Automobile Related Theory for Exercise 1.2.

09
Mechanic Diesel - Measuring, marking & workshop tools
Marking material
Objectives: At the end of this lesson you shall be able to
• name the common types of marking material
• select the correct marking material for different applications.

Common types of Marking Materials

The common marking materials are Whitewash, Cellulose
Lacquer, Prussian Blue and Copper Sulphate.

Whitewash
Whitewash is prepared in many ways.
Chalk powder mixed with water
Chalk mixed with methylated spirit
White lead powder mixed with turpentine
Whitewash is applied to rough forgings and castings with
oxidised surfaces. (Fig 1)

Copper Sulphate
The solution is prepared by mixing copper sulphate in
water and a few drops of nitric acid. The copper sulphate
is used on filed or machine-finished surfaces. Copper
sulphate sticks to the finished surfaces well.
Copper sulphate needs to be handled carefully as it is
poisonous. Copper sulphate coating should be dried well
Whitewash is not recommended for workpieces of high before commencing marking as, otherwise, the solution
accuracy. may stick on the instruments used for marking.
Cellulose Lacquer The selection of marking medium for a particular job
This is a commercially available marking medium. It is depends on the surface finish and the accuracy of the
made in different colours, and dries very quickly. workpiece.
Prussian Blue
This is used on filed or machine-finished surfaces. This
will give very clear lines but takes more time for drying
than the other marking media. (Fig 2)

Cleaning tools
Objectives : At the end of this lesson you shall be able to
• state the different types of Cleaning Tools and their use
• state the precautions to be observed in the use of Cleaning Tools.

Mechanical Cleaning Involves, brushing and abrasive Wire Brushes

Cleaning. It should be used very carefully on soft metals.
Wire brushes are generally used for cleaning the work
Heavy deposits that exists even after chemical Cleaning
surfaces.
can be removed by mechanical cleaning.
It is made of steel wires (or) Nylon bristles fitted on a
The General Cleaning Tools are
wooden piece.
1) Wire brushes
The steel wires are hardened and tempered for long life to
2) Emery sheets. ensure good cleaning action. Different types of wire
brushes is shown in Fig 1.

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Applications
1 Wire brushes can be used for cleaning uneven Surfaces
2 A hand wire brush can be used on exterior of the block
and on the head.
3 A round wire brush fixed with a hand drill motor spindle
can be used for cleaning of combustion chamber and
parts of the head.
4 A wire wheel can be used to clean the valves.
5 Nylon bristles with impregnated abrasive brush can
be used for Engine boring
6 A washing brush can be used to clean the cylinders
by using Soap and Water.
7 Oil passages of cylinder block can be cleaned by
running a long bottle type brush through all holes in
the cylinder block.
8 It is used to clean work surface before and after welding
Safety precautions
Steel wire brushes should be used carefully on soft metals.
It should not make any scratches on the finished surface.
EMERY Sheet (Fig 2)
This is a type of paper used for sanding down hard and
rough surfaces and also used for resistant technology
purposes to give a smooth, shiny finish to manufactured
products.
Emery paper is defined as a paper coated with abrasive
particles in one side and used to produce smooth, shiny
finish to manufactured products.
Description
The each and every abrasive particle act as a cutting edge.
The emery is considered for a suitable abrasive for
workshop practices and the final adjustment of steel parts
for a perfect fit. The emery paper is also used for cleaning,
to remove rust from polished metal components.
The emery is graded by numbers and the Common sizes
are from coarse to fine: 40, 46, 54, 60, 70, 80, 90. 100.
120, F and FF.

Safety Precautions
After cleaning with emery paper, component
should be rinsed properly.

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Scrapper
Objectives : At the end of this lesson you shall be able to
• name the different type of scrappers
• state the features of each type of scrapper
• state the precaution to be observed while uses scrapper.

Scraper is a hand tool which is used to scrap the workpiece

surface by removing the smallest metal particles.

Application
It is used to obtain a smooth non scored and uniformly
bearing surface which is required for sealing, sliding and
guiding surface.

