BASICS OF APPLIED BENCH

WORK

-List the basic duties of a bench worker.

-List the tools used and the operations performed in bench work.
-Explain the proper care of bench tools.
-Describe bench work layout procedures with regards to accuracy
and productivity.
 INTRODUCTION
 Bench work is the start and finish of machine
work. The Machine trade can be divided into
machine work and bench work.
 Machine work is work done in the shop by
machine tools, such as Lathes, Milling, Drill
presses, Saws, and Grinders.
 Bench work is the term used to describe work that
can be placed on a bench or in a bench vise to be
worked on. The operations done on this work
mainly involve tools that are controlled by the
hand. This tools are called Hand tools.
 Floor work refers to larger-type work that cannot
 DUTIES OF THE BENCHWORKER
 Select the proper material indicated on the print.
 Cut these materials to size.
 Accurately layout the work piece for hand or
machine operations.
 Clean and finish the work.
 Inspect the finished work for quality and accuracy
requirements.
 Assemble and properly fit parts together.
 Test the completed workpiece assembly.
Attitudes and Safe Work
Habits
 Attitudes and safe work habits are two very
important items in any place of work.
 Bench work presents some challenging layout,
fitting, and assembly tasks.
 Workers in the machine trades must think
logically and apply good judgment to every task.
 Most tools used in bench work can be dangerous.
If proper though is not given before an act is
made, serious damage or personal injury may
result.
 The main cause of accidents in the shop is
carelessness. The student should learn the
accepted safe work habits at the same time
bench work tools and methods are learned.
Students are Trained and expected to work
in the following order:

 Safely – so you and other workers may

continue to work.
 Accurately – to avoid costly mistakes.
 Quickly – to make company profits.
In Shops, the following work habits and
attitudes are required:

 Maintain good attendance and be on time to

work.
 Be willing and ready to work.
 Have concern and care for tools and equipment.
 Be courteous and show respect for employers
and fellow workers.
 Be loyal and trustworthy.
 Work in a safe manner.
When working in shops, mistakes must be
avoided because:

 Materials are wasted.

 Shop time is lost two times.
 Loss 1. – first time the part was made wrong.
 Loss 2 – time to make the same part again
correctly.
 Mistakes cost time, and time is money.
Profits must be made by a company to
remain in business. From the profits
come wages, benefits, new tools and
equipment, and improved working
conditions. The following may be used
as a guide to profitable bench work:

 Work to the degree of accuracy required.

 Carefully plan the work.
 Carefully layout the work.
 Check the layout carefully before starting work.
 Select correct materials.
 Practice good, safe work habits.
The following operations are among the
several procedures used in Bench work:

 Chipping •Filing •Laying

out
 Sawing •Fitting
•Assembly
 Drilling •Scraping
•Disassembly
 Reaming •Polishing •Testing
 Tapping •Grinding
Tools

 Tools had been regarded as a partner of mans

quest for progress and survival from the early
stone age down to the present generation. The
mechanical advantages, accuracy, speed and
efficiency derived from the use of the right tools
and equipment, has prompted man to
continuously search for the refinement of old
tools aside from the invention and introduction of
new ones that could provide greater efficiency and
refinement of work.
 Experienced agrees, that the efficiency of the work
could be augmented by 25 percent or more with the
use of the right kind of tools aside from improved
quality of the work performed.
 Hiring an experienced worker who has a complete set of
tools however high his demand for pay is more
advantageous and cheaper than hiring a beginner with a
lower rate but without the necessary tools for a
particular job.
 Higher pay can accomplish work with better quality in a
short time than the latter whose work risks repair and
delay not to mention the extra cost involved.
 The efficiency and quality of
the work particularly in Bench
work depends upon three
factors:
 Availability and sufficiency of materials.
 Experience and skill of the workers in their
respective field.
 Complete set of tools and equipment of good
quality and standard make.
The following are some of the many tools
used in Benchwork:

