ADAMA SCIENCE AND TECHNOLOGY UNIVERSITY
SCHOOL OF MECHANICAL, CHEMICAL AND MATERIALS ENGINEERING
Mechanical Engineering Department
Basic Workshop Practice (MEng 2101)
By: Natnael Bekele
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Basic Workshop Practice
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Contents
1. Introduction
2. Measuring tools and Linear Measuring equipment’s /instruments
3. Bench Working Operations
4. Drills and Drilling
5. Thread Cutting By Hand(Taps and Dies)
6. Rivets and Riveting
7. Fundamental of Wood working operations
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1. Introduction
• General Safety and care of workshop facilities
• The need of safety
• Cause of accidents
• Accident prevention
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What is Safety?
What is workshop?
• a room or building in which goods are manufactured or
repaired.
What is Safety?
• Safety is the state of being safe.
• Safety is an altitude, that is, it is condition of mind.
• Safety is a state in which hazards and conditions
leading to physical, psychological or material harm are
controlled in order to preserve the health and well-
being of individuals and the community. 5
Safety in Workshops /Basic metal and Machine Shop/
• Safety is the state of being safe “Safety is
everyone’s business and responsibility’’.
• The work shop is a work place. Keep it clean. Metal
scraps/chips/ should be thrown in scrap box than just
putting them drop in the floor. Therefore they may
case you or fellow/members/ students to trip and fail.
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The need of safety in workshops
• Safety working habits cannot bought or manufactured
they must be learned through practice.
• Safety increased value of production with a minimum of
time lost from on one job injury.
• The safety education today has become an important
phase of every training program.
• The safety program prepared in different level.
Workshops, Industrial, governmental agencies to reduce
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the number of accident.
The need of safety in workshops
General rules for safety in metal workshop have been
established for three very good reasons.
1. To protect you and your colleagues from bodily
harm.
2. To minimize damage to facilities, machinery and
hand tools.
3. To provides you with experience in safety concepts.
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Accidents and Causes of Accidents
Causes of Accidents
Accidents don’t just happen; they are caused. The
• Ignorance of the proper handling of
cause of an accident can usually be traced to hand tools and machineries.
carelessness on some one’s part. • Ignorance of the danger existing at
once working place.
Accidents can be avoided, if a safe work habits
• Ignorance of the proper working
are developed. method and procedures.
• Carelessness.
• Lack of tidiness/Keeping things neat
and orderly/.
• Horse play etc.
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Generally causes of accidents
a) Causes of accidents from Personal Grooming
Generally causes of accidents
categories:
are categorized in to four 1. Never wear loose clothing around any machine.
major groups.
I. Personal grooming 2. Remove any watches, rings or bracelets; these
can get caught in the machine.
II. House-keeping
III. Handling tools and 3. Long hair must be protected by hair net or an
approved protective shop cap.
materials/work-piece/
IV. Operating machine Tools 4. Always wear approved safety, glasses when
cutting metals by machines.
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Generally causes of accidents
b) Causes of accidents from House Keeping Categories:
1. Keep the floor free from oil and grease.
2. Sweep up the metal chips on the floor frequently.
4. Always keep the machine clean. Use brush and proper T-slot
tool to remove any chips.
5. Always stop the machine before you attempt to clean it.
6. Do not place tools and materials on the machine body.
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Generally causes of accidents
c) Causes of accidents from Handling Tools and Materials/Work-
piece/Categories:
1. Be sure the work is clamped securely in the vise, chuck or to a machine table.
2. Before you handle any work piece, remove all burrs and sharp edges with a
file.
3. Do not attempt to lift heavy or odd shaped objects which are difficult to handle
on your own.
4. For heavy objects, follow safe lifting practices. Use your leg muscles for lifting
and not your back.
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Generally causes of accidents
c) Causes of accidents from Handling Tools and Materials/Work-
piece/Categories:
5. Never start a machine until you are sure that cutting tools clear the work piece.
6. Use proper wrenches to tight the nut. Replace worn out nuts.
d) Causes of accidents from Operating Machine Tools Categories:
1. Do not operate any machine before understanding its mechanism.
2. Always stop a machine before measuring, cleaning or making any adjustments. It
is dangerous to do any type of work around moving parts of a machine.
3. Never operate a machine unless all safety guards are in place.
4. Keep hands away from moving parts. It is dangerous practice to “feel” the
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surface of the revolving work or to stop a machine by hand.
Accidents Prevention
Accidents Prevention in House Keeping Categories
Keep the floor around a machine free of tools or stocks.
Keep the floor free of oil, grease and cutting fluids. Remove quickly as possible to
prevent dangerous fell.
Remove up the metal chips on the floor frequently.
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Accidents Prevention
Accidents Prevention in Handling Tools and Materials Categories
Always remove the burns or sharp edges from work-piece.
Never handle a sharp tools or cutters by hand.
Use the proper lifting Techniques, wherever lifting tools or materials.
