COLLEGE OF ENGINEERING
INSTITUTION OF ENGINEERS, SRILANKA
TRAINING STANDARDS
FOR
ADVANCED DIPLOMA IN MECHANICAL ENGINEERING
COLLEGE OF ENGINEERING
INSTITUTION OF ENGINEERS, SRILANKA
TRAINING STANDARD FOR ADVANCED DIPLOMA IN MECHANICAL ENGINEERING
CONTENTS
No
01
Description
Bench fitting
Page
01
Orientation to fitting work
Layout and mark work pieces
Perform general fitting work
Assemble components
02
Machine shop
02
Orientation to machine shop
Lathe machines
Drill machines
Boring machines
Shaping, planning and slotting machines
Milling machines
Grinding machines
Measuring and testing devices
03
Tool room work
04
Orientation to tool room
Make or repair metal cutting tools
Make or repair metal forming tools
Heat treatment of tools and dies
Making of gauges
Making jigs and fixtures
04
Welding and fabrication
Orientation to welding and fabrication shop
Gas welding and cutting
Electric arc welding
MIG, TIG and spot welding
Fabrication
06
05
Metal forming
08
Orientation to metal forming
Metal forming operations
Sheet metal forming
06
Smithy work
09
Orientation to smithy work
Hand forging
Soft soldering
Brazing
07
Foundry
10
Orientation to Foundry
Casting methods
Pattern making
Sand moulds and cores
Gravity die casting
Furnaces
Defects in castings
08
Installation and commissioning of plant, machinery and equipment
12
Orientation
Site preparation and installation
Commissioning
Ancillary equipment
09
Maintenance and repair of plant, machinery and equipment
13
Orientation
Maintenance and repairs
10
Servicing of vehicles
14
Orientation to Service bay
Servicing of vehicles
11
Maintenance of vehicles
Orientation to vehicle maintenance
Starting and running faults
Road tests
Wheels and tyres
14
12
Engine repairs
Orientation to engine repair shop
Overhaul petrol and diesel engines
Overhaul cylinder head
Overhaul cylinder and piston assembly
16
01. Bench fitting
Orientation to fitting work
Understand the physical layout, organization structure, stores facilities and procedures in the fitting
shop
Identify potential hazards, safety precautions and safe practices adopted in the fitting shop.
Identify materials, machinery and tools required for bench fitting work and describe their applications
Layout and mark work pieces.
Familiarize with common measuring and marking tools (steel ruler, try square, divider, caliper, scriber,
center punch, straight edge, surface gauge, ‘V’ block, marking table, surface plate etc)
Identify common engineering materials (by visual inspection and spark test)
Practice the correct use of measuring and marking tools.
Perform general fitting work
Familiarize with common tools used in the fitting shop for holding, tightening, hammering and cutting
purposes. (bench vice, spanners, sockets, screw drivers, hammer, chisel, file, hacksaw etc)
Familiarize with maintaining tools and equipment according to recommended maintenance schedule
Practice chipping, cutting and filing work piece to specified sizes
Practice operating portable drills
Familiarize with bench and pedestal grinders
Take measurements using outside and inside calipers, venire caliper, micro meter, depth gauge, and dial
gauge
Familiarize with selecting correct tap and die for a particular application (thread type, diameter and
pitch of thread)
Familiarize with selecting correct size of drill bit and drilling a hole to be tapped
Familiarize with cutting threads using stock and dies and wrench and taps
Familiarize with reaming holes after drilling
Familiarize with inspecting components for limits and fits, surface finishes etc.
