Benchwork to Handtools I PDF

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bench work to handtools...

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Workshop Theory and Practice Engr. Jay Pee A. Maalihan Engr. John M. Mame

INTRODUCTION TO WORKSHOP PRACTICE, SAFETY, CARE AND PRECAUTION IN WORKSHOP

Bench work is work carried out at a bench in a laboratory or workshop. It provides the basic working knowledge of the production and properties of different materials used in the industry. It also explains the use of different tools, equipment, machinery and techniques of manufacturing, which ultimately facilitate shaping of these materials into various usable forms.

PROCESSES 1. Primary shap shaping ing processes - Some of these finish the product to its usable form whereas others do not, and it requires further working to finish the component to the desired shape and size. 2. Machining process processes es - Large number of components need further processing after primary processes known as secondary operation to obtain desired shape and dimensional accuracy. 3. Joining processes - These processes are used for joining metal parts and in general fabrication work. 4. Surface finishing processes - These processes should not be misunderstood as metal removing processes in any case as they are primarily intended to provide a good surface finish or a decorative and/or protective coating on to the metal surface, although a very negligible amount of metal removal or addition may take place. 5. Processes effecting change in properties properties. - These processes are employed to impart certain specific properties to the metal parts to make them suitable for certain operations. Most physical properties like hardening, softening and grain refinement etc., call for a certain heat treatment.

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SAFETY AND ACCIDENT Accidents The common causes which lead to accidents are the following: 1. Unsafe working position. 2. Improper or defective tools or their improper use. 3. Improper acts- which result in violation of safety rules and non-observance of safety precautions.

General Safety in Bench Work 1. Good housekeeping means working tidily and orderly. 2. Always keep working areas unobstructed; when using a machine, keep an unobstructed space (2-2.5 m2) around the machine. 3. Also maintain floors, walkways, staircase and gangways, ensuring they are skid free (leak free) and clear obstructions. 4. Store materials in such a way that they cannot become tripping hazards. Immediately return all excess material to its proper storage place. 5. Put tools away when not in use. This prevents loss of tools and makes them available to others. 6. Place all scrap in scrap containers. 7. Stop work 10 minutes prior to the time you need to leave the shop. This will provide ample time to clean and replace tools to their homes. 8. KEEP THE SHOP CLEAN AT ALL TIMES TIMES. It is all our responsibility to keep the shop clean. There is no excuse for a cluttered or messy workspace. If your workspace is cluttered, then you are working too fast. Slow down. Know this: you will not anger someone if you clean up after them. In fact, they will likely do the same for you.

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The common methods of protection against accidents are the following: 1. 2. 3. 4. 5. 6.

Safety by position. Safety by construction. Safety by using interlock guards. Safety by using fixed guards. Safety by using automatic guards. Safety by using distance guards.

Care of Hand Tools 1. 2. 3. 4. 5.

Storing Hand Tools Cleaning Sharpening Lubrication Stick-To-Manual

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LAYING OUT AND LAY-OUT TOOLS

LAY-OUT TOOLS Scriber - is a layout tool that is used to produce these fine and accurate lines. The point is made of hardened steel and is kept chain by honing on an oilstone.

Figure 1. Scriber

Di Divider vider - when laying out circles, arcs, and radii, it is best to use the divider. The legs of the divider must be of the same length and be kept sharp. The divider cart be used to lay out and measure distances. Figure 2. Divider

Trammel - can be made to scribe larger distances with the use of extension rods. This layout tool is set in the same manner as the divider. Figure 3. Trammel

Hermaphrodite Caliper - is a tool used to layout lines that are parallel with the edges of the work piece.

Figure 4. Hermaphrodite Caliper

Surface Pl Plate ate - provides a true and smooth, plane surface. It is used in conjunction with surface and height gauges as a level base on which the gauges and the work piece are placed to obtain accurate measurements. Figure 5. Surface Plate

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Vernier Height G Gauge auge - is a caliper with a special foot block to adapt it for use on a surface plate.

