Machining

Level – I

Based on March ,2022 Curriculum Version 1

Module Title: - Perform Bench Work

Module code: IND MAC1 M 03 0322
Nominal duration: 120 Hours
Prepared by: Ministry of Labour and Skill
Augest , 2022

Addis Ababa, Ethiopia

Author/Copyright : Machining Version - I

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 Table of Contents

1. Acknowledgment...................................................................................................................IV
2. Introduction to the Module.....................................................................................................3
3. Unit one: work value or work ethics.....................................................................................5
4. 1.1 work value or work ethics................................................................................................6
1.1.2. Sense of responsibility....................................................................................................13
1.1.3. Team work......................................................................................................................13
1.2.4. Commitment/ Dedication.................................................................................................16
1.2 ethical standards, organizational policy and guidelines.....................................................17
1.2.1. Legal and organizational policy/guidelines and requirement.....................................18
1.2.1 5S..................................................................................................................................19
1.3. personal behavior and relationships..................................................................................20
1.4. company resources.............................................................................................................23
1.4.2.Human power................................................................................................................23
1.4.3. Financial resources.....................................................................................................24
1.4.4. Intellectual Resources.................................................................................................24
5. Self-Check 1........................................................................................................................26
6. Unit two : Plan and prepare work piece.............................................................................27
2.1 work activities sequentially..................................................................................................28
2.2 material selection.................................................................................................................30
2.2.1 Ferrous : - are those which contain iron as the main content......................................30
2.2.2 Non Ferrous : - are those which don’t contain an iron................................................31
2.3. Lay out................................................................................................................................31
7. Self-Check -2.........................................................................................................................39
8. Operation sheet 2.1: Planning work activities sequentially................................................40
9. LAP Test................................................................................................................................41
10. Unit three : Graduated Measuring Devices.......................................................................42
3.1. General Characteristics and Selection of Measuring Instruments.....................................43
3.2. Measuring device And measuring technique......................................................................43
3.3. finest graduation of instrument...........................................................................................49
11. Self-Check -3.........................................................................................................................51

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 Operation sheet 3.1.......................................................................................................................53
12. LAP Test................................................................................................................................55
13. Unit four : Perform hand tool operations.........................................................................56
14. Unit four : Perform hand tool operations.........................................................................57
15. 4.1 work holding devices.......................................................................................................57
Concepts of clamping or work holding.....................................................................................57
4.2 hand tools.............................................................................................................................59
4.3 Cut, Chip, file or scrap work pieces....................................................................................62
4.5 bench work operations........................................................................................................75
16. Self-Check 4........................................................................................................................77
17. Operation sheet 4.1: Perform hand tool operations..............................................................2
18. Operation sheet 4.2: Perform hand tool operations..............................................................3
19. LAP Test..................................................................................................................................5
20. Unit five : Perform basic drill, ream, hone and scraper operations................................6
5.1 personal protective equipment...............................................................................................7
5.2 Drill, Ream and Hon boreholes.............................................................................................8
5.3 Select scrapers.....................................................................................................................18
21. Self-Check 5........................................................................................................................19
22. Operation sheet 5.1: Perform hand tool operations............................................................20
23. LAP Test................................................................................................................................22
24. Unit six : Perform Off-hand grind cutting tools.............................................................23
Concepts of off-hand grinding...................................................................................................24
Concepts of Sharpening Cutters................................................................................................29
Grounding cooling agents.........................................................................................................35
grind using personal protective devices......................................................................................3
25. Self-Check 6..........................................................................................................................5
26. Operation sheet 6.1: Perform hand tool operations..............................................................3
27. LAP Test..................................................................................................................................5
28. Unit seven : Quality assure finished component...........................................................7
Unit seven : Quality assure finished component.................................................................8
7.1. Check component for conformance......................................................................................8
Factors affecting quality of services or products..................................................................10

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 7.2. Use appropriate techniques, measuring tools and equipment............................................13
7.2.1. Steel rule......................................................................................................................13
7.2.2. Vernier caliper.............................................................................................................13
7.2.3. Micro meter.................................................................................................................13
7.2.4. Straight edge................................................................................................................13
7.2.5. Gages...........................................................................................................................13
7.4. Handle deviations ..............................................................................................................13
7.4.1. Introduction to Quality Deviation...............................................................................13
Causes of Quality Deviation......................................................................................................14
Types of Deviations....................................................................................................................16
Investigation and reporting deviations......................................................................................17
7.5. routine maintenance and adjustments out..........................................................................17
29. Self-Check -7.........................................................................................................................23
30. Reference...............................................................................................................................24

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Ministry of Labor and Skills Level- I March, 2022
 Acknowledgment

Ministry of Labor and Skills wish to extend thanks and appreciation to the many
representatives of TVET instructors and respective industry experts who donated their time and
expertise to the development of this Teaching, Training and Learning Materials (TTLM).

Author/Copyright : Machining Version - I

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Ministry of Labor and Skills Level- I March, 2022
 Acronym

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Ministry of Labor and Skills Level- I March, 2022
 Table content for table
Table 1. Personal Work Values......................................................Error! Bookmark not defined.
Table 2. Team And Group..............................................................Error! Bookmark not defined.
Table 3 The uses of squares.........................................................................................................32
Table 4 The uses of rules.............................................................................................................44
Table 5 Saw teeth for different materials..................................................................................65
Table 6 grade of file cut...............................................................................................................68
Table 7 .Drill size.........................................................................................................................74
Table 8 cutting speed.......................................................................Error! Bookmark not defined.
Table content for figure
Figure 1 Datum edges............................................................................................................................31
Figure 2 Face edges................................................................................................................................31
Figure 3 Try square...............................................................................................................................32
Figure 4 Mortise gauge..........................................................................................................................33
Figure 5 Vernier Height Gauge............................................................................................................33
Figure 6 Scribers....................................................................................................................................34
Figure 7 A Center punch, and the punch in use.................................................................................34
Figure 8 Common types of ball peen hammer and its parts..............................................................35
Figure 9 A-place and swing the compass on the center point of the circle or arc...........................35
Figure 10 Odd leg caliper and divider.................................................................................................35
Figure 11 Trammel Points....................................................................................................................36
Figure 12 Surface plate.........................................................................................................................36
Figure 13 Surface gauge........................................................................................................................37
Figure 14 Angle plate.............................................................................................................................37
Figure 15 Using the surface gauge.......................................................................................................37
Figure 16 Using the Vee block.............................................................................................................37
Figure 17 Combination set....................................................................................................................38
Figure 18 Using the combination set: (a) try square;.......................................................................38
Figure 19 Figure given for operation sheet 2.1...................................................................................40
Figure 20 Steel rule................................................................................................................................44
Figure 21 outside micrometer...............................................................................................................45
Figure 22 Outside micrometer reading................................................................................................45
Figure 23 Inside Micrometer................................................................................................................46
Figure 24 Depth micrometer.................................................................................................................46
Figure 25 Depth micrometer reading..................................................................................................46
Figure 27 Vernier caliper......................................................................................................................47
Figure 26 Digital caliper capable of recording inside.........................................................................47
Figure 28 Vernier caliper reading........................................................................................................47
Figure 29 Outside caliper and inside caliper.......................................................................................48
Figure 30 A-firm joint outside caliper. B-Bow spring outside caliper. C-Firm joint inside caliper.
D- Bow spring in side caliper. E-Hermaphrodite caliper.................................................................48
Figure 31 Engineer's Protractor and Vernier Protractor..................................................................48
Figure 32 Dial Indicator........................................................................................................................49
Figure 33 dimensions A to F to be measured on a V-Block...............................................................53
Figure 34 A Bench Vice and Machine vice..........................................................................................57
Figure 35 V-Block and C- Clamp.........................................................................................................58
Figure 36 Pliers......................................................................................................................................58

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Figure 38 Division of tools.....................................................................................................................59
Figure 37 Parallel Clamps.....................................................................................................................59
Figure 40 Torque wrench......................................................................................................................60
Figure 39 spanners.................................................................................................................................60
Figure 41 Flat screw driver...................................................................................................................61
Figure 42 (a) Chuck key, (b) Lathe Chuck key,(c)Ball driver key...................................................61
Figure 43 Hand snips.............................................................................................................................61
Figure 44 tap and tap wrenches...........................................................................................................62
Figure 45 Die and die- stock.................................................................................................................62
Figure 46 Teeth setting..........................................................................................................................63
Figure 47 Using a hack saw...................................................................................................................64
Figure 48 Parts of hack saw..................................................................................................................64
Figure 49 Non- adjustable frame (fixed frame)..................................................................................65
Figure 50 Adjustable frame..................................................................................................................65
Figure 51 Working position..................................................................................................................65
Figure 52 Proper body position when chipping..................................................................................66
Figure 53 Common types of chisel.......................................................................................................67
Figure 54 Flat file and its parts............................................................................................................67
Figure 55 Methods of filing...................................................................................................................68
Figure 56 types of file............................................................................................................................69
Figure 57 Common types of scraper....................................................................................................70
Figure 58 Using half round scraper.....................................................................................................70
Figure 59 Taps and dies........................................................................................................................71
Figure 60 Drill, Countersink and tapping a hole................................................................................72
Figure 61 Tapping operation................................................................................................................73
Figure 62 Die and its operation............................................................................................................74
Figure 63 Sawing operation..................................................................................................................76
Figure 64 Figure given for operation sheet 4.1.....................................................................................2
Figure 65 Figure given for operation sheet 4.2.....................................................................................4
Figure 66 Variety of operations of drilling machine............................................................................8
Figure 67 Parts of drill Presses...............................................................................................................9
Figure 68 Twist drills bit.......................................................................................................................10
Figure 69 Body of Twist drills..............................................................................................................11
Figure 70 Honing Operation.................................................................................................................17
Figure 71 Schematics of lapping process showing the lap and the cutting action of.......................18
Figure 72 given for operation sheet......................................................................................................21
Figure 73 bench and pedestal grinder.................................................................................................24
Figure 74 Parts of Bench Grinding machine.......................................................................................25
Figure 75 portable grinder....................................................................................................................25
Figure 76 cut off machine......................................................................................................................26
Figure 77 Punches and their grinding angles......................................................................................30
Figure 78 Grinding angles of Twist drill points..................................................................................31
Figure 79 Grinding with Drill Holder Fixture....................................................................................31
Figure 80 Free Hand Grinding.............................................................................................................32
Figure 81 Heel Angle............................................................................................................................32
Figure 82 Twist drill point....................................................................................................................32
Figure 83 Twist drill bit........................................................................................................................33
Figure 84 . Web thinning.......................................................................................................................33
Figure 85 Holding the drill at a 30- degree angle...............................................................................33
Figure 86 Line up the end of the web with the corner of the wheel..................................................34

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Figure 87 Split point..............................................................................................................................34
Figure 88 The approach angle is steeper when web splitting............................................................35
Figure 89 PPE..........................................................................................................................................4
Figure 90 given for operation sheet .6.1.................................................................................................4
Figure 91 Dresser...................................................................................................................................18
Figure 92 lubricate and varnish...........................................................................................................21
Figure 93 Common Misuses and Abuses.............................................................................................21
Figure 94 Common Misuses and Abuses.............................................................................................22
Figure 95 Using file with handle and with out...................................................................................22
Figure 96 File Cleaning.........................................................................................................................22

Introduction to the Module

In machining filed; perform bench work helps to know good work ethic characteristics it
how to use work shop hand tools; to layout and mark features to know range of graduated devices to
measure; to Perform basic drill, ream, hone and scraper operations Perform basic drill; ream, hone and
scraper operation ;perform off hand grind cutting tools and quality assuring for irrigation filed.
The term 'bench work' refers to the production of components by hand on the bench, where as
fitting deals which the assembly of mating parts, through removal of metal, to obtain the required fit.
Both the bench work and fitting requires the use of number of simple hand tools and considerable
manual efforts. The operations in the above works consist of filing, chipping,
scraping, sawing drilling, and tapping.
This module is designed to meet the industry requirement under the machining occupational standard,
particularly for the unit of competency: perform bench work .
This module covers the units :
 work values/ethics
 prepare work piece
 range of graduated devices to measure/determine dimensions or variables
 hand tool operations
 basic drill, ream, hone and scraper operations
 Off-hand grind cutting tools
 Quality assure

Learning Objective of the Module

 Apply work values/ethics
 Plan and prepare work piece
 Use measuring devices and determining dimensions or variable
 Perform hand tools operation

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  Perform basic drill, ream, hone and scraper operations
 Perform Off-hand grind cutting tools
 Assure Quality for finished component

Module Instruction
For effective use this modules trainees are expected to follow the following module instruction:
1. Read the information written in each unit
2. Accomplish the Self-checks at the end of each unit
3. Perform Operation Sheets which were provided at the end of units
4. Do the “LAP test” giver at the end of each unit and
5. Read the identified reference book for Examples and exercise

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 Unit one: work value or work ethics
This unit is developed to provide you the necessary information regarding the following content
coverage and topics:

 work values/ethics/concepts
 ethical standards, organizational policy and guidelines
 personal behavior and relationships
 company resources.
This unit will also assist you to attain the learning outcomes stated in the cover page.
Specifically, upon completion of this learning guide, you will be able to:
 Apply work values or ethics or concepts
 Undertake and practices industry work ethical standards, organizational policy and
guidelines
 Conduct personal behavior and relationships with co-workers and/or clients
 Use company resources

1.1 work value or work ethics

1.1.1 work
A job or activity that you do regularly especially in order to earn money the place where you do your
job The things that you do especially as part of your job Activity in which one exerts strength or
faculties to do or perform something:
Work Ethics
Work ethics are a set of standards and rules that are required by an individual for satisfactory work
performance. The word ethics deals with moral issues and with right and wrong behavior in a
workplace. By setting work ethics, the workers will know the proper working attitude the company
expects from each one of them.
Types of Work Ethics:
A. Personal
Ethical Traits of Personal Work Ethics:

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These are the personal qualities normally included in classic descriptions of ethical consciousness and
integrity. Examples of such ethical qualities in social work are:
 Integrity
 Critical self-insight
 Responsibility
 Courage/moral courage
 A sense of justice
 Balanced judgment
 Tolerance/broad-mindedness
 Empathy/sensitivity
 A basic attitude of respect, friendliness and equality in relation to others
b. Specific to a Work Station
Examples of Work Ethics Specific to a Work Station:
 Keeping certain information confidential
 Maintaining cordial information with the clients and agencies that a company has
 Being prepared to take a new task
It Sets of formal and informal standards of conduct that people use to guide their behaviour at work.
These standards are partly based on core values such as honesty, respect, and trust, but they also can be
learned directly from the actions of others. For example, what people see their organizational leaders,
managers, and co-workers do on the job can influence their own views of what is acceptable or
unacceptable behaviour.
Ethics is a branch of philosophy that addresses the questions of morality through a set of behavioural
guidelines. A workplace being the source of bread and butter for many, also satisfies the self-
actualization needs. It provides a reason as a standard of living. Hence, by that virtue, business ethics,
which sustain morality and help evolution have to be followed at a workplace.
Honesty, loyalty, commitment and rights go in building a conducive work culture in a workplace.
Although personal ethics differ, they matter in making of the ethical standards of the organization.
Because of the difference, every employees needs to be put on one single ethical platform

 Keeping certain information confidential

 Maintaining cordial information with the clients and agencies that a company has
 Being prepared to take a new task
Classification of work values/ethics
 Work values can be divided into two functional categories.

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 1. Intrinsic; - values are those that relate to a specific interest in the activities of the work itself, or
to the benefits that the work contributes to society.
2. Extrinsic;-values relate to the favorable conditions that accompany an occupational choice, such
as physical setting, earning potential, and other external features. Most people, in order to
feel truly satisfied with their work, must find some personal intrinsic value in it.
 Work values/ethics/concepts are:
- Commitment/ dedication - sense of urgency
- Sense of purpose - love for work
- High motivation - orderliness
- Reliability and dependability - competence
- goal-oriented - sense of responsibility
- Being knowledgeable - loyalty to work/company
- Sensitivity to others - compassion/caring attitude
- Balancing between family and work -sense of nationalism
 Concept of Work practices
 Quality of work
 punctuality
 efficiency
 effectiveness
 productivity
 resourcefulness
 innovativeness
 cost consciousness
 attention to details
Here are the seven key components of a work ethic.
1. Professionalism
Being professional involves everything from how you dress and present yourself in the business world
to the way you treat others. Professionalism is such a broad category, in fact, that it basically
encompasses all the other elements of a strong work ethic.
2. Respectfulness
You display grace under pressure: No matter how tight the deadline or heated the tempers, you always
remain poised and diplomatic. Whether you’re serving a customer, meeting with a client or
collaborating with colleagues, you do your best to respect everyone’s opinions, especially under trying

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circumstances. This shows you value people’s individual worth as well as their professional
contributions.
3. Dependability
You can be relied on to keep your promises. You are always on time and prepared for meetings, and
deliver your work on schedule and on budget. Your reputation for reliability precedes you because
you’ve proven over time that customers, clients and colleagues can trust you to do everything you say
you will. In an uncertain world, your customers, colleagues and clients will appreciate the stability you
embody.
4. Dedication
You don’t stop until the job is done, and done right. “Good enough” is not good enough for you and
your team. You aim for "outstanding" in everything you do. You put in the extra hours to get things
right, giving attention to detail and devotion to excellence. Your passion shows in how hard you work
and the results you achieve.
5. Determination
You don’t let obstacles stop you, and enthusiastically embrace challenges like a mountain climber who
ascends higher and higher until the summit is reached. You know that your job as an entrepreneur is to
solve your clients’ problems, and you resolve to continually seek better and more innovative answers.
With purpose and resilience, you push ahead, no matter how far you have to go.
6. Accountability
You take personal responsibility for your actions and outcomes in every situation, and avoid making
excuses when things don’t go as planned. You admit your mistakes and use them as learning
experiences so you won’t make the same ones again. You also expect your employees to meet the same
high standards, and support those who accept responsibility instead of blaming others.
7. Humility
You acknowledge everyone’s contributions, and freely share credit for accomplishments. You show
gratitude to colleagues who work hard, and appreciation to your loyal clients. You have integrity in
spades, and are open to learning from others, even as you teach people through your words, actions and
example. And, while you always take your work seriously, you strive always to maintain a sense of
humor about yourself.
A work value
A value is a principal or standard that is held in high esteem by an individual and is related to all
aspects of one's personal and work life. You may have values around family, work, spiritual, leisure,
personal, etc. In this exercise you will focus on your work values. As you rank each value, think about

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how important the value is to you in a work setting. As you consider your work related values, keep in
mind that there are no right or wrong work values; rather it is a process of identifying what matters
most to you rather than someone else.
Often include such traditional virtues as trust, loyalty and commitment, honesty and respect for one
another, and avoiding conflicts of interest. Values may also include newer elements such as
innovation, teamwork, customer focus and continuous improvement.
Work Value Concepts
Often include such traditional virtues as trust, loyalty and commitment, honesty and respect for one
another, and avoiding conflicts of interest. Values may also include newer elements such as
innovation, teamwork, customer focus and continuous improvement.

