NAYPYITAW TECHNOLOGICAL UNIVERSITY

Department of Mechanical Engineering

Job - 2
Bench Work and T Fitting

Objective: To know the types of hack saw and sawing proess and also files and
fitting process and to make the smooth plane surfaces and straight edges
according to the operations.
Apparatus: (1) Bench Vice
(2) Try Square
(3) Steel Rule/Scale
(4) Hack Saw with Blade
(5) Scriber / Punch
(6) Odd Leg / Trammel Points
(7) File ( Flat/Round ) ( Rough/Smooth )
(8) Hammer
(9) Number Punch / Letter Punch

Safety in sawing process

1. The blade fix in the frame properly.
2. The teeth of the blade must point away from the handle.
3. The wing nut must be tightening sufficiently.
4. Never use excessive pressure and twisting movement during the cutting stroke.
5. The work must be held firmly in the vice.
6. Do not use new blade on hard material directly.
7. Coolant must be used throughout the operation except for sawing cast iron.

Theory of sawing process

A hack saw is used for cutting metal rods, bars, pipes, etc. It consist essentially a
frame and blade. They are classified according to the type and shape of the frame as
(a) solid frame and (b) adjustable frame. Adjustable frame can be fixed the different
sizes of blades.
Hacksaw blades are made from different materials like high carbon steel, alloy
steels and high speed steels. Also hacksaw blades have different number of teeth
ranging from 5 to 15 per centimeter. The teeth ate set by leaving are tooth straight,
bending the second towards left, the third towards right, or by marking the blade edge
slightly wavy instead of straight.
Sawing is the process of cutting different metal pieces to the desired shape and
size. In sawing, the handle of hacksaw in the right hand and the father edge of the
frame in the left hand. Cutting action in sawing takes place in the forward stroke and
no pressure must be applied on the return or idle stroke.

Safety in filing process

1. Apply pressure on the files in the forward direction only.
2. Before deeding the file in the kit, clean it properly.
3. Do not use the new files on soft metal.
 4. Use a bastard file for rough cuts and second cuts and a smooth file for the
finishing.
5. When using a new file for first time apply light pressure in the beginning.
6. Do not use a new file for cleaning welds.
7. Provide solid supports to the sheets before filing.

Theory of fitting process

Files are classified in different ways as list below:
1. According to their longitudinal shape and cross section.
2. Classification based on cuts.
3. Classification based on teeth.
4. Classification based on length of the file.
In filing the job is held in vice at such a height in that the top of the job is at
level with the Work’s elbow. Hold the handle in the right hand and the point of the file
with the left hand. The right hand exerts the force required for the cut whereas the left
hand guides the cut. The left foot of the worker should be forward beneath the vice.
Since forward stroke is the cutting stroke, force on the file is to be applied only on the
forward stroke and the file should be lifted clear in backward or idle stroke to avoid
blunting of the teeth.
Straight filing and draw filing are the two methods of filing. In straight filing
the file is pushed and pressed forward at angles to the length of the job. In draw filing
the file is gripped at each and pushed forward and drawn backward along the length of
job.

Procedure of sawing process

1. Mark out on the job to get required dimensions and forms for sawing operation.
2. Hold the job in a vice firmly as required position.
3. Select the suitable for job and fix the blade to the frame property.
4. Tighten the wing nut until the blade produces a musical twang when stroke lightly
with a finger.
5. Stand with the left foot forward below the vice and right foot behind. Move the
saw to and fro in the straight line.

Procedure of fitting process

1. Mark cut on the job to get required dimensions and forms for filing operation.
2. Hold the job in a vice firmly as required position.
3. Select the suitable file and then hold the handle in the right hand and the point of
the file with life hand.
4. Stand with the foot forward below the vice and right foot behind.
5. Cut and remove unnecessary parts for required surfaces or edges.
6. Take the proper movements of the file horizontally.
7. Check and test filling surfaces and edges with the help of tri square and surface
plate.
8. If needed take the proper movement of file next times.