chapter 3 - tools
TRANSCRIPT
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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