DEPARTMENT OF ENERGY AND MECHANICAL SCIENCES

CAREER OF MECHATRONIC ENGINEERING

LABORATORY OF MANUFACTURING PROCESSES

NRC LABORATORY: 2450

LABORATORY REPORT No 2
LABORATORY THEME: Adjustment techniques

Professor Laboratory: Ing. Javier Segura

Professor Theory: Ing. Byron Cortez

GROUP MEMBERS:
Mndez Katherine NRC theory: 2028
Reyes Diego NRC theory: 2028
Ypez Nicols NRC theory: 2028

DATE: November 9, 2016

Topic: Adjustment Techniques

Received by: __________________

LABORATORY REPORT N......2........TOPIC
Adjustment Techniques
GROUP MEMBERS
REPORT PRACTICE
1. Mndez K. 1. Mndez K.
2.Reyes D. 2.Reyes D.
3.Ypez N. 3.Ypez N.

DATE / TIME:.

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Table of contents

Objectives.......................................................................................................................... 4
1.1. General objective......................................................................................................... 4
1.2. Specific objectives....................................................................................................... 4
2. Theoretical Framework....................................................................................................... 4
Terms:............................................................................................................................ 5
Types of adjustments:......................................................................................................... 5
Dimensional tolerance in axle and hole:..................................................................................6
Introduction..................................................................................................................... 7
Basic Operations:.............................................................................................................. 7
Manual sawing:................................................................................................................ 7
Tracing........................................................................................................................... 8
Threading....................................................................................................................... 8
Table No 1 Thread Equivalences........................................................................................... 9
Drilling:....................................................................................................................... 11
Liming:........................................................................................................................ 11
Filing operation.............................................................................................................. 12
Filing Techniques............................................................................................................ 13
Flat Layer:.................................................................................................................... 13
Curl of curves:............................................................................................................... 15
Slotting holes:................................................................................................................ 15
Controlled surfaces:......................................................................................................... 15
Choosing the right file:..................................................................................................... 16
Cleaning and care of files:.................................................................................................16
3. Materials and supplies...................................................................................................... 16
5. Procedures.................................................................................................................... 17
Bibliografa................................................................................................................... 17

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Table of figures

Figure 1................................................................................................................................ 5
Figure 2................................................................................................................................ 6
Figure 3................................................................................................................................ 7
Figure 4................................................................................................................................ 7
Figure 5................................................................................................................................ 8
Figure 6................................................................................................................................ 8
Figure 7................................................................................................................................ 8
Figure 8.............................................................................................................................. 11
Figure 9.............................................................................................................................. 11
Figure 10............................................................................................................................ 12
Figure 11............................................................................................................................ 12
Figure 12............................................................................................................................ 13
Figure 13............................................................................................................................ 13
Figure 14............................................................................................................................ 14
Figure 15............................................................................................................................ 14
Figure 16............................................................................................................................ 14
Figure 17............................................................................................................................ 15
Figure 18............................................................................................................................ 15
Figure 19............................................................................................................................ 16

Topic: Adjustment Techniques

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Objectives.

1.1. General objective

Identify the most relevant tools and elements within the processes within the fabrication of the
proposed model with adjustment techniques.

1.2. Specific objectives.

Define a work plan for the construction of a mechanical element by means of the adjustment
techniques.
Develop the ability to manage and use adjustment techniques
Identify the most relevant parameters in the construction of mechanical elements by means of the
adjustment techniques

2. Theoretical Framework

Dimensions.-
The individual parts have a wide size range so not all processes are suitable for manufacturing them.
Often the minimum size is limited by laws of nature, while the maximum can also be set by the
availability of equipment.

Dimensional Units.-
The SI unit of length is the meter (m); The smallest dimensions are expressed in millimeters (mm) or
micrometers (m). Although the possibility of encountering another length measurement system is
very likely, such as the Imperial, the respective transformation is as follows: 1pulg = 25.4mm.

Dimensional Tolerances.-
Mass production requires that the parts be interchangeable; for this, dimensions must be controlled.
The different processes have inherently different ability to manufacture parts with controlled
dimensions. Although dimensions must be controlled, it is neither possible nor necessary to
manufacture parts with exact dimensions. Therefore, the maximum and minimum dimensions (length
or angle) are specified with two objectives in mind:

The limits must be close enough to allow the assembled parts (including interchangeable parts) to
work.

The limits should be as wide as the functionality allows, as usually the more stringent limits require
more expensive processes. The most important cause of excessive production costs is the specification
of unnecessarily closed dimensional boundaries.

Terms:

Dimension: Is the number that expresses the numerical value of a length or an angle.

