TECHNICAL REPORT

ON

STUDENT WORK EXPERIENCE PROGRAMME (TIT 299)

AT
BLACKSMITH SECTION, GENERAL MECHANICAL
WORKSHOP, WORKS AND MAINTENANCE, UNIVERSITY
OF IBADAN

BY
ADEFOKUN JUCAL LIFE
MATRIC NO: 215511
LEVEL: 200
SESSION: 2020/2021

DEPARTMENT OF INDUSTRIAL AND PRODUCTION

ENGINEERING
FACULTY OF TECHNOLOGY
UNIVERSITY OF IBADAN
OYO STATE

DECEMBER 2021 – JANUARY 2022

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 Department of Industrial and Production Engineering,

University of Ibadan,

Ibadan, Oyo State.

23rd November, 2022.

The Director,

Industrial Training Coordinating Centre,

University of Ibadan.

Dear Sir,

SUBMISSION OF WORK REPORT LETTER

I, Adefokun Jucal Life, with the matriculation number 215511, of the department of Industrial
and Production Engineering, write to inform you of the completion of my eight weeks Students’
Work Experience Programme that took place during the period of 6th December, 2021 to 28th
January, 2022 for the 2020/2021 academic session at the Blacksmith Section, General
Mechanical Department, Works and Maintenance, University of Ibadan.

I hereby tender this submission letter alongside my technical report and logbook as required
for the successful completion of the Students’ Work Experience Programme. Within it is
contained a detailed account of the knowledge and experience gained in my eight weeks spent
during the programme.

It is with immense gratitude that I say a hearty thank you to the Industrial Training Coordinating
Centre for enabling such a fulfilling and experienced filled programme.

Yours faithfully,

Adefokun Jucal Life.

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 ACKNOLEDGEMENT
I use this medium to express my deepest gratitude to my parents, Mr. and Mrs. Adefokun for
their unending love, support and concern. I would also like to wholeheartedly appreciate the
efforts of my siblings, Ahira and Imri Adefokun for always looking after their little brother.
You both are truly the best.

My sincere gratitude goes to my immediate supervisor, Mrs. Oluwafemi Taiwo, Head of

Blacksmith Section, General Mechanical Workshop, Works and Maintenance, University of
Ibadan, for making my time spent on the job a truly memorable one. Thank you for always
instructing, and looking out for me. I am eternally grateful.

My greatest thanks also goes out to Mr. John, Head of Department, General Mechanical
Workshop, Works and Maintenance, University of Ibadan, Mr. John for being welcoming, and
for always giving us much needed instruction when needed. I’m also immensely grateful to my
colleagues Christian, Victor, and John. Working with you all was absolutely lovely.

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 ABSTRACT

This technical report details major activities carried out in the Blacksmith Section, General
Mechanical Workshop, University of Ibadan. It also contains an overview of the experience
I attained during the entirety of my eight weeks during the Students’ Work Experience
Programme.

In all engineering workshops, safety is paramount, and as such safety precautions shall be the
be the first thing considered. Blacksmithing equipment and tools used in the workshop will
also be considered over the course of this report.

The blacksmithing, locksmithing, metal machining, and metal fitting processes shall also be
considered. We shall also be considering various skills required for the aforementioned
processes along with projects carried out.

To conclude the report, we shall consider locksmith regulations in Nigeria, and

recommendations for the improvement of Students’ Work Experience Programme.

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 TABLE OF CONTENTS

ABSTRACT .......................................................................................................................... 4
INTRODUCTION ................................................................................................................ 7
AN OVERVIEW OF WORKS AND MAINTENANCE, UNIVERSITY OF IBADAN 8
1 CHAPTER ONE: INTRODUCTION TO THE WORKSHOP ........................................ 10
1.1 SAFETY PRECAUTIONS IN THE WORKSHOP ............................................. 10
1.2 COMMON METALS USED IN THE BLACKSMITH WORKSHOP ............. 11
1.2.1 Carbon Steel ....................................................................................................... 11
1.2.2 Alloy Steel ......................................................................................................... 11
1.2.3 Stainless Steel .................................................................................................... 12
1.2.4 Wrought Iron ...................................................................................................... 12
1.3 TOOLS USED IN THE BLACKSMITH WORKSHOP ..................................... 12
1.3.1 Hammer.............................................................................................................. 12
1.3.2 Chisel ................................................................................................................. 13
1.3.3 Tong ................................................................................................................... 13
1.3.4 Punch.................................................................................................................. 14
1.4 EQUIPMENT USED IN THE BLACKSMITH WORKSHOP .......................... 14
1.4.1 Furnace ............................................................................................................... 15
1.4.2 Anvil .................................................................................................................. 16
1.4.3 Workbench ......................................................................................................... 17
1.4.4 Vice .................................................................................................................... 17
2 CHAPTER TWO: THE BLACKSMITHING PROCESS................................................ 18
2.1 TRAINING RECEIVED ........................................................................................ 18
2.1.1 Lighting the Forge.............................................................................................. 19
2.1.2 Forging Techniques Used in Blacksmithing ...................................................... 19
2.1.3 Heat Treatment Techniques in Blacksmithing ................................................... 20
2.2 BLACKSMITHING TASK CARRIED OUT ...................................................... 21
2.2.1 Making a Flat chisel end .................................................................................... 21
3 CHAPTER THREE: THE LOCKSMITHING PROCESS .............................................. 23

