HAMMER EXERCISE

Ball Pein Hammer

BEFORE YOU LEAVE:
Smooth Cut File

Bastard Cut File
1.)

Die and Die Wrench

300 mm Steel Ru

2.)
Tap Wrench

Centre Punch Dividers

Tap Scribe

le
Engineers
Square
3.)
Hacksaw

MAXIMUM DEDUCTION OF

MARKS CAN BE 100%.
Spare Hacksaw Blade

CONTENTS:

- 1 x Hammer Exercise Sheet - 1 x 300 mm Steel Rule - 1 x Bastard Cut File - 1 x Tap Wrench
- 2 x Instruction Sheets - 1 x Engineers Square - 1 x Smooth Cut File - 1 x Tap
- 1 x Ball Pein Hammer - 1 x Scriber - 1 x Hacksaw - 1 x Die
Last Revised: 11/02/19
- 1 x Centre Punch - 1 x Spring Dividers - 1 x Spare Hacksaw Blade - 1 x Die Wrench By: DERRICK HO
Hammer Exercise Instructions

Hammer head [45mins - 60mins]
1. Remove the burrs from all edges with a file.
2. Apply marking blue to the TOP and SIDE of the bar
3. On the SIDE, measure and scribe a line 65mm from
the striking face and 4.5mm up from the lower side (Fig 1)
4. Lightly centre punch point of intersection of the two lines from step 3.
5. Set dividers to 4.5mm and scribe a circle from the centre point from step 4.
6. On the TOP, scribe a line 35mm from the striking face (Fig 2)
7. On the SIDE, scribe the line from the 35mm edge to the top of the circle (Fig 3)
8. Centre punch along the line (from step 7) every 5mm to act as a guide for cutting.

[cutting stage]
9. Using a hacksaw, cut down the line to form the tapered tail of the hammer head.
Hint: You should leave some excess material to be safe, which can be filed off later.
10. Use the bastard cut file to remove majority of the excess material
11. Use the smooth cut file to finish off the surface
12. File the radius of the hammer tail (draw from step 5);
Start with the bastard cut, then finish off with the smooth cut.
13. Evenly file four chamfers on the striking face of the hammer head

[Intermission – demonstrator will explain how to make threads to class]

Tapping hole in hammer head [30mins – 60mins]
14. Countersink the two holes using a drill [See demonstrator]
15. Tap the M8 hole into the hammer head.
Ensure tap goes in straight and square. Use cutting fluid.

Hammer handle [20mins-30mins]
16. Chamfer the round bar (hammer handle) using the files.
(this aids the start of the thread making with the die)
17. Using the M8 button die and wrench, cut thread to approximately 18mm.

Assemble the hammer and finish [15mins]
18. Screw the handle into the head tightly to prevent it from coming loose.
19. Remove any sharp edges

20. Clean up/sweep up work station
21. Organise tools as per layout
22. Use masking tape and write your name/SID on the hammer

[END OF EXERCISE – PAGE 1 of 1]


 TOP

STRIKING

FACE
FIG. 1

4.5

65

R 4.5

FIG. 2

35

FIG. 3

ALL DIMENSIONS IN MM

NOT TO SCALE
Hammer exercise marking sheet Revised 08/02/19 Derrick Ho

Name: SID:

Mark:

Work Station: Marker:

Week Monday Tuesday Wednesday Thursday Friday

9am-12pm
2pm-5pm




Items to be marked circle one mark
in each box only

1 Punctual with all three correct PPE gear? 0 10

2 Sharp edges and burrs removed? 0 10

3 Hammer head M8 hole tapped through? 0 10

4 Handle thread made to sufficient length? 0 10

5 Correct assembly and representation of hammer to the drawing? 0 10

6 Chamfers on striking face of hammer equally round? 0 5

7 Centre punch marks(semicircular) still visible at 6mm intervals? 0 5

8 Correct radius on the end of hammer head? 0 10

9 Top section of hammer: filed smoothly and square (10), and 0 10

to correct length (10)? 0 10

10 Top of handle sufficient length into hammer head and peened? 0 10

TOTAL /100
Maximum deductions for not cleaning up, up to 100%.