John Glenn Matic BSABE 2-3

ENGR 2320
Laboratory Exercise/Report No. 3
Metal Bench Work

I. Introduction
Use the following guide questions in writing your introduction.
1. Define metal bench work.
2. History of metal bench work.
3. Discuss the importance of metal bench works in Agricultural and
Biosystems Engineering.

Introduction

Metal bench work involves the process of cutting or dividing certain parts or
pieces by hand with the help of some hand tools instead of the more practical way of
using less force and power. In other words, it is a manual work on a bench. Usual bench
work operations involve hand reaming, hand filing, hand tapping, and engraving. Metal
bench work is a difficult work to do and it requires high skill-set, procedural and safety
knowledge to perform it with efficiency, accuracy and quality. Being aware of not just
how, but why and when to perform it is a basic essential of this work.

Metal working has been attached to the civilization, way before on the time of the
Vedic Kings in India, Pharaohs in Egypt, and the Maya civilization in North America. The
metalworkers are all great with their jobs and being a skillful worker is highly required as
early on in this era. More centuries to come when this field of work became more
complex and innovative in which it was molded into something more. Metal working
have spread out to influence other fields and became key for its rise. Its value in the
economy and people has been significant because it also has changed throughout the
centuries and became flexible into whatever the needs or wants of the society was.
 Metal bench works surely is important in Agricultural and Biosystems
Engineering because it gives it more options to execute which helps it perform or
develop. Machines have been a trend throughout the years in making agriculture more
productive and easier. They just blend into one another and created something helpful
for the community.

II. Objective
1. To enumerate and identify the basic tools used in metal bench
work.
2. To operate the basic tools used in metal bench work.
3. To identify the safety standards when operating power tools in
metal bench woks.

III. Methodology
1. List and define the different tools used in metal bench works.
2. Tabulate the tools and its description with a figure.
3. Enumerate and discuss safety tips when operating equipment in
engineering shops such as lathe machine, drill press, Milling machine,
Electric arc welding and oxyacetylene welding.
 IV. Results and Discussion
Name Picture Description
Hacksaw Hacksaws were originally and
principally made for cutting
metal, but can also cut various
other materials, such as plastic
and wood; for example,
plumbers and electricians often
https://www.workshopheaven.com/starrett-exact-plus-high-
cut plastic pipe and plastic
tenstion-12-hacksaw-frame.html conduit with them.
Scribe A scriber is a hand tool used in
metal work to mark lines on
workpieces, prior to machining.
It is used by dragging the point
over the surface of the
workpiece to leave a shallow
https://www.lislecorp.com/specialty-tools/scribe
scratch on its surface.
Steel Rule A steel rule is a rule
manufactured from either
spring or stainless steel that
feature either metric or imperial
(or both) scales along its
length. One end is usually flat
https://www.workshopheaven.com/kinex-metric-stainless-
whilst the other end (frequently
steel-rule-mm-graduations-150mm.html including a hole for hanging) is
usually round.
Engineering An engineering square, also
known as a Machinist square,
Square
is a handheld marking and
checking tool used to assess
angles and mark straight lines.
Made up of two straight pieces
(stock & blade) which work
together to create a right angle
https://gaugehow.com/engineering-square/
at exactly 90°.
Bastard File A bastard file is a tool used to
remove fine amounts of
material from a workpiece. It is
common in woodworking,
https://www.wonkeedonkeetools.co.uk/files/how-did-bastard-
metalworking, and other similar
files-get-their-name trade and hobby tasks.
Engineer's Blue is a highly
pigmented paste used to assist
in the mating of two or more
Engineering components. Normally known
as Engineers Blue, this thick
Blue
blue grease which is used as a
thin even smear so when two
parts are fitted together the
https://www.workshopheaven.com/engineers-blue.html area of contact is marked by
the transference of the blue
color.
Half-round file Half-Round Files are two-sided
files featuring a rounded face
on one side, and a flat face on
the opposite side. Both the
rounded face and the flat face
https://sg.rs-online.com/web/p/files/1611476/
feature a double bastard cut
pattern.
Flat file A Flat File a steel hand tool
with small sharp teeth on some
or all of its surfaces; used for
https://www.halfords.com/tools/hand-tools/all-hand- smoothing wood or metal.
tools/halfords-200mm-flat-file-168930.html
 Safety Tips when operating equipment in Engineering Shops

