UNIT OF COMPETENCE: - Perform Bench Work

MODULE TITLE: Performing Bench Work

LO1: Lay-out and mark dimensions/ features on work

piece
2.1 Safety in workshop, Safety Rules, Accidents and
their causes OH safety practice.(Assignment )
2.2 Lay out and Marking.
2.3 Sawing
2.4 Filling
2.5 Chipping
2.6 Scrapping
2.7 Drilling
2.8 Thread Cutting
2.9 Basic Grinding Operation
2.10 Manufacturing of Parts
 2.2 Lay Out and Marking.
 Marking out is the preliminary work of providing guidance lines and centers before cutting
and machining. The lines are in 3-D and full-scale. The work piece can then be cut or
machined to the required shapes and sizes.
The common tools used for marking out are as follow:
 Layout fluid puts a deep-blue background on the workpiece so scribed layout lines and
punch marks stand out sharp and clear.
 Scribers, apply scratch marks to work indicating the position of holes, openings, and cut
lines. Good scribers have hardened and finely tapered points so they can get close to the rule
or straightedge, minimizing errors.
 Straight edges are useful for scribing straight lines and testing surfaces for flatness.
 Steel rules, have many uses and are a shop essential. They can be used to measure distances
directly on work, to set dividers or surface gages, or as straight edges.
 Scriber

 Engineer's Square
 Spring Dividers
 Punch (Prick punches and centre punches)
 Surface Plate
 Angle Plate
 Vee Block
 Vernier Height Gauge
Bench Vice
 Hold work securely when filing, sawing, or drilling.
 Support work across its open jaws when driving out a pin with a drive punch.
 Bend small metal bars, rounds, and sheet goods by inserting them up to the bend point and
striking the work with a ball peen hammer.
 Assemble force-fit parts by squeezing them together.
 Hold bench blocks and miniature anvils at a convenient level.
 Position work for soldering or brazing.
 Provide a small anvil behind the back jaw for light hammering.

Care of Vices
 Do not direct impact the vice body by the hammer.
 Light hammering can be done on and only on the anvil of the vice.
 To avoid over clamping, the handle of the vice should be tightened by hand only
 Protective Vies Jaws 
 They prevent damage to the workpiece from the hardened and diamond- serrated vies
jaws.
 There are many different materials used to make them. Rubber, lead, Teflon® and
polyethylene make very soft vies jaws, aluminium and brass, slightly harder ones.
Fibreboard, Masonite® and wood blocks also work well.
 Some protective jaws lay over the vies jaws, some have tabs bent to clasp the vies, and
others are held against the steel vies jaws with magnets.
2.3 Sawing/Hacksaw
Saw Blade
Saw blades are made of high carbon steel, alloy steel or High-Speed Steel.
They are supplied according to material, hardening, length and pitch.

1. Hardening - Usually the saw blade is supplied with all hard or flexible grades.
 The all hard is very brittle, and it is suitable for the skillful user only.
 The flexible grade is tough, so it can twist an angle. It is suitable for cutting a curve or for the beginner to use.

2. Material - Usually the saw blade is supplied with High Carbon Steel (HCS) and High-Speed Steel
(HSS).
 The HCS will annealed from the heat generated by fraction of cutting.
 The HCS saw blade will lost its hardness when cutting the hard metal.
 The HSS can keep its hardness unless improper use.
3. Pitch - It is grading according to the number of teeth per 25mm.
 Coarse blade (18T) is most suitable for soft material and thick work piece.
 Medium blade (24T) is suitable for steel pipe.
 Fine blade (32T) is suitable for the thin metal sheet and thin copper pipe.
For safety, it is advice that to keep at least 3 teeth of the blade, stand on the work piece.

4. Length - The length of the blade is determined by the distance between the outside edges of the
holes, which fit over the pegs.

