Wolayta Sodo University

College of Engineering
MECHANICAL ENGINEERING
Course Titile:Work shop practice
Safety in the work Shop

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 What is safety?
• Safety is the state of being "safe" , the condition of being
protected against physical, social, spiritual, financial,
political, emotional, occupational, psychological,
educational or other types or consequences of failure,
damage, error, accidents, harm or any other event which
could be considered non-desirable. This can take the form
of being protected from the event or from exposure to
something that causes health or economical losses. It can
include protection of people or of possessions.
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 Safety on the Job
• Develop safe work habits
• Be neat, tidy and dress for job being performed
• Develop responsibility for personal safety and safety of
fellow workers
• Think and work safely at all times
Safety in the Shop
• Divided into two broad categories
– Practices that will prevent injury to workers
– Practices that will prevent damage to machines& equipment
• Other considerations
– Proper housekeeping
– Safe work practices
– Fire prevention 4
 Chapter I
Bench work
Definition: The term bench work relates to
work performed by the mechanic at the
machinist‟s bench with hand tools rather than
machine tools.
 Operations that can be performed at the
bench may be classed as follows:
 Chipping
 Sawing
 Filing
 Scraping
 The Bench and Bench Tools
 The prime requirements for a machinist‟s bench
are that it should be strong, rigid, and of the
proper width and height that the work can be
performed conveniently.
Correct height is important, and this will depend
on the. h vise type used, that is, how far its jaws
project above the bench.
 The location of the bench is important. It
should be placed where there is plenty of light.
A great variety of tools is not necessary for
bench work.
They may be divided into a few
general classes:
Vises
Hammers
 Chisels
 Hacksaws
 Files
 Scrapers
 VISE
By definition, a vise is a clamping device, usually consisting of two jaws
that close with a screw or a lever, that is commonly attachable to a
workbench; it is used for holding a piece of work firmly.
 Use:- For holding work pieces during filing, sawing, threading,
drilling and other such operations.

Fixed jaw
 Bench vice (machinist vice):- Bench
Jaw Plate vice is made of Cast iron or Cast steel. The
Handle size of vice is stated by the width of jaw.
To hold a finished work use soft jaw (Vice
clamp) made of Aluminium over the
regular hard jaw. This will protect the
Base
Movable jaw
work surface from damage. This vice is
fitted directly on a work bench. So it is
 VISE
By definition, a vise is a clamping device, usually consisting of two
jaws that close with a screw or a lever, that is commonly attachable
to a workbench; it is used for holding a piece of work firmly.
 Use:- For holding work pieces during filing, sawing, threading,
drilling and other such operations.
Bench vise (machinist vise):- Bench vise
is made of Cast iron or Cast steel. The size
Fixed jaw
Jaw Plate of vise is stated by the width of jaw. To
Handle hold a finished work use soft jaw (Vise
clamp) made of Aluminium over the
regular hard jaw. This will protect the work
Base
Movable jaw surface from damage. This vise is fitted
directly on a work bench. So it is known as
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10
 Handle Pipe vise:- A Pipe vise is used for
Spindle
Holding round section of metal,
Upper jaw
tubes and pipes. In this vise, the
Lower jaw
screw is vertical and movable. The
Base
jaw works vertically. The pipe vise
grips the work at four points on its
surface. The parts of pipe vise are
Upper jaw, Lower jaw, Spindle,
Handle and Base.
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 Vise
• Mounted on a workbench
• Used to hold parts during cutting, drilling, hammering,
and pressing operations
• Vise caps or wood blocks should be used when mounting
precision parts in a vise
– vise caps are soft metal jaw covers

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 Rules for Vise Use
• Never hammer on a vise handle to tighten or loosen the
vise
• Keep the moving parts of the vise clean and oiled
• Wear safety glasses when using a vise
• Be careful not to damage parts in the jaws of a vise

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 QUESTIONS
• What are the parts of Vise ?
• Which material is used in Bench Vise ?
• What are the types of Vise ?
• What is the use of Bench Vise ?
• What are the difference between Bench Vise & Pipe
Vise ?

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 HAMMER
 Use:- Hammer is used for striking purpose while;
Punching, bending, straightening, chipping, forging,
riveting.
 Material:- Drop forged Carbon steel, Wood, Nylon, Lead.

