WORKSHOP TECHNOLOGY

EXPERIMENT 1: Hand and Machine

tools
(Making a pin hammer)

PREPARED BY:XXXXXXXXXX
(ID:XXXXXX)

Table of Contents:

No.

Content

1.

Table of content

2.

Title

3.

Objective

4.

Abstract

5.

Introduction

6.

Theoretical background

7.

Experimental Method, Procedure and Equipment

8.

Observations, Data, Findings, Results:

9.

Discussion

10.

Conclusion

11.

Appendices:

12.

List of References

Page

Abstract:
The purpose of carrying out this experiment is to learn how to make a pin hammer by
using various skill that we learnt throughout the experiment. The pin hammer is
made by a section of mild steel rod. The procedures, precautions, errors happened in
the processes were recorded down in the report. Besides, there were some errors that
we could not avoid such as the machine errors and human error, so we make the
possible to get the most accurate dimension for each part of hammer. The important
part of carrying out this experiment is to brief and teach students some skill in
machining and how to operate machines under the safety condition. Besides, it is
most important to teach the students to have good cooperation and good distribution
of works with members or friends rather than general knowledge of making the
hammer.
Objectives:
To learn how to use different hand tools and machine tools in the workshop
To make a pin hammer by using different tools.
Introduction:
A hammer is a hand tool used to strike another object to create a force on the object.
It consists of a handle to which is attached a heavy head, usually made of metal, with
one or more striking surfaces. The two major components of designing a hammer
are the head and the handle. The design of these two components depends on the
specific application, but all hammers have many common features. The most
common used hammer in our daily life is a claw hammer, which is used to drive and
pull nails, whereas there are still have other types which include the ball-peen
hammer and the sledge hammer.

In this experiment, we are given a task to making a pin hammer by using a section of
mild steel rod. We need to design two major components of a hammer which is a
handle and head from the limited section of rod therefore we need to be aware when
carrying out every process. The purpose of making this report is to show the flow of
the process that we have done and problem that we encountered in the whole
experiment.

Theoretical Background:
Milling machine-Milling process
Milling is the process of machining flat,
curved, or irregular surfaces by feeding the
workpiece against a rotating cutter
containing a number of cutting edges. The
usual milling machine basically consists of
a motor driven spindle, which mounts and
revolves the milling cutter, and a
reciprocating adjustable worktable, which mounts and feeds the workpiece. Milling
machines can be outfitted with a number of tool heads to satisfy different machining
needs. Some tool heads included cutters, rounding mills, fluted mills and ball end
malls.

Lathe machine - Turning pocess

The lathe is a machine tool used
principally for shaping and change the
diameter of metal (and sometimes
wood or other materials) by causing the
workpiece to be held and rotated by the
lathe while a tool bit is advanced into
the work causing the cutting action. The
basic lathe that was designed to cut cylindrical metal stock has been developed
further to produce screw threads, tapered work, drilled holes, knurled surfaces, and
crankshafts. Modern lathes offer a variety of rotating speeds and a means to manually
and automatically move the cutting tool into the workpiece. Machinists and
maintenance shop personnel must be thoroughly familiar with the lathe and its
operations to accomplish the repair and fabrication of needed parts.

Facing cut process

Facing is the process of removing metal
from the end of a workpiece to produce a
flat surface. Most often, the workpiece is in
cylindrical shape. The workpiece is rotated
while the tool is fed at some feed rate and
the materials removes is known as chips. In
most cases, the lathe is used by holding a
cutting tool in the tool-post. The tool post
can move along the slide, by turning the carriage wheel; the tool can also be moved
closer or further from the rotation axis of the part by turning the cross-slide wheel.
The surface finished of the workpiece will also depends on the cutting speed.

Drilling machine - drilling process

Drilling machines or also known as drill
presses are one of the most common
machines found in the machine shop. A
drill press is a machine that turns and
advances a rotary tool into a workpiece. It
is used primarily for drilling holes, but
when used with the proper tooling, it can
be used for a numbers of machining
operations.

