SHOP Power Tools

Use Power Tools/Hand
Held Operation
(MEM18.2B)
LEARNING RESOURCE
MANUFACTURING, ENGINEERING, CONSTRUCTION
AND TRANSPORT CURRICULUM CENTRE
Metal Fabrication and Welding
MEM18.2B/1
First Edition
Publishing details:
This published in June 2007 by
Manufacturing, Engineering, Construction and Transport Curriculum Centre
NSW TAFE Commission
Corner Showground and Green Roads, Castle Hill
Copyright details:
© Manufacturing, Engineering, Construction and Transport Curriculum Centre,
TAFE NSW, 2007
Copyright of this material is reserved to the Manufacturing, Engineering,
Construction and Transport Curriculum Centre, TAFE NSW. Reproduction or
transmittal in whole or part, other than for the purposes and subject to the
provision of the Copyright Act, is prohibited without the written authority of
Manufacturing, Engineering, Construction and Transport Curriculum Centre,
TAFE NSW.
Copyright acknowledgements:
MEC&T Curriculum Centre would like to acknowledge the assistance and
permission of the following companies for the use of copyright material:
x Silverwater Welding Supplies

x Hare & Forbes Pty Ltd
x Standards Association of Australia
Use Power Tools/Hand Held Operation MEM18.2B
ISBN 978-0-7348-2566-7
FEEDBACK
We value your opinion and welcome suggestions on how we could improve this
resource manual. Keep in mind that the manual is intended to help students
learn and is not a text book.
Send your comments and suggestions to:
Manufacturing, Engineering, Construction and Transport Curriculum Centre
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Contents
Introduction 1
Prerequisites 1
Assessment 1
Unit Purpose 1
Assessment Requirements 1
Unit Mapping 2
Recognition of Prior Learning (RPL) 3
Scope of Unit and Performance Criteria 4
5
Student Assessment Guide 6
Theory Lessons 8
Portable Power Tools 8

Introduction 8
Types of Portable Grinders 9
Angle Grinders 9
Die Grinder 9
Tungsten Carbide Burrs 10
Straight Grinder 11
Abrasive Consumables 11
Resinoid-Bonded Cut-Off Wheels 12
Industrial Wire Wheel Brushes 13
Flap Discs and Flap Wheels 13
Vitrified Grinding Products 14
Belt Grinding (Linishing) 15
Polishing Tools 15
Sticky Back and Velcro Discs 15
Pistol Drills 16
Saws 16
Nibblers 17
Power Hand Shears 17
Pneumatic Chipping Hammers 17
Power Screwdrivers 18
Pneumatic Wrenches 18
Holding Securing and Clamping Work 19
Care of Portable Power Tools 20
Care of Pneumatic (Air) Tools 20
Pneumatic Tools Safety 21
Grinding and Drilling Machinery 22
Off-Hand Grinding Machines 22

Bench and Pedestal Grinders 22
Tool Rest Adjustment 23
Inspection, Removal and Fitting of New Grinding Wheel 24
MEM18.2B Use Power Tools/Hand Held Operation i

First Edition –June 2007
© MEC&T Curriculum Centre, TAFE NSW
Contents
Inspection 24
Removal 24
Fitting of New Wheel 25
Tool Sharpening 26
Drilling Machines 27
Bench Drilling Machines 27
Column Drilling Machines 28
Radial Arm Drilling Machines 29
Routine Maintenance of Power Tools 30
Safety Checks 30
Electrical Tagging 30
Standard Operating Procedures (SOPs) 32
Safe Use of Power Tools and Machinery 32
Stance 34
Cutting Tools 34
House Keeping 35
Revision Questions – Use Power Tools/Hand Held Operation 36

37
38
Suggested Practical Exercises 39
40
Competency Worksheet 42
Work Method Statement – Job 1: Folded Lap Joint Using 0.9mm Gal Steel 43
Suggested Technique – Job 1 44
Suggested Technique – Job 1 Continued 45
Work Method Statement – Job 2: Folded Lap Joint Using Angle-3mm Plate 46
Work Method Statement – Job 3: Folding Camping Table 49
Work Method Statement – Job 4: Sash Clamp 52
Work Method Statement – Job 5: Drill Gauge 54
Appendix 56
Appendix A: Sample Report Form for Abrasive Wheel Breakages

– AS 1782.2 – 1987 58
59
60
61
62
MEM18.2B Use Power Tools/Hand Held Operation ii

First Edition – June 2007
MEM18. 2B Use Power Tools/Hand Held Operation iii
Introduction
This unit identifies a range of skills and knowledge applicable to the use of power tool
operation and standard operating procedures for power tool usage. Graduates of this
unit will be able to make informed decisions on the selection and suitability of safety
procedures for a given task in a normal work environment.
Working accident free should be the primary objective of every member of the
workforce and in order to reinforce this important aspect NSW TAFE emphasises and
builds upon workplace safety and hazard reduction throughout all practical study
pathways.
This learning resource contains theory-based learning material and revision

questions. The resource is designed to assist students to achieve the outcomes
described in the national competency unit descriptor MEM18.2B Use Power
Tools/Hand Held Operation.
The topics listed in the content of this resource package are arranged in the preferred
learning sequence. It is acknowledged that this is not the only sequence in which the
material can be learnt and that sections of this resource can be integrated with other
learning material and supplemented with appropriate demonstrations.
Prerequisites
Before you commence this unit of competency you should have completed the
following competency unit(s).
x None required for this unit.
Co-requisites
MEM12.23B Perform Engineering Measurements, MEM18.1C Use Hand Tools
Assessment
To pass MEM18.2B Power Tools/Hand Held Operation you must pass a theory test
based on the information contained in this resource. Your teacher will provide you
with a Student Assessment Guide which explains the details of how you will be
assessed in this unit and how assessment results are recorded.
Unit Purpose
When you have achieved this unit of competency you will have developed the knowledge
and skills to use a range of hand held and fixed position power tools for a variety of
applications in mechanical engineering.
Assessment Requirements
To achieve this unit of competency, you will need to provide evidence of having achieved
each of the elements of this competency. These are as follows:
x Select power tools appropriate to the task requirements.

MEM18.2B Use Power Tools/Hand Held Operation 1
x Use power tools for a determined sequence of operations, which may include
clamping, alignment and adjustment to produce desired outcomes, to job
specifications which may include finish, size or shape.
x Adhere to all safety requirements before, during and after use.
x Identify and mark unsafe or faulty tools for repair before, during and after use
according to designated procedures.
x Undertake operational maintenance of tools, including hand sharpening, according to

standard operational procedures, principles and techniques.
x Store power tools safely and in appropriate location according to standard workshop
procedures and manufacturers recommendations.
Assessment for this unit of competency may require you to provide a range of evidence
which may include reports from your employer, written tests, assignments and practical
class exercises. The actual assessment details will be provided to you by your teacher.
Unit Mapping
MEM18.2B Power Tools/Hand Held Operation is a fabrication stream unit in the Metal
& Engineering Industry Training Package MEM05.
Power Tools/Hand Held Operation is a core unit in Certificate III in Engineering –

Fabrication, and is also a unit of study in Certificate I and II in Engineering, which
contain a group of fabrication and specialist units.
This unit is a prerequisite for a comprehensive range of fabrication stream units and
provides students with a basic understanding of safety responsibilities in workshop
and site situations.
A common pathway for training in Using Power Tools/Hand Held Operation would
include the following competency units:
MEM5.11C A1;MEM10.1C MEM10.10B

Assemble Erect Install Pipe
Fabrication Structures Work and
Components Pipe Work
Assemblies
MEM5.5B
Carry Out
Mechanical
Cutting
MEM12.23B MEM18.1C MEM18.2B

Perform Use Use Power
Engineering Hand Tools/Hand
Measurements Tools Held Operation

Recognition of prior learning (RPL)
TAFE NSW allows students to have their current units of study assessed against
previous studies, workplace skills performed or life experience. Your teacher can
provide you with details of TAFE NSW requirements for the recognition of previous
learning.

