MINISTRY OF HIG! R EDUCATION Industrial Training Centre Management Board / / INDUSTRIAL TRAINING CENTRE BASIC HAND TOOLS AND TESTING EQUIPMENTS USED IN MOTOR VEHICLE ENGINEERING WORKSHOPS « Importance and Care of Tools ¢ Types of tools © Proper use of ToolsProper Care is Essential 1g clean, orderly and near Is dean, Fast efficient work and confusion cannot exist together, Keep Your te epfent drills) to files, chisels, Place detente measuring tools in protective cases. Separate eting tool (TCA Ce icayy tools prevent damage to their cutting edges, Tools that rust should be be Thole handy. Keep sockets, by themselves. In general, attempt to keep the most frequently u LE TIME IT TAKES TO KEE! open-end, and box end wrench sets together. REMEMBER: THE LITTLE TILT aye YOUR TOOLS CLEAN AND ORDERLY WILL BE GREATLY OFFSET JOB. Hammers included in Ball peen (14), plastic (33), brass, lead, rawhide, and rubber hammers should be includ every mechanic's selection. Various sizes of each are desirable. The ball peen is used for general striking, riveting and gasket cutting. The plastic, lead, brass ae rubber hammers are used to prevent marring of part surface. The rawhide is used to previ damage to pointed and sharp objects. When using a hammer, grasp the handle firmly. Place yout hand near the handle end. Strike so that the face of the hammer engages squarely with the work. Chisels ‘Ghisels' are used for jobs such as cutting off rivet heads, bolts, and rusted nuts. Flat, cape, diamond and half round chisels should be available. Hold a chisel securely yet not tightly. Grasp it as far from top as practical. This will protect your __ fingers somewhat if the hammer slips from the chisel head. For heavy hammering, a chisel holder shawn in fig 1-4 should be used. Keep the cutting edge of the sharp and the top chamfered (edges tapered) as in fig 1-5. This reduces the possibility of small chisel segments breaking off and flying outward. Wear goggles when using a chisel. Punches (figs 1-6 and 1-7) _ < Starting, drift, and pin punches are essential. A few sections of round brass stock in varying diameters are useful in driving parts that may be damaged with steel punches. SSSHASSS Ez kee Starting punch Drift PunchA starting punch is used to start driving rivets, bolts and pins from a hole. Due to its taper the punch nay fill the hole before the part is out. If it does the job is completed with a drift punch. A pin punch is similar to a drift punch but has a smaller diameter driving shank, Pin punches are useful in removing small pins, bolts etc. A centre punch is needed to mark work before drilling. The small V-shaped hole will align the drill bit, The centre punch is also useful for marking parts so they will be assembled in their original position. The aligning punch Is very useful in shifting parts so that the holes line up (fig 1-7), SH Ezz Fig 1-7 Aligning Punch Use care when sharpening chisels and punches. Grind slowly, keeping correct angles, and quench (dip in cold water) prevent, drawing the temper (overheating, turning the metal blue and rendering it soft). WEAR GOGGLES WHEN GRINDING. Files (fig 1-8) The most frequently used files are the flat mill, round, square, triangular and point files. Many ‘other special shapes are also made. The file's relative size and number of cutting edges per inch is one determination of the file cut. In general, the softer the metal the coarser the cut needed. Three popular cuts (bastard, second cut, and smooth) are shown in fig 1-9. Using the file Grasp the with the right hand and hold the tip with the fingers of the left hand. On the forwar stroke, bear down with enough pressure to produce a good cutting. On the return stroke, rise the file to avoid damaging the cutting edges. Keep the file clean and free of oil. Use a file card (special wire brush) to clean the teeth. Regular black board chalk may be rubbed into the file to help prevent clogging. Rotary files (fig 1-23) The rotary files are chunked in an electric hand drill. It is very handy for blind holes or recesses where a regular file will not work. Several shapes are shown in fig 1-12.Flat Square 10" HALF Half round ROUND Round Bastard cut Second cut ‘Smooth cut file features are shown in fig 1-11. Note the handle! Be sure the file handle is firmly affixed to the tang before using it, This will provide a firm grip and will eliminate the danger of the tang piercing the hand. Fig 1-11 File Features Hacksaws (fig 1-23) ‘A hacksaw Is used to cut tubing, bolts, and other parts. The mechanic should have blades 18, 24, and 32 teeth per inch. The 18 tooth blade is used for cutting thick metal, the 24-tooth for medium thickness, and the 32- tooth for thin