M04 Bench Works

FINISHING CONSTRUCTION
WORKS
Level – I
Based on March, 2022 Curriculum Version 1
Module Title: - PERFORMING BENCH WORK

Module Code: - EIS FCW M04 08 22
Nominal Duration: - 40Hour
Prepared by: Ministry of Labour and Skill
August, 2022
Addis Ababa, Ethiopia
Page 2 of 103 Ministry of Labor and Skills Performe Bench Wok Version -1
Author/Copyright August 2022
Table of Content Page
List of Figure ...................................................................................................................... 5
Acknowledgment ............................................................................................................... 7
Acronym ............................................................................................................................. 8
Introduction to the Module ............................................................................................... 9
Unit one: Layout and mark dimensions/ features on work piece ............................. 12
1.1. Select types and characteristics of materials ............................................... 12
1. 1.1. Clamping tools ........................................................................................ 12
1.1.2. Measuring and marking tools .................................................................. 14
1.1.3. Cutting tools ............................................................................................ 17
1.1.4. Striking Tools ........................................................................................... 19
1.1.5. Drill and lap holes .................................................................................... 19
1.2.1. Layout ...................................................................................................... 21
1.2. Layout and marking dimensions/features. ................................................... 21
1.1.2. Marking .................................................................................................... 22
1.3. Perform Bench work Operations .................................................................. 23
1.4.1. Use Personal Protective Devices............................................................ 27
1.4. Apply Safety procedures and OHS................................................................ 27
1.4.2. Classification of Safety ............................................................................ 29
Self-Check -1 ..................................................................................................... 32
OPERATION SHEET 1.1: - ............................................................................... 35
LAP Test............................................................................................................. 36
Unit Two: Cut, chip and file flat, rectangular or round blocks ................................. 38
2.1. Avoid damage and accidents in the work hold devices .................................. 38
2.2.1. Cutting ...................................................................................................... 42
2.2. Cutting, chipping, and work pieces ................................................................... 42
2.2.2. Chipping ................................................................................................... 46
2.3. Replace broken or dull hacksaw blades .......................................................... 48
2.4. Performbench work operations ........................................................................ 51
Self-Check -2 ..................................................................................................... 53
OPERATION SHEET 2.1: - ............................................................................... 55
OPERATION SHEET 2.2: - ............................................................................... 57
LAP Test............................................................................................................. 59
Unit Three: Drill, ream and lap holes ............................................................................ 61
3.1. Apply Drill, Ream, Spot-facing and Lapp Hole ................................................. 61
3.2. Perform sequentially drill, reaming and lapping hole. .................................... 64
3.3. Perform and applying drill, ream and lap hole operations. .............................. 66
Self-Check-3 ...................................................................................................... 71
OPERATION SHEET 3.1: - ............................................................................... 72
LAP Test............................................................................................................. 74
Unit Four: Cutting thread and fit gage system ............................................................ 76
4.1. Cutting thread and fit gage................................................................................ 76
4.2. Perform the Sequence of tapping ..................................................................... 78
Self-Check -4 ..................................................................................................... 85
Unit Five: Off-hand grind cutting tools ........................................................................ 87
5.1. Apply honing and cutting edges and free of burrs. .......................................... 87
5.2. Apply sharpening cutter .................................................................................... 90
5.3. Apply cutter cooling. .......................................................................................... 93
5.4. Apply personal protective devices .................................................................... 96
Self-Check -5 ..................................................................................................... 97
OPERATION SHEET 5.1: - ............................................................................... 98
LAP Test........................................................................................................... 100
Reference: ...................................................................................................................... 102
List of Figure
figure 1. 1 bench vice................................................................................................................................................... 12
figure 1. 2 hand vice .................................................................................................................................................... 13
figure 1. 3 pin vice ....................................................................................................................................................... 13
figure 1. 4 pipe vice ..................................................................................................................................................... 13
figure 1. 5 try-square.................................................................................................................................................... 14
figure 1. 6 combination square .................................................................................................................................... 14
figure 1. 7 scriber ......................................................................................................................................................... 14
figure 1. 8 center punch ............................................................................................................................................... 15
figure 1. 9 steel rules.................................................................................................................................................... 15
figure 1. 10 vernier caliper........................................................................................................................................... 15
figure 1. 11 outside calipers ......................................................................................................................................... 16
figure 1. 12 inside calipers ........................................................................................................................................... 16
figure 1. 13 divider ...................................................................................................................................................... 17
figure 1. 14 bow saw.................................................................................................................................................... 17
figure 1. 15 file ............................................................................................................................................................ 18
figure 1. 16 flat chisel .................................................................................................................................................. 18
figure 1. 17 pointed chisel ........................................................................................................................................... 18
figure 1. 18 hammers ................................................................................................................................................... 19
figure 1. 19 drill ........................................................................................................................................................... 19
figure 1. 20 taps ........................................................................................................................................................... 19
figure 1. 21 die and die stock ....................................................................................................................................... 20
figure 1. 22 portable drill machines ............................................................................................................................. 20
figure 1. 23 try square .................................................................................................................................................. 21
figure 1. 24 datum edges .............................................................................................................................................. 22
figure 1. 25 face edges ................................................................................................................................................. 22
figure 2. 1 bench vice................................................................................................................................................... 40

figure 2. 2 machine vice............................................................................................................................................... 40
figure 2. 3 pliers ........................................................................................................................................................... 41
figure 2. 4 rolling: tool turns ........................................................................................................................................ 42
figure 2. 5 turning: workpiece turns............................................................................................................................. 42
figure 2. 6 teeth setting ................................................................................................................................................ 43
figure 2. 7 cut with a hacksaw ..................................................................................................................................... 43
figure 2. 8 parts of hack saw ........................................................................................................................................ 44
figure 2. 9 types of hack saw blades ............................................................................................................................ 45
figure 2. 10 adjustable frame ....................................................................................................................................... 45
figure 2. 11 non-adjustable frame ................................................................................................................................ 45
figure 2. 12 working position....................................................................................................................................... 46
figure 2. 13 chipping .................................................................................................................................................... 47
figure 2. 14 hand tapping is the process of cutting ...................................................................................................... 52
figure 3. 1 drill, ream ................................................................................................................................................... 61
figure 3. 2 drilling operations ...................................................................................................................................... 63
figure 3. 3 lapping ........................................................................................................................................................ 64
figure 3. 4 hole lapping ................................................................................................................................................ 65
figure 3. 5 drilling machine ......................................................................................................................................... 69
figure 4. 1 thread cutting.............................................................................................................................................. 77

figure 4. 2 taps and dies ............................................................................................................................................... 78
figure 4. 3 drill, countersink and tapping a hole .......................................................................................................... 80
figure 4. 4 tapping operation ........................................................................................................................................ 81
figure 4. 5 die and its operation ................................................................................................................................... 83
figure 5. 1 honing......................................................................................................................................................... 87
figure 5. 2 edge honing ................................................................................................................................................ 88
figure 5. 3 burr free ...................................................................................................................................................... 89
figure 5. 4 punches and their grinding angles .............................................................................................................. 91
figure 5. 5 position of the tool rest ............................................................................................................................... 94
figure 5. 6 off-hand method of drill ............................................................................................................................. 95
figure 5. 7 personal protective equipment.................................................................................................................... 96
Acknowledgment
Ministry of Labor and Skills wish to extend thanks and appreciation to the many
representatives of TVT instructors and respective industry experts who donated their time and
expertise to the development of this Teaching, Training and Learning Materials (TTLM).
Acronym
OHS: Occupational Health Safety
PPE: Personal Protective Equipment‟s
PPD: Personal Protective Devices
Introduction to the Module
In finishing construction filed, bench work helps to how to use workshop hand tools, to layout
and mark features to know range of graduated devices to measure, to perform basic drills, reams,
hones and scraper operation, and perform off-hand grind cutting tools for finishing construction
work filed. And also, it helps to increase the efficiency and productivity of an operation of cut,
chip, file flat, drill, ream and lap holes.
This module covers the required knowledge, skills and attitude to perform basic bench work
operations (i.e., layout; cutting with hacksaw and chisel; filing; drilling; tapping etc.) and check
the components for conformance to specifications.
This module is designed to meet the industry requirement under the Finishing Construction
Work occupational standard, particularly for the unit of competency: Performing Bench Work.
This Module Covers the Units:
 Layout and mark dimensions/ features on work piece
 Cut, chip and file flat, rectangular or round blocks
 Drill, ream and lap holes
 Cut threads using tap and stock and die
 Off-hand grind cutting tools
Learning Objective of the Module
 Apply layout and mark dimensions/ features on work piece
 Perform cut, chip and file flat, rectangular or round blocks
 Perform drill, ream and lap holes
 Demonstrate Cut threads using tap and stock and die
 Apply Off-hand grind cutting tools
Module Instruction
For effective use these modules trainees are expected to follow the following module instruction:
1. Read the information written in each unit
2. Accomplish the Self-checks at the end of each unit
3. Perform Operation Sheets which were provided at the end of units
4. Do the “LAP test” giver at the end of each unit and
5. Read the identified reference book for Examples and exercise
Unit one: - Layout and mark dimensions/ features on work piece
This unit is developed to provide you the necessary information regarding the following content
coverage and topics:
 Select materials
 Laid-out and marking dimensions/features on the work piece
 Bench work tools and equipment.
 Perform layout and mark
 OHS Safety
This unit will also assist you to attain the learning outcomes stated in theabove coverage.
Specifically, upon completion of this learning guide, you will be able to:
 Select material according to the requirements specified in the drawing
 Lay out Dimensions/features for bench work device and equipment
 Marking the place of features for bench work device and equipment
 Perform layout and marking bench work
 Use Personal protective devices.
Unit one: Layout and mark dimensions/ features on work piece
1.1. Select types and characteristics of materials
Types and characteristics of materials for Bench working and fitting shop is a very important
work in engineering.Fitting work is a very important work in engineering. In fitting shop
unwanted material is removed with the help of hand tools. it is done repair and manufacturing
purposes. The person working in fitting shop is called fitter. a fitter should have the complete
knowledge of the tools used in the shop. Commonly used tools are hacksaw, files, chisels etc.
Fitting shop tools are classified as: -
 Clamping tools
 Measuring and marking tools
 Cutting tools
 Striking tools
 Drilling tools
 Threading tools
1. 1.1. Clamping tools
A. Bench vice: - it is a common tool used for holding jobs. It consists of cast iron body and cast-
iron jaws. Two jaw plats are fitted on both the jaws. Jaw plates are made up of high carbon steel
and are wear resistant. One jaw is fixed to the body and the second slider on a square threaded
screw with the help of a handle.
The jaw is opened up to require length job is placed in the two jaws and is fully tightened with
handle.
Figure 1. 1Bench vice
B. Hand vice: -used to grip very small objects. These are made in different shape and sizes.
Commonly used hand at the bottom, spring is provided between two legs and the jaws may be
adjusted from a flange nut.
Figure 1. 2Hand vice
C,Pin vice: - pin vice is used to hold wire or small diameter rods. It is also used for grinding
small drills. It consists of a small chuck made up of tools steels and a mild steel handle.
Figure 1. 3pin vice
D,Pipe vice: - it is used to hold pipes. It consists of a vertical screw with square threads. A
handle is attaché on the top of the screw. A movable jaw is fixed on the lower end of the screw.
Figure 1. 4Pipe vice
1.1.2. Measuring and marking tools
A. Try-square: - it is used for checking the square of two surfaces. It consists of a blade made
up of steel which is attached to a base at 90o. The base is made up of cast iron and steel try
square is also used for marking right angle and measuring straightness of surfaces.
Figure 1. 5Try-square
B. Combination square
It is a multipurpose instrument that can be use a level, miter, and try square.
Figure 1. 6Combination square
C. Scriber: - it made up of height carbon steel and hardened from the front edge. It used to
markline.
Figure 1. 7 Scriber
D. Center punch: - it is like dot punch except the angle of the punching end is 90 o. it is used to
make the center of the hole before drilling.
Figure 1. 8Center punch
E. Steel rules: - these are made up of stain less steel is available in many sizes ranging from ½ft
to 2ft. these are marked in inches or millimeters.
Figure 1. 9Steel rules
F. Vernier caliper: - venire caliper is a precision instrument used for measuring length
anddiameter.It can be used for measuring external and internal dimensions.
Figure 1. 10Vernier caliper
Two types of calipers
a. Outside calipers, as shown in are used for measuring external dimensions
such as the length, diameter, or even the thickness of a solid
Figure 1. 11Outside calipers
b. Inside calipers, as shown in are used for measuring internal dimensions