SCOPE OF UNIT AND PERFORMANCE CRITERIA
MEM18.2B Use of Power Tools/Hand Held Operation
The scope of this unit incorporates all theory content for completion of MEM18.2B Power
Tools/Hand Held Operation
Scope of Unit Addresses Unit Performance

Criteria
At the end of this unit you will be able to: 1.1 Select appropriate power tools
to job specifications.
Select and apply safe use of appropriate power
tools to job requirements and specifications
and carry out routine maintenance as well as
correct storage and identification of unsafe or
faulty power tools.
Portable power tool selection: 1.2 Use power tools to job

x Grinders. specifications.
x Drills.
x Saws.
x Hand shears.
x Nibblers.
x Other portable power tools.
x Offhand grinding.
x Drilling machines.
Power tool application:

x Metal removal.
x Cutting to size.
x Finishing to requirements.
x Tensioning.
x Assembling.
x Dismantling.
x Adjusting.
Safe use of power tools: 1.3 Safe use of power tools.

x Standard operating procedures.
x Personal protective equipment. 1.4 Unsafe or faulty power tools.
x Manufacturers’ recommendations and
instructions.
x Safe and correct use of power tools.
x Power sources.
x Cutting tools.
x Compressed air.
x Stance.
x Clamping/securing of workpiece.
x Sharp edges.
x Metal removal.
x Misuse of power tools.

Scope of Unit Addresses Unit Performance
Criteria
Routine maintenance of power tools: 1.5 Power tool maintenance.

x Cleaning and decontamination.
x Safety checks.
x Electrical tagging.
x Lubrication.
x Tightening and adjustment.
x Sharpening.
x Replacement of consumable parts.
x Minor repairs.
Storage of power tools: 1.6 Power tool storage.

xManufacturers’ recommendations.
xStandard operating procedures.
xLocation.
xAccessibility.
xSecurity.
xClimatic affects.

STUDENT ASSESSMENT GUIDE
Unit of competency
Power Tools/Hand Held Operation
name
Unit of competency
MEM18.2B
number
Unit Purpose
When you have achieved this unit of competency you will have developed the
knowledge and skills to use a range of hand held and fixed position power tools for a
variety of general engineering applications. MEM18.2B Power Tools/Hand Held
Operation is a fabrication stream unit of competency, designed to support your
ongoing skill development when undertaking more specialised metal and engineering
units.
Reporting of assessment outcomes
The assessment for this unit is ungraded and recorded as either competent or not yet
competent (UNGRADED). No marks are recorded centrally.
Your results will be reported as competent (AC) or not yet competent (NC).
All assessment events for this competency unit will be used to determine your result
and will be locally set and locally marked. (Grade Code 42)
Requirements to successfully complete this unit of competency
To successfully pass MEM18.2B Power Tools/Hand Held Operation you must show
competency in relation to the underpinning knowledge (the theory notes contained in
this unit).
You must pass a final assessment event at the completion of the unit.
Assessment Component Assessment Event Name Timing Wgt % Must

Pass
CLASS AC/NC-NO MARK KNOWLEDGE TEST 1 End of Event 30 YES
KNOWLEDGE TEST 2 End of Event 30 YES
SKILLS TEST 3 End of Event 40 YES

Assessment Events - Additional Information
Event Name: THEORY TEST

Types of items: Theory
Topics covered: Safe Use of Power Tools, Portable Power Tool selection, Power Tool
Uses, Unsafe or Faulty Power Tools, Power Tool Maintenance, and
Power Tool Storage.
Duration: 3 X 20 min assessments (1 hour in total)

Timing: At the end of each event
Conditions: No references or other aids permitted.
Event Name: SKILLS TEST

Types of items: Practical
Topics covered: Portable Grinders, Consumable Identification,
Fitting Replacement Discs, Off-Hand Grinding Machines,
Consumable Identification, Grade and Type, Wheel Inspection, Ring
Testing the Wheel, Wheel Selection, Wheel Replacement, Re-
Setting the Work Rest, Tool Sharpening, and Drilling Angle Bracket.
What you will need
You must provide and wear the following personal protective equipment (PPE), which
must comply with current Australian Standards, in ALL workshop areas and for all
practical demonstrations or practical tasks:
x Clear safety glasses

x Grinding goggles or face shield *
x Safety capped shoes / boots with leather upper and rubber soles
x Close fitting overalls, or heavy drill cotton shirt and trousers
* For specific tasks.
More about assessment
For information about assessment in TAFE please see "Every Student's Guide to
Assessment in TAFE NSW" which is available on the TAFE internet site at:
http://www.tafensw.edu.au/courses/about/assessment_guide.htm

THEORY LESSONS
Portable Power Tools
Introduction
Portable hand-held power tools are popular amongst workers in the engineering and
metals industries. Due to their availability, design, cost and efficiency, many tasks
can be completed quickly using hand-held power tools.
There is a wide range of hand-held power tools used in industry today. Typical power
tools found in engineering workshops and construction sites include:
x Angle grinders.
x Pistol drills.
x Hammer drills.
x Power Hand shears.
x Nibblers.
x Saws and Jigsaws.
Portable power tools can be operated using three types of power sources, they can
be:
x Electrically operated.
x Pneumatically operated.
x Battery operated.
The most common power tools are electric, however; battery operated powered tools
are gaining popularity, especially for pistol drills. Pneumatically powered tools can be
lightweight for the user but require an air compressor for their operation.
Types of Portable Grinders
Three types of portable grinders are:
x Angle grinder.
x Die grinder.
x Straight grinder.

Angle Grinders
Hand operated powered angle grinders are used to grind work where it is easier to
take the grinder to the job rather than the job to the grinder. These tools are
commonly used by welding operators to remove weld defects due to their portability
and ease of operation. Unlike the larger fixed bench and pedestal grinding machines,
hand held angle grinders have an adjustable guard to assist in streaming sparks and
particles away from the operator and the work. These units have a side-handle which
can be located on either the left or right hand side of the machine to suit the
operator’s needs. Also there is a myriad of purpose designed cutting and grinding
discs to suit the work and material and should only be used in accordance with the
manufacturer’s specifications.
Figure 1: Electric Angle Grinder (100mm) Figure 2: Electric Angle Grinder (230mm)
Die Grinders
When selecting a die grinder it is important to consider its intended use, the
attachments to be used and the amount of time that will be spent grinding down
materials i.e. thickness of area. Therefore, an incorrectly used die grinder will more
than likely wear out quickly from unnecessary overuse.
Figure 3: Pneumatic (Air) Die Grinder with Burring Tool

