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OBJECTIVES
To learn the skills involving the bench works such as chiseling, sawing, marking
out and filing. To more understand about the process of bench work.
To get acquainted with operations of marking out, chiseling, sawing and filing.
To know the work holding, metal removing and tools used.
To more understand about the process of drilling
To identify tools for countersink and counter boring.
To get acquainted with various type of drilling machines that use to finish this
project. Better understand the various features of a twist drill.
To gain more understanding of the drilling process and to get acquainted with the
machines that involved in drilling process.
To familiarize with all the apparatus used and the drilling process.
To know the proper method and safe manner in handling drilling machine.
To familiarize and study the important terms that use in drilling process.
To know about the precautions that must be taken in doing this project.
APPARATUS
Work piece : Mild Steel (102mmx65mmx9mm)
Marking tool
Table
Hand Scriber
Engineer Dividers
Odd-leg caliper
Engineers Steel ruler
Center punch
Engineering square
Scribing block
Parallel bar
Metal removal
Cold chisel
Hack saw
Flat file
Half round file
File brush
Drilling
Drilling machine
Hammer
Twist drills
Oil

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Center drill
Vernier caliper
Soft hammer
Countersink drill
Pillar Drilling Machine: H5 32
Two flute twist drill set:
Center drill: 6, 10, 8, 9
Counterbore drill

PROCEDURE
a)
First, the work piece is clamped on the vice tightly to ensure that it does not slip.
b)
Two sides of the work piece are chosen to be the reference plane. These two
sides are filed using a flat file. The surface of both sides must be level so that it is
balanced and would stand upright when placed on the parallel bar.
c)
The filing process should be done so that the work piece is 90 to each other and
until it is able to stand on its own over a smooth surface.
d)
One side of the metal is filed using the double cut file so that a flat surface will
be obtained. When the surface is almost flat, single cut files is used for finishing
work.
e)
The engineering square is used to check the flatness of the sides. During filing,
there are some metal chips left on the file. The file brush is used to remove these
chips.
f)
Then the other reference plane is filed until the angle between the two reference
planes is 90 to each other, which can be checked with the engineering square
whereby if the square rests on the two sides without any gaps, the two planes are
perpendicular.
g)
When this is finished, the work piece is placed on a flat surface horizontally with
the filed side on the flat surface. Using the height gage caliper a 25mm and
50mm mark is done on the work piece.
h)
The work piece is then placed vertically with the other filed side on the flat
surface and a 20mm, 40mm, 60mm, 80mm and 100mm mark is done.
i)
Two quarter circles with a 20mm radius is sketched using engineers divider and
the tangent of the circles to the 50mm line is marked.
j)
The center punch is then used to mark the line in order to make it more visible
while cutting is done. The center of the holes which are to be drilled are also
marked with the center punch. Please refer Figure 1.
k)
Next, the unwanted part of the work piece is removed using a hacksaw. Once the
unwanted part is removed, the surface is filed until it becomes flat and smooth.
l)
The drilling process is done after that. Four holes need to be drilled in this
project which are, the countersink hole, a hole with an internal thread, a thru hole
and a counterbore hole.
m) First the the work piece is placed on the drilling machine table and the machine
is switched on. To star drilling, the arm is pressed down on the work piece.
n)
Then, the center drill is selected. This is to make the next drilling process easier.

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o)
p)
q)
r)
s)

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The drilling process is done by drilling a smaller hole first then continued with
the right diameter.
Instead of using the twist drill with the actual diameter, each hole is drilled from
a much smaller diameter and will be increased until the actual diameter is
reached.
For the hole on the right and the left countersink and counterbore is done using
the countersink drill and counterbore drill respectively.
Then the internal thread for the second hole is done by using the tap wrench. For
safety, the angle file is used to file the sharp edges.
The work piece is measured again to make sure it is right.

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DISCUSSION
The workbench is the place where a craftsman carries out the most important
parts of completing his project, which includes marking out, chiseling, sawing and filing.
These operations need patience and skills for the project to come out beautifully. Of all
metal removing operations, work holding is the most important aspect as work pieces
need to be held tightly in place so that it does not move when filing, chiseling or sawing
is taking place. A workbench is usually provided with a parallel jaw vice to hold the
work piece. The best working height is when the hand elbow is about level with the vice
jaws.
Marking out tools or equipment are required to provide visual indication of the
outline of a component, position of slots, center lines of holes, by the use of described
lines. The finished shape of a work piece can be obtained by use of tools at the work
bench once its outline is marked out.
NOTE: The figure shows the main hand metal removal methods. The accuracy
decreases as we move upwards.
ACCURACY
Chipping action
Accurate work difficult
Sawing action
Straight lines only
Surface producing tool
Very selective metal removal

COLD CHISEL
HAKSAW
FILE
SCRAPER

Cold chisels are used for breaking down a surface rapidly. Its rate of metal
removal is very small and so accurate work is very difficult to obtain. A typical flat cold
chisel, shown in the figure below is made from high carbon steel and has a hexagonal or
octagonal section to prevent it from rolling off the workbench.

