CHAPTER 6. Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION. Jones & Bartlett Learning, LL NOT FOR SALE OR DISTRIBUT

Transcription

1 CHAPTER 6..

2 Applying Basic Hand Skills 6 Primary Learning Objectives After reading this chapter, you will be able to: NOT FOR SALE OR DISTRIBUTION Perform marking-off/marking-out exercises. (pp ) Perform grinding exercises. (pp ) Perform drilling exercises. (pp ) Perform cutting exercises. (pp ) Perform filing exercises. (pp ) Perform internal and external threading exercises. (pp ) Knowledge Objectives Jones & Bartlett Learning, LLC After reading this chapter, you will be able to: 1. List and describe basic marking and measuring tools. (pp ) 2. Use various tools and workshop equipment. (pp ) 3. Make alearning, puller. (pp ) Bartlett LLC & Bartlett & Learning, LLC Skills Objectives After reading this chapter, you will&bebartlett able to: Learning, LLC NOT FOR SALE OR DISTRIBUTION Procedure Mark off/mark out material. (p. 146) 2. Set up, adjust and use a bench grinder. (p.146) 3. Sharpen and face tools. (pp ) 4. Set up, adjust and operate a drill. (p. 149) Jones & Bartlett Learning, LLC 5. Set up, adjust and use a hacksaw. (p. 149) 6.NOT Set up, adjustsale and useor a file.distribution (p. 151) FOR 7. Set up, adjust and use dies and taps. (p. 153) 8. Make a puller. (pp ) Procedure 6-2 Procedure 6-3 Procedure 6-4 Procedure 6-5 Procedure 6-6 Procedure 6-7 Procedure _CH06_p indd 141 4/4/14 6:08 PM

3 142 chapter 6 Applying Basic Hand Skills Introduction types of inside calipers consist of the fixed-joint caliper and the spring-joint caliper. The spring-joint inside caliper NOT FOR During SALE the OR course DISTRIBUTION of any day within the workshop environment, technicians will handle a variety of different and an adjustment device. NOT FOR is made SALE up of OR two DISTRIBUTION legs, a circular spring, a pivot pin tools to complete the work tasks. For all tools, the workshop will supply some, and others will be part of the adjusting screw, which moves the legs against spring Spring jointed-type calipers are provided with an technician s everyday tool Jones chest. & Bartlett Learning, LLC tension. The firm joint has two Jones legs fastened & Bartlett together Learning, LL Regardless of who NOT owns FOR what, SALE it is the OR technician s DISTRIBUTION with either a nut or some NOT other anchoring FOR SALE device. OR All DISTRIBUT responsibility to: the adjustments are by hand. The spring joint type is the better of the two as it is much easier to adjust, thus Select the correct tools to complete the task. giving it a higher degree of accuracy. The sizes of the Use the tools in a safe manner and to manufacturer s calipers are determined by the lengths of their legs. They recommendations. Jones & Bartlett Learning, LLC are measured from the center of the joint to the bottom NOT Maintain FOR these SALE tools OR to a high DISTRIBUTION standard. Clean and store the tools in their correct and proper places. & The Bartlett tools and Learning, equipment LLC can be divided into three major categories that allow them to be identified easily. The groups are: Hand tools: general and manufacturer s special tools Measuring equipment Workshop equipment Basic Marking and Measuring & Bartlett Tools Learning, LLC Measuring NOT tools FOR are SALE precise OR instruments DISTRIBUTION and must be handled with care. These measuring tools must be cleaned, Figure 6-1 inspected and stored in such a matter as not to allow A typical inside caliper. them to get damaged. Some precision measuring instruments, & Bartlett such Learning, as micrometers, LLC vernier calipers and dial gauges, may require calibration by a suitably qualified person. When storing these tools for a period of time, they should be cleaned, inspected and given a protective coating such as a light lubricant to minimize the chances of rust forming. Calipers Calipers are used for transferring measurements or dimensions between the surface faces of a component to reduce sighting errors or mistakes. Calipers basically come Jones in two & Bartlett formats: inside Learning, calipers LLC and outside calipers. Inside Caliper An inside caliper is primarily used to measure the internal dimensions of a component Figure 6-1. The common Figure 6-2 A typical jenny caliper...

