CHAPTER THREE Tools Introduction Welcome to chapter three. The syllabus for this chapter covers five topics that are almost chapters in their own right. The common factor is that in each topic ‘we are dealing with equipment that we use to caery out maintenance and repair tasks. Important as it is to have a thorough knowledge of the aircraft structure and systems we work on, it is equally as important to have a thorough knowledge of the tools we use and their limitations. Common Hand Tools We can divide the hand tools that we use into four groups that roughly define their use, We may argue that some of these tools serve uses in more than one group but we are only using these headings to make their presentation to you easier, We will deal with each group in turn and, where possible, present the tools related to each group, by description, material, classification, use and any ° precautions that may apply. Tools used for crimping appear in section 7-7 (chapter 7) of the syllabus and tools used for riveting and dimpling appear in section 7-8 (chapter 8) of the syllabus so, to avoid duplication, we will not be including them in this chapter. £ ‘The groups we will be dealing with are: © Gripping tools * Cutting and shaping tools Dismantling and assembly tools ‘Marking out and measuring tools Gripping Tools Bench Vice Description The bench vice consists of a fixed and a sliding part, each carrying a detachable, hardened, serrated steel jaw for clamping work. The fixed paris 95 Copyright © Canlif and Vale Collge 2015. Al rights reserved wm part66.comTooLs. secured to the workbench and it contains a retractable half nut that is spring- loaded into engagement with a buttress-threaded operating screw located in the sliding part. When the tommy bar handle on the screw is turned, the sliding part is driven either towards or away from the fixed part. For quick adjustment of the working gap between the parallel jaws of the vice, a release lever can be moved that retracts the half nut, allowing the sliding part to be pulled or pushed into any position. The half nut will automatically re-engage with the screw when the lever is released. LR Detachable Operating Screw (Square or Steel Jaws Butress Thread) Release Lever Figure 3.1 - Bench Vice Materials The nwo main body parts of the bench vice are made from malleable cast iron or cast steel. The detachable steel jaws are hardened and tempered and have serrated work faces. The operating screw is made of mild steel and normally has a buttress thread, although some vices may have a square thread. Classification Bench vices are classified by their weight and the length of their jaws. A common example is 45Ibs weight and 4.5in jaws. Use “The bench vice is used to exert a firm grip on material while itis being worked. Precautions damaged by the serrated steel jaws. ‘The parts of the bench vice should never be used as an ‘anvil’ for hammering, 96 Copyright © Cariff and Vale Calige 2015 Al right reserved num pert66.008mCHAPTER THREE The operating handle should never be hammered or turned with an extension tube in an attempt to increase the grip on work. The vice should be cleaned after used to remove metal filings and the slide and the operating screw should be kept lubricated. Hand Vice Desetiption ‘The most common form of hand vice consists of two spring-loaded, hinged arms, each equipped with an integral jaw. A winged nut and screw are used to close the jaws and grip the work. Coa Figure 3.2 - Holding Tools PF p09 a4 pur 2? Materials Sag. ‘The arms are made of steel and the jaws are hardened and tempered. The winged mut and operating screw are mild steel. A leaf spring is fitted to drive the arms apart when the winged nut is released. Classification ‘There is 2 variety of shapes and sizes and these are identified by trade or manufacturer's names, The classification is by overall length. Use The hand vice is mainly used for gripping small parts, or for holding parts together, while they are being drilled or riveted. 