AT MICROFICHE REFERENCE LIBRARY
ATof Volunteers in AsiaA rcises Metal,by H.N.C.FundamentalSkills,PartStamPublished 018 AD oduction of this microfiche document in anyform is subject to the same restrictions as thoseof the original document.A
,, #r - pmyBl / ;yyiB ,,,/li:l-/--iFUNDAMENTALSKILLSINTEIWIS bvinter-continentalTechnical Education,i he NetherlandsMaterialsB Services
INTEMS PICTORIALSYSTEMPART ADAMENTAL SKILLS2nd editionEDITOR-IN-CHIEFING. H.N.C. STAMINTEMS bvInter-continental Technical Education, Materials & ServicesThe Netherlands
Copyright:rZJ 1982 INTEMS bv, Beusichem(Gld) The NetherlandsISBN 9021731002No part of the INTEMS PICTORIAL SYSTEM may be reproduced in any form, by print, photoprint, microfilm or anjother means, nor be translated into any other language without the written permission of INTEMS bv.INTEMS bvInter-continental Technical Education, Materials & ServicesPostal address: P.O. Box 262.4100 AG Culemborg, The NetherlandsAdministration: de Wielstraat 9,4112 JT Beusichem, The NetherlandsDistribution: Staalweg 15,4104 AS Culemborg. The NetherlandsRegistered at t\e Chamber of Commerceunder no. 14.821Bankers: ABN Bank, Markt 31, Culemborg,Postal account no. 4307639. ArnhemThis volume was printed by TECHNIPRESSfor &id-WestGelderland,Tiel. The Netherlandsaccount no. 559322313bv, Culemborg,The Netherlands
INTRODUCTtti::Intercontinental Educational Media B.V. was established in 1967 to meet the constantly grc;wing demandfor educational media suitable for use all over the world. The explosive development of technical educationand modem teaching methods throughout the world has led to a rapid increase in the internationalexchange of learning approaches and educational media, especially hocks and other kinds of printedmaterials.Technical and vocational education, in all its forms, will be progressivelymore important for balancedeconomrc growth In all parts of the world. For many countries, industrializationis essential for a properdevelopment of their manpower and natural resources.TechnIcal and vocational education 15 also an aspect of education that lends itself most readily to worldwide standardization.In general, tools and working methods are largely identical, despite the existence ofspecial tools and techniques that may be peculiar to certain countries.Experience in those industrially developingcountries showing an increasing interest in technicaleducation, and with a growing number of students, has made it clear that suitable learning aids, and inparticular textbooks, are hy no means easy to obtain.Existing texibooks compiled for students in highly industrialized countries, are difficult to adapt to localcircumstances and can seldom be fitted in with the programmes and curricula of other countries.Collaboraticn in the field of international educational media was established with ‘International TechnicalEducation Media Services‘ (INTEMS), in order to develop adequate learning and teaching material forsituations that differ in many respects from those in the industrialized world.The Directorate of tntemational Technical Assistance of the Netherlands Ministry of Foreign Affairs took apositive interest in this development and provided considerable financial support to the work.The Technical Education Inspectorate o! the Netherlands Ministry of Education and Science, in charge oftechnical assistance, especially In the field of technical education institutes collaborated closely on the editorial side of the material.It is hoped that this new approach to teaching in Technical and Vocational Education will contribute to theexpansion of his important aspect of economic and social development in many countries.May 1975IOctober1982Theeditor-in-chiefH.N.C. Stam