 Commitment/dedication: - understand to achieve anything requires faith and belief in

yourself, vision, hard work and determinations. Dedication or commitment is the act of
concreting an alter, temple, church or other sacred building. It also refers to the inscription of
books or other artifacts.
 Sense of urgency: - Drive people companies & countries to work much harder than normal and
the common traits of highly productive people, companies and countries. As you can see, a
tough of it can transform a person, company or a country to be highly productive.
1. Set a challenging goal with a dead line.
2. Set a minimum time to work on something.
3. Make yourself accountable.
4. See yourself to be in the losing side.
5. Be aware of potential danger.
 Sense of Purpose:- The quality of having a definite purpose, purposefulness and meaningfulness.
The quality of having great value or significant.
 Love for work:- If you work from home you probably spend more time on the phone and less time
doing work find out how to keep the balance between work.
 Orderliness: - It is associated with other qualities such as cleanliness, diligence the desire for order
and symmetry. Having a sense of where things belong and how they relate to each other and
keeping them organized (I want to arrange myself and my surroundings to achieve the greatest
efficiency, the quality or state of being orderly, also systematic functioning perhaps the most
fundamental form of organization is taking to higher.
 Sense of responsibility:- An awareness of your obligations, sense a general conscious, sense of
duty, a sense of should, ought to, have to.

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  Goal Oriented: - The concept of goal orientation was developed to describe variability in
dispositional or situational goal.
 Competence: - It is possession and application of skills, knowledge and attitudes to perform work
activities.
 General Types of Work Values:
1. Intrinsic or Self Actualization Values - directly express openness to change values-the pursuit of
autonomy, interest, growth, and creativity in work.
2. Extrinsic or Security or Material Values - express conservation values; job security and income
provide workers with the requirements needed for general security and maintenance of order in their
lives.
3. Social or Relational Values - express the pursuit of self-transcendence values; work is seen as a
vehicle for positive social relations and contribution to society. Values include being helpful,
responsible, affiliation to friends and the community, social justice, and environmental protection. This
is demonstrated by values that are near each other or on opposite sides of the diagram shown below.

Table 1Personal Work Values

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Top 5 Work Values:

1. Strong Work Ethic

Employers value employees who understand and possess a willingness to work hard. In addition to
working hard it is also important to work smart. This means learning the most efficient way to
complete tasks and finding ways to save time while completing daily assignments.
2. Dependable and Responsible
Employer’s value employees, who come to work on time, are there when they are supposed to be, and
are responsible for their actions and behavior.
3. Possessing a Positive Attitude
Employers want employees who take the initiative and have the motivation to get the job done in a
reasonable period of time. A positive attitude gets the work done and motivates others to do the same
without dwelling on the challenges that inevitably come up in any job.
4. Adaptability

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Employers want employees who are adaptable and maintain flexibility in completing tasks in an ever-
changing workplace. Being open to change and improvements provides an opportunity to complete
work assignments in a more efficient manner while offering additional benefits to the corporation, the
customer, and even the employee.
5. Honesty and Integrity
Employers value employees who maintain a sense of honesty and integrity above all else. Good
relationships are built on trust.
1.1.2. Sense of responsibility
1.2.3. Competence
Demonstrate a high degree of expertise and mastery of job skills and knowledge.
1.1.3. Team work
Team
Team is a group of people who work together a shared and meaningful outcome in ways that combine
their individual skills and abilities and for which they are all responsible.
How does the team happen?
The first thing to recognize is that a real team does not just happen –you have to work at it, create it,
maintain and sustain it. If you do all of these then you stand a good chance of having an effective team
–one that really works. This team can move mountains, create miracles and solve big problems. It acts
as a lens. It brings together and focuses all of the skill and abilities of the people who are a part of that
team. When this happens, you will say that there is a high level of teamwork or a good team spirit in
that team. Teams like this are powerful teams for all organizations and quite a lot of time spent trying
to find out how such teams develop and keep their cutting edge.
3.2 Features of Teams
 Teams are composed of highly communicative groups of People
 Team members must have diversity in their skills, abilities, background and perspective
 Teams have a shared sense of mission
 Teams have clearly identified goals
 Teams share the credit for victories and the blame for the losses.
 Teams can simply do more than an individual can. “One is too small a number to
achieve greatness”
 Make better decisions when issues are difficult
 Good when knowledge talent, skills, abilities are dispersed across organizational
members

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  Share responsibility
 Increased brainpower and group process
 Increases value of results
 Create synergy
3.3Team Building
John Ruskin
When you build something - like a sun deck or a fence - what you do is to erect or construct it. This
takes time, effort and planning; it is not usually an overnight process. But, if your building efforts are
going to be successful, then they also have to be preceded by a number of other events:
 First, you decide where you are going to put that sun deck or fence and roughly, what size it
will be.
 Second, you create or obtain a detailed design for your sun deck or fence.
 Third, you buy and bring together the material and parts that will make up your sun deck or
fence.
 Fourth, you fit together or assemble those separate parts.
If you think about this, you will soon see that only one of these stages - the last one - represents what is
usually thought of as what you do when you build something. But that last stage - the actual
construction - can't take place unless the preceding three stages - choice, design and procurement -
have been completed.
The process of building a team has much in common with all of this. For when you build your team,
you construct, frame, rise up and assemble that team.
 First, you identify or are told about what the team task is.
 Second, you decide how big your team needs to be and what sort of functional skills it
needs to handle this task.
 Third, you recruit people with those and other skills.
 Fourth, you enable these people to gel or meld together so that they can work as a real team
rather than a fragmented group.
Again, it is the last stage that represents what is usually thought of as the team-building stage. But, as
before, that stage can't take place unless the preceding three stages have taken place. But what takes
place in these three stages is different from what happened for your sun deck. For team building they
are, respectively, about:
 team task identification
 choice of team size and skills range

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  Team recruitment.
Effective teams need:
 Autonomy
 support and understanding
 time to develop and grow and
 Recognition.

Teams need from five to seven people who:

 have the right mix of functional skills

 have good interpersonal skills, and
 are able to adjust their team roles to complement those of others.
All of the above are important. They will give you a solid, firm, basis for team efforts, a launch
platform for team success. But, important as they are, they are not all that you will need. If you are
going to be successful in building your team, you will need a special something else.
Team building functions
Task Functions
 Initiating,
 Information giving and seeking,
 Opinion seeking and giving,
 Goal setting,
 Clarifying and elaborating,
 Summarizing
 Consensus testing,
 Problem solving and decision making
3.4 Characteristics of Effective Teams
 High level of interdependence among team members
 Team leaders have good people’s skills and is committed to team approach
 Each team member is willing to contribute
 Team develops a relaxed climate for communication
 Team members develop a mutual trust
 Team and individuals are prepared to take risks
 Team is clear about goals and established targets
 Team members roles are defined

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  Team members know how to examine team and individual errors without personal attacks
 Team has capacity to create new ideas.
 Each team member knows he can influence the team agenda
 Leadership role is shared and rotates among team members depending on the situation at
hand
 A working atmosphere that tends to be informal, comfortable, and relaxed.
 There is discussion in which virtually everyone participates, but it remains pertinent to
tasks
 The task or objective of the group is well understood and accepted by the members
 The members listen to each other
 There is disagreement. Disagreements are not suppressed or overridden by premature
group action
 When an action is taken ,clear assignments are made and accepted
 People are free to express their feeling as well as their ideas both on the problem and on
the group's operation
Table 2 The difference between Teams and Groups

Groups Teams

Task and individual oriented Oriented towards team goals and agendas
Tend to be autocratic and hierarchical in nature Participatory and self steering
Low level of interdependence High level of interdependence and synergy

Difference is suppressed Difference is welcomed

Avoid risks Risk is accepted
Leadership is solo Leadership is shared
Membership selection is not that much important Membership selection is important
Competition is inward Competition is with the outsiders

1.2.4. Commitment/ Dedication

When you have a good work ethic, you are dedicated to job that you deem valuable. You hold yourself
to high standards of responsibility. You also keep yourself accountable for getting work done right and
on time, and for making good business decisions that help people and companies succeed. Having a
solid work ethic means you understand that productivity, organizational skills, being reliable and
possessing good character are all attributes that successful people share.

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 1.2 ethical standards, organizational policy and guidelines

A job description defines a person's role and accountability. Without a job description, it is not
possible for a person to properly commit to, or be holding accountable for a role.

As an employee you may have or be given the opportunity to take responsibility for your job
description. This is good. It allows you to clarify expectations with your employer and your boss.

The process of writing job descriptions is actually quite easy and straightforward. Many people
tend to start off with a list of 20-30 tasks, which is okay as a start, but this needs refining to far
fewer points, around 8-12 is the ideal.

Any job description containing 20-30 tasks is actually more like a part of an operational manual,
which serves a different purpose. Job descriptions should refer to the operational manual, or to
'agreed procedures', rather than include the detail of the tasks in the job description. If you
include task detail in a job description, you will need to change it when the task detail changes, as
it will often do.

1.1 job descriptions are important

Job descriptions improve an organization’s ability to manage people and roles in the following
ways:

 clarifies employer expectations for employee

 provides basis of measuring job performance

 provides clear description of role for job candidates

 provides a structure and discipline for company to understand and structure all jobs
and ensure necessary activities, duties and responsibilities are covered by one job or
another

 provides continuity of role parameters irrespective of manager interpretation

 enables pay and grading systems to be structured fairly and logically

 prevents arbitrary interpretation of role content and limit by employee and employer
and manager

 serves as an essential reference tool in issues of employee/employer dispute

 provides important reference points for training and development areas

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  provides neutral and objective (as opposed to subjective or arbitrary) reference
points for appraisals, performance reviews and counseling

 enables organization to structure and manage roles in a uniform way, thus increasing
efficiency and effectiveness of recruitment, training and development,
organizational structure, work flow and activities, customer service, etc

 enables factual view (as opposed to instinctual) to be taken by employees and

managers in career progression and succession planning

1.2 Writing job descriptions - summary guidelines

 A good job description must be a brief concise document - not lots of detail of how each
individual task is done, which should be in an operational manual, which can of course
then be referenced by very

 many different job descriptions, saving lots of time, especially when operational details
change, as they inevitably do.

 A job description is in essence a list of 8-15 short sentences or points, which cover the
main responsibilities of the role, not the detailed processes.

1.2.1. Legal and organizational policy/guidelines and requirement

Definitions:
Policy: A general frame work to attain the organizational objectives.
Policies focus on how organizational objectives will be achieved. Policies provide a general
guideline to action. It is a framework for administrators to follow in making decisions and
handling problem situations. Policy statements should be clear and understandable, stable over
time and communicated to everyone involved.
Objective: It is a goal end toward the attainment of which plans and policies directed.
Objectives are statements of organization targets or the results that administrators seek to achieve.
It is the general statement of the mission of the organization and of what intends to do.
Goal: It is a desired state of affairs to which planned effort is directed.

Program: A group of related projects and activities with a specified set of resources (human,
capital, and financial) directed to the achievement of a set of common goals within a specified
period.

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 Planning; is the process of defining organizational objectives and then articulating strategies,
tactics, and operations necessary to achieve those objectives.

In planning process, it is necessary:

 To establish goals,

 To anticipate future developments,

 To identify course of actions required to attain the goals and

 To determine the time frame.

1.2.1 5S
5S Definition

A 5 level standard for organizing the workplace. The 5 stages (from most disorganized to most
organize) are:

 1S = “Seiri” = Sort: Separating needed and unnecessary, eliminating unnecessary material

 2S = “Seiton” = Store: A place for everything & everything in its place
 3S = “Seiso” = Shine: Cleaning: eliminating dirt, make like new
 4S = “Seketsu”= Standardize: procedures and responsibilities
 5S = “Shitsuke” = Sustain: making compliance automatic, a habit

5S Benefits to YOU
 It will make your workplace a safer, cleaner and more pleasant place to work

 Make your job more satisfying.

 Eliminate overburdens and disappointments.

 Make it easier to communicate with everyone you work with

 Gives you an opportunity to give creative input how your work place should be
 Gives you an opportunity to give creative input how your work place should be
5S Benefits to Organization
 Stability in the process allow optimization

 Zero defects brings higher quality

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  Zero west brings reduce cost

 Zero delay brings reliable delivery

 Zero accident, increase safety

 Zero breakdown, increase productivity

 Zero complaint brings greater confidence and trust

1.2.2. Innovativeness/Creativity
 Creativity is the act of turning new and imaginative ideas into reality. Creativity involves two
processes: thinking, then producing.
 Innovation is the production or implementation of an idea.
1.2.3. Quality of work
quality

If a product fulfils the customer’s expectations, the customer will be pleased and consider that the
product is of acceptable or even high quality. If his or her expectations are not fulfilled, the customer
will consider that the product is of low quality. This means that the quality of a product may be defined
as “its ability to fulfill the customer’s needs and expectations”. Quality needs to be defined firstly in
terms of parameters or characteristics, which vary from product to product. For example, for a
mechanical or electronic product these are performance, reliability, safety and appearance. For
pharmaceutical products, parameters such as physical and chemical characteristics, medicinal effect,
toxicity, taste and shelf life may be important. For a food product they will include taste, nutritional
properties, texture, and shelf life and so on.

1.3. personal behavior and relationships

Each person is different, with their own personal behavior, values and beliefs shaped by a number of
factors that include culture, religion, nature, and personal experiences.
 Values relate to our personal principles, morals, and ideals that is, what we consider to be
important.
 Attitudes relate to a person’s views, which may be evidenced in the way they behave.
 Beliefs relate to those things in which an individual has faith ‘religious beliefs for example which
may not necessarily be founded on fact.

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 Dignity’ is a difficult concept to define and has a strong association with respect. ‘Privacy’ has
been defined as ‘freedom from intrusion’ and ‘dignity’ as ‘being worthy of respect’ (DH, 2003).
Within this module, four types of dignity were identified as follows.
 Merit—this relates to dignity or social status that is ascribed to people because of their role or
position in society, or because of what they have achieved.
 Moral status—this is emphasized by the person’s moral autonomy or integrity. If an older person is
able to live according to their own moral principles, then that person will experience a sense of
dignity.
 Personal identity—this was found to be the most relevant in the context of older people: ‘It relates
to self-respect, and reflects an individual’s identity as a person. This can be violated by physical
interference as well as by emotional or psychological insults such as humiliation’.
By understanding these above mentioned differences among the co-workers and clients we can
minimize the differences by creating tolerance.
Ethical Guidelines:
Fundamental values in the work and for the profession are human rights and humanity. The work shall
contribute to creating a good and dignified life for all citizens and to developing the welfare of the
society.
1. Profession and Personality
Professional workers shall
 In their work and way of life respect each individual’s equal and high worth
 Show particular responsibility towards persons and groups in a vulnerable position
 Use their professional position with responsibility and be conscious of the limitations of their
own competence
 Maintain and develop their social work skills and strive towards ethical consciousness and
personal development.
2. The client/citizen
Professional workers shall
 show an equalitarian attitude to other citizens and treat clients with respect, empathic attention
and amiability
 respect the client’s personal integrity and safeguard the individual’s right to self - determination
in so far as the same right for others’ is not infringed upon and there is no risk of damage to the
client. Measures shall as far as possible be based on participation and mutual understanding

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  inform the client as to rights and duties, i.e. clarify the conditions and resources that exist
within the current activity and other authorities involved
 make sure that the demands placed on clients have a reasonable foundation and are capable of
contributing to an improvement of their situation
 never use the position of dependency of the client in different situations to own advantage
 Maintain client confidentiality and make sure that information concerning the client is handled
in conformance with the law and generally with great prudence.
3. The Organization, Colleagues and the Workplace
Professional workers shall
 Be aware of and show loyalty to the organization’s basic task
 show loyalty and respect towards colleagues and other members of staff as well as towards
members of the board
 Challenge and work against offensive or discriminatory attitudes and actions within the
organization or in the behavior of colleagues or clients, aware that this may be in conflict with
other loyalty demands
 contribute towards the upholding of high standards of quality in the work so that the profession
can develop in step with citizens’ needs and with changing conditions in the Society
 Help to make the workplace a constructive and responsive social environment.
4. Society
Professional workers shall
 Be open to cooperation with other organizations and other professions, under the condition that
this is of value to clients and other citizens
 Strive to build up confidence in social work and in their own professional competence, as well
as being open to demands for accountability and critical appraisal of the way the work is
performed
 As a professional and as a citizen stand for a democratic social ideal comprising human rights,
humanity and solidarity.
Respects Others
An employee with a strong work ethic is rarely late. You respect everyone's time, from coworkers to
clients to interviewees. You're also polite, conscientious of people's feelings and considerate of workers
in a shared workspace. In addition, someone with a strong work ethic uses time wisely so that
deadlines are met. You'll keep personal phone conversations quiet and not disrupt others. Out of
respect, you'll also hear and consider everyone's opinions.

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 1.4. company resources.

Concepts of resources

Resources are an organization’s assets and are thus the basic building blocks of the organization. They
include tangible assets, such as its plant, equipment, finances, and location, human assets, in terms of
the number of employees, their skills, and motivation, and intangible assets, such as its technology
(patents and copyrights), culture, and reputation.

Types of Company Resources

The Best types of Company Resources which are crucial to the business are the following:
 Material Resources
 Human Resources
 Financial Resources
 Intellectual Resources
1.4.1. materials/ Equipment/Machineries
Material Resources are the tangible assets of the company that can use to achieve its objectives and
targets. Material resources can be touched or seen.

Material resources are dynamic in nature. They are changed with the change in time and technology.
When new technology is implemented, it may replace old machines with a new ones for better
performance.

Some examples of Material Resources:

 Machinery and Technological tools

 Real state and for furniture
 Raw material
 Manufactured Product

1.4.2.Human power

Human resources are the building block of any company. Without Human resources, there are no
performance and achievement.

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If you work at an organization, you already know a little bit about Human Resources. The organization
has a department for recruitment of employees and dealing with staff, like paying salaries, on boarding,
training, and development.

In this article, We are talking about people who work for organizations and their skills, Knowledge,
Culture, and expertise. They play important roles in an organization because human resources impact
company performance and achievement.

1.4.3. Financial resources

Financial Resources
Financial resources are the assets of the company which are used for company activities like paying
salaries, buying raw materials, etc. The best financial resources management approach is important to
achieve the objectives and target of the company.

The condition where the shortage of financial resources can compromise the short-period operation
must be avoided. For example, if the organization does not have the fund to buy raw materials and pay
salaries.

When a company needs Financial resources, the company used the following types of sources of funds.

 Share Capital or Equity Shares

 Preference Capital or Preference Shares
 Retained Earnings
 Debenture
 Trade Credit
 Factoring Services
 Working Capital Loans
 Bill Discounting
 Venture Funding
 Lease Finance

1.4.4. Intellectual Resources

Intellectual Resources are the intangible assets of the company that can be used to achieve its
objectives. Intellectual Resources cannot be touched or seen.

