MACHINE SHOP LABORATORY REPORT

WEDNESDAY, FEBRUARY 17TH 2019, 17.00-20.05

MODULE 1

ALUMINUM FILING

By:

Elin Rachmawati (2017360005)

Gloria Aprilia (2017360006)
Steven Mark Levy (2016360004)
Wahyu Haykal Rahmanda (2017360015)

Lectured by:

Mr. Ifat

MECHANICAL ENGINEERING
FACULTY OF ENGINEERING AND TECHNOLOGY
SAMPOERNA UNIVERSITY
2018
 Table of Contents

Table of Content 1
CHAPTER 1: Introduction 2
1.1 Objectives 2
CHAPTER 2: Theoretical Background 3
CHAPTER 3: Technical Description 8
CHAPTER 4: Methodology 10
CHAPTER 5: Results and Analysis 11
5.1 The Various Cross Section of File 11
5.2 Reference Surface 12
5.3 Filing Tools Storage 12
5.4 Filing Result 13
CHAPTER 6: Conclusion 15
References 16

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 CHAPTER 1
INTRODUCTION

The filing is important finishing operation or process of some excess materials and
deburring the surface. Files have several types with different functions. Cutting teeth in the file
used to cut the workpiece. In general, hand files are made of high carbon steel with patterned
teeth to cut the workpiece. The file is heat treated after forming the teeth to increase the
mechanical properties of the file. So, when the teeth are rubbed into a softer part, the teeth will
dig into the material and eliminate some excess materials and deburring the surface.
The right technique is needed to get better results and keep the file from being damaged.
Most people do not do filing in the same direction. This back and forth movement is inefficient
and has the potential to damage files. The filing is done by pushing the file to the side to cut
the workpiece then lifting the file from the workpiece when the file is pulled back.
The filing is not as easy as what people imagine. In the process, there are several
considerations to get a good result to the workpiece. These considerations include the type of
file used must be in accordance with its function (rough surface to remove any excess materials,
smooth surfaces to smooth the workpiece surface, form a 60 degrees angle or make a surface
that has curved), techniques used, and the right way to clean and maintain to prevent the
damage of file. The filing process will be discussed further in the following chapters.

1.1 Objectives
In this experiment, there are some objectives that is needed to be achieved:
a. to understand the use of various life
b. to be able to produce the Charphy impact test specimen by filing

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 CHAPTER 2
THEORETICAL BACKGROUND

The filing is a process that aims to eliminate some excess material and deburring the
surface. The files are the tool used for the filing process. Most files are made from a case of
hardened steel bars and can be made from high carbon steel. Files have three distinguishing
features, namely length, cross-section or shape, and grade or cut. The handle is securely
attached to the pliers for comfort and to prevent injury. The cutting teeth are both faces of the
file.

Figure 2.1 The Features of File [1].

Files are distinguished based on several categories such as cross-section, grade of cuts,
and level or coarseness. There are several types of cross sections of files, such as flat, round,
half-round, triangular, square, etc.
Table 2.1 Types of Files based on the Shape
Cross-
File Name Shape Description
Section
The Hand File is parallel in width
for its length. It is Double Cut on
both faces, Single Cut on one edge,
Hand File
but the other edge is blank and called
the Safe Edge. Used for general
purposes.
The Flat File is Double Cut on both
faces and Single Cut on the edges. It
Flat File
tapers slightly towards the point.
Used for general purposes.

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 The Half-Round File is Double Cut
on the flat side and Single Cut on the
Half-
curved side. It tapers slightly towards
Round
the point in bothe width and
File
thickness. Used for filing concave
surfaces and internal corners.
The Round File is Double cut. It
Round tapers slightly towards the point.
File Used for enlarging holes and internal
corners.
The Square File is Double Cut on all
Square sides. It tapers slightly towards the
File point. Used for rectangular slots,
square holes and internal corners.
The Three Square File is Double
Three Cut on all sides. It tapers slightly
Square towards the point. It is triangular in
File section. Used for filing into internal
angles.

