College of Electrical and Mechanical Engineering
Department of Electromechanical Engineering
Workshop Practice for EME I
Lecture: 1. Introduction to Workshop
2. Using Conventional Tools &
Machines
BY Tolina T.
2020/21
AASTU
1. Introduction
1.1 Workshop practice
• Workshop is a place of work for preparing variety of
jobs/products by using different kinds of
Instruments, hand tools and machines.
• In order to prepare the products in workshop, the
workshop is divided in to many branches according to
nature of work.
1. Fitting shop
2. Welding shop
3. Sheet metal shop
4. Machine Shop
5. Foundry & Forging shop etc
Safety precaution
• Safety describes that it is the way of doing work
correctly to prevent accident.
• It can be defined as the way of prevention of
accidents.
• The prevention of accident concerns
The work man (operator) and his partner
The work piece
The working tool
The work shop
Causes of accidents
• Faulty attitude towards safety
• Failure to recognize danger.
• Emotions (anger, worry, excitements…)
• The other causes of accident are not to take safety
as a way of life.
General safety measures
• Dress correctly (wear apron, short sleeved beltless
coats).
• Remove rings, wrist watches, necklaces, bra- slates.
• Always walk in the shop
• Protect your eyes
• No horse play
• No scrap materials on the flour.
• Take care of injuries
2. Measuring and Marking Tools
2.1 Measuring Tools
• Accuracy: is the lowest dimension that can be measured
using the measuring tool.
• Example:
– The Accuracy of Steel Rule is 0.5 or 1mm
– The Accuracy of vernier calliper is 0.1, 0.05 and 0.02
mm
• Precision: the closeness or the agreement occurring
between the results obtained for a quantity measured
several times using the same instrument at the same
condition
• Example
– Vernier calliper is more precise than Steel Rule
– Micrometer is more precise than Vernier calliper.
• Error: is the difference between the result of the
measurement and the true value (Ideal Dimension) of
the quantity.
• Example
– True Value = 10mm, Measured value=9.75
– Error= 10-9.75=0.25mm
• Measuring tools are classified as
– Semi-precision measuring devices: Semi-precision
measuring devices are steel rule, Tape rule, Zigzag
rule and etc
– Precision measuring devices: Precision measuring
devices are Venier caliper and Micrometers
Semi-precision measuring devices
Precision measuring devices
Vernier Calliper
• Vernier Calliper is used to measure internar , exetrnal
and debth of a work pice
• Parts of a vernier caliper:
1. Outside jaws: used to measure external diameter or
width of an object
2. Inside jaws: used to measure internal diameter of an
object
3. Depth probe: used to measure depths of an object or
a hole
4. Main scale: gives measurements of up to one decimal
place
5. Vernier sclae gives measurements up to two decimal
places
6. Retainer: used to block movable part to allow the
easy transferring a measurement
Micrometre
• Micrometer: used to measure he external, internal or
depth.
• A micrometer is a very useful instrument. It enables
you to take measurements to within one hundredth of
a millimeter (0.01 mm).
• The metric micrometer is able to measure ranges of 25
mm (that is, for 0-25 mm, 25-50 mm, and so on).
• The micrometer has a thread with pitch 0.5 mm.
• This means that the spindle advances by 0.5 mm for
each turn. However, there are 50 graduations on the
thimble. So the movement advanced for each
graduation of the thimble is 0.5/50 = 0.01 mm.
Inside Micrometer
• This is similar in structure to an outside micrometer and is
used for measuring internal dimensions
Depth Micrometer
• A depth micrometer is used for measuring the depth of
a hole, slot and keyway etc. A complete set of depth
micrometer is equipped with spindles of different
lengths, which can be interchanged to suit different
measuring ranges
• Example:
– Upper main scale 12.00 mm
– Lower main scale (no half mm) 0.00 mm
– Circular thimble scale 0.13 mm
– 13 X 0.01 mm = 0.13mm
– Total reading 12.13 mm
Vernier height gauge
• A vernier height gauge is used for measuring height of
an object or for marking lines onto an object of given
distance from a datum base.
Combination Set
• Combination set is a set of equipment combining the
functions of protractor, engineer square, steel rule,
Centre finder, level rule, and scriber.
Trammel
• When scribing circles,
arcs, and radii that are too
large to be produced with
the divider, a trammel
should be used . The
trammel is made of three
main parts: the beam, two
sliding heads with scriber
points, and an adjusting
screw that is attached to
one of the heads.
Hermaphrodite Caliper
• The hermaphrodite
caliper is a tool used
to lay out lines that
are parallel with the
edges of the work
piece . It can also be
used to locate the
centre of cylindrical
shaped workplaces
3. Hand Tools for Workshop
Hacksaw
• Hack saw is a tool used to cut off metal to lengths or to
cut out shapes in sheet metal and other relatively thin
sections. It composed of three main parts; the frame,
the handle and the blade. The frame can be of either a
solid or an adjustable type.
Hacksaw blade
• Pitch - It is grading
according to the number of
teeth per 25mm.
Coarse blade (18T) is most
suitable for soft material and
thick work piece.
Medium blade (24T) is
suitable for steel pipe.
Fine blade (32T) is suitable
for the thin metal sheet and
thin copper pipe.
Hacksaw blade
• The blade is secured in the rigid frame. The teeth point
forward to enable the saw to cut on the forward stroke.
A wing nut at the back of the frame provides adjustment
for blade tensioning.
• The blades come in the following lengths: 225, 250 and
300 mm. They are also available with 14, 18, 24 and 32
teeth per 25 mm for cutting different materials (Table
1.1).
Number of teeth per Diameter of material Material to cut
25mm(1 inch) to be cut
14 25mm Aluminum, bronze,
cast iron
18 6mm Angle iron, cast iron,
tool steel
24 1.6mm Brass pipe, Heavy
sheet metal
32 Less than 1.6 mm Sheet metal
over18gage
Vise
• Vise is fastened near
the edge of the bench
with bolts fig. It is
often used to clamp
parts together while
cutting, filing or
chipping or being
assembling.
Chisel
• These are sometimes referred
to as cold chisels because they
are used to cut cold metals.
They are made of cast steel or
alloy steel, with a hardened and
tempered cutting edge.
• The common types of chisel
include:
1. The flat chisel, used for
general-purpose chiseling;
2. The cross-cut chisel, used
for cutting grooves such as
keyways, and for chipping;
Chisel
[Link] half-round round-nosed chisel, used for cutting
grooves (which are either curved or half-round);
[Link] diamond-pointed chisel, used for working into
corners and cutting small grooves
Chopping out, shearing and chiping/grooving
Files
• Files are the most important hand tools used for the
removal of materials. They are made of hardened high
carbon steel with a soft 'tang'. to which a handle can be
fixed. Files are categorised as follows:
1. Hand file
2. Flat file
3. Half round file
4. Round file
5. Square file
6. Needle file
• Hand File - The common file used for roughing and
finishing. It is a rectangular in section and parallel in
width. It has double cut teeth on two faces, single cut
teeth on one edge, and one save edge
• Flat File - It is similar to a hand file rectangular in
section, tapered slightly in width and thickness towards
the tip. It has Double Cut teeth on two faces and Single
Cut teeth on two sides used for general bench work
• Half-round File - The section is a chord of a circle with
its taper towards the tip. It is used for forming radii,
grooves, etc. and the flat side is used for finishing flat
surfaces.
• Round File - This is of round section tapering toward the
end. It is used for enlarging holes, producing internal
round corners. Usually double cut in the larger sizes,
and single cut for the smaller sizes.
• Square File - This is square in section, with tapered
towards the tip, and usually double cut on all four faces.
It is used for filing rectangular slots or grooves
• Trangular File - It is also known as triangular file. This is a
triangular in section, with tapered towards the tip with
double cut on both faces. It is used for filing corners or
angles less than 90°
• Needle Files - Needle files are a set of small files with
their shapes made in a way similar to the large ones.
They are generally used for small and delicate works such
as the repair of small instruments.
File grade
• This refers to the pitch (spacing) of the teeth that spread
throughout the whole length of the file.
• Files with a rougher grade of cut give a faster metal
removal rate but a poorer surface finish or the vice versa.
It should be noted that, for the same grade of cut, a
longer file would have a coarser pitch than a shorter one.
• Degrees of coarseness both single- and double-cut
files are manufactured in various degrees of
coarseness, such as rough, coarse, bastard, second-
cut, smooth, and dead smooth.
• Those most commonly used by the machinist are the
bastard, second cut, and smooth
4. Drilling machine
Drill and Drilling
• Drilling is the process of
cutting holes in metals by
using a drilling machine as
shown in figure.
• Drills are the tools used to
cut away fine shavings of
material as the drill
advances in a rotational
motion through the
material
Drill bit
• The twist drill is made
from High Speed Steel,
tempered to give maximum
hardness throughout the
parallel cutting portion.
Flutes are incorporated to
carry away the chips of
metal and the outside
surface is relieved to
produce a cutting edge
along the leading side of
each flute.
Special Type of Drill
• Counterbore Drill (figure
30) To form a flat, or
cylindrical recess to
accommodate the head of
the bolt. It is also used to
provide a level base on the
rough surfaces for nuts and
washers.
• Countersink Drill (figure
31) To form a conical
shaped recess to enable a
countersunk screw or bolt to
fit flush with the surface of
the work
Tap
• Taps are used to cut the internal
screw threads.
• Taps are made of hardened High
Carbon Steel or High Speed
Steel. Two, three, or four flutes
are cut lengthwise across the
threads to form cutting edges,
provide room for the chips, and
admit cutting fluid to lubricate
the tap The ends of the shank are
square to fit a wrench. Usually
taps are provided in set of three --
taper, second and plug tap
Tap
• 1. Taper Tap
The tap is tapered off for a
length of 6 to 8t hreads and is
the first tap to be used in a hole
to start the thread form.
• 2. Second Tap
The tap is tapered off for a
length of 4 to 5 threads to
facilitate picking up the
threads cut by the taper tap.
• 3. Plug Tap
This is fully threaded
throughout its length and is
called a 'bottoming' tap. This
tap used to cut the bottom of a
blind hole.
• Drill size = Tap drill size
– pitch
• Find the drill size of
M10x1.5
• Drill size = 10-1.5 = 8.5
Die
• Dies are used for
cutting external threads
on round bar or tubes.
Dies are made of
Hardened High Carbon
Steel or High Speed
Steel.
