INTRODUCTION

Safety precaution
 Safety describes that it is the way of doing
work correctly to prevent accident.

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 It can be defined as the way of prevention of
accidents.
The prevention of accident concerns
 The work man (operator) and his partner
 The work piece
 The working tool
 the work shop

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Causes of accidents
 Faulty attitude towards safety

 Emotions (anger, worry, excitements…)

 The other causes of accident are not to take safety as a

way of life.

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General safety measures
 Dress correctly (wear apron, short sleeved beltless
coats).
 Remove rings, wrist watches, necklaces, bra- slates.

 Protect your eyes

 No horse play

 No scrap materials on the flour

 Take care of injuries

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MEASUREMENT
o Measurement is the process of determining or
finding the size, quantity or degree of something .

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o The principle dimensional measurement is
length; secondary measurement is angle and
curvature. You can describe shape without
describing size, but not the reverse.
o Measurement science is vital for trade
&commerce ,&the basis of modern science&
technology.

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 MEANS OF MEASUREMENT

The means of measurement could be classified as

follows:

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I. Standards (reference masters or setting
standards)-these are used to reproduce one or
several definite values of a given quantity.
II. Fixed gauges-these are used to check the
dimensions, form, and position of product features.
III. Measuring instrument-these are used to
determine the values of the measured quantity.

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MEASUREMENT UNITS
SI UNITS

Measured Quantity Units Symbol

Length Meter m
Mass Kilogram Kg
Time Second s
Temperature Kelvin K
Electrical Current Ampere A
Quantity of substance Mole mol
Luminosity Candela Cd
Plane angle Radian rd
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ENGLISH UNITS

English unit Value Equivalent value

in SI

Miles 1mile=1760yard 1 mile = 1.609 km

Yard
1 yard = 3 ft 1yd = 91.44 cm

Foot
1 ft = 12 in 1 ft = 30.48 cm

Inch
in 1 in = 25.4 mm

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STEEL RULE
Use:- for linear measurement and
marking.
Material:- spring steel or stainless

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steel.
Graduation:- in 10mm, 5mm, 1mm
and 0.5mm in metric system. The
reading accuracy of the steel rule is
0.5mm.
Size:- available in 150mm, 300mm
& 600mm. 7
 Lengths can be measured by using the
following
 metre/half-metre rule
 accuracy = 1 mm / 0.1 cm / 0.001 m

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calipers
Calipers are the very simple tools used together with a
steel rule for the measurement or comparison of linear
dimensions

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Outside caliper
Outside calipers are used for measuring external
dimensions such as the length, diameter, or even the
thickness of a solid.

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remove the calipers and measure
the jaws are closed until the distance between the jaws
the points just touch the with a ruler 10

object to be measured
Inside caliper
Inside calipers are used for measuring internal dimensions such as
the diameter of a hole, or the width of a slot etc.

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VERNIER CALIPER
 Function
 To measure smaller distances
 Can measure up to .001 inch or .01mm.

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 Features
 Larger, lower jaws are designed to measure outer points e.g.
diameter of a rod.
 Top jaws are designed to measure inside points e.g. size of a hole.
 A rod extends from the rear of the caliper and can be used to
measure the depth.

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STRUCTURE OF VERNIER CALIPER

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STRUCTURE OF THE VERNIER CALIPER
 Main Scale
 Main scale is graduated in cm and mm.

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 Vernier Scale
 It slides on the main scale.
 On Vernier scale 0.9cm is divided into 10 equal parts.

 Jaws
 Two inside jaws (Upper)
 Two outside jaws (Lower)

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LEAST COUNT
 Leastcount (L.C) is the smallest reading we can
measure with the instrument.

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 L.C = one main scale division – one
vernier scale division
L.C = 1mm – 0.09mm
L.C = 0.1mm = 0.01cm
 LeastCount = Value of the smallest division on MS/
Total number of division on VS
L.C = 1mm / 10 = 0.1 cm / 10 = 0.01cm

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HOW TO USE VERNIER CALIPER?
 Close the jaws
 Calculate the least count

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 Place the object between the
two jaws
 Record the position of zero
of Vernier scale on the Main
scale (3.2cm)
 Notice the reading of VS
which coincides with MS
reading (3rd division in this
case)
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READING OF THE INSTRUMENT
 Reading of the instrument = MS div +
(coinciding VS div x L.C)

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 = 3.2 + (3 x 0.01)

 = 3.2 + 0.03

 = 3.23 cm

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TO MEASURE THE DEPTH
 A rod extends from the rear of the caliper and can be used to
measure the depth.

