Topics to be covered
• Safety.
• Bench tools.
• Properties of Materials
• Metals.
• Drilling
• The Centre Lathe.
• Joining.
SAFETY
Signed . . . . . . . . . . . . . . .
Seven Safety Hazards
• Spring dividers
• similar to a compass
• used to draw circles.
• Set radius using adjusting nut
• puc mark can be used to hold it on the centre
• Engineers tri-square.
• Used to mark lines at 90 degrees on materials.
• Used to check corners are square.
• Handle called stock other part called blade
• Engineers rule.
• This is a steel ruler.
• Only millimetres are to be used
Bench tools
• Cold Chisels
• similar to punches
• used to cut metal
• Spring dividers
• similar to a compass
• used to draw circles.
• Set radius using adjusting nut
• puc mark can be used to hold it on the centre
• Engineers tri-square.
• Used to mark lines at 90 degrees on materials.
• Used to check corners are square.
• Handle called stock other part called blade
• Engineers rule.
• This is a steel ruler.
• Only millimetres are to be used
Bench tools
• Bench vice
• made from cast iron
• bolted to the table
• used with vice clamps (protects the work piece)
• Ball pein Hammer
• name from rounded side
• used with dot punch and chisels only
• must be held at the end of the handle
• The scriber
• used to draw lines on the metal
• made from carbon steel (wont wear).
• The Dot / Centre punch.
• Used to mark the centre of a hole for drilling (puc).
• Used to mark along a line especially steel.
• made from High carbon steel (hardened and
tempered)
Properties of
Materials
Surface properties
• Colour
• Transparent or Opaque
• Reflection
• Lustre
Mechanical properties
• Hardness:
• resistance to scratching or
indentation. Hardness can be
tested by:
• Brinell,
• Vickers or
• Rockwell hardness testers.
Mechanical properties
• Malleability:
• the ability to be beaten into thin
sheets, e.g. aluminium, copper,
etc.
• Ductility:
• allows a material to be drawn
into wire, e.g. copper, brass,
steel, etc.
• Elasticity:
• allows a material to return to
it’s original shape after it has
been deformed, e.g. rubber.
Electrical properties
• Electrical conductor:
• allows electrical current to flow,
e.g. copper.
• Electrical insulator:
• prevents current flowing, e.g.
pvc.
Thermal properties
• Melting point:
• the temperature at which a
material turns to a liquid.
• Thermal conductor:
• will transmit heat, e.g. copper.
• Thermal insulator:
• will slow down or prevent heat
from escaping, e.g. polystyrene
foam.
Mechanical properties
• Brittleness:
• can be fractured by impact, e.g.
glass.
• Toughness:
• can withstand blows or impact, it
is tested by Charpy or Izod testers.
• Strength:
• a measure of the ability to
withstand forces such as tension,
compression or torsion.
Metals
Ferrous Metals
Non-ferrous Metals
Alloys.
Useful Terms for metals
• Ferrous Metals.
• Any metal that contains iron is a ferrous
metal.
• Non ferrous metals.
• This is any metal that does not contain
iron.
• An alloy.
• This is a mixture of two or more metals.
• The charge.
• These are the materials that are put into the
furnace to produce the metal.
• The operation (smelting).
• This is how the furnace works how it
makes the metal.
• The products.
• These are the materials that come out of
the furnace.
Ferrous Metals.
Iron ore
Blast furnace
Charging bells
Blast Furnace
• The Charge :
• iron ore,
• coke,
• limestone.
• Operations
• the charge is loaded into the furnace using the
charging bells. The coke burns when hot air is
blown in through the tuyere “the blast” and the
impurities mix with the limestone to give slag. The
slag is taken off leaving molten iron to be tapped
off.
• The Products :
• molten iron,
• Slag
• waste gasses
Basic Oxygen Furnace.
• The charge:
• Molten Iron and
• scrap steel
• limestone
• The operation:
• charging
• the blow (water cooled oxygen lance)
• sampling
• tapping (molten steel)
• emptying slag
• The products
• molten steel
• slag
• waste gasses
Basic oxygen furnace
• The Charge :
• molten iron
• scrap steel
• limestone.
• Operations
• Scrap charging
• molten iron charging
• oxygen lance lowered in (water cooled.
• The blow
• sampling
• slagging
• tapping
• The Products :
• molten steel,
• Slag
• waste gasses
Basic oxygen Furnace.
• The charge:
• Molten Iron and
• scrap steel
• limestone
• The operation:
• The furnace is charged firstly with scrap steel.
Molten iron from the blast furnace is then charged.
• The oxygen lance is then lowered in and oxygen is
blown in causing the impurities and extra carbon to
mix with the limestone making slag. The lance is
kept cool with water. The steel is sampled to check
for the right amount of carbon. The furnace is tilted
and the molten steel poured out through the tapping
hole. The slag is then emptied out the top.
• The products
• molten steel
• slag
• waste gasses
Electric Arc Furnace.
• The charge:
• Molten Iron and
• scrap steel
• limestone
• The operation:
• the carbon rods and roof are lifted off. The furnace
is charged. The rods are lowered and an arc is made
between the charge and the rods producing heat.