Threading sets - threading process

Threading is the process of creating screw

thread on surface of material.The process
can be carried out by hand or machine.
Threading sets consist of both external
screw threads and internal screw threads.
External screw thread is made of hardened
tool steel and having sharp internal cutting
edges, hand operated dies of common use, which are coaxially rotated around the rod
like blank with the help of handle or die stock. Internal screw threads is made of tool
steel or HSS and have sharp cutting edges produced by axial grooving over the
threads. Three taps namely, taper tap, plug tap and bottoming tap are used
consecutively after drilling a tap size hole which the taps are axially pushed helically
with the help of a handle or wrench.

Apparatus and equipment:

1. Reamer
2. Dies
3. Gradated steel rule
4. Files
5. Hacksaw
6. Set of taps
7. Tap wrench
8. Vice
9. Parallel bar
10. Sand paper
11. Rubber-head hammer
12. Ball peen hammer
13. Vernier caliper
14. Drilling machine
15. Turning machine
16. Milling machine

Procedures:

Head
1. All the

students

are

equipped

with

safety
goggles

and

apron so as

to

prevent

the

removed

chips

injure our

eyes and body.

2. The original length and diameter of mild steel rod is measured and
obtained the readings of 230mm and 20mm.
3. The rod is marked to 65mm so as to make the head component of
the pin hammer.
4. The rod is tightly clamped on the vice then cut into separate part
by the hacksaw.
5. Firstly, milling process is carried out so as to make the head
component of the pin hammer.
6. The 65mm circular rod is clamped to the vise with parallel bar
placed beneath it so that to support the circular rod. The workpiece
was hammered by soft hammer so as to ensure it is closely lie on
the bar.
7. The vertical feed crank was adjusted until it nearly contact with
cutting tool. Then, the cross transverse wheel was adjusted to
make the cutter could cut more than half of workpiece surface.
8. All scales are set to zero. Then the vertical feed crank was adjusted
by lift up 0.5mm upwards. Then the table hand wheel was turn and
reversed with constant speed as to move the workpiece toward
and backward to cutter.
9. Same methods are repeated by changing the workpiece surface so
as to obtain dimension of 15cm x 15cm.
10.Then, the header part length of 65mm is shorten to 60mm by using
plain milling method.
11.Next, the vice is rotated to the angle of

30

so as to continue

angular milling process.

12.One end of hammer head is marked with horizontal line 6mm
height.

13.The workpiece is still placed with parallel bar underneath it so that

it can support the weight of hammer head.
14.The vertical feed crank was adjusted until it nearly contact with
cutting tool. Then, the cross transverse wheel was adjusted to
make the cutter could cut more than half of workpiece surface.
15.Then the vertical feed crank was adjusted by lift up 0.5mm
upwards. Then the table hand wheel was turn and reversed with
constant speed as to move the workpiece toward and backward to
cutter.
16.All the dimensions are measured by using vernier caliper after
cutting is finished.

Handle
1. Secondly, the 165mm of steel rod is clamped to the three jaws
chuck in turning machine.
2. The turning machine is switched on to check whether workpiece is
tightly clamped. If not, reopen and retighten the rod.
3. The tool post is adjusted until the cutting tip could contact with
4.

workpiece. Then, all the scale is set to be zero.

The cross slide wheel was turned to move away the tip but the

carriage hand wheel keep constant.

5. After 5.0mm is cut , the workpiece is taken out and measured by
vernier caliper.
6. Turning operation was used to get the desired diameter for
workpiece. The carriage hand wheel was turn to bring the cutting
tool away from the work piece, while the cross slide wheel was kept
constant.
7. The cross slide wheel was increased by 0.5mm toward the
workpiece.
8. The tip then feed forward and backward by turning the carriage
hand wheel to reduce the diameter.
9. The cross slide wheel was increment by o.5mm untill 2.0mm.
10.After finish first cut, same steps are repeated to reduce diameter of
16mm for 80mm long and 9.5mm for 15mm long.
Drill hole
1. A hole is to be drilled on the centre of hammer head.