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It can include recipes for those who deal with food. Or it can include a particular way of doing things.
It is impossible to measure the actual value of intellectual resources.
Some examples of Material Resources:

 Brand
 Patents
 Copyrights
 Partnerships
 Customer databases
 Software
Importance of Company Resources
 The company resources are basic building blocks of company authority and can use to achieve
its objective and target.
 It provides you with an overview of everyone and everything involved in your company.
 It enables utilization planning and gives you control.
 It makes the planning and management process more transparent and helps you see problems
before they start.

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Self-Check 1 Written Test
Directions: Answer all the questions listed below. (6 points)
Part I. choose the best answer (1 point for each)
Directions I: Choose the best answer for the following questions. (2 point each)
1.__________ product fulfils the customer’s expectations, the customer will be pleased and consider
that the product is of acceptable
A. Product B. Quality C. Test D. Value
2. ----------------is the classification of work values?
A. Intrinsic C. relational value
B. Extrinsic D. All
3. Which one of the following are not work values?
A. Commitment
B. sense of urgency
C. Sense of purpose
D. love for work
E. none of the above
Directions II :- short answer
1. list company resources
Directions III:- filling the blanck
1. ______________ is the process of defining organizational objectives and then articulating
strategies, tactics, and operations necessary to achieve those objectives.

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 Unit two : Plan and prepare work piece
This unit is developed to provide you the necessary information regarding the following content
coverage and topics:
 work activities sequence.
 materials Selection .
 Lay out and mark dimensions/features

This unit will also assist you to attain the learning outcomes stated in the cover page.
Specifically, upon completion of this learning guide, you will be able to:
2.1. Plan work activities sequentially.
2.2. Select materials.

2.2.1. Ferrous
2.2.2. Non Ferrous
2.3. carry out Lay out and mark dimensions/features

2.1 work activities sequentially

Definition of Planning

planning :-is the systematic process of establishing a need and then working out the best way to meet
the need, within a strategic framework that enables you to identify priorities and determines your
operational principles. Planning means thinking about the future so that you can do something about it
now. This doesn’t necessarily mean that everything will go according to plan. It probably won’t. But if
you have planned properly, your ability to adjust, without compromising your overall purpose, will be
that much greater.
2.1.2. Reason for Plan
Four reasons for planning:-
 Provides direction
 Reduces uncertainty
 Minimizes waste and redundancy

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  Sets the standards for controlling
Refer:- https://www.youtube.com/watch?v=J5_AYavfIUM
2.1. Engineering:-
 Engineering is a professional art of applying science and technology to optimize the conversion
of natural resources to the benefit of mankind. (Natural resources available in the universe are
Iron ore, Air, Sun, Water, Space, Human etc.)
 Human resource is a supreme strength to develop Engineering to contribute the welfare and
progress of the society or to this nation.
2.2. Engineer:-
 Engineer is a person having creative thoughts and ideas to develop technology for the noble
cause of the society or to nation.
 All objects begins an idea, Conceived and visualized by the Engineer. He makes an internal
representation of the object in his mind and communicates it to others through media of
expression.

2.4.1. Professional activities of an engineer:

1. Planning: (Proposal of doing something)
 It means a set of preparation is to do in order to achieve something or any kind of task/work.
(Preparation means programmes, drawings, Materials requirement and their sources, time
schedule, cost estimate, scheme and design and method of preparation etc.)
 It is a management function of defining goal of an individual / organizations.
 It determines the task/work and resources necessary to achieve set goals.
 It helps to save materials, labor, time, money efforts and process etc. so that any kind of
work/task can be performed successfully without having any difficulty with full confidence.
2. Visualization (related to vision / creating picture in mind)
 It is a behavioral technique of improving performance of his individual.
 It encourage for creating metal picture for successful execution of any work.
3. Hard work and practice (doing something repeatedly)

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 There is no substitute for hard work. A spiritual person says that “Work is Worship”, “Practice
makes the man perfect”. Practice makes a person to acquire skill to use their knowledge for gaining
self-assurance and confidence to handle any kind of work without any difficulty.
4. Punctuality (being in time):
Punctuality is a moral goodness, which is to be practiced very well punctuality is nothing but courtesy
to others. By being punctual you respect the value of time of others. This is more than anything else. It
helps you to plan your activities and schedule with precision and efficiency.
5. Work place Environment:
Workplace environment is to be maintained neat and clean, and spread happiness, cheerful, love &
affection around your work place, at home and also to the community.
6. Efficiency: It is the ability to do whatever we expected of us as promptly accurately and
economically as possible.
These activities are to be performed by an engineer to maintain quality and integrity for successful
execution of any task & to face the challenge of globalization.
2.3. Workshop:-
It 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 W/s, the w/s is divided in to many branches according to nature of
work.

Ex: 1.Fitting shop

2. Welding shop
3. Sheet metal shop
4. Machine shop
5. Foundry & Forging shop etc.
Required information to prepare the product
It is a common experience that when we want to prepare any product, the following
information’s are required:-
1. Actual Shape
2. Accurate Size
3. Manufacturing Method

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Before taking up the construction of a product, the person who prepares it must have a clear picture of
the shape and size of the object in his mind and to know the method of manufacturing process for
successful execution of the work.
2.2 material selection

Concepts of engineering materials

The knowledge of materials and their properties is significant for a design engineer. The machine
elements should be made of such a material which has properties suitable for the conditions of
operation.

Metals can be classified in to two groups:-

2.2.1 Ferrous : - are those which contain iron as the main content.
E.g. Pig iron, wrought iron, cast iron, steel, alloy steel etc.

2.2.2 Non Ferrous : - are those which don’t contain an iron.

E.g. Copper, zinc, tin, lead, brass, bronze, etc.
3.1.1. Identifying properties of ferrous and nonferrous metals
Metals are an element that can conducts heat & electricity. Metals have the following properties:
 Solid at room temperature
 Reflective when polished
 Expand up on heating &contract on cooling
 Good conductor of heat & electricity
2.3. Lay out
Marking out and measuring is a critical part of manufacturing and is usually subject to a number of
quality control checks. If components are marked out and measured wrongly before being cut out, there

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is no chance of them fitting together when they are assembled. Always take marking out measurements
from a datum as indicated in Figure 4.1. A datum edge is a flat face or straight edge from which all
measurements are taken. This prevents cumulative errors being made. If you are using timber, choose
the face side carefully, before marking it with a small symbol for identification purposes, as shown in
Figure 4.2. Then select a face edge that is at right angles to the face side. Take all your measurements
from this side and/or edge.

Figure 1 Datum edges

Figure 2 Face edges

2.3.1. Laying out and laying out tools

I . Laying out tools

Layout is the process of making lines, circles, and other marks with a variety of hand tools to
represent the features on the blueprint.

II. Laying out tools

 Squares:
There are a number of squares:
 Try square
 Miter square
 Engineer’s square.

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 Both the try square and engineers square are used to mark lines at 90° to an edge. A try square is
used on timber and an engineer’s square is used on metals. Both can be used for marking out plastics.
You can also use try squares and engineer’s squares to check that a cut or an edge has been made at
right angles to another. Hold the stock part of the square tightly against the edge that you have just cut.
If you can see light between the two edges then the cut is not square. A miter square is used for
marking out 45° or 135° angles on wood and plastic. Take great care when using any form of square
for marking out or checking, and ensure that it is being held firmly and tightly against the surfaces or
edges of the material.
In practice, try is used for checking the square ness of many types of small works when extreme
accuracy is not required .The blade of the try square is made of hardened steel and the stock of cast
Iron or steel. The size of the try square is specified by the length of the blade.

Figure 3 Try square

Table 3 The uses of squares

Gauges:

There are three basic types of gauge:

 marking gauge,
 mortise gauge
 cutting gauge.

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 A marking gauge is used for marking lines parallel to the face edge and side on wood. It consists of
a stock that slides up and down the stem, allowing various
measurements to be set. The gauge should be set using a steel rule that
has a zero end. The spur (sharp point) is pushed into the wood as the
gauge is pushed or pulled along the length of the timber. It is
important to hold the stock tightly against the edge of the timber to
ensure that you mark a parallel line.
A vernier height gauge is used for measuring height of an object or
Figure 4 Mortise gauge
marking lines onto an object of given distance from a datum base.
A cutting gauge is used for cutting across the grain. It is used in the same way as a marking gauge,
but has a blade instead of a spur. The blade cuts the fibers across the
grain, making it easier and neater to cut with a saw.
A mortise gauge has two pins; one pin is fixed and the other is
adjustable. It is used for marking two parallel lines where a mortise
and tenon joint is to be cut. The process of marking out is exactly
the same tise gauge as with the two other gauges.

Figure 5 Vernier Height Gauge

Scribers:
A scriber is used to scratch on the surface of metal and plastic lightly. If you are using a scriber on
metal, it is a good idea to apply a coat of engineer’s blue. This is a spirit-based liquid that is applied to
a metal surface. When the scriber is dragged across the engineer‘s blue it leaves a clean line, which can
be easily seen.

Figure 6 Scribers

 Punches:
Centre punches are used to make an indent in the surface where holes are to be drilled in metal, as
shown in Figure 4.19. They provide a starting point for the drill and stop it skidding over the surface.

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Dot punches are used for marking the centers where dividers are to be used. They are similar to a
center punch, except that the tips are ground to a 60° rather than a 90° point.
Center Punch Procedure
1. Make sure that the point of the punch is sharp before starting.
2. Hold the punch at a 45 degree angle and place the point carefully on the layout line.
3. Tilt the punch to a vertical position and strike it gently with a light hammer.
4. If the punch mark is not in the proper position, correct it as necessary.

Figure 7 A Center punch, and the punch in use.

 Hammer:
Hammer is a common work shop hand tools used for striking purpose. There are different types of
hammers based on their function.

Figure 8 Common types of ball peen hammer and its parts

 Divider:
It is basically similar to the calipers except that its legs are kept straight and pointed at the
measuring edge. This is used for marking circles, arcs laying out perpendicular lines, by setting

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lines. It is made of case hardened mild steel or hardened and tempered low carbon steel. Its size is
specified by the length of the leg.

Figure 9 A-place and swing the compass on the center point of the circle or arc.

B-Use the Divider to Step off Measurement

Figure 10 Odd leg caliper and divider.

Trammel Points:
Trammel points are used to mark large circles or make arcs that have large radii. They are used
similarly to dividers. The beam is usually made of metal.

Figure 11 Trammel Points

Surface plate

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 The surface plate provides a 'plane of reference' for checking other surfaces. The plate is made from
an iron casting. Its top surface is perfectly flat, and the underside is ribbed to prevent distortion of the
plate (Figure 4.22). It is used generally for setting up work for marking out and testing. The surface
table allows larger work to be checked for flatness.

Figure 12 Surface plate

Surface gauge:
You use the surface gauge for marking parallel lines and finding centers. Figure 4.24 shows the
procedure:
1. Set the scriber at the height you want, using the rule
2. Hold the work against an angle plate or on a vee block.
3. Move the block until the scriber touches the work.
Angle Plate:
The angle plate is made from a good-quality casting.
It consists of two faces machined at 90° to each other (Figure 4.25). You can fix work to the plate
using bolts, which can pass through the slots provided. You can also use the angle plate to support
work when you are using the surface gauge for marking out.
Vee Blocks:
You use vee blocks to support cylindrical work when you are testing it or marking it out. The blocks,
which are supplied in pairs, are made from cast iron. There are grooves along the sides, which allow
the clamp to be used (Figure 4.27). If the work is long, you will need a 'matching pair'.

Figure 13 Angle plate

Figure 14 Surface gauge

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Figure 15 Using the surface gauge
Figure 16 Using the Vee block

Combination Set:
The combination set (Figure 4.28) is an important tool in the workshop, because you can use it as a
center square, a try square, a protractor for marking out, measuring and testing. There are three heads
(protractor, square and center), which slide onto a rule, which can be fixed at any position using the nut
provided.
The main parts of the combination set are used as follows.
1. The try square has angles of 45° and 90°, which you can use to mark out, or to check that a surface is
vertical. You can also use it as a square (Figure 4.30(a)).
2. You can use the center square to find the center of circular pieces (Figure 4.30 (b)).
3. You use the protractor with the rule to mark out or measure angular surfaces (Fig 4.30 (c)).
Measuring and inspection tools
You can obtain detailed dimensions of work pieces using measuring tools such as the rule, or the
combination set. You can also test existing features (such as holes) for accuracy using inspection tools
such as plugs and gauges.

Figure 17 Combination set.

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 Figure 18 Using the combination set: (a) try square;

Self-Check -2 Multiple Choice

Directions I: Choose the best answer for the following questions. (2 point each)
1. The ability to do whatever we expected of us as promptly accurately and economically as
possible is: .
a. Skill b. Knowledge c. Attitude d. Efficiency
2. Why planning is necessary?
a. To provides direction b. To reduces uncertainty
c. To minimize waste and redundancy d. All

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3 Is a marking out tool used to scratch on the surface of metals and plastics lightly.
a. punch b. Steel rule c. Try square d. Scriber
4. Which one of the following steel is a more precise measuring instrument than the others?
a. Micrometer c. Steel rule
b. Vernier caliper d. Divider
Directions II: filling the blank
5.____________ is a moral goodness, which is to be practiced very well punctuality is nothing but
courtesy to others.
6_________ ability to do whatever we expected of us as promptly accurately and economically as
possible

Directions III: give short answer

7. What is lay out
8.what the deference between marking and measuring tool
Directions IV: marching
A B
9.____Combination Set A. consists of two faces machined at 90° to each other
10.____Surface gauge B. There are three heads protractor, square and center,
C.marking parallel lines and finding centers

Operation sheet 2.1: Planning work activities sequentially

 Operation title: Lay
out and mark dimensions/features
 Purpose: To Lay out and mark dimensions/features
 Instruction: Using the figure below and given equipments lay out the length of each line. You
have given 30Minut for the task

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 Figure 19 Figure given for operation sheet 2.1

 Tools and requirement:

1. 10*85*135 mm plate
2. Rule,
3. scriber
 Steps in doing the task
 Steps 1- Locate the reference plane.
 Step 2- Use the surface plate, surface gauge and steel ruler to set the
 required height as shown in Fig.2.1.
 Step 3- Use the angle plate, surface gauge to scribe the first line and
 repeat the same procedure to scribe the other three lines.
 Step 4- Punch the scribed lines by using the prick punch.

 Quality Criteria: the given geometrical shape is measured with 0.5mm accuracy
 Precautions: use the given steel rule and try square.

LAP Test Practical Demonstration

Name: _____________________________ Date: ________________

Time started: ________________________ Time finished: ________________

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Instructions: Given necessary templates, tools and materials you are required to perform the
following tasks within 1-2 hours.
Task 1: Marking out

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 Unit three : Graduated Measuring Devices

This unit is developed to provide you the necessary information regarding the following content
coverage and topics:
 Measuring device or equipment
 Measuring Technique.
 Finest Graduation of Instrument..

This unit will also assist you to attain the learning outcomes stated in the cover page.
Specifically, upon completion of this learning guide, you will be able to:
 Select appropriate device or equipment to achieve required outcome.
 Use correct and appropriate measuring technique.
 Measure accurately to finest graduation of instrument..

3.1. General Characteristics and Selection of Measuring Instruments

The characteristics and quality of measuring instruments are generally described by
various specific terms, defined as follows (in alphabetical order):
• Accuracy: The degree of agreement of the measured dimension with its true
magnitude.
• Amplification: The ratio of instrument output to the input dimension; also called magnification.

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• Calibration: The adjustment or setting of an instrument to give readings that are accurate within a
reference standard.
• Drift: An instrument’s capability to maintain its calibration over time; also called stability.
• Linearity: The accuracy of the readings of an instrument over its full working range.
• Magnification: The ratio of instrument output to the input dimension; also called amplification.
• Precision: Degree to which an instrument gives repeated measurement of the same standard.
• Repeat accuracy: The same as accuracy, but repeated many times.
• Resolution: Smallest dimension that can be read on an instrument.
• Rule of 10 (gage maker’s rule): An instrument or gage should be 10 times more accurate than the
dimensional tolerances of the part being measured. A factor of 4 is known as the mil standard rule.
• Sensitivity: Smallest difference in dimension that an instrument can distinguish or detect.
• Speed of response: How rapidly an instrument indicates a measurement, particularly when a number
of parts are measured in rapid succession.
• Stability: An instrument’s capability to maintain its calibration over time; also called drift.
The selection of an appropriate measuring instrument for a particular application also depends on:-
(a) the size and type of parts to be measured,
(b) the environment (temperature, humidity, dust, and so on),
(c) the operator skills required, and
(d) the cost of equipment.
3.2. Measuring device And measuring technique.
 Rules:
There are two basic types of rule: steel rule and steel tape. Both start at zero and have millimeter
graduations.

Table 4 The uses of rules

 Steel rule

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 These are made up of stainless steel and are available in many sizes ranging from 1/2 ft. to 2 ft.
These are marked in inches or millimeters. All the faces are machined true. The edges of steel rule
should be protected from rough handling.

Figure 20 Steel rule

 Micrometers:
A micrometer is a specialized instrument used to take very accurate measurements. The thimble,
which rotates as the micrometer is tightened, has 50 equal divisions around its diameter, giving an
accuracy of 0.01mm.A reading is taken by adding all the visible whole numbers to the nearest 0.5 mm.
The reading from the thimble, which will be between 0 and 0.49 mm, is added to the main reading to
get the exact measurement. Although the micrometer provides a very accurate measurement, it can be
difficult to learn how to read it. A micrometer is a very useful instrument. It enables you to take
measurements to within one hundredth of a millimeter (0.01mm).The metric micrometer is able to
measure ranges of 25 mm (that is, for 0-25 mm, 25-50 mm, and so on).A common type is shown in
Figure. 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.
Micrometers are one of the precision measuring tools, used to measure to one-hundredth of a mm
(0.01mm). On micrometers, the pitch of a screw thread is used to determine lengths or diameters. Each
complete turn of the measuring screw changes the distance between the measuring surfaces by the
pitch of its thread (e.g. 0.5mm).

Figure 21 outside micrometer

Types of Micrometers:

 Outside Micrometer:

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 An outside micrometer is used for measuring outside diameter of cylindrical objects, parallel
surfaces or other outside dimension. The work to be measured is placed between the anvil and the tip
of the spindle.
Reading the micrometer:

Figure 22 Outside micrometer reading

For example
1. Upper main scale (sleeve) 12.00 mm
2. Lower main scale (no half mm) 0.00 mm
3. Circular thimble scale 0.13 mm
4. 13 X 0.01 mm = 0.13mm
5. Total reading 12.13 mm

Inside Micrometer:
The structure of this micrometer is as similar as that of an outside micrometer. It is used for measuring
internal dimensions.

Figure 23 Inside Micrometer

Depth Micrometer:

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Depth micrometers are used for measuring the depth of holes, slots, grooves, Keyway and shoulders
etc. Note that the scales are graduated in reverse as compared with external or internal micrometers.

Figure 24 Depth micrometer

Figure 25 Depth micrometer reading

Vernir caliper
These are used for measuring outside as well as inside dimensions accurately. It may also be used as a
depth gauge. It has two jaws. One jaw is formed at one end of its main scale and the other jaw is made
part of a Vernier scale.

