First Year Metalwork.

Class Notes and Homework Workbook

Second Year Metalwork

Topics to be covered
Safety. Bench tools. Properties of Materials Metals. Drilling The Centre Lathe. Joining.

SAFETY

Accidents do not just happen, there is always a cause for them

Safety in Technical Rooms

My class may not use machines without a teacher in the room. I may not use equipment that I have not been shown how to use. All accidents must be reported to the teacher. Be prepared for class. I will not be allowed to work if my behaviour puts myself or others in danger. Signed . . . . . . . . . . . . . . .

Seven Safety Hazards

Hair - long hair should be tied back. Eye protection Hot metal Sharp metal and tools Clean workplace Fire Fumes -

Bench tools
Bench tools layout

benct tools dia

Bench tools
Cold Chisels
similar to punches used to cut metal

Spring dividers
similar to a compass used to draw circles. Set radius using adjusting nut

puc mark can be used to hold it on the centre

Engineers tri-square.
Used to mark lines at 90 degrees on materials. Used to check corners are square. Handle called stock other part called blade

Engineers rule.
This is a steel ruler. Only millimetres are to be used

Bench tools
Cold Chisels
similar to punches used to cut metal

Spring dividers
similar to a compass used to draw circles. Set radius using adjusting nut

puc mark can be used to hold it on the centre

Engineers tri-square.
Used to mark lines at 90 degrees on materials. Used to check corners are square. Handle called stock other part called blade

Engineers rule.
This is a steel ruler. Only millimetres are to be used

Bench tools
Bench vice
made from cast iron bolted to the table used with vice clamps (protects the work piece)

Ball pein Hammer name from rounded side

used with dot punch and chisels only must be held at the end of the handle

The scriber
used to draw lines on the metal made from carbon steel (wont wear).

The Dot / Centre punch.

Used to mark the centre of a hole for drilling (puc). Used to mark along a line especially steel. made from High carbon steel (hardened and tempered)

Machine tools
The Pillar drill. The Centre lathe.

The Pillar Drill.

The Pillar Drill

The Base
this is made from cast iron and is bolted to the floor. It can be used to support large pieces when drilling.

The column
This is attached to the base and supports the table as well as the motor spindle and the gears.

The table.
This is attached to the column and can be moved up or down and can be rotated.

The chuck
This is connected to the spindle and is used to hold parallel shank drills. The chuck is tightened using the chuck key.

The Pillar drill.

The Feed Lever.
This moves the drill to and from the piece.

Adjustable depth stop.

This is used to set the required depth of the hole. It stops the drill going all the way through the piece unless required.

The Motor.
This takes electricity and turns it into rotary motion powering the spindle.

The spindle and gears.

Different gears are needed for different jobs. The gears are connected to the motor and the spindle allowing it to turn at different speeds.

The Pillar drill.

Using the Drilling Machine

make sure long hair is tied back. have no loose clothing. Always wear safety glasses. Never use the machine if the teacher is not present. make sure the work is properly held. make sure the drill speed is correct. Have a dot punch in the center of the hole and center the drill on it. Make sure not to pull the feed lever to hard when breaking through the piece never drill into the table or machine vice. Always check the drill size before drilling.

The Pillar drill.

Holding the work for drilling.
The machine vice. This is the most common way of holding work. The piece should be clamped by two square edges and supported by wood underneath. The piece must be held level to ensure a round hole. The machine table. The machine table can be used to hold larger heavier work. The piece can be bolted to the table using clamps. The table can be lowered and rotated for difficult pieces. The base. The base can also have pieces bolted to it but this is unusual.

The Pillar drill.

Pilot hole.
This is used before drilling a large hole so as to keep the drill centred.

The Pillar drill.

Tapping hole.
This is drilled before threading a hole. The hole must be smaller than the tap being used.

The Pillar drill.

Clearance hole.
This hole is slightly larger than the bolt or bar passed through it.

The Pillar drill.

Blind hole.
This is a hole that does not go all the way through a piece.

The Pillar drill.

Countersink hole.
This enlarges the top of the hole and allows the head of a screw to sit in flush to the piece.

The Pillar drill.

Counterboring.
This also enlarges the top of the hole to allow cheese head screws to fit in flush to the piece.

The Pillar drill.

Parts of the drill bit.
The point angle of a drill bit is 118 degrees.

jc79

The Pillar drill.

Types of drill bit.
The Parallel shank.
This is used mostly for small size drills and is held in a chuck.

Morse taper shank.

This is used for larger drills and fits directly into the spindle or the tailstock of the lathe.

