BK0001

BASIC KNOWLEDGE
OF
COMMON HAND TOOLS

1
 Hand Tools

After attending the course, the trainee will

- be able to use the right tool for the right job.

- realize why hand tools are made with specific design and purposes.

- be able to identify hand tools according to the usage.

- be able to handle and use tools properly.

- know how to maintain and store the tools correctly.

2
Why we use hand tools?

- When you work on an engine or machine to repair you

know what you want to do and how to do it.

- But do you have the right tool to do the right job?

- Then you will need proper mechanic hand tools to get

your job done.
3
How do we select proper hand tools?
- You will need, firstly, general hand tools for day-to-day work.
- Though it is for general use, it must be durable, dependable, strong
and sturdy for work.
- It must be well built.
- It must have a unique cut to their socket and
wrenches that will remove nuts and bolts without
damage or being worn out or broken.
- It must be chrome plate or hardened surface and
withstand specific torque and turns.
- If possible and better if you can get life time warranty to
stand behind the tools.
- Above all they must stand up day to day use.
4
The right tools for right job !

- Now you have some ideas on how to select hand tools but what
should you have in your tool box?
- “The right tool for the right job” is our belief.
- These are the essentials for a good, well rounded tool box.
- Wrenches
- Ratchet and sockets
- Screw drivers
- Pliers and cutters
- Hammers
- Specific tool used
- Miscellaneous tools

5
Identifying Hand Tools

Wrenches, Ratchet and Sockets, Screwdrivers, Pliers and

Cutters, Hammer, Torque wrenches, Pullers.

6
Wrenches

- There are tons of wrenches to choose from.

- For a basic toolbox we can narrow down the choice.
- Wrenches come in 6-point and 12 points style.
- 12 point are more useful for general work, but 6 point wrenches have
more gripping power.

7
Open-end Wrenches

- Open-end wrenches have ends that are well open.

- For those jobs where a box wrench will not fit.

8
Open-end Wrenches

Flats of
Wrench at
1
Wrong Angle
Wrench to Flats of Nut
Strikes
Casting
2

Turn
Direction for Turning
Wrench
to Loosen Nut
Over-
3

-OK for
Turning

9
Box Wrenches

- Box wrenches have no open end and fit completely around the
fastener.
- The box wrench is preferable to an open-end wrench because it
will grip the fastener on all six sides.
- Box end wrenches have two types-
namely, 15 degree offset,
short length type and
double offset box end wrench.

10
Combination Wrench

- A combination wrench is a combination of both, box an one end

and open on the other.
- This is the most useful and eliminates the need for two sets of
wrenches.
- A good range of combination wrenches in SAE is ¼” to 7/8” and in
metric 8mm to 22mm.

11
Different Style of Wrenches
- Wrenches come in short styles for tight areas, standard length
and long when extra leverage is needed.
- For the basic toolbox a set of standard length combination
wrenches will do.

12
Line Wrench or Tubing Wrench or Flare Wrenches

- Line or tubing wrenches are designed to be used on fuel and

hydraulic lines.
- They are thicker than a regular wrench for more gripping area.
- One end is open and is like a box end, with a cutout to allow it to
go over a line and still allow it to grip all six sides of the fitting.
- A good range is ¼” to ¾” SAE and 8mm to 20mm in metric.

13
Half-moon Wrench

- This wrench is effective

when a straight handle cannot get to the screw.

14
 Adjustable Wrenches
Opening Worm(adjusting
thread) Handle

c ross
a
i dth ts
W fla

Lower
jaw

- Have two jaws that are adjusted with a screw mechanism

that open and close the jaws parallel to each other.
- A good size is SAE 6-inch adjustable and 300mm adjustable.
- For screws requiring a large tightening torque, the
adjustable wrench is not suitable.
15
Oil Filter Wrench

- It is for removing oil filters.

- Not used for tightening oil filters, because we all know that oil filters
should only be hand tightened.
- There are strap style and chain type.

16
Striking Wrenches

- It is so temping to beat normal wrenches with a hammer when

a nut or bolt sticks.
- Is potentially dangerous and can damage the wrench.
- A striking wrench is designed to take this kind of job.
- Available in long and short twelve point offset handles.

17
Striking Wrenches Contd.

- Heavy, box walls and a large striking surface transmit more torque
to the fastener, while the box end is designed to stay on the
fastener when you strike the wrench.
- Finished with a black oxide coating to resist corrosion.
- Standard sizes ranging from 1-1/16” through 3-1/8” and metric from
32mm to 80mm.
- Precautions: Use safety gloves, and don’t use a wrench if it shows
sign of damage. Use a lubricant or penetrating oil on fastener, for
better performance.