97 Copyrighe © Carli and Vale Colege 2015 Allright reserved separb6.omCHAPTER THREE TOOLS Precautions Due to the lever action of the hinged arms, che jaws are only truly parallel in one position so care is needed not to cause damage to work by applying too much point pressure. Toolmaker’s Clamp Description ‘The toolmaker’s clamp consists of two parallel jaws that are opened or closed by two screws. Final tightening is achieved by adjusting the captive screw and then the second screw. The grip of this type of clamp is parallel throughout its range of movement. Materials ‘The jaws are made of case hardened mild steel. Classification Toolmaker’s clamps are classified by the length of the jaws. Use They are used for holding small items of work together for drilling, riveting etc. Pliers Description Pliess are supplied in a variety of sizes and configurations. The most common type of pliers is the combination type. These have both serrated flat jaws and serrated curved jaws for gripping work. They are also equipped with side cutters and joint cutters, making them useful for cutting locking wire and trimming split pins for example. They are often equipped with thick electrical insulation on the handles. Other common configurations include: long flat-nosed, round-nosed and snipe-nosed pliers. The illustration shows diagonal cutting pliers or ‘snips’ and end cutting ‘nippers’. There are a few other configurations of pliers and these are described under their specific names. Slip-Joint Pliers Slip joint pliers get their name because of the two connected pivot holes that are provided to permit the jaws to have two opening ranges. This allows a wider range of material thickness to be gripped. 98 Copyright © Candi and Vale Catge 2015 Allright reserved wu: part66.comCHAPTER THREE Tools U Ss J Flat Nosed Side Cutters Round Nosed Snipe Nosed Cutting, Figure 3.3 - Pliers Vice-Grip Pliers (Mole grips) Vice grip pliers have an adjustable range of jaw openings that may be set be turning a knurled adjusting screw. They have an over-locking action that lock: % the jaws in position when the handles are squeezed together. There is a release’, lever provided to break the lock and release the grip when required. These plicrs are often referred to as ‘grips’ and they have the capacity to apply very high forces onto the serrated jaws. Because of the high leverage that can be applied, these pliers should not be misused. s ne any pe Interlocking Joint Pliers Figure 3.4 - Other Plier Configurations 99 Copyright © Cardi and Vale Callege 2015. Al rights seed wmipart66.comTOOLS Interlocking Joint Pliers Interlocking joint pliers have a number of different pivot positions that offer a range of jaw opening widths. They normally have long handles to produce very high grip forces. They can have flat or curved, serrated jaws. Again, care should be exercised in the use of these pliers to avoid damaging work through the high grip force. Wire-locking Pliers ‘These diagonal cutting pliers have flat, serrated jaws and are equipped with locking handles and a twisting screw mechanism designed to spin the pliers and so deliver a owist to locking wire. Many organisations now prohibit the use of these pliers because they tend to oversteain the locking wire. Circlip Pliers ‘These are equipped with peg fittings on the nose of each arm that are designed to fit the holes in a spring circlip. They can be used for inserting and removing internal and external circlips. Figure 3.5 - Circlip Pliers Materials Pliers are normally made of high-carbon steel with hardened and tempered jaws Classification Pliers are classified by type and overall length, Use Uses for pliers are dependent on the type. Precautions A hazard with most pliers is trapping the skin on the hand between the flat surfaces beneath the pivot point when the pliers are levered shut. Care should 100 Cpyright © Carkif end Vale Colige 2015 AM ighs svcd son part66.omCHAPTER THREE Toots be taken to avoid doing this as it can cause painful injuries, particularly if the pliers slip off the work and close up suddenly. Pliers should never be used on pipe unions, nuts or bolt heads as a substitute for a spanner. They will round off the hexagon heads and can slip, creating a high probability of skinned knuckles. Great care should be taken not to misuse slip-joint type pliers and vice-grip pliers. The high grip forces can easily overload and damage items Cutting & Shaping Tools Steel Hammers Description The most common types of steel hammer are the ball pein, cross pein and straight pein. The ‘pein’ is the end of the head opposite the striking face. The head is normally fitted onto a handle that is expanded in the head with a ‘wedge. The weights of the heads vary from a few ounces up to 3lb. ‘There is a specially designed bodywork hammer for removing dents and smoothing sheet metal. The head is light and has large, smooth, flat striking faces. This type of hammer is sometimes referred 10 as a Claw: & ad hammers are not normally used for aircraft work. They have a5 slightly convex striking face and a claw attachment, designed to extract nails, in place of the opposite face. The striking face is harder chan other hammers and is designed for driving nails. It is prone to chipping if used for other tasks involving harder materials. Cross Pain Figure 3.6 - Steel Hammers Materials ‘The heads of stcel hammers are forged from high carbon steel and the working faces are hardened and tempered. The wooden handles are normally made from straight-grained ash that is free from knots, Others materials, such as steel or fibreglass, may be used to construct the handles. 101 Copyright © Cardiff and Vale Colege 2015 All rights nsered vw part66.c0mCHAPTER THREE Toous Classification Steel hammers are classified by the type and weight of the head. Use The curved surface of the ball pein head is used primarily for riveting, whilst the flat surface is used for general work. The cross and straight pein ends of the head are used for work where access is limited. Hammers should always be held close to the free end of the shaft so that proper control can be exercised, and a harder blow can be achieved for minimum effort. Precautions It is important to check that the head is firmly attached to the shaft, and that the shaft is not split. Do not use a hammer if the wedge is missing or loose. The correct weight head should always be chosen for a task. For example, “4 and Yalb heads would be suitable for striking centre punches. IIb heads would be suited to driving pins, 2Ib heads would be suited to striking metal cutting chisels, and 31b heads would be reserved for heavier work. Soft-faced Hammers Description ‘There ate several types of soft-faced hammer. They have heads with identical flat striking faces that are attached to wooden shafis in a similar fashion to steel hammers. Nylon and hide-faced hammers have pads affixed to the striking faces of metal heads, whereas other types have heads constructed wholly from a chosen material. Materials Hide-faced hammers have renewable, rawhide pads affixed to the striking ends of a metal head. Nylon-faced hammers have renewable, nylon pads affixed to the striking ends of a metal head. Other soft hammers have heads constructed wholly from a choice of Classification Soft-faced hammers are classified by che material and weight of the head. For example, a 4lb lead hammer. 102 Copyright © Cantif and Vale Callge 2015 All rights reserved anmpart66.comCHAPTER THREE roo.s Hide Faced Lead or Copper Figure 3.7 - Soft Faced Hammers Use Soft-faced hammers are used ‘marks, Again, hammers should be held close to the free end of the shaft to exercise control, and achieve a harder blow for minimum effort. Precautions e 3 Again, itis important to check that the head is firmly attached to the shaft, and: that the shaft is not split. Do not use a hammer if the wedge is loose or & mising t Soft metal heads carry a tisk of metal chips and flakes falling off the striking E ends tnd extering che vor. CS oe. SSS MERIPEPRPSTER Care dao be taken v0 i only use these types of hammer where itis appropriate to do so. i rs Chisels Description There are four common shapes of metal cutting chisel point: flat, cross-cut, on pol: dha su. "There is inathen jpecll eitgeteon called Materials cutting edges of high carbon steel chisels are hardened and tempered w! rest is left soft and tough. Nickel alloy chisels are speciall GERERNGSREEBEAES The coring sc id ag aoe a dees ‘on the material to be cut for exampl 103 Copyright © Cardiff and Vale Callige 2015 AU rights reseed sm: part66.comCHAPTER THREE Convex Edge Flat Cross Cut ———S Half Round Diamond Point Figure 3.8 - Chisels Classification ent cing ic cased bythe Spee eg pe and Uses Chisels must be used in conjunction with steel head hammers. They are used for cutting and chipping mecals that are softer than the material of the chisel. Particular uses associated with each configuration of cutting edge are: Flat ‘The flat chisel has a slightly convex cutting edge. Tis wed for general in readiness for filing. Cross-Cut The cross-cut chisel is ‘sed For cutting narrow, fat bottomed grooves, like keyways. Diamond Point Diamond point chisels are probably best known for their use in correcting They are used mainly for cutting oil grooves and are particularly 104 Copyright © Cardiff and Vake College 2015. AM rights rsered wm part66.c0m aor " “ae. so 103 aan poe s3v*2 >CHAPTER THREE Too.s Half-Round Half-round chisels are also known for their tise in correcting drill starts. They are primarily used for cutting grooves. Single Bevel Single bevel chisels are ‘used for cutting