Figure 6. Vernier Height Gauge

Surface Gauge - is used for many purposes but is most often used for layout work. The gauge can be used to scribe layout lines at any given distance parallel to the work surface.

Figure 7. Surface Gauge

Bevel Protractor - consists of an adjustable blade with a graduated dial.

Figure 8. Bevel Protractor

Combination Square Set - is used for a number of layout operations. The set consists of a blade (graduated ruler), square head, protractor, and center head. Parts: • • • •

Square Head Protractor Head Center Head Blade

Figure 9. Combination Square Set

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PROCEDURE IN LAYING-OUT 1.) Study the shop drawing or blueprint carefully before you cut off the stock. Allow enough material to square the ends if required. 2.) Remove all oil and grease from the work surface and apply layout dye.

3.) Locate and scribe a reference or base line. All the other measurements should be made from this. If the workpiece already has one true edge, it can be used in place of the reference line. Figure 10. Scribe the reference lines

4.) Using the base line as a reference line, locate and scribe all center lines for each circle, radius, or arc. Mark the points where the center lines intersect using a sharp prick punch.

Figure 11. Scribe center lines for all circular, arcs and radii

5.) Scribe all circles, radii, and arcs using the divider or trammel. Figure 12. Scribe in all circles, arcs and radii

6.) Using the correct type protractor , locate and scribe all straight and angular lines. Figure 13. Locate and scribe in all straight and rectangular lines

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7.) Scribe all lines for internal openings.

Figure 14. Connect all internal openings

8.) All layout lines should be clean, sharp, and fine. Reapply layout dye to all messy, wide, or incorrect lines and re-scribe. Figure 15. Completed Product

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HAMMER AND VISE

HAMMER Claw H ammer - most common type of hammer. The head is smooth for clean finishing work. The claw is curved, allowing the hammer to rock when removing nails. Claw hammers are best for: •

Woodworking

•

Prying

•

Finishing

Figure 16. Claw hammer

Framing H ammer - also called a Rip Hammer, it is a modified type of claw hammer. The claw is straight instead of curved. Framing Hammer are best for: •

Framing

•

Splitting

•

Small Demolition

Figure 17. Framing hammer

Ball Peen Hammer - was originally designed for peening that is, shaping metal materials by hammering. One end of the head is ball-shaped for this purpose. The other end is flat and is used for driving. Ball Peen are best for: •

Metalworking

•

Rounding edges

•

Punching and riveting

Figure 18. Ball peen hammer

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Dry Wal Walll Hammer - types of hammers are lightweight hammers with a rounded head on one end. This helps with preventing imperfections in the drywall. The other end is hatchet-shaped, for cutting boards. Dry Wall are best for: •

Hanging drywall

•

Drywall demolition

•

Plaster

Figure 19. Dry Wall hammer

Brick H ammer - is used in all kinds of masonry work. The chisel end is for clean breaking of brick and stone while the blunt end is also for breaking stone or concrete, though less neatly. Brick Hammer are best for: •

Bricklaying

•

Demolition of hard materials

•

General masonry

Figure 20. Brick hammer

Tack Hammer - are designed for driving small, delicate nails. These hammers may also be called upholstery hammers and were made for attaching fabrics to furniture. Tack Hammer are best for: •

Upholstery

•

Precision

•

Lightweight hammering

•

Setting tacks

Figure 21. Tack hammer

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Rubber Mal Mallet let - is a block on a handle, which is usually used for driving chisels. The head on a rubber mallet is made of rubber. These types of hammers deliver softer impact than hammers with metal heads. Figure 21. Rubber mallet

Sledgehammer - are a large hammer with a metal, mallet-like head. These types of hammers deliver a mighty blow, designed for breaking stone and demolition work. Sledgehammer are best for: •

