Measuring workpiece using angular measuring instruments

DLM 03 Developing print-based Learner’s Guide including all related documents
Notes Format of Learner’s Guide

Course: Machining NC-II
Unit of competency: Measure workpiece using angular measuring instruments
Measuring workpiece using angular measuring instruments
Module: At the end of the session, learners should be able to:
Learning outcomes: 1. Select angular measuring tools
2. Use angular measuring tools
Duration: 3. Maintain angular measuring tools
Situating Learning: 4. Clean and store measuring tools
8 Hours
You have been hired as an apprentice of a machining industry firm for a year
now. As an apprentice, you seldom operate a machine. The manager of the
firm had just received a job order to fabricate a prototype wood vise. The
lead screw, nut, spacers, guide bars, and the handle had already been
completed, but not the vise plate. The machinist assigned to the task had to
file a leave of absence due to his ailing father. Thus, leaving the task
hanging. The manager informs you to finish the plate immediately to
complete the whole task. But in order to proceed to the machining operation,
you have to lay-out the dimensions first. Before you start the task, you have
to consider the following:

1. The type of angular measuring instruments to be used.
2. The level of accuracy required.
3. The appropriate measuring technique to be used.
4. The capability of every measuring instrument.
5. The safe handling of the tools.

In order for your task to be acceptable to the firm, it must :
1. Conform to the design given by the client.
2. Follow the specifications indicated in the drawing.

Assessment Criteria: 1. Angular measuring instruments are identified according to uses.
2. Angular measuring tools are used according to specification with 100%
accuracy.

Learning chunk Performance Criteria Learning Activities Learning documents
(Brief description of (Documents
1: Select angular  Angular measuring strategies, sequence
measuring tools tools are selected of lesson, evaluation) referenced by each
according to the level learning activity)
of accuracy required. 1.1 Identify the different
types of angular  Read information
 Measurements taken measuring Sheet 1.1.1 – Types
are accurate to the instruments, its uses of angular
finest graduation of and accuracy. measuring
the selected instruments, its uses
measuring and accuracy.

 Answer Worksheet
1.1.2 questions.

Pedagogical Training in Instructional Design & Delivery for TVET Page 1
© 2010, Institute of Technical Education, Singapore

DLM 03 Developing print-based Learner’s Guide including all related documents
Notes Format of Learner’s Guide

Learning chunk Performance Criteria Learning Activities Learning documents
(Brief description of (Documents
2: Use angular instruments. strategies, sequence
measuring tools  Angular measuring of lesson, evaluation) referenced by each
learning activity)
tools are used 2.1 Sequence the
according to the level procedures on how Read Information
of accuracy required. to read angular Sheet 2.1.1 –
measurements. Procedures how to
read angular
measurements.

Answer Worksheet
2.1.2 questions.

3: Maintain angular  Measuring tools are 3.1 Demonstrate the Perform procedures
measuring tools adjusted and calibrating on Operation Sheet
maintained to the procedures on 3.1.1.
4: Use angular required accuracy angular measuring
measuring tools utilizing tools. Perform procedures
manufacturer’s or on Operation Sheet
5: Clean and store worksite procedures. 4.1 Demonstrate 4.1.1
measuring tools measuring technique
 Angular measuring appropriate to the Perform procedures
tools are used device used. on Operation Sheet
according to the level 5.1.1
of accuracy required. 5.1 Perform the
procedures on how
 Care and storage of to clean and store
devices undertaken angular tools.
to manufacturer’s
specifications or
standard operating
procedures.

Pedagogical Training in Instructional Design & Delivery for TVET Page 2
© 2010, Institute of Technical Education, Singapore

Information Sheet 1.1.1: Types of Angular Measuring Instruments, Its Uses
and Accuracy

Learning outcomes:
1 Select Angular Measuring Tools
Learning Activity:
1.1 Identify the different types of angular measuring instruments, its uses and accuracy

Gage Blocks

Gage blocks, also known as Slip Gauges, are length standard having flat and parallel
opposing surfaces. The surfaces are polished and are very precise. These are usually
purchased in sets comprising a specific number of blocks in different sizes. To obtain a
particular desired length, individual blocks with different sizes can be combined
mathematically. These are available in inch and metric sizes in specific sets.

