Fitting and fabrication workshop

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By

M. SAAD YASEEN & M. RAFAY

2021-MC-37 & 2021-MC-39

To

HAFIZ FURQAN SABIR

“SEMESTER PROJECT”

“ADJUSTABLE SPANNER”

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Mechatronics and Control Engineering Department
University of Engineering and Technology, Lahore
Contents
1. INTRODUCTION:...................................................................................................................1
Socket Wrench:...................................................................................................................1
History: ………………………………………………………………………………………………….…1
Hex Sockets: ………………………………………………………..…………………………………….1
Metric Sizes: …...…………………………………………………………………………………………2
Uses: ………………………………………………………………………………………………..………2
Working: …………………………………………………………………………………………………...2
Manufacturing Methods: ………………………………………………………………………………..3
2. METHODOLOGY:..................................................................................................................3
3. RESULTS:................................................................................................................................4
4. DISCUSSION:.........................................................................................................................4
5. DETAILS:................................................................................................................................4
6. REFERENCES:........................................................................................................................5
 1. INTRODUCTION:
SOCKET WRENCH:
A socket wrench (or socket spanner) is a type of spanner (or wrench) that
uses a closed socket format, rather than a typical open wrench/spanner to turn a fastener,
typically in the form of a nut or bolt.
HISTORY:
Wrenches in the form of sockets have existed for centuries. Early examples include
the keys used to wind clocks since the Middle Ages. The heads and sockets were typically
square; hex heads eventually became more common starting in the 20th century.
The ratcheting socket wrench, with interchangeable (index able) sockets, was invented. A ratchet
is a tool with a gear that moves when turned in one direction and locks when it is turned the other
direction. Square heads and sockets were the easiest to make in the era when hand filing was the
typical method of manufacture. With the proliferation of modern manufacturing methods it
became just as easy to make hex heads and sockets as square ones. The hex form allows easier
wrenching in confined surroundings[1].

HEX SOCKETS:
A “hex” socket—short for “hexagonal”—is a socket that fits around a
hexagonal (six sided) nut or bolt head.

"6 point" hexagonal socket

Hex keys are formed from a single piece of hard steel hexagonal rod having blunt ends that fit
snugly into similarly-shaped screw sockets. The rods are bent to 90º, forming two arms of
unequal length resembling an "L". The tool is usually held and twisted by its long arm, creating a
relatively large torque at the tip of the short arm; it can also be held by its short arm to access
screws in difficult-to-reach locations and to turn screws faster at the expense of torque.

Hex keys of various sizes

Hex keys are designated with a socket size and are manufactured with tight tolerances. As such,
they are commonly sold in kits that include a variety of sizes. Key length typically increases with
size, but not necessarily proportionally so.

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METRIC SIZES:
Standard metric sizes are defined "Assembly tools for screws and nuts—
Hexagon socket screw keys", also known as DIN 911, and, measured in millimeters (mm) are:

 0.7, 0.9, 1.0, 1.25, 1.3, 1.5

 2 to 6 in 0.5 mm increments
 7 to 22 in 1 mm increments
 24, 25, 27, 30, 32, 36, 40, 42 and 46 mm.

USES:
Hex keys are just a simple hand tool system for tightening and loosening certain types of
bolts and screws. Specifically, they’re intended for use on bolts with a recessed hex drive socket,
meaning a hexagonal ‘slot’ in the screw head (or sometimes the shaft, in the case of headless
fasteners). Hex keys have a number of important characteristics that make them particularly well
suited to the straightforward, user-friendly fastening role that has made them so popular among
operators of all experience levels.

Some characteristics of hex keys are:

 The tool is simple, small and light.

 Are simply constructed and fairly robust.
 The contact surfaces of the screw or bolt are protected from external damage.
 There are six contact surfaces between bolt and driver.
 Very small bolt heads can be accommodated.
 The tool allows the use of headless and recessed-head screws.
 The screw can be held by the key while it is inserted into its hole.
 The torque applied to the screw is constrained by the length and thickness of the key.
 The tool is cheap to manufacture, so it can be included with products requiring end-user
assembly.
 Either end of the tool can be used to take advantage of reach or torque.
 The tool can be reconditioned by grinding the worn-out end.

WORKING:
Using them is remarkably simple - you just insert one end of the driver into the
recessed hexagonal fastener head, and apply torque at the other end to turn it. Typically, you’d
use the shorter of the hex key’s two shanks as the handle, giving the tool a longer reach and
increased maneuverability in smaller spaces. However, the longer shank can also be used as the
‘handle’ when more torque is required, provided the work area allows enough room to turn a
longer-handled tool in[2].

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MANUFACTURING METHODS:
Hex socket screw heads are usually made by stamping the head with a die, plastically deforming
the metal. Other ways to generate the hex socket include linear broaching and rotary broaching.
Broaching the heads with a linear broach is essentially the metalworking analog of mortising
wood with a mortising machine; a hole is drilled and then the corners are broached out. This
operation often leaves little telltale curled chips still attached at the bottom of the socket. These
are negligible for most applications. Hex keys are made by imparting the hexagon cross-section
to steel wire (for example, with a drawing die), then bending and shearing[3].

2. METHODOLOGY:

 First we bought the Hex socket spanner from the market.

 Then we measure the dimensions of circular gauge which is 40mm.
 Then we drilled 3 holes at the angles of 120° at the sides of gauge. The size of the drilled
hole is 6.5mm.
 We used tap set to make threads in the hole.
 First we used taper tap. It is required higher cutting forces than other taps.
 Then we used plug tap and bottom tap later.
 After threading, the size of hole will be 8mm
 After this, we insert three hexagon type bolts of length 55.8mm in the drilled holes of the
gauge socket.
 Then we fixed the L-handle driver in the gauge socket. The length of the driver is 20
inches.
 The adjustable hex socket spanner is made so now we can drive any bolt with the help of
it.

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 3. RESULTS:
The final look of adjustable hex spanner will be:

4. DISCUSSION:
It was a good experience to make this type of project. We faced some
difficulties in doing it but we enjoyed it too. We assumed the dimensions of holes and angles of
120° by myself. We learnt many things during making of this project. Overall it was neither a
difficult nor an easy project. But we improved many skills in this workshop project.

5. DETAILS:
We faced difficulty in drilling these holes in the hex socket gauge.

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Also, with great power and difficulty, we made threads in these holes.

6. REFERENCES:
1. Socket wrench 9 January 2022, at 22:06 [cited 2022 17-02-2022]; Available from:
https://en.wikipedia.org/wiki/Socket_wrench.
2. The Complete Guide to
Hex Keys. [cited 2022 18-02-2022]; Available from:
https://ie.rs-online.com/web/generalDisplay.html?id=ideas-and-advice/hex-keys-guide.
3. Hex key. 8 February 2022, at 17:38 [cited 2022 17-02-2022]; Available from:
https://en.wikipedia.org/wiki/Hex_key.