2011

Workshop Practice
Design Principles Metal Plate Cutting, Filing & Drilling

Praneet Choudhury TP021883 6/14/2011

Table of Contents

Contents
Fitting Shop ............................................................................................................ 1 Fitting Shop or Bench Work ................................................................................ 1 Safety Precautions .............................................................................................. 1 Fitting tools ......................................................................................................... 2 Measuring:....................................................................................................... 2 Holding: ........................................................................................................... 2 Cutting: ............................................................................................................ 2 Striking:............................................................................................................ 2 Drilling: ............................................................................................................ 2 Threading: ....................................................................................................... 2 Marking: .......................................................................................................... 2 Fixing: .............................................................................................................. 2 Checking: ......................................................................................................... 2 Measuring Tools ................................................................................................. 3 Steel Rule ......................................................................................................... 3 Try Square ....................................................................................................... 3 Scriber ............................................................................................................. 3 Center Punch ................................................................................................... 4 Divider ............................................................................................................. 5 Holding Tools ...................................................................................................... 5 Bench Vice ....................................................................................................... 5 Cutting Tools ....................................................................................................... 6 File ................................................................................................................... 6 Types of Files ................................................................................................... 6 Hack Saw ......................................................................................................... 8

Table of Contents

Cold Chisel ....................................................................................................... 9 Striking Tools .................................................................................................... 10 Types of Hammer .......................................................................................... 10 Job ....................................................................................................................... 12 Cut 1 ................................................................................................................. 12 Cut 2 ................................................................................................................. 13 Cut 3 ................................................................................................................. 13 Cut 4 ................................................................................................................. 13 Cut 5 ................................................................................................................. 14 Conclusion ........................................................................................................... 14

Workshop Practice

Fitting Shop

Fitting Shop or Bench Work

The fitting and bench work plays an important role in engineering work shop. The work carried out at the fitting bench or bench vice is called bench work.

Safety Precautions
The following safety precautions should be taken when using hand tool and equipments. Precautions are most important for safety from accident. Keep proper discipline in the shop. Do not play with the tools because they are sharp All files should be fitted with suitable handle at the end of file. When using Hacksaw, check its teeth should be sharp and forward position. When using chisel its direction should be kept away from other working persons. When files are of forward cut, then only apply the force in forward stroke not in backward and vice versa. When using Hacksaw check its blade which must be fitted in pins properly. When using the micrometer and vernier caliper, must check its error. Clean up oil and grease or other liquid which spills on the flour otherwise they may be a cause of accident. Always wear the apron and closed shoes, not loose clothes. Do not wear any neck tie, jewelry, rings, watches during in the working in shops.
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Fitting tools
The tools used in fitting shop may be classified into following groups. Measuring: Steel Rule, Inside Caliper, Outside Caliper and Vernier Caliper Holding: All types of vices Cutting: Chisel, Hacksaw and Files Striking: All types of Hammers Drilling: Various types of Drills Threading: Tap and Dies Marking: Scriber, Divider and Center Punch Fixing: Spanner, Wrenches, Keys and Screw Driver Checking: All types of Gauges

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Workshop Practice
Measuring Tools
Steel Rule

It is a cliff straight steel strip having all faces machined true. One of flat face graduation mark and in inches and also in centimeters. It is used to set out dimensions.

Try Square

It consists of steel blade fixed at right angle to the edge of cast iron stock. It is used for checking of right angles, the squareness and surface and also draw line at right angle.

Scriber

It is made of steel and one end is sharp pointed and other end is similar but bent. This tool is used for scribing line on work piece.

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Center Punch

A punch is primarily a marking tool used in bench work and known as center punch, this tool is used for making center for turning on lathe machine as well as for centering of holes for drilling.

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Workshop Practice

Divider

It is used chiefly for spacing, scribing, circling and laying out work. Distance may be taken or transferred from the steel rule to the work piece.

Holding Tools

Bench Vice

The bench vice is very essential tool in every shop but commonly used in fitting shop. It is used for holding and attaching the work to the bench. It has two jaws, one is fixed and other is
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Workshop Practice
movable. Parts of the Vice are Cast Iron or Steel Body, Square Threaded Screw, Two Jaws & Nut Handle. It is used for holding the work such as metal sheet for drilling or fitting.