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 Nominal dimension (dN for axes, DN for holes): it is the theoretical heat that has a dimension, in
relation to which the limit measures are considered.
Effective dimension: (for axis, De for holes): is the actual value of a dimension, which has been
defined by measuring on the part already built.
Limit dimensions (maximum, dM for axes, DM for holes, minimum, dm for axes, Dm for holes):
these are the extreme values that the effective dimension can take.
Deviation or difference: it is the difference between a dimension and the nominal dimension.
Effective difference: the effective difference between the effective measure and the nominal
dimension.
Difference higher or lower: it is the difference between the maximum / minimum dimension and the
corresponding nominal dimension.
Basic difference: is any of the boundary deviations (upper or lower) conveniently chosen to define
the position of the tolerance zone in relation to the zero line.
Reference line or zero line: it is the straight line that serves as reference for deviations or differences
and corresponds to the nominal dimension.
Tolerance (t for axes, T for holes): is the maximum variation that can have the measurement of the
part. It is given by the difference between the boundary measures, and coincides with the difference
between the upper and lower deviations.
Zone of tolerance: is the area whose amplitude is the value of tolerance.
Fundamental tolerance: it is the tolerance that is determined for each group of dimensions and for
each quality of work.

Types of adjustments:

Three different types of adjustment are considered:

Fixed setting: the play is always less than zero.

Mobile adjustment (with game): the game is always greater than zero.
Undetermined adjustment: game greater or less than zero.

Figure 1. Types of adjustments

Dimensional tolerance in axle and hole:

It establishes a table for axes and a table for holes with 21 possible positions (from A to Z)

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 a-h: for axes indicates a measurement always smaller than the nominal measurement.
k-z: for axes indicates a measurement always greater than the nominal measurement.
A-H: for holes indicates a measurement always smaller than the nominal measurement.
K-Z: for axes indicates a measurement always smaller than the nominal measurement.

Figure 2. Dimensional tolerance in axle and hole

Introduction

The fitment comprises a set of works that are performed in order to make a metal part fit into place
properly. Adjustment work is done with the tools of the adjuster, be these manual or mechanized, or
also in the manufacturing processes.

Basic Operations:
The most common operations in the works are: plotting, chiselling, straightening, bending, cutting
metals, filing, drilling, countersinking, reaming, drilling, tapping, scraping, , Grinding and finishing,
welding, bonding and gluing.

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 Figure 3. Basic Operations

Manual sawing: it is a roughing operation that is performed with the saw blade by chip start and
whose object is to cut the material partially or totally. This operation is productive, since the work is
carried out with remarkable speed, sometimes avoiding the laborious work of other tools and also
with little loss of material.

Figure 4. Sawing

In industrial practice, alternative sawing, circular and ribbon sawing for the cutting of bar and
roughing pieces and sawing by hand are used, only in those works in which previous ones can not be
applied for technical or economic reasons.

Tracing: it is intended to mark lines or strokes to limit the outlines of the pieces, the axes of symmetry
of the same or their origins and the points of intersection of these axes of symmetry. It is done on the
raw or machined products, in the manufacture of unit parts or very small series.

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 Figure 5. Tracing

By tracing it is known if the raw material contains the piece to be machined, this work is done by an
adjuster or a specialized operator who possesses knowledge of geometry and trigonometry, drawing
and technology.

Threading: the work of making threads on certain surfaces of the parts is called. A part of a part
whose surface is in the form of a thread or protruding flange wound in the form of a propeller is called
a thread. The threads may be internal when it is in the inner part of a drill (Fig. 4), or outside when
forming the outer surface of a cylinder.

Figure 6, Threading

The tools used for the construction of threads are different depending on whether the thread is inside
or outside. For the construction of internal threads, the so-called lugs are used, while the external
threads use the so-called taps.

Figure 7. External Threading

To make a threaded hole it is necessary to previously establish what type of thread is required (UNC
coarse American thread, UNF fine American thread or metric thread with its respective pitch). In the
case of holes to be threaded it is necessary to determine the diameter of the hole to be able to properly
carve the thread.
Table No. 1 shows the equivalence of threads and the diameter of the drills to make the initial holes.

Table No 1 Thread Equivalences

BSW Thread whitworth (British Standard) UNC Thick American Thread

M Standard pitch metric thread UNF Fine American thread
MF Fine pitch metric thread UNFE Extra fine American thread

BSW UNC UNF UNEF M MF DIMETRO

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Dim. TP Di T Dim T Di Dim T Dim T Dim
Nom. I m. P . P m. . P . P .
No I Nom. I No Nom. I Nom. I Nom.
m. m.

