OBJECTIVES:

The are several objectives for having this bench work practice . Through this project:

1.) Students will be able to carry out basic bench work such as marking, sawing, filing, drilling
and fitting.

2.) Students will be able to read and interpret engineering drawings accurately.

3.) Students will be able to practice the correct use of hand tools.

4.) Students also can know the safety precautions that must be carried out during workshop.

5.) Students also can identify the size of drill bits and can know how to handle a drill machine .

6.) Students can also identify and select various tools for holding, assembling or dismantling the
work piece.

7.) Students also will be able to learn housekeeping after using the tools. They should keep the
tools in right place.

APPARATUS:
1.) Files (used to remove fine amounts of material from a work piece.)

2.) Hacksaw ( used to cut the mild steel block)

3.) Vernier calipers (used to take accurate measurements)

4.) Scribers ( scribers are used to put marks on the mild steel block)

5.) L-square ruler (used to determine 90 degrees and also can be used to draw a straight line)

6.) File card ( used to clean the files)

7.) Drill bits (used to make holes in the mild steel block. Examples of drill bits size are 1/8’ ,

1/4’,1/2’ , 5/16’).

8.) Center punch ( to mark the center of a point before drilling)

9.) V Blocks ( used to hold the mild steel block firmly)

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10.) Anvil ( Steel block is placed on anvil when using center punch to make tiny holes before

drilling).

11.) Hammer (used to hit the center punch to make a small hole in the mild steel block)

12.) Tap (They are used for internal threading by inserting them into the hole at right angel to

face of the hole).

13.) Die (It is used for external threading on studs).

14.) Surface Plate ( used for testing the flatness of the mild steel block after filing)

(The diagram above shows the hacksaw and a few types of files are kept in the toolbox)

SAFETY PRECAUTIONS:
There are several safety precautions that should be taken during workshop:

1.) First of all students must wear the correct clothes during workshop. The clothes they are

wearing must not be too loose and the t-shirt must not be long-sleeved.

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2.) Students also must wear proper personal protective equipment (PPE). For example gloves,

safety boots, goggles, safety jackets and etc.

3.) When handling with rotating machines such as drilling machines ; rings, wrist watches,

Bracelets or jewelry that can get caught in the equipment are not allowed when using

this type of machine. Students who have long hair must make sure that it is tied back and

will not touch any part of the machine in particular the rotating spindle.

4.) Do not interrupt anyone when they are operating any machine such as drilling . Wait until

they finish machining.

5.) When operating a drilling machine always remove the chuck key after tightening the chuck

to avoid the chuck key from flying off during the start-up which can cause serious injury or

death.

6.) The gangway/floor through the workshop must be kept clear. Any oil spillage or grease must

be cleaned immediately because anyone can slip and fall if they step on it.

7.) Students must not horse play and run during workshop because it may cause severe

accident. Always be patient and never rush in the workshop.

8.) Students should not play with tools because some of the tools are sharp and may harm

other students (friends).

9.) When using vernier calipers to take measurements , make sure to check it’s error.

10.) When using hacksaw to cut , make sure the blades are sharp enough and the blades must

be tightened so that it would not come out when sawing the mild steel block.

11.) Students also must ensure that the files are fitted with suitable handle at the end of file.

12.) Students must report any defective equipment to the mechanical staff/lecturer.

13.) Students must only operate the machine after informing the staff of the Mechanical

Workshop. Make sure someone else knows that you are using the machine and is

available in case of emergency.

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THEORY / BACKGROUND:
‘Workshop Theory’

Engineering Workshop is a place where students acquire knowledge on the operation of various
processes involved in manufacturing and production. The Workshop Practice course makes
students competent in handling practical work in engineering environment. Engineering
Workshop is also involved in different maintenance/repair works. Students also can know about
the tools that are used in workshop and they also can know how to use the tools correctly.

‘Bench work and Fitting’ :

Bench work and fitting has its own importance in engineering work. Even after machining,
finishing by hand , to get a exact accuracy is necessary is called bench work. Basically bench
work refers to a activity that had been carried out on a bench; but in engineering workshop bench
work means a work is done on the bench in the workshop. Normally bench work includes
sawing, filing and marking.

Fitting is assembly of two mating parts; there may be either tightness or looseness between them.
The degree of tightness or looseness between them is termed as fit. Manufactured parts are very
frequently required to mate with one another. They may be designed to slide freely against one
another or they may be designed to bind together to form a single unit.

‘Workshop Fitting Operations’:

1.) Measuring Operation:

- Measuring is a process in which we consider the physical features of an object. We get

knowledge about its length, mass, height, internal or external diameters, depths etc. This is done
with the help of measuring tools like Vernier calliper, callipers, screw gauge, ruler.

