MEchanical Fundamentals

Mechanical Engineering Fundamentals I
EMM410
1
EMM410- G9-Term1 A.A-version 01-2018/2019
Contents:
Elements Performance criteria page

Introduction to 1.1 Recognize and understand the Safety rules for the workshops and accident prevention
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workshop safety
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2.1 Use the correct PPE -Personal safety.
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3.1 Use the hand tools safely and correctly
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4.1 Recognize the importance to keep the workshop clean
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Safety contract.
Perform engineering Identify and recognize the metric and Imperial (US) measurements systems used in 12
5.1
measurements mechanical engineering
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6.1 Measure lengths using a steel rule to an accuracy of 0.5 mm.
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6.2 Recognize how to take care of the steel rule
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7.1 Describe the main parts of Vernier calipers
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8.1 Recognize the uses of the Vernier calliper
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9.1 Reading the Vernier caliper to an accuracy of 0.05 mm
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10.1 Use the Vernier height gauge correctly
Routine care and storage of devices is undertaken to manufacturers' specifications or 24
11.1
standard operating
3 Mark out ,Transfer 12.1 Recognise and select marking out equipment.
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dimension
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13.1 Carry out all marking off/out to the specifications using appropriate tools and equipment
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14.1 Establish a datum point and mark out accurately following an engineering drawing
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15.1 Transfer the dimensions correctly and appropriate calculations are used where required
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Elements Performance criteria page
4 Use hand tools 16.1 Identify the Work benches and vices
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17.1 Explain and demonstrate the correct use of a bench vice.
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18.1 Correctly and safely use a hacksaw and identify its parts.
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19.1 Select and fit the correct hacksaw blades according to the required material.
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20.1 Identify and select different types of files.
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21.1 Describe the correct methods for maintaining and storing files.
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22.1 Correctly use a file to remove metal and achieve a desired shape and finish.
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23.1 Identify different types of hammers and their uses.
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24.1 Using various hammers safety:
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25.1 Identify and describe various types of cold chisel
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26.1 Identify and recognize the Safety precautions required when using cold chisels
Assessment Guidelines:
Assessment Assessment % Of Course

