UNIVERSITI TEKNIKAL No.

Dokumen:
No. Isu./Tarikh:
BMCU 2932
MALAYSIA MELAKA 1/25-04-2011

SUBJECT: ENGINEERING PRACTICE No. Semakan/Tarikh: Jum. Mukasurat

MODULE 13 : FITTING 0/25-04-2011 18

1.0 Objectives

After completing this workshop session, students should be able to:

a. Identify and select various tools for holding, assembling or dismantling the work
piece.
b. Carry out basic work bench such as marking, sawing, filing, drilling and fitting.
c. Appreciate accuracy in engineering product to ensure work pieces fitting.

2.0 Learning Outcomes

At the end of this workshop session, the expected outcomes are as following:

a. Produce a product through the given technical drawing.

b. Use appropriate engineering tools and equipments in workshop project.

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3.0 Introduction

Although this modern era is looked on as machine era, the importance of hand tool
operations or bench work should not be overlooked. Term ‘bench work’ relates to the work
performed by the mechanic at the machinist’s bench with hand tools rather than machine
tools. Among of the operations that can be performed at the bench such as marking, cutting,
filing, chiseling, drilling, sawing and fitting. The prime requirements for machinist’s bench
are should be strong, rigid and proper width and height that the work can be performed
conveniently. It should be placed where there is plenty of light. The various stages of work
processes are describe in the following chapter.

3.1 Measurement and marking

Vital aims of this exercise are transfer of drawing measurements to the work piece,
marking with scribe and do center punching. Measuring and marking on work piece is the
process of scribing center points, circles, arcs or straight lines on given metal to indicate the
shape of the object, area on metal that need to be removed during machining process and
position of the holes to be drilled. Basic tools for linear measurement are a ruler and vernier
caliper as shown in Figure 1. It can be used to measure linear distance, circle diameter and
part thickness.

Figure 1: Vernier caliper

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 Then, another important measurement is angular measurement. Normally using ‘L’ square
as shown in Figure 2 and can serve several purposes including laying out lines on metal and
checking two surfaces for right angle (90 degrees).

Figure 2: L square

3.1.1 Equipments and hand tools

One of the important equipment that we need before perform marking on the work piece
is working table with vise and toolbox. Vise is a clamping device that usually consists of two
jaws that close with a screw or a level as shown in Figure 3. It is commonly attachable to a
workbench and used to hold work piece securely for sawing, chipping, filing and tapping
operations. The vise is made of casting iron except adjusting screw and the mounting, made
of harder steel. Normally work piece will be clamped between softer materials to avoid
damage. eg: brass, wood, etc.

Figure 3: Vise

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 Next, one of the important hand tools is scribes. It is use for marking out of fine lines on
metal. There are various type of scribes which are pocket scribes, machinist scribes and
double-end scribes. Next is center punch. It is a hardened tool and used for center punching
preparatory before drilling process. The center punch mark aids in guiding the drill bit so that
drilling process will be on desired location without drifting to the side. Another hand tool is
hammer. It may be classed with respect to the peen as ball peen hammer, straight peen
hammer and cross peen hammer. Ball peen hammer normally used for general applications
such as hammering metal to indent or compress it, bending and forming of riveting. Straight
and cross peen hammers are used for hammering of narrow areas, riveting of portions or
edges of the metal. Figure 4 shows example of machinist scribes, center punch and ball peen
hammer.

Scribe Center punch

Figure 4: Example of scribe, center punch and hammer

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3.2 Cut work piece

Aim of this exercise is using hand hacksaw to saw along the marking line. Hand hacksaw
is available with a fixed frame and adjustable frame. The main components of hacksaw are
handle, frame and blade. A suitable blade pitch must be selected based on material to be cut
(for harder material, use the finer blade) and thickness or shape of the material. Normally, the
blade is made from tool steel and high speed steel (HSS) due to their good mechanical
properties. Figure 5 shows example of hand hacksaw and correct hand position when sawing.

Figure 5: Hand hacksaw

3.2.1 Working tips

a. Clamp work piece vertically in vice. Make sure the work piece in a firm position.
b. Saw the external marking shape of the work piece. Do not saw to size. Apply the
correct method of holding the hacksaw and sawing angle.

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3.3 Filing

Filing is a process to remove surplus metal and to produce finished surfaces. File
components consist of tang, heel, face, edge and point as shown in Figure 6. When a file is
applied to a metal surface with a reciprocating motion, the teeth act as small chisel, each
removing small chips. Shapes of files in common use are flat, hand, square, three square, half-
round and round files. In the workshop, there are three types of file which are flat, three-
square and half round.

Figure 6: File

Flat file is used for filing rectangular work piece, key ways, orthogonal edge and general
filing works. Then three square file and half round file are used for filling sharp angle or
internal edge and curve surface respectively. Filing techniques is very important to ensure a
good working result. There are three filing techniques which are parallel, perpendicular and
crossing techniques as shown in Figure 7.

Figure 7: Filing techniques

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 3.3.1 Working tips

a. Make sure height from work piece to vice clamp is suitable when clamp the work
piece.
b. During filing, push the file to work piece and move your hand forward. Push the file
during moving forward and releasing it during pulling backward.
c. Use only one filing direction to ensure a good surface finish.
d. Clean a file with a brush.
e. Remove chips with a wire to clean the file teeth.