01
Familiarize with shaping and polishing surfaces as required
Assemble Components
Familiarize with fitting and removing bushes, sleeves, bearings, shafts etc. using pullers and presses
Familiarize with fastening components together with bolts and nuts, screws, studs and rivets
Inspect work pieces for defects, dimensional accuracy and surface finish
02. Machine shop
Orientation to machine Shop
Understand the physical layout, organization structure, stores facilities and procedures in the machine
shop
Identify potential hazards, safety precautions and safe practices adopted in the machine shop
Identify various machine tools available in the machine shop and describe their applications
Lathe machines
Identify different types of lathe machines (center lathe, capstan lathe, turret lathe, NC lathe)
Identify different parts of the lathe machine and their functions
Familiarize with operation and general maintenance of the machine
Familiarize with work holding devices (three jaw and four jaw chuck, collet chuck, face plate, tail stock
and steady rest)
Familiarize with different types of lathe tools and tool holders (high speed steel, tungsten carbide tips
and inserts) and selection of tools for particular application
Familiarize with facing, turning, step turning, taper turning, thread cutting, drilling, boring and parting
operations
Study and observe machining parameters (cutting speed, feed and depth of cut)
Observe different operations of the lathe machine
Inspect machined components for defects, dimensional accuracy and surface finish
02
Drill machines
Identify different types of drill machines (hand drill, bench drill, pedestal drill and radial drill)
Identify different parts of the drill machine and their functions
Familiarize with operation and general maintenance of drill machines
Identify different types of tools and work holding devices (straight shank and taper shank drill bits, drill
chuck, work holding vice) and selection of tools for a particular application
Observe drilling operations
Inspect drilled components for defects, dimensional accuracy and finish
Boring machines
Identify different types of boring machines (vertical, horizontal, universal and line boring machines)
Identify different parts of the machine and their functions
Familiarize with operation and general maintenance of boring machines
Identify different boring tools, boring bars and their applications
Observe boring work pieces
Inspect finished components for defects, dimensional accuracy and surface finish
Shaping, Planning and Slotting machines
Identify different types of shaping, slotting and planning machines
Identify different parts of the machines and their functions
Familiarize with operation and general maintenance of the machines
Identify different types of tools and work holding devices of the machines
Familiarize with mounting work pieces and tools and adjusting cutting strokes
Observe shaping, planning and slotting work pieces
Inspect finished components for defects, dimensional accuracy and surface finish
Milling machines
Identify different types of milling machines (vertical, horizontal and universal milling machines)
03
Identify different parts of the milling machine and their functions
Familiarize with operation and general maintenance of milling machines
Identify different milling cutters and their applications
Familiarize with mounting of work piece on machine table, mounting milling cutters, and adjusting
cutting distance and cutting parameters
Familiarize with different types of milling operations (plane milling, face milling, side milling, angular
milling, form milling, gang milling, end milling, slot milling, key way milling etc)
Familiarize with the use of dividing head in gear cutting
Inspect finished components for defects, dimensional accuracy and surface finish
Grinding machines
Identify different types of grinding machines (hand grinder, portable flexible grinder, angle grinder,
bench grinder, pedestal grinder, surface grinder, cylindrical grinder)
Identify different parts of the grinder and their functions
Identify various types of grinding wheels
Familiarize with operation and general maintenance of grinding machines
Observe different grinding operations
Inspect finished components for defects, dimensional accuracy and surface finish
Measuring and testing devices
Identify different types of measuring instruments and gauges used in the machine shop and their
applications
Familiarize with all measuring and checking devices
03. Tool room work
Orientation to Tool Room
Understand the physical layout, organization structure, stores facilities and procedures in the tool room
Identify potential hazards, safety precautions and safe practices adopted in the tool room
Identify various machine tools available in the tool room and describe their applications
04
Make or repair metal cutting tools
Familiarize with different cutting tool materials (high carbon steel, high speed steel, tungsten carbide
tips and inserts) and identify using spark and other test methods
Identify different types of cutting tools (lathe tools, form tools, milling cutters, drill bits, reamers, thread
cutting taps, dies etc)
Familiarize with brazing of tool tips of different types on to tool shanks
Familiarize with grinding of tools to correct rake, clearance and tool angles
Make or repair metal-forming tools
Familiarize with different forming tools, die materials and their fields of application.
Familiarize with die machining and finishing techniques
Familiarize with die repair work using welding and other methods
Heat treatment of tools and dies
Familiarize with iron-carbon diagram and use of other metallurgical charts
Familiarize with different types of furnaces, temperature measuring devices and heating control
methods
Familiarize with media used in heating and quenching related to hardening processes (salt baths, oil
baths etc.)
Familiarize with normalizing and annealing procedures
Familiarize with hardening and tempering techniques and identifying the temperature ranges and
significance of different stages of heat treatment.
Familiarize with temperature estimation by colours
Familiarize with surface hardening techniques (induction hardening, carburizing, niteriding etc.)
Practice hardness measuring techniques
Making of gauges
Familiarize with gauging principles and different types of gauges used in an engineering workshop
Familiarize with materials used in making gauges
Familiarize with making of gauges and periodic checking of gauges
05
Making jigs and fixtures
Identify different types of jigs and fixtures
Identify different materials and tools used in making jigs and fixtures
Familiarize with different elements of jigs and fixtures such as locating elements, clamping elements,
securing elements, tool guiding elements and other auxiliary elements
Familiarize with machining plates, bodies, pins and other parts for manufacture of jigs and fixtures
Familiarize with machining, hardening and mounting jig bushing
Familiarize with making templates and dressing grinding wheels to get required curvatures
Familiarize with assembling jigs and fixtures
Familiarize with checking assembled jigs and fixtures
Familiarize with repairing jigs and fixtures
04. Welding and fabrication
Orientation to welding and fabrication shop
Understand the physical layout, organization structure, stores facilities and procedures in the welding
and fabrication shop
Identify potential hazards, safety precautions and safe practices adopted in the welding and
fabrication shop
Identify materials, equipment and tools required for welding and fabrication work and describe their
applications
Prepare metal for welding by cutting, chipping, grinding, filing, wire brushing and using degreasing
solutions etc.
