Mapua University

Muralla St. Intramuros, Manila

Department of Mechanical and Manufacturing Engineering

SHOP PRACTICE NO. 7

OFF HAND METHOD:
BALL-PEEN HAMMER

CRUZ, Joshua Miguel L.

ME-2
ME137L – 2
2016142124 GRADE
Group 2 – A19

Engr. Jose V. Hernandez

INSTRUCTOR
 Shop Practice No. 7

OFF HAND METHOD

BALL-PEEN HAMMER
OBJECTIVES:
1. To be able to make a ball peen hammer head.
2. To be able to practice forming process in a lathe machine.

METHODS and ANALYSIS:

Forming is the machining of irregular and curved surfaces in a workpiece turned in a
lathe. This is accomplished with an off-hand method or with formed tools.

MATERIALS:
1-piece round bar 1-inch diameter x 2 ½ inch length

TOOLS AND EQUIPMENT TO BE USED:

Lathe machine and its accessories – to cut and shape metals by revolving it on a cutting tool.

Hack saw – for cutting.

Set of turning tools – for cutting in lathe machine.

Flat file – to smoothen the surfaces.

Vernier caliper – to measure the dimensions

PROCEDURE:

1. Mount the workpiece in the lathe machine.

2. Perform the straight turning cut to the workpiece.
3. Mark the workpiece to the preferred size with ball peen hammer head.
4. Perform the offhand forming on the parting division.
5. Set the automatic for a slow feed so that carriage will move slowly to the right.
6. With the tool set to a depth will produce the required large diameter. The automatic feed
is engaged, the carriage travel to the right. The tool is fed in gradual with the cross feed.
7. The tool be then followed the curved path as indicated by the arrows which show the
direction of the travel.
8. Finish the ball peen hammer head.
9. Bore the 8mm diameter on the center of the ball peen head.
10. From the exercise on straight turning which is the hammer handle.
11. Joint the handle and the ball peen head by riveting the handle to the head.
12. Finish.
QUESTIONS:

1. What is forming process?

Forming is mostly used for metals however plastic forming can also be done. The
forming process uses different stresses such as compression, tension, shear or the
combination of these stresses to deform the material into different predefined geometrical
shapes. The process also pertains to a shaped longitudinal prism that change in its cross-
sectional area.

2. What kinds of tools are needed in the forming process?

A forming tool is precision made into a pattern that resembles the part to be formed. They
are also usually flat or circular in shape. When used in a lathe machine, the shape of the
tool depends on the application such as milling machine cutters are generally flat while
screw machines are a mix of flat and circular shapes.

3. What is a straight forming tool?

A straight forming tool is a tool that can be both used for left or right cut. It is used to
convention a workpiece. It is also used for wide forming operations. And is clamped in a
horizontal position upon the cut off slide.

4. What should be done to lessen the chattering noise produced by forming tools?

To lessen the chattering noise, we should look at how the workpiece is clamped up or
situated in the chuck in the case of the lathe machine. We should also look if the
workpiece is properly supported by the tailstock if it is long. Another thing to note is that
various parameters such as feed, depth of cut, type of material being machined, tool used,
and cutting speed should be assessed to see if adjustments can be made to lessen the
 chattering noise. This noise could mean that the cutting speed is too fast or that the depth
is too deep so appropriate adjustments must be made.

5. What kind of materials can be used in forming tools?

Hard metals such as high speed steels, carbide steels can be used for this materials. But
ceramics can also be used as well.

6. What part of the ball peen hammer is needed for riveting?

The part that of the ball peen hammer that is needed for riveting is the top most part of
the handle which is to be connected to the head. The center of the ball-peen hammer head
must be located so that the hole of the drill can be made at that location so that the
hammer will be weighed evenly when fused with the hammer handle.

7. What type of spindle speed should be used in forming tools?

The optimal spindle speed for forming should be a high speed so that the desired shape
could be obtained. This will also result to a finer finish.

