First Year Metalwork.

Class Notes and

Homework
Workbook
Second Year Metalwork

Topics to be covered

• Safety.
• Bench tools.
• Properties of Materials
• Metals.
• Drilling
• The Centre Lathe.
• Joining.
 SAFETY

‘Accidents do not just

happen, there is always
a cause for them’
 Safety in Technical
Rooms
• My class may not use machines
without a teacher in the room.
• I may not use equipment that I have
not been shown how to use.
• All accidents must be reported to the
teacher.
• Be prepared for class.
• I will not be allowed to work if my
behaviour puts myself or others in
danger.

Signed . . . . . . . . . . . . . . .
Seven Safety Hazards

• Hair - long hair should be tied

back.
• Eye protection -
• Hot metal -
• Sharp metal and tools -
• Clean workplace -
• Fire -
• Fumes -
 Bench tools
• Bench tools layout

• benct tools dia

 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
• 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.

All metals that contain iron are ferrous metals

Iron ore

Blast furnace

Iron Iron and steel Scrap

Cupola Basic oxygen Furnace Electric arc Furnace.

cast iron steel steel

 Blast furnace

• The blast Furnace.

 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 basic Oxygen Furnace.

 Basic oxygen Furnace
• Stages in Production.
 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 electric arc furnace.

 Electric arc furnace
• The Charge :
• molten iron
• scrap steel
• limestone.
• Operations
• the lid containing the electrodes are lifted off the
furnace and the furnace is charged. The lid is
replaced and electricity is passed down the rods.
This jumps from the rods to the metal causing it to
melt. The impurities mix with the limestone to form
slag. The slag is taken off. The furnace is then
rotated on the rollers and tapped.
• The Products :
• molten steel
• slag.
 The Electric Arc.

• 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 Pillar drill.

The Centre lathe.
The Pillar Drill.
 The Pillar Drill

• 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.

• Using the Drilling Machine

• make sure long hair is tied back.
• have no loose clothing.
• Always wear safety glasses.
• Never use the machine if the teacher is not
present.
• make sure the work is properly held.
• make sure the drill speed is correct.
• Have a dot punch in the center of the hole
and center the drill on it.
• Make sure not to pull the feed lever to hard
when breaking through the piece
• never drill into the table or machine vice.
• Always check the drill size before drilling.
 The Pillar drill.
• Holding the work for drilling.
• The machine vice.
• This is the most common way of holding
work. The piece should be clamped by two
square edges and supported by wood
underneath. The piece must be held level
to ensure a round hole.
• The machine table.
• The machine table can be used to hold
larger heavier work. The piece can be
bolted to the table using clamps. The table
can be lowered and rotated for difficult
pieces.
• The base.
• The base can also have pieces bolted to it
but this is unusual.
 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.

• Parts of the drill bit.

• The point angle of a drill bit is 118
degrees.

jc79
 The Pillar drill.

• Types of drill bit.

• The Parallel shank.
• This is used mostly for small size drills and is held
in a chuck.

• Morse taper shank.

• This is used for larger drills and fits
directly into the spindle or the tailstock of
the lathe.

• A drift is used to remove the drill from the

spindle.
 The Pillar drill.

The drill gauge.

• This is a flat steel sheet with different
sized holes and is used to measure the
drill bits.
 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.

• The lathe is used to produce

cylinders and other operations
such as drilling on round bars.
This is known turning.
• Other shapes that can be worked
include square and hexagonal
bar.
• The lathe can work with most
metals as well as polymers
(plastic).
 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 lathe bed.

• This is made from cast iron as it is easily cast, a
natural lubricant and it absorbs vibration giving a
better finish. The bed sits on top of a stand and
supports the carriage and tailstock.

diagram page 143

 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

• The Feed Shaft.

• This allows the carriage and
cross slide to be moved
automatically.
• The Lead screw.
• This is used for screw cutting
on the lathe.
• The tool post.
• This holds the cutting tool or
tool holder in place.
 The Centre Lathe

• Safety on the Lathe.