Layout work piece and mark for welding according to drawings and specifications
Position and secure work piece in place by using clamps, jigs, fixtures etc.
Gas welding and cutting
Identify safety equipment required to perform oxy – acetylene welding
Examine gas cylinders, welding torch, welding rods and nozzles required to perform oxy acetylene
welding
06
Acquire skills in assembling regulators, hoses, welding and cutting torches and testing for leakages,
selection of correct type and size of blow pipes, adjusting gas pressures, igniting blow pipe and adjusting
flames
Select correct welding fluxes and welding rods
Familiarize with correct edge preparations and related processes prior to welding
Acquire skills in fusion welding in flat position with and without filler rods
Acquire skills in butt, lap and fillet welding in horizontal flat plates, angle sections, round bars, pipes etc.
Acquire skills in flame cutting plates, angles, pipes, bars, rivets and bolts
Acquire skills in heating, forming, bending and straightening of plates, angles, pipes etc. by flame.
Inspect welding defects and their causes
Electric arc welding
Identify safety equipment required to perform electric arc welding
Familiarize with setting up arc welding equipment, regulating current for a particular application,
selecting appropriate electrodes and maintaining correct arc
Acquire skills in welding all types of joints in horizontal position
Acquire skills in finishing weld by removing slag by chipping, wire brushing and grinding
Inspect welding defects and their causes
MIG, TIG and spot welding
Identify safety equipment required to perform MIG, TIG and spot welding
Prepare work pieces for MIG, TIG and spot welding
(a) Identify various parts of the MIG welding plant (welding torch, electrode feeding, inert gas supply
and welding current supply mechanisms)
Identify correct electrode, current and inert gas supply to perform MIG welding
Observe MIG welding operations
(b) Identify various parts of the TIG welding plant (welding torch with fixed tungsten electrode, inert gas
supply and welding current supply mechanisms)
Identify correct filler material, current and inert gas supply to perform TIG welding
Observe TIG welding operations
07
(c) Identify various parts of the spot welding plant (copper welding electrodes, welding current supply
mechanism and time control unit)
Observe spot welding operations
Investigate for welding defects and their causes for MIG, TIG and spot welding
Fabrication
Familiarize with fabrication work done by bolting, riveting and welding
Familiarize with the preparation of material and manpower requirements, work schedules and final
reports for fabrication work
05. Metal forming
Orientation to metal forming
Understand the physical layout, organization structure, stores facilities and procedures in the metal
forming shop
Identify potential hazards, safety precautions and safe practices adopted in the metal forming shop
Metal forming operations
Familiarize with different metal forming operations (forging, rolling, stamping, extrusion and drawing)
Acquire knowledge of temperature ranges used in hot working operations
Familiarize with the construction and functions of rolls, dies, hammers, presses and other fixtures used
in metal forming operations.
Familiarize with the use of lubricants in metal forming
Familiarize with heat transfer process between the work piece and the rolls, dies and tools used in metal
forming operations
Sheet metal forming
Identify materials, machinery and tools required for sheet metal work and describe their applications
(rolling machine, shear, guillotine, snips, hammers, stakes and stake holder, jigs and fixtures)
08
Familiarize with selecting types and sizes of sheet metal, tubes and pipes as required
Familiarize with preparation of templates, surfaces and test blocks and mark in accordance with
specifications and drawings
Familiarize with cutting sheet metals (using snips, shears, guillotine etc.), bending sheet metals (using
stakes and bar folders) and identifying different types of bends (single bend, double bend)
Familiarize with forming cylindrical parts using rolling machine
Familiarize with making different types of seams (butt, lap, folded and grooved seams)
Familiarize with typical uses of different bends and seams in actual industrial projects
Practice wire edging of sheet metal to strengthen sheet metal work and join sheet metal to metal tubes
and pipes by riveting, welding etc.
