SAFETY IN SHOP

Observe the following safety to avoid injury to yourself and co-

workers .
1. Be well dressed i.e., avoid loose garments, roll up sleeves,
put on suitable footwear and remove watch and ring.
2. Keep the work place neat and cl ean i.e., place the tool s at
p_roper position. The scraps an d chips should be dropped in
waste bins.
3. Concentrate on your job and avoid talking with co-workers.
4. The shops are no place to play . R unning and pushing in the
shop may cause ·accidents.
5. Understand the use of tools and machines before handling.
6. Never use dull tools. The use rnay damage the tools
completely or may lead to injury.
7. ln case you are in doubt contact the instructor. .,,
8. Always check the fitting of the handle in th e hammerhead.
9. Be familiar with the locations of First Aid Box a nd Fi re
Extinguisher in the shop. In case of e1nergency o ne sh o uld
reach them quickly.
I 0. Laziness _and carelessness are your deadly enemies.
Always be active and carefu l in the shop
 ,- TI

- ·-~ ~- • hy Use Hand Tools1

. v1th tools he IS all " - T
an without Tools is nothing 'oiing to a man his sentence 1s defined by Thom
~~ .. ' ela borated the importance of to as Carlyle h
as we11
~ -f 1h
The term T ooli ng· as applied 10 e ~ngineenng disciphne refers to any equipment .
helps tn the production of a product o any related act1v1t1es Simply speaking it ran or instruments
, fundamental type of hand iools such as a File to the very complex m achine t~ols su9es from them that give
Centre ch as a CNc Most
achining
Thus, one may ask the question - Why we still have to use band tools 1n this mod
",::-- ern age of teen
f . . no\og1es?
Yes, it is reasonable to say thal the e f1c1ency of any hand processes is low and th
depends h ighly upon the skill of ind1 viduals Perhaps 1t 1s fair to consider the folio e outcome quality
definite answer is given to the above que stion· _ wing points before a

1 . Accuracy

Although the C NC machine can give a higher degree of dimensional accuracy when co .
·
1ncons1stent outcome of han d f'tt·
I tng, th e extreme hig h degree of flatn ess requ1red for a mpared
s rf with the
mac hine slideway 1s usually obtained by hand scraping only u ace table or a

2. Flexibility

H an d proc esses are very flexible an d can be carried out at any place where necessary while machinin
processes a re not. In add1t1on, m ach1n1ng usually require a rigid setting up, while fitting is simple g

··::/ 3 . Q uantity
~~ -
For large b atch size advanced production mach ines a re commonly employed in order to maintain the
accuracy a s w e ll as the eff1c1ency But for "Jobbing type" works, such a s the manufacture of a prototype or
the repa1nng of a single component, it would be uneconomic to use these advanced machine tools Instead,
"Jo bbing type " w orks are usually produced by conventional machining and followed by hand fitting where
n ecessa ry

4 . Final Assem b ly

In the assembly of precise co mponent parts, no matter how accurate they are being produced , a skilled fitter
1s often required to give the n ecessary "finishing to uch" on them to ensure that everything goes together
correctly

<:,0
·,,.0' ,,_~ 3. Measuring Tools in Workshop
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3a . Calipers

Calipers are the very simple tools used together with a

~ ee ru le for the measurement or comparison of linear
;,wens ons An experienced worker can achieve +/-
0 osr,rn 1n the measu rement Ca li pers are classified in to
two typ es -

Outside Ca lipers

Outside cali pers (figure 1) are used for measuring external

d1mens1ons such as the length, diameter, or even the
Figure 1. Outside Cal ipers
thickness of a solid

Inside Cal ipers

Inside calipers (figure 2) are used for measuring internal

dimensions such as the diameter of a hole, or the width of
a slot etc. ...... ,,

Figure 2. Inside Calipers

3b. Vernier Calipers

Vern ier Ca li pers (figure 3) are more

precise tools cap able for measuring
externai d1mens1ons , internal
dimensions, and depths. Besides the
two pairs of measuring jaws and the
depth gauge , its main features also
include a main scale and a vern ier scale. Figure 3. Vernier Calipers

The resolution of a vern ier scale is determined by the difference

on th e dista nce of one division on the main scale and one
division on the vernier as shown in figure 4 For example: A
vernier scale of length 49m m is divided into 50 equal divisions.
That means ONE division on the vernier represents 49/50=0.98
mm while ONE division on the main scale represents 1mm .
Then , the resolution of the vern ier is 1mm - o98mm = 0.02mm .

