Mapua University

School of Mechanical and

Manufacturing Engineering

FLATBACK
Shop Exercise 2

PARADO, Jacob A. Date Performed:

2017142560 16 November
2019

ME123L-2 / A13 Date Submitted:

19 November
2019
Engr. Sherwin Magon
Instructor
Objectives:

1) To be able to manufacture a
flatback

2) To be able to understand the

concepts of wood processing and
providing allowances in measurements

3) To know how to safely use the tools

borrowed from the tool shed
DISCUSSION/ANALYSIS
Patterns are used in casting objects.
It is used to act as the replica of the
object that is to be cast. Patterns are
placed in molds and removed in order
for the mold to take the shape of the
replica. Liquid material is then poured
into the mold to produce the exact
shape as the pattern. One-piece
patterns are an example of a pattern.
One-piece patterns are the simplest
type of pattern. It is also the most
inexpensive among the patterns, but is
only used in cases where the job is very
simple. It may also be used in
application in very small-scale
production or in some cases, prototype
development. A one-piece pattern is
expected to be entirely in the drag and
one of the surfaces is expected to be
flat. The flatback is an example of this
pattern.
A flatback is generally a pattern that
has one broad flat surface that serves
as the parting surface of the mold. The
flat surface is on the cope side, making
a straight line parting on the joint
between the cope and drag of the
mold. Flatback patterns are very simple
to create. It also makes molding and
drag patterns easier since one of its
parts can be molded as a one-piece
pattern.
TOOLS/MATERIAL/EQUIPMENT.
1. Kiln-dried wood, 1pc 120 x 60 x
14.5mm
2. Backsaw
3. Keyhole saw
4. Small triangular file
5. Rasp file
6. Flat file
7. Half-round file
8. Steel brush
9. Try-square
10.Drill press
11.Drill bit (1/8" size)
12.Ruler
13.Caliper
14.Chair
15.Sandpaper (fine and rough)
16.Pencil
17.Eraser
18.Bench vise
19.Work bench
20.Work apron
21.Dust mask
22.Eyeglasses
MECHANICAL DRAWINGS
The drawings for the report must be
hand-made, using proper drawing
tools and equipment (pencils, erasers,
rulers, templates, French curves
which were previously used in
DRAWING CLASS) and finalized by
using black ink. Labels for dimensions
should likewise be written by hand,
using proper engineering lettering
format in a 2/4/4 mm template
slanted to the right @75 degrees.
Black ink will also be utilized for
dimensional constraints/lines,
including arrowlines, arrowheads. The
drawings should also include the TOP
VIEW, RIGHT SIDE VIEW, FRONT VIEW
and ISOMETRIC VIEW, all drawn into a
suitable scale that can be
conveniently drawn in a bordered
letter bond paper, with proper units
derived from the provided example.
PROCEDURE
Usage of a Technical flowchart,
including using the correct symbology
and designated by arrows to visualize
the workflow. It must have a START
and END.
1. Wear your PPE
2. Get tools and materials to be
used.
3. Prepare 120mm x 63mm x
14.5mm kiln-dried wood.
4. Use a ruler and try-square to
measure a 120x60mm rectangle
while providing allowance.
5. Using the same tools, hold the
workpiece in landscape, measure
a distance of 20mm from the top
left corner going to the right and
going down from the same point.
6. Connect these two dots.
7. On the bottom right corner, from
the same point, measure 20mm
going up and going left.
8. Connect these two dots.
9. On the top left corner, from the
same point, measure 40mm to the
left and down.
10.Connect these two dots.
11.On the bottom left corner, from
the same point, measure 40mm
going up and down.
12.Connect these two dots.
13.Draw the same shape, but smaller
inside three times, each shape
5mm apart.
14.Place the wood with the wide side
flat on the platform of the drill
press with drill bit and drill four
holes on the corners of the inside
of the smallest shape. Give
allowances.
15.Lock the piece of wood in the
bench vise and cut the sides of the
bigger shape using a back saw.
Give allowances.
16.Cut the inner part into shape with
the keyhole saw from the holes
created from the drill. Give
allowances.
17.Using the rasp file, file the excess
sides of the wood until little
allowance is left.
18.File the inner part slanting
outwards until the top part is
shaved by 5mm while keeping the
bottom part untouched.
19.Repeat for all sides, use small
triangular file for the small
corners.
20.File the outer part slanting
inwards until the top part is
shaved by 5mm while keeping the
bottom part untouched.
21.Use fine sandpaper to finish the
job.
22.Write necessary labels such as the
section and group number.
23.Submit.
24.
TOPIC QUESTIONS.

1) What specific tools and equipment

did you use during the practical work?
Enumerate and Explain how you used
each tool to finish your work.
a) Backsaw- for cutting the outer
corners of the wood.
b) Keyhole saw- for cutting the
center part of the wood.
c) Small triangular file- used for the
creating and smoothening the
inner corners.
d) Rasp file- used to grind and
remove large portions of wood in
a short time.
e) Flat file- used to remove and
smoothen wood into shape.
f) Half-round file- used to remove
and smoothen the wood into
shape.
g) Steel brush- used to clean the file
from wood dust.
h) Try-square- used to measure and
outline the wood with lines that
has 45o angles.
i) Drill press- used to control the rill
bit.
j) Drill bit (1/8" size)- used to create
holes into the wood.
k) Ruler- used to create lines with
specific lengths.
l) Caliper- used to measure the
thickness of the wood.
m) Chair- for sitting.
n) Sandpaper rough- used to grind
away a considerable amount of
wood.
o) Sandpaper fine- used to finish the
workpiece.
p) Pencil- used to create the outline
onto the wood.
q) Eraser- used to erase pencil
marks.
r) Bench vise- used to hold the
workpiece while it was being filed
or sawed.
s) Work bench- where other
necessary tools and equipment
were placed for ease of access.
t) Work apron- to keep clothes clean
from the wood dust.
u) Dust mask- to avoid inhaling
wood dust.
v) Eyeglasses- to protect the eyes
from the wood dust and pieces of
wood that may be flung.

