Pancyprian Machine Elements T.S. (Practical) study plan

Read and reproduce the ISO 286 tolerance-grade table logic: calculate upper and lower deviations for a Ø40 H7/g6 fit without looking at a chart

Sketch, freehand and to scale, a three-view orthographic drawing of a stepped shaft with a keyway, applying correct line types and section hatching

Convert between limit dimensions, bilateral tolerances and geometric tolerance frames (straightness, cylindricity, perpendicularity) on the same shaft drawing

Set a vernier caliper and a micrometer to five given nominal-plus-tolerance values and record the readings in a log with the correct number of decimal places

Classify ten given fits as clearance, transition or interference by computing maximum and minimum clearance/interference

Explain and apply the 20 °C reference temperature, Abbe error and parallax rules when choosing between caliper, micrometer and dial gauge for a stated measurement

Calculate gauge block stack combinations for three target sizes using the minimum number of blocks

Identify surface roughness parameters Ra and Rz from a drawing callout and match them to a plausible machining process

Select a material and condition for four stated duties (gear, shaft, bearing housing, clamping lever) using a plain-carbon/alloy/stainless/cast-iron comparison table you build yourself

Explain the purpose and typical temperature range of annealing, normalising, hardening, tempering and case-hardening, and predict the property change for each

Describe the sequence and risks of induction hardening and nitriding on a shaft, including distortion and post-process finishing needs

Match five surface-finishing processes (grinding, honing, lapping, shot blasting, anodising, electroplating) to the duty and roughness they suit

Read a hardness value and state which scale (HB, HRC, HV) is appropriate and roughly how to convert between them

List the main parts and axes of a centre lathe and a vertical milling machine and state the function of each

Calculate spindle speed and feed rate from cutting speed, diameter and feed per tooth for turning, drilling and milling examples

Select the correct tool geometry and material (HSS vs carbide insert) for turning steel, aluminium and cast iron, and justify rake and clearance choices

Explain the causes and corrections of chatter, built-up edge and poor surface finish in turning and milling

Describe the safe setup sequence for holding a workpiece in a three-jaw chuck and in a machine vice, including dial-indicator alignment

Explain drilling, reaming, tapping, boring and countersinking and state which operation achieves which tolerance and finish class

Identify the correct extraction method for a broken tap, a seized bolt and a damaged thread insert, and describe each step

Describe the correct use of a torque wrench, a puller and a press for fitting and removing a bearing, and state what damage each wrong method causes

Explain fits and interference for press fits and how to compute the required interference for a given torque transmission

Describe alignment checks after reassembly: shaft runout, end float and gear backlash measurement

Classify bearings by load direction (deep groove, angular contact, cylindrical roller, tapered roller, thrust) and select one for three stated duties

Explain bearing designation suffixes (clearance class, shield/seal, cage) and decode three real designations

Compute bearing life L10 from dynamic load rating, applied load and speed, and state when to prefer grease over oil

Describe the correct mounting and dismounting of a bearing by induction heater, oil bath and press, including the maximum heating temperature

Select the right seal for a rotating shaft: lip seal orientation, radial preload, surface roughness and speed limits; explain labyrinth and O-ring alternatives

Explain lubrication regimes (boundary, mixed, hydrodynamic) and choose a lubricant grade and viscosity for a stated bearing and temperature

Explain the geometry and ratio of spur, helical and bevel gears and compute module, pitch diameter, centre distance and ratio for a given pair

Describe belt, chain and coupling types and state the alignment and tension checks each requires

Perform shaft alignment with a dial indicator or laser: explain the rim-and-face method, correct for sag and thermal growth, and interpret the result

Diagnose misalignment, unbalance, looseness and bearing wear from vibration and noise symptoms

Describe a preventive maintenance schedule for a geared motor: oil change interval, grease points, belt tension check and vibration trend

Apply lockout/tagout, machine guarding and safe hand-tool practice to a written task risk assessment for one machining job

Identify the personal protective equipment required for turning, grinding, welding and solvent handling, and state why each item is needed

Classify and segregate workshop waste (swarf, coolant, oily rags, batteries, aerosol cans) according to hazardous-waste rules

Explain first-angle vs third-angle projection and check a drawing for missing dimensions, wrong tolerances and unsafe or unmanufacturable callouts

Describe the elements of a simple quality control loop: incoming inspection, in-process check, final inspection and non-conformance handling