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 Open the jaws of caliper and place the rod inside hole of the
object, such as the rod reaches the inner most portion of the
object.
 Read the Vernier caliper. (same procedure as described in
previous slides)

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MEASURING EXTERNAL DIAMETER

Use the outside jaws of the

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caliper as shown

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MEASURING DEPTH OF A HOLE

Use the depth gauge of

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the caliper as shown

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 READING THE VERNIER SCALE
 Read the “0” position of the vernier scale on the main scale to
get a rough reading. Rough reading = 18mm

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Look along the veriner
scale until one of the
veriner division
coincides with the
mail scale.
Accurate reading
=18.46mm ±0.01

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EXAMPLE 1: The external measurement (diameter) of a round section piece of steel is
measured using a vernier caliper, metric scale.

A. The main metric scale is read first and this shows that there are 13 whole divisions
before the 0 on the hundredths scale. Therefore, the first number is 13.
B. The’ hundredths of mm’ scale is then read. Only one division on the main metric
scale lines up with a division on the hundredths scale below it, whilst others do not. In
the example below, the 41st division on the hundredths scale lines up exactly with a

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division on the metric scale above.
C. This 41 is multiplied by 0.02 giving 0.82 as the answer (each division on the
hundredths scale is equivalent to 0.02mm).
D. The 13 and the 0.82 are added together to give the final measurement of 13.82mm
(the diameter of the piece of round section steel).

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 EXERCISE
What is the reading in the caliper shown?
Please click on one of the following answer.

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A. 3.51cm

B. 3.57cm 3 4

C. 3.62cm 3.5

D. 3.642cm
0 5 10
E. 3.67cm

overlap
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 SOLUTION
Read the “0” position of the
vernier scale on the main scale

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to get a rough reading.
Rough reading = 3.6cm
Look along the vernier scale
until one of the vernier division 3 4
coincides with the main scale
Accurate reading =
3.67cm±0.005cm
0 5 10

overlap
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vernier depth gauge
A vernier depth gauge is
used for measuring depth
of hole, slots and

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recesses.

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Vernier Height Gauge
A vernier height gauge is used for
measuring height of an object or

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for marking lines onto an object of
given distance from a datum base.

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LAYING OUT

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 Laying out is the process of scribing lines, points and arcs on to
the metal to indicate the shape and size of the object or it is
transforming the drawing of the object to be made on to the metal.
Accuracy of a layout is very important to the accuracy of the

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

finished product.
 Good layout will entail the proper and careful use of all layout
tools.

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 SCRIBER
Use:- scribe lines to indicate the dimensions of the work
piece to be filed or machined.
Material:- They are made of high carbon steel.

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Types:- 1. Single ended 2. Double ended
3. Knife edge 4. Off-set.
1. Single ended:- This scriber is also
known as Hand scriber. Point is
made on one side only. Knurling is
made on the body of this scriber. It
is used for general marking
purposes. 32
Straight 2. Double ended:- This scriber has
Point
one point each at both ends. One of

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which is bent at 90º, another point
is kept straight. Centre portion of
body is knurled for better gripping.
Grip This scriber is used mainly in
accordance with scribing block.
Bent
Point

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 3. Knife edge:- This scriber has one
point each at both ends. One of
which is knife edge, another point
is kept straight. Centre portion of

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body is knurled for better gripping.
This scriber is used mainly for
plastic and wood working

4. Off-set:- Point of this scriber is made

offset to facilitate the marking of
minimum height and to set zero when
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used with Vernier Height Gauge.
 TRY SQUARE
Use:- to check the squareness of
machined surface, flatness of
surface, make lines at 90º to the edge

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Blade of work pieces & to set work piece at
right angle on work holding device.
90º Material:- hardened steel.
Size:- available in 100mm, 150mm
& 200mm.
Types:- 1. Fixed try square
Stock 2. Adjustable try square35
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 DIVIDER

Use:- for scribing circles, arcs

and transferring and stepping

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of distances.
Material:- tool steel or high
Spring
carbon steel.
Type
Size:- 50mm to 200mm.

