WTP MODULE 1: INTRODUCTION
INTRODUCTION  There are other operations too that fall in
Machine shop – facility with equipment and
supplies for machining
 Machining - process where parts are cut,
fabricated, and finished to prepare them for
use
o manufacturing process that involves
removing materials using cutting
tools for getting rid of the unwanted
materials from some workpiece and
converting it into the shape you
desire
o A large piece of stock is used for
cutting the workpiece.
 Machine shops are used in the creation of
new parts, as well as repairs of existing
equipment and parts
 Personnel – specialized training, depending
on the type of work done at the shop
o Some machining tasks require a
unique skill set, as well as a deep
understanding of the kind of work the
finished parts will be used for
 Found in educational and research facilities,
where people learn about machining in the
context of:
o Repair
o Fabricating parts for custom
applications (developing equipment
for use in experiments)
 Both an engineer's laboratory and an artist's
studio
o Some operations require a lot of
precision and planning and three
dimensions, while others are more
free form
 Each material and each operation require
different machines, but they all follow the
same basic principles
o By knowing the possibilities and
limitations of the tools, you can better
design the objects you create
3 PRINCIPLE PROCESSES OF MACHINING
OPERATIONS
rotate the workpiece as the primary
method of moving metal against the
Turning
cutting tool.
operations
 Lathes are the principal machine
tool used in turning.
the cutting tool rotates to bring
cutting edges to bear against the
Milling
workpiece.
operations
 Milling machines are the principal
machine tool used in milling
holes are produced or refined by
bringing a rotating cutter with cutting
edges at the lower extremity into
Drilling
contact with the workpiece.
operations
 Drilling operations are done
primarily in drill presses but
sometimes on lathes or mills.
1
miscellaneous categories such as:
o Boring
o Sawing
o Shaping
o Broaching
 A specific machine tool is required for taking
care of each machining operation.
COMMON LAYOUT TOOLS AND MEASURING
EQUIPMENT
Measuring instruments have an important role in a
mechanical workshop.
 The quality of work is based on the
accuracy and precision of the instruments
used for inspection
Steel rule – measuring instrument having a long,
thin stainless steel strip with a marked scale of unit
division such as in centimetres or inches
 Used for drawing lines, measuring distances
between two points, etc.
 Available in different sizes, such as in 15cm,
30cm, 60cm, 1m, 1.5m, 2m, 3m, 4m, 5m &
6m.
 Generally, least count of a steel rule is
0.5mm
Vernier caliper - precision instrument
 used for measuring internal and external
distances between two points extremely
accurately.
 Two versions: manual and digital.
o manual version – both an imperial
and metric scale.
 does not need any power
source
o digital version – requires a small
battery
 Available in the range of 0-100mm, 0-
150mm, 0-200mm, 0-300mm, 0-600mm and
0-1000mm
Scriber – to obtain an accurate layout, fine lines
must be scribed in the metal.
 The point is made of hardened steel and is
kept chain by honing on an oil stone
 WTP MODULE 1: INTRODUCTION
Divider – best used when laying out circles, arcs,
and radii
 The legs of the divider must be of the same
length and be kept sharp.
 The divider cart be used to lay out and
measure distances
Trammel – layout tool which should be used when
scribing circles, arcs, and radii that are too large to
be produced with the divider.
 Made of three main parts:
o Beam
o two sliding heads with scriber points,
o adjusting screw attached to one of
the heads.
 Can be made to scribe larger distances with
the use of extension rods.
 Set in the same manner as the divider.
Hermaphrodite Caliper - used to layout lines that
are parallel with the edges of the workpiece.
 Can also be used to locate the center of
cylindrical shaped workpieces.
Surface Gage - used for many purposes, but is most
often used for layout work.
 The gage can be used to scribe layout lines
at any given distance parallel to the work
surface.
 The scriber can be positioned at any height
and in any desired direction on the spindle by
adjusting the scriber.
 A surface plate and combination square are
needed to set the surface gauge to the
correct dimension.
Surface Plate - provides a true, smooth, plane
surface.
 Used in conjunction with surface and height
gauges as a level base on which the gauges
and the workpiece are placed to obtain
accurate measurements.
2
 Made of semi-steel or granite and should
never be used for any job that would scratch
or nick the surface.
Vernier Height Gauge – caliper with a special foot
block to adapt it for use on a surface plate.
 Height gauges are available in several sizes:
the most common are the 10, 18, and 24 inch
gauges in English measure and the 25 and
46 cm gauges in metric measure.
 Like the vernier caliper, these height gauges
are graduated in divisions of 0.025 inch and
a vernier scale of 25 units for reading
measurements to thousandths of an inch.
 Always be sure the bottom of the foot block
is clean and free from burrs.
Combination Square Set – used for layout
operations.
 The set consists of:
o blade (graduated rule)
o square head
o protractor
o center head
Blade – designed to allow the different heads to
slide along the blade and be clamped at any desired
location.
 The groove in the blade is concave to
eliminate dirt buildup and permit a free and
easy slide for the heads.
 By removing all the heads, the blade may be
used alone as a rule.
Square Head – designed with a 45° and 90° edge,
which makes it possible to be used as a try square
and miter square.
 By extending the blade below the square, it
can be used as a depth rule.
 The square head can also be used as a level.
Protractor Head – equipped with a revolving turret
graduated in degrees from 0 to 180 or to 90 in either
direction.
 WTP MODULE 1: INTRODUCTION

