Republic of the Philippines

BATANGAS STATE UNIVERSITY

The National Engineering University
BatStateU-Alangilan, Batangas City
College of Engineering
https://batstate-u.edu.ph/, Tel. No. (043) 425-0139 loc. 2121

ME 403 - WORKSHOP THEORY AND PRACTICE LAB

LABORATORY REPORT #2 - BENCHWORK,

LAYOUT AND PATTERN MAKING

Submitted by:

De Luna, Perrie Jabez H.

21-09373

BSME - 2112

Presented to:

Engr. Niel Ivan Vergara

November 2022
I. Introduction

Benchwork, layout and pattern making are key skills to master for design manufacturing
and maintenance repair. Handwork requires years of experience and can be a technician's most
challenging skill. The Layout and Bench Work training course identifies the basic hand tools and
hand work methods required to manufacture replacement or repair parts.

Bench work is work carried out at a bench in a laboratory or workshop. It provides the
basic working knowledge of the production and properties of different materials used in the
industry. It also explains the use of different tools, equipment, machinery and techniques of
manufacturing, which ultimately facilitate shaping of these materials into various usable forms.
Layout is the process of marking a workpiece prior to cutting in order to have a visual guideline
during cutting operations.

Benchwork includes various cutting processes that machinists complete by hand rather
than on a machine when creating part features that require less power and force. Common
benchwork operations include hand tapping, hand reaming, hand filing, and engraving. A Pattern
making may be defined as a replica model of the desired casting which, when packed in a
suitable molding material, produces a cavity called mold. This cavity, when filled with molten
metal, produces the desired casting after solidification of the poured metal. A ‘Pattern
Development’, or simply a ‘Development’ is a full size layout of an object made on a surface of
the flat metal sheet. It is the surface area of a product or an object that has not yet been folded or
rolled.

II. Objective

● To describe tools and methods for workpiece layout, bluing, measuring, scribing lines,
and marking hole centers.

● To describe tools and methods for hand cutting material with a hacksaw, including
hacksaw parts, blade types, cutting edge alloys, and tooth pitch.

● To describe the different types of files and methods for filing and draw filing.
III. Materials and Tools/Instruments

Benchwork Tools and Equipment

● A punch made from a steel rod with a length of 90 to 150 mm and a diameter of
8 to 13 mm is used in bench work for marking purpose and locating centers in a
more permanent manner. The punch with a tapered point angle of 400 is called a
prink punch and that of 600 point angle is called a center punch.

● Calipers are the devices used for measuring and transferring the inside or outside
dimensions of components. Although gradually they are being replaced by the
more accurate and precision instruments and gauges, like micrometers in modern
workshops, still they stand as the in general work on account of their cheapness
and ease in handling.

● Screw Drivers is a very useful hand tool for rotating the screws. It consists of a
wooden or a plastic handle and steel blade, shaped at the end. The flat end of the
tool is inserted into the slot provided on the head of the screw for rotating it.
Screwdrivers are made in various sizes to suit the corresponding sizes of the slots
on the screw heads. Sometimes a star headed screwdriver is used for star headed
screws.
● Drill. Drilling is an important operation carried out in a fitting shop for producing
different types and sizes of holes in various materials. There are many forms of
drills used for this purpose.

● Tap. The hand operated taps used in fitting shops are employed for cutting
internal threads in cylindrical holes or for cleaning damaged threads in similar
parts. A tap consists of a toothed body having flutes (usually 4) cut on its surface,
a round shank and a square formation at the end of the shank.

● Dies and stocks. Dies are used to cut threads on a round bar of a metal, such as
the threads on a bolt. It is a round or square block of hardened steel with a hole
containing threads and flutes which form cutting edges. Die may be a solid or
adjustable type. Solid die has fixed dimensions. An adjustable die may be split
type with a split through one side or two-piece rectangular type.

● Scraping is a very important hand operation in bench work employed for

obtaining a fine surface finish on the work, particularly for removing convex
spots from machined surfaces, and the tools used for doing this operation are
known as scrapers.

● The hammer is one of the most widely used fitter’s tools. It is used for striking
chisels in chipping and cutting and the punch in marking.
Layout Tools and Measuring Instruments

● Scriber - is a layout tool that is used to produce these fine and accurate lines. The
point is made of hardened steel and is kept chain by honing on an oilstone.

● Divider - when laying out circles, arcs, and radii, it is best to use the divider. The
legs of the divider must be of the same length and be kept sharp. The divider cart
can be used to lay out and measure distances.

● Trammel - can be made to scribe larger distances with the use of extension rods.
This layout tool is set in the same manner as the divider.

● Hermaphrodite Caliper - is a tool used to layout lines that are parallel with the
edges of the workpiece.

● Surface Plate - provides a true and smooth, plane surface. It is used in

conjunction with surface and height gauges as a level base on which the gauges
and the workpiece are placed to obtain accurate measurements.

● Vernier Height Gauge - is a caliper with a special foot block to adapt it for use
on a surface plate.

● Surface Gauge - is used for many purposes but is most often used for layout
work. The gauge can be used to scribe layout lines at any given distance parallel
to the work surface.