3.4 Chiseling

Chiseling is the working on material with a sharpened wedge-shaped tool named chisel.
The cutting effect is achieved by striking the head of the chisel with hammer. The most
common type of chisel is flat chisel as shown in Figure 8.

Figure 8: Flat chisel

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3.5 Drilling

Drilling is the processing of a material by mechanical cutting using a drilling tool

(drilling machine and twist drill) that revolves on its longitudinal axis and thereby carries out
a longitudinal motion. Drilling produces drilled holes to a required diameter. There are
various types of hole making operation. For examples drilling, boring, counter boring, counter
sinking and taping as in Figure 9.

Figure 9: Various type of holes

3.5.1 Equipment and tool

There are various models of drilling machine used in industry. In addition to its principal
task of drilling holes, the drilling machine is widely used for hole-machining operations such
as reaming, boring, counter boring, countersinking and tapping. Figure 10 shows example of
drilling machine.

Figure 10: Press drilling machine

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 Next, an important tool during drilling process is twist drill. Twist drill is a pointing
cutting tool, usually round, used for cutting holes in metal or other substances and driven by a
machine (drilling machine). The main parts of the twist drill are the shank, body, and point as
shown in Figure 11.

Point

(Shank) (Body)

Figure 11: Major parts of twist drill

Twist drill identified as to size in three different ways as follows:

a) Number size (1 to 80)
b) Letter size (A to Z)
c) Fractional size (1/64 upward by sixty-fourths inch)

In ISO Standard, twist drill size begins with ‘M’ and followed by the sizes. Example, ‘M10’
is the size for 10 mm. The use of fluid when drilling metals increases the life of the drill bit.
For example of fluid that aid drilling operation are as follows:

a) Oil – used for steel

b) Soluble oil – use for bronze, soft steel, wrought iron
c) Kerosene – use for aluminum, aluminum alloy

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Table 1: Typical example of drill sizes

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Table 2: Recommended drilling speeds for materials

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 Table 1 shows the typical example of drill sizes. On the other hand, drilling speed is
refers to the revolution per minute (rpm) of the drill press spindle. As in Table 2, there are
recommended drilling speeds for each material. For example, the suitable cutting speed for
cast iron is approximately 30 surface meter / minute (100sfpm).

3.5.1 Working tips

a. Clean the work piece surface from oil and dusk.

b. Put work piece onto clamping device and check their level as well as position
correctly.
c. Press the twist drill center to drill point and reset the scale at drilling machine.
d. Release back the twist drill position and switch on the machine.
e. Check the rotation of twist drill before drilling.
f. Put oil / fluid on the work piece during drilling for cooling the twist drill and
work piece.
g. Remove the scrap using hand brush. The sharp edges will scratch your hand.
h. Use goggle while drilling.

3.6 Performing tapping

Tapping is a process to produce internal thread of certain holes. This tool is rotated by
hand about its longitudinal axis. Taps are made of hardened tool steel, either carbon steel or
high speed steel. A tap is a multi-flute cutting tool with cutting edge on each blade resembling
the shape of thread to be cut. Figure 12 shows the example of hand taps.

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 Figure 12: Hand taps

The square end on the tap is used for holding tap with wrench as shown in Figure 13. Taps
are hard and brittle. It can easily break when excessive force is applied.

Figure 13: Tap wrench

3.6.1 Working tips

a. Make a pre-drilling operation correspondence to the required size.

b. Make sure that the tap is started in proper alignment with the hole.

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c. When starting, keep the hands near the tap on tap wrench and shift the hands to
the end of the tap wrench after the thread has been started.

d. During tapping, always reverse the tap slightly to break the chip and clear the
chip space in the normal way.

e. Use lubricant or cutting fluid while tapping.

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3.7 Performing Counterbore and Countersunk

Counter boring and countersinking are the processing of a work piece by using particular
tool with one or more cutting edges, which revolves on its axis and thereby carries out a
longitudinal motion. Counter boring produces spot-face for bolts and screws to enlarge holes
to receive the head of fillister head screws. While countersinking with the rose-bit produces
cone-shaped surfaces in drilled holes. Figure 14 and 15 show the counterbore and counter
sink processes respectively.

Figure 14: Counter bore hole and counter boring process

Figure 15: Counter sink shape and counter sinking process

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NOTES

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 UNIVERSITI TEKNIKAL No. Dokumen:
No. Isu./Tarikh:
BMCU 2932
MALAYSIA MELAKA 1/25-04-2011

SUBJECT: ENGINEERING PRACTICES No. Semakan/Tarikh: Jum. Mukasurat

EVALULATION GUIDE 0/25-04-2011 1

PANDUAN PERMARKAHAN LATIHAN INDUSTRI

1. Pyscomotor (3 markah)

Keterangan Markah
Kemas, dimensi tepat, padanan sempurna 3
Kemas, padanan sempurna 2
Kemas dan memuaskan 1
Tidak kemas, tidak tepat dan tidak sempurna 0

2. Etika dan moral (2 markah)

Keterangan Markah
Faham dan mematuhi arahan keselamatan serta berdisiplin 2
Berdisiplin, faham tetapi tidak mematuhi arahan keselamatan 1
Tidak berdisiplin, tidak mematuhi arahan keselamatan dan tidak faham 0

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