Book STS EMM420 2018 2019

Mechanical Engineering Fundamentals II- EMM420- G09-Term2
EMM420- G09-Term2 1 A.A-version 05-2018/2019

Course description:
The course starts with performing engineering measurements, how to use different tools and gauges to take the liner and angular
measurements, Describe the main parts of a micrometre, how to use micrometre correctly and safely, read the micrometre, how
to make a calibration to the micrometre and how to take care of micrometre. Students will use the combination square and
protector for angles measurements Then the student will learn how to use hand tools such as taps and dies to cut manually internal
and external thread safely and correctly, and how to find the thread parameters. In riveting operations, the student will learn how
to use rivet gun correctly and how to recognize and identify rivet types, and how to remove blind rivets by different methods. In
power tools, the topic student will learn how to use power tools effectively to achieve the required outcomes of finish, size or shape.
Select appropriate power tools to suit the task requirements. Differentiate between drill machine types (hand drill, electrical
hand drill, bench and pillar drill) in term of their speed, feed and axis, Use the correct grinding wheels for the job and recognize
their safety, how to re-sharpen twist drills within the standard.
Course learning outcomes:

On successful completion of this module (and practical tasks), the student should be able to:
1 Perform Linear measurement using Micrometre

2 Perform Angular measurement using protractors and combination square
3 Describe and demonstrate the correct procedure for producing internal and external screw threads
4 Identify Revit’s types and use them correctly and safely to perform joints to the standard
5 Recognize different drilling machine types and use them correctly and safely to perform drilling operations
6 Identify the grinding wheels types and use them correctly to resharpening the twist drill
Assessment Guidelines:

Contents:
Term2
Standard Learning Outcome Performance Criteria

Definition Metrology is the 1 Perform Linear 1.1 Describe the main parts of Micrometre
name given to the science of measurement using 1.2 Use a micrometre correctly to take the measurement
pure measurement the Micrometre 1.3 Read the Micrometre to an accuracy of 0.01 mm
Engineering Metrology has 1.4 Recognise the types of micrometre and their usage
restricted to measurements of 1.5 Calibrate the micrometre
length & angle Measurement. 1.6 Undertake routine care and storage of the micrometre
2 Perform Angular 2.1 Use a protractor to perform angular measurement
measurement using 2.2 Identify the Combination square parts and use them to
protractors and perform angular measurements
combination square 2.3 Recognise the different applications of a combination square
2.4 Perform thread measurement using a thread gauge
Hand tools used in creating a 3 Describe and demonstrate 3.1 Identify the manual thread cutting operations
screw thread and rivet joints the correct procedure for 3.2 Differentiate between the Coarse and fine threads and identify
are commonly required in the producing internal and their usage
mechanical workshop. external screw threads 3.3 Identify the main differences between thread systems in term
of thread angle and pitch
3.4 Understand the international different thread systems in use
3.5 Describe and demonstrate the correct procedure for producing
internal and external screw threads
3.6 Maintain and store taps and dies.
3.7 Recognise and follow the safety Precautions while working
with taps and dies
3.8 Maintain and store taps and dies
4 Identify Revit’s types and 4.1 Identify the advantages of Revit joints
use them correctly and 4.2 Identify the different types of rivets
safely to perform joints to 4.3 Form a solid rivet head correctly and safely using Snaps
the standard and Dollies
4.4 Identify the required clearance to form the solid Revit

4.5 Recognise the Riveting faults
4.6 Identify the minimum allowances required for riveted joints
4.7 Understand the forming process for the head of a pop rivet
4.8 Use the pop Rivet tools correctly and safely to perform Revit
joints
4.9 Recognize and implement the Safety Precautions while
working with riveting works
4.10 Remove blind rivets correctly and safely with drill and Chisel
Drilling machines used to 5 Recognize different drilling 5.1 Identify different Drilling machine types
perform many operations in machine types and use 5.2 Understand and implement the standard operating procedure
the mechanical workshop, them correctly and safely while working on drill machines
they are available in many to perform drilling 5.3 Identify different types of machine vice used with drill
types. operations machines
5.4 Identify different drill types, their usage and securing
methods
5.5 Identify drill bit gauge types and their usage
5.6 Recognise the importance of the twist drill angles for making
holes
5.7 Identify different drilling operations and Implement them
correctly and safely to manufacture holes
A tool grinder used to sharpen 6 Identify the grinding 6.1 Recognise the main parts of the bench and pedestal tool
cutters and tool bits along wheels types and use them grinders, and their importance in the workshops
with a host of other cutting correctly to resharpening 6.2 Adjust the tool rest correctly to provide support for the tools
tools. It is an extremely the twist drill. while being ground
versatile machine used to 6.3 Recognize the Safety precautions for tool grinders and
perform a variety of grinding implement the standard operating procedures
operations. 6.4 Understand the grinding wheels safety, speed and dressing
6.5 Re-sharpening the twist drill correctly and safely use offhand
method considering the twist drill angles

