Workshop Practice

N.A.Kapuruge
(11144)
PH 3033 Electronics Laboratory

May 26, 2014

Contents
Contents i

List of Figures ii

List of Tables ii

1 Introduction 1

2 Tools and machineries 2

2.1 Try square . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Power hacksaw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.3 Hacksaw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.4 Center punch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.5 Bench drilling machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.6 Bench vice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.7 Arc welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.8 Gas welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.9 Grinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.10 Lathe machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.11 Die nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.12 Tap tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.13 Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.14 Vertical milling machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3 Methodology 13

4 Results and analysis 16

5 Discussion 18
5.1 Industrial Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

6 Conclusion 23

References 24

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List of Figures
1 The parts of the coconut scrapper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 The Try square . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 The Power hacksaw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4 The Hacksaw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5 The Center punch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
6 The Bench drilling machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
7 The types of drilling tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
8 The Bench vice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
9 The Arc welding machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
10 The arc welding process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
11 The gas welding setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
12 The Grinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
13 The basic parts of a Lathe machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
14 The wood lathe machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
15 The vernier scale of tool post of the lathe machine . . . . . . . . . . . . . . . . . . . . . . . . 9
16 The list of some ISO 262 standard sizes of thread dimensions (Wikipedia, 2014d) . . . . . . . 10
17 The Die nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
18 The Tap tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
19 The file tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
20 The vertical milling machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
21 The clamp part of the coconut scrapper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
22 Cut from bending edges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
23 Dimensions of the flat metal bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
24 Bent edges looks like before welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
25 The dimensions of the cross section of axle base is to be made . . . . . . . . . . . . . . . . . . 14
26 The shape of the hub shell after ground it . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
27 A part of the clamp of the coconut scrapper . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
28 The axle base of the coconut scrapper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
29 The bolt of the coconut scraper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
30 The wood handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
31 The final product of the workshop practice . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
32 Some types of rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
33 The safety wears used for the workshop practice . . . . . . . . . . . . . . . . . . . . . . . . . 22
34 The welding hand shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
35 Some of safety symbols should be displayed in the workshop . . . . . . . . . . . . . . . . . . . 23

List of Tables
1 Some British standard thread dimensions (Wikipedia, 2014a) . . . . . . . . . . . . . . . . . . 9

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1 Introduction
In the workshop practice the task is to make a coconut scraper. The coconut scraper is the final product of
this workshop practice. But there are some other main goals are to be obtain in this workshop practice.

In this workshop practice some machinery and tools in the workshop were used. And also safety guide
lines during working with the machinery and workshop environment were followed.

Workshop practice is important to get a basic knowledge of working with mechanical machinery and improve
hand skills. We were able to do some mechanical works by using tools and machinery by our self. So the
workshop practice improved both theoretical side and practical side. And also it was learn some basic safety
and health guide lines while working in a practical working environment.

The basic parts of the coconut scraper (see Figure 1) is to be made in the workshop.

Figure 1: The parts of the coconut scrapper

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2 Tools and machineries
2.1 Try square

Figure 2: The Try square

A try square is a woodworking or a metal working tool used to measure length or mainly used to check
the straightness of a surface to an adjoining surface by right angle(90 degrees). In workshop practice the
try square was used to check right angle bends in Figure 21 and used the length scale of the try square to
measure some lengths and to draw straight lines for marking points.

2.2 Power hacksaw

Figure 3: The Power hacksaw

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The power hacksaw is a machine which is used in cutting metals automatically by using an electrical motor.
The cutting blade is made by high speed steel. After clamped the metal bar to correct length and start the
machine, it automatically switched off after finishing the cutting. It is cut with a small angle.

2.3 Hacksaw

Figure 4: The Hacksaw

The hacksaw is a hand saw having high speed steel tooth blade is attached to a frame. It is used to cut mild
steels and some other materials which has lower strength than the blade.

2.4 Center punch

Figure 5: The Center punch

It is not easy to get the drill point on a metal using a drilling machine. Therefore it is recommended to
mark a drill point on the metal before drilling by the drilling machine. The center punch is used to do that.
The center punch is placed on the marked point and was hit by a hammer. Then a point with little depth
is created. The center punch is made from mild steel and they are in various point sizes.

