MEM18001C Use Hand Tools - Learner Guide

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MEM05 Metal and Engineering

Training Package

Learner guide

Version 1

Training and Education Support

Industry Skills Unit

Meadowbank

Product code: 5520

MEM18001C

Use hand tools


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TAFE NSW (Training & Education Support Industry Skills Unit Meadowbank), 2012

MEM18001C Use hand tools

AcknowledgmentsThe TAFE NSW Training and Education Support Industry Skills Unit, Meadowbankwould like to acknowledge the support and assistance of the following people in theproduction of this learner resource guide:

Writer

Jim Miles (from existing TAFE resources)TAFE NSW

Reviewer

Ed Harkness Illawarra InstituteMark Pollard South Western Sydney Institute

Project Manager

Stephen DaviesEducation Programs ManagerTAFE NSW

Enquiries

Enquiries about this and other publications can be made to:

Training and Education Support Industry Skills Unit, MeadowbankMeadowbank TAFELevel 3, Building JSee StreetMEADOWBANK NSW 2114

Tel: 02-9942 3200 Fax: 02-9942 3257

TAFE NSW (Training and Education Support, Industry Skills UnitMeadowbank) 2012

Copyright of this material is reserved to TAFE NSW Training and EducationSupport, Industry Skills Unit Meadowbank. Reproduction or transmittal in whole

or in part, other than for the purposes of private study or research, and subject tothe provisions of the Copyright Act, is prohibited without the written authority ofTAFE NSW Training and Education Support, Industry Skills Unit Meadowbank.

ISBN 978-1-74236-262-5


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Introduction ................................................................................... 7

1. General introduction ............................................................................. 7

2. Using this learner guide ........................................................................ 7

3. Prior knowledge and experience ............................................................. 9

4. Unit of competency overview ................................................................. 9

5. Assessment ....................................................................................... 11

Topic 1: Hand tools ...................................................................... 17

Hammers .............................................................................................. 17

Cutting tools .......................................................................................... 18

Chisels .............................................................................................. 18

Files .................................................................................................. 21

Hacksaws .......................................................................................... 27

Snips ................................................................................................ 29

Cutters and strippers ........................................................................... 30

Hand Taps ......................................................................................... 31

Dies .................................................................................................. 32

Mechanical tools..................................................................................... 33

Spanners ........................................................................................... 33

Screwdrivers ...................................................................................... 39

Hexagon wrenches .............................................................................. 41

Pliers................................................................................................. 42

Pipe wrenches .................................................................................... 43

Care of hand tools .................................................................................. 44

Safe use of hand tools ............................................................................ 44

Review Questions ........................................................................ 45

Practical jobs, projects, instruction and demonstration ............... 47

Practical assessment ............................................................................... 47

Job 1: Hand tool identication................................................................. 49

Job 2: Hacksaw use ............................................................................... 50

Table of Contents
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Job 3: Using metal removal hand tools ..................................................... 51

Job 4: Multi-purpose gauge .................................................................... 52

Job 5: Toolbox square ............................................................................ 53

Job 6: Cutting sheet metal ...................................................................... 54

Job 7: Sharpening tools ......................................................................... 55

Job 8: Drill and tool gauge ...................................................................... 56

Resource Evaluation Form ............................................................ 57
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Page 17 of 60 TAFE NSW (Training & Education Support, Industry Skills Unit Meadowbank), 2012

Topic 1: Hand tools

Introduction

Tools are common place in our lives today and it is easy to overlook that they cancause injury in untrained hands. With the introduction of the Work Health andSafety Laws (WHS) all tools are manufactured with the operators safety in mind.

Some hand tools are common to a number of occupations while others are generallyonly used in specic elds. As a number of common hand tools are used acrossa broad range of occupations and trades in manufacturing and engineering it isimportant to learn their purpose and application. It is also necessary to know how toselect and safely use them for a given task. Quality hand tools are often expensiveso it is also important that users know how to properly maintain them.

Hammers

Hammers are impact tools used to imparta force either directly, or indirectly throughanother tool such as a chisel or punch, toa workpiece. The most common hammersused by the mechanical tradesperson arethe ball pein (engineers), cross pein and softfaced hammers.

Ball pein hammers

The Ball Pein or engineers hammer is themost common of the hammers used bymechanical tradespeople. It has a slightlyconvex face for striking tools such aspunches, chisels, centre punches or theworkpiece itself.