 It is used to measure or lay out angles to an of the supervisor and shop supervisor for
accuracy of 1°. completion of training. help.
Never use damaged Always wear safety
Center Head – when inserted on the blade, is used or malfunctioning glasses. Some
to locate and lay out the center of cylindrical equipment operations and
workplaces. equipment may require
personal protective
Bevel Protractor – consists of an adjustable blade equipment (PPE).
with a graduated dial. Never distract a Always remove
 The blade is usually 12 inches long and 1/16 machine operator jewelry before working
inch thick. when they are – including rings,
 The dial is graduated in degrees through a working. If you must necklaces, bracelets,
complete circle of 360°. communicate, wait until and watches.
 The most common use for this tool is laying the operator can give
out precision angles. you their full attention.
 The vernier scale is used for accurate angle Never wear loose Always secure long
adjustments and is accurate to 5 minutes or clothing in the shop – hair, including
1/12°. including ties, scarves, beards.
jewelry, and loose
sleeves. No open toed
shoes allowed in the
shop.
Never use cell phones Always use all guards
while in the shop. and shields. They
Headphones/earbuds must be secured prior
are also prohibited. to operating equipment.
MACHINE SHOP SAFETY Never work if you are Always check wood
RULES AND REGULATIONS tired. Take frequent for screws or other
Machine shops contain many potential hazards, but breaks to stay alert. embedded metal
with proper training, knowledge, common sense and objects.
caution, you can avoid these dangers. Never use Always clear dust and
Safety must be your primary concern when using compressed air to debris before and after
the Machine Shop. clean skin or clothing. machine use.
 Good safety practices will ensure a Never bring food or Always keep aisles,
productive and safe project for everyone. drink into the shop. exits, and access to
In addition to the General Shop Safety rules, there Store food and drink at emergency
are many Machine Shop specific rules and the entrance to the equipment clear.
regulations. shop prior to working.
In addition to machine hazards, there are chemical, Always immediately
electrical, fire, and environmental hazards. report all problems or
Your best chance of avoiding injury comes when concerns to the shop
you: supervisor or monitor.
 Understand how tools and machines work Shop supervisors and monitors may prohibit
before attempting to use them. shop access or machinery use for any reason.
 Know and follow basic shop safety rules.
 Learn the precautions necessary for safely SAFETY SIGNS AND SYMBOLS
handling hazardous materials by studying Signs and symbols are no substitute for training,
their MSDSs. but they do serve as important reminders.
 Plan ahead and anticipate what is likely to  Can be particularly helpful for workers who
happen next. are not familiar with a specific area or
 Take your time and do not rush your work. process.
SHOP SAFETY RULES  A simple sign with a safety symbol allows
Never work alone. Always complete workers to efficiently identify the potential
Always use the buddy general and shop- hazard and make an immediate decision.
system. specific training
before using facility.
Never use machinery Always understand
without the approval your operation before
you begin or ask the
MEANING SHAPE & SYMBOLS: are put inside the safety shape. These are
COLOUR used in all EEC countries.

3
 WTP MODULE 1: INTRODUCTION

You must
not.
PROHIBITION Do not do.
Stop. Red means
STOP
You must
do.
Carry out
MANDATORY
the action Blue means
given by OBEY
the sign.
Caution.
Risk of
danger.
WARNING Hazard
Yellow
ahead.
means risk
of DANGER
The safe
way.
SAFE Where to
CONDITION go in an Green
emergency means GO

DESCRIPTION SIGNS

Multi-purpose signs – To be used when

the hazard requires more than one of the
four types to convey the safety message.

Supplementary text – If the safety sign

needs additional information it may be
added in words.

Fire equipment signs – for indicating the

location of firefighting equipment and how
they should be used.

Works traffic signs – are the same

design as public road signs.