2. The center of hammer head is 30mm from both end is marked with
centre punches.
3. The needed size of drill was fitted into geared drill chuck. The
cutting tool is ensured to be placed vertically straight before
drilling.
4. The spindle was lowered by pushing the hand lever until it reached
the point needed to drill.
5. The drill must be pulled out every 30s to remove chips to outside
as to prevent chip deposit in the hole and jammed the drill.
6. After it is done, we proceed to last part.
Threading
1. The head is clamped to the vise and the needed size of taper was
chosen.
2. The taps are axially pushed helically in clockwise direction by using
handle or wrench. Make sure the taper in straight .
3. A little bit of lubricant are applied into the hole to reduce friction.
4. The taper is allowed to reversed for 2 times to break the chips
5.
6.
7.
8.
9.

formed inside the hole, then finish threading process of head part.
External screw thread method was used in handle of hammer.
The handle is clamped inside the jaw with desired size was chosen.
The die as coaxially rotated in clockwise direction around the rod .
Repeat the steps same as step 3 to 4.
Lastly, the hammer head and hammer body need to be scrubbed
with sand paper to remove the surface roughness.

Result

7.0m
m
30
o

8.5m

59.9m
m
30.0m
m

18.25m

15.2m
m

16.00m

9.00m

79.20m
m
15.00m
m

158.2m
m

Discussion:
After comparing the dimensions, there are some difference in dimensions compared
to the actual dimensions provided. This is because there is some errors occur during
the experiment.
1. Errors occurs for Milling machine:
a. As the cutting tool was continue used for so many times by the students
without take a break, the cutting teeth or the cutting edge maybe worn out and
thus make it cannot produce a very accurate cutting.
b. The work piece may move when it is not properly fixed in the vise, thus it
results into serious damage to the surface of the rod if work piece straight
away fly out from vice. In this case, it causes dimensions errors to occur.
c. When cutting the 30 angle in making hammer head, due to the line that
mark on the sectional area is too thick thus we are not able to get precise
readings.
Solution:
a. Use coolant as lubricant to reduce friction and heat or change the cutter the
HSS type of cutter so it can last longer for cutting purposes.
b. Reopen and clamp again the work piece to test the machine whether the work
piece will vibrate or not.
c. Make the marking line more thinner so that we can accurately cut workpiece .
2. Errors occur for turning machine:
a. The cutting speed or the feeding speed was too fast result in rough surface
finished.
b. The cutting angle was wrong.
Solution:
a. Choose the most suitable cutting speed so that can equally cut the surface and
apply coolant when cutting the material.
b. Choose the correct cutting angle which consist of different function .

3. Errors occurs for drilling machine:

a. Drill point does not exactly point at the mark.
b. Dull drill point

Solution:
a. Adjust properly of drilling machine before the drill point hits the centre
mark.
b. Sharpen the drill point to make it sharper or change a new drill.
.

4. Errors happen in taping process:

a. Chips formed jammed the taping process.
b. When rotate the dies and reamer does not in vertical position
Solution:
a. Lubricant was used during the process so as to reduce friction..
b. The die was turned counterclockwise for 1-2 turn to remove the chips formed
5. Wearing the apron and protective goggle is the most important safety features
before we start to do any machining in workshop.
6. Always make sure the work place is clean and neat in order to avoid unnecessary
injuries.

Conclusion:

At the ends of the experiment, We have learnt some useful machining skill for the
whole experiment. Besides that, I could understand the basic machining process from
various types of machines and I could master some machining skill. I am able to
finish the given task on time and objective of this experiment was achieved.

List of references
1.
2.
3.
4.
5.

http://www.mini-lathe.com/Mini_lathe/Operation/Facing/facing.htm
http://www.roymech.co.uk/Useful_Tables/Manufacturing/Milling.html
http://www.madehow.com/Volume-4/Hammer.html
https://www.princeton.edu/~achaney/tmve/wiki100k/docs/Hammer.html
http://www.thomasnet.com/articles/machinery-tools-supplies/how-millingmachines-work

Appendix: