MANUAL METAL WORKING

1. MANUAL METAL WORKING
BY- PRAKASH BEHERA 1

2. THE PROCESS OF SHAPING, CUTTING, AND
FORMING METAL MATERIALS USING HAND TOOLS
AND TECHNIQUES.
2

3. CONTENTS
1. WORK BENCH 11. SPANNER
2. VISE 12. SCRAING
3. FILES
4. MARKING TOOL
5. SYSTEM OF MARKING
6. TOOLS FOR MARKING
7. HAMMER
8. HACKSAW
9. CHISEL
10. SCREW DRIVER
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4. 1. WORK BENCH
A WORKBENCH IS A STURDY AND FLAT SURFACE
DESIGNED FOR VARIOUS MANUAL TASKS,
INCLUDING WOODWORKING, METALWORKING,
CRAFTING, AND OTHER HANDS-ON ACTIVITIES.
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5. WHEN IT COMES TO SETTING UP A WORKBENCH
OR WORK AREA, THE LAYOUT PLAYS A CRUCIAL
ROLE IN EFFICIENCY, PRODUCTIVITY, AND SAFETY.
HERE ARE SOME NOTES ON WORKBENCH LAYOUT
AND WORKPLACE ORGANIZATION:
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6. A. SPACE CONSIDERATION
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7. B. WORK BENCH PLACEMENT
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8. C. LIGHTING
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9. C. ERGONOMICS
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10. D. TOOL STORAGE
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11. E. MATERIAL STORAGE
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12. F. POWER OUTLETS
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13. G. SAFETY EQUIPMENTS
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14. 2. VISE
A MECHANICAL DEVICE USED TO HOLD AND
SECURE WORKPIECES DURING VARIOUS MANUAL
TASKS SUCH AS CUTTING, SHAPING, OR
ASSEMBLING.
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15. VICES ARE AVAILABLE IN VARIOUS SIZES, DESIGNS,
AND MATERIALS TO SUIT DIFFERENT
APPLICATIONS. SOME COMMON TYPES OF VICES
INCLUDE:
A. BENCH VISE
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16. B. HAND VISE
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17. C. LEG VISE
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18. D. MACHINE VISE
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19. E. HYDRAULLIC VISE
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20. F. PNEUMATIC VISE
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21. 3. FILES
FILES ARE VERSATILE AND ESSENTIAL TOOLS USED
IN MECHANICAL WORKSHOPS FOR SHAPING,
SMOOTHING, AND FINISHING METAL AND OTHER
MATERIALS.
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22. SOME COMMON TYPES OF FILES ARE-
A. FLAT FILE
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23. B. HALF-ROUND FILE
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24. C. ROUND FILE
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25. D. TRIANGULAR FILE
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26. E. SQUARE FILE
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27. F. NEEDLE FILE SET
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28. G. RASP
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29. H. DIAMOND FILE
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30. I. FILE CLEANER
30

31. the main parts of a mechanical workshop file:
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32. METHODS OF FILING
A. FLAT FILLING
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33. B. DRAW FILLING
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34. C. CORSS FILLING
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35. D. CURVED FILLING
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36. E. RASP FILLING
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37. F. SPOT FILLING
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38. G. BEVEL FILLING
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39. H. STRAIGHT FILLING
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40. 4. MARKING TOOL
MARKING IS AN IMPORTANT PROCESS IN A
MECHANICAL WORKSHOP THAT INVOLVES
CREATING VISIBLE INDICATORS OR REFERENCES ON
A WORKPIECE OR MATERIAL
40

41. 41

42. MARKING SERVES SEVERAL PURPOSES,
INCLUDING:
1. IDENTIFICATION
2. MEASUREMENT & LAYOUT
3. GUIDANCE FOR CUTTING OR DRILLING
4. ALLIGNMENT & ASSEMBLY
5. NOTATION OF CRITICAL INFORMATION
6. VISUAL INSPECTION
42