Marks
Type Mode Final Mark
Participation 5
Formative Homework 5
60
Assessment Practical Tasks, Project 30
Quizzes 20
Summative End-of-Term Competency Exam
40 40
Assessment (Knowledge & Practical)
3
Objectives:
Mechanical Engineering Fundamentals I course introduces the fundamental concepts and applications in the mechanical
workshop. The course starts with an introduction to the workshop safety. This is followed by measurements, Use the steel rule and
Vernier gauges correctly and safely to obtain the measurement. Perform marking off/out procedures to transfer the dimensions
correctly then how to Use the Work benches and vices correctly and safely in the workshop to perform mechanical works, the
course explains how to use a hacksaw correctly and safely to cut metal to required size and how to use hand files to remove metal
to achieve a desired shape and finish
Then hoe to identify different types of hammers and their uses to perform mechanical works and how to use different types of cold
chisels to perform mechanical works
On successful completion of this module (and practical tasks), the student should be able to:
1. Dress and behave safely in the workshop.
2. Demonstrate an awareness of the workshop safety rules.
3. Prevent accidents in the workshop, by keeping the workshop clean and tidy.
4. Identify and select all the required personal protective equipment for workshop works.
5. Use the metric system of measurement, read the Vernier caliper and micrometer accurately,
6. Perform engineering measurements. Use steel rule and Vernier caliper.
7. Identify the appropriate tools required to perform marking out tasks and Transferring dimensions.
8. Demonstrate the ability to cut using hacksaws, file correctly in the workshop.
9. Identify and select the correct tool for the task.
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1. Introduction to workshop safety
1.1 Recognize and understand the Safety rules for the workshops and accident prevention:
Millions of workers die, get injured or fall ill every year as a result of workplace hazards including falling down stairs, slipping on
wet floors, hitting or being hit by objects, breathing in dangerous fumes, getting an electric shock and getting burnt or killed in a
fire.
Improving occupational health and safety is in the best interests of all employers and workers.
Definitions:
Health: The general condition of a person’s mind, body and spirit, meaning to be free from illness, injury or pain.
Health and Safety: The protection of the safety, health and welfare of people.
Hazard: Anything that might cause harm.
Risk: The chance of harm being done.
Engineering workshops have tools, materials and machines that could cause serious injuries if people do not act safely.
Safety is the most important part of any workshop activity and it is essential that you fully understand and follow the correct
safety precautions.
We will look at workshop rules that you must follow and at the Personal Protective Equipment (PPE) that you should use when
starting any workshop task.
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Accident prevention
https://www.youtube.com/watch?v=dBf6BTX1bmM
https://www.youtube.com/watch?v=73zfbMmXlPk
1. A workshop is where you learn to use tools and machines to make things. It can be a dangerous place, so you must learn the
safety rules for the workshops.
2. The safety rules tell you how to dress appropriately and how to behave whilst working with tools that may cause harm.
3. You must not wear loose clothes or sandals.
4. You must wear overalls and safety boots.
5. You must never play in the workshop, run around or throw equipment to one another.
Employers have responsibilities towards you.
You have responsibilities towards your employer and your co-workers.
Your employer is responsible for making sure that the workplace is safe, and that your health and safety are not at risk.
You are responsible for looking after your own health and safety. You must also take care, do not put other people at risk.
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2.1- Use the correct PPE -Personal safety. https://www.youtube.com/user/SafetyMemos
In engineering we wear specialized Personal Protective Equipment for each task. For example in welding we need to wear special masks
and clothing to protect us from the hazards of extreme heat, sparks and bright light.
In workshop technology you will need to protect yourself from hazards such as sharp objects, heavy objects falling from benches,
and moving machinery.
Incorrect Correct
Fig. 1.1 Correct dress in the workshop
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Right and safe Wrong and dangerous
Fig1.2 differences between the right and wrong dress
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3.1 Use the hand tools safely and correctly: https://www.youtube.com/watch?v=GbdeOIKS7jE
Hand tools are extensions of our hands. When we misuse our hands, we experience pain. When we misuse hand tools, the possibility of
injury to ourselves or people working around us increases considerably. Furthermore, using a tool incorrectly can damage the tool or
even cause the tool to fail. Here are some guidelines for hand tool safety:
1. Use the Right Tool for the Job.
2. Use Insulated Tools When Needed.
3. Use Well-Designed, High-Quality Tools.
4. Follow General Safety and Maintenance Practices
You will learn to use many tools in the workshop. You must listen to the instructor when he tells you how to use them safely. If you
do not understand, asks your instructor, do not ask your friend.
Fig 1.3 use hand tools
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4.1- Recognize the importance to keep the workshop clean. https://www.youtube.com/watch?v=Ma_kPUN2Xms
1. It is very important to keep the workshop clean. This will help prevent accidents. When you have finished using tools, they must be
put away. Do not leave tools lying around the benches or workshop.
2. When you finish work you must clean the workshop and empty the rubbish bins.
Fig 1.4 shows an untidy bench, unsafe working area. Fig 1.5 which shows a tidy workbench area. Safe working area
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Safety contract: https://www.youtube.com/watch?v=A1-EpCVKfJY
1. You must read and sign the safety contract on the next page.
2. The safety contract says that you understand that safety is your responsibility.
3. The safety contract must be signed before you carry out any work in the workshop.
Safety contract
This contract applies to all work carried out by students within STS school.
I understand that if I do not observe and obey these safety rules and instructions, I will not be allowed in the workshop.
I, _____________________________________________ promise:
1. to obey all the safety rules at all times;

2. to wear safety clothes and use safety equipment provided;
3. not to play around in the workshop;
4. to clean and tidy the workshop after use;
5. to use tools correctly and keep tools in a good condition;
6. not to use any tools or machines until I have been shown how to use them correctly;
7. not to use any tool or machine, without permission;
8. to inform an instructor if I am hurt;
9. to ask my instructor if I am not sure what I am doing;
10. that I have read and understood all of the above safety instructions.
Signature: __________________ Number: __________________

Class: __________________ Date: __________________
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Perform engineering measurements.
1-Identify and convert common systems of unit
1.1-Identify basic SI units, 1.2- SI units: metre (m), kilogram (kg), second(s), ampere (A), kelvin (K).1.3- Identify names and
symbols for preferred SI prefixes
The SI (System International)is a globally agreed system of units, with seven base units.
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1. The ampere (A) The ampere is the SI base unit of electrical current. ...
2. The candela (cd) The candela is the SI base unit of luminous intensity. ...
3. The kelvin (K) The kelvin is the SI base unit of thermodynamic temperature. ...
4. The kilogram (kg) The kilogram is the SI base unit of mass. ...
5. The metre (m) ...
6. The mole (mol) ...
7. The second (s)
1.4-Names and symbols: giga(G), mega(M), kilo(k),micro
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1.5-Identify the American engineering units
 The Metric System https://www.youtube.com/watch?v=_N9yUVtbtec
The main system of measurement used in most countries of the world is called the METRIC system.
In the metric system the basic units of length used are the metre (m), the centimetre (cm) and the millimetre (mm).
Where:
10 mm = 1 cm.
100 cm = 1 m.
1000 mm = 1 m.
(NB. In this book we will not be looking at Kilometres (Km) or other metric units)
 The Imperial system