The approved methods of lifting materials are as follows:
Step 1: Squat down, bending your knees, but be sure to keep your back straight.
Step 2: Grasp the material securely and use your leg muscles to raise the load. Keep
your back straight.
Step 3: Lower the materials to the floor by bending. 15
Accidents Prevention
Accidents Prevention in Operating machine Tools Categories
Never attempt to operate any machine tools until you fully understand its mechanism and
know how to stop it quickly.
Be sure that all the safety guards are in place before starting operation on any machine
tools.
Never wear loose clothing or jewellery around machine tools.
Always wear approved safety glasses in machine shop, especially when operating
machine tools.
Keep your hand away from moving parts.
Stop the machine before attempting to clean or measure the size of the work-piece.16
Hazard
A Hazard is a potential source of harm or adverse health effect on a person or
persons.
Cut you Burn you Crush you
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Hurt your hearing Hurt your eye
Workshop Safety Signs
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Before leaving the shop
The shop must be:
Floors (Swept)
Tools (Cleaned and put away)
Desks & Tables (Brushed off)
Machines (Cleaned)
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2. Measuring tools
What is measurement?
Measurement is defined as the process of comparison
of an unknown quantity with a known or standard
quantity.
Types of linear measuring tools (a measure of length):
Steel rule
Caliper
Micrometer
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Steel rule
A steel rule is the simplest and most common measuring tool.
Available in different size.
Most common units are:
• Metric system
• Inch-pound system
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Using steel rule
When measuring a length, the steel rule must be kept in
straight line parallel to the centreline of the work piece.
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Using steel rule
Avoid parallax error when taking measurement or holding the work piece.
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Using steel rule
Never use the end of the rule to align with edge of the work
piece.
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Using steel rule
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Types of steel rule
Hook rule: automatically aligns the end of the rule with the
end of the work piece.
Narrow rule: used to measure the depth of narrow slots and
small diameter holes.
Hook rule
Flexible rule: are designed to measure curves or round
surfaces.
Narrow rule with holder: used to measure grooves, recesses,
keyways.
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Flexible rule
Reading metric rules
A =22mm, B = 12mm
C =31.5mm, D = 40.5mm
Errors in steel rule
Parallax error
Recording failure
Line up error
Unit conversion
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Caliper
Caliper is a device used to measure the
dimensions of an object.
Used to measure the distance between
two opposite sides of an object.
Most calipers don't have graduation.
Used in many fields like, Mechanical
Engineering, Science, Medicine,
Woodworking, Metalworking, etc.
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Types of Caliper
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Vernier Caliper
Is sliding measuring device that can make inside, outside, and depth measurements
with considerable accuracy.
Measurements as small as 0.001" (0.025 mm) can be taken.
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Vernier Caliper
Types Vernier based on accuracy
• 1/10th with accuracy of 0.1mm
• 1/20th with accuracy of 0.05mm
• 1/25th with accuracy of 0.04mm
• 1/50th with accuracy of 0.02mm
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Vernier Caliper
1/20th with accuracy of 0.05mm
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Vernier Caliper
1/50th with accuracy of 0.02mm
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Vernier Caliper
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Vernier Caliper
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Vernier Caliper
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Micrometer
Is a measuring device used for precisely measuring
thickness, inner and outer diameters, depth of slots.
Available in sizes of, 0-25, 25-50, 50-75, 75-100mm.
Types based on application;
• Outside micrometer
• Inside micrometer
• Depth micrometer
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Micrometer reading
• Measure in hundredths of a millimetre (0.01 mm).
• One complete turn of thimble = 1/2 mm.
• Sleeve marked in “millimetres” below the line.
• Marked in half-mm above line.
• Thimble marked in 50 divisions.
• Each division =1/50 of a 1/2 millimetre or 1/100
(.01)mm.
Step 1: Note whole millimetre mark on sleeve.
Step 2: Note whether a half-mm mark is showing
between whole millimetre mark and thimble.
Step 3: Read thimble for hundredths reading.
Step 4: Add readings. 39
Micrometer reading
Whole millimeter marks: 10 x 1 mm
= 10.00 mm
Half millimeter marks: 1 x .50 mm
= .50 mm
Thimble Reading: 16 x .01 mm
= .16 mm
Reading = 10.66 mm
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Micrometer reading
Whole millimeter marks: 7 x 1 mm
= 7.00 mm
Half millimeter marks: 1 x .50 mm
= .50 mm
Thimble Reading: 22 x .01 mm
= .22 mm
Reading = 7.72 mm
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Micrometer reading
Whole millimeter marks: 3 x 1 mm
= 3.00 mm
Half millimeter marks: 0 x .50 mm
= 0 mm
Thimble Reading: 9 x .01 mm
= .09 mm
Reading = 3.09 mm
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Micrometer reading
Whole millimeter marks: 3 x 1 mm
= 3.00 mm
Half millimeter marks: 0 x .50 mm
= 0 mm
Thimble Reading: 46 x .01 mm
= .46 mm
Reading = 3.46 mm
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Micrometer reading
Whole millimeter marks: 3 x 1 mm
= 3.00 mm
Half millimeter marks: 1 x .50 mm
= 0.5 mm
Thimble Reading: 6 x .01 mm
= .06 mm
Reading = 3.56 mm
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Vernier Micrometer
Has the ability to measure to two
thousandths of a millimeter (0.002-mm).
The vernier is graduated in increments of
0.002 mm starting and ending with 0.
If either 0 on the vernier graduation scale
lines up with the thimble reading, no
additional thousandths of a millimeter are
added to the reading.
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Reading Vernier Micrometer
15mm
0.5mm
0.08mm
0.006mm
15.586mm
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Reading Vernier Micrometer
15.00 mm
0.5 mm
0.08 mm 47
0.004mm
15.584mm
Inside micrometer
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Depth micrometer
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3. Layout
Transferring of information from a working
drawing to metal surfaces.
Making of lines, circles, arcs and points on metal
surfaces for drilling holes or making cuts.
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Layout tools
Layout Dye
Is a fast-drying coloured liquid.
Is brushed onto a work-piece to prepare it for laying out guide lines.
Scriber
Is a sharp-pointed tool used for scribing lines on metal pieces.
are available in different size and shape.
Vernier height gauge Vernier height Scriber
Is used for measuring height of an object gauge
or for marking lines on metal of given
distance from a datum base.
Always used on a surface plate.
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Layout tools
Surface plate (bench plate)
Used as accurate reference for layout or inspection.
They should never be used for any job that might damage
or nick the surface.
Combination Square
Consists of a steel rule, level, and 90 and 45 degree angles.
Used to layout markings on metal.
V-block
Used to support round work for layout
work and inspection.
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Layout tools
Center Punch
Is used to enlarge a mark for a drill to follow in order
to prevent wandering of the drill bit.
Divider
Used to transfer a dimension from a rule to the
metal.
Used to make circles or arcs and to space holes or
other dimensions on metal.
Vise
Is a metal tool with movable jaws
which are used to hold an object
firmly in place while work is
done on it, typically attached to a 54
workbench.
Layout tools
Angle plate
Used as a fixture for holding work which is to be laid out, inspected
or machined.
Used for supporting or setting up work vertically.
Hermaphrodite caliper
Used to scribe a line a set distance from the edge of work-piece.
Prick Punch
Is used to transfer directly from the
drawing to the sheet metal.
Used to mark the location of holes after the
lines have been scribed.
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Layout tools
Hand sawing
Sawing is a process of cutting metal stock that is
impractical to use a file, a chisel or a machine.
A hacksaw is a saw with a frame and a blade
designed for cutting metal.
There are two types of frame:
• Fixed length
• Adjustable
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Layout tools
Hacksaw blade
Hacksaw blades vary in type and size
• All-hard blades are hardened
throughout and are used for sawing
heavy work, tool steel, cast iron, and
brass.
• Flexible blades are hardened only
the teeth and are used for sawing
light and hollow materials.
Hand hacksaw blades are made in 8 inch,
10 inch and 12 inch lengths, with 14, 18, 24,
or 32 teeth per inch. 57
Layout tools
Using a Hacksaw
Press down lightly on the forward
stroke. Use 50-60 strokes per minute.
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Files
A file is made of hardened high-carbon steel,
with flat or rounded surfaces that are made rough
with teeth or grit.
They are used for smoothing surfaces or
sharpening metal objects.
Files come in various shapes and sizes and in
various sizes of cuts.
• A file with straight teeth all going in the same
direction is a single cut file.
• A file with teeth in two directions is known as a
double cut file.
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Files
Both single cut and double cut files are
made in different degrees of coarseness.
Rough, middle, bastard, second cut, and
smooth are examples of coarseness.
The coarseness also varies with the length
of the file.
Cuts of a File
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Files
Common files are flat, rasp, half round, round bastard,
and taper triangular.
Flat files are used for smoothing both wood and metal.
Rasp cut files are used for smoothing coarse wood work.
Half round files are used for both metal and wood.
Round bastard files are used for enlarging and
smoothing holes.
Taper triangular files are used for filing saws or
cleaning threads.
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Files
Square File
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Files
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Cold Chisels
When using a cold chisel to cut cold metal, the chisel
must be harder than the metal it is intended to cut.
The four standard shapes for cutting edges for cold
chisels are flat, cape, diamond-point, and half-round
nose.
1. Flat chisels: are used for chipping, removing metal
from a flat surface, and cutting sheet metal.
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Cold Chisels
2. Cape chisels: are used for cutting
narrow, flat grooves and slots.
3. Round nose chisels: are used to cut
round corners and grooves.
4. Diamond point chisels: are used to cut
v-shaped grooves and square inside
corners.
Cape chisels
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Cold Chisels
Cutting angle
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Cold Chisels
Shearing sheet metal
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Cold Chisels
Cutting rods and rivets
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