 Hammers •Vises •Measuring tools

 Wrenches •Chisels •Assembly tools
 Cutting tools •Punches • Hand reamers
 Hacksaw •Polishing •Hand taps
 Files •Threading dies •Drills
 Layout tools •Screwdrivers
Classification of Hand Tools
 Measuring Tools
 Steel rule
 Pull push rule
 Zigzag rule
 Contact type caliper
 Vernier caliper
 Micrometer caliper
 Fixed value gages
 Telescoping gages
 Radius & Fillet gages
 Angle gages
 Screw pitch gage
 Thickness or feeler gages
 Pin or Plug gages
 Go/No-Go Plug gages
 Single –end progressive-type go/no-go plug gage
 Thread go/no-go plug gages
 Taper plug gages
 Snap gages
 Gage blocks
 Taper ring gages
 Ring gages
 Go/No-Go ring gages
 Optical Comparators
Zigzag rule
Steel rule
Inside contact type caliper
Outside contact type caliper
Transferring an outside caliper measurement to a rule.
Method for setting an internal caliper.
Vernier Caliper
Assignment

 1. What is a Vernier caliper?

 2. Where does the name Vernier Caliper came
from?
 3. What is the basic working principle of a
vernier caliper?
 4. What are the parts of a vernier calipeer?
 5. What are the advantages
 Vernier caliper, instrument for making very
accurate linear measurements introduced in
1631 by Pierre Vernier of France. It utilizes
two graduated scales: a main scale similar to
that on a ruler and an especially graduated
auxiliaryscale, the vernier, that slides parallel
to the main scale and enables readings to be
made to a fraction of a division on the main
scale. Vernier calipers are widely used in
scientific laboratories and in manufacturing
for quality control measurements.
 https://www.britannica.com/technology/
vernier-caliper
Advantages
 Vernier calipers provide accurate and precise
measurements over a large range.
 Versatility
 Vernier calipers can be used to take a variety of different
measurements. These include internal dimensions,
external dimensions and depth measurements.
 Durability
 Most vernier calipers are made out of stainless steel. Since
steel is a very durable material, with proper care, a
stainless steel vernier caliper can last a life time.
 Cost
 Compared to other types of caliper, vernier calipers are
relatively inexpensive.
Disadvantages
 Good eyesight is required
 The vernier scale of a vernier caliper is quite small, and
so can sometimes be difficult to read. It is not difficult to
misread the last digit of your measurement.
 Good eyesight or a magnifying glass is required when
taking readings.

 Reading a vernier caliper

 As the vernier scale is a unique measuring instrument,
users must learn how to read a vernier caliper before
taking measurements.
 Possibility of errors
 Taking a series of measurements one after
the other can lead to reading errors, because
concentration is required.

 More accurate tools are available

 Vernier calipers are not as accurate as digital
calipers.
Let’s have a short quiz?

½ cross wise
please
Determine the dimensions A, B, C. & D of
this casting in inches?
Determine dimensions A, B, C, D, E, & F of
this drill jig in inches?
Least count of a Vernier caliper:

 Metric system
 1/20 mm (0.05 mm.)
 1/25 mm (0.04 mm)
 1/50 mm (0.02 mm)
 1/100 mm (0.01 mm)

 English system
 1/1,000 (0.001”)of an inch
How to read a Vernier Caliper?

 Procedure on how to read a vernier caliper.

 Metric system
 English system
Micrometer Caliper

 Instrument that measures the thickness or

the diameter of relatively small parts; it
produces finer results than a vernier caliper.
Assignment

1. Who invented the micrometer caliper ?

2. when was invented?
3. when was it introduced to the people to be
used?
4.The basic operating principles of a
micrometer ?
5. Define pitch and lead as applied in a screw
thread?
Micrometer

 A Micrometer is one among the precision

measuring instruments used to measure
dimensions of objects especially very small
whom accurate measurement cannot be
achieved by using other common measuring
tool or scales .
History of Micrometers

