Workshop Practice

Hand Cutting
Tools
HAND CUTTING AND WORK HOLDING
work holding devices
 Vice is fastened near the edge of the bench
with bolts fig. It is often used to clamp parts
together while cutting, filing or chipping or
being assembling.
Hacksaw

 Hack saw is a tool used to cut off metal to lengths

or to cut out shapes in sheet metal and other
relatively thin sections.

 Hacksaw blades are made of carbon or high-speed

steel. There are two types: all-hard and flexible.
 The length of the blade is measured as the distance
between its pin holes.
 The most usual blade for hand work is 250mm long
&12.5mm wide.
 The pitch is measured by the number of teeth per
25mm length.
Cont… Hack saw
 Solid metals should be cut with a good
pressure &tubes with light pressure.
 The point of the teeth are bent, to cut a wide
groove & prevents the body of the blade from
rubbing or jamming in saw cut.
 The bending of the teeth to the sides is called
the setting of tooth.
The breakage of the blades may be due to
 rapid and erratic strokes,
 Too much pressure
 Blade held too loosely in the frame
 Work not held firmly in vice.
 Hack saw blade classification
Number of teeth per Diameter of material Material to cut
25mm(1 inch) to be cut
14 25mm Aluminum, bronze,
cast iron
18 6mm Angle iron , cast
iron, tool steel
24 1.6mm Brass pipe ,Heavy
sheet metal
32 Less than 1.6 mm Sheet-metal
over18gage
Chisel

 They are made forging from cast steel or alloy steel, with a hardened and
tempered cutting edge.
 These are used to cut the cold metals. Octagonal cross section.
 The length of the chisels is about 15cm to 20cm & the tapered part is from
5cm to 8cm long. The chisels are being made from 10mm to 25mm thick
material.
 The most commonly used cutting edge angle is 60 o
 The common types of chisel include
1. TheFlat chisel, used for general-purpose chiseling;
2. The Cross-cut chisel, used for cutting grooves
such as keyways, and for chipping;
3. The Half-round round-nosed chisel, used for cutting
grooves (which are either curved or half-round);
4. The Diamond-pointed chisel, used for
working into corners and cutting small grooves.
Files

Filing is a method of removing metal, which is the most

widely used hand tool in the school workshop, is used for
this cutting operation. It is made of carbon tool steel
containing about 1.3 per cent carbon.
Cont…

The files are classified according to the size, cut of teeth,

grade and shape or cross section of file.
A. Size of file:- the size of file is indicated by its length.
It is the distance from the point to the heel with out tang.

B. Cut of teeth:-the files according to the cut of teeth, are divided in to

two groups, single cut & double cut.
in single cut files, the teeth are cut parallel to each other running across
the faces &at angle and are particularly used for very hard metals.
Cont…
Cont…

In double cut files, there are two sets of teeth. The first
set of teeth are similar to those of single cut files( i.e.
60o to the centre line of the file) while the second set
of teeth are cut diagonally across the first set of teeth
at an angle of about 80o to the center line of the file.
C. Grade of cut of file:- the single cut and double cut
files, depending upon the pitch of the teeth(spacing
b/n the rows of teeth) may be classified as
rough(R),bastard(B),Second cut(SC),Smooth(S),
Dead smooth(SD),Super fine(super smooth/SS).
s.N Grade of file Effective length of file in mm Uses
o 100 150 200 250 300 350 400 450

No. of cut per 10mm of length

1 Rough(R) 10 8 7.1 6.3 5.5 5.3 4.8 4.5 It is used for heavy
reduction and filing casting
after chipping.
2 Bastard(B) 18 13 11 10 9 8 7 6 It is used for reducing bulk
work.
3. Second 21 17 16 15 14 13 12 11 It is used for general work.
cut(Sc
4 Smooth(S) 30 24 20 20 19 18 16 15 It is used for smoothening
surfaces &filing delicate work
5 Dead 35 33 31 30 28 These are used by tool
Smooth(DS) makers and silver smiths
for high accuracy and
6 Super 63 49 45 40 finish.
Smooth(ss)
 Cont…
D. Shape of File:-the files according to their shape or cross section
are classified as follow
 Flat file:-it is mostly used for general work and for filing flat
surfaces,
It has double cut on both faces & single cut on both side.
 Square file:-it is used for filing square corners & slots.
 Round file:- used for opening out holes, producing round
corners etc
 Half round file:-it is used for filing curved surfaces.
 Triangular file:- used for filing square shoulders or corners
 Knife edge file:-used for finishing a sharp corners of groove
&slots.
 Diamond file:- used for special work.
 Needle file:- used for filing very thin and delicate work.
 Hand file:- rectangular cross section, both faces are double cut
& one edge single.
.
Method of Filing
Draw filing:-Draw filing produces a finer
surface finish than cross filing. Small parts, as
shown in figure A, are best held in a vice. Hold
the file as shown in the figure.
Cross filing:-Figure B, shows a piece of mild
steel being cross filed. This means that the file
is being moved across the surface of the work
in a crosswise direction. Keep your feet spread
apart to steady yourself as you file with slow,
full-length, steady strokes
Figure A Figure B
Drilling
 Bench drilling Pedestal drilling machine
Drilling
portable hand drills portable electric drill
 Drill Press
 Drilling machine
 Principle of rotating tool to make hole
 One of most common and useful machines in
industry

