INSTITUTE
OF ENGINEERING
PULCHOWK CAMPUS
REPORT ON WORKSHOP
TECHNOLOGY
Prepared by:
TITLE OF THE PROJECT:
CONSTRUCTION OF A BOTTLE OPENER_(Bench work)
INTRODUCTION:
For a technical
student, apart from the theoretical knowledge, a good knowledge of practical
work is essential. The preliminary and most important part of work is bench
work, which includes all basic operations of the number of tools such as hand
tools, measuring tools and layout tools.
In this project the bottle opener was made out of the flat mild steel
bar by using number of hand tools and some machine tools.
OBJECTIVES:
The main objective
of this project is to become familiar with basic operations on bench work using
hand tools, measuring tools, layout tools and some machine tools. This include marking, layout, cutting,
filing, drilling. All these operations
are included during the construction of bottle opener.
1. Hammer:
It is one of most important tool, shaped to suit the particular work to be carried out. There are generally two types of hammer, i.e. hard headed and soft headed. However, in this project we used only hard headed hammer made of carbon steel for striking punches, bending and straightening.
2. Files:
The file is hard
steel cutting tool with large number of teeth cut diagonally on the face. There
are many types of files with various shapes and sizes to suit for particular job
and material selected. It is used to
make metal surface smooth.
3.
Hacksaw:
It is a hand tool especially designed for
cutting metals. It consists of metal
frame with metal clips at its ends for holding cutting blades.
4. Bench vice:
It is especially
used to hold the work piece securely.
It is fixed on its base to the bench with bolts. The faces of the jaws are lightly serrated
and hardened to ensure a firm grip on the work.
MEASURING AND MARKING TOOLS USED:
1. Steel ruler:
The steel ruler is
used to take the measurements of the work piece and to draw the straight lines.
2. Try square:
It consists of a
blade fitted into a slot in the stock, the two parts being riveted together at
90°. It is used to check the plainness,
straightness, and perpendicularity of the edges and also to draw perpendicular
line.
3. Vernier caliper:
It consists of
fixed main scale and the movable vernier scale. It is used to get inside, outside and depth measurements of the
work piece accurately.
Marking Tools:
1. Scriber:
It is a sharp,
pointed steel tool used to scratch the lines on metal. Its bend end on the other side is used to
scratch lines in places where straight end cannot reach.
2. Center punch:
It is the sharply
pointed tool made of steel rod. It is
used to obtain a deep mark for locating centers and layout lines.
3. Divider:
It consists of a pair
of steel legs adjusted by a screw and hold together by a circular spring at one
end. It is used for measuring distance between
points, scribing circles and arcs on work piece.
MACHINE TOOLS USED:
1. Drilling machine:
It is used to make
accurate holes of required diameter in the work piece using suitable drill
bits. A skilled drilling machine
operator should be able to setup and operate the various cutting tools
according to the routine instructions.
MATERIAL SUPPLIED:
A piece of flat mild steel bar. The dimensions of the given metal are: M.S. (6x25x125)
BRIEF PROCEDURE:
1. Drawing and its
measurements were understood.
2. The required tools
were gathered.
3. The work piece was
clamped in bench vice and was filed on
all sides to remove rust. Then, one of the surface (125X25 mm2 side) was made smooth and plane with the
help of file.
4. After this, the
other edge with surface (125X5 mm2
side) was filed until it was plane and perpendicular to the previous smooth
plane by checking frequently with the help of try square.
5. Taking the plane
surfaces as base, the edge with surface
(25X5 mm2 side) was also made plane and perpendicular to each
other.
6. Getting the plane perpendicular reference sides of
length 125 mm. and 25 mm. as base, the marking were scribed on the other sides
with required dimensions according to the given drawing with the help of steel
ruler, scriber and divider.
7. The centers and
layout lines were made distinct by hammering through the center punch.
8. The unwanted edges
were removed by using hacksaw and filed to smooth.