2.) Marking Operation:

- Marking out or layout is the process of transferring a design or pattern to a work piece, as the
first step in the manufacturing process. Marking out consists of transferring the dimensions from
the plan to the work piece in preparation for the next step, machining or manufacture.

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 3.) Sawing Operation:

- A saw is a tool consisting of a hard blade, wire, or chain with a toothed edge. It is used
to cut through relatively hard material, most often wood. The cut is made by placing the toothed
edge against the material and moving it forcefully back and forth. This force may be applied
by hand.

4.) Filing Operation :

- The process of making up or something putting into a hole, cavity, space or container is called
filling.

5.) Punching Operation:

- Punching is the process of engraving or embossing some impression (forcefully or by

hammering) on any other surface. In fitting shop, it is divided into:

Centre punching
Number punching

6.) Drilling Operation:

- Making a hole with the help of drill bit is called drilling. Drilling is one of the most complex
machining processes. The chief characteristic that distinguishes it from other machining
operations is the combined cutting and extrusion of metal at the chisel edge in the centre of the
drill. The high-thrust force caused by the feeding motion first extrudes metal under the chisel
edge. Then it tends to shear under the action of a negative rake angle tool.

7.) Counter Sinking Operation:

- The cutting of a bevelled edge at the end of a hole so that the head of a screw can rest flushes
with the work piece surface. A countersink is a conical hole cut into a manufactured object, or
the cutter used to cut such a hole. A common use is to allow the head of a countersunk bolt or
screw, when placed in the hole, to sit flush with or below the surface of the surrounding material.

8.) Threading Operation :

- The process of cutting a long, spiralling groove into a work piece with a single-point tool.
Threading processes are essential for the creation of fasteners. A thread is a uniform helical
groove cut inside of a cylindrical work piece, or on the outside of a tube or shaft. They are
according to desired pitch. It is of two types:

· Internal threading:
When the threads are on the inner surface of work piece.

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· Outer threading:
When the thread are on the upper surface of work piece.

Fitting Tools:

Fitting tools can be classified as marking and measuring tools, work holding tools, striking
tools, cutting tools, finishing tools and other tools.

a.) First and foremost marking and measuring tools. These tools are used for measuring and
marking before carrying out any fitting operation. There are certain tools stated below:

1.) Vernier Caliper:

- Basic tools for linear measurement are vernier caliper as shown in the figure below. a
measuring device that consists of a main scale with a fixed jaw and a sliding jaw with an
attached vernier.

(The Figure above shows the vernier scale and it’s parts)

- Calipers without a vernier scale originated in ancient China as early as the Qin dynasty (AD
9). The secondary scale, which contributed extra precision, was invented in 1631
by French mathematician Pierre Vernier (1580–1637).

2.) Steel rule and ‘L’ square ruler:

- Steel rule is a linear measuring tool which may have a length of 150mm or 300mm. It is made
of tempered rust-free steel or stainless steel. Steel rule is used for measuring a length and also to
draw a straight line.

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- ‘L’ square ruler is used to serve several purposes including laying out lines on metal and
checking two surfaces for right angle (90 degrees). It is made up of stainless steel too.

( The picture above shows a ‘L’ square ruler)

3.) Scribers:

A scriber is a hand tool used in metalworking to mark lines on work pieces, prior to machining.
The process of using a scriber is called scribing and is just part of the process of marking out.
They are a rod with a tip made of cast steel that has been hardened and tempered. The point is
sharpened to an angle of 30 or 40 degrees. Some scribers have a point at both ends. It is used by
drawing the point over the surface of the work piece to leave a shallow scratch on its surface. It
is normally made of carbon steel.

4.) Center Punch:

- A center punch is used to mark the center of a point. It is usually used to mark the center of a
hole when drilling holes. A drill has the tendency to "wander" if it does not start in a recess. A
center punch forms a large enough dimple to "guide" the tip of the drill. The tip of a center punch
has an angle between 60 and 90 degrees. When drilling larger holes, and the web of the drill is
wider than the indentation produced by a center punch, the drilling of a pilot hole is usually
needed.

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 (The picture above shows a center punch tool)

b.) Next, work holding tools. Work holding tools are used for holding the work piece while
performing fitting operation. There is a example of work holding tools below:

1.) Bench vice:

- Bench vice is a holding device attached to a work bench in workshops. It has two jaws to hold
the work piece(mild steel block) firmly in place. Usually in engineering workshops the work
piece (mild steel bar) is clamped to the bench vice during filing or sawing. It is very heavy too.

(Bench vice)

c.) Besides that striking tools such as hammers are used to strike the center punch.

1.) Hammer:

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- The hammer consists of a head, a peen, a striking face and a handle. Hammer is used for strike
a object.

d.) Cutting tools are used sawing and failing. There is a example below:

1.) Hacksaw:

- 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.