Typically this tool is used to remove small metal spurs or rag that often results where
a cut has been made in metal pipe or tubing and is also used to deburr, polish and/or
buff the inside of cylindrical sections. A cylindrical grinding/polishing attachment
known as a grinding nose is selected by the operator for the task and fitted to the die
grinder in a similar fashion to that of a drill bit.
Rotary Burrs
Rotary burring (cutting) tools can be used on a wide range of pneumatic and electric
hands held grinding tools are designed for:
x Fast freehand stock removal

x Weld preparation and surface removal
x Dressing of welds
x High durability
Figure 4: Selection of Rotary Burring Tools
To achieve optimum performance of the tool it may be necessary to adjust the rate of
speed of rotation of the burr, for instance if the speed of rotation is below the cutting
tool’s optimum speed it may cause chipping. Harder metals and extra long burrs will
require slower speeds. Running the tool at excessive speed will cause tooth wear and
caution should be used to avoid tool from becoming too hot. Should the braze weld
holding the head of the shank become too heated it could loosen, causing the head to
detach. An operator should always apply constant light pressure and movement and
during use of the tool and not use collets that are worn as this will encourage
chipping of the workpiece.
Burrs can be used to grind and finish the many different types of metals, such as:
x Aluminium, Brass, Copper and Zinc Alloys
x Titanium Alloys, Cast Iron, Alloy Steel, Bronze, Nickels and Stainless Steels

Straight Grinder
The straight or barrel grinder is ideal for grinding steel pipe and tube and also buffing
and polishing applications in stainless steel and aluminium using a combination of rag
and sisal mops.
Figure 6: Electric Straight Grinder
Abrasive Consumables
A range of abrasive consumables such as grinding discs, cut-off wheels, sand papers
and sanding discs are commonly available as well as the products listed below:
- Resinoid-bonded cut-off wheels
- Industrial wire brushes
- Flap discs and Flap wheels
- Vitrified grinding products
- Rotary burrs
- Abrasive belts
- Polishing tools
- Sticky back discs
Figure 7: Selection of Abrasives

Angle grinders fitted with abrasive cut-off wheels can be used to cut bar, tube and
plate. The thin cut-off wheels are designed to suit either a depressed or flush centre
mounting and are generally made from Carborundum. The main applications of these
cut-off wheels include:
x Thin-walled tube.
x Sheet metal items made of steel and stainless steel.
x Nonferrous metals.
x Composite materials.
Resinoid-Bonded Cut-Off Wheels
These wheels are designed for use with hand held grinding machines and are
generally suitable for use with a variety of metals and cutting applications, such
as normal steel pipe, steel bar, steel plate but should not be used on non-ferrous
metals. The wheels are fibreglass re-enforced for strength and are required to run at
speeds of up to 80 m/s (metres per second). Manufacturers’ recommend a wheel
thickness in the range of 2 - 3.2mm for cutting and depressed centre wheels with a
thickness of 4-10mm for grinding.
Figure 8: Abrasive cut-off wheels
Reinforced cutting and grinding discs are generally made of corundum (aluminium
oxide), and have a medium to hard bond and are less brittle than vitrified wheels.
They are also typically flat and are coloured black but are available in a raised hub
variety. These discs can also include the following materials:
Aluminium Oxide White Aluminium Oxide
Single Crystal Aluminium Zirconia Aluminium
Green Silicon Carbide Black Silicon Carbide

Industrial Wire Wheel Brushes
Specially designed wire brushes can also be fitted to angle grinders. These brushes
are used to clean metal surfaces prior to priming or painting.
Figure 9: Wire wheel brushes for angle grinders Figure 10: Wire cup wheel for angle grinders
Flap Discs and Flap Wheels
The flap disc surface is made up of flat

overlapping sections and is designed to
include roughing to smoothing tasks for either
surface or edge grinding. This disc can be
used for cleaning weld seams and spot welds
on most metal types, such as stainless steel,
steel, cast metals, non-ferrous metals,
aluminium, etc.
The benefits of this disc type include:
x Reduced decibel noise levels as compared

to other types of cutting and grinding
discs i.e. 10dB(A) Figure 11: Flap Disc for angle grinders
x No clogging or glazing of the disc
Figure 12: Side View of Flat Disc

Vitrified Grinding Products
Grinding Wheels used on bench, pedestal and low speed portable grinding machines
are available in; straight, cylinder, cup and dish forms. Abrasives commonly used in
these grinding wheels are usually composed of aluminium oxide, zirconia and silicon
carbide and these are known as the vitreous and rubber-bonded or bakelite-bonded
types. Each of the above identified abrasive media has different characteristics and
produce different finishing results. For each grit size, an abrasive medium will
produce a different result from other medium types. Grit sizes range typically from 20
(heavy removal of material) to 36 grades for coarse cutting (For rough grinding) and
46 for (Medium) general purpose grinding to achieve acceptable finish up to 60/80 for
(Fine) finishing operations.
It should be noted that the surface speeds for solid wheels generally run around 1500
to 2000 metres per minute. Extreme care should be taken as debris could be thrown
out at high velocity making eye protection essential whilst working with off-hand
grinding machines.
Grinding wheels are manufactured in a wide variety of

standard dimensions and grit sizes which include:
x Diameters: 25, 50, 75, 100, 125, 150, 175, 200,

250, 300 and 350mm.
x Thickness: 6.25, 12.5, 18, 25, 32, 37.5 and
50mm.
x Hole Size: 6.25, 12.5, 18, 25, 32, and 37.5mm.
Figure 13: Vitreous and Rubber-Bonded Type Grinding Wheels - Coarse to Fine Grit comply with ANSI Safety Code B7.1.

Belt Grinding (Linishing)
Figure 14: Pneumatic Hand Linisher or Belt Grinder
Belts carrying abrasives of various grit sizes are

widely used for grinding and polishing of various
metal surfaces. They are commercially available in
many widths ranging from those used for the
grinding of wide sheet down to narrow sizes for
working on relatively small parts.
Figure 15: Electric Hand

Linisher or Belt Grinder
Polishing Tools
In finishing or polishing, the difference between fine

grinding and polishing is not always clear as both
processes involve metal removal. Where the metal is
removed rapidly it is considered as grinding and generally
employs coarser grits i.e. 80. Where the emphasis is
applied to attaining smoothness it is classed as polishing
and as a rule will apply finer grits.
Sticky Back and Velcro Discs
Figure 16: Velcro and Sticky Back Discs Figure 17: Pneumatic Sander
with Velcro attachment Pad

Pistol Drills
Pistol drills vary in drill size capacity and purpose.

When drilling larger sized holes a side or auxiliary
handle can be clamped to the machine near the chuck
for stability.
Some machines are single speed only; some are two

speeds; whereas others have variable speeds.
Figure 18: Cordless pistol drill
Hammer drills have an internal hammering action

that when activated increases the speed of
drilling holes in concrete and brick.
Angle head drilling machines allow holes to be

drilled in confined spaces.
Note: Wear hearing protection when using this

type of machine as typical A-weighted noise
levels of this type of machine are: sound
pressure level approximately 86 db (A) as determined according Figure 19: Hammer drill
to EN 60745.
Saws
Jig saws and sabre saws, (all purpose); use a reciprocating action to move the blade.
The blade must be suitable for the material being
cut and should be changed to accommodate a
different type of material. For example, fabricators
may use saws and jigsaws to cut metal shapes from
aluminium sheet and plate.
Figure 20: Jig Saw
Figure 22: Metal Jig Saw Blade
Figure 21: Sabre saw
Fabricators also use woodworking circular saws which can utilise a metal cutting blade
or disc to cut metals such as Aluminium.