• Glasses must be worn at all times.
• Long hair and loose clothing must be tied
back or tucked away.
• Never use the machine if the teacher is not
in the room.
• Never use the machine to do something
unless you have been shown how to do so
and you are sure you know how to use it.
• Never leave the chuck key in the chuck.
• Never have the work touching anything
when starting the machine.
• Never check the work when the machine is
moving.
 The Centre Lathe.

• Make sure that the work is held tightly and

is centred in all three jaws before starting
the machine.
• Never handle swarf as it is extremely
sharp.
• After you have finished clean the machine
down and move the tool away from the
chuck.

• “accidents do not happen they are

caused”.
 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

• Calculating Spindle speed.

• This can be calculated using the following
formula:
• N = S x 1000
• ПxD
• N = rotation speed / spindle speed.
• S = cutting speed (given in chart).
• D = Diameter of the bar or work piece.
• Π = 3 or 22
7
 The Centre Lathe.
• Worked Example.
• Calculate the spindle speed required to turn
a 25mm round mild steel bar.
• N = S x 1000
• ПxD
• N = ? S = 30 П = 3 D = 25.
• N = 30 x 1000
• 3 x 25.
• N = 30000
• 75.
• N = 400 rpm.
• The spindle speed is set at 400 on the
lathe.
 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.

jc145
 The Centre Lathe

• The American tool post.

• This can only hold one tool at a time but
the tool height can be adjusted quickly.
The tool is held by only one bolt which can
lead to chatter.

jc145
 The Centre Lathe.

• The Universal toolpost.

• This is similar to the American toolpost.
The tool height cannot be adjusted quickly
and it is not suitable for heavy work.

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

Operations on the Lathe.

• Facing off (surfacing).

jc149

• This operation produces a flat surface on the

end of the bar. The tool is moved using the
cross slide.
 The Centre Lathe

• Sliding cuts (parallel turning).

jc149

• This operation is used to reduce the outside

diameter of the bar. The carriage is used to
do this.
 The Centre Lathe

• Taper turning (Topslide)

lc250

• Here the topslide is set to the angle required

and the tool is moved by the topslide giving a
cone shape to the end of the bar
 The Centre Lathe
• Taper turning (off-set tailstock).

lc251

• Here the tailstock can be set to give the taper. It

is ideal for long tapers but is not possible in the
workshop.
 The Centre Lathe
• Taper turning (attachment).

lc254

• This is a tool that is attached to the carriage.

It is set as required and moves the tool at the
required angle as the carriage moves.
 The Centre Lathe
• Knurling.

jc151

• This operation is carried out at a very slow

speed. It is used to cut lines that cross each
other into the bar. This produces a grip on
the bar as seen on a scriber.
 The Centre Lathe

• Drilling.

jc151

• This is carried out using the tailstock. Small

drills are held in a chuck while larger drills
are Morse taper and are held directly in the
tailstock. A centre drill or slocombe drill is
used to find the centre.
 The Centre Lathe

• 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.

jc 152

• Here the part is cut or parted off from the rest

of the bar. It is important to be very careful
here as the part to fly or be damaged as it
drops.
 The Centre Lathe

• Under cutting.

Jc 152

• This is very similar to parting off accept that

the tool only moves in part of the way. It is
used when screw cutting on the lathe.
 The Centre Lathe

• Holding long bars.

jc153

• Long bars are held between centres. A

rotating centre is placed in the tailstock. The
bar is held in the chuck or as in the diagram .
 The Centre Lathe
• A mandrel.

lc268

• This is used to hold a piece with a hole in

the centre and where it is necessary to
machine the whole of the outside of the part.
 The Centre Lathe
• Travelling Steady.

lc268

• This is attached to the carriage and moves

along with the cutting tool preventing a long
bar from deflecting as it is cut.
 The Centre Lathe

• Fixed steady.

