UNIT 2 SHOP TOOLS Shop Tools HAND TOOLS

UNIT 2: SHOP TOOLS

Shop Tools HAND TOOLS 2

LESSON INFORMATION • Lesson 1: Hand Tools Lesson Description In this lesson, we will identify simple manufacturing tasks that hand tools may be used to accomplish. We will also detail the safety considerations for their use, the features and distinguishing characteristics of each tool, and the applications for which they are commonly applied. 3

TOOL SAFETY Before we get started, we need to know about tool safety. Tools can hurt you and fellow workers in several different ways. Tools can be: Falling objects Flying objects

TOOL SAFETY Tools can also hurt you and other through other movements, like Abrasion Splash Harmful dusts, fumes, mists, vapors, and gases

BASIC POWER TOOL SAFETY • • • Maintain regularly Use right tool for the job Inspect before use Operate according to manufacturers’ instructions Use the right personal protective equipment (PPE) Use guards 6

HAND TOOLS PROTECTION • Use appropriate Personal Protective Equipment (PPE) • Keep floor surfaces free from debris and tripping or slipping hazards • Keep cutting tools sharp 7

HAND TOOLS USED IN AEROSPACE Deburring tools Files Hacksaw Hammers Plyers Punches Snips Screwdrivers Wrenches Clamps 8

DEBURRING TOOLS • • Burr Qwik Tool Chip Chaser Deburring Tool Red Devil Scraper Weldon Deburr Tool Edge Breaker Machinist’s Triangular Blade 9

DEBURRING TOOLS Burr Qwik Tool 10

DEBURRING TOOLS Chip Chaser 11

DEBURRING TOOLS Deburring Tool 12

DEBURRING TOOLS Red Devil Scraper 13

DEBURRING TOOLS Weldon Deburr Tool 14

DEBURRING TOOLS Edge Breaker 15

FILES Several kinds of hand files are used in manufacturing areas. Hand Files are classified by length, shape, and cut. Rotary Files have cylindrical shanks for chucking in drill motors. These files are used to break and chamfer edges, remove burrs and fins, elongate holes and slots, and perform similar jobs in otherwise inaccessible places. 16

FILES: LENGTH Length is usually 6 -12 inches, to suit job requirements and the mechanic’s preference. Tooth coarseness generally increased as the length of the file increases. 17

FILES: SHAPES Shape indicates the cross-section of the file or the general configuration of blunt or taper. Shape can be rectangular, half round, round or square. 18

FILES: CUT Tooth forms most often used in fabrication and assembly: Cut describes the file’s teeth in Single cut – generally used for coarseness and form finishing Smooth – finest cut (rarely used) Double cut – Generally used for Second cut – intermediate (widely roughing (not “second cut” which used) is a degree of tooth coarseness, Bastard – quite coarse (most not a tooth form) often used) Curved tooth – special coarse Coarse – roughest cut (very tooth for aluminum and other seldom used) soft materials. 19

FILING OTHER METALS Files are used on aluminum alloys for finishing sheet edges after final trim, removing burrs, breaking sharp corners, removing machine marks, providing clearance for sealant, and removing superficial nicks or mars produced in handling. 20

FILING OTHER METALS For finishing an edge, braking a corner or removing a burr on stainless steel or titanium, you’ll need a different approach. Always start with a file at least a grade finer than you would use on aluminum for example, where a bastard would be used on aluminum, try a second cut on stainless steel or titanium. The harder or tougher the material is, the finer and smoother the tooth form must be. 21

USING A FILE Using the file – the material must be held securely , with the area to be filed at elbow height. If necessary, clamp the work to a bench top or securer it in a vise. Allow minimum overhang beyond the clamping point to eliminate vibration; use a wooden or metal backing if needed. Protect the material from damage at the clamp pints by using jaw liners on the vise. 22

STRAIGHT FILING • Hold the handle in your palm. Grasp the end of the file in your other hand so you are holding it with two hands. • Keeping the file level, carry the stroke forward as far as the length of the file • Raise the file for the return stroke. Dragging the file back over the work rapidly dulls the file. • The file only cuts on the forward stroke. Use sufficient downward pressure to maintain constant cutting. 23