such as the diameter of a hole, or the width of a slot, etc.
Figure 1. 12Inside calipers
It can be used for measuring external and internal dimensions. It consists of a graduated bar of
rectangular section. It has two jaws one is movable with a small vernier head and the other is
fixed.
A fine adjustment nut is also attached to the head. The dimension is measured by the jaw and is
indicated on graduated bar. Minimum dimension that can be expressed on vernier caliper is
0.001 or 0.02mm generally. The material of the part is stainless steel.
G. Divider: - these are a made up of steel. Dividers have two legs having sharp feet. These
arehinged at the top. It is used for marking arcs dividing a line or transferring the dimensions.
The blade should be tightened sufficiently.
Figure 1. 13 Divider
1.1.3. Cutting tools

 A modern bow sawis a metal-framed crosscut saw in the shape of a bow with a coarse
wide blade. This type of saw is also known as a Swede saw, Finn saw or bucksaw. It is a
rough tool that can be used for cross-cutting branches or firewood, up to six inches (150
mm) in diameter.
Figure 1. 14Bow saw
 File: - this used to remove material by rubbing it on the metal. Files are available in a number
of sizes, shapes and degree of coarseness classification of the bases of shapes and size file
shapes are flat, square, round, triangular half round.
Figure 1. 15File
 Chisel: - this are used for chipping away the material from the work piece. This are made up
of high carbon steel. Generally, 6” to 8” long.
This top is flattened and a sharp cutting edge is made on the bottom side.
 Flat chiselused for general work cross cut chisel of half round chisels are used for
grousing and diamond point chisels is used for precision work.
Figure 1. 16Flat chisel
 Pointed chisel
Figure 1. 17Pointed chisel
1.1.4. Striking Tools
 Hammersare only tools generally used for striking in fitting shop. These are used for
chipping,
fitting punching etc. a hammer consists of a heavy iron body with a wooden handle.
Figure 1. 18Hammers
1.1.5. Drill and lap holes
 Drill: - the tool used for moving round holes is called drill. It is made up of high-speed steel.
Figure 1. 19Drill
 Taps: - are used for making internal threads. It is inserted in to the face of the hole at right
angle. In hand tapping a set of three taps used.
Figure 1. 20Taps
 Die and die stock: - it is used for cutting external threads die are made from steel have
internal threads, by holding the die and die stock, the handle is rotated by hand.
stock
die
center spring screw
Figure 1. 21Die and die stock
Figure 1. 22Portable drill machines
1.2. Layout and marking dimensions/features.
1.2.1. Layout
Layout is the process of making lines, circles, and other marks with a variety of hand tools to
represent the features on the blueprint. These marks act as a reference for the operator during
machining. They indicate features such as hole locations, dimensions, and other specific areas to
be machined. The work piece is coated with a special layout dye, which helps the lines appear
more clearly. Layout lines guide the operator to ensure the part fits within the acceptable
tolerances. By preventing errors, layout reduces costs
 Squares:
There are a number of squares:
 Try square
 Miter square
 Engineer‟s square.
Both the try square and engineers square are used to mark lines at 90° to an edge. A try square is
used on timber and an engineer‟s square is used on metals. Both can be used for marking out
plastics. You can also use try squares and engineer‟s squares to check that a cut or an edge has
been made at right angles to another. Hold the stock part of the square tightly against the edge
that you have just cut. If you can see light between the two edges then the cut is not square. A
miter square is used for marking out 45° or 135° angles on wood and plastic.
Figure 1. 23Try square
1.1.2. Marking
Marking out and measuring is a critical part of manufacturing and is usually subject to a number
of quality control checks. If components are marked out and measured wrongly before being cut
out, there is no chance of them fitting together when they are assembled. Always take marking
out measurements from a datum as indicated in Figure24A datum edge is a flat face or straight
edge from which all measurements are taken. This prevents cumulative errors being made. If you
are using timber, choose the face side carefully, before marking it with a small symbol for
identification purposes, as shown in Figure 25Then select a face edge that is at right angles to the
face side. Take all your measurements from this side and/or edge.
Figure 1. 24Datum edges
Figure 1. 25Face edges
1.3. Perform Bench work Operations
Bench work has its own essential position in all engineering works. In the mechanized
workshops, where most of the work is carried out on an automatic machine, while bench work
has its own importance. Benchwork includes various cutting processes that machinists complete
by hand rather than on a machine when creating part features that require less power and force.
Common benchwork operations include hand tapping, hand reaming, hand filing, and
engraving.
Chipping
Removing the metal with a chisel is called chipping and is normally used where machining is not
possible. While chipping, safety goggles must be put on to protect eyes from the flying chips. To
ensure safety of others, a chip guard is placed in position. Care should be taken to see that the
chisel is free from mushroom head.
Figure 1.26 Proper body position when chipping
Chisels
There are many verities of chisels used for chipping work by a fitter. Some very commonly used
forms are flat, cross-cut, round nose and diamond point.
All the chisels are forged from bar stock of carbon steel, to the desired shape and the cutting-
edge ground to the correct angle.
 The flat chisel: used for general-purpose chiseling;
 The cross-cut chisel: used for cutting grooves such as keyways, and for chipping;
 The half-round-nosed chisel: used for cutting grooves (which are either curved or half-
round);
 The diamond-pointed chisel: used for working into corners and cutting small grooves.
Figure 1. 27Types of chisels
Filing
Filing is a method of removing metal, and the file Figure below, which is the most widely used
hand tool in the school workshop, is used for this cutting operation. It is made of carbon tool
steel containing about 1.3 per cent carbon.
 The Main Parts
A file is a hand cutting tool made of high-carbon steel, having a series of teeth cut on the body
by parallel chisel cuts.
Figure 1. 28Flat file and its parts.
Methods of filing:
There are several methods of filing, each with a specific purpose. With reference to the figure,
the following may be noted:
i. Holding the file: For heavy work and to remove more metal, a high pressure is used.
For light and fine work, a light pressure is applied.
ii. Filing internal curves: A part of half round file only makes contact as shown during
filing operation. Movement of the file is indicated by arrows.
iii. Cross filing: It is the most common method of filing. Cross filing is carried out across two
diagonals, to produce medium surface finish. It is used when large an amount of metal is
to be removed. By cross filing „rounding‟ the surface is reduced.
iv. Straight filing: When a short length of work piece is required to have a flat surface,
straight filing is used. File marks made during cross filing may be removed, to produce a
relatively smooth surface.
v. Draw filing: It is done to get a finely finished surface. It produces a smoother surface
finish than straight filing. A smooth or dead smooth flat file is used for this.
Use the single cut on softer materials (such as brass and aluminum) and the double cut for
general filing, especially on iron and steel.
Figure 1. 29Methods of filing
Types of files based on their shapes:
Figure 1. 30Types of files based on shapes.
Scraping
Scraping is the process of removing high spots on the surface of a piece of work. It is a difficult
operation, and is not often performed in the school workshop.
 Types of scrappers:
These sharp-edged tools are used to remove uneven spots on the surfaces. They are of different
shapes.
 Flat scraper
It is used for removing metal from flat surfaces. The blade must have a slight curvature at the
cutting edge. The corners are rounded to help the user, scrape at the exact spots.
 Half round bearing scraper
This is used for scraping curved and cylindrical surface split bearings, big bush bearings etc.
 Triangular scraper
This is used for scraping curved surfaces, holes and bores. Specification is by length. Example:
200 mm, 300 mm etc.
Figure 1. 31Using half round scraper
1.4. Apply Safety procedures and OHS
1.4.1. Use Personal Protective Devices
Safety means the right way of doing things. The safety in Workshops has been written not only
to provide appropriate safety procedures but also to assist trained workshop personnel with the
provision of a reference document outlining the general principles of safe working practices
relevant to the mechanical engineering aspects. It relates to specific areas where definite safety
measures are required for workshop operations.
General safety rules are established for three good reasons: -