In automobiles it is used to remove carbon particles from

cylinder head, piston head and manifold pipes The curvature at the cutting edge helps to make point
contact while scraping, and also helps to remove small
It is also used to scrap the bearings of cranks halt and spots. (Fig 3)
sometimes the cylinder liner.

Type of scrapers
1. Flat scraper
2. Special scraper

Flat scraper
The cross section of this scraper is Flat. The cutting edge
has Flat surface. Three- square scraper (Fig 4)
This scraper is used for scraping small diameter holes
Use and deburring the edges of holes.
It is used to scrap the high spots of a flat Surface The cross-section of this is triangular. This has more
number of cutting edges and the hollow portion between
Special Scrapper
the cutting edges helps in re-sharpening easily.
Special scraper is available for scraping and finishing curved
surfaces.
They are :
- half round scraper
- three-square scraper
- bull nose scraper

Half round scraper

The cross- section of this scraper is a segment and it Bull nose scraper (Fig 5)
tapers to a rounded point (Fig 1) This scraper has the cutting edge shaped into a flat circular
disc. The cutting edge forms about two thirds of the circle.

The round bottom face is curved and is hollow in the middle.

The bottom facet and the flat surfaces are ground along
the edge to form the cutting edge. (Fig 2)
The cutting angle is between 450 and 650.

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It is useful for scraping large bearings. (Fig 6) This scraper
can be used in a longitudinal direction lika a flat scraper
or with a circumferential movement like a half round
scraper. This dual action helps to prevent ridges on the
scraped surfaces.

Always use scrapers with firmly fitted handles.

Protect the cutting edges with a rubber cover
when not in use.
Apply oil or grease on the cutting edges when
not is use.

Surface plates
Objectives : At the end of this lesson you shall be able to
• state the constructional features of surface plates
• state the application of different grades of surface plates
• specify surface plates and state the uses of marking tables.
Surface plates - their necessity For the purpose of steadiness and convenience in leveling.
When accurate dimensional features are to be marked or a three point suspension is given.
to be checked it is essential to have a datum plane with a Smaller surface plates are placed on benches while the
perfectly flat surface. Marking using datum surfaces which larger surface plates are placed on stands.
are not perfectly flat will result in dimensional
inaccuracies. (Fig 1) The most widely used datum Other materials used
surfaces in machine shop work are the surface plates Granite is also used for manufacturing surface plates.
and marking tables. Granite is a dense and stable material. Surface plates
made of granite retain their accuracy, even if the surface
is scratched. Burrs are not formed on these surfaces.

Classification and uses

Surface plates used for machine shop work are available
in three grades - Grades 1, 2 and 3. The grade 1 surface
plate is more acceptable than the other two grades.

Specifications
Cast iron surface plates are designated by their length,
breadth, grade and the Indian Standard number.

Example
Materials and construction Cast iron surface plate 2000 x 1000 Gr1. I.S.2285.
Surface plates are generally made of good quality cast Marking-off tables (Fig 3)
iron which are stress-relieved to prevent distortion. The
work-surface is machined and scraped. The underside is
heavily ribbed to provide rigidity. (Fig 2)

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These are heavily ribbed cast iron tables fitted with strong These lines serve as guides for positioning components
rigid legs. The top surface is accurately machined flat, while setting and marking.
and the sides square.
These are used for carrying out marking on heavy
components. On certain types-parallel lines are engraved
in both directions at a set distance.

Try square
Objectives : At the end of this lesson you shall be able to
• name the parts of a try square
• state the uses of a try square.

The try square (Fig. 1) is a precision instrument which is • check flatness of surfaces (Fig. 3)
used to check squareness (angles of 900) of a surface.

• mark lines at 900 to the edges of workpieces (Fig. 4)

The accuracy of measurement by a try square is about

0.002 mm per 10 mm length, which is accurate enough
for most workshop purposes. The try square has a blade
with parallel surfaces. The blade is fixed to the stock at
900.
• set workpieces at right angles on work. holding devices.
Uses (Fig. 5)
The try squareness is used (Figs 2 & 3)

Try squares are made of hardened steel.

Try squares are specified according to the lengths of the
blade, i.e 100 mm, 150 mm, 200 mm.
Use of a try square and steel rule.

