LG-MEMCOR0111A

USE POWER TOOLS

LEARNER GUIDE
USE POWER TOOLS

Published by

HEART TRUST/NATIONAL TRAINING AGENCY

Produced by

Learning Management Services Department Gordon Town Road Kingston 7 Jamaica W.I.

This material is protected by copyright. Copying this mat erial or any part of it by any means, including digital or in any form is prohibited unless prior written permission is obtained from the HEART Trust/NTA.

*** 2003 ***

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TABLE OF CONTENTS
PAGE Introduction .......................................................................................................................... Welcome ............................................................................................................... This Competency Unit ................................................................................................ Before You Start ......................................................................................................... Planning Your Learning Programme .......................................................................... Self-Assessment Checklist.......................................................................................... How To Use This Learner Guide ................................................................................ Using the Computer and other Resources ................................................................... Method of Assessment ................................................................................................ 1 1 1 2 2 3 4 5 5

Element 1: Use Power Tools...............................................................................................

Self-Assessment Checklist.........................................................................................

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INTRODUCTION Welcome Welcome to the Learner Guide for Unit of Competency Use Power Tools. This is just one of a number of Learner Guides produced for the Core Skills stream of the Metal Engineering and Maintenance Industry, and it is designed to guide you, the learner, through a series of learning processes and activities that will enable you to achieve the specified learning outcomes for the competency unit. The content of this guide was developed from the Competency Standard MEMCOR0111A, which is one of the basic building blocks for the National Vocational Qualification of Jamaica (NVQJ) certification within the industry. Please refer to your Learner Handbook for a thorough explanation of standards and competencies, and how these relate to the NVQJ certification. You are also advised to consult the Competency Standard for a better understanding of what is required to master the competency.

This Competency Unit Use Power Tools addresses the knowledge and skills requirements to effectively use power tools. There is one main area or element:

Element 1:

Use power Tools

As you go through each element, you will find critical information relating to each one. You are advised to study them carefully so that you will be able to develop the necessary knowledge, skills and attitudes for using power tools.

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Before you start Before you start this Learner Guide, you need to: a. Obtain a Learner Logbook that you will use to record evidence of your new skills/competence. As you demonstrate your new skills, record your activities and have your learning facilitator sign off on them. This will allow you to provide evidence of your competence when you are being assessed against the competency standard. b. Ensure that you have access to the facilities and equipment necessary for learning. c. Ensure that your learning resources are available. d. Ensure that you are wearing suitable clothing, that tools and equipment are safe, and that the correct safety equipment is used. e. Plan your learning programme (see below) f. Understand how to use this Learner Guide (see below)

Planning your learning programme The self-assessment checklist on the following page will assist you in planning your training programme as it will help you to think about the knowledge and skills needed to demonstrate competency in this unit. As you go through the checklist you will be able to find out what competencies you have already mastered and which ones you will need to pay more attention to as you go through the learning process. To complete the self-assessment checklist, simply read the statements and tick the Yes or No box. You should do this exercise now.

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Self-Assessment Checklist Use Power Tools

Element 1 1.

Use Power Tools

Yes

No

I can select appropriate power tools according to the task requirements I can use power tools following a determined sequence of operations which may include clamping, alignment and adjustments to produce desired outcomes to job specifications which may include finish, size or shape I can adhere to all safety requirements before, during and after use I can identify and mark unsafe or faulty tools for repair according to designated procedures before, during and after use I can undertake operational maintenance of tools, including hand sharpening, according to standard workplace procedures, principles and techniques I can store power tools safely in appropriate location according to standard workshop procedure and manufacturers recommendations

( )

( )

2.

( ) ( )

( ) ( )

3. 4.

( )

( )

5.

( )

( )

6.

( )

( )

How did you do? If you ticked all or most of the Yes boxes then you might not need to go through the entire guide. Ask your learning facilitator to assist you in determining the most appropriate direction for this competency. If you ticked a few of the Yes boxes or none at all then you should work through all of the guide, even though some of the material my be familiar to you. Plan your learning based on your answers. Be sure to involve your learning facilitator in the planning process.

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How to use this Learner Guide This Learner Guide is designed to assist you in working and learning at your own pace. We suggest that you: Go through the sections/elements as they are presented (starting at Section 1) Check your progress at each checkpoint to ensure that you have understood the material Observe the icons and special graphics used throughout this guide to remind you of what you have to do and to enhance yo ur learning. The icons and their meanings are as follows: Complete Assessment Exercise This exercise requires you to think about the knowledge and skills that you have or will develop in this competency unit.

Definition Box Words/phases are defined or explained in this box. The words/phases being explained are in bold print.

Checkpoint This denotes a brain teaser and is used to check your understanding of the materials presented. No answers are provided for the questions asked.

Activity This denotes something for you to do either alone or with the assistance of your trainer/supervisor.

Reference Points you to the reference materials and other support documents or resources used in compiling the unit content.

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Ask your learning facilitator for help if you have any problems with the interpretation of the contents, the procedures, or the availability of resources. Complete each activity as you come to it. If the activity requires you perform an actual task, be sure to tell your learning facilitator when you get to that activity so that he/she can make any arrangements, if necessary. Get your learning facilitator to sign and date the Learner Logbook when you have completed an activity. Complete the self-assessment checklist at the end of each section or element.

When you have worked through all elements of the guide, and when you can tick every Yes box, you are ready for assessment and may ask your learning facilitator to assist you in making the arrangement to have your performance assessed.

Using the Computer and Other Resources Where your activities refer you to the library, computer and Internet resources, ask your learning facilitator to assist you with locating these resources. If you are getting your training in an institution, there may be a library and a computer laboratory. If this is not the case, visit the local library and find out what resources are available. If you are new to the computer and the Internet, someone in the computer room should be able to show you how to use these resources. Please note that in many of your activities you have been referred to information on the Internet. This is because the Internet has a vast amount of information that can help you in acquiring the particular competencies. We would like to advice you, however, that we cannot guarantee that all the sites will be available when you need them. If this happens, ask your learning facilitator to assist you with locating other sites that have the information you require.

Method of Assessment Competency will be assessed while work is being undertaken under direct supervision with regular checks, but may include some autonomy when working as a team. You are advised to consult the associated competency standard for further details relating to the assessment strategies. You may now start your learning. Have fun while you work!

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ELEMENT 1:

USE POWER TOOLS

LEARNING OUTCOMES

As you go through this element it will provide you with the knowledge, skills and attitude required to use power tools. Your learning facilitator is there to assist you through the various activities. Upon completion of the element you should be able to: 1. 2. 3. 4. 5. 6. Select appropriate power tools according to task requirements Use power tools in correct sequence according to job sheet specifications Follow all safety requirements during and after using power tools Identify and mark faulty power tools Perform operational maintenance of power tools Store power tools safely

SELECTING AND USING APPROPRIATE POWER TOOLS

You should analyze the work sheet specification then choose the most suitable power tool/s that can best be used to achieve the desired out come. Power tools are power driven metal cutting or forming machines that you will use to cut or shape metals by: Removing chips Drawing Shearing Pressing Using electrical machining processes

These tools are so constructed that they: Hold and support the work piece Hold and support the cutting tool Rotate/reciprocate to the cutting tool or the work Can feed the cutting tool or the work so that the cutting action and accuracy is achieved

They all fall into three categories: Chip-producing tools- these form metal to size and shape by removing unwanted sections Non-chip-producing tools- these will form metals to size and shape by: Drawing Pressing Punching and, Shearing

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Modern tools- these use electrical or chemical energy to form metal to size and shape

Before you use any power tool for work, try to access information on its performance to determine its suitability for the type of work to be performed. These specifics are: Metal removal rate (MRR)- depends on the: Cutting speed Rate of feed Depth of cut

Accuracy-how accurate the cutting tool can be positioned to a given location once Repeatability-the ability to position the cutting tool repeatedly to any given position

The machine shop that you are familiar with has a lot of machines that are used for various operations, namely: Threading Drilling Sawing Filing and, Grinding

Some machines can perform several of these operations and when you actually use one of these machines, be sure that the process is: Economical - use a machine that has the right metal removal rate and accuracy etc Time saving - use the most appropriate machine for the job; the machine that will enable you to do multiple operations on a single setting of the work piece

The standard power tools that you will become familiar with in a machine shop are: Drill Press This is used to produce round holes in materials. They range from the simple ones in a machine shop to the much larger automated ones in large manufacturing industries. You may use them for: Drilling Reaming Spot facing Counter sinking Tapping Counter boring

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You can produce holes in work with a flat drill, twist drill, straight flute drill, three and four flute drills, and single-flute drills: Flat drill Twist drill Straight flute Three and four flute drills - best used on chilled iron - suitable for drilling castings - used to drill holes in thin sheet metal and brass - are used when a hole exists and has to be opened out to a diameter slightly larger, these drills will not drill a solid work piece

Fig. 1 Bench Type Sensitive Drill Press Fig. 2 Standard Upright Drilling Machine (Krar, Steve F., Check, Albert F.,(1997) Technology of Machine Tools, fifth edition, McGraw-Hill)

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Fig. 3 Diagram showing the parts of a twist drill bit used in drilling machines (Krar, Steve F., Check, Albert F.,(1997) Technology of Machine Tools, fifth edition, McGraw-Hill)

CHECKPOINT What are power tools? What are they used for? Name two important features a drill should have

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Threading When you have a number of holes to be tapped (internal threading), doing this by hand will be long and tedious. Using a drilling machine running at a slow speed is ideal. For cutting external threads on bars or tubes a die is used. Grinder This is used to cut a work piece to accurate size and to produce high surface finish. There are several different grinders for various processes: Surface grinders-used to produce flat, angular, or contoured surfaces Cylindrical grinders-used to produce internal and external diameters, which may be straight, tapered or contoured. Cutter and tool grinders-used to sharpen milling machine cutters Bench/pedestal grinders- used to sharpen, chisels, punches, drills, and lathe tools.

