FME 5 – Workshop Theory and Practice

Laguna State Polytechnic University

Prepared by: Engr. Jane N. Anda

Title Workshop Theory and Practice

The course deals with the basic principles of machine shop practices. It includes workshop safety and organization; simple
workshop safety organization; simple workshop measuring instruments, hand tools, fitting bench work, bench drill and bench
Description
grinder, sheet metal working; principles of welding processes; welding metallurgy; joining processes; testing and inspection of
welds; foundry and metal casting.
Course Code FME 5
Credit Units/Hrs. per
1 unit/3 hrs laboratory
meeting
Prerequisites/Co-requisites None

Lab 1: Introduction to Machine Shop Operations and Measuring Instruments

MACHINING

Machining is a subtractive manufacturing process that involves the use of cutting tools, discs, abrasive wheels, and more to remove excess material
from a workpiece. Furthermore, this process is used to remove unwanted materials to achieve the desired product shape. Stock mills like flats and
bars and welded or cast parts are often recipients of machining operations.

Examples of machined products include automobile parts, drill bits, plaques, nuts and bolts, flanges, and many other parts and tools used in various
industries.

Let us examine the different types of the machining process.

CONVENTIONAL MACHINING PROCESS

Also known as traditional machining in manufacturing, this process involves the use of cutting tools to remove excess materials from a workpiece
on direct contact. Furthermore, this machining operation occurs when the cutting tool directly interacts with the workpiece.

Besides, there are different types of conventional machining, and they include;

1. Turning

In the turning process, the cutting tool remains

stationary while the workpiece rotates. Furthermore, it
is a lathe operation and involves the removal of excess
material from a workpiece with the aid of a cutting tool.
Besides, the cutting tool works along two axes of
motion, creating cuts with precise width and depth.

Additionally, the turning process works great for

machining the interior or exterior part of a material.
Turning performed on the material exterior part is
known as facing, while that done on the inside is known
as boring.

2. Milling

Milling is a machining process that involves the use of

rotating cutters to remove material from a workpiece.
Furthermore, there are two main types of milling
operations; face milling and slab milling.

Face milling is a machining manufacturing process used

for smoothening or flattening the surface of workpieces.
Conversely, slab milling is ideal for machining a wide flat
surface. It also involves making planar cuts across a
workpiece’s surface using the mill cutter’s peripheral
edges.
 FME 5 – Workshop Theory and Practice
Laguna State Polytechnic University
Prepared by: Engr. Jane N. Anda

3. Drilling

Drilling involves using drill bits (multi-point cutting tools) to

produce cylindrical holes in solid materials. Furthermore,
drill bits used for this procedure feature two spiral
channels. These channels, also known as flutes, evacuate
the swarf or chips out of the hole as the drill bit progresses
into the material.

Additionally, the holes created by this drill press often aid

part assembly. Besides, drilling is applied first before
tapping, reaming, or boring to create threaded holes or
bring the dimension of a hole within an acceptable
tolerance. This makes this operation one of the most
important out of the other types of the machining process.

4. Grinding

Grinding is one of the types of machining process ideal for

improving the finish on a machined part’s surface and
tightening its tolerance. Furthermore, the process produces
parts with identical shapes, finishes, and sizes. It is also the
first step in further finishing operations like honing, lapping
and superfinishing.

Additionally, there are two main types of grinders; Surface

grinders and Cylindrical grinders. Surface grinders remove
small amounts of materials from flat surfaces, but
cylindrical grinders remove materials from cylindrical
shapes.

5. Sawing

Sawing aims to create shorter lengths from extruded shapes, bars, and other materials, performed
by cut-off machines. Furthermore, there are different cut-off machines engineers use for sawing,
including; power hack saws, circular saws, and abrasive wheel saws.

Besides, the saw band speed for sawing depends on the material. For instance, softer materials
like aluminum alloys require a cutting speed of 1000 fpm or more. On the other hand, some high-
temperature alloys require a slower cutting speed of 30fpm.