 To protect you and your colleagues from badly harm.
 To minimize damage to facilities, machinery and tools with which you work.
 To enable you experience a positive safety attitude not only in the work shop but also in
your entire professional career.
Safety is not only the responsibility of a single fellow. It is the responsibility of everyone.
Personal protective equipment, commonly referred to as "PPE", is equipment worn to minimize
exposure to hazards that cause serious workplace injuries and illnesses. These injuries and
illnesses may result from contact with chemical, radiological, physical, electrical, mechanical, or
other workplace hazards. Personal protective equipment may include items such as gloves, safety
glasses and shoes, earplugs or muffs, hard hats, respirators, or coveralls, vests and full body
suits.
1.4.2. Classification of Safety
1.4.2.1. Personal safety:
 Wear approved safety glasses or goggles at all times.

 Wear approved foot wears at all times.
 Remove all rings, Watches, or bracelets.
 Long hair must be protected by a hair net or an approved protective shop cap.
 Avoid horse play at all times, since an accidental slip or fall can cause a serious cut or
body injury.
 Never handle sharp tools or cutters by hand.
 Use proper lifting techniques whenever lifting tools or machines.
 Do not carry sharp tools on pockets.
 Remove all rings, Watches, or bracelets.
 Don‟t wear loose clothes.
 Do not use a file without handle.
1.4.2.2. Bench work and fitting shop safety:
 Keep hands and tools wiped clean and free of dirt, oil and grease.
 Always keep the work shop clean.
 Do no keep working tools at the edge of the table.
 Keep the floor free of oil and grease
 While sawing, keep the blade straight; otherwise, it will break
 Clean the vice after use.
 Keep the floor around a machine or bench free of tools or stock.
 Sweep up the metal chips on the floor frequently.
1.4.2.3. Machine and tool safety
 Do no keep working tools at the edge of the table.

 Never place tools or materials on machine tools.
 Always keep the machine clean.
 Always stop a machine before attempting to clean it.
 Do not use vice as an anvil.
Cause of accidents
 improper dressing
 poor house keeping
 insensible behavior
 incorrect procedure
Preventing accidents
 proper dressing
 good house keeping
 sensible behavior
 correct procedure
How to practice occupational health and safety in the workplace?
Here are some ways you can work to stay safe on the job.
 Be Aware.
 Maintain Correct Posture.
 Take Breaks Regularly.
 Use Equipment Properly.
 Locate Emergency Exits.
 Report Safety Concerns.
 Practice Effective Housekeeping.
 Make Use of Mechanical Aids.
Figure 1. 32Safety in the workplace
Self-Check -1 Written Test
Directions: choose the correct answer for the following questions (2 points each):
1. Which one of the following is not clamping tools?
a. Vice
b. V- block
c. hacksaw
d. C- clamp
2. One of the following is not the parts of bench vice.
a. Jaw face
b. Thimble
c. Fixed jaw
d. Movable jaw
3. ______is used for clamping work piece.
a. Bench vice
b. C-clamp
c. V-block
d. All
4. _______is used to cut internal threads in holes which are usually drilled for the purpose
of attaching an item with bolts or metal threads.
a. Tap c. snips
b. Die d. all
5. _______are hand tools used for holding and turning materials.
a. Snip c. trammel
b. Wrench d. Screwdrivers
6. Which one of the following is not include under hand tools?
a. Wrench c. Taps
b. Power hacksaw d. all
7. Removing the metal with a chisel is called________
a. Scrapping
b. Filling
c. Chipping
d. All
8. Some of the most common tools used to cut metals are_______
a. hacksaws
b. tin snips
c. cold chisels,
d. all
9. ______a file is used when large an amount of metal is to be removed.
a. Cross filing
b. Straight filing
c. Draw filing
d. All
10. _____ is used to mark the center of a hole and make an indentation for a twist drill.
a. Scriber
b. Center punch
c. Trammel point
d. None
11. _____is used for scraping curved and cylindrical surface split bearings, big bush etc.
a. Flat scraper
b. Half round bearing scraper
c. Triangular scraper
d. All
12. Which one of the following is not a bench work and fitting shop safety?
a. Do not carry sharp tools in your pockets c. keep your-self from car accident
b. Clean the vice after use d. do not use a file without handle
13. What is the reason that general safety rules are established for?
a. To protect you and your colleagues from badly harm
b. To decrease accidents in the work shop
c. To minimize damage of facilities, machinery and tools d. All
14. Which one of the following is the cause of accident?
a. Improper dressing c. Sensible behavior
b. Good housekeeping d. Correct procedure
15. Safety is only the responsibility of a single fellow.
a. True b. False
16. Which one of the following is a personal safety?
a. Remove all rings, watches, bracelets c. Wear approved safety glasses or
goggles
b. Wear approved foot wears at all times d. All
Note: Satisfactory rating - 16 points Unsatisfactory - below 16 points
You can ask your teacher for the copy of the correct answers.
Score = ___________
Rating: ____________
Name: _________________________ Date: _______________
OPERATION SHEET 1.1: -Layout and mark dimensions/ features on work piece
Operation Title: Lay out and mark dimensions/features
Purpose: To Lay out and mark dimensions/features
Instruction: Using the figure below and given equipment lay out the length of each line. You
have given 40-Minut for the task
Figure show operation sheet 1.1A

Tools and requirement:
1. 10*85*135 mm plate
2. Rule,
3. Scriber
Steps in doing the task
 Steps 1-Locate the reference plane.
 Step 2- Use the surface plate, surface gauge and steel ruler to set the required height as
shown in above Fig 1.1A.
 Step 3- Use the angle plate, surface gauge to scribe the first line and repeat the same
procedure to scribe the other three lines.
 Step 4- Punch the scribed lines by using the prick punch.
Quality Criteria: the given geometrical shape is measured with 0.5mm accuracy
Precautions: use the given steel rule and try square.
LAP Test Practical Demonstration
Name: _____________________________ Date: ________________
Time started: ________________________ Time finished: ________________
Instructions: Given necessary templates, tools and materials you are required to perform the
following tasks within 1-1:30 hours.
Task 1:Marking out
Unit Two: - Cut, chip and file flat, rectangular or round blocks
This unite is developed to provide you the necessary information regarding the following
content coverage and topics:
 Avoid damage and accidents
 Cutting, chipping, and work pieces
 Replace broken or dull hacksaw blades
 Bench work operations
This guide will also assist you to attain the learning outcomes stated in the above coverage.
 Avoid damage and accidents in work holding devices.
 Cutting, chipping, and work pieces
 Replace broken or dull hacksaw blades
 Performbench work operations
Unit Two: Cut, chip and file flat, rectangular or round blocks
2.1. Avoid damage and accidents in the work hold devices
How to avoid workplace accidents? In lines of work like construction, shipping,
manufacturing and repair, using dangerous equipment can‟t be avoided. However, workplace
accidents don‟t have to be an inevitable part of the job. Perform regular inspections of
machinery, equipment and tools.
Accidents are unplanned occurrences that result in injuries, illness, death, and loss of property
and/or production. While there is no way to completely eliminate accidents, there are certain
plans, preparations, and actions that can be taken to reduce them.
To Know the Hazards
 Be aware of surroundings.
 Look around and identify workplace hazards that could cause harm.
 Look for ways to reduce or eliminate hazards, and implement them.
 Report unsafe areas or practices.
 Dress for the weather.
a) Create a Safe Work Area
 Keep an orderly workplace. Poor housekeeping can cause serious health and safety
hazards.
 The layout of the workplace should have adequate egress routes and be free of debris.
 Inspect vehicles before and after use.
 Continually cultivate a safety standard.
 Take breaks and move around regularly throughout the day. Small breaks (standing up
and moving around) can make a big difference in combating the dangers of staying in a
static position all day long.
 Pay attention to workstation ergonomics.
b) Use Safe Lifting Techniques
Follow the following safe lifting practices:
 Lift from a position of power
 Keep the load close
 Use a staggered stance
 Don‟t twist while lifting
 Training in body mechanics can reduce strain injuries and keep employees safe during
lifting and moving.
c) Personal Protective Equipment
The proper use of Personal Protective Equipment (PPE) can dramatically reduce the risk of
injury. Examples of PPE include gear such as earplugs, hard hats, safety goggles, gloves, air-
purifying respirators and safety shoes.
d) Regular Communication
 Notify supervisors about safety hazards.
 Speak up and be involved in safety planning.
 Continually cultivate a safety standard.
Clamping
Once work piece is located, it is necessary to press it against locating surfaces and hold it there
against the force acting upon it. The tool designer refers to this action as clamping and the
mechanisms used for this action are known as clamps. It is necessary that the work should be
properly and securely held on for machining operations, a VISE is an effective work holding
device.
Workpieces roust be clamped in such a way that they cannot fling around or be drawn up. Small
workpieces can be held by clamp dogs or hand vices on a support if only a small rotary power is
to be expected (small bore holes).
Vises: Vises are the most common appliances for holding work on table due to its quick loading
and unloading arrangement.
 Bench vice
A bench vise is like an extra hand and is a common tool found in any shop or garage. It is
attached to a workbench and its purpose is to hold material steady, allowing you to use both
hands to work on the material with other tools. They are ideal for sawing, sanding, plaining,
drilling, screwing, soldering and more.
Figure 2. 1 Bench vice
Figure 2. 2Machine vice
 Pliers
There is a vast range of pliers used in the vehicle body building industry, with the most common
being combination pliers, slip joint pliers, side cutters, circlip pliers, long-nosed pliers and multi
grips. The correct pliers to use depend on the type of vehicles being built. For example, long-
nosed pliers are used to hold and grip small work in awkward places so these may be used
extensively with hydraulic or electrical work. However, they may not be much use when
building a semitrailer. Name these pliers:
Figure 2. 3Pliers
Clamping device are used to minimize the distortion during the machining process. Once the
workpiece is located, it is necessary to hold it against the machining force. The mechanism used
for this is known clamps. They are work holding devices usually positioned above the supporting
surfaces.
2.2. Cutting, chipping, and work pieces
2.2.1. Cutting
Cutting is a technique where the operator moves a material (workpiece) such as metal and the tool in
relation to each other in order to shape the workpiece into the desired form through shaving, drilling, etc.
Cutting can be broadly divided into two methods: rolling, where the workpiece is restrained while the
tools turn, and turning, where the workpiece is turned instead.
Figure 2. 4Rolling: Tool turns
Figure 2. 5Turning: Workpiece turns
Cutting process
The saw is moved from the right to left and shows how the chip is formed. The cutting process is
the result of the horizontal cutting direction and the pressure on the work piece. The angle of the
teeth enables the saw to cut the material effectively. The teeth are set (bent out) that they do not
get jammed in the cut.
Figure 2. 6Teeth setting
a = clearance b = cutting angle
forces on a saw blade:

1 = indicates the cutting direction
2 = indicates the pressure on the work piece
Making the Cut with a Hacksaw
Place the metal to be cut in a vise and mark it. The mark should be placed near the jaws,
especially if the metal is thin. It may be necessary to use boards between the vise jaws to prevent
scarring the work. Mark over the original mark with a file.
Figure 2. 7Cut with a Hacksaw
Depending upon the direction of cut, blades are classified as:
 Forward cut
 Backward cut.
Depending upon the pitch of the teeth (Distance between the two consecutive teeth) blades is
classified as:
 Coarse (8-14 teeth per Inch)
 Medium (16-20 teeth per inch)
 Fine (24-32 teeth per inch)

Replace broken and dull hacksaw blades
a. Parts of a hacksaw
1. Saw frame
2. Handle protector
3. Handle
4. Tang
5. Blade holder
6. Blade
8. Pins
9. Wing-Nut
10. Pins
Figure 2. 8Parts of hack saw
b. Types of blades for hacksaws
Figure 2. 9Types of hack saw blades
One side toothed both sides toothed

c. How to handle a hacksaw?
1 and 3 indicate the forward stroke with pressure2 and 4 the backward stroke without pressure
the circle shows the direction of teeth (facing the front of the hacksaw) all strokes should be in a
straight line and along the whole length of the blade.
Figure 2. 10Adjustable frame
Figure 2. 11non-adjustable frame
The work piece must be clamped to allow free movement when sawing. Left-handed people
clamp their work to the right of the vice and right-hander people to the left.
Figure 2. 12Working position
2.2.2. Chipping
Chipping is working on materials by a wedge-shaped tool (the chisel) in order to separate or chip
material. The cutting effect of the chisel is achieved by hammering on the head end of the chisel,
which is an energy and time-consuming operation.
It is the operation employed for removing the excess metal by means of cold chisels. To have a
properly chipped surface it is essential that the same cutting angle should be maintained
throughout the operation.
 It is the operation employed for removing the excess metal by means of cold chisels.
 To have a properly chipped surface it is essential that the same cutting angle should be
maintained throughout the operation.

 In case the surface is too large it is advisable to cut grooves along the whole surface by
means of a cross cut chisel and then chip off the remaining metal.
 The cutting angles of the chisels differ for different metals.
 Frequent lubrication and cooling of the cutting edge, while taking heavy cuts for
removing large amount of metal, it helps considerably in chipping the metal easily and
more effectively.
 To the correct cutting angle of the chisel, proper gripping of the chisel and the hammer
and correct standing position of the operator play a significant part.

 The chisel should be firmly gripped in one hand leaving about 3 to 5 cm length above the
thumb of the hand, and hammer should be held near the end of the handle to ensure more
power in the blows.
 The operator should stand erect with his two feet sufficiently apart to balance his own
weight equally on both the feet.

 The operator should always see the cutting edge of the chisel and not the top of the same.
Figure 2. 13Chipping
2.3. Replace broken or dull hacksaw blades
Shop for Hacksaws

Please note: How this is done may vary depending on the
make and model. One method is shown below:
How is the blade attached?

A hacksaw has a removable blade mounted in a metal frame.
Like all frame saws, the blade must be held taut in order to cut
efficiently. The blade is held in place by two metal pins on
either end of the frame. These pins hook onto two
corresponding holes on either end of the hacksaw‟s blade.
Removing the blade

Step 1 – Loosen wingnut
Turn the wingnut in an anti-clockwise direction. This
controls the position of a metal bar at the end of the
frame‟s arm.
This bar holds one end of the blade. Turning the wingnut
anti-clockwise pushes, the bar forward, so that it‟s no
longer stretching the blade.
Step 2 – Unhook blade from pins
Once enough tension is released, you can remove the
blade by unhooking it from the pins.
Installing the blade

Please note: Hacksaw blades come in two lengths: 250 or
300mm. Ensure you select the correct one for your
hacksaw.
Step 1 – Loosen wingnut

Ensure the wingnut is loosened before hooking the blade
onto the pins.
When installing a blade, ensure the teeth are on the outside

of the frame, and are facing away from the handle. This is
to ensure the hack saw cuts on the push stroke
Step 2 – Tighten wingnut

Once the blade is in place, turn the wing nut in a clockwise
direction. This will cause the metal bar to move back,
stretching the blade tightly in the frame.
How tight should the blade be?
If the blade is too loose, it will move about on the pins and
could even fall off. A blade with too much movement will
also make it hard to control the saw when working.
However, stretch the blade too much and it could snap,
potentially causing an injury. As a general rule, you should
tighten the blade enough so that it does not move about on
the pins, but can still flex very slightly in the centre.
2.4. Performbench work operations
Benchwork operations for the manual mill often occur before and after the machining of the
part. These operations are commonly performed on a standard workbench with the part secured
in a vise, or secured to the worktable depending on the operation. Benchwork operations
performed prior to machining include the following:
 Blueprint reading involves interpreting part specifications on a part drawing. You must
be aware of a part's accepted tolerances before machining.
 Layout is the process of marking lines and circles on metal workpieces to represent the
features on a blueprint, as Figure 14 shows. Layout helps to eliminate machining errors.
Benchwork operations performed after machining are often necessary to enhance the quality or
improve the accuracy of the part according to its specifications. These operations include the
following:
 Hand tapping, illustrated in Figure 15, is the process of cutting internal
threads manually. Hand tapping requires a tap wrench to manually turn the tap into the
hole.
 Hand reaming slightly enlarges a pre-drilled hole to a certain diameter. Hand reaming is
performed when extreme accuracy is required.
 Filing is a process used to smooth the rough surfaces of a workpiece after machining. A
hand file shapes the material through abrasion.
 Chamfering is a process used to create a bevel to eliminate sharp edges. Chamfers allow
the easy assembly of workpieces.
 Engraving, often parts are engraved with lettering to represent a serial number or other
identification marks. Hand stamping is another process that impresses a shape or
lettering into the workpiece.
Benchwork operations involve processes that allow the workpiece to achieve the accuracies
specified by the blueprint. These operations require operator skill and attention to detail.
Figure 2. 14Hand tapping is the process of cutting
Directions: choose the correct answer for the following questions (2 points each):
1. Which one of the following is not clamping tools?
a. Vice
b. V- block
c. hacksaw
d. C- clamp
2. One of the following is not the parts of bench vice.
a. Jaw face
b. Thimble
c. Fixed jaw
d. Movable jaw
3. ______is used for clamping work piece.
a. Bench vice
b. C-clamp
c. V-block
d. All
4. Removing the metal with a chisel is called________
a. Scrapping
b. Filling
c. Chipping
d. All
5. Some of the most common tools used to cut metals are_______
a. hacksaws
b. tin snips
c. cold chisels,
d. all
6. ______a file is used when large an amount of metal is to be removed.
a. Cross filing
b. Straight filing
c. Draw filing
d. All
7. _____ is used to mark the center of a hole and make an indentation for a twist drill.
a. Scriber
b. Center punch
c. Trammel point
d. None
8. _____is used for scraping curved and cylindrical surface split bearings, big bush etc.
a. Flat scraper
b. Half round bearing scraper
c. Triangular scraper
d. All

You can ask you teacher for the copy of the correct answers.
Score = ___________
Rating: ____________
Name: _________________________ Date: _______________
OPERATION SHEET 2.1: -Cut, chip and file flat, rectangular or round blocks
Operation title:Bench work operations