Fig. 4 Diagram showing grinders being used to sharpen tools (Krar, Steve F., Check, Albert F.,(1997) Technology of Machine Tools, fifth edition, McGraw-Hill)

ACTIVITY Have your learning facilitator discuss with you a sample specification and carry out a threading activity according to the same specifications.
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Metal saws These are used primarily for the cutting of metals. There are two main types you will see in your workshop: the horizontal band saw and the cut off saw.

Fig. 5 Types of motorized metal saws (Krar, Steve F., Check, Albert F.,(1997) Technology of Machine Tools, fifth edition, McGraw-Hill) Jigsaws They are used to cut curves and round. There are two types: The modern corded jigsaw is a sophisticated curve cutting machine with a multitude of features that enable it to accomplish all

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kinds of cuts in all kinds of materials. These jigsaws can cut a certain thickness of aluminum and mild steel.

Sanders Sanding machines are primarily used for polishing and providing high quality finishing. Here are some examples:

4300A Belt Sander

4200A Belt Disc Sander Fig. 6 Types of Sanders americanmachinetools.com

4400A Disc Sander

You may use power tools for: adjusting dismantling assembling finishing cutting scraping threading cleaning lubricating tightening simple tool repairs hand sharpening

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ACTIVITY Select an appropriate power tool according to the task requirement designated by your learning facilitator and discuss your choice.

USING POWER TOOLS IN CORRECT SEQUENCE ACCORDING TO JOB SHEET SPECIFICATIONS

The sequence in which power tools are used should be determined from the type of operation to achieve the desired outcome. Let us say that you intend to carry out a drilling operation. Unless the work is large enough that there is no chance of movement taking place, you should always clamp the work. A great majority of work may be held in a vise or clamp. Care should be taken to ensure that the cutting tool passes through the work safely without touching the vise. Ensure that all necessary marking out details are done prior to clamping so that the work is aligned correctly in the vise or clamp. If work is aligned incorrectly then adjust to suit the requirement. Adjust according to the requirement which may affect the size, shape and ultimately the finish.

ACTIVITY After discussing the specificatio n sheet with your learning facilitator, carry out a determined sequence of operation using a power tool.

FOLLOWING ALL SAFETY REQUIREMENTS

What should you do before using powered hand tools? Ensure that you have been properly trained to use the tool safely. Read the operator's manual before using the tool and operate the tool according to the manufacturer's instructions.

Ensure that the power tool has the correct guard, shield or other attachment that the manufacturer recommends.

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To prevent shocks, ensure that the tools are properly grounded using a three-prong plug, are double- insulated (and are labelled as such), or are powered by a low-voltage isolation transformer: this will protect users from an electrical shock.

Fig. 7 Electrical plug When using the tool:

Do not use electric-powered tools in damp or wet locations Keep guards in place, in working order, and properly adjusted. Safety guards must never be removed when the tool is being used Avoid accidental starting. Do not hold a finger on the switch button while carrying a plugged- in tool Safety switches must be kept in working order and must not be modified. If you feel it necessary to modify a safety switch for a job you're doing, use another tool Work areas should have adequate lighting and be free of clutter Observers should remain a safe distance away from the work area Be sure to keep good footing and maintain good balance Do not wear loose clothing, ties, or jewelry when operating tools Wear appropriate gloves and footwear while using tools

CHECKPOINT Why is it important to maintain a good balance when using power tools?

IDENTIFYING AND MARKING FAULTY POWER TOOLS

When and how should you inspect powered hand tools?

Inspect tools for any damage prior to each use. Check the handle and body casing of the tool for cracks or other damage. If the tool has auxiliary or double handles, check to see that they installed securely. Inspect cords for defects: check the power cord for cracking, fraying, and other signs of wear or faults in the cord insulation. Check for damaged switches and ones with faulty trigger locks. Inspect the plug for cracks and for missing, loose or faulty prongs.

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ACTIVITY Discuss safety requirements during use of power tools with colleagues.

What should you do if you find a tool defective?