6. Broaching

Broaching involves using a broach to produce square holes, spline holes, keyways,
and other shapes. Furthermore, a broach is a tool with many teeth arranged in
sequence, similar to a file. However, it differs from a file in that a broach has
uneven teeth, while a file consists of even-sized teeth.

There are two types of broaching; pull broaching and push broaching. vertical
press-type machines are ideal for use in push broaching, while vertical or
horizontal press-type machines are ideal for use in pull broaching.

Besides, when pulled or pushed past a surface or through a leader hole, a broach
takes a series of cuts with increasing depth. Also, the cutting speed of a broach is
dependent on material strength. For instance, cutting speeds are often as high as
50 fpm for softer metals and as low as 5 fpm for metals of higher strength.

7. Planing

Planing is ideal for large flat surfaces especially surfaces that would still undergo scraping as a
finishing method. Also, to reduce machining costs, manufacturers sometimes gang small parts
together for simultaneous planning.
 FME 5 – Workshop Theory and Practice
Laguna State Polytechnic University
Prepared by: Engr. Jane N. Anda

TYPES OF MEASURING TOOLS

Following are the types of measuring tools used for all purposes:

#1 Angle Locator

The angle locator is sometimes also known as an angle finder. It is the perfect tool to measure angles and
replicate the angle of an existing area. These are commonly used for construction or carpentry purposes. These
measuring tools have a magnetic base that allows them to be attached to metal measuring sections. It is a
manual tool with a digital display.

You will need to place the ends of this angle locator on the workpiece and use the readings obtained to determine
your angle. The angle locator allows easy at-a-glance measurement of angles from 0° to 90°. There will be times
when you need to find an angle inside a closet or small space, so having a tool like this will greatly simplify the
process.

#2 Bubble Inclinometer

An inclinometer is essential and a smart choice if you need to determine a particular inclination.
These are specifically designed to measure the range of motion of a joint and are also used to
measure the stability of the grade.

To identify the range of motion of a joint to be measured, set the bubble inclinometer to zero, and
then determine what the difference is as it undergoes its changes. It is often used by sports therapists
to test a healthy range of motion at critical junctures of the body.

#3 Digital Angle Gauge

It is very essential for workers to measure angles, and they need access to accurate data so angle gauges have
been invented. These types of measuring tools allow quick measurement of any angle surfaces attached to them.

Compared to an analog angle gauge, a digital angle gauge is faster, easier to use, and more accurate. It consists
of a powerful magnetic base and automatic calibration controls that are useful for determining precise bevel and
miter angles on powered saws. They are relatively cheap and also very precise tools.

#4 Caliper

A caliper is a measuring tool used to measure the dimensions of an object such as thickness, outside and inside
diameter, length, width, and depth. These measuring tools provide multiple dimension measurements and are
usually made of steel. They are used in various fields such as engineering, medicine, construction, household, and
metalworking.

By adjusting the tips of the calipers to fit across the object to be measured, then removing the calipers, the total
length can be easily measured via a fixed ruler. There are different types of calipers that allow the measurement
to be read on a controlled scale, dial, or digital display.

#5 Compass

Compass is a very important tool that is used for various tasks like maths, drafting, navigation, and other
purposes. If you are an architect then you will already be familiar with a compass. It is commonly used in
process of shipbuilding as well as in carpentry.

Compasses are usually made of metal and have two “legs” attached to a hinge that can be adjusted to
allow varying the radius of the circle drawn. A compass is a technical drawing tool that can be used to
write circles or arcs. As a divider, it can also be used as a tool for separating distances, in particular, on
maps.
 FME 5 – Workshop Theory and Practice
Laguna State Polytechnic University
Prepared by: Engr. Jane N. Anda

#6 Level

Level - Measuring Tools

It is a type of measuring tool that is used to indicate the horizontal plane. The level is an
optical device that consists of air bubbles in a liquid medium to display measured results.
The tube is sealed and fixed horizontally to a block of wood with a smooth bottom surface.