There are two types of cuts that are usually made for files, single cut, and double cut. The
Single Cut File has a single row of teeth extending across the face at an angle of 65 ° to 85 °
for the length of the file. The Double Cut File has two rows of teeth which cross each other.
For double cut, the angle of the first row is 40 ° to 45 °, and the second row can be anywhere
between 30 ° and 87 ° [1].

Figure 2.2 Teeth Files (a) Single cut file, (b) Double cut file, (c) curved cut file, (d) Rasp cut
file [2]

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 Files can be classified by the coarseness of the teeth. The bigger teeth mean the feel of
the file, and the quicker the files to remove the material. Four main levels of coarseness in the
metalwork room are:
➢ Rough
➢ Bastard
➢ smooth
➢ Very smooth
If it is cannot tell by looking at the File which it is, then just rub our finger gently along
it and figure it out. Besides choosing tools and some specifications based on needs, to provide
maximum results, the right technique is needed when filing. Following are some of the
techniques commonly used in the filing process.
➢ Heavy filing; is used when a lot of materials needs to be removed. Hold the file by its
handle with the dominant hand. With the opposing hand the palm onto the tip of the
file. the palm is used to help press down while the dominant hand is used to guide and
control the direction of the file. Rather than press hard for aggressive cuts to a more
aggressive (coarse) file. Pressing too hard will dull the file more quickly.

Figure 2.3 Heavy filing technique [2]

➢ Light Filing; This technique is used when the material must be removed slowly. It uses
the same pressure with the general technique as heavy filing but rather than applying
pressure with the thumb only. With the practice of thumb, the amount of material which
is removed can vary.

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 Figure 2.4 Light filing technique [2]

➢ Draw filing; is a modified technique that should be used with single and double-cut
files. In this technique, the file is turned on sideways and is grasped on both ends. The
file is then sawed back and forth to remove material. The reason for backing is
acceptable for the case with the diagonal teeth of the single and double-cut files. As the
file is drawn back and for the newly cut material forces the material is off the teeth.
With the double-cut variety of files, both strokes of the files are cutting into the material
reducing the chance of dulling.

Figure 2.5 Draw filing technique [2]

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 The position of the body is important to get good results when filing. The right body
position when filing is shown in figure 2.6.

Figure 2.7 Standing Position for Filing [3]

Before beginning to file make sure that the vice has the correct height and the workpiece
is firmly clamped. The weight of the body is resting on one leg; the other leg is always
straightened; both feet have to be firmly on the ground. The file is moved with the arms only,
not with the upper part of the body . The upper part of the body must not swing. The file is
pressed onto the workpiece when pushing the file forward only; It is pulled back without
pressure. The file is to be guided so that the movement is always horizontal.While filing, never
apply pressure on the draw (pull) strokes so the file teeth will not break off. The potential cause
of pinning can be reduced [3].
File cleaning and maintenance is important due to tool life. Files need to be cleaned
before, after and during use because any debris is stuck in teeth file. This cleaning process for
the file will give you the best result for the surface of the workpiece.

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 CHAPTER 3
TECHNICAL DESCRIPTION

In this laboratory activity, the most frequently used tools are the metal files. There are
several types of metal file that are functioned to process the aluminum plate. Those are the
rough file, the triangular file, and the flat file. Each of them has different shape of surface, so
they have distinct usage.

Figure 3.1 (a) Rough metal file. (b) Triangular metal file. (c) Flat metal file.

The rough metal file has bold single-cut surface. Mostly, it is used after cutting the metal
using the hand saw. The main function of this rough file is to slightly trim the metal. Since it
can trim up to 0.1mm at one move, it is considered to have a big effect of trimming compared
to the triangular and flat metal file.
Besides, the triangular metal file has softer double-cut surface. The result of this softer
surface is that the file cannot trim the metal as significant as the rough metal file, but the result
of trimming using this triangular metal file is quite smooth. As it has equilateral shape, the
triangular metal file is functioned to make a 60-degree trim on the surface of the metal plate.

