TOOL MAKING-Bench Work-Practical. Reference notes for Engineers.

THE VICE AND ITS ACCESSORIES

The vice

The main parts are:Jaws, spindle, anvil plate, fixed part,moving part, handle.

The height of the vice depends on the height of the operator.The height shown on picture should bemaintained.

For operation of work piece, protectionjaws are made of soft material.e.g.Aluminum, copper.

Chamfering clamp.

It is fitted in the vice when 45 degreechamfer has to be done on the work piece.

Jaws for clamping round jobs.Usually made up of soft materials.

THE FILES

Nomenclature of the file

Length.Tang.Cut.

Classification of filesSingle cut fileOnly provided with single rows of tooth.Every tooth makes one cutting edge.

Double cut file.Provided with cross cut tooth.Makes many small cutting edges

Shape of file

SquareRectangularRoundHalf roundTriangular.

GradeCourseRoughSmooth.

FILE AND THEIR APPLICATIONS

FILING

Filing

During filing operation it is important to have the right working position

Bend in the knees and use the weight of the body as a lever.

Feet position as per figure.

Using a big file , hold around the end file with the right hand

Using smaller files,

give pressure with one or two

finger at the end of the file.

THE HACKSAW

The Hacksaw

Consists of a frame,

handle, saw blade and clamping dog

No of teeth

For cutting heavy material of tool steel, select 18 tooth per inch

For cutting profiles of soft steel cast iron and bronze select 24 tooth per inch

For cutting thin

pipes select 32 tooth

per inch

Working procedure

The right working position is important.See the feet position.

CHISELS

Flat chisel.

For planishing cutting and removing of sharp edges and welding spots

Cross cut chisel.

For slots and channels.

Grooving chisels. For oil grooves slots and key ways

While chiseling always

look at the

Cutting point.Don’t look at the

end of the chisel.

During grooving chip from both sides to prevent broken corners.

MARKING TOOLS.

Scribers.

Ordinary scriber made of hardened steelOne end is bend to unable marking at corners etc

Pocket scriber can be provided with

tungsten carbide points.

The detachable point is put back inverted in the scriber body when it is not in use.

Dividers.

Use for

marking of circles, arcs etcMade of

hardened steel

Two types of dividers are normally used

The divider shown at the picture is called spring joint divider.

Other type is called firm joint caliper.

Height gauge

There are two types

Vernier height gauge type is shown on the picture

Other type is called surface gauge. .It is used along with a marking table to scribe parallel lines

Locating center of a round bar Checking heights etc

MARKING OUT

MARKING WITH STEEL RULE AND SCRIBER.

Using Steel Rule.

Always mark at the end of the

rule by setting

dimension form the edge

of the job.

Using Scriber.

Always keep the scriber inclined away from the edge of the rule.Marking a straight line at a right angle to the job by using scriber and try-square.Marking out by using vernier height gauge angle plate and surface plateNote apply

marking media on the job

before marking

Purpose:

To get a visible and clear thin line.Lime powder solution Fine lime powder is made into a thin paste by adding water.

Copper sulphate solution.

Add copper sulphate crystals into water (eg 200ml) till the solution are saturated and there after 10-2- drops of sulphuric or nitric acid.Apply the solution with the brush.Caution: copper

sulphate and acids

are poisonous

Center punching.Hold the punch with the left hand and support it with finger contact on work piece

MEASURING

Steel rule.

Always keep the steel rule 90 degree to the job

And always read as shown in the figure

Vernier scale.

Available with a least count of 1/10th or 1/20th of a mm

Outside checking.

Inside checking.

Depth checking.

TAPPING AND THREAD CUTTING

Tap wrench

Different sizes are available according to the size of the tap

Tapping

1.select the tap

2. fix the tap in the wrench and with the light pressure downwards rotate the wrench until the tap grips.

Use cutting oil. Check that the tap is in a right angle according to the job.

3. Rotate the wrench half a revolution and then turn anti clockwise in order to break the chips.

Die wrench

Different sizes are available according to the shape and size

Before starting give the job a chamferSelect the die and fix into the wrench

Position the die so that the taper entrance engage first

Use cutting oil

TO FIT A HAMMER HANDLE

To fit a hammer handle.

Select the correct size of handle.

