ABE 31Engineering Shop

Submitted by:Anjelou M. Ibañes

Jeezle Irish M. RoyoMark Lester Teodoro

B-2L / Group3

Submitted to:Ralph Kristoffer Gallegos

Partial fulfilment of the requirements in ABE 31: Engineering Shop 2nd Semester, AY 2013-2014

April 4, 2014

ABOUT THE AUTHORS

ANJELOU M. IBAÑES2010-67123Bachelor of Science in Industrial Engineering

Anjelou is a conversationalist and loves to talk for hours. She is a girl who wants to take risks and enjoys the challenges that come her way. Amidst the obstacles that she faces, she still sees the world as a wonderful place. She is someone who is easy to love and considers hanging out with her family and friends as a time well spent. Being a girl who is fond of taking challenges, she considers the practical exam as the most memorable part of ABE 31. In the said exam, not only was she tested mentally but also physically and emotionally.

JEEZLE IRISH M. ROYO2010-56950Bachelor of Science in Industrial Engineering

Smart, funny and lovable – that’s Jeezle. She is artistic and sees beauty in everything. Most often, she looks at herself as inferior to others; unknown to her, she is seen as strong, compassionate and extraordinary. Once she starts reading a book, she can’t seem to stop flipping the pages and finishes a book in no time. She is keen in choosing her friends but once she acknowledges someone as such, she makes efforts to keep the relationship intact. Learning has always been her thing and she found the Art in Welding very challenging and takes pleasure in doing every part of it.

MARK LESTER G. TEODORO2010-32344Bachelor of Science in Industrial Engineering

Mark believes in the three principles, wisdom, diligence and courage. With these three principles, he faces all challenges optimistically. Although some people see studying as a hardship, he sees it as an opportunity to improve his horizons. He loves being surrounded by people who make him happy and most often, these people are the ones that keep him going.

Of all the activities done, making the stool is the most memorable for him because he sees wonder in experiencing how a very common furniture is made.

ACKNOWLEDGEMENT

The group would like to extend their sincerest gratitude to the people who, in one way or another helped in the completion of this paper.

First and foremost, the group would like to thank the Almighty Father for his guidance and unconditional support during the conduct of every activity in the laboratory and for keeping everyone safe.

To Assistant Professor Fernando O. Paras, Jr., for sharing his knowledge and teaching the basic tools and concepts needed in the completion of the projects.

To Ralph Kristoffer Gallegos, for helping in the accomplishment of every requirement that needs to be fulfilled and proving the group all the guidance that they need whenever they make their projects.

To the technicians, Mang Medes, Mang Eugene and Foreman for guiding the group in undertaking the processes that they need to learn and for teaching the basic concepts and processes that every student needs to know.

Without their efforts, the completion of this projects would not have been a success.

1.0 FOLDING STOOL

I. Introduction

Wood is one of the most common materials used in engineering application. It is a material used in making furniture, floorings, household utensils and interiors which is derived from the fibrous structural tissue found in trees and woody plants.

In the Philippines, wood is considered as the most common shop material because of its relative abundance compared to others. Also, it is known to resist high flexural stress which makes it very practical in being used as beams and trusses. Wood is also relatively lighter than metal and significantly cheaper depending on the type of wood.

Using wood as a product material entails several considerations such as quality, cost, species, surfacing and working. Evaluation of how these factors can affect the wood construction should be done in order to ensure that the product produced will last for a long time and serve its purpose while minimizing costs.

One particular application of wood is in the production of a folding stool. In this project plan, the processes involved in constructing a stool out of wood together with the other materials and tools used are illustrated.

II. Objectives

This project aims to introduce the basic foundations of woodworking. At the end of this project, the student must:

be familiar with the tools used in woodworking identify the functions of each tool and machine used in woodworking practice safety in woodworking operation be knowledgeable of the processes undertaken in making a folding stool appreciate the importance of wood in production

III. Materials and Methods

A. Materials

The materials used in this project include: Lumber Nails Flat washers Copper rod Wood glue

In Table 1, the tools and equipment used in making the folding stool is enumerated and classified according to their corresponding function.

