UNIT III

WORKSHOP PRACTICE
LESSON 15:

Bench Working Processes plate, scriber, surface gauge, divider, centre punch & hammer,
Bench working processes comprise all those processes or angle plate, V-block, parallels, clamps, trammels and combina-
operations, which relate to filing, drilling, reaming and thread- tion set. Help of a number of measuring instruments like steel
ing of metal pieces and are accomplished with the help of hand scale, calipers, micrometer, bevel protector and sine bar is taken
operated bench working tools or fitter’s tools such as hacksaw, for measuring dimensions and angles during the process of
chisel, file,scraper and tap & die. These are conducted on the laying out and marking.
metal piece to bring it to the desired shape and size a product, So here you can take knife example mentioned above see what
which may form part of an assembly of a device or a machine tools can be used.
or may find some other, direct use.Like threading in nuts and
bolts, key way manufacturing, key manufacturing, chamfering Cutting and chipping processes
on corners, burr removing, etc. Various benchworking processes To be simple removing peel of potatoes, because potato is to
have been discussed under the following broad classification: be eaten and not the peel. So I can say peel is exta material which
needs to be removed. The operations used for removing excess
• ·Laying out and Marking Processes
material is nothing but chipping. Same way you peel peas,
• Cutting and Chipping Processes oranges and so on…
• Filing and Finishing Processes You cut potatoes into further small pieces to make chips, or
• Drilling and Reaming Processes vegetables or french fries after peeling is over. So this is nothing
• Threading Processes but cutting operation and chipping operation.
• Measuring Processes Cutting and chipping are the two main bench-working opera-
tions used for removing excess metal from a blank. Cutting is
• Fitting and assembling
performed with a hacksaw and is done either to cut the blank
Laying out and marking processes into pieces or to reduce it in size by removing a part of metal
These are not the complicated terms as they sound. In simple Similarly, chipping is done to shape the blank by removing extra
words, if you have to construct a buliding you need to draw the metal from its edge for reducing it in size. Chipping is also
layout on paper, drawing flow chart is layout of any done to cut a chase or slot on the sides (faces) or edges of the
programme, talior does the layout on cloth before stiching and blank. The operation of Chipping is performed with the help
so on…. of a chisel driven into the metal with hammer blows. Chipping
Same ways to make components you are required to do the is also used to cut rivets or nuts which get jammed due to
marking and layout on the workpiece blank. rusting. The chisel and hammer are sometimes used to cut flats
angles, plates, bars and rods. The process is often used for
The raw material in a fitting shop is received in standard market
cutting blanks in the steel yard or store.
sizes of different sections, like angles channels, rods, flats and
plates. A ‘blank’, which is a rough form (of the product to be
made, in shape and size, is first cut from the available stock. For
this, marking and laying out of the blank profile is first done
on the stock to provide guidance for cutting the blank from the
stock a, per the markings. Cutting may be done using a hand
shears, reciprocating power saw, chisel, hammer, hand hex saw
and sometimes even oxy-acetylene flame. The edges of the cut
blank (or blanks) are finished by grinding or filing. The cut
blank is straightened if it is bent. It is then prepared for
marking and laying further details to help subsequent bench
working operations.
Laying out relates to developing a guiding profile of the
product to be made on the blank and it is achieved by marking Cutting with a hacksaw.
or scribing centre points, circles, angles, straight lines, centre
distances between holes. Operations of cutting, filing or drilling
are later carried out on the blank along these markings. Accuracy
is the most important factor in marking a layout, because once
a work-piece or blank has been marked out, all the subsequent
operations of cutting, filing or drilling etc will be done only on
the markings. Tools used for marking generally include surface

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 brought to the drilling machine and the portable drilling
WORKSHOP PRACTICE

machine is either not available or may not be used for some

reasons. Boring can be done by using either a bigger size drill or
a reamer.

The operation of removing metal by chipping, Two long

parallel grooves or cuts along the cuter lines of the slot (to be Portable electric drilling machine. Drilling with Ratchet Brace
cut) are first material, cross cut chisel. Later the material between
the grooves is removed by chipping
Filing and finishing processes
Filing is done for bringing to correct size the blacks cut by
hacksaw, chisel, or any other method. Besides bringing the job
to correct dimensions, filing is also done for imparting a good
finish on the faces and edges of the job ,which may be flat,
slant, curved or circular. This is achieved with files of different The reamer is a precision tool and removes only small amount
shapes and sizes. Files used in the finishing operation have of metal. Reamers are available in different types and sizes.
hardened cutting teeth on their faces and edges to cut the metal Reaming is primarily done for sizing and finishing the drilled
when the file is pressed and pushed against the job surface. holes. It is also sometimes used for increasing the size of a
drilled hole slightly to help fitting a male mating pan in the
hole.

