Chapter 6

Hand Tools

LEARNING OBJECTIVES
After studying this chapter, students will be able to:
H Identify the most commonly used machine shop hand tools.
H Select the proper hand tool for the job.
H Maintain hand tools properly.
H Explain how to use hand tools safely.

INSTRUCTIONAL MATERIALS chapter is extensive, it is recommended that it

Text: pages 91–126 be divided into several parts. It can be taught as
Test Your Knowledge Questions, a series of short lessons in which students can
pages 123–125 become actively involved.
Workbook: pages 33–38
Instructor’s Resource: pages101–120 Student Presentations
Guide for Lesson Planning Assign pairs of students or request volunteers
Research and Development Ideas to demonstrate and explain the proper care and
Reproducible Masters: use for the family of tools on which they are pro-
6-1 Torque Measurement viding instructions. The following preparations
6-2 Mounting Work for Hand Sawing should be made before each presentation:
6-3 Starting a Hand Reamer • All tools in safe working condition.
6-4 Using a Hand Reamer • Additional tools in reserve.
6-5 Specifications for Thread Sizes • Demonstration clearly visible to all.
6-6 Inch-Based and Metric-Based Threads • All safety precautions taken.
6-7 Thread Nomenclature
• Have students read and study the
6-8 Starting a Die
assignment.
6-9 Cutting Threads to a Shoulder
6-10 Test Your Knowledge Questions Students should furnish a written outline for
Color Transparencies (Binder/CD only) the lesson they are to present. Aid them in prepar-
ing their topic for discussion and questions. In
addition to becoming more involved in the
GUIDE FOR LESSON PLANNING class, students will gain experience in preparing
This chapter serves to present the numerous and giving presentations.
hand tools that a machinist will use as well as An outline for hand threading, for example,
their proper handling and care. Since this would include the following:
101
102 Machining Fundamentals Instructor’s Resource

I. Objectives • How threads are depicted on drawings

A. After studying this topic, students should be • How UNC and UNF threads of the same
able to: size differ
1. Understand how threads are specified on • Thread nomenclature
drawings. • Why there are taper, plug, and bottom taps
2. Explain thread nomenclature. • Tap drills and their importance
3. Select the proper tap(s) and tap wrench • Proper way to tap a hole
for each job.
• Why cutting fluids are necessary
4. Determine the correct tap drill size for
specified thread to be tapped. • Removing broken taps
5. Adjust a die for different classes of fits. • The proper way to cut threads with a die
6. Use, clean, and store threading tools • Advantages of using adjustable dies
properly. • Precautions to be taken when hand
7. Observe hand threading safety. threading
• How to clean and store hand threading
II. Instructional Aids tools
A. Text pages 114–122 • Importance of washing hands thoroughly
B. Reproducible Masters: after hand threading
3-3 How Threads are Depicted on A review of the demonstrations will provide
Drawings students the opportunity to ask questions.
6-5 Specifications for Thread Sizes
Technical Terms
6-6 Inch-Based and Metric-Based Threads
Review the terms introduced in the chapter.
6-7 Thread Nomenclature
New terms can be assigned as a quiz, home-
6-8 Starting a Die work, or extra credit. These terms are also listed
6-9 Cutting Threads to a Shoulder at the beginning of the chapter.
A list of necessary equipment should also be abrasive
prepared. For example, the list below includes American National Thread System
equipment necessary to demonstrate hand blind hole
threading. classes of fits
• Examples of UNC, UNF, and metric foot-pounds
threaded sections (bolts, nuts, threaded newton meters
rods, etc.) number sizes
• Different tap sets safe edges
torque
• Different size tap wrenches
Unified System
• Material drilled for tapping
• A selection of dies Review Questions
• Different size die holders Assign Test Your Knowledge questions. Copy
and distribute Reproducible Master 6-10 or have
• Stock for threading with a die
students use the questions on pages 123–125 and
• Cutting fluid write their answers on a separate sheet of paper.
The demonstration area should be clearly
visible to all students. Workbook Assignment
Have students read and study the material Assign Chapter 6 of the Machining Funda-
prior to the presentation, paying special atten- mentals Workbook.
tion to the illustrations. Allow students to use
the Reproducible Masters as overhead trans- Research and Development
parencies or handouts, as they discuss and Discuss the following topics in class or have
demonstrate their topic. The following list students complete projects on their own.
includes some areas that should be covered. 1. Industry makes considerable use of the
Chapter 6 Hand Tools 103