RISK MANAGEMENT  Prioritizing hazards can prepare you to

Risk assessment, in the context of safety, refers to
the identification of potential hazards in the
workplace as well as the likelihood that they will
occur.
 By extension, risk assessment should also
involve the implementation of measures to
reduce or mitigate those hazards.
 Completing a risk assessment is an excellent
way to evaluate identified hazards and
prioritize them based on threat levels.
 By estimating the length of exposure to the
hazard and assessing the worst injury
possible, the risk prioritization matrix can
be used to determine the level of threat from
each hazard that has been identified.
correct the most dangerous situations first
and make plans to correct lower ranking
hazards in the future.
Five steps to managing risk:
1. Identify hazards
2. Assess the risk level of risk each hazard
identified
3. Control the risk to reduce the harm and its
severity
4. Reassess the level of risk for each hazard
5. Review and monitor that controls are working
and risk levels are acceptable
RISK PRIORITIZATION MATRIX

4
WTP MODULE 1: INTRODUCTION

5
 WTP MODULE 2: METAL WORKING PROCESSES

METALWORKING PROCESS Workpiece compressed between

A science, art, hobby, industry and trade. Forging two dies containing shaped
 Its historical roots span cultures, civilizations, contours.
and millennia. The metal is compressed or pushed
 Metalworking has evolved from the discovery in to the die opening to take the
of smelting various ores, producing Extrusion shape of the die hole as its cross
malleable and ductile metal useful tools and section. Quenching (cooling after
adornments. extrusion)
This process is uses the tensile
Wire or
MARKING OUT strength of material to pull through
Rod
The process of transferring a design or pattern to a the die opening to take the cross-
Drawing
work piece, as the first step in handcraft of section.
metalworking. A method of making holes in metal
 Also known as “Lay out” Friction in which the material is pushed out
Drilling of the way with the aid of heat from
CASTING friction.
A process which a liquid metal is somehow delivered A term covering a wide range of
into a mold that contains a negative impression of ways in which materials or
Powder
the intended shape. components are made from metal
Metallurgy
Different forms of casting: powders. Parts are heated below
1. Investment Casting melting the point
2. Centrifugal Casting The plastic deformation of a surface
3. Die Casting due to sliding contact with another
Burnishing
4. Sand Casting object. It smooths the surface and
5. Shell Casting makes it shinier.
6. Spin Casting
Metal Fabrication Process - broad term that refers
3 MAIN CATEGORIES OF METAL WORKING to any process that cuts, shapes, or molds metal
PROCESSES material into a final product.
1. Forming
2. Cutting SHEET METAL FORMING PROCESS
3. Joining Is a process of forming operations performed on
metal sheets, strips, and coils
FORMING
Is the process of fashioning metal objects through TYPES OF SHEET METAL FORMING
deformation, without adding or removing any PROCESS
material. Sheet material is stained by
 The tools used to such deformation are punch to give a bend shape
called die, punch, etc. depending on the type Bending (angle shape) like V-shape, U-
of process shape, or channel shape along a
straight axis.
Plastic Deformation – involves using heat or Deep (or Forms a flat metal sheet into a
pressure to make a workpiece more conductive to Cup) hollow or concave shape like a
mechanical force. Drawing cup.
Making coins, badges/medals,
Categories of metal forming processes: buttons, precision-energy
1. Bulk metal forming process Coining springs and precision parts with
2. Sheet metal forming process small or polished surface
features
BULK METAL FORMING PROCESS Removing camber, or horizontal
Severe deformation process resulting in massive Decambering bend, from strip shaped
shape change. materials.
 The surface area of the work is relatively Placing flat sheet metal in either
small blank or coil form into a stamping
 Mostly done in hot working condition or Stamping press where a tool and die
above recrystallization temperature. surface forms the metal into a net
shape.
TYPES OF BULK METAL FORMING PROCESS A metalworking technique
Metal stock is passed through one whereby sheet metal is
or more pairs of rolls to reduce the Raising depressed in a stump or other
Rolling
thickness and to make the solid object by repeated 'courses'
thickness uniform of hammering and annealing