● Bevel Protractor - consists of an adjustable blade with a graduated dial.

● Combination Square Set - is used for a number of layout operations. The set
consists of a blade (graduated ruler), square head, protractor, and center head.

● Steel scale is a single piece linear measuring instrument. The steel scale indicates
two units that are cm and inches, cm division on one side and inches, on another
side.

● Vernier Caliper is a widely used linear measurement instrument with a least

count of 0.02 mm. It is used to measure linear dimensions like length, diameter,
depth.

● External Micrometer is also known as Outside Micrometer. It is used to check

the outside diameter of the circle by means of the accuracy of 0.01 mm or up to
 0.001 mm.

● Vernier height gauge is used to measure vertical dimension from reference

ground. Vernier Height Gauge consists of a graduated scale or bar that is held in a
vertical position by a finely ground fixed base.

● Vernier Depth Gauge as the name suggests is used to measure the depth from the
surface of reference of an object.

● Vernier Bevel Protractor. A simple protractor is a basic device used for

measuring angles with a least count of 1° or ½°.

● The dial indicator or the Plunger dial gauge is one of the simplest and the most
widely used mechanical comparators.

● Lever Dial Gauge is also known as Test Indicator. It is used to measure sensitive
contact.

● A ruler can be used to draw straight lines but there is no guarantee that the line
drawn is accurate and exactly straight, this is where the engineering square is
brought into use.

● V-Block. In Industries where precise marking and firm holding of objects is

required, V-Blocks play a major role and are extremely important metalworking
jigs.

● Radius Gauge. Gauges are derived from the French word ”jauge” which means
the result of the measurement.

● Digital Vernier Caliper is an upgraded version of Analog Vernier Caliper, which

is a widely used linear measurement instrument with a least count of 0.01 mm,
more accurate than Analog.

● Inside Micrometer is used to measure the larger internal dimension. The

Micrometer can measure the internal Diameter of holes and registers.

● Depth Micrometer. We also measure depth through the Vernier caliper, but the
Vernier caliper does not deliver as much accuracy and precision, because the
extension rod of the Vernier caliper has no standard, it is used only for
comparison purposes.
 ● Measuring tape is used to measure long distances.

● Spirit level is used to check the level of any surface or table, a spirit level is used
for leveling.

● Feeler gauge is used to measure the clearance between two parallel flat faces for
example piston and cylinder.

IV. Procedure

Bench Work Processes

1. Primary shaping processes - Some of these finish the product to its usable form
whereas others do not, and it requires further working to finish the component to
the desired shape and size.

2. Machining processes - Large numbers of components need further processing

after primary processes known as secondary operation to obtain desired shape and
dimensional accuracy.

3. Joining processes - These processes are used for joining metal parts and in
general fabrication work.

4. Surface finishing processes - These processes should not be misunderstood as

metal removing processes in any case as they are primarily intended to provide a
good surface finish or a decorative and/or protective coating on to the metal
surface, although a very negligible amount of metal removal or addition may take
place.

5. Processes effecting change in properties - These processes are employed to

impart certain specific properties to the metal parts to make them suitable for
certain operations. Most physical properties like hardening, softening and grain
refinement etc., call for a certain heat treatment.

Some Common Bench Work Processes

1. Marking

2. Chipping

3. Sawing

4. Filing

5. Draw Filing
 6. Threading

7. Grinding

Procedure in Laying-out

1. Study the shop drawing or blueprint carefully before you cut off the stock. Allow
enough material to square the ends if required.

2. Remove all oil and grease from the work surface and apply layout dye.

3. Locate and scribe a reference or base line. All the other measurements should be
made from this. If the workpiece already has one true edge, it can be used in place
of the reference line.

4. Using the base line as a reference line, locate and scribe all center lines for each
circle, radius, or arc. Mark the points where the center lines intersect using a sharp
prick punch.

5. Scribe all circles, radii, and arcs using the divider or trammel.

6. Using the correct type protractor, locate and scribe all straight and angular lines.

7. Scribe all lines for internal openings.

8. All layout lines should be clean, sharp, and fine. Reapply layout dye to all messy,
wide, or incorrect lines and re-scribe.

V. Conclusion

In conclusion, the fundamentals of benchwork, layout, and pattern making are necessary for
design, manufacturing, and maintenance and repair. Handwork takes years of practice and can be
the most difficult skill for a technician to master. We learned that bench work is work done at a
bench in a lab or workshop, laying out is the process of marking a workpiece before cutting so
that cutting operations have a visual guideline, and pattern making is the act of creating a replica
model of the desired casting that, when packed in an appropriate molding material, creates a
cavity known as a mold. We describe tools and methods for workpiece layout, bluing, measuring,
scribing lines, and marking hole centers. We also learned different types and instruments used for
bench work, layout, and pattern making like screwdrivers, drills, scribers, gauges, and calipers
etc. We also learned different kinds of processes from benchwork, like marking, sawing and
grinding, from laying-out and pattern making. All of the tools and procedures require safety to
avoid accidents so better be careful all the time.