(Hacksaw)

PROCEDURE:
1.) First and foremost, a briefing was given by the lecturer to the students about the tools and
machines in the workshop. The lecturer also explained how to use the basic tools and
machines such as drilling machines in workshop.

2.) Besides that, safety precautions that should be ensured in the workshop was briefly
explained to the students. Students also were adviced to wear personal protective
equipment (PPE) such as safety boots, goggles , gloves and safety jackets.

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3.) Next, the lecturer also explained and showed the dimensions of the mild steel block
project on the white board. The lecturer drew the work piece project on the white board
and stated the dimensions clearly as a reference for the students.

4.) After that, the students was given a long mild steel bar. Then each of them must take
measurement of the correct length that using a vernier caliper and marked on the mild
steel bar using a scriber. When filing and sawing the work piece must be clamped to the
bench vice. The actual length of the work piece should be 3 ¾ inches but the students are
required to saw 1/16 inches more. The sawing process is done using a hacksaw.

5.) After sawing the long mild steel bar into small mild steel block (work piece), students
must file the side of the work piece until the correct length which is 3 ¾ inches. Bastard
file, second cut file and smooth file are the types of files that is used to file the work
piece. Before filing students are required to fix a datum line as a reference to get an
accurate length of the work piece.

6.) Then, students are required to draw a line (diagonal line) using a scriber and a steel ruler
across the front surface from the top right to the bottom left at both sides of the work
piece. After that, at the top students are required to divide 6 lines from the left end edge
to the right end of the work piece . The difference between lines must be ½ inches.
Measurements must be taken using vernier caliper. Mark the line at top using a scriber.
The last line and the right end edge of the work piece must be ¾ inches difference.

7.) After marking at the top, draw a straight line vertically at the front surface of the work
piece referring to the line marked at the top of the work piece until it touches the diagonal
line which was drawn earlier at both sides . After that, cut (saw) the lines vertically from
the top until it reaches the diagonal line using a hacksaw.

8.) After sawing, file the height of the work piece .The height of the work piece must be 2 ½
inches. Actually to get the accurate height , students cannot take measurements and cut
(saw) using a hacksaw but they have to file it either using bastard file or second cut file.

9.) Next, mark the point that needed to drill. Firstly, draw lines according to the
measurements stated in the diagram. Then, use a center punch to make a slight dent at the
center point of 3 holes. This step is done to ensure that the drill bits can determine the
point that needed to be drilled accurately without shaking. Students have to remember
that , they must not exert too much force when drilling because it may lead the drill bit to
break.

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10.) After that, use an electrically powered pillar drill machine to drill the three holes.
At first, use a pilot drill bit (1/8 inches) to drill the three center point of the holes. The
first and second hole must be drilled fully but the third hole must be drilled 1cm only.
The, third hole is known as blind hole. Then, use the ¼ inches drill bit to make a bigger
hole than the pilot drill bit on the work piece. This step must be done for the three holes.

11.) After that, use the 5/16 inches drill bit to drill a bigger hole for the first and third
hole. Use a counter-sink drill bit with a radius of 3/8 for the second hole. Students have
to apply oil as a lubricant when drilling to smoothen the drilling process.

12.) Then, clamp the work piece to the bench vice to carry out the next step. The next
step is making thread using tap shock and hand taps.

13.) The tap shock must be adjusted and tighten using screwdriver so that the hand tap
is held firmly. The hand tap must be fully go through in the first hole. Firstly, use a tapper
hand tap and tighten it to the tap stock to make the thread . Next, use a intermediate hand
tap and tighten it to the tap stock. Let the hand tap to pass through fully in the first hole
while in the third hole turn the tap stock until it reaches the metal surface which is 1cm
deep.

14.) The next step is to check the flatness of the work piece using a surface plate. The
engineers glue must be rubbed on the surface plate. Then use the v-blocks to hold the
work piece firmly and just move the v-blocks. The glue which will be in blue colour can
be seen evenly on the work piece. If the work piece is not 90 degrees the blue colour
cannot be seen evenly on the four sides of the work piece. If the work piece is not even
then file it till it becomes 90 degrees but ensure the length is not short.

15.) Besides that, students must file the front surface and the four sides of the work
piece until all the burrs are removed. After that, use different grade of sandpapers to
make the work piece smooth and shiny. Firstly, start with smaller grades and then to
higher grades. Examples of sandpaper grades are (P150,P320,P600,1000CW,1500CW,
2000CW and 50005W). Sand the work piece until it becomes shiny. Then, students must
do number punching on the mild steel bar (work piece). The number should be included
with the particular student’s registration number and also the year of the project is done.
For example : JUN 16 / F1012.

16.) Then, champfer must be filled at the 4 edges of the work piece. The angle is
calculated using a radius gauge which is 1/8.