4 chapter 6 Applying Basic Hand Skills 143 of the legs; the most common caliper sizes are 3 inch, 4 & inch Bartlett and 6 Learning, inch (75 mm, LLC 100 mm and 150 mm). NOT FOR SALE Another OR form DISTRIBUTION of inside caliper is the jenny caliper Figure 6-2. They are used to scribe lines that are parallel to an edge or to determine the center of circles when boring. Outside Caliper This type of caliper and its construction are the same as the inside caliper except the legs are facing inward. Outside calipers are utilized for taking outside Figure 6-5 Scribers are sharply pointed marking tools used to make lines on metal to mark cutting or drilling points. measurements, such as obtaining the diameter of a pipe Figure 6-3. Figure 6-3 A typical set of outside calipers. Figure 6-4 A typical divider compass. Dividing Compass A dividing compass is used for drawing circles and curves on metal. Both legs of the compass have sharpened points and the radius can be set by utilizing the adjustable set screw Figure 6-4. & Bartlett Learning, LLC Before using NOT the FOR dividing SALE compass, OR DISTRIBUTION a small pilot mark is stamped on the metal to allow one leg to be held in its relative position while the other leg scribes a mark onto metal as it is rotated. Scriber & Bartlett Learning, LLC Also known as an engineer s scriber, this tool is a sharp, pointed marking tool and is used for drawing lines on metal Figure 6-5. Normally, it has one straight pointed end, and the other end is bent at a 90-degree angle and also has a sharpened point on it. To ensure & Bartlett that the tool Learning, LL can be correctly gripped, the NOT center FOR portion SALE is knurled. OR DISTRIBUT This knurling allows the technician to firmly grip the scriber when marking the metal surface. Retractable Steel & Bartlett Tapes Learning, LLC One of the most valuable and versatile measuring instruments in the motorcycle tool kit is the retractable steel tape measure Figure 6-6. Measuring tapes can range in size from 3 feet to more than 100 feet (1 meter to more than 30 meters)...

5 144 chapter 6 Applying Basic Hand Skills Figure 6-6 Retractable tape measure being used to measure a component. Figure 6-7 A steel ruler being used to measure scriber marks on a piece of metal that was drilled. Flat Steel Ruler/Straight Edge A flat steel ruler/straight edge is used when absolute accuracy is not a priority Figure 6-7. It & is Bartlett reasonably Learning, accurate LLC for measuring smaller NOT jobs. FOR It can SALE also double OR DISTRIBUTION up as a small straight edge when checking a surface for flatness. Steel Squares Steel squares Jones are & used Bartlett for checking Learning, the angles LLC when long metal NOT sections FOR are SALE at right angles. OR DISTRIBUTION They have graduations in either imperial or metric values Figure 6-8. Engineer s Square Sets Try-Square The try-square is used for squaring lines across a metal plate. NOT FOR Figure SALE 6-8 Steel OR squares DISTRIBUTION come in various sizes, depending It has many uses in the workshop, such as marking ends on the measuring to be done. of bars and checking the 90-degree angles of components. Combination Square A combination square is Jones a tool used & for Bartlett multiple Learning, purposes LLC Determining flatness: When Jones working & Bartlett with wood, Learning, LL in metalworking. It is composed NOT FOR of a SALE ruled blade OR DISTRIBUTION and one the first step is to designate NOT a FOR reference SALE surface OR on DISTRIBUT a or more interchangeable heads that may be affixed to it. board, which is known as the face side. The rest of The most common head is the standard or square head, the workpiece is measured from the face side, with which is used to lay out or check right- and 45-degree the next surface being the face edge. angles. The Jones combination & Bartlett set combines Learning, the features LLC of the Measuring the center & Bartlett of a circular Learning, bar or LLC dowel 45-degree NOT square, FOR SALE center OR square, DISTRIBUTION protractor, try-square Setting NOT and FOR measuring SALE angles: OR The DISTRIBUTION protractor head and mitre square. Combination square uses include: allows angles to be set and measured between the Measuring angles: A combination square can base and ruler. reliably measure 90-degree and 45-degree angles. Approximating level surfaces: A rudimentary spirit & Bartlett The 45-degree Learning, angle LLC is commonly used to create or & bubble Bartlett level Learning, is incorporated LLC in the protractor and NOT FOR SALE mitre OR joints. DISTRIBUTION NOT FOR also SALE the 45-degree OR DISTRIBUTION holder...

6 chapter 6 Applying Basic Hand Skills 145 Figure 6-9 This combination square has a bubble level incorporated into the design to help take level measurements. Measuring depth or transferring dimensions: By Use safety eyewear when using cutting equipment. moving and setting the head, it can be used as a Do not run your fingers down a newly cut material depth gauge or to transfer dimensions. or threads. They have many sharp edges that will Marking the work surface: & The Bartlett included Learning, scribe LLC cut your fingers, and small metal Jones particles & Bartlett will start Learning, LL an infection in the cut. point stored in a drilled hole in the square base can be used to mark the work surface. The combination set has a blade that is graduated and a head that is used in conjunction with this blade Figure 6-9. The & set Bartlett can be adapted Learning, into a LLC depth gauge. The NOT head has FOR a SALE 45-degree OR angle DISTRIBUTION and incorporates a spirit level. Some even have a scriber housed in the unit for convenience. appropriate for the task and that conforms to your local safety regulations and policies. Among other items, this NOT may FOR include: SALE OR DISTRIBUTION Work clothing, such as coveralls and steel-toed footwear Eye protection, such as Jones safety glasses & Bartlett and face Learning, LL masks Ear protection, such as earmuffs and earplugs Hand protection, such as rubber gloves and barrier cream Respiratory equipment, & Bartlett such Learning, as face masks LLC and valved NOT respirators FOR SALE OR DISTRIBUTION If you are not certain what is appropriate or required, ask your supervisor. NOT FOR Safety SALE OR DISTRIBUTION Make sure that you understand and observe all legislative and personal safety procedures when carrying out the procedures included in this chapter. If you are unsure of what these are, ask your supervisor. Marking-Off/Marking-Out Exercises & Bartlett Using Learning, Various LLC Tools and To perform & Bartlett the marking-off Learning, exercise LLC (also known as a NOT FOR SALE Workshop OR DISTRIBUTION Equipment NOT marking-out FOR SALE exercise) OR DISTRIBUTION you ll need the following tools: Vise The following workshop procedures will guide you in the skills you need to use various tools and workshop Mild steel equipment, including the steps needed to make a puller Scriber from steel. Each procedure will take you through a specific step-by-step process NOT to FOR master SALE the use OR of each DISTRIBUTION tool Machine blue Measuring instrument (steel rule or vernier calipers) or piece of equipment. Center punch Personal Safety Appropriate file Whenever you perform & Bartlett a task Learning, the workshop, LLCyou must To mark off/mark Jones out & Bartlett material, follow Learning, the guidelines LLC use personal NOT FOR protective SALE clothing OR DISTRIBUTION and equipment that is in Procedure NOT 6-1 FOR. SALE OR DISTRIBUTION..

7 146 chapter 6 Applying Basic Hand Skills NOT FOR SALE PROCEDURE OR DISTRIBUTION 6-1 Marking NOT Off/Marking FOR SALE OR DISTRIBUTION Out Material 1 Clean up the material by hand filing to make flat, rightangle surfaces. 2 Apply a coating of machine NOT blue and FOR let it SALE dry. OR DISTRIBUT 3 Using a measuring instrument, scribe lines on the steel following the work diagram measurements. For right angle lines, use a square to ensure accuracy of scribe lines. 4 Note that, NOT if measuring FOR SALE with a steel OR rule, DISTRIBUTION you start the measure at least 3 8 inch (10 mm) from the beginning of the rule. 5 Use the center punch to mark off/mark out any drill holes. PROCEDURE 6-2 Setting Up, Adjusting and Using a & Bartlett Learning, Bench LLC Grinder 2 If needed, adjust the tool 1 8-inch (3.2-mm) gap and the shatter guard 1 16-inch (1.6 mm) gap between the wheel. The tool rest should be slightly below the center & Bartlett of the wheel. Learning, To adjust the LLC tool rest, locate the NOT FOR adjusting SALE bolt OR and loosen DISTRIBUTION it with a box-end wrench. Set the tool rest at the right height and distance from the wheel, and then tighten the adjusting bolt. If you are unsure of how to do this, ask your supervisor. 3 Connect the grinder to the power Jones supply. & Bartlett Adjust your Learning, LL face protector, stand to the side of the wheel, and switch the grinder on. 1 Before you start using the bench grinder, inspect the wheels and check to see if the tool rest, safety shield and shatter guard are adjusted properly. There should also be water in the pot. 4 After the grinder is fully up to speed, move to the front of the wheel, hold the part you are going to grind firmly onto the tool rest, and move it slowly and gently forward until Jones it comes & into Bartlett contact Learning, with the wheel. LLC The grinding NOT wheel FOR removes SALE the OR metal DISTRIBUTION it contacts. Use the full face of the grinding wheel to prevent wearing one area of the wheel...

8 chapter 6 Applying Basic Hand Skills 147 Performing & Bartlett Learning, Grinding LLC Exercises To set up, adjust and use a bench grinder, follow the guidelines in Procedure 6-2. When grinding metal, the metal must not be allowed to overheat because this will adversely affect its hardness. If the metal NOT FOR To sharpen SALE and OR face DISTRIBUTION tools, follow the guidelines in Procedure 6-3. becomes too hot and is allowed to cool slowly, it may become soft. If it is cooled quickly (quenched), it may become brittle. As you grind the metal, stop and dip it regularly into the water TECHnICIAn TIP pot attached to the base of the grinder, which will prevent the metal from getting too hot. Some bench grinders are not Ask your supervisor to demonstrate the differences supplied with a water pot. If this is the case, you will need between grinding wheels for soft and hard materials to have a water can located near the grinder so that you can and wire brush wheels. As the abrasive wheel wears cool the piece you are grinding. Always make sure you wear down, the gap between the wheel and the tool rest personal protective & equipment Bartlett when Learning, grinding. LLC TECHnICIAn TIP When using the grinding wheel, you will occasionally & dip Bartlett the part Learning, into the water LLC to keep it cool. This is NOT FOR SALE known as OR quenching. DISTRIBUTION When you have finished, turn off the power and unplug the grinder. will increase. This creates & Bartlett a dangerous Learning, situation, LLC because if NOT the gap FOR enlarges SALE toward OR the DISTRIBUTION thickness of the metal you are grinding, the metal could be pulled into the gap, which could cause the metal to be thrown with much force. Be very careful when grinding thin metal pieces, as they are more easily grabbed & Bartlett by the wheel. Learning, Your mentor LLCwill also explain NOT FOR and demonstrate SALE OR how DISTRIBUTION to dress a grinding wheel to allow accurate grinding. PROCEDURE 6-3 Sharpening and Facing Tools 1 Using the grinding wheel to sharpen a drill bit. The bit should be held firmly on the tool rest before beginning the grinding process. When grinding, the bit should be higher than the shank when the bit is moved against the grinding wheel. STEP 1 2 Using a combination rule to measure the bit angles. After grinding, use a combination rule to measure the bit angles to make sure they are correct. STEP 2..

9 148 chapter 6 Applying Basic Hand Skills NOT FOR SALE PROCEDURE OR DISTRIBUTION 6-3 Sharpening NOT FOR and SALE Facing OR DISTRIBUTION Tools, continued 3 Dressing the head of a flat screwdriver. When grinding the head of a flat screwdriver, you are grinding the point. The angle of the point should be parallel to the wheel when you lightly press the tip against the wheel. When finished, you need to make sure the tip of the screwdriver is even on both sides. STEP 3 STEP 4 4 Dressing a cold chisel. The chisel has two ends that need to be ground: the striking end and the cutting edge. For the striking end of the chisel, rest the chisel at an angle and rotate it so there is an even edge around the chisel and it isn t mushrooming. For the cutting edge, hold it evenly against the grinding wheel and grind a bit at a time before flipping the chisel over and doing the same. The edge, when finished, should be even and sharp. Ask your mentor to demonstrate the correct angles for sharpening before you attempt the grinding process. NOT FOR Performing SALE OR DISTRIBUTION Drilling Exercises Knowing how to operate a drill is an essential part of being a motorcycle technician. Drills are used to make, countersink and counterbore holes in components, and to remove broken studs. Always & make Bartlett sure you Learning, wear LLC personal protective equipment NOT FOR when SALE drilling. OR DISTRIBUTION To set up, adjust and operate a drill, follow the guidelines in Procedure 6-4. Drill presses can also be used for counterboring, countersinking and reaming holes. Counterboring is a technique that involves & Bartlett drilling Learning, an initial pilot LLChole to a adjustable reamers. Reamers allow a small amount of material to be removed from a hole. Ask your mentor to demonstrate these other drilling techniques. Performing Cutting Exercises Jones & Bartlett Learning, LL Hacksaws are the main cutting devices used in the workshop. The blade of a hacksaw is tensioned in a frame and is used primarily to cut metal. The blades of the hacksaws are rated according to their cutting pitch, which governs the types of metal Jones they & can Bartlett be used Learning, to cut. LLC certain NOT depth, FOR and SALE then using OR a DISTRIBUTION bigger drill bit to enlarge When cutting NOT with FOR a hacksaw, SALE OR you DISTRIBUTION should make starting notches as guides for the starting action. Like a file, the hole part-way through the depth of the workpiece. Countersinking produces a conical hole in the workpiece which allows the head of the fastener to sit flush blades can be brittle, so care must be taken when sawing the main cutting action is away from your body. Hacksaw & with Bartlett or below Learning, the surface LLC of the surrounding material. with one & Bartlett to prevent Learning, the blade from LLCfracturing. A reamer is a fluted cutting device that enlarges an To set up, adjust and use a hacksaw, follow the guidelines in Procedure 6-5 existing hole in a piece of metal. There are fixed and...

10 chapter 6 Applying Basic Hand Skills 149 NOT FOR SALE PROCEDURE OR DISTRIBUTION 6-4 Setting NOT Up, FOR Adjusting SALE OR DISTRIBUTION and Operating a Drill 4 Fit the drill bit into the chuck and Jones tighten & it. Bartlett Learning, LL 5 Before turning on the press, NOT make FOR sure you SALE are OR DISTRIBUT wearing eye protection and any other prescribed personal protection equipment. Turn on the press. 6 Slowly lower the drill toward the starter hole to be drilled. 7 Drill into NOT the start FOR hole SALE about ¼ OR inch DISTRIBUTION (or a few millimeters) before raising the drill. Use cutting lubricant to reduce friction of the drill bit. 8 Lower the drill again and make the hole deeper. 9 Continue & Bartlett this process Learning, until the hole LLCis complete Secure the piece you are going to be working with Turn off the drill press. the appropriate vise. 11 Use a brush to blow off the metal shavings. 2 Choose the correct drill bit. 12 Remove the piece from the clamps. 3 Select the correct speed Jones the & Bartlett drill press for Learning, the size LLC 13 Remove the drill bit from the chuck. & Bartlett Learning, LL drill you are using. PROCEDURE NOT FOR SALE OR 6-5 DISTRIBUTION Setting Up, Adjusting and Using a Hacksaw 2 Tighten the blade in the frame. Do not overtighten the & blade Bartlett because Learning, this may distort LLC the hacksaw frame. NOT FOR If the SALE blade is OR too loose, DISTRIBUTION it may bend and jam while you are trying to cut. 3 Correctly position your feet and grip the hacksaw with both hands. 4 Commence cutting by lightly drawing Jones the & hacksaw Bartlett Learning, LL across the job. Once the cut NOT has commenced, FOR SALE more OR DISTRIBUT pressure can be applied, but be careful not to apply too much pressure, as the blade may jam in the material. 5 Continue cutting while constantly checking to ensure you are cutting along the marked cutting line. 6 When you get close to the end of the cut, reduce the force you are putting into the cutting action, slow 1 Select the correct blade for the material to be cut. down and lightly cut until the final cut is made. In general, fine-tooth blades are used for material 7 When you have finished cutting, release the tension of a thinner diameter and coarser blades are used on the blade so the frame does not become distorted for thick material. over & Bartlett time. Learning, LLC..

