TOOLS - Licence By Post “The apes in is book ean cach fingers. Not suiable fr small chuldren. Care when handl ALL 7.3 ISSUE 151 rea By Post © copyrightAUTHORITY It is IMPORTANT to note that the information in this book is for study /training purposes only. When carrying out a procedure/work on aircraft/aircraft equipment you MUST always refer to the relevant aircraft maintenance manual or equipment manufacturer's handbook. You should also follow the requirements of your national regulatory authority (the CAA in the UK) and laid down company policy as regards local procedures, recording, report writing, documentation etc. For health and safety in the workplace you should follow the regulations /guidelines as specified by the equipment manufacturer, your company, national safety authorities and national governments.CONTENTS Simple machine tools Hand tools Marking out Precision measuring equipment Power tools Torque wrenches PAGE 41 44 69 72HOW TO TACKLE THIS BOOK Applicable to both the A line mechanic and the B licensed engineer. A thorough understanding of the use and care of tools is required. For many it will be revision from the days of basic training/apprenticeships. For some it Will be all new. For those, some parts of the book will need a second, or a third reading, but the remainder should be fairly straight forward.MACHINE TOOLS Lathe Used for turning, drilling, thread cutting. On modern production lines are automatic computer controlled. LATHE Drilling Machine Usually has a selection of drilling speeds and may have automatic feed. Milling Machine May be a horizontal or vertical mill. A horizontal mill is shown and is used for milling down metal to a close tolerance and good surface finish.MILLING MACHINE Grinding Machine (Not shown) Similar to a milling machine but will grind to closer tolerances and a better finish. Grinding Machine - Bench Type Most workshops and hangars have a grinding machine, the most common type is the double-ended bench machine with coarse and fine abrasive wheels or stones. ‘Tool rests are fitted in front of each wheel to support the item being sharpened. Tools being sharpened can be ruined if allowed to "lose their temper" by overheating. The item being sharpened must be dipped in water or oil to keep the tip cool (depending on the type of wheel). When grinding move the tool from side to side to avoid forming ridges on the wheel, NEVER use the side of the wheel. Safety Precautions ALWAYS wear protective goggles when using a grinding machine. Make sure the tool rests are as close to the wheel as possible, but not touching, * DO NOT grind soft metals or materials such as aluminium, brass, magnesium, etc. The wheels should be dressed from time to time b y a qualified personOFF HAND GRINDING MACHINE Guillotine Used for cutting sheet steel, aluminium, rigid composites, etc. May be small enough to be fitted to a bench. Folding Machine Folds metals ductile/malleable enough to be bent.FOLDING MACHINE Fly Press Used to stamp/shape metal by a downward force of the stamping head. NOTE. For information on portable powered hand tools used on aircraft refer to the book in this series "Basic Engineering 3"HAND TOOLS HAMMERS Classified by the weight and type of head. Hammer heads are forged from high carbon steels with faces hardened and tempered. Shafts are made from straight grained ash. aut pam STRAIGHT PRIN TYPES OF HAMMERS ‘The main types are:- 1. Ball Pein - The flat surface is used for most general work. 2. Cross Pein - At right angles to the shaft, for general work, the cross pein being suitable for use where access to working area is limited. 3. Straight Pein - Pein inline with shaft similar usage as the cross pein. 4. Nylon Faced - Used to deliver blows to the work without damaging the surface. 