DMM1911 Mechanical Technology

Laboratory 1

Benchwork
Name : Praveen Varman A/L Kolandaveloo
ID No : MB15165
Lecture : Mr. Ngui Wai Keng
Lab assistant : 1) Mr. Aziha Abdul Aziz

1) Objective
To study the basic knowledge about the benchwork tools and machines and its usage.
2) Apparatus
Bench vise, marking out table, hand hammer, files, centre punch, ruler, engineering
L square, steel; file brushes, scriber, high vernier caliper, hack saw, radius gauge, hand
tapping machine, tapping machine, lab goggle
3) Materials
Cast Iron
4) Introduction
The workbench is like the builder s home where the skills in handling hand tools
such as filling, sawing, chiselling and marking out are appropriately practice out. In other for
those skills to be mastered, students will be introduced to the basic complement of hand tools
commonly used in all branches of mechanical technology such as bench vise, files,
hacksaw, center punch, and scriber.
a) Bench vise
The bench vise is used to help grip the work piece for filing, hacksawing,
chiseling and bending light metal. The bench vice mainly consist of a fixed jaw,
movable jaw and jaw plates (Figure 1). Most bench vises have hardened insert jaws
that are sharply serrated and will dig into finished work pieces enough to mar them
beyond repair.

Figure 1
Hence,
soft jaws made
of copper, other soft metals or wood are often slip over the vise jaws to protect the
work pieces finished surface.
b) Filing
Filing involves the small scale removal of material from a surface, corner,
or hole, including the removal of burrs. Files are usually made of hardened steel and
are available in a variety of cross sections such as flat, round, half round, square and
triangle (Figure 3).They are commonly manufactured in four different cuts: single,
double, curved tooth and rasp. Each cut design has its own purpose. For instance, rasp
files are frequently used with wood while curved tooth files are used with soft
materials such as aluminium, brass, plastic, or lead. Files also vary in their coarseness;
rough, coarse, bastard, second cut, smooth and dead smooth.

Figure 2

Figure 3
In order to produce a flat surface, work should be held firmly in the vise with
the minimum amount of projecting and with the surface to be filed to be truly
horizontal. The right hand pushes and presses while the left hand only presses with
the same amount of pressure. Pressure should only be applied during forward stroke
only.
The Figure 4 below illustrates the proper technique of hand filing. Success in
filing flat is dependant on hand control to keep the file horizontal throughout its stroke
and an equal distribution of pressure. In order to test the surface of work during filing,
a straightedge can be placed on it. If rays of light can be seen between the two
surfaces of the work piece and the straight edge, then the surface of the work piece is
not flat.

Care
should be taken
while filing to
avoid dulling and
breakage of its
teeth. Teeth on files
will break if
the tools lie on top
of each other
and if too much
Figure 4
pressure is applied while filing. Dulling of teeth is caused by the filing of hard
materials or by filing too fast. A good rule of thumb is the harder the material, the
slower the strokes should be; the softer the material, the coarser the file should be.
c) Center Punch
The centre punch is used when circular dot marks are required. When job
has been marked out it is usual to follow along the lines with small dot marks in case
the line becomes obliterated. It is also used to mark the centre point of drilling holes
for the purpose of giving starts to the drill and to mark the centre of circles to provide
a point for placing the leg of the dividers to scribe the circle. Various types of center
punch are illustrated as below.

d) Sawing
The hacksaw is one of the more frequently used hand tools. It consists of the
frame, the handle and the saw blade (Figure 6). The spacing of the teeth on a hand
hacksaw blade is called the pitch. Standard pitches are 14, 18, 24 and 32 teeth
per inch, with the 18-pitch blade used as a general-purpose blade. The hardness and
thickness of a work piece determine to a great extent which pitch blade to use.
Generally, a coarse tooth blade should be used on soft materials and a fine tooth blade
on harder materials. There are a few points that should be noted in order to obtain
maximum performance from a blade:a) Make long steady strokes using the full length of the blade

b) Maintained sufficient pressure on the forward stroke to keep the teeth cutting.
Too much pressure on the saw blade will cause its teeth to dull.
c) Do not apply any pressure at the blade during return stroke since this will also
dull the teeth
d) The sawing speed should be at the rate of 40~60 strokes per minute. Cutting
stroke that is too fast causes friction
that6 will overheat the teeth and dull it.
Figure
5) Project Prosedure
1) Use L square and appropriate file to obtain flat surface (180)
2) Select another side of the work piece and file as previous step to obtain a flat
90surface.

3) Use engineering L square to check the surfaces, if rays of light cannot be viewed
between the work piece and the engineering square, i.e. the surface is already flat.
Make sure that the work piece is filed to the correct dimension.
4) Select the flat surface as the reference surface for marking process
5) Mark the work piece using high vernier caliper and plate angle on the marking table.
6) Create the rounded curve by using smooth surface file based on given dimension.
7) In order to make the cross section point line more visible, use the center punch. This
to ensure the measurement is consistently correct.
8) Begin the removing process by cutting the unused material using hacksaw only.
9) Smooth the edges of the work piece through filing.
10) Perform the drilling work for counter bore according to the steps described below:a) Center drill
b) Drill size 5 mm
c) Counter bore M10x5mm
11) Do the drilling work for through hole accordingly as below:a) Center drill
b) Drill bit size 5 mm
c) Drill bit size 6 mm
d) Drill bit size 8 mm