the heads off rivets after they have ‘been diilled through. The nasrow cutting edge is well suited to this task in that ‘it does not interfere with the surrounding metal, Precautions It is dangerous to use a chisel that has developed @ ‘mushroomed’ impact head because it can split and chips can fly offit. The head should be reground. Nickel alloy chisels undergo a special heat treatment process during ceanufscrce and chy Ee ee A chisel should be held firmly with one hand and struck squarely on the head with a steel hammer. Hacksaws % ‘A hacksaw may consist of a fixed frame, or @ frame that can be adjusted to accept different lengths of replaceable, flexible saw blade. A hole at each end of the blade fits over a sliding pin mounting on the adjacent end of the hacksaw frame. The blade is always mounted in the frame with its cutting teeth away ftom the frame handle. One of the pin mountings incorporates a screwed adjustment fitting that is used to tension the blade.< Many makes of hacksaw have pin mountings that can be repositioned so that the blade can be mounted at right angles to the frame if so desired. Depending on their make, hacksaw frames may have either a wooden handle or a shaped metal handgrip. % Description ® Flexible blades are supplied in a range of cuts that vary from a coarse cut, at 14 teeth per inch, to a fine cut, at 32 teeth per inch. The number teeth per inch is often referred to as being the pith? ofthe blade, The teeth of hacksaw blades are alternately offset either side of the plane of the blade to provide a clearance for the non-cutting part of the Dade, ESAS on it produces a cut that is wider than the blade plain portion to reduce sawing effort and prevent jamming. Typical blade lengths are 8in, 10in and 12in but there is also a range of blades available for miniature hacksaws. 105 Copright © Cari and Vale Coleg 2015. Al rights resernd um partbb.comCHAPTER THREE Toots Figure 3.9 - Hacksaw Materials ‘The hacksaw frame is normally made from mild steel that incorporates either a wooden or metal handle. There are two types of © (Hlexible:"The teeth are hardened and the back of the blade is annealed. “This type of construction is less brittle and the blades are not so prone to snapping under heavy loads. Suit less skilled operatives. © All Hard: Hardened throughout. These blades retain their sharpness longer but are brittle and will snap if subjected to heavy loads. Suit more experienced operatives. Classification Hacksaw blades are classified by the length between their attachment hole outer «ss Canin eacee PGMS Use The hacksaw should ‘The cutting strokes should be limited to between 40 to 50 strokes per minute and as much of the blade length as possible should be used to avoid overheating, dulling of the teeth, uneven went end ftactore, AEGIS ea re Tea GGERRESUEUGUSERHIMID coc che sare seasons. When curing tice mer, the lower mate would be considered to be more appropriate. The saw should be 106 Copyright © Can ond Vale Collge 2015 All rights reserved empart66.comCHAPTER THREE Tools Flexible blades with fine teeth, for example 22 ~ 32 teeth per inch, are better suited for cutting thin walled tubing and thin sheet metal because coarser teeth tend to straddle the material and break or jam. When using fine teeth on thin material chere will be several teeth in contact with the material and the cutting will be much more effective. As a guide, there should be at least three teeth in contact with the material surface at any one time. In the case of thin-walled tubing, that is interpreted as three teeth in contact with each wall of the tube. You sometimes see this as interpreted as at least two teeth in contact at any time depending on which publication you pick up. Three seems to be the more ‘generally accepted value in exam questions. All-hard blades with coarse teeth, for example 14 — 18 teeth per inch, are better suited for cutting thick materials because finer teeth tend to clog up with material and then not cut effectively. Soft metals, such as brass and aluminium, should be cut with coarse toothed blades to avoid the teeth clogging with the cut material, Hard metals, such as iron and steel, should be cut with fine- toothed blades, for example 32 teeth per inch. The choice of blade is a matter of experience. The guideline is to select fine-toothed blades for thin or hard materials and select coarse-toothed blades for thick or soft materials. Precautions © Choose the right blade for the task * Ensure the blade is correctly fitted, with the teeth facing