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 WTP MODULE 2: METAL WORKING PROCESSES
Cuts stock without the formation
Shearing of chips or the use of burning or
melting.
Cutting a sheet metal strip by a
punch with two cutting edges that
Parting
match the opposite sides of the
blank
A shearing processes created by
feeding a coil of sheet metal into
Blanking
a press and die.
 Produces the outside features
A shearing process where a
punch and die are used to create
Piercing a hole in sheet metal or a plate.
 Produces internal holes or
shapes.
A sheet metal cutting process
with circular knives, which is
Slitting
used to split wide coiled sheet
metal into narrower widths
A press operation in which a
single line cut or slit is made on
Lancing
part way across the strip stock,
without removing any metal
A method to punch overlapping
holes in sheet metal.
Nibbling  Nibbling is when a large
number of holes are punched
in sheet metal.
Producing raised or sunken
Embossing
designs or relief in sheet metal.
Only removes metal from the
outside of a work piece.
Notching
 Is capable of making different
angle notches.
METAL FORMING BASED ON TEMPERATURE
Warm Working – carried out above the temperature
range of cold working, but below the recrystallization
temperature of the metal.
 Advantages:
o Enhanced plastic deformation
properties
o Lower forces required
o Intricate Work Geometries Possible
o Annealing stages can be reduced
Hot Working – metals are plastically deformed
above their recrystallization temperature
 Recrystallization temperature: between
400-700 degrees Celsius.
 Examples:
o Hot rolling
o Hot extrusion
o Hot forging
o Hot drawing
 Advantages:
o Plastic deformation
o Change in workpiece shape
o Lower forces are required
o Materials with premature failure can
be hot formed
2
o Absence of strengthening due to
work hardening
 Disadvantages:
o Shorter tool life
o Poor surface finish
o Lower dimensional accuracy
o Sample sulfur oxidation
Cold Working – metal is shaped below its
recrystallization temperature, usually at the ambient
temperature
 Usually classified into 4 major groups:
o Squeezing
o Bending
o Drawing
o Shearing
 Advantages:
o Closer tolerance
o Good surface finish
o Higher strength and hardness
o Fuel, electricity furnace cost are
minimized.
o Machining requirements are
minimum
 Disadvantages:
o Higher forces and power are required
o Strain of hardening work metal limit
the amount of forming that can be
done
o Cold forming annealing-cold forming
cycle should be followed.
CUTTING
Process during which material is given shape by
removing some parts using tools
 Includes such technologies as:
o CNC milling
o Routing
o Turning
TYPES OF CUTTING PROCESS
The complex shaping of metal or
Milling other materials by removing material
to form the final shape.
A metal cutting process for
producing a cylindrical surface with a
single point tool.
Turning
 The workpiece is rotated on a
spindle and the cutting tool is fed
into it radially, axially or both
The process of creating a screw
thread.
 A tap is used to cut a female
Threading thread on the inside surface of a
pre-drilled hole, while a die cuts a
male thread on a preformed
cylindrical rod
A machine tool used for producing
very fine finishes, making very light
Grinding cuts, or high precision forms using
an abrasive wheel as the cutting
device.
 WTP MODULE 2: METAL WORKING PROCESSES

 This wheel can be made up of  Automobile Industry

various sizes and types of stones,  Construction Industry
diamonds or inorganic materials.  Transportation Industry
A combination of grinding and saw  Medical Industry
tooth cutting using a file.  Oil And Gas Industry
 Today filing is rarely used as a  Aerospace Industry
Filing
production technique in industry,
though it remains as a common
method of deburring.

JOINING
Merging several parts of a metal product by
processes like welding.
TYPES OF JOINING PROCESS
A fabrication process that joins
materials, usually metals or
thermoplastics, by causing
coalescence.
 Often done by melting the
workpieces and adding a filler
Welding
material to form a pool of molten
material that cools to become a
strong joint, but sometimes
pressure is used in conjunction with
heat, or by itself, to produce the
weld.
A joining process in which a filler
metal is melted and drawn into a
capillary formed by the assembly of
two or more work pieces.
 The filler metal reacts
metallurgically with the
Brazing workpiece(s) and solidifies in the
capillary, forming a strong joint.
Unlike welding, the work piece is
not melted. Brazing is similar to
soldering, but occurs at
temperatures in excess of 450 °C
(842 °F).
A joining process that occurs at
temperatures below 450 °C (842 °F).
 It is similar to brazing in the way
that a filler is melted and drawn into
a capillary to form a joint, although
Soldering at a lower temperature.
 Because of this lower temperature
and different alloys used as fillers,
the metallurgical reaction between
filler and work piece is minimal,
resulting in a weaker joint.
Holes are drilled or punched through
the two pieces of metal to be joined.
 The holes being aligned, a rivet is
Riveting passed through the holes and
permanent heads are formed onto
the ends of the rivet utilizing
hammers and forming dies