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Fig 6 shows the method of using a try square and a steel
rule for accurate measurements.

For maintaining accuracy it is important to see

it, that the edges and surfaces of instruments
are protected from damage and rust.

An experienced person can transfer measurements from

a steel rule very accurately.
The steel rule graduations are accurately engraved, with
the line thickness ranging from 0.12 to 0.18 mm.
Do not place a steel rule with any cutting tools. Apply a
thin layer of oil when not in use.
For Accurate reading it is necessary to read vertically to
avoid errors due to parallax

Types of calipers
Objectives : At the end of this lesson you shall be able to
• name the commonly used calipers
• compare the features of firm joint and spring joint calipers
• state the advantage of spring joint calipers.
• state the uses of inside and outside calipers
Calipers are simple measuring instruments used to The size of a caliper is specified by its length - which is
transfer measurements from a steel rule to objects, and the distance between the pivot centre and the tip of the
vice versa. leg.
Calipers are of different types depending on the type of The accuracy of the measurement taken depends very
joint and the shape of leg. much on the sense of feel an touch. While measuring the
Types of joint job, you should get the feel when the legs are just touching
the surface.
The commonly used calipers are:
- firm joint calipers
- spring joint calipers.
Firm Joint calipers (Fig. 1)
In the case of firm joint calipers, both legs are pivoted at
one end. To take measurements of a workpiece. It is
opened roughly to the required size. Fine setting is done
by tapping the caliper lightly on a wooden surface.

Types of legs
Outside and inside calipers are differentiated by the shape
of the legs.
Calipers used for outside measurements are known as
outside calipers. The calipers used be internal measure-
Spring joint calipers (Fig. 2)
ments are known as inside calipers.
For this type of calipers, the legs are assembled by means
of a pivot loaded with a spring. For opening and closing Calipers are use along with steel rules, and the accuracy
the caliper legs, a screw and nut are provided. is limited to 0.5 mm; parallelism of jobs etc. can be
checked with higher accuracy by using a caliper.
Spring joint calipers have the advantage of quick setting.
The setting made will not change unless the nut is turned.
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Jenny calipers
Objectives : At the end of this lesson you shall be able to
• state the constructional features of jenny calipers
• name the types of jenny calipers
• state the uses of jenny calipers.
Jenny calipers are used for marking and layout work.
These calipers are also known as hermaphrodite calipers,
odd leg calipers, and leg and point calipers.
Jenny calipers have one leg with an adjustable divider
point, while the other is a bent leg. The legs are joined
together to make a firm joint.
USES
Jenny calipers are used for marking lines, parallel to inside
and outside edges and for locating the centre of round
bars.
These calipers are available with the usual bent leg or
with a heel. The calipers, with ordinary bent legs, are used
for drawing lines parallel along an inside edge, and the
heel type is used to drawing parallel lines along outer
edges (Figs 1 & 2).
The jenny calipers should be slightly inclined while scribing
lines.

While setting dimensions for accurate setting the jenny

caliper point should `click’ into the graduation (Fig. 5).

Jenny calipers can also be used for scribing lines along

curved edges (Figs 3 & 4). While setting dimensions and
scribing lines, both legs should be of equal length.

28 Automobile : Mechanic Diesel (NSQF LEVEL - 4) Related Theory for Exercise 1.2.09
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Dividers
Objectives : At the end of this lesson you shall be able to
• name the parts of a divider
• state the uses of dividers
• state the specifications of dividers
• state the important aspects of be considered in respect of divider points.

Dividers are used for scribing circles, arcs and transferring The sizes of dividers range between 50 mm to 200 mm.
and stepping of distances. (Figs 1, 2 and 3) The distance from the point to the centre of the fulcrum
roller (pivot) is the size of the divider. (Fig 5)
For the correct location and seating of the divider legs,
prick punch marks of 30o are used. (Fig 6)

Dividers are available with firm joints and spring joints.

The measurements are set on the dividers with a steel
rule. (Fig 4)

Both the legs of the divider should always be of equal

length.
Dividers are specified by the type of their joints and length.
The divider point should be kept sharp in order to produce
timelines. Frequent sharpening with an oil stone is better
than sharpening by grinding. Sharpening by grinding will
make the points soft.

