Name Picture Cross section Uses: Cut pattern:: Hand file used for roughing and finishing. It has double cut teeth on two faces, single cut teeth on one edge, and one safe edge Flat file used for roughing and finishing. It has double cut teeth on two faces and Single Cut teeth on two sides. Half -round It is used for,forming radii grooves. Double cut Mill file It is used for polishing, deburring and sharpening tools. Single cut in all sides. Round file Square file Page 1 of 48 Use foe enlarging holes and producing internal around corners. Filing slots and grooves. * double cut in the larger size * single cut in the small size Double cut on all faces.
Three square ( triangle ) Filing corner or angle less than 90. Double cut on all faces. Needle files small and delicate works such as the repair of small instruments. Double cut. Question 2 The graph shown below is the data collected for the cutting speed of six different material workpiece. a. Define cutting speed Cutting speed is the speed at the outside edge of the tool as it is cutting the work piece. b. Analyze the graph, compare and determine why the cutting speed is shown to be increasing. Page 2 of 48
The students must be able to answer as follows: Point 1 - As we have learned in our Mechanical Workshop course, cutting speeds depend on the type of material being cut and the type of cutting tool being used. Point 2 - The hardness (the ability of the material to resist being scratched) of the work material has a great impact on selecting the cutting speed. Point 3 - Also, the cutting speed is inversely related to the work material hardness. Point 4 - We have also learned the softer the work material, the faster is the cutting speed. Thus the 25m/min is the cutting speed for the softest material from the batch of 6. c. Establish three examples of a material workpiece and show the order of the cutting speed from the lowest cutting speed to the highest. Steel Aluminum Lead The cutting speed increases in this direction Question 3 a. Define what a drilling process entails. Drilling is a process of creating round holes by a rotating tool that is typically has two cutting edges. 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. The student must be able to provide a rough sketch of the drawing shown below with the proper picture of the rotating motion of the drill and direction of the feed motion. The tool is fed in a direction parallel to its axis of rotation into the work-part to form the round hole Page 3 of 48
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 F 2 The yard is the basic unit of length in the metric system F 3 4 5 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. T T T 6 The Vernier caliper with 10 divisions in Vernier scale is accurate T Page 4 of 48
7 to ±0.1 mm The Vernier caliper with 50 divisions in Vernier scale is accurate to ±0.05 mm. F 8 Stem of vernier caliper is used to measure outer dimensions F 9 Outside jaws of vernier caliper are used to measure external lengths T 10 Inside jaws are used to measure internal lengths T 11 The main scale of the vernier caliper is a movable part while vernier scale is the fixed part. F 12 Scribers are used to mark circle on work pieces F 13 A center punch has a point angle of 90 T 14 A prick punch produces a bigger indentation than a center punch F 15 A prick punch has a point angle of 90 F 16 17 18 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 T T T 19 The spring dividers are used for scribing arcs and circles T Page 5 of 48
20 The Vee blocks are used for holding circular work pieces T 21 The sizes of metric spanners are identified by the distance across flats of a nut. T 22 The flathead screw driver is identified by its point size. F 23 The crosshead screwdriver is identified by its length. F 2. Select the correct answer (A, B, C or D). 1- Always look at to the rule to help you measure correctly A. 30 B. 60 C. 90 D. 40 2- The steel rule can take linear measurements to accuracy of A. ± 0.01 mm B. ± 0.1 mm C. ± 0.5 mm D. ± 0.002 mm 3- The vernier caliper can take measurements to accuracy of A. ± 0.02 mm Page 6 of 48
B. ± 0.005 mm C. ± 0.0002 mm D. ± 0.0001 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 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 Page 7 of 48
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 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? Page 8 of 48
A B C D 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 By using scriber By using prick punch By using height gauge Page 9 of 48
D By using caliper 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. Goggle is used to protect our eyes from injuries. b. Ball peen hammer is used to strike punches and chisels. c. Safety boot will protect your feet if you accidentally drop something. Page 10 of 48