Designated Shapes of Gage Blocks
1. Rectangular Shapes
2. Square with a center accessory hole
3. Other shapes as may be specified by the buyer or purchaser.

Blocks are made of:
1. Steel
2. Carbide
3. Ceramic

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Information Sheet 1.1.1: Types of Angular Measuring Instruments, Its Uses
and Accuracy

The four different Tolerance Grades of a Gage Block
1. Grade 0.5 – special reference gages used for extremely high precision gauging work
and are not recommended for general use.
2. Grade 1 – laboratory reference standards used for calibrating inspection gage blocks
and high precision gauging work.
3. Grade 2 – are used as inspection and tool room standards.
4. Grade 3 – are used as shop standards.
Note:
Grades 0.5 and 1 are calibration masters.
Grades 2 and 3 are for measurement and gauging purposes.

Uses of Gage Blocks
1. Checking the Vernier Caliper
2. Checking the Micrometer
3. Setting the Dial Indicator
4. Setting the Height Gage
5. To raise one end of the sine bar in an angular Set-up
6. To measure the finished work.

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Information Sheet 1.1.1a: Types of Angular Measuring Instruments, Its
Uses and Accuracy

Learning outcomes:
1 Select Angular Measuring Tools
Learning Activity:
1.1 Identify the different types of angular measuring instruments, its uses and accuracy

Sine Bar
It is a precision tool used for laying out, setting, testing and dealing with angles in

machine shop works. It consists of a precision ground body which is hardened and with two
precision ground cylinders mounted at both ends. The distance of two cylinders at both ends is
halfway from the body. It is primarily used to setup work at different angles for further
machining or for inspection purposes.

When a sine bar is placed on a level surface, the top edge will be parallel to that
surface. If one roller is raised by a known distance, usually by using gage blocks, then the top
edge of the bar will be tilted by the same amount forming an angle that may be calculated by
the application of the sine rule. Angles may be measured or set with this tool.

o The hypotenuse is a constant dimension (100mm, 10” or 5’)
o The height is obtained from the dimension between the bottom of one roller and the

table’s surface.

Uses of Sine Bars

o Used to measure angles on a workpiece and to lay out an angle on the workpiece that
is to be machined.

o Used to measure how much a vertical surface is off from plumb. It can be used for

setting surfaces to be exactly plumb, such as:
 Saws
 Anvils
 Line Bars
 Face Plates
 Press Rolls

o Used to measure small angles off to plumb.

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Information Sheet 1.1.1a: Types of Angular Measuring Instruments, Its
Uses and Accuracy

o Calculate how much shim is needed to make a surface plumb.
o Extremely useful measuring tool for aligning and maintaining sawmill equipment.
o Used to setup angles on a Layout Table or in a Milling Machine vise.
o Measure known angles or locating any work to a given angle.
o Checking of unknown angles.
o Checking of unknown angles of heavy component.
o Check the accuracy of angles on the work.
o To set up the work to a given angle within close limits.

Sine bar comes with different types and sizes. Aside from 3” – 10” which are used in the US,
there are also metric sizes ranging 100mm to 300mm. However, the most commonly used
sizes are the 5” and the 100mm bars.

The sizes of the two rollers are chosen to be a whole number for ease in the calculations.

Types of Sine Bar

o Sine Centre – is used for conical objects having male and female parts. It cannot
measure the angle more than 45°.

o Sine Table – also known as Sine Plate, is used to measure angles of large workpieces.
o Compound Sine Table – used to measure compound angles of large workpieces. In

this case, two sine tables are mounted one over the other at
right angles. The tables can be twisted to get the required
alignment.

Limitations of Sine Bars

The sine bars naturally becomes impractical and inaccurate as the angle exceeds 45
degrees because:

o It is physically awkward to hold in position.
o The body of the sine bar obstruct the gage blocks stack even if relieved.
o Slight errors of the sine bar cause large angular errors.
o Long gauge stacks are not nearly as accurate as shorter gauge blocks.
o Temperature variation becomes more critical.
o A difference in deformation occurs at the point of roller contact to the support surface

and to the gauge blocks, because at higher angles, the weight load is shifted more
toward the fulcrum roller.
o The size of gauges, instruments or parts that a sine bar can inspect is limited, since
it is not designed to support large or heavy objects.