MAJOR INDUSTRIES THAT USE METAL

WORKING PROCESSES
 Computer Industry
 Farming Industry
 Marine Industry

3
 WTP MODULE 3: FAMILIARIZATION OF THE USE MACHINE TOOLS AND EQUIPMENT
IMPORTANCE OF MACHINE TOOLS AND
EQUIPMENT
 Aids in removing unwanted differences at
each phase of the machining process.
 Play an important part in various
manufacturing companies.
 Helps in delivering products and components
to the maximum possible specifications.
 Main foundation for precision manufacturing.
MACHINE TOOLS AND EQUIPMENT
Tool – can be any item that is used to achieve a goal
 Can be non-mechanical
Equipment - usually denotes a set of tools that are
used to achieve a specific objective
 There is a certain mechanical aspect that
cannot be ignored
Benefits:
 The Issue of Safety
 Future Prospects
 Making Job Easier
 Better Training Options
EXAMPLES
Also spelled callipers
 Tools which have two adjustable
legs or jaws for accurately
measuring the dimensions of
Caliper objects
 Mechanical engineering tools
which are often associated with
metalworking, gunsmithing,
woodturning, and woodworking.
Tool consisting of a weighted “head”
fixed to a long handle that is swung to
Hammer
deliver an impact to a small area of
an object
 Drill press
Other  Saw
examples  Grinding Machine
 Gear Shaper
HISTORY OF CALIPER
Nogisu – first traces of caliper which lead back to
the Chinese Yin era
 Sliding measuring instrument
 Consisted of two jaws and sliding scales
 Originally made of horn, bone, or mammoth
 Later made with glass, wood, or iron
 Nogisu is a Japanese word; does not sound
Japanese
 Derived from “Nonius” – the division of the
main scale into smaller increments
Nunes Scale – invented by Pedro Nunes
 Improved and modified the accuracy of
inclinometers used by astronomers and
astrologers
 Consisted of equally divided arcs, each of the
arcs had one less division that the one that
was outside it
Vernier scale – named after Pierre Vernier
1
 He invented the Vernier graduation scheme
in 1580-1637
 Vernier calipers were already being used but
Pierre Vernier added the Vernier graduation
scheme to an ordinary caliper
Joseph R. Brown – leading mechanical engineer
and founding father of Brown and Sharpe Mfg. Co
 It is said that he invented the Vernier caliper
specially designed for automated linear
graduations in the year 1850
 There is another thought process that
believes that the Vernier caliper was
invented in the US
 The machine he made for automated linear
graduations was then used to manufacture a
Vernier caliper in 1851
France – The oldest caliper was made in 1840 in
France
 All the Vernier calipers were first made in
France which means that France had a lot of
advancement in manufacturing calipers
 Vernier calipers had millimeter graduations
on the main scale and Vernier scale
Different Vernier calipers have different ranges and
were used for a variety of purposes
Sliding calipers with a Vernier scale – had the
ability to take measurements very accurately
 Used in a lot of mechanical related work
 Found to be around parallel with the
simplified caliper in the 1940s in the Mitutoyo
Museum
HOW DO CALIPERS WORK?
Used to measure objects which cannot be easily
measured using a ruler or other measuring
equipment.
 Feature two legs attached to a central hinge,
which enables them to move closer together
or further apart to reach a measurement.
TYPES OF CALIPERS
A caliper that has two legs with feet
that turn outward
Inside
 used to measure inside
Caliper
dimensions, as the diameter of a
hole.
It is a precision device that is
Outside
designed to take accurate external
Caliper
measurements of different objects.
Used in the process of marking out
locations.
 The points are sharpened so that
they act as scribers; one leg can
Divider then be placed in the dimple
Caliper created by a center or prick
punch and the other leg pivoted
so that it scribes a line on the
workpiece's surface, thus forming
an arc or circle.
 WTP MODULE 3: FAMILIARIZATION OF THE USE MACHINE TOOLS AND EQUIPMENT
is a caliper having the points of its
Oddleg legs bent in the same direction for
Caliper measurements on stepped
surfaces or similar surfaces.
Also known as micrometer screw
gauges,
 used to measure very small
Micrometer
distances.
Caliper
 also used to show depth, length
and thickness using the anvil and
spindle.
Precision instrument that can be
used to measure internal and
external distances extremely
Vernier accurately.
Caliper  Have dual scales which run along
the top and bottom, showing both
imperial and metric
measurements
type of slide caliper with a
graduated scale and a dial indicator
for precise measurements of the
inside and outside dimensions of
Dial an object as well as the depth of a
Caliper hole.
 Used in metalworking,
mechanical engineering,
machining, carpentry, and
medical applications
Latest innovation in the technology.
 Rather than a rack and pinion
Digital mechanism, an internal
Caliper microprocessor calculates the
position of the legs and shows the
reading on an electronic display.
HISTORY OF HAMMER
Archaeologists have now discovered the first
appearance of a tool used as a hammer was 3.3
million years ago (149 found in Lake Turkana in
northern Kenya in 2015) when a “hammer stone”
was used to splinter more brittle stones like flint, into
cutting and killing tools.
After they began to perfect their technique, they
formed and shaped axes, knives, then more intricate
arrow heads and spear heads. Still later these proto-
humans used the formed shards into carving tools
for wood, to break open animal skulls, bones, shells
and even make jewellery
 This embryonic hammer, was little more than
a heavy elliptical stone between 300 grams
to a kilo smoothly formed at the bottom of a
river bed, or from the sea.
 The stone was used to hit an object, which
was sitting on a large flat stone below it, like
an anvil. If a more intricate point was
needed, the stone hammer would be
replaced with a smaller stone, bones, ivory
and antlers using more finesse for finishing
the new cutting tools.
Around 30,000 BC, an incredible 3.27 million years
later, the next stage of the hammer’s evolution came
into being.
2
 The addition of a handle; the stone being tied
to either a piece of wood or bone with leather,
vine, sinew, hair or similar substance tying
the head to the handle.
 Creating the more familiar modern day
looking hammer, similar to those made by
native Americans in the 1800’s
Metal and the Bronze age.
 Around 3,000 BC, 27,000 years after the last
important update of the hammer.
Bronze age hammer face.
 The hammer was fitted on to a piece of wood
or bone, then used as a hammer.
Iron age (post medieval) hammer head
It wasn’t until 1200 BC that iron was properly
extracted and used to make tools and weapons.
Making the old bronze hammers and equipment
obsolete. Hammers started to evolve their shapes at
this point in their history.
The discovery of Steel was the advent of modern
day hammers and tools. From the unrecognisable
embryonic elliptical stone of 3million years
previously.
 Originally created around 1800 BC, but
spread across the world properly in the 11th
century.
 The process was refined and augmented by
the 1500’s with the birth of today’s standard
of steel making.
The Hammer’s produced next were “forged” by the
industrial revolution starting in 1760 and 1870 the
explosion in industry and the need for tools to repair
and maintain the new machinery created.
COMMON HAMMERS
A ball-peen or ball pein hammer, also
Ball
known as a machinist's hammer, is a
Peen
type of peening hammer used in
Hammer
metalworking.
Primarily used for driving nails into, or
pulling nails from, some other object.
Claw
 Generally, a claw hammer is
Hammer
associated with woodworking but is
not limited to use with wood products.
sometimes called a lump hammer, is
designed to be used one-handed for
Club heavy-duty hammering.
Hammer  Suited to light demolition work and is
often used with a steel chisel to cut
stone or concrete.
specialized mallet which absorbs
tremors when the hammer strikes.
Dead Extremely useful tool as it minimizes
Blow damage to a struck surface and it's
Hammer minimal rebound helps to avoid
accidental damage to precision work,
especially when working in tight areas
Closely resembling a claw hammer,
Framing
the framing hammer has a straight
Hammer
claw and waffled head.
 WTP MODULE 3: FAMILIARIZATION OF THE USE MACHINE TOOLS AND EQUIPMENT