5. Copper or Lead - Similar to the nylon faced hammer in terms of application. CENTRE PUNCH Made of high carbon steel hardened and tempered. Used for making light Pop Marks along scribed lines for surer guidance and a heavier Pop Mark “Indentation” to locate the point of a drill at the start of the drilling operation. A sharp point should be maintained by grinding, the angle should be 90° for general work and for light work such as marking out should be reduced to 60°. Remember that titanium should not be centre punched nor should marking out lines on aluminium alloy.THE CENTRE PUNCH PIN PUNCHS - Parallel and Tapered Are both made of high carbon steel - hardened and tempered. ‘The parallel pin punch is used to drive out rivets, (after head removal), bolts, split pins, shackle pins etc. Always use the correct size punch and never use a tapered punch as this will tend to enlarge the hole. PIN PUNCHESDRIFTS Flat ended punches either solid or tubular which are used for localising the effect of hammer blows and preventing damage to finished surfaces. Also used for dismantling and assembling tight fitting parts. Drifts are made from Copper, Brass Steel, or Aluminium. Steel drifts only should be used to drive Ball or Roller bearings as softer drifts may break and fragments from the drift could lodge in the bearing. Ends must be clean and any damage removed, PLIERS ‘There are various types of pliers, each designed for a specific use e.g. 1. Combination - Can be used to hold round or flat material and have cutting edges for cutting split pins, locking wire, etc. 2. Flat Nose - Used to hold flat material. 3. Snip Nose - For twisting locking wire. 4. Diagonal or Side Cutting - Used for cutting soft wire cutting split pins. 5. Cable Stripping - For removing the insulation from electrical cables. 6. Circlip Pliers - Removing circlips, internal and external. Pliers are classified by type and overall length, usually made of high carbon steel, jaws hardened and tempered. AAA RowD Nose ae cCURCLIP, TYPES OF PLIERSSCREWDRIVERS Common or flat bladed - Blade of high carbon or alloy steel. The end of the blade ground flat to fit the slot cut in the head of the screw. Handle is made of wood or plastic. Classified by length of blade. Ratchet - Usually flat bladed. Watchmakers - Has a long thin blade with a flat plastic handle. Used for smaller screws such as in electrical work. Pump Screwdrivers - Drill operated on the Archimedes principle. Pushing or pumping the handle turns the screwdriver via the screw mechanism. Phillips - Blade head has a cruciform shape tapered to the correct angle. The end is further machined and four tapered flutes provide correct engagement with the slots and face of the cruciform recessed head of the screw. Electric - These are usually battery powered and are re-chargeable. Bits are supplied of different sizes and shapes that fit into a chuck or adapter. The electric motor can be controlled in such a way that provides for a varying speed and torque output. All screws slots or recess should be cleared of paint or dirt before applying the screwdriver and the shaft of the screwdriver should be aligned with the screw during use. Blade fit in the screw is most important otherwise screw head will be damaged making removal or tightening difficult. Use correct size screw- driver and never grind the flat blade to a chisel head. SCREWDRIVERSSPANNERS ‘These are supplied in a variety of forms and have the size marking stamped on them. This size relates to the size of nut or bolt to which it fits, e.g. 1), BSF 3/g BSW O BA etc. or, which is more common the spanner is marked with the across flats size ¢.g. 32mm T/g" etc. This size relates to the distance across the flats of the nut or bolt. Qpen Ended Spanners - Made of high carbon steel with a different size at each end. The length of the spanner is indicative of the torque to be applied to the nut/bolt. (Based on the strength of the average person). The greater the size the longer the spanner. This rule also applies to ring spanners. OPEN ENDED SPANNERRing Spanners - These give full enclosure to bolt head or nut. Each corner fits snugly with an angle in the aperture of the spanner and is usually bi-hexagonal to facilitate its use when angular movement is restricted. Supplied in double ended form to fit nuts of consecutive sizes, the ends are generally off set but straight shank types are available RING SPANNER Box Spanners - These also fully enclose the nut or bolt head and are ~ particularly useful where access to the nut or bolt head is restricted to the centre line of the screw axis. BOX SPANNER WITH TOMMY BAR Socket Spanners - These are used with various types of attachments and again this type of spanner fully encloses the nut or bolt head. The socket aperture is bi-hexagonal at one end and the other end the aperture is square to take the various attachments. Attachments can include:- extension bar, drive bar, T bar, universal joint, flexible extension bar and reversible ratchet. Socket spanners are usually supplied in sets complete with the requisite attachments.