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Information Sheet 1.1.1: Types of Angular Measuring Instruments, Its Uses
and Accuracy

Learning outcomes:
1 Select Angular Measuring Tools
Learning Activity:
1.1 Identify the different types of angular measuring instruments, its uses and accuracy
Universal Bevel Protractor

It is a semicircular protractor with a pivoted arm used in marking and measuring off
angles. The difference of a regular, semicircular protractor from a universal bevel protractor is
that it has a movable arm that can extend and measure up to 360 degrees. And it is more
accurate than a regular protractor.

Parts of a Universal Bevel Protractor

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Information Sheet 1.1.1: Types of Angular Measuring Instruments, Its Uses
and Accuracy

Uses of a Bevel Protractor

It is an instrument used for precision measuring and layout of angles. It checks also the
accuracy of work machined at an angle or bevel.

Accuracy of a Bevel Protractor

A universal bevel protractor is more accurate than a regular protractor. It can measure
to within 5 minutes (1/60th of a degree).

Unit of measurement of a Universal Bevel Protractor

Basically, the unit of a bevel protractor in the main scale is in terms of degrees. The
reading in the vernier scale is in minutes. Both readings are combined for example, 45° 30’.

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Worksheet 1.1.2: Types of Angular Measuring Instruments, Its Uses and
Accuracy

Learning outcomes:
1 Select Angular Measuring Tools
Learning Activity:
1.2 Identify the different types of angular measuring instruments, its uses and accuracy

Read the questions carefully. Answer the questions on a separate sheet of paper.

1. What is the difference between a regular protractor to a universal bevel protractor?
Answer: ____________________________________

2. What is the function of a universal bevel protractor?
Answer: ____________________________________

3. What is the unit of measurement of a universal bevel protractor in the main scale?
Answer: ____________________________________

4. What is the unit of measurement in the vernier scale?
Answer: ____________________________________

5. How accurate is the reading of a universal bevel protractor?
Answer: ____________________________________

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Worksheet 1.1.2: Types of Angular Measuring Instruments, its Uses and
Accuracy

Learning outcomes:
1 Select Angular Measuring Tools
Learning Activity:
1.2 Identify the different types of angular measuring instruments, its uses and accuracy

Read the questions carefully. Answer the questions on a separate sheet of paper.

1. How are gage blocks being sold?
Answer: ____________________________________

2. What is the other name of gage blocks?
Answer: ____________________________________

3. What grades of gage blocks are considered to be calibration masters?
Answer: ____________________________________

4. What grades of gage blocks are used for measurements and gauging purposes?
Answer: ____________________________________

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Worksheet 1.1.2: Types of Angular Measuring Instruments, Its Uses and
Accuracy

Learning outcomes:
1 Select Angular Measuring Tools
Learning Activity:
1.2 Identify the different types of angular measuring instruments, its uses and accuracy

Read the questions carefully. Answer the questions on a separate sheet of paper.

1. What is the main use of a Sine bar?
Answer: ____________________________________

2. What consists of a Sine bar?
Answer: ____________________________________

3. What is used with the Sine bar during angular set-up?
Answer: ____________________________________

4. At what angle is the Sine bar becomes inaccurate and impractical to use?
Answer: ____________________________________

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Information Sheet 2.1.1: Procedures on how to read Angular Measurements

Learning outcomes:
2 Use Angular Measuring Tools
Learning Activity:
2.1 Sequence procedures on how to read angular measurements

Bevel Protractor

A bevel protractor is more accurate than a regular protractor. The limitation of a regular
protractor is that it can only measure up to 180 degrees, whereas a bevel protractor, which has
a movable arm, can extend to measure up to 360 degrees. It can measure to within 5 minutes
(1/60th of a degree).

How to read a Bevel Protractor
1. Take note of the reading on the main scale (whole degree).
2. In the same direction when reading on the main scale, find the line on the vernier scale
that coincides with the line on the main scale. Multiply the number of graduations by 5
mins.

Vernier Scale

Main Scale

Note:

1 – Reading on the main scale.
2 – Reading on the vernier scale.

