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Purdue Hammer

An aluminum hammer was fabricated by machining a hammer head and handle from hex and round stock using manual milling, drilling, tapping, turning, threading, knurling, and finishing operations. The activity provided hands-on experience with foundational subtractive manufacturing techniques and illustrated how tolerances and process choices influence assembly fit and final product quality.
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Taher Mustafa Mukadam

Project Timeline

Sep 2025 - Oct-2026

HighlightS

  • Machined the head and handle using both a milling machine and a lathe, including drilling and tapping the head and turning and threading the handle.
  • Added functional and ergonomic features, including one half by thirteen UNC threads for assembly, a knurled grip section, and a tapered handle profile.
  • Verified the finished part against design tolerances using measurement tools and confirmed the hammer assembled cleanly.

SKILLS

Milling
Turning
Buffing/Polishing
Stamping

External Links

PROBLEM STATEMENT

Machine and assemble a functional aluminum hammer by producing a hammer head and handle from aluminum stock to the provided engineering drawings. The build should develop proficiency with manual lathes and milling machines while applying core operations (facing, turning, threading, knurling, milling, drilling), and demonstrating how dimensional tolerances affect fit, assembly, and final product quality.

BILL OF MATERIALS

ItemQtySpecificationPurpose
Aluminum hex stock11.25 in aluminum hexagonal stockRaw material for hammer head
Aluminum round stock11 in diameter aluminum round stockRaw material for handle
Tapping fluidas neededstandard tapping fluidLubrication for drilling and tapping operations
Buffing compoundas neededpolishing compoundFinishing and polishing the parts

IMAGES

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