INTRODUCTION

The benchwork is the craftsman’s head quarter, where operations involving the use of
hand tools such as sawing, filing, chiseling and marking out are appropriately carried
out. In this section, students will be introduced to the basic complement of hand tools
commonly used in all branches of mechanical technology such as bench vise, files,
hacksaw and center punch and scriber.

 Bench Vise
The bench vise is used to help grip the work piece for filing, hacksawing, chiseling
and bending light metal. The bench vice mainly consist of a fixed jaw, movable jaw
and jaw plates (Figure 1). Most bench vises have hardened insert jaws that are sharply
serrated and will dig into finished work pieces enough to mar them beyond repair.
Hence, soft jaws made of copper, other soft metals or wood are often slip over the vise
jaws to protect the work piece’s finished surface.

Figure 1: Bench Vise (Workshop Manual)

 Filing
Filing involves the small scale removal of material from a surface, corner, or hole,
including the removal of burrs (Kalpakjian and Schmid, 2001). Files areusually made
of hardened steel and are available in a variety of cross sectionssuch as flat, round,
half round, square and triangle (Figure 3).They are commonlymanufactured in four
different cuts: single, double, curved tooth and rasp. Eachcut design has its own
purpose. For instance, rasp files are frequently used withwood while curved tooth files
are used with soft materials such as aluminium, brass, plastic, or lead. Files also vary
in their coarseness; rough, coarse, bastard,second cut, smooth and dead smooth.
 Figure 2: Basic components of a file (Workshop Manual)

Figure 3: Various file cross sections (Workshop Manual)

 Sawing
The hacksaw is one of the more frequently used hand tools. It consists of the frame,
the handle and the saw blade (Figure 5). The spacing of the teeth on a hand hacksaw
blade is called the pitch. Standard pitches are 14, 18, 24 and 32 teeth per inch, with the
18-pitch blade used as a general-purpose blade. The hardness and thickness of a work
piece determine to a great extent which pitch blade to use. Generally, a coarse tooth
blade should be used on soft materials and a fine tooth blade on harder materials.
There are a few points that should be noted in order to obtain maximum performance
from a blade:-

• Make long steady strokes using the full length of the blade
•Maintained sufficient pressure on the forward stroke to keep the teeth cutting. Too
much pressure on the saw blade will cause its teeth to dull.

•Do not apply any pressure at the blade during return stroke since this will also dull
the teeth

•The sawing speed should be at the rate of 40~60 strokes per minute. Cutting stroke
that is too fast causes friction that will overheat the teeth and dull it.
 Figure 5: Main components of a hacksaw

 Center Punch
The centre punch is used when circular dot marks are required. When job has been
marked out it is usual to follow along the lines with small dot marks in case the line
becomes obliterated. It is also used to mark the centre point of drilling holes for the
purpose of giving starts to the drill and to mark the centre of circles to provide a point
for placing the leg of the dividers to scribe the circle. Various types of center punch
are illustrated as below.

Figure 6: Types of center punch (Workshop Manual)

 Scriber
The scriber is a round steel piece of about 150mm to 300mm long and 3mm to 5mm
in diameter.Its one end is sharp and pointed and the other end is also sharp but
bent.The bent end is used to scratch lines in places where the straightend cannot reach.

Figure 7: Scriber (Workshop Manual)

Methodology
1. Select all uneven side of the work piece and file as previous step to obtain a flat
90˚surface

2. Use “L” square to check the surfaces, if rays of light cannot be seen between the
work piece and the “L” square, it shows the surface is flat(180°).

3. Measure desired dimension with vernier caliper and plate angle on the marking
table.

4. Select one flat surface as the reference surface for marking process

5. Begin the removing process by cutting the unused material using hacksaw only.

6. Smooth the edges of the work piece through filing.

7. Create the rounded curve using divider based on given dimension which is radius 8
mm

8. Cut the square’s hole 20mm x 20mm using drill and use filing to flat the surface. In
order to make square’s hole perfectly must use “L” square to obtain 90° and 180°
surface.

9. Do the drilling work for through hole accordingly as below:-

a. Drill bit size M6x1.0 mm

b. Drill bit size M8x1.2 mm

c. Drill bit size M10x1.5 mm

Conclusion

Hence it was concluded that every operation needs bench work to perform even the
single task at critical case which was done by use of hacksaw, scales, markers and
files. After completion of this report, we come to know about the different
components of workshop and description and procedure to use different hand tools,
machine tools etc. In order to make different equipment like hammers, dustpans, etc.
Similarly we got knowledge about different types of metals and their description and
their work in the workshop. Similarly, we become familiar about drilling, shaping,
filing, threading, knurling etc.