A drift is used to remove the drill from the spindle.

The Pillar drill.

The drill gauge.
This is a flat steel sheet with different sized holes and is used to measure the drill bits.

The Pillar Drill.

Reamer.
The reamer is used to finish a drilled hole. The reamer gives the exact size hole, more rounded and a better surface finish.

The Centre Lathe.

The lathe is used to produce cylinders and other operations such as drilling on round bars. This is known turning. Other shapes that can be worked include square and hexagonal bar. The lathe can work with most metals as well as polymers (plastic).

The Centre lathe

diagram of lathe

The Centre lathe

The Headstock.
This part of the machine contains the motor and the gearbox. The spindle is connected to the gearbox. The spindle is hollow to allow long bars pass through.

The tailstock.
This mounted on the slideways and can be clamped in any position. It is used for drilling and also in holding long bars.

The slide ways.

These are similar to train tracks and are machined into the lathe bed. They guide the tailstock and the carriage along the bed.

The Centre lathe

The lathe bed.
This is made from cast iron as it is easily cast, a natural lubricant and it absorbs vibration giving a better finish. The bed sits on top of a stand and supports the carriage and tailstock.

diagram page 143

The Centre lathe

The carriage.
This moves between the head stock and the tailstock. It is made up of the saddle and apron. It is used to take sliding cuts.

The Cross slide.

This is attached to the saddle. It moves the tool at 90 degrees and is used for taking facing of cuts.

Top slide / compound slide.

This is attached to the cross slide and can be set to any angle. It is used to cut tapers on the work.

The Centre Lathe

The Feed Shaft. This allows the carriage and cross slide to be moved automatically. The Lead screw. This is used for screw cutting on the lathe. The tool post. This holds the cutting tool or tool holder in place.

The Centre Lathe

Safety on the Lathe.
Glasses must be worn at all times. Long hair and loose clothing must be tied back or tucked away. Never use the machine if the teacher is not in the room. Never use the machine to do something unless you have been shown how to do so and you are sure you know how to use it. Never leave the chuck key in the chuck. Never have the work touching anything when starting the machine. Never check the work when the machine is moving.

The Centre Lathe.

Make sure that the work is held tightly and is centred in all three jaws before starting the machine. Never handle swarf as it is extremely sharp. After you have finished clean the machine down and move the tool away from the chuck.

accidents do not happen they are caused.

The Centre Lathe.

Spindle speeds.
Different speeds are required for different operations depending on the condition of the lathe. Factors that effect spindle. The diameter of the work. The material being turned. The type of cutting tool. The type of operation. The condition of the lathe. Use of coolant. Method of holding the work.

The Centre Lathe

Calculating Spindle speed.
This can be calculated using the following formula:

N = S x 1000 xD
N = rotation speed / spindle speed. S = cutting speed (given in chart). D = Diameter of the bar or work piece. = 3 or 22 7

The Centre Lathe.

Worked Example.
Calculate the spindle speed required to turn a 25mm round mild steel bar.

N = S x 1000 xD

N = ? S = 30 = 3 D = 25. N = 30 x 1000 3 x 25. N = 30000 75. N = 400 rpm. The spindle speed is set at 400 on the lathe.

The Centre Lathe.

Toolposts
There are three different type of tool post available:

The four way toolpost.

This can hold up to four tools at a time. The tools are clamped by three locking bolts making it very secure. The different tools can be rotated into position quickly but changing the tools in the holder takes time. jc145

The Centre Lathe

The American tool post.
This can only hold one tool at a time but the tool height can be adjusted quickly. The tool is held by only one bolt which can lead to chatter.

jc145

The Centre Lathe.

The Universal toolpost.
This is similar to the American toolpost. The tool height cannot be adjusted quickly and it is not suitable for heavy work.

Universal toolpost

The Centre Lathe

Tool types. Tool bit.
This is the one used in the engineering workshop. The tool is ground from high speed steel to the correct angles and held in the toolpost. Smaller tools can be held in a tool holder.

Tipped tool.
This is the typed of tool used on the cnc machine. A tungsten carbide tip is clamped to the tool holder. This tip can be replaced when blunt.

The Centre Lathe

Operations on the Lathe. Facing off (surfacing).

jc149

This operation produces a flat surface on the end of the bar. The tool is moved using the cross slide.

The Centre Lathe

Sliding cuts (parallel turning).

jc149

This operation is used to reduce the outside diameter of the bar. The carriage is used to do this.