pneumatic chisel. Secure information on this abrasive materials are best for aluminum,
tool for a bulletin board display and, if pos- brass, cast iron, and tool steel. The experiment
sible, borrow the tool for examination from should include the quantity of material
a local industry. removed within a specified period of time;
2. Design a safety poster that shows the correct surface finish of the completed piece; degree
way to use a chisel. of clogging, if any, of the abrasive cloth; and
3. Secure samples of the various types of hack- the effect lubricating oil has on the surface
saw blades used for hand sawing. Prepare finish. Abrasives of similar grade value must
them as a bulletin board display. be used if tests are to be valid.
4. Design and produce a series of safety posters 16. Give a demonstration on the different
on the file that illustrate the following unsafe methods for removing broken taps. Industry
practices: often uses a technique that erodes the tap
electrically, permitting the parts to be
• Using a file as a pry.
removed easily. Secure information on this
• File used without a handle. process for a bulletin board display.
• File used as a hammer. 17. Prepare a study on the accuracy of hand
5. Design a panel that shows the file in various reamers. Make sample holes and measure
stages of manufacturer. Secure samples. them to determine whether they are within
6. Inspect the files in your shop. Clean and acceptable limits. Does the application of
repair or replace damaged file handles. cutting fluid affect the size of a reamed hole?
Make a new file rack if the present rack is 18. Demonstrate the proper way to tap a blind
badly worn. hole.
7. Examine the screwdrivers in your shop. 19. Demonstrate the correct way to run a thread
Repair or regrind the tools as needed. down to a shoulder.
8. There are many other types of wrenches not
covered in this unit. Prepare a paper
featuring these wrenches. Include drawings. TEST YOUR KNOWLEDGE
Reproduce the report for distribution to the ANSWERS, Pages 123–125
class. 1. Solid base and swivel base.
9. Give a demonstration on the proper way to 2. By the width of the jaws.
use a torque-limiting wrench.
3. soft metal caps (copper, brass or aluminum)
10. Contact various tool manufacturers for
4. Avoid letting the vise handle or work project
information on how wrenches are manufac-
into aisle beside bench.
tured. Prepare a bulletin board display with
the material. 5. C-clamp, parallel clamp
11. Repair and lubricate all adjustable wrenches 6. They can be opened wider at the hinge pin
in the shop. to grip larger size work.
12. Make a safety poster illustrating the proper 7. Permits them to cut flush with the work
way to use a wrench. surface.
13. Prepare a sample block of metal that can be 8. Student answers will vary but may include
used to show the difference between a any three of the following: never using as a
drilled hole and a reamed hole. substitute for a wrench; not trying to cut
metal sizes that are too large, or work that
14. Develop and construct displays that show:
has been heat-treated; not applying addi-
• Samples of various abrasive materials. tional leverage to the handles; cleaning and
• A flow chart showing how synthetic oiling them; storing in a clean, dry place; not
abrasives are manufactured. If possible, throwing them in a drawer or tool box with
secure samples of the raw materials. other tools; using pliers that are large
• Metal samples in various stages of pol- enough for the job.
ishing. Spray them with lacquer or 9. Pliers that can be adjusted to various size
acrylic plastic to prevent rust. work and can clamp tightly on the work.
15. Set up an experiment to determine what They have a quick release.
104 Machining Fundamentals Instructor’s Resource