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 The last one is the flat metal file. It has a soft double-cut surface that allows the file to
trim the metal very slowly with a quite smooth surface. The main use of this file is to trim a
small amount of metal’s surface to make it more straight and smooth.
Every metal file in this experiment needs to be cleaned by the cord brush, to remove the
metal debris that left on the gap between file’s cut lines. Since this laboratory activity takes
soft metal (aluminum) as the object, it will be harder to clean the file because the debris may
stick strongly on the cut gaps. A little press on the brush is necessary to get rid of that sticky
debris

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 CHAPTER 4
METHODOLOGY

1. All the safety things (gloves, mask, goggles, apron) was wore.
2. The tools and device (filing tools, measurement tools) was prepared.
3. The material was prepared and measured with dimension 52 mm x 12 mm x 12 mm.
4. The material was cut by used seesaw.
5. The material with dimension 52 mm x 12 mm x 12 mm was clamped in the vise.
6. The material was filed using bastard cut filing tools.
7. The flatness was checked using knife edge.
8. After several filed process, the dimension was measured using Vernier caliper.
9. Step 6 and step 7 was repeated until the dimension of the was closed to 50 mm x 10 mm
x 10 mm.
10. Then, the material was filed using smooth cut filing tools until the dimension became 50
mm x 10 mm x 10 mm with uncertainty ±0.1 mm.
11. After that, the mid point of the material was created to made v-notch.
12. The material was clamped again and filed using triangular filing tools to made v-notch
with 2 mm in depth.
13. The v-notch was smoothed using smooth cut filing tools.
14. Then, the material was smoothed using paper sand.
15. And the last was cleaned the working table and the filing tools. The filing tools was
cleaned using brush.

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 CHAPTER 5
RESULTS AND ANALYSIS

In this chapter, the data collected during the laboratory experiment will be explained and
analysed. Starting from the file tools which used in the process, the importance of reference
point during the filing process, proper storing of hand file tools, and the filing result of this
laboratory experiment.

5.1 The Various Cross Section of File

Figure 5.1.1 The Cross Section of the File [4]

The cross section of the file is the shape we will get if we cut the file in half widthways.
Figure 5.1 shows several kinds of file cross section and those cross sections have different
function. In our practicum, because we will create a v-notch specimen, we only use the two
common cross sections, which are rectangular and triangular. There are several kinds of file
tools with rectangular cross section, such as flat file, hand file, etc and there is one file tool
with triangular cross-section such as three-square. Occasionally, the rectangular cross section
file tools used for removing or smoothing the material surface. While triangular cross section
file tool sometimes used for shaping the material. In our practicum, the rectangular cross
section file tools used for removing and smoothing the material surface and the triangular cross
section file tools used for creating a v-notch.

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5.2 Reference Surface
Reference surface was used to be the guidance of the straightness and flatness
of the specimen. In order to create a perfect product in this experiment, it was extremely
important that only one reference surface which was used as the guidance of straightness
and flatness. During the process, the straightness was tested using the water-level to create
a surface without inclination with ground reference (that was why a water-level was used
to test the straightness since water level is straight with the ground). When one side has
been decided to be the reference point, all of the remaining sides will follow the
straightness of the reference surface during the filing process. Using this method, all of the
remaining surfaces will have the same straightness with the reference surface which
resulted in perfect flat, straight, and square specimen. Using more than one reference
surface was not recommended since the remaining sides can only follow one reference
point in order to make a perfect flat, straight, and square specimen. The filing process of
reference surface will be different from one reference surface to another reference surface
since both did not have a guidance straightness in the first trial of filing. Therefore, one
reference surface was the only recommended technique to create a perfect flat, straight,
and square specimen.

