Question 1. Flat file. Half -round. Round file. Three square ( triangle ) Needle files. Page 1 of 46

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1 Question 1 Name Picture Cross section Uses: Cut pattern:: Flat file Half -round Round file Three square ( triangle ) Needle files Page 1 of 46

2 Question 2 The graph shown below is the data collected for the cutting speed of six different material workpiece. a. Define cutting speed b. Analyze the graph, compare and determine why the cutting speed is shown to be increasing. Page 2 of 46

3 c. Establish three examples of a material workpiece and show the order of the cutting speed from the lowest cutting speed to the highest. Question 3 a. Define what a drilling process entails. b. By an aid of a sketch (drill bit and workpiece), outline and explain the direction of the tool feed, the rotating motion of the tool including its orientation in relation to the axis of rotation towards the workpiece. Page 3 of 46

4 Worksheet (module1,2,3) 1. Mark (T) for true and (F) for false statements. No. Statement T / F 1 The meter is the basic unit of length in the imperial system 2 The yard is the basic unit of length in the metric system The vernier caliper can take measurements to accuracy of ± 0.02 mm No gap between the work piece and RULE means the work piece edge is FLAT. Gap between the work piece and the RULE means the work piece edge is NOT FLAT. The Vernier caliper with 10 divisions in Vernier scale is accurate to ±0.1 mm The Vernier caliper with 50 divisions in Vernier scale is accurate to ±0.05 mm. 8 Stem of vernier caliper is used to measure outer dimensions 9 Outside jaws of vernier caliper are used to measure external lengths 10 Inside jaws are used to measure internal lengths 11 The main scale of the vernier caliper is a movable part while vernier scale is the fixed part. Page 4 of 46

5 12 Scribers are used to mark circle on work pieces 13 A center punch has a point angle of A prick punch produces a bigger indentation than a center punch 15 A prick punch has a point angle of The engineer s square is used for checking the straightness of a work piece The micrometer can take measurements to accuracy of ± 0.05 mm A surface gauge is used for scribing lines and checking parallel surfaces and heights 19 The spring dividers are used for scribing arcs and circles 20 The Vee blocks are used for holding circular work pieces 21 The sizes of metric spanners are identified by the distance across flats of a nut. 22 The flathead screw driver is identified by its point size. 23 The crosshead screwdriver is identified by its length. 2. Select the correct answer (A, B, C or D). 1- Always look at to the rule to help you measure correctly A. 30 Page 5 of 46

6 B. 60 C. 90 D The steel rule can take linear measurements to accuracy of A. ± 0.01 mm B. ± 0.1 mm C. ± 0.5 mm D. ± mm 3- The vernier caliper can take measurements to accuracy of A. ± 0.02 mm B. ± mm C. ± mm D. ± mm 4- is used as a datum surface for marking out and for measuring purposes. A. Scriber B. Divider C. Surface plate D. V-block Page 6 of 46

7 5- is used for checking the straightness of a work piece. A. Engineer s square B. Divider C. Surface plate D. V-block 6- A produces a smaller indentation than a center punch. A. Engineer s square B. prick punch C. Surface plate D. V-block 7- used for scribing arcs and circles A. Engineer s square B. prick punch C. Surface plate D. Spring divider 8- The ends of open-ended spanners are generally oriented at an angle of to the axes. A. 30º B. 60º C. 15º Page 7 of 46

8 D. 90º 9- is spanner that has a moving jaw to fit different bolt/nut sizes. A. Open-ended spanner B. Adjustable spanner C. Ring spanner D. Combination spanner 10- is used on socket head cap screws and grub screws. A. Allen key B. Spanner C. Pliers D. Hammer 11. Which tool of the following is used to scratch lines on metal? A B C D Page 8 of 46

9 12. How can scratches on metal be made to appear more clearly? A B C D By using pen By using chalk By covering a metal with marking blue By using pencil 13. How is the pivoting leg of a pair of dividers stopped from sliding over the surface of metal? A B C D By using scriber By using prick punch By using height gauge By using caliper Page 9 of 46

10 3. Fill in the blanks by selecting your answer from the following list: Crosshead/Phillips Micrometer Dial Goggle Safety vernier boot caliper Ball peen Long nose Vernier Chuck hammer plier Flathead/slotted caliper a. is used to protect our eyes from injuries. b. is used to strike punches and chisels. c. will protect your feet if you accidentally drop something. d. has inside, outside jaws and stem to measure different dimensions. e. has indicator which can gives you the reading directly. f. is used to measure even smaller dimensions than the vernier calipers. g. is used by electricians to bend, re-position and cut wire. Page 10 of 46

11 h. The two most common screw drivers are: and Read the micrometers and the vernier calipers illustrated bellow: A) Accuracy = 0.01 mm Reading is mm B) Accuracy = 0.01 mm Page 11 of 46