Engineering Metrology is restricted to measurements of length & angle
https://www.youtube.com/watch?v=Fi6EmDVtphs
1 -Perform Linear measurement using Micrometer
A micrometre is a precision measuring instrument, used to obtain very fine measurements and available in metric and imperial
versions.
1.1-Describe the main parts of Micromere.
https://www.youtube.com/watch?v=rVjCmOrneGw

1-Micrometre measuring faces:
Objects to be measured are placed between the measuring faces; the anvil and the spindle. The anvil
is the stationary measuring face against which parts are held until the spindle makes contact with the
work. The threaded spindle is the moving measuring face of the micrometre
2-Micrometre main scale:
The scale on the sleeve of the micrometre is the instrument's primary measuring
scale. Together with the thimble scale, the main scale displays the measurement
taken.
The first significant figure of measurement is taken from this scale. This part of the measurement is the first value immediately to the
left of the thimble.

3-Micrometre thimble scale:
The secondary measuring scale, the thimble scale, provides the two remaining significant figures of a measurement.
This part of the measurement is the value on the scale that aligns with the index line on the sleeve scale.
4-Micrometre index line:
The index line, which runs along the sleeve of the micrometre, is used to indicate the value shown on the thimble scale.

5- Micrometre thimble:
When the thimble is turned, the spindle rotates and alters the distance between the measuring faces of the micrometre.
Some micrometre thimbles incorporate a friction drive. This allows for a more accurate reading, particularly when used by the
inexperienced user.

6-Micrometre ratchet:
The ratchet increases the speed at which the spindle rotates, so the space between the anvil and the spindle is reduced more quickly
than it would be if the thimble were used.
Using the ratchet reduces the time it takes to use the micrometre.
The ratchet incorporates a slipping clutch mechanism that prevents over-tightening and aids the user to apply a constant measuring
force to the spindle, helping to ensure reliable measurements.

7-Micrometre locking device:
The locking device secures the spindle and preserves the measurement so that the micrometre can be removed from the workpiece before
taking the reading.
Some micrometres have a lock nut (as shown), whilst others may have a locking lever (see image below).
8-Micrometre frame:
The U-shaped frame is designed to be rigid and stable. It supports the anvil and the sleeve of the micrometre.
The frame is held by the user whilst measurements are taken.

The micrometre is available in a range of sizes: 0-25mm, 25-50mm.50-70mm

1.2. Use a micrometre correctly to take the measurement.
Clean all surfaces that you want to measure. Place the anvil at one end and the spindle at the other. Turn the thimble with the
ratchet, the spindle will move until it meets the object being measured then the ratchet will slip (click). Using the ratchet ensures
that the same force is used each time a measurement is taken. This gives accuracy and ensures that the micrometre is not damaged.
The spindle lock prevents the measurement from slipping when removing the micrometre from the workpiece.
Always use the ratchet; it must never be screwed tightly by using the thimble to take a measurement!
1.3 Read the Micromere to an accuracy of 0.01 mm:

https://www.youtube.com/watch?v=i_jygJkJujE
Measurements provided by a micrometre are made up of a combination of values taken from the main scale, the thimble scale and,
on some micrometres, the Vernier scale. The sleeve scale of a metric micrometre has a measuring range of 25mm. It is graduated in
millimetres and half millimetres. The scale is numbered every 5mm.
The thimble scale has a measuring range of 0.5mm (the smallest value that can be measured on the sleeve scale). It is divided into 50
increments; with each increment representing 0.01mm (0.5 ÷ 50 = 0.01).The scale is numbered every 0.05mm.

Example: 01

Example: 02

Example: 03

Exercises:

1.4 Recognize the types of micrometre and their usage: https://www.youtube.com/watch?v=wW5NSBDyxD4
1 Outside (External) micrometre: The outside micrometre is the most commonly used type of micrometre. It is used to measure
external dimensions such as the outside diameter of an object.

2 Inside (Internal) micrometre: Inside micrometres are used to measure inside dimensions like the inside diameter of a hole or
tube.
3 Depth Micrometer: Depth micrometres are used to measure the depths of holes, slots and steps. They come with a variety of
interchangeable rods of different lengths so that they can be used to measure a range of depths.

