Mechanical Workshop
Module 3: Marking out and Hand Tools
PREPARED BY
IAT Curriculum Unit
January 2010
Institute of Applied Technology, 2010
ATM-1022 Mechanical Workshop
Module 3: Marking out and Hand Tools
Module Objectives
After the completion of this module, student should be able to:
1. Identify different marking out tools and their usage.
2. Select the appropriate tool required for marking out.
3. Mark out workpieces according to the dimensions given in engineering
drawings.
4. Identify the different hand tools and their uses.
5. Identify and select the correct tool for the task.
6. State the care and safe use of hand tools.
Module Contents
Introduction to marking out
Common marking out tools
Practical Task
Introduction to hand tools
10
Worksheet
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Module 3: Marking out and hand tools
ATM-1022 Mechanical Workshop
3.1. Introduction to marking out
Marking out is the process of transferring a design, layout or dimensions from
the plan to a workpiece, and it is considered as the first step in the
manufacturing process.
3.2. Common marking out tools
The common tools used for marking out
are as follows:
1. Marking blue
2. Scriber
3. Punch
4. Engineers square
5. Surface plate
(a)
6. Surface gauge
7. Angle plate
8. Vee block
9. Spring dividers
10. Ball peen hammer
1. Marking blue.
Marking
blue
is
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.
(b)
Fig. 3.1: (a) Marking blue layout
dye. (b) Using of marking blue for
marking out.
Module 3: Marking out and hand tools
ATM-1022 Mechanical Workshop
2. Scriber
Scribers are used in metalworking to mark lines on workpieces prior to
manufacturing. They are used instead of pencils as the marks from
pencils can rub off easily. They consist of a rod of steel that has been
sharpened to a point at one or both ends. Scribers are used to draw
shallow scratches on the surfaces of the workpieces.
There are two types of scribers:
A) One-end scriber as shown in
(a)
Fig. 3.2a.
B) Double-end scriber as shown in
Fig. 3.2b.
3. Punch
(b)
Fig 3.2: (a) One-end scriber (b)
Double-end scriber.
A punch is a hard metal rod with a shaped tip at one end and a rounded
butt at the other end that is usually struck by a hammer.
There are many types of punches,
and the most commonly used ones
for marking out are:
A) Center punch: It 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 as Fig 3.3a: Center punch
shown in Fig. 3.3a.
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B) Prick
punch:
It
is
used
for
layout. A prick punch produces a
60
smaller indentation than a center
punch, which acts as a useful
(b)
datum point in layout operations.
A prick punch has a point angle of
60 as shown in Fig.3.3b.
C) Letter
stamps
or
number
stamps: These are used to print a
letter or number into a workpiece.
See Fig.3.3c.
(c)
Fig 3.3: (b) Prick punch (c) Letter
stamp set
4.Engineers square
The engineers square is shown in
Fig. 3.4. It is used for checking the
straightness of a workpiece. It can
also be used for marking
perpendicular lines onto a workpiece.
Fig 3.4: Engineers square.
5.Surface plate
The surface plate is shown in Fig 3.5.
It has a high degree of flatness. The
flat surface is being used as a datum
surface
for
marking
out
and
for
measuring purposes. it is also called
surface table If it can stand on the
Fig 3.5: Surface plate
floor.
Module 3: Marking out and hand tools
ATM-1022 Mechanical Workshop
5.1 Care to the surface plate
YOU MUST
1. Keep the surface in a good condition.
2. Keep the surface lightly oiled to prevent corrosion.
3. Take care when placing marking out tools on the surface.
YOU DO NOT
1. Place anything on the surface that would damage it.
2. Drop tools on the surface.
3. Hammer on the surface.
6. Surface gauge
A surface gauge shown in Fig 3.6 is
used on surface plates for scribing
lines on work pieces and checking
parallel
surfaces
and
heights
as
shown in Fig 3.6b.
(a)
(b)
Fig 3.6: (a)Surface gauge (b) setting the height of the surface gauge.
Module 3: Marking out and hand tools
ATM-1022 Mechanical Workshop
7. Angle plate
The angle plate shown in Fig 3.7 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.
Fig 3.7: Angle plate
8. Vee block
The Vee blocks shown in Fig 3.8 are
generally used for holding circular
workpieces
for
marking
out
or
machining.