Wing
Type
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 • For the correct location and setting of the
divider legs, prick punch marks of 30º are
used.
• Both the legs of the divider should always

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be of equal length.
• Dividers are specified by the type of their
joints and length.
• The divider point should be kept sharp in
order to produce fine lines. Frequent
sharpening with an oil stone is better than
Firm Joint sharpening by grinding. Sharpening by
grinding will make the points soft. 38
TRAMMEL
Used to scribe larger circles and arcs that are not within
the capacity of dividers

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 CALIPER
CALIPER:- Calipers are simple measuring entinstrum
used to transfer measurement from steel rule to objects
and vice versa. They are made from tools steel or high

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carbon steel.
Outside Caliper
1. Firm joint caliper:- In the case of firm joint
caliper, both legs are pivoted at one end.
To take measurement of a work piece, the
caliper is opened roughly to the required
size. Fine setting is done by tapping the
caliper lightly on a wooden surface.
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Spring 2. Spring joint caliper:- For this type of
caliper, the legs are assembled by means of
Pivot a pivot loaded with a spring. For opening

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and closing the caliper legs, a screw and nut
are provided.
Spring joint caliper have the advantage
of quick setting. The setting made will not
change unless the nut is turned. The size of
caliper is specified by its length, which is
the distance between the pivot centre and
Adjusting the tip of the leg.
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Unit
 Inside Caliper

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3. Inside Caliper:- This caliper is used to measure the inside
dimensions like the width of slots, diameter of holes, etc.
Legs of this caliper are bent in outward direction as shown
in figure beside.
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4. Odd leg Caliper:- This caliper is also known as Jenny
caliper or Hermaphrodite caliper or leg and point
caliper.They are used for marking lines parallel to inside
and outside edges, locating the centre of round bars,
drawing parallel lines along outer edges, scribing lines
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along curved edges.
 Engineer’s bevel:- is a tool that is used for transferring
angles and testing angular surfaces for accuracy. This
tool not used for measuring angles.
Bevel Protractor:- is used to check the angles of

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inclined surfaces, marking out, and for transferring
angles. Graduated in degrees from 0-1800

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Combination set:- is a versatile too used in laying out that
consists of a steel rule, square head, bevel protractor and
center head.

bevel protractor

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steel rule,

center head square head

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Blade
The blade is designed to allow the different heads to slide along the blade
and be clamped at any desired location. The groove in the blade is
concave to eliminate dirt buildup and permit a free and easy slide for the
heads. By removing all the heads, the blade may be used alone as a rule.

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Square Head
The square head is designed with a 45° and 90° edge, which makes it
possible to be used as a try square and miter square. By extending the
blade below the square, it can be used as a depth rule. The square head
can also be used as a level.

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Bevel Protractor
The protractor head is equipped
with a revolving turret graduated in
degrees from 0 to 180 or to 90 in
either direction. It is used to
measure or lay out angles to an

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accuracy of 0.5°.

Center Head
The center head, when inserted on
the blade, is used to locate and lay
out the center of cylindrical work
pieces.
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 PUNCH
Use:- Punches are used in order to make certain
dimensional feature of the layout permanent.

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Material:- They are made of high carbon steel.

Types:- 1. Centre punch(90º)

2. Dot punch(60º)
3. Prick punch(30º)
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1. Centre Punch:- The angle of
the point is 90º. The punch
mark made by this is wide and

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not very deep. This punch is
used for locating hole. The
wide punch mark gives a good
seating for starting the drill. Centre Punch

2. Dot Punch:- The angle of the

point is 60º. This punch is used
for marking witness marks. 49

Dot Punch
 Prick Punch
3. Prick Punch:- The angle of the
point is 30º. The 30º point

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punch is used for making light
punch marks needed to position
dividers. The divider leg will
get a proper seating in the
punch mark.
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 SURFACE PLATE

Use:- Surface plates are used most widely as a datum

surface in machine shop work.

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Material:- Gray cast iron and Granite.