SERIES TECHNOLOGY METALTECHNOLOGYPartPartPartPartPartA:B:C:D:E:METAL IFundamental skillsWorkshop processesMechanisms, transmissions and fittingsIntroduction to machine-toolsThe workshop, organisation and artA:B:C:D:E:F:G:H:METAL IIHand and power tools for fittingLimits and tolerancesSheet-metal workMachine toolsSoldering and weldingForgingPipe fling and installationFerro tPartA:B:C:D:E:F:METAL IllmaterialsEXERCISESMETALFundamental skillsFittingSheet-metal workMachiningSoldering and weldingForgingOPEPATIONSHEETSMETALOTHER VOLUMES OF !hTEMS PICTORIAL SYSTEMAutomobile mechanicsElectricityTechnology woodWorkshop exercises woodSafetyTechnicat drawing, blue-print reading and free-handWorkshop mathematicsApplied science arid m2thematicsTeaching outlinessketching
I
EXERCISESWORKSHOP--- ---- ----------------------------------METALPARTA- FUNDAMENTAL SKILLS,,,,,,L,,,-,-,,,,,----,,,,Contents-- ------Code-w-eTitle-----1001Clamp 008Staff1009Saw-frame .Pasn.flangeironwithstand.2.holder.719743537385
CLAMPPICTOSTEPSWORKSHOPINSTRUCTIONMETAL
WTE : kkonceon au dimtinrymm40cs-II---II‘II;IiIIIItII,,l-l9\t
USEThe clamp is used for holdingtable of a drillingor millingthe work on themachine .MATERIALDIMENSIONSMild100 x 50 x 12 7 mm(4 x 2 x in jsteelTOOLSBlunt bastardfileTry squareOutsidecallipersVerniercallipersSteel straightedgellividersCentre p wrenchScriberRuleViceVice clampsChalk or varnishStop blockBevelRound fileSaw frameSaw bladeTwist drill(8.5 mm)(11 mm)Twist drillOPERATIONholding.lliceVice clampsFile flatand crosswise,i.e.aftera few strokesin onedirectionreversethe actionby filingin the other direction.Change directionsregularly.BluntfileTest fordirection.Try squareflatnessilirection0in everyof testing.bastard
Turn work. File flat to 12 mmthickness.File crosswise. Change directionregularly-.Blunt bastardfile.Test on even thickness all oversurface.Outsidecalipers.Test on correct thickness:12 mm.Reading:Verniercalipers.File one long end flat,straight and square.Blunt bastardfile.Test flatness of this side.Try square.
-.-.-Test this side on squareness.Keep try square at right anglesto side.Try square.-Apply chalk or varnish.Draw line at right angles tofinished side nearest to edge.Mark a distance of 96 mm fromscribed line.Place V-mark with pointexactly at 96.za; sRule.Scriber.line across at distanceDraw line exactly through pointof V-mark.-e-----------f-Mark distance of 48 mm onboth lines.Place V-mark with pointexactly at 48.8::block.Scrit;er.11
Scribe line through both V-marks.Steel straightedge.3cri ber.Draw ime exactiy throughpoints of V-mark.Marked out result.BI,,y;t bastardFile long side to line.Remove any filings.Test on squareness (x) and onflatness and straightness (xx).Try square.Test width: 48Verniercalipers.Reading:I
File the two short sides untilthey are truly flat,straight and parallel.Blunt bastardfile.Test on squareness to other sides.Try square.Result: total length 96 mmReading:Mark 24 mm from edge at twoplaces.Do not forget to chalk or varnish.Put V-mark with point exactlyat 24.Draw line exactly through V-marks.This is the centre line.A centre line is sometimes alsocalled: datum line.Verniercalipers.E J block.Scriber.S;;;lestraight
Mark 4 V-marks on this line atdistances of 24 mm, 50 mm,62.5 mm and 75 mm fromone short edge.;;,pblock.Scriber.Scribe short lines through thesefour points.Centre punch at intersections.Put centre punch at angle forfinding exact positions.Keep upright when hitting.CZZ;ee;unch.Mark out half circle tangentto three edges.Take 24 mm point for centre.Dividers.Dot-punch to make circlepermanent.Punched dots should bevery light.\.
Mark distance of 10 mm from)pposite edge.!3 :. block.Scriber.Marking:square line across at thisjistance.&Y;qJare.Mark angle line on long sidesJsing a 45 deg. bevel.Do this on both sides.Bevel.Scriber.On short side scribe lineconnecting intersectionsof angle lines with edges.TSrcYr;zare.File to scribed line.(Work in vice held at angle).Vice.Bfl,y;t bastard
rAngle 135O.Drill 8.5 mm hole in centreof scribed line.Use cutting lubricant.Bevel.Drillingmachine.8d;,;;m TwistVice Lamp(machinevice).Drill three 11 mm holes inremaining drill centres.Drillingmachine.l;rzlm TwistVice &(machinevice).16Scribe two lines tangentto drilled holes.%x&straightFile slot.Round file.Scriber.