Figure 4. Vernier Reading

 ~ \..,:=,"-; l";;?c- ,.- _,
:

3c. Vernier Height Gauge

A vernier height gauge (figure 5) is used _for measuring height of
an obJect or for marking lines onto an obJect of given distance
from a datum base.

Figure 5. Vern ier Height Gauge

... ·.

3d. Micrometer

A micrometer is a more precise measuring instrument than the vernier ca li pers. The accuracy is come from
the fine thread on the screw spindle. The ratchet prevents excess force from being applied. Generally , the
screw spindle has a pitch of 0.5mm. The thimble is divided into 50 equal divisions.

Common types of micrometers used in the workshops are: -

Outside Micrometer

~~ ~$:,,/'.::~-
An outside micrometer (figure 6) is used for measuring
external dimensions. The work to be measured is placed
between the anvil and the tip of the spindle.

Figure 6. Outside Micrometer

Inside Micrometer

This is similar in structure to an outside micrometer and

is used for measuring internal dimensions as shown in
figure 7.

Figure 7. Inside Micrometer

0
~
~
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~ ~-
.% %
l6% · ....., ~
~ C)

tii~~ -
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 oept/1 Mic

-
A de;::,tri mic ure 8) is used for measuring the
dept ri of a ho nd keyway etc. A complete set of

,
der:'l microme uipped with spindles of different
ierigths, which interchanged to suit different
measuring ranges.

Figure 8. Depth Micrometer

3e. Protractor

Engineer's Protractor

Engineer's protractor (figure 9) is a general purpose tool

used for the measuring / checking of angles e.g. the angle
of drill head, angle of cutting tool , and even for the
marking out of angles on a component part.
Vernier Protractor

Th is is a precision measuring tool that the accuracy of

measurement can reach i65 minutes of an angle through
the vern ier scale as shown in figure 10.

Figure 10. Vernier Protractor

3f. Combination Set

Combination set (figure 11) is a set of equipment combining the functions of protractor. engineer square,
steel rule, Centre finder, level rule, and scriber.
 Figure 11. Combination Set

3g. Dial Indicator

The principle of dial indicator (dial g~uge) 1s that thedhnear f ed

mechanical movement of the stylus is magnified an trans err f
to the rotation of pomter as shown in fiQure 12 The ac~u;acy o
dial indicator can be up to 0.001mm. It ,s usually used o
calibration of machme

4. Marking Out Tools in Workshop

Marking out ,, the P<ehm,nary ""'1< ol l)(Ovld,ng guMlance lines and . . , _ before cutting Bnd lnacl\ ng
SiZestines
The Theare in 3-D tools
common and lull-scale The~
Used for marking out arecan then be CU1 o, -
II follow- d lo lh< •equ •d • ~ • anc
 4a . Sc riber
.;, s.: rit-.er (f..gure 13) ,s used for scratching lines onto the Figure 13. Sc rib er
": ,r t>.:e It ,s made of t,ardened tool steel

4b. Engineer's Square

Engineer's square (figure 14) 1s made of hardened tool

steel It 1s used for checking the straightness and the
squaren ess of a workpiece It can also be used for
marking perpendicular lines onto a work piece