18
 Ratchets and Sockets

Ratchet Handles
Lower Profile Head for
Teardrop Up to 25% Greater
Shaped Access Than the
Full Polish,
Head Leading Competition
Balanced
Handle

60 Teeth for Flush Mounted

Greater Lever ON/OFF
Access Switch

- The three most common sizes of ratchets are ¼”, 3/8”, ½” , ¾” and
1” drivers.
- ¼” drive is for lighter duty work and ½” drive is for heavier jobs.
19
Ratchets and Sockets

Ratchet Handles Contd.

- The socket drive end has a square shaped hole.

- The section of the handle which fits into the socket hole is called the
drive square.
- A ball fitted to the drive square settles in an indentation on the inner
surface of the socket and prevents from slipping off the drive square.
20
Ratchets and Sockets

Ratchet Handles Contd.

- A ratchet mechanism allows the drive square to turn in one

direction and prevents from turning in the opposite direction.
- Thus, a screw can be turned by reciprocal movement of the
handle.
- No need to refit socket and is efficient.
- Drive square turning direction can be switched by a lever on the
handle.

21
Ratchets and Sockets

Ratchet Handles Contd

- The pawl engages a ratchet tooth for every 18 degree the handle in
turned.
- Thus the ratchet handle can be used in tight spaces.
- Fine tooth ratchet is preferable, because you will get more turns per
swing than a coarse tooth.
- A contoured handle is more preferable than with a knurled handle.

22
Socket Wrench

- Socket wrench is a handle bar with a square end which fits into
the drive end of a socket.
- By selecting a suitable handle, it is possible to use a socket
wrench efficiently even when the use of a spanner is
impractical.
- Various adaptors and extensions are available which make
socket wrench set extremely flexible.
23
Sockets
- The socket end, fits over the head of a screw, has a hexagonal
(6 points) or 12-sided holes (12-points) hole.
- The size of the hole is designated by the width of across the
flats of screw thread.
- The drive end hole is a square, which the handle fits and
comes in ¼”, 3/8” , 1/2”, ¾” or 1” sizes.
- The greater the size of the socket end hole, the greater the size
of the drive end hole

24
Extensions
- Extensions are used to extend the reach of socket.
- To turn a screw in a confined place, an extension can be coupled to
the drive square of a ratchet handle.
- The handle can be turned in a wider space and torque transmitted
to the socket via extension.
- The extension bar has a square hole in one end for the drive square
of the handle and a drive square on the other end for the socket.
- A good range of extension is 1” to 12” .

25
Universal Joint
A universal joint connected between the handle and the socket permits
using the handle from any direction.

26
Universal Socket or Flexible Socket
- They are similar to a universal joint but have a regular socket on
one end.
- They are good for very tight situation.

27
Torque Wrenches
- Is a tool that allows one to control torque, when removing or
tightening a bolt or nut.
- It comes in many different styles and level of complexity depending
upon its application.

28
Torque Wrenches Contd.
- A beam torque wrench has a scale on the wrench, which will
measure the amount of torque being used.
- This type of wrench may be good for general use but it tends to
be somewhat in accurate.
- For specific measurement of torque using thin simple torque
wrench is in advisable.

29
Torque Wrenches Contd.

- In a Click Torque Wrench, prior to using the wrench, one can set
their wrench to provide a specific amount of torque.
- When the amount of torque needed is reached, the torque wrench
mechanism slips so that no more force can be applied.

30
Torque Wrenches Safety

- After using the torque wrench, always put it to the lowest level
on the scale.

31
Torque Multiplier

- Provides ample power to loosen the toughest threaded

fasteners.
- It generates torque’s from a few hundred pound-feet to
thousands of pound-feet with precision and use.
- Relatively in small size torque multipliers may be used with
practically all necessary tooling yet provide simple wrench
power in limited work areas.
- In many cases it eliminates dismantling
of near by equipment.
- The multiplication of torque,
is achieved through a planetary
gear train at a ratio depending
on model.
- The precision gear train is totally
enclosed.
32
Allen Wrench
- The Allen wench has a hexagonal cross section that fits screw
heads with six-sided.
- It is a special “L” shaped six-sided head wrench, used to turn screw
with hexagonal sockets.
- Allen wrench is known as hex key, hex head wrench.

33
Screwdrivers
- A screwdriver is a tool for driving screws and rotating other machine
elements with mating drive system.
- Head or tip of the screwdriver engages with a screw, a mechanism to
apply torque by rotating the tip and some way to portion and support
the screwdriver.
- The handle is an approximately cylindrical handle to be held by a
human hand.
- The handle and shaft allow the screwdriver to be positioned and
supported end, when rotated, to apply torque.