IFinish slot.Blunt bastardfile.Edges and arcs should connectaccurately.File to shape,rough shapefirst.File flats in different directions.Mark out angled edges.35 mm on. 4longedges,\,9mmonshortones.\B;,u;t bastardRule.g;;;;er.straightedge.\\\\\*-1Saw off corners.Saw on outsideline, leavingthe latteron the work.File to line.Saw frame.Saw blade.Bfl,y;t bastard17
‘ut Nr. 1 tap in wrench.‘ighten securely.rlr. 1 Tap‘3/a” UNF).hrench.start with a few turns in the hole.Turn clockwise, applying slight3ressure.Nr. 1 Tap.uVrench.Test tap on being accuratelyat right angles to work.Nr. 1 Tap.Wrench.Try square.Nr. 1 Tap.Tap through work.Apply the right cutting lubricant.If tap sticks turn slightly backwardRelease pressure.EE.iZth’WORK IS FINISHED.Code 1001-TNTEMS B.V.4100 AG CuLwbokj--P.O.BoxThe Ne&m’ hzdh262
BLINDFLANGEPICTOSTEPSWORKSHOPINSTRUCTIONMETAL.
KITE . lderance,20,I!:aIim cdl dimensions‘/z”IIII
USEThe blindflange may be used for sealingopening normallyprovidedwith a flangeidenticalshape and size.MATERIALMildanofDIMENSIONSsteel,packingBlunt bastard fileTry squareOutsidecallipersVerniercallipersScriberRule (inches)Spring compassesSteel straightedgeCentre punchEngineers'hammerLength:X 33 inWidth:xx ye,,"")Thickness. XXX hz'i?)9(63.5mm)Hack sawStop blockBlunt smooth filePacking shearsHollow punch (& in)PencilViceVice capsChalkVarnishTwist drill(4 in)Twist drill(3 in)OPERATIONTOOLSFile flatand crosswise.Change directionof filingregularly.Use clean vice caps.ViceVice capsBlunt bastardfileCheck flatnesstions.9Turnflatin alldirec-TrysquareCheck lines.work upside down,to 4 in thickness.File crosswise.Change ciirectionregularly.fileViceVice capsBlunt bastardfileof filing21
Check flatness in all directions.0Try square.Check linesRegularly check work on equalthickness.Check all over surface.Outsidecalipers.Test on correct thickness.Verniercalipers.Fi!e one side flat and square.o 15deg.Vice.Vice caps.’Blunt bastardfile.Check on flatness X andsquareness XX.Apply chalk or varnish formarking out.Put V-marks at two places ts/te”from finished sideUse stop block.Points of V-marks accuratelyatlS/lS".Rule.Scriber.;;dykb;rck.varnish
Scribe line exacly through pointsof V-marks.Scriber.S;&&straightAccuratelv in middle of line putV-mark. -Rule.Scriber.Stop block.Middle of work is at 1 3/4”from side.Mark 1 3116” on either sideof middle.Rule.Scriber.Put rule with 1 s/16” at midpoint.Scribe V-marks at 0 and 2 3/B”.Scribe short crosslines throughthese three points.Centre punch intersections.Find exact point by tiltingthe punch.Hold punch upright whenstriking it.”VMiddle centre shallow, outercentres deep.23-
:rom midpoint of line scribe circleangent to finished side.Check circle on correct radius:liameter should be 1 7/B”.Springcompasses.iule.-ram either outer centre scribe:ircle with radius t/2”.Springcompasses.Rule.Il’lii/!l” ISs; 112” from-24(\I’“-1IIiScribe 4 lines tangent to circlesas shown:Steel straightedge.Scriber.Drill two holes 114” dia.Use cutting lubricant.Drillingmachine.Twist drill 3”Machine vice.Packings.Enlarge holes to 112” dia.Use cutting lubricant.Drillingmachine.Twist drill 8”Machine vice.Packings.
Saw off fourcorners.Saw frame.Saw blade.Vice.Vice caps.File flat and square to lines.File round. First rough shape,file faces in various directons,then finish off.Round corners. First shape roughlyby filing faces in various directions.Then finish off.For the finishing touch use smoothfile. A real polished sheen isobtained if the file is first justrubbed along a piece of chalk.Blunt bastardfile.Vice.Vice caps.Vice.Vice caps.Blunt bastardfile.Vice.Vice caps.Blunt bastardfile.Vice.Vice caps.B;;rt smoothPiece of chalk.25
Now the gasket will be made.Fetch a piece of packing materialabout the size of the flange andabout l/16” thick.Vlark out gasket by tracingalong flange.‘lo not forget the holes!Pencil.Cut out gasket along lines.Packingshears.Punch the holes.Hollow puncl 1.Hammer.Gasket is ready.Code 100.2-ZNTEMS B.V.4100 AG cu.&mbong--P.O.RoxTbw Nethtind.426
NMETAL27
PICTOSTEPSWORKSHOP INSTRUCTIONiOLDERlNGIRONANDMETALSTANDISE: The soldering iron is a tool used for soldering,that is joining metallic edges or surfaces bymeans of molten metal or alloy (solder). Thehot soldering iron is rested on the stand.DOLS: Smjth:s fire.z;;;h s tongs.Smith’sRubber mallet.Pair of pliers.%&ingIron.hammer.SRC,iLber*Try square.CZ ;;e nch.Drilling machine.Vice.Bastard hand file.Slnnn h*.““.I file.Wooden packing.Small square file.Ledge (50 cmlength).Steel straight edge.Lever shears.Twist drill (3 mm).Boring tool.Flux. Solder.Bevel protractor.Piece of wood (at least10x21 cm).Panel pins.Vice clamps.Metal strip 15 x 3 mm.Short !ength of !O mmdia. bar, (150 mm).Short length of 6 mmdia. bar, ( 150 mm).Emery paper.MATERIAL:MAENSIONS:1. Mild steel.ength 175 mm, dia. 5 mm.2. Copper.10x iOx40mm.3. Wooden handle(from stock).4. Tinned steel sheet.200x75x0.5mm.5. Copper-platedwelding wire.Length 450 mm, dia. 2 mm.