11 150 chapter 6 Applying Basic Hand Skills Performing & Bartlett Learning, Filing Exercises LLC smoother. On a job, the coarse file is used first to remove material quickly; then a smoother file gently removes the Files are hand tools designed to remove small amounts NOT last FOR of it SALE and leaves OR a DISTRIBUTION clean finish to the work. of material from the surface of a workpiece. Files come The full list of grades in flat files, from rough to smooth, in a variety of shapes, sizes and coarseness, depending on follows: the material being worked and the size of the job. Files have a pointed tang on one end that is fitted to a handle. Rough files have the coarsest teeth, with approxi- Files are often sold without handles, but they should not mately 20 teeth per inch (8 teeth per centimeter). be used until a handle of the right size has been fitted. They are used when NOT a lot FOR of material SALE must OR be DISTRIBUT A correctly sized handle will fit snugly, without working removed quickly. They leave a very rough finish loose while in use. Always check the handle before using and will have to be followed by the use of finer files the file. If the handle is loose, give it a sharp rap to tighten to produce a smooth final finish. it up, or Jones if it is the & threaded Bartlett type, Learning, screw it on LLC tighter. If it Coarse bastard & files Bartlett are still Learning, a coarse file, LLC with fails to NOT fit snugly, FOR you SALE must OR use DISTRIBUTION a different-sized handle. approximately NOT FOR 30 teeth SALE per OR inch DISTRIBUTION (12 teeth per centimeter), but they are not as coarse as the rough file. They are also used to rough out or remove material TECHnICIAn TIP quickly from the job. Second-cut & Bartlett files Learning, have approximately LLC 40 teeth Hands should always be kept away from the surface NOT FOR SALE of the file OR and DISTRIBUTION per inch (16 teeth per centimeter) and provide a the metal that is being worked on. Filing smoother finish than the rough or coarse bastard can produce small slivers of metal that can be difficult file. They are good all-round intermediary files and to remove from a finger or hand. Clean hands will help avoid slipping and will lessen the corrosion caused by leave a reasonably smooth finish. acids and moisture from the skin. Smooth files have approximately & 60 Bartlett teeth per inch Learning, LL (24 teeth per centimeter) and are a finishing file used to provide a smooth final finish. What makes one file different from another is not just the shape but also how much material it is designed to remove with each stroke. The teeth on the file determine how much material will be removed Figure Because NOT the FOR teeth face SALE one direction OR DISTRIBUTION only, the file cuts in one direction only. Dragging the file backward over the surface of the metal only dulls the teeth and wears them out quickly. Teeth on a coarse-grade file are longer, with a greater & space Bartlett between Learning, them. A coarse-grade LLC file working on a Dead-smooth files have 100 teeth per inch or more (40 teeth per centimeter) and are used where a very fine finish is required. Some flat files are available with one smooth edge, called safe edge files. They allow filing up to an edge without damaging it. Flat files are fine on straightforward jobs, but files must be able to work in some awkward spots as well. A warding file is thinner than other files and comes to a point; & it is Bartlett used for working Learning, narrow LLCslots Figure 6-11a. NOT FOR piece SALE of mild OR steel DISTRIBUTION will remove a lot of material with each stroke, but it leaves a rough finish. A smooth-grade file has shorter teeth cut more closely together. It removes much less material on each stroke, and the finish is much A B C Figure 6-10 The teeth on a file. Figure 6-11 A. Warding file. B. Square file. C. Triangular file...