5. Set - The teeth have a "set" to either side alternately, which causes the blade to cut a slit wider
than the thickness of the blade, to prevent jamming.
Safety and Care of Hacksaw
 The cutting action is carried on the forward action only. So the
blade must be mounted with its teeth pointing forward.
 Suitable tension should be applied on the blade to avoid
breakage or loosen.
 Change the blade if some teeth are broken.
 Avoid rapid and erratic strokes of cut.
 Avoid too much pressure.
 Work piece must be hold firmly.
2.4 Filling/Files

Files are mainly used to sharpen, smooth edges, remove burrs, or make small adjustments, but they
remain an important and handy tool.

Files are categorized as follows:-

 Length - measured from the shoulder to the tip. Length for most files lies between 4 and 14 inches. The most
common lengths are 4, 6, 8, and 12 inches
 Shape - the cross-sectional profile.

 Grade - the spacing and pitch of the teeth.

 Cut - the patterns of cutting edge.
Type of file

 Single-cut files have one row of parallel teeth diagonally along their face. With relatively
light pressure, they produce a smooth finish on hard materials.
 Double-cut files have two intersecting rows of teeth which produce fast stock removal and
good clearing of chips, but leave a coarse surface. Heavy cutting pressure is often used.

 Rasp-tooth files, have a series of individual rounded teeth raised from the surface of the file
blank by a sharp narrow, punch-like cutting tool. They are used for soft materials like
wood, leather, and lead, where fast material removal is needed. Heavy cutting pressure may
be used.
 Curved-tooth files, work well on softer materials like lead, aluminum, brass, copper, plastics,
wood, die cast zinc, auto body fillers, and hard rubber. This tooth design tends to resist
pinning, filling the teeth with filed particles.
Coarseness is the number of teeth per inch of file length. Both single- and double-cut files
are manufactured in various degrees of coarseness.
Varying degrees of coarseness are comparable only when files of the same length and shape are
considered.

File coarseness: coarse to smooth (left to right).

Single Cut Double Cut

Rough —
Coarse Coarse
Bastard Bastard
Second Cut Second Cut
Smooth Smooth
— Dead or Super Smooth

File coarseness.
The grades are as follows:
 Bastard cut - medium teeth for general purposes, especially suitable for mild steel.
 Second cut - finer teeth for cutting hard metals.
 Smooth cut - fine teeth for finishing.
Three grades of cut are in common use

Cut Pattern
 Single Cut - There is only one set of cutting teeth to one edge. It gives a less efficient cutting but
a better finish. It is suitable for the soft metal.
 Double Cut - A double cut file has one set of teeth cut at 70 degrees to one edge, and another set
of grooves cut at 45 degrees to the other edge. It is thus more efficient in cutting. It is easy to clog the
teeth when it is work on the soft metal.
 Rasp - Very coarse teeth, like the nail, it is commonly used for the cutting off soft materials such as
rubber, PVC, or wood etc.
 Edge design, with and without a safe edge.
 Safe edges allow the face of the file to cut while the edge does not.
 It is a good idea to run a stone along the safe edges of files the first time they are used to insure
that the edges are smooth.

Files with and without a safe edge.

 Safety and Care of Files
 Files teeth are brittle and therefore file should be placed properly and
should not be stacked on other tools.
 New files should never be used on hard materials. E.g. castings or
welding.
 Remove the pinning regularly by a file card/wire brush.
 Cutting is carried on the forward stroke.
 It is very danger to use files without handles.
2.5 Chipping
2.6 Scrapping
2.7 Drilling
 2.5 CHISEL/CHIPPING

 Use:- To chip and cut flat surfaces, slots and grooves.

 Material:- High carbon steel or Chrome vanadium steel

 Types:- A. Cold chisel B. Hot Chisel

Point

Body
Head
 Use:- They are used to remove
metal from large flat surface and chip
Flat Chisel excess metal weld joints and
castings.
 Cross cut Chisel

 Use:- These are used for cutting

keyways, grooves and slots.

Half round nose Chisel

 Use:- They are used for cutting

curved grooves (oil grooves)
Diamond point chisel

 Use:- These are used for

squaring materials at the corners.

