7.2 Workshop Practices Flashcards
What are the methods for caring for tools?
Regular cleaning, lubrication, and proper storage
Cleaning involves removing dust and dirt with a stiff brush or rag, while lubrication prevents corrosion and reduces wear.
Why is controlling tools important in a work environment?
To prevent accidents and ensure safety; misplaced tools can lead to disaster
A lost tool could potentially result in loss of life or damage to aircraft.
What is the methodology of tool storage?
Dedicated storage areas with organized layouts for easy access and accountability
Tools should be labeled and stored in a controlled location to prevent loss.
Why is tool calibration important?
Ensures accuracy and reliability of measurements
Tools requiring calibration must be sent for recalibration before expiration.
How should personal tools be treated?
Cleaned regularly and stored properly; avoid misuse
Personal tools include common hand tools and should be maintained to high standards.
List safety precautions when working with workshop materials.
- Use personal protective equipment (PPE)
- Ensure all tools are in good condition
- Keep work areas tidy
- Follow proper operating procedures
- Report any hazards immediately
What are appropriate environmental conditions for storing materials?
Dry, clean, and well-ventilated areas
Conditions should prevent corrosion and damage to tools and materials.
What types of tools are included in a personal tool set for maintenance engineers?
- Hand tools
- Sockets
- Files
- Wrenches
- Pliers
- Pneumatic drills
- Riveting equipment
- Drill bits
What materials are most tools manufactured from?
Alloy steels prone to corrosion
Corrosion resistance is enhanced through finishes and sealed mechanisms.
How should metal-covered workbenches be maintained?
Cleaned with an oiled rag
This prevents corrosion and maintains surface integrity.
What is the purpose of using a hardwood or steel block on a workbench?
To protect the bench surface from damage during drilling or punching
This prevents metal swarf from embedding in the bench.
How should vices be maintained?
Wiped with an oily rag and lubricated regularly
Check and retighten jaw-insert screws and bolts.
What maintenance is required for drilling machines?
Regular cleaning, inspection, and lubrication
Clamping screws should be slackened for lubrication of the threads.
How should precision measuring instruments be stored?
In their own dedicated protective cases
This prevents damage from being left unprotected.
What is a shadow board in tool control?
A board used for organized storage of tools to quickly identify missing items
Each tool has a specific place, enhancing accountability.
What is the final check procedure for tool control at the end of a shift?
All tools must be collected and checked against the tool register
The aircraft cannot be released for service until every tool is accounted for.
What should be done if a tool is found to be missing?
Report to the Supervisor and conduct a thorough search
Accountability is critical to prevent accidents.
What is involved in typical tool control procedures?
- Assigning identification numbers
- Maintaining service history
- Documenting issuance and return of tools
- Inspecting tools for discrepancies
True or False: Personal tools are always allowed in a Part-145 organization.
False
Many organizations do not allow personal tools to enhance tool control.
Fill in the blank: Tools that require frequent repairs should be __________.
investigated for possible mishandling
What are some common workshop materials that an aircraft engineer might encounter?
- Greases
- Oils
- Solvents
- Sealants
- Contact cement
- Paints
- Paint strippers
These materials have various health and safety risks associated with their use.
What must be available for all materials used in a workshop?
Material Safety Data Sheet (MSDS) and a specification sheet
MSDS provides information on the properties of each material, including hazards and handling instructions.
Where should flammable materials be stored when not in use?
In an appropriate flammable storage facility
This is crucial for ensuring safety and maximizing usage.
True or False: Certain materials used in aircraft engineering can be highly toxic.
True
Contact with or intake of toxic materials can lead to serious injuries or even death.
What should be done before using a specific material in the workshop?
Check the expiry date/shelf life
Using expired materials could compromise the integrity of the task.
What personal safety equipment should be used when handling toxic materials?
Personal Protective Equipment (PPE)
PPE includes items like gloves, goggles, and masks to protect against exposure.
What is important to ensure when working with toxic materials?
Proper ventilation or a Local Exhaust Ventilation (LEV) system
This helps to minimize inhalation of harmful fumes.
What must be done with containers of materials after completing a task?
Ensure the container is properly sealed
This allows for the material to be re-used later.
Fill in the blank: Mixed two-pack sealants need to _______ completely before disposal.
cure
Proper curing is essential before following disposal procedures.
How should mixed two-pack sealants be disposed of?
In accordance with company procedure for disposal of hazardous waste
Following proper disposal procedures is important for safety and compliance.
What is a dimension?
A measurable limit of some kind, such as length, width, or height.
What is a limit dimension?
The maximum or minimum dimension of a machined part or component.
What is the nominal size of an item?
An approximate dimension used for general identification.
What is the basic size?
The theoretical size from which the size limits are derived by applying allowances and tolerances.
What is tolerance?
The total amount by which a given dimension is allowed to vary.
How is actual size determined?
By measuring the part and confirming it is within tolerance.
What is an example of a basic size and its tolerance?
Diameter of a bearing shaft is 4 in with a tolerance of +/- 0.005 in.
What is a bilateral tolerance?
A tolerance that can be added to or subtracted from the basic size.
What is a unilateral tolerance?
A tolerance that only has a limit in one direction.
What is meant by ‘fit’ in engineering?
The dimensional relationship between two parts.
What is a clearance fit?
A fit that allows for sliding or rotating between the parts.
What is an interference fit?
When the dimensions of two parts overlap, such as a pin diameter larger than the hole.