The steel is sampled. The furnace is on rollers and
is tilted for slagging and then tapping.
• The products
• High Quality molten steel
• slag
Non Ferrous Metals.
• Aluminium.
This is silver in colour, it is very
strong but light and is malleable and
ductile. It is a good conductor of
heat and electricity. An oxide forms
on the outside preventing corrosion.
It is used for aircraft bodies, drinks
cans, high tension wires.
• Copper.
This is reddish brown in colour and
is malleable and ductile. It is a good
conductor of heat and electricity. It
turns green as it corrodes. It is used
in electrical wiring, heating pipes
and for roofing.
Non Ferrous Metals.
• Lead.
This is a very heavy metal, it is a dull
grey colour and is flexible at room
temperature. It is poisonous if
handled to often. It is used for
making batteries and also for
roofing.
• Zinc
This is a grey colour. It does not
corrode easily and so it is used for
galvanizing (coating steel) to stop
rusting.
• Tin
This is a silvery white metal, it is
weak and generally combined with
other metals.
Alloys.
An alloy: is a mixture of two or
more metals. Steel is one example.
• Brass.
This is a combination of copper and
zinc. It is a gold colour and does not
rust easily. It is used to make hinges,
screws, outside taps and musical
instruments.
• Bronze.
This is a combination of copper and
tin. It is a dark green colour and is
easily cast making it ideal for
statues.
• Soft solder.
This is a combination of lead and tin.
It has a very low melting point and
so it can be used to join electronic
components.
Machine tools
• The Base
• this is made from cast iron and is bolted to
the floor. It can be used to support large
pieces when drilling.
• The column
• This is attached to the base and supports
the table as well as the motor spindle and
the gears.
• The table.
• This is attached to the column and can be
moved up or down and can be rotated.
• The chuck
• This is connected to the spindle and is used
to hold parallel shank drills. The chuck is
tightened using the chuck key.
The Pillar drill.
• The Feed Lever.
• This moves the drill to and from the
piece.
• Adjustable depth stop.
• This is used to set the required depth of
the hole. It stops the drill going all the
way through the piece unless required.
• The Motor.
• This takes electricity and turns it into
rotary motion powering the spindle.
• The spindle and gears.
• Different gears are needed for different jobs.
The gears are connected to the motor and the
spindle allowing it to turn at different speeds.
The Pillar drill.
• Pilot hole.
• This is used before drilling a large hole so as
to keep the drill centred.
The Pillar drill.
• Tapping hole.
• This is drilled before threading a hole. The hole
must be smaller than the tap being used.
The Pillar drill.
• Clearance hole.
• This hole is slightly larger than the bolt
or bar passed through it.
The Pillar drill.
• Blind hole.
• This is a hole that does not go all the
way through a piece.
The Pillar drill.
• Countersink hole.
• This enlarges the top of the hole and
allows the head of a screw to sit in flush
to the piece.
The Pillar drill.
• Counterboring.
• This also enlarges the top of the hole to
allow cheese head screws to fit in flush
to the piece.
The Pillar drill.
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The Pillar drill.
Reamer.
The reamer is used to finish a drilled
hole. The reamer gives the exact size
hole, more rounded and a better
surface finish.
The Centre Lathe.
diagram
of lathe
The Centre lathe
• The Headstock.
• This part of the machine contains the
motor and the gearbox. The spindle is
connected to the gearbox. The spindle is
hollow to allow long bars pass through.
• The tailstock.
• This mounted on the slideways and can be
clamped in any position. It is used for
drilling and also in holding long bars.
• The slide ways.
• These are similar to train tracks and are
machined into the lathe bed. They guide
the tailstock and the carriage along the bed.
The Centre lathe
• The carriage.
• This moves between the head stock and the
tailstock. It is made up of the saddle and
apron. It is used to take sliding cuts.
• The Cross slide.
• This is attached to the saddle. It moves the
tool at 90 degrees and is used for taking
facing of cuts.
• Top slide / compound slide.
• This is attached to the cross slide and can
be set to any angle. It is used to cut tapers
on the work.
The Centre Lathe
• Spindle speeds.
• Different speeds are required for different
operations depending on the condition of
the lathe.
• Factors that effect spindle.
• The diameter of the work.
• The material being turned.
• The type of cutting tool.
• The type of operation.
• The condition of the lathe.
• Use of coolant.
• Method of holding the work.
The Centre Lathe
• Toolposts
There are three different type of tool post available:
• The four way toolpost.
• This can hold up to four tools at a time. The tools
are clamped by three locking bolts making it very
secure. The different tools can be rotated into
position quickly but changing the tools in the holder
takes time.
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The Centre Lathe
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The Centre Lathe.
Universal toolpost
The Centre Lathe
• Tool types.
• Tool bit.
• This is the one used in the engineering
workshop. The tool is ground from high
speed steel to the correct angles and held in
the toolpost. Smaller tools can be held in a
tool holder.
• Tipped tool.