WERATIONroom--Ne start by forging the shank.The drawing is on page 16.ieat bar over about 2 cm untilNhite hot.Smith’s fire.Smith’s tongs.Take bar from fire.Smith’stongs.Rest bar on anvil at small angle.Zh ;h’stongs.Hammer point 40 my in length.iy;;J bar through 90 after eachSn;;h’stongs.Smith’shammer.Heat other end of bar over about2 cm until white hot.Smith’s fire.Smith’s tongs.
rake bar from fire and rest it ontnvil at small angle.Smith’s tongs.4nvil.Hammer tip to a point 15 mm inlength and square over 3 mm.Anvil.;kn;;;‘stongs.‘5hammer.Now we start making the head or,,bit” of the soldering iron.It is made from the piece of copper.The working drawing is on page 16.Scribe V-mark 5 mm from end.Scribe line through point ofV-mark.Scriber.Square.
Find midpoint of this line(5 mm from edge).Scriber.Rule.Centre punch at this point.Drill hole 3 mm dia.Use wooden packing in vice.Drillingmachine.Twist drill3 mm dia.Woodenpacking.10 mm from other end scribe linesquare to side.EiLberSquare.Scribe same distance on allsurfaces around piece of metal.Scriber.Square.31
Scribe V-mark at centre of frontface (5 mm from edge).icribe line through point of V-markarallel to drilled hole.scriber.square.3cribe four oblique lines as shown.Scriber.Square.File off to oblique lines.Finish with smooth file.Vice.Bastard file.Smooth file.At this stage the ,,bit” lookslike this.32icriber.lule.
File square-section tapering holeto fit the end of the shank.Point of shank should extend about3 mm through bit.Sm,all squareVice:Clamp shank in vice, and placebit on it.Vice.Hammer round head on shank.Vice.Hammer.Fit handle to other end of shank.The soldering iron is now ready.--Now we are going to make thestand.First the base. We start from oneedge which is cut accuratelystraight. We will call this thebottom edge.Scribe a line at right angles tothis edge, as near the edge aspossible.Scriber.Square.Ledge.
Scribe V-marks at distances of20, 31, 47, 52.5, 147.5, 153,169. 180 and 200 mm from thisline.*Scribe lines through these V-markssquare to the bottom edge.These are the bending lines.Scriber.Rule.iScriber.fzC ;z.Mark off distances of 75 mm onthe outermost lines.I-\Y‘7Scribe lines through theseV-marks.Scriber.Steel straightedge.Cut off on outermost lines.LezyLa;hdears,shears.
At 100 mm from short edgescribe line.Eber*Square.Put V-mark at midpoint of thisline (37.5 mm from edge).Centre punch at this point.Fasten plate to piece of woodwith panel pins.Drill hole 3 mm dia.Drillingmachine.Twist drill3 mm dia.Set boring tool to 40 mm dia.Bore hole.Drillingmachine.Boring tool.Clamp plate together with 10 mmdia. bar in vice. The bending linesecond to last should be at sameheight as the centre line of bar.Bend to right angles.Vice.y;“,“;bar.millet.’35
Continue bending as shown.Vice.Rubber mallet.10 mm dia.bar.Check that angle is 60’.The three previous operationsshould be repeated on the otherside of the base.(Bend to same direction)60’ bevelClamp base together with 10 mmdia. bar in vice. The innermostbending line should be at sameheight as centre line of bar.Bend.Vice.Rubber mallet.10 mm dia.bar.Continue bending until upper andlower surfaces are parallel.Repeat the two previous operationson the other side of the base.The base is now finished.Vice.Rubber mallet.10 mm dia.bar.or bevelprotractor.‘.36t - fkNow we are going tomake the wire rest.This is easily bent byhand from welding wireClamp wire with 10 mndia. bar in vice. Wireextends 186 mm abovecentre line of bar. Bendto right angle. Repeaton other end of wire.--------------Vice.Rule.10 mm dia.