Figure 14. Engineer's Square

4c. Spring Dividers

Spring d1 v1ders (figure 15) are made of hardened tool

steel The legs are used for scribing arcs or ci rcles onto a
workpiece

Figure 15. Spring Dividers

4d . Pu nch

There are iwo types of pun ch namely the Centre Punch and the
Dot Punch A dot punch has a point angle of 60¢X and it is used
for making of small dots on the reference line . The centre punch
has a point angle of 90¢X as shown in fi gure 16 and it is used for Figure 16. Punch
making a large indent on a workpiece for drilling . Both punches are
made of hardened tool steel
 4 e. surfa ce pl ate de of malleable
17) is f11ad and scraped to a
Surface plate (figu re machine t surface is being
cast iron It has been s fh e fla rking out and for
high deg ree of flatn~a~e for rn fa nd on the floor ,
used as a datum su If it can s
measuring purposes
it is ca ll ed surface ta ble

Figure 17. Su rface Plate

4f. Angle Plate

An angle plate (fig ure 18) are used for supporting or

setting up work vertically, and are provided with holes and
slots through which securi ng bolts can be located . It is
made of ca st iron and ground to a high degree of
accuracy

Fig ure 18. Angle Plate

4g. Vee Block

Vee blocks (figure

iron or steel in 19) usually in a cou le
holding circu larcase-harden ing . They te are made of cast
Workpiece for marking o (enerally used for
u or machin ing .
 Figure 19. Vee Block

.
5. Hand Tools for Workshop
Sa. Bench Vice

A bench vice (figure 20) is th e device for holding the workpiece

where most hand processes to be carried out The body of the
vice is made of cast iron while the tw o clamping jaws are made
of hardened too\ steel. Some bench vice has a swivel base ,
which can set the workpiece at an angle to the table . The vice
height should be correct ergonomically . Vice clamps , made of
copper are fitted over the vice jaws when holding finished work
to avoid damage to the finish surfaces .

Care of Vices

a Do not direct impact the vice body by the hammer

b. Light hammering can be do ne on and only on the anvil
of the vice .
c . To avoid over clamping , the handle of the vice should
be tightened by hand only
Figure 20 . Bench Vice

.. .
Sb.Files

Files are the most important hand tools used for the removal of materials . They are made of hardened high
carbon steel with a soft 'tang' to which a handle can be fixed . Files are categonsed as follows:-

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- Figure 21 . File

Length - measured from the shoulder to the tip.

Shape - the cross-sectional profile .
Grade - the spacing and pitch of the teeth
Cut - the patterns of cutting edge

Save Edge

There are no cutting edges on one side of the hand file . The purposes for the save edge is to avoid the
worl<.er damage the work , when he is filing a shoulder position . Shape of Files

--

A
 f11o
d for roughing and
n file use n and parallel in
8 ctI0
i [___
ut
le

;---===
. The cof11 Iar ins two faces , sing e c
1 Figure 22a.
H nd file - ngu 11 on
1 ·s~ing It is a rectacul 1eel save edge
fin1 h II has double d one d file rectangular in
w1dtth on one edge, an 10 a han nd th ickness towards tJ ~ I . 22b Flat File
tee F"le - It is similar n width a two faces and Single Figure ·
2 fl a t , d sl1g hllY i eth on
section , tapere ble c ut te ~ - - - - - ; ; : :;:--
: -~7

C ~
the tip It has o~usideS- . n is a ch ord of a circle ..
cut teeth on tw . .,.he sectio . used for forming rad 11 , Half-round File
nd File - ' 1·p It is fl t Figure 22c.
3. Half-rou dS the 1 . used fo r finishing a
with its taper towar 11at s,de is
rooves , etc. and the .
9 rfaces und sectio n ta pen ng (----...
su . s of ro . h les ; .J
ound File - Thi s I for enlarging o , . ---.;.,-'
~:ard the end . It is usedcorners. Usually double cut in
roducing internal rou nd le cut for the smaller sizes .
P · nd sing · d
the larger sizes, a
. •s squar
I
e in section with tapere
5. square File - Th is ual ly double cut on all four
· la
towards the tip , and us ctangular slots or grooves.
·
faces. Itis use
d for filing re
Isa known as triang ular ~
-~- - - ----~
f"l e _It Is a
6. Three Squa_re , in section , with tapered towar s
d F:- ·[
"
--~ -
file This Is a triangular b th faces It is used for f1l1ng Figure 22f. Three Square File
the tip with double cut on o900
corners or angles less than
. . of small files with their shapes made in a way similar to the large
7. Needle Files - Needle f1lesdafre a setll d delicate works such as the repair of small instruments .
ones. They are generally use or sma an