The Centre Lathe

Taper turning (Topslide)

lc250

Here the topslide is set to the angle required and the tool is moved by the topslide giving a cone shape to the end of the bar

The Centre Lathe

Taper turning (off-set tailstock).

lc251

Here the tailstock can be set to give the taper. It is ideal for long tapers but is not possible in the workshop.

The Centre Lathe

Taper turning (attachment).

lc254

This is a tool that is attached to the carriage. It is set as required and moves the tool at the required angle as the carriage moves.

The Centre Lathe

Knurling.

jc151

This operation is carried out at a very slow speed. It is used to cut lines that cross each other into the bar. This produces a grip on the bar as seen on a scriber.

The Centre Lathe

Drilling.

jc151

This is carried out using the tailstock. Small drills are held in a chuck while larger drills are Morse taper and are held directly in the tailstock. A centre drill or slocombe drill is used to find the centre.

The Centre Lathe

Centre Drill.
This locates the centre of the bar for frilling and acts as a pilot hole for normal drills.

The Centre Lathe

Parting off.

jc 152

Here the part is cut or parted off from the rest of the bar. It is important to be very careful here as the part to fly or be damaged as it drops.

The Centre Lathe

Under cutting.

Jc 152

This is very similar to parting off accept that the tool only moves in part of the way. It is used when screw cutting on the lathe.

The Centre Lathe

Holding long bars.

jc153

Long bars are held between centres. A rotating centre is placed in the tailstock. The bar is held in the chuck or as in the diagram .

The Centre Lathe

A mandrel.

lc268

This is used to hold a piece with a hole in the centre and where it is necessary to machine the whole of the outside of the part.

The Centre Lathe

Travelling Steady.

lc268

This is attached to the carriage and moves along with the cutting tool preventing a long bar from deflecting as it is cut.

The Centre Lathe

Fixed steady.

Lc 269

This clamped to the bed of the late and the bar is supported on three sides preventing it from deflecting.

The Centre Lathe

Capacity of the lathe

lc264.

Metal Joining
Metal joints can be temporary or permanent. Temporary joints include nuts and bolts magnetic catches and compressions joints as in wheel bearings. Permanent joints include riveting, soldering, welding and adhesives.

Mechanical Joining.
This refers to joining materials using nuts, bolts and rivets. There are four different thread types or forms.

Mechanical Joining.
The different parts of the isometric thread can be seen below.

When looking at working drawings the size of the thread to be used will be given as M.5 or M.6. The M. stands for metric meaning every dimension is in millimeters. The number gives the actual size of the finished thread .or the outside diameter.

Mechanical Joining.
Bolts

Mechanical Joining.
Nuts.

Mechanical Joining. Internal threading

Holes can have threads cut into them allowing parts to be joined together, this is called tapping. There are three types of tap: Taper Tap. This is used to start of the threads in the hole or to thread thin sheets. The first 5-6 threads are tapered making it easy to start the tap. Second tap. This is used after the taper tap and is used to finish of the threads in deeper holes. Plug tap. This tap has threads all the way down and is used to thread blind holes. When threading a hole it must be drilled smaller than the tap to be used. When drilling you should refer to the chart next to the drilling machine

Mechanical Joining.
Tap and wrench.

Mechanical Joining. External threading

Bars or shafts can have threads cut into them using split dies.

Here the die is placed in a stock. The top of the bar is usually tapered making it easy to start cutting the threads. When starting the thread it is important to start the thread straight so as to cut a square thread. The split die has writing on one side and this must be face down when threading.
Hard materials such as steel require oil or grease to be used to lubricate the cutting process. When cutting threads on a bar or shaft the bar must be the same size as the split die being used. For example cutting an M10 thread requires a diameter 10 bar.

Mechanical Joining.
Split die and stock.

Mechanical Joining. Riveting

Rivets can be solid or pop rivets. Solid rivets come in four different forms Round or snap, countersunk, pan or flat head. Solid rivets form a very strong joint and were commonly used in producing gates, ships and bridge panels. Pop rivets are much more common now. They are used in the manufacture of aero planes and are a very quick way to join materials.

Mechanical Joining. Riveting

page 97

Thermal Joining Soft Soldering

Solder is an alloy of lead and tin. It melts at a temperature of only 183 degrees c. Solder is mainly used for electronic circuits and to join copper pipes. Soft soldering is not a very strong joint as solder is a soft metal.

 Fluxes are used to remove oxides from the surface of the parts being joined together. This ensures that the joint between the pieces are a good quality. There are two different types of flux passive and active flux. Active Flux. Active fluxes remove oxides from the surfaces of the parts and also prevent any oxidation when the soldering is taking place. The parts must be washed well afterwards to remove any remaining flux. Passive flux. Protective fluxes prevent oxidation during soldering but they do not clean the surfaces first. They are used for electrical work and anywhere that the parts cannot be washed afterwards.