 Named after its primary function,

which is assembling house frames.
The most common type of mallet, its
rubber head allows for softer blows.
Rubber  Can be used on sheet metal, in
Mallet woodworking and upholstery, and is
gentle enough to force plasterboard
into place without damaging it.
This long-handled hammer has a
metal double-head similar to a mallet,
Sledge but designed for heavy, large blows.
Hammer  Can be used for driving stakes, or
breaking up concrete and masonry,
making it a popular demolition tool.
also known as upholstery hammer is a
lightweight hammer used for securing
upholstery fabric to furniture frames
Tack
using tacks or small nails.
Hammer
 Many styles have two faces, one face
usually being magnetized to aid in
placement of tacks.

SPECIALTY HAMMERS
For metal works, concretes, steels, woods
 Blocking Hammer
 Straight Peen Hammer
 Stone Sledge Hammer
 Brick Hammer
 Blacksmith Hammer
 Power Hammer
 Brass Hammer
 Nail Gun

APPLICATION OF MACHINE TOOLS AND

EQUIPMENT IN DIFFERENT INDUSTRIES
 Automotive
 Construction
 Computer And Electronics
 Material And Metal

3
 WTP MODULE 4: GRINDING AND DRILLING MACHINE
GRINDING MACHINE
History of the Grinding Machine
 Before the Industrial Revolution of the 18th
century, hand tools were used to cut and
shape materials for the production of goods
such as cooking utensils, wagons, ships,
furniture, and other products.
o After the advent of the steam engine,
material goods were produced by
power-driven machines that could
only be manufactured by machine
tools.
 The production of artificial abrasives in the
late 19th century opened up a new field of
machine tools that of grinding machines.
o C.H. Norton of Massachusetts
dramatically illustrated the potential
of the grinding machine by making
one that could grind an automobile
crankshaft in 15 minutes, a process
that previously had required five
hours.
Grinding Machine – most common form of abrasive
machining
 process of removing material by abrasive
action of a revolving wheel on the surface of
a work-piece in order to bring required shape
and size
2 types of grinding
1. Offhand grinding
2. Precision grinding
OFFHAND GRINDING
Engineering term which describes the process
where work is held by the hand while the materials
remove by the abrasive wheel.
4 COMMON TYPES OF OFFHAND GRINDING
MACHINE
Are used to sharpen high-speed steel
cutting tools used on the lathes and
Pedestal
milling machines, debur, or used to
grinder
remove surface imperfections and to
work extremely hard materials
Are attached to workbenches to
efficiently carry out grinding work
 Essential tool in many
woodworking and engineering
workplaces, whether they are used
Bench for sharpening tools or shaping
grinder metal.
 Range of bench grinders can be
used to hone and grind for both
light and heavy-duty processes,
with options available for both fine
and coarse grinding
It is used for lathe cutting tools.
Tool
 it has an adjustable tool rest that
grinder
can be tilted to various angles
Remove material at slower rates
Abrasive
 Often use for only lighter deburring
belt and
tasks
1
disc  Ferrous and nonferrous metals can
machines be grounded
GRINDING WHEELS
Used for cutting, grinding, or finishing metal or other
objects
 Made of abrasive particles that are bonded
together
 Characteristics of the grinding wheel are
labeled on the side of the wheel called the
blotter
Blotter – round disc of heavy paper surrounding
area of a grinding wheel
 Provides cushion when the wheel is mounted
and provides information about the wheel
TYPES OF GRINDING WHEELS
most common and is used for
Aluminum general-purpose grinding of
Oxide Wheel ferrous metals.
 gray in color.
used for grinding the extremely
Green
hard carbides used in cutting tools
Silicon
as well as non-ferrous metals.
Carbide
 green in color and are usually
Wheel
used on tool grinders
it is used for fine grinding of
carbide cutting tools.
Diamond
Impregnated  Carbide is the only material that
Wheel should be ground on a diamond
impregnated wheel
PRECISION GRINDING
Machining process which uses an abrasive grinding
wheel as cutting tool.
TYPES OF PRECISION GRINDING
Provides a precision of ground
surface
 A rotating wheel is used to
smoothen the flat surface of a
work piece.
Two types:
Surface
 Horizontal spindle – peripheral
Grinders
surface grinder used to produce a
flat surface on a work piece
 Vertical spindle – also known as
wheel-faced grinders which uses
a wheel, cup, or cylinder to flatten
a surface.
Also known as center type grinding
Cylindrical  Grinds the shoulders and
Grinders cylindrical surface of a work
piece
CENTERLESS GRINDER
Lewis Rasmus Heim (September 19, 1874 to
March 29, 1964) American machinist and
businessman who invented the centerless cylindrical
grinder
In this type of grinding the work piece is not held in
between centers, so it is called a centerless grinding.
 This method of grinding is used for mass
production of similar objects.
 WTP MODULE 4: GRINDING AND DRILLING MACHINE

