467_AGE 204 LECTURE NOTES TOTAL new.ppt

SAFETY OF PERSONELS IN THE WORKSHOP IS
ESSENTIAL TO PREVENT ACCIDENTS FROM
OCCURING IN THE WORKSHOP.
MOST CASES OF ACCIDENTS THAT OCCUR
IN THE WORK ARE DUE TO THE INABILITY
OF THE PERSONEL AND VISITORS TO BE
SAFETY CONCIOUS.
HENCE IT IS PARAMOUNT FOR INDIVIDUAL
WORKERS TO TAKE PRECAUTIONS WHILE
WORKING IN THE WORKSHOP.

 THERE ARE SAFETY MEASURES THAT MUST
BE PUT IN PLACE BY EMLOYERS OF
LABOUR TO PREVENTS ACCIDENTS FROM
OCCURING IN THE WORKSHOP
 MANY ACCIDENTS CAN BE PREVENTED
FROM UCCURING IF THE WORKSHOP
OWNERS WILLPROVIDE SAFE WORKING
CONDITIONS AND AS WELL AS TRAIN ITS
PERSONNEL IN SAFE WORKING
TECHNIQUES.
 THE DUTY OF THE EMPLOYER IS TO
PROVIDE;

 PROTECTIVE CLOHTING AND ATTIRE
 WELL PLANNED WORSHOP LAYOUT WITH
ADEQUATE WORKING SPACE THAT IS NOT
CONGESTED WITH GOOD LIGHTNING
AND VENTILATION.
 PROPER MACHINE GUARDS FOR
REVOLVING PARTS
 FUNDS TO REPAIR AND MAINTAINANCE
OF ALL MACHINERY TO BE IN GOOD
WORKING CONDITION.
 SAFE TOOL STORAGE AREA

 FIRST AID AND FIRE FIGHTING
EQUIPEMENT
 TRAIN PERSONNEL ON:
THE CORRECT WAY TO
PROSECUTE A JOB
THE CORRECT USE OF TOOLS
AND MACHINES
THE CORRECT WAY TO CARE
AND MAINTAIN TOOLS

OTHER FACILITIES SUCH AS ADEQUATE
EMERGENCY EXITS ,PROVISION OF
EXTRACTOR FANS, HOODS, HIGH CEILING
DESIGN, EMERGENCY SHOWERS,
CONVENIENCIES SUCH AS LAVATORIES
AND FREE SPACE FOR PEOPLE TO MOVE
AROUND WITHOUT COMING TO CLOSE
MACHINES MUST BE PROVIDED TO MEET
THE MINIMUM REQUIREMENT FOR
WORKSHOP CERTIFICATION.

THE DUTY OF THE PERSONNEL IS TO MAKE
SURE THAT WHENEVER PERFORMING ANY
JOB IN THE WORKSHOP IT MUST BE DONE
WITH UTTERMOST CARE NOT HAVE ANY
INJURY OR ACCIDENT BY ADHERING TO
SAFETY GUIDES. HE OR SHE MUST KEEP THE
WORKSHOP TIDY AND ORGANIZED .
AVOID OVER CONFIDENCE ,
THOUGHTLESSNESS, FOOLISHNESS AND
BEING ABSENT MINDED.

 PERSONNEL MAKING USE OF THE
WORKSHOP MUST ADHERE TO FOLLOWING
GUIDES:
1. DO NOT WEAR LOOSE GARMENT
2. MUST WEAR TIGHT FITTING CLOTH
3. WEAR PROTECTIVE CLOTHING’S SUCH AS
EYE SHIELD, HELMET, NOSE PROTECTOR .
4. AVOID PLAYING IN THE WORKSHOP
5. ALWAYS WALK AND NOT TO RUN IN THE
WORKSHOP
6. REMOVE WRISTWATCHES OR ANY
JEWELRIES WHEN IN THE WORKSHOP

7. WEAR SHOES WITH STRONG TOECAP
AND HIGHSOLED
8. REMOVE TIE TO WHILE WORKING IN THE
WORKSHOP
9. AVOID SPILLAGE OF OIL ON THE FLOOR
OF THE WORKSHOP.
10. AVOID POURING OF WATER ON THE
FLOOR OR ANY MACHINERY IN THE
WORKSHOP.
11. NEVER OPERATE ANY MACHINERY YOU
DO NOT KNOW HOW TO USE.
12. DO NOT LEAN ON ANY MACHINERY

13. ALWAYS KNOW THE CONDITION OF ANY
MACHINE BEFORE OPERATING IT
14. NEVER MANAGE A FAULTYMACHINE
15. AVOID ANY ACTION THAT CAN LEAD TO
INJURY E.G. FORGETING THE JACOBS’
CHUCK KEY IN MACHINE CHUCK
16. CHECK TERMINALS AND CABLES OF
ELECTRICAL APPLIANCES FOR ANY
EXPOSED PARTS MUST BE INSULATED.