1/16" 60 1/16" 6

3/32" 40 3/32" 4

1/8" 40 1/8" 4

5/32" 36 5/32" 3

3/16" 24 3/16" 2

7/32" 24 7/32" 2

1/4" 20 1/4" 2
1/4" 2 1/4" 2
1/4" 2 1/4 1/4" 28

5/16" 18 5/16 1 5/16" 1 5/16" 1

5/16" 2 5/16" 24
5/1

3/8" 16 3/8" 1 3/8" 1 3/8" 1

BSW UNC UNF UNEF M MF DIMETRO

Dim. TP Di T Dim T Di Dim T Dim T Dim
Nom. I m. P . P m. . P . P .
3/8" 2 3/8" 24
3/8

7/16" 14 7/16 1 7/16" 1 7/16" 1

7/16" 2 7/16" 20

7/1
1/2" 12 6" 1/2" 1
1/2 1 1/2 1
3 1/2 2 3 1/2 20
0 1/2'
9/16 12 9/16 1 9/16 1 9/16 1

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 9/16 1 9/1 9/16 18
5/8 11 5/8 1 8 6 5/8 1 5/8 1

5/8 1 5/8 18
8 5/8
11/16 11 11/16 1
1
3/4 10 3/4 1 11/ 3/4 1 3/4 1
0 3/4 1 16 0 0 3/4 16
6 3/4
13/16 10 13/16 1
0
7/8 9 7/8 9 13/ 7/8 9 7/8 9
7/8 1 16 7/8 14
4 7/8

1" 8 1" 8 15/ 1" 8 1" 8

1 1 16 1 12
2 1"
1 1/8" 7 1 7 1 7 1 1/8 7
1/8 1 1/8"
1 1/8 1 1/1 1 1/8 12
2 1
1 1/4 7 1 7 1/8 1 1/4 7 1 1/4 7
1/4
1 1/4 1 1 1 1/4 12
1 3/8 6 1 6 2 1/4 1 3/8 6 1 3/8 6
3/8
1
13/8 1 5/1 13/8 12
1 1/2 6 1 6 2 1 1 1/2 6 1 1/2 6
1/2 13/8
7/1
Table 1 Thread Equivalences

Drilling: This is a procedure that involves a chip start and is used to execute round holes in metallic
or nonmetallic materials. The drills are practiced in the material by means of cutting tools called
drills.

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 Figure 8. Drilling

Within the technology, special attention should be given to the angles of the tool tip, cutting speed,
feed rate, etc. Other operations that can be performed similar to drilling are countersinking, flaring
and reaming or rhyming which require specific tools and techniques for a correct execution of the
work.

Figure 9. Parts of a drill

Liming: it is the adjustment operation with which to thin or finish surfaces of pieces that by their
irregular shape or volume can not be machined in a machine tool or that the use of the file is more
economical. Slurry is laborious work of very small production, with good ability and suitable tools
can be reached tolerances up to 0.02 mm with surface finish type n7.

Characteristics of the files: the files are bars of hard tempered steel, with one end drawn in a point
(Fig. 8) called a tail, in which a wooden handle is adapted. The surface of the file is formed by a
special toothing called chopped, which constitutes the cutting teeth of the tool. The shape of the
profile of the pruning is shown in Figure 9. In some files the toothing is made by milling and its
profile has the shape shown in figure 10.

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 Figure 10. Liming

The most common forms of files are shown in Figure 10, with their respective names. Other less
common forms are used for complicated work such as the manufacture of metal dies and molds.

Figure 11. Limes

According to the thickness of the teeth, from major to minor, they are classified into: bastas,
semifinas, fines and extrafinas. The size of the teeth determines the degree of smoothness that is
obtained in the surface worked. Another feature of files is their size that is measured by the length of
files. You have limes from 4 in. To 12 in.

Filing operation

Depending on the amount of material to be removed from a piece per file, this work takes different
names.
When it is a matter of removing only the oxidized, rough or husk layer of a casting or forging blank,
the operation is usually called barking. This operation is usually performed as a preliminary to other
trim operations. It should be done with already used files and that they are not used for other more
delicate works, as the oxide of the surface of the parts and the husk quickly deteriorate the new files.

The grinding of a relatively large amount of material to leave the piece close to its final measurements
(until only about a half millimeter thick to remove) is given the name of roughing. The work is done
with files of coarse or gross chopping.

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The finish consists in filing the piece to its final dimensions, using thin files first and extrafine, this is
done when the work has to be precision.

If it is desired to leave a very smooth surface, the polishing operation is used; This is done with extra
fine or thin files with the cutting surfaces rubbed with chalk and the movement is made transverse to
the length of the file.

Filing Techniques

The filing is done with the piece firmly fastened, either on the vise, if it is of small size, or by any
other procedure. The toothing of the file is applied to the file surface and pushing the tool as shown in
Figure 11 is given a forward and reverse movement.

