1) The document provides instructions for safely using various hand tools and machines for fitting components, including checking tools for damage, selecting appropriate datums, sawing, filing, scraping, chiseling, drilling, tapping threads, and measuring components. 2) Proper planning is important, considering datums, work holding, process sequence, quality checks, and available tools and equipment. 3) Safety checks of tools like files and hammers are necessary to prevent injury from cracks or loose heads.

1. Chapter 4 Producing components using hand
fitting equipment
© Pearson Education 2012 Printing and photocopying permitted
Producing components
using hand fitted
equipment

2. Chapter 4 Producing components using hand
fitting equipment
© Pearson Education 2012 Printing and photocopying permitted
Using tools
● Cables, extension leads and hoses should be checked for damage.
● Files must have a secure handle and checked for cracks and splits.
● Hammers should be checked for cracks and chips and the head
should be secure on the handle.
● Chisels should not be used if the
striking face has ‘mushroomed’.
Tools should always be kept in the best possible condition:
What could happen if these checks
are not made to the tools?

3. Chapter 4 Producing components using hand
fitting equipment
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Making a plan
Before starting a plan you need to consider:
● Correct choice of datums to suit the work you are making.
● The work holding techniques you are going to use.
● The correct process of work in the right sequence.
● The quality checks you will need to make.
● Whether the tools and equipment you need are available.

4. Chapter 4 Producing components using hand
fitting equipment
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Datums
Datums are the workpiece reference points so must be correct as the
work’s accuracy depends on them. The three types of datum are:
● Edge of face datum taken from a true edge, it allows accurate̶
marking out using a surfaced table.
● Linear datum a line marked on a component (e.g. through the̶
centre or in a convenient position for a range of features).
● Point datum – the simplest datum, taken from a single point (e.g. a
hole or a mark), often used as castings where the hole position is the
most important so must be central.

5. Chapter 4 Producing components using hand
fitting equipment
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Hacksaws
Designed to cut metal with adjustable frames
to accept different blade sizes. Blades are
made from three different materials:
● High carbon steel ̶ cheap blades used
for softer materials.
● High speed steel very hard and brittle̶
and can shatter if twisted while cutting.
● Bi metal blades expensive, high̶̶
speed steel teeth welded into a carbon
steel backing.

6. Chapter 4 Producing components using hand
fitting equipment
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Using hacksaws
● Select the correct blade for the material being cut.
● Fit the blade to the frame, with teeth facing away from the handle.
● Tension the blade until it is taut.
● If right handed, stand facing the saw and hold the saw in your right
hand. Use your left hand to hold the front of the saw and steer it
and hold it straight.
● Concentrate on moving the saw forward and back in a controlled
manner, at a steady pace and not pushing too hard. Make sure you
use the full length of the blade.

7. Chapter 4 Producing components using hand
fitting equipment
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Steps for good filing
● Step 1 Hold the workpiece tight in a bench vice at the correct height.̶
Avoid too much metal sticking out as this can cause the vice to vibrate.
● Step 2 Stand almost sideways to the̶
bench with your feet shoulder width apart.
As you file the line you move in should be
roughly in line with your right toes
(if right handed).
● Step 3 Grip tight; if right handed grip the̶
file tight in your right hand and support the
front of the file with your left. The right hand
is for power, the left for control. As you file
move the weight from the front of the file to
the back, to stop the file rocking.

8. Chapter 4 Producing components using hand
fitting equipment
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Achieving a flat surface with filing
This is known as cross filing.
● Clean the surface table with a light oil or rag.
● Lightly cover the surface with engineer’s blue.
● Rub the surface to be filed flat over the engineer’s blue. The high spots will
be revealed.
● Select a flat file, place the workpiece in a vice and file at 45˚ to the front of the
workpiece, focusing on the areas shown in engineer’s blue.
● Clean the workpiece and recheck with engineer’s blue.
● Continue until there is an even blue surface on the workpiece.
Describe the process used for drawfiling and for filing external and internal curves.

9. Chapter 4 Producing components using hand
fitting equipment
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Scraping
Scrapers are used to make a more
accurate surface than filing. They can
also be used to produce a decorative face.
Scrapers remove only a small amount of
metal and should only be used on a
surface that has been worked true.
Types of scrapers include:
● Flat scraper
● Half-round scraper
● Triangular scraper

10. Chapter 4 Producing components using hand
fitting equipment
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Chiselling
Cold chisels are effective cutting tools and can be used for a variety
of work. They are made from high carbon steel and hardened and
tempered at the cutting edge.
The end that is hit with a hammer is left soft to prevent it chipping.

11. Chapter 4 Producing components using hand
fitting equipment
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LappingLapping
Lapping produces a good surface finish or an accurate fit between two
parts.
An abrasive paste or slurry is used when lapping.
The grit size of the abrasive is chosen to suit the required finish.
● Clean all traces of dirt and old abrasive from the lapping plate.
● Apply the appropriate abrasive paste evenly to the plate.
● Lay the workpiece on the lapping plate and with gentle pressure
move the workpiece in a circular motion on the lapping plate,
rotating the piece with your hand.

12. Chapter 4 Producing components using hand
fitting equipment
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Drilling
For hand fitting most drilling will use
a bench drill or pillar drill. They have
a table that can be raised or lowered.
They have a range of different spindle
speeds.
Using the Internet, catalogues and
Your workshop, find out about the
different drills bits that can be used.

13. Chapter 4 Producing components using hand
fitting equipment
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Cutting fluids and compounds
There are three main types of these:
• Straight oils – vegetable, animal, synthetic or mineral oils. Usually clear
and act mainly as a lubricant, they are expensive but are good for low
speed operations.
• Soluble oils – these can be emulsified with water and are effective
coolants that allow fast cutting speeds and are cost effective. They
do make the work harder to see and are not such good lubricants as
straight oils.
• Greases – soft and used for tapping, rearming and other cutting
operations where friction needs to be reduced. Give a good surface
finish and reduce tool wear but do not remove swarf in the same way as
soluble oils.

14. Chapter 4 Producing components using hand
fitting equipment
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Cutting screw threads
Screw threads are used to fasten components together. They are self
locking and can be opened and closed to help disassemble a component.
You need to always use the
correct tap or die for the thread
required. Taps are made from
high speed steel (HSS) or high
carbon steel (HCS).

15. Chapter 4 Producing components using hand
fitting equipment
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Taps
Taps are available in sets of three:
• Taper tap – tapered for two thirds of its length and used to start the
thread, the taper helping it to align with the hole and cut a new thread.
• Second cut (intermediate) tap – a taper for a third of its length and
used after the taper tap to enlarge the thread to the correct size
• Plug (bottoming) tap – cut a parallel thread for their whole length but
have a chamfered thread to help with cutting.

16. Chapter 4 Producing components using hand
fitting equipment
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Cutting external threads
External threads are cut by a die. They are made from the same materials
as taps.
• The die has a split in it for adjusting
depth of cut. To do this, screw the
tapered ended centre screw into the
die, spreading the die and making it
a large diameter.
• The die should then be locked in place
using the two locking screws.
• A thread is then cut and checked either
with a thread gauge or a suitable nut.
• All three screws must be present in
the die stock to prevent the die shifting.

17. Chapter 4 Producing components using hand
fitting equipment
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Reaming
Reamers are used when holes need to have an accurate size. A hole is
drilled slightly undersize and then finished by reaming.
Reaming is best done using a hand reamer to ensure accuracy.
• Turn the reamer slowly and smoothly avoiding excessive pressure.
• Workpiece must be properly supported and firmly held in position.
• The correct size tap wrench must be used.
• Never turn the reamer backwards even when removing the reamer.

18. Chapter 4 Producing components using hand
fitting equipment
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Hand grinding machines
This is used for sharpening cutting tools.
It has a coarse wheel and a fine wheel.
When using a grinder:
• Always stand to the side when you
turn the machine on.
• Never use the side of the wheel
to grind.
• Move the tool evenly over the wheel,
using all the surface.
• Only grind for a short time then cool
the workpiece.

19. Chapter 4 Producing components using hand
fitting equipment
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Micrometers
Micrometers are some of the most accurate measuring tools used.
• The spindle has a pitch of 0.50 mm.
• The thimble is graduated with 50 divisions around its circumference,
meaning each of these divisions is 0.01 mm.

20. Chapter 4 Producing components using hand
fitting equipment
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Measuring work: Vernier calipers
These are versatile measuring instruments used to measure internal and
external measurements and depths.
A metric Vernier calliper
has two scales:
• The main scale is on the
body of the calliper and
graduated in mms.
• The scale on the sliding jaw
has 50 divisions and is
numbered from 1-5 in every
five divisions.
• Each division has a value
of 0.02 mm.

21. Chapter 4 Producing components using hand
fitting equipment
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Measuring work: Dial test indicators
These are sensitive
instruments, using a set of
gears and a rack or pinion
mechanism to compare
measurements.
• A 1 mm move of the
plunger will turn the dial
hand one full circle.
• The face of the circle is
graduated to 0.01 mm
divisions so accurate
comparisons can be
made.