43. 5. SYSTEM OF MARKING
IN THE CONTEXT OF MARKING IN A WORKSHOP,
THE TERMS "POLAR SYSTEM" AND "RECTANGULAR
SYSTEM" ARE NOT TYPICALLY USED.
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44. Rectangular Coordinate System
IT IS BASED ON A SET OF PERPENDICULAR AXES
(USUALLY LABELED AS X AND Y). IT IS A TWO-
DIMENSIONAL SYSTEM USED TO DEFINE POINTS OR
LOCATIONS ON A FLAT SURFACE.
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45. POLAR COORDINATE SYSTEM
IT IS BASED ON DISTANCE AND ANGLE
MEASUREMENTS FROM A FIXED REFERENCE POINT
CALLED THE POLE OR ORIGIN.
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46. 6. TOOLS FOR MARKING
A. SURFACE PLATE
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47. B. MARKING STAND
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48. C. SCRIBER
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49. D. DIVIDER
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50. E. V-BLOCK
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51. F. ANGLE PLATE
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52. G. TRAMMEL
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53. 7. HAMMER
THE PRIMARY FUNCTION OF A HAMMER IS TO
DELIVER A POWERFUL BLOW OR FORCE TO DRIVE,
SHAPE, OR BREAK OBJECTS.
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54. PARTS OF HAMMER
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55. SPECIFICATION
1. HEAD MATERIAL
2. HEAD WEIGHT
3. HEAD SHAPE
4. HANDLE MATERIAL
5. HANDLE LENGTH
6. GRIP
7. FACE TEXTURE
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56. TYPES OF HAMMER
A. BALL PEEN HAMMER
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57. B. CORSS PEEN HAMMER
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58. C. STRAIGHT PEEN HAMMER
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59. D. NAIL HAMMER
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60. 8. HACKSAW
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61. TYPES OF FRAME
1. FIXED FRAME
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62. B. ADJUSTABLE FRAME
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63. C. JUNIOR FRAME
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64. D. BOW FRAME
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65. E. TABULAR FRAME
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66. F. PISTOL GRIP FRAME
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67. G. CONVERTIBLE FRAME
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68. SETTING OF SAW TEETH
1. CHOOSE THE RIGHT SETTING TOOL
2. INSPECT THE BLADE
3. DETERMINE THE SET REQUIRED
4. Position the Blade in the Setting Tool
5. SET THE TEETH
6. CHECK THE SET
7. ADJUST AS NEEDED
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69. SELECTION OF BLADE
1. MATERIAL TO BE CUT
2. TEETH PER INCH
3. BLADE LENGTH
4. BLADE THICKNESS
5. BLADE MATERIAL
6. BLADE DESIGN
7. CUTTING SPEED
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70. FIXING THE BLADE
1. CHOOSE THE RIGHT BLADE
2. PREPARE THE HACKSAW FRAME
3. POSITION OF THE BLADE
4. ALLIGN THE BLADE
5. CHECK THE BLADE TENSION
6. VERIFY BLADE POSITION
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71. PRECAUTION WHILE
HACK SAWING
1. WEAR PPE
2. SECURE THE WORKPIECE
3. CHOOOSE THE RIGHT BLADE
4. CHECK BLADE TENSION
5. USE PROPER TECHNIQUE
6. CUTTING FLUID/LUBRICANT
7. BE MINDFUL OF BLADE POSITION
8. WORK AT A COMFORTABLE HEIGHT
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72. SPECIFICATION OF BLADE
1. BLADE LENGTH
2. TEETH PER INCH (TPI)
3. BLADE THICKNESS
4. BLADE MATERIAL
5. BLADE GEOMOTRY
6. BLADE COMPATIBILITY
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73. 9. CHISEL
Chisels typically consist of a handle and a blade
made of high-carbon steel or other hardened
materials.
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74. TYPES OF CHISEL
1. BENCH CHISEL
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75. 2. MORTISE CHISEL
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76. 3. CARVING CHISEL
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77. 4. COLD CHISEL
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78. 5. BUTT CHISEL
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79. 6. PARING CHISEL
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80. 7. GOUGES
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81. MATERIAL OF CHISEL
1. HIGH CARBON STEEL
2. TOOL STEEL
3. CHROMIUM VANADIUM STEEL
4. STAINLESS-STEEL
5. CARBIDE TIPPED
6. CERAMIC
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82. 10. SPANNERS
SPANNERS, ALSO KNOWN AS WRENCHES IN SOME
REGIONS, ARE TOOLS USED FOR GRIPPING AND
TURNING NUTS, BOLTS, AND OTHER FASTENERS.
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83. TYPES OF SPANNER
1. ADJUSTABLE WRENCH
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84. 2. COMBINATION WRENCH
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85. 3. SOCKET WRENCH
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86. 4. BOX-END WRENCH
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87. 5. OPEN-END WRENCH
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88. 6. RATCHETING WRENCH
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89. 7. ALLEN WRENCH/ HEX KEY
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90. METHOD OF USING SPANNER
1. SELECT THE CORRECT SPANNER
2. POSITION THE SPANNER
3. APPLY PRESSURE
4. MAINTAIN PROPER GRIP
5. USE THE CORRECT TECHNIQUE
6. APPLY STEADY PRESSURE
7. CHECK THE TIGHTNESS
8. STORE PROPERLY
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91. 11. SCREW DRIVER
A SCREWDRIVER IS A HAND TOOL USED FOR
TURNING SCREWS, TYPICALLY WITH A SLOTTED OR
PHILLIPS HEAD.
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92. TYPES OF SCREW DRIVER
1. SLOTTED/ FLATHEAD SCREWDRIVER
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93. 2. PHILLIPS SCREW DRIVER
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94. 3. POZIDRIV SCREW DRIVER
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95. 4. SQUARE SCREW DRIVER
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96. PROPER HOLDING METHOD
1. CHOOSE THE RIGHT SIZE SCREWDRIVER
2. POSITION YOUR HAND
3. WRAP YOUR FINGERS
4. APPLY PRESSURE
5. ALIGN THE SCREWDRIVER
6. KEEP THE SCREWDRIVER STRAIGHT
7. APPLY STEADY FORCE
8. USE YOUR NON-DOMINANT HAND FOR SUPPORT
9. ROTATE THE SCREWDRIVER
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97. 12. SCRAPPING
IT INVOLVES THE USE OF SCRAPING TOOLS TO
REMOVE SMALL AMOUNTS OF MATERIAL FROM A
SURFACE, CREATING A SMOOTHER AND FLATTER
SURFACE FOR PROPER ALIGNMENT AND FITTING
OF MACHINE COMPONENTS.
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98. PURPOSE OF SCRAPING
1. PRECISION MACHINING
2. SURFACE FLATNESS
3. WEAR CORRECTION
4. ALLIGNMENT AND PARALLELISM
5. SURFACE QUALITY
6. RESTORATION AND REFURBISHMENT
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99. CONCLUSION
OVERALL, MANUAL METAL CUTTING TECHNIQUES
PROVIDE A FUNDAMENTAL BASIS FOR WORKING
WITH METAL MATERIALS.
BY MASTERING THESE TECHNIQUES, INDIVIDUALS
CAN PERFORM A RANGE OF METAL CUTTING TASKS
EFFECTIVELY AND SAFELY, CONTRIBUTING TO THEIR
SUCCESS IN METALWORKING ENDEAVORS.
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100. THANK YOU
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