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FACULTYOFMECHANICAL&AUTO
MOTIVE ENGINEERING
TECHNOLOGY
BMM 1722
MECHANICAL LABORATORY 1

BENCHWORK
Fitting Process
Laboratory Date 28.3.2022

10.4.2022
Submission Date

Lecturer MOHD FADHLAN BIN MOHD YUSOF

JP/PJP 1) NOOR SAADAH BINTI NOR AZMI

2)

3)

Learning objectives:
By the end of semester, students should be able to:
∙ Identify various types of hand tools.
∙ Describe the application of various types of hand tools.
∙ Use various types of hand tools properly within safe practice.
∙ Determine the correct tools for threading process.
∙ Apply the knowledge to produce bench work project.
Members ID Section Signature
LINGES A/P SUBRAMANIAM FA21006 01
S.linges
MUHAMAD DANIAL BIN MUHD DINESH MA21151 01 M.Danial
 AHMAD AZHAD RIFQI BIN REDZUAN MA21001 01 RIFQI

NURUL FARAHYNN BINTI MUSTAFA FA21003 01 FARAHYNN

LAB REPORT:

For your project report, provide the following:

1. Use a cover page similar to the lab sheet format.
2. Contents for the report are;
➢ Introduction
➢ Hand tools (Name & applications)
➢ Process Plan
➢ Methodology
➢ Conclusion/Lesson learned
➢ References (not less than 5 references)
3. Discuss the strengths and weaknesses of this laboratory. Did the laboratory help you
to learn the material better? Explain why or why not.
4. Equations should be numbered and plots should be numbered and referenced with a
descriptive caption.
Contents
1.INTRODUCTION ............................................................................................................................... 5
2.HAND TOOLS .................................................................................................................................... 7
3.PROCESS PLAN ............................................................................................................................... 13
4.PROJECT METHODOLOGY ........................................................................................................... 14
5.CONCLUSION .................................................................................................................................. 18
6. STRENGTH AND WEAKNESS ..................................................................................................... 18
6.REFERENCES .................................................................................................................................. 19
1.INTRODUCTION

The technique of fitting parts together after fabrication or manufacturing the parts is called
assembly work. To do so, it is necessary to do some parts fillings, threading, hammering or
sawing jobs which are done on a working bench or fitting table. Most jobs or fasteners would
be useless without quick, easy means of installing and removing them. A good workman
always selects the proper tool for the job and must be skilled in the use of the numerous hand
tools.

What is a workbench?

A workbench is a sturdy flat, smooth, moulded surface that comes in a variety of sizes
designed for specific tasks. They can be very complex for engineering design work,
complicated machining, and intricate precision tooling or be a highly finished wood table for
woodworking, metal work, and project design.

Well-constructed workbenches have strong supports that can handle jobs requiring the use of
heavy tools and machinery. Manufacturing and production workbenches are referred to as
workstations. Though there is a great deal of similarity between workbenches and
workstations, workbenches tend to have a larger area and are used for a wider variety of
activities, while workstations are normally a part of a production or assembly operation.

How are workbench used?

⮚ Supporting Tools:

The first major function of a workbench is to support applications that involve large tools.
Industrial workbenches are used for finishing, assembly, and component repair. The majority
of heavy-duty industrial workbenches are capable of holding 750 kg (over 1600 lbs). and are
designed to support heavy tools and equipment.
⮚ Durable:
In an industrial setting, all equipment must be able to withstand hard use and the demands of
manufacturing. This includes workbenches. The work surface has to be thick and covered
with a protective material, such as a coating of resin or Formica. They have to be resistant to
chemical spills, harsh solvents, oil, and alcohol.

⮚ Testing:

All manufacturers do frequent tests of their products to determine the products stability,
performance, and quality. These necessary tests have to be performed away from production
at specially designed workbenches, as seen in the image below, which is designed for the
testing of electronics.

What are hand tools?

Hand tool, any of the implement used by crafts persons in manual operations. Hand tools are
simple tools which can use with hand, and which are usually not powered also. Hand tools is
any tool that is powered by hand rather than a motor. An example, cutters, files, striking
tools, hammers, screwdrivers, hacksaws, drills, clamps, and chopping.

Important of hand tools?

Hand tools are very essential for day-to-day jobs. They have been used by humans since
ancient times to complete various useful tasks.

Hand tools are of different types and can be used for any kind of work. Some tools are
versatile and some of them are specifically used for a specific job.