5.3 Filing Tools Storage

Filing tools storage method were also very important. When a filing process has
been completed, there are several things which needed to be done in order to make the
filing tool have a better lifespan. After filing process completed, it was very necessary to
remove excess metal scrapped using the tools which were stuck between the teeth of the
tools using a metal brush. Clean filing tools will result in clean filing result since metal
excess between the teeth of the filing tools can scratch the surface of the material which
being filed using the filing tools. Furthermore, using vinegar to remove excess rust was
also very important to maintain the lifespan of the tools themselves. Aside from cleaning
the filing tools with metal brush and vinegar, the technique of storing the tools are very
important. In the workshop, the filing tools storage was looked like as the Figure 5.3.1
below.

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 Figure 5.3.1 Shows the Filing Tools Storage Cabinet

The figure above shows that each hand files are being hung vertically without
touching each other. This is very important to protect the files from damaging each other.
Hand files were created to trim out other materials, meaning that they were very hard. The
material of the file which used during the process in this laboratory experiment was the
high carbon steel. This type of metal was very strong and hard. Since the file tools were
created using the same material, they had approximately similar hardness to each other. If
the files were stored unproperly, meaning that the file tools were touching each other, it
would be creating a major defect on the file tool’s cross section teeth. The teeth of the tools
will trim out each other, creating a bad cross-sectional teeth which will result in bad filing
result when the tools are going to be used again in the future. Therefore, using a cabinet
shown in the Figure 5.3.1 above was very important to keep the file tools safe and protect
them from damaging each other in order to increase the lifespan of the tools.

5.4 Filing Result

After doing filing process, the workpiece have a new dimension of length, width,
and the thickness. The new dimension of the workpiece in shown in figure below. The
width of the workpiece (Figure 5.4.1) is 10.4 mm, the length of the workpiece (Figure
5.4.2) is 50.5 mm, and the thickness of the workpiece (Figure 5.4.3) is 10.7 mm. It can be
seen that the dimensions result is not accurate since the difference is more than the
uncertainty (± 0.1 mm).

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 Figure 5.4.1 The Width of the Workpiece

Figure 5.4.2 The Length of the Workpiece

Figure 5.4.3 The Thickness of the Workpiece

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 CHAPTER 6
CONCLUSION

After having this laboratory activity, there are several things that can be concluded. The
first thing, metal file comes in different types and textures. Types and textures of the metal file
can be chosen by the user according to the purpose and the needs. For example, in making
specimen for Charpy impact test, the flat rough metal file, flat soft metal file, and triangular
metal file are functioned. Secondly, reference surface is vital. In making the specimen, the
reference surface is used as the standard in ensuring the flatness and straightness of another
surfaces. In making a specimen, it is not recommended to have more than one reference surface.
More than one reference surface can cause an irregularity in the straightness of another
surfaces. Lastly, about the dimensional tolerance. Since this project has trimming process in its
procedures, the dimensional tolerance need to be noticed. This dimensional tolerance measures
how accurate the dimension of the product, therefore dimensional tolerance is important to
make the product as perfect as possible.

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 References

[1] “Metalwork - Bench Tools - Files,” PracticalStudent.com. [Online]. Available:

http://www.practicalstudent.com/subjects/metalwork/benchtools/pages/files.shtml.
[Accessed: 12-Mar-2019].

[2] Hope Wadle, “How to Use a Hand File,” DISHER, 02-Jan-2019. [Online]. Available:
https://disher.com/2016/08/12/filing-away-use-hand-file/. [Accessed: 12-Mar-2019].

[3] 5. Standing position and guiding of the file. [Online]. Available:

http://www.nzdl.org/gsdlmod?e=d-00000-00---off-0cdl--00-0----0-10-0---0---0direct-
10---4-------0-1l--11-en-50---20-about---00-0-1-00-0--4----0-0-11-10-0utfZz-8-
00&cl=CL2.6&d=HASH9f0ac4a8e6becce8098a39.6>=1. [Accessed: 12-Mar-2019].

[4] “Chapter 3: Filing & Sawing,” Chapter 3: Filing & Sawing | Metal Arts Press.
[Online]. Available: http://www.metalartspress.com/books/chapters/chapter-3-filing-
sawing. [Accessed: 12-Mar-2019].

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