MABENGO N.D.

MMEPRA2 PROJECT APRIL 2015

TABLE OF CONTENTS

Content

Page

Introduction ............................................................................................................ 2
Material used and technical information .......................................................... 3
Marking out procedure ........................................................................................ 4
Tools used ............................................................................................................... 7
Reasons for choice of fasteners used ................................................................. 8
Drawing of the Bevel Protractor ......................................................................... 9
Discussion ................................................................................................................ 10
Conclusion ............................................................................................................. 10
References ............................................................................................................. 11

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 MABENGO N.D. MMEPRA2 PROJECT APRIL 2015

INTRODUCTION
In order for a student to be considered as though a student has successfully passed
the Mechanical Manufacturing Engineering module, he must complete a practical
project pertaining to all the theory learned during the semester.
In doing such, he will not only be exposed to a workshop environment but also apply
the theory learn in following scrupulously all the safety rules and regulations set out
thereto because as a future engineer, life of many people will depend upon him.
After being exposed to the workshop environment and using all the tools and
equipment he may find necessary to the completion of his project, he must
thereafter state all the activities he performed in the workshop in a form of report.
Consequently, the following is the summary of all activities performed and tools we
have used during our practical project which was based on the manufacturing of
bevel protractor from a 6mm thick plexi glass.
We therefore welcome all comments and suggestions which may be proven very
helpful in the perfection of this work as no mans work is perfect.

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MATERIAL USED AND TECHNICAL SPECIFICATIONS

A 6mm thick Perspex has been used to manufacture the Bevel Protractor requested.
Acrylic plastic sheet is produced in several formulations to provide specific physical
properties required for various types of applications.

Generally speaking, however, the physical characteristics of acrylics are:

Transparency - In colourless form acrylic plastic is as transparent as the finest optical
glass. Its total white light transmittance is 92%, the highest transmittance physically
possible of any material.
Breakage Resistance - Acrylic sheet has from 6 to 17 times greater impact resistance
than ordinary glass in thicknesses of 0.125" (0.3cm) to 0.250 (0.6cm). When subjected
to blows beyond its resistance, acrylic sheet reduces the hazard of injury because it
breaks into large relatively dull edged pieces which disperse at low velocity, due to
the light weight of the material.
Weather Resistance - The many years of actual outdoor exposure of acrylics in a
wide variety of applications, proving its weather resistance, cannot be matched by
any other transparent plastic material.
Chemical Resistance - Acrylic plastic has excellent resistance to most chemicals,
including solutions of inorganic alkalis and acids such as ammonia and sulphuric
acid, and aliphatic hydrocarbons such as hexane, octane and VM&P naphtha. It is
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 MABENGO N.D. MMEPRA2 PROJECT APRIL 2015

attacked by the following chemicals: Gasoline; Chlorinated hydrocarbons such as

methylene chloride, a solvent cement widely used, and carbon tetrachloride;
Aromatic solvents such as turpentine, benzene, and toluene; Ethyl and methyl
alcohol; Organic acids such as acetic acid, phenols and Lysol; Lacquer thinners and
other esters, ketenes, and ethers.
Light Weight - Acrylic sheet is less than half as heavy as glass: it is 43% as heavy as
aluminium and 70% as heavy as magnesium.
Dimensional Stability - Acrylic sheet is notable for its freedom from shrinking and
deterioration through long periods of use. Many drawing instruments requiring exact
dimensional stability have been fabricated from Plexiglas.
Combustibility - Acrylic sheet is a combustible thermoplastic and should be treated
as an ordinary combustible material such as wood. The self-ignition temperature
(spontaneous combustion) of acrylic is between 454 degree Celsius and 469 degree
Celsius. The temperature at which the material will ignite in the presence of a flame
is between 288 degree Celsius and 299 degree Celsius. While the ignition
temperatures of acrylic are higher than that of most woods, it burns vigorously and
generates heat rapidly when involved in fire. The primary products of acrylic
combustion are carbon monoxide and carbon dioxide; however, burning acrylic
plastic does not produce either excessive quantities of smoke or gasses more toxic
than those produced by burning wood or paper. Observe fire precautions
appropriate for comparable forms of wood and paper products.
Heat Resistance - The maximum "continuous service temperature" of acrylic is
between 82 degrees Celsius and 93 degrees Celsius depending on the particular
use. This means that while the material can withstand higher temperatures for very
short periods of time, it will soften and lose its form or shape if subjected to these
higher temperatures for any period of time. While acrylics respond to heat, they are
not affected by cold, and will not become cracked or brittle in cold weather.
Electrical Properties - Acrylic plastics are affected only a minor degree by
weathering or moisture. Its surface resistivity is higher than that of most other
materials, and makes an ideal insulator.