Breaking stone

•

Driving stakes

•

Demolition

Figure 22. Sledgehammer

Dead Blow Hammer - is a type of mallet designed to strike surfaces with great force. They deliver a no-bounce hit—that is, they don’t rebound after striking. Dead Blow Hammer are best for: •

Automotive

•

Setting joints

•

Dent removal

Figure 23. Dead blow hammer

Welder's Hammer - is made of a barrel spring, which is designed to interrupt the flow of heat through the handle, keeping the welder’s hand safe from the high temperatures. Welder's Hammer are best for: •

Welding

•

Removing slag

•

Chipping

Figure 24. Welder's hammer

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VISE A vise, a common mechanical device that is used to hold a workpiece stationary, is an integral tool in many woodworking, metalworking, and other manufacturing applications.

Figure 25. Vise

Types of vise: Fixed - a vise with a fixed base attaches straight to the workbench as it supports stability. Figure 26. Fixed vise

Swivel - can be rotated so that the position of the vice can be altered to suit activities.

Figure 27. Swivel vise

Vacuum - this base work by holding onto the surface of a work piece by sucking.

Figure 28. Vacuum vise

Clamp - clamps or attaches a wide size range of metal materials due to its strength and ability to withstand pressure.

Figure 29. Clamp vise

Engineer Engineer’’s Vise - it is typically heavy-weighted with a thick metal body. It works by clamping large objects for security during projects.

Figure 30. Engineer's vise

Multipurpose Vise - it is equipped with integrated pipe jaws and a swivel base for holding a variety of objects/materials.

Figure 31. Multipurpose vise

Pipe Vise - is a type of vice that deals with holding a pipe or tube securely so that it can be cut or threaded

Figure 32. Pipe vise

Chain Pipe Vise - style is made with a high-tensile steel chain that tends to attach a work piece by fastening it to the bench to provide a secured activity. It typically holds loops over irregularly shaped objects.

Figure 33. Chain pipe vise

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Hinged/Yoked Pipe Vise - tends to hold onto pipes between a pair of V-shaped jaws having a fixed bottom and movable top parts. The vise has a hardened steel physical property for clamping properly.

Figure 34. Yoked pipe vise

Handheld Vise - tends to undergo fastening onto a bench vice in order to hold objects locked down. Relatively, it operates much lighter on work pieces compared to many other vises.

Figure 35. Handheld vise

Mini Hand Vise - it is like a smaller version of the hand vise. Due to its design, it is deemed ideal for performing smaller holding tasks.

Figure 36. Mini hand vise

Rotary Vise - has the ability to rotate around the same axis with that of the hook’s shank. This feature allows its user to tie down material and rotate the hook to apply the work piece.

Figure 37. Rotary vise

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SCREWDRIVERS, PLIERS AND WRENCHES

SCREWDRIVER Slotted Screwdriver - used to drive or fasten negative slotted screws

Figure 38. Slotted screwdriver

Phillips Screwdriver - used to drive or fasten positive slotted crews. it is a screwdriver that could take greater torque and could provide tighter fastening.

Figure 39. Phillips screwdriver

Jeweler's Screwd Screwdriver river Set - is a set of small screw drivers composed of slotted and Philipps screwdrivers.

Figure 10. Jeweler's set

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PLIERS Slip Joint Pliers - these types of pliers feature an adjustable pivot point that allows the two pieces of the plier to shift, extending the range of the jaws. Slip joint pliers can grip materials of varying thickness Best use in: • • • •

Bending and holding Crimping metal Looping wire Cutting wire and soft nails

Figure 11. Slip joint pliers

ToungeTounge-and-groove and-groove pliers - tongue-and-groove pliers operate on the same principles as the slip joints so much so that they’re probably actually a subset of that category rather than an entirely separate one.

Figure 12. Tounge-and-groove pliers

Locking Pliers - work well for clamping down on things, especially during those times when having both hands free is helpful. Figure 13. Locking pliers

Linesman’s pliers - aka electrician’s pliers, side cutting pliers, or Kleins – hinge at a set pivot point. The jaws have the flat front with shallow serrations for gripping flat objects, and which also allow electricians to twist wires together.