Specification:- Cast iron surface plates are designated by

their length, breadth, grade and the Indian Standard
number. i.e. C.I. Surface plate 2000 X 1000 Gr1. I.S.
2285. 51
SURFACE PLATE

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TOP
Heavy
Ribs

3 Point suspension 52

BOTTOM
 SCRIBING BLOCK

Use:- It is used for ;

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- Scribing lines parallel to a datum surface.
- Setting job on machines parallel to a datum surface.
- Checking the height and parallelism of jobs, setting
jobs concentric to the machine spindle
Types:-
1. Fixed scribing block
2. Universal scribing block. 53
 Fixed Scribing Block

Scriber
1. Fixed Scribing Block:- The

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fixed type of surface gauges
Snug Nut
consists of a heavy flat base
and a spindle, fixed upright,
Spindle to which a scriber attached
with a snug and a clamp nut.

Base

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 Universal Scribing Block
2. Universal Scribing Block:- This
surface gauge has the following Spindle Scriber
additional features;
Snug

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- The spindle can be set to any
position. Nut
- Fine adjustments can be made Fine
Base
quickly. adj.
screw
- Can also be used on cylindrical
surfaces.
Rocker
- Parallel lines can be scribed from Guide
Pin arm
any datum edge with the help of
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guide pins.
 ANGLE PLATE

Use:- To support the job and to provide a vertical or

angular plane for marking.

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Material:- Angle plates are made from Cast iron or
Steel.
Types:-
1. Solid Angle plate
2. Adjustable Angle Plate
3. Box Angle plate. 56
Solid Angle Plate:- This angle
plate is most common. It has the
two plane surfaces perfectly

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machined at 90º to each other.
Such angle plates are suitable for
supporting work pieces during
layout work. They are
comparatively smaller in size.
Slots are provided to clamp the
work piece and to reduce the
weight. 57
Adjustable Angle Plate:-
This angle plate is available to

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support job in different angles.
Graduations are marked on it
to set the job at particular
angle. Slots are provided on it
to clamp the job by clamping
bolts. They are available in
Grade-I and Grade-II
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Box Angle Plate:- They have
applications similar to those of

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other angle plates. After setting,
the work can be turned over
with the box enabling further
marking out or machining. This
is a significant advantage. This
has all the faces machined
square to each other.
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Vee Block
Vee blocks usually in a couple are made
of cast iron or steel in case-hardening.
They are generally used for holding

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circular work piece for marking out or
machining.

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 METHODS OF LAYING OUT
Laying out fluids
The surface of metals is usually coated with a
lay out solution to make layout lines visible.
Several types of layout solutions are available,

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however to use any of them grease free and
clean surface is required.
 Layout die or bluing is the commonly used
solution.
• copper colored surface- drop of sulfuric acid.
• Aluminum- mixture of vermilion powder and
shellac b/s other layout solution corrode the
maximum.
• Casting and rolled steel- merely chalking the 61
surface.
Reference edges and lines
In order laying out gives best results, it usually must be done
from finished edges or datum checking edges and/or surfaces
for exactness is done using squares .

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Permanent layout
After the layout lines have been scribed on the work piece,
they should be permanent marked by means of prick punch
marks along the layout.
Doing this will ensure the visibility of the lay out line location
should the line be rubbed off through handling.

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 STEPS IN MAKING A LAYOUT
Planning before beginning any layout is one of the most important steps.
Each job may require different layout tools depending on the accuracy
needed; however, there are certain procedures which should be followed

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in any layout. Figure 1-20 shows a typical layout.

• Study the shop drawing or blueprint carefully before you cut off the
stock. Allow enough material to square the ends if required.

• Remove all oil and grease from the work surface and apply layout dye.

• Locate and scribe a reference or base line. All the other measurements
should be made from this. If the workpiece already has one true edge, it
can be used in place of the reference line. 63
• Using the base line as a reference line, locate and scribe
all center lines for each circle, radius, or arc.
• Mark the points where the center lines intersect using a
sharp prick punch.
• Scribe all circles, radii, and arcs using the divider or

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trammel.
• Using the correct type protractor, locate and scribe all
straight and angular lines.
• Scribe all lines for internal openings.
• All layout lines should be clean, sharp, and fine. Reapply
layout dye to all messy, wide, or incorrect lines and 64
rescribe.