12 Reading is mm C) Accuracy = 0.01 mm Reading is mm D) Accuracy = 0.02 mm Reading is mm Page 12 of 46

13 E) Accuracy = 0.1 mm Reading is mm F) Accuracy = 0.1 mm Reading is mm 2. Read the rule illustrated bellow: A- 7 mm B- 27 mm Page 13 of 46

14 C- 44 mm Identify the main parts of the vernier caliper illustrated bellow: Stem Outside jaws Vernier scale Screw clamp Main scale Inside jaws 1-2- Page 14 of 46

15 Identify the main parts of the micrometer illustrated bellow: Stem Frame Thimble Sleeve Lock Inside jaws Ratchet Anvil Spindle Page 15 of 46

16 Page 16 of 46

17 Find out five mistakes in the safety dress shown in the picture: Page 17 of 46

18 8. Identify the three types of the vernier caliper illustrated bellow: A. B. C. 9. Select the correct words from the list to fill in the following blanks: Inside jaws Stem Outside jaws Screw clamp Page 18 of 46

19 A- used to measure external dimensions. B- used to measure inner dimensions. Page 19 of 46

20 C- used to measure the depth. A B C Name Marking out tools Definition - Used for checking the of a work piece. - Also be used for marking Used to on metal Used for scribing and Page 20 of 46

21 Used to punches and chisels Forms an in which the tip of the drill will fit. has a point angle of Produces a than a center punch. has a point angle of Used as a for and for purposes Used to assist in the to the table Used for: 1. on work pieces 2. checking 3. Checking Page 21 of 46

22 Used for work pieces 11. Match the following. Match the marking out tools in column B with their correct functions in column A, Write your answer in the box below? Column A Column B Column A Column B 1) Is used for checking the straightness of a workpiece. A) 2) Is used to scratch lines B) Page 22 of 46

23 3) Is used for making indents that position the drill points and stop them slipping C) 4) Is used for supporting or setting up work vertically. D) E) 5) Is used for scratching lines parallel to a surface. Match the hand tools in column B with their correct names in column A, Write your answer in the box below? Column A Column B Page 23 of 46

24 Column A 1) Combination pliers Column B A) B) 2) Adjustable spanner C) 3) Allen key D) 4) Crosshead screwdriver 5) Open-ended spanner E) F) 6) Ring spanner G) 7) Pipe wrench Page 24 of 46

25 H) 8) Flathead screwdriver Worksheet (module-4) 1. Mark (T) for true and (F) for false statements. No. Statement T / F 1 Hack sawing is a process of cutting metals to size 2 Different standard lengths of blades can be fitted to solid hacksaw frame. 3 A particular standard length of blade can be fitted to an adjustable hacksaw frame. 4 The hacksaw blade is classified by its length and the teeth pitch. Page 25 of 46

26 5 A coarse pitch blade has more teeth per 25 mm than a fine pitch blade. 6 Fast blunting can be occurred if wrong teeth number is chosen. 7 Fast blunting is the result of low pressure. 8 The breaking of blade teeth is the result of un tightened work piece. 9 Curved cutting can be occurred if material is insufficiently tightened 10 Breaking of saw blade is the result of Jammed material. Fill in the blanks. Select your answer from the list bellow. Adjustable hacksaw Forward Fine blade Alternate Page 26 of 46

27 Coarse blade Wave Hack sawing Solid hacksaw Jamming Three Pitch Fine 50 Backward 40 Two 1- is a process of cutting metals to size. 2- A particular standard length of blade can be fitted to a frame 3- frame allows different standard lengths of blades to be fitted. 4- A is the number of teeth per 25 mm. 5- A is used to cut thick and soft work piece. 6- A is used to cut thin and hard work piece. 7- and are the most common types of saw blade set. 8- A hacksaw cuts best at about to strokes per minutes. 9- At least or teeth should be cutting all the time. Page 27 of 46

28 10- Blade setting helps to prevent the blade from when cutting the metal. 11- Hacksaws cut on the stroke, not on the stroke. 12- A pitch blade has more teeth per 25 mm than a coarse pitch blade. Circle the most correct answer: 1. Which of the following saw blade has coarse pitch teeth? a) 32 teeth per 25 mm. b) 18 teeth per 25 mm. c) 14 teeth per 25 mm. d) 20 teeth per 25 mm 2. Which of the following saw blade has fine pitch teeth? a) 32 teeth per 25 mm. b) 18 teeth per 25 mm. c) 14 teeth per 25 mm. d) 20 teeth per 25 mm 3. The pitch of saw blades is expressed as: a) The length from hole-to-hole centre of the blade. b) The material of the blade. c) The number of teeth per linear inch. d) None of the above Page 28 of 46

29 4. If wrong teeth number of blade is chosen the result is: a) Curved cutting b) Breaking of saw blade c) Fast blunting of teeth d) None of the above 5. While hack sawing, if material is not tightened well the result is: a) Teeth breaking. b) Breaking of saw blade. c) Curved cutting d) All of the above Give only one cause for each saw blade defect: Causes Defects Figures Fast blunting Page 29 of 46