sheet metal and tubing. The blades should be ofhigh quality steel. il pe auisy ‘The hole saw, driven with an electric drill is handy for cutting large holes in Vise A vise suitable for automotive work is pictured in fi r ig 1-24. copper jaw covers can be used for work that may be marred. Oil the working parts and avoid hammering on the handle and other parts. Cleaning tools (fig 1-25) Having a selection of cleaning tools speeds up the cleaning work. The wire wheel and power cleaning brushes are mounted on an electric drill. Use goggles when using the power wheels. ‘Screw Drivers (fig 1-26) The mechanic should own several different sizes of screwdrivers of the standard, reed and prince, Phillips, and clutch types. The offset screwdriver is useful in tight quarters where a stubby cannot be used. Use a screwdriver properly. Avoid prying or hammering on it. Pliers Pliers are commonly used for cutting wires, holding parts, crimping connections and bending cotta pins. The combination slip joint, vice grip, adjustable rib joint, battery, pump, ignition, long nose, diagonal, side cutter, and snap ring pliers are often used, Avoid cutting hardened objects; never use the pliers to turn nuts, bolt, or tubing fittings.sjerpos alg jo eseq aun ul ajoy BulAup aienbs ata J0 9ZIS tp SeyeOIpU! 221s anup ayy, ‘sanuip 12610) pue “v6 /*4 ‘a/E “¥/, ul ajgejiene aye Adu) “seyDUBIM ||P JO JUBIUBAUOD 3SOU PUB ysayseJ BY} JO BUD S| 1940S SUL ypuieum pue 399205 ‘azis SWeS Quy JO ale spua YjOg ‘pua JeyJO Btn UO pua Uado Ue pUe Pula BUD UO PUD XOq e SEY JOO} S/LLL (9 oN) youaim pua uadg pue xog uoReUIqUIOD “saaubep O€ Jo BuIms e UIUyIM ayesedo UeD youeiM pua uado ey} Pow SILy Ag Ju SUR Uo y! adeIde1 pue JAAO YDUAIM ayy diy UaUy OB UeD 3! se 4ey se BipueY atq |jnd “peyIw!) S| Bums 2\6ue aij o1eym su@uenb qYBR UT ‘a|Gue ue Je Jes Peay ayy arey saysuaIM pus uado “ypuaiM pua Uado Ue Jo p2aisul 19905 @ 40 YpUaM PUB xOq © asn “aiqissod sensuayym “pasn aq Aeu! 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SSejUN “S}eY ONY AjUO UO ynu aly sdse46 Youeim pus Udo ou) (Se oN) youssm pue-uado ‘Mo punos pue dijs ued } “suonesiidde Auew sey pue asn 03 3Sey 5131 “uBisep pua xoq Sulsn joo} Bujsuoyes e S| si 2 (9 ON) (Gun Jayoqe1) youeim pua xoq Joysjey -s6umy 48lfO pUe seyeiq WNNDen YoyeungieD 404 ysnu e s| YUEIM ynu aley ayL suede qulod-zr 40 qujod-9 Jatpie sey Youaim su 3nu Guign ep sano paddoyp pue Bulg punole paddyjs aq AeL1 3} 3UA OS JNO IND LONDIS & sey IT “YDUSIM PLD og 24} 0} Je|)LUIS ayINb S| YUBA JNU Gey Oy) (ET ou) youamm gnu aiely (Ze “ou) Jesujo 63p-st sejndod ain sesn Jeujouy “souele9p aipuey eiow ani6 0 (¢ oN) 19SYO aignop e sesn UBISEP eUO “!eMod BuIpjoy 401Jadns sepjAoid (69 ON) JUIOd-9 ay *}00y 24 Jo Bums JeLOYS moje (Z ON) WiOd-2T SUL “BulLedo qUIOd-g 10 yUIod-T U) ajqellene ave soYUSIM PUB xog (Grouueds pus Guy 10) saysuaum pug xog Sle INEShe 6 ative Is used for small fasteners, the 3/8 drive is used for medium sizes and the ¥2 and 4 tives are Used for the remainder of the work. Sockets come In two depths; the standard and deep. Standard sockets will do the bulk of the work while the extra reach of the deep sockst is ‘occasionally used, uw swivel sockets (No 21) allow the user to turn fasteners at an angle, and is handy for many jobs. Socket handles Several different drive handles are used. The speed handle (No 29) is used to tum a fastener rapidly. Flex handles (No 25) of different lengths provide heavy turning leverage and may be used at many angles. The sliding T-handie has some. applications too and must be Included in a socket set (No 43). Spinner handles (fig 1-41) are used much as screw drivers and will accept all socket attachments, The ratchet handle (No 9) allows both heavy turning force and speed. The fastener can be tured ‘in or out’ by flicking @ lever in the ratchet. The ratchet is also useful where the swing angle is limited. The ratcheting adapter can be used with the flex handle, T-handle, etc thus making them quite fast (fig 1-43), ‘The universal joint will permit driving at different angles with the various socket handles (No 20). Sockets of particular drive size can be turned with handles from another by using an adapter, (No 11). ‘Other socket attachments Screwdriver, drag link, and crowfoot socket attachments are a few of the many offered. Refer to fig 1-46. Socket extensions ‘The long, medium and short extensions allow the user to extend the reach of a socket. They may be used singly or snapped together if so desired (No 19, 1, and 36 respectively. Flex head wrench ‘The flex head wrench is 4 valuable addition to the tools box. It can be used through various angles and in cramped quarters. (No 45). Extractors (fig 