 The concept of micrometer was invented way back in

the 17th century. Mr. William Gascoigne invented
micrometer screw as a better version of Vernier to help
his study on stars. But the real father of today's
micrometer is Jean Louis Palmer from France. It was
Palmer who proved that micrometer concept can be
used in measuring very accurate small dimensions. The
original equipment was not so precise like today's
modern micrometers. But it was Mr.Palmer's
contribution which helped his successors to develop
high precision micrometers which are widely used by
precision manufacturing industries.
 200BC screw thread invented.
 In 17th century (1639) William Gascoigne invented a
micrometer caliper comprising of jaws and scale.
 18th century (1772) James Watt invented the table
top micrometer.
 19th century (1805) Henry Maudslay the table top
micrometer called “Lord Chancellor”, was the
most precise of that day and considered as the
beginning of precision measuring instruments. He
was known as “The Producer of best machine
Tools” in London.
 (1848) J. Palmer received a patent for his
micrometer called “Palmer System” in France.
 (1868) Brown & Sharpe invented pocket-sized
micrometer for measuring plate thicknesses.
 (1877) Victor Machine placed an ad for their
micrometer in the inaugural issue of
American machinist.
 20th century 1920-1935 several Japanese
manufacturers start producing micrometers.
 1938 Mitotoyo starts producing micrometers.
 1947 Mitotoyo restarts producing
Micrometers after WWII.
 1953 Mitotoyo produced the 3 meter outside
micrometer, the largest in the world.
 1969 Mitotoyo started producing 3-pointed
inside micrometers.
 1979 First digital micrometer in Japan
intoduced by mitotoyo.
 21th century 2003 Mitotoyo introduced its
first coolant-proof micrometer.
 2004 Mitotoyo introduced its improved
ratchet-thimble micrometer.
Principle of Operation

 The basic principle of operation of a

micrometer is as follows:
 The amount of axial movement of a screw that is
made accurately can be measured by the amount
of rotational movement of it. This is because the
pitch of the screw is constant.
 The measurement made due to the rotational
movement is some amplified form of the actual
axial movement of the screw.
Working Principle

 In a micrometer screw gauge measurements

are done actually through a precisely made
integrated screw with a pitch of usually but
not necessarily 02 threads per millimeter,
which means that on completing exactly one
revolution the displacement achieved is half
of a mm i.e. 0.5 millimeter.
Least Count.

 The least count of screw gauge represents minimum value of a

dimension which measurable hence it actually shows the
degree of accuracy to which an instrument can work. The least
count of a screw gauge is represented as:
 Least Count = Pitch of the screw / No. Of divisions on the
circular scale
 If we are working with the screw whose pitch is ½ mm and the
number of divisions on the circular scale is 50 then, using the
formula stated above least count for our micrometer is going
to be
 Least Count = 0.5mm / 50 = 0.01mm
 This means that we can measure up to the 100th part of a mm.
Construction
Give me the reading of the ff.

 1. 3.66 cm
 2. 2.72 cm
 3. 1.11 cm
 4. 1.01 mm
 5. 1.001 mm
Fixed Gages
Telescoping Gages

 Is shaped like a “T” and has two arms that

expand when the locking screw is loosened.
Telescoping gages are use to measure
internal diameters. Use one motion and do
not place the gage back in the hole after
tightening because it will collapse the arms
and give a false reading. After being set,
telescoping gages are usually measured with
a micrometer to obtain measurements.
Screw pitch gage determines the distance
between threads.
 Ring gages

 Used to inspect external diameters similar to

the way pin or plug gages are used to check
internal diameters.
 Ring gages can be used As go and no-go sets
also. The go gage should always fit over the
diameter while the no-go gage should never fit.
If either condition is not met, the diameter is
not within the tolerance and the part should be
considered scrap. The no-go ring gage is easily
identified by a groove around its circumference.
 Gage Blocks
 Are extremely accurately sized blocks with very smooth
surfaces that can be used for part inspection or to check
the accuracy of other precision measuring tools. They
are normally purchased in sets with a certain number of
blocks of various sizes and are available in rectangular
and square versions.
 Gage blocks are available in different grades of
accuracy. The allowable deviations are given in
millionths of an inch (0.000001= one millionth)
 Gage blocks can be made of steel, carbide, or ceramic.
 All gage blocks should be handles with great care, they
should not be dropped, bumped, or hit against other
surfaces. After use, gage blocks should be oiled and
stored in their cases.
A typical rectangular gage block set
 Optical Comparator

