MANUFACTURIN

G & WORKSHOP
PRACTICES I
(MWP11A1)
Learning Unit 3
Faculty of Engineering, Built Environment & Information Technology
Hand Processes
Department of Mechanical & Mechatronics Engineering
Hand Tools
• Hand tools are used to remove small amounts of material, usually from
small areas of the workpiece.
• By their nature, hand processes are physically tiring.
• Therefore, the material removed by hand processes should be kept as little
as possible.
• Why use hand tool?
• Unavailability of machine for the job
• Workpiece size/geometry - too large or too intricate
• Cost of setting up a machine

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• Files
• Hack saws
• Cold chisels
• Engineer’s hammer
• Scrapers
• Screwdrivers
• Taps
• Dies
• Hand reamers
• Powered hand tools

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Files
• File uses
• Removing sharp edges
• Removing excess material to get parts into required dimensions
• To smoothen surfaces of components
• Single cut files have a single series of teeth cut across their face
• Double cut files have two sets of teeth cut across their face

Single cut teeth Double cut teeth

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Files
• Grade of cut – refers to the spacing of the teeth and determines the
coarseness or smoothness of the file
• 3 standard grades of cut, from roughest to smoothest are:
• Rough
• Second cut
• Smooth
File Types

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File Types
Type Key features Applications (Uses)

Hand Double-cut on both faces Flat surfaces

Single cut on one edge, the
other edge has no teeth
(safe edge)
Pillar Narrow slots and keyways

Flat Double-cut on both faces Flat surfaces

Single cut on both edges
Square Square cross-section Keyways and slots

Three-square Triangular cross-section Recesses; holes

Round Circular cross-section Enlarging round holes; elongating slots; finishing

internal curved surfaces
Half-round One flat side Flat surfaces and curved surfaces
One round side
Knife Wedge-shaped cross-section Filing acute angles

Dreadnought Curved teeth For soft materials to avoid clogging of the file

Needle Slender circular handle For very fine work, where very small amounts of
material have to be removedFor intricate shapes or 7
in a confined space.
Care of Files
• Wire brushes can be used to remove filings that might have clogged/
embedded into the file faces

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Hacksaws
• Where large amounts of waste metal have to be removed, this is more easily done
by hacksawing away the surplus rather than by filing.
• The hacksaw blade fits into a hacksaw frame on two holding pins, one of which is
adjustable in order to tension the blade.
• The hacksaw frame should be rigid, hold the blade in correct alignment, tension the
blade easily and have a comfortable grip.

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Hacksaw types

Tubular frame hacksaw Hardwood handle hacksaw

Pistol-grip handle hacksaw Junior hacksaw frame

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Hacksaws
• When fitting hacksaw blade to the frame, the teeth must always point
away from the handle
• The cutting operation is achieved during the forward stroke

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Hacksaw blade selection
• When selecting a hacksaw blade, the following must be considered
• Type of material being cut, whether hard or soft, and
• The nature of the cut, whether thick section or thin.
• When performing cutting, the removed material lodges between the
hacksaw teeth. Thus, for soft materials the gap between the teeth should be
huge to accommodate the (bulk) material removed

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Cold chisels
• Cold chisels are used for cutting metal. They are made from high-carbon
steel, hardened and tempered at the cutting end.
• The opposite end, which is struck by the hammer, is not hardened but is left
to withstand the hammer blows without chipping.
• Too steep or too flat angles must be avoided when using a chisel as these
could cause the chisel to dig into the metal, or skid on the workpiece surface
respectively
• When using the chisel, the end which is struck by the hammer must be kept
free of “mushroom” head by grinding it off as soon as mushrooming is
evident.

Correct angle for holding chisel – 10 to 40 O Avoid mushroom head 13

Cold chisels
• Cold chisels can be classified as flat or cross-cut
• Flat chisels have a broad flat point and are used to cut thin sheet metal, remove rivet
heads or split corroded nuts.
• Cross-cut chisels have a narrower point than flat chisels and are used to cut keyways,
narrow grooves, square corners and holes in sheet metal which are too small for the
flat chisel

Flat chisels Cross-cut chisels

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Engineer’s hammer
• Engineer’s hammers

Ball-pein hammer Soft-face hammers for plastics and soft metals

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Scrapers
• Scraping is done to selectively remove small amounts of material, usually to give
a flat surface for sliding parts.
• Applied to remove high spots on rough surfaces
• Also used to create small pockets in which lubricant can be held between the
two surfaces

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Screwdrivers
• Screwdrivers are exclusively used to tighten or loosen screws. They must not be used
for chiselling or scrapping etc.
• To avoid damage to the screwdriver and the screw, always select the screwdriver to
suit the size and type of screw

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Taps – internal thread cutting
• Tapping is the operation of cutting an internal
thread by means of a cutting tool known as a
tap.
• Taps are supplied in sets of threes:
• The one with the longest lead is referred to
as the taper or first tap,
• The next as the second or intermediate tap
• The third, which has a very short lead, as the
bottoming or plug tap

Set of taps

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Taps – internal thread cutting
• A square is provided at one end so that
the tap can be easily rotated by holding
it in a tap wrench

Tap wrenches

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Taps - internal thread cutting
• The first stage in tapping is to drill a hole of the correct size.
• This is known as the tapping size and is normally slightly
larger than the root diameter of the thread. Tapping sizes are
shown in Table 2.2
• Tapping is then started using the first tap securely held in a
tap wrench. The long lead enables it to follow the drilled
hole and keep square.
• The tap is rotated, applying downward pressure until cutting
starts. No further pressure is required, since the tap will then
screw itself into the hole.
• The tap should be turned back quite often, to help clear chips
from the flutes.
• For through holes, only the second tap is necessary. Blind
holes require the bottom tap or plug tap to be used as well

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Dies - external thread cutting
• Dies are used to cut external threads and are
available in sizes up to approximately 36 mm thread
diameter.
• The common type, for use by hand, is the circular
split die, made from high-speed steel hardened and
tempered and split at one side to enable small
adjustments of size to be made.
Circular split die
• Dies have a lead on the first two or three threads, to
help start cutting, but it is usual also to have a
chamfer on the end of the component.
• The die is placed squarely on the end of the bar and
is rotated, applying downward pressure until cutting
starts, ensuring that the stock is horizontal Die holder

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Thread cutting

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Hand reamers
• Hand reamers are used to improve the accuracy and surface finish of
drilled holes
• Also used to slightly enlarge drilled holes

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Powered hand tools
• The main advantages of powered hand tools are the reduction of manual effort and the
speeding up of the operation.
• The operator is also less fatigued, and is more efficient
• However, accuracy of metal-removal operations is not as good with powered hand tools

Hand tool and powered hand tool comparison

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Powered hand tools
• Hand drills
• Electric and air-operated drills are available with a maximum drilling capacity in steel
of about 30 mm diameter for electric and about 10 mm diameter for air models. Air-
operated tools are more ideally suited to the rapid drilling of the smaller diameter
holes.
• Screwdriver
• Used for inserting screws of all types. Some models are reversible and can be used
with equal ease to remove screws. The tool bits are interchangeable to suit the
different screw-head types
• Electric and air-operated screwdrivers are available with a maximum capacity of
about 8 mm diameter thread with a variety of torque settings to prevent the screw
being over tightened or sheared off

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Powered hand tools
• Impact wrenches
• Used for tightening and also, with the reversal mechanism, for loosening hexagon-
headed nuts and screws.
• They have the advantage of being able to tighten all nuts or screws to the same
predetermined load.
• Grinders
• Used to remove metal from the rough surfaces of forgings, castings and welds usually
when the metal is too hard or the amount to be removed is too great for a file or a
chisel.

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Powered hand tools
• Metal shears
• Used to cut metal, where the sheet cannot be taken to a guillotine or where
profiles have to be cut. Electric or air-operated shears are available capable
of cutting steel sheet up to 2 mm thick by means of the scissor-like action of
a reciprocating blade.
• Hammers
• Can be fitted with a wide range of attachments for riveting, shearing off rivet
heads, removing scale or panel cutting.

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Faculty of Engineering, Built Environment & Information Technology