9. Holes were drilled
according to the drawing at the markings of the punch with the help of drilling
machine using specified drill bits.
10. The unnecessary
portions left after drilling were removed by using hacksaw. The necessary curves were obtained by using
rough files as well as needle files of required shapes. The semi-circular shape at the lower end by
cutting and filing process.
11. The rough face
of the work piece remained was also
filed carefully to obtain plane face with 4 mm. Thickness by the frequent use of vernier caliper for accuracy.
12. The top end was
filed in inclined position from both the sides to obtain the tip of 1 mm.thick
as shown in drawing.
13. Finally, the
finishing touch was given to all the dimensions with different needle files and
roll number was punched in-between two holes.
14.
The
bottle opener was lubricated to prevent from rusting and submitted at the
workshop lab.
SAFETY PRECAUTIONS:
While working on
the workshop great care and precautions must be taken in order to avoid the
accidents as well as to protect the job and tools from being spoiled. So, during the work, following safety
precautions were obeyed to get rid of possible accidents.
1. Dress
safety
I.
Apron
should be always worn whenever we were at work.
II. The shoes opened to the upper part like
slippers were never worn.
III.Sharp
edged tools were never carried on the clothing pockets.
2. Safety
on Hand Tools
I.
Tools
were handled properly and placed at their proper positions.
II. Files without the handle were never used.
III.Burrs
and abrasions were removed from the file before using it.
IV.The
tightness of the hammerhead and handle was ensured before use.
V.
Size
of the hammer was properly chosen according to the job.
VI.The
work piece was gripped in the vice so that the saw cut would be near the jaws.
VII.The
pressure was applied to the saw only on the forward stroke in order to prevent
the blade from being broken.
3. Safety on Drilling
I.
The
work piece was securely held and bolted down.
II. Before drilling, the drill table was made
free from other tools.
III.Drill
bit was set tightly and properly in the machine.
IV.Head
was kept back from revolving parts to prevent the hair from being caught.
V.
The
chips were never removed while the machine was on.
VI.Glasses
were worn, wristwatch was removed and sleeves were folded.
VII.The
chuck key was never left on the drill chuck at any time.
4. Job safety
I.
Job
was clamped tightly and carefully without damaging it.
II. Marking, cutting and filing of the job was done
carefully in order to prevent from disorder and wrong dimensioning.
III.The
edges were made uniform and smooth.
IV.The
job was never dropped on the hard surfaces to prevent its edges from being
crumbled.
V.
The
job was lubricated with oil to prevent from rusting.
COMMENTS AND CONCLUSIONS:
Hence, conducting
series of operations, the bottle opener was made out of the flat mild steel bar
and the product looked well and shining.
The project work
dealt mostly with the filing work more than any others, which was time
consuming and tiring one. More practice
should be made for machine works and less on filing.
However, with the
completion of this project, we became familiar with basic operations of many hand, measuring, layout and machine
tools as well as the safety that had to be undertaken in the workshop.
TITLE OF THE PROJECT:
INTERNAL TOOL HOLDER (Machine tool operations)
INTRODUCTION:
In the age of
modern technology, the workshop is of no sense without modern equipments and machine
tools. Some of the versatile machine
tools used in modern workshop are lathe machine, milling machine and shaping
machine.
Lathe is the power driven machine used for the production of various sizes of components, which are symmetrical about their axis of rotation. We prepared a step turning using this machine.
Shaper is used to
produce flat surfaces on horizontal, vertical and angular plane. We used it to
reduce height of the rectangular work piece in the workshop.
Milling machine is
used to produce accurately machined surfaces such as flats, angular surfaces,
grooves, gear teeth, helical grooves, accurately sized holes etc. However, we
prepared a flat-machined surface of the rectangular job in the workshop.
OBJECTIVE:
The objective of
this project is to be familiar with the working procedures with lathe and learn
about its safety measures. The main objective of lathe job is to know basic
operations of lathe machine such as facing, cylindrical turning, center
drilling, boring, parting and chamfering.