The operation of filing with the job held in the vice

Finishing is the operation of giving a smooth surface finish on
the job free of surface marks, scratches and undulations.
Finishing may be done on grinding machines of different types A Reamer, for finishing drilled holes
but in a fitting shop, the operation of finishing is accomplished Threading processes
usually with the help of a smooth file and ‘draw filing’ Threading is the operation of cutting threads (or screws) on a
technique .Hand scrapers of different types are used for finding work-piece. Threading involves cutting of internal threads with
flat and curved surfaces by removing high spots on the job the help of ‘taps’ mid external threading using a ‘threading die.
surface left during filing or machining operations like shaping, The tap has hardened cutting teeth. A hole is first drilled, little
planing or milling. smaller in size than the size of tapped hole (to be made). The
tap is inserted into the drilled hole and rotated with the help of
Drilling and reaming processes
a tap wrench or a handle fitting on the square shank of the tap
‘Drilling’ is the operation of making a hole and ‘boring’ is the
for cutting internal threads. A threading die has a split nut
operation of enlarging (in cross-section) the drilled hole.
(with cutting teeth) fitted in the Stock die stock. The job
Drilling is done by employing a rotating tool called ‘drill’ which
(usually a rod or pipe) is held in a bench vice and the threading
is pressed into the work-piece to make a hole. Drilling is
die stock is mounted at the end of the rod where threads are to
performed by employing different types of drills such as twist
be Split out cut. The die stock, when rotated with its handle,
drill, straight fluted drill or flat drill but a twist drill is most
moves along the rod leaving behind the cut threads.
common. Drilling is done with the help of a portable drilling
machine or a Bench Drilling Machine. Drilling with Ratchet
Brace is sometimes done in a large size job which can not be

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38 7.152
 It is a one dimension entity. Right. How do you find the

WORKSHOP PRACTICE
dimension? You use scale to measure and get the value of the
dimension. Now if you see carefully, it appears that two lines
are of different lengths. One is shorter than the other. This you
can predict only if you know the dimensions, and for getting
Tap dimensions you need to measure them. And the process is
known as measuring process.
Measuring or measurements of dimensions, surface finish, level
or plainness or trueness, of surfaces are important operations
carried out by a fitter using various marking and measuring
instruments. These instruments not only help in laying out job
profiles or working guidelines on work-pieces to the required
specifications, they also make possible comparing the finished
Die Set Handle work with the given dimensions, inspection and checking of
alignment, trueness Or flatness of surfaces and the surface
finish on the job. The marking and measuring instruments are
of various types according to the function they perform, for
example, for the linear measurement, instruments used include
steel scale or rule, dividers, calipers, surface gauge, mid microme-
Threading Metal ters. For the angular measurement, instruments used are bevel
protector. sine bar, combination set etc, For measuring plain-
ness of a surface, instruments used are level, straight edge,
w Threads may be cut surface plate, dial indicator and gauge blocks.
into a hole in metal w/ Fitting and assembling processes
a tap. The processes of ‘fitting’ and ‘assembling’ are in a way are
w A tap is a hardened, complimentary to each other. While ‘assembling’ is related to
brittle tool that cuts the process of joining together two or more parts to form an
threads into a hole. assembly the process of ‘fitting’ essentially ainis at making the
w A tap is turned w/ a tap assembling process possible by trimming, filing or scraping the
wrench. mating parts so that they could be assembled and fitted
together easily. Another essential feature of the operation of
fitting is ensuring a required ‘fit’ (or the relationship) between
the mating parts of the assembly as the functional requirement
of the assembly, Fitting is a regular process being carried out at
various stages of mass production through forming sub-
Threading Metal (cont.) assemblies of mechanical components. In the final stage, when
these sub-assemblies are fitted and joined together, they result
into the final machine in the marketable form. Later, during the
w Threads are cut onto a use of machines, fitting is carried out for the maintenance,
rod or bolt w/ a die. repair and replacement of worn out parts.
w A die is turned w/ a die
stock. Mind Teasers
w Common types of • Define bench working? How is it different from fitting?
threads used are • Name various bench working processes. Explain the role
National Course(NC), of laying out & marking processes?
National
Fine(NF/SAE), & • Expalin in short threading process giving and application?
metric. • Expalin the role of fitting & assembling processes?
References
1. Manufacturing Technology (Vol. 1) by- PN Rao
2. Workshop Technology (Vol.1) by- Hajra Chodhry
Measuring processes
3. Workshop Technology by- BS Raghuwanshi
4. Workshop Technology by- OP Khanna
What are these two? Lines. Obvisouly yes. Now I would like to 5. Workshop technology by- B.S.Raghuvanshi
ask how you define a line?
6. Workshop technology by- W A J Chapman

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