The glass tube of the level is tilted and the adjustment in the horizontal is indicated by
the movement of the bubble. Builders typically use longer-level instruments that are
range from 2-, 4- or 6-feet in length. They are used in construction works, woodworking,
and metalworking shops.

#7 Laser Level

A laser level is a measuring tool consisting of a rotating laser beam projector that can be firmly
attached to a tripod. This is leveled as per the accuracy of the tool and projects a fixed red or green
beam in a plane about the horizontal and/or vertical axis.

Certain types can measure the distance from the unit to the end of the laser beam, making a fast and
accurate solution for worksite distance measurement. Laser levels are commonly used for leveling
and aligning applications in the construction and surveying industry.

#8 Micrometer

The micrometer resembles a caliper that screws down instead of sliding. The spindle is
very precise and the object to be measured is placed between the spindle and the anvil.
The spindle is rotated by adjusting the ratchet knob until the object is measured. In
addition to the name micrometer, they are also known as screw gauges.

Digital micrometers produce a quick reading of the work distance between their two
caliper heads. A micrometer is widely used for the precise measurement of components
in mechanical engineering and machining as well as in most mechanical trades, along
with other metrological devices such as dials, verniers, and digital calipers.

#9 Measuring Squares

A square is a tool used to mark and refer to a 90° angle, although a miter square is used for a 45°
angle. A square measuring instrument consisting of two straight edges set at right angles to each
other. These tools are available in a variety of special forms such as combination squares, drywall
squares, framing squares, and speed squares.

These are commonly used by carpenters and machinists to check the accuracy of right angles when
drawing lines on the material before cutting. Some types of square measuring instruments include
a scale (ruler) for measuring distances or for calculating angles.

#10 Protractor

Protractors are measuring instruments usually made of plastic or glass shaped like a half-circle.
These are used for measuring angles and are usually marked with degrees. Sometimes, you will
find more mathematically oriented protractors that measure in radians.

A typical protractor is in the shape of a semicircle with an inner scale and an outer scale and marks
from 0° to 180°. Engineers and designers use an angle protractor tool that gives more accurate
measurements. A bevel protractor is an improved version of a protractor with one or two swinging
arms, which can be used to help measure angles.
 FME 5 – Workshop Theory and Practice
Laguna State Polytechnic University
Prepared by: Engr. Jane N. Anda

#11 Ruler

A ruler is a tool used in geometry and technical drawing as well as in the engineering
and construction industries to measure distances or draw straight lines. Commercially,
they are mostly found in engineering, where they are used to ensure accurate
measurements on flat surfaces.

A ruler is measured in both metric and customary units. The standard distance above
the ruler is indicated in centimeters and below in inches, and the interval in the ruler is
called the hash mark. Rulers are probably the most common measuring tool in use
today.

#12 Tape Measure

A tape measure is a flexible ruler that can be folded into any shape and used to measure size
or distance. In their simplest form, they consist of a ribbon of fabric or plastic marked with
measurements in inches, centimeters, and/or millimeters.

The most common tape measures are ranges from 12 feet, 25 feet, or 100 feet in length. Its design
allows large length measurements to be easily carried in the pocket and also allows measuring
curves or corners. Today it is everywhere, appearing even in miniature as the keychain fob, or
novelty item.

References:

Machining Operation and Types of Machining Tools - https://www.engineeringarticles.org/machining-operation-and-types-of-machining-tools/

Types of Machining Operations: Classifications and Differences - https://www.rapiddirect.com/blog/types-of-machining-operations/

DIFFERENT TYPES OF MEASURING TOOLS AND THEIR USES - https://www.theengineerspost.com/measuring-tools/

FME 5 – Workshop Theory and Practice
Laguna State Polytechnic University
Prepared by: Engr. Jane N. Anda