1.5 Calibrate the micrometre: www.youtube.com/watch?v=bzjBY_QahRA
To calibrate means to check, adjust, or systematically standardize the output of a measuring or test instrument.
Micrometres can be calibrated using a special set of gauge blocks and a set of optical parallels. The sizes of the gauge blocks
are chosen to test booth the periodic and progressive error of the micrometre.
Using test piece (gauge block set): is used to check the micrometre for accuracy. Fine adjustment is made using the adjusting
screw at the end of the ratchet. Be careful when handling and storing the test piece.
Gauge block set
Calibration guidelines for micrometres:
1. Look at the frame, for signs of damage, such as indications that it was dropped on the floor.
2. Observe both spindle and anvil faces. They must be flat, free of pinholes and clean. Frosted surfaces may indicate wear.
3. If the micrometre needs repairs, they must be done first. Calibration may proceed only when the gage is in good working order. Move
the micrometre from 0 to 25 millimetres or the entire range and check if the spindle feels continuously smooth throughout the range. In
short, check if it is good enough for its intended use. A hard to turn spindle is a sign of age or damage. Do not force it to rotate and have
someone look into the cause of the malfunction.
4. The micrometre should turn smoothly and freely throughout the entire range, and it should not bind or freeze during the check.
5. Set master block into four height ranges, .watch the video

1.6 Undertake routine care and storage of the micrometre
Maintenance of micrometres
The following actions are required to maintain micrometre accuracy:
• Daily inspection; micrometre should be checked continuously after each use and before storage.
• Cleaning and rust prevention;
• Storage of micrometres.
Cleaning and rust prevention
 After using the micrometre, wipe off oil.
 Separate the two measuring faces slightly before storing the instrument.
 If a micrometre is not going to be used for an extended period, wipe it thoroughly and
apply high-grade rust-preventing oil.
Storage of micrometres:
Note the following points when storing a micrometre.
• When storing the micrometre do not expose it to direct sunlight.
• Store the micrometre in low humidity, well ventilated and dust free environment.
• Leave the measuring faces separated by 0.1 mm to 1 mm.
• Do not clamp the spindle
• Store the micrometre in a case.

2- Perform Angular measurement using protractors and combination square
Angular measurement is closely associated with a linear (straight-line) measurement. Parts that are manufactured may have angles or tapers
that are required to fit accurately to mating parts. Certain measuring equipment has been designed to measure angles or tapers in degrees or parts
of a degree.
2.1-Use a protractor to perform angular measurement: Protractors have a dial face graduated in degrees, with a
straight blade that can be swivelled to an angle, and then locked in position. Protractors are used for:
 Setting work to an angle
 Testing angles
 Marking out the position of holes
NOTE: Because they are graduated only in degrees, protractors should not be used for
the accurate measurement of angles.
Applications of Protractor:
Testing angles marking out angle on the work setting work to an angle marking out the position of holes

2.2-Identify the Combination square parts and use them to perform angular measurements:
A combination square is a tool used for multiple purposes in metalworking. The square refers to the primary use of the tool;
measuring the accuracy of a right angle (90°). At its minimum, the tool is composed of primarily two parts; a rule and ahead.

2.3 Recognize the different applications of a combination square
 Measuring angles – a combination square can reliably measure 90° and 45° angles. The 45° angle is used commonly in creating
mitre joints.
 Determining flatness – when working with metal, a first step is to designate a reference surface on a workpiece. The rest of the
workpiece is measured from the reference point. The rule of the combination square is assumed to be flat.
 Measuring the centre of a circular bar or dowel. The rule is assembled through the centre of the centre square, the two cast iron
legs of the centre square are then placed against the outside of the bar (dowel) allowing a centre line to be scribed alongside the
ruler. Perform this action at two locations and the intersecting lines will approximate the centre of the bar (dowel).
 Protractor head allows angles to be set and measured between the base and ruler.
 A rudimentary level for approximating level surfaces is incorporated in the protractor and also the 45° holder.
 Marking the work surface; with the included scribe point stored in a drilled hole in the square base
 The protractor is useful for non-critical jobs in metal work for setting large items at the required angle in machine vices. The long
reach of the ruler and firm, heavy base aid the setting up process.

2.4-Perform thread measurement using a thread gauge
Thread gauge:
A thread pitch gauge, also known as a screw pitch gauge or pitch gauge, is used to measure the pitch or lead of a screw thread.
Thread pitch gauges are used as a reference tool in determining the pitch of a thread that is on a screw or in a tapped hole. This tool
is not used as a precision measuring instrument. This device allows the user to determine the profile of the given thread and
quickly categorize the thread by shape and pitch. This device also saves time, in that it removes the need for the user to measure
and calculate the thread pitch of the threaded item
Thread gauge usage:

 For measuring ISO metric thread form
 For measuring the Acme thread form,
 For measuring Whitworth screws.

3. Describe and demonstrate the correct procedure for producing internal and external screw threads
3.1- Identify the manual thread cutting operations.

Taps and dies are tools used to create screw threads, which is called threading.
A tap is used to cut or form the female portion of the mating pair (e.g., a nut).
A die is used to cut or form the male portion of the mating pair (e.g., a bolt).
Tapping: The process of cutting or forming threads using a tap.
Threading: The process of cutting or forming threads using a die.
Chasing: The process of cleaning up a thread with a tap or die.
A screw is a cylindrical bar on which a thread has been cut. A thread is a continuous spiral groove. The shape of the thread depends
on:
1. It's use
2. The country that it comes from.
Most screws have what is called a ‘right - hand thread’. This is where the spiral groove (thread) has been cut into the bar in a
clockwise direction. The nut, when used with a screw, must have the same type of thread.
3.2-Identify the Parts of threads.

