Shop Tools and Techniques 2
Industrial Tool Usage
• Two categories• Hand tools• Machine tools
• Importance of hand tools should not be overlooked
• Bench work includes operations of inspecting, fitting, and assembling
Shop Tools and Techniques 4
Two Classes of Hand Tools• Noncutting
• Include vises, hammers, screwdrivers, wrenches, pliers, and etc.
• Used basically for holding, forming, assembling, reassembling, destroying, or dismantling parts
Shop Tools and Techniques 5
Bench Vise
• Also Called Machinist’s Vise
• Used to hold small work securely for sawing, chipping, filing, polishing, drilling, reaming, and tapping
• Size determined by width of jaws
Shop Tools and Techniques 7
Bench Vise
Solid or swivel base
Jaw caps made of brass, aluminum, or copper to protect the work surface from being marred or damaged
Shop Tools and Techniques 9
Clamping Device
• C-Clamp• Popular in Plant settings• 2” to 12”• Allows clamping two or
more items together or clamping one item to another
Shop Tools and Techniques 11
Hard Faced Hammers
• Ball Peen• Peen: smaller, rounded
end• Used in riveting or
peening operations
• Variety of sizes
Shop Tools and Techniques 12
Hard Faced Hammers
• Sledge• Largest striking surface• Used in persuading or
“nudging” objects• Variety of sizes: head
mass range 1 to 12 lb• Smaller sizes used for
gentle persuasion• Larger sizes used for
serious business
Shop Tools and Techniques 13
Hard Faced Hammers
• Claw type• Smaller striking surface• Claw end can be used
for prying nails and etc
• Variety of sizes: head mass range 10 oz to 22 oz
• Smaller available with ergonomic handles
Shop Tools and Techniques 14
Soft-Faced Hammers
• Faces made of plastic or rubber.
• Plastic or rubber faced hammers are fastened to steel body and replaced when worn
• Used in assembling or dismantling parts so finished surface of work not marred
Shop Tools and Techniques 15
Soft-Faced Hammers
• Heads with replaceable faces made of plastic or rubber
Shop Tools and Techniques 16
Soft-Faced Hammers
• Heads made of rawhide, aluminum, brass, copper, copper/bronze or lead
• Entire head made of above material
• Used in assembling or dismantling parts so finished surface of work not marred
Shop Tools and Techniques 18
Soft-Faced Hammers
• Dead Blow hammers• Filled with lead or steel shot• Do not “bounce back” or
“rebound” after striking object
• Do not lose shape and last longer than lead hammers
Shop Tools and Techniques 19
Safety Precautions When Using a Hammer1. Be sure handle is solid and not cracked
2. Be sure head is tight on handle and secured with proper wedge to keep handle expanded in head
3. Never use with greasy handle or when your hands are greasy
4. Never strike two hammer faces together
Shop Tools and Techniques 20
Screwdrivers
• Two most common types • Standard or flat blade
• Blades for smaller make of round stock• Blades for larger often square for
leverage• Phillips
• Different sizes and styles• Standard shank• Stubby shank• Offset
Shop Tools and Techniques 21
Regular Screwdrivers
• Tip for use with slotted-type screw
• Manufactured in various sizes• To suit various-sized slots in heads of
fasteners
Shop Tools and Techniques 22
Phillips Screwdrivers
• Tip for use with Phillips-type screws
• Manufactured in sizes: #1, #2, #3, #4• To suit various-sized recesses in heads
of fasteners
Shop Tools and Techniques 23
Torx Screwdrivers
shaped tip for use with Torx-type recessed screw heads
• Manufactured in assorted sizes• To suit various-sized recesses in heads
of fasteners
Shop Tools and Techniques 24
Square Head Screwdrivers• Tip for use with Square-type screw
heads• Manufactured in assorted sizes
• To suit various-sized recesses in heads of fasteners
Shop Tools and Techniques 25
Star Head Screwdrivers
• Star shaped tip for use with Star-type recessed screw heads
• Manufactured in assorted sizes• To suit various-sized recesses in heads
of fasteners
Shop Tools and Techniques 26
Allen Head Screwdrivers• Tip for use with Allen-type screw
heads
• Manufactured in assorted sizes
Shop Tools and Techniques 27
Care of a Screwdriver
1. Choose correct size of screwdriver for job
• Too small, both screw recess and tip of screwdriver may become damaged
2. Do not use screwdriver as pry bar, chisel, or wedge
3. If tip or handle breaks or wears out, replace the screwdriver
Shop Tools and Techniques 28
Wrenches
• Many types used in machine shop work
• Each suited for specific purpose• Name derived from use, shape, or
construction
• Most available in both inch and metric measuring systems
Shop Tools and Techniques 29
Open-End Wrenches
• Single-ended or double-ended
• Openings usually offset at 15º angle• Permits turning nut or bolt head in
limited spaces by "flopping" wrench• Double-ended have different-size
opening at each end
Shop Tools and Techniques 30
Box-End Wrenches
• Completely surround nut and useful in close quarters where only small rotation of nut can be obtained at one time
• Box end has 4, 6, or 12 precisely cut notches around inside face
• Notches fit closely over points on outside of nut
• Have different sizes at each end
Shop Tools and Techniques 31
Combination Wrenches
• Box end at one end
• Open end at other• May have socket attached as one end
• Wide variety available
Shop Tools and Techniques 32
Line Wrenches
• Also referred to as Flared nut wrenches
• Six point construction• One section of wrench
head removed to enable the head to encircle a flared nut with a line or tube running through it.