Fit the handle so that it just can enter the hole in the hammer

With a hacksaw cut a groove for the wedge

Use a wooden wedge. Tap the wedge into a slot by holding the hammer with the left hand and supporting it in a table and striking it by another hammer

GRINDING MACHINES

Bench grinder

Bench grinder can be fitted on a work bench.

Pedestal grinder

Pedestal grinder provide with adjustable tool rest and dust exhaust safety guards for protection are provided

For coolant a small container in front of the m/c is mounted.

Tool grinder

Provide with an adjustable table and coolant system.

A cup wheel is fixed

SAFETY AND GRINDING WHEELS

Personal safety

If the m/c is not provide with a transparent safety guard then goggles must be used

Mounting a grinding wheel

Check the wheel is free from visible defects

Sound test the wheel by using a mallet A clear metallic sound will come if the wheel is o.k.

Check the paper washer

The size of the washer must be as big as the diameter of the flanges

MOUNTING AND TRUING THE GRINDING WHEEL

Mounting the grinding wheel

Fix the wheel on the spindle.Make sure that the wheel enters with out any resistance.

The bore of the wheel must not be too strong.

Truing the grinding wheel

Start the machine and test the wheel for True the wheel until the right geometrical shape is achieved.

Stop the machine and adjust the work rest.

Maximum two mm, gap between rest and wheel. Should be maintained.

DRILL GRINDING

Hand grinding of drills

Support the drill approximately 40mm, from tip with one hand and grasp the shank with the other hand.

Position the drill so that the drill edge is parallel to the face of the wheel.

Apply coolant.

Give a light pressure forward; Lower the hand grasping on the shank at the same time turn the drill clockwise to give the drill clearance.

Release the pressure and bring the drill cutting edge parallel to the wheel.

Repeat the operation until the desired angle and clearance is achieved.

Repeat the operation on the other cutting edge.

Position drill gauge and check the angle .

Check both angles and rectify if necessary.

DRILL AND TOOLGRINDING

Drill and Tool Grinding

Position the drill against back of a gauge and scribe a line.

Turn the drill 180 degree and check the second lip. Both lips should coincide.

Hold drill with both hands one hand near to the drill point, position of back edge on one web, to the corner of grinding wheel. The other hand supporting the drill around the shank.

Give light pressure and thin the point.Repeat the operation on the second web.

Hand grinding centre punch .

Hold the punch with the left hand fingers. Rest the hand on the too rest.

Hold the edge of the punch with the fingers of the right hand.

Position the tip at the angle of 60degrees to the wheel.

Grind the punch turning the head with the right hand.

Do not allow the point to get over heated.

GRINDING OF A CHISEL

Hand grinding of chisel

Hold the chisel with the left hand supporting on the tool rest.

Hold the head of the chisel with right hand.

Move the chisel slowly backwards and forward slowly across the face of the wheel.

Do not allow the chisel to get over heated.

Repeat the operation on the other side of the chisel.

Check the cutting angle using the gauge.

DRILLING MACHINES

BENCH TYPE FLOOR TYPE.

Is normally mounted on a fitting bench Mounted directly on the floor. Can accommodate bigger jobs than the bench type.

RADIAL DRILLING MACHINE

RADIAL DRILLING MACHINE.

Used for heavy and big jobs. The arm can move in a radius of its column.

Has got high capacity for drilling large holes. Has a large clamping surface and

large range between spindle and bore. In general elevation of the arm is

carried out with the help of a motor. Has wide range of spindle speeds and

feeds.

ACCESSORIES FOR DRILLING MACHINES.

Co-ordinate Table.

Machine table can be shifted in “x” and “y’ direction.

Provided with a graduation on each spindle.

COOLANT SYSTEM

Consists of tank, motor fitted on pump, feeding and drain hoses.

For starting and stopping of the machine

For changing the spindle revolution for tapping.

THE VICE AND ITS ACCESSORIES

Twist drills

Smaller drill size are provided with a straight shank

Bigger drill sizes are provided with a MORSE tapered shank.

The MORSE size varies from No. 1 to No. 6, and the size depends on the drill diameter.

Parts of a Twist Drill

COUNTERSINKS AND BORES.

Counter Boring Tool

Consists of shank, cutter and pilot. Cutter and pilot diameter can be changed.

Makes counter bore for e.g. socket head screws.

Counter Sinking Tool.

Tapered and straight shank.