Grade

This refers to the pitch (spacing) of the teeth that spread throughout the whole length of the file . F il es with a
rough er grade of cut give a faster metal removal rate but a poorer surface finish or the vi ce versa . It should
be noted that, for the same grade of cut, a longer file would have a coarser p itch than a shorter one .

The grades are as follows

Bastard cut - medium teeth for general purposes , especially suitable for mild steel.

Seco nd cut - finer teeth for cutting hard metals.

Smooth cut - fine teeth f or f.Inis

. h.1ng .

Three grades of cut are in comm on use

Cut Pattern

Single Cut - There is o .

f1n1sh It is suitable for~~~~~ :~t~i cutting teeth to one edge . It gives a I . .
Double Cut - Ad ess eff1c1ent cutt ing but a better
oub\e cut file has one set of t
eeth cu t at 70 degrees to
one edge d
, an another set of
grooves cu t at 45 degrees to the other edge It 1s thus more efficient 1n cutting It 1s easy to clog the teeth
when 1t 1s wo rk on the soft metal

Rasp - Very coarse teeth, like the nail, it is co mmonly used for the cutti ng off soft materi als such as rubber
PVC, or wood etc. '

Safety and Care of Files

Files teeth are brittle and the refore file should be pl aced properly and shou ld not be stacked on other too ls
New files should never be used on hard materials. E.g ca stings or weldi ng. Some brittle metal, e.g. brass 1s
not read ily filed w ith the worn teeth A new file should be used for these pu rpose s and the file must be kept
in another stock. Remove the pinn ing regula rly by a file ca rd/wire brush Cutting 1s carried on the forward
stroke . It is very da nger to use files without handles .

Sc. File Card

When fil ing the soft metals, the small pieces of metal wi ll tend to clog the teeth If the file 1s not cleaned , th is
small piece of metal will scratch on the surface of the work . We ca ll 1t pinning Th is case is frequently
appeared when applying a new smooth file on the soft metals . The pin ning can be removed with a File Card
as shown 1n figure 23, which is a wire brush mounted on a block of wood . Sweep th e file card along the
grooves on the fil e until the pinn ing 1s rem oved .

. - . - . -

Figure 23 . File Card

5d . Hacksaw

A hacksaw 1s generally used for cutting a metal into pieces

It cons ists of a frame and a saw blad e as shown be low It is a "U" shaped steel frame with a pistol handgrip
and a saw blade as shown in figure 24 The fr ame may be of fixed type to ta ke on ly on e le11gth of blad e, or
adjustable to take different blade lengths. It has a wing nut to adJust the tension of the blade

Figure 24. Hacksaw

Saw Blade
 h carbon steel , alloy steel or High S peed Stee 1 T hey are supplied acco rd ing to
de of h1g h
Saw blades are ma th and pItc
material , hardening. Ieng . de The all hard is very brittle ,
saw blade is supplied with all hard or flexible gra . t an a n le It is su itable for
1. Hardening - Usually ~k~llfu l user on ly The flexible grade is tough , so it can tw is g
th
and ii Is suitable for e beginner to use
ti g a curve or for the
cu in and High S peed Ste e l (HS S)
th saw blade IS supplied with High Carbon Steel (HCS) aw b la de will lost its
2. Material - Usually e om the heat generated by fraction of cutting T he HCS , s se
The HCS will annealed fr hard m etal The HSS can keep its hardness unless imp ro per u
hardness when cu tting the

3 _Pitch _ It is grading according to the number of teeth

per 25mm r 12" GOL OFLE X
Coarse blade (1 8T) 15 most suitable for soft material and GID STAHD:..RD STEt L c, .', <, '• SAN [
thick workpiece .
·. . ·- ,.-.. @.
Medium blade (24T) Is suitable for steel pipe
Fine blade (32T) Is suitable for the thin metal sheet and
thin copper pipe
.
• ' ►

•
~

11h, , .HOii Uh .