Used primarily to produce holes in metal

19 Shop Tools and Techniques

 Standard Operations
 Drilling
 Operation of producing hole by
removing metal from solid mass
using twist drill

• Countersinking
• Operation of producing tapered
or cone-shaped enlargement
to end of hole
• the tapering or bevelling of the end
of a hole with a conical cutter called
a machine countersink
20 Shop Tools and Techniques
 Standard Operations
 Reaming
 Operation of sizing and producing
smooth, round hole from previously drilled
or bored hole

• Boring
• Truing and enlarging hole by
means of single-point cutting
tool
21 Shop Tools and Techniques
 Standard Operations
 Tapping
 Cutting internal threads in hole with
cutting tool called tap

• Counter boring
• Enlarging top of previously
drilled hole to given depth
to provide square shoulder
for head of bolt or capscrew

22 Shop Tools and Techniques

 Standard Operations
 Spot-Facing
 Smoothing and squaring surface around hole to
provide seat for head of cap screw or nut.

 Lapping is the removal of material to produce a

smooth, flat, unpolished surface. Lapping
processes are used to produce dimensionally
accurate specimens to high tolerances (generally
less than 2.5 μm uniformity)

23 Shop Tools and Techniques

Principal Types of Drilling
Machines
 Wide variety of drill presses

 Size of drill press may be designated in different

ways by different companies

 Some state size as distance from center of spindle

to column of machine
 Others state size by diameter of largest circular
piece that can be drilled in center

24 Shop Tools and Techniques

 Sensitive Drill Press Parts
 Hand feed lever
Controls down feed
pressure
 Four main parts
Base,
column,
Table and
drilling head

25 Shop Tools and Techniques

 Sensitive Drill Press Parts
 Base
 Provides stability for machine
 Cast iron with holes to be bolted to table or bench
 Slots or ribs in base allow work-holding device or
work piece to be fastened

 Column
 Accurate cylindrical post that fits in base
 Table may be adjusted any point (base to head)
 Drill press head mounted near top

26 Shop Tools and Techniques

 Sensitive Drill Press Parts
 Table
 Round or rectangle shaped
 Used to support work piece to be
machined
 Surface 90º to column (move around)

 Drilling Head
 Mechanism used to revolve
cutting tool
 Spindle: round shaft holds cutting
tool
27
 Quill: housesShopspindle
Tools and Techniques
 Twist drill
 Twist drills are the most common cutting tools
used with drilling machines.
 Twist drills are designed to make round holes
quickly and accurately in all materials. They
are called twist drills mainly because of the
helical flutes or grooves that wind around the
body from the point to the neck of the drill
and appear to be twisted (Figure ).
Hand thread cutting
•

• A thread is a spiral or helical groove cut on the

inside or outside of a cylinder or cone.
 The thread on a rod is called an external
thread,
 The thread in side of a hole or nut is called an
internal thread.
 Threads are used to hold parts together,
transmit power and provide accurate
measurements.
 Taping
Taps are used to cut threads on the inside of a hole, as in a nut.
There are three basic styles of taps.
Taper Taps - This style has an 8-10 thread chamfer, it has the
longest chamfer of the three to distribute action over the
maximum number of teeth; and the taper also acts as a guide in
starting the cutting action in the hole.
taper taps are used to start threads.

Plug Taps - This style has a 3-5 thread

chamfer, is most widely used in through holes
and where there is sufficient room at the bottom
in blind holes. plug taps are used for general-
purpose threading
Cont…
 Bottoming Taps - This style has 1-2 thread chamfer, is
made with just enough chamfer for starting in the hole; as the
name implies, it is designed to thread blind holes to the bottom.
 bottom taps are used to thread near the
bottom of a hole.

Tap holder or tap wrench is used to hold taps

during internal thread
Cont…
 Die stock is used to hold dies during cutting
of external threads.

 External threads
Dies are just the opposite of taps in that they cut
external threads on the outside of pipes, rods or
bolts. The die is held in a Die Stock and worked in
much the same manner as a tap.