Republic of the Philippines

UNIVERSITY OF SOUTHERN MINDANAO

Kidapawan City Campus
Sudapin, Kidapawan City, North Cotabato

MECHANICAL TECHNOLOGY
MT 111

Benchwork
And
Pipe Fitting

JAKE F. TIGAO
 Chapter 6 Power Tools

Intended Learning Outcomes: At the end of this chapter, the students are expected to:
1. Identify the types of hand and power tools.
2. Discuss the hazards and injuries of electric/ power tools.
3. Identify the portable electric drill parts and Portable Grinder parts.
4. Learn how to operate power Hand drills and Portable Grinder

6.1 Types of Power Tools

Employers are responsible for maintaining in good repair any tools and equipment supplied to
workers. Workers must use tools and equipment properly and report any defects to supervisors. The
Construction Regulation (O.Reg. 213/91) requires that tools and equipment be used according to the
manufacturer’s operating manuals, that operating manuals for tools and equipment rated at more than
10 horsepower be kept readily available on the project, and that tools and equipment be inspected
regularly.
Our finest tools are our hands. Too often they are damaged by tool accidents. Hands can be caught
in machines, crushed by objects, or cut by sharp-edged tools such as chisels, knives, and saws. Hands can
also be damaged by being burned, fractured, or sprained unless you stay alert.

Tools
Tools can be divided into two main groups: hand tools and power tools. Hand tools are operated
by the physical strength of the user. Power tools require an external source of power such as electricity
or compressed air to operate. Each of these groups can also be divided into subgroups.
The advantage of power tools over hand tools is that they do not rely entirely on the physical
strength of the operator to do the job at hand. Power tools are often much faster and, in some cases,
more accurate than hand tools. It would be difficult to operate a business without the use of power tools.
However, the disadvantages of power tools are the increased risk of injury if not used properly and
elevated noise levels.

There are four types of power used to drive portable power tools:
▪ Electric
▪ Pneumatic (Air)
▪ Hydraulic
▪ Explosive.

Electrical tools
These tools are used in smaller factories where the operation of a compressor is deemed
uneconomical. Most static tools such as bench grinders and drill presses operate on electricity. With the
increasing use of rechargeable batteries or cordless drills, electrical tools can be used well away from a
mains power supply

Pneumatic tools
Commonly called air tools, these operate at higher revolutions per minute (RPM) than electrical
tools and therefore do the work more quickly. Pneumatic tools alleviate some of the common dangers
associated with using electrical tools such as having electrical leads running across workshop floors,
dangers associated with working in damp conditions, and sparking off the machines in volatile fume areas
such as paint workshop areas. Pneumatic tools are lighter to handle than those powered by electricity.

Hydraulic tools
Common jacks such as bottle jacks and trolley jacks use hydraulic power. Hydraulic power is slow
compared to other forms of power but can deliver the very high pressures required to lift trucks (trolley
jacks) or bend heavy pipes (hydraulic pipe bender).
Explosive tools
A license is required to operate portable explosive tools. Explosive tools can fire fasteners such as
threaded studs into a steel main runner without the need to drill a hole. These devices use an explosive
charge (the cartridge) to fire a projectile (the fastener) into the material.
6.2 Safety Practices in using Power Tools

Appropriate personal protective equipment such as safety goggles and gloves must be worn to
protect against hazards that may be encountered while using hand tools. Workplace floors shall be kept
as clean and dry as possible to prevent accidental slips with or around dangerous hand tools.

Power tools must be fitted with guards and safety switches; they are extremely hazardous when
used improperly. The types of power tools are determined by their power source: electric, pneumatic,
liquid fuel, hydraulic, and powder-actuated.

Hazards

▪ Portable power tools present hazards similar to stationary machines performing the same
▪ Power tools have inherent risks because of their extreme mobility. It can easily come in
contact with the operator’s body. At the same time, it is difficult to guard such equipment
completely.
▪ Dropping or rough handling can cause tools to
▪ Hazards of exposure to repetitive vibration/motion (repetitive strain injury)
▪ Also there are inherent hazards of the power source.

