Module 7.

Tools
Continued
 Screwdrivers
• Screwdrivers consist of a high-
carbon steel or alloy steel blade,
fixed to a wood or composite
handle.
• The high-carbon steel blades are
also hardened and tempered.

• They are divided into two main

groups:

1. Blade Screwdrivers

2. Cross-Point (Cruciform)
Screwdrivers
 Blade Screwdrivers

• The end of a blade (or common) screwdriver is

ground to engage the diagonal slot of the screw
head.

• Blade type screwdrivers are classified by type and

length of blade.

• This can range from 35mm (1.5”) to 500mm (20”) in

special cases.
 Blade Engagement
• Using the correct size blade for fastener ensures
proper engagement of the screwdriver into the
fastener head.
• This should avoid serious damage to the fastener and
surrounding structure.

Blade too Blade Blade too

Small Correct Large
 Cross-Point Screwdrivers
• Cross-point screwdrivers are available in many
different types of end.
• They allow a greater torque to be applied to the
fastener.
• The screwdriver end and fastener head must be
compatible to avoid damage.
• Special types such as the ‘off-set’ (cranked)
screwdriver and drivers with interchangeable bits are
also used.
• The handle or drive may be unique but the end blade
or bit must be the correct one for the fastener head.
Continued...
 Reed And Price
Plan of
Screwdriver Fastener
Head Head

Fastener
Head

Continued...
 Phillips
Plan of
Screwdriver Fastener
Head Head

Fastener
Head

Continued...
 Posidrive
Screwdriver Plan of
Head Fastener
Head

Plan of
Screwdriver
Head

Continued...
 Triwing

Plan of
Screwdriver
Fastener
Head
Head

Plan of
Screwdriver
Blade

Continued...
 Torq-Set Head
Side View of
Screwdriver Bit
Plan of
Fastener
Head

11
S

02
A
N

A
Front Face of
Screwdriver Bit
End
 Pliers
• Pliers are classified by type and overall length and
usually made from alloy steel, with an insulated
handle.

• They are used for gripping and bending components

or moving small items that are difficult to hold.

• Various types are available, the name usually

describing the pliers tip or its function.

• Round-Nose, Flat-Nose, Needle Nose, Side Cutting,

Wire Locking and Circlip.
Continued...
 Engineers Pliers
Side Cutting
Action

Serrated
Round Section

Serrated Flat
Section

Continued...
 Long Nose Pliers

Side Cutting
Action
Insulated Handles
give good tactile
properties

Serrated Flat
Section

Continued...
 Lock Wire Pliers
• Wire Locking Pliers are designed specifically for lock
wire tasks, these pliers incorporate:
1. Lockable grip function
2. Integral Archimedes’ Screw for wire twisting.
3. Cutting function to snip wire

Continued...
 Circlip Pliers
• Circlip Pliers are used for the removal and fitting of
internal and external circlips.
• Normally made for internal only or external only
circlips, the better types can be adjusted to fit both
types of circlip.

Continued...
Right Angle Circlip Pliers

Continued...
 Mole Grips
• Pliers that can be locked onto a component are
usually known as ‘Mole-Grips’.
• They have a mechanism that allows gripping without
the need to continuously squeeze the handles.

Continued...
The jaws of
Mole grips can
be adjusted to
accommodate
a large range
of shapes and
sizes.

Continued...
 Slip-Joint Pliers

• Slip-Joint (Water Pump or

Swan Neck) Pliers have an
adjustable range to the size
of the components they can
accommodate.

• This is achieved by the

multi-pivot joint at the
hinge part of the pliers.

Continued...
Continued...
 Wire Snips

• Wire Snips (or Nippers) are used to cut and strip

wires.
• Aircraft wiring should have its insulation removed
with the correct wire stripping pliers.
• The larger sized ones are useful for removing split
pins.
• The cutting jaws of the small types may be rendered
useless by the tough split pin.
• The cutting jaw is usually positioned either at right-
angles to or parallel with the handles.

Continued...
 Side cutting
snips.

Parallel end cutting snips.

End
Any Questions on
Screwdrivers and
Pliers?
 Spanners
• Spanners are usually made from either:
(a) Case Hardened Mild Steel
(b) Hardened and Tempered High-Carbon Steel
(c) Alloy Steels containing Chromium and
Molybdenum.
• The size should be marked on the handle or the jaw
face in unit of measurement for that system.

• The two main sizing methods are:

1. Distance across the jaw opening
2. Distance across the thread diameter
Spanner Sizing Systems

Older British systems such

as Whitworth, measure the
dimension across the
fasteners thread diameter.