The imperial system is a very old system that was developed and used in the United Kingdom. However it has been replaced by
the metric system in the United Kingdom and most other countries. The United States of America is one of the few countries that
still use the imperial system of measurement.
In the imperial system the basic units of length used are the Yard (yd), the foot (ft), and the inch (in).
Where:
12 inches = 1 foot
3 feet = 1 yard
36 inches= 1 yard
(NB. In this book we will not be looking at Miles (mi) or other imperial units)
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1.6- Perform calculations to convert units from one system to another
 Converting Metric and Imperial measurements.
To convert imperial measurements into metric measurements:
1 inch = 25.4 mm
Examples:
To convert 4 inches to millimetres:
4 inches = 4 x 25.4 mm = 101.6 mm
To convert 50mm into inches:
50 mm = 50 / 25.4 inches = 1.97 inches
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 Accuracy and precision: https://www.youtube.com/watch?v=8Cl5CeiT7hU
Accuracy is closeness to the true value.

Precision is degree of reproducibility of measured value.
If we measure 5cm distance by screw gauge and its showing 4.99 then its accurate and if its showing 4.90 in 5-10 repeated
observations then its precision.
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3-Select and maintain measuring tools, Vernier caliper and steel rule
Measure lengths using a steel rule to an accuracy of 0.5 mm.

https://www.youtube.com/watch?v=PoSQelBsLoY
A steel ruler is a measuring tool made of stainless steel sheet. The lines are engraved on the ruler, on the upper and lower sides.
There are six different nominal lengths of the common steel ruler: 150, 300, 500 (600), 1000, 1500, and 2000 mm. The square
end of the ruler is the working edge. The other end is semi-circular, with a suspension hole at its center. The metric steel rule is
divided into millimetres (mm) and centimetres (cm). Use the correct scale.
Fig 2.1 steel rules.
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Examples Reading steel rule:
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Recognize how to take care of the steel rule (Demonstrate correct care and storage of measuring devices)
The engineers steel rule is a very accurate instrument. Treat it with care.
1. Keep the rule clean and lightly oiled and in the safe place.
2. Protect from damage.
3. Never use as a screwdriver.
4. Never use the end as a scraper.
5. Never bend or twist the rule.
Using the steel rule correctly and safely (Compare a range of measuring techniques for function and accuracy)
 Get measurement.
Always look straight down at 90° to the rule. If you look from the side you will get an inaccurate measurement.
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 Used in marking out from an edge or datum.
 Use the rule to check that the work edges are flat (The edge of the rule is flat and true)
No gap between work and rule means the work edge is flat A gap between work and rule means the work edge is not flat
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-Describe the main parts of Vernier calipers. http://www.youtube.com/watch?v=4hlNi0jdoeQ
A Vernier caliper is a measuring device used to precisely measure linear dimensions.
It is a very useful tool to use when measuring the diameter of a round objects like cylinders because the measuring jaws can be
secured on either side of the circumference. Vernier calipers have both a fixed main scale and a moving Vernier scale. The main
scale is graduated in either millimeters or tenths of an inch. The Vernier scale allows much more precise readings to be taken
(Usually to the nearest 0.05mm) some Vernier calipers come with 0.02mm accuracy.
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The Digital Vernier Caliper
Fig.7 vernier caliper
Dial/Vernier caliper
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Recognize the uses of the Vernier calliper (Compare a range of measuring techniques for function and accuracy,
3.2 Use a range of techniques to measure objects accurately, 4.4- Select and demonstrate a range of measuring devices to
accurately measure depth, internal diameter, and external diameter)
Vernier Calipers are used to measure widths, diameters and depths on work pieces.
Figure a) shows the Vernier caliper being used to measure an inside (internal) size.
Figure b) shows the Vernier caliper being used to measure an outside (external) diameter.
Figure c) shows the Vernier caliper being used to measure an outside dimension.
Figure d) shows the Vernier caliper being used to measure the depth.
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Reading the Vernier caliper to an accuracy of 0.05 mm https://www.youtube.com/watch?v=4hlNi0jdoeQ
(4.3Verify measurements taken using basic calculations, 4.1-Record measurements accurately )
 The accuracy of the 20 division Vernier is 0.05 mm. Make a reading in 2 parts.
 Take one reading from the main scale, and one reading from the Vernier scale.
 The exact point where lines on the main scale and Vernier scale meet is called the ‘point of coincidence’.
Example:
To find the final reading, add the following two readings:

1. from the main scale: The last whole mm before zero on the
Vernier scale = 24.00
2. from Vernier scale: Direct reading at the point of
Coincidence = 0.15
Measurement = main scale reading + Vernier scale reading
= 24mm + 0.15mm
= 24.15 mm
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Exercises
Pictures main scale Vernier scale Total
22.0 0.60 22.60mm
5.0 0.30 5.30mm
66.0 0.20 66.20mm
70.0 0.75 70.75mm
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Use the Vernier height gauge correctly https://www.youtube.com/watch?v=pirr21PjYNc
https://www.youtube.com/watch?v=-oSKiVioFws
Use for marking out or measuring a height of a surface accurately. Always use on a surface plate or table.
Marking out using a Vernier height gauge
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Routine care and storage of devices is undertaken to manufacturers' specifications or standard operating procedures.
(3.3-Demonstrate correct care and storage of measuring devices)
1. Always treat gauges with great care.
2. Clean gauges with a light oil.
3. Replace gauges in correct storage box when not in use.
4. Never use for anything they are not intended to be used for.
5. When in use always place down carefully on a work surface.
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5- Perform routine workshop tasks
Mark out, Transfer dimension. https://www.youtube.com/watch?v=gwspqN4ZTZE
Marking out is the process of transferring a design, layout or dimensions from the plan to a work piece, and it is considered as the
first step in the manufacturing process.
Recognise and select marking out equipment.
The common tools used for marking out are as follows:
1. Marking blue 2. Scriber 3. Prick /center punch 4. Letter stamps 5.

Engineer’s square
6. Surface plate 7. Angle plate 8. Spring dividers 9. Ball peen hammer 10-odd-leg caliper:-
1. Marking blue.
Marking blue is a dye used in metalworking to aid in marking out. See Fig. 3.1a.
It is used to paint a metal object with a very thin layer of dye that
can be scratched off using a scriber to show the bright metal
Underneath as shown in Fig. 3.1b.
The advantages of using the marking blue are:
• The existing scratches are covered with the dye.
• The new lines have a contrasting background.
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2. Scribers:
A scriber is a hand tool used in metalworking to mark lines on work pieces, prior to machining. Made from hardened steel with sharp points at each
end.
3. Center and prick punch
Center punch is used as an aid to drilling operations. A center punch forms an indent in which the tip of the drill will fit. A center
Punch has a point angle of 90°.
prick punch is used to make small indentations along scribed lines; a prick Punch has a point angle of 60°.
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4. Letter stamps or number stamps:
These are used to print a letter or number into a work piece.
2. Engineer’s square:
It is used for checking the straightness of a workpiece. It can also be used for marking perpendicular lines onto a workpiece.
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6. Surface plate:
The surface plate has a high degree of flatness. The flat surface is being used as a datum surface for marking out and for
measuring purposes. These are essential for accurate marking out. They have metal tops which have been accurately machined flat.
To maintain their accuracy take the following care:
DO NOT
1- Place anything on it that would damage the surface.
2- Drop tools on the surface.
3- Do not hammer on the surface.
4- Do not centre punch on the surface.
7. Angle plate:
The angle plate is used to assist in holding the workpiece perpendicular to the table. The angle plate is provided with holes and
slots to enable the secure attachment or clamping of workpieces.
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8. Spring dividers:
The spring dividers are used for scribing arcs and circles as shown or marking off lengths onto a workpiece.
9. Ball peen hammer:
The ball-peen hammer: The crowned, or rounded, edge (hemispherical head) works metal smoothly without marking it. The other
end of the hammer can be used to strike punches and chisels
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10-odd-leg caliper:-
The odd-leg Calipers are manufactured from polished tool steel and have a large headed nut and screw assembly that provides a
firm and rigid friction joint, with no play. The leg which holds the round adjustable hardened point is offset and has a locating spur
on the straight leg.
This is used to scribe a line parallel to a DATUM edge.

http://www.teachertube.com/video/how-to-use-a-pair-of-odd-leg-calipers-109971
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Carry out all marking off/out to the specifications using appropriate tools and equipment
Preparation of surfaces.
To help show up a line more clearly use one of the following methods. Surfaces may be brushed with a suitable marking out solution. For
machined surfaces use marking blue.
Marking out.
Set the Vernier height gauge the correct measurement supported against a vee block or angle plate.
With the datum face of the work piece set in contact with the surface table, and the work piece held firmly against the vee block or angle
plate, scribe a line along the work. The point of the scriber should trail the base of the Vernier height gauge to prevent it digging into the
work. Always pull the Vernier height gauge, do not push it.
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Establish a datum point and mark out accurately following an engineering drawing.
Marking-out Using Datum
https://l2teautomotive.wikispaces.com/file/view/MARKING-OUT+TOOLS+INFORMATION+SHEETS+MEL02INF4436+v1.2.pdf
A datum is a line, point or edge from which measurements are taken. It must be noted that if marking out is not undertaken from datum,
errors in dimensions may accumulate as shown in Fig. below.
It is also necessary to use a measuring instrument which can provide the degree of accuracy required for the workpiece e.g. using
a rule and scribing block may only have an accuracy of 0.5 mm. If the tolerance on the dimension is 0.02 mm then this method of
marking out is clearly unsuitable.
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Transfer the dimensions correctly and appropriate calculations are used where required
Example 01:-
1-All dimensions in millimeters general tolerance ±2mm
Steps
1. Scribe centre line.
2. Step of 75.0 hole centre with dividers.
3. Lightly prick punch hole centers.
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4. Scribe in 18.0 diameter hole with dividers.
5. Scribe in 18.0 radius with dividers.
6. Scribe in 25.0 diameter hole with dividers.
7. Scribe in 25.0 radius with dividers.
8. Join 18.0 and 25.0 radii with tangential lines use a rule as straight edge to guide the scriber.
9. Prick punch outline of link.
10. Enlarge hole center marks with center punch ready for drilling.
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Example 02:-
Marking hole Positions along a Centerline.
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Identify the Work benches and vices ( 7-Use the Work benches and vices correctly and safely in the workshop to perform
mechanical works)
The work bench https://www.youtube.com/watch?v=JFVjTda6U0Q
The work bench: Is a very heavy, solid table. It must be strong enough to support the work and firm enough not to move when the
work is being carried out. To avoid back strain, have the bench at the correct height.
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Bench vice https://www.youtube.com/watch?v=qaF7IDjCWvc
The vice has two jaws. One jaw is fixed; the other jaw can be opened or closed by a handle. The faces of the jaws are serrated to
give a firm grip of the material. To prevent damage to work piece, always use aluminum vice clamps.
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Explain and demonstrate the correct use of a bench vice.
1- Always ensure that the workbench is firm.