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 17.) Next, measure the mild steel rod using a vernier caliper and mark it .The length of
the rod that needed to be cut (saw) is 2 ¾ inches. The mild steel rod is also known as
stud. After that, using a file , file the front of the stud slightly slunting.

18.) Then, use the die stock to make a thread on the stud. The length of the thread
must be ¾ and students must measure and mark it using a vernier caliper. Make sure the
die stock is turned straightly. After done, try to enter the stud into the work piece thread.
Then sand the stud using sandpaper.

19.) Finally, apply oil on the surface of stud and work piece and sent it to the lecturer.

RESULTS:

( Front view of work piece)

(side view of the work piece)

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(Back view of the work piece)

( Full view of the work piece)

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DISCUSSION :
State 5 safety precautions when moving around workshop:

When moving around the workshop there are several safety precautions that should be taken.
First of all, students must wear proper personal protective equipment (PPE) before start working
in the workshop. For example gloves safety boots, goggles, safety jackets and etc. Besides that,
students must know where the emergency stop buttons are positioned in the workshop. If you see
an accident at the other side of the workshop you can use the emergency stop button to turn off
all electrical power to machines. Next, when learning how to use a machine, listen very carefully
to all the instructions given by the lecturer. Ask questions, especially if you do not fully
understand and do not operate any machines if you are not been shown how to operate it safely
by the lecturer. Other than that, report any damage to machines/equipment as this could cause an
accident. Next, students must wear proper clothings. The clothings must not be too loose for the
particular person. Besides that, Students must not horse play and run during workshop because it
may cause severe accident. Always be patient and never rush in the workshop. Finally, when
attempting practical work all stools should be put away.

When filing metal it is a common practice to rub a chalk into the teeth of a clean file. Why?

It is advisable to rub a chalk into the teeth of a clean file when filing a metal. There are several
reasons why chalk is rubbed into the teeth of the file. Firstly, it is done because it prevents chips
of metal from clogging the teeth of the file (since they are mostly filled with chalk). This makes
the filing more efficient (faster) and the finish smoother because all of the teeth are working
uniformly instead of having some clogged with chips of metal (thus not filing correctly and
scratching away at the piece you are working on.)

What are the problems that you encountered while doing the project and the defects on the
project?

While doing the project I encountered many problems. First and foremost, it was hard to file
the work piece because the handle of the files does not fit properly. So, when filing fast the
handle came out. This happened many times whenever I do filing. Luckily it does not cause
injury to my hand. Besides that, after filing it is hard to mark the surface area due to the shiny
surface of the work piece. So it is very hard to see the lines marked on the surface. However I
managed to mark the lines and I was able to saw the work piece accurately. Next, when I was
sawing the work piece I was unable to saw it according to the straight line which is marked
earlier. This is because the my posture while sawing is less effective. Then, my lecturer corrected
my posture and finally I was able to saw in a straight line. Other than that, there were many dents
on the work piece and it makes difficult for me when I was filing to get rid of the burrs. Besides

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that, the blade of the hacksaw was not really sharp. So when sawing, it takes longer time to
complete the sawing process. However, later on I identified the problem and change the hacksaw
blade. After changing the blade, I was enable to saw more faster. Although I faced many
problems , finally I managed to complete my project successfully.

CONCLUSION:
Through this bench work practice students could learn many things. First of all, students
will be able to carry out basic work bench such as marking, sawing, filing, drilling and fitting.
Besides that, students also would learn about the safety precautions that must be ensured
during workshop. They also will know about the things they should do and things they should
not do during engineering workshop. Next, students will be able to read and interpret
engineering drawings accurately. They also know how to read the dimensions and apply it when
doing their project. Other than that, students also know how to use and calibrate the tools in the
workshop. Next, students can learn about the personal protective equipment that must be weared
during workshop to prevent bodily injuries. Other than that, students can also identify and select
various tools for holding, assembling or dismantling the work piece. Finally, students can learn
what kind of clothings they should wear during workshop.

REFERENCES:
Book reference:

1.) Material and Hardware (DWM 2062), En. Amaluddin Salihin bin Muhammad.

2.) Maintenance Practices (DWM 2073) , Muhammad Faez Nordin, excess on 25/01/2017.

3.) Occupational Safety and Health (DWM 1212),En. Khairun Nizam bin Saadan.

4.) Workshop - encyclopedia

5.) Practical Bench Work for horologists paperback- November, 1998 by author Louis Levin

Author Samuel Levin .

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Internet reference:

1.)
http://sharadavikas.com/CourceMeterials%5CWORKSHOP%20MANUAL%20DIP%20FIRST
%20SEMESTER%201%2029-05-12.pdf

2.)
http://www3.utem.edu.my/fke/index2.php?option=com_docman&task=doc_view&gid=168&Ite
mid=67

THE END
THANK YOU

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