Web Chisel

 Use:- These chisels are used for

separating metals after chain
drilling.
 Point angle:- The correct point/ cutting angle of
Point
angle the chisel depends on the material to be
Inclination chipped. Sharp angles are given for soft material and
angle wide angles for hard material.
The correct point angle and angle of inclination
generates the correct rake and clearance angle
 Rake angle:- Rake angle is the angle between the top
Rake face of the cutting point and normal to the work
angle
surface at the cutting edge.
Clearan
ce
angle

Clearance angle:- Clearance angle is the angle between the bottom face of
the point and tangent to the work surface originating at the cutting edge.
If the clearance angle is too low or zero, the rake angle increases. The
cutting edge cannot penetrate into the work. The chisel will slip. If the
clearance angle is too great, the cut progressively increases.
 2.6 Scrapping
 A hand scraper is a single-edged tool used to scrape metal
from a surface.
 This may be required where a surface needs to be trued ,
corrected for fit to a mating part, needs to retain oil (usually on
a freshly ground surface), or to give a decorative finish.
2.7 Drilling

 Drilling is the process of cutting holes in

metals by using a drilling machine as
shown
 Drills are the tools used to cut away fine
shavings of material as the drill advances
in a rotational motion through the
material.
 Drill Bit
 The twist drill or drill bit is made from High Speed
Steel, tempered to give maximum hardness
throughout the parallel cutting portion.

 Flutes are incorporated to carry away the chips of

metal and the outside surface is relieved to produce a
cutting edge along the leading side of each flute.
 Twist drill
 Twist drills are available with parallel shanks up to
16mm diameter and with taper shanks up to 100mm
diameter and are made from high-speed steel.
 Standard lengths are known as jobber-series twist
drills, short drills are known as stub series, and long
drills as long series and extra long series.
 Different helix angles are available for drilling a range of
materials
Drill Bit

Fit in chuck

Fit direct into spindle

Drill Bit Features
 Drill Bit Features
 The point of the drill is ground to an
angle of 118 degrees
 each side is ground back to give "
relief " of about 12 degrees to each
cutting edge as shown
The nomenclature of the twist drill is shown
 Twist drills - Helix Types

 The helix angle of the twist drill is the equivalent of the

rake angle on other cutting tools and is established during
manufacture.
 The standard helix angle is 30 degrees, which, together
with a point angle of 118°, is suitable for drilling steel and
cast iron.
 Helix types

Standard slow quick helix

Helix types

 Drills with a helix angle of 20° — known as slow-helix

drills — are available with a point angle of 118° for
cutting brass and bronze and with a point angle of 90°
for cutting plastics materials.

 Quick-helix drills, with a helix angle of 40° and a

point angle of 100°, are suitable for drilling the softer
materials such as aluminum alloys and copper
Drill Bit
 Wood bits

masonry

steel
Tool Holding parallel shank drill

 Drills and similar tools with

parallel shanks are held in a
drill chuck.
 By rotating the outer sleeve,
the jaws can be opened and
closed.
 To ensure maximum grip, the
chuck should be tightened using
the correct size of chuck key.
This prevents the drill from
spinning during use and
chewing up the drill shank.

Drill bit is only gripped by the shank

 The Drill Chuck

Keyless
Chuck

Morse Taper
Chuck

Chuck Key
Tool Holding
Holding taper shank drills
Morse Taper Sleeve
Drill Drift
 To remove a shank from the spindle, a taper key known as a drift is
used.
 Using the drill drift
 The drift is inserted through a slot in the spindle

Strike here
to remove

Most modern machines

have a built-in drift
Typical Drilling Processes
 Reaming
 A reamer enters the workpiece
axially and enlarges an existing hole
to the diameter of the tool.

 A reamer is a multi-point tool that

has many flutes, which may be
straight or in a helix.