10. They permit tightening a threaded fastener removed with a file or abrasive cloth; the
or part for maximum holding power without screwdriver should have an insulated handle
danger of fastener or part failing, or causing and the power should always be turned off
work to warp or spring out of shape. before working on electrical equipment;
11. Work equally well in either direction but for screwdrivers should not be carried in pockets.
safety, they should be pulled. 27. By the weight of the head.
12. Pipe wrench, monkey wrench, and regular 28. Used to strike heavy blows where steel faced
adjustable wrench. hammers would damage or mar the work.
13. Any three of the following: the movable jaw 29. Student answers will vary but may include
should face the direction the fastener is to be any three of the following: never strike two
rotated; the thumbscrew should be adjusted hammers together; do not use a hammer
so the jaws fit the bolt head or nut snugly; an unless the head is on tightly and the handle
extension should not be used for additional is in good condition; do not “choke up” too
leverage; should never hammer on the far on the handle when striking a blow, or
handle to loosen a stubborn fastener; the you may injure your knuckles; strike each
smallest wrench that will fit the fastener blow squarely, or the hammer may glance
should be used. off of the work and injure you or someone
14. pipe, damage working nearby; place a hammer on the
15. Socket wrenches are box-like and are made bench carefully so that it doesn’t fall and
with a tool head-socket (opening) that fits cause a painful foot injury, or damage preci-
many types of handles (either solid bar or sion tools on the bench.
ratchet type). 30. mushroomed, grinding
16. Pin, hook, and end spanner wrenches. 31. removing rivets
17. larger 32. Flat, cape, round nose, and diamond point
18. Any five of the following: always pull on a chisels.
wrench; never push; select a wrench that fits 33. different length blades
properly; never hammer on a wrench to loosen 34. 40, 50
a stubborn fastener; rather than lengthening a 35. Vibration and chatter are eliminated. They
wrench handle for additional leverage, use a cause blade to dull rapidly.
larger wrench; clean any grease or oil off the 36. As a blade dulls the slot made by it becomes
handle and the floor in the work area before narrower. To continue in this slot will cause
using a wrench; and never try to use a wrench a new blade to bind and be ruined in a few
on moving machinery. strokes.
19. Standard has a wedge-shaped tip. Phillips 37. three or more, teeth will straddle work and
has an X-shaped tip. be broken off
20. e. Tip is similar to that of a Phillips head 38. Mount it between two sections of wood.
screwdriver.
39. Place soft wood blocks between the vise
21. a. Has a flattened wedge-shaped tip. jaws and the work to prevent marring the
22. f. Has an insulated handle. exterior surface of the tubing and insert a
23. c. Has a square shank to permit additional snug-fitting wooden dowel into the tubing.
force to be applied with a wrench. 40. file card/brush, your hand
24. g. Is short and is used when space is limited. 41. Single-cut, double-cut, rasp, and curved
25. b. Moves the fastener on the power stroke, tooth.
but not on the return stroke. 42. Flat, pillar, square, 3-square, knife, half-round,
26. Student answers will vary but may include crossing, round.
any three of the following: screwdrivers 43. Student answers will vary but may include
should not be used as a substitute for a chis- any three of the following: never use a file
el, hammered on, or used as a pry bar; without a handle; files should be cleaned
should always wear safety goggles when with a file card, not your hand; files should
grinding screwdriver tips; burred heads (on not be cleaned by slapping it on the bench,
screws) should be replaced or the burrs since it may shatter; files are very brittle and
Chapter 6 Hand Tools 105

should never be used for prying tasks; a 14. A. Standard

piece of cloth should be used to clean the B. Phillips
surface being filed, not your bare hand; you C. Clutch
should never hammer on or with a file
D. Square
because it could shatter.
E. Torx
44. When a hole must be finished accurately to
size and with a very smooth surface finish. F. Hex
45. 0.005″ to 0.010″ (0.15 mm to 0.25 mm) 15. A. For general cutting.
46. tap, die B. To cut grooves.
47. e. None of the above. C. To cut radii and round grooves.
48. tap drill D. For squaring corners.
49. UNC has fewer threads per inch for a given 16. entire length
diameter than the UNF of the same diameter. 17. b. chatter and vibration will dull the teeth
50. In order: taper, plug, and bottom. 18. a. cut will be too narrow for the new blade
51. Neither. It must be the same size as the 19. a. the teeth will straddle the section being
desired threads. cut and snap off
52. tap wrench, die stock 20. c. general outline and cross section
53. An abrasive is any hard, sharp material that is 21. A. Single cut
used to cut or grind away another material. B. Double cut
54. Machined C. Rasp
D. Curved tooth
22. draw
WORKBOOK ANSWERS,
23. surface finish
Pages 39–46
24. c. expansion hand
1. d. All of the above.
25. b. spiral-fluted
2. a. using the handle to turn the heavy screw
26. Student answers will vary but may include
3. paper any three of the following: to prevent injury,
4. b. overall length of the tool remove all burrs from holes; never use your
5. e. Both b and c. hands to remove chips and cutting fluid from
6. Under no condition should the handle be the reamer (use a piece of cotton waste); store
lengthened for additional leverage. reamers carefully so they do not touch one
7. Pulled. Pushing any wrench is considered another, they should never be stored loose or
dangerous. thrown into a drawer with other tools; clamp
work solidly before starting to ream; do not
8. a. the movable jaw should face the direction
use compressed air to remove chips and cut-
the fastener is to be rotated
ting fluid or to clean a reamed hole.
9. c. box wrench
27. e. None of the above.
10. Torque is the amount of turning or twisting
28. In order: taper, plug, and bottom.
force applied to a threaded fastener or part.
29. Diameter must be same size as threads.
11. d. All of the above.
30. Any of the following: too little or lack of cut-
12. Hook, pin, and end.
ting oil, dull die cutters; stock too large for
13. Any four of the following: always pull on a threads being cut; die not started square;
wrench; never push; select a wrench that fits one set of cutters could be upside down
properly; never hammer on a wrench to when using a two part die.
loosen a stubborn fastener; rather than length-
31. b. used to wear away another material
ening a wrench handle for additional lever-
age, use a larger wrench; clean any grease or 32. Emery
oil off the handle and the floor in the work 33. Silicon carbide
area before using a wrench; never try to use a 34. A–F, evaluate individually.
wrench on moving machinery. 35. Evaluate individually.
106 Machining Fundamentals Instructor’s Resource
Chapter 6 Hand Tools 107