Ball Peen Hammer:- The parts of a

hammer as per its head are;
1. Face:- The face is the striking portion.
Slight convexity is given to it to avoid
FACE digging of the edge.

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 2. Peen:- The peen is the other end of
PEEN the end. It is used for shaping and
forming work like riveting and bending.
Cheek The peen is of different shapes like ball
peen, cross peen or straight peen.

3. Cheek:- The cheek is the middle portion of the

hammer-head. The weight of the hammer is stamped
here. This portion of the hammer head is left soft.

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 4. Eye hole:- A eye hole is meant for
fixing the handle. It is a shaped to fit
the handle rigidly. The wedges fix the
handle in the eye hole.
Handle
5.Handle:- A handle is meant for
giving leverage during striking. It is
Eye hole made of wood.

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 Types of Hammer
Hammers find frequent use in benchwork. Machinist‟s
hammers may be classed with respect to the peen as
follows:
 Ball peen
 Straight peen
 Cross peen
By definition, peening is the operation of hammering
metal to indent or compress it in order to expand or stretch
that portion of the metal adjacent to the indentation.
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Ball Peen:- This hammer head is used most
commonly for general striking purpose. It is
used for forming rivet head and for forging
purpose. Shape of its head is ball hence it is
called ball peen hammer. It is available in 0.11
to 0.91 Kg.

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Cross Peen:- This hammer head is formed
at 90º to the direction of its handle. It is
used for making channel, „V‟ groove, to
make inside corner of the jobs and
expanding metal sheets. It is available in
0.22 to 0.91 Kg.

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Straight Peen:- This hammer head is
formed in straight line to the direction of
its handle. It is also used for making
channel, „V‟ groove, to make inside
corner of the jobs and expanding metal
sheets. It is available in 0.11 to 0.91 Kg.

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 Hammer Safety

Do‟s Don‟ts
 Always wear safety  DO NOT strike steel, concrete,
glasses!!!!! stone, or any hard metal object
with a steel hammer!
 Make sure handle fits tightly
on the head  NEVER strike a hammer against
another hammer!
 Only use hammer for its
designed purpose  DON‟T use a hammer with a
chipped or mushroomed face.
 DON‟T use a hammer with
cracked handle or claw.
 Do not use a hammer if your
hands are oily, greasy or wet.
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 QUESTIONS
• State the different type of Hammer.
• Which material are used in Hammer ?
• What are the parts of Hammer ?

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 HAND SAWING
• Hand sawing is a process of cutting materials to shape
and size using a hand cutting tool known as a hand
hacksaw.

• Sawing is done after measuring and laying out jobs have

been done on the surface of the metal to give the rough
dimension and size of the piece to be made.

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 HACKSAW
The Hacksaw is used for cutting materials, and for cutting
away waste parts of the work. Most Hacksaws are made
from Low Tungsten Steel or Carbon Steel, however the
more expensive blades are made from High Speed Steel.
(Frame )Metal arch

Handle
Tension/Tightening Blade
screw and Nut
Prongs 25
Frame : There are two types of Hacksaw Frame, a fixed
and an adjustable. The fixed frame can only take one
length of Blade, but is more rigid that the adjustable type,
which can take Blades of different lengths
Frame Types
1.Solid Hacksaw frame:-
Only a particular
standard length of blade
can be fitted to this
frame.

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2. Adjustable Hacksaw frame
(Flat):- Different standard
lengths of blades can be
fitted to this frame.

Adjustable Hacksaw
frame (Tubular):- This is
the commonly used type.
It gives a better grip and
control, while sawing.

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Handle : the handle is the part that provides the gripping
surface. It can be simple wooden type or the plastic pistol
grip type. There are three types of Hacksaw Handle used :
(a) File Handle or Straight Handle (b) Pistol Grip Handle

(c) Woodsaw Handle

The most commonly used handles are the File Handle and the Pistol
Grip Handle. 28
The pin supports(prongs)are parts that contain the pins,
which hold the blade.