Figure 26 Digital caliper capable of recording

inside

Figure 27 Vernier caliper

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Outside, diagonal, hole edge and hole dimensional measurements Reading a 1/50th Vernier Caliper

Figure 28 Vernier caliper reading

 Calipers:
They are indirect measuring tools used to measure or transfer linear dimensions. These are used with
the help of a steel Rule to check inside and outside measurements. These are made of Case hardened
mild steel or hardened and tempered low carbon steel. While using, but the legs of the calipers are set

against the surface of the work, whether inside or outside and the distance between the legs is
measured with the help of a scale and the same can be transferred to another desired place. These are
specified by the length of the leg. In the case of outside caliper, the legs are bent inwards. Calipers are
used for transferring measurements.
The three common types are:
Outside
inside and
odd-leg Hermaphrodite
You can use inside calipers as outside calipers by merely turning the legs about the hinge. and in the
case of inside caliper, the legs bent outwards.

Figure 29 Outside caliper and inside caliper.

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 Figure 30 A-firm joint outside caliper. B-Bow spring outside caliper. C-Firm joint inside caliper. D- Bow spring in side caliper.
E-Hermaphrodite caliper

 Protractor:
Engineer's Protractor
An engineer's protractor, as shown in Fig. 4.13, is a general purpose tool used for the measuring /
checking angles, e.g. the angle of drill head, angle of cutting tool, and even for the marking out of
angles on a component part.

Figure 31 Engineer's Protractor and Vernier Protractor

 Vernier Protractor:
This is a precision measuring tool that the accuracy of measurement can reach ±5 minutes of an angle
through the vernier scale as shown in Fig.31.

 Dial Indicator:
A dial indicator (dial gauge) can measure dimensions up to an accuracy of 0.01mm or even less. The
principle of it is that the linear mechanical movement of the stylus is magnified and transferred to the
rotation of pointer as shown in Fig. 12. It is usually used as a comparator for calibration or alignment
of machine.

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 Figure 32 Dial Indicator.

3.3. finest graduation of instrument

The term graduation refers to the marking present on a measurement instrument that signifies a
particular space or distance. The graduation indicates the measurement.

There are two different kinds of graduation,

 linear graduation and

 curved graduation.

Whenever the instrument is straight in shape, such as a ruler, then there will be linear graduation.
These can be linear in nature, such as the common inches or millimeters on a ruler or tape measure, or
they can be non-linear in nature. The non-linear graduations are typically either logarithmic scales,
which are based on orders of magnitude, or transcendental scales, which are based on algebra
independent from the variable. Volumetric graduations also fall within the title of linear graduations,
and are used to measure a particular volume of liquid at a particular temperature. Curved graduations
are typically seen on a circular limb or offshoot of a measurement instrument. There are both non-
circular and circular graduations. The circular graduations tend to divide up angular space, as is done
by degrees and seconds.

Graduations can be made using a couple of different methods and are usually classified based on their
style. The marks signifying different graduations can be put on an instrument through etching or
engraving, as well as through printing or painting. Etching and engraving is preferable because these
marks will last longer and ensure more accurate measurements in the long term. Sometimes both an
engraving and paint or ink are combined to better mark the surface. Additionally, some higher-grade
measurement tools are even built with a double layer of plastic or glass to protect the graduation marks.

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Graduation styles are demarcated using a number and the letter R. For example, a graduation of 3R
shows 1/10th, 1/32nd, 1/50th, and 1/64th increments; 4R shows 1/8th, 1/16th, 1/32nd, and 1/64th
increments; 5R shows 1/10th, 1/32nd, 1/64th, and 1/100th increments; and 16R shows 1/32nd, 1/50th,
1/64th, and 1/100th increments.

Graduated measurement instruments are vital to both precision and accuracy. The degree of sensitivity
of a graduated instrument increases as the distance between graduations decreases. The overall
accuracy of a measurement using a graduated instrument is impacted by a few important factors. The
original graduation measurements must have been accurate themselves, the degree of resolution on the
marks needs to be high, and the mark lines must not be too thick or poorly defined in order to ensure
higher accuracy. Basically, the graduation marks themselves hold a great deal of power when it comes
to the final measurement taken from the tool they are on. There is also potential for observational or
user error when reading off the graduation marks. However, the best practice is to start with the best
made graduation marks possible.

The graduation of an instrument, while simple in concept and design, is incredibly important in the
final accuracy of a measurement. Understanding how they are made and work, as well as knowing how
to judge their quality will help any metrologist when choosing an instrument that includes graduation
marks. In the end, the better the graduation on your precision measurement tool, the greater the
accuracy of your measurements.

Refer:https://www.govst.edu/uploadedFiles/Academics/Colleges_and_Programs/CAS/
Trigonometry_Short_Course_Tutorial_Lauren_Johnson.pdf

Self-Check -3 Multiple Choice

Directions I: matching
A B
___1. Accuracy The adjustment or setting of an instrument to give readings that are

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 accurate within a reference standard.
___2.Amplification The degree of agreement of the measured dimension with its true
magnitude.
___3.Calibration The ratio of instrument output to the input dimension; also called
magnification.

Directions II: Choose the best answer for the following questions. (2 point each)
4. Which one of the following information is required when we want to prepare any product?
a. Actual shape b. manufacturing method c. accurate size d. All
5. Which one of the following is ferrous metal?
a. Zinc b. Wrought iron c. Lead d. Bronze
6. What is the basic source of iron?
a. Pig iron b. Steel c. Iron ore d. Furnace
Directions III: filling the blank (2 point each):
7______ is made up of stainless steel and are available in many sizes ranging from 1/2 ft. to 2 ft.
8._____ used for measuring outside as well as inside dimensions accurately. It may also be used as a
depth gauge .
Directions IV: give brief explanation
9.Write types micrometer
10. what is the meaning of graduated instrument
Directions VI: read the following instrument

1. . mm

2. . mm

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 ______.____mm

____.____mm

Operation sheet 3.1 Use a range of graduated devices to measure/determine

dimensions or variables

 Operation title: Measuring device And measuring technique

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  Purpose: To Lay out and mark dimensions/features
Instruction: Using the figure below and given equipments lay out the length of each line. You have
given 30Minut for the task
NOTE:
The accuracy of your readings should be in a range of 0.5 mm.

Fig.1.1: V-Block
Table of measurements:
Dimension A B C D E F
Dimension in (mm)

Figure 33 dimensions A to F to be measured on a V-Block.

 Tools and requirement:

1. V block
2. Steel rule
3. Vernir caliper
 Steps in doing the task
Steps 1- Measuring work pieces using different measuring instruments;
Steps 1- Use bench work tools and equipment.
Step 2- Use measuring instruments.
Step 3- Prepare work piece to be measured.
Step 4- Select the appropriate measuring instruments.
Step 5- Measure the work piece.

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Step 6- Record the results
Quality Criteria: the given geometrical shape is measured with 0.5mm accuracy
Precautions: use the given steel rule or vernier caliper.

LAP Test Practical Demonstration

Name: _____________________________ Date: ________________

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Time started: ________________________ Time finished: ________________
Instructions: Given necessary templates, tools and materials you are required to perform the
following tasks within 30-60 min.
Task-1: Perform liner measurement using rule and virner caliper

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 Unit four : Perform hand tool operations
This unit is developed to provide you the necessary information regarding the following content
coverage and topics:
 work holding devices.
 hand tools
 Cut, Chip, file or scrap work pieces.
 Cutting threads
 Internal threads
 External threads
 bench work operations

This unit will also assist you to attain the learning outcomes stated in the cover page. Specifically,
upon completion of this learning guide, you will be able to:
 Clamp work pieces in work holding devices.
 Select and use hand tools according to task and safety regulations.
 Cut, Chip, filed or scrape work pieces within tolerances.
 Cut threads
 Internal threads
 External thread
 Perform bench work operations

Unit four : Perform hand tool operations

4.1 work holding devices.

Concepts of clamping or work holding

Once work piece is located, it is necessary to press it against locating surfaces and hold it there
against the force acting upon it. The tool designer refers to this action as clamping and the mechanisms
used for this action are known as clamps. It is necessary that the work should be properly and securely
held on for machining operations, a VISE is an effective work holding device.
Vises: Vises are the most common appliances for holding work on table due to its quick loading and
unloading arrangement.
1.1. Types of work holding devices
 Bench vice

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 A bench vise is like an extra hand and is a common tool found in any shop or garage. It is attached
to a workbench and its purpose is to hold material steady, allowing you to use both hands to work on
the material with other tools. They are ideal for sawing, sanding, planing, drilling, screwing, soldering
and more.
Bench Vises with Swivel Base
There are mainly three types of vises commonly used:
 Plain vise
 Swivel vise
 Tool makers universal vise
2. Removable hardened alloy steel jaw inserts.
3. Completely enclosed center screw.
4. Attractive hammered enamel finish

Figure 34 A Bench Vice and Machine vice

V‐block
V‐block is rectangular or square block with a V‐groove on one or both sides opposite to each
other. The angle of the ‘V’ is usually 900. V‐block with a clamp is used to hold cylindrical work
securely, during layout of measurement, for measuring operations or for drilling for this the bar is
faced longitudinally in the V‐Groove and the screw of V‐clamp is tightened. This grip the rod is
firm with its axis parallel to the axis of the v‐groove
 C‐Clamp
This is used to hold work against an angle plate or v‐block or any other surface, when gripping
is required. Its fixed jaw is shaped like English alphabet ‘C’ and the movable jaw is round in

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 shape and directly fitted to the threaded screw at the end .The working principle of this clamp is
the same as that of the bench vice.

Figure 35 V-Block and C- Clamp

Pliers
There is a vast range of pliers used in the vehicle body building industry, with the most common
being combination pliers, slip joint pliers, side cutters, circlip pliers, long-nosed pliers and multi grips.
The correct pliers to use depend on the type of vehicles being built. For example, long-nosed pliers are
used to hold and grip small work in awkward places so these may be used extensively with hydraulic
or electrical work. However, they may not be much use when building a semitrailer. Name these pliers:

Figure 36 Pliers

 Parallel Clamps
Jaws are made of hardened and tempered steel. Clamps are equipped with spring clips

Figure 37 Parallel Clamps

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 4.2 hand tools

Tools

Tools can be divided into two main groups: hand tools and power tools. Hand tools are operated by
the physical strength of the user. Power tools require an external source of power such as electricity or
compressed air to operate. Each of these groups can also be divided into sub groups.

Figure 38 Division of tools

2.3. Hand tools

Hand tools have been devised to enable trades people to carry out a job more efficiently, quickly and
safely than would otherwise be possible. Some tools are quite simple, such as a screwdriver, which is
almost indispensable for undoing a countersunk screw located in a recess. Others are more
complicated, such as a micrometer; these are indispensable are when measuring fine tolerances.
2.3.1. Hand tools can be classified into several groups:
 fastening tools
 gripping and clamping tools
 impact tools
 cutting tools
 marking-out tools
 Measuring tools.
Fastening tools
2.3.1.1. Spanners
There are several types of spanners, each suitable for a specific job. The most commonly used
spanners in a vehicle body building workshop are:
 open-ended spanners
 ring spanners
 combination spanners

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Figure 39 spanners
  sockets and their accessories
 hook spanners
 pin spanners
 adjustable spanners
 ratchet spanners
 Flare nut spanners.
2.3.1.2. Wrenches
Wrenches are tools used for holding and turning. A variety of wrenches are used in the vehicle body
building industry. Adjustable pipe wrenches are sometime called still son wrenches. Typically, they are
used on cylindrical objects such as pipes and rails where there are no flats on which to use a spanner.
Another type of wrench is the hexagon wrench, which would typically be used for undoing hexagonal
recessed drain plugs. Smaller hexagon wrenches are called Allen keys. Torque wrenches are used to
tighten nuts or bolts to a specific tension and are sometimes called tension wrenches. They are used to
correctly tension down the bolts holding engineering components such as power take-off units or bolts
on kingpins. Never use a torque wrench to undo nuts or bolts, as this may damage or alter the accuracy
of the wrench.

Figure 40 Torque wrench

2.3.1.3. Screwdrivers
Screwdrivers are accurate precision tools and are not designed to be used as punches
or cold chisels. The most common types of screwdrivers are the standard (straight blade
or flat) type and the Phillips screwdriver, and they are available in many different sizes
and lengths. There are also special screwdrivers designed for hard-to-get screws, for example right-
angle screwdrivers.

Figure 41 Flat screw driver

2.3.1.4. Keys
Keys used in the trade include drill chuck keys, lathe chuck keys and hexagon keys.
Hexagon keys are also called Allen keys and include ball driver keys which can be
used at an angle, unlike straight hexagon keys, which must be inserted squarely into
the hexagonal recess.

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 Figure 42 (a) Chuck key, (b) Lathe Chuck key,(c)Ball driver key

2.3..1.5 Hand snips

Figure 43 Hand snips

2.3.1.6. Taps and wrenches

Taps are used to cut internal threads in holes which are usually drilled for the purpose of attaching an
item with bolts or metal threads. Taps come in all sizes and threads to match the wide variety of bolts
and metal threads available in the trade.

Figure 44 tap and tap wrenches

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2.3.1.7. Stock and dies
Dies are used to cut external threads on rods, studs, shafts or bolts. They can also be used to
clean up or repair damaged external threads.

Figure 45 Die and die- stock

4.3 Cut, Chip, file or scrap work pieces

1.1. Concepts of Cutting metals
Sawing is the process of cutting metal stock that is impractical to use a file, a chisel or a machine
with a multi-point cutting tool called a hand hack saw. A hand hack saw can also be used for cutting
off a jammed bolt, pipes, tubing and rods for special or custom fittings on the job (on the field work).
Some of the most common tools used to cut metals are hacksaws, band saws, cold chisels, bolt
cutters, tin snips, and abrasive saws. Large stock is sawed, while bar stock is either sawed or cut
with a cold chisel. Sheet metal is usually cut with metal snips. In fabrication facilities, large amounts of
metal are cut with horizontal band saws or metal shears, commonly called “ironworkers. Layout tools
are used to measure and mark metal stock before cutting, shaping, and doing other types of work with
cold metal.
1.1.1. Saws
Saws are used to cut material that is not needed away from material which is. Saw blades have
alternate teeth bent out or ‘set’ in opposite directions. This is so that when they cut, they make a gap,
called the kerfs. The kerfs must be wider than the saw blade so that the blade cannot get stuck. When
using a saw, you should always cut to the waste side of the marked line so that you leave a small
amount for finishing by either sanding or filing. Whatever you are cutting, it is important to keep as
many teeth in contact with the piece being cut as possible. You should choose the correct saw for the
type of material you are using. Table 2.3 on the next page shows the most common types of saws used
in school workshops.
 Cutting process
The saw is moved from the right to left and shows how the chip is formed. The cutting process is the
result of the horizontal cutting direction and the pressure on the work piece. The angle of the teeth

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enables the saw to cut the material effectively. The teeth are set (bent out) that they do not get jammed
in the cut.

Figure 46 Teeth setting

a = clearance b = cutting angle

Forces on a saw blade:
1 = indicates the cutting direction
2 = indicates the pressure on the work piece
 Steps to Follow in Making the Cut with a Hacksaw
Place the metal to be cut in a vise and mark it. The mark should be placed near the jaws, especially if
the metal is thin. It may be necessary to use boards between the vise jaws to prevent scarring the work.
Mark over the original mark with a file.

Figure 47 Using a hack saw

Depending upon the direction of cut, blades are classified as:

 Forward cut
 Backward cut.
Depending upon the pitch of the teeth (Distance between the two consecutive teeth) blades is classified
as:
 Coarse (8-14 teeth per Inch)
 Medium (16-20 teeth per inch)

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  Fine (24-32 teeth per inch)
 Parts of a hacksaw
1. Saw frame
2. Handle protector
3. Handle
Figure 48 Parts of hack saw
4. Tang
5. Blade holder
6. Blade
7. Pins
8. Wing-Nut
9. Pins
 Types of blades for hacksaws

One side
toothed Both sides toothed
Fig.3.4. Types of hack saw blades.
How to handle a hacksaw?

1 and 3 Indicate the forward stroke with pressure

2 and 4 The backward stroke without pressure the circle shows the direction of teeth (facing the
front of the hacksaw) all strokes should be in a straight line and along the whole length of the
blade.

Figure 49 Non- adjustable frame (fixed frame)

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 Figure 50 Adjustable frame
The work piece must be clamped to allow free movement when sawing. Left-handed people clamp
their work to the right of the vice and right-hander people to the left.

Figure 51 Working position.

Table 5 Saw teeth for different materials
No of teeth /inch Functions
14 For solid sections of soft materials
18 Suitable for general use. Solid sections of soft materials and large sections of hard
materials (e.g. alloy steel)
24 Small solid sections, between 3 and 6 mm(e.g. heavy tubing and sheets)
32 For sections less than 3 mm thick
Note: At least three consecutive teeth should be in contact with the material. If the material is soft and
has a large section, use a blade with few teeth per 25 mm (14 or 18 teeth per 25 mm) Use a fine-tooth
blade when cutting a fairly thin section.
Hacksaw blades are made of high-speed steel.
There are two types: all-hard and flexible. The difference between the two is that the all-hard snaps
easily, and it is therefore not recommended for school work. The blades come in the following lengths:
200, 250 and 300 mm. They are also available with 14, 18, 24 and 32 teeth per 25 mm for cutting
different materials
3.2. Chipping
Removing the metal with a chisel is called chipping and is normally used where machining is not
possible. While chipping, safety goggles must be put on to protect eyes from the flying chips. To

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ensure safety of others, a chip guard is placed in position. Care should be taken to see that the chisel is
free from mushroom head.

Figure 52 Proper body position when chipping

 Chisels
 Types of chisls:
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 (Figure 3.8) 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;
3. The half-round-nosed chisel: used for cutting grooves (which are either curved or half-round);
4. The diamond-pointed chisel: used for working into corners and cutting small grooves.

Figure 53 Common types of chisel

3.3. Filing

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Filing is a method of removing metal, and the file (Figure 3.9), which is the most widely used hand
tool in the school workshop, is used for this cutting operation. It is made of carbon tool steel containing
about 1.3 per cent carbon.
 The Main Parts

A file is a hand cutting tool made of high-carbon steel, having a series of teeth cut on the body by
parallel chisel cuts. The parts of a file are shown in figure. 3.9. Files are used to remove surplus metal
and to produce finished surfaces.

Figure 54 Flat file and its parts

 Methods of filing:
There are several methods of filing, each with a specific purpose. With reference to the figure, the
following may be noted:
1. Holding the file: For heavy work and to remove more metal, a high pressure is used.
For light and fine work, a light pressure is applied.
2. Filing internal curves: A part of half round file only makes contact as shown during
filing operation. Movement of the file is indicated by arrows.
3. Cross filing: It is the most common method of filing. Cross filing is carried out across two
diagonals, to produce medium surface finish. It is used when large an amount of metal is to be
removed. By cross filing ‘rounding’ the surface is reduced.
4. Straight filing: When a short length of work piece is required to have a flat surface,
straight filing is used. File marks made during cross filing may be removed, to produce a
relatively smooth surface.
5. Draw filing: It is done to get a finely finished surface. It produces a smoother surface
finish than straight filing. A smooth or dead smooth flat file is used for this.
Use the single cut on softer materials (such as brass and aluminum) and the double cut for general
filing, especially on iron and steel.