If a tool is defective, remove it from service, and tag it clearly "Out of service for repair". Replace damaged equipment immediately - do not use defective tools "temporarily". Have tools repaired by a qualified person - do not attempt field repairs.

ACTIVITY Mark unsafe or faulty tools for repair and allow your learning facilitator to check your work.

PERFORM ING OPERATIONAL MAINTENANCE OF POWER TOOLS

Servicing and storing tools:

Never modify a tool to use for a job it's not intended to do Disconnect power tools while servicing or storing Do not wrap the cord around the tool for storage Use only damp cloth to clean tools Never let any liquid get inside the tool Never immerse any part of tool into a liquid Where self-lubricating bearings are use period lubrication is not required

If tools need sharpening ensure that tools are sharpened to manufacturers specifications. Tools specific angles must be maintained. Sharpening of tools: You should sharpen the cutting tool usually with a floor grinder so that dangerous chips cannot be formed when cutting metals. The tool can be ground so that the chips are broken into short lengths. Long continuous chips are produced when cutting soft and tough steels, but there are no problems experienced when cutting brittle steels and cast iron.

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A small groove can be ground across the top face of the tool 3mm to 6mm back from the cutting edge. The groove does not have to be very deep, but it has the effect of breaking up the chips into short lengths.

Let us look at the example of drill bits: Drill bits should be sharpened (by a suitable grinder) to facilitate easy boring of metals. The drill point should be central and the lip angles equal when properly ground. Errors that can occur when ground are: lips at unequal angles, lips of unequal lengths, lips having both unequal angles, and unequal lengths in each case, the cutting is unequally shared between the two cutting edges and the hole drilled oversize. The center of the drill point should be ground thinner to prevent it from reducing the efficiency of the drill. This is because it gets thicker as grinding reduces its length. Gauges can be used to check the lip angle and the point. Fig. 8 Drill Grinding

(Krar, Steve F., Check, Albert F.,(1997) Technology of Machine Tools, fifth edition, McGraw-Hill)

Refer to: Learner Guides for competency MEMCR10071A Use Hand Tools, MEMCR10021A Apply Principles of Occupational Health and Safety (OH&S) in Work Environment , LG MEMMPO0021A Perform General Machining, (Ask your learning facilitator how to access them)

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Refer to: Learner Guide for competency MEMMPO0081A Use Workshop Machines for Basic Operations, (Ask your learning facilitator how to access this)

ACTIVITY Have your learning facilitator demonstrate tool sharpening procedures and techniques and follow his/her example. Discuss what you may have done incorrectly and use the technique suggested.

STORING POWER TOOLS SAFELY

When you are developing a system of racks, bins and tool panels, make it easy to find the right tools quickly. Don't store tools, supplies or spare parts in the aisle or on the floor where they become tripping hazards. Store tools in a dry place

CHECKPOINT What do you have to take into consideration when storing power tools?

ACTIVITY Develop your system of storing tools and have your learning facilitator check and comment on how best to improve it.

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ARE YOU READY TO PROVE YOUR COMPETENCY? Now that you have complete this element see if you have fully grasped all the components by doing the following self-assessment: Checklist 1 1. I know how to select appropriate power tools according to the task requirements Yes No

( )

( )

2.

I know how to use power tools following a determined sequence of operations which may include clamping, alignment and adjustments to produce desired outcomes to job specifications which may include finish, size or shape ( ) I can adhere to all safety requirements before, during and after use I know how to identify and mark unsafe or faulty tools for repair according to designated procedures before, during and after use I understand how to undertake operational maintenance of tools, including hand sharpening, according to standard workplace procedures, principles and techniques I can store power tools safely in appropriate location according to standard workshop procedure and manufacturers recommendations ( )

( ) ( )

3. 4.

( )

( )

5.

( )

( )

6.

( )

( )

Checklist 2 1. Appropriate power tools are selected according to task requirements

Yes

No

( )

( )

2.

Power tools are used to follow a determined sequence of operations which may include clamping, alignment and adjustments to produce desired outcomes to job specifications which may include finish, size or shape ( )

( )

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Checklist 2(Contd)

Yes

No

3. 4.

All safety requirements are adhered to before, during and after use

( )

( )

Unsafe or faulty tools are identified and marked for repair according to designated procedures before, during and after use ( ) Operational maintenance of tools is undertaken including hand sharpening, according to standard workplace procedures, principles and techniques ( ) Power tools are stored safely in appropriate location according to standard workshop procedure and manufacturers recommendations ( )

( )

5.

( )

6.

( )

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Learning Management Services Department Learning Resources Development Unit Learner Guide Feedback Form
Your feedback on the Learner Guides is important to us. Please complete the form below to indicate areas for review as you see necessary. For each component tick [v ] the appropriate column. Learner Guide Title: Learner Guide Code:

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