Nibblers
Used to cut sheet metal, nibblers have an up

and down cutting action which removes a small
quarter moon or “c” shaped piece of material
with each down stoke. They do not normally
distort the material being cut.
Figure 23: Power hand nibbler
Power Hand Shears
This machine uses the same cutting

action as a pair of scissors or bench
shears. Power hand shears generally
cut neatly and quickly but can
distort the metal being cut. The
compactness and portability of these
shears can assist sheetmetal
workers and fabricators where large
cut-outs are required.
Figure 24: Power hand shears
Other hand-held power tools used in mechanical engineering, metal fabrication and
welding include:
x Pneumatic Chipping hammers.
x Power Screwdrivers.
x Pneumatic Wrenches.
Pneumatic Chipping Hammers
Pneumatic chipping hammers and scalers give a straight hammering action without
rotary motion. They are used to remove weld slag and clean castings and masonry
surfaces.

Power Screwdrivers
Specific purpose power screwdrivers or standard drilling machines with screw driving
bits are available in corded or the more popular cordless varieties and are used to
tighten and/or loosen all types of screws. Power screwdrivers are generally variable in
speed and torque. An operator should understand the term ‘Torque’ as it is often
misunderstood. Generally speaking the term torque is the amount of power supplied
to the chuck. For instance, if the revolutions per minute (RPM) or speed is slow; then
the chuck will also turn slowly. However; the torque will be high, meaning that the
chuck turns with extreme force. Torque setting can generally be adjusted by turning a
dial (see figure 25) preferably to a low setting. High torque settings can cause over
tightening of screws and cause damage to the screw and also cause drill bits to break
off during a drilling operation.
Figure 25: Cordless Power Screw Driver
Power screw drivers are generally fitted with self-locking chucks which do not
require a chuck key to tighten a bit into the barrel. They operate by the user simply
turning the chuck and the barrel by hand, in opposite directions which locks the bit
into position.
Pneumatic Wrenches
Impact wrenches are used to tighten or loosen nuts and bolts quickly. The tightening
torque can be adjusted to suit the application.
Figure 27: Pneumatic Wrench Socket

Tools and Extension Bar
Figure 26: Pneumatic Wrench

Holding, Securing and Clamping Work
Portable power tools are often used because the job or workpiece cannot be moved or
is too big and too heavy to be moved. In these cases, holding the job in place does
not pose a problem to the operator. However; when the work piece is small and light
it is likely that through the actions of cutting the job or workpiece will move. This
movement is dangerous and in such cases the job should be secured in one of the
following ways:
x Held in a vice.
x Clamped to a bench.
x Clamped to a large object.
x Secured so it can’t move.
In each of the above job securing situations the operator must make sure that the
clamping and cutting actions do not cause damage to the surfaces of the workpiece or
job.
Figure 28: Sheetmetal securely clamped to the edge of a bench by two Vice Grip Clamps to prevent vibration during jig
sawing.

Care of Portable Power Tools
Portable power tools used in engineering tasks can often be exposed to severe
environments. Metal particles and sparks from grinding as well as sparks from
welding and cutting are typical examples of how power tools can be damaged in daily
use in a workshop or construction environment.
To prolong the life of power tools apply the following procedures:
x Always inspect tools for damage before and after use.
x Tag damaged tools and report or repair them before they are used.
x Store tools and their leads in a way that prevents damage.
x Follow manufacturers’ instructions for the use of portable power tools.
x Replace power tools which are beyond economical repair.
Electrical power tools and extension leads are required to be inspected for compliance
and tagged by a qualified electrician before their use in workshops and construction
sites. Where portable electric power tools are used in conjunction with extension
leads to allow greater accessibility to the job or work, care should be exercised to
prevent exposed leads on the ground from becoming tripping hazards. Measures
should also be taken to prevent mobile machinery such as forklifts and trolleys
causing damage to the lead(s), and therefore
preventing a potential dangerous situation.
Care of Pneumatic (Air) Tools
Air contains foreign particles and moisture

which can damage tools. The amount of these
in compressed air can be reduced with the use
of filters. Also, air does not have any
lubrication properties and oil needs to be
added to compressed air to reduce wear in
pneumatic tools. This is done using a
lubricator.
Figure 29: Air service unit
Some air tools are made with a self lubricating material like Teflon in the bearing
surfaces and so don’t need a lubricant in the air supply. There are also some air tools
that have provision for lubrication to be added by an oil can and as a result don’t
need a lubricant to be added to the air supply.

Pneumatic tools do not need to run at maximum system pressure. This would cause
the tool to run at excessive speed or revolutions and would result in unnecessary
wear. To reduce and control pressure to the tool a regulator is fitted to the system.
When a system has a lubricator, filter and regulator all together it is known as an air
service unit.
PNEUMATIC TOOL SAFETY
Observe the following safety measures:
x Use eye and hearing protection devices when using pneumatic tools.
x Do not use an air hose that leaks air or has cuts or bulges.
x If a pneumatic tool leaks air, disconnect it immediately and inform your

supervisor or employer.
x Do not use a pneumatic tool that is missing fasteners or screws.
x Never use sockets intended for use with a hand wrench with an air impact
wrench.
x Never point a pneumatic fastening device at yourself or others. Treat the

device as you would a loaded firearm whenever it is connected to the air
supply. Always fire a pneumatic fastener into a work surface only, keeping the
hand which is not holding the tool away from the area being fastened.
x When clearing jams disconnect the tool from the air line.
x Disconnect the tool from the air line when you have finished using it.
Note: Only use an approved device intended for the purpose of providing
compressed air for the running of pneumatic tools i.e. air compressor.

Grinding and Drilling Machinery
Off-Hand Grinding Machines
There are two types of off-hand grinding machines:
x Bench.
x Pedestal.
Figure30: Bench grinder used for smaller applications
Bench and Pedestal Grinders
Bench grinders are used to grind small work and cutting tools. A bench grinder has
grinding wheels up to 200mm in diameter and approximately 25mm in thickness.
The floor or pedestal grinder is similar in

design, but is usually larger and of heavier
construction. The floor model has wheels of
around 300mm in diameter and a thickness
of 50mm.
These machines are usually double ended,

as illustrated above. This allows the
machine to be fitted with a roughing wheel
at one end and a finishing wheel at the
other. The grit of the roughing wheel is
larger and coarser than the grit of the
finishing wheel.
Figure 31: Pedestal grinders are used

for larger work

Because the wheel runs at a speed of approximately 1700 rpm/min there is some
danger of the wheel bursting. Therefore it is important that the wheel be enclosed in
a steel guard. Note: The machine is not to be operated without the guards being in
place.
Figure 32: Tool Rest Adjustment
Tool Rest Adjustment
At the front of each wheel there is a tool

or work rest which steadies and guides
the work whilst grinding. The tool or work
rest must be carefully adjusted so that
the space or gap between the work and
the wheel is very small i.e. between 1
and 2.0mm.
The machines are also fitted with a

toughened glass or plastic eye shield to
further protect the operator from flying
particles. An operator should not rely
upon these fittings for eye protection
alone and must wear suitable safety
glasses and goggles.