What is an allowance?
The minimum clearance space intended between two parts.
What does a limit represent?
The maximum or minimum dimension formed when maximum or minimum tolerance is considered.
What are standards of workmanship?
The skill of a craftsman, quality of the product, and attitude towards care.
Why are the highest standards of workmanship crucial in aviation engineering?
An error could compromise the airworthiness of the aircraft, risking human life.
What are Aircraft Maintenance Manuals (AMM)?
Procedures designed for the engineer to use as mandatory instructions for maintenance.
What factors control the standards of workmanship during hand working of materials?
The skill of the craftsperson and the quality of the tools being used.
What is the role of different grades of files in metalworking?
Used to obtain a rough surface finish before applying finer finishing methods.
What is the purpose of using a reamer?
To smooth the material inside a hole for better surface contact with a tight-fitting pin.
Fill in the blank: The quality of a finished item depends on the _______ and the equipment used.
[skill of the craftsperson]
What is the requirement for aircraft maintenance organisations regarding precision tooling and equipment?
Regularly inspect and calibrate to prescribed acceptable standards
Ensures safety and compliance with regulations.
What should a clear labelling system indicate about tools?
Whether the tool is within the calibration period
Labels provide essential information for tool usage.
What information should be included on a calibration label?
- The date of the last test
- When the next inspection or calibration is due
- The authorised person’s signature or stamp
Ensures traceability and accountability of calibrations.
What type of register should maintenance organisations maintain?
A register for all precision tooling and equipment with calibration records
Helps in tracking the status and history of tool calibrations.
How can tools requiring periodic calibration be managed?
In-house in a controlled environment or sent to an independent test company
Flexibility in calibration processes to ensure compliance.
What should an engineer ensure regarding tools that require periodic calibration?
That calibration is performed; otherwise, the tool is not suitable for use
Safety is paramount in aircraft maintenance.
What is the general guideline for calibration intervals?
Follow manufacturers’ instructions or show results for a different period
Ensures tools are calibrated as frequently as needed.
What is the common calibration frequency for tools that hold calibration well?
Annual calibration
Ensures continued accuracy of the tools.
How should sensitive instruments like electrical instruments be calibrated?
Calibrated by the user before each use and require periodic calibration
Ensures high accuracy and reliability.
What should be detailed in the written record for tools requiring calibration?
- When last done
- When next due
- Calibration requirements
Important for maintaining an accurate history of tool usage.
What should a sticker on a tool indicate?
The due date of the next calibration
Quick reference for users to avoid using out-of-calibration tools.
What should be done if a tool shows signs of damage or measurement doubt?
Remove from service and label accordingly
Prevents the use of potentially unsafe tools.
What must happen before unserviceable equipment can return to service?
The reason for unserviceability must be eliminated and calibration revalidated
Ensures safety and compliance before tool use.
What information should calibration records or certificates contain?
- Identification of equipment
- Manufacturers Standard used for calibration
- Obtained results
- Uncertainty of measurement
- Assigned calibration interval
- Limits of permissible error
- Authority of the release document
- Limitations in the use of the equipment
- Date of calibration
Comprehensive records are crucial for accountability and traceability.
True or False: Tools should be used even if they are out of calibration.
False
Using out-of-calibration tools can lead to inaccurate measurements and safety issues.
What should calibration results be reviewed for?
To ensure tooling remains within acceptable AMM or CMM limits
Regular review is essential for maintaining accuracy.
What is an example of acceptable torque wrench values?
+/- 5%
Precision is critical in aircraft maintenance.
What should a Purchase Order/work request to the testing house specify?
Calibration requirements
Ensures that the testing house meets necessary standards.
Why is accurate measurement essential in aviation engineering?
It ensures precision and safety in engineering practices
Accurate measurements are critical for ensuring that all components function correctly and meet safety standards.
What must be done before using any precision measuring tool?
Ensure it is within its calibration period
Tools must be calibrated by an approved person or organization.
What does it mean for a tool to ‘zero’ correctly?
The reading on the instrument should read zero when measuring faces are closed
If zero is not achieved, the tool requires recalibrating.
Why is calibration essential for torque wrenches?
It maintains accuracy and longevity
Calibration ensures compliance with stipulated standards for reliable measurements.
What can general wear and tear do to torque wrenches?
It can lead to incorrect and unreliable readings
Regular calibration helps mitigate these effects.
What is the purpose of a torque analyser?
To check and calibrate all types of torque wrenches and power tools
It conforms to torque tool standards ISO 6789, BS 6703, and ANSI/ASME B 107.14M.
What units of measurement can a torque analyser display?
- N.m
- dN.m
- cN.m
- lbf.ft
- lbf.in
- ozf.in
- kgf.m
- kgf.cm
- gf.cm
The unit can be selected according to the operator’s requirements.
Who performs the calibration of torque wrenches and other measuring equipment?
Approved organizations employing certified personnel
Ensures that calibration adheres to industry standards.
How are pressure gauges and transmitters calibrated?
By hydraulic pumps using water or oil, or pressure generators using oil or gas
This method ensures accurate pressure readings.
What is the process to recalibrate a micrometer?
Insert a precision block between the anvil and spindle, then align the longitudinal line with the zero mark
A special wrench is used to rotate the sleeve for calibration.
What environmental factor can affect the calibration of a micrometer?
Extreme temperatures
Temperature fluctuations can impact the accuracy of the calibration process.
