Part A (Theory)

CHECK YOUR PROGRESS – HAND TOOLS - NAME:______________
Part A marks = 35% Part B marks = 65%

Theory

Question 1 (2 Marks)

State two uses for a form gauge

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Question 2 (1 Mark)

Name the gauge shown

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Question 3 (1 Mark)

Describe the purpose for which these gauges would be used.

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Question 4 (2 Marks)

Name the type of gauge shown and state a practical use for which it would be used.

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Question 5 (1 Mark)

What is the gauge in the figure being used for?

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Question 6 (2 Marks)

What is incorrect with the way this gauge is being used and how should it be used correctly to measure a narrow gap?

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Question 7 (1 Mark)

In the figure below, is the component radius too large or too small in comparison with the radius gauge?

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Question 8 (2 Marks)

List two applications for a thickness gauge.

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Question 9 (2 Marks)

Why would a set of metric screw pitch gauges be unsuitable for measuring all thread profiles?

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Question 10 (2 Marks)

State the major reason for using a ring spanner in preference to an open ended spanner for loosening a tight nut.

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Question 11 (3 Marks)

Referring to the figure below, list the tools required to undo the nut and remove it.

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Question 12 (1 Mark)

State the major difference between a socket spanner used on an impact wrench and a socket spanner used with a hand tool.

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Question 13 (2 Marks)

Name the two types of screw heads show.

Name: _______________ Name: _________________

Question 14 (2 Marks)

Which illustration, (A or B), shows the correct direction of rotation for a Stillson pattern pipe wrench?

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Question 15 (1 Mark)

Name the type of spanner that would be best used to tighten the nut shown in the figure below.

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Question 16 (1 Mark)

State the major advantage of a square bladed screwdriver compared to a round bladed screwdriver.

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Question 17 (2 Marks)

Under what circumstances would it be necessary to use a tension wrench instead of a ring or open ended spanner to tighten a nut or bolt?

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Question 18 (1 Mark)

When regrinding the point of a scriber, why is it important not to overheat the metal?

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Question 19 (1 Mark)

When would it be necessary to use trammels instead of dividers during marking out?

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Question 20 (3 Marks)

An 80 m diameter circle is to be scribed onto a piece of sheet steel.

(a) To what distance must the points on the dividers be set?

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(b) How would you get the most accuracy when setting the dividers with an engineers steel rule?

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Question 21 (1 Mark)

When scribing a line with a surface gauge, why is it best to pull the scriber along the surface instead of pushing it?

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Question 22 (2 Marks)

How should a surface gauge be stored so that you will avoid personal injury and protect the instrument from damage?

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Question 23 (3 Marks)

List three things that can be done when storing tools to prevent damage to the tools.

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Question 24 (3 Marks)

List three actions that should be taken when tools are found to be faulty.

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Question 25 (14 Marks)

Answer the questions by writing the letter T for True or F for False in the brackets ( ).

(a)	Jenny callipers can be used to find the centre of round bar.	( )
(b)	Marking blue is the best marking medium for rough cast iron.	( )
(c)	A centre punch has a 60° point.	( )
(d)	Vernier callipers are accurate to 0.01mm.	( )
(e)	A flat file has a safe edge.	( )
(f)	Double cut and second cut mean the same thing.	( )
(g)	A cross cut chisel is used to cut a rectangular groove.	( )
(h)	The head of a chisel is harder than the cutting edge.	( )

(i)	A hacksaw blade with 18TPI should be used when cutting material less than 3mm thick.	( )
(j)	When tapping a blind hole, the plug tap should be used last.	( )
(k)	A die nut is used to cut an external thread.	( )
(l)	The cutting angle of a chisel on mild steel is 50° - 70°.	( )
(m)	To file a slot less than 3mm wise it is best to use a warding file.	( )
(n)	Rubbing chalk on a file helps to prevent pinning.	( )

Practical Job HT 13

Measurement Suggested time: 15 minutes Mark 20%

Task

Use gauges, rule and vernier calliper to measure the features indicated on the component shown.

Safety

Follow workplace safety procedures at all times.

Instructions

1 Obtain an actual component similar to the one shown.

2 Obtain from store the following tools:

a set of feeler gauges

a set of radius gauges

a depth gauge

a set of screw pitch gauges (metric and imperial)

a 150mm rule

a 150mm vernier calliper

3 Measure and write down the sizes of the features indicated in the table. All sizes must be within ± 0.2mm to pass.

4 Write your name on your answer sheet with the identification number of the component and submit it to your teacher for assessment.

Quality Requirements

To pass this part of the assessment:

• all measurements must be correct to the limits specified

• workplace safety standards must be followed at all times

• tooling and workpiece must be cleaned and stored correctly.

Tool	Measurement	Yes	No
Feeler gauge
External radius gauge
Internal radius gauge
Screw pitch gauge
Depth gauge
150mm rule
Vernier calliper
Micrometer

To Pass

All measurements must be ticked Yes to pass.

Part B Practical Job HT 14

Dismantle, Make And Assemble. Suggested time 1 hour Marks 45%

Task

Dismantle an assembly, make a replacement part and re-assemble the components into a working assembly.

Safety

Follow workplace safety procedures at all times.

Instructions

1 Obtain a valve similar to the one shown below from the store

2 Select the appropriate tools and dismantle the valve answering the questions on the “Record of Activity” sheet.

3 Cut sufficient material from the bar supplied with a hacksaw.

4 Make the handle by bending it up first, then marking out the square hole and drilling and filing it to size.

5 Mark out and file the radii on the end of the handle using radius gauges.

6 Re-assemble the valve with the replacement handle.

7 Submit the re-assembled valve, “Documentation Record” sheet and the original handle to your teacher for assessment.

Quality Requirements

• the correct tools must have been selected and used to dismantle and re-assemble the valve

• the correct tools must have been selected and used to make the replacement handle

• the re-assembled valve must be functional

• the replacement handle must be of an industry acceptable quality

• workplace safety procedures must have been followed at all times

• all tools must have been cleaned and stored correctly

Documentation Record of Practical Activity

Sheet Dismantle, Make And Re-Assemble

(a) What was the size and type of spanner used to undo the nut item 3?

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(b) What was the size and type of spanner used to undo the nut item 5?

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Diameter __________ Length __________ Pitch __________

(d) What is the size of the hole through the ball?

Hole diameter __________

(e) With the valve in the open position what is its’ overall size including the handle?

Height __________ Length __________ Width __________

Practical Check List

Dismantle, Make And Assemble

The following check list will be used to assess the practical exercise.

To Pass

All points must be ticked Yes to pass.

Feature	Yes	No
Correct size and type of spanner used to undo nut item 3
Correct size and type of spanner used to undo nut item 5
Diameter of bolt item 6
Length of bolt item 6
Pitch of thread item 6
Size of hole through ball
Overall height of valve
Overall width of valve
Tooled cleaned
Tools stored appropriately
Replacement handle - size
- shape
- no burrs
- no sharp edges
- hole marked out
- hole fit to valve
Re-assembled valve functional
Workplace safety standards maintained

Answers