Useless or unwanted part of the metal can be removed using a hand hacksaw. For
each job, a correct blade should be chosen instead of using the same one for everything.
Hacksaws cut only in the forward direction so on the forward or cutting stroke, the

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hacksaw is pressed downwards and pressure is eased on the return stroke. While cutting
is done, it must be made sure of that at least two teeth is in contact with the material work
piece at all time. It is classified by the pitch of its teeth, length of the blade and material
of which it is made. Pitch is number of teeth in one mm.

The file has an important role in material removal and filing operations from
roughing to finishing on flat and curved surface and can be specified according to its
length, pitch and cross section. Without file, a flat and smooth surface cannot be obtained.
The single cut file has a series of parallel teeth at an angle to file axis while double cut
file has a second series of parallel teeth in the opposite direction and crossing the others
at an angle of about 45 to file axis.

Most of the engineering components have holes drilled either in or through them.
The machine tool to produce holes is then naturally called the drilling machine. For
ordinary workshop purposes, there are three main types of drilling in use which are:
Sensitive drilling machine. Its vertical feed is actuated by hand, which enables the
operator to sense how fast the drill is cutting and therefore is able to control it
according to the condition of the moment. It is very necessary for holes of small
diameters (less than 12 mm).
Pillar drilling machine. It is rigid and of heavy construction and equipped with a
power feed. It is suited for holes up to 30 mm and a wide variety of operations such
as reaming, counterboring, countersinking and spotfacing.
Radial arm drilling machine. It is designed to drill holes in heavy castings or
forging that are difficult to reposition for each succeeding hole. The drill arm is
capable of vertical movement and of a radial swing, while the drilling head
mounted on the arm is capable of lateral movement along the arm as well as
automatic vertical feed. It is designed to drill holes in heavy castings or forging that
are difficult to reposition for each succeeding hole. The drill arm is capable of

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vertical movement and of a radial swing, while the drilling head mounted on the
arm is capable of lateral movement along the arm as well as automatic vertical feed.
In all the drilling operations it is essential to ensure rigidly of both cutting tool and work
piece. The drill must be correctly held and the work piece clamped to the table or held in
a vice, and it is good practice to ensure that the drill sleeve is at its highest position and
the worktable raised to reduce the distance between the drill and the work piece as shown
in figure below.
Sleeve in highest position

NON-RIGID

RIGID SET UP

SET UP
Excessive amount
Of sleeve protecting

Table raised

Correct setting of the drill sleeve

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Cutting speed, Feed, and Depth of cut

1) Cutting speed
Cutting speed in drilling is the peripheral speed of the cutting edge V = DN
where D is the drill diameter and N is the rotational speed (rpm). The cutting
speed selection depends on both the work piece and cutter materials.
N = V X 1000 r.p.m
D
2) Feed
Feed (f) is the distance the drill penetrates per revolution (mm/rev); the share
of each cutting edge is f/2.
3) Depth of cut
Depth of cut is taken as half the diameter for drilling (D/2).
4) Drilling time
The drilling time (T) can be given by the equation:
T = L / fN
Where f is the feed (mm/rev),
N is the rotational speed (rpm),
L is the sum of hole depth, approach and over travel distances.
The approach is usually considered as (0.4 D) while over travel ranges from 1
to 3 mm.
5) Material removal rate
The material removal rate (MMR) in drilling is the volume of material
removed by the drill per unit time.
MRR = ( D2 / 4) (f) (N)
This project took a lot of time because it takes quite a while to master the
techniques of filing and chiseling since two sides of the work piece has to be flat and
perpendicular to each other. The flat surface took a lot of time to obtain because while
filing, the force exerted on the work piece is different which resulted in some sides
becoming higher than the other. This also occured in obtaining the 90 between the two
sides. If the filing was done slowly and carefully maybe it would take less time to get the
flat surface.
Due to the number of our group, there is no problem during the measurement is
done. The equipment is enough for us. For marking operation, the problems are while
drawing the curve and mark the line. The tools used for drawing the curve, which is
engineer divider, does not have sharp end, so marking had to be done several times.
Because of wrong technique used during removing the excessive work piece
using the hacksaw, a lot of time had been taken just only to remove the small part of the
work piece. If correct technique is used when using the hacksaw, metal removal can be
done in a short while. While cutting, at least two teeth of the saw must be in contact with
the work piece and the right skills on how to use a hacksaw can also be very handy. Then

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the work piece had to be filed again. It was quite hard to obtain a flat surface so, the
engineering square should always be used to make sure that the surface is indeed flat.
The only problem during drilling procedure is to wait for turn, as there is a few
numbers drilling machine in the workshop which is not enough. It is also hard to level the
center drill since the accuracy of the table support lock is not absolutely correct. The table
might move as we were setting the center of the drill and while fasten it.
There are some precautions that we have to take note like, the work piece should be
clamp straight and tight and the position of the drill sleeve should be at highest position
so that the elbow is at the same level as the work piece to reduce the distance between the
drill and the work piece.
CONCLUSION
Bench work is one of the most important processes when in the workshop. It is
involved in most of all the projects here. Each equipment has its own style and skills
needed to operate it. I have learned a lot of things from this project. It has taught me
patience, as the project took quite a while to finish, and perseverance almost always bring
good results. It has undoubtedly taught me about bench working and drilling. I learned
the correct techniques of filing, measuring, chiseling, sawing and others, which are very
important and should be mastered by all engineering students. Although the objectives of
this project is successfully achieved, I still have to learn to improve my skill and
knowledge. For now, Im satisfied with what I have done so far. But Insya Allah in the
next projects will try my best to produce the desired work piece.
ANSWERS TO QUESTION
1. Sketch the tools shown in the table below.
No Tool or Equipment
Purpose
1
Surface plate or table
To provide a datum face or reference plane from which
measurements can be made
2
Hand scriber
To scribe lines on metal components
3
Engineers dividers
To scribe circles on metal components
4
Odd-leg calipers
To scribe line parallel to an adjacent surface
5
Engineers steel rule
To set off marking-out tools to prescribed distances and to
check it.
6
Center punch
To provide a location point for dividers, or a start for a twist
drill.
7
Try-square
To mark out lines at 90 to an adjacent surface
8
Scribing block
To mark out lines parallel to a reference plane.

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a) Surface plate or table

To provide a datum face or reference plane from which
measurements can be made.

b) Hand scriber
To scribe lines on metal components

c) Engineer's dividers
To scribe circles on metal components

d)
Engineer's steel rule
To set off marking-out tools to prescribed distances and to check it.

e) Center punch
To provide a location point for dividers, or a start for a twist drill.

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f) Engineering square
To mark outlines at 900 to an adjacent surface.

2. Sketch the hacksaw shown in workshop.

`
3. Sketch the files shown in workshop

4. Sketch the cold chisels shown in workshop.

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Draw a twist drill and a workpiece indicating the two motions and the chip
movement.

Draw parallel and taper shank reamers.

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HOMEWORK PROBLEMS:
1) A 20 mm diameter drill is on a drilling machine with cutting speed 25 m/min. If the
feed is 0.25 mm/rev, what is the MRR? What is the MRR if the drill diameter is tripled?
Answer:
D = 20 mm; f = 0.25 mm/rev;
V = 25 m/min
N = V X 1000 r.p.m
(D
= 25 X 1000
3.142 X 20
= 397.8 r.p.m
MRR = (( D2 / 4) (f) (N)
= [ 3.142 (20)2 / 4 ] (0.25) (397.8)
= 31.248 mm3/min
= 520.8 mm3/s
If the diameter is tripled, the value of MMR is increased by 9 times.
2) The hole of a diameter of 44.7 mm is to be drilled to a depth of 60 mm and reamed to
diameter of 45 mm. The feed is 0.56 mm/rev for drilling. The cutting speed is 70.6
m/min. The reaming approach is 0.55 mm and over travel is 2 mm. Determine:
The feed and spindle speed for the reaming operation
The drilling time
The reaming time
The depth of cut for both drilling and reaming operations
The MRR for the drilling operation
Answer:
Given information
Diameter of the hole = 44.7mm
Depth of the hole = 60mm
Diameter of the ream = 45mm
Feed = 0.56mm/rev
Cutting speed = 70.6 m/min
The reaming approach = 0.55mm
Over travel = 2mm
A) The feed = 0.56x2
= 1.12 mm/rev
Spindle speed = ((1000V)/(D) )/2
= ((1000x70.6)/(3.14x45))/2
= 251.37 rpm

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B) The drilling time

(T) = L/fN
=(60+2+0.4(44.7)/(0.56)x70.6(1000/44.7)
= 0.2837min
= 17s
C) The reaming time (T)= L/fN
= (60+2+0.55)/(0.56x502.7)
= 0.22min
= 13s
D) The depth of cut both drilling and reaming operations
Depth of cut for drilling = D/2
= 44.7/2
= 22.35mm
Depth of cut for reaming = 45-44.7/2
= 0.15mm
E) MRR for drilling operation
MRR = (D/4) x fN
= (3.14x 20/4) x (0.56 x (70.6(1000/44.7))
= 441 815mm/s
REFERENCE
i.
MEC 1105 Workshop Technology Course Manual
Kulliyyah of Engineering, IIUM
ii.

Machine tool Practices, 6th Edition

Richard R.Kibbe, John E. Neely, Roland O.Meyer, Warren T. White
Prentice Hall

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