 It is used to grind cylindrical, tapered and COMPONENTS OF A JIG GRINDER

formed surfaces on work pieces also called the spindle head
MAIN COMPONENTS OF A CENTERLESS  fixed on the column in the front.
GRINDER Head-  The spindle is held in the shaft.
supports the grinder and contains stock  As this shaft is moving upward and
the grinding and regulating wheel downward it becomes more like a
Bed
head assembly and hydraulic telescopic mechanism.
reservoir hollow component made of cast iron.
Wheel contains the grinding wheel and the  It is supporting the headstock,
Head grinding wheel spindle. Column
guideways and vertical head gives
wheel composed of an abrasive axis for positioning.
compound and used for various Tools on which the machine is
Grinding grinding. grounded
Wheel  Ceramic Aluminum Oxide, Silicon Bed  Made of cast iron which supports the
Carbide, Zirconia Alumina & pillar, saddle, control panel, and the
Aluminum Oxide whole machine
mounted to the bed and tilts or align connected to the table and saddle.
Swivel Pick-up
Plate
the regulating wheel parallel to the  It is helping to control various
grinding wheel Devices
machine operations automatically.
attached to the swivel plate and Table – helps to fasten and hold the
Lower moves the regulating wheel and workpiece in a fixture in the required
Slide work rest blade towards or away Table
position.
from the grinding wheel. and
 has T-shaped slots built into it.
attached to the lower slide and Saddle
Upper Saddle – gives the longitudinal motion
move the regulating wheel towards to the workpiece.
Slide
or away from the work rest blade.
Regulating mounted to the upper slide and Main Jig Grinder
Wheel houses the regulating wheel and  The most important factor on a jig grinder is
Housing regulating wheel spindle. the dual spindle configuration.
Regulating determines the work piece’s  The machine operates by a high speed air
Wheel rotational speed. spindle rotating a grinding bit.
mounted to the lower slide and o The air spindles are removable and
Work Rest
supports the work rest blade. interchangeable to achieve varying
Work Rest where the work piece is rest surface speeds.
Blade
Applications
THREE TYPES OF CENTERLESS GRINDER  Accurate placements of shapes or holes on
the work piece fed in the end and a workpiece
Through
comes out in the other end as a  Customized products
feed
finished product.
End the work piece is moved until it hits the DRILL PRESS
feed end stop. Drill press - also called Drilling Machine
after placing the workpiece on the  device for producing holes in hard
work rest, the regulating wheel is substances.
In feed
moved in, to feed the piece against the  The drill is held in a rotating spindle and is
grinding wheel fed into the workpiece, which is usually
clamped in a vise resting on a table.
Applications  The drill may be gripped in a chuck with three
 Workpiece size jaws that move radially in unison, or it may
 Workpiece shape have a tapered shank that fits into a tapered
 Workpiece material hole in the spindle.
 Means are always provided for varying the
JIG GRINDER spindle speed and on some machines for
Early in the 1930's, Mr. Moore developed a jig borer automatically feeding the drill into the
for his own work and that of fellow die makers; these workpiece.
machines were the first to utilize the famous Moore  One of the most common machines found in
lead screw and double-vee construction. As tool and the machine shop
die making progressed in the 1940's, the Company  Machine that turns and advances a rotary
added the jig grinder to grind hardened steel tool into a workpiece
components.  Used primarily for drilling holes
Jig Grinding is a specialty process that allows us to
 When used with the proper tooling, it can be
grind complex geometrical shapes in our tools with used for a number of machining operations
extremely high precision and accuracy

