FACULTY OF ENGINEERING AND TECHNOLOGY

EME3016 WORKSHOP TECHNOLOGY

Experiment 2: Practice Of Workshop Machining ( Making a Pin Hammer)

NAME OF STUDENT Ong Voon Yeow Ong Chii Han Sivarhubhen Sivapragasam

ID NUMBER 1091101744 1091103482 1091103478

Group Number Date of Experiment Date of Submission Name of Lecturer Lecturers Room

: : : : :

21 18th April 2011 25th April 2011 Mr. Chew JouhYeong R2/018

MAKING A PIN HAMMER OBJECTIVE

To learn how to use different hand tools and machine tools in the workshop. To learn how to make a Pin Hammer using tools.

INTRODUCTION
A hammer is a tool meant to deliver an impact to an object. The most common uses are for driving nails, fitting parts, forging metal and breaking up objects. Hammers are often designed for a specific purpose, and vary widely in their shape and structure. The usual features are a handle and a head, with most of the weight in the head. The basic design is hand-operated, but there are also many mechanically operated models for heavier uses, such as steam hammers. Our task is to make a pin hammer with different hand tools and machine tools. Therefore, in this report, we will explain the steps and procedures of making a pin hammer with different operations of machine such as milling machine, drilling machine, lathe machine (turning machine) and so on. On top of that, appropriate precautions which should be taken will also be discussed.

APPARATUS AND MATERIALS

Gradated steel rule Files Hacksaw/cutter set of taps tap wrench chamfer tool drilling machine turning machine milling machine Grinding machine.

Figure 1:Milling machine

Figure 2: Turning machine

Figure 3:Drilling machine

Figure 4:hacksaw

PROCEDURE
1. The steel rod was cut into 2 pieces by using hacksaw. The procedures of longer side for
the handle and then another side which is shorter are for head of the hammer are stated as below:-

(A) The Making of The Head of The Hammer

Milling Machine 1. The steel rod is needed tobe reduce become a square shape with the thickness of 15mm for each side by using the milling machine. 2. The block is needed to set under the steel rod to maintain it in position all the time during the milling process. 3. After that, the length of the steel rod is needed to reduce until 60mm. 4. Then, the steel rod is needed to be set with an angle of 30 blockwhich made the steel rod will be in parallel 30 angle slide and cut the one end top of steel rod part by 7.8mm. 5. After all milling processes, the steel rod is needed to mark a hole with pin which position is 30mm from the 60mm in total length and 7.5mm from the thickness of the steel. And then, begun to drill a hole which passing through the steel rod with drilling machine. Drilling Machine 6. A 9.5mm diameter hole was drill at the center point by drilling machine. 7. Lastly, lock the drilled steel rod on table clamp and use the tapping wrench to make the tread of the hole.

(B) The Making of Handle of The Hammer

Lathe Machine(Turning Machine) 1. The material (mild steel) is obtained. 2. A length of 160mm is marked using a prick punch out the steel rod surface. 3. The marked portion is cut using an electric hacksaw. 4. The work piece was left aside for a while to cool down and later placed in the vices. 5. The chips from the work piece were chipped off using a file to produce a smoother surface and remove impurities. 6. The process was repeated in both ends of the work piece. 7. After that, the work piece diameter was measured using a vernier caliper. A reading of 18mm was obtained. 8. The work piece was checked for abnormalities and manufacturing defects. 9. The lathe machine was checked before the machine is used. 10. The procedure to check the lathe machine:

Before start to using lathe machine, it is recommended to have a machinist tool box with all wrenches, screwdrivers, and common hand tools. A dial indicator may be necessary for some procedures on the lathe. Keep all safety equipment, along with necessary cleaning marking, and lubricating equipment, in the immediate lathe area to use as needed. ii. Before machining a work piece, the following measurements must be considered: the diameter of the work that will swing over the bed and the length between lathe centers. iii. When installing the chuck or an attachment that screws onto the lathe headstock spindle, the threads and bearing surfaces of both spindle and chuck must be cleaned and oiled. iv. The chuck in placed in position on the spindle. v. The draw nut thread is engaged and is tighten. vi. The spindle is rotated 180o, the spanner wrench is engaged and four or five hammers are given to blows the spanner wrench handle. vii. To center work in the independent chuck, line of four jaws up to the concentric rings on the face of the chuck, as close to the required diameter as possible. Work will automatically centered itself in the universal (3 jaw) scroll chuck, drill chuck, collets chuck, and step chuck, but must be manually centered in the independent (4 jaw) chuck. viii. The work piece is mounted and is tighten the jaws loosely onto the work piece. ix. The work piece is spin by hand and make approximately centering adjustments as needed, then the jaw is firmly tighten. x. When removing chucks from the lathe machine, a wooden chuck block is used under the chuck to support the chuck on the lathe ways. xi. Avoid dropping the chuck on the ways, since this can greatly damage the lathe ways or crush the operators hand. 11. The work piece was placed in the lathe machine in a secure position and was tightening, and was checked for vibration while rotating using the Jog button. 12. The cutting head was checked in order to avoid wear. 13. The coolant, speed and the angle was set up by the requirement needed for work piece turning. 14. A few test runs were conducted in order to ensure the settings were suitable for the desired turning process. 15. The work piece was cut by 0.5mm for 4 times gradually throughout the work piece while the coolant was pouring into the tip of cutter. 16. The work piece was taken out and measured and its diameter of 16mm throughout work piece was recorded. 17. The work piece was marked at the length of 15mm and 80mm respectively. 18. The cutting tool was reset to match the new measurement of work piece. 19. Then the work piece was cut 0.5mm for 4 times gradually up to 80mm. 20. The cutting was reset to match the new measurement of work piece.

i.