Lc 269

• This clamped to the bed of the late and the

bar is supported on three sides preventing it
from deflecting.
 The Centre Lathe

Capacity of the lathe

lc264.
 Metal Joining

• Metal joints can be temporary

or permanent.
• Temporary joints include nuts
and bolts magnetic catches and
compressions joints as in wheel
bearings.
• Permanent joints include
riveting, soldering, welding and
adhesives.
 Mechanical Joining.

• This refers to joining materials using nuts,

bolts and rivets.
• There are four different thread types or
forms.
 Mechanical Joining.

• The different parts of the isometric thread

can be seen below.

• When looking at working drawings the

size of the thread to be used will be given
as M.5 or M.6. The M. stands for metric
meaning every dimension is in
millimeters. The number gives the actual
size of the finished thread .or the outside
diameter.
 Mechanical 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.

• There are three types of tap:

• Taper Tap.
• This is used to start of the threads in the
hole or to thread thin sheets. The first 5-6
threads are tapered making it easy to start
the tap.
• Second tap.
• This is used after the taper tap and is used
to finish of the threads in deeper holes.
• Plug tap.
• This tap has threads all the way down and
is used to thread blind holes.
• When threading a hole it must be drilled
smaller than the tap to be used. When
drilling you should refer to the chart next
to the drilling machine
 Mechanical Joining.

Tap and wrench.

 Mechanical Joining.
External threading
• Bars or shafts can have threads cut into
them using split dies.

• Here the die is placed in a stock. The top of

the bar is usually tapered making it easy to
start cutting the threads. When starting the
thread it is important to start the thread
straight so as to cut a square thread.

• The split die has writing on one side and

this must be face down when threading.

• Hard materials such as steel require oil or

grease to be used to lubricate the cutting
process.

• When cutting threads on a bar or shaft the

bar must be the same size as the split die
being used. For example cutting an M10
thread requires a diameter 10 bar.
 Mechanical Joining.

Split die and stock.

 Mechanical Joining.
Riveting
• Rivets can be solid or pop rivets.

• Solid rivets come in four different forms

Round or snap, countersunk, pan or flat
head.

• Solid rivets form a very strong joint and

were commonly used in producing gates,
ships and bridge panels.

• Pop rivets are much more common now.

They are used in the manufacture of aero
planes and are a very quick way to join
materials.
Mechanical Joining.
Riveting

page 97
 Thermal Joining
Soft Soldering

• Solder is an alloy of lead and

tin. It melts at a temperature of
only 183 degrees c.

• Solder is mainly used for

electronic circuits and to join
copper pipes.

• Soft soldering is not a very

strong joint as solder is a soft
metal.
 Thermal Joining
Fluxes.
• Fluxes are used to remove oxides from the
surface of the parts being joined together.
This ensures that the joint between the
pieces are a good quality.

• There are two different types of flux

passive and active flux.
• Active Flux.
• Active fluxes remove oxides from the
surfaces of the parts and also prevent any
oxidation when the soldering is taking
place. The parts must be washed well
afterwards to remove any remaining flux.

• 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.

