CHAPTER ONE
workshop Safety
workshop Safety
In the school workshop, students always use tools with sharp edge and
operate some dangerous machine for the project work. Therefore,
students must be very careful during working and observe all workshop
safety rules.
1. Safety rules for student's outfit in the workshop.
i) Always wear protective clothing (an apron or overall)
ii ） Wear hard leather shoes or safety shoes. Do not wear sandals or
rubber shoes﹔
iii ） Roll up sleeves and take off your tie and watch﹔
iv ） Tie up long hair.
2. Use suitable tools or machines for your work.
3. Enter the workshop only with the teacher's permission.
4. Do not use any tools or machines without the teacher's permission.
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6. When carrying tools, point the sharp edge downwards.
7. A machine must always be operated by one student at a time.
8. Switch off the machine before adjusting or cleaning.
9. Do not run or play in the workshop.
10. When carrying large objects or tools, take great note of the surrounding.
11. Press the emergency button in case of accidents and inform the teacher
immediately.
12. Do not put tools or materials near the edge of the bench.
13. Do not leave any tools, materials or waste on the bench, machine or floor
after working.
14. Always clean the bench, machine and floor after working and make sure
that there is no paint, oil, dirt or rubbish left behind.
15. No eating in the workshop.
Measuring &Testing
Measuring Instruments and Gages
Measurement is a procedure in which an unknown
quantity is compared with a known standard, using an
accepted and consistent system of units.
Two systems of units have evolved in the world:
(1) the U.S. customary system (U.S.C.S.), and
(2) the International System of Units (or SI, for System
International dugites), more popularly known as the metric
system (Historical Note 5.1).
Both systems are used in parallel throughout this book. The
metric system is widely accepted in nearly every part of the
industrialized world except the United States, which has
stubbornly clung to its U.S.C.S. Gradually, the United
States is adopting SI.
Measurement provides a numerical value of the quantity of interest, within
certain limits of accuracy and precision.
Accuracy is the degree to which the measured value agrees with the true
value of the quantity of interest.
A measurement procedure
is accurate when it is absent of systematic errors, which are positive or
negative deviations from the true value that are consistent from one
measurement to the next.
Precision is the degree of repeatability in the measurement process.
Good precision means that random errors in the measurement procedure are
minimized. Random
errors are usually associated with human participation in the measurement
process.
Examples include variations in the setup, imprecise reading of the scale,
round-off approximations, and so on.
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Nonhuman contributors to random error include temperature
changes, gradual wear and/or misalignment in the working
elements of the
device, and other variations.
Closely related to measurement is gaging. Gaging (also spelled
gauging) determines simply whether the part characteristic meets
or does not meet the design specific cation.
It is usually faster than measuring, but scant information is
provided about the actual value of the characteristic of interest.
This section considers the variety of manually operated measuring
instruments and gages used to evaluate dimensions such as length
and diameter, as well as features
such as angles, straightness, and roundness. This type of
equipment is found inmetrology labs, inspecti
Calipers
are available in either no graduated or graduated styles. A no
graduated caliper (referred to simply as a caliper) consists o
two legs joined by a hinge mechanism, as in Figure
The ends of the legs are made to contact the surfaces of the
object being measured, and the hinge is designed to hold the
legs in position during use.
The contacts point either inward or outward. When they poin
inward, as in Figure 5.2, the instrument is an outside caliper and
is used for measuring outside dimensions such as a diameter
When the contacts point outward, it is an inside
caliper, which is used to measure the distance between two
internal surfaces.
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An instrument similar in confi guration to
the caliper is a divider, except that both legs
are straight and terminate in hard, sharply
pointed contacts.
Dividers are used for scaling distances
between two points or lines on a surface,
and for scribing circles or arcs onto a
surface.
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A variety of graduated calipers are available for various
measurement purposes.
The simplest is the slide caliper, which consists of a
steel rule to which two jaws are added, one fi xed at the
end of the rule and the other movable, shown in Figure .
Slide calipers can be used for inside or outside
measurements, depending on whether the inside or
outside jaw faces are used.
In use, the jaws are forced into contact wit the part
surfaces to be measured, and the location of the movable
jaw indicates the
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dimension of interest. Slide calipers permit more accurate and precise
measurements than simple rules. A refi cement of the slide caliper is the
Vernier caliper, shown in Figure .
In this device, the movable jaw includes a Vernier scale, named after P.
Vernier (1580–1637), a French mathematician who invented it.
The Vernier provides graduations of 0.01 mm in the SI (and 0.001 inch in
the U.S. customary scale), much more precise than the slide caliper.
The micrometer is a widely used and very accurate measuring device, the
most common form of which consists of a spindle and a C-shaped anvil,
as in Figure .
The spindle is moved relative to the fi xed anvil by means of an accurate
screw thread. On a typical U.S.
micrometer, each rotation of the spindle provides 0.025 in of linear travel.
Attached to the spindle is a thimble graduated with 25 marks around its
circumference
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each mark corresponding to 0.001 in. The micrometer sleeve is usually
equipped with a Vernier, allowing resolutions as close as 0.0001 in. On
a micrometer with metric scale, graduations are 0.01 mm.
Modern micrometers (and graduated calipers) are available with
electronic devices that display a digital readout of the measurement (as
in the fi gore).
These instruments are easier to read and eliminate much of the human
error associated with reading conventional graduated devices.
The most common micrometer types are
(1) external micrometer, .
called an outside micrometer, which comes in a variety of standard
anvil sizes;
(2) internal micrometer, or inside micrometer, which consists of a
head assembly and a set of rods of different lengths to measure various
inside dimensions that might be encountered; and
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3)
( depth micrometer, similar to an inside micrometer but adapted to
measure hole depths.
Comparative instruments are used to make dimensional comparisons
between two objects, such as a work part and a reference surface.
They are usually not capable of providing an absolute measurement of
the quantity of interest; instead, they measure the magnitude and
direction of the deviation between two objects.
Instruments in this category include mechanical and electronic gages.
Mechanical Gages: Dial Indicators Mechanical gages are designed
to mechanically magnify the deviation to permit observation.
The most common instrument in this category is the dial indicator,
Figure which converts and amplify es the linear ovement of a contact
pointer into rotation of a dial needle. The dial is graduated in
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A simple protractor
consists of a blade that pivots relative to a
semicircular head that is graduated in angular units
(e.g., degrees, radians).
To use, the blade is rotated to a position
corresponding to some part angle to be measured,
and the angle is read off the
angular scale.
A bevel protractor, Figure , consists of two straight
blades that
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