30 Teeth breaking Breaking of saw blade Curved cutting Answer: Select one of the following causes: Fast blunting: Teeth breaking: Breaking of saw blade: Curved cutting: Page 30 of 46

31 - Identify the following types of blade set: a- (a) b- (b) Identify the following types of hacksaw frames: Page 31 of 46

32 Name the parts shown by the arrows. Page 32 of 46

33 Reorganize the following steps in order to cut the work piece illustrated bellow. Put your answer in the list bellow: Install the hacksaw blade. Use the blade check list to ensure proper installation. Mount the work piece firmly on the vice. Use the hacksaw to cut the work piece. Choose the correct blade. Wear the safety clothes and equipment required. 80 All Dimensions are in mm 64 Sawing lines Arrange the steps in the correct order respectively: 1- Choose the correct blade 2- Install the hacksaw blade Page 33 of 46

34 3- Wear the safety clothes and equipment required. 4- Use the hacksaw to cut the work piece 5- Use the blade check list to ensure proper installation 6- Mount the work piece firmly on the vice Worksheet (module-5) No. Statement T / F 1 Hand file is a half-round in section and parallel in width 2 Flat file is a rectangular in section and tapered in width 3 A double cut file has one set of teeth cut at 70 degrees 4 Files with a rougher grade of cut give a poor surface finish 5 6 A file with a short length would have a coarser pitch than a longer one The pining can be removed with a handle of file 7 The pining can be removed with a file card Page 34 of 46

35 8- Which file of the following is used for filing corners or angles less than 90? A B C D 9- Files are categorized according to Length and. A B C Shape Grade Cut patterns Page 35 of 46

36 D All of the above 10-Which one of the following files is used for filling internal and external curves? A B C D 11-Which of the following file grades is commonly used in the Work shop? a single cut file b double cut file c d rasp file all of the above 12- The purposes for the safe edge are to avoid the. Page 36 of 46

37 a b damage of the file handle damage of the file teeth c damage of the work piece d damage of the file tip Fill in the blanks. Select your answer from the list bellow. Rasp file Half-round file Hand file File Flat file 1- has double cut teeth on two faces and single cut teeth on two Side. 2- is commonly used for the cutting off soft materials such as wood, PVC and rubber. 3- A is a metalworking tool used to cut fine amount of material from a work piece 4- is a rectangular in section and parallel in width. 5- is used for forming radii and grooves. Page 37 of 46

38 Match the pictures in column B with their correct names in column A, Write your answer in the box below? Column A Column B Column A Column B 1) Half round file A) 2) Needle file B) 3) Square file C) Page 38 of 46

39 4) Triangular file D) 5) Round file E) Match the items in column B with their correct names in column A, Write your answer in the box below? Column A Column B Column A Column B 1) File card A) Page 39 of 46

40 2) Hand file B) 3) First cut file C) 4) Second cut file D) 5) Bastard file E) 6) Draw filing F) Worksheet (module-6) Page 40 of 46

41 No. Statement T / F 1 The most common tool used to cut a hole is the twist drill 2 The twist drill is made of Aluminum 3 Most of small drills up to 13 mm in diameter have tapered shanks. 4 Most of small drills up to 13 mm in diameter have straight shanks. 5 Most drills that are larger than 13 mm are tapered. 6 Most drills that are larger than 13 mm are straight. 7 drill gauges are used to determine and check the drill diameters 8 Chuck is mainly used for drills with tapered shanks 9 Chuck is mainly used for drills with straight shanks 10 Vises are used to hold the drill twist 11 Vises are used to hold the work piece Page 41 of 46

42 Twist drill Drift Drilling Vices Straight Drill gauges Friction Hardness Tapered Cutting tool material Speed Harder Softer Chuck 1- is used to create round holes 2- The most common tool used to cut a hole is the 3- Most of small drills up to 13 mm in diameter have shanks 4- Most drills more than 13 mm in diameter have shanks Page 42 of 46

43 5- are used to determine and check the drill diameters 6- The is mainly used for drills with straight shanks. 7- The drill is locked in the spindle with and is removed from the spindle by using a 8- are used to hold the work piece during the drilling process. 9- The are used to hold a round work piece. 10- Cutting speeds depend on the type of and the type of 11- a great impact on selecting the cutting speed. 12- The the work material, the slower the cutting speed. 13- The the work material, the faster the cutting speed. Identify the following process: Filling Drilling Sawing Page 43 of 46

44 A- B- C- A B C Name the parts of the floor press drill machine Page 44 of 46

45 Name the parts of twist drill illustrated bellow: Identify the following objects and their usages Name Usage Figure Drill gauge To create a hole Chuck Page 45 of 46

46 Drift To hold the work piece T-bolt Page 46 of 46