Table 1. Tools and equipment used in folding stool making classified according to function.

Layout tools

Cutting tools

Boring tools

Driving tools

Holding tools

Power tools

Steel tape Hand saw Power bit Curved claw

hammer

Bench vise Drill press

Try square Wood chisel

Twist drill bit

Radial arm saw

Metal rule Smoothing plane

Marking gauge

Jointer planeSpoke shave

B. Methods

1. Using a smoothing planer, make the sides of the pre-cut wood pieces into an s2s lumber. In order to secure the wood while making the sides of the wood smooth, use the bench vise.

2. Check the two smoothened sides of the wood if they are perfectly perpendicular to each other using a try square. Do the same on all the wood pieces.

3. Mark the smoothened sides of the wood with a thickness equal to 2cm and width of 4cm using the marking gauge.

4. Using a jointer planer, remove the excess wood.5. Measure the distance of the circles that needs to be drilled using a metal

rule then create a mark using a pencil. Do it to all the woods that need to be drilled.

6. After creating the mark, bring the woods to the drill press. Using a twist drill bit, drill the woods from one end to another. Then, use the power bit to make a bigger hole which is approximately 1 inch deep. Put flat washers in each drilled holes.

7. Align the 46cm and 25cm pieces of wood and clamp it using the bench vise.

8. On one end of the woods, use the spoke shave to make a curve.9. Mark the 46cm woods using pencil wherein you will use a wood chisel to

form a curve that will serve as the support when the folding chair is formed. Make a 1 inch deep hole.

10.Mark the 25cm woods using a pencil. Again, use a wood chisel to form a 1 inch deep rectangular hole to the wood. This will be the utilized in connecting the two front legs.

11.Put wood glue in the holes of the woods then insert the 20.6cm wood in order to connect the front legs. The connected woods were then clamped on a bench vise to ensure maximum glue contact.

12.The 35.5cm long wood pieces were nailed on the connected woods in a distance of 2cm between each other except for the two middle woods which are nailed exactly adjacent each other.

13.Cut the feet of the stool using a handsaw to make it level with the floor. 14.Use sand paper to make all surfaces of the assembled folding stool

smooth.15.Varnish was applied to protect the wood and improve its appearance.

IV. Bill of Materials

Table 2. Bill of materials for the folding stool.

Item Description QuantityUnit Cost

(Php)Total Cost

(Php)

Lumber11’x2’’x12’½’x2’’x7’

1 179 179

Copper tube ¼’’ 1 32 32

Flat washer

¼’’ inner diameter¾’’ outer diameter

12 0.40 4.50

Common nail 1’’ 28 0.08 2.25

VarnishPlastic varnish

(walnut)1 bottle 23 23

Total 240.75

V. Finished Projects

Anjelou M. Ibañes Jeezle Irish M. Royo

Mark Lester G. Teodoro

2.0 Barrel Bolt

I. Introduction

Metals are most commonly used in construction industry such as for roofing of houses, trusses in buildings, manufacturing industry for the machinery parts, and automobile industry. It is used in a wide variety of materials ranging from the jewellery you wear to the materials used in the construction of your house.

Metals are used because of their different characteristics that enhance the quality of the desired product to produce. The general classifications of metals used in bench metalwork are ferrous metals such as cast iron and steel and non-ferrous metals like gold and bronze. The metal comes in different form like sheets, rods, wires and bars.

In relation, several factors should be taken into consideration when deciding what type of metal is the most appropriate to use. Metals can be chosen based on the characteristics such as malleability, rust-resistant properties, toughness, hardness and appearance.

One particular example of the application of metal is the production of barrel bolt. In this project plan, the materials use and the procedures in making the barrel bolt is discussed and illustrated in this project plan.