2- Ensure the vice is securely fixed to the workbench (bolted).
3- Have the vice at the correct height.
4- The vice and bench should be kept clean and tidy at all times.
5- Cutting action- example when using a chisel on work held in a vice, the cutting action should always be towards the fixed jaw of
the vice, and towards the chip screen of the workbench.
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8- Use hand tools effectively and safely (hand files, hacksaws, hammers and chisels) to produce the work
Correctly and safely use a hacksaw and identify its parts https://www.youtube.com/watch?v=G0NGoPF3Q6A
Use a hacksaw to cut metal to size.
Main parts of hacksaw
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Types of hacksaw frames:
There are two types of hacksaw frames:

1- Solid hacksaw frame: In this type, only one particular length of blade can be used.
2- Adjustable hacksaw frame: In this type different standard lengths of blades can be fitted
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Using a hacksaw
When using a hacksaw:

1. Hold the blade at an angle; apply pressure on the forward stroke only. By using the hacksaw carefully, it is possible to cut close
to a scribed line leaving the minimum amount of metal to file to the final size and finish.
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Select and fit the correct hacksaw blades according to the required material.
Classifying hacksaw blades
A hacksaw blade is classified by:
1- The number of teeth per 25 mm (teeth pitch).
2- Its length from hole centre to hole Centre.
The standard hacksaw blade is nominally 12 inches long (actually 12 3/8 inches). Ten-inch blades are also made, and the typical
hacksaw frame is adjustable to take blades 8, 10 or 12 inches long
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Blade offset
The teeth are ‘offset’ to prevent the blade from jamming when cutting the metal.
Blade pitch
Blades are made with:
a) Coarse pitch teeth.

b) Medium pitch teeth
b) Fine pitch teeth.
A fine pitch blade has more teeth per 25 mm than a coarse pitch blade.
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Teeth Per Inch(25 mm) Name of pitch class Minimum of material Suitable for cutting
thickness
14 TPI coarse 1.8 mm Large size, soft metals
(Aluminium, brass,
copper, cast iron and mild
steel
18 TPI Medium 1.4 mm General use
24 TPI Fine 1.1mm For cutting steel plates
32 TPI Fine 0.8 mm Thin plate, light tubes &
small sections
Hacksaw blade checklist:
The following points should be taken in consideration before using the hacksaw:
1. Select the correct pitch for the material you want to cut.
2. Ensure that the blade has the correct tension.
3. Ensure that the blade is not twisted or discolored.
4. Ensure that the blade is not pointed away from the handle.
5. Ensure that there are no broken or blunt teeth,
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When choosing a hacksaw blade follows the rule:
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Identify and select different types of files. https://www.youtube.com/watch?v=lOR2UwZRBws
Use a file to remove small amounts of metal.
Main parts of file
File types:-
Files can be classified by:-
1. File cut.
2. File Grades.
3. File shape.
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1-Types of file cut
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2- Grades of file
Files have teeth of different grades (sizes). The most common are:
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3- File shapes
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Describe the correct methods for maintaining and storing files.
Cleaning a file
Clean a file in the direction of the cut. Use a file card.
4.6.2 File storage

