chapter 3 - tools

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ENGINEERING TECHNOLOGYManufacturing > Communication > Transportation and Power > Construction > Industrial Design

Prepared by:Engineering Technology TeachersUnit Kurikulum, Jabatan Pelajaran Perak.


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ENGINEERING TECHNOLOGY

Manufacturing > Communication > Transportation and Power > Construction > Industrial Design

LEARNINGOUTCOMES

HOLDING AND CLAMPINGTOOLS

MARKING,MEASURINGAND TESTING TOOLS

CATEGORIES OFHAND TOOLS

DRIVING TOOLS

CUTTING TOOLS

INTRODUCTION TO

MANUFACTURING

MAIN PAGE

Prepared by:Engineering Technology TeachersUnit Kurikulum, Jabatan Pelajaran Perak.


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LEARNING OUTCOME

Students should be able to :Identify hand tools in an engineeringworkshop.

State functions of hand toolsMeasure with a vernier caliper and

micrometer

Determine the appropriate top andthreading tool sizes to cut threads.

Complete a fitting project.


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Marking,measuringand testing

tools

Holding &Clampingtools

Drivingtools

Cuttingtools

CATEGORIES OF HAND TOOLS


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Marking, Measuring And

Testing Tools

STEEL RULER SURFACE PLATE

SCRIBER EXTERNAL CALIPER

PUNCH INTERNAL CALIPER

L-SQUARE ANGLE PLATE

SPRING DIVIDER VERNIER CALIPER

TRAMMEL MICROMETER

SURFACE GAUGE


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Steel Ruler

Made of stainless steel.Available in 3 sizes :150mm, 300mm and1000mmUsesa) measure distanceb) test flatness of a workpiece.c) draw a straight line.Accuracy 0.5mm

DIAGRAM: STEEL RULER


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Scriber

Made of steel with hardened points.Uses

(i) to draw a line on a metal surface(ii) to mark on a metal surface.


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Punch

Made of tool steelTypes of punch

Prick punchUse: Mark on theobject line beforecutting

Center punchUse : Mark the centreof a circle beforedrilling

Pin punchUse : to remove arivet on a work piece


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Center Punch Application

The use of prick punch to

mark cutting line


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L-square

Made of tool steelConsists of two main parts, the blade and the bodyUses:

i) test a 90 angleii) draw a vertical line from the workpieceiii) test flatness of a workpiece.


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Spring Divider

Has a pair of sharp, pointed legs.Usesi) To make a curve or a circle

on a workpieceii) To measure distance.


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Trammel

This tool has a pair ofsharp pointed legs.They can be adjustedalong the rod byloosening andtightening theadjusting nut.Usesi) To draw a curveand a large circleii) To mark parallellines.


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Surface Gauge

This tool is used

together with a surface

plate and an angle plate.

Uses :a) to draw parallel lines

b) to determine centre of

cylindrical workpiece.

c) to test a parallel line


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Surface Plate

Available in two sizes

-Small :(100 x150)mm

-L arge:(1000

x1000)mm

Made of cast iron

It is used together with

a surface gauge, angleplate and a vernier

height gauge


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External CaliperThis tool has a pair of sharppointed legs that are curved

inwards.There are two commontypes of calipers known asfixed calipers and spring

calipers.Usage :

a) to measure theoutside

diameter of shafts,

cylinders andspheres.b) to measure length,

width and thickness

of cubes or cuboids.


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Internal CaliperIt has almost the same

shape as external caliper

but the legs are curved

outwards

There are two common

types of calipers known asfixed calipers and spring

calipers.

Uses :

a) to measure internaldiameter of bush and

cylindrical pipes

b) to measure distance

between object.


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Angle Plate

Usage:

to support the work

piece while marking

to ensure that work

piece is stable during

marking by clamping the

work piece to the angle

plate

It is made of hardened cast iron . Thistool is right angled, L-shaped tool with a

flat surface as shown in Figure 3.17


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Vernier Caliper

MEASURES

Thickness of an object Diameter of a rod

Depth of slot


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Reading Vernier Caliper

0 5 10 MainScale

0 10Vernier Scale

Main scale = 7.00 mm

Vernier scale reading = 12 graduations x 0.02 = 0.24 mm__________________________________________________

Total reading = 7.24 mm


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Examples Of Usage


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Micrometers

THIS IS A PRECISION TOOL THATGIVES A READING WITH AN

ACCURACY OF 0.01 mm.


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Reading Micrometer Scale

8

.00

0.5

0.26

2530

25

20

0 5

Graduation reading on the upper barrel =8.00 mm

Graduation reading on the lower barrel =1 x 0.50 =0.50 mm

Reading on thimble scale (bevel)

located opposite the adjuster =26 x 0.01 =0.26 mm

Total reading = 8.76 mm


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Holding/Clamping Tools

ANVIL V-BLOCK VICE TONG


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Made of carbon steel

Use :

To support a work piece during the shaping process

such as folding or forging.

Normally ,the work piece will be hammered using awooden mallet or a hammer

Anvil


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V - BlockMade of cast iron or hardened carbon steel.

Use :

To support cylindrical workpiece during

drilling or marking process.


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VicesMade of cast iron or hardened carbon steel

Use :

To hold a workpiece strongly and firmly

while doing work

Bench vice Drill vice


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Tong

FLAT SQUAREROUND

Use :

To grip flat

workpiece

such as plate

Use :

To grip round

or cylindrical

workpiece

Use :

To grip

square

workpiece

3 TYPES OF TONG


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Driving Tools

Used to drive a work piece or other tools

while doing work.