 Lathe machine
1. Correct dress is important, remove rings and watches, roll sleeves above elbows and
always wear protective eye protection.
2. Always stop the lathe before making adjustments.
3. Do not change spindle speeds until the lathe comes to a complete stop.
4. Never lay tools directly on the lathe ways. If a separate table is not available, use a wide
board with a cleat on each side to lay on the ways.
5. Use two hands when sanding the workpiece. Do not wrap sand paper or emery cloth
around the workpiece.
 Drill press
1. Run drill at correct RPM for diameter of drill bit and material. Ask shop personnel for the
correct RPM.
2. Always hold work in a vise or clamp to the drill table.
3. Use a correctly ground drill bit for the material being drilled. Shop personnel can help
select the correct bit.
4. Use the proper cutting fluid for the material being drilled. Ask the shop staff about the
appropriate fluid for the material you are machining.
5. Remove chips with a brush, never by hand.
6. Ease up on drilling pressure as the drill starts to break through the bottom of the
material.
7. Don't use a dull or cracked drill. Inspect the drill before using.
8. Don't drill with too much pressure.
9. Always try to support part on parallels or a backing board when drilling thru material.
10. Never place taper shank tools such as large diameter drills or tapered shank reamers in
a drill chuck. Only straight shank tools such as standard drills can be clamped in
chucks.
11. Always clean drill shank and/or drill sleeve, and, spindle hole before mounting.
12. Remove taper shank tools from spindle or sleeve with a drill drift and hammer.
13. Never try to loosen the drill chuck while the power is on.
14. Lower the drill spindle close to the table when releasing the drill chuck or taper shank
drill to reduce the chance of damage should they fall onto the table.
15. Never clean a machine while it is in motion!!
16. If the drill binds in a hole, stop the machine and turn the spindle backwards by hand to
release the bit.
17. When drilling a deep hole withdraw the drill bit frequently to clear chips and lubricate
the bit.
18. Always remove the drill chuck key, or, the drill drift from the spindle immediately after
using it.
19. Wear safety eye protection while drilling.
20. Let the spindle stop of its own accord after turning the power off. Never try to stop the
spindle with your hand.
21. Plexiglas and other brittle plastics can be difficult to drill. Ask a shop technician for
advice on drill and coolant selection when drilling these materials.
 Milling machine
1. Work must be clamped securely in a vise and vise clamped tightly to the table, or, work
must be clamped securely to the table.
2. Do not take climb milling cuts on the shop’s mills unless instructed to do so.
3. Make sure cutter is rotating in the proper direction before cutting material.
4. Before running machine, the spindle should be rotated by hand to make sure it is clear
for cutting.
5. Make sure the power is off before changing cutters.
6. Always use the proper cutting fluid for the material being cut.
7. Never run the machine faster than the correct cutting speed.
8. Make sure that the machine is fully stopped before taking any measurements.
9. Always use cutters which are sharp and in good condition.
10. Don't place anything on the milling machine table such as wrenches, hammers, or tools.
11. Always stay at the machine while it is running.
12. Don't take too heavy a cut or use too rapid a feed.
13. Remove the collet tightening wrench immediately after using it.
14. If at all feasible rig a guard or shield to prevent chips from hitting other people.
15. Use the milling machine spindle brake to stop the spindle after the power has been
turned off.
16. Before cleaning the mill remove cutting tools from the spindle to avoid cutting yourself.
 Electric arc welding
1. Be sure the welder is properly installed and grounded.
2. Never weld without adequate ventilation.
3. Take proper precautions to prevent fires.
4. Protect your entire body with fire retardant clothing, shoes, and gloves.
5. Wear eye protection at all times.
6. Weld only in a firesafe area.
7. Never do any welding, cutting, or hot work on used drums, barrels, tanks, or other
containers.
8. Mark metal "HOT" with a soapstone.
9. Keep a well-stocked first aid kit handy.
  Oxyacetylene welding
1. Wear personal protective equipment.
2. Fasten cylinders securely. Never use oil on welding equipment. Open cylinder valves
correctly.
3. Keep the tip pointed away from your body. Light the flame with an approved lighter.
4. Set the operating pressure carefully.
5. Do not smoke or allow anyone else to smoke near the oxy-fuel gas welder.
6. Treat the flame with respect. Control flashbacks and backfires.
7. Do not leave the work area until the cylinder valves are closed.
8. Never stand in front of a regulator while you are opening a tank valve.
9. Do not weld or cut on containers that have held flammable materials. Remove regulators
and replace protective caps before transporting cylinders.
10. Store oxygen cylinders away from acetylene cylinders.
11. Handle hot metal with pliers or tongs. Check connections for leaking gases.

V. Conclusion

Conclusion

Metal bench work has been there for centuries and numerous civilizations have
made use of it at its best and also upgraded it into something more valuable. It became
so special in the world craft where one must possess a high skill, knowledge and deep
understanding of what does it means and when or how do we do it.

VI. References
http://metalworkprocesses.weebly.com/bench-process-tools.html
https://www.toolingu.com/class/280130/benchwork-and-layout-operations-241#
https://www.finewoodworking.com/2005/09/13/a-short-history-of-workbenches
https://ravimachines.com/safety-measure-while-operating-lathe-machine/
https://www.lsu.edu/eng/mie/cuf/ammf/safetyrules/DrillPress.php
https://www.lsu.edu/eng/mie/cuf/ammf/safetyrules/MillingMachines.php
https://nasdonline.org/1083/d000873/arc-welding-safety.html
https://nasdonline.org/944/d000785/agricultural-engineering-safety-lesson-plan-oxyacetylene-
welding-safety.html