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2.5 Bench drilling machine

Figure 6: The Bench drilling machine

The drilling machine is used to cut holes on metals or other materials having lower strength than the drilling
tool. There are various types of drilling tools made from high speed steel in various diameters (see Figure 7).
The rpm of the chuck can be controlled by changing the belt which is placed on the upper of the machine
to different pulleys. The hond feed is used to move the spindle vertically.

Figure 7: The types of drilling tools

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2.6 Bench vice

Figure 8: The Bench vice

The vice is used to hold or clamp the work piece material to do some work on the work piece. There is a fixed
jaw and a parallel moving jaw in the vice to hold the piece. Rotate clockwise to fix and rotate anticlockwise
to release.

2.7 Arc welding

Figure 9: The Arc welding machine

Arc welding uses a welding power supply to create an electric arc between an electrode and the base material
to melt the metals at the welding point. Commonly constant voltage and constant current power supplies
were used to generate the electric arc. The welding rod is made from mild steel. It has a flux coating and it
is clean the surface of the welding point and protect the weld area from atmospheric gases.
As in Figure 10 the ground is connect to the base material. When welding rod is brought near the welding
point is about 5 mm and arc is generated, then drag the welding rod slowly along the welding path to weld.

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 Figure 10: The arc welding process

2.8 Gas welding

Figure 11: The gas welding setup

In gas welding used a flame which generated from oxyacetylene gas. To produce oxyacetylene mix acetylene
(C2 H2 ) and oxygen (O2 ). A common propane/air flame burns at about 2000 ◦ C (3630 ◦ F), a propane/oxygen
flame burns at about 2500 ◦ C (4530 ◦ F), and an acetylene/oxygen flame burns at about 3500 ◦ C (6330 ◦ F)
(Wikipedia, 2014c). It can meltes steels at that temperature. It can controls the temperature of the flame.

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For welding purposes the welding point is heated using the flame and apply a brass welding rod to weld with
the metal.

2.9 Grinder

Figure 12: The Grinder

The grinding machine has two grinding wheels, one is used to grind hard materials and other one is used
to grind soft materials. These grinding wheels are made from high carbon steel. Therefore even high speed
steel can grind.

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2.10 Lathe machine

Figure 13: The basic parts of a Lathe machine

Figure 14: The wood lathe machine

The lathe machine is very useful to make bolts and grind metal bars to a given diameter with a given angle.
Using the lathe cylindrical components can be made. Work piece is held by using the chuck and rotated
around a horizontal axis while size and shape by the cutting tool. The wood lathe machine is used to made

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cylindrical shapes in wood pieces. A different type of chuck is used.
When the clutch gear is turned up then the chuck is started to rotate in anticlockwise and when clutch
gear is turned down chuck is started to rotate in clockwise. It can be change the rpm of the chuck using
spindle speed selector. There are two standard for threading, one is mostly common used ISO standard (see
table in Figure 16) and the other one is British standard (see Table 1). The British standard is defined for
number of threads in 1 inch and the ISO standard is defined for the distance of between two threads called
pitch. There is a information chart on the lathe machine, which shows how to set relevant gear leavers for
standard sizes. The tailstock is used to hold the work piece in horizontal while rotating. When set to thread
mode it can not be operate manually.
There is a vernier scale (Figure 15) which has a minimum reading of ∅0.05 to move the tool post. For
each one part of ∅0.05 in scale, a 0.05 mm is reduce in diameter of the work piece. It can be rotate the
compound rest horizontally in degrees to move the tool post in angular position.