STRAIGHT FILING If the file slides or chatters, vary the direction of stroke, the cutting pressure, or both. If sliding or chattering still occurs, and the file is clean, change to another file cut. Always keep the file clean. Loose chips can be removed by rapping the file handle lightly against a wooden block; packed chips must be removed with a file card. Do not oil a file. Oiling causes a file to dull rapidly in use. 24

HAND FILE CARD Cleaning a File Installing a File Handle Removing a File Handle Insert the tang into the socket in With the file on one hand the Use a file card to clean the file teeth. the handle. Using hand pressure handle in the other, pull the file Stroke the file with the wire brush with a rag wrapped around the file, from the handle while striking the parallel to the teeth. Finally, use the tap the handle repeatedly on the ferrule (metal part of the handle) fiber brush to clean the file bench top until the file is firmly lightly against the edge of the thoroughly. seated. Do not hammer the file into the handle. 25

HAND FILE HANDING PRECAUTIONS • • • Never use a file that does not have a securely attached handle. CAUTION Do not oil a file; this will cause dulling. If a finer finish is Never use a file as a chisel or lever. needed, use a finer cut. If misused in the way, the file could Never strike a file against a vise or other hard object to shatter and cause injury or remove chips. blindness. 26

HAND HACKSAW Hand hacksaws are occasionally used to cut metal in assembly areas when it is not possible or convenient to use other equipment. 27

HAND HACKSAW Hacksaw blades are available in 18, 24 and 32 teeth-per-inch. The TPI selected will depend primarily on the thickness of the material to be cut: the basic rule is to have least two teeth in the cut at all times. For example, a 32 -tooth blade should be used to saw 0. 060 -inch material and an 18 -tooth blade should be used to saw 0. 125 -inch material. 28

HAMMERS In most hammer uses, the thumb should be on the side Although the hammer is a simple tool, there are right Plastic tip hammers are used where precision-finished and wrong ways to use it. The beginner tends to grip of the handle. However, for light, accurate work, such or delicate parts would be damaged by metal hammers. the hammer too close to the head. This reduces the as center punching, better control of the hammer can effectiveness of the blow and makes it more difficult to be maintained with the thumb on top of the handle. strike the object with the full face of the hammer. 29

HAMMERS Hammer usage safety precautions: 1. Remove all chips or foreign material from the part surface and hammer face before hitting with the hammer. 2. Do not scar parts or material with hammer. 3. Keep hammer handle and hands free of grease. 4. Do not strike sharp edges or hardened surfaces with a hammer. 30

PLIERS The mechanic uses many types of pliers, but he or she uses each type only for its intended purpose. A good mechanic will never use pliers for loosening or tightening nuts, or on a hardened surface, or on anything that can be damaged by the teeth of the pliers. 31

CUTTERS Bolt cutters are high-leverage diagonal cutters used for cutting large-diameter wire and small bolts. Diagonal cutters (side cutters) are designed for cutting wire, cotter pins, and similar parts. 32

PLIERS Interlocking-joint or water pump pliers are quickly adjusted and will adapt to a wide variety of jobs. The jaw teeth are deep to permit a firm bite on the work. Needlenose pliers enable the mechanic to install or remove parts that would otherwise be hard to reach. Needlenose pliers sometimes have cutting edges on the inner part of the jaws. 33

PLIERS Locking pliers provide a powerful grip. When removing the pliers, a slight pressure on the release lever, located inside the handle of the tool, opens the jaws. Locking pliers should not be used on parts that can be damaged by extreme pressure. 34

PLIERS Precautions for handling pliers Always select the correct type and size of plier for the job. Using the wrong type and size may result in part damage or even personal injury. 1. 2. 3. 4. Keep your fingers away from the jaws of the pliers. Never hammer with a pair of pliers. Pliers must not be used on finished machine parts. Never turn bolts or nuts with pliers. 35

PUNCHES By first center-punching the The correct method to start a CAUTION A Center Punch can be used to hole location, the mechanic drill on a production part is Center punches should not be mark the location holes to be ensures a stabilized drill. to turn the drill motor by used on aircraft parts. They drilled. If a mechanic drills a Take good care of the center hand until an adequate can cause dimpling or hole without first centerpunch. Do not use it on metal starting hole is created. deplying on thin stacks punching the location, the drill that is hard enough to may move or wander. When a damage the punch point. drill wanders, accurate location is lost. 36