 Reaming removes a minimal amount

of material and is often performed
after drilling to obtain both a more
accurate diameter and a smoother
internal finish.
 Countersinking
 A countersink tool enlarges the top portion of an
existing hole to a cone-shaped opening.
 Countersinking is performed after drilling to
provide space for the head of a fastener, such as
a screw, to sit flush with the workpiece surface.
 Common included angles for a countersink
include 60, 82, 90, 100, 118, and 120 degrees.
 Counterboring
 A counterbore tool enlarges the top portion
of an existing hole to the diameter of the tool.
 Counterboring is often performed after
drilling to provide space for the head of a
fastener, such as a bolt, to sit flush with the
workpiece surface.
 The counterboring tool has a pilot on the end
to guide it straight into the existing hole
 Drilling holes to depth

 Holes can be drilled to a

particular depth by setting the
depth stop on the machine
e.g. 15mm
Radial Drilling Machine Pistol-grip (corded) drill

 A drill in the shape of a pistol.

 Commonly called electric hand
drill.

Cordless drills
Hand Drill  A cordless drill is a type of
electric drill which uses
rechargeable batteries.
 Drilling Thin Material

Support acts as thicker material so drill point is guided through work

 Drilling Machine Vice
 The Machine Vice has slots in the side of the base
of the vice which enable the user to screw the
Machine Vice to the Drilling Machine table.

Direct Clamping
Clamping set
2.8. Thread Cutting
 THREAD TERMINOLOGY
External (male) A thread cut on the outside of
thread a cylindrical body.

Internal (female) A thread cut on the inside of

thread a cylindrical body.

External thread
Internal thread
 THREAD TERMINOLOGY
Right-hand Thread that will assemble when
thread turned clockwise.

Left-hand Thread that will assemble when

thread turned un-clockwise.

Turnbuckle use RH and LH thread at

each end to double displacement.
 THREAD TERMINOLOGY
Crest The peak edge of a thread.

Root The bottom of the thread cut into

a cylindrical body.
Thread angle The angle between threads faces.

External Thread Internal Thread

Thread angle

Root Crest

Crest
Root
 THREAD TERMINOLOGY
The largest diameter on
Major diameter
an internal or external thread.
The smallest diameter on
Minor diameter
an internal or external thread.

External Thread Internal Thread

Minor dia.

Major dia.

Major dia.
Minor dia.
 THREAD TERMINOLOGY
The distance between crests of
Pitch
threads.

Lead The distance a screw will advance

when turned 360o.

External Thread Internal Thread

Pitch
Pitch
 THREAD TERMINOLOGY
Form is the profile shape of the
Thread Form
thread.

Example :
“knuckle thread form”
 EXTERNAL THREAD CUTTING
Tools Operation
Threading Die

Die stock
 Precautions and Operation of Die

 The diameter of the blank rod must not larger than the
outside diameter of thread to be cut.
 Ensure that the die is set perpendicular to the rod.
 Lubricant oil should be used except when cutting cast
iron and brass.

N.B. About every half-turn reverse frequently to break

the swarf otherwise the thread will tear.
 INTERNAL THREAD CUTTING
Tools Operation
Twist drill

Tap

Tap wrench
1. Taper Tap
The tap is tapered off for a length of 8 to 10 threads and is the first tap to be
used in a hole to start the thread form.
2. Second Tap
The tap is tapered off for a length of 4 to 5 threads to facilitate picking up
the threads cut by the taper tap.
3. Plug Tap
This is fully threaded throughout its length and is called a 'bottoming'
tap. This tap used to cut the bottom of a blind hole.

Taps
 Precautions & operation in tapping

 The size of the hole is important and the correct drill size should be
determined from the handbook, standard table in the workshop
or the recommendation on the shank of the tap.
 Use taper tap first ensuring that it is kept square with top surface
of work
 Always use the correct size of wrench for the tap in use.
 Lubricant oil should be used except when cutting cast iron and
brass.
 Use both hands to hold the wrench to maintain even torque.
 About every half turn reverse action slightly to break the swarf
and clear the threads.
 When the tap reaches the bottom of the blind hole, care must be
taken not to force as tap may break in the hole.
COMPARISON OF THREAD CUTTING
External Thread Internal Thread

Minor Dia.

Major Dia.