For counter sinking holes for screw etc.

Can be used for chamfering holes.

45’ for screws.60’ for piercing punches.

DRILL CHUCKS

Drill Chuck with key

Drill chuck with key is used for holding straight shank drills.

The drill is clamped with the key.

Different ranges are available.

Self- Locking Drill Chuck

It is used for holding straight shank drills.

The clamping is only done by hand.

There are different ranges of chucks.

Both types are provided with a MORSE tapered

shank.

DRILL SETTING WITH TAPERED SHANKS.

hammeTo Remove The Drill Chuck.

Support the chuck with the left hand and tap with the hammer on the drill drift, using right hand.

Setting

Before fixing a sleeve, make sure that the tapered sleeve and the internal Morse taper are clean.

Insert the sleeve and give a light tap upwards on drill joint with a soft hammer.

WORK HOLDING ON DRILLING MACHINE

Clamping round jobs in v- block.

Position the V- block parallel to the Tee slots in the table.

Place the job in the V- block ensuring both work piece and V- block are free from burrs.

Rotate the job to bring the mark center in position. Clamp the job V- block with a strap clamp.

Clamping flat jobs in vice

Ensure that the table and vice areclean. Place the vice and clamp withclamping with Tee bolts, washer and nuts

Place the job on

top of two equaland clean parallels. Make sure that the parallels are in such a positions that the drill will not damage the parallels when drilling.

Clamping the vice lightly. Lightly tap the work piece with a soft hammer to ensure that the job is correctly seated.

Clamp the vice securely. (Not with a hammer).

Aligned marked hole in position to drill by loosening the machine or shiftingthe vice in the Tee slots. Before drilling, table vice and job are securelyclamped.

WORKING HOLDING ON DRILLING MACHINE

Clamping flat job directly on the Table

Ensure that the table is clean.

Place two equal size parallels on thetable

Place the job on top of parallels. Clamp the job with Tee- bolt sand clamps.

Align marked holed in position by adjusting machine table or shifting the job.

Clamping on angle plate

Clamping angle plate to table using Tee bolts.

Position the job against the angleplate.

For small jobs, butt up parallelsunderneath.

Clamp the job lightly.

Tap the job with soft hammer to ensure that it is in correct position.

Clamp the

job securely.

EXERCISE NO- 01

OPERATIONS TOOLS / INSTRUMENTS

1) Study the working drawing and arrange the required tools and instruments. 2) Remove the burrs and scales from the work piece.

3) Check dimension of the raw material.4) Files surface "A" flat.

5) Check the flatness using the straight edge.6) File side "B" right angle to "A" and the squareness.

1) Flat file bastard -200mm.

2) Flat file second cut-200mm.

3) Straight edge.

4) Soft vice clamp.

5) File brush.

6) Steel rule -150mm.

7) Try square- 3"x4".

7) File surface "C" right angle to "A" and "B".8) Check surface "C" for squareness with "A” and "B".

9) File surface "D" parallel to "A".

10) Check surface "D" for parallelism with "A” and check the dimension.

11) File surface "E" parallel to "B" and check for parallelism with "B".

12) Check squareness of surface "E" with surface "A".

13) File surface "F" parallel to C and right angle to "A" and "B".

14) Inspect the dimension of the work piece as per drawing.

8) Vernier caliper- 150mm.

EXERCISE NO- 02


1) Study the drawing and arrange the required tools and instruments.

2) Remove the burrs and scale from the work - piece.

3) File the edges A and B right angle to each - other.

4) Mark the lines and the co-ordinates of the radii by using height gauge.

5) Mark other details by using spring divider and bevel protractor.

6) Cut along the marked lines using hacksaw by keeping 1.00mm allowance all over.

.1) Flat file second cut-200mm 2) Flat file second cut -150mm. 3) Flat file smooth-150mm.

4) Tool for engraving scale.

5) Height gauge-300mm.

6) Bevel protractor.

7) Straight edge.

8) Nylon hammer.

9) Wooden block.

7) File and control the dimensions as per drawing.

8) Check the angle 121 with the help of the combination set square.

10) Emery paper.

11) Hacksaw

EXERCISE NO- 03


1) Study the working drawing and arrange the required tools and instruments.

2) File the block to size 50.6x50.6x15.6mm.

3) Check the flatness and squareness as per drawing.