For safety , It Is advice that to keep at least 3 teeth of the

blade, stand on the workpiece

Figure 25. Pitches of Saw Blade

4. Length - The length of the blade is determ ined by the dista nce between the outside edges of the holes
which fit over the pegs

5. Set - The teeth have a "set" to either side alternately , which causes th e b lade to c ut a slit w ider th a n the
thickness of the blade to prevent Jamming.

Safety and Care of Hacksaw

1. The ~utting
pointing action is carried on the forward action only. So the blade m ust be mounted w ith its teeth
forward.
2. Suitable tension should be applied on the blade to avoid breakage or loosen .
3. Change the blade if some teeth are broken
4 . Avoid rapid and erratic strokes of cut
5. Avoid too much pressure
6. Workpiece must be hold firmly

Se. Hammer

The type most commonly used is the ball pein hammer w h1c

mpered, the centre of the head with the eye be ing left soft ~ts e e
f
\~all the pein) Hammer heads are m ade from m ed;um ~arboh h~s ~at striking face and a ba ll-shaped end
~-e two e nds must be hardened and
is spec1f1ed accord ing to its weig ht
•
Figure 26 . Hammer

Sa fet 'j :i n d Care o f Hammer

The hammer head is firmly fixed to the shaft by a wedge .

The striking face of the hammer head does not wear.

6. Drill and D rilling

Drilling is the process of cutting holes in metals by using
a drilling machine as shown in figure 27 . Drills are the
tools used to cut away fine shavings of material as the
drill advances in a rotational motion through the material.

6a . Twist Drill

The twist drill (figure 2 8) is made from High· Speed Steel ,

tempered to give maximum hardness throughout the
parallel cutting portion . Flutes are incorporated to carry
away the chips of metal and the outside surface is
relieved to produce a cutting edge along the leading side
of each flute

~~ ;;;;
~QS; WtS:t::t;tQ' :m :t 2➔
Figure 28 . Twist Dri\ls

6b . Ori\\ Features
 . . "'°d10 an angle ol 59¢X lo
The point o! the dnll 15 9 equal cuttmg edges, and
1,01 ( -Y''\
Clearance ' ; -:f. I
0
the centre line \o give tw\<. \OgNe " reliel " ol about '\ 2¢X. \ _ _ 1~~~; / !
~·
each side 1s ground bac hO'Nn m ligure 29
\o each cutting edge as 5 l \r
. ha\ dnll pomts are central and that
It is ver~ important t nd that the cutting edges are
the hp angles are equal a .
. d d the clearance ang1e correct. To obtam
uhnchi~pt a~ ensure correct angles it is important that
\ is s a e an · d·ng machine
drills are ground in a gnn 1
11

Figure 29 . Ori\\ Features

Sc. Drill Operating Parameters

It 1s essential to select the correct cuttmg speed and the leed Followings are the most common used cuttmg
speed and feed rate

Cutting Speed
Material Cutting Speed
MIid steel 6 -9 mlmm
Stainless Steel 4 1\/ 9 mlmm
Aluminium 30 i\J 36 mlmm

Feed Rate
5.5 mm diameter twist ctn\\ 0 08 i\J 0.'\5 mm/rev
30 mm diameter twist drill 0 04 i\J 0.55 mm/rev

Gd. Special "Type of Drill

Counterbore Ori\\ ,figure 30) i\J To form a flat, or cy\indncal
reces~ \o accommodate the head ol the bolt It 1s also used to
prov, ea \eve\ base on the rough surfaces lor nuts and washers.