forward, and correctly tensioned to avoid buckling in use. % % * Always cut on the forward stroke and do not overload the blade. g * Always maintain long steady cutting strokes (40 to 50 per minute). £ 2 5 ? Files ¢ Description A file consists of a blade that carries cutting teeth and a ‘tang’ that is designed to fit into a wooden handle. Files are supplied in a variety of lengths, cross- sections, cuts and grades. These are described in the paragraph on classification given below. Materials Files are made from high carbon steel. The blade of the file is hardened whilst the ‘tang’ is left soft to give it a degree of flexibility in the handle to prevent it snapping, File handles are normally made of wood and are equipped with a steel ferrule at the forward end to resist any tendency for the wood to split. ‘The handle is firmly fitted over the ‘tang’ of the file. 107 Copyright © Cardiff and Vale College 2015 All rights reseed swn:part66.comCHAPTER THREE Too.s Classification &Use Files are classified by their main features. These are: Tength, cross-section, ‘Begin tape ale Files are designed to cut on the forward ‘the rearward stroke, Length The length of a file is the distance ‘Blade, Files are available in a range of sizes from 3in to 14in. Wood Handle Shoulder © Figure 3.10 - Files g i Section & Shape There is a range of available file sections and shapes, these include: 1. Flat: A very common section that is tised for general filing work. The normally rectangular throughout the blade length but there are variations in shape, such as straight, tapered or ‘bellied’ blades. Some flat files are produced cn BE GREASE ‘SESS nah ERED Gg RENE for example. These files are referred to as ‘hand safe edge (HSB) files. The safe edge of the file is placed against the finished surface. 2. Half-Round: This cross-section is suited for filing large tadii and ‘ittegular shaped surfaces. The blade width is normally curved or “bellied” towards the tip but parallel width versions are also available. 3. Three-Square: The triangular cross-section is useful for filing internal: SESE EET UIGMESUURETD Te blace wih ic normally curved or ‘bellied’ towards the tip. 108 Copyright © Cardiff and Vale College 2015 Al rights reserved wom part6b.comCHAPTER THREE roo.s 4, Square: A square cross-section that can be supplied in pacallel, straight taper or ‘bellied’ shape. This type of file is 5, Round: A citcular cross-section that is Suited FOP fling Small Hidi/and ‘holes, It is sometimes called a ‘tat-tail’ file. Tt is supplied in parallel, straight taper and, more commonly, ‘bellied’ shape. 6. Knife: Knife files have a blade thickness that is tapered to give one sharp edge. They may also have a tapered width. They are primarily Cur The teeth on a file are atranged in particular patterns to suit work on different materials. The most common examples are: Double Cut Figure 3.11 - Types of Cut ot? 1. Single-Cut: This arrangement consists of weth that are cut in a series of parallel grooves that slant across the face of the blade. The pitch of the teeth is relatively broad so that si eh pac do ay when s Double-Cut: This arrangement consists of wo sets of single €ut teeth eALERTS STOTT This Be of cut is well suited to ae ferrous materials such as mild steel. 3. Dreadnought: This arrangement consists of deep, curved, parallel teeth cut across the width of the blade and it is normally only found on Ig se fs "(hide ER ETT ESTETSROAD 4. Rasp: This arrangement consists of a pattern of individual teeth and is suited for ROR, for rape, SED "0 apa pox 99 109 Copyright © Carkiff and Val College 2015 All rights reserved mipar66.comCHAPTER THREE TooLs. Grade ‘The grade of a file relates co depth and spacing of its teeth. Single and double- cut files are produced with different degrees or ‘grades’ of coarseness. These grades are given descriptive titles as follows: 1, Bastard: This is the coarsest grade and is designed specifically to ‘femove material quickly, It is often used to rough out a shape before moving on to use finer grade files. [eleaves a tough finish. 2. Second-Cut: This grade is finer and cuts at a relatively slower rate. It ‘produces a smooth finish and may be the final choice of grade where ‘this is acceptable. 