Shop Tools and Techniques 33
Spud Wrenches
• Similar to box or open end wrenches
• Only one end has a wrench head
• Other end used as an alignment tool
Shop Tools and Techniques 34
Striking End Wrenches
• Box or open end wrenches
• Only one end has a wrench head
• Other end used as an striking surface
Shop Tools and Techniques 35
Torque Wrenches
• Specialized wrenches for tightening nuts and bolts to specifications
• Beam Type
• Dial Type
• Digital Type
• Clicker Type
Shop Tools and Techniques 40
Torque Wrenches
3/8” Drive will measure 25-250 inchpounds
3/8” Drive will measure 10-75 footpounds
1/2” Drive will measure 20-150 footpounds
Shop Tools and Techniques 42
Sockets
• Size of Drives• ¼ inch
• Light duty• ⅜ drive
• General purpose• ½ inch drive
• General Purpose• ¾ inch drive and above
• Industrial Applications
Shop Tools and Techniques 46
Sockets
Specialty
Hex Head
Torx Head Internal
Torx Head External Flare Nut Crow’s Foot
Shop Tools and Techniques 50
Adjustable Wrenches
• May be adjusted to within certain range to fit several sizes of nuts or bolt heads
• Useful for odd-size nuts or when proper size not available
• Can slip when not properly adjusted to flats of nut
Shop Tools and Techniques 51
Pipe Wrenches
• Made of Cast Iron, Aluminum, or Beryllium/Copper
• Used to loosen or tighten pipe connections• 6” to 48”
Shop Tools and Techniques 52
Allen Setscrew Wrenches• Commonly called
hex keys• Hexagonal fits into
recesses of socket head setscrews and capscrews
Shop Tools and Techniques 54
Pin Spanner Wrenches
• Specialized wrenches supplied by machine tool manufacturer for use on specific machines
• Supplied in various sizes
Shop Tools and Techniques 55
Pin Spanner Wrenches
• Fixed-face spanners position in two fixed location holes on face of special nut or threaded fitting on machine
Shop Tools and Techniques 56
Pin Spanner Wrenches
• Adjustable-face spanners adjust to various positions of two holes on face of special nut or threaded fitting on machine
Shop Tools and Techniques 57
Pin Spanner Wrenches
• Hook-pin spanner used on circumference of round nut
• Pin of spanner fits into hole in periphery of nut
Shop Tools and Techniques 58
Strap Wrenches
• Specialized wrenches for use on pipe or large tubing
• Supplied in various sizes
Shop Tools and Techniques 59
Chain Wrenches
• Specialized wrenches for use on pipe or large tubing
• Supplied in various sizes
• Similar to the Strap wrenches
Shop Tools and Techniques 60
Hints on Using Wrenches1. Always select wrench that fits nut or
bolt properly• Don’t use inch on metric or vice versa
2. Pull rather than push on wrench3. Always be sure nut is fully seated in
wrench jaw• Misalignment will cause slippage
4. Use wrench in same plane as nut or bolt head
Shop Tools and Techniques 61
Pliers
• Useful for gripping and holding small parts for certain machining operations or when assembling parts
• Many types and sizes
• Names by shape, function or construction
Shop Tools and Techniques 62
Types of Pliers
• Combination or slip-joint pliers• Adjustable to grip both large and small
work• Grip work when small holes must be drilled
or for bending or twisting light, thin materials
Shop Tools and Techniques 63
Types of Pliers
• Side-cutting pliers• Used mainly for cutting, gripping, and
bending of small diameter (1/8 in. or less) rods or wires
Shop Tools and Techniques 64
Types of Pliers
• Channel-Locks• Available in variety of
sizes• Useful for holding just
about anything, loosening and tightening about anything, and about anything else you can think of.