Figure 15: The vernier scale of tool post of the lathe machine

Table 1: Some British standard thread dimensions (Wikipedia, 2014a)

fractional inches decimal inches thread per inch

3/16 0.19 32tpi
7/32 0.22 28tpi
1/4 0.25 26tpi
5/16 0.31 22tpi
3/8 0.375 20tpi
7/16 0.44 18tpi
1/2 0.50 16tpi
9/16 0.56 16tpi
5/8 0.63 14tpi
11/16 0.69 14tpi
3/4 0.75 12tpi
7/8 0.88 11tpi
1” 1.00 10tpi

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 Figure 16: The list of some ISO 262 standard sizes of thread dimensions (Wikipedia, 2014d)

2.11 Die nut

Figure 17: The Die nut

The die nut is used to create screw threads. The male portion is cut by the die nut. They are available in
different standard thread sizes. The die nut holder is used to rotate the die nut. It must be cut the tread
using a lathe machine before cutting using the die nut.

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2.12 Tap tool

Figure 18: The Tap tool

The tap tool is used to cut the female portion of screw tread. It can be rotate using the tap holder. There
are available different tap sizes for the standard tread sizes. Before taping, drill a hole having diameter in
nut diameter−depth of the tread using a drilling machine. Otherwise can not make correct taping. It is need
to taping through out the thread area of the tap.

2.13 Files

Figure 19: The file tools

A file is a metalworking tool used to cut fine amounts of material from a work piece. It is also used with
lathe machines to get some shapes. Mostly used it as a hand tool. There is a wood or hard rubber grip to
hold the tool. They are in different sizes and different shapes to easy of the fine materials in different shapes.

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2.14 Vertical milling machine

Figure 20: The vertical milling machine

Milling machines were first invented and developed by Eli Whitney (ARMY, 1998). In today there are
computerized machines have been developed to avoid errors and provide better quality in the finished product.
The milling machine removes metal with a revolving cutting tool. It can be used, milling machines for boring,
slotting, circular milling dividing, and drilling. In vertical milling machine it can be move the spindle in
vertical. There are also available horizontal milling machines which moves the spindle in horizontally. The
milling machines are very useful than the bench drill machine, because there are more clamps on the milling
machine to fixed the work piece. It can be clamped rigidly to the column in a position where the milling
point and the milling machine spindle are properly adjusted vertically for operation. There are also vernier
scales in both horizontal transverse and vertical transverse to get a proper size product.

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3 Methodology
1. First, some basic metal parts were cut using mild steel. A 8.5 inch×2 inch×6 mm flat mild steel bar,
20 mm diameter 6 inch mild steel bar, 4 inch×12 mm×6 mm flat metal bar, 25 mm×25 mm×6 mm flat
metal piece and 10 mm diameter 6 inch bar were cut by using the power hacksaw and the hacksaw.

2. First the clamp part was made, see in Figure 21 by using the 8.5 inch flat bar. Marked 2.5 inch and
2.0 inch lengths from two end of the flat bar. It is needed to set the axle holder at the end of the
2.5 inch side and bolt is going through the center of the 2.0 inch side. To do this, marked the center
points of the holes by using a center punch as in 23.

3. The two holes were drilled, 8.5 mm and 13 mm in diameter by using the bench drilling machine.

4. For easy to bend the flat metal bar, cut from the 2.5 inch and 2.0 inch marked places to 3/4 in thickens
as in Figure 22. After that held the flat metal bar using a bench vice and bent by hitting a hammer
to get the shape in Figure 21. Then bent edges looks like in Figure 24.

Figure 21: Dimensions of the clamp part is to be made of the coconut scrapper.

Figure 22: Cut from bending edges in 3/4 of thickness to bend easily.

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 Figure 23: Dimensions of the flat metal bar with marking center points of the holes

Figure 24: Bent edges looks like before welding

5. To get a strength piece, bent edges were welded by using arc welding. And to get a finished surface
the grinder was used.

6. After that the axle base was made by the 20 mm diameter 6 inch mild steel bar. First mark the center
axis of a one side of steel bar using the tail stock (Figure 13) of the lathe machine. After that got a
smooth surface by eliminate corrosive using the lathe machine. After that made the steel rod to the
shape in Figure 25 with one side having 18 mm diameter and the thin side having 15 mm diameter
and the angle shape in 2◦ by using the lathe machine. The half curve shape is got drilling a 13 mm
diameter hole using the vertical milling machine and cutting unnecessary parts.

