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Bench Working PDF
Bench Working PDF
MATERIALS
WORKSHOP TECHNOLOGY
MME 1103
BENCHWORK
MANUFACTURING AND MATERIALS DEPARTMENT
MME1103
Workshop Technology Manual
Benchwork
1
1. Objective
To identify various types of hand tools and its usage
2. Required Apparatus
Bench vise, marking out table, hand hammer, files, center
punch, ruler, steel
file brush, scriber, high vernier caliper, hacksaw, angle plate,
dividers
3. Required Materials
Cast Iron
4. Introduction
The workbench is the craftsman’s head quarters, where
operations involving the use of hand tools such as sawing, filing,
chiseling and marking out are appropriately carried out. In this
section, 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 and center punch, and scriber.
4.1 Bench Vise
The bench vise is used to help grip the workpiece 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 workpieces enough to mar them beyond repair.
Hence, soft jaws made of copper, other soft metals or wood are often
slip over the vise jaws to protect the workpiece’s finished surface.
Figure 1: Bench Vise (Workshop Manual)
Bench vise should be mounted correctly on the workbench where
the top of the vise jaws should be at elbow height. Inappropriately
mounted bench vises causes poor workpiece to be produced.
MANUFACTURING AND MATERIALS DEPARTMENT
MME1103
Workshop Technology Manual
Benchwork
2
4.2 Filing
Filing involves the small scale removal of material from a surface,
corner, or hole, including the removal of burrs (Kalpakjian and
Schmid, 2001). 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 (Kibbe et.al., 2002).
Figure 2: Basic components of a file (Workshop Manual)
Figure 3: Various file cross sections (Workshop Manual)
Make long steady strokes using the full length of the blade
MANUFACTURING AND MATERIALS DEPARTMENT
MME1103
Workshop Technology Manual
Benchwork
5
4.6 Scriber
The scriber is a round steel piece of about 150mm to 300mm long
and 3mm to 5mm in diameter. Its one end is sharp and pointed and
the other end is also sharp but bent. The bent end is used to scratch
lines in places where the straight end cannot reach.
Figure: Scriber
Figure 7: Scriber (Workshop Manual)
5. Project Methodology
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
90˚ surface
MANUFACTURING AND MATERIALS DEPARTMENT
MME1103
Workshop Technology Manual
Benchwork
6
3. Use engineering 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 workpiece is filed to the
correct dimension.
4. Select the flat surface as the reference surface for
marking process
5. Mark the workpiece using high vernier caliper and plate
angle on the marking
table.
6. Create the rounded curve using divider 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 workpiece through filing.
10. Perform the drilling work for counterbore according to
the steps described
below:-
a. Center drill
b. Drill size Ø5.5 mm
c. Counterbore M10x5.5 mm with a depth of 5 mm
11. Do the drilling work for through hole accordingly as
below:-
a. Center drill
b. Drill bit size Ø6 mm
c. Drill bit size Ø8 mm
d. Drill bit size Ø10 mm