DJJ 10033 WORKSHOP TECHNOLOGY CHAPTER 1: HAND TOOLS Nama Penulis e-Book: 1. Sharudin B. Hassan 2. Sarimah Bt. Atan 3. Mohd Helmi B. Salleh 4. Akmal B. Ismail. 5. Khairul Anuar Shah B. Hassan 6. Azlan Shah B. Katiman
Learning Outcome Upon completion of this chapter, students should be able to:- Classify hand tools in fitting work Classify the use of hand tools Classify the use of common measuring tools and equipment
Hand Tools Small, medium and heavy industries are using automatic machines What hand tools for? Importance in fitting work Still require minor operations to be performed to finish the job by hand
Classify hand tools in fitting work Classify the use of hand tools Classify the use of common measuring tools and equipment
Marking out / lay out Marking out is the scratching of lines on the surface of a workpiece (known as scribing). Purpose: to indicate the workpiece outline or the position of holes, slots, etc. to provide a guide to setting up the workpiece on a machine. The workpiece is set up relative to the marking out and is then machined.
Datum • to establish a reference position from which all dimensions are taken and hence all measurements are made. • The datum may be a point, an edge or a centre line, depending on the shape of the workpiece.
Marking out / lay out • For any plane surface, two datums are required to position a point and these are usually at right angles to each other.
Marking out tools / equipment Surface table
Marking out tools / equipment
Marking out tools / equipment Angle plate & surface gauge Vee block
Marking out tools / equipment Engineer’s square
Marking out / lay out Scriber Use to scribe all lines on a metal surface. The end of scriber should be always in sharp to give well-defined lines.
Marking out / lay out Divider to scribe circles or arcs and to mark off a series of lengths such as hole centres. Material: tool steel or high carbon steel.
Marking out / lay out Divider Trammels
Marking out / lay out Centre punch to provide a centre location for dividers and trammels when scribing circles, arc or to show permanently the position of a scribe lines by a row of centre dots. Type of punch Centre Punch Dot punch Prick punch
Marking out / lay out o Centre Punch:- o The angle of the point is 90º. The o punch mark made by this is wide and not very deep. o used for locating hole o Dot punch:- o The angle of the point is 60º. o is used for marking witness marks o Prick punch:- o The angle of the point is 30º. o is used for making light punch marks needed to position dividers.
Marking out / lay out Centre punch Dot punch Prick punch
Procedure of marking out Example: List the procedure to marking out on a plate as a figure.
Step 1 • Measure from each long edge and find the centre using a precision steel rule. Scribe the centre line using the edge of the rule as a guide. Find the centre of the small radius by measuring from one end the size of the radius plus 1 mm (this allows for the extra left on the end). Centre dot where the lines intersect.
Step 2 • Using dividers, set the distance from the centre of the small radius to the centre of the first small hole. Scribe an arc. Repeat for the second small hole and the large radius. Centre dot at the intersection of the centre lines. The dividers are set using the graduations of a precision steel rule.
Step 3 • Set dividers to the small radius. Locate on the centre dot and scribe the radius. Repeat for the large radius and if necessary, the two holes.
Step 4 • Complete the profile by scribing a line tangential to the two radii using the edge of a precision steel rule as a guide.
Classify hand tools in fitting work Classify the use of hand tools Classify the use of common measuring tools and equipment
Testing Tools Tools that are used to check, test and verify the workpieces are marked out / laid out according to the specification required.
Scribing Block It is used for scribing lines parallel to a datum surface. setting job on machines parallel to a datum surface. Checking the height and parallelism of jobs, setting jobs concentric to the machine spindle .
Scriber Nut Spindle Snug Base Fixed scribing block Universal scribing block
Hack Saw
Hack Saw 1. The hacksaw is used to cut metal. 2. Where large amounts of waste metal have to be removed, this is more easily done by hacksawing away the surplus rather than by filing. 3. If the workpiece is left slightly too large, a file can then be used to obtain the final size and surface.
Hack Saw 4. A hacksaw blade should be chosen to suit the type of material being cut, whether hard or soft, and the nature of the cut, whether thick section or thin. 5. Two important factors in the choice of a blade are the pitch, or distance between each tooth and the material from which the blade is made.
Hack Saw The standard hacksaw blade is 300 mm long 13 mm wide 0.65 mm thick and is available with 14, 18, 24 and 32 teeth per 25 mm for every length of blade.
Hack Saw
Hack Saw Types of hacksaw blades
Hack Saw Procedure to replace hack saw blade: i. Get correct blade (length, pitch, material, type) ii. Adjust Frame iii. Place ends of blade on pins with teeth pointing to front and teeth down iv. Tighten wing nut finger tight
Files and filing work PURPOSE: a) used to cut shape material b) used to smooth material c) removal of sharp edges
Files and filing work They can be obtained in a variety of shapes and in lengths from 150 mm to 350 mm. When a file has a single series of teeth cut across its face it is known as single-cut file, and with two sets of teeth cut across its face it is known as double-cut file.
Files and filing work
Files and filing work
Files and filing work • Flat Files: It is for general use. • Equaling / Hand Files : It is use for flat finishing. • Half round ring files : Use to touch up the finished parts. • Round Files / Rat Tail Files : Use to touch up the finished parts. • Square Files : To enlarge a square hole roughly. Also use to files groove and channel. • Triangular files : Use to cutting angles less than 90 degree. Also use to files sharp triangle and cleaning angled corner.
Files and filing work • Pillar Files : Use to files in narrow slot or gap. • Knife files : Use to sharpen saw blade teeth and other cutting tools teeth. • Needle Files Needle files are available in a set of files. One set consist 4 to 12 types of files. Use to finishing work after parts finished machining.The sizes range are 100mm, 140mm dan 160mm
Files and filing work
Files and filing work • Pillar Files : Use to files in narrow slot or gap. • Knife files : Use to sharpen saw blade teeth and other cutting tools teeth. • Needle Files Needle files are available in a set of files. One set consist 4 to 12 types of files. Use to finishing work after parts finished machining.The sizes range are 100mm, 140mm dan 160mm
Files and filing work ALWAYS USE WITH A HANDLE INSTALLED ON THE TANG
Files and filing work Procedure on how to prolong the life span of file:
Hammer FACE BALL PEEN EYE HEAD HANDLE NECK CHEEK
Hammer HARD TYPE HAMMER Ball Peen Hammer Shape : Has a rounded surface on one end of the head and hemispherical peen on the other. Usage : 1. Used for upsetting or riveting metal. 2. Used for hardened striking surface on the other.
Hammer HARD TYPE HAMMER Straight Peen Hammer Shape : Has a round face at one end and a blunt wedge (peen) which parallel to the handle on the other side. Usage : Used for spreading or drawing out metal in line with the handle.
Hammer HARD TYPE HAMMER Cross Peen Hammer Shape : Has a round face at one end and a blunt wedge (peen) , perpendicular to handle on the other. Usage : 1. Used for spreading or drawing out metal at right angles with the handle. 2. Round face - to spread force evenly in all directions. 3. Peen - to lengthen the metal in one dimension only.
Hammer HARD TYPE HAMMER Ball Peen Hammer Straight Peen Hammer Cross Peen Hammer
Hammer SOFT TYPE HAMMER Shape : Heads are made from soft material, such as lead, copper, babbitt, rawhide, wood, plastic, etc. Usage : Used to position workpieces that have finishes that would be damaged by a hard hammer. Types : 3 types of soft hammer
Hammer SOFT TYPE HAMMER Rubber mallet