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EMG 2103
WORKSHOP PROCESSES AND
PRACTICE I

COURSE OUTLINE
Work safety: rules Bench and marking out tools; use of marking
out table and instruments
such as scribers, calipers, height gauge.
Theory and use of vernier. Internal and external micrometers
and accuracy.
Measurement and inspection: use of dial, slip, limit, small hole
and telescope gauges. Use of
limit systems. Bore gauges for large holed degree of accuracy.
Checking and setting measuring equipment.
Test for acceptance or rejection of new or worn parts.
Measuring exercise including those
involving concentricity and run-out.
Bench tools: files, hacksaws, chisels, scrapers and hammers.
Metal jointing: Soft soldering and brazing, riveting, hand screw
cutting.

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Workshop Safety - Employer

1. Plant must be safe and in good working
order.
2. Storage must be safe – Equipment and
materials must be stored safely.
3. Entry and exit must be kept safe and clear.
4. Staff must be trained in safety.
5. Provide facilities such as well equipped
bathrooms.

Workshop Safety - Employee

1. Employees must take reasonable care of
themselves and others.
2. Do not interfere with equipment provided for
safety purposes like fire extinguishers.

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Workshop Safety – Health

1. Avoid inhaling harmful dust and fumes.
2. Treat injuries, no matter how small.
3. Protect yourself form excessive noise.
4. Use eye protection where required - e.g.
when welding, brazing, metal cutting etc.

Workshop Safety - Good House

Keeping
1. Always walk in the workshop, never run.
2. Don’t throw rubbish on the floor.
3. Keep gangways and work areas free of obstacles
such as metal bars and components.
4. Keep to gangways when walking around, no
shortcuts.
5. Wipe oil, water or grease spills immediately.
6. Wear safety shoes with anti-slip sole and steel toe
cap.

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Workshop Safety - Good House

Keeping
7. Listen carefully to instructions from
technicians or lecturer in charge. Ask
questions if you do not understand.
8. Bags should not be brought into the
workshop as people might trip over them.
9. Always return tools to safe storage and clean
your work bench/machine after use.

Workshop Safety - Ladders

1. Always use secured ladder when working at
heights.
2. Check ladders for damage before use.
3. Position ladder on a firm base at the correct
angle – height at top support should be
about 4 times the distance at the base.
4. Ladder must be long enough – at least one
metre above the highest rung to be used.

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Workshop Safety - Ladders

5. Ladders should be properly secured to avoid
sideways movement at the top and outwards
movement at the bottom.
6. Don’t over reach from a ladder.
7. Give enough warning to avoid people or
vehicles hitting the ladder at the bottom.

Workshop Safety – Hand Tools

1. Examine hand tools regularly – do not use
defective tools.
2. Handles must be securely fitted to files,
scrapers, screw drivers and hammers and
must not be split.
3. Avoid use of hammers with chipped heads –
a piece might fly off and cause injury to
hands or eyes.
4. Use correct size of spanner to avoid slipping.

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Workshop Safety – Hand Tools

5. Avoid use of chisels with mushroomed heads
– a piece might fly off and cause injury.
7. Avoid carrying loose tools in your pocket as
you might slip and fall on them.
8. Keep both hands behind the cutting edge
when using tools such as chisels.
9. Carry tools by your side with the tool facing
the floor.

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Workshop Safety – Hand Tools

10. Vice handles should be left in a loose
position, facing downwards to avoid someone
bumping into them.
11. Do not secure long work pieces in a vice or
leave tools lying close to the edge of your
work bench.

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Workshop Safety – Manual Handling

1. Lift with back straight (not necessarily
vertical) and knees bent. Straighten knees to
lift.
2. Get help with heavy objects.
3. Before lifting, check for sharp edges and
burrs, splinters, projecting nails and sharp
wire – use safety if necessary.
4. Check that your path is clear, that you can
see over and/or around the object and that
the place where you intend to place the
object is clear.

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Extra Reading – Correct Procedure

For Lifting
1. Stand close to the object with your feet
slightly apart, facing the direction in which
you intend to move.
2. Bend the knees keeping the back straight,
not necessarily vertical.
3. Position your elbows close to your body so
that the body takes the weight instead of the
fingers, wrist arm or shoulder muscles.

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Extra Reading – Correct Procedure

For Lifting
4. Grip using the palm and the roots of the
fingers – not the finger tips. Using finger tips
increases the risk of dropping the object.
5. Straighten the knees allowing the thigh
muscles to do the work and not the back.
Reverse procedure when setting down object.

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Workshop Safety: Machinery

1. Ensure you know how to stop the machine
before starting it.
2. Keep your attention on the machine when it
is running.
3. Do not distract or startle other machine
operators.
4. Never leave your machine unattended when
it is running.

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Workshop Safety: Machinery

5. Ensure that you know where all the emergency
stop buttons are for each machine and also
ensure that you know where the main
emergency power off button for the whole
workshop is. Thus if somebody is having an
accident in the opposite corner of the workshop
from where you are, you can turn the main
power off.
6. Listen carefully to instructions from technicians
or lecturer in charge. Ask questions if you do not
understand.
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Workshop Safety: Machinery

7. Don’t use a machine if you have not been
shown how to safely operate it by the
technician in charge or the lecturer.
8. Always use machine guards if provided when
operating a machine.
9. Keep hands away from moving or rotating
machines.
10. Report any damage to machines as
operating them in their damaged state might
cause an accident.

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Workshop Safety: Machinery

11. Long hair should be tied back to avoid
entanglement in moving parts.
12. Only one student at a time should use a
machine at any given time. Other students
must stand at least 2 metres away.
13. Work must be safely secured on a vice or
clamp before drilling.