 MEASURING TOOLS OR GAUGES
THESE ARE TOOLS USED TO
MEASURE DIMENSIONS ON WORKPEICE .
i. ENGINEER’S STEEL RULE : THIS MADE OF STEEL ON ONE
OF THE FLAT FACE GRADUATIONS ARE MARKED IN
CENTIMETER AND INCHES. USED TO SET OUT
DIMENSIONS.
ii. FOLDING RULE IS OF 2 METERS LONG USED TO
MEASURE AND LAYOUT LARGER WORK.
iii. STEEL TAPE ARE OF LONGER LENGTH AND MADE OF
FLEXIBLE STEEL CAN BE ABOVE 2 METERS IN LENGTH.
iv. STEEL SQUARE IT IS L-SHAPED OF HARDENED STEEL

WITH GRADUATIONS MARKS ON THE EDGES FOR
MEASUREMENT AND TO SET OUT 900
ON WORK PIECE.
v.UNIVERSAL BEVEL MADE OF STEEL. USED TO MEASURE
OUT ANGLES ON JOB. OTHER TOOLS IN THIS CATEGORY
ARE THE COMBINATION SET, PROTRACTOR, ADJUSTABLE
BEVEL
vi.CALIPERS ARE NON-PRECISION LINEAR MEASURING
TOOLS FOR TRANSFERING OR COMPARING DIMENSION
FROM ONE OBJECT TO ANOTHER USING THE STEEL RULE
OR THE VERNIER CALIPERS.
a. OUTSIDE CALIPERS FOR CHECKING OR MEASURING
OUTSIDE DIMENSIONS OR PLATE THICKNESS.
b. INSIDE CALIPERS FOR CHECKING OR MEASURING
INTERNAL DIMENSIONS OF HOLE DIAMETERS.
c. HERMAPHRODITE OR ODD LEG CALIPERS USED TO SET
OUT PARALLEL LINES TO THE EDGE OF WORK AND FOR
LOCATING CENTRE POINTS OF CYLINDRICAL WORK.

d. OTHER CALIPERS ARE INSIDE AND OUTSIDE SPRING
CALIPERS AND INSIDE AND OUTSIDE TRANSFER CALIPERS.
vii. PRECISION MEASURING TOOL
a. MICROMETERS: THESE ARE PRECISION MEASURING
TOOLS ARE OF VARIOUS TYPES:
-OUTSIDE MICROMETERS
- INSIDE MICROMETERS
- SCREW THREAD MICROMETERS
-DEPTH GAUGE MICROMETERS
THE OUTSIDE MICROMETER CAN MEASURE DIMENSION
OF 2.54 MICROMETERS (0.0001 IN). THE ACCURACY OF A
MICROMETER IS BASED ON THE TURNING OF A FINE
SCREW THREAD KNOWN AS THE RATCHET. TO USE A
MICROMETER, THE OBJECT TO BE

MEASURED IS PLACED AT THE OPENING BETWEEN THE ANVIL
AND SPINDLE OF THE MICROMETER FRAME. WHILE THE
THIMBLE, IS ROTATED UNTIL THE OBJECT IS HELD IN
PLACE. THE READINGS IS TAKEN ON THE THIMBLE AND
BARREL SCALES TO DETERMINE THE PRECISE
MEASUREMENT.
b. VERNIER CALIPER USED TO MEASURE THE INSIDE AND
OUTSIDE DIAMETER OF SHAFTS, THICKNESS OF PARTS,
DEPTH OF HOLES AND SLOTS. IT IS USED FOR LONGER
DIMENSION WHERE YOU CANNOT USE A MICROMETER
SCREW GAUGE. THE ACCURACY FOR VERNIER CALIPER
IS 0.002mm.
c. OTHER GAUGES USED IN THE WORKSHOP ARE:
-DEPTH GAUGE
-TELESCOPIC GAUGE
- SCREW THREAD MICROMETER
- DEPTH GAUGE MICROMETER
- VERNIER HEIGHT GAUGE