12 chapter 6 Applying Basic Hand Skills 151 A square file has teeth on all four sides, so you can use it in & a Bartlett square or Learning, rectangular LLC hole Figure 6-11b. A square NOT FOR file SALE can make OR the DISTRIBUTION right shape for a squared metal key to fit in a slot. A triangular file has three sides Figure 6-11c. A Because it is triangular, it can get into internal corners. It is able to cut right into a corner without removing material B from the sides. Curved files are either NOT half-round FOR or SALE round. OR A half-round DISTRIBUTION file has a shallow convex surface that can file in a concave hollow or in an acute internal corner Figure 6-12a. The C fully round file, sometimes called a rat-tail file, can make Figure 6-12 A. Curved file. B. Thread file. holes bigger. It can also file inside a concave surface with C. File card. a tight radius. The NOT thread FOR file cleans SALE clogged OR DISTRIBUTION or distorted threads on bolts and studs Figure 6-12b. Thread files come in either standard or metric configurations, so make sure you use To set up, adjust and use a file, follow the guidelines the correct file. Each file has eight different surfaces that in Procedure 6-6. & match Bartlett different Learning, thread dimensions, LLC so the right face must Taps and Dies NOT FOR be SALE used. OR DISTRIBUTION Files should be cleaned after each use. If they are Taps cut threads inside holes or nuts Figure 6-13a. clogged, they can be cleaned by using a file card, or file brush Figure 6-12c. This tool has short steel bristles They normally come in three different types. The first is known as a taper tap. It narrows at the tip to give that clean out the small particles that clog the teeth of it a good start in the hole where the thread is to be the file. Rubbing a piece of chalk over the surface of the cut. The diameter of the hole is determined by a tap file prior to filing will NOT make FOR it easier SALE to clean. OR DISTRIBUTION drill chart, which can be NOT obtained FOR from SALE engineering OR DISTRIBUT PROCEDURE 6-6 Setting Up, Adjusting and Using a File 1 Select the correct type of file for the work to be undertaken. & Bartlett Coarse-teeth Learning, files are LLC used to remove NOT FOR a lot SALE of material OR quickly, DISTRIBUTION whereas finer-teeth files are used to get a fine finish on the job. A number of different files may be used on the one workpiece to complete the task. For example, commence with a coarse file to remove a lot of material, and finish with a fine file to get a smooth finish. Jones & Bartlett Learning, LL 2 Ensure the file handle is securely NOT attached. FOR SALE OR DISTRIBUT 3 Commence filing by gripping the file in both hands and make gentle strokes away from your body. Hold the file parallel to the workpiece throughout the stroke. 4 At the end of the stroke, lift the file from the workpiece NOT and FOR return SALE to the start OR position DISTRIBUTION to file another stroke. 5 Constantly check the workpiece to ensure you are filing to any marked out lines...

13 152 chapter 6 Applying Basic Hand Skills may be split so that it can be adjusted more tightly onto the work with each pass of the die as the thread is cut NOT deeper FOR SALE and deeper, OR until DISTRIBUTION the nut fits properly. The die nut is also common in the workshop Figure 6-13d. A B It is hexagonal shaped to fit a wrench, and it is commonly used to clean up threads that are rusty or have been damaged. D Performing Internal and External Threading Exercises Before you commence the procedure, note the following points: C & Bartlett Learning, LLC A die NOT is a metalworking FOR SALE tool OR used DISTRIBUTION to repair or cut new outside threads on fasteners. A tap cuts internal threads on a workpiece. The die is installed in a diestock. It gives the leverage & Bartlett to turn the Learning, die over the LLC new thread. The die- Figure 6-13 A. Taps. B. Tap handle. C. Stock. D. Die nut. NOT FOR stock SALE locates OR the DISTRIBUTION die in place using thumbscrews that match indentations in the outer edge of the die. A tap is installed into a tap handle. It has jaws suppliers. This chart shows what hole size has to be to securely hold the square cross-section at the end drilled and what tap size is needed to cut the right of the tap. thread for any given bolt size. Just remember that if you are drilling a ¼-in (6-mm) NOT FOR or larger SALE hole, OR you DISTRIBUTION The die has a top and should NOT a bottom. FOR The SALE bottom OR has DISTRIBUT tapered threads to guide the thread into the die. use a smaller pilot drill first. Once the properly sized Use a thread-cutting compound with dies and taps. hole has been drilled, the taper tap can tap a thread It will keep the cutting edge sharp, allowing it to right through a piece of steel to enable a bolt to be be used many times. screwed into it. & Bartlett Learning, LLC The NOT second FOR type SALE of tap OR is an DISTRIBUTION intermediate tap, also When NOT cutting FOR a new SALE thread OR on DISTRIBUTION a bolt, stud or known as a plug tap, and the third is a bottoming tap. workpiece, make sure the tap or die is square onto They are used to tap a thread into a hole that does not the workpiece. come out the other side of the material, called a blind When cutting or repairing a thread, once the die hole. A taper tap is used to start the thread in the hole, or tap has started to cut, turn the die or tap about & and Bartlett then the Learning, intermediate LLC tap is used, followed by a Jones a & quarter Bartlett of a turn, Learning, and then LLC back off. Cut another NOT FOR bottoming SALE OR tap DISTRIBUTION to take the thread right to the bottom of NOT FOR quarter SALE of OR the thread DISTRIBUTION and back off again. Continue the blind hole. until the thread has been cut. This action clears A tap handle Figure 6-13b has a right-angled jaw the cutting teeth of any scrap and gives a better that matches the squared end common to all taps. finish. The jaws are designed to hold & the Bartlett tap securely, Learning, and LLC Once the thread has been cut and & the Bartlett die or Learning, tap LL the handles provide NOT the leverage FOR SALE for the OR operator DISTRIBUTION to removed, clean the new NOT thread FOR with SALE a wire OR brush. DISTRIBUT comfortably rotate the tap to cut the thread. To cut a This will remove any sharp edges and any leftover thread in an awkward space, a T-shaped tap handle is scrap from the new thread. very convenient. Its handles are not as long, so it fits Do not use a wrench to tighten the die-locating into tighter spaces; however, it is harder to turn and thumbscrews. to guide accurately. & Bartlett Learning, LLC To NOT cut a FOR brand-new SALE thread OR DISTRIBUTION on a blank rod or shaft, To set up, NOT adjust FOR and SALE use dies OR and DISTRIBUTION taps, follow the a die held in a diestock is used Figure 6-13c. The die guidelines in Procedure