To prevent hazards associated with the use of power tools, workers should observe the
following general precautions:

1. Use Personal Protective Equipment

If you can’t engineer out the threat, then using personal protective equipment (PPE) should be
your first precaution. If you haven’t already, purchase a pair of safety glasses. These will protect your eyes
from debris, dust, fiberglass, and shavings. In the same manner, a pair of earplugs will protect your
hearing. Don’t forget, even the best power tools can still be loud.

Keeping your hands safe is just as important. Use a pair of gloves that fit your hands and the environment
well. They shouldn’t inhibit your movement and impair dexterity. If you’re working at heights or in
confined spaces, you’ll also need a proper safety helmet.

2. Dress Right

When handling hand and power tools, you also need to dress for the job.

Avoid wearing loose-fitting clothing, jewelry, and neckties. Remove dangling objects of any kind
before you start working. If you have long hair, tie it behind your head so that it doesn’t get in your way.
When it comes to footwear, non-slip boots are recommended.

3. Educate Yourself

All hand and power tools come with instruction manuals, and these exist for good reasons. Even
a split second of improper operation can cause a life-threatening injury. For that matter, reading the
manual thoroughly is non-negotiable.

Demonstrating how to use a tool isn’t the manual’s only value. Most of them also provide
information on increasing the user’s safety and troubleshooting problems. Get to know your tool to help
reduce the risk of an injury.

4. Regularly Inspect Your Tools

All tools require periodic checks. Constant use causes wear and tear. Don’t take any chances, even
if your tools are brand new. Routine inspections are the key to staying safe.
 Check your devices for loose cracks, breakage, damaged plugs, and exposed wires. If you’re at
work, ask the boss to replace the damaged tool with a proper one. Never forget that using a damaged
tool is a recipe for disaster.

5. Keep Your Work Area Clean

Another thing that can result in an injury is a hazardous working area. Your environment itself can
pose a major risk to your safety. Keeping the workspace clean is vital to staying out of harm’s way.

Clean up the clutter — a floor with tangled cords can be extremely dangerous. Keep your power tools
away from flammable liquids. If you’re at home, ensure that the place is child-proof. Remove all starter
keys and master switches, and use padlocks wherever possible.

6. Be Extra Cautious With Power Tools

Unlike hand tools, power tools use electricity and are much more powerful. Having a quality
circular saw, for example, may allow you to finish a project more quicker and easier. Due to their power,
however, these tools are also much more dangerous.

Corded tools should never be carried by their cords. These wires need to be kept away from sharp
edges and heat sources. Accidental starting is another hazard. When carrying a plugged-in tool, avoid
holding your finger on the trigger.

7. Turn the Tools Off After Use

Leaving your tools plugged in and in “stand by” mode should be avoided at all costs. It can create
serious problems for people who don’t realize that the tool is powered. To prevent future injuries and
accidents, always turn them off after each use.

Make sure that your device is shut down, unplugged, and properly stored. Once unplugged, store
the tool in its original casing. Again, if you’re working at home, be sure to place it somewhere out of
children’s reach.

8. Use Proper Lighting

Another workplace situation that causes injuries is the lack of proper lighting. People often
overlook the importance of having a properly lit working environment. When used in dimly lit conditions,
power tools can be deadly.

If your work area’s light isn’t bright enough, make sure to use or bring in additional lights. You’ll
need lots of bright, shadow-free light. If you can’t see what you’re doing, you’re asking for trouble.

9. Ground All Tools

Is your tool equipped with a three-prong, grounding-type plug or an approved three-conductor

cord? If it is, you’ll have to plug it into a three-hole electrical receptacle. If you’re using an adapter to
connect to a two-hole receptacle, you’ll have to attach the wire to a known ground.