34
Pliers
- The primary purpose of pliers is to grip objects firmly.
- Pliers are commonly used for cutting wire, holding parts, crimping
connections, and bending cotter pins.
- The objects can be turned, bent, or otherwise manipulated.
- Pliers have parallel handle, a pivot where the handles join, and parallel
jaws that group the objects.
- Special purpose pliers includes wire cutting pliers.

35
Pliers Contd

Terminal pliers will strip and cut wire and crimp solderless terminal.

36
Pliers Contd
Round nose pliers are for bending and looping wires.

37
Pliers Contd.
- Snap-ring pliers are used for installing and removing snap rings.
- The noses are made in different shapes according to the type of
snap rings used.

38
Pliers Contd.
Slip-joint and plumber’s pliers are common, both with slip-
joint adjustments to change the width of the jaw grip.

39
Pliers Contd
Lock-Grip pliers are for firmly holding objects.

40
Hammers

Hammer are used to drive nails, or other uses when hitting and
pounding is necessary.
- A tool meant to deliver an impact to an objects.
- Used for driving nails, fitting parts, forging metal and breaking
objects.
- Are often designed for a special purpose and vary widely in their
shape and structure.
- The normal features are a handle and a head, with most of the
weight in the head.

41
Hammers Contd.
- Stone hammers are known which are dated to 2,600,000 BC. – the
oldest tool !
- The essential part of a hammer is the head, a compact solid mass that is
able to deliver the blow to the intended target without itself deforming.
- In recent years the handles have been made of durable plastic or rubber.

42
Taps and Dies
Taps and dies are cutting tools used to create screw threads, which
is called threading.

43
Taps and Dies
- A tap is use to cut the female portion of the mating pair, e.g. a nut.
- A die is used to cut male portion of the mating pair, e.g. a screw.

- The process of cutting threads using a tap is called tapping,

whereas the process of using die is called threading.
- Both tools can be used to clean up a thread, which is called
chasing.
44
Three Taps that are commonly used
- Bottom tap or plug tap has a continuous cutting edge with almost
no taper - between 1 and 1.5 threads of thread is typical.
- A bottoming tap cut threads to the bottom of a blind hole.
- It is usually used to cut threads in a hole that has already been
partially threaded using one or more tapered types of tap.
- The tapered end of a bottoming tap is too short to successfully
start into an unthreaded hole.

45
Three Taps that are commonly used contd.

- Intermediate tap, second tap or plug tap has tapered cutting edges,
which assist in aligning and starting the tap into an untapped hole.
- The number of tapered threads typically ranges from 3 to 5.
- Plug taps are the most commonly used type of tap.

Intermediate tap

46
Three Taps that are commonly used contd.
- Taper tap is similar to a plug tap but has a more pronounced taper
to the cutting edges.
- It gives the taper tap very gradual cutting action that is less
aggressive than that of the plug tap.
- The number of tapered thread typically ranges from 8 to 10.
- A taper tap is most often used when the material to be tapped is
difficult to work, e.g. (alloy steel) or the tap is a very small
diameter and than prone to breakage.

Taper tap for starting

47
Dies

The die cuts a thread on a preformed cylindrical rod, which creates a

male threaded piece which functions like a bolt.

48
Dies contd.
- A cylindrical blank, which is usually slightly less than the required
diameter, is machined with a taper (Chamfer) at the threaded end.
- The chamfer allow the die to ease onto the blank before it cuts a
sufficient thread to pull itself along.
- The adjusting screw allow the die to be compressed or expanded to
accommodate slight variation in size, due to material, manufacture, or
die sharpness.

49
Die Nuts

- Which are dies made for cleaning up damaged threads, have no split
for resizing and are made from a hexagonal bar so that a wrench or
shifter spanner can be used to turn them.
- Die nuts cannot be used to cut new threads.

50
Taps and Dies Set
Each tool is used independently, but are usually sold in pair set of both
types, one die and three taps.

51
Pullers

- Mechanical Jaw Pullers are used to safely remove blind housing

bearing assemblies without damaging shaft.
- They are used to pull flywheels, pulleys and bearings.

52
Pipe Wrenches
- Pipe wrench turns pipes, round bars, which cannot be gripped by
other types of wrenches.
- The drawback is that the wrench teeth dig into and mar the work.
- The greater the size of the object to be turned, the bigger the pipe
wrench is necessary.
- The size of a pipe wrench is designated by the overall length of the
wrench with its upper jaw fully extended.

53
Hacksaw
- Hacksaw is a fine-tooth saw with a blade under tension frame,
used for cutting material such as metal flat
plates and rods.
- Hand-held hacksaws consists of a metal arch with a handle, usually a
pistol grip, with pins for attaching a narrow disposable blade.
- A screw or other mechanism is used to put the thin plate under
tension.
Frame

File handle or
straight handle

Wing Nut Blade Handle

( Tensioning)

Pistol grip handle

54
Hacksaw Contd.
 The blade can be mounted with the teeth facing forward or away from
the handle, resulting in cutting action an either the push or pull stoke.
 On the push stoke, the arch will flex slightly, decreasing the tension on

the blade.