llire is clamped as shown.30th legs extend 125 mm aboveentre line of bar.Both legs are bentto angles of 75O.One end of wireis clamped asshown in figure.Wire extends57 mm abovecentre line of bar.Vice.Rule.10 mm dia.bar.Vice.Protactor.Vice.Rule.6 mm dia. bar.‘he wire is bent to right angles.Vice.6 mm dia. bar.‘his same end is clamped in theice as shown here.;Ihe”;;epshould be clamped byVice.10 mm dia.bar.Metal strip15 x 3 mm.Bend until the end is at rightngles to bottom line.Seenext page.37
Check that end of wire is at rightmgles to base.Square.Clamp wire in vice as shown here.The wire should be firmly clampedby the strip.End of wire should extend 13 mmabove centre bar.Vice.Rule.End of wire is bent round baras shown here.Vice.‘:arF” dia.Metal stript5x3mm.‘ObaYrn dia.Metal strip15x3 mm.Bend tip about 5 mm outward.Repeat the previous sevenoperations on other end of wire.The wire has now been bent to arest shaped as shown here.38Pliers.
Now the wire rest has to besoldered to the base.Solderingiron.Heat copper of soldering ironuntil flame is bright green.Keep point of copper bit upward.Dip point of bit in flux(soldering acid).Solderingiron.Flux.The tip is tinned by rubbing italong the solder.Solderingiron.Solder.Clean the wire with emery paperand place the rest on the base inthe position shown in the workingdrawing on page 15.Put flux at the places where thewire rest touches the base.E;u’v paper.Heat soldering iron until flame isgreen. Keep tip of copper bitupwards.S dneringBrush.
Dip point into flux.Solderingiron.Flux.Apply solder to point.S;&l;ring.Solder.SolderwholePressthat itWhenrest to base along thelength in contact with it.wire down and take caredoes not move.iron gets too cold, reheat.When soldering is completed anyflux left is thoroughly rinsed awaywith water.Dry with cloth.Now the whole stand is complete.Sio/nering
wtoleranceCLXXX.on a11 dimensionsm dcloil. devdopmcnlsolder1 mmof base
SOLCERIM; IRONtolerance an all dinensions 0.5 IMIunless otherwise da\edCode loosr-INTEhAS B.V.-P.O.Bax262-4100 AG Cdembw-Thct Nethdan&
IL
lplcrance on all dimensions 1 mm, unkrxx- -limdherwiathickness 0.599A05thickness 0.5straight length of bar 243stated
PICTOSTEPSWORKSHOP INSTRUCTIONMETALTOOL-BOXUSE:A tool-box is a box used for keeping andtransporting different tools.Plate shearsHand drillTwist drillsRule2.2 and 5.5 mmSteelstraight edge ViceLever-operatedFolding barssheerG-crampProtractorW;; yor plasticCentre punchSwage block2 StakesBar 30 mm dia.Rivet setSmith’s hammerSnapSmith’s fire12 Aluminium rivetsHammer2 mm 0-5
AT MICROFICHE REFERENCE LIBRARY A project of Volunteers in Asia Workshop Exercises Metal, Fundamental Skills, Part A edited by H.N.C. Stam Published by: INTEMS b.v. Available from: TOOL Entrepotdok 68a/69a 1018 AD Amsterdam THE NETHERLANDS Reproduced by permission. Reproduction of this microfiche document in any
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MICROFICHE REFERENCE LIBRARY A project of Volunteers in Asia Small Scale Weavina Published by: Internat ional Laborur Off ice . Publications Branch, ILO, same address Reproduced by permission. Reproduction of this microfiche document in any form is subject to the same restrictions as those of the original document. TECHNOLOGY SERIES Technical .
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APS 240 Interlude Ð Writing Scientific Reports Page 5 subspecies of an organism (e.g. Calopteryx splendens xanthostoma ) then the sub-species name (xanthostoma ) is formatted the same way as the species name. In the passage above you will notice that the name of the damselfly is followed by a name: ÔLinnaeusÕ. This is the authority, the name of the taxonomist responsible for naming the .