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 Figure 55 Methods of filing
Table 6 grade of file cut

Figure 56 types of file

http://www.simondssaw.com/handfiles/hand%20files%20publications/simonds-file%20catalog.pdf

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3.4. Scraping
Scraping is the process of removing high spots on the surface of a piece of work. It is a difficult
operation, and is not often performed in the school workshop.
 Types of scrappers:
These sharp edged tools are used to remove uneven spots on the surfaces. They are of different shapes.
3.4.1. Flat scraper
It is used for removing metal from flat surfaces. The blade must have a slight curvature at the cutting
edge. The corners are rounded to help the user, scrape at the exact spots.
3.4.2. Half round bearing scraper
This is used for scraping curved and cylindrical surface split bearings, big bush bearings etc.
3.4.2. Triangular scraper
This is used for scraping curved surfaces, holes and bores. Specification is by length. Example: 200
mm, 300 mm etc.

Figure 57 Common types of scraper

Figure 58 Using half round scraper

. 4.4 Cutting threads

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Introduction
Threads may be cut internally using a tap externally using a die. The proper selection and use of these
threading tools is an important phase of machine shop work.
 Dies
Dies are made either of high-carbon steel or of high-speed steel. Unlike taps, dies are used for cutting
external (male) threads. There are three types (Figure blow). The circular split die is a circular piece
with a split across one of the flutes. The split is provided to enable small adjustments to be made, using
three set screws in the stock. The half die comprises two loose pieces, which are held in the stock.
There is a small screw on the stock for adjustment. The die nut has a hexagonal body. This type,
strictly speaking, does not cut new threads but is used to 'clean up' threads that are damaged.
 Taps and dies
Screwing is a temporary method of fastening parts together. Methods for cutting screw threads include
the use of the centre lathe. For bench work, however, taps and dies are used.

 Taps
These are the tools used for cutting internal (female) threads. They are made of high-carbon steel or
high-speed steel. The tap has a shank with a square end to take the tap wrench or holder. The shank is
smaller than the threaded portion. The tap has four rows of threads, cutting edges or teeth, which suit a
particular thread form. They perform the cutting action. The grooves between the cutting edges are
called flutes. They allow waste material (chippings) to escape. They also allow cutting oil into the
work.

Figure 59 Taps and dies

The procedure for cutting external threads is as follows:

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 1. Square the end of the work and chamfer it (using a file, grinding machine or centre lathe) for an
easy start.
2. Grip the die, held in the stock, firmly and squarely on the work.
3. Turn clockwise, about a quarter-turn, and ease back to remove chippings.
4. Apply a good supply of oil (lubricant).
5. Make adjustments of the screws after making a full cut until the depth required is achieved.
Care and maintenance is important:
1. Do not use either the stock or the die as a hammer; the threads may be broken.
2. Remove the die from the stock after every thread cutting, clean them and pack them into their
boxes.
3. Use plenty of oil during cutting to reduce friction.
Tap Drill Size
Before a tap is used, the hole must be drilled to the correct tap drill size. This is the drill size that would
leave the proper amount of material in the hole for a tap to cut a thread. When a chart is not available,
the tap drill size for the ISO (International Standards Organization) thread can be found easily by
applying this simple formula:
TDS = tap drill size
TDS = M - P M = metric diameter of the tap
P = pitch of the thread in millimeters
Hand Tap
A tap is a cutting tool used to cut internal threads. Normally it’s made of high-speed steel (HSS). Hand
taps are usually made in sets of three, because it is better to distribute all the cutting work during the
thread−process to three taps.
No. 1 (taper) tap: 1 ring on shank
No. 2 (plug) tap: 2 rings on shank
No. 3 (bottoming) tap: without ring
The most common taps have two or three flutes in order to form the cutting edges, transport the chips
out of the hole and give way for the lubricant. The end of the tap is square so that a tap wrench can be
used to turn it into a hole.
Tapping a Hole
Before a tap is used, a hole must be drilled in the work piece to the correct tap drill size. The tap drill
size (T.D.S.) is the size of the drill that should be used to leave the proper amount of material in the
hole for a tap to cut threads. Then countersink both sides of the hole.

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 Figure 60 Drill, Countersink and tapping a hole

Working Steps for Hand Tapping

1. Select the correct size and type of tap for the job (blind hole or through hole).
2. Select the correct tap wrench for the size being used.
3. Use a suitable cutting fluid (No cutting fluid for brass or cast iron).
4. Place the tap in the hole as near to vertical as possible.
5. Apply equal down pressure on both handles, and turn the tap clockwise (for right-hand thread)
for about two turns.
6. Remove the tap wrench and check the tap for squareness. Check at two positions 90 degree to
each other.
7. If the tap has not entered squarely, remove it from the hole and restart it by applying slight
pressure in the direction from which the tap leans. Be careful not to exert too much pressure in
the straightening process, otherwise the tap may be broken.
8. Turn the tap clockwise one−half turn and then turn it backward about one−quarter of a turn to
break the chip. This must be done with a steady motion to avoid breaking the tap.

Figure 61 Tapping operation

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Table 7 .Drill size

Threading Dies
A threading die is used to cut external threads on round work pieces. The most common threading dies
are the adjustable and solid types. The round adjustable die is split on one side and can be adjusted to
cut slightly over or undersized threads. It is mounted in a die stock, which has two handles for turning
the dies onto the work. The solid die, cannot be adjusted and generally used for recutting damaged or
oversized threads. Solid dies are turned onto the thread with a special diestock, or adjustable wrench.

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 Figure 62 Die and its operation

Thread with a Hand Die Working Steps

The threading process requires the machinist to work carefully to produce usable parts and avoid
damage. The following describes the procedure to be used.
1. Chamfer the end of the work piece with a file or on the grinder. Consider that a 3/4” thread
requires a bolt with an outside diameter of 3/4”.
2. Fasten the work piece securely in a vise. Hold small diameter work short to prevent it from
bending.
3. Select the proper die and die stock.
4. Lubricate the tapered end of the die with a suitable cutting lubricant.
5. Place the tapered end of the die squarely on the work piece.
6. Apply down pressure on both die stock handles and turn clockwise several turns.
7. Check the die to see if it has started squarely with the work.
8. If it is not square, remove the die from the work piece and restart it squarely, applying slight
pressure while the die is being turned.
9. Turn the die forward one turn, and then reverse it approximately one half of a turn to break the
chip.
10. Apply cutting fluid frequently during the threading process.
Metric Threads
These threads are identified by the letter „M“, the nominal diameter, and the pitch. For example, a
metric thread with an outside diameter of 5mm and a pitch of 0.8mm would be identified as follows:
M5x0.80
Table1.2. Pitch of metric thread
nom. dia. pitch nom. dia. pitch
4.5 bench work operations
Bench work operations for the manual mill often occur before and after the machining
of the part. These operations are commonly performed on a standard workbench with the

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 part secured in a vise, or secured to the worktable depending on the operation. Bench work
operations involve processes that allow the work piece to achieve the accuracies specified by the
blueprint. These operations require operator skill and attention to detail.
 Follow safety and correct working procedures to perform bench work operations.
Bench work operations performed prior to machining include the following:
 Layout
 Cutting: in the metal work shop materials (especially metals) are cut to shape before filing.
There are numerous types of cutting operations.
 Points to watch when using the hack saw:
1. Hold the work securely in the vice.
2. Grip the hack saw firmly, using both hands.
3. Use the same stance as filing.
4. Use the full length of the blade.

Figure 63 Sawing operation

 Chipping:
 chipping metal (chiseling)
Chiseling is one of the methods of cutting materials.
-you can chip the metal to produce grooves or to reduce the width or thickness.
Procedures to chip metal:
1. hold the metal in the vice
2. Hold the chisel at an angle of about 450 to the work.
3. Hammer to remove the chip.
 Filing: is a method of removing metal.
 Filing: is a skill that is difficult to learn. It is not easy to explain how to use a file.

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 Self-Check 4 Written Test

Directions I : Choose the best answer for the following questions. (2 point each)
1. Which one of the following is not clamping tools?
a. Vice c. hacksaw
b. V- block d. C- clamp
2. One of the following is not the parts of bench vice.
a. Jaw face c. Fixed jaw
b. Thimble d. Movable jaw
3. ______is used for clamping work piece.
a. Bench vice c. V-block
b. C-clamp d. All
4._______is used to cut internal threads in holes which are usually drilled for the purpose of
attaching an item with bolts or metal threads.
a. Tap c. snips
b. Die d. all
5. _______is hand tools used for holding and turning materials.
a. Snip c. trammel
b. Wrench d. Screwdrivers
6. Which one of the following is not include under hand tools?
a. Wrench c. Taps
b. Power hacksaw d. all
7. Removing the metal with a chisel is called________
a. Scrapping c. Chipping
b. Filling d. All
8. Some of the most common tools used to cut metals are_______
a. hacksaws b. tin snips

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 c. cold chisels, d. all
9. ______a file is used when large an amount of metal is to be removed.
a. Cross filing
b. Straight filing
c. Draw filing
d. All
10. _____is used for scraping curved and cylindrical surface split bearings, big bush etc.
a. Flat scraper c. Triangular scraper
b. Half round bearing scraper d. All
Direction II short answer
1. Write procedures for cutting external threads. (4 points)

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Operation sheet 4.1: Perform hand tool operations

 Operation title: bench work operations

 Purpose: Cut the work piece to produce a drill gauge according to the dimensions given
Instruction: Use the given figure below (Figure 2.13), the tools and equipment lay out and
mark on the work piece. For this operation you have given 2Hour and you are expected to
operation.
 Tools and requirement:
1. Steel Rule,
2. scriber
3. work piece 80*130
4. hack saw
 Precautions: Measure at least three times before cutting
 Procedures in doing the task
Step-1: . Wear the safety clothes required.
Step 2. Measure the stock to the required dimension.
Step- 3. Mount the work piece firmly on the vice.
Step- 4. Choose the correct blade according to the type of material and thickness being cut.
Step- 5. Install the hacksaw blade.
Step- 6. Use the blade check list to ensure proper installation.
Step- 7. Use the hacksaw to cut the work piece. Use the marked sawing lines to guide the
cutting process

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 Figure 64 Figure given for operation sheet 4.1

 Quality Criteria: the given bench work operation measuring with 0.5 mm accuracy

Operation sheet 4.2: Perform hand tool operations

 Operation title: bench work operations

 Purpose: Cut the work piece to produce a drill gauge according to the dimensions given
Instruction: Use the given figure below (Figure 2.13), the tools and equipment lay out and
mark on the work piece. For this operation you have given 2Hour and you are expected to
operation.
 Tools and requirement:
1. Steel Rule,
2. Scriber
3. Hammer
4. Center paunch
5. Different size of drill bit
6. Bench drill machine
7. work piece 60*98
8. Different size of taps and tap wrench
 Precautions: Measure at least three times before punching
 Procedures in doing the task
Step-1 Select the correct taps and tap wrench

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Step- 2. Apply suitable cutting fluid to the tap
Step-3. Place tap in hole as vertically as possible
Step-4. Press downward on wrench, applying equal pressure on both handles
Step-5. If tap is not entered squarely, remove from hole and restart it by applying pressure
Step- in direction from which tap leans
Step-6. Turn tap clockwise one-quarter turn, and turn it backward about ½ turn to break the
chip (must turn with steady motion)
Step-7. Care must be taken not to tap too deep for a blind hole
Step- 8. When finished, clean hole and check with thread gage or appropriate bolt

Figure 65 Figure given for operation sheet 4.2

 Quality Criteria: the given bench work operation measuring with 0..2 mm accuracy

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LAP Test Practical Demonstration

Name: _____________________________ Date: ________________

Time started: ________________________ Time finished: ________________
Instructions: Given necessary templates, tools and materials you are required to perform the
following tasks within 2-5 hours.
Task 1: lay out mark feature
Task 2: cut and file
Task 3 Cut the work piece to produce a drill gauge according to the dimensions given.
Task 3 : taping according to their pitch

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Unit five : Perform basic drill, ream, hone and scraper operations

This unit is developed to provide you the necessary information regarding the following content
coverage and topics:

 personal protective devices.

 Drill, Ream and Hon boreholes.
 scrapers

This unit will also assist you to attain the learning outcomes stated in the cover page. Specifically,
upon completion of this learning guide, you will be able to:

 Perform all operations using personal protective devices.

 Perform Drill, Ream and Hone boreholes.
 Scrap

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 5.1 personal protective equipment

Do you work in an industry that uses a drill press on a regular basis? Featuring a motorized
transmission with spur gearing these devices are used to create a consistent, powerful drive. Businesses
of all shapes and sizes use drill presses in their daily applications. Due to the powerful nature of these
machines, however, certain safety precautions must be taken to ensure workers' safety.

As with any piece of heavy machinery, a drill press should only be used by someone who's familiar
with its mechanics and function. The exact method of operation varies depending on the particular
model, which is why it's important to read the owner's manual. In the even if you no longer have the
owner's manual, visit the manufacturer's website to see if you can download a copy. As a last ditch
effort, you can always call the manufacturer to request another owner's manual.

In terms of personal protective equipment (PPE), the only piece of equipment that's absolutely
necessary when operating a drill press is a pair of high-grade, shatter-proof goggles with side shields.
Eye injuries are known to occur when metal shards or debris are shot from underneath the drill. This is
easily avoided, however, be wearing proper eyewear. Check out the Occupational Safety and Health
Administration's (OSHA) website at https://www.osha.gov/SLTC/etools/eyeandface/faqs.html for more
information on choosing the right eyewear.

Safety Tips To Follow When Operating a Drill Press

 A good rule of thumb is to keep a 2-foot perimeter of clearance around your drill press at all
times.
 Noise-cancelling headphones may also be worn to minimize the sound produced by a drill
press.
 Never wear watches, rings, necklaces, bracelets, or other jewelry.
 Contrary to what some people may believe gloves should not be worn when operating a drill
press. The fabric material may stick to the drill, dragging the user's hand inside.
 Perform an inspection of your drill press to ensure all covers and safety guards are functional
before operating it.
 The wood shavings produced by a drill press are hot due to friction, so avoid touching them.

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  Keep your hands at least 4 inches away from the drill.
 Maintain a clean workstation that's free of obstruction and debris.
 Center-punch the initial drill hole into the composition.
5.2 Drill, Ream and Hon boreholes

1. Introduction to drilling
Drilling: is a process of producing round holes in a solid material or enlarging existing holes with
the use of multi tooth cutting tools called drills or drill bits. In other words it is the process of making
holes of cylindrical shape on metals and other materials using drill bits and drilling machines.
Drilling machine: are driven either manual or by electrical power.
1.1. Classification of drilling machines
Drilling machines: are classified into hand and breast drill, portable electrical drill, bench drill, pillar
dills and others.
1. The hand and breast drill: are driven by hand and are commonly used where electricity is
unavailable and are used for light work
2. Portable electrical drill: are most suitable to work which cannot be done with bench drill.
3. Bench drill: is one of the most common used machines in the work shop. This machine has the
following parts. The base, the column, the head, the spindle, the pulleys, the motor, the belt, the
safety swatch, the feed handle, the depth gauge, the head locking handle, the gear lever, the
collar, the chuck and the main switch.
4. Pillar dills: is similar in design to the bench drill. But it is floor mounted and usually much large.
Various cutting tools are available for drilling, but the most common is the twist drill.
 Standard Operations
Drilling machines may be used for performing a variety of operations besides drilling a round hole.
A few of the more standard operations, cutting tools and work set-ups will be briefly discussed.
A. Drilling – may be defined as the operation of producing a hole by removing a metal from a
solid mass using a cutting tool called a twist drill.

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 Figure 66 Variety of operations of drilling machine.

B. Countersinking – is the operation of producing a tapered or cone shaped enlargement to

the end of the hole.
C. Reaming – is the operation of sizing and producing a smooth round hole from a previously
drilled or bored hole with the use of a cutting tool having several cutting edges.
D. Boring – is the operation of enlarging and truing a hole by means of a single-point cutting
tool which is usually held in a boring bar.
E. Spot-facing – is the operation of smoothing and squaring the surface around a hole to
provide a seat for the head of a cap screw or a nut. For the spot facing operation, the work
being machined should be securely clamped and the machine set approximately ¼ of the
drilling speed.
Spot facing is a process of machining a flat surface around the mouth of a hole in order to
provide a flat seat for the head of a bolt or a nut.
F. Tapping – is the operation of cutting internal threads in a hole with a cutting tool called a
tap. Special machine or gun taps are used with a tapping attachment when this operation is
performed by power in a machine.
G. Counter boring – is the operation of enlarging the top of a previously drilled hole to a
given depth to provide a square shoulder for the head of a bolt or a cap screw. Counter
boring is used to form a flat, recessed seating for a cheese head bolt or cap screw.

Sensitive Drill Presses

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 Figure 67 Parts of drill Presses.

1.2. Drill Bits

Introduction
Twist drills are end-cutting tools used to produce holes in most types of material. On standard drills,
two helical grooves, or flutes, are cut lengthwise around the body of the drill. They provide cutting
edges and space for the cuttings to escape in the drilling process. Since drills are one of the most
efficient tools, it is necessary to know the main parts, how to sharpen the cutting edges, and the correct
speeds and feeds for drilling various metals in order to use them most efficiently and prolong their life.
1.2.1 Parts of Twist drills
Shank
Most twist drills used in machine shop work today are made of high-speed steel. High-speed drills have
replaced carbon-steel drills since they can be operated at double the cutting speed and the cutting edge
lasts longer. A drill may be divided into three main parts: the shank, the body and the point.
 Generally drills up to 13mm in diameter have straight drill shanks, while those over this diameter
usually have tapered shanks. Straight-shank drills (fig. 08/02) are held in a drill chuck; tapered-
shank drills (fig. 08/01) fit into the internal taper of the drill press spindle.

 A tang (fig. 08/01) is provided on the end of tapered-shank drills to prevent the drill from slipping
while it is cutting and to allow the drill to be removed from the spindle or socket without the shank
being damaged by using a drill drift.

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 Figure 68 Twist drills bit

Body
The body is the portion of the drill between the shank and the point. It consists of a number of parts
important to the efficiency of the cutting action.

The flutes are two or more helical grooves cut around the body the body of the drill. They form the
cutting edges, admit cutting fluid, and allow the chips to escape from the hole.
 The margin is the narrow, raised section on the body of the drill. It is immediately next to the flutes
and extends along the entire length of the flutes. Its purpose is to provide a full size to the drill body
and cutting edges.
 The lip clearance is the undercut portion of the body between the margins and the flutes. It is made
smaller to reduce friction between the drill and the hole during the drilling operation.
 The web is the thin partition in the center of the drill which extends the full length of the flutes.
This part forms the chisel edge at the cutting end of the drill. The web gradually increases in
thickness toward the shank to give the drill strength.
 Point The point of a twist drill consists of the chisel edge, the lips, the lip clearance angle and the
heel.
 The chisel edge (web) is the chisel-shaped portion of the drill point.