Do not sharpen the divider points on grinding

wheels.

Surface Gauges
Objectives : At the end of this lesson you shall be able to
• state the constructional features of surface gauges
• name the types of surface gauges
• state the uses of surface gauges
• state the advantages of universal surface gauges.

The surface gauge is one of the most common marking Surface gauge-fixed type (Fig. 2)
tools used for.
• setting jobs on machines parallel to a datum surface
scribing lines parallel to a datum surface • checking the height and parallelism of jobs
Types of surface gauges • setting jobs concentric to the machine spindle.
• Surface gauges/scribing blocks are of two types. The fixed type of surface gauge consists of a heavy flat
• Fixed base and a spindle, fixed upright , to which a scriber is
• Universal (Fig. 1) attached with a snug and a clamp-nut.

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 Universal surface gauge (Figs 3 & 4)
This has the following additional features.
• The spindle can be set to any position.
• Fine adjustments can be made quickly.
• can also be used on cylindrical surfaces.

30 Automobile : Mechanic Diesel (NSQF LEVEL - 4) Related Theory for Exercise 1.2.09
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Scriber
Objectives : At the end of this lesson you shall be able to
• state the features of scribers
• state the uses of scribers.

In layout work, it is necessary to scribe lines to indicate

the dimensions of workpieces to be filed or machined .
The scriber is a tool used for this purpose. It is made of
high carbon steel which is hardened. For drawing clear
and sharp lines, a fine point is ground at one end.
Scribes are available in different shapes and sizes. The
one most commonly used is the plain scriber (Fig. 1).

Scriber points are very sharp, and they are to

be handled very carefully. Do not put the
scriber in your pocket. Place a cork on the point
when not in use to prevent accidents.( when it
is not in use)

While scribing lines, the scriber is used like a pencil so

that the lines drawn are close to the straight edge (Fig.2).
The point of the scriber should be ground and honed
frequently for maintaining its sharpness.

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Automobile Related Theory for Exercise 1.2.10
Mechanic Diesel - Measuring, marking & workshop tools
Wheelbase, wheeltrack and measuring tape
Objectives: At the end of this lesson you shall be able to
• define wheelbase
• define wheeltrack
• state measuring tape, its types and uses.

The wheelbase of a vehicle equals the center distance

between its front and rear wheels. (Fig 1)
Wheel/Track : The wheeltrack of a vehicle equals the center
distance between its front wheels. As shown in the
diagram. (Fig 4)
Measuring tape is a flexible ruler. It is made of ribbon
cloth plastic fiber glass metal strip with lines for
measurements. It is very common measuring tool used
by many people. The available range are 3m, 5m and 10m.

Types
1. Plastic Tape (Fig 3)
2. Metal Tape (Fig 2)
3. Fibre glass
4. Ribbon cloth

Application
Dress makers
Civil Engineers
Mechanical Engineers
Surveyors
Carpenters
Medical field

Accuracy
Measuring tapes are marks in metric and British system.
The accuracy in metric system is 1mm and in British
system is 1/8”.
Limitation: Accouracy is not possible, because the tape
is flexible and likely to elongate while measuring long
ranges and distances.

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Automobile Related Theory for Exercise 1.2.11
Mechanic Diesel - Measuring, marking & workshop tools
Length measurement
Objectives: At the end of this lesson you shall be able to
• name the base unit length measurement as per the International system of units of measurement (SI)
• state the multiples of a metre and their values.
When we measure an object, we are actually comparing
it with a known standard of measurement.
The base unit of length as per SI is the METRE Length SI
UNIT and MULTIPLES

Base Unit
The base unit of length as per the System International
is the metre. The table given below lists some multiples
of a metre.
METRE (m) = 1000 mm
CENTIMETRE(cm) = 10 mm
MILLIMETRE (mm) = 1000 mm
MICROMETRE (m) = 0.001 mm
The British system of length measurement
Measurement in engineering practice An alternative system of length measurement is the British
Usually, in engineering practice, the preferred unit of length system. In this system, the base unit is the Imperial
measurement is the millimetre (Fig. 1). Standard Yard. Most countries, including Great Britain
itself, have, however, in the last few years, switched over
Both large and small dimensions are stated in millimetres to SI units.
However in a regular Steel rule & in vernier caliper the
main scale readings of metric in the bottom and imperial
in inches in the top wih corrosponding vernier scales.