Figure 25: The dimensions of the cross section of axle base is to be made

7. The bolt was made by the 10 mm diameter steel bar using the lathe machine. First set the lathe

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 machine to tread mode with 1.5 mm pitch and made the tread on the 10 mm diameter steel bar to the
depth of 1.5 mm. After that got a finished tread by using the 1.5 mm die nut.

8. Cut the female portion with a 1.5 mm pitch through the 8.5 mm diameter hole of the clamp part using
the 1.5 mm thread tap.

9. To make the handle, first cut a 4 inch×2 inch×2 inch wood piece and using the wood lathe machine
ground it until it can get a cylindrical shape about 20 mm diameter. Used a file (Figure 19) as the tool
and handle it by hand to get some round shapes. To get a smooth surface applied a sand paper on
the surface and to get a finished wood handle applied wax on the surface and polished using a bundle
of ropes. For attaching the handle a 6 mm hole is drilled along the center axis of the wood handle by
using the lathe machine and the drilling machine.

10. To make the arm of the handle, drilled a 8 mm hole in one end and 4.5 mm hole in the other end on the
4 inch×12 mm×6 mm flat metal bar. Drilled a little bit on the 4.5 mm hole about depth in 2 mm using
8 mm drill bit for riveting. A nail was dipped through the center of the wooden handle and through
the small size hole of the handle arm metal piece and riveted the nail to the handle arm by hitting on
top of the nail using a ball-peen hammer until it get a round head.

11. For rotating the bolt, drilled a 6 mm hole on the flat surface part of the bolt and dipped a 5 mm
diameter 2 inch metal bar and riveted both end by hitting on end of the metal bar using a ball-peen
hammer until it get a round head. Using the lathe machine a little length about 8 mm at the end of
the screw thread is ground about to 4.5 mm to rivet it to the wood handle.

12. Drilled a 8 mm hole on the center of the 25 mm×25 mm×6 mm flat metal piece. and one side is drilled
a little bit using the 10 mm drill bit for riveting it to the bolt. Dipped the bolt to the axle base and
dipped square metal piece to the top of the bolt and riveted it by placing a metal ball on the top of
the bolt and hitting on it.

13. Bought a standard size bicycle hub and detach all the nuts, balls and the axle from the hub. Ground the
unnecessary parts of the hub shell using the grinder and got a finished shape using the lathe machine
until it got a shape in figure 26.

14. Welded the hub shell on to the axle base by using gas welding with a brass welding rod.

15. Attached the handle to a end of the axle using the nuts and attached the axle to the hub shell by
replacing balls and nuts.

Figure 26: The shape of the hub shell after ground it

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4 Results and analysis

Figure 27: A part of the clamp of the coconut scrapper

In figure 27,
The width of the steel piece = 19.02 ± 0.02 mm
Diameter of the upper hole = 13.06 ± 0.02 mm
The thickness = 5.80 ± 0.02 mm

Figure 28: The axle base of the coconut scrapper

The axle base should be fixed to the upper hole in the figure 27. In figure 28, x = 5.50 ± 0.02 mm and
d = 13.00 ± 0.02 mm.
The difference between the thickness of the clamp part in figure 27 and the x dimension of the figure 28
is 0.30 ± 0.03 mm.

Figure 29: The bolt of the coconut scraper

The x dimension in figure 29 is 20.3 ± 0.02 mm and the d is 10.00 ± 0.02 mm.

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 Figure 30: The wood handle

The length of the wood piece in figure 30 is 3.81 ± 0.03 inch and the diameter of the nail is 5.04 ± 0.02 mm.