Figure 14. Lineman's pliers

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Cutting Pliers - are a staple in electrical tool bags. The cutting knives extend to the tips and give you the ability to accurately snip wires that are in a crowded gang box or even cut small nails and screws.

Wire Strippers - it will usually include wire cutting blades to cut the same wire gauges as the strippers’ holes cover along with a crimping tip.

Figure 16. Wire strippers

Needle Nose Pliers - will have a longer jaw that tapers down to a point. These types of pliers work well for more delicate tasks or jobs that need to be done in smaller spaces. Bending wires, holding fittings, placing fasteners, and even cutting, needle nose pliers do a lot of work that a more heavy-duty plier might not excel at.

Figure 17. Needle nose pliers

Fencing Pliers - the hammer shape really is for hammering staples into wooden fencing. Moving across to the top, you can grab a staple with the pincers at the top to remove it in case it’s easier than getting the spike on the opposite side to do the job. Figure 18. Fencing pliers

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WRENCHES Adjustable Wrench - it is a wrench similar to an open end wrench but having one fixed jaw and one adjustable jaw Adjustable Wrench are used for: •

Tighten/loosen nuts and bolts

•

Moveable lower jaw to adjust wrench size

•

Works with both standards and metric fasteners.

Figure 19. Adjustable wrench

Combination Wren Wrench ch - a wrench with one open end and one socket end Combination Wrench are used for: •

Tighten/loosen nuts and bolts

•

Metric and standard sizes

•

One open end and one box end (usually the same size)

Figure 20. Combination wrench

Open-End Wren Wrench ch - a wrench with jaws having fixed width of opening at one or both ends of the handle

Figure 21. Open-end wrench

Ratchet/Socket W Wrench rench - is a type of wrenches that has rachet on one side or even both side that you can apply a nut or bolt and tighten and loosen without the traditional wrench slip that may occur.

Figure 22. Ratchet wrench

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Online References References:: http://ecoursesonline.iasri.res.in/mod/page/view.php?id=98829 https://www.toolingu.com/class/280130/benchwork-and-layout-operations-241 https://www.charlottestories.com/how-to-care-for-hand-tools/ https://smithy.com/machining-handbook/chapter-1/page/3 https://www.toolingu.com/class/280130/benchwork-and-layout-operations-241 http://lwtcmachining.pbworks.com/w/page/39631225/Benchwork%20Operations http://uhv.cheme.cmu.edu/procedures/machining/ch1.pdf https://www.slideshare.net/futuremanagers/mechanical-technology-grade-12-chapter-3safety-in-theworkshop?fbclid=IwAR2gddYfIKyKudXCYRLlIlliqi0aBlNhe1gSYX33Bkthxo17WEkBj 0nU3to https://apps.carleton.edu/machinesafety/rules/ https://www.safetyandhealthmagazine.com/articles/15187-bench-visesafety#:~:text=Bench%20vise%20safety%20tips&text=Cover%20your%20face%20and%20 eyes,long%20pieces%20away%20from%20interfering https://smithy.com/machining-handbook/chapter-1/page/3 https://www.wisconline.com/LearningContent/mtl3002/layoutPced.htm#:~:text=Laying%20out%20is%20 the%20planning,worker%20in%20completing%20the%20job https://www.slideshare.net/ramiltuason/basichandtools-140619222426phpapp01 https://www.protoolreviews.com/buying-guides/buying-pliers/3904/ https://www.lowes.com/n/buying-guide/wrench-buying-guide https://www.thomasnet.com/articles/machinery-tools-supplies/vises-guide/#register https://www.youtube.com/watch?v=eRfTZpEmnys https://prezi.com/tk4mhbmr6zow/hand-tools-presentation/ https://prezi.com/luqsckxtdjhk/hand-tools/ https://drillly.com/different-types-of-vise/ 19...