If you want the best results for your work, it is very important to know their construction and
proper usage. Lack of knowledge or negligence may lead to several mistakes and injuries.

Proper use and precision are more important than speed of work while using hand tools.
Based on the type of work that needs to be done, a craftsman must choose the right kind of
tools. He must be aware of the right tool for the job. Otherwise, the quality and efficiency of
work will suffer.

2.HAND TOOLS

2.1 Bench Vise

A bench vise is a mechanical apparatus used to secure or help grip the workpiece that is to be
worked on. It features two parallel jaws as part of the design. The bench vice mainly consists
of a fixed jaw, movable jaw and jaw plates. The fixed jaw is typically the heavier of the two
jaws and as its name implies, remains stationary during operation. The fixed jaw is usually
fastened to the table or bench either directly or indirectly via an optional connected swivel
base

The movable jaw or called as sliding jaw moves when the handle is turned. It also applies
pressure on the object that being clamped.
Bench vise should be mounted correctly on the workbench where the top of the vise jaws
should be at elbow height. Inappropriately mounted bench vises cause poor workpiece to be
produced.

2.2 Hacksaw

Hacksaw is a hand-powered, small toothed saw used for cutting metal pipes, rods, brackets
and etc. hacksaw can also cut through plastic. The hacksaw has a U-shaped frame and a
handle at one end. Hacksaws have small pins at each end of the frame that receive blade. The
basics of operating a hacksaw:

• Be sure that the blade is tightened and tension.

• Mark the pipe or conduit at the appropriate length.

• Line up the blade with the mark.

• Draw the saw back and forth on the mark.

A cut on a workpiece should be started with only light cutting pressure, with the thumb or
fingers on one hand acting as a guide for the blade. A small vee-notch could also be filed
onto the material to help start blade. In order to avoid vibration and chatter, ensure that the
cutting is done close to the vise jaws. A hacksaw is mainly used for cutting thin metal such as
aluminium, brass, steel, or copper. Hacksaws are also used for cutting plastics such as PVC,
PEX, or ABS on pipes or on sheet goods made of PVC, polystyrene, and etc.

2.3 File

A file is a tool of hardened steel in the form of a bar or rod with many small cutting edges
raised on its longitudinal surfaces, it is used for smoothing or forming objects, especially of
metal. It is also used to grind and shape the ends of wood. Its size is determined by the length
of the file and the grade of its cutting edge. The cutting or abrading action of the file results
from rubbing it, usually by hand, against the workpiece.

2.4 “L” SQUARE RULER

L-square is a two-piece ruler arranged in an L shape. The L-square is used to measure right
angles and scaled patterns from original sewing patterns. They have degrees from 0 to 360
and are usually L-shaped. An L-square ruler is used by drawing a line from the ruler’s corner
to the desired number on one of the ruler’s scales. The ruler includes scales for halves, thirds,
and eighths.
2.5 HEIGHT GAUGE

A height gauge is a measuring device used for determining the height of an object or
workpiece with extremely high precision and accuracy, or to provide marked locations on the
item relative to a reference plane for subsequent use. These measuring tools are used in
metalworking or metrology to either set or measure vertical distances the pointer is sharpened
to allow it to act as a scriber and assist in marking out work pieces. Height gauge usually
used:

• To measure the distance from a reference surface to a specific feature of a part to

verify that it meets specifications and tolerances

• To scribe a part with accurate vertical dimensions or features from a datum plane
so that additional machining can be done

• To perform 2D measurements of part features

• To verify centre-to-centre dimensions

• To measure flatness

• To measure angles

• To measure straightness/squareness or perpendicular of parts

2.6 CENTER PUNCH

A punch is a tool used to indent or create a hole through a hard surface. They usually consist
of a hard metal rod with a narrow tip at one end and a broad flat "butt" at the other. When
used, the narrower end is pointed against a target surface and the broad end is then struck
with a hammer or mallet, causing the blunt force of the blow to be transmitted down the rod
body and focused more sharply onto a small area. Typically, woodworkers use a ball-peen
hammer to strike a punch.
- It gives a physical resting place for a drill bit so it stays right where you want your hole to
be

- When you begin drilling, the recess of the dimple relieves pressure from the flat tip of the
bit (the "chisel tip" or the "web".) This prevents bending, chipping, breaking.