Purpose: Cut the work piece to produce a drill gauge according to the dimensions given
Instruction: Use the given figure below Figure 2.1A, the tools and equipment lay out and mark
on the work piece. For this operation you have given 2Hour and you are expected to operation.
1. Steel Rule,
2. Scriber
3. Work piece 80*130
4. Hack saw
Precautions: Measure at least three times before cutting
Procedures in doing the task
Step 1. Wear the safety clothes required.
Step 2. Measure the stock to the required dimension.
Step3. Mount the work piece firmly on the vice.
Step4. Choose the correct blade according to the type of material and thickness being cut.
Step5. Install the hacksaw blade.
Step6. Use the blade check list to ensure proper installation.
Step7. Use the hacksaw to cut the work piece. Use the marked sawing lines to guide the cutting
process.
Figure given for operation sheet 2.1A
 Quality Criteria: the given bench work operation measuring with 0.5 mm accuracy
OPERATION SHEET 2.2: -Cut, chip and file flat, rectangular or round blocks

Purpose: Cut the work piece to produce a drill gauge according to the dimensions given
Instruction: Use the given figure below (Figure 2.2B), the tools and equipment lay out and mark
on the work piece. For this operation you have given 2:30Hour and you are expected to
operation.
1. Steel Rule,
2. Scriber
3. Hammer
4. Center paunch
5. Different size of drill bit
6. Bench drill machine
7. work piece 60*98
8. Different size of taps and tap wrench
Precautions: Measure at least three times before punching
Step-1.Select the correct taps and tap wrench
Step- 2. Apply suitable cutting fluid to the tap
Step-3. Place tap in hole as vertically as possible
Step-4. Press downward on wrench, applying equal pressure on both handles
Step-5.If tap is not entered squarely, remove from hole and restart it by applying pressure
Step- in direction from which tap leans
Step-6. Turn tap clockwise one-quarter turn, and turn it backward about ½ turn to break
the chip (must turn with steady motion)
Step-7. Care must be taken not to tap too deep for a blind hole
Step- 8.When finished, clean hole and check with thread gage or appropriate bolt
Figure given for operation sheet 2.2B
Name: _____________________________ Date: ________________

following tasks within 2-4 hours.
Task 1:lay out mark feature
Task 2: Cut and file
Task 3: Cut the work piece to produce a drill gauge according to the dimensions given.
Task 4: Taping according to their pitch
Unit Three: - Drill, ream and lap holes
 Drill, ream, spot-facing and lap hole
 Perform sequentially
 Perform operations
 Apply drill, reaming, spot-facing and lap hole
 Perform sequentially drill, reamand lap hole.
 Perform and applying drill, ream and lap hole operations.
Unit Three: Drill, ream and lap holes
3.1. Apply Drill, Ream, Spot-facing and Lapp Hole
Drilling is a conventional machining process that utilizes a two-flute drill to plunge into the solid
surface to originate a hole. Diameter of the hole is limited by the drill diameter; in fact, they are
equal. Sometimes to enlarge the hole diameter, boring is carried out after drilling.
The chief operation performed on the drill press is drilling, but other possible operations include:
reaming, countersinking, counterboring, and tapping.
Reaming process utilizes a multi-point cutter (called reamer) to remove very small volume of
material to improve upon dimensional accuracy and tolerance. Since reaming smoothens the hole
surface, so a hole is prerequisite for reaming, and thus drilling must be carried out prior to
reaming. As usual reaming produces better surface finish as compared to drilling. Following
sections elaborate various similarities and differences between drilling and reaming.
Figure 3. 1Drill, ream
Differences between drilling and reaming
Drilling Reaming
Drilling is performed to originate a Reaming is performed to finish internal surface of

hole on a solid surface. an existing hole.
Drilling is the first step of hole making. Reaming can be carried out only if a hole exists.
After drilling either boring or reaming So reaming is performed only after drilling (or
can be carried out depending on the boring).
requirement.
Cutting tool used in drilling operation Cutting tool used in reaming operation is called
is called Drill. Reamer.
Metal cutting drill usually consists of Reamer contains large number of cutting edges
two cutting edges. So, drill is (minimum 4). So, reamer is a multi-point cutting
considered as a double point cutting tool.
tool.
Surface of a drilled hole is not highly Reaming is performed to highly finish (i.e.,
finished (i.e., high surface roughness). reducing the roughness) the internal surface of the
holes.
Tight tolerance cannot be obtained by Reaming can easily provide tight tolerance.
drilling operation alone. Sometimes
tight tolerance is required for assembly,
especially for press fit applications.
Axial length of hole can be easily Axial length of the hole cannot be altered by
increased by drilling operation. reaming. Only diameter of the hole can be
increased slightly.
Material Removal Rate (MRR) in MRR in reaming operation is comparatively lower.

drilling is significantly higher.
Drilling is the operation of producing a cylindrical hole by removing of metal by the
rotating edge of cutting tool called the drill.
 The drilling is the simplest method of producing a hole.
 Before drilling, the centre of hole is located on the workpiece by drawing two lines at
right angles to each other and then center punch is used to produce an indentationat
the center.
 Drill point is pressed at this centre point to produce the required hole.
 Drilling does not produce an accurate hole in a workpiece and the hole is generated
by drilling becomes rough and the hole is always slightly oversize than drill used due
to vibration of the spindle and drill.
 A 12 mm drill may produce a hole as much as 0.125 mm oversize and 22 mm drill
may produce 0.5 mm oversize.
Spot facing: -
Spot facing is a mechanical drilling, or milling, process. After the initial hole is drilled, a larger
well, or recess, is drilled into the material. The head of the screw or nail fits into this well. This
allows the nail or screw to sit flush with the surface of the item that is drilled.
This term is also spelled as spot-facing and spot-facing by machinists and parts manufacturers.
The term spot facing is sometimes used to identify a specific type of counter boring. Some
machinists use the term to refer to working with an object that is not flat, or has been cast in
metal. For example, when drilling an object with an angled or round surface, that is referred to as
spot facing.
Figure 3. 2Drilling Operations
3.2.Perform sequentially drill, reaming and lapping hole.
Lapping is a machining process in which two surfaces are rubbed together with
an abrasive between them, by hand movement or using a machine.
Lapping often follows other subtractive processes with more aggressive material removal as a
first step, such as milling and/or grinding.
Lapping can take two forms.
 The first type of lapping (traditionally often called grinding), involves rubbing a
brittlematerialsuch as glass against a surface such as iron or glass itself (also known as the
"lap" or grinding tool) with an abrasive such as aluminum oxide, jeweler‟s
rouge, optician'srouge, emery, silicon carbide, diamond, etc., between them.
This produces microscopic conchoidal fractures as the abrasive rolls about between the two
surfaces and removes material from both.
 The other form of lapping involves a softer material such as pitch or a ceramic for the lap,
which is "charged" with the abrasive. The lap is then used to cut a harder materialthe
workpiece.
Laps and lapping tools are used for precision surface finishing, often in conjunction with loose
abrasive compounds. Lap is a soft material that is charged with an abrasive and is used for
cutting harder material. A lapping machine uses a charged lead piece as lap for cutting a
hardened steel piece.
Figure 3. 3Lapping
Hole lapping
Home Manual hole lapping. The flexible hone is an abrasive tool composed of small balls
impregnated of silicon carbide. It is used in rotation and at low rpm. The result they get is like
a polished or lapped surface. Another characteristic flex hones offer is to improve holes bumpy
texture.
Figure 3. 4 Hole lapping
3.3. Perform and applying drill, ream and lap hole operations.
Procedures
Successful operation of the drill press requires the operator to be familiar with the machine and
the desired operation. The following are some good observations to follow when drilling a hole:
Prior to drilling a hole, locate the hole by drawing two crossing lines.
1. Use a center punch to make an indentation for the drill point to aid the drill in starting the
hole.
2. Select the proper drill bit according to the size needed.
3. Select an appropriate size center drill.
4. Select a cutting fluid.
5. Properly secure the workpiece to the table.
6. Select the correct RPM for the drill bit. Take into account: size of bit, material, and depth
of hole to be drilled.
7. Use an interrupted feed, called peck drilling, to break up the chips being produced.
8. Pilot holes should be used on holes larger than 3/8” dia. Holes are to be enlarged in no
more than 1/4” increments.
9. Clean the drill press and surrounding area when finished.
Necessary Supplies for Drilling into Concrete
A home improvement project might require you to drill into concrete to reinforce a structure,
access cables or plumbing, or anchor something to a wall or floor.
1. Masking tape: Use duct tape or masking tape to cover your work area with protective
plastic and to serve as a depth stop marker. Measure the length of your fastener, masonry
nail, or concrete screws, and place a piece of tape on the drill bit at the same distance from
the sharp tip of the bit. You can then drill until you reach your tape marker without
worrying you have drilled too deep.
2. Masonry drill bit: Use tungsten carbide drill bits or SDS Max drill bits (SDS stands for
slotted drive shaft or slotted drive shaft system) when drilling holes into concrete, brick, or
stone. These drill bits are stronger and sharper than the regular drill bits for use with
wood. Manufacturers design masonry drill bits with deep shanks, which lock the bit into
place, and wider, spiraling flutes on the bit to reduce the chance of it catching on
obstructions or overheating your power tool.
3. Rotary hammer drill: This type of drill has more torque and power than a standard drill
and can assist in heavy-duty drilling tasks, such as into hard materials or concrete
surfaces. There are corded and cordless drill options homeowners can purchase at local
home improvement stores.
4. Safety gear: Wear safety goggles or eye protection when you drill into concrete since
drilling can produce chips of concrete and dust that can irritate or damage your eyes.
Additionally, concrete dust encompasses particles of silica dust, which can damage your
respiratory system. Use a dust mask or respirator to drill concrete in confined spaces.
Steps for Drilling into Concrete
Once you have collected all the necessary supplies for drilling into concrete, you are ready to
continue your home improvement project. Here are the general steps of the concrete drilling
process:
1. Plan ahead. It is more difficult to patch concrete walls than drywall surfaces, so double-
check you will be drilling into the correct location. You can also place protective plastic
on the floors or set up a vacuum system to mitigate concrete dust from spreading
throughout your home. Planning ahead will decrease your cleanup time.
2. Don safety equipment. Use eye protection and a respiratory filter when you drill concrete.
Also, use the auxiliary handle on the side of the drill to keep the tool stabilized during
use. The handle will provide steady control while you drill, but it can also protect your
hands and wrists if the drill bit catches on rebar or other obstructions in the concrete. A
stuck bit will force the back of the drill to spin and twist in the user's grip, sometimes
causing injury.
3. Drill a pilot hole. When you start drilling, set your drill to a slow speed setting and place
a guide hole in the wall. This pilot hole should be approximately one-eighth-inch deep
and perpendicular to the wall surface. This hole will guide your drill bit to create a
straight, ninety-degree hole into the wall surface.
4. Apply steady, firm pressure. Drill in a stabilized position, allowing the hammer action of
the rotary hammer drill to assist the drill bit through the material. This force can cause a
slight recoil for the user, so ensure you hold the tool with a strong grip. Push the drill bit
into the wall with steady pressure. Be aware there might be inconsistent thicknesses and
air pockets throughout a concrete wall prepare for the drill to meet resistance or move
deeper into the wall than you intended.
5. Withdraw your drill bit every ten to fifteen seconds. Giving your drill bit an intermittent
break releases pressure and allows the flutes of the bit to clear away debris and dust in the
hole. This dust and debris can build up and cause a drill bit to stick or burn out the gears
of your rotary drill. Keep in mind, each withdrawing of the drill bit might cause a puff of
concrete dust, so have a vacuum nearby to mitigate dust.
6. Clean your work area. Protect yourself and the people in your home by cleaning up silica
dust with a HEPA-filtered shop vacuum or a mop. Refrain from using a broom or a
vacuum without a special filter since these methods could disperse silica molecules into
the air and cause irritation and respiratory problems.
Figure 3. 5 Drilling Machine
Understand the safety rules.
1. Be familiar with the location of the start and stop switches.
2. The drill press table should be cleared of miscellaneous tools and materials.
3. Ensure that all drill bits are sharpened and chucks are in working condition. Any dull drill
bits, battered tangs or sockets should not be used.
4. Never attempt to remove scraps from the table by hand. Use brushes or other proper
tools.
5. Never attempt to perform maintenance on the machine without the power cord
unplugged.
6. Never insert a chuck key into the chuck until the machine has been turned off and
stopped completely.
7. Belts and pulleys should be guarded at all times. If any are frayed, immediately report to
the instructor for replacement.
8. All workpieces should be secured by a vise or clamp before starting the machining.
9. If the workpiece moves while in the vise or clamp:
 Do not attempt to hold the workpiece in place by hand.
 Do not try to tighten the vise or clamp while the machine is turned on.
 Turn the power off and wait for the machine to stop completely before re-tightening
the vise or clamp.
10. Use the proper speed settings and drill type for the material to be machined.
11. When mounting a drill bit, it should be to the full depth and centered in the chuck.
12. Eliminate the possibility of the drill bit hitting the table by using a clearance block and by
adjusting the feed stroke.
13. Always feed the bit slowly into the workpiece. If the hole to be drilled is deep, draw the
bit back often to remove shavings.
14. Before leaving the drill press for any amount of time, the power should be turned off and
machine should be at a complete stop.
15. In any unsafe condition or movement is observed on the drill press, report it to the
instructor immediately.
16. Leave the drill press cleaned and tidy at all times.
Self-Check-3 Written Test
Directions I: Choose the best answer for the following questions. (2 point each)
1_____is the process of producing round hole in a solid material or enlarging existing holes.
a. Reaming b. Drilling c. Honing d. Filling
2. Which one of the following is a finishing process of drilled holes?
a. Honing b. filling c. Sawing d. Drilling
3 ____is the process of enlarging a hole that has already been drilled.
a. Drilling b. Honing c. Boring d. None
Directions II: Answerall the questions listed below. (4 points)
1. Write the steps to provide drilling operation. (2 points)
2. Write the importance of PPE in the work shop. (2 points)

