Chapter 4

Basic bench working

operations
 introduction
• Industrial Tool Usage
• Two categories:
– - Hand tools
– - Machine tools

• Bench work includes operations of

inspecting, fitting, and assembling using
hand tools.
 introduction
• The term bench work refers to the
production of components by hand on the
bench.
• Machine tools are capable of producing
work at a faster rate, but there are
occasions when components are
processed at the bench.
 Bench work
• Using hand tools in the workshop still has a place
in modern industry, although the large range of
machine tools are available.
• Bench work is too slow and costly for batch and
flow line production, but it has a place in the
making of prototypes and development projects.
• Powered hand tools is used, not only to reduce
fatigue but also to increase the speed of the
operation and so reduce the cost.
 Advantages of bench work

• Hand tools are relatively cheap.

• Small and weak components may not be strong
enough to withstand the clamping and
machining forces, hand processes will then be
the only choice.
• Hand tools are more easily maintained
compared with machine tool cutters.
• No capital investment in costly plant is required.
 Disadvantages of bench work
• Compared with machining, the rate of
material removal by hand tools is limited and
production using hand tools is relatively slow.
 The bench work classification

• The bench work can be classified into three basic

processes.
1. Cutting processes (shears, chisels, and saws).
2. Drilling processes ( Punches, and threading).
3. Finish work (files and scrapers).
Cutting processes
• Hand shears.
Used to cut
sheets with
thickness not
exceed 1mm.
 Cutting processes
• Chipping: It is
the operation
employed for
removing the
excess metal by
means of cold
chisels.
 Cutting processes

• Sawing :
The hacksaw is used to
cut metal.
• The blade specifications
are;
1. Dimensions
2. Materials
3. Pitch = (1/ no. of teeth
in cm.)
 CUTTING TOOLS:
DRILL:

A drill is a tool for making holes in a

metal. It usually consists of two cutting
edges set at an angle with the axis.

•The following are the part of the drill bit:

1.Length,
2. Neck,
3. Shank,
4. Lip,
5. Lip angle,
6. Heel
 Threading
The hand operated taps are employed for cutting internal threads in
cylindrical holes or for cleaning damaged threads in similar parts.
Internal threads
Internal threads
 Threading
Dies are used to cut threads on a round bar of a metal,
such as the threads on a bolt(External thread).
Countersink Tool & Counterbore Tool
 Finishing processes
Filing :
• Similar to the saw
blades, most of the files
have their teeth pointing
away from the operator
such that they cut during
the forward stroke.
• It should always be more
in a perfect horizontal
plane for obtaining a
truly plane and smooth
surface.
 Marking
• It is the basic and one of the most important
operations in bench work.
• Lines can easily be marked with the help of a try
square. Circles and arcs on flat surfaces are
inscribed by means of dividers.
• Using the scriber to draw Lines with the help of a
try square. Circles and arcs on flat surfaces are
inscribed by means of dividers.
• Indentations on the surface are made, by using the
center punch and hammer
 STEEL RULE:
• On one of the flat faces,
graduations are marked in
inches and centimeters. The
least count is1mm.It is used
to set out dimensions
MARKING AND MEASURING TOOLS

STEEL RULE
MARKING AND MEASURING TOOLS
MARKING AND MEASURING TOOLS

SCRIBER:

A scriber is a slender steel tool, used to scribe

or mark lines on metal work pieces.
MARKING AND MEASURING TOOLS
DOT PUNCH:
This is used to lightly indent along the layout lines, to locate center of holes
and to provide a small center mark for divider point, etc. For this purpose,
the punch is ground to a conical point having 60 degrees included angle.

CENTRE PUNCH:
This is similar to the dot punch, except that it is ground to a conical point
having 90 degrees included angle. It is used to mark the location of the
holes to be drilled.
MARKING AND MEASURING TOOLS
PRICK PUNCH:

It is sharply pointed tool. The tapered point of punch has an

angle of usually 40 degrees. it is used to make small punch
marks on layout lines.
 MARKING AND MEASURING TOOLS

DIVIDER:

It has two straight legs sharpened at one end,

hinged at other end. This is used for marking
circles, arcs, laying out perpendicular lines,
bisecting lines, etc.
MARKING AND MEASURING TOOLS
CALIPER:

A caliper is used to transfer and compare dimensions from

one object to another or from a part to a scale.

INSIDE CALIPER:

These are also of two types ordinary, spring type. It has two
steel legs, which are bent outward. These are used to set
internal dimensions, to transfer them to work.

OUT SIDE CALIPER:

These are also of two types ordinary, spring type. It has two
steel legs that are bent inward. These are used to measure
the out side dimensions of round objects.
MARKING AND MEASURING TOOLS
 Hard Faced Hammers
• Ball Peen
– Peen: smaller, rounded
end
– Used in riveting or
peening operations
• Variety of sizes
 Bench Vise
Jaw caps made of brass,

aluminum, or copper to
protect the work surface
from being damaged

Solid or swivel base

 Regular Screwdrivers
• Tip for use with slotted-type screw
• Manufactured in various sizes
– To suit various-sized slots in heads of
fasteners

Shop Tools and Techniques 29

 Phillips Screwdrivers
• Tip for use with Phillips-type screws

Shop Tools and Techniques 30

 Torx Screwdrivers
•  shaped tip for use with Torx-type
recessed screw heads
• Manufactured in assorted sizes
– To suit various-sized recesses in heads
of fasteners

Shop Tools and Techniques 31

Square Head Screwdrivers
• Tip for use with Square-type screw
heads
• Manufactured in assorted sizes
– To suit various-sized recesses in heads
of fasteners

Shop Tools and Techniques 32

 Open-End Wrenches
• Single-ended or double-ended
• Openings usually offset at 15º angle
– Permits turning nut or bolt head in
limited spaces by "flopping" wrench
– Double-ended have different-size
opening at each end

Shop Tools and Techniques 33

 Box-End Wrenches
• Completely surround nut and useful in
close quarters where only small rotation
of nut can be obtained at one time
• Box end has 4, 6, or 12 precisely cut
notches around inside face
– Notches fit closely over points on outside
of nut
• Have different sizes at each end

Shop Tools and Techniques 34

 Sockets

Six Point Eight Point Twelve Point

 Socket Accessories

Universal Joints

Various
Adapters
 Socket Drivers
Rachets
Allen Setscrew Wrenches
 Types of Pliers
• Side-cutting pliers
– Used mainly for cutting, gripping, and
bending of small diameter (1/8 in. or less)
rods or wires