Countersink I) -11 ,1. . Figure 30. Counterbore Drill

n , 1gure 3'\) i\J To form a corneal shaped recess
\a enab\e a cou t .
the woil<. n ersunl<. sciew or bolt to flt \lush with \he surface o\
 Figure 31 . Countersink Drill

Ge . Safety and Care on Drilling

Twist drill must be clamped in the drill chuck tightly
1. The workpiece to be drilled must be firmly secured by vice,
or clamps.
111. Drill guard (figure 32) must be closed before switch on the
machine.
.
iv. Use the correct drilling speed and apply suitable drilling
force It is advisable to release the drill occasionally, lift the
4
drill, and clear the hole of cutting.
v. Apply cutting fluid in the cutting except for drilling Cast iron .
vi. Take care, when the drill is nearly penetrated through the
workpiece .
v11. The "screw in" action can lift up the workpiece ~
~
Figure 32. Drill Gaurd

.. .
7. Reamer and Threading T ools

7a. Reamer

Functions of reamer are ,t'

1· to control the diameter of a hole

2. to improve the internal surface finish
3 · to improve the roundness of the hole

Reamer
machineisreamer.
made of hardened High c arbon Steel or High
. Speed Steel. It is classified into h an d reamer and

1. Hand Reamer

Figure 35. Hand .R ea~er

Hand reamer (figure 33) has tw
and spiral flutes. The spiral flut~st~pe~ of flutes· - straight
hand spiral flutes The purpose of t~n dre~me_r has a left
prevent the reamer "screw in" the h~e.es1gn is to
 ,-,_
_ ~ •~.:::: ~ - ---
=: tV'la c h i n c R c a n ..,c r- Fi g~ r c 35 . IV'l a c h l n e Reame r
. ._is cl s1ra1gt1 t s h a r, k. o r taper
, ,. -¾ ...- ,- e .....~r,""l~ • ,;; l C _1 _, ,c s h an k c a r"'l f t d i r e c tly n to
t ..~,~t'
~";. t
:::,..t .. .:., ... .._ 7'.Jt o r s~ ., ~ tt,e s tra g t,t s h a ,...,...._ s. h o d
~L-- ,..,d e o f c-. f 'l"'t J C ,..
r ~ co e t
.:; E xp.an d,ng Ro .;-1 , , ,cr A cfJus t a b l c R e am e r ~;;;;; ti? ,r ' --:-~ - 7£!11£~ ~~ ~ - ·--~ ~ ~ --?iffl>.\.:t:•;;r~~.-,
T h e c utt-.ng dtameter ,:_'l~'"' oe sllgh tt y varied by a d j u s t i ng F i g u re 35 . .A. c:lj .... s t a b l e R ea m e r
an n ne r taoe.r aga nst •-, ,e os s cu t ting blades a s s h o w n 1n
!,9.....,r e ::ts T h i s type ::,. .. s c- d pnma r ily for repetitive w o r k to
--.a ,n ta n, a cons , s!e n · - .::e th rough o ut

~ Sa fe ty . P r e c a ut ions & Op era t io n i n R e a ming

a . Care the s ha r o cuttin g e d g e e s p e c i a l l y 1n h a n d l i n g _

b
The amount o f rnatena l t o be removed by a r eame r s h ou l d be as s m a ll a s p ossible , a pp rox i m a t e ly
2-4°/o o f d amete r
...:
Reamer m us· or. Y be t ur n e d , n o n e d i r e c t on bo th c u tt i n g a n d r eme>v n g the tc:>e>fs
may Jam
d otherw i se t h e too l
Lubricant o shou d b e used e x c e p t vvhe n cut t ing c a st i ron a n d b ras s
e
Rea mi ng can en arg e the s i z e o f h o l e but can not co r r ec t th e posi t io n e r ro r in d r i lling