Be extra careful when you have to work in wet locations. Keep your feet and hands dry. Put a
rubber mat on the ground, place a wooden stool on it, and sit on the stool while working. By doing this,
you’ll reduce the risk of electrical shocks.

10. Maintain a Firm Grip and Balance

As their name suggests, power tools are powerful. For that matter, it is of paramount importance
to stay in control of them at all times. Besides using non-slip footwear, you also need to plant your feet
and maintain a good balance.

Keeping a firm grip is just as important, especially with handheld tools. Losing control is
guaranteed to create a hazardous situation. If you feel that a tool may be too heavy for you, do not use it.
11. Stay Calm and Confident

Keeping your cool while handling these devices is the key to staying safe. This is especially true
for power tools. They need to be handled with care and respect.

Don’t get reckless if things aren’t going the way you’d like. Take a break, calm down, and only
then resume working on the project. Stay away from power tools if you’re under the influence of alcohol
or drugs, feeling unwell, in pain, distracted, or tired. Staying safe is easy when you think ahead!

https://www.coatingspromag.com/articles/safety/2020/10/11-safety-tips-when-handling-hand-and-power-tools

6.3 Power Hand Drill

Portable power tools, such as a drill, are particularly useful because they can easily be taken to
the job site, do not require extensive setup, and are relatively affordable. The main parts of a portable
drill include an on/ off switch, power cord, handle, chuck (the part that holds the drill bit), and chuck key.
A chuck key is used to loosen and tighten the chuck. Portable drills are used to do various woodworking
jobs, such as drilling and boring, driving and removing screws, and operating hole saws. Drills can also be
used for sanding and polishing.

Portable drills come in different sizes. The size of a drill is based

on the maximum size of the drill bit that the chuck will hold. For
example, with a 1/4-in. drill, the chuck holds a bit with a shank that is
no larger than 1/4 in. Some drills have only one motor speed while
others have different speeds. Variable-speed drills are useful for
driving screws. Screws can be removed by reversing the drill.

Electric Drill Types Fig. 7.1 Parts of Power Hand drill

1. Brace
2. Pistol Grip
3. Hammer Drill
4. Cordless Drill

Brace
Is a hand tool used with a bit (drill bit or auger) to drill holes,
usually in wood? Pressure is applied to the top and the tool is rotated with
a U-shaped grip.

Fig. 7.2 The Brace type drill

Pistol Grip Drill

Is the most common type of corded drill available. These are also the
most versatile types of drills. With this type of drill, you can purchase bits and
attachments that will turn the drill into an orbital sander, a small hand saw,
or a boring device.

Fig. 7.3 Pistol grip drill

Hammer Drill
ls called a masonry drill, is used most
commonly with concrete or brick. They are designed
with a hammer mechanism that can also rotate. Some
types of hammer drills don't have a drill-only action,
and others can be used for both drilling and
hammering. Fig. 7.4 The hammer drill
Cordless Drill
Is an electric drill that uses rechargeable batteries. They are available in
the hammer drill configuration and most have a clutch, which aids in driving
screws into various substrates while not damaging them. Also available are right-
angle drills, which allow a worker to drive screws in a tight space.
Fig. 7.5 Cordless drill

Electric Drill Parts and Uses

1. Piston Grip
2. Cord Strain Reliever
3. Electrical cord
4. Switch Lock
5. Trigger Switch
6. Chuck Wrench
7. Reversing Switch
8. Chuck Fig. 7.6 The electric drill parts

6.3.1 Powered Hand Drill Safety

▪ The following safe work practices will help you avoid injuries when using a hand drill.
▪ Pre-Operation Inspection and Set Up
▪ Wear safety glasses and other appropriate personal protective equipment.
▪ Disconnect the plug from the power source or remove the battery pack from the drill before
inspecting, adjusting, cleaning, or repairing it.
▪ Inspect the drill and power cord for damage before each use. Check the drill for
misalignment or binding of moving parts.
▪ Select a drill bit suitable for the size of the drill, the material to be drilled (e.g. wood,
masonry, metal, etc.), and the work being performed.
▪ Ensure the drill bit is in good condition, sharp and clean.
▪ Ensure the bit is properly seated and tightened in the chuck.
▪ Ensure the chuck key is removed from the chuck.

