
electrode must be kept at an ideal height around 2 to 2.5mm above the work piece and
the angle is around 70 to 75 degree in comparison to the horizontal plane for flat
position welding process and around 45 degrees for tee joint welding process. The
welding action taken by the welder must be not too quick nor too slow, moving speed
should be constant and the welder must remain the ideal distance due the melting
consumable electrodes. During the procedure, the outer layer, which wraps around the
molten metal cores, is also burned in the process. burns together with the inner metal
wire, which creates a layer of gas to protect the weld beads that easily oxidates when
interacting with air and makes the weld looks better and have greater endurance.
Finally, wait for the weld to cool down then gently removes the slags and uses a metal
brush to remove the excessive tiny slags.
Figure 33: Arc welding operation
(Source: Rajender Singh, (2006), Introduction to basic manufacturing
processes and workshop technology, p. 322)
27
Advantages





Well-priced and affordable equipment.
Easy to carried out.
Works on a wide range of metals and alloys.
Works on hard facing and metal resistance.
The processes can be completed during wind or rain.
Disadvantages



A lot of waste is produced leads to low efficiency.
Difficult to work on thin materials.
Higher chance of getting slag entrapment comparing to TIG or MIG welding.
Figure 34: My arc welding result
Intern
Date, signature, and full name
Supervisor or Training center
Stamp
Date, signature, and full name
28
Week 5 Overview
Filling is the last module in the basic internship. In this module, we used different
equipment to make a nut form a round piece of work piece.
For the week from 16.09.2024 to 20.09.2024
Module: Filling.
Department of workshop: VGU campus, cluster 5, room 307
Day
Short description of executed activities
Single
hours
Daily
hours
Hours
of
absence
Monday
Safety and introduction to equipment
Cutting the first face
1
5
6
0
Tuesday
Cutting the other faces
6
6
0
Wednesday
Cutting the other faces
0.5
5
0.5
6
0
Thursday
Filling all the sides and control the
angles
6
6
0
Friday
Chamfer
Finishing all the faces
3
3
6
0
30
0
Total
29
Report on the executed work in the week from 16.09.2024 till 20.09.2024
No. of work report: 05
Filling equipment
Figure 35: Tools (hand saw, pen, ruler, brush, file)
Figure 36: Workbench and vise
30
Figure 37: Gloves
Exercise
Figure 38: Nut drawing
Step 1: Flatten the 1st face to make it parallel with the 2nd face.
31
Figure 39: The face after flatten
Step 2: Draft a hexagon shape on the nut to mark the area the need to be removed.
Figure 40: Draft the nut shape
Step 3: Cut off the unwanted parts using the hand saw
Step 4: Constraint the angles and file the sides at the same time.
Step 5: Chamfer and polish the work piece with a 240 grit sand paper.
32
Figure 42: Nut after cutting
Figure 41: The nut final result
33
Intern
Date, signature, and full name
Supervisor or Training center
Stamp
Date, signature, and full name
34