3, Smooth: As the name implies, the teeth have a shallow depth and are closely set. This grade of file is used to produce very smooth finishes. It is cuts very slowly so it is normally reserved for final surface finishing work only. ‘This stops the file picking up metal chips that could scratch the surface. Using a File The ball of one hand is placed on top of the free end of the file and is used to apply pressure and direct the file. The handle of the file is gripped between the thumb and forefinger of the other hand. Keeping the handle in line with the wrist, the remaining three fingers are used to press the handle into the palm of After filing in one direction, the direction is then changed to strokes that are at right angles to the previous direction, FH open pu se? ‘finish, The file is drawn across the surface of the metal at right angles to the work, with equal downward pressure being applied by both hands. Chalk is sometimes applied to the teeth of a smooth file to produce a finer finish. Care of Files | File teeth become clogged with metal chips that will scratch surfaces. A ‘wire brush, or alternatively a called a should be used to clean the teeth. The 110 Copyright © Cardiff and Vale Clee 2015 AU rights nscmed upar66.0m oo ap,CHAPTER THREE roors © Pile blades are Weiylbfittlé and must never be stored in contact with each other and must not be exposed to impact from other tools Precautions When fitting a wooden handle to a file tang, you should tap the rounded end of the handle lightly on the bench to drive the tang in, not the tip of the blade. Care should be taken not to split the wooden handle of the file whilst doing this. Always use the correct size handle and ensure that it is a firm fit on the tang, ‘¢ Never use a handle that split or has its ferrule missing. Always select the correct file for the task. Ensure that the item being filed is firmly secured and use vice ‘clams’ if ina vice, Drills % Description 4 Drills are cutting tools designed to cut holes. The most common type is the spiral fluted twist drill. Other configurations of drill are specially designed to = cut non-metallic materials such as wood and composite: ‘of flat, arboring and dagger drills. We will take a brief look at each type: = ‘Twist Drill < The parts of a twist drill are: the shank, body, flutes, land, web and tip, Figure 3.12 - Twist Drill 111 Capyrighs © Cardiff and Vale College 2015. All rihts naerved nm par66.c0rtTOOLS parallel shank that is gripped in a self-centring chuck. Larger drills intended for use in fixed, power drilling machincs have a Morse” taper (Vin 20) shank and a flat driving tang designed to give a positive drive when fitted into a tapered socket. A fixed, power drilling machine has a chuck that is mounted in a tapered socket. When the chuck is removed, large drills may be fitted directly into the tapered socket of the machine, or they may need a ‘Morse’ taper adaptor that fits over the shank prior to inserting it into the machine. Extraction Drift (Wedge) Shank Taper 1 in 20 Adaptor Figure 3.13 - Morse Taper Adaptor 2. Body: The body of a drill is the Flite POHIOR and includes the deill ‘ point. %, 3. Flutes: These are the two spiral grooves that run along the body, % forming cutting edges at the tip that are angled to 2 ‘They also the F tip. f 4. Land: This is the surface of a drill body between the flutes. The land < The raised part of the land contacts the wall of the hole and guides the drill. The land duces a clearance a EE 5. Web: The part of a drill tip that is not involved in cutting. 6. Tip: If the cutting edges are not of equal length, or the point is not central, the drill will Garman anes 112 apyright © Cardi and Veale Colige 2015 AU right reserved svpart6. comCHAPTER THREE TooLs The tip of a twist drill is ground to form the angles that will produce an accurately drilled hole. The angles include: che GREATS 1 Gu le There are two cutting edges of equal length and the cutting angles are equal. The cutting angle most commo: adopted is 59° giving a total included point angle of 118° hough To give you a rough guide: the included angle for twist drills when drilling soft metals would be 90°, the included angle for drilling stainless steel at low speed would be 140° and the included angle for drilling titanium would be 105° to 120°. 2. Clearance Angle: The angle formed between the tip end of a flute and ‘the horizontal, The clearance If this angle is insufficient. 