7 b . T ap ....
Taps «•gu r e 36 a e useo <o cu, <he •n <e r n a , screw <h r eacts T a p s a r e m acte o < h a r d e n e d H ,g h C a r b o n S < e e ,
• n se t of t h ree -- tape r secon d a n d plug t a p
or H,gh S = e o s,ee The encts o , <he shank are s qua r e <o M a w r e n c h (<, g ure 37 ) U s u a U y <aps a r e p r o ~ od e d
1 _ Ta p e r T a p

The
usedtap
n a•sno1e
tapeto
r ed th e a th
off for
start len o rf m8
g thfo
read to 1 O th r e a d s a n d 1s t h e f i r s t t ap t o be
~ ----
I
. -4~}~f_
·-•-~,..,....._ _
t:"--!.L~
2 . Second T a p

th r eads cut by the t a p e r tap

~~-:- ~s:~;:
~ -·""
if!. t
- -- -. -- --~ ~ ~
;~
~
•

The ~ P ,s ••o e,eo ott <or a •e ng, h o, 4 <o 5 <h r eacts <o <ac,,,.a,e P•ck,ng u p <h e -:._: -~~;.; _ . . ; ; ; ~ ~ ~-
3 . P lu g T a p

tap used
Th,s os to <h
cu, teaoeo '" "Y
t h e bo<hro•ag
ttom ohou
f a b, l," nd hnog,h
• •e le a nct •s c aueo a ' b o U o m ; n g • <ap ,-h os
-r££iE_:.: ~¥~~~:·:----
F i g u r e 36 . T aps

Pr e c a u t i o ns & o p e r a ti o n
in
'l._;.,z

t a ppin g
;._ ~

::a·F i g u .re -~-::::t:"I

.._ - - ....... _
•
__- .. ,::
3 7 _ T a p VV r e
......-1.. -
-. " "' -
""-·-
nch
?clFqp - - "- -~ =
 h Id be de termined from th e handbook
d the correct dri ll size s o u t
of the hole ,s ,mportant an dation on the shan k of th e a p
a. The size . rkshop or the recommen
standard table rn the wo_ th t t kept square with top surfac e o f w ork
tap first ensuring a 1 ,s
b. Use taper e correct size of wrench for the tap ,n use
c Always uselthh Id be used except w hen c utting ca st iron a nd brass
d Lubricant oI s ou
d to hold the wrench to ma1n ta1n e ve n torque
e Use both han s ht/ to break the swarf and clea r th e threads
.~ ~~:~t ; :e;: Ph~~: ~~::~: :r;~t~:o; f :~; bli~d hole , care must be taken not to force a s ta p m a y
c break ,n the hole

7c. Die

o,es are used for cutting external threads on round bar o r tubes Dies are m ade of Ha rden ed High C a r bon
Steel or High Speed Steel

1. Split Die or Button Die

Split die is held in place in the stock as shown ,n figure 38 Th e s plit pe rmits a small amo unt of adjustment ,n
the size of the die by ad1usting the scre ws ,n th e stock Sm ee split d ies cut th e ir th r ead c om p lete ,n one cut,
the die thread are tapered and back off for one third o f their leng th

Figure 38. Split Die & Stock

2. Die nuts
Die nuts (figure 39) are not capable f
employed for cutting threads from th~ :a7 adJustmen!. They a re not usually I
(,r~-n \r-
,,ll ~\:-

r-
... :.3€.
"\s -.·-1-
threads They are externally formed to h , but for rect1fyrng damage to existing , , r ffJ
e xagonal sha pe for use w ith a spanner I '7
'v.S{-~
Figure 39. Die Nut
Precautio ns and Operation of Die

ta. The diameter of the blank rod must n t I

c~ure that the d ie is set perpendicul~ r
u ncant oil should be used exce t w
t:~:~
.
~::n the o utside dia m eter o f th read to be c u t.

d. About every half-turn reverse f P hen c utting cast iron and bras s
reque ntly to break the swarf oth
e rw,se the thread wi ll tea r