Score = ___________
Rating: ____________
Name: _________________________ Date: _______________
OPERATION SHEET 3.1: -Perform hand tool operations

Purpose: filing, checking, marking, punching, cutting, drilling, tapping, reaming, and
finishing
Instruction: Use the given figure below (Figure below) the tools and equipment lay out and
mark on the work piece. For this operation you have given 2Hour and you are expected to
operation.
1. Steel Rule,
2. Scriber
3. Hammer
4. Center paunch
5. Different size of drill bit
6. Bench drill machine
7. Work piece 60*98
8. Different size of taps and tap wrench
 Precautions: Measure at least three times before punching
1. Hold the mild steel flat piece of 50 x 50 x 6mm between the jaws of the bench vice.
2. Start filing on first flat surface after removing the rust with the tip of flat file.
3. Straight filing is continued till the surface is formed perfectly flat.
4. Check the straightness by using straight edge.
5. Turn to the adjacent side which is narrow and make it straight, flat and 90° with flat surface
prepared.
6. File the next adjacent side and make it flat and perpendicular to both flat surface and first
narrow side which is already prepared.
7. Apply chalk on the finished flat surface and mark dimensions
8. Use surface plate V-block and vernier height gauge for marking.
9. Marked lines are punched by using dot punch and ball peen hammer.
10. File to correct dimensions in length and width and check the dimensions using an outside
caliper and steel rule.
11. Mark two curve on the edge of M.S flat using divider.
12. Make curve using round file.
 Quality Criteria: the given drilling operation measuring with 0.2 mm accuracy
Name: _____________________________ Date: ________________
Task 1. Lay out mark feature

Task 2. Punching
Task 3. Cutting
Task 4. Drilling
Task 5. Reaming,
Task 6. Tapping
Task 7. Checking
Task 8. Finishing
Unit Four: - Cut threads using tap and stock and die
 Cutting thread and fit gage.
 Sequence of tapping.
 Perform and apply thread cutting operations.
This guide will also assist you to attain the learning outcomes stated in theabove coverage.
 Cutting thread and fit gage.
 Perform the sequence of tapping.
 Perform and apply thread cutting operations.
Unit Four: Cutting thread and fit gage system
Threads may be cut internally using a tap externally using a die. The proper selection and use of
these threading tools is an important phase of machine shop work.
Dies: - are made either of high-carbon steel or of high-speed steel. Unlike taps, dies are used for
cutting external (male) threads. There are three types (Figure blow). The circular split die is a
circular piece with a split across one of the flutes. The split is provided to enable small
adjustments to be made, using three set screws in the stock. The half die comprises two loose
pieces, which are held in the stock. There is a small screw on the stock for adjustment. The die
nut has a hexagonal body. This type, strictly speaking, does not cut new threads but is used to
'clean up' threads that are damaged.
4.1. Cutting thread and fit gage
Thread cutting is a process for generating a thread. It's used for the production of threads on the
outer surface of a cylinder or on the inner surface of a bore. Tools used for thread cutting are the
thread cutting die, the screw tab or for serial production a process called cold or hot forming.
Thread cutting (threading) is a method to create helical patterns on a cylindrical or conical object
to mate it with other parts. The friction is enough to prevent a rotational movement. Threaded
components are also commonly used to convert a linear movement to rotation, or vice versa.
Two cutting tools are normally used for thread cutting; taps and dies. Dies creates external
threads, and taps are for internal threads.
Cutting the external threads is known as threading or in some cases chasing, meanwhile cutting
internal threads is called tapping.
Figure 4. 1Thread Cutting
4.2. Perform the Sequence of tapping
Tapping is the process of cutting a thread inside a hole so that a cap screw or bolt can be
threaded into the hole. Also, it is used to make thread on nuts. Tapping can be done on the lathe
by power feed or by hand. Regardless of the method, the hole must be drilled with the proper
size tap drill and chamfered at the end.
Taps and dies
Screwing is a temporary method of fastening parts together. Methods for cutting screw threads
include the use of the center lathe. For bench work, however, taps and dies are used.
 Taps
These are the tools used for cutting internal (female) threads. They are made of high-carbon steel
or high-speed steel. The tap has a shank with a square end to take the tap wrench or holder. The
shank is smaller than the threaded portion. The tap has four rows of threads, cutting edges or
teeth, which suit a particular thread form. They perform the cutting action. The grooves between
the cutting edges are called flutes. They allow waste material (chippings) to escape. They also
allow cutting oil into the work.
Figure 4. 2Taps and dies
The procedure for cutting external threads is as follows:
1. Square the end of the work and chamfer it (using a file, grinding machine or center
lathe) for an easy start.
2. Grip the die, held in the stock, firmly and squarely on the work.
3. Turn clockwise, about a quarter-turn, and ease back to remove chippings.
4. Apply a good supply of oil (lubricant).
5. Make adjustments of the screws after making a full cut until the depth required is
achieved.
Care and maintenance are important:
1. Do not use either the stock or the die as a hammer; the threads may be broken.
2. Remove the die from the stock after every thread cutting, clean them and pack them
into their boxes.
3. Use plenty of oil during cutting to reduce friction.
Tap Drill Size
Before a tap is used, the hole must be drilled to the correct tap drill size. This is the drill size that
would leave the proper amount of material in the hole for a tap to cut a thread. When a chart is
not available, the tap drill size for the ISO (International Standards Organization) thread can be
found easily by applying this simple formula:
TDS = tap drill size
TDS = M - P M = metric diameter of the tap
P = pitch of the thread in millimeters
Hand Tap
A tap is a cutting tool used to cut internal threads. Normally it‟s made of high-speed steel (HSS).
Hand taps are usually made in sets of three, because it is better to distribute all the cutting work
during the thread−process to three taps.
No. 1 (taper) tap: 1 ring on shank
No. 2 (plug) tap: 2 rings on shank
No. 3 (bottoming) tap: without ring
The most common taps have two or three flutes in order to form the cutting edges, transport the
chips out of the hole and give way for the lubricant. The end of the tap is square so that a tap
wrench can be used to turn it into a hole.
Tapping a Hole
Before a tap is used, a hole must be drilled in the work piece to the correct tap drill size. The tap
drill size (T.D.S.) is the size of the drill that should be used to leave the proper amount of
material in the hole for a tap to cut threads. Then countersink both sides of the hole.
Figure 4. 3Drill, Countersink and tapping a hole
Working Steps for Hand Tapping
1. Select the correct size and type of tap for the job (blind hole or through hole).
2. Select the correct tap wrench for the size being used.
3. Use a suitable cutting fluid (No cutting fluid for brass or cast iron).
4. Place the tap in the hole as near to vertical as possible.
5. Apply equal down pressure on both handles, and turn the tap clockwise (for right-hand
thread) for about two turns.
6. Remove the tap wrench and check the tap for squareness. Check at two positions 90
degree to each other.
7. If the tap has not entered squarely, remove it from the hole and restart it by applying
slight pressure in the direction from which the tap leans. Be careful not to exert too much
pressure inthe straightening process, otherwise the tap may be broken.
8. Turn the tap clockwise one−half turn and then turn it backward about one−quarter of a
turn to break the chip. This must be done with a steady motion to avoid breaking the tap.
Figure 4. 4Tapping operation
Drill size
Threading Dies
A threading die is used to cut external threads on round work pieces. The most common
threading dies are the adjustable and solid types. The round adjustable die is split on one side and
can be adjusted to cut slightly over or undersized threads. It is mounted in a die stock, which has
two handles for turning the dies onto the work. The solid die, cannot be adjusted and generally
used for recutting damaged or oversized threads. Solid dies are turned onto the thread with a
special diestock, or adjustable wrench.
Figure 4. 5Die and its operation
Thread with a Hand Die Working Steps
The threading process requires the machinist to work carefully to produce usable parts and avoid
damage. The following describes the procedure to be used.
1. Chamfer the end of the work piece with a file or on the grinder. Consider that a 3/4”
thread requires a bolt with an outside diameter of 3/4”.
2. Fasten the work piece securely in a vise. Hold small diameter work short to prevent it
from bending.
3. Select the proper die and die stock.
4. Lubricate the tapered end of the die with a suitable cutting lubricant.
5. Place the tapered end of the die squarely on the work piece.
6. Apply down pressure on both die stock handles and turn clockwise several turns.
7. Check the die to see if it has started squarely with the work.
8. If it is not square, remove the die from the work piece and restart it squarely, applying
slight pressure while the die is being turned.
9. Turn the die forward one turn, and then reverse it approximately one half of a turn to
break the chip.
10. Apply cutting fluid frequently during the threading process.
Directions: Answer the following questions. (2 points)

