UNIVERSITY OF GONDAR

INSTITUTE OF TECHNOLOGY
DEPARTMENTS OF MECHANICAL

BASIC WORKSHOP PRACTICE

Cr. 2 (1-lect and 3-lab)
 Workshop
• It is a place of work for preparing variety of products by
using different kinds of Instruments, hand tools and
Machines.
• In order to prepare the products in workshops, the
workshops is divided in to many branches according to
nature of work.
 Bench work and Fitting shop
 Welding shop
 Sheet metal shop
 Machine Shop
 Foundry shop etc.
 Introduction to Safety Precaution and
Hazards
• Safety is the primary requirement that a student
should learn before starts working in a workshop.
• Rules and regulations, posters and lectures about
safety measures are very important, but they will
never replace intelligent precautions taken by the
student in doing work.
• A good and safe worker is the one, who is safety-
conscious and always adopt safe and accepted
procedures.
 Introduction to Safety ……
Causes of Accidents
1) Faulty attitude towards safety
2) Failure to recognize a danger in the act being performed
3) Emotions which take the mind from the work such as worry, fear,
anger, uncertainty
-It is very important to follow the safety rules that can avoid
accidents on oneself and on others
-Safety must be taken as a way of living
-Safety in the workshop means
1) Learning how to handle tools, machines and materials with care
2) Learning how to follow instructions and never taking chances
 General Safety measures
• Dress properly, wear good strong shoes
• Remove rings, wrist watches, necklaces and bracelets
• Always be patient, never rush in the workshop.
• Protect your eyes
• No horseplay (Noisy playful activity)
• No scrap materials on floor
- Place all scrap materials in container
- Keep floors free of oil, grease or any other liquid
- Aisles ( a passage ) should be clear at all times
- Store materials in the proper place
- Get help for handling long or heavy materials
 CONT’D
• Do not use any tools, machines ,materials until
you have been thought how to use them
• Use the right tool for the right work
• Learn by watching, listening to your instructor
• Learn by asking not by making dangerous
mistakes
 Tools and simple machines
1) Measuring Tools (Linear and Angular)
It is a process of finding the dimensions of the work

piece by using the following instruments.

-Steel rule
-Tap-rule
-Protractor
-Vernier calipers
-Micrometers, etc
2) Checking Tools
-Try squares
-Thread gauges
-Calipers
-Feeler gauges- used to measure gap widths
-Sprit levels- indicate whether the surface is horizontal/vertical
3) Layout/Marking Tools
-Scribers-used to mark lines on work pieces
-Divider-The circles and arcs on a flat surface are marked
-Punch-is used to mark the center of hole before drilling
4) Cutting tools
-Hack saw-used for cutting of rods, bars, pipes, flats etc.
-File-It is used to remove the material by rubbing it on the
metals
-Chisel-Chisels are used to cut metals, either in hot or cold
state.

5) Assembly tools
-Clamps
-Screw drivers
-Wrenches
 Measuring instruments
Vernier Caliper-
The Vernier caliper instruments generally used
in workshop to determine the length/thickness , internal
and external diameter and depth of a components.
Vernier calipers are made to measure at different range of
accuracy. The most common are :-
- 1/10th of a mm (0.1mm)
- 1/20th of a mm (0.05mm)
- 1/50th of a mm (0.02mm)
Vernier Caliper with 0.1 mm accuracy
 This caliper has 10 graduation (divisions) on the
sliding scale or vernier scale.
 These 10 divisions occupy the same space as 9
divisions on the main scale. Therefore
1 vernier division = 9/10= 0.9 mm
 The difference between 1 main scale division &
1vernier scale division is:
1- 0.9 = 0.1 mm
 To get the Total reading, the vernier scale which
coincide with the main scale is multiplied by this
number, i.e 0.1mm & add with the main scale reading
.
Read the “0” position of the
vernier scale on the main
scale to get a rough reading.
Rough reading = 36 mm
Look along the vernier
3 4
scale until one of the
vernier division coincides
0 5 10
with the main scale
Accurate reading = 36.7mm Over lap
Vernier Caliper with 0.05 mm accuracy
 This caliper has 20 graduation (divisions) on the
sliding scale or vernier scale.
 These 20 divisions occupy the same space as 19
divisions on the main scale. Therefore
1 vernier division = 19/20= 0.95 mm
 The difference between 1 main scale division &
1vernier scale division is:
1- 0.95 = 0.05
 To get the total reading, the vernier scale which
mm
coincide with the main scale is multiplied by this
number, i.e 0.05mm & add with the main scale
reading .
• EXAMPLE 1
 A shaft diameter is measured with a 0.05 mm
accuracy vernier caliper. The measurement
shows that the main scale reading is 33 mm &
the two scales coincide on the 17th division of the
vernier scale. Calculate the total reading.
Solution
main scale reading= 33 mm
vernier scale = ( 17 x 0.05)= 0.85mm
Total reading= 33.85 mm
Vernier Caliper with 0.02 mm accuracy
 This caliper has 50 graduation (divisions) on the
sliding scale or vernier scale.
 These 50 divisions occupy the same space as 49
divisions on the main scale. Therefore
1 vernier division = 49/50= 0.98 mm
 The difference between 1 main scale division &
1vernier scale division is:
1- 0.98 = 0.02
 To get the total reading, the vernier scale which
mm
coincide with the main scale is multiplied by this
number, i.e 0.02mm & add with the main scale
reading .
• EXAMPLE 2
 Bore diameter of a cylinder is measured with a
0.02 mm accuracy vernier caliper. The
measurement shows that the main scale reading is
64 mm & the two scales coincide on the 46th
division of the vernier scale. Calculate the total
reading.
Solution
main scale reading= 64 mm
vernier scale = (46 x 0.02)= 0.92mm
Total reading= 64.92 mm
1)