Torque Measurement

Force
(in pounds)

+ +

Distance
(in feet)

Torque = Force (in pounds) ⫻ distance (in feet)

= foot-pounds
= ft.-lbs.

US Conventional

+ +

Distance
(in meters)

Torque = Force (in newtonss) ⫻ distance (in meters)

= newton-meters
= Nm

SI Metric

Copyright Goodheart-Willcox Co., Inc. 6-1

 108

Mounting Work for Hand Sawing

Blade

Vise
Material
being cut
Preferred Avoid
Preferred Avoid

Preferred Avoid

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Machining Fundamentals Instructor’s Resource

6-2
Chapter 6 Hand Tools 109

Starting a Hand Reamer

90°

Always make sure that the reamer is square with the work.

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110 Machining Fundamentals Instructor’s Resource

Using a Hand Reamer

Always turn a hand reamer in a clockwise direction.

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Chapter 6 Hand Tools 111

Specifications for Thread Sizes

M 10 ⫻ 1.5 –6g
Thread symbol
for ISO (metric)

Major diameter
of thread in
millimeters

Pitch of thread
in millimeters

Thread tolerance
class symbol
(class of fit)

ISO Metric thread series

3/8–16 UNC –2A

Major diameter of
thread in inches

Threads per inch

(pitch = 1/threads
per inch)

Thread series

Class of fit
(thread tolerance)

Unified National coarse thread series

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112 Machining Fundamentals Instructor’s Resource

Inch-Based and Metric-Based Threads

ISO Metric Unified National
Thread Series Coarse Thread Series

A comparison of ISO metric coarse and Unified Coarse (UNC) inch-based thread sizes. Even though several of them
seem to be the same size, they are not interchangeable (one cannot be substituted for the other).

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Chapter 6 Hand Tools 113

Thread Nomenclature

Length of
Nut engagement

Major diameter
Pitch diameter
Minor diameter
Thickness
Crest
of thread

Helix angle

Pitch
30°
60°

Root

Screw

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 114

Starting a Die

Common

Common
Starting taper
on die

Common

A die will start more easily if a small chamfer is cut or ground on the end of the shaft to be threaded.
Section through die and die stock shows proper way to start threads.

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Machining Fundamentals Instructor’s Resource

6-8
 Cutting Threads to a Shoulder
Chapter 6
Hand Tools

Taper

Taper

Not full
threads

No threads
next to Threads
A shoulder B cut flush

After die has been run down as far as possible, the die is reversed. When rotated down the shaft, it will cut threads almost flush with shoulder.
A—Running die down normally. B—Reversing die to cut flush.
115

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116 Machining Fundamentals Instructor’s Resource

Hand Tools
Name: ______________________________________________Date: _______________ Score: ________

1. List two variations of the machinist's vise. ______________________________________________

____________________________________________________________________________________
2. How is vise size determined?__________________________________________________________
____________________________________________________________________________________
3. Work held in a vise can be protected from damage by the 3. ____________________________
jaw serrations if _____ are placed over the jaws.
4. To prevent injuries, what should be avoided when mounting work in a vise?________________
____________________________________________________________________________________
5. Work is often held together with a _____ and/or _____ 5. ____________________________
while being machined or worked on.
____________________________
6. How do combination pliers have an advantage over many other types of pliers?_____________
____________________________________________________________________________________
7. Why are the cutting edges on diagonal pliers set at an angle?______________________________
____________________________________________________________________________________
8. List three ways of extending the working life of pliers.
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
9. What are adjustable clamping pliers? ___________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
10. Of what use are torque-limiting wrenches? ______________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
11. Do torque-limiting wrenches give a more accurate reading when they are pushed or when they
are pulled? __________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
12. Several different wrenches can be classified as adjustable wrenches. Name three. ____________
____________________________________________________________________________________

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(continued)
Chapter 6 Hand Tools 117