Removal, Inspection & Fitting of New Grinding Wheel
Removal
Floor, bench and hand grinders are designed

for tasks such as removing surplus metal
and smoothing metal surfaces. Off-hand
grinders are generally fitted with both a
coarse grain and finer grain abrasive wheels.
When there is a need to remove a
considerable quantity of metal it is often
more practical to grind with the coarse wheel
first and finish up with the fine wheel. With
continual grinding use of these wheels it will
become necessary for them to be replaced
as they wear and reduce in diameter (size).
Figure 33: Wheel guards

It will also be necessary to change and remove wheels when they show signs or have
been damaged.
According to AS 1788.2- 1987 only one competent person shall be assigned to the
mounting, care and inspection of abrasive grinding wheels and grinding machines.
It should be noted that when a grinding wheel breaks in service an investigation is to
be made by the user to ensure that any conditions that differ from requirements
contained in the above standard and state laws are corrected. A wheel Breakage
Report Form is provided in the standard to assist in preventing a reoccurrence of the
breakage see (Appendix A) P56.
Inspection
Inspection is necessary for both new and previously used wheels after unpacking or
removal from storage. As all abrasive wheels are breakable and it is essential that
care should be exercised during handling to prevent accidental dropping or bumping.
To ensure that wheels are free from damage a sound test should be conducted of the
wheel prior to fitting and this is known as a ring test. The test is conducted by gently
tapping the wheel with a non-metallic tool such as a screwdriver handle for light
wheels and a wooden mallet for heavier wheels. It should also be noted that organic-
bonded wheels do not produce the same sound during a ring test as vitrified and
silicate wheels. Usually a sound and undamaged wheel will give off a metallic ring and
a cracked wheel produce a dull sound with little or no ring.
In accordance with the code: The wheel shall be ‘tapped’ about 45 degrees each side
of the vertical centre line and about 25mm or 50mm from the periphery as indicated
by the spots in Fig. 5.2; the wheel shall then be rotated 45 degrees and the test
repeated (see Figure 34: Copy of Ring Test Procedure).

Figure 34: Copy of Ring Test Procedure - AS 1788.2-1987 Fig. 5.2
Fitting of New Wheel
Grinding wheels should be replaced when they show signs of visible cracks, severe
surface damage or are out of balance and cannot be corrected or salvaged through
dressing. The wheel selected for replacement must match the grinder’s RPM and be
properly sized for the spindle of the machine and have been stored vertically in a dry
room.
After carrying out the ring test on the wheel/s the assembly should be in a specific
order. First the wheel should be sandwiched between two blotters or compressible
washers (which serve as cushions) supplied by the manufacturer and two flanges of
the same size and be approximately one third of the wheels diameter. After placing
the washer against the flange on the threaded side of the spindle, the nut is securely
tightened. With the flanges fitting securely against the wheel on either side the force
from securing the nut is distributed across the surface of the flanges evenly on both
sides of the wheel, lessening any chance of the wheel from cracking.
With all guards and safety fittings restored the power to the unit can be turned back
on. The operator is to stand to one side of the unit as the machine is started and let it
run for several minutes to test that machine is satisfactory for further use.
Figure 35: Correctly Mounted Wheel

Tool Sharpening
Chisels, centre points, scribers and drills are commonly sharpened to extend their life
using an off-hand grinder. With use a drill will become blunt and will require
resharpening. Continued use of a blunt drill being forced into a metals surface will
overheat and burn the cutting end of the drill. The drill bit should never be placed into
water to be cooled should it become overheated as rapid cooling could cause the high
speed steel to crack.
When drills are to be resharpened a fine wheel should be first used. However, if the
bit requires a considerable amount of metal to be ground away due to damage a
coarse wheel should be used instead and the fine wheel be used for its final
completion.
Note: Never carry out grinding on the side of the wheel.
To hand sharpen a drill bit the following procedure can be employed:
1. Holding the drill shank with the right hand and its remainder with the left hand,
rest the fingers of your left hand against the tool rest for support. The tool rest
should be set at approximately 20mm below centre on a 150mm wheel of an
off-hand grinder.
2. Adjust your posture so you are standing so that the centre line of the drill bit is
at angle of approximately 60 degrees and gently place the lip of the drill bit
horizontally against the wheel (see Figure 36).
Figure: 36 Positioning of
Drill Bit for Resharpening
3. Pivot the shank with the left hand and slowly lower it to position with the right,
gently applying pressure until the heel is reached. Apply procedure to each lip
until the drill has been resharpened and the drill point during operation against
a drill point gauge (see Figure 37).
Figure: 37 Checking Drill Bit

Against a Drill Point Gauge

Drilling Machines
There are three broad categories of fixed position drilling machines:
x Bench.
x Column.
x Radial.
Bench Drilling Machines
Bench drilling machines are mounted on a bench or other types of stand and are
generally used for small work. The table can be swivelled and raised or lowered to
position or suit the work.
The speed of the drill is usually changed by moving the drive belt to a different set of
pulleys. The largest hole that can be drilled is normally 13mm or half inch is
dependent on the size of the chuck. The speed of the machine should be adjusted to
suit the drill bit size. Generally the larger the drill bit the slower the speed.
The work can be held by clamping or bolting to the work table or held firmly in a vice
on the work the table.
Note: Work must never be held by hand when drilling.
Figure 38: Bench Drilling Machine

Column Drilling Machines
Similar in design to the bench drill, the column drill has a longer column. The base of
the machine is secured to the floor.
This allows larger pieces of work to be drilled.
Holes up to 25 mm or 1 inch can be drilled as the machine spindle has provision for
tapered shank drills to be inserted.
Work is held in the same way as the bench drill and it can be secured to either the
work bench or the machine base.
Figure 39: Pillar /Column Drill

Radial Arm Drilling Machines
These drilling machines have a radial arm which swings around a vertical column and
mounted on the arm is a sliding drill head.
Drilling operations on several hole locations on the one workpiece can be rapidly
carried out on the radial drilling machine, since positioning the drill head takes less
time than shifting the workpiece for each hole operation.
These machines are available with radial arms from 600mm to 3600mm in length.
They are fitted with a wide range of speeds and feeds and are capable of carrying out
all the operations expected of a drilling machine.
Familiarisation of typical drilling machine’s features:
x Guards and emergency stop buttons.
x Speed control.
x Feed control.
x Work table adjustment.
x Machine capacity.
Figure 40: Radial Arm Drill Components

Routine Maintenance of Power Tools
Safety checks
An operator should look for general safety issues prior to using power tools and
equipment, for example:
x All safety devices fitted to a power tool and equipment are intact and in
working condition.
x Electric cords are in good repair.
x Electrical equipment tested regularly and tagged, if applicable.
x Air lines to pneumatic equipment are in good repair and condition.
x Power tool fittings and other attachments are securely mounted to avoid or
reduce noise and damage due to vibration.
x Cutting and punching tools are properly shaped and sharpened.
x Grinding wheels have been visually checked prior to use to ensure they have
not fractured during storage or previous use.
x Fastening parts on power tools such as bolts that are critical to safety are
secured sufficiently so that they will not vibrate loose during operation.
x Saw blades in good order prior to use.
x Safety devices and guards are in place on all power tools or equipment.
x Tools cleaned and adjusted properly if required.
x Extension cords in good condition and properly placed when in use (where
allowed).
x Power tool storage racks are structurally sound.
Electrical Tagging
A safe working environment is essential to all

operators whether working on-site or in a
workshop. Under duty of care for Occupational
Health & Safety (OH&S) in the work place,
employers or self employed persons must ensure all
electrical equipment of the plug in type is assessed
for risk periodically. All work places must also have
their portable electrical equipment and power tools
tested and tagged regularly to comply with the
current standards (AS/NZS 3760:2003). Figure 41: Plug in Type Electrical Equipment

The specific clauses of the OH&S Act 2003 which relate to testing and
tagging are as follows:
x Division 8 Clause 64 Electricity—particular risk control measures
(1) An employer must ensure that any risk of injury from electricity at a place of
work is eliminated or, if elimination is not reasonably practicable, the risk is
controlled.
(2) An employer must ensure that:
(a) Electrical installations at places of work
all electrical installations at a place of work are inspected and tested, after
they are installed and prior to their energising for normal use, by a
competent person to ensure they are safe for use, and
(a1) all electrical installations at a place of work are maintained by a

competent person to ensure they remain safe for use, and
(a2) Electrical articles used in construction work
all electrical articles that are used in construction work are regularly inspected,
tested and maintained by a competent person to ensure they are safe for use if
the articles are supplied with electricity through an electrical outlet socket, and
(a3) Electrical articles that may be affected by hostile environment
all electrical articles that are supplied with electricity through an electrical
outlet socket that are at a place of work where the safe operation of the
electrical article could be affected by a hostile operating environment are
regularly inspected, tested and maintained by a competent person to ensure
they are safe for use, and
(a4) Electrical installations and articles found to be unsafe
all electrical installations and electrical articles at a place of work that are found
to be unsafe are disconnected from the electricity supply and are repaired,
replaced or permanently removed from use, and
(3) In this clause, hostile operating environment means an operating

environment at a place of work where an electrical article is in its normal use
subjected to operating conditions that are likely to result in damage to the
article, and, for example, includes an operating environment that may:
(a) cause mechanical damage to the article, or
(b) expose the article to moisture, heat, vibration, corrosive substances or dust
that is likely to result in damage to the article.