Figure 31: The final product of the workshop practice

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5 Discussion
Carbon steel is steel in which the main material is carbon in the range of 0.12–2.0% (Wikipedia, 2014b).
As the carbon percentage content rises, steel has the ability to become harder and stronger. Mild steel is
also called plain carbon steel which contains 0.05–0.3% low carbon percentage. Mild steels are relatively low
strength but it is cheaper and easy to handle. A low carbon steel can be cut by using a high carbon steel.
In this workshop practice mild steel were used to make metal parts. Because it is easy to handle to make
parts of the coconut scraper. High speed steel tools are used to cut mild steel. If some one want to repair
a steel material like hoe blades having high carbon percentage , it is needed to convert it to low carbon
steel by heating and allow to cool slowly. Otherwise any one can not cut by even high speed steel tool.
After repairing using high speed steel tools, again heated and sink in water. Then it becomes again higher
strength.
It is recommended to grind all the cutting edges of the flat steel bars. Because it can damage the worker
if it falls on. When it grinds the cutting edges, they become round shape. Therefore it cause a lower damage
if an accident occurred. It can be grind smoothly by using fine grinding wheel (see Figure 12).
When cutting using power hacksaw, the material should be fixed correctly to the jaws. If it is loose the
high speed blade may be damaged. And also power hacksaw is used to cut bending edges like in Figure 22.
The machine must be off manually when reaches the necessary depth. Otherwise it may cut the whole part.
Since power hacksaw cutting with a some angle, it can be cut from both edges to get a horizontal depth.
The power hacksaw is not suitable for cutting metal bars having smaller diameter or width. Because it may
be slight the material due to blade and may be damaged both material and the blade. It is very easy to cut
using power hacksaw than the hand hacksaw. When cut using hand hacksaw it is recommended to drag the
hacksaw as cutting using the whole blade. Otherwise it may be decay some part of the blade and it can not
be used a long time. In most of the machineries, the power on switch is in black colour and the power off
switched in red color. Because if an accident occurred it can be seen easily a red colour switch to stop the
machine.
To mark the cutting markers on the flat metal bars, first roughly get the length and draw around point
using a chalk. Again get the marker point using a nail to the correct length and using the try square draw
the cutting line. It can be draw a perpendicular line by doing that way.
It is needed to hit using a hammer on the steel parts to bend. If directly hit on the surface then the
surface gets damaged. Therefore it is recommended to use a piece of wood and place it on the surface and
hit on to the wood piece.
When trying to drill a hole it is recommended to mark the drill point using a center punch. If trying to
drill without mark the point using center punch, then it is very difficult to drill through the correct point.
When it marked it can be align the drilling tool and the center punched point easily. When drilling a 13 mm
hole, it is not suitable to start drilling using 13 mm drilling tool. In this workshop practice, drilled a 8.5 mm
hole before drilling 13 mm hole. It is recommended to drill large holes by starting a small size drilling tool
and drilling number of times using different size of drilling tools. It is called pilot drill fit. While drilling it
is needed to do some force on hond feed (Figure 6) to move the tool post (Figure 6) in vertical. It should be
slowly move the tool post while drilling. If do a strong force while drilling it may be damaged the drilling
tool. Cylindrical shape metal parts and small metal parts were drilled by using the milling machine. Because
there are clamps to hold the work piece in milling machine. It should be applied water while drilling.
When welding the bent edges using arc welding, first weld the two end points of a bent edge. It is called,
make tagging. Then it is fixed to fill the other space using arc welding. It is needed to be move the welding