Name: ______________________________________________

13. List three points that should be observed when using an adjustable wrench. ________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
14. Round work can be gripped with a _____ wrench. Its 14. ____________________________
main disadvantage is that the jaws will probably _____
____________________________
the work.
15. Describe socket wrenches. ____________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
16. What wrenches are employed to turn flush and recessed types of threaded fasteners? The fasteners
have slots or holes to receive the wrench lugs.______________________________________________
____________________________________________________________________________________
17. Rather than lengthen the wrench handle for additional 17. ____________________________
leverage, it is better to use a _____ wrench.
18. List five safety precautions that should be observed when using a wrench.
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
19. What is the difference between a standard screwdriver tip and a Phillips screwdriver tip?
____________________________________________________________________________________

• Match each phrase in the right column with the correct screwdriver name in the left column.

______ 20. Pozidriv® a. Has a flattened wedge-shaped tip.

______ 21. Standard b. Moves the fastener on the power stroke,
but not on the return stroke.
______ 22. Electrician c. Has a square shank to permit additional
______ 23. Heavy-duty force to be applied with a wrench.
______ 24. Stubby d. Useful when handling small screws.
e. Tip is similar to that of a Phillips head
______ 25. Ratchet screwdriver.
f. Has an insulated handle.
g. Is short and is used when space is limited.

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(continued)
118 Machining Fundamentals Instructor’s Resource

Name: ______________________________________________

26. List three safety precautions that should be observed when using a screwdriver.
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
27. How is the size of a ball-peen hammer determined?
____________________________________________________________________________________
28. Why are soft-face hammers and mallets used in place of a ball-peen hammer?_______________
____________________________________________________________________________________
29. List three safety precautions that should be observed when using striking tools.
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
30. There are few things more dangerous than a chisel with 30. ____________________________
a head that has become _____ from use. This danger can
____________________________
be removed by _____.
31. The chisel is an ideal tool for _____ _____. 31. ____________________________
32. List the four general types of cold chisels. _______________________________________________
____________________________________________________________________________________
33. The standard hacksaw is designed to accommodate 33. ____________________________
_____.
34. A hacksaw cuts best at about _____ to _____ strokes per 34. ____________________________
minute.
____________________________

35. Why should work be mounted solidly and close to the vise before cutting with a hacksaw?
____________________________________________________________________________________
____________________________________________________________________________________
36. Should a blade break or dull before completing a cut, you should not continue in the same cut
with a new blade. Why? ______________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
37. The number of teeth per inch on a hacksaw blade has an important bearing on the shape and
kind of metal being cut. At least _____ or _____ should be cutting at all times, otherwise _____.
____________________________________________________________________________________
____________________________________________________________________________________

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(continued)
Chapter 6 Hand Tools 119

Name: ______________________________________________

38. What is the best way to hold thin metal for hacksawing?__________________________________
____________________________________________________________________________________

39. What is the best way to hold thin wall tubing for hacksawing?
____________________________________________________________________________________
____________________________________________________________________________________
40. Files are cleaned with a _____, never with _____. 40. ____________________________
____________________________

41. Files are classified according to the cut of their teeth. List the four cuts. _____________________
____________________________________________________________________________________
42. What are the most commonly used file shapes? __________________________________________
____________________________________________________________________________________
43. List three safety precautions that should be observed when files are used. __________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
44. When is reaming done?_______________________________________________________________
____________________________________________________________________________________
45. How much stock should be left in a hole for hand 45. ____________________________
reaming?
46. A _____ is used to cut internal threads. External threads 46. ____________________________
are cut with a _____. ____________________________

47. The hole to be tapped must be: 47. ____________________________

a. The same diameter as the desired thread.
b. A few thousandths larger than the desired thread.
c. A few thousandths (0.003"–0.004") smaller than the threads.
d. All of the above.
e. None of the above.
48. The drill used to make the hole prior to threading, is 48. ____________________________
called a _____.

49. How does the UNC thread series differ from the UNF thread series? _______________________
____________________________________________________________________________________

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(continued)
120 Machining Fundamentals Instructor’s Resource

Name: ______________________________________________

50. List the correct sequence taps should be used to form threads the full depth of a blind hole.
____________________________________________________________________________________
51. Should a shaft be larger or smaller than the finished size if external threads are to be cut on it?
____________________________________________________________________________________
52. Taps are turned in with a _____ . A _____ is used with 52. ____________________________
dies.
____________________________
53. What is an abrasive? _________________________________________________________________
____________________________________________________________________________________
54. _____ surfaces are never polished with an abrasive. 54. ____________________________

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