Standard Operating Procedures (SOPs)
Standard Operating Procedures or SOPs are a written set of instructions that serve as
an explanation of steps in process that operators should follow to complete a job
safely without accident or injury.
SOPs should provide:
x All Occupational Health and Safety (OH&S) and operational machine

information necessary to perform a work task properly. SOPs also standardise
and specify job steps in production of the finished product.
x Consistent production operations and quality control of processes and products

by ensuring against process shut-downs caused by equipment failure or
accidents i.e. spills.
x SOPs ensure that approved procedures and compliance with government

regulations are satisfied.
x SOPs are used for providing a basis for standardised training for employees
that are new to a particular job skill and also for those who require re-training.
x The best practice (knowledge) that can serve new operators when others move
on providing a historical record of steps in an existing process or for revising
the steps and procedure when a process or equipment has changed.
Safe Use of Power Tools and Machinery
Portable power tools, grinding and drilling machinery are dangerous if used
incorrectly. These machines should only be used for the purpose intended and as
designed by the manufacturer and the manufacturers’ instructions should be followed
at all times.
Important safety considerations are:
x Make sure safety guards are fitted to power tools and machines and ensure that
they are never removed prior to use.
x Familiarise yourself with the machinery emergency stop buttons.
x Ensure the power tool is the appropriate one for the job.
x Do not exceed the safe working speed for the power tool or machine.

x personal protective equipment should include, where necessary:
- protective goggles
- gloves (not to be used with reciprocating equipment)
- ear protection
- protective clothing and footwear
- respirator or face mask
x Hold rotating spindles and wheels well away from your body and clothing.
x When using a grinder or drill take into consideration the torque of power tools.
Should a cutter, drill bit or grinding/cutting wheel get jammed in the work, an
operator could have their wrist twisted or be thrown off balance and sustain a fall.
Therefore it is necessary to hold power tools in the correct manner.
Other safety rules for this section:
x Avoid cutting or getting tangled in power supply leads/lines.
x Avoid breathing particles which may fill the air while you are grinding, drilling or
cutting - wear a dust mask.
x Check the condition of electrical cables prior to use.
x Don’t use electrical cables while they are rolled up.
x Don’t leave cables lying on the floor.
x Make sure an earth-leakage protection-device is fitted to the power supply.
x Electrical tools that are not double-insulated should have their resistance tested
regularly - and after repair.
x Disconnect leads before making adjustments to the power tool.
x Switch off power before removing cable from the power source.
x Do not use electrical tools in wet conditions.
x Be careful when you are using compressed air.
x Do not fool around with compressed air – it has the potential to cause serious
injury or death.
x Make sure the workpiece is clamped rigidly so it cannot move under the cutting
forces.

x Check the condition of all tools and power leads and fitted hoses i.e. pneumatic
tools, hydraulic etc.
x Do not use any faulty equipment - report it to the appropriate person for repair.
x Wipe/clean up any fluid spills from hydraulic equipment.
x Do not direct sparks and spatter on to electrical cables.
Stance
Keep your balance and proper footing when working with power tools, being careful
not to overreach. When you've finished with the tool, put it down or store it so that it
can't cause injury to another worker. Keep the work area well lit and clean. Cluttered
areas and benches invite accidents.
Cutting Tools
Before using a cutting power tool, verify that:
x All its fasteners (screws etc.) are in place.

x Machine is free of obvious damage.
x Guard operates properly and freely.
x Power cord is in good condition.
Always disconnect a power tool before changing a blade or drill bit.
Ensure that you have removed Allen keys, Chuck keys or Spanners before using a
power tool.
When using a tool that cuts, check the blade or bit for sharpness. Do not use a tool if
teeth are missing or it appears to be dull.
Never force a tool through the metal being cut or worked.
Prior to commencing any work check that you will not be overreaching and that the
power cord will be long enough to complete the task.
Never dangle a power tool by its cord.
Always unplug a tool from a power outlet by grasping the plug end. Never pull or
yank on the power cord to remove the plug from the socket.

HOUSEKEEPING
The radial arm drill and table are to remain clear at all times.
Return tools to their storage as soon as you are finished with them.
Wipe steel parts of tools with an oil rag when returning them.
Clean off portable electric tools thoroughly and tie off the cord before returning the
tool for storage.
Do not allow the accumulation of oily rags in piles as there a possibility of

spontaneous combustion or fire hazard.
Do not return damaged drill bits, blades and consumable cutting and grinding discs to
the store for re-use. Discard if damaged.
Prevent damage from dust contamination of the pneumatic tools and air hoses as well
as the plug end of extension cords by plugging together the ends of power cords and
air hoses before tying them off and returning them to their storage place.

Revision Questions
These questions will help you revise what you have learned in the theory notes.
1. List three items of protective clothing which you are required to wear when
using portable power tools.
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
2. When replacing a wheel or disk on a portable grinder, what steps should you
take to make the portable power tool safe to work on?
__________________________________________________________________
__________________________________________________________________
3. List two dangers that could occur should a portable drill jam in the workpiece.
__________________________________________________________________
__________________________________________________________________
4. Air (pneumatic) powered tools usually need lubrication. List two ways to do
this.
__________________________________________________________________
__________________________________________________________________
5. What is the name of the item placed in the air supply line to prevent and
remove water and dirt from entering into the air tool?
__________________________________________________________________
__________________________________________________________________

6. List three types of power sources which can be used to run portable hand
grinders and give an example of an application for each type.
________________________________________________________________
__________________________________________________________________
_________________________________________________________________
__________________________________________________________________
_________________________________________________________________
__________________________________________________________________
_________________________________________________________________
__________________________________________________________________
_________________________________________________________________
__________________________________________________________________
7. Give an example of an application or use for a metal cutting jigsaw.
__________________________________________________________________
__________________________________________________________________
8. Explain why it is important to make sure the workpiece is held securely when
using hand power tools.
__________________________________________________________________
__________________________________________________________________
9. Explain the difference between bench drills and column drills.
__________________________________________________________________
__________________________________________________________________

10. Explain why it is necessary that work be held in a vice or clamped instead of
being hand held when using a drilling machine.
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
11. State an advantage of having two wheels on either a pedestal or a bench

grinder.
__________________________________________________________________
12. Name the three power sources for portable power tools.
__________________________________________________________________
__________________________________________________________________
13. Explain how you would secure a small sheet metal job that had to be cut with a
jigsaw?
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
14. Describe three steps you should observe when placing portable power tools into
storage.
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
15. List two means to deal with a faulty portable power tool.
__________________________________________________________________
__________________________________________________________________