1. Which one of the following is used for cutting external threads?
a. Tap b. drill bit c. Die d. saw
2. Write procedures for cutting external threads. (4 points)
Note: Satisfactory rating – 3 points Unsatisfactory - below 3 points

Score = ___________
Rating: ____________
Name: _________________________ Date: _______________
Unit Five: - Off-hand grind cutting tools
 Honing and cutting edges
 Sharpening cutter
 Cools Cutter.
 Personal protective devices
 Apply honing and cutting edges and free of burrs.
 Apply sharpening cutter.
 Apply cutter cooling.
 Apply personal protective devices
Unit Five: Off-hand grind cutting tools
5.1. Apply honing and cutting edges and free of burrs.
Honing is the abrading process done mostly for finishing round holed Produced by drilling,
reaming or boringly means of bonded abrasive stones Called „hones”. Honing is a machining
process and is used to remove metal up to 0.25 mm. The surface roughness value can be
maintained between 0.025and 0.4 microns. So honing is used to correct some out of roundness,
tapers, tool marks and axial distortion.
Honing is a finishing process performed by a honing tool, which contains a set of three to a
dozen andmore bonded abrasive sticks. The sticks are equally spaced about the periphery of the
honing tool. Theyare held against the work surface with controlled light pressure, usually
exercised by small springs. Thehoning tool is given a complex rotational and oscillatory axial
motion, which combine to produce acrosshatched lay pattern of very low surface roughness:
Figure 5. 1Honing
Honing is an abrasive machining process that produces a precision surface on a metal workpiece
by scrubbing an abrasive grinding stone or grinding wheel against it along a controlled path.
Honing is primarily used to improve the geometric form of a surface, but can also improve the
surface finish.
Figure 5. 2Edge honing
Edge honing, also referred to as edge rounding or radiusing, stabilizes the cutting edge of cutting
tools made from brittle materials such as carbide to greatly extend their flake and wear
resistance.
Burr-free: -
Depending on the process, burrs, flaking and particles on edges and surfaces can occur during
production. They interfere with the usability of parts and can even make them unusable.
Polegate processes remove them reliably – regardless of the geometry of the component.
Figure 5. 3Burr Free
5.2. Apply sharpening cutter
Sharpening cutters
The word sharpening is usually used for the final finishing of edge tools. Like all edge tools, a
drill bit needs to have the right shape before you can start to sharpen it. Creating the initial shape
often means that quite a lot of steel needs to be re-moved when for example, you change the
point angle of a drill or you shape a broken or heavily worn drill. Once the geometry of the point
is established, you maintain the sharpness by sharpening. With the Tomek system you can
exactly replicate an existing shape and therefore you just need to touch up the edges.Shaping and
Sharpening
Edge tools need to be sharp to work efficiently. The bevels of a sharp edge tool end in a uniform
tip. After a period of use the tip becomes rounded and the edge is no longer sharp.
You can sharpen tools with a bench stone or, in the case of knives, with a sharpening steel. This
means that you work on the very tip of the bevel and the tool is sharp again. When sharpening
with a steel or a bench stone, a very limited amount of steel is removed.
After several sharpening or honing, the edge angle becomes too wide and the tool must be re-
shaped. Sooner or later all edge tools need to be re-shaped and this is done by grinding on a
grindstone or a grinding wheel. When only a limited amount of steel is removed this operation is
also called sharpening.
Grinding means that so much steel is removed from the tool that the edge is restored to the
original angle or altered on purpose to a new angle. The shape of the tool can also be changed
according to your requirements.
Tool Sharpening
For some tools it is very important to keep them sharp at all times. Common tools, such as
scribers, center punch, chisels, drill bits, tool bits for lathe machine needs to be sharpened every
time you feel that they do not cut well.
 Sharpening Scriber and Center Punch
1. Scriber and center punch should be ground in the position as shown beside.
2. Use the tool rest to rest your hands while bringing the tool in the right position.
3. Rotate the tool while grinding.
4. Cool the tool down from time to time.
5. Do not overheat the metal.
Figure 5. 4Punches and their grinding angles
Sharpening Chisel
 Use the tool rest to rest your hands while bringing the tool in the right position.
 Use the whole grinding wheel while grinding. Move with the tool regularly from
the left to the right side and back.
 Cool the tool down from time to time.
 Do not overheat the metal.
 Grind the chisel−point parallel and straight. See also the pictures below.
5.3. Apply cutter cooling.
Cooling cutting tools and tool holders during the machining process is a must in terms of process
reliability. The method of cooling is crucial for the quality of the machining results and the tool
life.
The critical functions of coolant in the machining process include: Reducing and removing the
heat build-up in the cutting zone and workpiece. Provides lubrication to reduce friction between
the tool and removal of the chips.
Grinding is a metal cutting operation like any other process of machining removing metal in
comparatively smaller volume. The cutting tool used is an abrasive wheel having many numbers
of cutting edges. The machine on which grinding the operation is performed is called a grinding
machine.
Grinding is done to obtain very high dimensional accuracy and better appearance. The accuracy
of grinding process is 0.000025mm. The amount of material removed from the work is very less.
Grinding machines are made in a variety of types and sizes, depending upon the class of work
for which they are to be used.
Pedestal grinders are used to sharpen high-speed steel cutting tools used on the lathes and milling
machines, debur, or used to remove surface imperfections and to work extremely hard materials.
Procedure for Grinding:
1. Examine the grinder to see that the tool rest is set at the required height, iswithin 1/8 if an
inch to the face of the wheel, and is securely fastened in thisposition (Figure 2).Tongue
guard is to be set at ¼” from the wheel (figure 1).
2. Adjust safety glass shields on the grinder to permit clear vision of the part to be ground and
still protect the oprator from flying particles.
CAUTION: Always wear safety glasses and/or face shield when using
Figure 5. 5Position of the tool rest
3. Start the grinder.