II. Objectives

This project aims to introduce the basic foundations of metalworking. At the end of this project, the student must:

be knowledgeable in metalworking especially using flat bars through producing a barrel bolt

be at ease in using the tools used in metalworking observe proper safety procedures while working on the project apply the safety precautions and measures in handling metal tools appreciate the importance of metal in everyday life

III. Materials and Methods

A. Materials

The materials used in this project are:

Flat bar Round bar Steel rod Electrode Chalk 3 pieces of pre-prepared 15mm long bushing Sand paper

Table 3, shows the tools and equipment used in making the barrel bolt. The equipment/tools are classified according to their function.

Table 3. Tools and equipment used in barrel bolt making classified according to functionLayout Tools

Cutting Tools

Driving Tools

Holding Tools

Other Tools

Power machines

Steel Rule Chisel Ball pen

HammerMachinist

Vise Metal Files

Electrode Arc

Welding Machine

Try Square

Chipping Tool Vise Grip

Engine Lathe

Machine

Scriber Hack Saw Drill Press

Center Punch

Floor Shearing Cutter/Bar

CutterPower

Hack SawGrinder

B. Methods

1. Prepare all the materials needed in making the barrel bolt. Make sure that all the materials and equipment needed are correct and complete.

Also, prepare the appropriate personal protective equipment (i.e. gloves, goggles)

2. Using the floor shearing cutter, cut a 220mm long by 50mm flat bar.3. Cover one surface of the 220mm-long flat bar with the chalk. This will

make the construction lines that you will create later on more visible.4. Using the scriber, steel rule, and try square, follow the layout shown in

Figure 2 -1.

Figure 2-1. Layout of the barrel bolt.

5. Encircle the intersections of the lines as indicated in Figure 2-1 using the chalk. If possible, use chalk of different color.

6. Using the center punch and the ball peen hammer, mark the encircled intersections of the lines. To deepen the mark, repeat the process while the workpiece is on top of the anvil.

7. Drill a 6mm diameter hole using the drill press.8. Using the grinder, remove the sharp edges created from the drilling

process.9. Make a triangle end from the right end of the flat bar (See Figure 2-2).

Figure 2-2. Right-end of the flat bar

10.Weld the pre-prepared bushing to the flat bar. (Note: use continuous weld)

11.Set aside the flat bar.

12.Cut a 140mm long steel rod.13.Bend the steel rod using the ball peen hammer. Use the bench vise to

hold the rod in place. To make sure that the bend created is perpendicular, use the try square.

14. Insert the rod in the bushing connected to base of the barrel bolt (flat bar).

15.Make a spot weld on the steel rod between the two bushings.16.From the right end of the barrel bolt, cut the 50mm part using the

power hack saw.17.Wash the barrel bolt with water to remove the cooling agent.18.Remove the flux from welding using the chipping tool. Make sure that

all the flux is removed to ensure a good finish.19.Using the file, remove the sharp edges from cutting and the beads

from welding.20.Use sand paper to remove rust from the metal as well as to smoothen

the surface of the barrel bolt.21.Paint the barrel bolt.

IV. Bill of Materials

Table 4. Bill of materials for the barrel boltITEM DESCRIPTION QUANTITY UNIT COST TOTAL COST

Flat Bar 220mm x 50mm 1 120 120

Steel Rod 3.8” Diameter x 5.5” long 1 120 120

Round Bar 1 120 120Electrode E-6031 1 2.50 2.50

Total 362.5

V. Finished Projects

Anjelou M. Ibañes Jeezle Irish M. Royo

Mark Lester G. Teodoro

3.0 CANDLE HOLDER

I. Introduction

Sheet metal working has a significant impact commercially. Its most common applications include automobile bodies, utensils, cabinet’s appliances, electronic components, electrical parts, and aerospace parts. It is used in cutting and forming operations of relatively thin sheets of metal. A sheet metal is characterized as a plate with thickness of less than 5mm.