8. For finishing the works, what tools are needed?

In finishing the workpiece, a file is usually needed to remove excess material and to
smoothen the edges and to make tapers if needed. Uneven surfaces are also filed down to
improve the quality. Also, sandpaper can also be used to provide a better finish and to
take one step further, metal polish can be applied as the finishing touch as well.

9. What is needed for cooling while cutting with a forming tool?

 Cutting fluids such as oil are needed for this type of machining processes. The benefits of
using this cutting fluids are the reduction of friction thus reducing the damage to the tool,
reducing thermal deformation to the workpiece, improving surface finish, and washing
away of chip and debris from the cutting process.

10. Forming tools are best suited in what kind of production machine?

A lathe machine would be the most optimal type of production machine for forming
tools. Since a lathe machine utilizes different tools and bits to form desired shapes and
results, then they are a perfect fit for forming tools which are used to get precise and
patterned shapes.
DISCUSSION:
In this particular activity, we were tasked to use a lathe machine for a forming process. In this
process, we should be able to create one of the needed hammer heads which is the ball-peen
hammer.
In doing the ball-peen hammer, we were given a round bar to be formed into the trademark ball-
peen hammer head. The process started like any other process with a lathe machine where the
workpiece is mounted on the chuck and is supported by the tailstock. In this case, the support
was not needed because the workpiece was not that long. In shaping the piece, we utilized
different cutting tools to get the desired shape. Getting the optimal dimensions proved to be quite
challenging since the group made a mistake which resulted to a change in the dimensions of the
hammer head. We also utilized a file as a cutting tool to get the desired shape of one of the ends
of the head.
After finishing the head, we bore a hole thru it as well using a drill press and riveted it. In
riveting, we utilized the extra length of rod from the handle as the rivet by using an oxyacetylene
flame to soften the rod and hammer it down until it fused with the hammer head. After a
thorough hammering, the piece was left to cool under running water. After that, we used a file to
remove any sharp edges left and to improve the surface of the hammer. Next, is we also used
sandpaper to improve the surface finish and as a finishing touch we applied metal polish.
CONCLUSION AND RECOMMENDATION:
In conclusion, this activity taught the students of another process that can be achieved with the
lathe machine. The lathe machine is not only used for centering, turning, or knurling but it can
also be used for forming which is to shape a material to a desired form or shape by utilizing the
rotation of the workpiece in the lathe machine and using cutting tools to make the desired
patterns or shapes. The activity also taught the students, the importance of having an accurate
orthographic drawing and measurements because the group had a problem in this regards which
took a lot of time to correct.
As for recommendations, the group advises those who will be doing the activity to listen
attentively and take down notes if possible. This process is important because the forming
process is applicable to a wide array of production of parts. Also, be mindful of the
measurements and dimensions of your desired shape and make sure to not cut too much material
away so that any problems like the ones the group encountered could be avoided. Another thing
to note is that when using a file to shape the piece, always wear proper PPE like a face mask
because chips could fly towards your face and hit your eye. And also refrain from goofing
around when the machine is running because you may get into an accident. Moreover, have
patience when doing this activity because this is very tedious and labor intensive especially if
you make a mistake since correcting that mistake will require a number of procedures and will
eat a bulk of your time.
REFERENCES:
http://engineering.myindialist.com/2009/lathe-operations-knurling/#.XYuladIzbIU
https://smithy.com/machining-handbook/chapter-3/page/25
https://www.globalspec.com/learnmore/manufacturing_process_equipment/cutting_tools/knurlin
g_tools
https://www.mscdirect.com/basicsof/knurls
https://www.practicalmachinist.com/vb/south-bend-lathes/oil-knurling-232615/
https://en.wikipedia.org/wiki/Knurling
http://www.fastonline.org/CD3WD_40/CD3WD/METALWRK/GTZ103BE/EN/BHTM
http://www.fastonline.org/CD3WD_40/CD3WD/METALWRK/GTZ103BE/EN/B592_3
http://www.fastonline.org/CD3WD_40/CD3WD/METALWRK/GTZ103BE/EN/B592_4.HTM
https://smithy.com/machining-handbook/chapter-3/page