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rod slowly to weld sharply. It is clearly display through the hand shield while arc is generated, metal near
the arc is melted, end point of welding rod is melted and joining them together. After welding put the metal
piece in to water. If the welding rod hold on more time in that place, then the joining metal part is again
melted. A more practice of welding is needed to get a better welding output. In arc welding, the voltage is
related to the length of the arc and the current is related to the amount of heat input. In manual welding the
arc length is fluctuate. Therefore voltage is fluctuate. Therefore it is recommended to use constant current
power supply for manual arc welding process.
When using the lathe machine chosen a low rpm value or moved the tool post (Figure 13) fast, then there
is some ground lines on the metal bar. If used a high rpm, then got a smooth ground shape even moving
manually. The rpm and the moving speed of the tool post of the lathe machine are affect to the smoothness
of the ground surface. If grind length is long it is recommended to fixed the end side of the material by using
the tailstock (Figure 13). Otherwise it is not rotate about it horizontal axis. If want to grind out some larger
amount even 3 mm, it is recommended to grind several times by 1 mm by 1 mm. Otherwise it is not grind by
a larger size. The vernier scale (Figure 15) is very useful to make diameter with a ±0.025 mm uncertainty. A
0.05 mm is reduced from outer diameter of the metal bar for each ∅0.05 scale part in the vernier scale. That
means the tool post (Figure 13) is move 0.025 mm for each minimum parts of the vernier scale. There is
play of the cross feed hand wheel (Figure 13). If some small vernier parts are pass the correct vernier point,
it is not correct if passed vernier points are get back to the correct point by by rotating reverse little bit. At
that movement the tool post doesn’t move due to the play of the cross feed hand wheel. To avoid that kind
of error, reverse the vernier scale by some large parts and again rotate to the correct point. It is sense to
the hand while rotating the cross feed hand wheel, if there is a play then it is loosely rotate and when it is
move for vernier parts it is some tough to rotate. When some number of materials are to be grind to a same
diameter, it can be adjust the 0 in vernier scale after the first correct grind and grind other materials until
vernier reaches the 0 value. Otherwise it wants to measure diameter of all parts using a vernier calliper.
When making threads on the steel bar any one can not move the saddle manually. It is move automatically
for take the pitch size correctly. To get back to the start point reverse clutch is used. Because even in the
thread mode it is not suitable for get the depth of a pitch in first time.
It can not be get a finished bolt only using the lathe machine. It must be used a relevant die nut to make
a standard thread size bolt. When applying the die nut on the bolt it is very difficult to rotate continuously.
It can be done rotate the die nut forward one cycle and rotate in backward half of cycle. Because when
rotating backward it removes irregularities again. And also by applying oil on between bolt and die nut it
is easy to rotate. It must be rotate carefully, otherwise it may be damaged the threads. Since the correct
diameter of a tap tool is on the upper part of the tool, it should be tapping a hole through out the tool.
It is very easy to polish the wood handle with sand paper and wax while the handle is attached to the
wood lathe machine and turning. But it is not a safety method, because it may be damaged to the hand.
And also when using files with the wood lathe machine, the file should be tightened to the template (Figure
14).
In this workshop practice two types of riveting methods are used. One is got a round head shape at the
end of a steel bar by hitting using ball hammer. It should be used only a ball hammer to get the proper
shape. In other method, placed a metal ball and hold it using a metal bar and hit on to the metal bar by
using a hammer. Then due to the curve shape of the metal ball, the end of the metal bar get a counter sunk
(see in Figure 32) head shape.

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 Figure 32: Some types of rivets

Used a standard size bicycle hub for axle of the coconut scrapper. Because scrappers are made to fit with
the size of the standard bicycle hub axle. It can not be used arc welding to weld the hub shell on to the
axle base. Since hub shell is made from thin steel, if used arc welding then hub shell is melted and damaged.
Therefore used gas welding to weld the hub shell on to the axle base. In gas welding process produced the
high temperature flame using acetylene (C2 H2 ) and oxygen (O2 ) gases.

2C2 H2 (g) + 5O2 (g) =⇒ 4CO2 (g) + 2H2 O(g) + HEAT

Since the temperature of the flame is about 3500 ◦ C the steel piece can be melted. Therefore drooped the
temperature and heated until the steel piece becomes red colour at the flame without melting. When ap-
plied a brass rod to that point then the brass is melted and touched the steel piece. Because the melting
temperature of brass is about 900 ◦ C and melting temperature of carbon steel is about 1500 ◦ C. Therefore
it should be held a temperature about 900 ◦ C–1500 ◦ C at the welding point for welding carbon steel with
brass. It is need to inflame using some fire to start the flame. As in arc welding it is not need to see the
flame using a hand shield. After welded it should be cool down without putting in to water.

The final product of the workshop practice can be seen in figure 31. It can be paint the product to
protect from corrosions and can be fixed a scrapper blade to use for coconut scrapping.
The staff members of the workshop (Technicians, 2013) were guide us how to make the coconut scrapper
and they taught to us how to use various type machineries in the workshop.

It may be get tired the user of the coconut scrapper since it should be operate by using hand. It can be
further developed the rotation of the scrapper by using a electrical motor. And also it can be developed to
hold the coconut shell itself instead of holding by user’s hand.