For identifying different types of thread, the following names are given to its different parts.

3.3-Differentiate between Coarse and fine pitch threads.
Coarse pitch threads
Coarse pitch threads have only a few threads per unit length. They are used in general engineering and on specialized equipment.
Fine pitch threads
Fine pitch threads have many threads per unit length. They are used because they resist loosening by vibration and they are
stronger.

3.4-Understand the international different thread systems in use.
There are many types of thread systems in use. The main differences are in the thread angle and the pitch of the thread.
Care must be taken when selecting screws and nuts because the threads of one system will not fit the threads of a different system.
The following types of thread system are in common use:
1. ISO METRIC the thread size is in millimetres. This system is used on all new engineering products.
2. UNIFIED NATIONAL FINE and UNIFIED NATIONAL COURSE. (UNF & UNC). This is an American thread system. It has the same
type of thread form as the ISO METRIC system but the size is in inches.
3. BRITISH STANDARD PIPE. (BSP). This is a British Standard thread. The size refers to the bore diameter of the pipe. This thread
system is used for pipe fitting; it can have a parallel or tapered thread.
Thread gauge

3.5 Describe and demonstrate the correct procedure for producing internal and external screw threads.
Determine the Threads: Tapping is when your threads are cut into a hole. A die set is used to cut threads onto a cylinder (bolt). To
use a tap or a die, first determine the threads: https://www.youtube.com/watch?v=Gdvtw0pTAOs
1-Per inch: (TPI) teeth per inch, of the part to be fixed. A gauging system that has a number of different pins can be used to
calculate the TPI of a bolt or nut. After determining the TPI of a bolt, choose the die that corresponds to it. A tapered die will tell
which side to begin using. The die fits into a special wrench that holds and guides the
die
2-Metric: By using a micrometre or calliper, determine the major diameter; use the
metric thread gauge to measure the thread pitch.
The tap wrench: The tap wrench is fitted to the top of the tap to provide a secure method of holding and turning the tap.
Using a tap wrench:
1. Drill the hole to the correct size. This is the minor diameter of the thread that you want to tap. The information can be obtained
from THREAD DATA TABLES.
2. Ensure the work is secure.
3. Ensure the tap is at 90° to the work surface.

4. Use lubricant.
5. After each half turn (180°) of cutting, the direction should be reversed for a quarter turn (90°). This will break the metal that has
been cut (swarf) and prevents the tap from jamming.
6. Do not use a lot of force, as taps break very easily.

Taps and tapping:
Tapping is the process of cutting an internal thread. Hand taps are used in sets of three:
1. TAPER TAP is used to start the thread. The first 8 - 10 threads are tapered off so that they gradually cut to the full size of the
thread.
2. The SECOND TAP is used to complete a thread in a hole that passes completely through the material. The first 4 - 5 threads
are tapered.
3. PLUG TAP is used to finish tapping blind holes (holes that only go part way through the material).

Dies and die cutting:
This is the process of cutting external threads onto the round bar. There are two types of die.
1. A DIE NUT is only used to repair damaged threads. Never use it to cut a new thread.
2. A BUTTON DIE fits into the die stock. Adjust it to the fully open position for the first cut and then gradually close it until you get
the finished sized thread.

The die stock: The die stock is used to hold the die. It provides handles for turning the die. Use the adjustment screws to open and
close the die. This gives a certain amount of adjustment in the depth of cut.
Using the die stock
1. Always chamfer the work to ease the starting of the thread.
2. Ensure the work is secure.
3. Ensure the die and die stock is at 90° to the work.
4. Use lubricant.
5. After each half turn (180°) of cutting, the direction should be
reversed for a quarter turn (90°).

Metric Nuts and Bolts http://www.myronsmopeds.com/category/service/threads/
Metric thread nuts and bolts are used in products made in every country in the world, except for the USA.
Size: Metric bolts (male thread) and nuts (female thread) are named by the outer diameter of the male thread. The name begins
with a capital M and the size. So an M4 bolt is a 4 mm metric, M5 is 5mm metric.
Pitch: After the size is the thread pitch, which is the width of each thread. A 1.0 pitch is 1mm wide, so 10 threads are 10mm. A 1.25
pitch is 1.25mm wide, so 10 threads are 12.5mm. A 1.50 pitch, 10 threads are 15mm. A metric ruler laid alongside a bolt can
measure the length of 10 threads. Then the thread pitch is calculated by dividing by 10.
Length: After the pitch is the length, in millimetres. The length of a bolt does not include the head. It is the length of the shank,
from the base of the head to the end. So an M6 x 20 hex bolt has a 20mm long shank. But counting it’s 5mm tall hex head, the total
length is 20 + 5 = 25mm.