CAUTION: Stand to one side of the wheel when operating the grinder.
4. Hold the work in one hand, and steady it with the other. Place the work on the tool rest; then
guide it against the face of the revolving wheel and apply enough pressure togrind,
depending upon the hardness of the material and the wheel itself.
Note: Support the work on the tool rest to steady it when grinding, except in the case of the
small tool bits which can be guided better by supporting them with the fingers or with a hand
resting on the tool rest.
5. Cool work in a water pot as it becomes heated from grinding, especially the small hardened
tools that would lose their temper if overheated. Twist drills should not be cooled by dipping
in water, as it may cause cracking. Grind the job to the required shape or size by moving the
work back and forth across the face of the wheel. This will prevent wearing a groove into
the wheel and will result in a flatter surface on the work.
CAUTION: Keep fingers away from the revolving wheel, especially when grinding small
pieces. Also make sure that the tool rest is close enough to the wheel to prevent the work from
slipping into the space between the two.
Note: Remove as much metal by rough grinding as is possible; then use the finer wheel for
finishing.
Do not grind on the side of the wheel except when absolutely necessary, and then with only light
pressure.
6. Check work with a gage or other measuring tool.
7. Stop grinder.
Sharpening the twist drill bit
To get a good performance from a drill bit the sharpening must be done correctly, this means that
all the angles and the lengths of the edges must be exactly as established and will not occur
during the grinding edge of the material structural modifications.
Drill bits are cutting tools used to create cylindrical holes, almost always of circular cross-
section. Bits are held in a tool called a drill, which rotates them and provides torque and axial
force to create the hole. There are several types of drill bits are used currently such as Spade, lip
and spur (brad point), masonry bit and twist drill bits. Our focused will be on standard size Twist
Drill Bits. Twist drills become dull and must be sharpened.
To execute the correct sharpening are therefore required special equipment and dedicated
grinding machines.
The geometric elements to consider are:
 Point angle
 Lip relief angle
 Length of cutting edges
Figure 5. 6Off-hand method of drill
5.4. Apply personal protective devices
Personal protective equipment (PPE) refers to protective clothing, helmets, gloves, face shields,
goggles, facemasks and/or respirators or other equipment designed to protect the wearer from
injury or the spread of infection or illness.
Figure 5. 7Personal Protective Equipment
Directions: Answer all the questions listed below. (2 points):

1. Which one of the following is the geometric element to consider for twist drill bit?
A) Shape B) lip relief angle C) point angle D) B & C
2. Always keep hands at a safe distance from moving machine parts.
A. False B. True
3. A utility grinder mounted on its own freestanding base is called?
A. freestanding grinder B. An upright grinder
C. A post grinder D. A pedestal grinder
4. The main purpose of a grinding wheel guard is to?
A. Limit grinding to a small part of the wheel
B. Protect the operator from flying sparks
C. Prevent pieces from being thrown from a broken grinding wheel
D. Prevent the work piece from being pulled into the grinding wheel
E. All of the above
5. Which one of the following is a finishing process of drilled holes?
b. Honing b. filling c. Sawing d. Drilling
6. ____is the process of enlarging a hole that has already been drilled.
b. Drilling b. Honing c. Boring d. None
Note: Satisfactory rating – 6 points Unsatisfactory - below 6 points

You can ask you teacher for the copy of the correct answers
Name: _________________________ Date: _______________
OPERATION SHEET 5.1: -Perform hand tool operations

Purpose: filing, checking, marking, punching, cutting, drilling, tapping, reaming, and finishing
Instruction:Perform the following tasks using necessary bench work operations.
1. Measure the stock using proper tools.

2. Lay out according to the drawing.
3. Cut within the given dimension.
4. File and make it smooth.
5. Drill according to given dimension
6. For this operation you have given 2Hour and you are expected to operation.
1. Drill bit
2. Center punch
Precautions: Measure at least three times before punching
Adjust safety glass shields on the grinder to permit clear vision of the part
Step1- To be ground and still protect the operator from flying particles.
Step 2- Dress grinding wheel with dressing tool.
Step 3- Hold drill bit against face of wheel at 59 0angles on cutting lip.
Step 4- Carry drill bit up the wheel face by dropping end and rotating very slightly in a
clockwise direction.
Step5- Make slow deliberate strokes, the full width of the cutting lip.
Step 6- Do not lower cutting lip below the horizontal position as this will round the cutting edge.
Step 7- When one lip is ground, rotate the drill one half turn and grind the other lip.
Step 8- Use tool gauge to check equal lengths of lips, 590 angle cutting lip and 12-150 lip
clearance.
Step 9- Test bit by boring hole in mild steel plate.
Step 10-Stop while drilling, turn drill press in reverse direction to release drill bit from hole.
Step 11- Make grinding corrections on drill bit as indicated by hole.
Step 12- Submit drill bit and metal for evaluation.
Figure given for operation sheet 5.1A
Name: _____________________________ Date: ________________

Task 1- Perform center punch grinding operation with its correct point angle following
safetyregulation.
Task 2- Sharpen 12mm diameter twist drill bit by using bench type grinder with its
appropriateangle.
Task 3- Perform the following tasks using necessary bench work operations.
Reference:
1. Book: Manufacturing Processes by J. P. Kaushish (PHI).
2. Book: Manufacturing Science by M. I. Haque and S. Khan (PHI)
3. http://www.simondssaw.com/handfiles/hand%20files%20publications/simonds-
file%20catalog.pdf
4. https://www.bing.com
5. Workshop Technology Parts 1, 2 and 3, Author: WAJ Chapman Publisher: London: Edward
Arnold, 1972
6. Manufacturing Technology Author: G Bram & C Downs Publisher: London: MacMillan,
1975
7. http://ecoursesonline.iasri.res.in/mod/page/view.php?id=3783
8. https://www.youtube.com/watch?v=VW6a1TIqjxA
9. https://www.youtube.com/watch?v=J5_AYavfIUM
10. http://ecoursesonline.iasri.res.in/mod/page/view.php?id=3783
11. https://www.osha.gov/personal-protective-equipment
12. https://www.youtube.com/watch?v=VW6a1TIqjxA
13. https://www.youtube.com/watch?v=zxvbKlur96A
14. CHEA (2001). Glossary of Key Terms in Quality Assurance and
Accreditation: http://www.chea.org/international/inter_glossary01.html.
15. ENQA (2005). Standards and Guidelines for Quality Assurance in the European
Higher Education Area (ESG): Helsinki, ENQA, originally available
at http://www.enqa.eu/index.php/home/esg/, accessed 3 January 2017.
16. Guo, Sheng; Yang, Tao; Gao, Wei; Zhang, Chen (2018). A Novel Fault Diagnosis Method
for Rotating Machinery Based on a Convolution Neural
Network". Sensors. 18 (5):1429. doi:10.3390/s18051429. PMC 5982639. PMID 29734704.
17. Hoang, Duy-Tang; Kang, Hee-Jun (March 2018). Rolling element bearing fault diagnosis
using convolutional neural network and vibration image; Cognitive Systems Research. 53:
42–50. doi:10.1016/j.cogsys.2018.03.002.
Participants of this TTLM (training material) preparation
No Name
(Level)
Qualification
Field of Study
Institution
Organization/
number
Mobile
E-mail
1 Fikadu Girma BSC Construction EthioPoly 0975284843 Fike
Technology Technic girma13@
College Gmail.com
2 Yonannes MSC Construction Sebet Poly 0913328144 Yohannese
Tadesse Technology Technic 44@gmail.
College com
3 Abdulmenan MSC Urban Planning and General 0921779179 Abmuha1
Muhaba Development wingate @gmail.co
poly m
technic
college
4 Lakew Girma BSC Construction a/mpoly 0916852674 Lakewgir8
management tecnic @gmail.co
college m
5 Jamel Abdulahi BSC Construction 0921228986 jemalabdul
technology ahi@gmail.
com

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M04 Bench Works

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FINISHING CONSTRUCTION

Based on March, 2022 Curriculum Version 1

Module Title: - PERFORMING BENCH WORK

Prepared by: Ministry of Labour and Skill

figure 2. 1 bench vice................................................................................................................................................... 40

figure 4. 1 thread cutting.............................................................................................................................................. 77

1. 1.1. Clamping tools

Figure 1. 1Bench vice

Figure 1. 2Hand vice

Figure 1. 3pin vice

Figure 1. 4Pipe vice

Figure 1. 6Combination square

Figure 1. 8Center punch

Figure 1. 9Steel rules

Figure 1. 10Vernier caliper

Figure 1. 11Outside calipers

b. Inside calipers, as shown in are used for measuring internal dimensions

Figure 1. 12Inside calipers

1.1.3. Cutting tools

Figure 1. 14Bow saw

Figure 1. 16Flat chisel

Figure 1. 17Pointed chisel

1.1.5. Drill and lap holes

Figure 1. 21Die and die stock

Figure 1. 22Portable drill machines

Figure 1. 23Try square

Figure 1. 24Datum edges

Figure 1. 25Face edges

Figure 1.26 Proper body position when chipping

Figure 1. 27Types of chisels

Figure 1. 28Flat file and its parts.

Figure 1. 29Methods of filing

Types of files based on their shapes:

Figure 1. 30Types of files based on shapes.

Figure 1. 31Using half round scraper

1.4. Apply Safety procedures and OHS

1.4.1. Use Personal Protective Devices

General safety rules are established for three good reasons: -

 Wear approved safety glasses or goggles at all times.

1.4.2.2. Bench work and fitting shop safety:

1.4.2.3. Machine and tool safety

 Do no keep working tools at the edge of the table.

Note: Satisfactory rating - 16 points Unsatisfactory - below 16 points

Name: _________________________ Date: _______________

Figure show operation sheet 1.1A

Name: _____________________________ Date: ________________

Time started: ________________________ Time finished: ________________

Task 1:Marking out

 Cutting, chipping, and work pieces

 Replace broken or dull hacksaw blades

 Bench work operations

 Cutting, chipping, and work pieces

 Replace broken or dull hacksaw blades

 Performbench work operations

 Speak up and be involved in safety planning.

 Continually cultivate a safety standard.

Figure 2. 1 Bench vice

Figure 2. 2Machine vice

Figure 2. 4Rolling: Tool turns

Figure 2. 5Turning: Workpiece turns

Figure 2. 6Teeth setting

a = clearance b = cutting angle

forces on a saw blade:

Figure 2. 7Cut with a Hacksaw

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