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 MABENGO N.D. MMEPRA2 PROJECT APRIL 2015

U-Factor - Heat transfer through 0.5cm thick acrylic is approximately 20% less than
through equivalent thickness of glass.
Ease of Fabrication - It can be sawed, drilled, and machined like wood or soft
metals. When heated to a pliable state, Plexiglas can be formed to almost any
shape.

MARKING OUT PROCEDURE

a)

Marking out equipment

The following marking out tools has been used:
-

120mm long scriber to scribe lines;

Engineers rule to take measurements

Dividers to draw radii

Protractor

Center Punch to punch tiny holes;

Dot Punch

Hammer to dot punch;

Vernier Callipers to take the exact measurements from the datum face;

Marking Blue.

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 MABENGO N.D. MMEPRA2 PROJECT APRIL 2015

b) Marking out procedure

The marking out procedure is quite a simple process because it only consist of
vertical lines:
1. I have sprayed the marking blue on the surface of the Perspex;
2. I chose datum faces from which all the measurements will start;
3. I have drawn an horizontal line 10 mm away from the datum face using the
scriber;
4. Thereafter I have drawn another horizontal line 40mm away from and at the
bottom of the previous line;
5. I have repeated the same procedure 4 times to have at least 4 pieces of
40mm each to allow for smaller pieces of 200mm each to be cut from a long
one.
6. Afterwards, from each piece obtained we have drawn centre lines from
which 10mm was drawn on the left and right-hand side to allow for the drilling
of holes.

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 MABENGO N.D. MMEPRA2 PROJECT APRIL 2015

TOOL USED

Bench Vice with standard serrated jaws to firmly handle work-pieces;

Hack saw to remove excessive material;

Hand file with a single cut body to remove the burst;

Hand file with a smooth grade to have a smooth surface finish on the borders;

Round file for radii;

Set of fine files to smoothen the internal groove of the top part of the
protractor.

Pillar drilling machine with a speed of 750 rpm (high) for centre drill and a
speed of 1000 rpm (low) for 8 mm and 6 mm drills hole.

8mm and 6mm High Speed Steel drill bits.

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 MABENGO N.D. MMEPRA2 PROJECT APRIL 2015

REASONS FOR CHOICE OF FASTENERS USED

All the fasteners used in this project are, first of all manufactured by a well-known
brand: Eureka, to be more precise.
M8 Wing nut: this kind of fastener is used firstly because an 8mm groove is to be cut
on the moving side of the protractor and secondly, a wing nut allows for adjustments
to be made without using a tool. This nut will be used together with an 8mm x 30mm
bolt for a better clearance when tightening or untightening the protractor.

M6 screws: are used to hold the connecting piece in the middle and the two ruler
elements of the protractor together because they have a better grip.

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DRAWING OF THE BEVEL PROTRACTOR

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 MABENGO N.D. MMEPRA2 PROJECT APRIL 2015

DISCUSSION
This assignment was a good test to challenge our abilities both theoretically and
practically as we had to make some research on one hand and on the other hand
we had to master our hand skills.
In addition to what is said above, we have found
it a unique opportunity to discover the properties
of Plexiglas and it uses as an alternative to toxic
and not so environmental friendly materials.
As to the manufacturing of the Bevel protractor
as requested, working with Plexiglas was not very
difficult as it is a mild material compared to steel
or aluminium; less force was put into action and
the whole process was as fast as one can
imagine. The only difficult part was the cutting of
the groove where the wing nut had to be inserted; it required more meticulous
techniques such as drilling first holes of 7.5mm along the drawn groove and the use
of fine files to smoothen its corners and surfaces.

CONCLUSION
Be it as it may and at the wrapping up stages of this report, this conclusion
can only take the form of a suggestion in the sense that in future work-pieces
should be made out of different materials such as steel or aluminium to afford
students the opportunity to grasp knowledge on these materials and to get
skills and techniques to work on same.

The final assembled product

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REFERENCES
1. Salmon, D. & Powdrill, P., 2002. Mechanical Engineering Level 2 NVQ: Performing
Engineering Operations. Oxford: Elsevier.
2. Engelbrecht, J., 2008. Engineering Graphics and Design. Hatfield: HSE cc.
3. Groover, M.P., 2013, Principles of Modern Manufacturing. John Wiley & Sons, Inc.

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