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 The lip (cutting edge) a formed by the intersection of the flutes. The lips must be equal length and
have the same angle so that the drill will run true and will not cut a hole larger than the size of the
drill.
 The lip clearance angle is the relief which is ground on the point of the drill extending from the
cutting lops back to the heel. The average lip clearance is from 8 to 12, depending upon the
hardness or softness of the material to be drilled.

Figure 69 Body of Twist drills.

1.2.2
Speed
A wide range of drills and drill sizes is used to cut various metals; an equally wide range of speeds is
required for the drill to cut efficiently. For every job, there is the problem of choosing the drill speed
which will result in the best production rates and the least amount of downtime for regrinding the drill.
The recommended cutting speeds for drilling various types of materials may be found in the table
shown below. The most economical drilling speed depends upon many variables such as:
 the type and hardness of the material
 the diameter and material of the drill
 the type and condition of the drill press
 the efficiency of the cutting fluid employed
To determine the correct number of r/min (revolution per minute) of a drill press spindle for a given
size drill, the following should be known:
 the type of material to be drilled
 the recommended cutting speed of the material
 the type of material from which the drill is made
Table 1.1.Drill size and types of materials.

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Table 8 Cutting Speed

Drill size stainless steel tool steel cast iron machine steel aluminum
2 1910 2865 3820 4775 9550
3 1275 1910 2545 3185 6365
4 955 1430 1910 2385 4775
5 765 1145 1530 1910 3820
6 635 955 1275 1590 3180
7 545 820 1090 1365 2730
8 475 715 955 1195 2390
9 425 635 850 1060 2120
10 350 520 695 870 1735
15 255 380 510 635 1275
20 190 285 380 475 955
25 150 230 305 380 765

CS = 12 CS = 18 CS = 24 CS = 30 CS = 60
 CS in m/min CS x 1000 CS x 320
 Formula r/min = ---------  -------  -------------
  x D in mm 3.14 x D
 D For metric calculations, the formula is used:
CS (m)
rpm=
ΠD (mm)

It is necessary to convert the meters in numerator to millimeters so that both parts of the equation are in
the same unit. To accomplish this, multiply the CS in meters per minute by 1000 to bring it to
millimeters per minute.
CS×1000 CS×320
rpm= rpm=
ΠD This can be simplified to D

This is done for the reason that not all machines have variable speed drives and therefore cannot be
set to the exact calculated speed. Dividing 1000 by π (3.14) we arrive at the formula above. This
formula is accurate enough for most drilling operations.

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 Example:
Calculate the rpm required to drill a 15mm hole in tool steel using a high speed steel drill.
Solution:
CS×320 18×320 5760
rpm= = = =384
D 15 15
1.1.1. Feed
Feed is the distance that a drill advances into the work for each revolution.

In other words the feed of a drill is the distance the drill moves into the job at each revolution of the
spindle. It is expressed in millimeter. The feed may also be expressed as feed per minute. The feed per
minute may be defined as the axial distance moved by the drill into the work per minute. The feed per
minute may be calculated as:

F = Fr × N
The rate of feed is generally governed by:
 the diameter of the drill
 the material of the work piece
 the condition of the machine
Table1.2. Drill size and feed per revolution.

Drill size feed per

revolution

1 to 3 0.02 to 0.05
3 to 6 0.05 to 0.10
6 to 13 0.10 o
0.18
13 to 25 0.18 o
0.38
2. Boring holes
2.1 Introduction to Boring
In machining, boring is the process of enlarging a hole that has already been drilled (or cast) by means
of a single-point cutting tool (or of a boring head containing several such tools), such as in boring a
gun barrel or an engine cylinder
3. Reaming holes
Reaming: is similar to drilling operation. It is basically used for finishing of holes and

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 enlarging of small holes. Reaming is carried out by the reamer, which has large
number of flutes. Each component in a product must be made to exact standards in order for that
product to function properly. Since it is impossible to produce holes which are round, smooth and
accurate to size by drilling, the reaming operation is very important. Reamers are used to enlarge,
and finish a hole previously formed by drilling or boring. Speed, feed, and reaming allowances are
the three main factors which will affect the accuracy and finish of the hole and the life of the
reamer.
a. Reamers
A reamer is a rotary cutting tool with several straight or helical cutting edges along its body. It is used
to accurately size and smooth a hole which has been previously drilled or bored. Some reamers are
operated by hand (hand reamers), while others may be used under power in any type of machine tool
(machine reamers).
3.3 Parts of the Reamer
Reamers generally consist of three main parts: shank, body and angle of chamfer.
The shank, which may be straight or tapered, is used to drive the reamer. The shank of machine
reamers may be straight or tapered, while hand reamers have a square end on the end to
accommodate a tap wrench.
The body of a reamer contains several straight or helical grooves or flutes, and lands (the portion
between the flutes). A margin (the top of each tooth) runs from the angle of chamfer to the end of the
flute. The body clearance angle is the relief or clearance behind the margin which reduces the
friction while the reamer is cutting. The rake angle is the angle formed by the face of the tooth when
a line is drawn from a point on the front marginal edge through the center of the reamer. If there is no
angle on the face of the tooth, the reamer is said to have radial land.
The angle of chamfer is the part of the reamer which actually does the cutting. It is ground on
the end of each tooth and there is clearance behind each chamfered cutting edge. On rose reamers, the
angle of chamfer is ground ion the end only and the cutting action occurs at this point. On fluted
reamers, each tooth is relieved and most of the cutting is done by the reamer teeth.

Flute length (body) Taper shank

blade

Angle of chamfer

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 Parts of the reamer

Cutting lips

Fig1.5.Reamer and its parts.

3.4 Types of Reamers
Reamers are available in a variety of design and sizes; however, they fall into two general
classifications: machine and hand reamers.
 Hand Reamers
Hand reamers are finishing tools used when a hole must be finished to a high degree of accuracy and
finish. Holes to be hand reamed should be bored to within 0.07 to 0.12mm of the finish size. Never
attempt to ream more than 0.12mm with a hand reamer.
A square on the shank end allows a wrench to be used for turning the reamer into the hole. The teeth
on the end of the reamer are tapered slightly for a distance equal to the reamer diameter so that it can
enter the hole to be reamed.
A hand reamer should never be used under mechanical power and should never be turned backwards.
When using a hand reamer, keep it true and straight with the hole. The dead center in a lathe or a stub
center in a drill press will help keep the reamer aligned during the hand reamer operation.

Straight and helical fluted hand reamers

Fig1.6. Hand reamers

Reaming cannot correct a badly positioned hole; it can only smooth it.
Points to remember in hand reaming include the following:-
1. Drill the hole to be reamed with care.
2. Hold the work securely in the vice.

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 3. Use a good supply of cutting lubricant to help remove chips and reduce friction to obtain a
smooth finish.
4. Honing holes
 Purpose of Honing
Honing is the abrading process done mostly for finishing round holed Produced by drilling,
reaming or boringly means of bonded abrasive stones Called ‘hones’. Honing is a machining process
and is used to remove metal up to 0.25 mm. The surface roughness value can be maintained between
0.025and 0.4 microns. So honing is used to correct some out of roundness, tapers, tool marks and axial
distortion.
Honing is a finishing process performed by a honing tool, which contains a set of three to a dozen and
more bonded abrasive sticks. The sticks are equally spaced about the periphery of the honing tool.
They are held against the work surface with controlled light pressure, usually exercised by small
springs. The honing tool is given a complex rotational and oscillatory axial motion, which combine to
produce a crosshatched lay pattern of very low surface roughness:

Figure 70 Honing Operation

Schematics of honing process showing the honing tool, how the abrasive sticks are pressed against the
work surface by springs, and the resulting surface pattern.
In addition to the surface finish of about 0.1 µm, honing produces a characteristic crosshatched surface
that tends to retain lubrication during operation of the component, thus contributing to its function and
service life. A cutting fluid must be used in honing to cool and lubricate the tool and to help remove the
chips. A common application of honing is to finish the holes. Typical examples include bores of
internal combustion engines, bearings, hydraulic cylinders, and gun barrels.
5. Lapping

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 In lapping, instead of a bonded abrasive tool, oil-based fluid suspension of very small free
abrasive grains (aluminum oxide and silicon carbide, with typical grit sizes between 300 and 600)
called a lapping compound is applied between the work piece and the lapping tool.
The lapping tool is called a lap, which is made of soft materials like copper, lead or wood. The lap
has the reverse of the desired shape of the work part. To accomplish the process, the lap is pressed
against the work and moved back and forth over the surface in a figure-eight or other motion pattern,
subjecting all portions of the surface to the same action. Lapping is sometimes performed by hand,
but lapping machines accomplish the process with greater consistency and efficiency.
The cutting mechanism in lapping is that the abrasives become embedded in the lap surface, and the
cutting action is very similar to grinding, but a concurrent cutting action of the free abrasive particles in
the fluid cannot be excluded. Lapping is used lo produce optical lenses, metallic bearing surfaces,
gages, and other parts requiring very good finishes and extreme accuracy.

Figure 71 Schematics of lapping process showing the lap and the cutting action of

5.3 Select scrapers

Scraping
Scraping is the process of removing high spots on the surface of a piece of work. It is a difficult
operation, and is not often performed in the school workshop.
 Types of scrappers:
These sharp edged tools are used to remove uneven spots on the surfaces. They are of different shapes.
3.4.1. Flat scraper
It is used for removing metal from flat surfaces. The blade must have a slight curvature at the cutting
edge. The corners are rounded to help the user, scrape at the exact spots.
3.4.2. Half round bearing scraper
This is used for scraping curved and cylindrical surface split bearings, big bush bearings etc.

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 3.4.2. Triangular scraper
This is used for scraping curved surfaces, holes and bores. Specification is by length. Example: 200
mm, 300 mm etc.

Self-Check 5 Written Test

Directions I: Choose the best answer for the following questions. (2 point each)
1_____is the process of producing round hole in a solid material or enlarging existing holes.
a. Reaming b. Drilling c. Honing d. Filling
2. Which one of the following is a finishing process of drilled holes?
a. Honing b. filling c. Sawing d. Drilling
3 ____is the process of enlarging a hole that has already been drilled.
a. Drilling b. Honing c. Boring d. None

Directions II: Answer all the questions listed below. (8 points)

a. .What mean by PPE? (2 points)
b. Write the steps to provide drilling operation. (2 points)
c. Write the importance of PPE in the work shop. (2 points)
d. List out the types honing tools. (2 points)
e. Write the function of honing operation. (2 points)

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 Operation sheet 5.1: Perform hand tool operations

 Operation title: bench work operations

Purpose: filing, checking, marking, punching, cutting, drilling, tapping, reaming, and finishing
 Instruction: Use the given figure below (Figure below) the tools and equipment lay out and
mark on the work piece. For this operation you have given 2Hour and you are expected to
operation.
 Tools and requirement:
2. Steel Rule,
9. Scriber
10. Hammer
11. Center paunch
12. Different size of drill bit
13. Bench drill machine
14. work piece 60*98
15. Different size of taps and tap wrench
 Precautions: Measure at least three times before punching
 Procedures in doing the task
step 1. Hold the mild steel flat piece of 50 x 50 x 6mm between the jaws of the bench vice.
step 2. Start filing on first flat surface after removing the rust with the tip of flat file.
step 3. Straight filing is continued till the surface is formed perfectly flat.
step 4. Check the straightness by using straight edge.
step 5. Turn to the adjacent side which is narrow and make it straight, flat and 90° with flat surface prepared.

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 step 6. File the next adjacent side and make it flat and perpendicular to both flat surface and first narrow side
which is already prepared.
step 7. Apply chalk on the finished flat surface and mark dimensions
step 8. Use surface plate V-block and vernier height gauge for marking.
step 9. Marked lines are punched by using dot punch and ball peen hammer.
step 10. File to correct dimensions in length and width and check the dimensions using an outside caliper and
steel rule.
step 11. Mark two curve on the edge of M.S flat using divider.
step 12. Make curve using round file.

Figure 72 given for operation sheet

 Quality Criteria: the given drilling operation measuring with 0..2 mm accuracy

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 LAP Test Practical Demonstration

Name: _____________________________ Date: ________________

Time started: ________________________ Time finished: ________________
Instructions: Given necessary templates, tools and materials you are required to perform the
following tasks within 2-5 hours.
Task 1. lay out mark feature
Task 2. Punching
Task 3. Cutting
Task 4. Drilling
Task 5. reaming,
Task 6. Tapping
Task 7. Checking
Task 8. finishing

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Page 98 of 151 Ministry of Labor and Perform bench work Version -1
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 Unit six : Perform Off-hand grind cutting tools

This unit is developed to provide you the necessary information regarding the following content
coverage and topics
▪ Hone cut edges

▪ cutter Sharpening

▪ cooling agents

▪ personal protective devices.

This unit will also assist you to attain the learning outcomes stated in the cover page. Specifically,
upon completion of this learning guide, you will be able to:
▪ Hone cut edges free of burrs

▪ Sharpen cutter to conform to specifications

▪ Ground cutters using appropriate cooling agents

▪ Perform cutting tool grinding using personal protective devices

Concepts of off-hand grinding

Off – hand grinding is the term used in engineering to describe the process where the work is held by
hand material is removed using an abrasive wheel.

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This type of grinding is carried out in the workshop for such work as:
a. Removing excess materials
b. Smoothening surfaces
c. Preparing plates for welding
d. Sharpening cutting tools (drills, chisels, punches, shaper and lathe tools)

Off – hand grinding must be performed with great regard of safety. The principle of operation
requires an exposed portion of the abrasive wheel to be in close proximity to the operator.
Hazard may be created by having relatively heavy abrasive wheels rotating a high speed. The wheels
on all types of machines must be heavily guarded.
The guard exposes enough of the wheel surface to enable the operator to perform the work required.

Figure 73 bench and pedestal grinder

 Parts and Functions (features of machines)

a. Work Rests
b. Wheel Guards
c. Wheel Speed
d. Wheel Rotation

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 Figure 74 Parts of Bench Grinding machine.

ANGLE GRINDER:
An angle grinder, also known as a side grinder or disc grinder, is a handheld power tool used for
cutting, grinding and polishing. Angle grinders can be powered by an electric motor, petrol engine or
compressed air. The motor drives a geared head at a right-angle on which is mounted an abrasive disc
or a thinner cut-off disc, either of which can be replaced when worn. Angle grinders typically have an
adjustable guard and a side-handle for two-handed operation. Certain angle grinders, depending on
their speed range, can be used as sanders, employing a sanding disc with a backing pad or disc. The
backing system is typically made of hard plastic, phenolic resin, or medium-hard rubber depending on
the amount of flexibility desired.
Angle grinders may be used both for removing excess material from a piece or simply cutting into a
piece. There are many different kinds of discs that are used for various materials and tasks, such as cut-
off discs (diamond blade), abrasive grinding discs, grinding stones, sanding discs, wire brush wheels
and polishing pads. The angle grinder has large bearings to counter side forces generated during
cutting, unlike a power drill, where the force is axial.
Angle grinders are widely used in metalworking and construction, as well as in emergency rescues.
They are commonly found in workshops, service garages and auto body repair shops.

Figure 75 portable grinder

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CUT OFF MACHINE:
An abrasive saw, also known as a cut-off saw or metal chop saw, is a power tool which is typically
used to cut hard materials, such as metals. The cutting action is performed by an abrasive disc, similar
to a thin grinding wheel. The saw generally has a built-in vise or other clamping arrangement, and has
the cutting wheel and motor mounted on a pivoting arm attached to a fixed base plate.
They typically use composite friction disk blades to abrasively cut through the steel. The disks are
consumable items as they wear throughout the cut. The abrasive disks for these saws are typically 14 in
(360 mm) in diameter and 7⁄64 in (2.8 mm) thick. Larger saws use 410 mm (16 in) diameter blades.
Disks are available for steel and stainless steel.

Figure 76 cut off machine

https://www.google.com/search?
q=Bench+grinder&sa=X&stick=H4sIAAAAAAAAAOOQUeLUz9U3MEkptyw2EiupLEgtVshPU0gv
ysxLSS1SKMnPzymO0ihILUrLL8oFyqQpZCTmpUDkFZJLS0oy89IhqhQKUtJOMXKBTDNNM8k
wsoRyjAotipNSTjGC7TEzMDCtgLKBdlokI9iWxb8YxUKwOmARK69Tal5yBkwUAE4BQFm2AA
AA&biw=1366&bih=654&tbm=isch&source=iu&ictx=1&fir=Jx_vFe5gKAMPaM%253A
%252CeNBPSNeMKubL8M%252C%252Fm%252F04dw9s&vet=1&usg=AI4_-
kQcrE1IkrmOKmrHBKwq6r6bOJlC8A&ved=2ahUKEwilsq6UvITlAhUDPFAKHZ2HAewQ_B0wGn
oECAgQAw#imgrc=Jx_vFe5gKAMPaM:

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 Honing cut edges
Importance of honing:

Honing is an abrasive machining process that produces a precision surface on a metal work piece
by scrubbing an abrasive stone against it along a controlled path. Honing is primarily used to improve
the geometric form of a surface, but may also improve the surface texture. Typical applications are the
finishing of cylinders for internal combustion engines, air bearing spindles and gears. There are
many types of hones, but all consist of one or more abrasive stones that are held under pressure against
the surface they are working on.
In terms of sharpening knives, a honing steel does not actually hone knives, but simply realigns the
metal along the edge.
Other similar processes are lapping and super finishing.
Honing uses a special tool, called a honing stone or a hone, to achieve a precision surface. The hone is
composed of abrasive grains that are bound together with an adhesive. Generally, honing grains are
irregularly shaped and about 10 to 50 micrometers in diameter (300 to 1,500 mesh grit). Smaller grain
sizes produce a smoother surface on the work piece.

A honing stone is similar to a grinding wheel in many ways, but honing stones are usually more friable
so that they conform to the shape of the work piece as they wear in. To counteract their friability,
honing stones may be treated with wax or sulfur to improve life; wax is usually preferred for
environmental reasons.

Any abrasive material may be used to create a honing stone, but the most commonly used are
corundum, silicon carbide, cubic boron nitride, or diamond. The choice of abrasive material is usually
driven by the characteristics of the work piece material. In most cases, corundum or silicon carbide are
acceptable, but extremely hard work piece materials must be honed using super abrasives.

The hone is usually turned in the bore while being moved in and out. Special cutting fluids are used to
give a smooth cutting action and to remove the material that has been abraded. Modern advances in
abrasives have made it possible to remove much larger amount of material than was previously
possible. This has displaced grinding in many applications where "through machining" is possible.
External hones perform the same function on shafts.