Cutting Tools
The cutting tools used in fitting shop are: File Hacksaw Cold Chisel
File

The file is a harden piece of high grade steel or high carbon steel with slating saws. It is used for cut smooth or fit metal parts. It is used to cut the metal expected harden steel and it is used in forward stroke. Types of Files Flat File It has double cut on both sides and single on both edges. It is mostly used for general work and filing flat surfaces. A large amount of metal can be removed with this file, and they don't produce smooth surfaces.

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Workshop Practice

Square File

It is double cut file on all sides, and used for enlarging square holes and filing of slats and key ways.
Triangular File

Its section is triangular and faces are double cut and edges are single cut. Its each side on 60 degrees. It is used for filing internal angles, shoulders or corners and for sharpening wood working saws.
Round File

Round file is also usually double cut. It is used for enlarging holes, slots, concave and for enlarging the holes.

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Half-Round File

It is one side is flat and other side is half round. The flat side is double cut and curved side is single cut. It is used for filing curved surfaces.
Hack Saw

The hack saw is chief cutting tool used for cutting rods, bars, pipes into desired length. It consist of metal frame the blades which fits over two pins. The wing nut of the frame is used for tensioning the blade. The blades are made of high carbon or high speed steel. The most useful blade for handwork is 30 cm long and 12-24 mm width (24 teeth).

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Cold Chisel

The cold chisel is an important cutting tool. These are used to cut the cold metal and made by forging process from tool steel. The length of chisel is 15 cm to 20 cm and taper part is from 5 cm to 8 cm. The edge should be hardened and tapered, but not quite straight. The most commonly used cutting angle is 60 degrees but can vary according to the type of the metals.

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Striking Tools
All types of hammers are called striking tools. It consists of head face, peen and a handle. Its

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head is made of plane carbon steel and have both end hardened and tapered. Its handle is made of wood.
Types of Hammer

Ball Peen Hammer

The ball peen hammers peen is like as a ball, therefore it is called ball peen hammer. It is used for riveting. Straight Peen Hammer

The straight peen hammer has a flat and tapered peen. It is used for striking or bending metal by hammering.
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Cross Peen Hammer

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The cross peen hammer is used hammering into shoulders or hammering inside curves for bending or stretching metals.

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Workshop Practice Job

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The job given is as shown below. An unpolished metal plate is provided and it has to be cut according to the given dimensions. The tools mentioned above are to be used in this process as described for each cutting.

Cut 1

Ruler and try square and scriber are used to mark off a square of dimensions 16x15mm. A cut is made using hacksaw and the hammer and chisel are used to break that square piece of metal away from the metal plate. Square file is then used on all edges to make it smooth and accurate dimensions. The 2mm step cut on the vertical sides is then achieved using the smaller edge of the square file.

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Cut 2

A square cut similar to cut 1 is made, but this time with dimensions 10x10mm, the hammer and chisel are used to break away the piece and small square file is used to smooth the edges and achieve necessary dimensional accuracy.

Cut 3

Ruler, try square and scriber are first used to mark a square a24x15mm.The divider is then used to scribe a semicircle of radius 12mm on top of this square. Vertical cuts are made till the edges of the radius of this circle. Not two but many cuts are made thru the inscribed figure to make it easy to break off the piece. The hammer and chisel are subsequently used to break off each small piece. The square file and round file are used for the straight and round edges respectively to achieve given dimensions and smoothness of finish.

Cut 4

Ruler, try square and scriber are first used to mark a square a30x10mm.The divider is then used to scribe a semicircle of radius 15mm on top of this square. Vertical cuts are made till the edges of the radius of this circle. Not two but many cuts are made thru the inscribed figure to make it easy to break off the piece. The hammer and chisel are subsequently used to break off each small piece. The square file and round file are used for the straight and round edges respectively to achieve given dimensions and smoothness of finish.

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Cut 5

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The holes are made by first marking off the centers of the circles using ruler and punch. The whole piece is then mounted on the drilling clamp and adjusted so that the drill bit is aligned accurately with the punch mark. Appropriate sized drill bit is then mounted on the drill and each hole is made using proper sized drill bits.

The whole metal plate was polished using sand paper to give a shiny appearance and remove oxide film on top.

Conclusion
Considerable knowledge was gained in the usage of workshop tools and instruments. The process of manufacturing a metal piece by hand with given dimensions was learnt and applied in practice. The process of suing a drill machine to drill holes of appropriate dimensions was also learned successfully.

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