2
 WTP MODULE 4: GRINDING AND DRILLING MACHINE
HISTORY OF DRILL PRESS
Arthur James Arnot and William Blanch Brain –
two men in Melbourne who were the first to patent
the electric drill in 1889
 Human powered drills had been around for
hundreds of years beforehand – and were
referred to as “drilling machines”.
 The breakthrough these two men made was
seismic, however, and opened up a wealth of
new possibilities to machine precision parts
in metal and wood.
Early Drill Press Features
 Early drill presses had many of the main
features you’ll see on a drill press today –
such was the power of this invention.
 Just like a modern press, they had a motor,
and handle which you could use to feed the
drill into the workpiece.
 Adjustable tables were added very quickly,
allowing you to use larger and smaller
workpieces, and drill to different depths.
Accuracy Improves
 Into the 1930s drills improved greatly, mostly
in terms of precision.
 By 1917, Black and Decker had patented a
hand-held electric drill with a trigger, much
like those in use today.
 For drill presses though, it was all about
accuracy.
 Heavyweights such as Delta, JD Wallace
and others were all entering the industry and
starting to product very high-quality shop drill
presses.
 These machines featured variable speeds
via belt drives, much like a modern drill
press.
Modern Developments
 Besides cost reductions and continuing
accuracy improvements, there are two main
recent advancements in drill design:
o variable speed without belt changes
o laser
 Advancements in modern motor design and
electronics have introduced the ability to
control the drill using a knob electronically,
rather than altering the gear ratio of the drill
using a system of belts.
 Besides allowing more seamless speed
changes, this technology is impressive
because the torque and power of the drill can
be preserved without changing the gear ratio.
TYPES OF DRILLING PRESS
heavy duty type of drilling machine
normally incorporating a geared drive
Upright
spindle head.
Drill
 used on large hole-producing
Press
operations that typically involve
larger or heavier parts
3
allows the operator to position the
spindle directly over the work piece
Radial rather than move the work piece to
Arm Drill the tool.
Press  Its design gives it a great deal of
versatility, especially on parts too
large to position easily.
Also known as a gang drill press
 Has several work heads positioned
over a single table.
 Used when successive operations
are to be done.
Gang  For instance, the first head may be
Drilling used to spot drill.
Machines  The second head may be used to
tap drill.
 The third head may be used, along
with a tapping head, to tap the hole.
 The fourth head may be used to
chamfer.
equipped with several drilling heads
mounted on a turret.
 Each turret head can be equipped
Turret with a different type of cutting tool.
Type  The turret allows the needed tool to
Drilling be quickly indexed into position.
Machine  Modern turret type drilling
machines are computer-controlled
so that the table can be quickly and
accurately positioned
extremely accurate, high spindle
speed drill press.
Micro  Typically very small and is only
Drill capable of handling very small
Press parts.
 Equipped with chucks capable of
holding very small drilling tools
Twist Drill – metal rod of a specific diameter that
has two, three, or four spiral flutes running most of
its length.
 Two flute drills are for primary drilling
DRILLING PROCEDURE
Used to make a little dimple in the
work piece that keeps the twist
Spot Drill
drill from walking so that the hole
winds up in the right place.
are short, double-ended drills
used to produce a shallow conical
or center hole, typically on the
Combination end of work piece to be held
Drill and between centers before turning in
Counter a lathe or cylindrical grinding.
Sink  Stubby double-ended design
provides excellent rigidity for
dependability and reduced
down time.
Bell type center drills produce a
120 degree chamfer which
Bell Type protects the edges of a 60 degree
center hole from breaking down
under high temperatures,
 WTP MODULE 4: GRINDING AND DRILLING MACHINE

protecting tooling & reducing

downtime.
 Long reach and metric models
are available, as well as solid
carbide center drills for
stainless steel.

COUNTER BORING AND COUNTER SINKING

operation of enlarging one end of an
existing hole concentric with the
original hole with square bottom.
 done to accommodate the heads of
bolts, studs and pins.
 The cutting edges of the counter-
bore (tool used for counter boring)
may have straight or spiral teeth.
Counter
A counterbore hole is usually used
Boring
when the head of a fastener, such as a
hex head or socket head capscrew, is
required to be flush with or below the
level of a workpiece’s surface
 For a spotface, material is removed
from a surface to make it flat and
smooth, usually for a fastener or a
bearing.
conical hole cut into a manufactured
object, or the cutter used to cut such a
hole.
Counter  A common use is to allow the head of
Sinking a countersunk bolt, screw or rivet,
when placed in the hole, to sit flush
with or below the surface of the
surrounding material.