55
Hacksaw Blade 14 TEETH PER INCH 18 TEETH PER INCH

- Blade are available in

standardized lengths, and with
anywhere from three to 32 teeth
per inch (tpi).
- The blade used is based on the
thickness of the material being For large sections For large sections
of mild material of tough material
cut, with a minimum of three
teeth in the material.
24 TEETH PER INCH 32 TEETH PER INCH
- Hacksaw blades are normally
brittle, so care needs to be taken
to prevent brittle fracture of the
blade.
- A hacksaw blade has a hole at
each end that fits onto posts on
the frame. For angle iron, For thin tubing
heavy pipe ,
brass, copper
56
Hacksaw Blade Contd.
- The way the teeth are positioned in the blade called ‘set’ .
- There are three typical tooth sets

SET

RAKER TOOTH SET SAW GAGE

SET

WAVE TOOTH SET SAW GAGE

SET

STRAIGHT TOOTH SET SIDE CLEARANCE

57
Hacksaw Blade Contd.
Regular
- These work well on softer metals
that don’t contain iron.
- The teeth are lined up touching each
other and alternating to the left and Alternate Set
right.
Raker
- Perfect for cutting into thin metals.
- The teeth are set in a wave pattern
Uniform Set Angle
from left to right for a smooth, fine
Raker Set
cut.
Wavy
- The right choice for hard, thin
metals.
- The teeth are set in a wave pattern
from left to right for a smooth, fine Wavy set
cut.
58
Frame Types
- Hacksaw frames can be either fixed or adjustable.
- A fixed frame accepts on blade length; while the adjustable typically
handler 10-to 12 inch blade.
- Some can accept blades ranging from 8 to 16 inches.

Adjustable Frame
Fixed Frame

Blade Blade

Handle
Handle

59
Chisel

Chisels used in metal work can be divided into two main categories: hot and cold
chisels.

Hot Chisel

A hot chisel is used to cut metal that has been heated in a forge to soften the
metal. One type of hot chisel is the hardy chisel, which is used in an anvil hardy
hole with the cutting edge oriented up. The hot work piece cut is then placed
over the chisel and struck with a hammer.

60
Cold Chisel

A cold chisel is a tool made of tempered steel used for cutting ‘cold’ metals,
meaning that they are not used in conjunction with heating torches, forges, etc.
Cold chisels are used to remove waste metal when a very smooth finish is not
required or when the work cannot be done easily with other tools, such as file,
bench shears or power tools.

61
Cold Chisel Contd.

Cold chisels come in a variety of sizes, from fine engraving tools

that are tapped with very light hammers, to massive tools that are
driven with sledge hammers. Cold chisels are forged to shape and
hardened and tempered (to a blue colour) at the cutting edge.

62
Cold Chisel Types
There are four common types of cold
chisel. There are flat chisel, cross cut
chisel, round nose chisel and diamond.

The flat chisel

The most widely known type, which is
used to cut bars and rods to reduce
surfaces and to cut sheet metal which
is too thick or difficult to cut with tin
snips.

The cross cut chisel

The cross cut chisel is used for cutting
grooves and slots. The blade narrows
behind the cutting edge to provide
clearance.

63
Cold Chisel Types Contd.

The round nose chisel

The round nose chisel is used for cutting
semi-circular grooves for oil ways in
bearings.

The diamond point chisel

The diamond point chisel is used for
cleaning out corners or difficult places and
pulling over center punch marks wrongly
placed for drilling.

64
Files

The file is a cutting tool made of steel, with teeth cut into the metal. It is
used to shape wood or metal. Files are made in various lengths,
shapes, and teeth sizes. The length of a files is measured from the
point to the heel. The most common shapes are flat, round, half-round,
square, and triangular.

65
Files
Flat file:
- It is rectangular in cross section, tapering both in length and in width.
Round file:
- It is tapering throughout its length.
Half round file:
- Having one flat side and one curved side; the edges and the convex
side are tapered.
Square file:
- Square in cross section and its sides are tapered.
Triangular file:
- It is triangular in cross section, tapering on all sided from the point to
the heel.

66
How to handle hand tools properly

67
68
Q – What force (kg) should the spanner be pulled perpendicularly to the
handle to obtain a tightening torque of 3 kg.m?

69
70
71
72
73
74
Hand Tools Maintenance

- Always clean hand tools with dry cloth after use and store them
in their respective place in the toolbox or tools trolley.

75
Thank You

76