- VERNIER DEPTH GAUGE
- VERNIER GEAR-TOOTH CALIPER
d. SPECILIASED MEASURING TOOLS (GAUGES)
GAUGES ARE FIXED-DIMENSION INSTRUMENT USED TO
CROSS CHECK PARTICULAR DIMENSION IN WORK PIECE
FOR SPECIFIED TOLERANCE. IT REQUIRES MINIMUM TIME
AND SKILL WHEN USED (GUPTA 1981). GAUGES DO NOT
HAVE GRADUATIONS AND CANNOT BE ADJUSTED THEY
ARE MADE TO CARRYOUT SPECIFIC MEASUREMENT FOR A
SOME PARTICULAR JOB WHICH IS TO BE PRODUCED IN
LARGE QUANTITIES.
GAUGES CAN BE CLASSIFIED :
-ACCORDING TO TYPES(E.G. STANDARD AND LIMIT
GAUGES) (GUPTA 1981)
- ACCORDING TO THEIR PURPOSE AND
- ACCORDING TO THE FORM OF THE TESTED SURFACE.
TYPES(E.G. SNAP , RING AND THREAD GAUGES) (GUPTA
1981)

i. THREAD GAUGE: ARE USED TO CHECK THE PITCH
DIAMETER OF SCREW THREADS.
ii. SNAP GAUGE: USE TO CHECK EXTERNAL DIMENSIONS.
iii. RING GAUGE: FOR CHECKING DIAMETERS OF SHAFTS OR
STUDS
iv. PLUG GAUGE: TO TEST ACCURACY OF HOLES
v. SLIP GAUGE: ALSO KNOWN AS PRECISION GAUGE
BLOCK. ARE USED TO CROSS CHECK THE ACCURACY OF
MEASURING INSTRUMENT SUCH AS MICROMETERS,
CALIPERS, SNAP GAUGES , DIAL INDICATORS ETC
vi. FEELER GAUGE TO CHECK AND SET CLEARANCE BETWEEN
TWO SURFACES. MADE OF MANY THIN STEEL SHEET
( LEAVES) . EACH LEAF IS MARKED WITH ITS THICKNESS
WHICH VARY FROM 0.05mm TO 1mm.
vii. SCREW PITCH GAUGE TO CHECK THE PITCH OF SREWS IT
IS SIMILAR TO A FEELER GAUGE EXCEPT THE LEAVES ARE
NOTCHED AT ONE EDGE ACCORDING TO THE VARIOUS
PITCHES OF SPECIFIC THREADS.

 MARKING OUT TOOLS
MARKING OUT TOOLS ARE TOOLS USED TO
MARK OUT LINES, ARCS ,CIRCLES AND
POINTS ON SURFACE OF SHEET METALS
OF AREAS TO WORK ON. UNDER THIS
CATEGORY OF TOOLS YOU HAVE THE
FOLLOWING:
a) SCRIBER MADE OF HARDENED STEEL. BOTH ENDS ARE
SHARP POINTED. ONE OF THE END IS BENT. USED TO
SCRATCH OUT LINES ON METAL SURFACE.
b) DIVIDER USE TO TRANSFER DIMENSIONS. TO DRAW
ARCS AND CIRCLES.

c) TRAMMEL POINTS USE FOR DRAWING LARGER ARCS
AND CIRCLES.
d) PUNCHES ARE MADE OF TOOL STEEL .PUNCHES ARE
OF TWO TYPES:
- PRICK PUNCH: THE END HAS
TAPER ANGLE OF 600
FOR MAKING SMALL
INDENTATIONS. ESTABLISHING POINTS
FOR THE DIVIDER AND TRAMMEL POINTS
-
CENTRE PUNCH THE END HAS
TAPER ANGLE OF 900
FOR MAKING BIG
INDENTATIONS FOR POINTS TO DRILL.