PUNCHES The drive-pin punch has a straight shanks and is used to knock out rivets, bolts, etc. The size used must be just under the hold size. Available sizes range from 0. 063 (1/16) inch to 0. 25 inch in diameter, in 0. 31 (1/32 inch graduations. 37

SCREWDRIVERS Precautions for using screwdrivers Conventional slotted-head screws, One-piece screwdrivers are not 1. Do not use any screwdriver bit Phillips-head screws, cross recess recommended in assembly areas. not issued by the tool room. screws, and Hi-Torque screws are Instead, the mechanic uses a 2. Do not use a screwdriver bit that presently in common use at Boeing. socket handle or power is too small or too large. A fourth type of screw, the Tri-Wing screwdriver with replaceable bits. 3. Do not use a screwdriver bit with torque set, may someday replace the For all types of screw heads, the a worn or damaged point. Worn screw head and screwdriver systems screwdriver bit must be a good fit. or damaged points damage now in use. The Tri wing screw head The mechanic must determine expensive fastener heads, design may provide a more positive which size he or she should use resulting in rejected parts. and slip-proof drive. to fit a given screw head. 38

SNIPS Snips are used to trim straight lines, curves, or holes in thin sheet metal. To cut large holes in the lighter gages of sheet metal, start the cut from a hole sawed or punched in the center of the area to be cut. With aviation or narrow-bladed snips, make a spiral cut from the starting hole out toward the circle and continue cutting until the circle is complete. 39

REGULAR SNIPS Aviation or narrow-bladed Regular or straight snips are used snips are designed for cutting straight lines or circles heat-treated aluminum alloys of large diameter. Straight snips and stainless steel. These snips are available for both right- and can be used to cut stock up to left-handed use. 0. 050 -inch thick. The blades have small teeth on the cutting edges and the handles give leverage for heavy cutting. Aviation snips are also available for both right- and left-handed use. 40

WRENCHES CAUTION The installation of nearly all threaded fasteners in aircraft structure requires precise torque control and must be done with a certified torque controlled tool in order to meet engineering requirements. 41

WRENCHES An Allen wrench is an L-shaped An Allen wrench is more bar of hexagonal tool steel that commonly used in the fits the hexagonal socket in a installation and removal of hex headless setscrew or socket-head driver bolts (Hi-Loks®). Some cap screw. The short end of the power Hi-Lok installation tools wrench is inserted into the head use a straight bar instead of the L of the fastener when it is to be -shape shown. tightened or broken loose. A loosened fastener can be unscrewed rapidly by inserting the long end of the wrench into the fastener head. 42

WRENCHES The box wrench completely It is easier to use an open-end An open-end wrench is a encloses the nut or bolt head; wrench to remove a nut or bolt nonadjustable wrench with consequently, it is not likely to once it has been broken loose openings at each end. The slip and damage the fastener. because the box end wrench openings are at a slight angle to Because the walls of a box must be lifted each time it is the body of the wrench. The wrench are thin, it can be used reset on the fastener. For this wrench must fit the nut or bolt with nuts that are hard to get at reason, many mechanics prefer a head and must sit squarely on with an open-end wrench. combination box and open-end the flats to prevent the wrench. from slipping. A mechanic should always pull, never push, an openend wrench. 43

WRENCHES The adjustable (crescent) wrench The adjustable wrench does not is similar to the open-end fit nut flats as well as an openwrench; however, it has a end, box or socket wrench, and movable jaw. Thus, one wrench has a tendency to slip. Because of may be used for a range of nut or the possibility of damaging the bolt head sizes. When using the fastener or nut, the adjustable wrench, the mechanic wrench should never be used on should tighten the adjusting knurl production parts. with the wrench in place so that the wrench fits snugly. 44

SOCKET WRENCHES The square drive socket is the Socket wrenches completely enclose the bolt head of nut and most commonly used socket. The provide the most positive and deep square drive socket is used slip-proof means of installing or when the bolt protrudes beyond removing threaded fasteners. the nut. The flex socket is very Many different types of socket, versatile, since the socket is an handles and attachments are integral part of a flexible joint. available. 45

SOCKET HANDLES These are different socket handles. The ratchet is used to tighten or loosen nuts or bolts without removing the socket from the fastener. 46

