Cut and Form Materialsusing Handtoolsand Power Tools
MakeaPencilHolder
Description
Welders arerequired towork with manyother metalworking trades. Tobesuccessful asawelderone must have an understanding of manyothermetalworking skillsetsand anunderstandingof theentireproject.This activity planwill demonstrateto students how tosuccessfullycut, layout,assemble, and weld awood stump pencilholderforuseas a
paperweight and pencil/penholder.Thesetaskswillexpose studentstoskillsusedbyweldersandmetalfabricators.
LessonObjectives
Studentswilllearnto:
•Work safely usingmetalworkingtools
•Performaccuratelayout
•Cut and form materialsusing handtoolsand power tools
•Joinand shape metal byweldingprocesses
•Perform finishingtechniquesusinghandtoolsandpowertools
Assumptions
Studentswill:
•Haveknowledgeof measurementsystemsusedin metalworking
•Haveknowledgeoflayout proceduresused in metalworking
•Havean understandingofsafeshop practices
•Knowthe safeuse andproceduresof hand tools, bench grinders, beltsanders, andwelders
Terminology
MIGwelding(GMAW):aweldingmethodinwhichelectriccurrentflowsthroughthefillermetalwiretomaintainthearc.Aninertorsemi-inertgasshieldsthearcfromoutsideair.MIGisanabbreviationof“metalgas welding,”andGMAWisanabbreviation of“gasmetalarc welding.”
Porosity:aconditioninwhichbubblesformintheweldduetotheabsorptionofatmosphericgasesinthemolten weld.
Shieldinggas:aninertorsemi-insertgasusedtoprotecttheweldareafromatmosphericgasessuchas oxygen,nitrogen,and watervapour.
Thisworkis licensedunder aCreativeCommonsAttribution-NonCommercial-ShareAlike4.0InternationalLicenseunlessotherwiseindicated.
Stickwelding(SMAW):aweldingmethodthatusesflux-coatedelectrodeswithinahigh-amperagecircuittomeltanddepositmetalforsurfacingandjoiningmetalcomponents.SMAWisanabbreviation of“shieldedmetalarcwelding.”
Tackweld:asmallweld(s)thatholdspiecestogetherfor assembly.They canberemoved moreeasilythanafullweldifadjustmentsareneeded.
Weld bead: a deposit offiller material into the weldjoint.
EstimatedTime
6 hours
Thetime willdepend onthe students’ experiencein themetalworkshopand the number oftoolsavailable to them.
RecommendedNumberofStudents
20, basedontheBCTechnology Educators’Best Practices Guide
Facilities
A standardsecondary schoolmetalworkshop
Equipment/Machinery
•MIGwelder(GMAW)
•Stickwelder(SMAW)
•Drill press
•Benchgrinder
•Beltsander
•Benchvice
•Beverly shear
•Foundryfurnace
•Weldingtorch
•Wirewheel
Tools
•Hacksaw
•Metal file
•Machinist square
•Scribe
•Layout hammer
Materials
•Mildsteelflatstock⅛" × 2"
•Mildsteelpipe0.100"–0.1875"wall × 2"diameter or similar
•Mild steel round stock 3⁄16"
•Spray paint
•Sandpaper
Resources
Safetytests:GenericsafetytestsareavailableintheHeadsUpforSafetybooklet
Weldingvideoandinstructionsrangingfrompreparationtovariousweldingpositions
Videoexplainingdifferenttypesofwelders:oxyacetylene,MIG,TIG,andstick
Videoaboutthecareerofwelding
Weldjointsandtypes
BCITMetalFabricationtradesvideo
Teacher-ledActivity
Demonstratethefollowingprocedures to theclass. Students willthen replicatetheprocesses.
Note: Inthe followingactivities other dimensionsof metalcanbeused, butmeasurements willneedtobeadjusted.
Part1:LayoutandCuttingofStump
1.Use a ruler and a scribe tomake a mark at3" on a piece ofmildsteelpipe0.100"–0.1875"wall × 2"diameter or similar.
2.Usingahacksawor bandsaw,cutpipe tolength.
3.Using a benchgrinder,beltsander, or file,squarebothendsofthepipe.
4.Using a 2" hole saw on a drillpress, or a hacksawandgrinder,cut a 2" circle outofmildsteelflatstock⅛" × 2".
Part2: LayoutandCuttingofAxe
1.Using a ruler and a scribe,make a mark at1" on a piece ofmildsteelflatstock⅛" × 2"andcut itoffwithahacksawor band saw.
2.Usingahacksaw or band sawand hand tools, cutout an axe head.Axecouldbedifferentstyles, suchas abattle axe, splitting axe, throwing axe,or adouble-edgeaxe.
3.Using a hacksaw,cut a 2.5" piece of 3⁄16" mildsteelroundstockfortheaxehandle.
Part3:StumpFabrication
1.Tackweldthe bottom ofthestumpontothepipewithanopen corner filletweld.
2.If correctly placedafter tacks,completely weldit on.
3.Grind theweldflushtothesidesandflattenthem on thebottom.
4.Weld multiple beads from thetopto bottom. Thesewelds will replicatethebark of a tree.Manyoverlapping weldsmayberequiredto produce the desired look.
Part4:AxeFabrication
1.Tack weld bothsidesoftheaxe headto the handle.
2.File the axehead andthe tack welds intoarealisticallyshaped axe.
3.With a hacksawandsmallfile,cut a notchinthebladeoftheaxe.Thenotchneedsto fit overthe stump tolooklikethe axe is stuckin.
Part5: StumpandAxeAssembly
1.Placetheaxe notchover the topof the stump
2.Tack weld theaxe tothe stump in a manner thattheattaching weld isnot obvious.
Part6:Finishing
1.Usinga wire wheel or wirebrush,polish all surfaces, removing welding tarnish anddiscoloration.
2.Apply finish coat. Optionsforfinish could includespraypaint,powdercoating, or oilblackening.
Assessment
Consider co-creatingthe assessment criteriawith yourstudents atthebeginningoftheactivity/project. You maywanttoincludethe following:
•Pipelength is correct.
•Stumpsitsflatandlevel.
•Axe is shaped realistically.
•Welds donot contain porosity.
•Finishing workwasdonecorrectly.
•Safework habits weredisplayed.
OptionalExtensionActivity
Students who haveexperience withMIG welding steel could use astick welderinstead.Astumptopcould alsobe addedto make it intoapaperweight/sculpture instead of a pencilholder.