Operation
▪ Wear safety glasses when operating with a portable electric drill.
▪ Disconnect the drill from the electrical supply when installing bits.
▪ Clamp stock so it will not move during the drilling operation.
▪ Before drilling, turn the drill on to see if the bit is centered and running true.
▪ Align the bit with the desired hole location before turning the drill on.
▪ Hold the drill firmly with both hands while drilling.
▪ When drilling deep holes with a twist drill, move the bit up and down several times while
drilling to remove cuttings and reduce overheating in the bit.
▪ Do not allow the cord to become wrapped around the drill when working.
▪ If the electrical cord becomes frayed or starts to separate from the drill housing, repair it
immediately!
▪ Remove the bit from the drill as soon as the work is completed.
▪ Select the correct bit for the finish and material being drilled. Make sure the bit is securely
tightened in the drill chuck.
▪ Be extremely careful when using larger portable electric drills (3/8" and 1/2"). If the bit
should hang or get caught the drill will twist in the operator’s hands causing a sprain or
bruised fingers.
▪ Always remove the key from the chuck before drilling.
▪ To prevent seizing, reduce the feed pressure when the drill bit is about to come through the
material.
▪ Keep the working area clear of backpacks, binders, coats, etc. that could get in the way and
cause an accident.
▪ Remove loose clothing, jewelry, etc. that could get caught in the rotating drill.
▪ Tie back long hair so it doesn’t get wrapped up in the drill.
▪ Have the Teacher check your setup.
Post-Operation
▪ Clean and store the drill and accessories in a secure place.
▪ Address any safety and maintenance issues.

6.4 Portable Grinder

An angle grinder, also known as a side grinder or disc

grinder, is a handheld power tool used for grinding (abrasive
cutting) and polishing. Although developed originally as tools for
rigid abrasive discs, the availability of an interchangeable power
source has encouraged their use with a wide variety of cutters and
attachments.
Angle grinders can be powered by an electric
motor, petrol engine, or compressed air. The motor drives a
geared head at a right angle on which is mounted
an abrasive disc or a thinner cut-off disc, either of which can Fig. 7.7 The Portable Grinder parts
be replaced when worn.
Angle grinders typically have an adjustable guard and a side handle for two-handed operation.
Certain angle grinders, depending on their speed range, can be used as sanders, employing a
sanding disc with a backing pad or disc. The backing system is typically made of hard plastic, phenolic
resin, or medium-hard rubber depending on the amount of flexibility desired.

Angle grinders are standard equipment in metal fabrication shops and on construction sites. They are also
common in machine shops, along with die grinders and bench grinders.

6.4.1 Common Hazard of Portable Grinder

The portable grinder is used in the field or maintenance shop to grind excess metal from welds,
remove rust, and for special finishing operations. Since this tool is hand-operated, the quality of the work
depends upon the ability and experience of the operator.

1. High-speed flying particles -a grinding wheel’s speed can be greater than a mile a minute.
➢ from the grinding wheel itself
➢ from the workpiece being ground
2. Inhaling dust and fumes generated
3. Explosion or fire
➢ if sparks ignite flammable or combustible materials nearby or below grinding operation.
4. Defective power cord
5. Noise
6. Musculoskeletal disorders (MSDs)
➢ from repetitive use
➢ of awkward body positions

6.4.2 Portable Grinder Operating Procedures

Using Portable Grinders Safely:

Like all power tools, portable grinders can present safety concerns, including flying particles and
electrical hazards. This procedure outlines requirements in the Occupational Safety & Health
Administration's (OSHA) standards regarding abrasive wheels and tools (29 CFR 1926.303).

