workshop hammer report

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TABLE OF CONTENT

1 Title Page 1

2 Table of Contents 23 Objectives 34 Introduction + (Theoretical background and Abstract) 35 Equipment 4-56 Experimental Method and Procedures 6-107 Results 118 Discussions 12-139 Conclusions 1310 List of References 1411 Appendices 14


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MAKING A PIN HAMMEROBJECTIVE

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 variousshaped stones were used to strike wood, bone, or other stones to break them apart and shapethem. 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 andstructure are often designed for a specific purpose. Usually, a hammer s features are a handle anda head, with most of the weight in the head. Currently, the basic design is hand-operated, butthere 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 lightweighthammer which is ultilised for very fine work. They are commonly used for nailing very smallnails, panel pins and tacks on the surface. Plus, pin hammers usually have lightweight woodenhandles, 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 differentoperations of machine such as milling machine, drilling machine, lathe machine (turningmachine) and so on. On top of that, appropriate precautions which should be taken will also bediscussed.

Figure 1 A commercial pin head hammer
http://en.wikipedia.org/wiki/Nail_(fastener)http://en.wikipedia.org/wiki/Nail_(fastener)


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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 2: hacksaw Figure 3: Turning machine (LATHE machine)

Figure 4: Drilling machine Figure 5: Milling machine

Figure 1:30 Parallel Bar


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Figure 6: Vernier Calipers

Figure 8: Ball Peen Hammer and Mallet

Figure 7:Double Cut File

Figure 9: Parallel Bars

Figure 11: Tap Wrench Figure 12 Die Wrench


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PROCEDURE

1. The steel rod was cut into 2 pieces by using hacksaw. One piece being longer, about165mm 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 byusing 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 is30mm from the 60mm in total length and 7.5mm from the width of the steel. And then, ahole 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 drillingmachine.

7. Lastly, the drilled steel rod is locked on table with clamp and the tapping wrench is usedto make the tread of the hole.


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(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 lathecenters.

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 14: (B) The Making of Handle of

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

Figure 13: (A) The Making of The Head ofThe Hammer. Step 4 The s teel rod is set 30

from the horizontal surface and was cut.


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Figure 15b: (A) The Making of Head ofThe Hammer. Step 7. Thread of thehole drilled is made with a tappingwrench on the secured hammer

head .

Figure 15a: (A) The Making of Head ofThe Hammer. Step 7. Thread of thehole drilled is made with a tapping

wrench on the secured hammer head.

Figure 16: (B) The Making of Handle ofThe Hammer Step 23. The hammerhead and handle are combined and iscovered with oil to prevent rusting.


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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 clampedtightly on the work rest.

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

observer s 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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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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http://en.wikipedia.org/wiki/http://en.wikipedia.org/wiki/http://en.wikipedia.org/wiki/http://en.wikipedia.org/wiki/

workshop hammer report

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