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 3.1 ROLES OF A LOCKSMITH ................................................................................. 23
3.2 LOCKSMITHING TOOLS ................................................................................... 23
3.3 TRAINING RECEIVED ON MANUAL KEY CUTTING ................................. 27
3.3.1 When the Original Key is Available .................................................................. 28
3.3.2 When the Original Key is not Available ............................................................ 29
3.4 TRAINING RECEIVED ON THE REPAIR AND MAINTENANCE OF
DOOR LOCKS ................................................................................................................... 30
3.5 UPVC LOCKS ......................................................................................................... 32
3.5.1 Major Parts in UPVC Doors .............................................................................. 32
3.5.2 Common Problems with UPVC Doors .............................................................. 32
3.6 DEFU 998C KEY CUTTING MACHINE ............................................................ 33
3.6.1 Parts of the DEFU 998C Key Cutting Machine................................................. 34
3.6.2 Steps on How to operate the machine ................................................................ 35
3.7 TRAINING ON KEY DIE CASTING .................................................................. 36
3.8 LOCKSMITH REGULATIONS IN NIGERIA ................................................... 38
4 CHAPTER FOUR: WELDING, AND METAL FITTING PROCESSES....................... 40
4.1 CUTTING/SAWING OPERATIONS ................................................................... 40
4.2 METAL FINISHING OPERATIONS .................................................................. 41
5 CHAPTER FIVE: RECOMMENDATIONS, CONCLUSION, AND REFERENCES ... 44
5.1 RECOMMENDATIONS ........................................................................................ 44
5.2 CONCLUSION ........................................................................................................ 44
5.3 REFERENCES ........................................................................................................ 45

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 INTRODUCTION

Blacksmithing is the process by which a metalworker primarily works with wrought iron or
steel (other metals are employed occasionally) to forge items. Forging in itself can be defined
as the manufacturing process that involves the shaping of a metal through hammering, pressing,
or rolling, and is often categorized based off the temperature it is performed at – cold or hot
forging. These compressive forces are applied with the aid of a hammer or die.

At the University of Ibadan’s Blacksmith Section, two main activities were carried out as listed
below.

- Blacksmithing
- Locksmithing

We shall be considering both of these activities at length in the chapters to follow.

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 AN OVERVIEW OF WORKS AND MAINTENANCE,
UNIVERSITY OF IBADAN

Works and Maintenance, University of Ibadan, as can be inferred from its address, is
rightfully located in the University of Ibadan, Ibadan, Oyo State. The Works and
Maintenance Department is charged with the provision and maintenance of infrastructural
facilities used for teaching, learning and research in the University. The department has two
main divisions

– Operations and Maintenance, and Physical Development and Construction. The

General Mechanical Workshop, and the Blacksmith Section by extension, is one of the
multiple subsets of the Operations and Maintenance Division. Below is an organogram
detailing the two main divisions at Works and Maintenance, University of Ibadan.

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 Works and Maintenance,
University of Ibadan

Physical Development and

Operations and Maintenance
Construction

Water and Sewage, Power

House, General Electrical Architectural Design Unit,
Workshop, General Mechanical Civil/Structural Engineering Unit,
Workshop, Water Treatment Mechanical and Electrical
Plant, Awba Dam, Eleyele Engineering Services, Quantity
Pumping Station, Sign-Writing Surveying Unit, Wood Workshop,
and Spraying Workshop, Roads and Grounds, Land
Refrigeration and Air- Surveying, Drawing Office,
conditioning, Auto-Mechanical Public and Residential Buildings,
Workshop, Meter Reading, Building Services Design and
Rewinding Workshop, Electrical Installation, Direct Labour Unit
Mains, Over-head Cables.

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1 CHAPTER ONE: INTRODUCTION TO THE WORKSHOP

1.1 SAFETY PRECAUTIONS IN THE WORKSHOP

From the first day of my Students’ Work Experience Programme, safety precautions in
the workshop were emphasized. I was made to understand that the precautions were to
be strictly adhered to to prevent accidents that could easily occur in the workshop.
These safety instructions are listed below.