Preparation
✓ Remove flammable materials from the work area.
✓ Ensure the work area is clean, free from slip, trip, and fall hazards, and
well maintained.
✓ Keep the power cord away from the grinding wheel and the material
being ground.
✓ Have personnel not involved in the immediate work step away a safe
distance from the grinding area.
✓ Secure work with clamps or a vice to free both hands to operate the
too Fig. 7.8 Installation of Grinder
wheel
Inspection
▪ Unplug the power cord from the power supply before inspecting, adjusting, removing, or
replacing parts.
▪ Ensure wheel guard is in place*. see OSHA Guard Removal Exception below
▪ Check the abrasive wheel for cracks or flaws – replace if necessary.
▪ Verify the maximum RPM rating of the grinder does not exceed the RPM rating on each abrasive
wheel.
▪ When using a grinder that can switch between left-handed and right-handed operation,
remember to move the blade guard when you move the handle.
▪ Tag out the grinder if a deficiency is found – do not use the grinder until the deficiency has been
corrected.

OSHA Guard Removal Exception only allows the guard to be removed for “internal grinding. The
term "internal grinding" is defined as "the precision grinding of the inside surface of the hole in a
workpiece." This does not include snagging or off-hand grinding operations such as grinding the welds
inside a box or frame or the concave areas of auto bodies.

Ring Test
▪ Before installing an abrasive wheel, visually inspect it for cracks or flaws and perform a “Ring
Test”:
▪ Place your finger through the mounting hole of the new abrasive wheel.
▪ Lightly tap its face with a hammer or metallic object.
▪ A “ring” will sound from a good wheel.
▪ A “dull thud” will sound from a wheel with an internal fracture.

Replacing the Wheel

▪ The abrasive wheel should not be forced onto a grinder nor should the mounting hole size be
changed. To control the cracking of the abrasive wheel, it must fit freely on the spindle and be
tightened to hold the wheel in place without distorting the flange.
▪ The mounting nut should not be tightened excessively.
▪ Run a newly mounted wheel at operating speed for 1 minute before grinding.
▪ Always follow the manufacturer's instructions.

▪ Don required Personal Protective Equipment (PPE)

▪ Wear appropriate PPE - safety glasses or goggles, face protection to protect against flying
particles, and hearing protection to guard against hearing loss.
▪ Gloves – Caution: Wear snug-fitting gloves to avoid snagging on the abrasive wheel or wire brush.
• Apron, metatarsal safety boots, and respiratory protection may also be required depending on
the work being performed.
▪ Do not wear jewelry or other items that could become entangled in moving parts.
▪ Avoid wearing loose clothing or secure loose clothing.
▪ Tuck or secure long hair.

Switch Grinder “ON”

▪ Stand to one side and switch on the grinder.
▪ Ensure the grinder operates smoothly and does not vibrate. If you notice any unusual vibrations
or noises, STOP. Re-inspect the grinder and fix the problem immediately.

Grinding:
▪ Use both hands to maintain hold of the grinder.
▪ Allow the grinder to reach full rpm before grinding.
▪ Position yourself to avoid overbalancing.
▪ When grinding avoid placing excessive pressure on abrasive wheels.
▪ Do not grind objects on the sides of grinding wheels.
▪ Materials may become hot when grinding – use gloves when necessary.
▪ Clean and service grinders according to manufacturers' recommendations.
▪ Record all maintenance.
▪ Ensure the floor around the work area is clean.
▪ Do not use wheels that are cracked or those that excessively vibrate.
▪ Do not operate the grinder on wet floors.
Switch Grinder “OFF”
▪ Switch off the grinder when done.
▪ Wait until the wheel has stopped turning before placing the grinder on the working surface.
▪ Unplug the power cord from the power supply.
▪ Clean the area and dispose of grinder particles.