Thermal Joining Fluxes.

First Year Metalwork. Workbook.

First Year Metalwork. Workbook.

Rules for homework 1. Take down the question in red and write your answers in blue or black. 2. Leave space after each question for giving the answer.(5 lines) 3. All diagrams should be drawn with a pencil and ruler. 4. All homework to be written in the homework copy. 5. Homework copies will be collected and signed by the teacher each week if you do not have your copy it is assumed you do not have your homework complete.

Homework Sheet 1. Safety.

1. 2. How should we enter the room and why? How do we move around the metalwork room safely 3. Why is it important to keep your desk area tidy? 4. List five safety precautions or rules necessary when using a machine? 5. Why is it necessary to return the tools to the tool press at the end of class? 6. Why do we brush down the vices and never blow the filings? 7. After tidying your desk, what do you do before returning to your seat? 8. When leaving the room you have to lineup. What is the reason for this? 9. If the fire alarms sounds what are you supposed to do? 10. Finish the sentence, accidents do not happen they are .

Homework Sheet 2. Bench Tools

Draw the tools into your copy and name all the tools.

Homework Sheet 3. Bench Tools

1. What is the bench vice made from? 2. What do we use a scriber for? 3 .What is the scriber made from and why? 4. What tool do we use to scribe circles on metal? 5. What is a dot punch used for? 6. What tool is used to draw straight lines on the metal and also used to make sure the edges are square? 7. What tool is used to prevent the vice jaws damaging the work piece. 8. A hacksaw is used for cutting large work what tool is used to cut smaller work. 9. Why is it important not to move around the room with tools. 10. Why must all the tools be put away properly at the end of class

Homework Sheet 4. Blast Furnace.

Draw the diagram and name the parts.

Homework Sheet 5. Blast Furnace.

1. What is meant by the charge for the furnace? 2. What is the charge for the blast furnace. 3. Where does the heat for the furnace come from? 4. The charging bells allow the charge into the furnace and stop heat getting out. How? 5. What materials are produced in this furnace and what are they used for? 6. How is the slag removed from the furnace? 7. What is the purpose of the tuyere? 8. What are ferrous metals? 9. What happens to the waste gasses produced in the furnace? 10. What is meant by the word tapping?

Homework Sheet 6. Basic Oxygen Furnace.

Draw the diagram and name the parts.

Homework Sheet 7. Basic Oxygen Furnace.

1. What is the charge for the basic oxygen furnace? 2. What part of the charge is put into the furnace first? 3. What is the oxygen lance used for? 4. How is the lance kept cool? 5. List the six steps in the production of the steel? 6. Why do we have to take a sample of the steel? 7. How is the slag removed from the furnace? 8. How is the steel removed from the furnace? What is this called? 9. What two materials are mixed together to produce the steel. 10. What type of metal is steel ferrous or non ferrous?

Homework Sheet 8. Electric Arc Furnace.

Draw the diagram and name the parts.

Homework Sheet 9. Electric Arc Furnace.

1.

2.
3. 4. 5. 6. 7. 8.

What is the charge for the electric arc furnace? Where does the heat for this furnace come from? How is this furnace charged? What are the steps in how this furnace works? How is the slag removed from the furnace? How is the steel removed from the furnace? What is the purpose of the rollers under the furnace? What advantage does this furnace have over a basic oxygen furnace?

Homework Sheet 10. Ferrous Metals

1. 2. Name three types of ferrous metals? Name the two materials combined to make steel? 3. What is the difference between cast iron and steel? 4. Give three uses for cast iron? 5. Give three uses for steel? 6. What is galvanized iron made from? 7. What is rusting? 8. Why do we coat steel with zinc? 9. Name two other ways to stop ferrous metals from rusting? 10. What is pig iron also known as?

Homework Sheet 11. Steels.

1. What are the two materials that make up mild steel? 2. Give three uses for mild steel? 3. What is high carbon steel and what is it used for? 4. What is silver steel made from? 5. What is it used to make? 6. What is tinplate, what is it used for? 7. What is galvanized iron? 8. What is high speed steel and what is it used for? 9. What is stainless steel made from? 10. What is stainless used for and why?

Homework Sheet 12.