Engineer’s steel rule

Objectives : At the end of this lesson you shall be able to
• state the constructional features of an engineer’s steel rule
• explain the uses of a steel rule
• state the maintenance aspects to be considered in respect of steel rules.

When dimensions are given in a drawing without any The reading accuracy of the steel rule is 0.5 mm.
indication about the tolerance, it has to be assumed that
measurements are to be made with a steel rule.
Steel rule are made of spring steel or stainless steel. The
edges are accurately ground to form straight edges.
The surface of the steel rule is satin-chrome finished to
reduce glare, and to prevent rusting.
Sizes of steel rules (Fig. 1)
Steel rules are available in different lengts, the common
sized being 150mm, 300 mm and 600 mm.
The engineer’s steel rule is graduated in 10 mm, 5 mm,
1mm and 0.5 mm.

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Automobile Related Theory for Exercise 1.2.12
Mechanic Diesel - Measuring, marking & workshop tools
Air impact wrench, air ratchet
Objectives: At the end of this lesson you shall be able to
• explain the use of air impact wrench
• explain the working principle of air impact wrench.
Air impact wrench (Fig. 1) Air Ratchet (Fig.3)
Air Impact Wrench (also known as an impact or, Air Rattle An Air Ratchet is a quite identical to General ratchet
Gun windy gun), Air wrench is a socket wrench power wrench.
tool, which is used to deliver high torque. It works by storing
energy in rotating mass and suddenly delivering it to output It is also having square drive at different sizes.
shaft. The socket drive is turned by a Air Motor. When we pull
Compressed Air is commonly used as the power source. the trigger, Air motor gets activated it turns the socket
Electric power can also be used as the source of power. drive.
cordless Electric devices are also used, and are very The direction of socket drive can be changed to clockwise
popular due to ease of working. (or) anti clockwise as per the user requirement.
Air Ratchet operates with more speed unless torque. In
case where more torque is required we should use Air
impact wrench.
Air Chisel
Air chisel is used for cutting the bolts to nuts of vehicle
body sheet.

The Air impact wrench is to be used along with a specially

hardened impact socket extension and joints to withstand
sudden force.
Generally a special 6 inch pin socket is used with air
impact wrench. (Fig. 2)

The compressed Air provides more force and

much efficient than a hand chisel and Hammer.

Air chisel can be used with different types of chisel kit,

depending upon the job.

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Automobile Related Theory for Exercise 1.2.13
Mechanic Diesel - Measuring, marking & workshop tools
Hand tools
Objectives: At the end of this lesson you shall be able to
• state the application of punches.

Punches are used in sheet metals and other work to mark

position on work. (Fig 1)
Prick punches

These punches are used to make witness marks on

scribed lines. (Fig 2)

Centre punches are used:

• to make deeper witness marks on scribed lines and to
locate a centre position and make it easier for the drill
This makes it easier to see accurate marking out lines. to start correctly. (Fig 5)
• to check the location of the centre positions before
centre punching. (Fig 3)
• to locate the pivot points of compasses for scribing
circles. (Fig 4)
A 100 mm prick punch with a 7 mm diameter body could
have a 2.5 mm diameter point ground to an angle of 60° or
30°
Centre punches
These punches are similar to prick punch, and it is
generally larger then prick punch.
A 100 mm centre punch could have a 10 mm diameter
body and a 6 mm diameter point ground to an angle of 90°

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Solid punch (Fig 6) These punchase are also used to punch holes in thin sheet
metal, leather, plastic cork etc. Gaskets, seals and
spacers are made using hollow punches.
While using solid or hollow punches, the materials is rigidly
supported with a block of wood (with the end of grain up) or
lead. This will also avoid any damage to the tip of the punch
while punching.
Pin punches (Fig 8)
Pin punches are used to drive locating or locking pins,
dowels and rivets out of their holes.
Pin punches are available in a set of 5 pins of dia.3,4,5,6
and 8 mm with a knurled body to a length of approximately
150 mm.