ScrewdriverSpanner

Hammer


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Screw Driver

Two common typesi) flat screwdriver

ii) Phillips screwdriverUsed to tighten or loosen screwsTo choose a screwdriver depends

on the shape of the screw heads.


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Spanner

Made of chrome-vanadium steel oralloy steel.Three common type ofspanner

i) Open-endedii) Combinediii) Ring

Used to tighten orloosen bolts and nuts.


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Type Or Specifications Spanner

Types of spanner ApplicationAdjustable spanner For tightening and looseningbolt and nut of varying sizeswithout changing to spanners ofdifferent sizes.Pipe Spanner For tightening and looseningcylindrically object such as apipe.

Allen key For tightening and looseninghexagonal bolts.


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Type or Specifications Spanner

Types of spanner Application

Socket For gripping bolts firmly to

prevent slippage.

L- Spanner For tightening and

loosening bolts and nuts.

T Spanner For tightening and loosening

bolts and nuts.

Self adjustable

Spanner

For tightening and loosening

bolts and nuts of varying

sizes.


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Hammer

Two categoriesi) hammerii) soft hammer

Hammer is commonly used in marking andchiseling. Soft hammer is used to shape or assemble a

workpiece


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a) Leather hammer

b) Plastic hammer

c) Aluminium hammer

Soft Hammer


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Ball Pein Hammer

Claw Hammer

CrossPeinHammer

Hammer


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Cutting Tools

CHISEL

FILE

HACKSAW

DRILL

TAP

DIE


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Chisel

Categories of Chiseli. Woodwork chisel ii. Metalwork chisel


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Types Of Metal Work Chisels

They are :

Flat chisel

Crosscut chisel

Round nose chisel

Diamond shaped chisel


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Table Types Of Chisels And Their Usage


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How To Use A Chisel

Correct method Wrong method


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File

End Edge Face Shoulder Handle

Length Nipple

CollarFigure 3.38 File

Made of hardened steel

Use :

For cutting, thinning or smoothening the

surface of a workpiece


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The Categories Of A File

FILE

SIZE

BASED ON FILE

LENGTH

SHAPE

TAPER

FLAT

HALF ROUND

ROUND

SQUARE

THREE SQUARE

TEETH TYPE

PARALLEL TEETH

CROSS TEETHCURVED TEETH

GRATER TEETH

TEETH GRADE

BASTARD CUT

SECOND CUTSMOOTH CUT

T th T A d U


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Teeth Types And Usage

Fil Sh A d Th i U


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File Shapes And Their Usage

FILE SHAPE USAGE

TAPER For general work

FLAT For finishing work

HALF ROUND For finishing/curve surfaces

ROUND For enlarging a curve or Round hole

SQUARE For enlarging a square hole

THREE

SQUARE For filing and finishing

sharp interior corners


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Hacksaw

It consists of a frame, a handle, an adjusting

nut and a blade.

The blade of hacksaw is made of high-carbon

steel, tungsten or molybdenum steel alloy.

Used to cut a workpiece into desired sizes. The blade length is either 250 mm or 300 mm.


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The Parts Of Hacksaw


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The Suitable Distance Tooth Sizes For

Different Workpiece Materials

Workpiece Tooth

size

(mm)

Blade

Width(mm)

Mild Steel 1.8 13-18

Cast Iron 1.4 13

Copper

Pipe

1.2 13

Sheet

metal

0.8 13

Tooth size

Blade

width


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Drill

Drill bit made of durable steel ortungsten carbide.

Used to make holes in workpieces. The drill size is determined by the

diameter of the shank. Two types of drill.i) Portable drillii) Hand drill


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Portable Drill

It can be battery or electricity operated. Commonly used in homes, office and small

business.


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Hand Drill

Use for light application such as plastic,

wood and metal sheet metal.


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Tap

Taps are used to cut inner thread. It is made

from carbon steel or durable steel.

Taps are used together with wrench.

Tap sizes are printed on its shank.

The marked M 10 x 1.5 stands for

M - thread in metric unit10 - major diameter in mm

1.5 - thread pitch in mm unit


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Before cutting internal thread, a hole should be

drilled according to the tap drill size.

There are two ways of getting a tap drill size :

i. By Table

ii. By Calculation

Calculation Example:To cut internal thread M12 x 1.75

Solution:

Tap drill size (TDS)= Major dia.- Pitch

= 12 1.75

= 10.25 mm

Procedure To Cut An Inner Thread In A


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Procedure To Cut An Inner Thread In A

Through Hole.

aper Tap :Preliminary work

Plug Tap :Used after a taper tap

Bottoming Tap :Final threading

1. Drill a hole of suitable size.

2. Choose a desired tap size.

3. Positioned tap vertically.

4. Turn wrench clockwise half/fullcycle. Drip cutting fluid.

5. Turn wrench anticlockwise.

6. Repeat steps 4 and 5.

7. Repeat steps 4 & 5 using Plug

and Bottoming tap

Di


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Die

Die is used to cut an external thread.

It is used together with a wrench.

The materials used to make dies are carbon steel or

durable steel.

Die sizes are printed on its surface.Die Wrench

Procedures Of Cutting


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Procedures Of Cutting

External Thread

i. Clamp the workpiece to the vice at 900 vertically.

ii. Chamfer the edge of workpiece.

iii. Choose a correct die and fit it to the wrench.

iv. Fix die to the workpiece as shown in the diagram below.

v. Turn wrench clockwise to half cycle and anticlockwise toquarter cycle. Apply cutting fluid during threading.

vi. Repeat step v until the thread length is reached.

vii. Test the finished thread with nut or thread pitch gauge.


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END OF

CHAPTER 3

chapter 3 - tools

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