06. Smithy work
Orientation to smithy work
Understand the physical layout, organization structure, stores facilities and procedures in the smithy
shop
Identify potential hazards, safety precautions and safe practices adopted in the smithy shop
Hand forging
Familiarize with the use of blacksmith tools (tongs, hammers, chisels, punches, flatters, fullers, groovers,
swages, swage blocks, anvils, cutters)
Familiarize with the preparation and operation of blacksmith’s hearth (forge)
Familiarize with different types of furnaces used for smithy work
Familiarize with material selection and working temperature ranges for specific metals and alloys
Familiarize with smithy operations (bend, twist, draw, spread, upset, punch, drift)
Soft Soldering
Study the types of joints which are typically soft soldered
Familiarize with different types of solder and forms in which they are available
Familiarize with different types of fluxes and their applications
09
Practice tinning of soldering iron
Practice soft soldering
Brazing
Familiarize with joint design features for brazing as against soldering
Familiarize with brazing alloy types, melting temperature ranges and fluxes
Familiarize with heating methods such as gas torches, furnace heating, induction heating etc.
Observe brazing simple joints and inspecting and testing for faults
07. Foundry
Orientation to Foundry
Understand the physical layout, organization structure, stores facilities and procedures in the foundry
Identify potential hazards, safety precautions and safe practices adopted in the foundry
Identify materials, machinery and tools required for foundry work and describe their applications
Casting methods
Familiarize with different casting methods available in the foundry (sand, gravity die, pressure die and
centrifugal castings, shell moulding, investment/loss wax process)
Familiarize with raw materials, tools, machinery and equipment used to make castings
Pattern making
Familiarize with method of transferring engineering drawings to pattern making drawings using the
contraction scale
Acquaint with the use of power and hand tools to make patterns.
Familiarize with different materials used for pattern making (wood, metal, plastic, plaster, wax)
Familiarize with making different types of patterns (solid, split and sweep patterns)
Familiarize with making core boxes
10
Sand moulds and cores
Familiarize with ingredients and preparation of sand moulds (green sand and dry sand moulds) and
cores
Familiarize with ingredients and preparation of surface coatings and their application on moulds and
cores
Familiarize with moulding boxes and moulding tools (rammers, trowels, gate knives, cleaners, vent
wires)
Familiarize with preparation of moulds and cores and practice making a mould and a core
Familiarize with location of gates, runners and risers
Observe pouring of molten metal into the sand mould
Observe removal and trimming of excess material
Gravity die casting
Identify different metal moulds designed for different applications
Observe assembly and clamping of the metal mould
Observe pouring of molten metal into the metal mould
Observe removal and trimming of excess material
Furnaces
Identify raw materials required for ferrous and non-ferrous foundry work
Familiarize with furnaces, crucibles and accessories required for melting non ferrous alloys
Familiarize with preparation and operation of cupola to melt cast iron
Defects in castings
Inspect castings for defects, dimensional errors and surface finish (flash, mould shift, porosity, sand
inclusions, gas inclusions, mis-runs)
11
08. Installation and Commissioning of Plant, Machinery and Equipment
Orientation
Identify site location, ground conditions, boundaries and layout of existing plant, equipment and
structures
Identify potential hazards, safety precautions and safe practices adopted in the work site
Familiarize with legal requirements
Identify accepted legal levels of plant waste, their effect on environment and pollution control
Familiarize with reading and interpretation of manufacturer’s installation and service instructions,
diagrams, specifications and other literature
Site preparation and installation
Familiarize with excavation, soil stabilization foundations and back filling
Familiarize with safe methods of handling, lifting, placing and erection of plant and machinery
Familiarize with methods of aligning, checking and fixing plant and machinery
Familiarize with supply of power and other ancillary equipment and services for the commissioning of
plant and machinery
Commissioning
Familiarize with lubricants and methods of lubrication
Familiarize with test checks, pilot runs, trial runs and methods of recording performance
Familiarize with measurements and methods of obtaining the readings
Familiarize with monitoring and adjusting the plant and equipment to achieve specified performance
Ancillary equipment
Familiarize with different types of pumps, valves, pipe fittings, connections, joints, packings and their
functions, working principles and testing methods
Familiarize with different type of gauges, safety alarms and defuses
12
Familiarize with drive belts, drive chains and clutches
Familiarize with different methods of cooling, type of coolants, heat exchangers and control valves
Familiarize with hydraulic systems, properties of hydraulic oil, test methods and test equipment
09. Maintenance and repair of Plant, Machinery and Equipment
Orientation
Understand the physical layout, organization structure, stores facilities and procedures in the plant
maintenance and repair division