The tension screw is a wing nut used for tightening the

blade in its place. It is connected to one of the prongs and
has a screw thread to loosen or tighten the blade

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Blade
• The bade is the part with serration cut on its thickness, and performs
the cutting action. it is made from hard materials like high carbon
steel, high speed steels, and low alloy steels like molybdenum and
tungsten alloy steels to comply to the rule that says "the cutting
material must always be harder than the material to be cut”.
• Blade made from high-speed steels are general purpose blades,
whereas those of low alloy steels are used on harder materials.
• Classification of the different type of hacksaw blades can be made on
The way the heat treatment is done
The pitch of the blade
Teeth setting
Teeth type
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 HACKSAW BLADES

Material:- Low alloy steel or High speed steel

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 Heat treatment Types
1. All hard blades :- These blades are hardened to the full
length between the pin holes.
2. Flexible blades :- For these types of blades, only the teeth
are hardened. Because of their flexibility, these blades are
useful for cutting along curved lines.

Pitch
A Blade is classified by the number of teeth per 25mm of
the Blades length. To make the most of a Blade and do less
damage it is good to know what number of teeth should be
used in each circumstance. 32
Teeth per 25mm Use

14 Soft thick materials. Aluminum, Copper, Mild Steel

General use. Soft materials in thin sections. Hard materials

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in thick sections.
Is used for sawing plates up to about 6mm thick and for
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thick walled tubes. Large angle section etc.
Is suitable for sawing small sections, angles very thin
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materials such as thin tubing and sheet metal.

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  Teeth settings

1. Alternate (straight) set:- Alternate

teeth or groups of teeth are
staggered. This arrangement helps
for free cutting, and provides for
good chip clearance.
2. Raker (Staggered) set:- the set type used
for most metal cutting operations. The
teeth are set one tooth is bent to the left,
the next tooth straight and the third
tooth bent to the right
3. Wave set:- In this, the teeth of the
blade are arranged in a wave form.
This type of setting is done blades
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of fine grade and super fine grade.
Teeth type
Hacksaw blades come with three types of teeth shape:
regular tooth,
 hook tooth,
 skipped tooth

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 THE SAWING PROCESS
Selecting the proper blade
Select appropriate blade , the material from made, the
condition, and the pitch must be considered depending
on the material to be cut.
 Select coarse blade to provide a plenty of chip clearance
and cut the work as quickly as possible.
 The blade selected should have at least two teeth in
contact with the section to be cut.

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 Fitting the blade
 Fit the blade in the frame making sure that the teeth of
the saw blade are pointing forward.
 Then tighten the blade using the tightening screw but do
not apply excessive pressure b/s very tight blades will
break so easily. Thumb pressure is enough to tight the
blade.

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 Holding Work to be cut

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 Holding the Hacksaw
Grasp the handle firmly with
your dominant hand(right or
left)and use the other hand to
grip the other end of the saw
frame
To start a hacksaw cut, it is a
good practice to guide the blade
until the cut is well established.
To start an accurate cut, use the
thumb as a guide and saw slowly
with short strokes.
Press down lightly on the forward stroke. Use 50-60 strokes per minute
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  Body position
When sawing, stand with one foot a head of the
other . The left foot should point toward the bench
if you are right handed. The arch of your right foot
should be about 30 cm from the heel of the left
foot and the body should make about a 30 0 angle
with the sawing stroke.
Pressure should be applied on the forward stroke and
released on the return stroke because the blade cuts
only on the forward stroke. Do not permit the teeth
to slip over the metal as this dulls the teeth and may
cause blade breakage. Once the kerf (the slot made
by the blade) is established, the hacksaw should be
moved at about 50 strokes per minute.
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 Sawing Safety
• Keep control of saws by releasing downward pressure at the end of
the stroke.
• Do not use an adjustable blade saw such as a hacksaw, coping saw,
keyhole saw or bow saw, if the blade is not taut.
• Do not use a saw that has dull saw blades.
• Oil saw blades after each use of the saw.
• Keep your hands and fingers away from the saw blade while you are
using the saw.
• Do not carry a saw by the blade.
• When using the hand saw, hold the work piece firmly against the work
table.
• Use the circular saw guard when using the circular saw.
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 FILES AND FILING
 Use:- Files are used to remove excess material from a
workpiece to shape and size, and to improve the surface
finish of the work..
 Material:- High carbon steel.
 Parts of File:-

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 FILE
1. Tip / Point:- The end opposite to tang.
Ferrule

