Mapua University

Muralla St., Intramuros, Manila

Department of Mechanical and Manufacturing Engineering

Shop Exercise 1:
Common Tools Use in 123 Lab

Flat Back

SAMBRANO, Dave V

ME-2

ME123L / A4

2015110907

Engr. Jose V. Hernandez

Instructor
Objectives:

1. To be able to construct a flat back pattern.

2. To be familiarize with basic hand tools.
3. To enhance the creativity and technological knowledge of the students in woodworking
practice.
4. To test the student’s comprehension and skills in making a one piece pattern (flatback).

Methods/ Analysis:

Proper use of different hand tools will be tackle in this project. The creativity of the
student will enhance their skills while working in this project. Pattern making is a fabrication of
a pattern to be use in casting. It is usually made of wood plastic and metal. It must be bigger than
the actual size for easy removal from the mold and for the surface finishing and machinery. The
pattern makers must have knowledge of engineering materials and its properties.

Materials:

1x Kiln Dried Wood (125mm x 65mm x 7mm)

Tools to be used:

1. Flat file
2. Half Round File
3. Backsaw
4. Coping Saw
5. Try Square
6. Jackplane
7. Electrical Drill Press with Drill Bits (size 1/8”)
8. Sandpaper (Grit size P1000)
9. Pencil with Erasers
10. Steel Ruler

Procedures:

1. Prepare the wooden material with given dimensions.

2. In the next procedure, we will refer to the top view (Facing the area of 125mm x 65mm)
of the material. By using the drawing tools, mark a chamfer of 27mm long at top left and
bottom right, and 62.5mm long at bottom left and top right.
 3. Inside of the flat back, mark a line 56.1mm with a distance of 16mm from the top and
bottom edge. Both lines are parallel. Mark a line 44.25mm long twice located on bottom
left and top right with a distance of 16mm from 62.5mm long line. These recent made
four lines will form a shape of parallelogram.
4. Bore a hole inside the inner parallelogram part with given drill press with drill bits. Then
use the backsaw for cutting all unnecessary parts, Coping saw for inner part of the
material, and a file for further smoothen the edges.
5. Mark for a taper of 3.5mm in all inner and outer edges of material. Then the taper should
be done by creating a slant from bottom (front) to the top (back). This is same thing with
inner edge part.
6. Smoothen all the surfaces using flat file, jack plane, and given sand paper.
7. As for the second model of flat back, they both have the same dimensions and
smoothening procedure. The only difference is that the longer chamfer is at top left and
bottom right instead of top right and bottom left. Also the shorter chamfer is at top right
and bottom left. The inner parallelogram is in reverse of first flat back.

Questions:

1. What are the different types of pattern?

- Single piece pattern
- Split piece pattern
- Loose piece pattern
- Gated pattern
- Match pattern
- Sweep pattern
- Cope and drag pattern
- Skeleton pattern
- Shell pattern
- Follow board pattern

2. Is knowledgeable of engineering materials significant in making pattern? Why?

- Yes, because materials interact with each other as in coexistence and
enhancement. Many things swell and shrink with heat and cold, linen is easier to sew
then fleese, patternmakers must take in all factors concerning the product they are
working with.

3. What is a quality of a good pattern?

- Easy to work, shape and join
- Strong, hard and durable so as to be resistant to wear
- Light in weight
 - Dimensionally stable
- Cheap and easily available
- Resistant to corrosion and chemical action
- Able to take good finish

4. What is the purpose of a working drawing?

- Describe the exact geometry of parts
- Indicate other details associated with drawings (for example, material)
- Show how parts are assembled
- Indicate manufacturing preferences

5. What properties of wood that makes it a good material for pattern making?
- Light in weight
- Comparatively inexpensive
- Good workability
- Lends itself to gluing and joining
- Holds well varnishes and paints
- Can be repaired easily

6. What other materials can be used as a pattern materials?

- Wood
- Metals
- Plaster
- Plastics
- Wax

7. What kind of wood is suitable for pattern making?

- Mahogany is the most commonly used material for patterns, primarily because it is
soft, light, and easy to work, but also once properly cured it is about as stable as any
wood available.

8. Why should the pattern made to be bigger than the finish product?
- Patterns are made bigger and with some extra features like drafts, so that the casted
product would be dimensionally accurate. Depending upon the shrinkage required for
different parts the pattern will be designed a little bigger which is known as pattern
allowance. The allowances are given to compensate for the changes in physical
properties that occur during the casting process like shrinkage of metal during
solidification and loss of metal during machining, etc.
 9. Is there a need to incline a little bid the side of the pattern? Why?
- When the pattern is to be removed from the sand mold, there is a possibility that any
leading edges may break off, or get damaged in the process. To avoid this, a taper is
provided on the pattern, so as to facilitate easy removal of the pattern from the mold,
and hence reduce damage to edges.

10. What are the advantages of a metal pattern?

- More durable and accurate in size than wooden patterns.
- Have a smooth surface.
- Do not deform in storage.
- Are resistant to wear, abrasion, corrosion and swelling.
- Can withstand rough handling.

Discussion:

The flat back is a good example of One or Single piece pattern. It is the most inexpensive
of all types of patterns. This type of pattern is used only in cases where the job is very simple and
does not create any withdrawal problems. It is also used for application in very small-scale
production or in prototype development. This type of pattern is expected to be entirely in the drag
and one of the surfaces is expected to be flat which is used as the parting plane. A gating system
is made in the mold by cutting sand with the help of sand tools. If no such flat surface exists, the
molding becomes complicated.

Conclusion:

At the end of the period, we were produce our flat back with different shape from the
wooden block that were provided to our group. With given dimension that has larger scale, we
were able to make a pattern with original dimensions. A flatback is made using one of the many
common patterns. It is called one-piece because there is no other materials needed to be added or
glued on to the workpiece. It is also called a flatback as the back of workpiece has the only flat
surface, the rest is tapered.

By using each student’s individual creativity and knowledge in woodworking, with each having
different approach in the pattern making, the flat back was constructed, thus enhance their personal
skills. The students were able to familiarize themselves with the basic woodworking hand tools in
the process of making the pattern. The use of given tools such as backsaw and file helped us create
this product. By finishing this product, we were familiar with our members and the use of the tools
in woodworking.
Recommendations:

I would recommended that to have more tools provided to force all members working at
the same time, rather than one member doing certain task that would take a time to finish it. Also,
I would like to recommend that to allow us to use tools that we are unfamiliar such as smooth
plane or caliper to enhance our skills in woodworking.

When finishing the workpiece make sure that it must be filed first then smoothing it by using the
rough sandpaper then the fine sandpaper(P100 to P1000). Filing it first would remove the markings
of the bench vise that the sandpaper could not.