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Information Sheet 2.1.1: Procedures on how to read Angular Measurements

In the example shown, the reading of the main scale is 17 degrees. The number of graduations
on the vernier scale is 5. We multiply the number of graduations by 5 minutes, we get an
answer of 25 minutes.

Main scale reading : 17°

Vernier Scale reading : 25’

Total Reading : 17°25’

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Information Sheet 2.1.1: Procedures on how to read Angular Measurements

Learning outcomes:
2 Use Angular Measuring Tools
Learning Activity:
2.1 Sequence procedures on how to read angular measurements

Gage Blocks

Gage blocks have no available exact size. To attain a certain dimension, two or more
blocks are combined together. Use as few blocks as possible. The procedure for selecting
blocks is based on successfully eliminating the right hand figure of the desired dimension.

88–piece Set of Metric Gauge Blocks

9 Blocks – 0.001 mm Series

1.001 1.002 1.003 1.004 1.005 1.006 1.007 1.008 1.009
49 Blocks – 0.01 mm Series

1.01 1.02 1.03 1.04 1.05 1.06 1.07 1.08 1.09
1.10 1.11 1.12 1.13 1.14 1.15 1.16 1.17 1.18
1.19 1.20 1.21 1.22 1.23 1.24 1.25 1.26 1.27
1.28 1.29 1.30 1.31 1.32 1.33 1.34 1.35 1.36
1.37 1.38 1.39 1.40 1.41 1.42 1.43 1.44 1.45
1.46 1.47 1.48 1.49

19 Blocks – 0.5 mm Series

0.5 1 1.5 2 2.5 3 3.5 4 4.5
5 5.5 6 6.5 7 7.5 8 8.5 9
9.5

9 Blocks – 10 mm Series

10 20 30 40 50 60 70 80 90

Two 2mm Wear Block

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Information Sheet 2.1.1: Procedures on how to read Angular Measurements

Procedure in selecting Gauge Blocks to build up a Dimension

1. Write down the dimension. Gauge Block Example
2. Use the two 2 mm wear block. 4 mm 75.754
4.000_
3. Select a block that will eliminate 1.004 71.754
the last digit of the said dimension. 1.25 1.004_
70.750
4. Select a block that will eliminate
the last digit and that will leave .0 1.250_
or .5 as the last digit. 69.500

5. Select a block that will eliminate 1.50 1.500_
the last digit. 68.000

6. Select a block that will eliminate 8.00 8.000_
the last digit and that will leave a 60.000
number divisible by 10.
60.000_
7. Select a block that is the same 60.00_ 0.000
as the number left. 75.754
Reading:

Therefore, in order to attain the 75.754 dimension, these are the following gage blocks to be
used: 2mm, 2mm, 1.004 mm, 1.25 mm, 1.50 mm, 8 mm and 60 mm.

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Information Sheet 2.1.1: Procedures on how to read Angular Measurements

Learning outcomes:
2 Use Angular Measuring Tools
Learning Activity:
2.1 Sequence procedures on how to read angular measurements

Sine Bar and Gage Blocks

Basically, the unit of measurements of sine bar and gage blocks depends largely on its
type, whether English (in inches) or metric (in millimeters). Both instruments were considered
to be indirect measuring instruments, which meant that you cannot get an actual reading from
it when used separately. Both instruments, when used together, and using the mathematical
application of the Sine Rule, can determine the angle θ as shown in the figure below. l
represents the Sine bar length which is constant and h as the height of the gage blocks.

Where:
l – Sine bar length (constant)
h – Height of gage blocks
θ - Angle of the plate

sin θ = h
l

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Worksheet 2.1.1: Procedures on how to read Angular Measurements

Learning outcomes:
2 Use Angular Measuring Tools
Learning Activity:
2.1 Sequence procedures on how to read angular measurements
Read the questions carefully. Answer the questions on a separate sheet of paper.
Determine the angle on the figure shown.

1.

_______________

2.

________________

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Worksheet 2.1.1: Procedures on how to read Angular Measurements

Learning outcomes:
2 Use Angular Measuring Tools
Learning Activity:
2.1 Sequence procedures on how to read angular measurements

Read the questions carefully. Answer the questions on a separate sheet of paper.