4) Apply copper sulphate solution on surface "A".

5) Prepare the marking place.

6) Mark the co-ordinates as per drawing with the help of height gauge.

7) Check the marked co-ordinates with the vernier caliper.

8) Punch the center of 12 holes with center punch.

1) Emery cloth.

2) Copper sulphate solution.

3) Angle plate.

4) Center punch.

5) Height gauge - 300mm.

6) Vernier caliper.

7) Set of files.

EXERCISE NO- 04

EXERCISE NO- 04


1) Study the working drawing and arrange the required tools and instruments.

2) Center drill and drill the holes A, B, C to the required size for M6, M8, and M10 tap.

3) Center drill and drill the hole D, E, F for 10H7, 8H7 and 6H7.

4) Locate the hole G, H, I. Center drill and drill to the required size as shown in drawing.

5) Counter bore the hole G, H, I to the given depth and diameter as shown in drawing.

6) Locate holes L, K, J and drill it to the required hole size.

7) Counter sink the hole J, K, L to the given depth as shown in the drawing.

8) Check the dimension as per the drawing.

1) Flat files.(Bastard and second cut)

2) Center punch.

3) Set of drills.

4) Set of taps.

5) Set of reamers.

6) Counter bore and counter sink drills.

7) Vernier caliper 150mm.

8) Height gauge 300mm.

EXERCISE NO- 05



2) File two blocks "A" and "B" to the size 53.00x35x6mm and 55x35x6mm respectively.

3) Cut with hacksaw by keeping 0.8mm allowance for filing.

4) File R8.5 on the block "A" and check the radius 8.5 with radius gauge.

5) Finish R8.5 on the block "B" by using half round file.

1) Flat file bastard- 200mm. 2) Flat file second cut- 200mm.

3) Flat file second cut- 150mm.

4) Flat file smooth 150mm.

5) Square file smooth 150mm.

6) Half round file.

7) Half round file

6) File and finish 17.2 with 120 Angle, on block "A" and block "B".

7) Check the dimensions and angle with outside micrometer and combination set square.

8) Assemble male block "A" and female block "B" to get the snug fit at both the sides.

bastard 150mm.

8) Micrometer 0-25mm. 9) Try square 3"x4".


11) Bevel protractor.

12) Spring divider.

13) Radius gauge.

EXERCISE NO- 06

EXERCISE NO- 06



2) File three blocks 1,2,3 to 120x73x16mm, 24x22x22mm and 36.2x22x16.2mm respectively.

BLOCK NO 3

3) File chamfer on block as shown in the drawing.

4) File R8 on block as shown in drawing and check with radius gauge.

BLOCK NO 15) Mark with height as per drawing.

6) Drill Ø3, Ø8, Ø20, Ø6.5,

1) Set of files. 2) Set of drills. 3) Height gauge 300mm.

4) Hacksaw

5) Spring divider.

6) Hammer 250gms.

7) Center punch.

8) Emery paper.

9) Copper sulphate.

10) Set of needle files.

11) M6 tap set.

and Ø5 on block as per drawing and perform M6 tapping.

7) Cut the inside profile by keeping 1.0mm allowance.

8) File and finish profile "A" and "B" and check the profile as per drawing.

9) Fit block 2 and 3 in the profile "A" and "B” respectively to get a light snug fit.

EXERCISE NO- 07

EXERCISE NO- 07


1) Study the drawing and arrange the tools and instruments. BLOCK NO 4

2) File block to size 36x22x22mm.

3) Mark as per drawing.

4) File R6 and R2 as shown in the drawing. BLOCK NO 1

5) Mark the profile and the co-ordinates with help of height gauge as shown in the figure, for opening "C".

6) Drill pilot holes of Ø3.8, Ø15 as per drawing at "C".

7) File and finish the profile "C".

8) Check the profile "C" as per drawing.

9) Fit block 4 in profile "C"

1) Set of files.

2) Set of drills.

3) Set of needle files.

4) Combination set square.

5) Vernier 200mm.


7) Center punch.

8) Radius gauge.

9) Scriber.

to get a light snug fit.

FITTING WORK RECOMMENDED FOR CONDUCTING TEST

TOOL MAKING-Bench Work-Practical. Reference notes for Engineers.

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Transcript of TOOL MAKING-Bench Work-Practical. Reference notes for Engineers.