FACULTY OF ENGINEERING AND TECHNOLOGY

LAB REPORT
WORKSHOP TECHNOLOGY
EME1226
TRIMESTER 2 (2014/2015)

Experiment 1:

Hand and Machine Tools Making a pin hammer

Prepare by:
NAME OF STUDENT

ID NUMBER

Chong Kah Leong, Joshua

1131122826

Group Number

34

Date of Experiment

10th November 2014

Date of Submission

12th December 2014

Name of Lecturer

Lecturers Room

Mr. Jee Kian Siong

Mr. Palanisamy Chockalingam
Mechanical Workshop
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TABLE OF CONTENT
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2
3
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Title Page
Table of Contents
Objectives
Introduction + (Theoretical background and Abstract)
Equipment
Experimental Method and Procedures
Results
Discussions
Conclusions
List of References
Appendices

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2
3
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4-5
6-10
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12-13
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MAKING A PIN HAMMER

OBJECTIVE

To learn how to use different hand tools and machine tools in the workshop.
To learn how to make a Pin Hammer using tools.

INTRODUCTION ( along with Theoretical background and Abstract)

Hammers is one of the earliest tools dates back about 2,600,000 BCE which various
shaped stones were used to strike wood, bone, or other stones to break them apart and shape
them. Later on, these stones are attached to sticks with strips of leather or animal sinew were
being used as hammers with handles at the middle of the Paleolithic Stone Age.
A hammer is a tool meant to deliver an impact to an object especially for driving nails,
fitting parts, forging metal and breaking up objects. Their wide choices in their shape and
structure are often designed for a specific purpose. Usually, a hammers features are a handle and
a head, with most of the weight in the head. Currently, the basic design is hand-operated, but
there are also many mechanically operated models for heavier uses, such as steam hammers.
A simpler and finer version of these hammers, a pin hammer is a very lightweight
hammer which is ultilised for very fine work. They are commonly used for nailing very small
nails, panel pins and tacks on the surface. Plus, pin hammers usually have lightweight wooden
handles, but now they are also available with metal or fiberglass shafts.
Our task is to make a pin hammer with different hand tools and machine tools. Therefore,
in this report, we will explain the steps and procedures of making a pin hammer with different
operations of machine such as milling machine, drilling machine, lathe machine (turning
machine) and so on. On top of that, appropriate precautions which should be taken will also be
discussed.

Figure 1

A commercial
pin head hammer
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APPARATUS AND MATERIALS

Gradated steel ruler

Files
Hacksaw/cutter
set of taps
tap wrench
die Wrench
30 Parallel Bar
drilling machine
turning machine
milling machine
grinding machine.
parallel Bars

Figure 1:30 Parallel Bar

Figure 2: hacksaw

Figure 3: Turning machine (LATHE machine)

Figure 4: Drilling machine

Figure 5: Milling machine

Figure 6: Vernier Calipers

Figure 7:Double Cut File

Figure 8: Ball Peen Hammer and Mallet

Figure 9: Parallel Bars

Figure 12 Die Wrench

Figure 11: Tap Wrench

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PROCEDURE
1.

The steel rod was cut into 2 pieces by using hacksaw. One piece being longer, about
165mm and another remaining piece being shorter. The procedures of the longer side for
the handle and then another side which is shorter are for head of the hammer are stated as
below :-

(A) The Making of The Head of The Hammer

Milling Machine
1. The steel rod is reduced to a square shape with the thickness of 15mm for each side by
using the milling machine.
2. The block is set under the steel rod to maintain it in stable and perfectly horizontal
position all the time during the milling process.
3. After that, the length of the steel rod is reduced to 60mm.
4. Then, the steel rod is set with an angle of 30 from the horizontal surface which made
the steel rod will be in parallel 30 angle slide and cut the one end top of steel rod part
by 9.0 mm.
5. After all milling processes, the steel rod is marked a hole with pin which its position is
30mm from the 60mm in total length and 7.5mm from the width of the steel. And then, a
hole is drilled passing through the steel rod with drilling machine.

Drilling Machine

6. An 8.0 mm diameter hole was drilled at the center point of the steel rod by drilling
machine.
7. Lastly, the drilled steel rod is locked on table with clamp and the tapping wrench is used
to make the tread of the hole.

(B) The Making of Handle of The Hammer

Lathe Machine(Turning Machine)
1. A length of 180mm is marked on the steel rod surface as the length of the handle.
2. The chips from the work piece were chipped off using a file to produce a smoother
surface and remove impurities.
3. The process was repeated in both ends of the work piece.
4. After that, the work piece diameter was measured using a vernier caliper. A reading of
18.0mm was obtained.
5. The work piece was checked for abnormalities and manufacturing defects.
6. The lathe machine was checked before the machine is used.
7. The procedure to check the lathe machine:
i.

Before start to using lathe machine, it is recommended to have a machinist tool

box with all wrenches, screwdrivers, and common hand tools. A dial indicator
may be necessary for some procedures on the lathe. Keep all safety equipment,
along with necessary cleaning marking, and lubricating equipment, in the
immediate lathe area to use as needed.

ii.

Before machining a work piece, the following measurements must be considered:

the diameter of the work that will swing over the bed and the length between lathe
centers.

8. The work piece was placed in the lathe machine in a secure position and the spindle was
tightened. The steel rod was checked for any vibration while rotating using the Jog
button.
9. The cutting head was checked in order to avoid wear.
10. The coolant, speed and the angle was set up by the requirement needed for work piece
turning. The cutting process is done slowly and gradually to create a smoother and
brighter surfaces of work piece.
11. A few test runs were conducted in order to ensure the settings were suitable for the
desired turning process.
12. When cutting, the oil tap should be open for the coolant to flow out to the work piece but
the flow rate is controlled to avoid wastage.
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13. The marked portion of the steel rod is cut using the turning machine while ensuring the
continuous coolant flow on the cutting side of the work piece (steel rod).
14. The work piece was left aside for a while to cool down and later back placed in between
of the chucks.
15. The work piece was cut by 0.5mm for 4 times gradually throughout the work piece while
the coolant was pouring into the tip of cutter and the cutting side of the work piece.
16. The work piece was taken out and measured every 0.5mm cut interval and stopped when
its diameter reaches 16.0 mm. The measurement throughout work piece was recorded.
17. The work piece was marked at the length of 15mm and 80mm respectively.
18. The cutting tool was reset to match the new measurement of work piece.
19. Then the work piece was cut 0.5mm for 4 times gradually up to 80mm.
20. The cutting was reset to match the new measurement of work piece.
21. The handle was cut into 9.5mm diameter for length of 15mm gradually using a 0.5mm of
cutting diameter and the process was repeated until a diameter of 9.5mm was obtained.
22. The handle was finally polished using a sand paper to smoothen the surface.
23. Finally, the two parts were combined and the hammer was done. Oil is added to covered
the surface of the hammer to prevent rusting.

Figure 13: (A) The Making of The Head of

The Hammer. Step 4 The steel rod is set 30
from the horizontal surface and was cut.

Figure 14: (B) The Making of Handle of

The Hammer. Step 12 Cutting process
with coolant flowing out to the work

Figure 15a: (A) The Making of Head of

The Hammer. Step 7. Thread of the
hole drilled is made with a tapping
wrench on the secured hammer head.

Figure 16: (B) The Making of Handle of

The Hammer Step 23. The hammer
head and handle are combined and is
covered with oil to prevent rusting.

Figure 15b: (A) The Making of Head of

The Hammer. Step 7. Thread of the
hole drilled is made with a tapping
wrench on the secured hammer
head .

Figure 17: The Complete Blueprint of Pin Hammer

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Result

Figure 18: Completed Pin Hammer after Oiling

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DISCUSSIONS:
1.) Precaution taken during machining:1.

Any physical contact with the work piece and the cutter must be avoid at all times.

2.

Wear the safety spectacles or googles when operating the machine.

3.

Chips must be cleaned once in every cutting.

4.

All tooling must be clean and in good working order. Make sure that there are no

broken tooling should in the milling machine. If not, the broken tool will break into
pieces and be ejected from the machine which could spell hazards
5.

For better handling, test run on the motor and spindle speed of milling machine

should be done a couple of times to ensure the rotation and speed is correct.
6.

Before starting the operation of milling process, the work piece must be clamped

tightly on the work rest.

7.

Parallax error should be avoided by making sure that the position of the

observers eye is in line with the reading of the scale to be measured or set before
machining operations.
8.

Be careful when making the taps because if the tap is broken in the work piece, it

can be almost impossible to remove.

9.

Also, the hammer parts should be allowed to cool down first before making any

contact with it. The temperature of the parts is high enough to cause scalding on the bare
skin after cutting.
10.

For extra points, the surface of the head and handle are being filed with a piece of

fine sand paper or file to ensure a good and smooth surface finish.

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2. The diameter of our hammer is slightly smaller than the required diameter in the pin
hammer blue print. This is cause by overcutting due to vibration as we were reducing the
diameter of the handle. The material we are using is a kind of soft iron steel which will rust
easily. As a result of being clamped to tightly on the chucks of the turning machine, dents
appeared on the surface of the handle are which is being gripped by the chucks. On the other
hand, cutting also causes the steel handle temperature to increase; and when it cool, the
shrinkage of the steel handle created dimensional charges. To correct this mistake, we even
out the surface of the handle and increase the flow rate of coolant on the cutting point
sufficiently. Hence, due to these errors, our steel handle diameter becomes smaller than what
we hoped for.

CONCLUSION
In accomplishing this experiment, we were able to learn the techniques and methods of operating
each different machine tools and hand tools such as a set of taps. Plus, we were also cementing
our current knowledge on how to use hacksaw with the correct way in which the cutting is done
on the forward stroke of hacksaw blade, but not the backward stroke. Furthermore, we were also
able to learn and practices different general machining operations of forming a pin hammer such
as milling, drilling and turning. Besides, we understand the function of a pin hammer as a force
amplifier and also the effects of the heads mass and handle, such as its physics. On top of that, it
can be shown that technical drawings are very important for engineers to detect flaws during
operation and improve the designation in order to minimize or treat hazards.

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LIST OF REFERENCES
1. S. Kalpakjian, Manufacturing Engineering and Technology, Prentice Hall, 2001.
2. Internet Encyclopedia : http://en.wikipedia.org/wiki/
3. MMU,"Workshop Lecture Notes", MMU, 2014

APPENDICES
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