Given the following dimensions, select the gage blocks that is appropriate to build up
each dimension.

1. 59.379
2. 45.871
3. 16.989
4. 95.123
5. 77.177

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Worksheet 2.1.1: Procedures on how to read Angular Measurements

Learning outcomes:
2 Use Angular Measuring Tools
Learning Activity:
2.1 Sequence procedures on how to read angular measurements
Read the questions carefully. Answer the questions on a separate sheet of paper.
Answer the following questions below. Just refer to the figure shown.

1. Using a 100 mm long sine bar, calculate the angle A if the stack of blocks is 75.453 mm
high.

2. Calculate the stack of blocks if you are using a 100 mm long sine bar inclined at an
angle of 32 degrees.

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Operation Sheet 3.1.1: Demonstrate the calibrating procedures on Angular
Measuring Tools

Learning outcomes:
3 Maintain Angular Measuring Tools
Learning Activity:
3.1 Procedures on how to calibrate Angular Measuring Tools

Universal Bevel Protractor

Procedures:
1. Wipe the bevel protractor and the precision square clean.
2. Check the locking status of the screw.
3. Lock the screw and check the backlash of the instrument.
4. Test the instrument against the precision square to make sure the instrument reads 90
degrees with the square.

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Operation Sheet 3.1.1: Demonstrate the calibrating procedures on Angular
Measuring Tools

Learning outcomes:
3 Maintain Angular Measuring Tools
Learning Activity:
3.1 Procedures on how to calibrate Angular Measuring Tools

Gage Blocks

Procedures:
1. The stone and block should be cleaned with alcohol before stoning.
2. Sweep the surfaces with a brush.
3. Slide the damaged surface of the block onto the stone. Be sure there is no foreign
matter trapped between the two surfaces.
4. With a firm downward pressure, the block is moved over the stone in either a circular or
a back and forth motion, until the metal is restored to its original placement.

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Operation Sheet 3.1.1: Demonstrate the calibrating procedures on Angular
Measuring Tools

Learning outcomes:
3 Maintain Angular Measuring Tools
Learning Activity:
3.1 Procedures on how to calibrate Angular Measuring Tools

Sine Bars
Procedures:

1. Examine the cylindricity of the contact bars and their distance.
2. Examine the plate for bumps and snags that could interfere with its plane surface.
3. Inspect for any twist in the plate or displacement of the contact bars.

 With the use of angle bars, set up 10, 20, 30, 40 degrees.
 At each step, place a corresponding angle block on the sine plate.
 Sweep the top of the angle block with a test indicator.
 Record the error in angularity as “full indicator movement”.
4. Move the gage block stack across the cylinder of the sine plate’s contact bar to see if
there is detectable difference in angularity. This will detect cylindricity errors of the
contact bar.
5. Move the precision angle block across the sine plate to see if there is a detectable warp.

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Operation Sheet 4.1.1: Perform Measuring Technique appropriate to the
device used

Learning outcomes:
4 Use Angular Measuring Tools
Learning Activity:
4.1 Demonstrate measuring technique appropriate to the device used

Universal Bevel Protractor

Procedures:
1. Unscrew the clamp of the protractor to loosen and swivel the blade.
2. The protractor base must be align on one side of the angle. To form the other side of
the angle, allow the blade to swivel.
3. Locate the zero point on the vernier scale.
Note:
Vernier Scale – is the smaller scale inside the protractor.
4. Read the angle in degrees on the main scale, above the zero mark on the vernier
scale.
5. After reading the angle on the main scale, read the minutes on the vernier scale. It is
found by looking counterclockwise on the vernier scale. Note the first place where
the line on the vernier scale lines up exactly with the line in the main scale.
6. Add the reading on the main scale (in degrees) and the reading on the vernier scale
(in minutes) to get the actual reading of the angle.

