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Hand Process

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92 views

Hand Process

Jhg

Uploaded by

mr1384853
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Manufacture Processes

Modern manufacturing can be divided into the following


four main categories: subtractive, additive, continuous,
and net shape.
Subtractive Processes:
Subtractive processes involve material removal via
machining (e.g., turning, milling, boring, grinding and
cutting)
 Additive Processes
Additive processes involve material being added, such as in
joining (e.g., welding), rapid prototyping, and 3D printing.
Manufacture Processes
Modern manufacturing can be divided into the following
four main categories: subtractive, additive, continuous,
and net shape.
Continuous Processes:
Continuous processes involve a product that is continuously
produced, such as in the extrusion of metals and plastics.
 Net shape Processes:
A net shape process occurs when the output is at or near its
final shape, such as stamping, forging, casting, injection
molding and blow molding.
Manufacturing is the process of converting raw materials
(either by manual labor or by machines) into finished
products, especially in large quantities.
Hand Process
Hand tools are used to remove small amounts of
material, usually from small areas of the
workpiece.
This may be done because no machine is
available, the workpiece is too large to go on a
machine, the shape is too intricate or simply that
it would be too expensive to set up a machine to
do the work.
The term bench work denotes the production of
an article by hand on the bench.
Cutting Tools
• They involve various types of files, scrapers, chisels,
drills, reamers, taps, and hacksaws
Files
 Files are used to perform a wide variety of tasks, from simple
removal of sharp edges to producing intricate shapes where the
use of a machine is impracticable.
 They can be obtained in a variety of shapes and in lengths
from 150 mm to 350 mm.
Cutting Tools
 A file has a single series of teeth cut across its face it is known
as single-cut file, and if it has with two sets of teeth cut across
its face it is known as double-cut file.
 The grade of cut of a file refers to the spacing of the teeth and
determines the coarseness or smoothness of the file. Three
standard grades of cut in common use, from coarsest to
smoothest, are bastard, second cut and smooth.
Files
• Used to remove burrs, nicks, and sharp edges
to smooth material
• Types
– Coarse: for soft material
– Fine: for smoother finished surface & harder
materials
Types of file

 There are different types of files such as flat, square, round, triangular,
knife, pillar, needle and mill.
Types of file
Hand file:
 The hand file is for general use, typically on flat surfaces.
 It is rectangular in cross-section, parallel in width along its length, but tapers
slightly in thickness for approximately the last third of its length towards the
point.
 It is double-cut on both faces, single-cut on one edge and is plain on the
second edge.
Pillar file:
 This file has the same section as a hand file but of a thinner section.
 It is used for narrow slots and keyways.
Flat file
 It is similar to hand file except that it both edges are single-cut.

Square file:
 It has a square cross-section, parallel for approximately two-thirds of its length,
then tapering towards the point. It is double cut on all sides.
 This file is used for filing keyways, slots and the smaller square or
rectangular holes with 90° sides.
Types of file
Three‐square file or triangular file:
 It has a 60° triangle cross-section,
 The three faces are double-cut and the edges sharp.
 This file is used for surfaces which meet at less than 90°, angular holes and
recesses.
Round file:
 The round file is of circular cross-section, parallel for approximately two-
thirds of its length and then tapering towards the point.
 This file is used for enlarging round holes, elongating slots and finishing
internal
Half round file:
 The flat side is double-cut and the curved side is single-cut on second-cut
and smooth files.
 This is an extremely useful double-purpose file for flat surfaces and for
curved surfaces too large for the round file.
File Safety
 Never use without handle
 Only apply pressure on forward stroke
 Hold with 2 hands
– 1 on handle & 1 on tip
 Hold firm
 Apply light, even pressure
 File slowly= 1 stroke per second
 Clean file with wire brush
 Never hammer on use as a pry bar
– Files are brittle and break easily sending small part flying like shrapnel
Hacksaw
• Most hacksaw blades are made in standard lengths of 8, 10, and 12 in.
• Blade length is the distance between the centers of the holes at each end.
• Hand hacksaw blades are generally inch wide and 0.025 in. thick.
• The kerf, or cut, produced by the hacksaw is wider than the 0.025-in
thickness of the blade because of the set of the teeth.
• The spacing of the teeth on a hand hacksaw blade is called the pitch and is
expressed in teeth per inch of length

The kerf is wider than


the blade because of
the set of the teeth. The pitch of the blade is expressed as the number of teeth per inch.
Hacksaw

Straight (alternate) set Wavy set


• The straight or alternate set in which one tooth is bent to the right and the
next tooth to the left for the length of the blade.
• The second kind of set is the wavy set, in which a number of teeth are
gradually bent to the right and then to the left.
• A wavy set is found on most fine-tooth hacksaw blades.
Selection of Hacksaw Blades
Cold Chisels
• Cold chisels are classified as Flat or cross cut according to the
shape of the point. They are made from high carbon steel,
hardened and tempered at the cutting end.
Flat:
• This chisel has a broad flat point and is used to cut thin sheet
metal, remove rivet heads or split corroded nuts.
• The cutting edge is ground to an angle of approximately 60°.
Cross-cut:
• This chisel has a narrower point than the flat chisel and is used
to cut keyways, narrow grooves, square corners and holes in
sheet metal too small for the flat chisel.

Flat
Cross-cut
Cutting Angles
Cutting angles
Rake angle (γ) :This angle helps in removing the chips away from the work piece.
Relief or clearance angle (α): It is the angle that allows the tool to cut without
rubbing on the work- piece.

Relief
Taps
Taps

Cutting action of spiral pointed taps.

Chamfer designations for cutting taps. Top to


bottom: starting tap, intermediate tap, and
bottoming tap

Tapping thread by hand


Thread-Cutting Dies
• A die is used to cut external threads on the surface of a bolt or
rod.
• Many machine parts and mechanical assemblies are held
together with threaded fasteners, most of which are mass-
produced. If necessary, the threaded portion of a bolt may be
extended with a die toward the head.
• Dies are used to cut external threads on round materials.
• Some dies are made from high carbon steel, but most are made
from high-speed steel.
• Dies are identified by the markings on the face as to the size of
thread, number of threads per inch, and form of thread.

A round split adjustable die


Thread-Cutting Dies
Adjustments on these dies are made by turning a fine
pitch screw that forces the sides of the die apart or
allows them to spring together.
The range of adjustment of round split adjustable dies
is very small, allowing only for a loose or tight

Diestock for round split


adjustable die
Holding Tools

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