17
Answer: 3.090 cm
2)

18
Answer: 0.810 cm
3)

19
Answer: 12.17 cm
 Micrometer
 A micrometer allows a measurement of the size of
a body. It is one of the most accurate mechanical
devices in common use.
 The spindle is rotated in a fixed nut by means of
the thimble, which opens and closes the distance
between the ends of the spindle and anvil.
 Reading of a Micrometer
 The sleeve of a micrometer is graduated in to mm & in
to half mm above or below the indexing line.
 The thimble of a micrometer has 50 divisions on its
circumference.
 The spindle which passes through the sleeve is fitted to
the thimble by a screw thread whose pitch is 0.5 mm.
 When the thimble is rotating, it drives the spindle
longitudinally.
 The spindle of a micrometer has an external thread
whose pitch is 0.5 mm.
 Cont…
 1 complete revolution of the thimble, i.e. passing
through the 50 divisions, moves the spindle a
distance of 0.5 mm which is equal to the spindle
thread pitch.
 Therefore, since the thimble has 50 divisions around
its circumference, rotating 1 division moves the
spindle a distance of 0.01mm (0.5/50= 0.01 mm)
Reading a Micrometer
• Example
 A connecting rod of a piston is measured with a
micrometer. The reading shows that the main
scale reading on the sleeve shows 38mm & the
38th division of the thimble coincide with the
indexing line of the sleeve. Calculate the total
reading.
 Solution
Main scale reading= 38.00 mm
Thimble reading=38 x 0.01= 0.38 mm
Total reading= 38.38 mm
Reading a Micrometer
Reading a Micrometer
Reading a Micrometer
Reading a Micrometer
1)

Answer: 7.880 mm29

2)

30
Answer: 3.560 mm
3)

31
Answer: 3.090 mm
Thank you !!
 Hand Tools
• Hand Tools: The devices used for preparing the job with various
operations by hand are called hand tools.
• Machine Tools: The devices used for making various operations with
machines like, lathe, milling m/c, etc.
• Hand tools are used to remove small amounts of material,
usually from small areas of the work piece.
• This may be done because no machine is available, the work
piece is too large to go on a machine, the shape is too intricate
or simply that it would be too expensive to set up a machine
to do the work.
 Engineer’s files
• Files are used to perform a wide variety of tasks, from
simple removal of sharp edges to producing intricate
shapes where the use of a machine is impracticable.
They can be obtained in a variety of shapes and
in lengths from 150 mm to 350 mm. When a file has
a single series of teeth cut across its face it is known
as single-cut file, and with two sets of teeth cut across
its face it is known as double-cut file
 The hacksaw
• The hacksaw is used to cut metal.
• Where large amounts of waste metal have to
be removed, this is more easily done by
hacksawing away the surplus rather than by filing.
• If the work piece is left slightly too large, a file
can then be used to obtain the final size and
surface.
 Chisels
• Chisels are used for cutting metal. They are
made from high-carbon steel, hardened and
tempered at the cutting end.
• The opposite end, which is struck by the hammer,
is not hardened but is left to withstand the
hammer blows without chipping.
• Cold chisels are classified as ‘flat ’ or ‘cross-cut ’,
according to the shape of the point.
 Screwdrivers
• The screwdriver is one of the most common tools,
and is also the one most misused.
• Screwdrivers should be used only to tighten or
loosen screws. They should never be used to chisel.
• Once a screwdriver blade, which is made from
toughened alloy steel, has been bent, it is very
difficult to keep it in the screw head.