Tang 2. Side(face):- The broad part of the file with teeth cut
Tip / PointLength on its surface.
3. Edge:- The thin part of the file with a single row of
Handle parallel teeth.
 Parts of File:- Shoulder 4. Heel:- The portion of the broad part without teeth.
Heel

5. Shoulder:- The curved part of a file separating tang

Edge from the body.
Side
6. Tang:- The narrow and thin part of a file which fits
into the handle.
7. Handle:- The part fitted to the tang for holding the
file.
8. Ferrule:- a protective metal ring to prevent cracking
of the file.
9. Length:- Length of file is measured from Tip to43 the
end of Shoulder.
 File Characteristics

A file differs from a chisel in that it has a large number of cutting points
instead of a single cutting edge, and the file is driven by hand, rather
than by a hammer. When a file is applied to a metal surface with a
reciprocating motion, the teeth act as small chisels, each removing
small chips. Files have three distinguishing characteristics
 Length—Always measured from the heel to the point, the tang not being
included

 Kind—The shape or style

 Cut—Both the character and the relative degrees of coarseness of the teeth
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45
TYPES OF FILE AS PER CUT
 Single cut file:- It has rows of teeth cut
in one direction across its face. The
teeth are at an angle of 45º -85º to the
centre line depend on the material to be
cut. It can cut chips as wide as the cut
of the file.
 Use:- for filing soft metals like brass,
aluminium, bronze and copper
 Double cut file:- It has two rows of teeth
cut diagonal to each other. The first row of
teeth is known as “over cut” and they are
cut at an angle of 40º-45º. The other cut,
made diagonal to this is known as “up cut”
and is at an angle of 70º -80º.
 Use:- to remove stock faster than the single
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 Rasp cut file:- It has individual,
sharp, pointed teeth in a line.
These files are available only in
half round shape.
Use:- for filing soft materials like
wood, leather, etc.
Curved cut file:- These files have
deeper cutting action. These files are
available only in a flat shape.
Use:- for filing soft material like
aluminium, tin, copper, plastic, etc.
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 TYPES OF FILE AS PER GRADE
Coarseness:- the coarseness of a file is measured by the size of the teeth.
The nearer these teeth are to one another, the smoother will be the file.
The grade is generally mentioned on the file for easy identification. The
grades in the order of roughness are rough, bastard, second cut, smooth cut
and Dade smooth
Rough file:- It is used for removing
rapidly a larger quantity of metal. It is
mostly used for trimming the rough of
soft metal castings.

Bastard file:- It is used in cases

where there is a heavy reduction of
material. 48
Second cut file:- It is used to give a
good finish on metals. It is excellent to
file hard metals. It is used for bringing
the job close to the finishing size.

Smooth file:- It is used to remove

small quantity of material and to
give a good finish.

Dead Smooth file:- It is used to

bring to accurate size with a high
degree of finish. 49
TYPES OF FILE AS PER SHAPE
Flat file:- The Flat File is Double Cut on both faces and
Single Cut on the edges. It tapers slightly towards the
point These files are used for general purpose work. They
are useful for filing and finishing external and internal
surfaces.

Hand file:- The Hand File is parallel in width for its

length. It is Double Cut on both faces, Single Cut on one
edge, but the other edge is blank and called the Safe Edge.
Used for general purposes. They are useful for filing
surfaces which are at right angle to surfaces already
finished.
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 Square file:- The Square File is Double Cut on all
sides. It tapers slightly towards the point. Used for
rectangular slots, square holes and internal corners.
They are used for filling square angles, enlarging the
square slots, making keyways and spline.

Round file:- The Round File is Double cut. It tapers

slightly towards the point. Used for enlarging holes
and internal corners. They are used for filing round
shapes, enlarging the holes, and making fillets.

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 Triangular file:- The Three Square File/ triangular file
is Double Cut on all sides. It tapers slightly towards the
point. It is triangular in section. Used for filing into
internal angles. They are used for filing angles which are
smaller than 90º. They are also used to repair the teeth
of saw.

Half round file:- The Half-Round File is Double Cut on

the flat side and Single Cut on the curved side. It tapers
slightly towards the point in bothe width and thickness.
Used for filing concave surfaces and internal corners.
They are used for filing concave surfaces like bearings
and bushings.