- Protective clothing such as overalls, safety boots, and hand gloves, depending
on the task, must be worn at all times.
- The eyes are very vulnerable to damage and as such safety goggles should
always be worn when carrying out tasks in the workshop
- The workspace should always be kept clean and tidy at all times.
- Standing in line of a flying object is strictly prohibited.
- Tongs should be employed in carrying objects out of the furnace.
- The fire in the forge must always be put out whenever operations are done.
- A machine should never be operated unless the operator is familiar with its
operation.
- The anvil should always remain clean and free of moisture and grease at all
times.
- Running in the workshop is strictly prohibited.
- Safety guards should always be employed in the operation of machines in the
workshop.

Once I was done receiving instruction on safety precautions in the workshop, I

proceeded to receive instruction on the equipment and tools used in the blacksmithing
process.

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1.2 COMMON METALS USED IN THE BLACKSMITH WORKSHOP

Common metals used in the blacksmith workshop include the following.

- Carbon Steel
- Alloy Steel
- Stainless Steel
- Wrought Iron

1.2.1 Carbon Steel

The most popular type of steel used in manufacturing and forging is carbon steel. The
carbon content of carbon steels can vary. For instance, low- to mild-carbon steels
have a carbon percentage of about 0.30 percent, whereas high-carbon steels have a
carbon content of about 0.61%. High-carbon steels can be some of the toughest to
forge and are also extremely brittle because of these impurities and their high carbon
content. However, they continue to be a well-liked option for forging when it comes
to strength. These steel types are versatile and can be used to forge a wide range of
objects.

1.2.2 Alloy Steel

The basic qualities of the steel structure, such as its strength, resistance, and ductility,
are improved by the alloying of various elements. Alloy steel is easier to work with
during the forging process than carbon steel because it has more strength, resistance,
formability, and other properties compared to carbon steel. However, it could need
particular heating treatments during the procedure, and working with it can make it
brittle. This steel is more expensive to work with as a result of its additional
components.

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1.2.3 Stainless Steel

Stainless steel has one significant advantage over the stronger kinds of carbon steel:
corrosion resistance. Another advantage of stainless steel is that the forging process
can actually make it stronger, as it can tolerate high temperatures. This makes it a
very popular choice in forging, especially given that it gets stronger during the
process.

1.2.4 Wrought Iron

An iron alloy with a very low carbon content is wrought iron. Due to its texture and
the fibrous slag inclusions that make up its composition, it is used for decorative
blacksmithing works a lot. In contrast to the high carbon steel variants, it has a very
low carbon content and little imperfections. Wrought iron can be worked with using a
variety of methods, including etching, engraving, embossing, and more, all of which
enhance its ornamental properties.

1.3 TOOLS USED IN THE BLACKSMITH WORKSHOP

The following are tools used for blacksmithing.

- Hammer
- Chisels
- Tongs
- Punch
-

1.3.1 Hammer

Hammers are a type of forging tool that can be employed in a variety of ways
depending on the type of forging that needs to be done, such as hot forging, cold
forging, closed die forging, upset forging, and press forging. Two types of hammers
were employed in the workshop – ball peen hammers, and sledge hammers.

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 Ball Peen Hammer: The ball peen hammer was initially developed to be used for
peening, or hammer-shaping metal products. One end has a spherical form on one
side for this reason. Driving is done with the flat end on the other.

Sledge Hammer: Sledge hammers have a metal, mallet-like head and are larger than
most hammers. Longer, heavier sledge hammers are designed to be wielded with two
hands.

1.3.2 Chisel

Metal is chopped and chipped out with chisels. It has an octagonal cross-section
constructed of high petroleum steel with a tapered cutting edge on one end.
There are two types of chisels used in forging: hot and cold chisels. For hot forging,
one uses a hot chisel, and for cold forging, one uses a cold chisel.

1.3.3 Tong

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 Hot metals are held and turned using these kinds of forging tools. There are numerous
types and sizes of tongs. The tongs' grip (shape of jaw) determines how they are
categorized. They are made in two pieces riveted together to form a hinge. The
holding jaw, which are created in various shapes and sizes to suit the matching shapes
and sizes of the jobs, are carried by the shorter length on one side of the hinge, and the
longer section on the other side of the hinge forms the arms that the smith holds in his
hands.
The following are some of the different types of tongs we have.
- Flat or square tong
- Round nose tong
- Hollow nose tong
- Angle or vee nose tong

1.3.4 Punch

These forging tools are used in creating hot holes on hot metal parts. They are
constructed of high carbon steel, and have a typical shape that comes in several sizes.

1.4 EQUIPMENT USED IN THE BLACKSMITH WORKSHOP

Equipment used in the Blacksmith Section include:

- Furnace
- Anvil
- Bench
- Bench Vice

We shall now consider each of these pieces of equipment one after the other.

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1.4.1 Furnace

A blacksmithing furnace is a type of hearth that a blacksmith uses to heat and shape
metals into objects, tools, and more. It is typically a basin that consists of a heat
source and an oxygen input to bring metals up to a temperature where they can be
easily worked and shaped

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1.4.2 Anvil

The anvil is an iron block on which metal is placed to be shaped, originally by hand
with a hammer. The anvil is usually of wrought iron, but sometimes of cast iron, with
a smooth working surface of hardened steel. A projecting conical beak, or horn, at one
end is used for hammering curved pieces of metal. Sometimes the other end has a
beak with a rectangular section. Tools such as the anvil cutter or chisel can be placed
cutting edge uppermost into a holder consisting of a square hole in the anvil’s surface.

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1.4.3 Workbench

The workbench is a sturdy table that is used in the execution of manual work. Bench
vices, used or holding work pieces, are usually attached to it.

1.4.4 Vice

Vices are tools used for holding workpieces firmly in place while they are being
worked on in the workshop. They are employed during processes such as filling,
cutting, drilling, tapping, and dyeing. There are various types of vices used in the
workshop namely bench vice, pipe vice, tool makers vice, hand vice, leg vice, drill
vice, and pin vice.
At Works and Maintenance, University of Ibadan, the bench vice was what was used
for our operations

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 2 CHAPTER TWO: THE BLACKSMITHING PROCESS
At the Blacksmith Section, Works and Maintenance, University of Ibadan, blacksmithing
and locksmithing tasks were carried out, of which locksmithing was the majority. Over
the next two chapters, I shall consider both tasks in detail. This chapter shall detail the
blacksmithing processes as carried out at the Blacksmith Section.

2.1 TRAINING RECEIVED

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2.1.1 Lighting the Forge

At the Blacksmith Section, Works and Maintenance, University of Ibadan, sawdust

was employed in lighting the forge. The following steps were involved.

- To begin, remove clutter from the last session around the tuyere nose.
- Spread some sawdust in the space created.
- Ignite a fire using some kindler, and make sure fire spreads to the rest of the
saw dust.
- After ignition, turn the air on, and introduce some extra sawdust to sustain the
fire.

2.1.2 Forging Techniques Used in Blacksmithing

All blacksmiths need to be conversant with the following forging methods. One of
these fundamental blacksmithing methods will most likely need to be employed
during each forging session, depending on the project.

- Bending

In bending, the metal can be bent or curved by heating it, holding it over the anvil
horn, and then striking it with a hammer to create the desired curve. Instead of
heating the entire piece of metal, heating can be selectively carried out in the forge
before bending. Metals can also be re-bent by warming the metal and going
backwards through the process.

- Punching

Punching is the process of making holes in heated metal with a punching tool. The
metal is first heated, then the location of the hole is marked with a punching tool
and gently hammered until resistance is felt from the anvil. To prevent damaging
the anvil's surface, care is taken to ensure the strikes are not forceful.

- Drawing

Drawing is a crucial blacksmithing technique that is used to lengthen and thin

metal. Tongs are used to secure the piece on the anvil, then hammer strikes are
applied to both sides to lengthen the piece.
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 - Upsetting

Upsetting is the opposite of drawing as it carried out to make the metal thicker,
shorter, and narrower. Compared to typical forging methods, upsetting requires
some more technical expertise. The procedure, which is utilized in more advanced
levels of blacksmithing, can be challenging to control. Instead of heating the entire
piece of metal in the forge, just the portion that will be shaped is heated.

- Shrinking

Shrinking involves the compression of metal between the hammer's flat head and
the anvil's flat surface. This technique performs the best when the anvil and
hammer's flat head have the same width as the target object.

2.1.3 Heat Treatment Techniques in Blacksmithing

Blacksmiths employ heat treatment methods to strengthen metal and make it easier to
deal with during forging. The three main heat treatment methods used in
blacksmithing are annealing, hardening, and tempering.

- Annealing

The process of annealing makes the material simpler to deal with when forging.
The material becomes softer as a result, making it easier to bend and form.
Additionally, annealing shields metal from breaking or cracking. To anneal
material, the material is fired up in the forge and then slowly cooled down by
setting in sand. The process of annealing clears the grain of impurities, improves
the material's strength, and lessens its hardness.

- Hardening

To increase a material's strength, hardening is carried out. This involves carefully

heating it up and cooling it down the material. The metal is heated to its greatest
temperature and quickly cooled by quenching it in a liquid—typically water, salt
water, or oil—. The material that quenches the fastest is water, but adding oil or
salt can make the cooling process take longer, which would help ensure that the
materials would avoid brittleness.

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 - Tempering

The forged metal is then tempered to boost toughness and decrease excess
hardness after it has been hardened. Tempering involves the heating and cooling
of the metal at room temperature in order to make a metal less brittle and more
resilient.

2.2 BLACKSMITHING TASK CARRIED OUT

2.2.1 Making a Flat chisel end

The following steps were involved in the making of a flat chisel end.

- Light the forge

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- Place the tip of a metal bar into the forge fire and allow the tip heat until it is
red hot.
- Remove the metal bar using tongs, and then hold it on the anvil.
- Holding it with the aid of tongs, strike repeatedly at the red hot tip until it
flattens.
- Turn the bar over to the other side and repeat the process.

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 3 CHAPTER THREE: THE LOCKSMITHING PROCESS
Locksmithing is the art and science of installing, repairing, and adjusting locks. These locks
can range from car locks to office building locks. Locksmith services are offered to people
who might be locked out of their apartments or offices, or people who need a key duplicated.
Locksmithing is a rather ancient profession. Too put it in other words, as long as locks have
existed, there have been people specialized in working with them.

At the Blacksmith Section, Works and Maintenance, University of Ibadan, locksmithing

comprised the bulk of tasks that were carried out. This chapter shall detail the locksmithing
processes as carried out at the Blacksmith Section.

3.1 ROLES OF A LOCKSMITH

The roles of a locksmith include the following:

- Duplication of keys. The keys might have been lost, or a copy might simply be
needed.
- Replacement and installation of new locks.
- Sometimes involves the design of new keys or lock systems.

3.2 LOCKSMITHING TOOLS

As with any profession, using the right tools of the trade is integral to successfully carry
out a task. Below are the tools employed in locksmithing at the Blacksmith Section,
Works and Maintenance, University of Ibadan.

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- Hack Saw

This is used for tasks that require heavy cutting such as cutting of padlocks or
damaged door handles.
- Files

This is used to shape key teeth after cutting, and for light finishing. It comes in
different shapes, and examples are round file, flat file, triangular file, half round
file, and square file.

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- Pliers
This is a hand tool used for gripping objects firmly. There are different types
of pliers such as combination pliers, diagonal pliers, and long nose pliers. The
long nose plier in particular can be used for extracting broken parts of keys in
lock cylinder.
- Bench Vice
This is mostly used to keep keys firmly in place during the key duplication
process. It is also used to hold other workpieces in place in situations when
stability is needed.
- Drilling Machine

Drilling machine is used for creating holes in door locks and keys when
necessary.

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- Key Die Cast

This is a mould used for casting keys with the aid of molten metal.
- Key Blanks

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 Key blanks are plain keys used in the duplication of keys. This means that they
have not been cut, and have a specific cross-sectional profile to match the
keyway in a corresponding lock cylinder.

- Screwdriver
As the name implies, this is used in driving screws in and out of locks
- Vernier Caliper

This is used to gauge the depth of cut while cutting keys is the same as the
original.
- Lock Pick
This is the tools used for manipulating the components of lock device in the
absence of the original key.

3.3 TRAINING RECEIVED ON MANUAL KEY CUTTING

The best way to start the journey into key cutting is with the proper understanding of
manual key cutting using tools such as the bench vice, file, and saw. A locksmith not
properly trained in manual key cutting will still be able to carry out key duplication
tasks in the absence of key cutting machines. That being said, I shall be considering
manual key cutting in two situations.

- When the original key is available.

- When the original key is not available
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3.3.1 When the Original Key is Available

- Select the Right Key Blank.

This is the first and very important thing to do. Every key has its specific blank that
matches it. One must make sure that the key blank used is the right one, or else the
work would have failed before it even started. There are are tolerances which must
be confirmed by inserting the blank to the lock cylinder. If the key blank
successfully enters the lock cylinder, it means it can be used for duplication.

- Clamp the Key Blank and Original in Place

The bench vice is used to clamp the original and key blank firmly in in place
horizontally so the original can be used as a reference frame for the duplicate. The
vice is properly tightened to prevent damage of both the original and blank.

- Start the Filing Process

This step requires a great deal of patience, as the original key can be damaged if
done incorrectly. Starting at the height of the tallest "mountain" on the original, start
filing down the key blank. Try to avoid scraping any metal off the original as this
could damage the key.

- Complete the Filing Process

Filing of the valleys is carried out at this stage, and care is taken to ensure that the
keys are properly lined up during the process. Filing is done at an angle of 45
degrees to create proper grooves in the key blank. To prevent overcutting, the
cutting depth is regularly gauged with the aid of a vernier caliper or simple gauge.

- Test and Fine Tune the Duplicate

The key needs to be tested as it is not unusual for it to not work upon the first test.
In the instance where it doesn’t work, compare the duplicate with the original, fine
tune it, and test again.

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3.3.2 When the Original Key is not Available

- To begin, the right key blank for the lock cylinder is selected.
- The next step is to use a file to shape the key blank into a sharp point, almost like a
blade. The sides of the key are filed off to obtain a thin point.
- Once the key has been filed down, the blank is held firmly in place with a pair of
vice grips. A lighter is used to keep the flame there for a short while. The transfer
marks formed by the lock become easier to see because of the smoke left on the
blank.
- The sharpened key blank is placed into the lock using the vice grips, and it is then
turned around. This is done so that the lock's pins or wafers really mark the blank.
This makes it possible to see where cuts will be necessary to allow the key to turn
freely. A number of methods can be used to achieve this, including shaking it up
and down and back and forth.
- The key would need to be filed down after following the tiny impressions made
onto the key blanks. It is only gently filed and gradually shaved down.
- The process is repeated by inserting the blank key back into the lock. The procedure
is progressive, beginning with little grooves and depths; taking fresh impressions to
determine where the filing should be continued.
- Once the blank spins inside the lock, further impressions are taken and it is further
filed down. Eventually, it is discovered that when turning and twisting, the key will
flip over when it is returned to the lock for a fresh set of markings.
- The key is checked for any fresh markings after it has been allowed to rotate in the
cylinder, By filing it in accordance with these new imprint markings, the key can
be fine-tuned.
- Iteration is carried out as necessary. Once the key successfully opens the lock, the
necessary cuts would have been obtained to create a new key for that lock. Given
that the key has been filed down, making it thinner and weaker than it should be, it
shouldn’t be used.
- The key is taken back, and a copy is created, using the impression and a brand-
specific key blank.

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3.4 TRAINING RECEIVED ON THE REPAIR AND MAINTENANCE
OF DOOR LOCKS

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During my time at the Blacksmith Section, Works and Maintenance, University of
Ibadan, of all the locks we dealt with, most of them were crystal locks – the locks that
can be found in most of the old buildings in the University of Ibadan. The skills gained
from maintaining, and repairing these locks are rather transferrable to other locks
however, hence I shall be detailing how these locks can be serviced below.

- First, remove the handle from one side of the door and remove the spindle (metal
bar) that connects both handle through the lock.
- Remove the front (face) plate from the lock that in visible in the edge if the door.
- After the second step above, the fixing screw that holds the lock in place will
need to be removed
- Lock the face of the door and place a screw driver through the spindle hole in
the lock, and gently pull the lock horizontally towards the edge of door until
you can access it well enough to pull the lock from the door.
- For the maintenance, remove the back cover from the lock (two screws should
be holding the in place), and take care as some internal parts like the “levers”
which is spring loaded could jump out.

Remove the “levers” with care and lay them out in a set order as they and any spacer
between them must go back in the exact same order.

- Clean each moving part of the lock with WD40 or similar lubricant and then
replace damaged parts it any.
- Reassemble the lock, and make sure to test the key operation before the
installation process which is the reverse of the above processes.
- A spot of oil in the handle mechanism will help to keep the parts running
smoothly.
- After reinstalling the lock and handle, it is best to carry out a test of the lock
operation before closely the door. To do so, close the door and test the lock
operation from inside and outside the house.

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3.5 UPVC LOCKS

Due to their relatively low cost and ease of installation, UPVC doors, which have been
available for almost 25 years, have essentially become a standard in most homes. With
UPVC doors, a variety of issues might arise, from the door jarring to the locking
mechanism malfunctioning. By fixing the UPVC lock mechanism or changing the
cylinder, many problems can be avoided. Below we shall consider some major parts in
UPVC doors, and common problems affecting UPPVS doors.

3.5.1 Major Parts in UPVC Doors

- Euro Lock
You insert the key here to lock and unlock. In most cases, the keyhole is in the shape
of a circle, but some doors, particularly older or apartment doors, have a narrow
oval underneath.
- Multipoint Locking System
Only visible when the door is open, this lock component engages when you pull the
handle. It will include a door latch, a door bolt or hook, and two to four hooks or
sliders that heighten the security of the door.
- Door Keep
This part of the lock, which is only noticeable while the door is open, activates when
you pull the handle. It includes a door latch, a door bolt or hook, and two to four
hooks or sliders that all contribute to increase the door's level of security.

3.5.2 Common Problems with UPVC Doors

- Door catches on the frame, and it becomes hard to lift the handle lock
Misalignment of the door in the frame is a very typical issue with UPVC doors.
Wearing hinges and improperly packed door panels or glass are the two main causes
of misalignment, however other causes can also contribute.

Lifting the handle to engage requires greater force since the keep and the multipoint
are not aligned, which increases the parts' wear and tear. Re-aligning the hinges will
usually repair the issue quickly, but in some more extreme cases, new hinges may
be required.

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 - Euro lock cylinder problems
The most frequent issues are when you can't remove the key after locking or
unlocking the door or when the key won't turn to unlock the door (this could also
be an indication that the multipoint has failed). The lock will need to be taken out
in both situations and either repaired or replaced.
- Bowed or bent door
Damage from vandalism might result in the UPVC door being misshapen, affecting
the multipoint lock, and being difficult to close or open. To see the damage and
potential remedies, an inspection is required.
- Multipoint Lock problems
Was it difficult to lift the multipoint? Do your handles sag a little bit? These may
indicate that the Cam is worn or that the multipoint is being overworked.
Most of the time, you won't notice a problem until the lock malfunctions and, due
to its nature, either leaves the door locked or prevents you from locking it. When a
multipoint fails, it must be removed and a replacement installed.

3.6 DEFU 998C KEY CUTTING MACHINE

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 Manual key cutting serves as the foundational skill that every proper locksmith must
develop, but not all keys can be duplicated manually. As a result, I was also trained in
the operation of the DEFU 998C key cutting machine. Below are details on the machine
itself, and its operational procedures.

3.6.1 Parts of the DEFU 998C Key Cutting Machine

- Electric Motor: It is enclosed within the machine by the electric motor cover at the
top of the machine. It transmits rotational motion required for cutting to the cutter
through its timing belt.
- Electric Motor Cover: It is used to control the vertical feed during operation. It is
located at the right-hand side of the machine.
- Horizontal Handle Feed: Horizontal handle feed is used to control the horizontal
feed during cutting operation. It is located at the left-hand side of the machine.
- Setting bolt: The setting belt is can be found on the chuck of the cutter located at
the right-hand side and the leading needle chuck, located at the left-hand side of the
machine. They are both used for tightening the cutter and the leading needle firmly.
- Cutter chuck: The cutter chuck holds the cutter in position.
- Leading Needle Chuck: The leading needle chuck holds the leady needle in
position.
- Duplicate Key jig: The duplicate key jig is located that right hand side of the
machine. It holds the duplicate key in position and aligned with the cutter.
- 99999Original Key Jig: The original key jig holds the original key in position for
the leady needle. It is located at the left-hand side of the machine.
- Duplicate key Jig locking Handle: The duplicate key jig locking handle is the
adjustment and the locking device for the duplicate key jig.
- Original key Jig Locking Handle: The original key jig locking handle is the
adjustment and the locking device for the original key jig.
- Forward/Back Jig Base: It is movable base where both the original and the
duplicate key jigs are mounted.
- Left/Right Jig Base Slide: It is located under the forward/Backward jig base. It
controls the left/right movement of the jigs.
- Cutting bit drawer: It is a draw for keeping bits or leady needle not in used. It is
located at the base of the machine.
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 - AC Plug: Used for connect the m/c to power supply

3.6.2 Steps on How to operate the machine

- Install the leading needle, and lock the regular screws

- Move the vertical depth buttons in clock wise direction till the spring is totally
compressed.
- Get a name card (flat object) and put it on the surface of the jig under the leading
needle. This is to ensure that the two jigs are at the same level.
- Put the cutter into axis hole, then press the vertical handle feed slowly, make the
name card happen to be pressed during leading needle and jig.
- Pull down cutter gently, make terminal surface of the cutter and jig surface contact
each other, then lock cutter’s regular screw along the direction of the clock.
- Put the original key into the jig and lock the rotary handle of the jig.
- Place one corner of the name card on the cut part of the original then press down
the vertical feed handle slowly, press one corner of the name card on the cut part of
the leading needle and original spoon, then lock the vertical depth of regular screw
along the direction of the lock.
- Pack the jig into the base of the original key, move the handle of the jig and fasten
it.
- Start the machine, move the cross slide slowly to start the cutting. If the cross slide
moves in the curing direction, it will damage the cutter.

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3.7 TRAINING ON KEY DIE CASTING

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 I and my colleagues were priviledged to receive training on key die casting - the process
carried out in the production of keys and key blanks. While the finishing on the casted
keys was not industry standard due to the lack of equipment, it was still a very educative
process.

The following steps were carried out during the process of key die casting.

1. Material (zinc) to be melted is selected.

2. The furnace fire is ignited and the zinc is melted.

3. The right die (mould) for the key to be moulded is selected.

4. After the zinc melts, it is gently poured into the die held firmly in position.

5. The molten zinc is then allowed to cool and solidify.

6. The key is then properly filed and drilled as necessary.

3.8 LOCKSMITH REGULATIONS IN NIGERIA

The Professional Locksmiths Association of Nigeria has been established to provide

the public with the re-assurance that when selecting a Locksmith displaying the
Association Logo, they do so in confidence that the engineer has been carefully vetted
and found to have:

- No criminal record.
- Provided at least 2 work references (within the Association) that have been
undertaken and verified.
- Agreed to follow the association’s constitution to the letter.

Any claimed registered locksmith must present their current and valid identity cards
and display their membership certificate (displaying their registration number) on the
wall of their office.

Mobile locksmiths without an office are operating illegally. All locksmiths are
mandated to have a physical well equipped business location because of the sensitive

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nature of the profession. There have had reported cases where these "mobile
locksmiths" defrauds customers and abscond without trace

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 4 CHAPTER FOUR: WELDING, AND METAL FITTING
PROCESSES
During my Students’ Work Experience Programme, beyond my primary duties
(blacksmithing and locksmithing) at the Blacksmith Section, Works and Maintenance,
University of Ibadan, I also carried out other tasks at the General Mechanical Workshop such
as accompanying the head of the General Mechanical Workshop on any number of tasks,
cutting/sawing operations and finishing operations. In this chapter, I shall consider those
tasks in detail.

4.1 CUTTING/SAWING OPERATIONS

Sawing is cutting of work pieces in a narrow kerf by many chisel-type teeth on a

saw blade arranged one after the other for the purpose of cutting off or of providing
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 work pieces with slots or recesses.
Manual sawing is used only in single-piece production and repair work on small-
section work pieces because it is hard and time-consuming manual work. For
bigger cuts hack sawing, circular sawing (slitting) and band sawing machines are
used.

4.2 METAL FINISHING OPERATIONS

The following metal finishing operations were part of my tasks at the General
Mechanical Workshop, Works and Maintenance, University of Ibadan.

- Sandpapering: This is done with the use of sandpapers. The sand paper
is a strong paper coated on one side with sand or another abrasive, used to
smooth the surface of metals and other surfaces. Sandpapering is done by
robbing the sandpaper against the metal surface in any direction and the
rough or rusty faces are scraped off in the process living behind a smooth
lustrous surface. Sandpapering is usually done before painting to make
sure the surface is smooth enough to retain the paint.

- Painting: This is done as usual with the use of a paint (a colored liquid
applied to a surface in order to decorate or protect it, or in order to create
a painting) and brush for applying the paint. Usually, we use kerosene or
turpentine to dilute the paint especially when it is too thick for the purpose
it is to be used for. Before any painting is carried out the metal work must
be properly wiped to remove any possible particles on the surface.
Whenever mistakes are made in the painting they are quickly cleaned with
kerosene or turpentine using a rag because it gets harder to clean the paint
once it is already dry. The paintbrush is cleaned after use, or for use with
another color of paint using kerosene, turpentine or any other non-polar
solvents.

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One of the highlights of my Students’ Work Experience Scheme was when I and
my colleagues accompanied the head of the General Mechanical Workshop,
Works and Maintenance, University of Ibadan, to the University of Ibadan main
gate to help take down the University of Ibadan’s logo. We were taught during
the process the importance of designing for long term use, as the damaged logo
could have been easily repaired if the design had been different.

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5 CHAPTER FIVE: RECOMMENDATIONS, CONCLUSION,
AND REFERENCES

5.1 RECOMMENDATIONS

During my Students’ Work Experience Programme, I repeatedly took note of one

fundamental problem, and that was the lack of equipment and funding at the General
Mechanical Workshop, University of Ibadan Works and Maintenance, the Blacksmith
Section inclusive. This invariably prevented us (my colleagues and I) students from
learning as much as we could have as resources were limited.

I therefore recommend that the Industrial Training Coordinating Centre looks into
providing more funding for Works and Maintenance, University of Ibadan, as it is one
of the primary organizations that helps to provide work experience to students of the
University of Ibadan.

5.2 CONCLUSION

My eight weeks long Students Work Experience Programme at the Blacksmith

Section, Works and Maintenance, University of Ibadan has allowed me to gain
practical work experience regarding blacksmithing and locksmithing, and also allowed
me to truly understand how to relate, interact, and maintain personal relationships that
help a workplace thrive.

The training I received has genuinely helped me appreciate how theory meets practical.
I am truly glad to have participated in this programme.

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5.3 REFERENCES

Dwivedi, K. (2022, November 12). Types of Vices Used in Workshop and Clamp
Devices. https://www.mechical.com/2021/02/types-of-vices-used-in-workshop.html

Different Types of forging tools and equipment. (2021, May 26). Student Lesson.
https://studentlesson.com/types-of-forging-tools/

Owens, H. (2022, March 17). A Comparison of the Common Metals Used in

Blacksmithing. CastMasterEliteShop. https://castmastereliteshop.com/blogs/news/a-
comparison-of-the-common-metals-used-in-blacksmithing

The Crucible. (2022, March 28). Blacksmithing Forge 101: How To Make Forges At
Home. https://www.thecrucible.org/guides/blacksmithing/blacksmithing-techniques/

Strauss, C. (2022, September 26). How Do Locksmiths Make Keys Without An

Original Key? Great Valley Lockshop. https://www.gvlock.com/blog/make-keys-
without-original/

UPVC Door Lock Problems And Solutions. (2021, September 23). 24 Hour Locksmith
Services. https://lockfit.co.uk/upvc-door-lock-problems-and-solutions/

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