5.1 Industrial Safety

The safety is a most important part in workshop practice. There are various types of machineries and tools
in the workshop. We must be careful about our safety and health when operating those machineries and
tools. We used safety wears in figure 33 in this workshop practice. The overall, safety boots and gloves
are wore through out the workshop time and the goggles and the ear protection are wore when they are
necessary.
The goggles are used for eye protection. Since it covers the eyes any equipment hit on the goggles by
avoiding hit on the eye. In this workshop practice goggles are used to protect eyes from sparks when throw
away while using the grinder.

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 But do not used goggles while arc welding to see the welding point. It must be used a hand shield (Figure
34) while arc welding to see the welding point. It may be damaged to eardrum by large sounds and hearing
a long time to a some large sound. Ear protectors are used to protect ears from large sounds. When ear
protectors are wore a lot of amount of sounds are reduced hitting on the eardrum.
In this workshop practice Safety gloves are used to safe the hand by heating and scratching. While
grinding steels, the piece of steel is get heated. Safety gloves were useful to touch metal piece for that kind
of works and at the arc welding it is saved hand by melted steels.
The overall is a suit which can be covered the whole body. Due to long sleeves of the overall it is saved
the hand by falling sparks on to the hand while arc welding. But while using machines having rotational
wheels like lathe, bench drilling and grinding machines, the sleeves of the overall are rolled above elbow.
Because if a part of the clothes is touched with the rotational wheel it tries to rotate with the clothes. It
is more dangerous, because the clothes is around the body and it tries to rotate with the body on to the
machine. In that kind of case gloves are not very dangerous. Because if a glove is touched and rotate with
the wheel, then it is wear out from the hand.
The safety boots are made from hard leather. Therefore it protects the legs by falling some materials or
tools on to the foot of the leg.

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 (a) Safety goggle (c) Safety gloves
(b) Ear protector

(e) Safety boots

(d) Overall

Figure 33: The safety wears used for the workshop practice

Figure 34: The welding hand shield

There are some other safety guides are used in this workshop practice.

• In arc welding process

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 In arc welding process it should be more careful about the safety. Because the generated arc is very
harmful to human eyes and the temperature at welding point is in temperature of melting steel. On
the welding hand shield (Figure 34) there is a filtered screen on it. Any one can not see any thing
through the hand shield screen if there is no arc. When ark is generated it is clearly displayed through
the filtered screen of the hand shield. Therefore in arc welding placed the welding rod near the welding
point without looking through the hand shield and by looking through the hand shield get the welding
rod near to the welding point until arc is generated.

• When using lathe machines and drilling machines

I Always stopped the machine before making adjustments.

I Did not change spindle speed of the lathe machine until the lathe comes to a complete stop.
I Handled cutting tools and drilling tools with care and only used files having a handle.
I Removed chuck keys before operating the machine.
I Knew where the emergency stop is before operating the lathe.
I Did not try to get a measurement of the work piece while it is turning.

Safety check list

• Walkways can be kept in good condition and free from obstacles.

• Can be marked walkways using yellow lines.

• In the workshop area there should be safety symbols (Figure 35) to know about what safety equipments
are want to be used.

Figure 35: Some of safety symbols should be displayed in the workshop

6 Conclusion
There are lot of tools and machinery available in the workshop to make a coconut scrapper and those
machinery and tools were handled and operated. And also it can be made some other products and repair
some products by ourself using tools and machineries in a workshop. It is very important and a must to
follow safety guide lines in the workshop.

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References
US ARMY. Milling machine operations. US Army Warrant Officer Advanced Course, 1998.

Wikipedia. British Standard Fine - wikipedia, the free encyclopedia, May 2014a. URL http://en.
wikipedia.org/wiki/British_Standard_Fine.

Wikipedia. Carbon steel - wikipedia, the free encyclopedia, May 2014b. URL http://en.wikipedia.org/
wiki/Carbon_steel.

Wikipedia. Oxy-fuel welding and cutting - wikipedia, the free encyclopedia, 2014c.

Wikipedia. Iso metric screw thread - wikipedia, the free encyclopedia, May 2014d. URL http://en.
wikipedia.org/wiki/ISO_metric_screw_thread.

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