Figure 12. Filling

The pressure is applied only in the forward movement, loading the body slightly forward and then
pushing the file along its entire stroke by moving only the arms. At the end of the advance the body
returns to its primitive position and the arms are carried backwards, until the file is in position to start
a new pass.

Figure 13. Movement body during liming

Figure 12 clarifies this sequence of movements. The cadence cadence should be regular from 40 to 55
strokes per minute, and there should be no sudden variations.

Flat Layer:

Depending on the shape of the surface to be filed, one form or another of lime must be used and
different procedures must be followed in order to achieve perfection at work. One of the most
frequent cases is the filing of flat surfaces and is one of the most difficult to achieve with perfection.
To achieve a well-flat filing surface the first condition is to keep the file horizontal throughout the

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stroke of each stroke without pressing more at one end than in the other of the file, and without
oscillation of the file, since it would give rise to a surface pumped.

Figure 14. Crossing liming

Figure 15. Lime for large surfaces

Figure 16. Curves liming

The file is arranged at an angle of 45 degrees to the length of the piece and the forward movement is
made such that at the end of the stroke the file has laterally moved a length equal to the width of the
file. In this way the work progresses until it has completely covered the surface of the piece, resulting
in a uniform scratching of all of it. The position of the file is then changed at a 90 degree angle with
respect to the first pass (Fig. 13) and another is made which would result with the crossed stripes on
the first pass. The uniformity of the cross-linking of the stripes provides guidance on the quality with
which the work is being carried out.

To slice large surfaces (greater than the length of the file), replace the wooden handle with a metal
handle, such as the one shown in Figure 14.

Curl of curves:

In the slicing of curved surfaces there may be two cases: the filing of convex (curved out) surfaces
and the filing of concave (curved inwardly) surfaces. The convex curves are worked with flat files; To

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thin them the fillet is made transversely to the curve, as shown in Figure 15. The finish is made by
longitudinally filleting, starting with the handle of the raised file and ending the advance with the
handle down and the tip up.

Figure 17. Liming curves

The filing of concave curves is done with round or half cane files; The curve of the file must in any
case be more closed than the curve to be filed. The forward movement is accompanied by a lateral
movement movement and a rotation of the file handle (fig 16).

Slotting holes:

When an open hole with a drill is to be enlarged with the file and only a small part of the file is
passed, the work is started by pushing the file with both hands on the handle (Fig. Opens the entire
length of the file, continuing the work in the normal way.

Figure 18. Liming holes

Controlled surfaces:

Inspection of flat surfaces is usually done with a ruler and with the method backlit, in the case of
perpendicular surfaces are used squares.

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 Figure 19. Flat Inspection.

Choosing the right file:

One of the most important points to do a good job of filing is the choice of file to be used. In addition
to the type of operation and the shape of the piece must also take into account the size of the surface
and the class of material to work. The larger the surface to work the greater the length of the file.
Very soft materials, such as tin and lead, will be used for the work of very soft materials. The files of
double pruning are not adequate, as the bottoms of the teeth are filled with filings and the cut is lost.
Aluminum and light alloys are filed with. Milled tooth files. The files of double chopping are not
suitable for this work.

To file bronze, brass, iron, cast iron and steel should be used double-chip files. It is preferable to use
new limes to smooth softer metals, such as bronze and brass, and then to iron, steel and cast iron.
When the files are already used enough they can be used for debarking.

Cleaning and care of files:

In order to preserve their maximum cutting capacity, the toothing of the working faces must be
prevented from touching or rubbing with other hard tools (other files, hammers, etc.), which happens
when tools are stacked without order in a Drawer or on the work bench.

The file must also be prevented from touching the screw jaws. The contact of the working faces with
the skin of the hands causes the file to dull and lose edge, should be avoided.

When working with the file, filings are left tightly grasped between the teeth. To remove them are
used steel brushes, called cards, with which the file is brushed parallel to the lines of teeth. If any
filing can not be removed with the card, it is blown with a small brass flute.

Again it is emphasized that the other adjustment techniques should be studied following the same
scheme presented for the case of filing, for which the student is recommended to consult the
specialized literature.

3. Materials and supplies

Steel block AISI 1045, dimensions 75 x 40 x 30 mm

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 A shaft AISI 1018, diameter 70 mm and length 8 mm
M10 x1.5 x 60 Hex Head Bolt
Two axes AISI 1018 diameter 6mm length 50mm

4. Necessary equipment, accessories and tools

Work Benches and Bench Presses

Lima, Wire Brush, King's Foot, Squadron, Rayador, Granete, Hit Numbers
Drills of various sizes, Flare, Countersink, Taps and Taps

5. Procedures

Students must attend the explanatory class on the use and handling of hand tools and drilling.
Students should perform a practice by following the plane of the requested piece.
Students should draw up a diagram indicating the logical order of processes to be performed

Figure 20 Body sketch

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