In riveting sheet metal, holes must be equally spaced and

lined up. The holes in the metal are usually punched with
solid punches.
Letter and number punches
Also known as letter stamps or number stamps, letter
punches are used to emboss the impression of a letter of
number into a workpiece. They are most common in the
reverse image, this allows the end result to be immediately
readable, however they may be made as a positive image.
This is essential in the case of die or mold making and
ensure that the finished product will be readable, as a die
is a negative image.
Hollow punch (Fig 7)

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Chisel
Objectives : At the end of this lesson you shall be able to
• list the uses of a cold chisel
• name the parts of a cold chisel
• state the different types of chisels.
The cold chisel is a hand cutting tool used by fitters for • Hall round nose chisel
chipping and cutting off operations. (Fig. 1)
• Diamond point chisel
Flat chisels (Fig. 3)

Chipping is an operation of removing excess metal with They are used to remove metal from large flat surfaces
the help of a chisel and hammer. Chipped surfaces being and chip excess metal of weld joints and castings.
rough, they should be finished by filing. Cross-cut or cape chisels (Fig. 3)
Parts of a chisel (Fig. 2) These are used for cutting keyways, grooves and slots.
Half round nose chisels (Fig. 4)
They are used for cutting curved grooves (oil grooves)

A chisel has the following parts.

Head
Body
Point or cutting edge
Chisels are made from high carbon steel or chrome
vanadium steel. The cross-section of chisels is usually
hexagonal or octagonal. The cutting edge is hardened
and termpered.
Common types of chisels
There are four common types of chisels
• Flat chisel (1)
• Cross-cut chisel (2)

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Diamond point chisels (Fig. 5) Chilsels are specified according to their
These are used for squaring materials at the corners. • length
• width of cutting edge
• type
• cross-section of body
The length of the chisels ranges from 150mm to 400mm.
The width of the cutting edge varies according to the type
of chisels.

Web chisels/punching chisels (Fig. 6)

These chisels are used for separating metals after chain
drilling.

Angles of chisels
Objectives : At the end of this lesson you shall be able to
• select the point angles of chisels for different materials.
• state the different cutting angles of a chisel
• state the effect of rake and clearance angles.
Point angles and materials (Fig 1) If the clearance angle is too low or zero (Fig. 2), the rake
angle increases. The cutting edge cannot penetrate into
Correct point/cutting angles of the chisel depends on the
the work. The chisel will slip.
materials to be chipped. Sharp angles are given for soft
materials, and wide angles for hard materials.

The correct point angle and angle of inclination generate

the correct rake and clearance angles.
Rake angle (Fig. 1)
Rake angle `γ’ is the angle between the top face of the
cutting point, and normal to the work surface at the cutting
edge.

If the clearance angle is too great (Fig. 3), the rake angle
reduces. The cutting edge digs in, and the cut
progressively increases.

Clearance angle (Fig. 1)

Clearance angle `α’ is the angle between the bottom face
of the point and tangent to the work-surface originating at
the cutting edge.
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 Material to Point Angle It is made of Bakelite frame fitted with clear glasses and
be cut angle Inclination an elastic band to hold it securely on the operator’s head.
It is designed for comfortable fit, proper ventilation and full
High carbon protection from all sides.

steel 65o 39.5o

cast iron 60o 37o

Mild steel 55o 34.5o

Brass 50o 32o

Copper 45o 29.5o

Aluminium 30o 22o

Chipping goggles (Fig. 4): It is used to protect the eyes
while chipping the slag or grinding the job.

Hammers
Objectives : At the end of this lesson you shall be able to
• state the uses of an engineer’s hammer
• list the parts of an engineer’s hammer and state their functions
• name the types of engineer’s hammers
• specify the engineer’s hammer,

An engineer’s hammer (Fig. 1) is a hand tool used for

striking purposes while
• punching
• bending
• straightening
• chipping
• forging
• riveting

The parts of a hammer head are the

• face (1) • pein (2)
• cheek (3) • eyehole (4)
• wedge (5)
The face is the striking portion. Slight convexity is given
to it avoid digging of the edge.
The pein is the other end of the head. It is used for shaping
and forming work like riveting and bending. The pein is of
different shapes like the (Fig. 3)

Major parts of a hammer (Fig. 2)

The major parts of a hammer are a head and a handle.
The head is made of drop-forged carbon steel, while the
wooden handle must be capable of absorbing shock.