1. What is a non-ferrous metal.

2. List five non-ferrous pure metals?
3. Give a use for each of the above metals?
4. What is an alloy?
5. Why are alloys generally used instead of
pure metals?
6. List three non-ferrous alloys?
7. State a use for each of the alloys above?
8. Non-ferrous metals do not rust but they do
c_ _ _ _ _ e.
9. What materials would be suitable for the
following items
A. Soldering iron bit.
B. Electric cables.
C. Hinges for indoor use.
D. Hinges for out door use.
10. Name one ferrous alloy?
 Homework Sheet 13.
Drilling.
Draw the diagram and name the parts.
 Homework Sheet 14.
Drilling.
1. List five safety precautions associated
with the drilling machine?
2. How are pieces held safely in the
machine vice?
3. What is the purpose of the slots in the
table?
4. When drilling what is the purpose of the
puc. mark?
5. What is the depth gauge used for?
6. The table can be raised and lowered why
is this necessary?
7. How can very large pieces be held for
drilling?
8. State the two circumstances when the
pupils should not use the drilling
machine?
 Homework Sheet 15.
Drilling.
1. List five different types of hole?
2. Sketch each type of hole above?
3. When drilling a hole of a very large
diameter hole explain how you would do
it?
4. How can the size of a drill bit be
checked quickly?
5. Sketch this tool?
6. What are the two types of drill bit
available?
7. Sketch each type of drill bit and say
where they are used?
8. What is a reamer? explain your answer
with a sketch.
9. Why is it necessary to ream a hole after
drilling?
10. What is the benefit of using a cutting
fluid when drilling?
 Homework Sheet 16.
The Centre Lathe
Draw the diagram and name the parts.
 Homework Sheet 17.
The Centre Lathe
1. What is the purpose of the
headstock?
2. What is the lathe bed?
3. What is it made from and why?
4. The slideways are machined into
the lathe bed, what are they for?
5. The tailstock is mainly used for
what?
6. The carriage is made up of three
parts, what are they?
7. State the purpose of each of the
parts above?
8. What is the top slide, what is it
used for?
9. The toolpost is used for what?
10. The spindle is hollow, why is this?
 Homework Sheet 18.
The Centre Lathe
1. Name the two types of chuck?
2. What is the purpose of each type
of chuck?
3. Why should the chuck guard never
be left open when the machine is
running?
4. Why should no more than one
person operate the machine?
5. In an emergency how can the
machine be stopped quickly?
6. Name the three ways of stopping
the lathe?
7. What direction should the spindle
turn?
8. What is the purpose of the
automatic feed?
 Homework Sheet 19.
The Centre Lathe
1. With the aid of sketch explain facing
off?
2. With the aid of a diagram explain
Sliding or parallel turning?
3. What is taper turning?
4. How is taper turning carried out on the
lathe?
5. How are holes drilled on the lathe, use a
diagram to explain your answer?
6. How are finished pieces cut off from the
rest of the material on the lathe?
7. What other operation can be performed
using the above tool.
8. Sometimes it is necessary to have grip
on a part how can this be carried out?
9. It is not always possible to get a drill to
produce a hole to the size required how
else can this be done?
10. How is a good surface finish achieved on
the lathe?
 Homework Sheet 20.
The Centre Lathe
• Calculate the spindle speed for each of
the following tasks.

1. A 25mm brass bar with a cutting speed

of 540m/min is to be turned. With П =3
calculate he spindle speed.
2. A 30mm mild steel bar is to be turned,
the cutting speed is 30m/min. calculate
the spindle speed.
3. A 50 mm aluminum bar with a cutting
speed of 100m/min is to be turned
calculate the spindle speed.
4. A high carbon steel bar with a cutting
speed of 15m/min and a diameter of
30mm has to be turned, calculate a
suitable spindle speed.
 Homework Sheet 21.
Mechanical Joining.

1. Name four different types of

rivet head?
2. Sketch the four types of rivet?
3. What type of joint do rivets
produce?
4. What are pop rivets used for?
5. Sketch a pop rivet and say
how it works?
6. Sketch a pop riveter that you
have seen.
 Homework Sheet 22.
Mechanical Joining.
1. What is the job of a tap?
2. Name three different types of tap?
3. Sketch a taper tap and a tap
wrench.
4. When cutting threads M6 what
size hole would be drilled 5 or
6mm, explain your answer?
5. In threading what does the m stand
for?
6. What conditions would lead to a
tap breaking in the hole?
7. Describe all the stages in tapping a
hole.
 Homework Sheet 23.
Mechanical Joining.
1. What tools are used to cut external
threads?
2. Sketch a split die and name the parts?
3. Sketch a stock for holding split dies and
name the parts?
4. When cutting threads of m5 on a bar
what diameter should the bar be?
5. Name four different types of thread?
6. Which thread do we use most in the
metalwork room?
7. Sketch the four different thread types
and give a use for each?
8. What conditions could cause poor
threads when cutting external threads?