Carefully store files in a tool box or in a file rack. This will prevent the teeth from blunting or breaking.
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Correctly use a file to remove metal and achieve a desired shape and finish.
Working position
It is important to stand correctly. Your legs should take your weight and keep you balanced at all times.
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Preparing a file for use
Push the tang a little way into the handle. Gently tap the file on the bench, as shown below, until the tang fits securely inside the
handle. Care should be taken not to split the handle.
Safe edge
Some files have a safe edge, this lets you file without damaging another finished surface.
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Identify different types of hammers and their uses. https://www.youtube.com/watch?v=Hei2WecZIks
A hammer consists of a steel head fitted to a wood shaft. The striking face and pein are hardened and tempered. The shaft must be the
correct size for the head. It must fit the head and be secured by a wedge driven into the end of the shaft making it a tight fit.
Main parts ball pein(peen)hammer
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Using various hammers safety:
Hold the hammer in a firm grip at the end of the shaft.
Hammers are used with other tools such as punches and chisels. A hammer can be used in direct contact with the work, such as
shaping metals, forming joints, and riveting. Hammers, mallets, and sledges are used to apply a striking force. The tool you select
will depend upon the intended application. Machinists' hammers are mostly used by people who work with metal or around
machinery. The ball-peen hammer, as its name implies, has a ball that is smaller in diameter than the face. It is
therefore useful for striking areas that are too small for the face to enter.
Special hammers
Soft hammers are used when you need to prevent damage to finished surfaces.
The heads may be made of materials such as:
1. hide (animal skin)
2. rubber
3. plastic
4. brass
5. copper
6. lead
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Mallets and Sledges: The mallet is a short-handled tool used to drive wooden-handled chisels, gouges, and wooden pins, or to form or
shape sheet metal where hard-faced
hammers would mar or damage the finished work. Mallet heads are made from a soft material, usually wood, rawhide, or rubber. For
example, a rubber-faced mallet is used for knocking out dents in an automobile. It is cylindrically shaped with two flat driving faces that
are reinforced with iron bands. Never use a mallet to drive nails, screws, or any other object that can damage the face of the mallet.
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The safety precautions when using various hammers.
1. You must use the correct hammer for the job.

2. You must report damaged hammers.
3. Do not use a hammer with a split or damaged shaft.
4. Do not use a hammer with a loose head.
5. Do not use a hammer without a wedge in place.
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Identify and describe various types of cold chisel:
A chisel is a hand-held tool used to make cuts in material. Different types of chisel exist to be used on different materials. A chisel is
usually used in conjunction with a hammer.
Use of a chisel: The cold chisel is a general purpose cutting tool Used:
1. To cut sheet metal.
2. To cut slots.
3. To chip excess metal from large surfaces.
4. To chip off rivet heads, and rusted nuts and bolts.
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Parts of a chisel:
Chisels have a hardened and tempered cutting edge. The body and the head are soft to avoid fracture when struck by a hammer.
Chisel cutting edge angle:
The chisel has its cutting edge across its full width. The final cutting edge has a combined angle of 60° and is slightly rounded across
the face.
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Chisel cutting action:
When using a chisel on work held in a vice, the cutting action should always be towards the fixed jaw of the vice, and towards the
chip screen of the workbench.
Types of cold chisels:
1. Flat chisel: The most widely known type, which is used to cut bars and rods to reduce surfaces and to cut sheet metal that,
is too thick or difficult to cut with tin snips.
2. The cross cut/cape chisel: is used for cutting grooves and slots. The blade narrows behind the cutting edge to provide
clearance.
3. The round nose chisel: is used for cutting semi-circular grooves for oil ways in bearings.
4. The diamond point chisel: is used for cleaning out corners or difficult places and pulling over center punch marks wrongly
placed for drilling.
5. The half round chisel: used for making narrow channels
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Identify and recognize the Safety precautions required when using cold chisels:
After a period of time, the hammer blows will cause the head to become Mushroom shaped. This will have sharp edges that will cut
through skin and could also cause the hammer to slip off the head of the chisel. Before this happens the head should be re-ground to
its original shape.
What are some safety tips to know when using a chisels:
 Wear safety glasses or goggles, or a face shield (with safety glasses or goggles).
 Use the tools only if they are good condition (i.e., cutting edges are sharp, struck head is not mushroomed or chipped).
 Hold the chisel, for shearing and chipping, at an angle which permits the bevel of the cutting edge to lie flat against the shearing
plane. Never chip towards your own body or towards any other person.
 Provide hand protection
 Always clean up the chippings when the task is complete.
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Cold chisel maintenance and care:
As with every other tool, it is important to look after, maintain and store your chisels correctly.
Cold chisel maintenance:
It is important to keep your chisels sharpened correctly. How sharp you keep them may vary depending on the type of chisel and what
you are using it for.
Rust may also become a problem on some chisels. However, it can be removed by wiping the chisel
with an emery cloth, and then using a little oil to give the chisel greater protection from rust in the
future.
What is mushrooming?
Mushrooming is the phenomenon that occurs when a tool which is struck with a hammer deforms, (as seen in the picture) spreading out
into a mushroom shape and eventually rolling back onto itself. Mushrooming can cause serious problems as the metal can splinter,
injuring the user.
It is therefore advised that you grind down these mushroomed heads regularly to keep them from becoming hazardous,
However, a user can often grind the head of their chisel, producing a chamfered head.
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mushroom shape grind the head producing a chamfered head
Cold chisel storage
It is possible to buy cold chisels in sets which may come with a tool roll or case to store them in. However, because of the varying sizes of
builders' and cold chisels, it may not be possible to store larger chisels and bolsters in these rolls, When storing them, you may wish to
place a piece of split hosepipe over the cutting edge of your chisels.
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Suggested Practical task01:
Use the aluminum (mild steel) workpiece (100x50x3mm) provided by your teacher to produce the finished workpiece as in
the drawing below.
Procedure:-
Use the below given drawing for all dimensions and references.
1. Manufacture all datums- file two datums at 90º to each other.
2. Mark out from datums. Transfer the dimensions to the workpiece
3. Hacksaw and file step 1 and step 2 to tolerance.
4. Hacksaw and file radius of 25 mm.
5. File to the final dimensions.
6. Remove all burrs and sharp edges. The workpiece will be provided by your teacher
7. Finish surfaces by emery paper.
8. Punch your number and class. Give your finished work to the teacher.
9. The finished workpiece will be used in the practical task 02 so keep it.
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Rubric:-
I-Observation :( 15marks)
Operation Mark Achieved