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• ball pein
• crosspein
• straight pein
The face and the pein are hardened.
The cheek is the middle portion of the hammer-head.
The weight of the hammer is stamped here.
This portion of the hammer-head is left soft.

The face of the hammer is used for general work, such

as striking chisels and punches and levelling and working
over joints. (Fig. 7)

An eyehole is meant for fixing the handle. It is shaped to

fit the handle rigidly. The wedges fix the handle in the eye
hole. (Fig 4,5)

Specification
An engineer’s hammers are specified by their weight and
the shape of the pein. Their weight varies from 125 gms to
1.5 kg.
Ball pein hammer (Fig. 8)
The ball pein hammers are used for general work in a
machine/fitting shop. A ball pein head is used to spread metal in all directions.

Before using a hammer This hammer has a semi-spherical pein suitable for
riveting. (Fig. 9)
make sure the handle is properly fitted
It is used for shaping the cylindrical end of a metal rivet to
select a hammer with the correct weight suitable for form a rivet head.
the job
Cross pein hammer (Fig. 10)
check the head and handle for any cracks
ensure the face of the hammer is free from oil or A cross pein head is used to spread metal in one direction
grease. in the line of striking.

The figure shows the different parts of a hammer (Fig. 6). This has a blunt wedge-shaped pein at right angles to the
The handle is fitted in the eye-hole of the hammer. axis of the handle.

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 Straight pein hammer
A straight pein hammer is used to spread metal in one
direction at right angles to the line of striking (Fig. 11)

This hammer has a blunt wedge-shaped pein in line with

the axis of the handle.
A lump hammer or club hammer is a small sledgehammer
(Fig. 12) whose relatively light weight and short handle
allow single-handed use. It is useful for light demolition
work, driving masonry nails, and for use with a steel chisel
when cutting stone or metal. In this last application, its
weight drives the chisel more deeply into the material being
cut than lighter hammers.

Wooden Mallet
Objectives : At the end of this lesson you shall be able to
• name the different types of mallets
• state the uses of each type of mallets.

Mallets Types and uses

Mallets are soft hammers and are made of raw hide, hard Standard wooden mallets (Fig. 1) are used for general
rubber copper, brase, lead or wood, and are used to strike purpose work like flattening, bending etc.
a soft and light blow on the metal.
Bossing mallets (Fig. 2) are used for hollowing panel
beatings etc.
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 An end-faked mallet (Fig. 3) is used for stretching,
hammering etc.

Screwdrivers
Objectives : At the end of this lesson you shall be able to
• classify the hand-held screwdrivers
• state the features of standard screwdrivers
• list out the different types of special screwdrivers and their specific uses
• specify standard screwdrivers.

Screwdrivers are used to tighten or loosen screws which • flared tips which vary in length and thickness with the
are fixed in the machine element. length of the blade.
Classification Standard Screwdrives
• Standard type with tips to suit recessed head Standard screwdrivers are classified as:
screw slots.
• heavy duty screwdrivers
• Special type with tips to suit recessed head
• light duty screwdrivers
screws
• stumpy screwdrivers
Features of Standard screwdrivers (Fig. 1)
Heavy duty screwdrivers (Fig 2 & 3)
Screwdrivers must have:
This screwdriver has a square blade for applying extra
• tips (1) of turn screws with slotted heads
twisting force with the end of the spanner. Heavy duty
• handles of metals, wood or moulded insulating screwdrivers of London pattern have a flat blade and are
material(2), shaped to give a good grip for turning (3). mostly used by carpenters.
• blades of hardened and tempered carbon steel or alloy
steel
• round or square blade with length (4) ranging from
40mm to more than 350mm.
42 Automobile : Mechanic Diesel (NSQF LEVEL - 4) Related Theory for Exercise 1.2.13
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 Light duty screwdrivers (Fig. 4)
This screwdriver has a round blade with parallel tips. This
screwdriver is used by electricians. The blades are
sheathed in insulation to avoid short circuting live parts.

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Stumpy screwdrivers (Fig. 5) They are used for slackening or tightening with a medium
force.
These are small sturdy screwdrivers. They are used when
other types of screwdrivers cannot be used due to the They are used in mass production.
space limitations.

Special screwdrivers and their uses

Offset screwdriver (Fig. 6)
Offset screwdrivers are used on screws which are placed Phillips (cross-recess) screwdrivers (Fig. 8)
in blind spaces. Phillips screwdrivers have cruciform or cross-shaped tips
They are made with short blades and with the tips at right that are unlikely to slip from the cruciform slots in Philips
angle. recessed head screws.

Greater turning force can be applied on screws by these The end of the four flats is tapered to an angle of 53o
screwdrivers because of their leverage. The extreme end is ground to 110°.

Ratchet screwdriver (Fig. 7)

The following are the features of ratchet screwdrivers.
These screwdrivers are made with a three-position ratchet
contol for screwing, unscrewing of a screw and also
providing a neutral position.
They are used for tuning screws in confined spaces.
They can be operated without changing the hand grip.

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Four different sizes to cover the full range of screws are
available. These are specified by point sizes 1,2,3 & 4
which correspond to the size of the Phillips screw heads.
For quicker application ratchet offset screwdrivers are also
available with renewable tips. (Fig. 9)

Specification
Screwdrivers are specified (Fig. 10) according to the
• length of the blade (a) Precautions
• width of the tip (b).
Use screwdrivers with tips correctly fitting into the screw
Normal blade length : 45 to 300mm. Width of blade : 3 to slot. (Fig. 13)
10mm.
The blades of screwdrivers are made of carbon steel or
alloy steel, hardened and tempered.

Make sure your hand and the handle are dry.

Hold the screwdrivers axis in line with the axis of the
screw.
While using a Philips screwdriver apply more downward
pressure.
Screwdrivers for special uses Keep your hand away to avoid injury due to slipping of the
screwdriver. (Fig. 14)
Small sturdy screwdrivers (Fig. 11) are available for use
where there is limited space.

Screwdrivers with blades sheathed in insulation are

available for the use of electricians (Fig. 12)

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Do not use screwdrivers with split or defective handles. Screw driver (Fig 16): There are several different size of
(Fig. 15) screw drivers of the standard, reed & prince & phillips
types.
The offset screw driver is useful in tight quarters where
even a “Stubby” cannot be used.
Safety:
1 Always use correct type and size screw drivers.
2 Don’t do repair work by holding the job on the hand
with the help of screw driver, if may slips it pierce
the hand.
In the case of damaged screwdrivers, the blades can be
ground (the faces will be parallel with the sides of the
screw slot) and used. While grinding ensure the end of
the tips is as thick as the slot of the screw.
While using screwdrivers on small jobs, brace the job on
the bench or hold them in a vice.
Specification of a screwdriver
Screwdrivers are specified according to the
• length of the blade
• width of the tip
The normal blade length varies from 45mm to 300mm
and the width of the blade varies from 3mm to 10mm.

Allen keys
Objectives : At the end of this lesson you shall be able to
• state the features and uses of hexagon socket screw keys
• specify hexagon socket screw keys.

Hexagon socket screw keys/Allen keys are made from Allen keys, available in different sets in plastic wallets,
hexagonal section bars of chrom vanadium steel. surprise of a set of 8 (2 to 10mm)
These are hardened and tempered. These are bent to `L’ 2,3,4,5,6,7,8 and 10mm
shape. The size of an Allen key is identified by the size
Sizes of Allen keys (Fig. 1)
across the flat of the hexagon.
Individual pieces are available as follows.1, 1.5, 2, 2.5,
Uses
3, 4, 5, 6, 8, 10, 12, 14, 17, 19, 22, 24, 27, 32 and 36.
They are used to tighten or loosen screws having internal
Designation of Allen keys (Fig. 2)
hexagon sockets, (Fig.1)
A hexagonal socket screw key of width across flat 8 mm
shall be designated as Key 8 IS:3082.

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