14 chapter 6 Applying Basic Hand Skills 153 NOT FOR SALE PROCEDURE OR DISTRIBUTION 6-7 Setting NOT Up, FOR Adjusting SALE OR DISTRIBUTION and Using Dies and Taps 4 Apply a small amount of thread-cutting & compound Bartlett to Learning, LL the exposed, damaged threads of the bolt or to the tap. If the bolt, stud or workpiece is a separate item, hold it upright in a vise. Make sure the vise is equipped with soft jaws so you do not damage the thread any further. Then tighten the vise so that the bolt or workpiece is vertical. & Bartlett Learning, LLC 5 Slowly NOT and carefully FOR turn SALE the diestock OR DISTRIBUTION or tap in a clockwise direction. Make sure to keep the pressure vertically above the bolt or workpiece. You will feel the die or tap removing the metal from the bolt or workpiece. Continue to turn the die or tap until you reach & Bartlett the depth Learning, to which the matching LLC nut or bolt NOT FOR will SALE be tightened. OR DISTRIBUTION 6 1 Determine the thread size by using a thread pitch To remove the die or tap, turn the diestock or tap gauge to confirm the size. This should match the handle counterclockwise up and away from the bolt. thread it will go into. Clean any filings or particles from the cutting threads of the die. 2 Choose the correct die or tap set for the job. It will be 7 Use a rag and then a wire NOT brush to FOR clean SALE the OR DISTRIBUT either inch or metric. compound and metal particles from the thread of the 3 Fit the die to the diestock or the tap to the handle. For dies, use the locating screw on the stock to engage bolt or workpiece before you remove it from the vice. Test the job by using the correct-size nut or bolt and the hole on the die and secure it into place. For taps, tightening it by hand all the way down. If the repair secure by & tightening Bartlett the handle Learning, jaws. LLC is sound, dismantle Jones the & Bartlett die from the Learning, diestock, clean LLC them both NOT and FOR put them SALE away. OR DISTRIBUTION..

15 154 chapter 6 Applying Basic Hand Skills drill press can be used. To make the puller, you will need & Bartlett Making Learning, a Puller LLC access to the following tools: In this practical exercise, you are going to make a Scriber Files puller from a metal bar and rod. You will be supplied Ruler Hacksaw with all the materials required to make the puller. You Square Drill press and drill bits will need to use various hand tools to make the puller. Vernier calipers The procedures for using the hand & Bartlett tools and Learning, marking LLC Tap Jones and die & Bartlett Learning, LL off/marking out the NOT puller FOR are contained SALE OR previously DISTRIBUTION Steps to Follow in this chapter. You should refer to the various procedures for step-by-step instructions on how to perform Plans for the puller are contained in the following pages. marking off/marking out, drilling, cutting, filing and Make sure you have assembled all the tools you need and thread-cutting activities. & Bartlett Learning, LLC have at hand all Jones the materials & Bartlett required Learning, to make the LLC puller. Note: The measurements used in this exercise are The parts of the puller should be made in the following order: metric. However, if you wish to use American standard 1. Mark and cut the mm bar. measurements as an alternative, consult your teacher on 2. Mark and cut the two mm bar. how to calculate them based on the figures provided. You ll find it a useful mathematics exercise. 3. Mark and cut the 6 mm round bar. 4. Mark & Bartlett and cut the Learning, round rod LLC mm. NOT FOR Tools SALE Required OR DISTRIBUTION To make a puller, follow the guidelines in When making the puller, all work should be done by Procedure 6-8. hand with the exception of drilling holes, for which a Plans for the exercise are shown on the following pages. PROCEDURE 6-8 Making a Puller 1 Examine NOT the plans FOR that SALE follow this OR procedure. DISTRIBUTION Look carefully at each plan and ensure you have the correct material for making the puller. 2 Gather the material for marking off/marking out. 3 Prepare & Bartlett the material Learning, for marking LLC off/marking out by NOT FOR filing SALE the workpiece OR DISTRIBUTION surfaces to ensure they are flat and square. Always make sure measurements are taken from flat and square surfaces. 4 Mark off/mark out the workpiece using measuring tools and a scriber. Use a center punch & to Bartlett mark the Learning, LL center of any holes that are required to be drilled. 5 Perform the required cutting activities by filing, hacksawing or drilling. Always ensure you keep to the marked lines when cutting or filing. 6 Perform the Jones required & thread Bartlett cutting Learning, activities. LLC Ensure threads are cut square to the workpiece...

16 chapter 6 Applying Basic Hand Skills 155 NOT FOR SALE PROCEDURE OR DISTRIBUTION 6-8 Making NOT a Puller: FOR SALE Plans OR DISTRIBUTION 80mm 8mm 6mm 8mm 10mm 90mm 8mm A 6mm hole 10mm in from sides 10mm 20mm 6.5mm B 10mm 90mm 20mm 20mm 6mm C 90mm..

