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The course starts with performing engineering measurements, how to use different tools and gauges to take the liner and angular
measurements, Describe the main parts of a micrometre, how to use micrometre correctly and safely, read the micrometre, how
to make a calibration to the micrometre and how to take care of micrometre. Students will use the combination square and
protector for angles measurements Then the student will learn how to use hand tools such as taps and dies to cut manually internal
and external thread safely and correctly, and how to find the thread parameters. In riveting operations, the student will learn how
to use rivet gun correctly and how to recognize and identify rivet types, and how to remove blind rivets by different methods. In
power tools, the topic student will learn how to use power tools effectively to achieve the required outcomes of finish, size or shape.
Select appropriate power tools to suit the task requirements. Differentiate between drill machine types (hand drill, electrical
hand drill, bench and pillar drill) in term of their speed, feed and axis, Use the correct grinding wheels for the job and recognize
their safety, how to re-sharpen twist drills within the standard.
Assessment Guidelines:
A micrometre is a precision measuring instrument, used to obtain very fine measurements and available in metric and imperial
versions.
1.1-Describe the main parts of Micromere.
https://www.youtube.com/watch?v=rVjCmOrneGw
The scale on the sleeve of the micrometre is the instrument's primary measuring
scale. Together with the thimble scale, the main scale displays the measurement
taken.
The first significant figure of measurement is taken from this scale. This part of the measurement is the first value immediately to the
left of the thimble.
The secondary measuring scale, the thimble scale, provides the two remaining significant figures of a measurement.
This part of the measurement is the value on the scale that aligns with the index line on the sleeve scale.
The index line, which runs along the sleeve of the micrometre, is used to indicate the value shown on the thimble scale.
When the thimble is turned, the spindle rotates and alters the distance between the measuring faces of the micrometre.
Some micrometre thimbles incorporate a friction drive. This allows for a more accurate reading, particularly when used by the
inexperienced user.
The ratchet increases the speed at which the spindle rotates, so the space between the anvil and the spindle is reduced more quickly
than it would be if the thimble were used.
Using the ratchet reduces the time it takes to use the micrometre.
The ratchet incorporates a slipping clutch mechanism that prevents over-tightening and aids the user to apply a constant measuring
force to the spindle, helping to ensure reliable measurements.
The locking device secures the spindle and preserves the measurement so that the micrometre can be removed from the workpiece before
taking the reading.
Some micrometres have a lock nut (as shown), whilst others may have a locking lever (see image below).
8-Micrometre frame:
The U-shaped frame is designed to be rigid and stable. It supports the anvil and the sleeve of the micrometre.
The spindle lock prevents the measurement from slipping when removing the micrometre from the workpiece.
Always use the ratchet; it must never be screwed tightly by using the thimble to take a measurement!
Measurements provided by a micrometre are made up of a combination of values taken from the main scale, the thimble scale and,
on some micrometres, the Vernier scale. The sleeve scale of a metric micrometre has a measuring range of 25mm. It is graduated in
millimetres and half millimetres. The scale is numbered every 5mm.
The thimble scale has a measuring range of 0.5mm (the smallest value that can be measured on the sleeve scale). It is divided into 50
increments; with each increment representing 0.01mm (0.5 ÷ 50 = 0.01).The scale is numbered every 0.05mm.
1 Outside (External) micrometre: The outside micrometre is the most commonly used type of micrometre. It is used to measure
external dimensions such as the outside diameter of an object.
3 Depth Micrometer: Depth micrometres are used to measure the depths of holes, slots and steps. They come with a variety of
interchangeable rods of different lengths so that they can be used to measure a range of depths.
1. Look at the frame, for signs of damage, such as indications that it was dropped on the floor.
2. Observe both spindle and anvil faces. They must be flat, free of pinholes and clean. Frosted surfaces may indicate wear.
3. If the micrometre needs repairs, they must be done first. Calibration may proceed only when the gage is in good working order. Move
the micrometre from 0 to 25 millimetres or the entire range and check if the spindle feels continuously smooth throughout the range. In
short, check if it is good enough for its intended use. A hard to turn spindle is a sign of age or damage. Do not force it to rotate and have
someone look into the cause of the malfunction.
4. The micrometre should turn smoothly and freely throughout the entire range, and it should not bind or freeze during the check.
5. Set master block into four height ranges, .watch the video
Storage of micrometres:
Note the following points when storing a micrometre.
• When storing the micrometre do not expose it to direct sunlight.
• Store the micrometre in low humidity, well ventilated and dust free environment.
• Leave the measuring faces separated by 0.1 mm to 1 mm.
• Do not clamp the spindle
• Store the micrometre in a case.
NOTE: Because they are graduated only in degrees, protractors should not be used for
the accurate measurement of angles.