Identify potential hazards, safety precautions and safe practices adopted in the plant maintenance and
repair division
Identify materials, machinery and tools required for plant maintenance work and describe their
applications
Read and interpret service manuals and parts catalogues
Maintenance and repairs
Acquire skills in using common hand tools (vices, hammers, spanners, sockets, wrenches, alignment
gauges)
Familiarize with correct usage and application of various types of lifting tackle and safe lifting capacities
Familiarize with scheduled and emergency shutdown procedures
Acquire skills in fault tracing procedures
Familiarize with dismantling, cleaning and examining of dismantled parts and components for re-use
Familiarize with different processes of reconditioning of worn parts and components
Familiarize with safety requirements if any prior to testing
Acquire skills in testing and reporting of test results after repair/reconditioning
Familiarize with re-checks after specified period of running time
13
10. Servicing of vehicles
Orientation to Service bay
Understand the physical layout, organization structure, stores facilities and procedures in the service
bay
Identify potential hazards, safety precautions and safe practices adopted in the service bay
Identify equipment and tools required for servicing of automobiles and describe their applications
Acquire skills in cleaning, maintaining and repairing service bay tools and equipment
Identify locations and uses of different type of lubricants and their dispensers
Maintain service bay records
Servicing of vehicles
Read and interpret service manuals
Observe positioning of vehicles on service pit, ramp and hydraulic lift
Familiarize with under carriage washing of vehicles
Familiarize with lubricating chassis according to lubricating chart
Familiarize with changing or topping up oil (engine, gear box, differential, steering, automatic
transmission, hydraulic brake, hydraulic clutch)
Inspect and top up battery, check specific gravity and clean battery terminals
Inspect and top up cooling system
Inspect tyres and inflate to specified pressure
Observe washing and cleaning vehicle body
Maintain vehicle customer records
11. Maintenance of vehicles
Orientation to vehicle maintenance
Understand the physical layout, organization structure, stores facilities and procedures in the
maintenance section
14
Identify potential hazards, safety precautions and safe practices adopted
Identify equipment and tools required for maintenance and repair of automobiles and describe their
applications
Acquire skills in cleaning, maintaining and repairing tools and equipment used in the maintenance
section
Starting and running faults
Acquire skills in testing and correcting faults in starting system
Acquire skills in testing and correcting faults in ignition system
Acquire skills in testing and correcting faults in generating system
Acquire skills in testing and correcting faults in fuel system
Acquire skills in testing and correcting faults in cooling system
Acquire skills in testing and correcting faults in lighting system
Road tests
Familiarize with testing brakes for uniformity and adjusting brakes
Familiarize with testing steering gear for wobbles or vibrations and taking corrective action
Familiarize with testing for suspension defects and undue noises
Familiarize with adjusting brake and clutch pedal free play
Wheels and Tyres
Familiarize with inspecting tyres for wear and faults
Familiarize with re-grooving, re building and vulcanizing of tyres and tubes
Familiarize with checking rims for distortion and repairing them
Familiarize with wheel balancing
15
12. Engine repairs
Orientation to engine repair shop
Understand the physical layout, organization structure, stores facilities and procedures in the engine
repair shop
Identify potential hazards, safety precautions and safe practices adopted in the engine repair shop.
Identify materials, machinery and tools required for engine repair work and describe their applications
Read and interpret engine and equipment manufacturers’ service manuals, parts catalogues,
specification tables, charts, diagrams etc.
Familiarize with maintaining engine repair shop records.
Overhaul petrol and diesel engines
Familiarize with washing and cleaning engines.
Familiarize with removing engine sub units (starter motor, generator, fuel injection pump, air
compressor, air conditioner pump, power steering pump, water pump)
Familiarize with removing engine parts (manifold, oil sump and pump, cylinder head, valve system
components, pistons and connecting rod assemblies, crankshaft, cam shaft, pulleys, vibration dampers,
timing case covers, flywheel, flywheel housing)
Overhaul cylinder head
Familiarize with checking the seating of valves on valve seats and grinding and lapping of valves on valve
seats.
Familiarize with cylinder head facing and pressure testing cylinder heads for cracks.
Familiarize with re-fitting cylinder heads and sequence of tightening cylinder head nuts.
Practice skills in adjusting tappet clearance.
Overhaul cylinder and piston assembly
Inspect pistons, piston rings and connecting rods for re-use.
Inspect cylinder block for cracks and cylinder wear,
Familiarize with replacing cylinder liners
16
Familiarize with re-boring cylinder blocks and honing
Familiarize with re-fitting piston assembly
Inspect crankshaft for alignment, cracks and wear
Obsrve crankshaft grinding
Familiarize with re-fitting engine
Familiarize with testing of fuel injection pumps and injectors
Familiarize with engine testing
17