Remove all Sharp edges and prepare the workpiece for marking out 2
Use engineering blue or permanent marker to cover one side of the 2
workpiece
Prepare the two datums. 3
Transfer the dimensions to the workpiece 3
Use the hacksaw and files correctly and safely 5
Total 15
II-The finished workpiece :( 15marks)
Dimension Mark achieved

Two datums are perpendicular to each other 2
The step 1 is perpendicular to datum 1. 2
The step 2 is perpendicular to datum 1. 2
The radius 25mm is correct and in the correct position 3
The finished workpiece dimensions are with the tolerance ±2mm 4
Punch the number and class 2
Total 15
Student Practical task 01 final mark:
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Suggested practical task 02: [15marks]
In this practical task students have to use the workpieces they did in the practical task01 as a base, part one (the base of the second
piece) then they have to make part two.
Part 01: students have to search from the internet or from their imagination to make their second workpiece. Students can select any
shape.
Steps:
1. Students have to search from the internet or from their imagination (any shape can be done by using sheet metal) to make their
second workpiece. Students can select any shape. They have to sketch or print their selected shape on A4 paper .the size of the
shape depend on the teacher approval.
2. Students have to copy their shape on the aluminum (steel or brass) sheet for this purpose they can use scriber; permanent
marker .they can use center punch to make contour around the shape.
3. Hacksaw around the outline of the marked shape. Use file to remove metal and achieve a desired shape.
4. Cut a slot in the first piece, use chisel and hammer to fix the figure in the base.
Note: Teachers have the right to reject any idea.
Suggested ideas:
 Animal zoo –each student do different animal shapes.

 Math garden –each student do different geometrical shape.
 Hand tool-each student cad do different hand tool shape. And so on
Key words:
Steel rule, Vernier caliper, Spring dividers, engineers square, square file, bench vice, center punch,
letter punch, scriber, hacksaw, ball peen hammer, soft jaws, pillar drill, machine vice, safety goggles,
drill bit, chisel
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Example as in the drawings:
Part 01 Part 02 Final product
Rubric: - Practical task 02-Part 1

I-Observation :( 15marks)
Operation Mark Achieved

Remove all Sharp edges and prepare the workpiece for marking out 2
Use engineering blue or permanent marker to cover one side of the 2
workpiece
Prepare the two datums. 3
Transfer the dimensions to the workpiece 3
Use the hacksaw and files correctly and safely 5
Total 15
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Part 02: Read the Information from technical drawings: [15 marks, 1each]
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Look at the drawing and answer the following questions.
1. What is the material of the workpiece? __________________________

2. What is the date of the drawing? __________________________
3. What is the scale of the drawing __________________________
4. How many datums you need for marking out? __________________________
5. What is the height of step 2? __________________________
6. What is the width of step 1? __________________________
7. What is the safety issue mentioned in the drawing? __________________________
8. What is the measuring instrument you will use to measure the dimensions? __________________________
9. What is the dimensions unit? __________________________
10. What is radius size? __________________________
11. What is the general tolerance for the drawing? __________________________
12. Write the following tolerance in other format? __________________________
13. Write the following tolerance in different format 60±1? __________________________
14. Find the largest permissible dimension 200±2? __________________________
15. What is the tolerance for the 70±3 dimension? __________________________
Student Practical task 02 final mark: _____/15
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The project’s material package will be provided by your teacher this is just overview of the projects .
There will be two options, the students can select any one of these projects hopefully each school will make
both.
Assessment Tool
Grade 9 Term 1 Mechanical Engineering Fundamentals I
Project
Name N0 Date Signature