Applications of Protractor:
Testing angles marking out angle on the work setting work to an angle marking out the position of holes
Thread gauge:
A thread pitch gauge, also known as a screw pitch gauge or pitch gauge, is used to measure the pitch or lead of a screw thread.
Thread pitch gauges are used as a reference tool in determining the pitch of a thread that is on a screw or in a tapped hole. This tool
is not used as a precision measuring instrument. This device allows the user to determine the profile of the given thread and
quickly categorize the thread by shape and pitch. This device also saves time, in that it removes the need for the user to measure
and calculate the thread pitch of the threaded item
A screw is a cylindrical bar on which a thread has been cut. A thread is a continuous spiral groove. The shape of the thread depends
on:
1. It's use
Most screws have what is called a ‘right - hand thread’. This is where the spiral groove (thread) has been cut into the bar in a
clockwise direction. The nut, when used with a screw, must have the same type of thread.
Coarse pitch threads have only a few threads per unit length. They are used in general engineering and on specialized equipment.
Fine pitch threads have many threads per unit length. They are used because they resist loosening by vibration and they are
stronger.
Care must be taken when selecting screws and nuts because the threads of one system will not fit the threads of a different system.
1. ISO METRIC the thread size is in millimetres. This system is used on all new engineering products.
2. UNIFIED NATIONAL FINE and UNIFIED NATIONAL COURSE. (UNF & UNC). This is an American thread system. It has the same
type of thread form as the ISO METRIC system but the size is in inches.
3. BRITISH STANDARD PIPE. (BSP). This is a British Standard thread. The size refers to the bore diameter of the pipe. This thread
system is used for pipe fitting; it can have a parallel or tapered thread.
Thread gauge
Determine the Threads: Tapping is when your threads are cut into a hole. A die set is used to cut threads onto a cylinder (bolt). To
use a tap or a die, first determine the threads: https://www.youtube.com/watch?v=Gdvtw0pTAOs
1-Per inch: (TPI) teeth per inch, of the part to be fixed. A gauging system that has a number of different pins can be used to
calculate the TPI of a bolt or nut. After determining the TPI of a bolt, choose the die that corresponds to it. A tapered die will tell
which side to begin using. The die fits into a special wrench that holds and guides the
die
2-Metric: By using a micrometre or calliper, determine the major diameter; use the
metric thread gauge to measure the thread pitch.
The tap wrench: The tap wrench is fitted to the top of the tap to provide a secure method of holding and turning the tap.
1. Drill the hole to the correct size. This is the minor diameter of the thread that you want to tap. The information can be obtained
from THREAD DATA TABLES.
Tapping is the process of cutting an internal thread. Hand taps are used in sets of three:
1. TAPER TAP is used to start the thread. The first 8 - 10 threads are tapered off so that they gradually cut to the full size of the
thread.
2. The SECOND TAP is used to complete a thread in a hole that passes completely through the material. The first 4 - 5 threads
are tapered.
3. PLUG TAP is used to finish tapping blind holes (holes that only go part way through the material).
This is the process of cutting external threads onto the round bar. There are two types of die.
1. A DIE NUT is only used to repair damaged threads. Never use it to cut a new thread.
2. A BUTTON DIE fits into the die stock. Adjust it to the fully open position for the first cut and then gradually close it until you get
the finished sized thread.
4. Use lubricant.
Care of dies:
3.7 Recognize and follow the safety Precautions while working with taps and dies:
1-Before using either tap or dies, test the material to determine that it is not hardened by attempting to mark it with a file:
• If the material marks with a file, the material should be cut-able.
• If the material will not mark with a file, do not cut threads to avoid tool damage.
2- Inspect before every use; do not use if parts are loose or damaged. Do not use cracked or chipped tap/die.
3- Keep the handles clean, dry, and free from oil and grease at all times.
4- The flutes on these tools are sharp and can cut you. Handle with care.
5- Do not apply excessive force on the cutters. Allow the tool to do the work. Use cutting oil when tapping or threading hard
materials.
6- Taps and Dies are heat-treated, and not designed to be sharpened.
4-Understand the reviting process and use them to join parts together
Rivets are identified by the shape of the head and the length and diameter of the shank.
One types of the hollow rivet are the pop or blind rivet
Forming a solid rivet head is done using special tools called Snaps and Dollies
The hole size must allow Clearance around the rivet shank to allow the head to form correctly
1-The hole is too large in diameter; the rivet shank will bend inside the hole.
3-The rivet shank is too long, the rivet will bend outside the hole and form a weak head.
4.8- Use the Pop Rivet Tools correctly and safely to perform riveting operations
Hand tools: https://www.youtube.com/watch?v=gcA5F5vvWHE
There are a number of different hand riveters on the market, all designed to suit the users’ budget and usage requirements.
• The basic riveters all come with a variety of nibs to accommodate different stem thicknesses.
• Riveters (rivet gun) can also have longer handles, which provide extra leverage,
• And there are even hands riveters designed to fit into difficult to get to and confined spaces
3- Ensure your body position allows you to have control of the tool at all times.
4- Clamp the two pieces together and drill a hole into the workpiece slightly larger than the rivet.
5- Place the rivet into the end of the gun and place the gun over the hole. Squeeze the handles of the gun together. Control the
rivet gun with your hand. Do not push hard on the gun while riveting. The pop rivet pinhead is pulled into the rivet and the
end of the rivet is expanded. The pin will break off and leave the rivet permanently fixed into position.
4.10- Remove blind rivets correctly and safely with drill and Chisel:
https://www.youtube.com/watch?v=g7o0IxhfwyI
If circumstances arise that requires a blind rivet to be removed, it is recommended that the following steps are undertaken
carefully or damage to the clamped material may result.
1 Remove Rivets with a Drill:
1. Ensure the stem is well below the rivet head; drive it below the head with a punch.
2. Select a drill bit with the same diameter as the recommended hole size for the rivet, and drill through the head until enough
material is removed to separate the head from the shell.
3. Punch the remainder of the shell clear of the clamped material.
1-Shear off the head of the rivet by placing chisel flushes with the metal just under the lip of the rivet head. Use a hammer to tap
the end of the chisel until the head of the rivet is removed.
2- Use a punch to tap out the pin of the rivet.
Pistol Grip. A pistol grip drill is the most common type of corded drill available. ...
Hammer Drill. A hammer drill also called a masonry drill, is used most commonly with concrete or brick. ...
Drill Press. A drill press is a fixed style of drill that can be used on a workbench. ...
Cordless Drills
The machine vice: works in exactly the same way as a bench vice and is bolted to the machine table.
Machine vice
Twist drill bits: Drill can be defined as a rotary end-cutting tool having one or more cutting lips and having one or more helical or
straight flutes for the passage of chips and the admission of a cutting fluid
Drill bits are used for machining holes and for general use. They are usually made from high-speed steel (H.S.S.). They are identified
by their diameter and the material from which they are made.
1. Parallel shank.
2. Tapered shape
Parallel shank drills are used in hand-held drills, drilling machines and machine tools (lathes, milling machines).
Morse taper shank drills are supplied in diameters ranging from 3 mm diameter to100 mm diameter.
Morse tapers are self - holding tapers.
The tang on the end of the drill shank is for removal purposes only.
To remove a drill with Morse taper shank from the machine spindle, a drill drift is used.
The drift is made from mild steel to ensure there is no damage to the drill or machine spindle.
The sizes of a bit are based on the bit's diameter and are available in both metric and fractional units. Metric drill bits are typically used
in countries that use the metric system, while fractional-sized bits are used in the US and other countries that do not typically use the
metric system
Clearance angle
The clearance angle should be kept between 12˚ - 15˚. If no clearance is provided, the drill will not cut.
Helix angle
The helix angle is produced by the spiral of the flute. This angle produces the rake angle and cannot be changed. Drills can have
various helix angles for drilling different materials.
It is very important that the point or lip angle is equal on the two cutting edges. It is also important that the lengths of the cutting edges
are equal to prevent oversize holes being drilled.
https://www.youtube.com/watch?v=KbI_7IHAsyw
Drilling is a cutting process that uses a drill bit to cut or enlarge a hole of circular cross-section in solid materials. The drill
bit is a rotary cutting tool, often multipoint. The bit is pressed against the workpiece and rotated at rates from hundreds to
thousands of revolutions per minute.
Center drills
Countersinking: Countersinking is similar to counterboring except that the step is angular to allow flat-head screws to be
seated below the surface.
Drilling holes to depth: Holes can be drilled to a particular depth by setting the depth stop on the machine
Wheel speed:
The speed of the wheel is related to its diameter. Check the information on the wheel’s paper washer for its maximum speed in
Rev/min. Do not use a wheel on a grinding machine whose speed exceeds the rev/min written on the wheel’s paper washer.
https://www.youtube.com/watch?v=BkyLua8t10M
A wheel which has become either loaded or glazed will not cut metal. To return the wheel to a good condition it must be dressed
using a Huntington dresser (wheel dresser).
To dress the wheel, support the dresser on the tool rest so that the point of contact is slightly above the centre, and with the handle
tilted upward at an angle
https://www.youtube.com/watch?v=72syhJoOsHM
Twist drills become dull and must be re-sharpened. The preferred method of re-sharpening a twist drill is with the tool grinding
machine, but this machine is not always available in field and maintenance units, so the offhand method of drill re-sharpening must
be used.
The offhand method requires that the operator have knowledge of the drilling geometry and how to change drill angles as needed for
any drilling job
workshop tools to cut the workpiece as in the drawing below. Students can
Tools box