Other Precautions:
▪ Do not use liquid coolants with grinders as this may cause the metal to shatter.
▪ Do not clamp portable grinders in a vise for grinding hand-held work.
▪ Do not keep any materials close to the grinding wheel when it is not in use.
▪ Do not carry a grinder by the power cord.
▪ Do not pull on the power cord to disconnect it from the power supply.
▪ Keep cords away from heat, oil, and sharp objects or edges.

Maintenance & Storage

▪ Store portable grinders on racks or hooks, not on the floor or ground.
▪ Clean and service grinders according to the manufacturer's recommendations, including
lubricating and changing accessories.
▪ Keep a written maintenance record on portable grinders.

Portable Disc Grinder Safety

▪ Wear safety glasses, or a face shield at all times when using the portable disc grinder.
▪ Wear hearing protection when grinding and operating the portable disc grinder.
▪ Position the grinder so that sparks and grit thrown off during grinding will not hit the operator or
others working in the area.
▪ Make sure the material being ground is well secured.
▪ Never grind with the portable disc grinder in an area that houses flammable materials or
combustible gases.
▪ Replace the grinding disk when it becomes worn to half its original diameter.
▪ Wear long sleeve leather gloves when grinding with the portable disc grinder to protect hands
and forearms.
▪ Hold the portable disk grinder with both hands when grinding.
▪ Never lay the portable disc grinder down until the disk has stopped rotating.
▪ Keep the electrical cord and extension cords out of the way of the work when grinding.
▪ When using the wire brush attachment on the portable disc grinder, hold the grinder extra firm
to prevent it from being thrown about and causing an accident.
▪ Caution others in the work area to wear safety glasses, and hearing protection and to watch out
for flying sparks and grit.

Operating Procedures
1. Tighten the grinding disk snuggly when mounting it on the portable disc grinder. The disk will
tighten itself during normal operation.
2. Be sure to hold the portable disc grinder firmly when the off/on switch is turned on. The
centrifugal force created by the rotating disk will cause the portable disc grinder to move or jump.
3. For extended periods of grinding the operator may lock the off/on switch in the on position to
avoid fatigue from holding the switch on manually.
4. When an extension cord is used with the portable disc grinder make sure the cord is sufficiently
large in size for the grinder being used. A #14 gauge extension cord is minimum and #12 gauge is
preferred.
5. Keep the electrical and extension cords positioned away from the grinding area. Cords are easily
severed by the portable disc grinder.
6. When laying the portable disc grinder down, always position it on the tool rest.
7. Before using the switch lock on the portable disc grinder always check to make sure the lock is
functioning properly.
8. Hold the portable disc grinder so that sparks and grit are thrown away from the operator and
others working in the area.
9. Using the portable disc grinder is hard work and causes rapid fatigue, rest frequently and do not
become exhausted to help avoid accidents.
6.4.3 Other Accessories and Attachments

Wire Buffing Wheel:

Wire wheel brushes are wheel-shaped brushing tools with sturdy
hubs and metal wire filaments. They are used for cutting, cleaning, deburring,
edge blending, polishing, and surface finishing.
Fig. 7.9 The Wire buffing wheel

Cup brushes:
Cup brushes are used for the removal of scale, rust, and
paint, as well as for deburring and polishing. Utility Cup Brushes:
Designed for removing light deposits of scale, paint, rust, and
small burrs. Standard models are available in carbon steel,
stainless steel, brass, and nylon.
Fig. 7.10 Cup brushes wheel

Cup Stones and Nose Cone:

Cup Stones are designed for heavy-duty flat surface grinding with an
angle grinder. This product’s ultimate performance and consistent stock
removal at an exceptional rate make them ideal for coarse and aggressive
grinding applications.
Fig. 7.11 The Cup nose and nose cone