Suggested Practical Exercises
Note to Teachers:
The following series of SUGGESTED exercises and assessments, which if completed

to the standards specified will enable students to comply the practical requirements of
MEM18.2B Use Power Tools/Hand Held Operation. These exercises have been
designed for development of the knowledge and skills relating to this unit of
competency. However, not all jobs listed need to be completed to prove competency.
Teachers can alternatively develop and use practical exercises and assessments of
their own should they prefer.
It has been considered that this unit of competency would be delivered concurrently
with MEM18.1C, MEM5.5B as a cluster as well as with mandatory units such as
measurement. The suggested exercises may require a student to be provided with
instruction on all clustered units as well as any mandatory units in order to complete
each exercise.
Instruction and Demonstration
Your teacher will provide you with instruction and a demonstration for each practice
exercise and assessment exercise.
After a period of initial practice, exercises may be customised by your teacher to suit
your trade requirements, however it is suggested that all students should first
practise the exercises on heavy gauge steel plates.
Recording Results
Each practical exercise is illustrated on the WORK METHOD STATEMENT sheet and
your teacher will explain to you how the worksheet should be completed. Successful
completion will be recorded by your teacher. However, make sure your teacher
signs your worksheet as this will be your record of successful completion of the
practical exercise and or assessment.

Suggested Practical Exercises
Suggested
Suggested Practical Exercises Time
Portable Grinders: 3 Hours

1 x Consumable Identification i.e. Grinding and
Cutting Types
x Fitting Replacement Discs
Off-Hand Grinding Machines: 3 Hours

2 x Consumable Identification i.e. Grade and
Bond Type
x Wheel Inspection
x Ring Testing the Wheel
x Wheel Selection
x Wheel Replacement
x Resetting the Rest
Practice Exercise
3 Tool Sharpening: 3 Hours

x Drills
x Scribers
x Centre Punches
x Chisels
Practice Exercise
4 Drilling Projects i.e. Job1: Folded Sheetmetal Lap

Joint, Job 2: Folded Lap Joint Using Angle Bar and 2 Hours
3mm Plate, Job 3: Folding Sheetmetal Clamping
Table, Job 4: Sash Clamp
Assessment
Portable Grinding and Off-Hand Grinding Projects:

5 i.e. Job 1: Folded Sheetmetal Lap Joint, Job 2: 2 Hours
Folded Lap Joint Using Angle Bar and 3mm Plate,
Job 3: Folding Sheetmetal Clamping Table, Job 4:
Sash Clamp
Assessment
Assembling Projects i.e. Job 1: Folded Sheetmetal

Lap Joint, Job 2: Folded Lap Joint Using Angle Bar
6 and 3mm Plate, Job 3: Folding Sheetmetal Clamping 2 Hours
Table, Job 4: Sash Clamp
Assessment

COMPETENCY WORKSHEET
UNIT PERFORMANCE CRITERIA 1.5
Inspection, Removal, and Fitting of New Grinding Wheel
STUDENT PROCEDURE TASK: Teachers/Trainers must demonstrate to the student/s the correct method of Inspection, Removal & Fitting
of New Grinding Wheels and Discs prior to the student/s being assessed for this unit performance criteria 1.5
Identification of Fitting Identification Identification
Appropriate Replacement of Off-Hand of Off-Hand
Portable Cutting or Grinding Grinding
Grinders Grinding Machine Machine
Disc Disc Wheel Wheel
Inspect original disc for damage and determine type for

replacement
Suitable grinding/cutting disc selected for machine type.
Replacement disc/s visually inspected for damage
Old disc removed from grinder and spindle and machine
cleaned
Replacement disc/s ring tested
Replacement disc/s correctly fitted
Inspect original wheel for damage and determine type for
replacement
Suitable grinding wheel selected for machine type.
Replacement wheel visually inspected for damage
Old wheel removed from grinder and spindle and machine
cleaned
Replacement wheel ring tested
Replacement wheel correctly fitted
COMPETENCY
Competent = C Competent = C Competent = C
DEMONSTRATED Not Yet Competent = NYC Not Yet Competent = NYC Not Yet Competent = NYC
Competent = C
Not Yet Competent = NYC
Teacher’s Teacher’s Teacher’s Teacher’s

Initials Initials Initials Initials
MEM18.2B Use Power Tools/Hand Held 42

Work Method Statement
Skills Competency and Performance Criteria
Unit Title: Use Power Tools/Hand Held Unit Code: MEM18.2B
Student Name: _________________________________ Student ID No. _____________________
JOB 1: Folded Lap Joint Using 0.9mm Gal Steel
Description: Fabricate Folded Lap Joint.

Equipment: Including but not limited to; Electric or IMPORTANT INFORMATION
pneumatic/hydraulic drills, grinders, jigsaws, nibblers, cutting
saws, sanders, pedestal drills and pedestal grinders. Setting up equipment: Check that all tools are in good working order.
Setting Up Equipment:
1. Check the drilling capacity of the machine or power tool.
1 2. Check the lip length of drill is set to the correct angle and is suitable for the material type and thickness being used.
3. Check all safety guards are in place and in working order.
4. Know where the start up, stop and emergency stop controls are located on power tool.
5. Secure material in place using clamping devices, vice or drill vice.
6. Operate machine to drill or grind parts.
7. Inspect drilled or ground part for accuracy.
8. Make any required adjustments and complete drilling and grinding tasks.
9. Clean away swarf from the machine, and close down the drilling equipment in accordance with standard operating
procedures.
10. Retain work pieces for assembly and inspection.
2
Student’s Signature:__________________________ Teacher’s Signature:_________________________
Practice 3 Hours
Date: _____________________ Date: _____________________
Note: this exercise is suggested for students of light
Fabrication. Teacher’s use only Yes No Teacher’s use only Yes No
Initial level of competency Initial level of competency
Specifications are:
Competent to 1.1 Competent to 1.4
1. Safe working practices and procedures adhered to.
2. Demonstrated economical uses of materials. Competent to 1.2 Competent to 1.5

Job 1:
Unit Title MEM 18.2B Use Power Tools/Hand Held
This exercise
covers the 1.1 Select appropriate power tools to job specification.
1.2 Use Power tools to job specifications.
following 1.3 Safe use of power tools.
elements: 1.4 Unsafe or faulty power tools.
1.5 Power tool maintenance.
1.6 Power tool storage.
Suggested Time: 3.0 Hour
Suggested Technique
Folded Lap Joint
200
25
45° 1
Fold down 90°
80
15
30
20
5 Holes Ø 3.5

Job 1: Continued
Unit Title MEM18.2B Use Power Tools/Hand Held
This exercise
covers the 1.1 Select appropriate power tools to job specification.
following 1.3 Safe use of power tools.
elements: 1.4 Unsafe or faulty power tools.
Suggested Time: 3.0 Hour
Suggested Technique
20
15
5 Holes Ø 4.5
2
110
Bend Up @ 90°
Note: Corners of sheet to be
cut using snips at a radius of
35
25 mm and sharpe edges

removed.
25 25
200

JOB 2: Folded Lap Joint Using Angle and 3mm Plate
Description: Fabricate Folded Lap Joint to Angle Bar.

pneumatic/hydraulic drills, grinders, jigsaws, nibblers, cutting Setting up equipment: Check that all tools are in good working order.
saws, sanders, pedestal drills and pedestal grinders.
Folded Lap Joint Setting Up Equipment:

to Angle Bar 2. Check the lip length of drill is set to the correct angle and is suitable for the material type and thickness being used.
1 4. Know where the start up, stop and emergency stop controls are located on power tool.
procedures.
2
Practice 3 Hours
Date: _____________________ Date: _____________________
Specifications are:

Job 2: Continued
Unit MEM 18.2B
Title Use Power Tools/Hand Held
This exercise covers

1.1 Select appropriate power tools to job specification.
the following
elements: 1.3 Safe use of power tools.
1.4 Unsafe or faulty power tools.
Suggested Time: 1.5 Hours
Suggested Technique
Angle Bar with Front View

corners mitred. 200 200
25
Remove
45°
15
corners with
hacksaw or
30
30
drop saw.
Top View
6 Holes Ø 4.5 1
prepared for tapping.