Fig 3.8: Vee blocks set
9. Spring dividers
The spring dividers shown in Fig 3.9a
are used for scribing arcs and circles
as shown in Fig. 3.9b or marking off
lengths onto a workpiece.
(a)
(b)
Fig. 3.9: (a) Spring dividers
(b) Spring Dividers in use.
Module 3: Marking out and hand tools
ATM-1022 Mechanical Workshop
10. Ball peen hammer
The ball-peen hammer is shown in
Fig.3.10. 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
Fig 3.10: Ball peen hammer
3.3. Practical Task
3.3.1. Objective:
To mark out the workpiece to produce a drill gauge according to the
dimensions given (see the drill gauge project document)
3.3.2. Required Tools
SR
Tool
SR
Tool
Steel ruler
Center punch
Surface plate
Spring dividers
Scriber
Ball peen hammer
Surface gauge
Vernier caliper
Prick punch
10
Angle plate
3.3.3. Procedure:
1. Marking out the hack sawing and filling lines. See Fig. 3.11.
A)
Locate the reference plane.
B)
Use the surface plate, surface gauge and steel ruler to set the
required height as shown in Fig.3.6b.
C)
Use the angle plate, surface gauge to scribe the first line and
repeat the same procedure to scribe the other three lines.
D)
Punch the scribed lines by using the prick punch.
Module 3: Marking out and hand tools
ATM-1022 Mechanical Workshop
Filling lines
All Dimensions are in mm
80
64
Hack sawing lines
60
Reference Plane
98
102
130
Fig 3.11: The filling and hack sawing lines.
2. Marking out the Fillets. See Fig.3.12.
A)
Locate and scribe centers for fillets.
B)
Punch the centers by using a prick punch.
C)
Scribe the fillets by using spring dividers.
4
R4
All Dimensions are in mm
4
60
This fillet is repeated for all corners
Reference Plane lines
98
Fig 3.12: Shows the fillets arcs
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3. Marking out for drilling. See Fig.3.13.
A)
Locate and scribe lines for holes centers using the same
procedure used for scribing the hack sawing and filing lines.
B)
Punch the intersection of the lines by using a center punch.
12.25
20
12.25
20
60
14
14
98
Fig 3.13: The lines for holes centers.
3.4 Introduction to hand tools
The mechanical engineer very often have to use a number of various hand
tools in the course of his duties as a fitter or machinist, many of these
tools are common to both.
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3.4.1 Spanners/Wrenches
In British English spanner and in
American
English
describe
the
wrench
same
tool.
Spanners/Wrenches are different in
S= 24 mm
shape to provide ease of operation
under certain conditions. They are
manufactured from high tensile or
alloy steel. The sizes of metric
spanners
are
identified
by
the
distance across flats of a nut or
Fig. 3.14: Distance across flats (s)
bolt head as shown in Fig 3.14.
3.4.1.1 Spanner Types
1- Open-ended spanners
The ends of this type of spanners are
generally oriented at an angle of 15
to the longitudinal axis of the handle
to allow greater range of movement
Fig. 3.15: Open-ended spanners
in enclosed spaces. Fig. 3.15 shows
open ended spanners of different
sizes.
2- Ring spanners
Ring spanners or box-end wrenches
are recommended to be used when a
better grip is needed and when the
spanner swing is restricted. Fig. 3.16
shows
sizes.
ring
spanners
of
different
Fig. 3.16: Ring spanners
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ATM-1022 Mechanical Workshop
3- Combination spanners
This type comes with an open end
from one side and a ring end from
the other side and usually both ends
Fig. 3.17: Combination spanner
are having the same size. Fig. 3.17
shows a combination spanner.
4- Adjustable spanners
Adjustable
that
have
spanners
a
are
moving
spanners
jaw
to
fit
different bolt/nut sizes. Fig. 3.18
shows an adjustable spanner.
Fig. 3.18: Adjustable spanner
3.4.1.2 Accidents Prevention
When working with spanners, accidents are usually caused by the slipping
of a spanner from a nut or bolt head and in order to avoid that the
following should be taken into consideration:
Use the correct size spanner for the job.
Pull towards the body whenever possible.
Do not obtain extra leverage by using pieces of pipe.
Use a steady pull not a jerking action.
Do not hit a spanner with a hammer.
Make sure your hands will not strike any obstructions.
3.4.2 Allen keys
They are referred to as Allen keys
and sometimes Allen wrenches (Fig.
3.19a). Allen keys are used on socket
(a)
head cap screws (Fig. 3.19c) and
grub screws (Fig. 3.19b). The size of
Allen keys is measured across flats.
(b)
(c)
Fig. 3.19: (a) Allen keys (b) Grub
screw (c) Socket head cap screw
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Module 3: Marking out and hand tools
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3.4.3 Screwdrivers
Screwdrivers (Fig. 3.20a) are made
in different lengths and designs, the
two most common are:
1. Flathead/slotted
2. Crosshead/Phillips
The flathead (Fig. 3.20b) is identified
by its length and in some cases by
the blade width. The crosshead (Fig.
3.20b) screwdriver is identified by its
point size. Always use the correct
(a)
size screwdriver for the screw head;
the blade should fit the width of the
screw head.
Flathead
Crosshead
(b)
Fig. 3.20: (a) Different types of
screwdrivers. (b) Flathead and
Crosshead.
3.4.4 Pliers
Pliers are a hand tool used to hold objects firmly, or for cutting and
bending tough materials such as wires. There are different types such as
flat nose pliers, long nose pliers, combination pliers and circlip pliers.
These types are designed to deal with different types of jobs.
1- Flat nose pliers
These are used to hold pins and
small
objects
confined spaces.
when
working
in
Fig. 3.21 shows a
flat nose pliers.
Fig. 3.21: Flat nose pliers.
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ATM-1022 Mechanical Workshop
2- Long nose pliers
Long nose pliers (Fig. 3.22) are both
cutting and gripping pliers used by
Fig. 3.22: Long nose pliers.
electricians and other tradesmen to
bend, re-position and cut wire.
3- Combination pliers
These pliers (Fig. 3.23) incorporate
side cutters, joint cutters and pipe
grip.
Fig. 3.23: Combination pliers
4- Circlip pliers
Circlips are retaining devices (Fig. 3.24). They are fitted inside a groove
on bores and shafts. The internal circlip (Fig. 3.24 a) has to be squeezed
to be removed and the external circlip (Fig. 3.24 b) which is fitted onto a
shaft has to be opened out to be removed. Fig. 3.25 shows internal and
external circlip pliers. The nose is either straight or bent depending on the
type of job.
(a)
(b)
Fig.3.24: (a) Internal circlip
(b) External circlip
(a)
(b)
(c)
Fig. 3.25: (a) Straight internal
circlip pliers. (b) Bent nose
external circlip pliers. (c) Bent
nose internal circlip pliers. (d)
Straight external circlip pliers.
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Module 3: Marking out and hand tools
(d)
ATM-1022 Mechanical Workshop
3.4.5 Pipe wrench
A pipe wrench is designed to tighten
its grip on the part being rotated. It
has serrated jaws that leave marks
on the part and so it might damage
the surface of the part. Accordingly,
Fig. 3.26: Pipe wrench
pipe wrenches must not be used to
loosen a nut, unless the nut is to be
replaced. Fig. 3.26 shows a pipe
wrench.
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ATM-1022 Mechanical Workshop
Students notes
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Worksheet
Solve the following questions.
1. Choose the correct answer.
1. Which tool of the following is used to scratch lines on metal?
A
B
C
D
2. How can scratches on metal be made to appear more clearly?
By using pen
By using chalk
By covering a metal with marking blue
By using pencil
3. How is the pivoting leg of a pair of dividers stopped from sliding
over the surface of metal?
A
By using scriber
By using prick punch
By using height gauge
By using caliper
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ATM-1022 Mechanical Workshop
2. Match the following.
a. Match the marking out tools in column B with their correct functions
in column A, Write your answer in the box below?
Column A
Column B
Column A
Column B
1) Is used for checking the
straightness of a workpiece.
A)
2) Is used to scratch lines
B)
3) Is used for making indents that
position the drill points and stop
C)
them slipping
4) Is used for supporting or
setting up work vertically.
D)
E)
5) Is used for scratching lines
parallel to a surface.
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Module 3: Marking out and hand tools
ATM-1022 Mechanical Workshop
b. Match the hand tools in column B with their correct names in column A,
Write your answer in the box below?
Column A
Column B
Column A
1) Combination pliers
Column B
A)
B)
2) Adjustable spanner
C)
3) Allen key
D)
4) Crosshead screwdriver
E)
5) Open-ended spanner
F)
6) Ring spanner
G)
7) Pipe wrench
H)
8) Flathead screwdriver
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