TORQUE WRENCH Other types of torque wrenches With the rigid frame wrench with include: the cam operated rigid dial reading, the mechanic can frame wrench with torque snap, see when the specified torque wrench with open end had been applied by watching for tube fittings and with a the dial. torque pin snap and torque wrench with tee handle, square drive and ratchet snap are preset by turning the gate to the specified torque. When that force has been reached, the wrench will click. 47

TORQUE WRENCH Preset torque-control pneumatic nut runners are generally used in production work. However, the hand torque wrench is widely used in limited-access areas, for large bolts, and when only a small number of bolts in an area require torquing. Also, Quality Assurance inspectors use them for checking proper torque. 48

CLAMPS AND TEMPORARY FASTENERS Assemblies must be firmly held in place during hole preparation before a hole is drilled, during the drilling, and during subsequent operations. Until a hole is drilled, the parts must be clamped together using clamps and after the hole is drilled the parts can be held together by using Cleco fasteners or temporary fasteners.

CLAMPS AND TEMPORARY FASTENERS The term “Cleco fastener” is a common use name for Wedgelock™ fasteners manufactured by Monogram Aerospace Fasteners. Clecos are temporary fasteners used to held together two of more pieces of sheet metal while drilling, bolting, etc. , or to secure a template to a part. The Cleco fasteners used most often in assembly areas are the clamp and the pin. 50

CLAMPS AND TEMPORARY FASTENERS CAUTION Spring-loaded Cleco fasteners Since Cleco pins can be bent very must be installed or removed easily, care must be taken when with special pliers. The fastener is inserting or removing them. They placed in a Cleco pliers so that can easily scratch the sheet of the forked jaw us under the hole, or they may release shoulder of the pin and the suddenly and hit the user or recessed jaw is over the blunt another worker. end of the pin. Closing the pliers compresses the fastener spring; on the Cleco pin, it reduces the shank diameter for insertion into a hole. 51

CLAMPS AND TEMPORARY FASTENERS The color codes shown in the table indicate the sizes of the most common Cleco fasteners. 52

C-CLAMPS AND TOGGLE CLAMPS C-clamps and toggle clamps are used to clamp parts together. The part surface should be protected by placing heavy cardboard, fiber, or wooden blocks between the part and the clamp. 53

SPARK RESISTANT TOOLS Around flammable substances, sparks produced by iron and steel hand tools can be a dangerous ignition source. Where this hazard exists, spark-resistant tools made from brass, plastic, aluminum, or wood will provide for safety. 54

SUMMARY In this lesson, we identified simple manufacturing tasks that hand tools may be used to accomplish. Now that you are familiar with the tools, you should be aware of the safety considerations for their use, the features and distinguishing characteristics of each tool, and the applications for which they are commonly applied. 55

Acknowledgements Aerospace Joint Apprenticeship Committee (AJAC), American Society of Metals (ASM), The Boeing Company, National STEM Consortium (NSC), Skills Inc. , Washington Manufacturing Advanced Training Institute (WMATI) About These Materials Copyright © 2015 by Washington Manufacturing Advanced Training Institute (WMATI) The Core. Plus: Manufacturing Skills Curriculum is a collaboration among Boeing and WMATI License Unless otherwise specified, this work is licensed under a Creative Commons Attribution-Share. Alike 4. 0 International License. Attribution and Citation To attribute this course please reference Washington Manufacturing Advanced Training Institute (WMATI). Some of the slide deck, activities, and lab projects are derivative works used under CC-BY 4. 0. National Stem Consortium. (2015). Composites Technology certificate program of the National STEM Consortium. Retrieved from http: //oli. cmu. edu. Some slide decks, activities, and lab projects are derivative works used under CC-BY 4. 0. Aerospace Joint Apprenticeship Committee. (2015). Manufacturing Academy. To cite this course please use the following citation example: Washington Manufacturing Advanced Training Institute (WMATI). Core. Plus Manufacturing Skills Curriculum: Precision Measurement course. [URL if applicable. ] Core. Plus, 2015. Disclaimer This workforce solution was built from open license materials from many sources. There are no guarantees, warrantees, or assurances of any kind, express or implied, with respect to such information, including any information on linked sites and including, but not limited to, accuracy of the information or its completeness, timeliness, usefulness, adequacy, continued availability, or ownership.