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Refer:https://www.youtube.com/watch?v=KjRyy5IhHZo
Refer:https://www.youtube.com/watch?v=-jLcA5z99r8

Refer: https://www.youtube.com/watch?v=T5hIXPBGBgw

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 Concepts of Sharpening Cutters
The word sharpening is usually used for the final finishing of edge tools. Like all edge tools, a drill bit
needs to have the right shape before you can start to sharpen it. Creating the initial shape often means
that quite a lot of steel needs to be re-moved when for example, you change the point angle of a drill or
you shape a broken or heavily worn drill. Once the geometry of the point is established, you maintain
the sharpness by sharpening. With the Tormek system you can exactly replicate an existing shape and
therefore you just need to touch up the edges. Shaping and Sharpening
Edge tools need to be sharp to work efficiently. The bevels of a sharp edge tool end in a
uniform tip. After a period of use the tip becomes rounded and the edge is no longer sharp.
You can sharpen tools with a bench stone or, in the case of knives, with a sharpening steel.
This means that you work on the very tip of the bevel and the tool is sharp again.
When sharpening with a steel or a bench stone, a very limited amount of steel is removed.
After several sharpening or honing, the edge angle becomes too wide and the tool must
be re-shaped. Sooner or later all edge tools need to be re-shaped and this is done by grind-
ing on a grindstone or a grinding wheel. When only a limited amount of steel is removed this
operation is also called sharpening.
Grinding means that so much steel is removed from the tool that the edge is restored to
the original angle or altered on purpose to a new angle. The shape of the tool can also be
changed according to your requirements.
1.1. Tool Sharpening
For some tools it is very important to keep them sharp at all times. Common tools, such as scribers,
center punch, chisels, drill bits, tool bits for lathe machine needs to be sharpened every time you feel
that they do not cut well.
 Sharpening Scriber and Center Punch
1. Scriber and center punch should be ground in the position as shown beside.
2. Use the tool rest to rest your hands while bringing the tool in the right position.
3. Rotate the tool while grinding.
4. Cool the tool down from time to time.
5. Do not overheat the metal.

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 Figure 77 Punches and their grinding angles

Refer: https://www.youtube.com/watch?v=zxvbKlur96A
 Sharpening Chisel
 Use the tool rest to rest your hands while bringing the tool in the right position.
 Use the whole grinding wheel while grinding. Move with the tool regularly from the left
to the right side and back.
 Cool the tool down from time to time.
 Do not overheat the metal.
 Grind the chisel−point parallel and straight. See also the pictures below.
1.2. Grinding twist drills
Twist drills may be ground in a drill holder fixture or free hand. Use fixture if available.
Grind drill lips or cutting edges at an angle of 59 degrees, as illustrated below (50 to 60degrees for
drilling brass or bronze, 68 degrees for extremely hard material). Both cutting edges must make
same angle with drill angle with angle drill axis, and both cutting edges must be same length.

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 Figure 78 Grinding angles of Twist drill points

Refer: https://www.youtube.com/watch?v=y0SQkzScQk0
 Using Drill Holder Fixture
Exact procedure for grinding will vary with make of drill grinding machine used. General
procedure, which applies to conventional type machine, is given in the following steps:
 Adjust machine to desired cutting edge and heel angles.
 Place drill in V- block of holder. Turn so cutting edge will contact abrasive wheel as drill is
feed in to wheel.
 Start motor and advance tailstock until drill makes contact with wheel.
 Hold drill in place in V- blocks and swing holder spindle slowly through its arc. Without
changing tailstock adjustment , revolve drill one- half turn in V- blocks and sharpen other lip of
dill in same manner.

Figure 79 Grinding with Drill Holder Fixture.

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  Inspect drill point to see if it has been ground block far enough to eliminate all nicks.
Repeat grinding and inspections operations until perfect appearing points are obtained.
 Free Hand Grinding
1. Adjust tool rest to convenient height for resting back of forehead on it while grinding.
2. Hold drill between thumb and index finger of right or left hand grasp body of drill near
shank with other hand.
3. Place forehand on drill rest with centerline of drill making desired angle with cutting
face of wheel and slightly lower shank end of drill as illustrated.
4. Slowly place heel of drill against grinding wheel.
5. Check results of grinding with a gage to determine if cutting edge Are same length and
at desired angle and if heel is ground to angle of 12 to 15 degree.

Figure 80 Free Hand Grinding

Figure 81 Heel Angle.

Web thinning
On a conventional twist drill bit there is what is known as a web. The web is the center part of the body
that joins the lands (Figure)

Figure 82 Twist drill point

The extreme ends of the web form the chisel edge. The thickness of the web is not uniform; it increases
from the point to the shank (Figure).

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 Figure 83 Twist drill bit

The web thickness gets larger toward the shank of the drill.

The cutting action of the chisel edge requires a relatively large amount of thrust be used to cause the
drill to penetrate into the work piece. The increased amount of thrust needed to drive the chisel edge
becomes more apparent as the drill is sharpened, since the web of the drill is made thicker toward the
shank. We can reduce the amount of force it takes to cause the drill to penetrate by thinning the web of
the drill (Figure).

Figure 84 . Web thinning

The best way to thin the web of a drill is by using a machine equipped with a drill point thinner. It is
possible, however, to thin the web of a drill by hand using a pedestal grinder.
Web Thinning on a pedestal Grinder
 When thinning the web be careful not to make the web any thinner than it was when original
and do not disturb the cutting lips of the drill. Start with a clean, sharp grinding wheel. Hold the
drill at approximately 35 degrees of the axial centerline of the drill.

Figure 85 Holding the drill at a 30- degree angle

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Line up the corner of the wheel with the tip of the web (Figure).
Turn the cutting lip out approximately 10 degrees. Lightly grind away the web of the drill. You have to
grind the same amount off of each web to assure that the drill point will remain on center. Try to stay
away from the cutting edge as much as possible.

Figure 86 Line up the end of the web with the corner of the wheel

Modified split point done on a pedestal grinder

It is sometimes easier for a beginning student to grind a modified split point by hand than it is to do
off-hand web thinning. The split point drill (Figure) accomplishes the same end result, a thinned web,
but you are actually grinding away the heel or non-cutting side of the drill point.
https://www.ibiblio.org/hyperwar/USA/ref/TM/pdfs/TM9-867.pdf

Figure 87 Split point

Procedures:
1. Start with a clean sharp grinding wheel. Hold the drill at approximately 55 degrees off of the
axial centerline of the drill (Figure).

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 Figure 88 The approach angle is steeper when web splitting

2. Line up the corner of the wheel with the tip of the web (Figure ). Turn the cutting lip out
approximately 10 degrees away from the wheel edge.
3. Lightly grind away the heel of the drill until you have ground away the appropriate amount of
the web of the drill.

Grounding cooling agents

3.1. Properties of Cutting Fluids
 Functions of cutting fluids
Cutting fluids are used in metal machining for a variety of reasons such as improving tool life,
reducing work piece thermal deformation, improving surface finish and flushing away chips from the
cutting zone.
Cutting fluids consist of those liquids and gases that are applied to the tool and the material
being machined to facilitate the cutting operation. Vast quantities are used annually to
accomplish a number of objectives. (Boston, 1952)
1) To prevent the tool from overheating, i.e. so that no temperature is reached where the
tool's hardness and resistance to abrasion are reduced, thus decreasing the tool life.
2) To keep the work cool, preventing machining those results in inaccurate final dimensions.
3) To reduce power consumption, wear on the tool , and the generation of heat, by
affecting the cutting process. This investigation wishes to establish a relationship
between the surface chemistry of the lubricants involved and how they can
accomplish reducing the contact length on the rake face of the tool where most of the
heat during cutting is produced.
4) To provide a good surface finish on the work.
5) To aid in providing a satisfactory chip formation (related to contact length)
6) To wash away the chips/clear the swarf from the cutting area.
7) To prevent corrosion of the work, the tool and the machine.

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  The desirable properties of cutting fluids in general are (Boston, 1952)
1) High thermal conductivity for cooling
2) Good lubricating qualities
3) High flash point, should not entail a fire hazard
4) Must not produce a gummy or solid precipitate at ordinary working temperatures
5) Be stable against oxidation.
6) Must not promote corrosion or discoloration of the work material.
7) Must afford some corrosion protection to newly formed surfaces.
8) The components of the lubricant must not become rancid easily
9) No unpleasant odour must develop from continued use
10) Must not cause skin irritation or contamination
11) A viscosity that will permit free flow from the work and dripping from the chips.
3.2 Types of cutting fluids
Cutting fluids may be divided into four main categories (FVTC, 2000):
i straight or neat cutting oils
ii- water miscible or water-based fluids
iii- gases
IV- paste or solid lubricants

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 i. Straight Cutting Oils
Straight cutting oils are not mixed with water. Cutting oils are generally mixtures of
mineral oil and animal, vegetable or marine oils to improve the wetting and lubricating
properties. Sulphur, chlorine, and phosphorous compounds are sometimes added to
improve the lubrication qualities of the fluid for extreme pressure applications. There are two
main types of straight oils: active and inactive.
ii. Water miscible or water-based fluids
The water-based fluids act mainly as coolants and the neat cutting oils act mainly as
lubricants. There are many variants of both types. Fatty acids are often incorporated in the neat
oils. Until recently both the emulsions or soluble oils as they are also called and the neat
oils, contained chlorine and sulphur additives that improved lubrication under extremely
difficult conditions. Chlorine affects the skin detrimentally and its degradation products are
often carcinogenic and sulphur is environmentally unacceptable. Consequently other
lubrication improvers under difficult conditions are searched for. Ester technology is used
successfully for softer materials where high rates of metal working are needed, and where
heat generation is not a major problem. (du Plessis, 2001)
These can operate at higher temperatures as they have better resistance to thermal
degradation than mineral oils. (Mortier & Orszulik, 1993) They arebiodegradable and do not
cause dermatitis and are therefore more environmentally acceptable. In many cases phosphor
and sulphur do however still form part of the cutting fluid. (FYTC, 2000)
For the water miscible fluids water quality has a large effect on the coolant. Hard water
(high mineral content) can cause stains and corrosion of machines and work pieces.
Water can be deionized to remove the impurities and minerals. Water is the best fluid for
cooling. It has the best ability to carry heat away. Water, however, is a very poor lubricant and
causes corrosion.
Oil is excellent for lubrication but very poor for cooling, and it is also flammable. It is
clear that, from a lubrication point of view water and oil have strengths but also some
weaknesses. If water and oil are combined and an attempt is made to minimise the

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weaknesses the best properties of both may be balanced to obtain desirable end properties for
the cutting fluid. Water-soluble fluids have been developed which have good lubrication,
cooling ability, low-flammability and corrosion resistance. These fluids are usually mixed on
site. It is crucial that the mixing directions and concentrations are followed very closely to
get the maximum benefit from the coolant. (FYTC, 2000)
Emulsions
An emulsion is a dispersion of oil droplets in water. Soluble oils are mineral oils that contain
emulsifiers. Emulsifiers are soaps or soap-like agents that allow the oil to mix with water
and stay in suspension. Emulsions (soluble oils) when mixed with water produce a milky
white product. Lean concentrations (more water, less oil) provide better cooling but less
lubrication. Rich concentrations (less water, more oil) have better lubrication qualities but
poorer cooling properties.
There are different types of soluble cutting fluids available including extreme pressure
soluble oils. These are used for extreme machining conditions like broaching and gear hobbing
for example. (FYTC, 2000)
Chemical Fluids
Chemical coolants are also miscible cutting fluids. Chemical cutting fluids are pre-
concentrated emulsions that contain very little oil. Chemical fluids mix very easily with
water to form an emulsion. The chemical components in the fluid are used to enhance the
lubrication, bacterial control, and rust and corrosion characteristics. There are several types
of chemical coolants available including coolants for extreme cutting conditions.
Inactive chemical cutting fluids are usually clear fluids with high corrosion inhibition,
high cooling, and low lubrication qualities. Active chemical fluids include wetting agents.
They have excellent rust inhibition and moderate lubrication and cooling properties.
Sulphur-, chlorine- and phosphorous- containing compounds are sometimes added to
improve the extreme pressure characteristics. These are usually in an organic form, i.e.
the sulphur, chlorine or phosphorus IS grafted onto a hydro-carbon backbone. (FVTC,
2000).

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 iii. Gases and vapours
Cutting oils and water miscible types of cutting fluids are the most widely used.
Compressed air, ineIi gases like carbon dioxide, Freon, and Nitrogen are sometimes used. A
vortex tube may be used to apply gaseous lubricants or coolants (ARTX, 2002). Using this
tube, it is possible to apply the gases at a very low temperature and under medium
pressure thereby facilitating a higher gas density and cooling and lubrication capability.
Cutting using sub-zero cold gas is known as cryogenic cutting. The gas stream also helps to blow
away chips from the cutting area. (FVTC, 2000)
iv. Paste and Solid Lubricants
Waxes, pastes, soaps, graphite and molybdenum disulphide are examples falling into this
category. These are generally applied directly to the work piece or tool or in some cases
impregnated directly into the tool, for example the grinding wheel of a grinder. One
example of a paste lubricant is lard. Many experienced journeymen recommend lard for tapping.
grind using personal protective devices

MACHINE SAFETY

Grinding machines are used daily in a machine shop. To avoid injuries follow the safety
precautions listed below.

 Wear goggles for all grinding machine operations.

 Check grinding wheels for cracks before mounting.

 Never operate grinding wheels at speeds in excess of the recommended speed.

 Never adjust the work piece or work mounting devices when the machine is operating

 Do not exceed recommended depth of cut for the grinding wheel or machine.

 Remove work piece from grinding wheel before turning machine off.

 Use proper wheel guards on all grinding machines.

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  On bench grinders, adjust tool rest 1/16 to 1/8 inch from the wheel.

Figure 89 PPE

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 Self-Check 6 Written Test

Directions I: Choose the best answer for the following questions. (2 point each)
2. Honing tool is used for .
a. cutting c. drilling
b. finishing d. none
3. Honing operation is .
a. Abrasive machining process c. grinding
b. drilling d. cutting
1. is usually used for the final finishing of edge tools. (2 points)
a) Sharpening b)cutting c)drilling d)boring
2. Twist drills may be ground in . (2 points)
a) Drill holder fixture b) drill chuck c) free hand d) a & c
3. Is the center part of the body of twist drill bit that joins the land . (2 points)
a) Shank b) web c) body d) chisel edge
4. The web thickness gets larger toward the shank of the drill. . (2 points)
a) True b) false
5. Which one of the following is correct point angle for center punches? . (2 points)
a) 30 degrees b) 45 degrees c) 90 degrees d) 75 degrees

6. Which one of the following is not the reason that cutting fluid is used in metal
machining? (2 points)
a) reducing work piece thermal deformation c) reducing surface finish
b) improving tool life d) flushing away chips from the cutting zone

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 7. Which one of the following oils are not mixed with water? (2 points)
a) straight cutting oils c) Gases and vapours

b) paste and Solid Lubricants d) Water miscible or water-based fluids

8. Which one of the following is paste and solid lubricants? (4 points)
a) be stable against oxidation c) must not cause skins contamination

b) good lubricating qualities d) all of the above

9. A dispersion of oil droplets in water is .
a) chemical fluids c) vapours
b) an emulsion d) Solid Lubricants
10. Which one of the following is the desirable property of cutting fluids?
a) be stable against oxidation c) must not cause skins contamination

b) good lubricating qualities d) all of the above

A) B) chisels C) center punches D) scribers
Direction II say true if the statement is true if not say false
1. Always keep hands at a safe distance from moving machine parts.
2. A utility grinder mounted on its own freestanding base is called upright grinder
3 . The main purpose of a grinding wheel guard is to Protect the operator from flying sparks

Operation sheet 6.1: Perform hand tool operations

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  Operation title: bench work operations
Purpose: filing, checking, marking, punching, cutting, drilling, tapping, reaming, and finishing
Instruction: Perform the following tasks using necessary bench work operations.
1. Measure the stock using proper tools.
2. Lay out according to the drawing.
3. Cut within the given dimension.
4. File and make it smooth.
5. Drill according to given dimension
6. For this operation you have given 2Hour and you are expected to operation.
 Tools and requirement:
1. drill bit
2. center punch
 Precautions: Measure at least three times before punching
 Procedures in doing the task
Adjust safety glass shields on the grinder to permit clear vision of the part
Step1- to be ground and still protect the operator from flying particles.
Step 2- Dress grinding wheel with dressing tool.
Step 3- Hold drill bit against face of wheel at 590 angle on cutting lip.
Step 4- Carry drill bit up the wheel face by dropping end and rotating very slightly in a
clockwise direction.
Step5- Make slow deliberate strokes, the full width of the cutting lip.
Step 6- Do not lower cutting lip below the horizontal position as this will round the cutting
edge.
Step 7- When one lip is ground, rotate the drill one half turn and grind the other lip.
Step 8- Use tool gauge to check equal lengths of lips, 590 angle cutting lip and 12-150 lip
clearance.
Step 9- Test bit by boring hole in mild steel plate.
Step 10- Stop while drilling, turn drill press in reverse direction to release drill bit from hole.

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Step 11- Make grinding corrections on drill bit as indicated by hole.
Step 12- Submit drill bit and metal for evaluation.

Figure 90 given for operation sheet .6.1

 Quality Criteria: the given bench work operation measuring with 0..2 mm accuracy

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 LAP Test Practical Demonstration
Name: _____________________________ Date: ________________
Time started: ________________________ Time finished: ________________
Instructions: Given necessary templates, tools and materials you are required to perform the
following tasks within 2-5 hours.
Task 1- Perform center punch grinding operation with its correct point angle following safety
regulation.
Task 2- Sharpen 12mm diameter twist drill bit by using bench type grinder with its appropriate
angle.
Task 3- Perform the following tasks using necessary bench work operations.

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Unit seven : Quality assure finished component

This unit is developed to provide you the necessary information regarding the following content
coverage and topics
▪ Check component for conformance

▪ Use appropriate techniques, measuring tools and equipment

Steel rule
Vernier caliper
Micro meter
Straight edge
Gages
▪ Handle deviations .

▪ routine maintenance and adjustments out.

This unit will also assist you to attain the learning outcomes stated in the cover page. Specifically,
upon completion of this learning guide, you will be able to:
▪ Check component for conformance
▪ Use appropriate techniques, measuring tools and equipment
Steel rule
Vernier caliper
Micro meter
Straight edge
Gages
▪ Handle deviations appropriately.

▪ Caring routine maintenance and adjustments out.

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 Unit seven : Quality assure finished component
7.1. Check component for conformance

Used to ensure that a manufactured product or performed service adheres to a defined set
of quality criteria or meets the requirements of the client or customer.

It involves testing of units and determining if they are within the specifications for the final
product. The purpose of the testing is to determine any needs for corrective actions in the
manufacturing process. Good quality control helps companies meet consumer demands for better
products.

The quality of services or products delivered to customers could be checked using the following
three methods.
 Visual inspection
 Physical measurements
 Check against specifications/preferences
Quality inspection are measures aimed at checking, measuring, or testing of one or more product
characteristics and to relate the results to the requirements to confirm compliance. This task is
usually performed by specialized personnel and does not fall within the responsibility of
production workers. There are different types of quality checks. The following are the common
types:
 Company Quality Check Policy
 Prototype quality testing
 Failure or stress testing
 Manufacturing quality inspections
Company Quality Check Policy:
One of the best overall quality control methods is to institute a company-wide quality control
policy. This policy should make it clear that product quality is a high priority, and should assign

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employees tasks for checking product quality at all stages, from design to manufacture and
finishing. Giving employees a convenient means of reporting quality problems or defects can
lead to early detection and can save money in the long term. After all, it is far more inexpensive
to fix a problem with a design at the design stage than repairing or fully discarding completed
products with a built-in design.
Prototype quality testing: Testing prototypes is a quality checking method that relies on real-
world testing by employees and their families, or by potential customers selected from the
general public. Prototype products should be as close as possible to production versions, and
users should be asked to fill out surveys or report problems with the product.