2) What are the various types of wood

that are available in the market
today? Enumerate and define each.

a) Ash- are straight, wide-spaced

grains.

b) Birch- common and inexpensive.

Has yellowish brown hue and straight
grain.

c) Cedar- its density and mechanical

properties vary widely across
geographic sources. It is highly
durable and resistant to decay and
easy to work with.

d) Cherry- often used lumber in

woodworking. It is rich-color, hard and
straight-grained heartwood makes for
an ideal material for furniture and
elaborate architectural fittings.

e) Hickory- prized for its unique grain

patter. The stark contrasts of light
and dark coloration make for
interesting-looking furniture pieces.

f) Mahogany- one of the hardest and

versatile wood that can be harvested
from various regions across the
globe.

g) Maple- used a lot in hardwood

flooring for its exceptional strength
and durability.

h) Oak- it is readily available and

affordable. A staple material for big
construction projects.

i) Pine- each species has its own set

of defining characteristics. Some
species are valued for its hardness
and density while others are valued
for their grain appearance.

j) Walnut- boasts a robust quality. Has

bold, rich brown grain patterns.

3) What is a board foot? Explain

A board foot is a wood measurement

for a piece of lumber 12" wide by 1'
long by 1" thick for estimating
purposes.
4) What tool or tools can you use
when marking the wood? Explain why
so.

Pencil and mortise gauge may be

used to mark lines. While other tools
may be used to mark by scratching
on the surface such as scriber
marking tool, scratch awl, gauge,
cutting gauge, wheel gauge and
marking knife.

5) In making the flatback, what is the

best way to cut the tapers? Explain
your method.

The best way to cut the tapers is by

filing it carefully slantwise in one
direction.
6) How can you make a flatback
accurately down to the specified
dimensions? What specific steps can
you ensure that the final product will
be according to the given
dimensions?

A flatback may be accurately made

by creating a clear and accurate
outline. Then cutting the large parts
with a saw while giving plenty of
allowance. Lastly, file the workpiece
bit by bit while following the outline
as a guide.

7) What is another conventional way

of determining the correct angle of a
workpiece aside from using a try
square? Explain.

Another conventional way in

determining the correct angle of a
workpiece is by using a protractor, as
it is also commonly available.

8) Why is the bench vise an

indispensable tool in the workshop?
Explain.

They are indispensable as it holds an

object safety and securely so that it
can be worked on. They make work
such as sanding, finishing, chipping,
sawing, and welding easier by freeing
the operator's hands to perform the
needed task.

9) What is the difference of a Hack

saw, scroll saw, ripsaw and a back
saw?

A hacksaw is used primarily for

cutting plastic and metal pipes and
other small household materials. A
scroll saw is used in making delicate
designs on wood pieces. Ripsaw is a
specialized handsaw for manually
cutting wood in the direction of the
grain. A backsaw is a specialized
handsaw for cutting tenons (joints or
grooves) in wood.

10) How can you draw straight lines

on a curved surface of a wood?

By using a measuring tape around the

curved surface them marking it.
CONCLUSION.

After completing the activity, I

therefore conclude that I was able
to meet all the objectives raised.
We were able to construct a
flatback with the dimensions
120x60x14mm. I was also able to
understand the concepts of wood
processing by being creative and
imaginative, especially when it
came to the outline. I also learned
to provide allowances in
measurements in case of errors.
Lastly, I was able to learn how to
safely use the tools borrowed from
the tool shed, including the
different types of files, saws,
measuring instruments and the
drill press.
RECOMMENDATIONS.
This applies to all related
recommendations that can be
considered for the particular shop
exercise, i.e. improvements,
discovery of new techniques that
were not previously discussed but
have learned during the course of
making the practical work
REFERENCES.
https://unruhfurniture.com/blog/workin
g-different-types-wood-best-
techniques-learned-hard-way/
https://woodmizer.com/us/Tips-and-
How-To/what-is-a-board-foot
http://www.joineryequipment.com/woo
dworking-marking-tools/
https://shopgraytools.com/blogs/news/
metalworking-bench-vises-a-closer-
examination
https://home.howstuffworks.com/hacks
aw.htm
https://drillly.com/scroll-saw-functions-
and-uses/
https://home.howstuffworks.com/ripsaw
.htm
https://home.howstuffworks.com/backs
aw.htm
http://mechanicalinventions.blogspot.c
om/2012/12/types-of-patterns.html
http://www.reliance-
foundry.com/blog/what-is-a-casting-
pattern#gref
http://nptel.ac.in/courses/112107144/1
7
http://techminy.com/pattern-types
http://www.atlasfdry.com/glossaryf.htm
http://4mechtech.blogspot.com/2014/0
4/types-of-patterns-and-uses.html
https://tinyurl.com/ybu7qf9d