Shop Tools and Techniques 65
Types of Pliers
• Needle-nose pliers• Available in both straight- and bent-nose
types• Useful for holding very small parts,
positioning them in hard-to-get-at places and bending wire
Shop Tools and Techniques 66
Types of Pliers
• Snap Ring pliers• External Type shown• Used to remove or install external snap
rings
Shop Tools and Techniques 67
Types of Pliers
• Snap Ring pliers• Internal Type shown• Used to remove or install internal snap
rings.
Shop Tools and Techniques 68
Types of Pliers
• Vise-grip pliers• Extremely high
gripping power because of adjustable lever action
• Many different styles• standard jaws, needle
jaws and C-clamp jaws
Shop Tools and Techniques 69
Hints on Using Pliers
1. Never use pliers instead of wrench
2. Never attempt to cut large-diameter or heat-treated material with pliers
3. Always keep pliers clean and lubricated
Shop Tools and Techniques 71
Two Classes of Hand Tools• Cutting
• Include saws, grinders, files, and etc.• Used to separate, part, trim, or divide
parts
Shop Tools and Techniques 72
Sawing, Filing and Scraping• Often necessary to perform certain
metal-cutting operations at bench or on job
• Common tools• Hacksaws• Files• Scrapers
Shop Tools and Techniques 73
Pistol-Grip Hand Hacksaw
• Solid frame rigid and will accommodate blades of one specific length
• Adjustable frame more common and will take blades from 10 to 12 in. long
• Wing nut provides adjustment
Shop Tools and Techniques 74
Hacksaw Blades
• High-Carbon Steel Blades• Short lasting• Blades relatively soft
• Blade wears quickly• Inexpensive
• High-Speed Molybdenum or Tungsten-alloy Steel Blades
• Long lasting• Blades with hardened and tempered teeth
Shop Tools and Techniques 75
Hacksaw Blades
• Two types• Solid blade (all-hard)
• Hardened throughout and very brittle• Flexible blade
• Teeth hardened, while back of blade soft and flexible
• Stand more abuse than all-hard blade, but will not last long in general use
• Used on channel iron, tubing, copper and aluminum
Shop Tools and Techniques 76
Blade Pitch
• Number of teeth per inch• Manufactured in various pitches
• 14, 18, 24, and 32• General use choice – 18 in. tooth blade• Choose as coarse blade as possible
• Provides plenty of chip clearance and to cut through work as quickly as possible
• Should have at least two teeth in contact with work at all times
• Prevent work from jamming and stripping teeth
Shop Tools and Techniques 81
Files
• Hand cutting tool made of high-carbon steel
• Series of teeth cut on body by parallel chisel cuts
• Used to remove surplus metal and to produce finished surfaces
• Manufactured in variety of types and shapes
• Two classes: single-cut and double-cut
Shop Tools and Techniques 82
Single-cut Files
• Single row of parallel teethrunning diagonally across face
• Used when smooth finish desired
• Include mill, long-angle lathe, and saw files
Shop Tools and Techniques 83
Double-cut Files
• Two intersecting rows of teeth• First row coarser and called overcut• Second row called upcut
• Hundreds of cutting teeth• Provides for fast removal of metals and
easy clearing of chips
Shop Tools and Techniques 84
Degrees of Coarseness
• Both single- and double-cut files come in various degrees of coarseness
• Rough• Coarse• Bastard• Second-cut• Smooth• Dead smooth
Most Common
Shop Tools and Techniques 85
Machinist Files
• Types most commonly used in shop
• Flat• Hand• Round• Half-round• Square
• Pillar • Three-quarter• Warding• Knife
Shop Tools and Techniques 87
Care of Files
1. Do not store files where they rub together
• Don’t throw into drawer with other files
2. Never use file as pry of hammer3. Do not knock file on vise or other
metallic object to clean it • Use brush or file card
4. Apply pressure only on forward stroke
Shop Tools and Techniques 88
Care of Files
5. Do not press too hard on new file• Too much pressure also results in
"pinning" which scratches work surface
• Small particles get wedged between teeth of file and clog it up
Shop Tools and Techniques 89
Rotary Files
• Teeth cut and form broken lines
• Dissipate heat of friction
• Useful for work on tough die steels, forgings, and scaly surfaces