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Knife edge file:- Knife edge file is a double cut
file. They are used for filing narrow slots and
grooves. They are also used to repair the teeth of
saw.

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54
Files
METHODS OF FILING
Straight filing:- In this
method of filing file is run
at an angle of 90º to the
work piece edge. In return
stroke, the file is carried
slightly up to prevent the
teeth to become blunt.
Those jobs whose width is
smaller than the width of
file are filed by this
method.
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Cross filing:- In this method
of filing, the file is run
across the job, which is from
left to right or right to left.
Thus filing is done
diagonally. In this method,
curves in work pieces can be
minimized. Maximum
material can be removed due
to the cross marks of files.
The whole surface of job is
covered in a stroke.

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Draw filing:- In this
method of filing, files are
handled by both hands
on the blade of file. File
is placed at right angle to
the surface of work
piece. This method
doesn‟t remove material
faster but gives better
finish than straight or
cross filing.

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Filing Curves :-There are two types of curves that you may
have to file smooth. With an internal curve, (which you can
see below on the left), you should move the fie across the
work while at the same time moving along the curve. As you
are moving the file along the curve change the angle of the
file as you see in the diagram. For an external curve, (as in the
diagram on the right), run the file along the curve while at the
same time "rocking" the file so that the point of the file rises
as you move forward.

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Position of hand to handle file

Correct position of hands Incorrect position of body

and arms in filing when filing

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 File cleaner

File brush
File card

Particles of metal, or pins, often remain in the teeth of the

file, and they either reduce its cutting qualities or scratch the
work. These particles can be removed by using either a stiff
brush (Figure A) or a file card (B) frequently for cleaning
them from the file. 62
 File Safety Rules
There are several precautions that any good craftsman will
take in caring for his files :
1. Choose the right file for the material and work to be
performed.
2. Keep all files racked and separated so they do not hit
against each other.
3. Keep the files in a dry place - rust will corrode the teeth
points.
4. Keep files clean - tap the end of the file against the bench
after every few strokes, to loosen and clear the filings. Use
the File Card to keep files clean ,a dirty file is a dull file. 63
5. New Files should be "broken in", which is the process of
wearing down prominent file teeth to the level of the
others. This is done by filing brass before any other
material.
6. Never use a file as a hammer
7. Di not knock a file on a vise or other metallic surface to
clean it.
8. Do not apply too much pressure to a new file.
9. Do not use a file with out the handle and Never use a file
without a handle securely attached
10. To prevent undue file wear, apply pressure only on the
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forward stroke
 QUESTIONS

• What is the use of file ?

• What are the parts of file?
• Which is material is used in file ?
• What are tye types of file ?

65
 Scrapers and Scraping
• Scraping means shaving or parting off thin slices or flakes
of metal to make a fine, smooth surface.
• Today's this operation is replaced by surface grinding and
more accurate machining and die-casting processes.
However, it is still used in fitting large machine parts and in
making machine repair, fitting soft bearing to a shaft,
correcting minor imperfection in machining .

66
 Scraper
Scraping is done with tools called scrapers which have
very hard cutting edges are usually left very hard.

Scrapers are made in many shapes, depending on the work

done (A)Flat or straight,
(B) Hook,
(C)Straight half-round,
(D)Curved half-round,
(E)Three-cornered or
triangular,
(F)Double-handle. 67
• Flat or straight and Hook used for flat surface
• Straight half-round and Three-cornered or triangular
are used for curved surface
• Three-cornered or triangular used to remove sharp
corner of burrs
• Straight half-round has two cutting edges on the
concave(hollowed)side

• Old files make excellent scrapers. First, grind off the

teeth on all sides and then sharpen the cutting edge.

68
 Scraping a Flat Surface
In scraping operations , a surface plate is used to indicate
irregularities or high spots. Any dust or grit should be
wiped off the surface, and any burrs on the metal should
be removed with a very fine file. After thoroughly
cleaning the surface plate, coat it with a marking
material( blue print) and rub the work over the surface
plate a few times. High spots on the work will be
indicated by the marking material that has been rubbed
off. These high spots are removed by scraping. Finding
the high spot is called spotting
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 After repeated scraping and testing with
the surface plate, the entire work
surface will be covered with marking
material, which indicates that the work
is finished. The correct use of the
scraper is important. When a flat
Correct method of holding scraper is used, cutting is done on the
a scraper.
forward stroke. Cutting is done on the
return stroke when a hook scraper is
used.