 CUTTING TOOLS
1. CHISEL COLD CHISLE ARE USED TO CUT AND SHEAR
METAL .THERE ARE DIFFERENT TYPES
-FLAT
-CAPE
- DIAMOND POINT
- ROUND
2. SNIPS: ARE SIMILAR TO A PAIR OF SCISSORS BUT ARE
HEAVIER AND USED TO CUT SHEET METALS OF LESS
THICKNESS

 PLIERS ARE USED FOR GRIPPING OR
HOLDING SHEET METALS ARE OF VARIOUS
TYPES WHICH ARE:
1. FLAT NOSE PLIER
2. ROUND NOSE PLIER
3. SLIP JOINT PLIER
 HACKSAW FOR CUTTING METALS
 FILES ARE USED FOR REMOVING SMALL
AMOUNT OF MATERIAL FROM METALS .

 ENGINEERING MATERIALS:
 a. Pig Iron: - It is a product of the blast furnace. It is the
basis of all ferrous metals, and is used for the manufacture of
cast iron, carbon steel and alloy steels. It is never used as a
structural material. It is weak and brittle, easily broken with a
sudden blow; this is due to the pressure of weekly 4% carbon,
absorbed from the cake used during the smelting process.
 Wrough Iron: - It is a pure iron left after the removal of carbon.
Its ferrite content is about 99.95%, the remaining 0.05% consisting
of slag inclusions picked up during the smelting process carried
out in a puddling furnace. It is a soft yet tough metal, easily
bent or twisted while cold, yet king excellent resistance to
corrosion is very good owing to the formation of film / scale of
iron oxide which tends to prevent further oxidation / scaling.

 c. Grey Cast Iron: -Reheating of pig iron refines it to produce this
iron provided the resulting liquid, cast iron, is allowed to cool slowly. It
contains 3½% carbon, and the pressure at this carbon gives great
fluidity to the molten cast iron, allowing it to be poured into sand
moulds to produce castings. N/B wrough iron does not contain carbon,
and even when heated it does not become liquid and cannot be
poured into a mould. Because of the carbon presence as graphite this
iron cannot stand up to sudden blows. Although this graphite promotes
a very good low-friction bearing surface.
 White Cast Iron: - If liquid cast iron is rapidly cooled or chilled it resulted
to a very hard cast iron which could not be machined using ordinary
tools; (cannot be filed or turned on a lathe). Engineers has little use for
this iron except when certain parts of a casting are required to be
dead hard.
 Carbon Steel: - Carbon steels are made in steelmaking furnaces, where
very careful control over the carbon percentage is maintained.
Rounded the carbon does not exceed 1 1½% it combines chemically
with ferrite, producing a very strong structure. The percentage of
Carbon determines the type of carbon steel.

 Alloy Steel: - These are used when carbon steels
are unsuitable for the kind of conditions to which
the component will be subjected. For example, if
a very strong steel is required, a nicked-chrome
steel is much stronger than a plain carbon steel; if
the component is required to resist corrosion, or
in other words to be ‘stainless’, an alloy steel is
used. They are also very suitable for making the
wide range of cutting tools required to machine
metals at high speed. The addition of metals
such as Chromium, nickel, cobalt molybdenum
and vanadium increases a plain carbon steel
into an alloy steel.

 Non-Ferrous Metals: -They are much weaker than ferrous metals.
However, they have a great advantage over most ferrous metals,
such as their resistance to corrosion, from figure 2 non-ferrous metals
divided into 2 groups.
 Pure metals – single metal
 Non-ferrous alloys – 2 or more metals e.g. nickel- chrome, brass
(copper & zinc)
 Pure Non-Ferrous Metals
 (i) Copper – attractive red colour, soft and excellent conductor of
heat and electricity
 (ii) Tin – Silvery in colour, soft, excellent resistance to corrosion,
most expensive metal, seldom used in its pure state except as a
protective coating for mild-steel sheet. So-called ‘tin’ cans are
made from this sheet, known as tinplate, which has a very thin layer
of tin on the surface.
 (iii) Lead – Silvery also in co lour, good resister of corrosion,
easily cold worked (easily bent, twisted or hammered into shape
with little risk of fracture or cracking.
 (iv) Zinc - Also silvery, easily bent and hammered into shape. Its
excellent resistance to corrosion makes it suitable for covering mild-
steel sheet, producing the easily recognized corrugated sheets.

467_AGE 204 LECTURE NOTES TOTAL new.ppt

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