Student
Name CO/NYC Date signature

Assessor
Instruction to students
 If you have any individual needs that may affect your participation in this assessment, inform your assessor.
 If you are allowed three attempts to demonstrate competence against this assessment.
 You have the right to appeal an assessment result.
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Project:
Objectives:
1. On successful completion of this project (and practical tasks), the student should be able to:
2. Dress and behave safely in the workshop.
3. Prevent accidents in the workshop, by keeping the workshop clean and tidy.
4. Identify and select all the required personal protective equipment for workshop works.
5. Perform engineering measurements. Use steel rule and Vernier caliper.
6. Select the appropriate tools for job.
7. Use hand tools correctly and safely (hacksaw, files, hammers and chisels).
8. Transferring dimensions. /All marking off/out is carried out to specifications using appropriate tools and equipment.
Overview:
This project is part of assessment tools so you have to keep it in your portfolio.
In this project students have to make shelf angle bracket to use it .the can use different material and different design .example have
been given as a guide.
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Steps:
1. Students have to search from the internet or from their imagination (any shape can be done by using sheet metal) to make their
design. Students can select any shape. They have to sketch or print their selected shape on A4 paper .the size of the shape depend
on the teacher approval.
Note: Teachers have the right to reject any idea.
2. Students have to draw freehand sketch for their selected shape they have to insert the dimensions agreed with their teacher
about on the sketch.
3. Manufacture all datums- file two datums at 90º to each other.
4. Mark out from datums. Transfer the dimensions to the workpiece; aluminum (steel or brass) sheet for this purpose they can use
scriber; permanent marker .they can use center punch to make contour around the shape.
5. Hacksaw, chisel (use chisel and hammer) and file to tolerance 1mm, Hacksaw around the outline of the marked shape. Use file to
remove metal and achieve a desired shape.
6. File to the final dimensions.

7. Remove all burrs and sharp edges.
8. Finish surfaces by emery paper.
9. Punch your number and class. Give your finished work to the teacher.
10. The finished workpiece will be used in the practical task 02 so keep it.
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Mechanical Engineering Fundamentals I

Elements Performance criteria page

Assessment Assessment % Of Course

1. Dress and behave safely in the workshop.

2. Demonstrate an awareness of the workshop safety rules.

6. Perform engineering measurements. Use steel rule and Vernier caliper.

9. Identify and select the correct tool for the task.

safety rules for the workshops.

3. You must not wear loose clothes or sandals.

4. You must wear overalls and safety boots.

Employers have responsibilities towards you.

You have responsibilities towards your employer and your co-workers.

Fig. 1.1 Correct dress in the workshop

Fig 1.3 use hand tools

1. to obey all the safety rules at all times;

Signature: __________________ Number: __________________

 The Imperial system

To convert 4 inches to millimetres:

4 inches = 4 x 25.4 mm = 101.6 mm

To convert 50mm into inches:

50 mm = 50 / 25.4 inches = 1.97 inches

Accuracy is closeness to the true value.

Measure lengths using a steel rule to an accuracy of 0.5 mm.

Fig 2.1 steel rules.

A Vernier caliper is a measuring device used to precisely measure linear dimensions.

Fig.7 vernier caliper

(4.3Verify measurements taken using basic calculations, 4.1-Record measurements accurately )

To find the final reading, add the following two readings:

Pictures main scale Vernier scale Total

22.0 0.60 22.60mm

5.0 0.30 5.30mm

66.0 0.20 66.20mm

70.0 0.75 70.75mm

Marking out using a Vernier height gauge

Mark out, Transfer dimension. https://www.youtube.com/watch?v=gwspqN4ZTZE

Recognise and select marking out equipment.

The common tools used for marking out are as follows:

1. Marking blue 2. Scriber 3. Prick /center punch 4. Letter stamps 5.

can be scratched off using a scriber to show the bright metal

Underneath as shown in Fig. 3.1b.

The advantages of using the marking blue are:

• The existing scratches are covered with the dye.

• The new lines have a contrasting background.

3. Center and prick punch

Punch has a point angle of 90°.

9. Ball peen hammer:

This is used to scribe a line parallel to a DATUM edge.

Marking-out Using Datum

1-All dimensions in millimeters general tolerance ±2mm

Marking hole Positions along a Centerline.

The work bench https://www.youtube.com/watch?v=JFVjTda6U0Q

1- Always ensure that the workbench is firm.

Use a hacksaw to cut metal to size.

Main parts of hacksaw

There are two types of hacksaw frames:

When using a hacksaw:

Classifying hacksaw blades

A hacksaw blade is classified by:

1- The number of teeth per 25 mm (teeth pitch).

2- Its length from hole centre to hole Centre.

Blades are made with:

a) Coarse pitch teeth.

b) Fine pitch teeth.

Hacksaw blade checklist:

Signature: Number: