CHAPTER 1: HAND TOOLS (Marking & Measuring Tools)

Marking Out – process of transferring a design, layout or dimensions from the drawing to a work
piece, as the first step in manufacturing process

1.2.1: Marking Tools

SCRIBER

Used for scratching lines onto the workpiece.

It is made of hardened tool steel.

CENTER PUNCH

Used for making large indents that position

divider legs & drill points & stop them slipping

DIVIDER

The legs are used for scribing arcs or circles onto a

work piece

SURFACE PLATE

Used as a datum surface for marking out and for

measuring purposes. If it can stand on the floor, it
is called surface table

PROTRACTOR

To assist in the transfer of angular

measurements

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HEIGHT GAUGE

Allows lines to be scribed at a preset distance from the table

surface

COMBINATION SQUARE

An alternative tool for transferring angular measurements

SQUARE

To transfer 90° angles to the workpieces

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1.2.2 Hacksaw (Gergaji Besi)

 Used for cutting steel and other metals. It can also be used to cut plastics, although it is not
normally used to cut woods.
 It consists of a frame, which holds a thin blade, firmly in position. Hacksaw blade is specified by
the number of teeth for centimeter.
 Hacksaw blades are supplied in 2 lengths – 250 mm & 300 mm.

Blades having larger

number of teeth per
centimeter are used for
cutting hard materials like
steel and cast Iron

Blades having lesser

number of teeth per cm are
used for cutting soft
materials like aluminium,
brass and bronze
Types of Hacksaw Frame

Type 1: Solid Hacksaw Frame

In types, only one particular standard length of
blade can be used with this frame

Type 2: Adjustable Hacksaw Frame

In this type different standard lengths of blades can be
fitted to this frame

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Blades eventually wear or break and need replacing.
The blade can be replaced by loosening the wing nut adjuster until it comes off the two ‘studs’ that
normally hold it in tension in the frame.
A blade should always be positioned with its teeth pointing away from the handle.

Causes of Hacksaw Blade Breakage

1. Faulty alignment & adjustment of the guide
2. Forcing or twisting a wide blade around a curve of short radius
3. Feeding too fast
4. Dullness of the teeth or the absence of sufficient set
5. Excessive tension on the blade
6. Top guide set too high above the work being cut

1.2.3 Hammer (Tukul)

These are used for causing a succession of blows to facilitate and forming metals.
Material : Ball peen / cross peen / straight peen = high carbon steel
Hammer shaft / handle = straight-grained ash wood

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Cross Peen Hammer
It is generally used in smithy shop for heavy work & spreading the hot material.
Cross peen hammer consist of peen, face, eye hole & handle.
Peen of ball peen hammer is like a wedge & is perpendicular to the shaft or handle.

Ball Peen Hammer

This type of hammer is widely used for general purpose, lay outing, riveting, chipping & forming.
Ball peen hammer consist of peen, face, eye hole & handle.
It’s peen is ball shaped thus it is called ball peen hammer

Straight Peen hammer

Straight peen hammer is generally used in smithy shop for swaging & riveting process.
Straight peen hammer consist of peen, face, eye hole & handle.
In straight peen hammer peen is parallel to the handle.

1.2.4 Chisel (Pahat)

 A chisel is a hard steel cutting tool that can be used for cutting and chipping any metal softer than
the chisel itself.
 It can be used in restricted areas and for such work as shearing rivets, or splitting seized or
damaged nuts from bolts.
 Lengths will vary, but chisels are seldom under 5 inches or over 8 inches long.
 The cutting angle should be 60° to 70° for general use, such as for cutting wire, strap iron, or
small bars and rods.

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 A cold chisel should be held "upside down" in
our hand, with the thumb closer to the cutting
edge.

Holding the chisel too tightly will result in the

user absorbing the shock instead.

When using a cold chisel, gently tapping the

head with the hammer allows the tool to make
the first cut into the metal.

When using the chisel it is important that,

rather than keeping your eye on the hammer,
you keep your eye on the chisel's cutting edge.

1.2.5 Hand Files (Kikir)

 Hand files are used in the workshop to smooth rough edges
 Used to smooth a range of materials including metals such as brass and steel
 Made from high carbon steel

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Kinds of Teeth

Hand File: Used for general filing of metals such as steel. They are rectangular in section & are the most
common type of file used in workshops.

Half Round File: Used for filing curved surfaces. A normal hand file with its flat cutting edges is
unsuitable for filing curved surfaces. However, the half round file has a curved surface which is especially
useful for filing internal curves.

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Three Square File: Is triangular in section & very useful when filing ‘tight’ corners/angles. The sharp
edges allow the file to fit into corners when filing

Knife File: Knife files are very useful when filing where there is little space. Knife files are very thin &
can fit into small gaps.

Square File: The square file is quite thin & fits into corners well. They can be used to file slots in metal
or for filing where there is little space.