Metric and Imperial A/F (Across

Flats) systems measure the
dimension across the fasteners
jaw flats.
 Set or Open Jaw Spanners
• These spanners are usually double-ended allowing
two sizes to be used on each spanner.
• The jaw opening of the set spanner is usually set at
an angle (15°) to make it more versatile in restricted
areas.

15°

• The jaws only bear against two available flats, and if

excessive force is applied, they may spring open.
 Ring Spanners
• Ring spanners give full enclosure and reduce the
problems associated with open-jaw spanners.
• Ring spanner internal faces are usually bi-hexagonal,
again to allow more versatility.
• The ends are usually offset or cranked downwards at
about 60° from the handle giving greater flexibility.

Offset or
Cranked at
about 60°

Continued...
 Flat Ring Spanners
• Flat ring spanners can be used in areas where access
is difficult with a normal cranked ring spanner.
• The shape of the spanner is usually either straight or
crescent shaped.

Continued...
 Flare Nut Spanners
• Flare nut spanners combine the best of both ring and
set spanners.
• This spanner allows an increased force to be applied
to pipe unions without slipping.
• The end sections are much thicker to compensate for
a loss of rigidity because of the open end.

Ring spanner Thicker section

with an open at ends
end.

End
 Sockets
• Sockets are just versatile spanners and are made
from the same materials as spanners.
• The faces that turn the fastener are either six or
twelve sided, with a square hole for applying force.

Six
Sides

Twelve
Sides
• The turning force can be achieved by a variety of
methods such as T-bars and ratchet handles.
• The drive size range form ¼” to 1½” with the 3/8”
being the most popular with aircraft engineers.
• The sockets are available in the same sizes and
systems as spanners, and with varying depths to
increase versatility.
Drive Size (ie 3/8”)

Ratchet

Sliding
T-Bar
 Socket Accessories

• Various types of adapters and drives can be used

with sockets.
• Ratchet handles, speed braces and extension bars
are just some of the more common types in use.
• Adapters are used to hold items such as screwdriver
bits or Allen keys.
• Universal joints and angle ended extensions can
allow the socket to be driven at acute angles.
• Converters allow the size of a drive and socket to be
interchanged, ie 3/8” drive with 1/2” socket.
Drive Adapter
1/2” to 3/8”

Allen Key
Socket
Allen Key

• An Allen key is an internal

hexagonal drives used to turn
Allen bolts.
• Made from hardened and
tempered hexagonal-section
steel bar.
• Classified by the dimension
across the flats.
• Used mainly when a requirement
for recessing is called for.
 Any Questions on
Spanners, Sockets or
Allen Keys?
 Torque
• Holding power of threaded fasteners is greatly
increased, by placing it under an initial tensile load,
greater than the load it experiences during service.
• Incorrect tightening of a fastener may subject the
component to unnecessary loads, or over stress the
fastener.

• Torque is the product of a force multiplied by the

distance it is applied. (T = F x d)
• Units of torque depend on the system being used,
but the value will always be force x distance (Nm).
 Units of Torque
• The main units of torque in general use are:

• SI Newton metre Nm

• Metric kilogram force metre kgf.m

• lmperial pound force foot lbf.ft

 Torque Wrenches

• Torque wrenches can control the amount of force

applied to a fastener.

• Three main types of torque wrench are:

1. Deflecting Beam
2. Torsion Bar
3. Toggle Type
 Deflecting Beam Torque Wrench

Scale
Pointer Handle

Beam
Square Drive
Deflecting Beam Torque Wrench

• One end has a square drive whilst the other end has
an accurately ground beam mounted on a pivot.
• A pointer is connected to the square drive, and a
scale is connected to the beam.
• When a force is applied the beam bends and the
pointer deflects.
• Deflection is directly proportional to the torque, so
the value is what the pointer indicates on the scale.
• Parallax error could make obtaining an accurate
reading difficult.
 Torsion Bar Torque Wrench

Scale
Handle

Pointer

Square Drive
 Torsion Bar Torque Wrench

• Torsion Bar type utilises the twist that occurs when a

force is applied.

• An accurately ground square drive has a rack gear on

one end.

• When the bar is twisted the rack moves a pinion in a

dial indicator to show the amount of deflection.

• The dial is calibrated in the required units of torque.