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Workshop Safety - Fire

1. Know how to act in case if fire. Know also the
position of fire alarms, fire fighting equipment
and emergency exits.
2. Know the type of extinguisher to use for a fire
and how to use it.
3. Do not block fire exits.
4. Fire fighting appliances should not be used for
any other purposes other than that intended.
5. Always put out matches and cigarettes before
throwing them away.

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Workshop Safety - Fire

6. Avoid spillage of flammable liquid such as
diesel.
7. Use flammable liquids only when non-
flammable ones cannot work.
8. Do not smoke in non-smoking areas.
9. Report defective electrical equipment.

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Workshop Safety – Fire – Fire Types

1. Classify fires according to fire type, causes of
the fire and method of extinguishing.
2. Standard used to classify the fire type. i.e.
American, European or Asian standards.

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Marking Out Tools – Marking Out

Table
This is a solid flat surface machined with a high
degree of accuracy. It is used as a basis for
marking out work pieces. It is mounted on
four legs to form a table like structure.
A surface plate is a smaller flat surface usually
placed on the bench and used for marking
out.

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Marking Out Tools – Marking out

table

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Marking Out Tools – Surface plate

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Marking Out Tools – Angle Block

This is an L-shaped block of metal with outer
faces that meet at 90 degrees. These faces
are machined with a high degree of accuracy.
The block faces have slots machined into
them to enable clamping of work. The angle
block is commonly used in conjunction with a
marking out table.

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Marking Out Tools – Angle Plate

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Marking Out Tools – Vernier Height

Gauge
A tool used together with the marking out table
to mark perpendicular distances from the
table surface.

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Marking Out Tools – Vernier Height Gauge

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Marking Out Tools – Others

1. Engineers square - Used for setting the work square to a
reference surface or when scribing a line square to a datum
edge. It consists of a stock and blade and is available in a
variety of blade lengths.
2. Scriber – Used to scribe or mark lines on a metal surface. It is
made from hardened and tempered steel ground to a fine
point.
3. Dividers – Used to scribe circles or arcs and to mark off a
series of equal lengths such as hole centres.
4. Odd leg calipers – Used to scribe lines parallel to the edge of a
workpiece.
5. Dot punch – Used to provide a centre location for dividers or
show permanently the position of a scribed line by a row of
centre dots. Its point is ground to an angle of 60 degrees. A
centre punch is similar to a dot punch and is used after a dot
punch to create an indentation to guide a small drill bit.
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Marking Out Tools – Engineer’s

square

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Marking Out Tools – Scriber

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Marking Out Tools – Dividers

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Marking Out Tools – Odd leg calipers

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Marking Out Tools – Centre punch

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Inside, outside Calipers

• Inside Caliper - Used to measure internal size of an
object. After the measurement is obtained, the
caliper is transferred to a remote measuring tool
such as a vernier caliper or steel rule.
• Outside Caliper – Used to measure external
dimensions. It is used in a similar manner as the
inside caliper. i.e the measurement must be
transferred to a remote measuring instrument.

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Inside, outside Calipers

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Measuring Equipment – Vernier

Calipers

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Measuring Equipment – Vernier Depth

Gauge
Clamping screw
Main scale

Vernier scale

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Measuring Equipment – Vernier Caliper

Vernier instruments consist of two scales, one moving
and one fixed. The fixed scale is graduated in mm. For a
0.02mm accuracy instrument, the moving/Vernier scale
is divided into 50 equal parts/divisions which occupy
the same length as 49 divisions or 49mm on the
fixed/main scale. Thus each graduation on the Vernier
scale = 49/50 = 0.98mm or 0.02mm less than each
division on the fixed scale.
If the two scales initially have their zeros in line and the
Vernier scale is then moved so that its first graduation
lines up with a graduation on the fixed scale, the
Vernier zero will have moved 0.02mm. In the same way,
if the 2nd graduation on the Vernier lines up with a
graduation on the main scale , the Vernier zero will
have moved 0.04mm and so on.
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Measuring Equipment – Vernier Caliper

If graduation 50 on the Vernier is lined up, the Vernier
zero will have moved 50x0.02 = 1mm.
To take a reading:
1. Note how many mm the Vernier zero is from the
zero of the fixed scale.
2. Note the number of divisions on the Vernier scale
from zero to a line which coincides exactly with a
line on the fixed scale.
3. Multiply the number in (ii) above by 0.02mm and
add to the number in (i).

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Measuring Equipment – Vernier Caliper

If graduation 50 on the Vernier is lined up, the Vernier
zero will have moved 50x0.02 = 1mm.
To take a reading:
1. Note how many mm the Vernier zero is from the
zero of the fixed scale.
2. Note the number of divisions on the Vernier scale
from zero to a line which coincides exactly with a
line on the fixed scale.
3. Multiply the number in (ii) above by 0.02mm and
add to the number in (i).

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Measuring Equipment – Vernier Caliper

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Measuring Equipment – Vernier Caliper

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Measuring Equipment – Micrometer

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Measuring Equipment – Micrometer

The micrometer relies on the accuracy of the spindle
thread for its measuring accuracy. For a 0.01mm
accuracy instrument, the spindle thread has a pitch of
0.5mm, i.e. for one revolution, the spindle and the
thimble attached to it moves a longitudinal distance of
0.5mm. For this instrument, the edge of the thimble is
graduated into 50 equal divisions. Thus for one
division on the thimble, the spindle advances 0.5/50 =
0.01mm.
To take a reading, note the number of whole divisions
uncovered by the thimble and add to the hundredths
of a mm indicated by the line on the thimble
coinciding with the longitudinal line on the sleeve.
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Measuring Equipment – Micrometer

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Measuring Equipment – Micrometer

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