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Standard Grip: For files needing two-handed operation, the handle should be grasped in one hand and
the point of the file in the other hand

Heavy Stroke Grip: When heavy filing strokes are required, the thumb on the point is normally in line
with the file; the tip of the thumb pointed forward

Light Stroke Grip: For lighter strokes, the thumb can be turned to as much as a right angle to the
direction of the stroke

Hand files are normally held in both hands

The file is held flat against the surface it is to

cut / smooth

The file is then pushed forward and it cuts on

the forward stroke.

It is then lifted away from the metal and

returned to the starting point for the next
push forward. This is called ‘through filing’.

Safe Edge
There are no cutting teeth on one side of the hand file. This is extremely useful when filing in corners.
The safe edge is placed into the corner & because it is smooth it does not damage the surface of the
metal.

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1.2.6 Tap & Dies

 A tap is used to cut threads on the inside of a

hole
 A die is for cutting external threads on round
stock

Hand Taps: Sets of Three

Taper
 Tapered from end six threads
 Used to start thread easily
 Used for tapping hole that goes through work
as well as blind hole
Plug
 Tapered for three threads
 Tread hole through workpiece

Bottoming Tap
 Not tapered but chamfered at end
 Used for threading to bottom of blind
hole

Before tapping the following should be determined:

 The proper tap hole has been drilled
 The tap has the correct specifications.
 The tap hole is clean & free if all chips (particularly for blind holes).
 A suitable cutting fluid has been selected for application during the tapping process.

If the thread is too tight, “chase” the threads by running the tap through again until it meets specifications.

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1.2.7 Calipers
Calipers are the very simple tools used together with a steel rule for the measurement or comparison of
linear dimensions. An experienced worker can achieve +/-0.05mm in the measurement. Calipers are
classified into two types:

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

Inside Calipers
Inside calipers are used for measuring internal dimensions such as the diameter of a hole or the width of a
slot

1.2.8 Rulers and Tapes

It is one of the most useful tools for taking linear measurements of blanks and articles to an accuracy of
range from 1.0 to 0.5 mm. It consists of a strip of hardened steel having line graduations etched or
engraved at internal of fraction of a standard unit of length. Depending upon the interval at which the
graduations are made the scale can be manufactured in different sizes and styles.

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1.2.9 Micrometer

Micrometer: Allows the measurement of the size of the body i.e thickness, depth, inner/outer diameter

Types of Micrometer

Used to measure external dimensions such as the outside

diameter of an object.

Used to measure inside dimensions like the inside

diameter of a hole or tube

Used to measure the depths of holes, slots and steps.

The parts of External/Outside Micrometer

Anvil: The shiny part that Spindle: The shiny

the spindle moves toward cylindrical part that the
& that the sample rests thimble causes to move
against spindle toward the anvil

Thimble: The part that

on’s thumb turns.
Barrel/Sleeve: Graduated markings
The stationary
round part with
Frame: C-shaped body the linear scale
that hold the anvil & on it. Sometimes
barrel/sleeve in constant vernier markings
relation to each other

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How to use Micrometer
1. Thimble
 The thimble rotates around a cylinder which is marked in millimeters.
 The left-hand side of the thimble has markings all around it.
 The line labeled 0 is the primary pointer.
2. Close the jaws
3. Calculate the least count
4. Place the object between the two jaws
5. Record the position of main scale where the two measuring rods met
6. Note the position of the circular scale which coincides with main scale

The thimble scale has 50

divisions, each of which is
0.01mm

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Example for micrometer reading

State the reading of the micrometer screw gauge in the figure below.

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EXERCISE
Write down the reading shown by the micrometer screw gauge

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1.2.10 Vernier Caliper

Vernier Caliper: To measure precise increments between two points.

Function: To measure smaller distances
Can measure up to 0.001 inch or 0.01mm
Features: Larger, lower jaws are designed to measure outer points eg. diameter of the rod
Top jaws are designed to measure inside points eg. size of a hole
A rod extends from the rear of the caliper & can be used to measure the depth

Internal Jaws: Internal Locking Screw:

length (diameter) blocks the
measurements are found by instrument’s movable
using this part parts

Imperial / Upper Scales: Vernier scale (inch)

Rail (inch)

Depth Probe: The part

used in order to find depth
measurement front end of
the rail

HOW TO READ???

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How to use Vernier Caliper
STEP 2:
Read the main scale directly
opposite the zero mark on
the vernier scale. In this
case, the reading on the
main scale is 31mm or
3.1cm

STEP 3:
The 4th vernier mark coincides
with a marking on the main
scale. This gives a reading of
+0.4mm or +0.04cm to be
added to the main scale
reading

STEP 1:
Grip the ball bearing gently using the outside
jaws of the calipers

STEP 4:
The diameter is found by
adding the main scale
reading to the vernier scale
reading: 31mm + 0.4mm =
31.4mm

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EXERCISE
Write down the reading shown by the micrometer screw gauge. Answer must in millimeter (mm).

ANSWER: ANSWER:

ANSWER: ANSWER:

The following calipers have no zero errors. Determine the actual readings on each caliper:

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