Sheet metal work has its own significance in the engineering work to meet our day-to-day requirements making it one of the most common choices in producing products. As compared to casting and forging, sheet metal parts offer various advantages like lower cost, lighter weight, higher strength, good dimensional accuracy and surface finish. In addition, machining is no longer required in sheet metal working; therefore, the time taken in sheet metal working is almost half of that required in machining process.

Candle holder is one of the many products that make use of sheet metals as its primary material. In this project plan, the processes involved in making a candle holder together with the other materials and tools used are illustrated.

II. Objectives

This project aims to introduce the basic foundations of sheet metal working. At the end of this project, the student must:

be familiar with the tools used in sheet metal working identify the functions of each tool and machine used in sheet metal

working practice safety in sheet metal working operation be knowledgeable of the processes undertaken in making a candle holder appreciate the importance of sheet metal in production

III. Materials and Methods

A. Materials

The materials used in this project include: Sheet metal Nicolite lead Muriatic acid

In Table 5, the tools and equipment used in making the candle holder is enumerated and classified according to their corresponding function.

Table 5. Tools and equipment used in candle holder making classified according to function.

Layout tools

Punching tools

Holding tools

Driving tools

Power tools

Other tools

Scriber Jigs C-clamp Ball peen hammer

Foot square shear

Soldering rod

Steel rule

Bench vise

Bending machine

File

Try square

Round cutter

Center punch

Hydraulic shop press

Grinder

B. Methods

1. Measure a 12cm x 12cm square in the sheet metal. Layout the measurements using a scriber and cut the sheet metal using the foot square shear.

2. Locate the center of the cut sheet metal by forming two diagonal lines from the corners using a scriber. Mark the center by utilizing a center punch and ball peen hammer.

3. Using the marked center as a basis, place the sheet metal in the round cutter then cut it into a circle with a diameter of 10 cm.

4. Use the grinder to remove any excess metal on the workpiece.

5. In the circular sheet metal, make a dent that corresponds to the pre-shaped die in the hydraulic press.

6. Measure a 3cm x 6cm rectangular area in another sheet metal. Layout the measurements using a scriber and cut the sheet metal using the foot square shear.

7. Drive the 3cm x 6m sheet metal into the round bar using a ball peen hammer. Use a bench vise to hold the round bar and sheet metal.

8. Make a fillet at the bottom of the cylindrical sheet metal using a ball peen hammer and jigs.

9. Layout 1.5cm x 22cm in the sheet metal and cut it according to the layout using a foot square shear.

10.Bend the sheet metal using a bending machine.11.Solder all the parts together using a soldering rod, Nicolite lead and

muriatic acid.

IV. Bill of materials

Table 6. Bill of materials for the candle holder.

Item Description QuantityUnit Cost

(Php)Total Cost

(Php)Sheet metal (gauge 22)

0.5’ x 0.5’ 1 35 35

Nicolite lead 1’’ 1 40/rod 4Muriatic acid 1/8 bottle 1 60/bottle 7.5

Total 46.5

V. Finished Projects

Anjelou M. Ibañes Jeezle Irish M. Royo

Mark Lester G. Teodoro

4.0 GEAR

I. Introduction

A gear is a rotating machine element that has teeth and meshes with other toothed part to transmit motion, change direction, and change speed. The oldest machinery, potter’s wheel was invented in as early as 3500 BC. During that time, primitive gears mesh with each other and transmit rotary motion to permit throwing of more pots.

Early gears were made of wood with cylindrical pegs for cogs and were often lubricated with animal fat grease. Today, gears are used on a daily basis and can be found in clocks and automotives. Also, gear elements have become vital to our industrial life and have a very significant impact in the engineering field.

In making gears, the milling machine is used. This machine is the most versatile of the conventional machine tools. When a part is being machined in a milling machine, it is securely fastened to the work surface, and the work surface is moved under the cutter.

In this project plan, the processes involved in using a milling machine together with the associated tools and equipment needed in gear making are discussed in detail.