 Toggle Type Torque Wrench

Handle
Scale
Reverse Switch

Lock Ring

Square Drive
 Toggle Type Torque Wrench

• Toggle type (or break back) torque wrenches uses a

spring whose length can be adjusted.
• This adjustment changes the value at which the
wrench will stop turning the fastener.
• When the pre-set torque value is reached, the
wrench handle carries on turning, and the socket
drive remains stationary.
• An audible click can be heard and felt through the
wrench to indicate the value has been reached.
• More expensive wrenches use the same principle
with an audible whine or squeal replacing the click.
 Castle Nut Torque
• When torque loading a castle nut to fit a split pin, a
minimum and maximum torque value should be
quoted.
• The nut should first be tightened to the lowest value
in the range.
• If the castle slots and the bolt hole do not align, then
the torque value is increased until the slots/holes
align to allow the split pin to be fitted.
• The maximum torque value should not be exceeded
at any point.
• Other more specific methods may be quoted in the
AMM/CMM and these will obviously take precedence.
Continued...
 Torque Wrench Extensions

• During some maintenance procedures an adapter

must be attached to the end of the torque wrench.
• This will change the overall effective length of the
lever mechanism as the distance part of the equation
will have increased.
• In most cases the torque wrench value given by the
AMM will account for this increase in length, but it
may have to be calculated.
• The scale reading that the torque wrench should be
set to, to take account of this increase in effective
length can be found mathematically.
Continued...
 Torque Wrench
Effective Length (L)

Adapter
L
Length
(A)

A Torque
Wrench

Extension
socket/spanner
End
 Extensions Calculation

• The effective length of a torque wrench is 350 mm

and an extension socket of 50 mm is fitted.

• To what value should the torque wrench be set if the

specified torque is 250 Nm?

L
Scale Reading = Specified Torque x
L+A

Continued...
 350
Scale Reading = 250 x
350 + 50

= 250 x (350/400)

= 250 x 0.875

= 218.75 Nm

Continued...
 Calculation Exercises

1. The effective length of a torque wrench is 300 mm

and an extension socket of 75 mm is fitted. To what
value should the torque wrench be set if the
specified torque is 200 Nm?

2. The effective length of a torque wrench is 15 inches

and an extension socket of 3 inches is fitted. To what
value should the torque wrench be set if the
specified torque is 175 lbf ft?

Continued...
• The effective length of a torque wrench is 295 mm
and an extension socket of 37.5 mm is fitted. To
what value should the torque wrench be set if the
specified torque is 195 Nm?

• The effective length of a torque wrench is 9 inches

and an extension socket of 2½ inches is fitted. To
what value should the torque wrench be set if the
specified torque is 55 lbf in?

Answers next....
• 1. 160 Nm

• 2. 145.83 lbf ft

• 3. 173 Nm

• 4. 43.04 lbf in

End
 Torque Wrench Pre-Use Checks
• Before a torque wrench can be used it should be
checked by the operator.

• A current calibration label should be fixed to the

wrench showing when it was calibrated and when the
next calibration check is due.

• The wrench should be set to the required torque

value and checked against a ‘Torque Wrench Master
Checking Rig’ to ascertain its accuracy.
 Torque Wrench Setting
The display should
be the same as that
set on the wrench

Torque Wrench is
turned until it clicks

Torque Wrench is
set to required value
and fitted into the
square drive
Any Questions on
Torque Wrenches?
 Power Tool Safety

• Powered tools can be dangerous so we need to

observe certain safety precautions.

• Personnel must be properly trained and currently

authorised to use the equipment.

• Always use the protective guards and fences.

Continued...
• Ensure no part of the body or clothing can come into
contact with moving parts.

• Protective clothing is correctly fastened with no loose

items protruding.

• All jewellery must be removed.

• Eye protection is worn wherever there is a debris

risk.

Continued...
• Where necessary have the correct fire extinguisher
readily to hand.

• A safety mat is available to stand on where electrical

machinery is used.

• Machinery is checked for any ‘Warning’ notices

indicating it is unsafe for use.