3, Web Angle: The angle formed between a cutting edge and the point of ‘a drill. There will be two web angles, each being 130°. Materials S a ‘Twist drills are manufactured from either high earbon steel (CS) or alloy steel. % Alloy steel drills are often referred to as ‘high speed steel’ (HSS) drills because of their ability to withstand the higher temperatures generated % cpenting them at higher drilling speeds. These alloys normally contain either a Some ‘high speed’ drills are tipped with rangsten carbide to maintain hardness at high temperature and to extend the life of the cutting = ald he oy a oa tg nk £ é ° Classification ‘Twist drills are classified by their diameter and the material they are made from. The size is normally marked on the shank of the drill together with letters indicating the material type, i.e. CS for carbon steel, HS ot HSS for ‘high speed steel’. Very small drill shanks do not have the room for size markings so a drill gauge has to be used, There are GHBBBBWith the onset of the metric system, many countries use metic sizes. America does not use the metric system. Drill size tables may be found in most engineers’ handbooks though many of them differ on the ranges of the fractional sizes so we will just examine typical examples. Fractional Sizes ‘These start at 1/64in dia, and increase in steps of 1/64in up to lin. From lin dia, they increase in steps of 1/32in up to 3.5in dia. 113 Copyright © Caniiff amd Vale College 2015 AU rights reserved sm part66.comCHAPTER THREE TOOLS ‘Numbered Sizes Lettered Metric Uses ‘The use of twist drills is well known but there are a few occasions where special requirements can arise. We will look at a few examples. Drilling Titanium ‘Titanium and its alloys have extreme work hardening properties and are reactive when in contact with other metals. They ce SORE SREETATEED and the tips of drills can become very hot when in contact with them. This can crs ing sng ‘hen this material is a machine = Note that Drilling Composite Materials Composite materials will blunt conventional drills quickly and this can cause the composite material to delaminate as the drill then pushes rather than cuts. described later in this section. Carbide drills ‘most types of composites. Diamond dust coated drills are effective on most composites except for tough fibre reinforced plastics like the aramid Kevlar where the dust grabs at the fibres and pulls them rather than cutting them. This creates ‘fuzzing’ in the drilled hole so diamond dust coated drills should be avoided. Especially ground, brad point carbide drills are supplied for deili, Kevlar that will cut the fibres rather than break them. eat should Be dalled at high speed with light pressure. 114 Copyright © Cardiff and Vale College 2015 A rights naened srvupar66.0m See, a ® toy area pox get FCHAPTER THREE Tools Carbon fibre and fibreglass materials can be drilled with conventional tools but these will blunt quickly. Carbide or diamond dust coated spade or dagger drills are more effective. Carbide dagger drills give the best results when drilling carbon/graphite fibre composites. High Tensile & Stainless Steels ‘High tensile aad stainless steels require very hard, shor, rigid dil. Tungsten ‘cobalt drills are well suited to this, If high carbon steel drills are used, the speed “must be kept low or the drill will simply overheat, ‘blue’ and blunt. Cutting Speeds Drills cut more efficiently when they are used at the correct speed. There are recommended (2ESSESSAEINMEEEMRED. As pens guide the euting speed fora Yin diameter carbon steel dil being used to dil ld sel is 4OOKPM with « feed of in per minute, When using different sized drills, the peripheral speed of the drill should be kept around the same so a {1/8in diameter dil vould be opetated at SOORPM snd 1 %4 in dil would be operated at 200RPM, However, these speeds would be doubled for brass. Lubricants We should not overlook the need for lubrication when drilling materials Lubricants cool the drill, improve the finish and extend the life of the drill, Typical lubrication requirements are: © Mild steel cutting oil of soda solution, or soap and water, © or oil and water . : © High carbon steel turpentine ot paraffin (kerosene) & © Alloy steel turpentine or paraffin (kerosene) 2 0 Gam aeraREg & © am emmER © Aluminium paraffin (kerosene) © Aluminium alloy paraffin (kerosene) © Titanium heavily chlorinated cutting oil Before we move on, it would be useful to look at a few other configurations of drill 115 Copyright © Cardiff and Vale College 2015 All rights resend ou pari66.comCHAPTER THREE Toots Flat Drill ‘The flat, or spade, drill has a very simple shape and has cutting angles that are related to the material it is used to cut. for very hard materials, up to 200° for soft materials like brass, The flat drill will not cut holes as accurately as a twist drill will but it is recommended for drilling composite materials. ) SD Flat (Spade) =