21. The handle was cut into 9.5mm diameter for length of 15mm gradually using a 0.5mm of cutting diameter and the process was repeated until a diameter of 9.5mm was obtained. 22. The handle was later knurled using the knurling tool to make thread lines of measurement 3/8 B.S.F. 23. A portion of 1mm was cut above the 15mm in order to make a trademark on the handle. 24. The handle was finally polished using a sand paper to smoothen the surface.

Result

DISCUSSIONS:
1.) Precaution taken during machining:a. Make sure that we are wearing the safety spectacles or googles when we are milling the work piece. Clean the chips away once in every cutting. b. Check to make sure all tooling is tight in the locking collets. Keep all tooling clean and in good working order.No broken tooling should be inserted into a milling machine. The broken tool can break again and pieces be ejected from the machine which in turn increases hazards around workshop because flying metal pieces can be a hazardous condition. c. Test run the motor and spindle speed of milling machine to ensure the rotation and speed is correct. Move the table (work bench) manually to lubricate the ways and test the ball screws. Damaged or improper operation of the table can cause a work piece to be thrown from any mountings. Secure all vises tightly to the table with only approved methods. Improperly mounted vises can cause a work piece to be thrown from its secure position. d. Before starting the operation of milling process, to make sure that the work piece is clamped tightly on the work rest, use the soft/mallet hammer to knock it into the work rest and being fixed tightly,therefore the work piece will not run out of scale during machining. e. Never make any adjustments while the machine is operating f. Do not support the work pieces by hand. Use a holding device to prevent the work piece from being tom from the operators mind such as metal blocks. g. Avoid zero error by making sure the position of zero point is set correctly in 3 axes before milling operation takes place. On top of that, random errors should be avoided such as the use of a wrong technique of machining and measurement and personal errors, for example, human limitations of sight and touch. h. Avoid parallax error by making sure that the position of the observers eye is in line with the reading of the scale to be measured or set before machining operations. i. We need to control the cutting speed to obtain a smooth and good surface finish. For example, during the operation of making handle with turning machine, we need to control the speed of operation manually with a constant movement. In addition, high cutting speed will cause rises in temperature of cutting as well as overheating of work piece. j. Built-up edge chips would be formed and deposited at the tool tip during machining if there are no appropriate precautions being taken. There are some methods to reduce the formation of built-up chips(BUE) as stated below: Maintain the cutting tool sharp. Use effective cutting fluids. k. When we make the threads using the tap or the die, care should be taken in respect for the following: Start the thread with a perpendicular positioning of the tap or the die. Turn the tap or die in quarter turns and "back off" quarter turns to remove metal chips so that they don't clog the tool. Always use cutting oil.

l. The thread cutting process using a die usually typically results in a smaller diameter of the original piece so care needs to be taken in selecting the correct size stock. If the stock is too small, this will result in a shallow thread depth resulting in an unsatisfactory thread. The die also created a bevel on the thread which is necessary for a close fit.For example, with the use of turning machine,the die is pushed by the drill chuck aligned perpendicularly to the piece and after. After enough thread is cut, the drill chuck is removed and the die handle is then turned by hand as shown below:-

Figure: Thread making process using die m. Taps can be easily broken and if the tap is broken in the work piece, it can be almost impossible to remove. It is therefore; very prudent to take care to ensure that metal chips do not build-up in the tap and also that the tap does not overheat as a result of the cutting process through the use of a cutting lubricant. n. The surface of the head and handle are being filed with a piece of fine sand paper to ensure a good and smooth surface finish. 2. There is a small gap between the bottom surface of the head of the pin hammer and the end of the handle of the pin hammer. The purpose of doing so is to create an unique symbol to represent our groups (GROUP 21) of Workshop Technology in order to prevent plagiarism.

CONCLUSION
After the accomplishment of this experiment, we were able to learn the technique and method to use different machine tools and hand tools such as a set of taps. In addition, we were also reinforcing our current knowledge on how to use hacksaw with the correct way in which the cutting is done on the forward stroke of hacksaw blade, but not the backward stroke. Furthermore, we were also able to learn different general machining operations of forming a pin hammer such as milling, drilling and turning. Besides, we know understand the function of a pin hammer as a force amplifier and also the effects of the heads mass and handle. On top of that, it can be shown that technical drawings are very important for engineers to detect flaws during operation and improve the designation in order to minimize or treat hazards.

LIST OF REFERENCES
1. S. Kalpakjian, Manufacturing Engineering and Technology, Prentice Hall, 2001. 2. Internet Encyclopedia : http://en.wikipedia.org/wiki/