For example, if you own a shoe company and want to ensure that your shoes will hold up to real
world conditions, you can send employees home with pairs for themselves and their families.
After a set period, for example, a month or three months, ask them to bring the shoes back in and
answer some survey questions about how often they wore them, what activities they performed
in them and how comfortable and supportive they found the shoes.
Failure or stress testing: Failure testing, or stress testing, is one of the most common quality
check methods for industrial products. Factories often contain a special area for failure testing,
where products are subjected to repeated use and misuse until they fail in some way.

This testing can include subjecting the products to extreme temperatures, submerging electronic
devices in water, and crushing or dropping products. Mattress testing, for example, involves
repeatedly pressing weights on the mattress to see how it will hold up to wear after a long period.

Failure testing not only gives manufacturers an idea of how much a product can endure, but also
gives them knowledge about what the form the failure will take and whether or not the broken
product will represent a safety risk.
Manufacturing quality inspections: Continuous quality checking should also occur at the point
of manufacturing. Employees who perform quality checks in a factory may look for defects at
several stages of production, or check random samplings of products at the end of the process.
Measuring tools can serve to check whether products meet certain quality standards in terms of

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size or shape, and a simple visual inspection can ensure that no severely flawed products leave
the factory.

Factors affecting quality of services or products

The quality of a product may be defined as the sum of number of related characteristics, such as
shape, dissension composition, strength, workmanship, adjustment, finish and color.
It is sum-total of features of a product which influence its capacity to satisfy a given need.
Quality of a product consists of the following attributes:
(a) Appearance of the product
(b) Product design or planned quality
(c) Suitability from customer’s viewpoint
(d) Reliability
(e) Durability
(f) Degree to which it conforms to the product specifications
(g) Its marketing and service, etc.
Quality characteristics may be directly measurable, e.g., diameter , volt-age, weight, etc. But
some quality features are non-measurable, e.g. blow holes, cracks, dents, etc. Quality is of two
types :
(a) Quality of design
refers to the manufacturing specification of the product. It consists of appearance, life, safety,
maintenance and other features of product design.
(b) Quality of conformance
implies the degree to which the product actually conforms to the design specification. Quality of
conformance is measured by the level of defects in the finished product. Usually, higher quality
of design means higher cost while higher quality of conformance means lower total cost.
Perfection in any type of quality is rarely possible and it may mean infinite cost Moreover,
exceptionally high quality product may not be accepted in the market unless sufficient number of
customers can pay for it.

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All business concerns exist to provide goods and services to society. They can be profitable and
successful only when the products and services are for use and meet the needs of consumers.
Such ‘fitness for use‘ of product is known as quality. While deciding the quality of his products,
a manufacturer has to reconcile two conflicting trends, viz., customer satisfaction and cost of
production.

Higher is the quality greater is the satisfaction of customer. But every improvement in quality
means additional costs. It is the responsibility management to build a quality level which
provides reasonable customer satisfaction at economical cost. The level of quality ultimately
depends upon the type of market (level of customer wants and the price he is willing to pay for).
Within a certain range quality level is a management decision taken on the basis of costs and
profits.
For example, it may be more profitable to supply a medium-quality item at a low price which
people can buy rather than to supply a top quality at a price so high that very few people can
afford. Thus, the level of quality has direct relation with customer’s purchasing power. This is
the economics of quality.
Quality of a product or service depends upon the following factors
(i) Market. Customer demand, his needs and purchasing power are the main determinants of
quality level.
(ii) Materials. The availability of right type of materials is essential for maintaining quality level
of finished products. A wide variety of materials may be available but material with right
specification has to be used.
(iii) Technology. Nature of technology and machinery used has a direct bearing on product
quality. Modem technology, methods and equipment have led to improvements in product
quality level.
(iv) Labour. The knowledge and experience of people who design and produce products
exercise significant influence on quality level. Competent and trained people can design and
manufacture better quality products.

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(v) Cost. Cost of quality maintenance and improvement has increased significantly. Increasing
competition, growing mechanization and decreasing profit margins may not permit greater
expenditure on quality improvements. Scrap and rework losses have become serious.
(vi) Management. The attitude and policy of management towards product quality is important
Some managers tend to be more quality conscious than others.

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 7.2. Use appropriate techniques, measuring tools and equipment
This topic discussed under lay out and marking Graduated Measuring
Devices
7.2.1. Steel rule.

7.2.2. Vernier caliper

7.2.3. Micro meter

7.2.4. Straight edge

7.2.5. Gages

7.4. Handle deviations .

7.4.1. Introduction to Quality Deviation

Quality deviation is departure from an agreed-upon course, design, mean, or method. The act of
deviating; a wandering from the way; variation from the common way, from an established rule,
etc.; departure, as from the right course or the path of duty.
It is a departure from standard procedures or specifications resulting in non-conforming material
and/or processes or where there have been unusual or unexplained events which have the
potential to impact on product quality, system integrity or personal safety.
In manufacturing, a deviation is a notable statistical different in the units being produced. It
typically means that there is an increase in product defects or a notable change in product quality
that is the same throughout several batches but not in accordance with product designs.
Deviations typically present serious problems for manufacturers in terms of both profit and
safety. Deviation processes help businesses quickly deal with such issues as effectively as
possible.
Deviation can quickly ruin batches that the manufacturer creates. Sometimes the product units
that have deviated from the planned model can be recycled, but in many cases the products lead
directly to profit losses and increased costs. But having deviation processes in place,

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manufacturers can use both software warning systems and planned emergency actions for
employees to quickly stop production and examine the problem when it appears that a deviation
is occurring.
Some deviations are subtle and manufacturers discover them only after looking carefully at past
periods and production results. In this case, it can be very difficult to discover what is causing
the deviation. It could be equipment malfunctions or a single part that needs to be oiled or
maintained. It could be the quality of new hydraulic fluid, or the quality of the latest shipment of
raw materials. By have a deviation process in place, the business can move through steps
designed to pinpoint the exact cause quickly and accurately.
A deviation process will also often include deviation accounts to store a certain expected loss
from deviation, which allows the business to keep more accurate books and analyze production
more effectively. Of course, sometimes a business also needs to plan for a deviation, if a supplier
wants a batch of products with a particular difference. The process will also make room for these
plans.
Causes of Quality Deviation
Minor Deviations
When the deviation does not affect any quality attribute, a critical process parameter, or an
equipment or instrument critical for process or control, it would be categorized as Minor, and
treated as such by the applicable procedure. Possible examples of minor deviations (*) are given
below:
 Skip of FEFO principle (first expired-first out) in raw material handling.
 Balance out of tolerance used to determine gross weight of raw materials upon reception.
 Pressure differential out of established limits in class D washing area.
 Inadequately trained personnel to perform warehouse cleaning activities.
Major Deviations
When the deviation affects a quality attribute, a critical process parameter, an equipment or
instrument critical for process or control, of which the impact to patients (or

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personnel/environment) is unlikely, the deviation is categorized as Major requiring immediate
action, investigation, and documented as such by the appropriate SOP. Possible examples of
major deviations (*) are given below:
 Use of unapproved reference standard to test an API or drug product.
 Inadequately trained personnel to perform sterility tests.
 Production started without line clearance.
 Filter integrity test has been carried out using equipment with no documented installation
qualification completed.
 Gross misbehavior of staff in a critical aseptic process.
 Pressure differential out of established limits in aseptic fill areas.
 Operational parameter out of range for a parameter defined as non-critical.
 Untrained personnel responsible for segregating the approved and rejected raw material in
the warehouse
Critical Deviations
When the deviation affects a quality attribute, a critical process parameter, an equipment or
instrument critical for process or control, of which the impact to patients (or personnel or
environment) is highly probable, including life threatening situation, the deviation is categorized
as Critical requiring immediate action, investigated, and documented as such by the appropriate
SOP.
Possible examples of critical deviations (*) are given below:
 Expired or rejected API component used.
 Sterilization record of product-contact material used in aseptic filling process not
available or unacceptable.
 Incomplete inactivation stage of fermentation.
 Temperature out of control limit during detoxification stage.
Different Levels of Deviation Risks:
For the ease of assessing risk any deviation can be classified into one of the three levels 1, 2 & 3
based on the magnitude and seriousness of a deviation.

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Level 1: Critical Deviation
Deviation from Company Standards and/or current regulatory expectations that provide
immediate and significant risk to product quality, patient safety or data integrity or a
combination/repetition of major deficiencies that indicate a critical failure of systems
Level 2: Serious Deviation
Deviation from Company Standards and/or current regulatory expectations that provide a
potentially significant risk to product quality, patient safety or data integrity or could potentially
result in significant observations from a regulatory agency or a combination/repetition of "other"
deficiencies that indicate a failure of system(s).
Level 3: Standard Deviation
Observations of a less serious or isolated nature that are not deemed Critical or Major, but
require correction or suggestions given on how to improve systems or procedures that may be
compliant but would benefit from improvement (e.g. incorrect data entry).
Types of Deviations
 Production Deviation - usually raised during the manufacture of a batch production.
 EHS Deviation - raised due to an environmental, health and safety hazards.
 Quality Improvement Deviation - may be raised if a potential weakness has been identified
and the implementation will require project approval.
 Audit Deviation - raised to flag non-conformance identified during internal, external,
supplier or corporate audits.
 Customer Service Deviation - raised to track implementation measures related to customer
complaints.
 Technical Deviation - can be raised for validation discrepancies. For example: changes in
Manufacturing Instruction.
 Material Complaint - raised to document any issues with regards to non-conforming,
superseded or obsolete raw materials/components, packaging or imported finished goods.

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 System Routing Deviation - raised to track changes made to Bill of materials as a result of
an Artwork change
Investigation and reporting deviations
Deviation investigations are one of the most important quality activities in any GMP (good
manufacturing practice) organization. Clearly, many organizations have room to improve in the
writing and managing of deviation investigations.
Check During The Deviation Assessment:
QA delegate has to conduct a primary Investigation on the deviation reported and evaluate the
following information
1. Scope of the deviation - batch affected (both in-process and previously released)
2. Trends relating to (but limited to) similar products, materials, equipment and testing processes,
product complaints, previous deviations, annual product reviews, and /or returned goods etc
where appropriate.
 A review of similar causes.
 Potential quality impact.
 Regulatory commitment impact.
 Other batches potentially affected.
 Market actions (i.e. recall etc)
The aim of the reporting process is to establish whether project objectives have been achieved,
what resources have been expended, what problems have been encountered, and whether the
project is expected to be completed on time and within budget. If performance is sufficient the
project will receive payment from the programme for costs incurred, paid and reported.
7.5. routine maintenance and adjustments out.
ABRASIVE WHEELS Maintenance
 Handle wheels with care at all times; they break easily.

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  Do not grind on sides or corners of wheel, unless it is impossible to grind the job at hand
on the face of the wheel. This rule should be observed, due to the difficulty of dressing
the sides of the wheel.
 When mounting wheel on spindle observe the following precautions
Truing: Removal of material from cutting face of a wheel so surface runs true.
Dressing: Restoring sharpness of a wheel face which is "loaded" or dulled

Figure 91 Dresser

Measuring Tools Maintenance

the proper care of measuring tools so important? Some of the benefits include the following.
 Increase accuracy: If measuring tools don’t receive proper care and maintenance, they’re
more likely to take inaccurate readings. A wide variety of factors can impact the accuracy of
a measuring tool, from improper storage temperature to excessive vibrations to physical
damage due to dropping it. Because damage or improper maintenance can affect accuracy,
it’s crucial that you’re careful to maintain them properly. A measuring instrument can also
fall out of calibration naturally over time, so regular gage calibration is essential.
 Extend life: Caring for precision tools properly also helps extend their life. With proper care,
many measuring instruments can serve you well for a long time. Without adequate
maintenance, however, your tools will break sooner, and you’ll have to replace them earlier.
Improper care increases the risk of a tool failing in the middle of a job or gradually becoming
less effective, reducing the efficiency and accuracy of your work.

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 Lower costs: Following the right care and maintenance procedures can help you reduce your
costs over the long term. It can help you avoid costly breakdowns, more extensive repairs
and downtime. It also means you’ll have to replace your tools less often, meaning you get
more out of your investments in quality instruments.
General MAINTENANCE
Calipers are precision instruments and must be used and handled with care at all times. Wipe
perspiration and finger prints from them with a soft cloth; if neglected, this may cause rust. Do
not force threaded parts. Use touch measurement. Do not spring or clamp calipers. Keep in case
or wrap in soft cloth when not in use.
Lubrication
Oil threaded and moving parts and friction surfaces (firm joint calipers) with preservative
lubricating oil (special). Coat non operating surfaces with a film of preservative lubricating
oil(special).
Cleaning, Inspection, and Repair
1. Disassemble caliper and wash parts in dry cleaning solvent. Dry with a clean, soft cloth.
2. Inspect all threaded parts to be sure all dirt is removed. Scarcely visible particles may cause
uneven thread motion and binding.
3. Inspect parts to see if they are rusted, corroded, burred, bent, or worn. Scour with crocus cloth
to remove rust or corrosion. Replace parts which are bent, broken, or worn.
4. Lubricate parts as instructed above, and reassemble caliper.
Repair Bent Firm Joint or Spring Caliper
If leg is bent, place caliper on soft metal block. Straighten bent leg to original shape by tapping
with brass hammer. Replace bent adjusting screws.
Adjustment of Micrometer
To compensate for thread wear, screw thimble from barrel. Tighten thread play adjustment nut
on fixed nut a fraction of a turn at a time. Test fit of micrometer screw in fixed nut. Repeat
tightening and test until operation is free from both binding and play.
NOTE: Some micrometers have an automatic spring-controlled thread play adjustment.

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Testing Micrometer
Clean measuring faces with a soft cloth Examine faces after cleaning and remove any lint
deposited by cleaning cloth. Measure length of micrometer test gage of same length as minimum
capacity of micrometer. Micrometer should read its exact minimum capacity. For 0-1 inch
micrometer, screw thimble down until spindle contacts anvil. Do not force thimble. Reading
should be 0.000 inch.
Measure length of a micrometer test gage of same length as maximum capacity of micrometer.
Micrometer should read its exact maximum capacity.
Check inside micrometers against outside micrometers or gage blocks.
If in checking it is found that micrometers do not read correctly refer to proper authority for
adjustment. Never use inaccurate micrometers.
Misuses
Never use micrometers with dirty anvil and/or threads. Dirt on micrometer anvil gives incorrect
readings. Dirty threads cause excessive wear and eventually inaccurate readings.
Do not carry micrometers in a pocket of work clothes, as dirt from the pocket works into the
threads.
Keep micrometers in a covered box on the job and wipe anvil and spindle clean with a soft,
slightly oiled rag each time after using and before returning them to their places in the box. Keep
cover closed to protect micrometers from dirt and grinding dust.
General-All Clamps
These are relatively heavy-duty but simple tools. Maintenance requirements are few:
Keep screws lubricated with small quantity of preventive lubricating oil (special) or engine oil
(SAE 10). Excessive lubricant interferes with use of tool. Keep metal surfaces free of rust. Scour
off rust or corrosion with crocus cloth or aluminum oxide abrasive cloth. Coat surfaces with
preservative lubricating oil (special) or engine oil (SAE 10).
Varnish hardwood jaws of hand screw clamps whenever finish becomes damaged extensively
enough to leave wood without protective coating. Replace all parts broken or damaged beyond
repair.

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 Figure 92 lubricate and varnish

Common Misuses and Abuses

Do not use a wrench or bar in tightening clamps. Too much pressure may warp, bend, or break them. Tighten clamps by hand.
When applying great pressure, observe clamps for indication of undue strain.

Figure 93 Common Misuses and Abuses

Common Misuses and Abuses

Do not strike file against vise or other object to clean it. This practice ruins file teeth and may
break file. There is danger from flying particles if file breaks. Clean file with a file card and pin.

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 Figure 94 Common Misuses and Abuses

Never use a file without a handle. It is dangerous. Install handle before using file for any job, no
matter how small.

Figure 95 Using file with handle and with out

Remove remaining particles from teeth by using a narrow strip of soft metal such as brass or
copper. A soft metal will not damage teeth.

Figure 96 File Cleaning

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 Self-Check -7 Written Test

Instruction I: Give short answer for the following questions.

1. What are quality checks(2 points).
2. List different types of quality checks(5 points).
3. What are the factors affecting quality of services or products(5 points).

Instruction II filling the blank

1. _________: Removal of material from cutting face of a wheel so surface runs true.
2. __________: Restoring sharpness of a wheel face which is "loaded" or dulled
3. _____________ The attitude and policy of management towards product quality is
important Some managers tend to be more quality conscious than others

Instruction III Matching

A B
_______1 Modem methods and equipment have led to improvements in A Market
product quality level.
_______2 The knowledge and experience of people who design and produce B Cost
products exercise significant influence on quality level
_______3 Customer demand, his needs and purchasing power are the main C Technology
determinants of quality level. .
_______4 quality maintenance and improvement has increased significantly. D Labour
Increasing competition, growing mechanization and decreasing profit
margins may not permit greater expenditure on quality improvements

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Reference

CHEA (2001). Glossary of Key Terms in Quality Assurance and

Accreditation: http://www.chea.org/international/inter_glossary01.html.
4.

5. ENQA (2005). Standards and Guidelines for Quality Assurance in the European
Higher Education Area (ESG): Helsinki, ENQA, originally available
at http://www.enqa.eu/index.php/home/esg/, accessed 3 January 2017.
6.

7. Guo, Sheng; Yang, Tao; Gao, Wei; Zhang, Chen (2018). A Novel Fault Diagnosis
Method for Rotating Machinery Based on a Convolution Neural
Network". Sensors. 18 (5):
1429. doi:10.3390/s18051429. PMC 5982639. PMID 29734704.
8. Hoang, Duy-Tang; Kang, Hee-Jun (March 2018).Rolling element bearing fault
diagnosis using convolutional neural network and vibration image; Cognitive Systems
Research. 53: 42–50. doi:10.1016/j.cogsys.2018.03.002.
9.

10. http://www.businessdictionary.com/definition/activity.html

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N Name Qualific Field of Study Organization/ Institution Mobile E-mail
o ation number
(Level)
1 Meseret W/Mariam A(MSC) Manufacturing Wolkite polytechnic college 0912117416 [email protected]

2 Solomon Negtu A(MSC) Manufacturing Harer polytechnic college 0912762152 [email protected]

3 Kibru Getahun B(BSC) Manufacturing M.G.M.B. polytechnic college 0912370975 [email protected]
4 Efrem Kebede B(BSC) MAT Batu polytechnic college 0910410054 [email protected]
5
6
7
Participants of this Module (training material) preparation

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