II. Objectives

This project aims to introduce the basic processes involved in using a milling machine. At the end of this project, the student must:

be familiar with the tools used in making a gear identify the functions of each tool and machine used in gear making practice safety in using milling machine be knowledgeable of the processes undertaken in making a gear appreciate the importance of milling machine in production

III. Materials and Methods

A. Materials

The materials used in this project include: Lumber Sand paper

In Table 5, the tools and equipment used in making the gear is enumerated and classified according to their corresponding function.

Table 7. Tools and equipment used in gear makingclassified according to function.

Layout tools

Boring tools

Cutting tools

Power tools

Pencil Drill press HacksawMilling

machineSteel rule

Lathe machine

B. Methods

1. Prepare all the materials needed in order to create the project plan. Make sure that all the things written in the project plan is correct and complete.

2. Measure 3-in diameter and width of 1.5 inch in the lumber. Layout the measurement with a pencil and cut the lumber by using a hacksaw.

3. Find the center on the surface of the wood by using a pencil and steel rule. Mark it using a center punch and ball peen hammer.

4. Drill a hole at the center using a drill press.5. Hold the wood with a workpiece holder.6. Cut the wood into a cylindrical shape with diameter of 3-in using a lathe

machine. 7. With the given number of teeth, N=40 and outside diameter of 3 inches, compute

the index for the indexing using the formula 40/N where N is the number of teeth. 8. Secure the cylindrical wood onto the milling machine with the help of the

workpiece holder. 9. Cut the teeth of gear using a milling machine.

IV. Bill of materials

Table 8. Bill of materials for the gear.

Item Description QuantityUnit Cost

(Php)Total Cost

(Php)Lumber 4”x4”x1.5 1 179 179

Sand paper T80 1 9.50 9.50Total 188.5

V. Finished Project

5.0 TOP

I. Introduction

The top is a toy made of wood with an iron tip. It is one of the oldest toys in the country. It is paired with a string rope that is winded to its body. Usually, one end of the string rope is attached to the bottle cap. The sudden unwinding of the said string sets the top in motion.

One of the power tools/machines that plays a significant role in the top making is the wood lathe. The wood lathe is a wood turning machine tool wherein wood is removed on a piece of work by slowly moving a suitably formed cutting tool against a revolving piece of work. Thus, the wood must be secured to ensure that there is no possibility of workpiece slipping. Proper control and care must be observed in making the cove of the top. The scraping action through the use of roundnose chisel produces a cove equal to the size of the chisel.

In this project plan, the processes involved as well as the materials needed in making a top are discussed further.

II. Objectives

This project aims to introduce the basic functions of the wood lathe. At the end of this project, the student must:

be familiarized in the function of the wood lathe through producing a functional top

observe proper usage of the tools apply the proper safety procedures while working on the project to make the top rotate appreciate the different products that can be produced by the wood lathe

III. Materials and Methods

A. Materials

For the top making, the following materials are needed: Block of wood Nail Sand paper

Table 9 shows the list of tools and equipment used in making the top. The tools/equipment are classified according to their function.

Table 9. Tools and equipment used in barrel bolt making classified according to functionLayout Tools

Cutting Tools

Driving Tools

Holding Tools

Other Tools

Power machines

Steel Rule

Roundnose Chisel

Ball pen Hammer

Bench vise Metal Files Wood

Lathe

Pencil Hack saw Sanding Machine

B. Methods

1. Prepare all the materials needed in making the top. Make sure that all the materials and equipment needed are correct and complete. Also, prepare the appropriate personal protective equipment (i.e. gloves, goggles, apron)

2. Measure 4 inches of good lumber using steel rule and try square to get a 2” x 2” x 4” sized lumber.

3. Cut the block using crosscut saw to obtain the desired measure.4. Using the pencil and the steel rule, locate the center of the block.5. Mark the center of the cross section of both ends.6. Use the crosscut saw to cut the block in 1/8” depth at the marked

center of the cross section. 7. Use the wood lathe machine to form a cylinder shape on the block.8. Create a cove similar to the shape of the top using the skew chisel for

the design, half round chisel, and flat chisel.9. Remove the excess wood using the hack saw.10.Smoothen or finish top into desired smoothness with sand paper.11.Drill the bottom of the top with 3/16” drill bit in the drill press for the

insertion of the nail.12.Mark the nail from the flattened tip to the measured depth.