1-51) These are used to extract broken screws/bolts from a hole. The screw is drilled into and the extractor inserted. Various sizes are available, Crescent or adjustable wrench (No 51) This is @ useful tool. Its size may be readily changed to that of the fastener. However, it is 2 very dangerous tool to nuts and bolts because it can loosen and slip thus rounding [Link] fastener. Its use must be avoided whenever possible by using other types of wrenches. Pipe wrench ‘The pipe wrench is used to grasp irregular or round surfaces. It provides great ‘gripping power. Both the inside (No 42) and the outside (No 64) pipe wrenches must be available. Chain wrenches ‘The chain wrench is extremely handy for holding or turning around irregular shaped and round objects such as oil and fuel filters. Some employ a fabric in place of a chain and are termed as ‘strap wrenches’,Allen wrenches (NO 61) - ‘These are used to turn set screws and cap screws. patvert Acere Banda @ 176 2009) Torque wrench (No 56) when a set of fasteners is being by use of This tool is used for determining the torque of a fastener, thus, ae driven in they can be tightened with the same tor , the torque wrench. In this way ‘over’ and ‘under’ tightening are avoided. It is used when installing such components as the cylinder head, flywheel, crankshaft and road wheels: Valve spring compressor (No. 80) The tool is used when removing and installing cylinder head valves. Ring compressor (No 80) 3 The ring compressor is used when compressing piston rings to allow the installation of the piston into a cylinder.Flat Square Half round Round Bastard Second SmoothStarting Punch Drift Punch872 Introduction to Basic Manufacturing Procenses and Workshop Technology [Link] Micrometers The micrometers a re commonly employed for measuring small dimensions with extreme accuracy of 0.01 mm. They may be of the three kinds ~ (@) External micrometer for measuring external dimensions, ©) Internal micrometer for measuring internal dimensions, and (©) Depth micrometer for measuring depths, . For measuring a dimension in external micrometer, the work piece is held between the fixed anvil face and the spindle face of the micrometer, The spindle of the micrometer is allowed to move linearly towards the work by rotating thimble, When the spindle will touch the work piece properly, the ratchet will give its sound. The small locking lever is then ae clamp the spindle go that reading can be taken more accurately. Outside micrometers are used for measuring the outside dimensions of jobs, such as diamoter of a bar, rod and thickness of plate, Generally, until and unless they are provided with the vernier attachment, the former can read up to 1/1000 or 0.001 inch and the latter up to 0.01 mm. The former are known as inches micrometers and the latter metric micrometers, which are gradually replacing the former due to the introduction or adopting of metric system. Inside micrometers are commonly used for measuring inside dimensions of the objects, such as inside dia. of a hole, width of a slot or cavity, etc. The outside micrometers are the most extensively used in industrial applications. All the micrometers, irrespective of the fact as to whether they carry graduations in inches or millimeters, are similar in construction. An out side micrometer is discussed as under. OUTSIDE MICROMETER Fig. 19.12 shows an outside micrometer. It consists of the following main parts. 1. Metallic frame Axial graduated sleeve Circumferential screwed spindle Hardened steel anvil ‘Thimble i Ratchet stop screw Lock nut None won Ratchet Spindle Lock Sleeve Thimble Retr Anvil Fig. 19.12 Outside micrometer i inci bly. The sleeve Micrometer works commonly on the principle of nut and bolt assem! carries inside threads at the end, which forms the nut, and the screwed part of the spindle passes through it. The spindle and the thimble are secured to each other such that by rotatingFitting 373 intla i it advances the thimble the spindle rotates. With the result, when the thimble is revolved, it a towards or retards away from the fixed avvil, together with the spindle of the etait ‘The sleeve carries the graduations, which, in conjunction with the beveled and gradvated part of the thimble, give the measure of the opening between the end faces of the Eee a dl spindle. ‘The ratchet arrangement provided at the end of the thimble prevents the spindle from pressing furthor against the surface of the piece being measured after the required fee has been attained, thus facilitating a uniform reading and preventing the instrument - being damaged. Lock nut or locking lever is used for locking the micrometer for a desire amount of time after taking or setting the reading. The construction of the outside micrometer is discussed as under. COMMON PARTS OF OUTSIDE MICROMETER (@) Frame. The U frame of micrometer is made of steel, cast steel, malleable cast iron or light alloy. (2) Hardened anvil. It protrudes from the frame for a distance of at least 3 mm for holding and supporting the jobs for measurement. (3) Serewed spindle. It does the actual measuring and possesses threads of 0.5 mm pitch, ® Barrel or Sleeve, It has datum or fiducially line and fixed graduations. 6) Thimble. This is a tubular cover fastened with the spindle and moves with the spindle. The beveled edge of the thimble is divided into 50 equal parts, every fifth being numbered. (©) Ratchet. This part is commonly recognized as friction stop of the micrometer, which acts as a precautionary measure also. It is a small extension to the thimble in which the ratchet slips when the pressure on the screw exceeds a certain amount. This produces uniform reading and prevents any damage or distortion of the instrument. ( Spindle clamp. It is used to lock the instrument at any desired setting or at any — particular reading . READING ON MICRO METER It works on the fine assembly of nut and bolt principle where pitch of both nut and bolt plays a big role. The graduation on the barrel of micrometer is in two parts, namely one above the reference line and the other below. The higher line graduation above the reference line is graduated in 1 mm intervals, The first and every fifth are long and numbered 0, 5, 10, 15, 20 and 25. The lower or small graduations are graduated in mm intervals but each graduation shall be placed at the middle of the two successive upper graduations to be read 0.5 mm. The micrometer screw has a pitch of 0.6 mm, while the thimble has a scale of 60 divisions round its circumference. Thus, on making or rotating through one complete turn, the thimble moves forward or backward by one thread pitch of 0.5 mm, and one division of its scale is, therefore, equivalent to a longitudinal movement of 0.5 x 1/50 mm = 0.01 mm. It is the value of one division on the thimble, which is the least that can be correctly read with the help of a micrometer and is known as the least count, For measurement, the job is kept between the end of the spindle and the fixed anvil, which is fitted to the frame, When the micrometer is closed, the line marked 0 (zero) on the thimble coincides with the line marked 0 (zero) on the graduated sleeve. In metric outside micrometer, the pitch of the spindle screw is 0.5 mm874 Introduction to and the graduations provided on the spindle of the micrometer are in millimeters and subdivided into 5 mm. Now in one turn of the thimble of the micrometer, owing to the 0.5 mm. pitch of the spindle screw, the spindle will move through 0.5 mm ‘and therefore, the corresponding opening between the faces of the fixed anvil and the spindle will be 0.5 mm. Thie opening will go on increasing, by the same distance 0.5 mm for each further rotation of the thimble. The beveled edge of the thimble carries 50 equal divisions on its periphery in which every 5th division is marked, It is soon above that for one complete turn of the thimble the spindle moves through 0.5 mm, Now let the thimble is rotated one small division on its beveled edge ie. 1/50 of the turn, The corresponding displacement of the spindle will then be 0.5 x 1/ 50 = 0.01mm. Depth micrometer is used for measuring depth of holes and is shown in Fig. 19.13. Screw thread micrometer (Fig, 19.14) is used to measure the pitch diameter of the thread to an accuracy, of 0.01mm_ and 0.001 inches. It comprises of similar parts as that of outside micrometer accept the shapes of fixed and moveable anvils. The fixed and moveable anvils possess the thread profiles for thread adjustment for measurement of the pitch diameter. Basic Manufacturing Provesnes and Workshop Technolowy Ratchet Thimble Sleeve Locking fog Head Fig. 9.13 A depth micrometer Fig. 9.14 A screw thread micrometer 19.2.3,2 Steel Rule It is the simplest measuring tool just like a gcale used in fitting shop. A six inch semi flexible rule is shown in Fig. 19.16 Other types of rules are described in the chapter on carpentry shop. Most of the dimensions are measured by the steel rule in workshops. Teen Fig. 9.18 A steel ruleFitting 373 intla i it advances the thimble the spindle rotates. With the result, when the thimble is revolved, it a towards or retards away from the fixed avvil, together with the spindle of the etait ‘The sleeve carries the graduations, which, in conjunction with the beveled and gradvated part of the thimble, give the measure of the opening between the end faces of the Eee a dl spindle. ‘The ratchet arrangement provided at the end of the thimble prevents the spindle from pressing furthor against the surface of the piece being measured after the required fee has been attained, thus facilitating a uniform reading and preventing the instrument - being damaged. Lock nut or locking lever is used for locking the micrometer for a desire amount of time after taking or setting the reading. The construction of the outside micrometer is discussed as under. COMMON PARTS OF OUTSIDE MICROMETER (@) Frame. The U frame of micrometer is made of steel, cast steel, malleable cast iron or light alloy. (2) Hardened anvil. It protrudes from the frame for a distance of at least 3 mm for holding and supporting the jobs for measurement. (3) Serewed spindle. It does the actual measuring and possesses threads of 0.5 mm pitch, ® Barrel or Sleeve, It has datum or fiducially line and fixed graduations. 6) Thimble. This is a tubular cover fastened with the spindle and moves with the spindle. The beveled edge of the thimble is divided into 50 equal parts, every fifth being numbered. (©) Ratchet. This part is commonly recognized as friction stop of the micrometer, which acts as a precautionary measure also. It is a small extension to the thimble in which the ratchet slips when the pressure on the screw exceeds a certain amount. This produces uniform reading and prevents any damage or distortion of the instrument. ( Spindle clamp. It is used to lock the instrument at any desired setting or at any — particular reading . READING ON MICRO METER It works on the fine assembly of nut and bolt principle where pitch of both nut and bolt plays a big role. The graduation on the barrel of micrometer is in two parts, namely one above the reference line and the other below. The higher line graduation above the reference line is graduated in 1 mm intervals, The first and every fifth are long and numbered 0, 5, 10, 15, 20 and 25. The lower or small graduations are graduated in mm intervals but each graduation shall be placed at the middle of the two successive upper graduations to be read 0.5 mm. The micrometer screw has a pitch of 0.6 mm, while the thimble has a scale of 60 divisions round its circumference. Thus, on making or rotating through one complete turn, the thimble moves forward or backward by one thread pitch of 0.5 mm, and one division of its scale is, therefore, equivalent to a longitudinal movement of 0.5 x 1/50 mm = 0.01 mm. It is the value of one division on the thimble, which is the least that can be correctly read with the help of a micrometer and is known as the least count, For measurement, the job is kept between the end of the spindle and the fixed anvil, which is fitted to the frame, When the micrometer is closed, the line marked 0 (zero) on the thimble coincides with the line marked 0 (zero) on the graduated sleeve. In metric outside micrometer, the pitch of the spindle screw is 0.5 mm874 Introduction to and the graduations provided on the spindle of the micrometer are in millimeters and subdivided into 5 mm. Now in one turn of the thimble of the micrometer, owing to the 0.5 mm. pitch of the spindle screw, the spindle will move through 0.5 mm ‘and therefore, the corresponding opening between the faces of the fixed anvil and the spindle will be 0.5 mm. Thie opening will go on increasing, by the same distance 0.5 mm for each further rotation of the thimble. The beveled edge of the thimble carries 50 equal divisions on its periphery in which every 5th division is marked, It is soon above that for one complete turn of the thimble the spindle moves through 0.5 mm, Now let the thimble is rotated one small division on its beveled edge ie. 1/50 of the turn, The corresponding displacement of the spindle will then be 0.5 x 1/ 50 = 0.01mm. Depth micrometer is used for measuring depth of holes and is shown in Fig. 19.13. Screw thread micrometer (Fig, 19.14) is used to measure the pitch diameter of the thread to an accuracy, of 0.01mm_ and 0.001 inches. It comprises of similar parts as that of outside micrometer accept the shapes of fixed and moveable anvils. The fixed and moveable anvils possess the thread profiles for thread adjustment for measurement of the pitch diameter. Basic Manufacturing Provesnes and Workshop Technolowy Ratchet Thimble Sleeve Locking fog Head Fig. 9.13 A depth micrometer Fig. 9.14 A screw thread micrometer 19.2.3,2 Steel Rule It is the simplest measuring tool just like a gcale used in fitting shop. A six inch semi flexible rule is shown in Fig. 19.16 Other types of rules are described in the chapter on carpentry shop. Most of the dimensions are measured by the steel rule in workshops. Teen Fig. 9.18 A steel rule