70
 Scraping a Round Surface

Round bearing must fit on other sliding or running

parts: any shaft bearing is an example of this. The same
way of marking and scraping the high spots of flat
surfaces is also used for round and curved surfaces.

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 CHISELING
Chiseling is an art of shaping metals using chisels. Hammers
are used to strike the heads of the chisels so that they can cut
while the work piece is held stationary.
Chiseling can take one of the two forms: chipping or shearing.
 Chipping is a chiseling operation in which small metal
pieces are removed and the work is shaped.
 Shearing(cutting), on the other hand, is a process of
separating metals in to pieces using chisels.
The basic difference between these two operations is that the
chipping produces chips whereas shearing is a chip-less
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process.
 CHISELS
 Chisels are made from high carbon steels commonly
known as chisel steels. The cutting edges are, forged to the
required shape, hardened, and tempered while the body is
remains soft to enable the chisel to absorb the hammer
blow.
 Chisels can be hot and cold chisels. The hot ones are
those used for cutting metals while red hot, whereas cold
chisels are used to cut metals in their cold state. But the
commonly used one is the cold one and hence the
discussion here will also focus on cold chisel.
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The cold chisel is the simplest form of metal cutting
tool. By definition, a chipping chisel is a hand tool made
of heat-treated steel, with the cutting end shaped
variously, for chipping metal when it is struck by a
hammer. The various types of chipping chisels are as
follows:
 Flat
Cape
 Diamond-point
 Round-nose

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 Flat chisel:This is the most common of
all kinds of chisels used in engineering.
It is used for chipping flat surfaces,
cutting off sheet metal, cutting bars and
Flat Chisel
Point rivets, and for most ordinary chipping
around the shop.
Head
Body
Cape chisel :-A cape chisel is used to
facilitate work in removing considerable
metal from a flat surface, or to break up
surfaces too wide to chip with a cold
chisel alone. It is also used, along with
other chisels, to cut keyways and
channels. 75
 Diamond point chisel:- The diamond
point chisel is used for cutting 'V'
groves. cleaning corners and equating
small holes. The chisel is drawn to a
square sector and end is ground off at an
angle producing a "diamond" shape.

Half round chisel :- A half round chisel is

used for cutting oil-warp or groves in,
bosses and pulley bearings, etc. They are
also used for settling over pilot holes.
When a hole is to be drilled a smaller or a
pilot hole is chilled first.
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 CHISEL

 Use:- To chip and cut flat surfaces, slots and grooves.

 Material:- High carbon steel or Chrome vanadium steel

 Types:- A. Cold chisel B. Hot Chisel

 A. Cold chisel;

Flat Chisel
Point
 Use:- They are used to remove metal from large
flat surface and chip excess metal weld joints and
Head
Body castings.

Cross cut Chisel

 Use:- These are used for cutting keyways, grooves

and slots.
 Half round
nose Chisel

 Use:- They are used for cutting curved grooves

(oil grooves)‫‏‬

Diamond point chisel

 Use:- These are used for squaring materials at the

corners.

 Use:- These chisels are used for separating metals

after chain drilling.

Web Chisel
 CHISEL ANGLES

 Point angle:- The correct point / cutting angle of the

Point angle
chisel depends on the material to be chipped. Sharp angles
are given for soft material and wide angles for hard material.
Rake angle The correct point angle and angle of inclination
Inclination
angle generates the correct rake and clearance angle

Clearance
angle
 Rake angle:- Rake angle is the angle between the top face of
the cutting point and normal to the work surface at the cutting
edge.

Point Inclination
Material
angle angle  Clearance angle:- Clearance angle is the angle between the
High carbon steel 65º 39.5º bottom face of the point and tangent to the work surface
Cast iron 60º 37º originating at the cutting edge.
Mild steel 55º 34.5º
If the clearance angle is too low or zero, the rake
Brass 50º 32º
angle increases. The cutting edge cannot penetrate into the work.
Copper 45º 29.5º The chisel will slip. If the clearance angle is too great, the cut
Aluminium 30º 22º progressively increases.