13.Hammer the nail until its marked part. Make sure that the nail is perpendicular to the top from all sides.

14.Cut the excess part of the block using the hack saw.15.Using the metal file, remove the sharp surfaces of the nail.16.Smoothen the top with sand paper. Finish it with paint of preferred

color or with varnish

IV. Bill of Materials

Table 10 shows the list of materials needed in making the top. The cost of each material is also shown.

Table 10. Bill of materials for top

ITEM DESCRIPTION QUANTITY UNIT COST TOTAL COST

Wood (good lumber) 2” x 2” x 4” 1 179 179

Concrete nail #3 1 2 2Rope ≈4’ 1 5 5

Bottle capRegular bottle

cap of 8oz softdrinks

1 0 0

Sand paper P-80 1 9.50 9.50Total 195.5

V. Finished Projects

Anjelou M. Ibañes Jeezle Irish M. Royo

Mark Lester M. Teodoro

6.0 ART IN WELDING

I. Introduction

Welding is one of the most well-known techniques in joining two pieces of metals together. It is also cheaper than most welding apparatuses. With the flexibility and ease-of-use of the process, even relative beginners can use the machine effectively and safely.

Applying welding enables individuals to bring out their inner artist to create a humanoid model using electric arc welding while maintaining technicality of the exercise. In this project plan, the techniques used in welding and the safety practices that need to be administered are discussed. The appropriate tools and materials needed are also discussed and enumerated.

II. Objectives

This project aims to introduce the basic processes involved in performing an arc welding. At the end of this project, the student must:

be familiar with the tools used in arc welding identify the functions of each tool and machine used in welding practice safety in using the electric arc welding machine be knowledgeable of the processes undertaken in electric arc welding appreciate the importance of welding operations in production

III. Materials and Methods

A. Materials

The materials used in this project include: Electric arc welding electrodes Scrap materials

In Table 11, the tools and equipment used in making the humanoid is enumerated and classified according to their corresponding function.

Table 11. Tools and equipment used in humanoid making classified according to function.

Layout tools

Cutting tools

Driving tools

Holding tools

Power tools

Steel rule Hacksaw Ball peen hammer

C-clamp Electric arc welding machine

B. Methods

1. Prepare all the materials needed in order to create the project plan. Make sure that all the things written in the project plan is correct and complete.

2. Create a specific humanoid design that you wish to make.3. Once the design is set, straighten any bends on the materials using a ball

peen hammer and the anvil as support. 4. Measure the desired dimensions of the material by using a steel rule and

cut the specified measurement using a hacksaw.5. Setup the welding apparatus.6. Weld 2 sheet metals bent like a triangle to the base. This will serve as the

feet of the humanoid.7. Weld a piece of bracket to each foot; this will serve as the legs.8. Using a round bar, cut specified lengths and form a rectangular solid that

will serve as the humanoid’s body.9. Weld the same round bar in the previous step to the legs connecting it to

the platform to serve as extra support.10.Weld a piece of bent sheet metal to the rectangular solid to serve as a

support for the head (casserole).11.Weld the body to the legs and the head.12.Bend a pair of round bar then weld it to the humanoid’s body. This will

serve as the arms of the humanoid.

IV. Bill of Materials

Table 12. Bill of materials for the humanoid.

Item Description QuantityUnit Cost

(Php)Total Cost

(Php)Metals Scrap 3 kilos 30/kilo 90

Electrode E6031 10 2.50 25Total 115

V. Finished Project