The opposite end of the hammer head isa hemispherical ball pein used to dome orshape the shanks of rivets or to stretch thesurface of a metal workpiece to straighten it.

All hard faced hammers are made fromtool steel by a drop forging process.After forging, the hammer is carefullyheat-treated so that the face and the peinare hardened and tempered while the metalaround the eye is left soft.

Because the hammer head has beenheat-treated it must not be subjected to hightemperatures, otherwise the hardness of theface and pein will be lowered.

Ball peinhammer


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The engineers hand hammer is made in a range of sizes. The smallest weighsaround 100 g and the largest 1500 g. The hammer size best suited to a fabricatorswork weighs about 600g while a 200 g hammer would suit most marking-offpurposes.

The weight of the hammer must be chosen to suit the job. For example, wherea heavy blow is required in a conned space, a heavy hammer should be usedbecause its larger mass will be able to deliver a greater amount of energy to theworkpiece or tool without being made to move fast. But for normal conditions theheavy hammer would be too tiring to use.

Hammer handles should be in good condition and of a size that is comfortable touse. It should be square with the head and t tightly into the head.The hammer should not be used if either the head or the handle is damaged,because it may cause injury to either the user, or the people around the user.

Cross pein hammers

This is a special purpose engineering hammer that comes in a variety of massesup to 450 g (1 lb) metal. The cross pein hammer is used in conned spaces or forstraightening or stretching when the is peined at right angles to the direction ofstretch or curve.

Cross peinhammer

Cutting tools

Chisels

Cold chisels are forged from medium carbon steel. Only the point of the chisel ishardened and tempered, the body being left soft. If the head of the chisel werehard it would chip or shatter as a result of hammer blows.

The point of the chisel should be formed into a cutting edge similar in nature toother cutting edges in that it requires the edge to be sharp.


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Pointangle

Cold chisel Correct cutting positionand angle

Because chisels are subjected to continualimpact loads, they are likely to show signs ofmetal fatigue or cracking after a period of use.In this condition they can become dangerous assmall pieces of metal or splinters may y off athigh speed causing injury to the operator or topeople standing nearby.

A new chisel should be used lightly until it isproved to be sound and only then should heavyblows be used on it.

A major problem associated with the useof chisels is the mushrooming of the head dueto the fact that the head is soft and constanthammering on the head distorts the metal asshown opposite. The head of the chisel shouldbe kept in good repair by keeping the chamferground cleanly as shown.

When resharpening a chisel care must be takennot to raise the temperature of the cutting edgeabove the tempering temperature. Ideally whengrinding a chisel's cutting edge no temperingcolours should show on the surface other than avery light straw colour, otherwise the intergrityof the chisel may be compromised. Dependingupon the type of chisel used a general guide isto use a 60 point angle as illustrated above.

Grind head alongdotted lines

Mushroomed head

Correctly prepared

chisel head

Restored head


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Chisel types

Flat Cross cut Round nose

Diamond Point Side Cutting Gouge or C

Common types of chisels

Unsafe or faulty hand tools

Damaged hand tools

Chisels, wedges and drift pins are impact tools and due to constant use these toolsform mushroom heads if not maintained. An impact tool must be kept free ofmushroom heads as they may cause injury to the user or to others as the head willeventually shatter on impact causing metal fragments to y off in any direction.


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Review Questions

These questions have been included to help you revise what you have learnt inTopic 1: Hand tools.

1. The following list contains 19 names and only 13 illustrations of hand tools.Place the corresponding number from the hand tool illustration as shown on thefollowing pages in to the brackets next to the hand tool name.

( ) Ball pein hammer ( ) Combination pliers

( ) Stillson pipe wrench ( ) Socket extension bar

( ) Double end ring spanner ( ) Combination open end andring spanner

( ) Hook or C spanner ( ) Half moon ring spanner

( ) Torque wrench ( ) Multi-grips

( ) Long nose pliers ( ) Crows foot spanner

( ) Double open end spanner ( ) Allen key

( ) Circlip pliers ( ) Standard socket

( ) Single open end spanner ( ) Adjustable/shifting spanner.

( ) Diagonal cutting/side cutting pliers


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Job 1: Hand tool identifcation

Task: Identify the hand tool pictured

1. Name the hand tools shown below.2. List typical uses and possible personal hazards associated with each hand tool/3. Briey descrie how the hand tool is maintained in good working order.

Hand tool Use and hazard Hand tool maintenance

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MEM18001C Use Hand Tools - Learner Guide

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