Vernier Scale

Main Scale

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Operation Sheet 4.1.1: Perform Measuring Technique appropriate to the
device used

Learning outcomes:
4 Use Angular Measuring Tools
Learning Activity:
4.1 Demonstrate measuring technique appropriate to the device used

Gage Blocks

Procedures:
1. Bring the blocks together flat and in a crosswise position; move them a little back and
forth. This will prevents or minimizes scratching. This will detect if foreign particles are
present between the two surfaces of the blocks.
2. Put the block on top of the other block in a crosswise position.
3. Apply slight pressure and twist them slightly until they hold on to each other. If the
blocks are clean, they will start to hold on.
4. Move the blocks so that their sides are in line. The combination of gage blocks that
were wrung together will be as solid as a single block.
Note:
Wringing – is a process of placing a block crosswise on the other block and
applying some pressure. Then swivel it to twist the blocks to a
parallel position, causing them to adhere firmly to one another.

`

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Operation Sheet 4.1.1: Perform Measuring Technique appropriate to the
device used

Learning outcomes:
4 Use Angular Measuring Tools
Learning Activity:
4.1 Demonstrate measuring technique appropriate to the device used

Sine Bar

Procedures:
1. Before using any sine device, whether it may be a sine bar, sine plate, or other sine
tool, the center distance C of the device must be determine first. Then the next thing
to determine is the angle A to be set.
2. Refer to the setting constant in the appropriate table. Other method of determining
the constant is by solving using the sine law.
3. When the appropriate constant had been obtained, assemble a stack of gage blocks
G that is equal in size with the setting constant.
4. Put the stack of blocks under one of the rollers of the sine bar, thus lifting one end of
the sine device and the desired angle is set.
5. If the device you are using has a locking mechanism, tighten it before you perform
the next activity.

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Information Sheet 5.1.1: Procedures on safe storage of angular tools

Learning outcomes:
5 Clean and store measuring tools
Learning Activity:
5.1 Sequence the correct safe storage procedures on angular tools

Gage Blocks

Gage blocks should be stored in trays covered with lint-free paper or on temperature
equalization plates that are clean. A cover of lint free towels should be used to secure the
blocks from dust and other airborne solids and liquids. When blocks are not in daily use, they
should be coated with anyone of the many block preservatives that is recommended by the
gage blocks manufacturers. It is advisable that steel gage blocks be coated to prevent rust
when the work area relative humidity exceeds 50%.

Foodstuffs should be banned from all calibration areas, as acids and salts will corrode
steel gage surfaces. Hands should be washed to reduced corrosion on blocks when gloves or
tongs are not used conveniently.

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Operation sheet 5.1.1: Perform procedures on how to clean and store
angular tools

Learning outcomes:
5 Clean and store measuring tools
Learning Activity:
5.1 Perform the procedures on how to clean and store angular tools

Universal Bevel Protractor

Procedures:

1. Keep the device always clean. Be sure to clean it before and after use.
2. When not in use, keep it in an enclosed box.
3. Handle the device only on non-measuring surfaces.
4. Do not drop the device anywhere especially on hard surfaces for it may damage the

device.

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Operation sheet 5.1.1: Perform procedures on how to clean and store
angular tools

Learning outcomes:
5 Clean and store measuring tools
Learning Activity:
5.1 Perform the procedures on how to clean and store angular tools

Gage Blocks

Procedures:
1. Keep the blocks clean. Make it a habit to clean the blocks before and after use.
2. If the blocks are not in use, keep them in an enclosed box. It is recommended that the
blocks be wiped all over with rust preventive oil if going to be stored overnight or taken
out of use.
3. Blocks must not be left wrung together for a long time. The moisture between the gages
can cause rust.
4. Handling of blocks must only be on non-measuring surfaces.
5. Check the instrument or equipment that is to be evaluated. Make sure it is free from
nicks and burrs. These will damage the blocks and gives inaccurate readings.

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Operation sheet 5.1.1: Perform procedures on how to clean and store
angular tools

Learning outcomes:
5 Clean and store measuring tools
Learning Activity:
5.1 Perform the procedures on how to clean and store angular tools

Sine Bar

Procedures:

1. Keep the device always clean. Cleaning the device before and after use is a nice habit
to implement.

2. If not in use, keep it in an enclosed box. It is recommended to wipe it all over with rust
preventive oil.

3. Handle the device on non-measuring surfaces.
4. Do not drop the device anywhere especially on hard surfaces for it may cause nicks and

burrs.

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