3.6 maintain and store taps and dies.
Care of taps:
1 Do not damage the cutting edges.

2 Always store taps in boxes or racks in a clean and lightly oiled condition.
3 Never use a chipped tap.
Care of dies:
1 Keep dies clean.

2 Store them carefully to avoid damage to their cutting surfaces.
3.7 Recognize and follow the safety Precautions while working with taps and dies:
1-Before using either tap or dies, test the material to determine that it is not hardened by attempting to mark it with a file:
• If the material marks with a file, the material should be cut-able.
• If the material will not mark with a file, do not cut threads to avoid tool damage.
2- Inspect before every use; do not use if parts are loose or damaged. Do not use cracked or chipped tap/die.
3- Keep the handles clean, dry, and free from oil and grease at all times.
4- The flutes on these tools are sharp and can cut you. Handle with care.
5- Do not apply excessive force on the cutters. Allow the tool to do the work. Use cutting oil when tapping or threading hard
materials.
6- Taps and Dies are heat-treated, and not designed to be sharpened.

Use hand tools, Riveting:
Riveting is a forging process that may be used to join parts together by way of a metal part called a rivet. The rivet acts to join
the parts through adjacent surfaces. A straight metal piece is connected through the parts. Then both ends are formed over the
connection, joining the parts securely
4-Understand the reviting process and use them to join parts together
4.1-Identify the advantages of Revit joints

Rivets are used to join metal. They form secure joints between plates. They have the following advantages over nuts and bolts.
• They are lighter.
• They are cheaper.
• They are quicker to use.
4.2-Identify the different types of rivets: http://www.technologystudent.com/joints/rivt1.html

Rivets come in many shapes and sizes.They can be solid or hollow
Solid rivets: can be made from, steel, aluminium and copper.

These are three common types of solid rivets; they are described by the shape of their head
Rivets are identified by the shape of the head and the length and diameter of the shank.

Hollow (blind) rivets:
One types of the hollow rivet are the pop or blind rivet

4.3- Form a solid rivet head correctly and safely using Snaps and Dollies.
https://www.youtube.com/watch?v=IDbTUt3OG9s
Forming a solid rivet head is done using special tools called Snaps and Dollies

4.4-Identify the required clearance to form the solid revit correctly.
The hole size must allow Clearance around the rivet shank to allow the head to form correctly

4.5- Recognize the Riveting faults.
1-The hole is too large in diameter; the rivet shank will bend inside the hole.
2-The rivet is too short, the weak head will be formed.
3-The rivet shank is too long, the rivet will bend outside the hole and form a weak head.

4.6-Identify the Minimum allowances for riveted joints.
Open the link below and watch hot riveting.

https://www.youtube.com/watch?v=P3ohhK15SCs

Types of riveted joins:

4.7- Understand the Forming process for the head of a pop rivet:
https://www.youtube.com/watch?v=kbWHOmofT8A
The pop or blind rivet head is formed using special tools called pop riveting (gun) pliers. The breakable pin has a weak section
which will break leaving a formed rivet head in the work. This type of rivet is used mainly when only one side of the work can be
reached.
Step 1 step2 step3 step 4
4.8- Use the Pop Rivet Tools correctly and safely to perform riveting operations
Hand tools: https://www.youtube.com/watch?v=gcA5F5vvWHE
There are a number of different hand riveters on the market, all designed to suit the users’ budget and usage requirements.
• The basic riveters all come with a variety of nibs to accommodate different stem thicknesses.
• Riveters (rivet gun) can also have longer handles, which provide extra leverage,
• And there are even hands riveters designed to fit into difficult to get to and confined spaces
Pneumatic Rivet Tools

4.9-Recognize and implement the Safety Precautions while working with riveting work
1- Inspect the tool for damage or improper assembly.
2- Faulty equipment must not be used.
3- Ensure your body position allows you to have control of the tool at all times.
4- Clamp the two pieces together and drill a hole into the workpiece slightly larger than the rivet.
5- Place the rivet into the end of the gun and place the gun over the hole. Squeeze the handles of the gun together. Control the
rivet gun with your hand. Do not push hard on the gun while riveting. The pop rivet pinhead is pulled into the rivet and the
end of the rivet is expanded. The pin will break off and leave the rivet permanently fixed into position.
6- Leave the gun in a safe, clean and tidy state.
7- Clean up and return tools to proper storage location after use.
4.10- Remove blind rivets correctly and safely with drill and Chisel:
https://www.youtube.com/watch?v=g7o0IxhfwyI
If circumstances arise that requires a blind rivet to be removed, it is recommended that the following steps are undertaken
carefully or damage to the clamped material may result.
1 Remove Rivets with a Drill:
1. Ensure the stem is well below the rivet head; drive it below the head with a punch.
2. Select a drill bit with the same diameter as the recommended hole size for the rivet, and drill through the head until enough
material is removed to separate the head from the shell.
3. Punch the remainder of the shell clear of the clamped material.