Job 2:
Unit MEM18.2B

the following
Suggested Time: 1.5 Hours
Suggested Technique
20
15
5 Holes Ø 4.5
Material:
3mm M/S 2
110
Bend up @ 90
Note: Corners of plate to be cut
using shears or cropper at a radius of
25 mm and finishing to be
35
completed with off-hand grinding

to remove sharpe edges.
25 25

JOB 3: Folding Camping Table
Description: Fabricate Folding Camping Table.

saws, sanders, pedestal drills and pedestal grinders. Setting up equipment: Check that all tools are in good working order.
2. Check the lip length of drill is set to the correct angle and is suitable for the material type and thickness being used.
procedures.
Practice 3 Hours Date: _____________________ Date: _____________________

Specifications are:

Job 3: Continued
Unit MEM 18.2B

the following
Suggested Time: 3 Hours
Suggested Technique
60 Hole 3 Ø
2
2
10
80
Material 0.8mm M/S gal
275
Hole 3 Ø
10
2
2

Job 3: Continued
Unit MEM 18.2B

the following
Suggested Technique
Jig for Assembly of Table Legs
15
All holes drilled 3.5Ø

and flange pop riveted
Cut
corner
at 45°
232
23 15
300
Material 0.8mm M/S gal
278

JOB 4: Sash Clamp
Description: Fabricate Sash Clamp.

saws, sanders, pedestal drills and pedestal grinders. Check that all tools are in good working order.
2. Check the lip length of drill is set to the correct angle and is suitable for the material type and thickness being used.
FRONT VIEW
procedures.
Practice 3 Hours 10. Retain work pieces for assembly and inspection.
Date: _____________________ Date: _____________________

Specifications are:

Materials
A - Shaft - 25 X 25 X 2.4 RHS F -Anti Skid–70 X 30 X 3 F/Bar 2off D - 50 X 18 Dia Water Pipe
B - Sliding Jaw - 30 X 30 X 2.4 RHS 70 X 19 X 3 F/Bar E – Screw- 230 X 12 X 1.75 Threaded
C - Flange 70 X 50 X 5 F/BAR ends 30 X 19 X 3 F/Bar 2off Mill Rod
J - Web 25 X 35 X 5 F/BAR G- 40 X 30 X 3 F/Bar 2off L – Handle – 115 X 8 Dia Bar
K – Fixed Jaw - as per B, C & J 40 X 19 X 3 F/Bar 2off I - Block – 20 X 25
ends 30 X 19 X 3 F/Bar 2off H – End Stop – 30 X 30

Job 4:
Unit MEM 18.2B

the following
Suggested Technique
25
1000
C
5
D
SASH CLAMP
20
70
K J I
50 100 Note: All holes 9 Ø E
25
B G L
A F
FRONT VIEW 30 H

JOB 5: Drill Gauge
Description: Fabricate Drill Gauge.

saws, sanders, pedestal drills and pedestal grinders. Check that all tools are in good working order.
Datum Edge 1. Check the drilling capacity of the machine or power tool.
60 2. Check the lip length of drill is set to the correct angle and is suitable for the material type and thickness being used.
Tolerances + 0.5 5. Secure material in place using clamping devices, vice or drill vice.
- 0.5
60 6. Operate machine to drill or grind parts.
Hacksaw Cut
140 9. Clean away swarf from the machine, and close down the drilling equipment in accordance with standard operating
2
12
1°
procedures.
Practice 3 Hours Date: _____________________ Date: _____________________

Specifications are:
2. Demonstrated economical uses of materials . Competent to 1.2 Competent to 1.5

Job 5:
Unit MEM 18.2B

the following
Suggested Technique
Datum Edge
60
Tolerances + 0.5
- 0.5
60
Hacksaw Cut
140
2
12
1 °

Appendix A
AS 1788.2-1987
Sample Report Form for
Abrasive Wheel
Breakages

TAFE NSW
MEM18.2B/1 © 2007

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Use Power Tools/Hand

Metal Fabrication and Welding

x Silverwater Welding Supplies

Use Power Tools/Hand Held Operation MEM18.2B

Portable Power Tools 8

Grinding and Drilling Machinery 22

Off-Hand Grinding Machines 22

MEM18.2B Use Power Tools/Hand Held Operation i

Revision Questions – Use Power Tools/Hand Held Operation 36

Appendix A: Sample Report Form for Abrasive Wheel Breakages

MEM18.2B Use Power Tools/Hand Held Operation ii

This learning resource contains theory-based learning material and revision

x None required for this unit.

MEM12.23B Perform Engineering Measurements, MEM18.1C Use Hand Tools

x Select power tools appropriate to the task requirements.

x Adhere to all safety requirements before, during and after use.

x Undertake operational maintenance of tools, including hand sharpening, according to

Power Tools/Hand Held Operation is a core unit in Certificate III in Engineering –

MEM5.11C A1;MEM10.1C MEM10.10B

MEM12.23B MEM18.1C MEM18.2B

MEM18.2B Use Power Tools/Hand Held Operation 2

MEM18.2B Use Power Tools/Hand Held Operation 3

Scope of Unit Addresses Unit Performance

Portable power tool selection: 1.2 Use power tools to job

Power tool application:

Safe use of power tools: 1.3 Safe use of power tools.

MEM18.2B Use Power Tools/Hand Held Operation 4

Routine maintenance of power tools: 1.5 Power tool maintenance.

Storage of power tools: 1.6 Power tool storage.

MEM18.2B Use Power Tools/Hand Held Operation 5

Reporting of assessment outcomes

Requirements to successfully complete this unit of competency

Assessment Component Assessment Event Name Timing Wgt % Must

MEM18.2B Use Power Tools/Hand Held Operation 6

Event Name: THEORY TEST

Duration: 3 X 20 min assessments (1 hour in total)

Event Name: SKILLS TEST

What you will need

x Clear safety glasses

* For specific tasks.

More about assessment

MEM18.2B Use Power Tools/Hand Held Operation 7

Portable Power Tools

x Power Hand shears.

x Saws and Jigsaws.

Types of Portable Grinders

Three types of portable grinders are:

MEM18.2B Use Power Tools/Hand Held Operation 8

Figure 3: Pneumatic (Air) Die Grinder with Burring Tool

MEM18.2B Use Power Tools/Hand Held Operation 9

x Fast freehand stock removal

Figure 4: Selection of Rotary Burring Tools

x Aluminium, Brass, Copper and Zinc Alloys

MEM18.2B Use Power Tools/Hand Held Operation 10

Figure 6: Electric Straight Grinder

- Resinoid-bonded cut-off wheels

- Industrial wire brushes

- Flap discs and Flap wheels

- Vitrified grinding products

- Sticky back discs

Figure 7: Selection of Abrasives

MEM18.2B Use Power Tools/Hand Held Operation 11

x Sheet metal items made of steel and stainless steel.