d. Vernier caliper has inside, outside jaws and stem to measure different dimensions. e. Dial vernier has indicator which can gives you the reading directly. f. Micrometer is used to measure even smaller dimensions than the vernier calipers. g. Long nose pliers is used by electricians to bend, re-position and cut wire. h. The two most common screw drivers are: Crosshead/Phillips and Flathead/slotted. 4. 1- Read the micrometers and the vernier calipers illustrated bellow: A) Page 11 of 48
Accuracy = 0.01 mm Reading is 5.80 mm B) Accuracy = 0.01 mm Reading is 3.09 mm C) Page 12 of 48
Accuracy = 0.01 mm Reading is 7.72 mm D) Accuracy = 0.02 mm Reading is 34.6 mm E) Page 13 of 48
Accuracy = 0.1 mm Reading is 3.7 mm F) Accuracy = 0.1 mm Reading is 14.4 mm 2. Read the rule illustrated bellow: A- 7 mm B- 27 mm C- 44 mm Page 14 of 48
5. 1. Identify the main parts of the vernier caliper illustrated bellow: Stem Outside jaws Vernier scale Screw clamp Main scale Inside jaws 1- Inside jaws 2- Screw clamp 3- Stem Page 15 of 48
4- Main scale 5- Vernier scale 6- Outside jaws 6. Identify the main parts of the micrometer illustrated bellow: Stem Frame Thimble Sleeve Lock Inside jaws Ratchet Anvil Spindle Page 16 of 48
1- Anvil 2- Spindle 3- Sleeve 4- Ratchet 5- Thimble Page 17 of 48
6- Lock 7- Frame 7. Find out five mistakes in the safety dress shown in the picture: 1- Long hair 2- Tie 3- Long sleeve 4- Long overall 5- No safety boot Page 18 of 48
8. Identify the three types of the vernier caliper illustrated bellow: A. Standard B. Dial C. Digital 9. Select the correct words from the list to fill in the following blanks: 1 2 3 4 Inside jaws Stem Outside jaws Screw clamp Page 19 of 48
A- Outside jaws used to measure external dimensions. B- Inside jaws used to measure inner dimensions. Page 20 of 48
C- Stem used to measure the depth. A B C Name Marking out tools Definition Engineer square Scriber - Used for checking the straightness of a work piece. - Also be used for marking perpendicular lines. Used to scratch lines on metal Spring divider Used for scribing arcs and circles Page 21 of 48
Ball peen hammer Used to strike punches and chisels Center punch Prick punch Surface plate Forms an indent in which the tip of the drill will fit. has a point angle of 90 Produces a smaller indentation than a center punch. has a point angle of 60 Used as a datum surface for marking out and for measuring purposes Angle plate Used to assist in holding the work piece perpendicular to the table Surface gauge Used for: 1. scribing lines on work pieces 2. checking parallel surfaces 3. Checking heights Page 22 of 48
V-block Used for holding circular 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 1 2 3 4 5 Column B B C D E A Column A Column B 1) Is used for checking the straightness of a workpiece. A) 2) Is used to scratch lines B) Page 23 of 48
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 1 2 3 4 5 6 7 8 Column B B G F E A D H C Page 24 of 48
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 25 of 48
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 T 2 Different standard lengths of blades can be fitted to solid hacksaw frame. F 3 A particular standard length of blade can be fitted to an adjustable hacksaw frame. F 4 The hacksaw blade is classified by its length and the teeth pitch. T Page 26 of 48
5 A coarse pitch blade has more teeth per 25 mm than a fine pitch blade. F 6 Fast blunting can be occurred if wrong teeth number is chosen. T 7 Fast blunting is the result of low pressure. F 8 The breaking of blade teeth is the result of un tightened work piece. T 9 Curved cutting can be occurred if material is insufficiently tightened T 10 Breaking of saw blade is the result of Jammed material. T Fill in the blanks. Select your answer from the list bellow. Adjustable hacksaw Forward Fine blade Alternate Page 27 of 48
Coarse blade Wave Hack sawing Solid hacksaw Jamming Three Pitch Fine 50 Backward 40 Two 1- Hack sawing is a process of cutting metals to size. 2- A particular standard length of blade can be fitted to a solid hacksaw frame 3- Adjustable hacksaw frame allows different standard lengths of blades to be fitted. 4- A pitch is the number of teeth per 25 mm. 5- A coarse blade is used to cut thick and soft work piece. 6- A fine blade is used to cut thin and hard work piece. 7- Alternate and wave are the most common types of saw blade set. 8- A hacksaw cuts best at about 40 to 50 strokes per minutes. 9- At least two or three teeth should be cutting all the time. Page 28 of 48
10- Blade setting helps to prevent the blade from jamming when cutting the metal. 11- Hacksaws cut on the forward stroke, not on the backward stroke. 12- A fine 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 29 of 48
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 1- --------------------- Fast blunting Page 30 of 48
1- ---------------------- Teeth breaking 1- ---------------------- Breaking of saw blade 1- --------------------- Curved cutting Answer: Select one of the following causes: Fast blunting: If wrong teeth number is chosen. If saw blade is not tightened well. If pressure is too high. Teeth breaking: Tooth pitch is too small If material is not tightened well Breaking of saw blade: Material is not tightened well. Jammed material while finishing. Page 31 of 48