2 Remove Rivets with a Chisel:
1-Shear off the head of the rivet by placing chisel flushes with the metal just under the lip of the rivet head. Use a hammer to tap
the end of the chisel until the head of the rivet is removed.
2- Use a punch to tap out the pin of the rivet.

5. Drilling machines
A drilling machine, called a drill press, is used to cut holes into or through metal, wood, or other materials (Figure 6-1). Drilling
machines use a drilling tool that has cutting edges at its point. This cutting tool is held in the drill press by a chuck or Morse taper
and is rotated and fed into the work at variable speeds. Drilling machines may be used to perform other operations. They can
perform countersinking, boring, counterboring,
5.1 Identify different Drilling machine types.
Drilling machine types come in all sizes, from the simple hand drill (used when extreme accuracy is not required) to large radial
arm drilling machines capable of several complex operations
1-Manual Hand Drill Hand drills may be considered old-fashioned, but are still useful for woodworking and other tasks where
you want to have total control and for who prefer not to use power tools

1 Electrical hand drill:
A cordless drill is an electric drill which uses rechargeable batteries. These drills are available with similar features to an AC
mains-powered drill. ... They are available in the hammer drill configuration and most have a clutch, which aids in driving screws
into various substrates while not damaging them. Can be used with a range of accessories, from grinding, drilling to cleaning.
Different Types of Electric Drills in the Market
 Pistol Grip. A pistol grip drill is the most common type of corded drill available. ...
 Hammer Drill. A hammer drill also called a masonry drill, is used most commonly with concrete or brick. ...
 Drill Press. A drill press is a fixed style of drill that can be used on a workbench. ...
 Cordless Drills

3. Bench drill: The table of the bench drill moves in a vertical direction. The bench drill has hand feed only. The drill size and range of
speeds is limited. https://www.youtube.com/watch?v=dTFECAJu0D4

4 Pillar drill: The pillar drill has a greater range of speeds than the bench drill. It can use larger drills so bigger workpieces can
be drilled. The table of the pillar drill moves vertically and it also swivel

5.2- Understand and implement the standard operating procedure while working on drill machines.

5.3-Identify different types of machine vice used with drill machines.
When carrying out any machining operation, you must secure the work, both for safety and accurate machining.
The machine vice: works in exactly the same way as a bench vice and is bolted to the machine table.
Machine vice
There are two other main types of machine vice:

5.4 Identify different drill types, their usage and securing methods
There are many types of drill bits regarding the purposes,
https://www.youtube.com/watch?v=hJItj_ISurY
https://www.youtube.com/watch?v=rUMTJ9GZIC8
https://www.youtube.com/watch?v=cqn2VPGYA9c
Twist drill bits: Drill can be defined as a rotary end-cutting tool having one or more cutting lips and having one or more helical or
straight flutes for the passage of chips and the admission of a cutting fluid
Drill bits are used for machining holes and for general use. They are usually made from high-speed steel (H.S.S.). They are identified
by their diameter and the material from which they are made.

They are classified by the shape of the shank:
1. Parallel shank.
2. Tapered shape

Parallel shank twist drill:
Parallel shank drills are used in hand-held drills, drilling machines and machine tools (lathes, milling machines).
The parallel shank drill fits into an adjustable chuck.
Key less chuck

Tapered shank twist drill:
Morse taper shank drills are supplied in diameters ranging from 3 mm diameter to100 mm diameter.
Morse tapers are self - holding tapers.
The tang on the end of the drill shank is for removal purposes only.

Tapered shank drill removal:
To remove a drill with Morse taper shank from the machine spindle, a drill drift is used.
The drift is made from mild steel to ensure there is no damage to the drill or machine spindle.
Use hammer lightly with drill drift.
Wear a glove to protect hands from drill sharp edges.

5.5 Identify drill bit gauge types and their usage: https://www.youtube.com/watch?v=EhR0R5nVxEY
A drill gauge is a device used to identify the size of a drill bit. It can be made from steel, aluminium, plastic or wood, and contains a
series of holes that represent various drill bit sizes.
The sizes of a bit are based on the bit's diameter and are available in both metric and fractional units. Metric drill bits are typically used
in countries that use the metric system, while fractional-sized bits are used in the US and other countries that do not typically use the
metric system

5.6- Recognize the importance of the twist drill angles
To sharpen a twist drill correctly, the drill angles must be known.
Clearance angle
The clearance angle should be kept between 12˚ - 15˚. If no clearance is provided, the drill will not cut.
Helix angle
The helix angle is produced by the spiral of the flute. This angle produces the rake angle and cannot be changed. Drills can have
various helix angles for drilling different materials.

Point angle
It is very important that the point or lip angle is equal on the two cutting edges. It is also important that the lengths of the cutting edges
are equal to prevent oversize holes being drilled.
Drill bits usually have a point angle of 118° or 130°.
Checking point angles:
Using marking blue

5.7- Identify different drilling operations and Implement them correctly and safely to manufacture holes
https://www.youtube.com/watch?v=-FunB2blKHg
https://www.youtube.com/watch?v=KbI_7IHAsyw
 Drilling is a cutting process that uses a drill bit to cut or enlarge a hole of circular cross-section in solid materials. The drill
bit is a rotary cutting tool, often multipoint. The bit is pressed against the workpiece and rotated at rates from hundreds to
thousands of revolutions per minute.

 Centring: Center drilling is used for accurately locating a hole to be drilled afterwards.
Center drills
 Countersinking: Countersinking is similar to counterboring except that the step is angular to allow flat-head screws to be
seated below the surface.
Combination with drill
Countersink tools maybe separate or combination with a drill

 Counterboring: Counter boring produces a larger step in a hole to allow a bolt head to be seated below the part surface.
 Tapping: A tap is used to provide internal threads on a previously drilled hole.

 Reaming: A reamer is used to enlarge a previously drilled hole, to provide a higher tolerance and to improve the surface finish of the
hole.
Drilling holes to depth: Holes can be drilled to a particular depth by setting the depth stop on the machine
 Some electrical hand drills include a depth stop in a secondary handle

Drill depth stops fixed on the drill bits directly

6. Identify the main parts of tool grinders their safety precautions and use them to re-sharp the twist drills to
achieve the correct drill angles. https://www.youtube.com/watch?v=GB-Pa73Snp4
The tool grinding machine in an engineering workshop is a very important part of the equipment necessary for a craftsman to make
or regrind cutting tools before and during a machining operation.
6.1- Recognize the main parts of the bench and pedestal tool grinders, and their importance in the
workshops.
The pedestal grinder stands on its own base and is secured to the floor, while the bench grinder has no pedestal and is secured
directly to the bench top. Both types are driven by an electric motor with a grinding wheel mounted at each end of the spindle. One
wheel is usually a coarse wheel, for rough grinding, while the other is a fine-grained wheel for finish grinding.

6.2 Adjust the tool rest correctly to provide support for the tools while being ground
http://www.finewoodworking.com/how-to/video/bench-grinder-basics.aspx
The work rests provide support for the tools while being ground. They are fitted, secured and adjusted as close to the wheel as
possible, without touching the wheel.
Hold the work in one hand, and steady it with the other. Place the work on the tool rest; then guide it against the face of the
revolving wheel and apply enough pressure to grind, depending upon the hardness of the material and the wheel itself.
Note: Support the work on the tool rest to steady it when grinding, except in the case of the small tool bits which can be guided
better by supporting them with the fingers or with a hand resting on the tool rest.

6.3 Recognize the Safety precautions for tool grinders and implement the standard operating procedures
1. Always wear approved safety glasses when operating the grinding machine.
2. Always stand to one side of the grinding machine when switching it on.
3. Always make sure the guards are fixed and secure.
4. Always check that the tool rest is set to a minimum gap between the wheel and the rest.
5. Always visually check the condition of the wheel before using it.
6. Never force the tool being ground into the wheel.
7. Do not grind on the side of the wheel unless it is designed for that purpose.
8. Report any wheel that is accidentally or otherwise damaged.
9. Never use a tool grinder that is not safe.

6.4-Understand the grinding wheels safety, speed and dressing.
The grinding wheel is made up of a hard substance called abrasive which is embedded in a bond. The abrasive grains project from
the wheel faces and act as tiny cutting tools. All tools become dulled by use, and the sharp edges of these grains will lose their
cutting effect. If the wheel is suitable for its work they will either split and form a new edge or break away from the wheel and
expose another grain to carry on with the work.
Grinding wheel safety:

 Select correct wheel for your operation.
 Adjust wheel guard and put safety glasses before starting wheel.
 Adjust tool rest.
 Stand aside and allow the wheel to run idles a full minute before starting to grind.
Wheel speed:
The speed of the wheel is related to its diameter. Check the information on the wheel’s paper washer for its maximum speed in
Rev/min. Do not use a wheel on a grinding machine whose speed exceeds the rev/min written on the wheel’s paper washer.

Wheel dresser: https://www.youtube.com/watch?v=WFTaW7O4_Ws
https://www.youtube.com/watch?v=BkyLua8t10M
A wheel which has become either loaded or glazed will not cut metal. To return the wheel to a good condition it must be dressed
using a Huntington dresser (wheel dresser).
To dress the wheel, support the dresser on the tool rest so that the point of contact is slightly above the centre, and with the handle
tilted upward at an angle

6.5- Re-sharpening the twist drill correctly and safely use offhand method considering the twist drill
angles
https://www.youtube.com/watch?v=y0SQkzScQk0
https://www.youtube.com/watch?v=72syhJoOsHM
Twist drills become dull and must be re-sharpened. The preferred method of re-sharpening a twist drill is with the tool grinding
machine, but this machine is not always available in field and maintenance units, so the offhand method of drill re-sharpening must
be used.
The offhand method requires that the operator have knowledge of the drilling geometry and how to change drill angles as needed for
any drilling job

Tools needed are:
1. Bench grinder with a dressed wheel/coolant

2. Drill point gage or protractor head on the combination square
3. PPE

Suggested Practical task: 01
The teacher can use this or another task to practice the contents with the students.
Material: Aluminum plate 100x50x20(thickness from 20 to 5mm is ok) Use the
workshop tools to cut the workpiece as in the drawing below. Students can
follow the steps below.

Phone/ laptop holder

Suggested Practical task for riveting: 02
1-Teacher can practice rivet joint with students


Suggested projects: 01
2-Instruction:
Waste shovel Steel sheets will be rigidly joined by rivets. The students use 4 mm rivet. This shovel for waste disposal can be
used for cleaning purposes in the workshop. The dimensions can be from students design.
Example:

Suggested project 02-group work project
Tools box


Book STS EMM420 2018 2019

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Book STS EMM420 2018 2019

Uploaded by

Copyright:

Available Formats

Mechanical Engineering Fundamentals II- EMM420- G09-Term2

EMM420- G09-Term2 1 A.A-version 05-2018/2019

Course learning outcomes:

1 Perform Linear measurement using Micrometre

EMM420- G09-Term2 2 A.A-version 05-2018/2019

Standard Learning Outcome Performance Criteria

EMM420- G09-Term2 3 A.A-version 05-2018/2019

EMM420- G09-Term2 4 A.A-version 05-2018/2019

1 -Perform Linear measurement using Micrometer

EMM420- G09-Term2 5 A.A-version 05-2018/2019

2-Micrometre main scale:

EMM420- G09-Term2 6 A.A-version 05-2018/2019

4-Micrometre index line:

EMM420- G09-Term2 7 A.A-version 05-2018/2019

EMM420- G09-Term2 8 A.A-version 05-2018/2019

EMM420- G09-Term2 9 A.A-version 05-2018/2019

The frame is held by the user whilst measurements are taken.

EMM420- G09-Term2 10 A.A-version 05-2018/2019

EMM420- G09-Term2 11 A.A-version 05-2018/2019

1.3 Read the Micromere to an accuracy of 0.01 mm:

EMM420- G09-Term2 12 A.A-version 05-2018/2019

EMM420- G09-Term2 13 A.A-version 05-2018/2019

EMM420- G09-Term2 14 A.A-version 05-2018/2019

EMM420- G09-Term2 15 A.A-version 05-2018/2019

EMM420- G09-Term2 16 A.A-version 05-2018/2019

EMM420- G09-Term2 18 A.A-version 05-2018/2019

EMM420- G09-Term2 19 A.A-version 05-2018/2019

Gauge block set

Calibration guidelines for micrometres:

EMM420- G09-Term2 20 A.A-version 05-2018/2019

EMM420- G09-Term2 21 A.A-version 05-2018/2019

EMM420- G09-Term2 22 A.A-version 05-2018/2019

EMM420- G09-Term2 23 A.A-version 05-2018/2019

EMM420- G09-Term2 24 A.A-version 05-2018/2019

Thread gauge usage:

EMM420- G09-Term2 25 A.A-version 05-2018/2019

3.1- Identify the manual thread cutting operations.

2. The country that it comes from.

3.2-Identify the Parts of threads.

EMM420- G09-Term2 26 A.A-version 05-2018/2019

Fine pitch threads

EMM420- G09-Term2 27 A.A-version 05-2018/2019

The following types of thread system are in common use:

EMM420- G09-Term2 28 A.A-version 05-2018/2019

Using a tap wrench:

2. Ensure the work is secure.

3. Ensure the tap is at 90° to the work surface.

EMM420- G09-Term2 29 A.A-version 05-2018/2019

6. Do not use a lot of force, as taps break very easily.

EMM420- G09-Term2 30 A.A-version 05-2018/2019

EMM420- G09-Term2 31 A.A-version 05-2018/2019

EMM420- G09-Term2 32 A.A-version 05-2018/2019

Using the die stock

1. Always chamfer the work to ease the starting of the thread.

2. Ensure the work is secure.

3. Ensure the die and die stock is at 90° to the work.

5. After each half turn (180°) of cutting, the direction should be

reversed for a quarter turn (90°).

EMM420- G09-Term2 33 A.A-version 05-2018/2019

EMM420- G09-Term2 34 A.A-version 05-2018/2019

1 Do not damage the cutting edges.

1 Keep dies clean.

EMM420- G09-Term2 36 A.A-version 05-2018/2019