 An OC projects a magnified image of a part on a

screen for measurement. They are very useful for
measuring small parts and features that are difficult
to see with the naked eye. The image appears as a
shadow of the part’s profile on a bright screen.
 Linear measurements can be made by moving the
part using a hand-operated wheel. A digital readout
or a micrometer scale shows the distance moved. The
outer ring of the screen contains an angular scale that
can be rotated to measure angled features.
 Marking & Layout Tools

Scriber – a sharp pointed steel tool used to

scribe lines on metals being laid out.
Divider – a laying out tool which consists of a
pair of steel legs adjusted by a screw and nut and
held together by a circular spring. It is used to
measure the distances between points, transfer
measurement directly from a rule and scribe arcs
and circle on metal.
Combination square - a laying out tool
forms 90 degrees angle on one side & 45
degrees angle on the other. There is
also a spirit level in the head, for
leveling up a machine or work piece and a
scribing tool.
Measuring depth with an adjustable square. The
blade can be lock in place after positioning by
tightening the clamping screw. The reading is then
taken where the blade intersects the beam.
Combination Set - a laying out and a
measuring tool which was design to function
as a protractor, square and center head.
Finding the center of a round piece of material using the center head and blade
of the combination set.
Miter try square – use for checking & laying out 90 & 45
degrees angle.
Steel square or Framing square or Carpenter’s Square – use
for checking and laying out 90 degrees angle on larger works.
How to solve math problems with
a square (Richard Gordon)
 Short-cut math on a Carpenter’s Square
 One of the most versatile tools you can own
may be one you’d never guess. It’s the
Carpenter’s square, also known as a Rafter,
Framing or Steel square.
 Actually, the Carpenter’s square is also a
valuable instrument for solving complicated
math problems around the home and shop
that would require time-consuming
calculations with paper and pencil.
 The secret of its use lies in the fact
that its two arms form a right
triangle. Add the diagonal across
the two arms, and you have a
right triangle. All of the
trigonometric functions that hold
true for a right triangle hold true
for the square.
Why a square solves problems
in trigonometry
 In a right triangle, the side opposite
an acute angle always remains in the
same ratio to the side adjacent to the
angle no matter how big the triangle.
Note how a 35º angle produces the
same 7:10 ratio regardless of the
length of the triangle’s two sides.
How to inscribe three small
circles inside a large circle?
 How you do it:
 Set the square at the 61/2” and 14” ratio.
Why it works?
The ratio of 61/2:14 that you set up holds true for
any three small circles enclosed in a larger one, no
matter what their size. Sliding the blade of the
square to any desired large diameter
automatically causes the correct small diameter,
always in the same ratio, to show up on the
tongue.
How to find one pipe that
equals two.
 How you do it:
 Locate the inside diameter of one
pipe on the blade of the square and
the inside diameter of the other pipe
on the tongue, then measure the
diagonal between the two points.
The result is the diameter of a pipe
equal in capacity to the other two.
Why it works::

This trick is based on the

ancient Pythagorean theorem: In
a right triangle, the square of the
hypotenuse equals the sum of the
squares of the other two sides.
The diagonal across the square is
the hypotenuse of a right triangle.
How to divide a line into
equal parts
 Example: Divide 7 3/8” into five equal parts.
 How you do it:
 Square a line to the edge of a board.
 Measure 7 3/8” from squared line and mark edge of
board.
 Place heel of square exactly on line using 10” as a
convenient scale, divide the diagonal carefully into
five equal parts .
 Draw squared lines from marks on diagonal down to
edge of board to divide 7 3/8” line into five equal
parts.
How to find the center of a
circle:
 Place heel of square on circumference.
 Mark circumference in two places where square
intersects the circle.
 Draw a line connecting the two marks. This is the
diameter of the circle.
 Place heel of square in a new position on the
circumference and make two more marks as in first step.
 Draw a line connecting the new marks to form a second
diameter.
 The intersection of the two diameters is the center of
the circle.
Trammel point- a marking tool which consists of a steel bar
and two legs called a beam compass is a type of divider
preferred for scribing large arcs and circle.
Hermaphodite caliper – a tool which has an outside caliper leg and
a divider leg in the other used to locate the center of a
cylindrical work piece or to layout line parallel to edge.
 Prick punch – a marking tool made of hardened tool steel and grounded to a
slender point having a 30 to 60 degrees included angle.

Set of Center punch – a tool similar in appearance with the prick punch except
that the point is grounded at an included angle of 90 degrees.
Bevel protractor – used for laying out angle other than 90
& 45 degrees at the range of one degree.
Universal bevel protractor - The bevel protractor
is used to establish and test angles to very close
tolerances. It reads to 5 minutes or 1/20o and can
be used completely through 360o.
The bevel protractor consists of a beam, graduated dial
and blade which is connected to swivel plate (with Vernier
scale) by thumb nut and clamp.
 Sine Tools

 Sometimes angles must be measured more

accurately than with a vernier protractor.
 They can be used to measure angled surfaces
relative to a reference surface (normally a
surface plate)
 Sine tools get their name from the fact that
the trigonometric sine function is used to
determine the size of gage block builds used
to incline the tools.
 Sine bar and sine blocks

 A sine bar is a narrow bar with rolls near each end

and is used to measure angles on relatively small
parts. A sine block is a wider version of a sine bar.
 Sine Plates = similar to a sine bar except
with a larger area to hold larger parts. The plate
usually has threaded holes for the use of clamps
to secure parts. A compound sine plate is like
one sine plate on top of another with pivot
points located at 90 degrees to each other. It is
used for measuring compound angles.
 Cutting tools
 Multiple point cutting tools
 Hacksaw
 Files
 Pipe cutter
 Thin shears
 Single point cutting tools
 Chisels
 scrapers
Hacksaw-
 Cutting Tools
 Hacksaw - a fine-tooth saw with a blade under
tension in a frame that is used for cutting hard
materials (as metal)
 It is sometimes called an adjustable hacksaw
because the length of the frame can be altered
to hold blades of different sizes.
 Blades are supplied in two lengths, 250mm and
300mm
Hacksaw blade

 Blades are also described by the number of

teeth per inch (TPI). Blades have 14, 18, 24, 32
teeth per 25mm (inch)
Hack sawing
Hack sawing operations

 At what speed should a hacksaw be used?

 50 to 60 strokes per minutes
 How much pressure required for hand hack
sawing?
 10 to 20 lbs per inch of contact.
Rules to be followed in hand hack
sawing

 Use a blade with teeth of the correct pitch for the

job to be done.
 Saw as close as possible to the point where work is
clamped to prevent chattering.
 Do not cut too fast.
 Relieve the pressure on the saw on the return
stroke.
 Do not press too hard on the work.
 Reduce pressure on the forward stroke when the
blade is almost through the cut.
Common causes of breaking hacksaw blade

 Using a coarse blade on thin work.

 Drawing the blade too tightly and then canting
(tilting it over).
 Using too much pressure.
Files
Files

 Files – is a piece of hardened, high-grade

steel with slanting rows of teeth chiseled into
its surface. These teeth cut and remove small
amount of material from a work-piece. Files
will not cut hardened steel or other materials
harder than the file.
Standard Shape of File

 Flat file – used for general purpose work.

 Triangular file – used to file corners square
and filing burrs from 60 degrees thread
grooves.
 Square file – used to enlarge rectangular-
shaped holes and slots.
 Round file – used to enlarge round holes.
 Half round file – used for a wide range of
different jobs.
Cuts of files

 The cuts of files must be considered when

selecting a file for roughing, finishing, or
draw-filing operations.
 The cut of a file is the coarseness of the
teeth, the spacing of the teeth.
Cuts of files must be considered when selecting a
file for roughing, finishing, or draw-filing operations.

 Rasp cut – is a pattern by which each tooth is

individually formed. The teeth are separate and
disconnected.
 Single cut – has a single set of diagonal rows of
teeth.
 Double cut – has two sets of diagonal rows of file
teeth. The first set of teeth is called over cut. The
other row of teeth, cut at a different angle, is
known as the upper cut.
 Curved cut – teeth curve across the face of the
 Tooth spacing varies with the shape and length
of the file.
 The spacing increases as the length of the file
increases.
 The coarseness of a file can only be compared
with files of the same length and shape.
 The spacing between teeth on files are:
 Rough
 Coarse
 Bastard
 Second cut
 Smooth
 Dead Smooth
 Filing Operations
Straightforward, flat filing – done by pushing the
file lengthwise, straight with or slightly diagonal
to the work piece.
Drawfiling – is a filing operation to produce an
even-grained, smooth, true flat surface. This is
done by pulling or drawing the file at right
angles across the work. Usually, a single cut file
should be used for drawfiling.
Cross filing – pushing the endways under more or
less pressure against the work.
Pipe Cutter- used for cutting
pipe.
Snips - also known as shears,
are hand tools used to cut
sheet metal
Chisels -
 The simplest of the cutting tools using a
wedging action to cut and chip cold metal.
 The cutting edges are hardened. The head is
tough and chamfered to prevent it from
spreading or splintering from hammer blows.
 The cutting edge is placed on the material to
be cut and the head is struck with a hammer.
 It is also used to shear off old, rusted bolt
heads or nuts, small rods and bars.
 Shearing heavy metal in a vise.
Cape chisel

 Clean up battered keyways

 Cut some special keyways , channels and slots
in metal
 Divide work so that a flat chisel can finish
Round nose chisel

 Is similar in shape to the cape chisel with one

edge ground flat leaving the other edge
round cutting edge.
• Cut round, half circle grooves in metal
• Clean up round corners on rough castings.
Types of Chisels
 Scrapers

 Scraping is the process of removing thin

shavings of metal from a work-piece surface
to make it flat and smooth.
 Scraping removes the high spots left after
machining to accurately fit one part to
another.
 Scraping is also done to provide small oil
pockets between mating surfaces.
Types of scrapers
1. Flat
2. Gook
3. Three cornered
4. Half-round
 Torsion Tools
 Open end wrench
 Combination wrench
 Box wrench
 Socket wrench
 Spanner wrench
 Allen wrench
 T – wrench
 Tap wrench
 Adjustable wrench
 Pipe wrench
 Monkey wrench
 Vise grip or lever jaw wrench
Open-end wrench- usually have a
different size on each end. The
wrench ends are often angled
different amounts to be used
easily in close areas.
Combination wrench- has two types of
openings of the same size. One end has a box type
opening with the opposite end designed as an open
end. It can be used in places where the space for
movement is limited; if one end will not work
conveniently, the other end will.


Box wrench- also double ended and
made offset to clear the user’s hand. Box
wrenches completely enclose the nut or
bolt head.
Socket wrench- similar to box wrenches
in that they also completely surround the bolt
or nut. Sockets are made in sets, detachable
from solid or ratchet handles.
Spanner wrench- two types of spanner
wrenches are fixed and adjustable. They are used
on adjusting collars, lock nuts, rings, and
spindle bearings.
Allen wrench – made of hexagonal
shaped stock to fit the holes in the head
of set screws.
Tap wrench- adjustable tap wrench
are used to hold the square end and drive
the tap throughout the cutting operation.
Adjustable wrench – has a movable
jaw which makes it adjustable to various sizes
of nuts and bolts.
Pipe wrench- designed with adjustable
jaws that are serrated, making it possible to
grip round pipe and other cylindrical parts.
Monkey wrench- adjustable monkey
wrench should only be used when non-
adjustable type wrench is not available.
Vise grip or lever jaw wrench or
Locking pliers - a combination
gripping tool with adjustable jaw which
may be locked in place.