• This is the typed of tool used on the cnc
machine. A tungsten carbide tip is clamped
to the tool holder. This tip can be replaced
when blunt.
The Centre Lathe
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• Drilling.
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• Centre Drill.
• This locates the centre of the bar for frilling
and acts as a pilot hole for normal drills.
The Centre Lathe
• Parting off.
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• Under cutting.
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• Fixed steady.
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Metal Joining
Bolts
Mechanical Joining.
Nuts.
Mechanical Joining.
Internal threading
• Holes can have threads cut into them
allowing parts to be joined together, this
is called tapping.
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Thermal Joining
Soft Soldering
• Passive flux.
• Protective fluxes prevent oxidation during
soldering but they do not clean the surfaces
first. They are used for electrical work and
anywhere that the parts cannot be washed
afterwards.
First Year Metalwork.
Workbook.
First Year Metalwork.
Workbook.
Rules for homework
1. Take down the question in red and
write your answers in blue or black.
2. Leave space after each question for
giving the answer.(5 lines)
3. All diagrams should be drawn with a
pencil and ruler.
4. All homework to be written in the
homework copy.
5. Homework copies will be collected
and signed by the teacher each week
if you do not have your copy it is
assumed you do not have your
homework complete.
Homework Sheet 1. Safety.
1. How should we enter the room and why?
2. How do we move around the metalwork
room safely
3. Why is it important to keep your desk
area tidy?
4. List five safety precautions or rules
necessary when using a machine?
5. Why is it necessary to return the tools to
the tool press at the end of class?
6. Why do we brush down the vices and
never blow the filings?
7. After tidying your desk, what do you do
before returning to your seat?
8. When leaving the room you have to
lineup. What is the reason for this?
9. If the fire alarms sounds what are you
supposed to do?
10. Finish the sentence, “accidents do not
happen they are “.
Homework Sheet 2.
Bench Tools
• Draw the tools into your copy and name all
the tools.
Homework Sheet 3.
Bench Tools
1. What is the bench vice made from?
2. What do we use a scriber for?
3 .What is the scriber made from and why?
4. What tool do we use to scribe circles on
metal?
5. What is a dot punch used for?
6. What tool is used to draw straight lines on
the metal and also used to make sure the
edges are square?
7. What tool is used to prevent the vice jaws
damaging the work piece.
8. A hacksaw is used for cutting large work
what tool is used to cut smaller work.
9. Why is it important not to move around the
room with tools.
10. Why must all the tools be put away
properly at the end of class
Homework Sheet 4.
Blast Furnace.
Draw the diagram and name the parts.
Homework Sheet 5.
Blast Furnace.
1. What is meant by the charge for the
furnace?
2. What is the charge for the blast furnace.
3. Where does the heat for the furnace
come from?
4. The charging bells allow the charge into
the furnace and stop heat getting out.
How?
5. What materials are produced in this
furnace and what are they used for?
6. How is the slag removed from the
furnace?
7. What is the purpose of the tuyere?
8. What are ferrous metals?
9. What happens to the waste gasses
produced in the furnace?
10. What is meant by the word tapping?
Homework Sheet 6.
Basic Oxygen Furnace.
Draw the diagram and name the parts.
Homework Sheet 7.
Basic Oxygen Furnace.
1. What is the charge for the basic oxygen
furnace?
2. What part of the charge is put into the
furnace first?
3. What is the oxygen lance used for?
4. How is the lance kept cool?
5. List the six steps in the production of the
steel?
6. Why do we have to take a sample of the
steel?
7. How is the slag removed from the furnace?
8. How is the steel removed from the furnace?
What is this called?
9. What two materials are mixed together to
produce the steel.
10. What type of metal is steel ferrous or non
ferrous?
Homework Sheet 8.
Electric Arc Furnace.
Draw the diagram and name the parts.
Homework Sheet 9.
Electric Arc Furnace.
1. What is the charge for the electric arc
furnace?
2. Where does the heat for this furnace
come from?
3. How is this furnace charged?
4. What are the steps in how this furnace
works?
5. How is the slag removed from the
furnace?
6. How is the steel removed from the
furnace?
7. What is the purpose of the rollers under
the furnace?
8. What advantage does this furnace have
over a basic oxygen furnace?
Homework Sheet 10.
Ferrous Metals
1. Name three types of ferrous metals?
2. Name the two materials combined to
make steel?
3. What is the difference between cast iron
and steel?
4. Give three uses for cast iron?
5. Give three uses for steel?
6. What is galvanized iron made from?
7. What is rusting?
8. Why do we coat steel with zinc?
9. Name two other ways to stop ferrous
metals from rusting?
10. What is pig iron also known as?
Homework Sheet 11.
Steels.
1. What are the two materials that
make up mild steel?
2. Give three uses for mild steel?
3. What is high carbon steel and what
is it used for?
4. What is silver steel made from?
5. What is it used to make?
6. What is tinplate, what is it used
for?
7. What is galvanized iron?
8. What is high speed steel and what
is it used for?
9. What is stainless steel made from?
10. What is stainless used for and
why?
Homework Sheet 12.
Non-Ferrous Metals and Alloys.