Workshop report

Table of contents
1.Introduction ......................................................................................................................................... 2
2. Design of the holder to be manufactured .......................................................................................... 2
................................................................................................................................................................ 2
3. Material used ...................................................................................................................................... 2
4. Procedures .......................................................................................................................................... 3
4.1 Step 1: Marking out....................................................................................................................... 3
4.2 Step 2: Cutting and shaping the corners of the work piece.......................................................... 4
4.3 Step 3: Removing the central part ................................................................................................ 4
4.5 Step 4: Drilling the hole................................................................................................................. 6
4.6 Step 5: Folding the work piece...................................................................................................... 7
5. Flowchart ........................................................................................................................................... 8
6. Some tools used: ................................................................................................................................. 9
7. Summary ........................................................................................................................................... 10
8. References ........................................................................................................................................ 10

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Workshop report

1.Introduction

The design of a letter holder was assign to us in order to realise it in the workshop individually. The
letter holder was to be made from a sheet of mild steel of 1 mm thick using several bench tools
available in the workshop. Various technics of operation acquired during the lecture were performed
to make the latter as accurate as possible. The realisation was made in several steps so that to
realise the proposed design precisely, facilitate the manufacturing procedures and thus reduce the
manufacturing time. Safety precautions were also considered so that incident was avoided.

2. Design of the holder to be manufactured

Figure 1: Design of the letter holder

3. Material used

Type: Sheet of mild steel 1 mm thick

Size: approx. 153mm x 92mm

Mild steel being a highly malleable material it is very commonly used in the workshop. The medium
presence of carbon (0.1 0.2%) makes it ideal for bench work since it is less brittle that metal with
high presence of carbon while remain tough. Being in the form of sheet reduces the material
bending resistant, which make it appropriate to be bent.

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4. Procedures
4.1 Step 1: Marking out

Tools and Equipment:

Engineer Try square, steel rule, scriber, divider, centre punch, flat file, odd leg calliper.

Procedures:

1. Two edges were check in the sheet to see where they were straight and squared using the
Engineer try square. The work piece was place to eye level to observe whether light go
through between the try square and the work piece.
2. Being neither straight nor squared, the work piece was mounted on an engineer vice
between two scrap materials and the edges were filed until they were perfectly squared.
3. Taking those edges a datum reference, all the dimensions and marking out were made in
accordance to those edges on the surface plate using the scriber, the odd leg calliper and the
steel rule. The odd leg calliper was used to scribe lines parallel to the datum edge for the
rectangle in the middle of the work piece.
The folding line were also marked
4. After locating the centre of the arc at the edges, it was centre punched for ease of marking
the curved edge with a divider.

Safety precautions taken:

Do not play with scriber since it is very pointed

Avoid applying too much force when marking because the tool may slip
To handle the hammer carefully

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4.2 Step 2: Cutting and shaping the corners of the work piece

Tools & equipment: Tinmans snip, flat file, engineer vice

Procedure:

1. The 4 corners of radius 30mm were cut using the tinmans snip as close as possible to
the marked line so that there was less to file.
2. After the corners were cut out, the work piece was clamped on an engineer vice with
the corner at the top. The, a rocking action was made with the file so that it become
perfectly round.

Safety precautions taken:

The work piece was handled on the far edge when using the Tinmans snip.
The file used was fitted with appropriate handle.

4.3 Step 3: Removing the central part

Tools & equipment:

Cold chisel, copper mallet, engineer vice, safe edge file.

Procedures:

1. The middle part of the work piece of size 90mm x 30mm was yielded with the cold
chisel and the copper mallet on a metal block. The cold chisel was placed perpendicular
to the work piece and was punched along the marked line. (Note: An allowance was left
for filling.)

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2. The work piece was then mounted on an engineer vice, with the yield line parallel to
the jaw of the vice.
3. Using the cold chisel and the mallet again, the chisel was twisted lightly so that it is
easier to tear the metal out. This was repeated until the central part was removed.
4. The work piece was left on the vice and was filed using a safe edge flat file until it was
squared. (Squareness was checked with a try square.)

Safety precautions taken:

The cold chisel was handled carefully because it was very sharp.
The hammer was tapped gently so that the chisel does not slip.
To never touch the sharp edge after the metal was tear out.

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4.5 Step 4: Drilling the hole

Tools & equipment:

Locking plier, pillar drill, twist drill 3.5mm

Procedures:

1. After having located and centre punch the centre, the work piece was hold firmly
between a locking plier and was brought to the pillar drill.
2. Work piece was placed on a piece of scrape wood and the drill was lowered using the
feed handle to check if it was well positioned in the spindle axis.
3. Then the guard was lower and with the assistance of a friend, the pillar drill was
switched on to drill the hole.
4. A reamer was passed thought the hole to makes it perfectly circular.

Safety precautions taken:

Googol was wear in case of wrap projectile.

There was the assistance of a friend so that in case of accident, to switch off the
machine.
The plier was verified to be well tighten before machining operation starts.

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4.6 Step 5: Folding the work piece

Tools & equipment:

Scrape wood 15mm thick (plywood, mdf in preference), copper mallet, engineer vice, hack
saw

Procedures:

1. The folding lines were lightly worn out with the hack saw.
2. The latter was then sandwiched between the woods on the vice for the 8omm folding
line first.
3. Then, using the copper mallet, the hit gently until it folds to 90. (The mallet was taped
close to the folding line)
4. The process was repeated for the other part.

Safety precautions taken:

Force was applied only on forward stroke the using the hack saw.
The mallet was handled carefully.

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5. Flowchart

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6. Some tools used:

The odd leg calliper is used to mark This tool has harden jaw which allows it
lines parallel to an edge to cutting thin sheets of metal

Figure 14: Odd leg calliper Figure 15: Tinmans sinp

The soft mallet is used to shape metal A scriber is used to mark lines on a
with damaging the metal surface metal

Figure 16: Copper mallet Figure 17: Scriber

Files are used to file and shape metal Locking plier is used to hold work piece
very firmly without continuing to press
Figure 18: Flat file the jaws together

Figure 19: Locking plier

It is used to tear out metal

Figure 20: Cold chisel

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7. Summary

The aim of this project was to solve the problem of keeping letters tidy. Letters are very often being
mesh up among other documents and easily being lost. So, the need of a letter holder is of high
priority.

The design of the letter holder was assign to us in order to be manufactured in the workshop using
the tool available. A sheet of mild steel 1mm thick was given to us to realise the holder.

The fabrication this holder has allowed us to develop our practical skills and understand much better
how a manufacturing process is undergone.

8. References

1. Workshop Technology Volume 1, 5th Edition by W. Chapman

2. https://www.machinemart.co.uk/c/metalworking/

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