Professional Documents
Culture Documents
Training Unit
No: ME 002
Training Unit
Basic Mechanics for Non-Mechanical Trades
Practical Part
No.: ME 002
Edition:
2008
All Rights Reserved
Editor:
CONTENTS
Page
Exercise 3 Drilling......................................................................................................5
8.1
Exercise 8 A.......................................................................................................10
8.2
Exercise 8 B.......................................................................................................11
Exercise 1 Filing
Exercise 3 Drilling
Exercise 4 Marking
62
93
Exercise 5 Sawing
93
62
8.1
Exercise 8 A
10
8.2
Exercise 8 B
11
Skills to be acquired
12
Skills to be acquired
Regrinding of cutting edges of flat and cape chisels at the pedestal grinder.
13
Skills to be acquired
The flank of the drill must be reground until the wear of the major cutting edge, chisel
edge and margin is completely eliminated. Grinding errors affect the accuracy of the bore
and the drill life.
14
Skills to be acquired
15
Skills to be acquired
Regrinding of a twist drill for steel to obtain a twist drill for brass with a rake angle of 0.
The rake angle of 0 is achieved by grinding a bevel at both major cutting edges parallel to
the drill center-line.
The bevel (a) is ground at the side face of the grinding wheel. The breadth of the bevel is
dependent on the twist drill diameter and amounts to a = 0.1 to 0.5 mm.
Method of holding the twist drill when grinding the bevel for drilling in brass
16
17
Procedure
1. Coarse file Surface flat 1 flat down to the 36 mm scribed line and square to Surface 2
and 3
2. Coarse file Surface 3 flat, square to Surface 1 and 2
3. Coarse file Surface 4 flat, square to Surface 1 and 2
4. Coarse file Surface 6 flat, square to Surface 2 and 3
5. Coarse file Surface 6 flat, square to Surface 2 and 3
6. Coarse file Surface 4 flat, square to Surface 2 and 6
7. Coarse file Surface 3 flat, square to Surface 2 and 6
8. Coarse file Surface 1 flat, square to Surface 2 and 3
Clamp workpiece 5 to 8 mm above and parallel to the vice jaws and in the middle of
the vice when clamping, use vice-jaws caps.
When smoothing, apply chalk to file to prevent the formation of tool marks.
Tools
Flat files 300 x 1, 200 x 3
Measuring and checking instruments
Steel rule, try square
Accident and damage prevention measures
-
18
Skills to be acquired
Marking out with scriber, centre punching of center points
Procedure
1. Check that part provided has sufficient dimensional allowance
2. File one end flat and square to the scribed longitudinal sides, filing along the length
3. File part to length
4. Mark out centre points of holes using steel rule, scriber and try square
5. Centre punch the points of the holes
Whenever measurements and checks are made, always carefully deburr workpiece,
otherwise there is a danger of false measurements.
The correct position of the hole depends on precise and correct marking out and
centre punching.
Tools
-
Scriber
19
Skills to be acquired
Drilling through holes on the drill press
Deburring holes
Procedure
Note: The drilled plate is marked out and centre punched. It is taken over from Exercise 2
Marking out and centre punching.
1. Check that scribed lines and centre punch marks are exactly located.
2. If necessary, centre-punch once more to ensure that drill starts correctly
3. Set up drill press
4. Clamp workpiece in machine vice
5. Drill holes
6. Deburr using the rose bit
7. Check that holes are correctly positioned with the vernier calliper gauge
Ensure that the drill starts correctly, centre punch once more if necessary.
When starting drilling, the centre-punch mark must be under the tip of the drill.
When drilling, use cooling fluid to improve chip removal and for cooling the drill and
workpiece.
Take into account that spindle speeds when drilling and when deburring are different.
Tools
-
20
Never remove drill chips with the hand, but use a brush.
Do not allow your hair to come too near to the rotating drill spindle; protect long hair by
a head covering.
It is easy for rings, bracelets, wrist watches or necklaces to foul rotating machine parts
and thus cause serve injuries; before commencing work remove all such objects.
Clamp and remove twist drills only if the machine is not running.
21
Skills to be acquired
Marking out the height gauge and dividers
Procedure
1. Check prepared part for sufficient working allowance and squareness
2. Cross-file one edge level and square to the marked-out longitudinal sides
3. File part to length
4. Apply a uniform layer of chalk or marking-out lacquer to the face to be marked out
5. Using the height gauge, mark out all corner points, centre lines and centre points of
radii and scribe those lines parallel to the edges
6. Centre-punch centre points of radii and important points of intersection
7. Scribe the radii using the dividers
8. Using the scriber, mark out those lines which are not parallel
Scribed lines must remain visible for subsequent sawing exercise, fine-working and
visual checking
Tools
-
Scriber,
Steel rule,
200 g hammer
90 try square
22
Skills to be acquired
Sawing using the hacksaw
Procedure
Part supplied is ready marked out (from Exercise 4)
1. If necessary, re-punch hole centers
2. Clamp part in bench vice and drill
3. Deburr drilled holes
4. Saw out corner, 31.5 x 31.5
5. Saw out corner, 15 x 15
6. Saw out square cut-out, 15 x 15
7. Saw out triangle, 21.5 21.5
8. Saw out triangle with base 40
9. Saw out cut-out, 15 x 15 to R5, blending into hole of 10 diameter
10. Saw out slow with breadth 8
11. Saw out slot with depth of 15
12. Cut-out mark out inside edge for drilling
13. Drill cut-out
14. Saw cut-out, 10 x 20, at sides
15. Deburr sawn edges
For easy starting of the saw blade, use the triangular file to make a small notch.
Make starting cuts at reduced pressure, so that the saw blade does not slide away.
For starting cuts, incline the saw slightly downwards, with the handle raised a little.
Scribed lines must remain visible, in order to allow any subsequent fine-working to be
performed up to the scribed line.
Guide the saw in a straight line; do not tilt, otherwise the saw cut will not be straight.
When clamping the saw blade, the teeth must point in the direction of the forward
stroke.
23
Tools
-
90 countersink,
Bench vice,
Hand hacksaw
Towards the completion of the saw cut, reduce cutting pressure so that hand and
finger will not be damaged by rebound.
24
INSTRUCTIONS EXERCISE 6
Skills to be acquired
Identification marking using letter and number punches.
Use workpiece from Exercise 1
Procedure
1. Mark out base lines for lettering
2. Punch letters and numbers
3. File punched surfaces
Tools
-
Try square
Steel rule
Scriber
Marking-out lacquer
200 g hammer
Centre punch
Try square
Steel rule
25
INSTRUCTIONS EXERCISE 7
Skills to be acquired
Contersinking, counterboring
Use workpiece from Exercise 3
Procedure
1. Bore out through-holes in stages
2. Deburr through-holes on each side
3. Produce 90 countersunk recesses
4. Counterbore using the piloted counterboring tool
5. Deburr outside diameters of the counterbores and through-holes
Check that the diameter of the guide pin for the piloted counterbore is as given in the
standard. Make use of coolant.
Tools
-
Twist drills for through-holes for countersinking, of diameters 4.3, 6.4, 8.4
Therefore hold machine vise securely to prevent it swinging round with the tool.
Remove rings, bracelets, wrist watches and necklaces before commencing work.
Clamp and remove twist drill, countersinks and counterbores only when the machine is
not running.
26
Skills to be acquired
Tapping a female thread
Use workpiece from Exercise 7
Procedure
-
Countersink both ends of drilled-out holes to 10 % greater than the major diameter of
the thread, using a 90 countersink
Working materials
Twist drills for minor diameters of 3,5; 5; 6,5
Machine vise, tap wrench, set of taps for M4, M6, M8, 90 countersink
Measuring tools
Vernier caliper gauge, try square
Handle the taps with care- when using small-diameter taps, there is a danger of tap
breakage.
27
Skills to be acquired
Cutting a male thread
Procedure
1. Mark out flats and length of the thread
2. File flats for clamping the bolt
3. File chamfers at both ends
4. Cut M10 thread
Working materials
Flat file 200 x 3, scriber, marking-out lacquer, M10 die with stocj
Measuring tools
Steel rule, vernier caliper gauge, try square or thin steel square
28
KEY TO EVALUATION
PER CENT
MARK
88 100
75 87
62 74
50 61
0 49
29