These operations are included in the preparation of step turning at the
workshop.
Hand tools:
1.
Wrenches
It is used to tighten the jaws of lathe
machine.
2.
File
It is to smoothen the surfaces of work
piece.
MEASURING
AND MARKING TOOLS USED:
1.
Steel
ruler
2. Vernier caliper
Machine tools:
1. Lathe machine:
It is the power
driven versatile machine used for the production of various shaped components,
which are symmetrical about their axis of rotation. The major parts of lathe are: bed, apron, carriage, saddle,
headstock and tailstock.
2. Power hacksaw:
It is very similar
to the hand hacksaw with the addition of suitable driving mechanisms. This machine uses a much heavier blade than
that of hand hacksaw and is used to cut the work piece with greater diameters.
BRIEF PROCEDURE:
Working principle of lathe:
Lathe removes
unwanted material from a rotating work piece in the form of chips with the help
of a tool, which is transverse across the work. The job is moved in rotating motion (providing cutting motion)
while the tools are moved in linear motion
(providing feeding motion) in any direction.
The spindle is
driven by a motor through a gearbox to obtain the appropriate range of
speed. The carriage moves the bed guide
ways parallel to the work piece and the cross slide provides the transverse
motion. A feed shaft and lead screw are
also provided to power the carriage and for cutting the thread respectively.
Material provided:
A cylindrical mild
steel work piece of 36-mm. diameter and 75 mm length.
Procedures undertaken:
1. Firstly, the work
piece was held in a chuck tightly and its end was faced to make it right angle
with centerline. For this, cutting was
fed from circumference towards the center at first and the finishing cut was
made from the center hole outwards.
2. From the flat
surface end, a distance about 45 mm.
Was marked and straight turning
was carried out through this length.
While feeding, it was observed that when the feed rate increased by 10
smallest divisions, the diameter reduced by 1 mm. So, the diameter of 15 mm.
Was obtained by removing the material not more than 2 mm. at a time.
3.Throughout entire length, it was turned to the diameter of
36 mm.
4.Then for the length of 20mm.,it was turned to 32mm. as in
drawing.
5.The tailstock was adjusted with drill bit of 8 mm. For centering and was bored up to 21
mm. Inwards from the edge using drill
bit of 10 mm.
6. The edge of work
piece was chamfered to 2 mm. in length
at 45° by using smooth file.
7. Finally, the sharp
edge was removed using smooth file to give finishing for the job.
SAFETY PRECAUTIONS:
Safety on the
lathe:
I.
Tools
and work piece were fixed properly and tightly before starting the machine.
II. The speed of the machine was adjusted
according to the properties of material.
III.Cooling
liquid was continuously used during turning operations.
IV.The
chuck key was never left on the sprindle.
COMMENTS AND CONCLUSIONS:
Hence, the project
was completed by conducting series of operations and became familiar with the
different operations to be carried out during operating the lathe machine and
the safety measures to be undertaken while working on these machines.
Project 3
TITLE OF THE PROJECT:
CONSTRUCTION OF DUSTPAN
Objective:
The
main objective of this project is to be familiar with different operation to be
carried out during sheet metal work such as marking & layout, bending,
cutting, folding and assembling by using various tools. All these operations
are included during the construction of dustpan.
Introduction:
Sheet metal is very important for the
workshop. It includes various mechanical operations like marking, layout, and
cutting operations. Marking means scribing of lines on a metal surface to
indicate the profile or out line of the finished component. The process of
layout involves the development of patterns. A pattern is a flat out line of
stretch out of a job that has to be made. One metal sheet work even involves
the process of bending and rolling. In this project fine square metal sheet was
given which is to be converted into dustpan.
Materials:
1.
Rectangular G.I. sheet
2.
Rivets
Measuring and marking tools used:
For the measuring and marking
purpose of the metal sheet mainly
Following
tools were used;
1.
Engineer's Steel Ruler:
It is the most common
measuring device consisting of stripes of harden steel having line graduation
etched or engraved at an interval
standard unit of length. It can be of two dimensions; One in metric
scale and other one in inches' scale. Some rulers carry graduation in
centimeter on the one side and inches in another side of ruler. Engineer's
steel ruler must be kept well polished and mustn't be used as temporary
screwdriver.
2.
Scribers:
Scribers
are made up from hardened and tempered steel having a long narrow sharp point.
These are made in various sizes and are used to scratch lines in metal surface.
Some scribers are like pencils while others are held in marking tools like a
scribing block or a universal surface gauge. Some times, one end of scriber is
bent so as to scratch lines where straight end can't reach. The point of the
scriber is always kept in good sharp condition.
3. Punches:
Punches
are used to provide a point , which is necessary to scribe a circle using
drivers, to provide a point to start drilling a hole and to mark out in bench
work. There are mainly two types of Punches:
a) Center
punch:
It is made
up of high carbon steel, hardened and tempered at the point. The points are of
two types. One is sharpened at 90 degree and is generally used to mark the
center of the hole before drilling and the other is sharpened at 60 degree to
make center mark for scribing a circle and for dot punching.
b) Prick
punch:
It is a sharp pointed punch and has an angle
of 40 degrees. It is used to make small punch marks on the scribed lines to
last longer. The body of the punch is octagonal in shape. Its length ranges from
90 mm to 150 mm and diameter from 8 to 15 mm.
4. Try Square:
A Try square is a small light square that
has a hardened steel blade with out graduation. It is used for checking the
perpendicularity of many types of small work when extreme accuracy is required.
Hand tools used:
The tools, which are light and
can easily be handled, are called hand tools. The tools small and easy to
handle. The following are some of the hand tools that were used during this
project.
1.
Hammers:
Hammers are one of the striking
tools to give different shapes to steels; different types of hammers are used.
The parts of hammers are; head, striking face peen and handle. The commonly
used hammers are; riveting hammer, raising hammer, setting hammer. The Riveting
hammer is used for cold riveting. To form a curved or hollow shape in the
sheet, raising hammer is used, and for setting down of the edge of the seam,
setting hammer is used.
2
Mallets:
These are also known as soft hammer.
These are usually made up of wood or rawhide, copper, lead or hard rubber.
These soft hammers are used to flatten the surface.
Hand
shears or snips:
Hand shear or snips are used for cutting the
metal sheet into the desired shape and sizes. There are several types of snips
for making straight and curve cuts. Some special types of snips like
combination snips and hawk-billed snip are used for creating compound curve.
1
Drawing and it's measurements were
understood.
2
The
given steel was made plane and uniform by hitting with the softheaded hammer.
3
The
sheet was marked with the help of scriber and steel ruler according to the
given dimensions of drawing.
4
Unnecessary
parts were cut away using notching tool and hand shear.
5
Various
step of folding were made at the marked line with the help of hemming machine
vice and hammer were also used at the portions where the folding machine was
inconvenient to be used,
6
Using
softheaded hammer leaved the folder part.
7
Holders
were drilled in the required place of the pan and the handle.
8
Hammering
the soft nails in the holes to obtain the complete pan joined the handles and
the pan.
9
Finally
the roll number was punched submitted.
Safety precautions must be followed
while working same of such works as follows.
Dress
safety:
Safety
on hand tools:
1. Files without
handle were never used.
2. The toughness of
the hammerhead and handle was ensured before use.
3. Hammer was
properly chosen according to job.
4. The worked piece
was gripped in the vice so that the saw cut would be near the jaw.
Job
safety:
1. The job was
clamped tightly without damping it.
2. Marking,
cutting, and folding of the job were done carefully in order to prevent from
disorder and wrong dimension.
3. The edges were
made uniform and smooth.
COMMENTS AND
CONCLUION: