EE 2114

Workshop Technology
Chapter 2: Basic Measurement &
Benchwork
Chapter Outline
2.1 Measuring Tools
2.2 Marking Tools
2.3 Hand Tools
2.4 Non-Cutting Tools
2.5 Cutting Tools
2.1
MEASURING TOOLS
Measuring Tools
• Calipers
• Vernier Calipers
• Micrometer
• Protractor
Calipers
• Simple tools used together with a steel rule for the
measurement or comparison of linear dimensions

Outside Calipers
measuring external
dimensions such as the
length, diameter, or even
the thickness of a solid
Inside Calipers
measuring internal
dimensions such as the
diameter of a hole, or the
width of a slot etc
Vernier Calipers
• precise tools for measuring external dimensions, internal
dimensions, and depths.
Vernier Calipers
• The resolution of a vernier scale is determined by the
difference on the distance of one division on the main scale
and one division on the vernier.
• E.g. A vernier scale of length
49mm is divided into 50 equal
divisions. ONE division on
the vernier represents
49/50=0.98 mm while ONE
division on the main scale
represents 1mm. Then, the
resolution of the vernier is
1mm - 0.98mm = 0.02mm.
 Micrometer
• More precise measuring instrument than the vernier calipers.
The accuracy is come from the fine thread on the screw
spindle. The ratchet prevents excess force from being applied
Outside Micrometer Inside Micrometer Depth Micrometer

Measuring external Measuring internal Measuring the depth of a

dimensions dimensions hole, slot etc
Protractor
• Measuring / checking of angles.

Engineer's Protractor Vernier Protractor

General purpose angle checking / Precision angle measuring tool

measuring
Dial Indicator
• linear mechanical movement of
the stylus is magnified and
transferred to the rotation of
pointer.
• The accuracy can be up to
0.001mm.
• Usually used for calibration of
machine
2.2
MARKING OUT TOOLS
Marking
• Marking is done on the job to locate the exact point where we
have to carry out some other processes like sawing, drilling
etc.
• Marking out tools such as
– Scriber
– Engineer's Square
– Spring Dividers
– Punch
– Surface Plate
– Angle Plate
– Vee Block
Marking
Scriber Engineer's Square Spring Dividers
• scratching lines onto • checking the straightness, • scribing arcs or circles
the workpiece squareness workpiece onto a workpiece
• marking perpendicular lines
onto a workpiece
Marking
Punch Surface Plate Angle Plate
• making a large indent • has high degree of flatness • supporting or setting
on a workpiece for • datum surface for marking up work vertically
drilling out and for measuring • holes and slots through
which securing bolts
can be located
Marking
Vee Block
• holding circular
workpiece for marking
out or machining
2.3
HAND TOOLS
Hand Tools Classes
• Non-cutting
– Include vises, hammers, screwdrivers, wrenches and pliers
– Used basically for holding, assembling or dismantling parts

• Cutting
– files, drills, taps, dies, reamers, hack saw, chizzle
2.4
NON-CUTTING TOOLS
Bench Vise
• Used to hold small
work securely for
sawing, chipping,
filing, polishing,
drilling, reaming,
and tapping
• Size determined
by width of jaws

Solid or swivel base

Bench Vise
• Jaw caps made of
brass, aluminum, or
copper to protect the
work surface from
being marred or
damaged

Solid or swivel base

Ball-Peen Hammer
• Most common
• Face: larger striking surface
• Peen: smaller, rounded end
– Used in riveting or peening operations
• Variety of sizes: head mass range 55 g to 1.4 kg
– Smaller sizes used for layout work
– Larger sizes used for general work
Ball-Peen Hammer
Soft-Faced Hammers
• Heads made of plastic, rawhide, copper or lead
– Fastened to steel body and replaced when worn
– Used in assembling or dismantling parts so finished
surface of work not marred
• Lead hammers
– Used to seat workpiece properly on parallels
• Plastic hammer heads
– Filled with lead or steel shot
– Do not lose shape and last longer than lead hammers
• Grasp end of handle for better balance and greater striking
force
Soft-Faced Hammers
Safety Precautions when
using a Hammer
1. Be sure handle is solid and not cracked
2. See head is tight on handle and secured with proper
wedge to keep handle expanded in head
3. Never use with greasy handle or when your hands are
greasy
4. Never strike two hammer faces together
Screwdrivers
• Two most common types
– Standard or flat blade
 Blades for smaller make of round stock
 Blades for larger often square for leverage
– Phillips
• Different sizes and styles
– Standard shank
– Stubby shank
– Offset
Phillips Screwdrivers
• + shaped tip for use with Phillips-type recessed screw
heads
• Manufactured in four sizes: #1, #2, #3, #4
– To suit various-sized recesses in heads of fasteners
• Use proper size screwdriver
• Hold firmly in recess and square with screw
Wrenches
• Many types used in machine shop work
– Each suited for specific purpose
– Name derived from use, shape, or construction
• Most available in both inch and metric measuring systems
Open-End Wrenches
• Single-ended or double-ended
• Openings usually offset at 15º angle
– Permits turning nut or bolt head in limited spaces by
"flopping" wrench
– Double-ended have different-size opening at each end
Open-End Wrenches
Box-End 12-Point Wrenches
• Completely surround nut and useful in close quarters where
only small rotation of nut can be obtained at one time
• Box end has 12 precisely cut notches around inside face
– Notches fit closely over points on outside of nut
– Cannot slip when proper size used
• Have different size at each end
Box-End 12-Point Wrenches
Socket Wrenches
• Similar to box wrenches
– Twelve points and surround nut
• Types of drives
– Ratchet
– Torque-wrench handles
• Used when nuts or bolts must be tightened to within
certain limits
Socket Wrenches
Adjustable Wrenches
• May be adjusted to within certain range to fit several sizes
of nuts or bolt heads
• Useful for odd-size nuts or when proper size not available
– Can slip when not properly adjusted to flats of nut
Adjustable Wrenches
Allen Setscrew Wrenches
• Commonly called hex keys
• Hexagonal and fit into recesses of socket head setscrews
• Made of tool steel
• Available in sets to fit wide variety of screw sizes
– Indicated size is distance across flats of wrench
Allen Setscrew Wrenches
Pin Spanner Wrenches
• Specialized wrenches supplied by machine tool
manufacturer for use on specific machines
• Supplied in various sizes
• Fixed-face spanners and adjustable-face spanners
positioned in two holes on face of special nut or threaded
fitting on machine
• Hook-pin spanner used on circumference of round nut
– Pin of spanner fits into hole in periphery of nut
Pin Spanner Wrenches
Hints on Using Wrenches
1. Always select wrench that fits nut or bolt properly
2. Pull rather than push on wrench
3. Always be sure nut is fully seated in wrench jaw
4. Use wrench in same plane as nut or bolt head
5. When tightening or loosening nut, give it sharp quick jerk
(more effective than steady pull)
6. Put drop of oil on threads when assembling a bolt and nut
to ensure easier removal later
Pliers
• Useful for gripping and holding small parts for certain
machining operations or when assembling parts
• Many types and sizes
• Names by shape, function or construction
Types of Pliers
• Combination or slip-joint pliers
– Adjustable to grip both large and small work
• Grip work when small holes must be drilled or for
bending or twisting light, thin materials
• Side-cutting pliers
– Used mainly for cutting, gripping, and bending of
small diameter (1/8 in. or less) rods or wires
Types of Pliers
Types of Pliers
• Needle-nose pliers
– Available in both straight- and bent-nose types
– Useful for holding very small parts, positioning them
in hard-to-get-at places and bending wire
• Diagonal cutters
– Used solely for cutting wire and small pieces soft
metal
Types of Pliers
• Vise-grip pliers
– Extremely high gripping power because of adjustable
lever action
• screw in handle allows adjustment to various sizes
– Several different styles: standard jaws, needle jaws and
C-clamp jaws
Hints on Using Pliers
1. Never use plier instead of wrench
2. Never attempt to cut large-diameter or heat-treated
material with pliers
3. Always keep pliers clean and lubricated
2.5
CUTTING TOOLS
Cutting Tool Processes
• Filing
• Sawing
• Drilling
• Reaming
• Dieing
• Tapping
Filing
• Cutting of a metal surface by using a specially designed tool,
called a file. A file (or hand-file) is a hand tool used to shape
material by abrasion.
• Classification of files
 Shape (Flat, round, square etc )

 Grade (Rough, Bastard, Smooth etc)

 Cut (Single cut, Double cut, Rasp cut etc)

 Length ( Ranging from 4-18’’)

Filing
Filing
• Files have forward-facing cutting teeth,
which means that the file cuts effectively
only when pushed over the work piece.
Pulling a file over a work piece or
scraping a file back and forth is ineffective
and will reduce the life of the file.
• The grooves in a file may become clogged
during use, causing the file to lose its
cutting ability.
• Files should always be used with a handle,
otherwise the naked tang can injure the
operator.
Sawing
• Saw – tool for cutting wood or other material. it consist of a
blade with the cutting edge toothed. The teeth of the saw are
each bent to specific angle and this angle is called "set".
• Types of Saw
 Hand saws: used manually for cutting operations.

 Mechanically powered saw: mechanically move the teeth

past the material while the saw itself is held stationary

Sawing
• Sawing is done to produce thin cuts.
• Hack Saw is a chief tool used, which is available in different
types and sizes depending on the length of the blade and its
cuts
Sawing
• Normal dimensions of a blade = 250x12 mm2

• Hacksaw teeth are specified by its pitch

(pitch=distance b/w two successive troughs or crusts)
Sawing
• Pitch of the teeth should give maximum clearance for the chips
and avoid clogging.( Normal pitch = 1.5mm)

• Sawing too sharply over a corner will result in teeth being torn
off.
Drilling

Drilling
Machine
Drilling
• What is a Drill?
− A tool or machine with a pointer for making holes of
different diameter.

(Hand Drill)
Instruments Use for Drilling
Drill Chuck Drill Chuck Key Drill Drift

Sleeve OR Socket Shank Twist Drill

Steps of Drilling
Step 1: Use a scribe to scratch a line on piece where we
wanted hole.
Steps of Drilling
Step 2: Use a center punch and a hammer to mark the
spot because the punch mark will hold the tip of
the drill in place until it begins to cut the metal.
Steps of Drilling
Step 3: Drilling deep or large holes, it is best to drill a
small reference hole first.
Steps of Drilling
Step 4: We will find a burr on the back surface of drill
hole. This can be removed by lightly drilling the
back side of the hole.
Reaming
Reaming
• What Is Reaming?
− a process which slightly enlarges a pre-existing hole.
Several cutting edges are arranged around a central shaft.
Its purpose is to finish the internal diameter of the hole.
Parts of Reamer
Reaming
Types of Reamers
• Straight Reamer

• Right Spiral Reamer

• Left spiral Reamer

• Machine Reamer
Types of Reamers
• Chucking Reamer

• Hand Reamer

• Expanding Reamer

• Taper Reamer
Dieing
• Die: Tool used to cut external
threads on bars and tubes.
• Consist of a nut having portions
of its thread circumference
which are shaped to provide
cutting edges.
• Die is screwed on to the bar
upon which the threads are to
be cut.
Type of Dies
Solid die nut

Split die and stocks

Stocks with loose dies

Stocks and dies for

fine threads

Pipe dies with guide

bush
Dieing Process
• The action of dieing a thread is
very similar to that of tapping
except that it is more difficult
to start the die square.
• Great care in necessary in starting
the die so that the threads are not
cross each other.
Precautionary Measures - Dieing
• The die should be rotated in both the direction at the
same time so that the threads are cleared from chips.
The die is pressed onto the end of the bar to help the
commencement of cutting.
• The action is assisted by chamfering off the end of the
bar for a distance equal to about two threads.
• The threads should be supplied with some form of
cutting oil.
Tapping
• Tapping is essentially the internal threading of a
hole. This may either be achieved by Hand tapping
by using a set of taps.
• Classification of tap
− Taper
− Plug
− Bottom
Tapping
• To hold a tap adjustable tap handle is used

• This is used for internal threading in the same manner as the die
is used.
Tapping
• Research has shown that the important reasons causing
tap breakage are as follows:
− Wearing of tap cannot be easily quantified (use of worn
out taps)
− Use of tap with improper tap geometry for a
particular application.
− Use of non standard/inferior quality taps.
− Chip clogging
− Tapping does not follow the pre-tap hole
(misalignment)
Precautions - Tapping
• Taps have self feed (Taps once engaged get pulled into the
job) due to helical angle.
• High Carbon taps should not be used as they cannot
sustain high speed.
• In order to retract tap from the hole, opposite torque
should be applied.
• Proper lubricant should be used during tapping.