Non-Ferrous Metals and Alloys.
1. What is a non-ferrous metal. 2. List five non-ferrous pure metals? 3. Give a use for each of the above metals? 4. What is an alloy? 5. Why are alloys generally used instead of pure metals? 6. List three non-ferrous alloys? 7. State a use for each of the alloys above? 8. Non-ferrous metals do not rust but they do c_ _ _ _ _ e. 9. What materials would be suitable for the following items A. Soldering iron bit. B. Electric cables. C. Hinges for indoor use. D. Hinges for out door use. 10. Name one ferrous alloy?

Homework Sheet 13. Drilling.

Draw the diagram and name the parts.

Homework Sheet 14. Drilling.

1.
2. 3.

4.
5. 6.

7.
8.

List five safety precautions associated with the drilling machine? How are pieces held safely in the machine vice? What is the purpose of the slots in the table? When drilling what is the purpose of the puc. mark? What is the depth gauge used for? The table can be raised and lowered why is this necessary? How can very large pieces be held for drilling? State the two circumstances when the pupils should not use the drilling machine?

Homework Sheet 15. Drilling.

1. 2. 3. List five different types of hole? Sketch each type of hole above? When drilling a hole of a very large diameter hole explain how you would do it? 4. How can the size of a drill bit be checked quickly? 5. Sketch this tool? 6. What are the two types of drill bit available? 7. Sketch each type of drill bit and say where they are used? 8. What is a reamer? explain your answer with a sketch. 9. Why is it necessary to ream a hole after drilling? 10. What is the benefit of using a cutting fluid when drilling?

Homework Sheet 16. The Centre Lathe

Draw the diagram and name the parts.

Homework Sheet 17. The Centre Lathe

1. What is the purpose of the headstock? 2. What is the lathe bed? 3. What is it made from and why? 4. The slideways are machined into the lathe bed, what are they for? 5. The tailstock is mainly used for what? 6. The carriage is made up of three parts, what are they? 7. State the purpose of each of the parts above? 8. What is the top slide, what is it used for? 9. The toolpost is used for what? 10. The spindle is hollow, why is this?

Homework Sheet 18. The Centre Lathe

1. Name the two types of chuck? 2. What is the purpose of each type of chuck? 3. Why should the chuck guard never be left open when the machine is running? 4. Why should no more than one person operate the machine? 5. In an emergency how can the machine be stopped quickly? 6. Name the three ways of stopping the lathe? 7. What direction should the spindle turn? 8. What is the purpose of the automatic feed?

Homework Sheet 19. The Centre Lathe

1. With the aid of sketch explain facing off? 2. With the aid of a diagram explain Sliding or parallel turning? 3. What is taper turning? 4. How is taper turning carried out on the lathe? 5. How are holes drilled on the lathe, use a diagram to explain your answer? 6. How are finished pieces cut off from the rest of the material on the lathe? 7. What other operation can be performed using the above tool. 8. Sometimes it is necessary to have grip on a part how can this be carried out? 9. It is not always possible to get a drill to produce a hole to the size required how else can this be done? 10. How is a good surface finish achieved on the lathe?

Homework Sheet 20. The Centre Lathe

Calculate the spindle speed for each of the following tasks. A 25mm brass bar with a cutting speed of 540m/min is to be turned. With =3 calculate he spindle speed. A 30mm mild steel bar is to be turned, the cutting speed is 30m/min. calculate the spindle speed. A 50 mm aluminum bar with a cutting speed of 100m/min is to be turned calculate the spindle speed. A high carbon steel bar with a cutting speed of 15m/min and a diameter of 30mm has to be turned, calculate a suitable spindle speed.

1.

2.

3.

4.

Homework Sheet 21. Mechanical Joining.

1. Name four different types of rivet head? 2. Sketch the four types of rivet? 3. What type of joint do rivets produce? 4. What are pop rivets used for? 5. Sketch a pop rivet and say how it works? 6. Sketch a pop riveter that you have seen.

Homework Sheet 22. Mechanical Joining.

1. What is the job of a tap? 2. Name three different types of tap? 3. Sketch a taper tap and a tap wrench. 4. When cutting threads M6 what size hole would be drilled 5 or 6mm, explain your answer? 5. In threading what does the m stand for? 6. What conditions would lead to a tap breaking in the hole? 7. Describe all the stages in tapping a hole.

Homework Sheet 23. Mechanical Joining.

1. 2. 3. 4. 5. 6. 7. 8. What tools are used to cut external threads? Sketch a split die and name the parts? Sketch a stock for holding split dies and name the parts? When cutting threads of m5 on a bar what diameter should the bar be? Name four different types of thread? Which thread do we use most in the metalwork room? Sketch the four different thread types and give a use for each? What conditions could cause poor threads when cutting external threads?