2.7 CORDLESS DRILL

The purpose of the cordless drill is to spin “bits”. “Bits” are the tools that go in the end of the
drill and they come in many different shapes, to accommodate driving, drilling, mixing or
cutting. Things that can be driven include screws with Philips heads, flat Heads or hex shaped
heads. For drilling, drill bits come in many sizes, from small fractions of an inch up to about
an inch in diameter. The material of the drill bits varies as well, depending on the surface
being drilled in to. There are also attachments for mixing, such as egg beaters or whisks. For
cutting, one could even insert small cutting wheels, though in general, the main intended use
for cordless drills, are drilling and driving. The cordless drill is meant to be portable and
small enough to get in tight places, making it suited for the home or automobile. It has no
harmful exhaust so it may be used indoors or outdoors but kept from getting water inside the
casing.

Operation

To operate the drill, one must first charge the drill’s battery. This involves sliding the battery
off the drill and onto the 12V charging device that plugs into the wall. After about 2 hours,
the battery will be fully charged and may be slid onto the base of the drill. Once the battery is
in place, the chuck’s teeth must be opened to allow a bit to slide in. To open the chuck’s
teeth, hold the top of the drill steady, and turn the collar on the end of the drill counter-
clockwise. The teeth will begin to open up. When they are open wide enough for the bit you
desire to use, place the bit into the chuck and turn the collar clockwise to tighten the teeth.
When the bit is secure select the cut-off torque you desire to use by spinning the collar with
drill bit pictures to the desired setting. Push the clutch into forward or reverse depending on
the application, and place the bit on the desired surface. While bracing it firmly, gently
squeeze the trigger while pushing forward. Continue squeezing until the drill is moving at the
desired speed. Once the task is completed, push the clutch back into the centre position and
set the drill down.

3.PROCESS PLAN
Step 1: Place the workpiece at the Bench Vise to hold workpiece

Step 2: Cut the workpiece using Full-Size Hacksaw

Step 3: Use flat file to trim sharp edges and make a curve side

Step 4: Use “L” square ruler to create accurate angle and straight edges

Step 5: Use “L” square ruler to check the surfaces

Step 6: Select the flat surface and make as reference

Step 7: Mark the workpiece by vernier high gauge and angle plate

Step 8: Create rounded curve

Step 9: Use centre punch to make cross section line visible

Step 10: Remove unused materials

Step 11: Smooth the edges

Step 12: Drill tap holes

Step 13: complete drilling operation

Step 14: Saw the workpiece

Step 15: Do finishing work

4.PROJECT METHODOLOGY

a. Place the workpiece at the Bench Vise. Use the Full-size hacksaw to cut the
workpiece to the correct dimension and file the workpiece into square with the
dimension 100mm x 50 mm

a-1) Use the Full-Sized Hacksaw

Also known as senior hacksaws, full-sized hacksaws are large, versatile tools that are
straightforward to operate and will make short work of tougher materials. They are
compatible with 12, 18, 24 and 32 teeth per inch blades. For this workpiece we will use the
(24 TPI) to cut the workpiece. Blades eventually wear or break and need replacing.

The blade can be replaced by loosening the wing nut adjuster until it comes off the two
‘studs’ that normally hold it in tension in the frame.

a-2) Use the Bench vise to hold the workpiece and cut it carefully.

Pressure is exerted by the handle, through the screw which then moves the sliding jaw. When
rotated anti-clockwise the handle moves the sliding jaw away from the stationary jaw and
opens the gap between them. Then in contrast, when rotated clockwise the handle moves the
sliding jaw closer to the stationary jaw, thus closing them together.

a-3) Use a Flat file to trim the sharp edges and make a curve side with a radius of 10.
 Files have forward-facing cutting teeth, and cut most effectively
when pushed over the workpiece. A variety of strokes are
employed to stabilize the cutting action and produce a varied
result. Pulling a file directly backwards on a workpiece will
cause the teeth to dull. Draw filing is an operation in which the
file is grasped at each end, and with an even pressure alternately pulled and pushed
perpendicularly over the work. A variation involves laying the file sideways on the work, and
carefully pushing or pulling it across the work. This catches the teeth of the file sideways
instead of head on, and a very fine shaving action is produced.

b. Use “L square Ruler.

The “L” square is one of the most basic of the pattern making rulers. This ruler helps to
create accurate 90° angles and straight edges. It measures, rules, and squares simultaneously.
Use the flat surface to obtain (180-degree angle) and (90-degree angle).