Curved cutting: Wrong fixing of blade in the frame. Blade is not tightened well. Material is not tightened well. a- Alternate set - Identify the following types of blade set: (a) b- Wave set (b) Identify the following types of hacksaw frames: Page 32 of 48
Adjustable frame Solid frame Name the parts shown by the arrows. Page 33 of 48
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 102 130 Enter the steps respectively: 1- Wear the safety clothes and equipment required. 2- Mount the work piece firmly on the vice 3- Choose the correct blade 4- Install the hacksaw blade 5- Use the blade check list to ensure proper installation Page 34 of 48
6- Use the hacksaw to cut the work piece Worksheet (module-5) No. Statement T / F 1 Hand file is a half-round in section and parallel in width F 2 Flat file is a rectangular in section and tapered in width T 3 A double cut file has one set of teeth cut at 70 degrees T 4 Files with a rougher grade of cut give a poor surface finish T Page 35 of 48
5 A file with a short length would have a coarser pitch than a longer one F 6 The pining can be removed with a handle of file F 7 The pining can be removed with a file card T 8- Which file of the following is used for filing corners or angles less than 90? A B C D Page 36 of 48
9- Files are categorized according to Length and. A B C D Shape Grade Cut patterns 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 Page 37 of 48
b c d double cut file rasp file all of the above 12- The purposes for the safe edge are to avoid the. a b c d damage of the file handle damage of the file teeth damage of the work piece 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- Flat file has double cut teeth on two faces and single cut teeth on two Side. 2- Rasp file is commonly used for the cutting off soft materials such as wood, PVC and rubber. 3- A file is a metalworking tool used to cut fine amount of material from a work piece 4- Hand file is a rectangular in section and parallel in width. Page 38 of 48
5- Half-round file is used for forming radii and grooves. Page 39 of 48
Match the pictures in column B with their correct names in column A, Write your answer in the box below? Column A 1 2 3 4 5 Column B B A E C D Column A Column B 1) Half round file A) 2) Needle file B) 3) Square file C) 4) Triangular file D) Page 40 of 48
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 1 2 3 4 5 6 Column B D F E C A B Column A Column B Page 41 of 48
1) File card A) 2) Hand file B) 3) First cut file C) 4) Second cut file D) 5) Bastard file E) 6) Draw filing F) Page 42 of 48
Worksheet (module-6) No. Statement T / F 1 The most common tool used to cut a hole is the twist drill T 2 The twist drill is made of Aluminum F 3 Most of small drills up to 13 mm in diameter have tapered shanks. F 4 Most of small drills up to 13 mm in diameter have straight shanks. T 5 6 Most drills that are larger than 13 mm are tapered. Most drills that are larger than 13 mm are straight. T F 7 drill gauges are used to determine and check the drill diameters T Page 43 of 48
8 Chuck is mainly used for drills with tapered shanks F 9 Chuck is mainly used for drills with straight shanks T 10 Vises are used to hold the drill twist F 11 Vises are used to hold the work piece T Twist drill Drift Drilling Vices Straight Drill gauges Friction Hardness Tapered Cutting tool material Speed Harder Softer Chuck Page 44 of 48
1- Drilling is used to create round holes 2- The most common tool used to cut a hole is the twist drill 3- Most of small drills up to 13 mm in diameter have straight shanks 4- Most drills more than 13 mm in diameter have tapered shanks 5- Drill gauge are used to determine and check the drill diameters 6- The chuck is mainly used for drills with straight shanks. 7- The drill is locked in the spindle with friction and is removed from the spindle by using a drift 8- Vices are used to hold the work piece during the drilling process. 9- The T-bolt are used to hold a round work piece. 10- Cutting speeds depend on the type of material and the type of drill 11- Hardness has a great impact on selecting the cutting speed. 12- The hard the work material, the slower the cutting speed. Page 45 of 48
13- The softer the work material, the faster the cutting speed. Identify the following process: Filling Drilling Sawing A- Drilling B- Sawing C- Filling A B C Name the parts of the floor press drill machine Head ON/OFF switch Chuck Motor Feed Handle Column Table Table Handle Page 46 of 48
Name the parts of twist drill illustrated bellow: Identify the following objects and their usages Name Usage Figure Drill gauge To check the drill diameter Twist drill To create a hole Page 47 of 48
Chuck To hold the twist drill To remove the drill Drift from the spindle Vise To hold the work piece To hold a round work T-bolt piece Page 48 of 48