End
 Electric Drills

• Electric Pillar Drills are used for heavy duty drilling

tasks when large and/or precise holes are required.
• Speed of rotation can be changed on a pillar drill to
suit the material or drill size and also the efficiency.
• Mains electric hand drills should not be used on
aircraft unless they are flame or spark proof.
• Cordless battery operated drills offer more flexibility,
but again should be flame or spark proof.
• A drills chuck size indicates the maximum size bit it
can accommodate.
 Pneumatic Drills

• Pneumatic power drills can be used for the same

tasks as an electric drill, but it is flame/spark proof.
• Three most common types are:
1. Straight Drill
2. Angled Drill
3. Pistol Grip Drill
• Operation of these drills can be by a trigger, push
button or lever mechanism.
• The type of drill used for the task depends on the
access available.
 Straight Pneumatic Drills
Operating
Button Chuck

• Chuck capacity of a straight pneumatic drill is either

5mm or 8mm.
• Drill bit securing is usually by a chuck key, although
some have the bulkier key-less chucks.
• The compressed air is ejected at some point on the
body of the drill.
• The more expensive types form a cone around the
chuck to blow swarf away from the operators face.
 Angled Pneumatic Drills
• These drill types
secure the drill bits
via a pair of collets.
• Each set of collets
Rotatable Head only fits one size of
Collets drill bit.
• The collets screw into
the rotating part of
the drill and are
tightened by collet
Right-Angled Head
spanners supplied
with the drill.
 Pneumatic Hammers

• Pneumatic Hammers provide the percussion impact

to enable solid rivets to be formed.
• Usually made from aluminium alloy castings to
reduce the weight.
• Two basic types refer to the stroke and hitting speed
of the hammers:
1. Short-Stroke fast-hitting giving light blows.
2. Long-Stroke slow-hitting giving heavy blows.
• The short stroke is used mostly for aircraft riveting as
the majority of rivets are the smaller diameter.
 Hammers Shapes
Pistol Grip
Operating
Lever
Swan Neck

Snap Securing
Spring

Air Connection

Straight or
Push Button
Operating Button
 Pneumatic Miller

Rubber Feet
Operating
Cutting Blade Trigger

• Pneumatic Miller (Microshaver) is used to ensure the

heads of countersunk rivets leave a smooth surface.
• They have a height adjustment to prevent the high
speed blades from cutting too deep into the skin.
• Two rubber feet ensure stability of the tool during
operation.
Unformed Formed Milled
Rivet Rivet Rivet
 Nibblers

• A nibbler is basically a high speed hacksaw used for

cutting holes in thin sheet.
• These small to medium sized holes will require hand
finishing to dimensions after cutting.
• The cutting action is similar to a reciprocating punch
that nibbles a path approximately 1mm wide, so care
must betaken to cut on the ‘waste’ side of the line.
• This tool is very good at rapid metal cutting but can
easily become uncontrollable when used by the
inexperienced.
 Pneumatic Tool Maintenance

• The air supply for pneumatic tools should be filtered

and moisture free.
• Daily draining of water traps within the workshop
gallery will help keep moisture away.
• These ‘air tools’ have built in filters, a pressure
reducing valve and a facility to allow lubrication.
• Lubrication usually by placing drops of oil into the
hose line before and after use, or via a small
reservoir connected to the same point.
• Ensure both ends of the connecting hose are free
from debris before connecting.
Any Questions on
Powered Tools?
 Abrasive Wheels
• Abrasive Wheels (Bench Grinder)
usually have coarse grade wheel
for rapid metal removal and a fine
one for finishing work.
• Protective guards and adjustable
rests are fitted and should always
be used by the operator.

• Two main types of abrasives used

for grinding wheels are:
1. Aluminium Oxide
(Corundum)
2. Silicon Carbide
(Carborundum)
 Aluminium Oxide

• Aluminium Oxide wheels are next in hardness to

diamonds, with two varieties, the blue sapphire and
the red ruby.

• They are used to grind ferrous metals of high tensile

strength.

• Aluminium oxide wheels must never be used with

soft materials, they are liable to clog and this may
cause it to explode!
 Silicon Carbide

• Silicon Carbide formed by fusing silica with carbon in

an electric furnace.

• Used mainly on low tensile, brittle metals like cast

iron, but can also be used on non-ferrous metals such
as aluminium, brass or copper.
 General
• Only trained and authorised personnel are allowed to
use abrasive wheels.

• The machine should be secured to a bench or wall.

• Wheels should be secure, not chipped and the

bearings have no excessive play.

• Guards correctly attached and secure, with the tool

rests set at the correct distance.

Continued...
• No loose clothes to catch on the rotating wheel.

• Eye protection should be worn.

• Correct fire extinguisher available.

• Operator should stand on an insulated mat.

• The item being ground should be moved across the

full width of the wheel to avoid grooving it.

Continued...
• Uneven wheels can be dressed by an authorised
dresser using special extra hard tools.

• When grinding cutting tools keep them cool as high

temperatures could draw out their temper.

• On completion the machine should be switched off

but not left unattended until the wheel is stationary.

End
Any Questions on
Abrasive Wheels?