Place your pattern on a piece of pattern paper. Hold the pattern firmly with your non-drawing
hand, and use your pencil in your drawing hand to trace around the outside of the original
pattern.

c. After filing, we can also use the L square to check the surfaces, if rays of light can
past through the ruler. If light can past through meaning the surface of the filing to not
even or not flat. Make sure that the workpiece is filed correctly with the dimensions

d. Select the flat surface as the reference surface for making process for all side of the
workpiece.
 e. Mark the workpiece using vernier high gauge and angle plate on the marking table

e-1)

Measurement:

1. Thoroughly clean the height gage, surface plate and workpiece. Apply oil to the side
way of the main beam.
2. Zero-point checking: Make sure that the hight gage reads zero when the scriber
measuring face touches the surface plate while under the normal light measuring
force.
3. Measuring force: When taking measurements, be careful not to exert excessive force
on the workpiece with the scriber. Special care is needed when fine feeding the
scriber using the fine feed screw. The base may be jacked up as shown unless the
base is held down by a hand.

4. Scribing: When scribing lines, clamp the slider firmly and slide the scriber in one
direction. Sliding the main scale plate.
 5. Loosen the clamp screw by turning it counter clockwise. Move the plate up or down
so that the zero point is adjusted by turning the fine-feed wheel.

6. After use it, put the vernier high gauge at a safe place with care.

e-2) Angle plate is a work holding device used as a fixture in metalworking. Angle plates are
used to hold workpieces square to the table during marking out operations. Adjustable angle
plates are also available for workpieces that need to be inclined, usually towards a milling
cutter.

f. Create the rounded curve using divider based on given dimension.

g. Create the rounded curve using divider based on given dimension.
h. Use the centre punch to draw attention to the cross section point line. This is done to
guarantee that the measurement is consistent.
i. Begin by eliminating the unneeded material with a hacksaw, drilling, and chisel.
j. File the workpiece's edges to make them smooth.
k. Drill taps holes in accordance with the procedures outlined below.
i) Centre drill
ii) Drill size 5mm
iii) Tap M6 thru
l. As seen below, complete the drilling operation for the through ream hole.
 i) Centre drill
ii) Drill bit size 05.8 mm
iii) Reamer 6H7

m. Saw the workpiece (3 lines) until the right dimension is obtained.

n. Finish up any loose ends. Remove any sharp or rusted edges.

5.CONCLUSION

In conclusion, this project has provided us knowledge about the uses and the importance of
common hand tools such as Hacksaw, L Square Ruler, Height gauge and many more. During
the laboratory session, we need to use and handle the hand tools properly and safely to avoid
injury to oneself or others while working with it. Furthermore, we must use the right
techniques to handle the hand tools to avoid accidents and maintain them in the workplace. In
addition, this project makes us familiar with the tools. Finally, we get to determine the work
step according to the drawing given.

6. STRENGTH AND WEAKNESS

• STRENGTH

Hand tools offer the strength of precision. Fine carving and detailed work such as
cabinetry, building of musical instruments and decorative work requires minute
control over a tool that is sometimes easier with hand tools. Hand tools also always
 work. You require no power, fuel or air pressure and can utilize the tool at any time.
The smaller and more compact nature of hand tools compared to power tools makes
them easier and lighter to transport as well.

• WEAKNESS

The primary weakness of hand tools is the time that it takes to complete simple tasks.
Hammering shingles into a roof by hand, for instance, takes much more time than
nailing down shingles with an air-nailer. Industrial woodworking companies could
never meet demand with handsaws. Also, more skill is required to use hand tools than
most power tools. Making a clean and straight cut using a handsaw is much more difficult
than when using a tool like a table saw with guides and a high cutting speed.

6.REFERENCES

▪ https://drillly.com/bench-vise-parts-and-functions/

▪ https://shopgraytools.com/blogs/news/metalworking-bench-vises-a-closer-examination

▪ https://www.familyhandyman.com/article/hacksaw/

▪ https://en.wikipedia.org/wiki/Height_gauge#:~:text=A%20height%20gauge%20is%20a,items
%20to%20be%20worked%20on.

▪ https://www.thomasnet.com/articles/instruments-controls/all-about-height-gauges/

▪ https://www.thisoldhouse.com/tools/21014962/choosing-and-using-squares

▪ https://technologystudent.com/equip_flsh/hacksw2.html

▪ https://fashion-incubator.com/how-to-use-the-humble-l-square-or-tailors-ruler/