17 156 chapter 6 Applying Basic Hand Skills NOT FOR SALE PROCEDURE OR DISTRIBUTION 6-8 Making NOT a Puller: FOR SALE Plans, OR DISTRIBUTION continued Step 1 & Bartlett Learning, Top LLC 90mm Side C D E E Step 2 Step 3 Top Steps 4/5 B/1 B/2..

18 chapter 6 Applying Basic Hand Skills 157 NOT FOR SALE PROCEDURE OR DISTRIBUTION 6-8 Making NOT a Puller: FOR SALE Plans, OR DISTRIBUTION continued Cut & block Bartlett = 90 mm Learning, x 20 mm x 20 LLC mm 20mm 20mm 90mm Mark out 45mm 20mm Top 10mm Side 8mm 10mm..

19 158 chapter 6 Applying Basic Hand Skills NOT FOR SALE PROCEDURE OR DISTRIBUTION 6-8 Making NOT a Puller: FOR SALE Plans, OR DISTRIBUTION continued Step 1 & Bartlett Learning, LLC Step 2 90mm 20mm 20mm Tool list: 1. Hacksaw 2. Square 3. Scriber 4. Vernier Tool list: 1. Hammer 2. Center punch..

20 chapter 6 Applying Basic Hand Skills 159 NOT FOR SALE PROCEDURE OR DISTRIBUTION 6-8 Making NOT a Puller: FOR SALE Plans, OR DISTRIBUTION continued & Bartlett Learning, 20mm LLC Drill 8.5mm Drill 8mm & Bartlett Saw Learning, LL 8mm 20mm 6mm x 70mm 90mm Pin = 6mm x 20mm Rod 10mm x 80mm 8mm x 10mm 10mm 20mm NOT 80mmFOR SALE OR DISTRIBUTION..

21 160 chapter 6 Applying Basic Hand Skills NOT FOR SALE PROCEDURE OR DISTRIBUTION 6-8 Making NOT a Puller: FOR SALE Plans, OR DISTRIBUTION continued Step 3 90mm 20mm Tools: 1. Saw 2. Drill 20mm..

22 chapter 6 Applying Basic Hand Skills 161 Vocabulary Builder and Review Questions Vocabulary Builder file A hand tool designed to remove small amounts of material from a workpiece s surface. calipers A tool that measures either a component s internal dimensions or a component s & outside Bartlett measurements, Learning, LLC hacksaw The main cutting device used & in the Bartlett workshop. Learning, LL such as its diameter. A hacksaw s blade is tensioned NOT in FOR a frame SALE and is OR used DISTRIBUT primarily to cut metal. combination square A tool composed of a ruled blade and one or more interchangeable heads that may be affixed quench To quickly cool a metal piece that you are to it; it is used for multiple purposes in metalworking. grinding. die A metalworking Jones & Bartlett tool for Learning, repairing or LLC cutting new scriber A sharp, Jones pointed & Bartlett marking Learning, tool used for LLC drawing lines on outside NOT threads FOR on SALE fasteners. OR DISTRIBUTION NOT metal. FOR Also SALE known as OR an DISTRIBUTION engineer s scriber. dividing compass A hand tool used for drawing circles steel square A tool for checking angles when long metal and curves on metal. sections are at right angles. drill A tool used to make, countersink and counterbore try-square A tool for squaring lines across a metal plate. & holes Bartlett in components, Learning, and LLC to remove broken studs...

23 162 chapter 6 Applying Basic Hand Skills Review & Bartlett Questions Learning, LLC 4. Tech A says that a countersunk hole allows you to fit a fastening device snugly against the workpiece 1. Tech A says that when using a hacksaw, the cutting NOT FOR surface. SALE Tech OR B disagrees. DISTRIBUTION Who is correct? or filing motion should be toward you. Tech B says a. that when using a file, the cutting or filing motion Tech A b. should be away from you. Who is correct? Tech B a. Tech A b. Tech B c. Both A and B d. Neither A nor B c. Both A and B d. Neither A nor B 5. If you need to mark a piece of metal with accurate lines, you would use the edge of a drill bit. a. 2. If you need to create a new thread inside a piece of True b. metal, Tech A says you should use a grinding wheel. False Tech NOT B FOR says you SALE should OR use DISTRIBUTION a tape and die set. Who 6. When NOT using a FOR grinding SALE wheel, OR Tech DISTRIBUTION A says there is a is correct? danger of flying sparks. Tech B says there is a danger a. Tech A of eye injury. Who is correct? b. Tech B a. Tech A c. Both A and B b. Tech B d. Neither A nor B c. Both A and B d. 3. Tech A says screwdrivers can be sharpened on a Neither A nor B grinding wheel. Tech B says chisels and punches can 7. When making a tool from drawings, it is best to be sharpened on a grinding wheel. Who is correct? start by cutting your main components with a a. Tech A hacksaw. b. Tech B a. True c. Both A and B b. False d. Neither A nor B..

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