7.3 Tools Flashcards
What do combination sets have?
Ruler
Protractor
Level
What should be used to cut through sheet metals and what for tougher materials?
Sheet metal with aviation snips
Hacksaws with fine toothed blades for tougher materials
What are two taps and dies used for?
Thread cutting
What are the parts of a screwdriver?
Tip/ blade; shank and handle
What is a basic description of a screw?
A machined bolt with a thread cut in to it with a countersunk or protruding head that a cavity is cut in to to apply torque
What is the handle of a screwdriver made of?
Wood or plastics that are non conductive of electricity or heat
What is the shank of a screw driver made from?
Carbon steel
Sometimes sheathed to protect user from eclectic shock
What is the blade or tip of a screwdriver made from?
Carbon steel but hardened to give protection and long life
How are screw drivers classified?
By their type of tip
What size are different screwdriver socket bits?
1/4 inch AF
How much of the screw slot dimensions must the screwdriver tip fill?
At least 75%
What is the point angle of a Phillips screw driver?
30 degrees
What is the point angle of a Reed & prince/ Frearson screwdriver?
V shape 45 degrees
What is the difference between a Phillips and Reed/ Frearson screwdriver?
Phillips has slightly larger centre in the cross
Phillips is blunt on the end
What do Frearson screw drivers allow for?
Higher torque to be applied and they have greater resistance for cam out
What size Frearson screwdriver should be used for different screws?
Size 1 for #5 and smaller
Size 2 for #6 and larger
How is a pozidriv screw driver an improved version of the Phillips?
- Allows more contact area between bit and screw so less cam outs with a greater torque applied
How can you tell the difference between a posidrive and Phillips screwdriver?
Has prefix PZ
What are the benefits of a torx/ star drives?
- apply more torque w reduced cam- out risk
-: requires less operator effort - good when removing screws that have become clogged with debris
What size do torx screwdriver/ bits range from?
What must be noted when choosing a size?
T1 to T100
The screw and driver must be the same t#
What can internal hex’s also be known as?
Allen key screws
What is a torq set screwdriver?
Like a Phillips but the cross is offset
Allows for greater torque transfer
What is the advantage given by mortorq shallow recess?
The fastener can be smaller yet retain its strength
When are hi- torques used?
When you need to repeatedly remove and install the fastener
Can execute installation without applying high force
What specialty tool can be used if fasteners are very tight?
Screw extractor
How are hammers classified?
By their Pein, face, weight or shape
What is the head of a hammer made from?
Steel
What is the handle of a hammer made from?
Usually from wood but can be plastics or composite materials
What is done to the handle of a hammer to reduce fatigue of the operator?
Sheathed in shock absorbing polymers
How is the handle secured to the head of a hammer?
Handle is secured to the Head through the eye by a wedge and composite hammers are often sealed with a resin too
What are the most common types of hammer used in aviation?
- ball Pein
- DIN general purpose
- soft face mallet
What are ball Pein hammers manufactured from? What is its use?
- high grade drop forged steel which is fully heat treated
- used for shaping metals, with cold chisels and punches
What are DIN hammers used for?
Same purpose as a ball Pein hammer
How does a soft face mallet reduce the force transmitted back to the user?
Temporarily deforms more than a metal hammer would
What can a soft faced mallets faces be made from?
Plastics incl. nylon or natural rubber (which is heavier)
How are soft face mallets graded?
By weight of the head and by hardness of the striking face
What is a plier?
Tool that has a pair of handles joined by a fulcrum/ pivot
How are pliers classified?
By their function and type of nose they have
How should pliers be constructed? (what materials are used)
- made of high quality alloy steel with induction hardened cutting edges
- Handles sheathed in comfortable soft plastic or rubber
How is a single fixed joint plier made?
Halves of the pliers are half cut out and placed inside each other w a pivot point
What is the toggle compound joint plier?
Combines single fixed joint w a toggle joint
The extra joint allows you to apply more leverage to the jaws
What is a lap joint?
Both halves of the pliers are jointed on top of each other
When is a lap joint used?
For heavier pliers and when greater leverage when cutting
When are slip joints used?
When you need to move the pivot point to make the jaws move according to the job
What are diagonal pliers used for?
Cutting of wire
How do diagonal pliers cut?
- By indenting and wedging the wire apart
- jaw edges make a v shape
How are diagonal cutters made?
- From tempered steel
- inductive heating and quenching is used to harden the jaws
Why are diagonal/ flush cutters used instead of symmetrical cutters?
Allow wires to be cut flush to the solder joint to avoid a sharp tip
What are combination/ lineman’s pliers used for?
- Base is used to cut wire
- centre of serrated jaw rotates round objects nuts and bolts
They are multifunctional
What are long nose pliers used for?
Detailed work with wire
What are multi grips/ swan neck pliers?
- several curved grooves that make up a series of interlocking joints
- have a slip joint that make them adaptable to different situations
- long handles so a large force can be applied to the jaws
How are the vice grip pliers jaws adjusted?
With the knurled screw at the end of the main handle
What are vice grip pliers used for?
To hold things incl. pipes, cut wire or hold a bolt
What are circlip pliers used for?
For fitting and removing circlips
What length are wire locking pliers available in?
Usually 230mm
150mm also popular
How is the size of a vice measured?
By jaw width and the capacity of the vice when the jaws are open
What are the two types of metal working vices?
- fixed/ stationary
- rotating (using a swivel base)
What thread do clamping device screws usually have?
ACME thread
What is type 1 of torque wrenches?
Indicate torque via a mechanical scale, dial or electronically .
What is type 2 of torque wrenches?
Fixed or adjustable to a preset torque value
What are the common types of type 1 torque wrenches?
- wrench with torsion or flexing bar
- wrench w rigid body and an indicator
- wrench w rigid body and electronic measurement
- screwdriver w indicator
- screwdriver w electronic measurement
What type of force is measured by a torque wrench?
Reaction force
How do convert Nm to lbs- ft?
Divide Nm by 1.356
How do you convert from lbs- ft to lbs-inch?
X12
How should a torque wrench not be cleaned?
DO NOT SOAK in a solvent as it may ingress the tool, wash away any lubricant and introduce inaccuracies.
What must be done when using an extension with a torque wrench.
Torque has to be reduced to account for the extension thats been added
What is the torque angle tightening method?
- uses initial torque loading like usual
- for a final torque it’ll give an angle that has to be used instead of a torque value
When would a calibrated ruler need to be used?
If it’s being used to measure an item for inspection, modification or so on
What is the difference between a tri square and a combination set?
The head slides along the rule and it can be clamped where ever
You can scribe lines at a 45 degree angle
What is a scrubber made of?
Tool steel
Since dividers can damage skins, what can be used instead for marking out?
Pencil
How are punches classified?
By the shape of their head
What are the two types of punches that are generally used?
Solid or hollow punches
What are punches usually made of?
Hardened steel
A type of punch called “drift” can be made of copper or bronze to minimise damage to the object that’s being drifted out
What is a prick punch used for? What is its tip angle?
- used when marking metal to show where holes should be drilled
- angle 30 ° or 60 °
What is a centre punch used for? What is its tip angle?
- making indentations in metal to stop wandering when drilling
- light work 60 °
- General work 90 °
Why is a hammer not necessary when using an automatic centre punch?
- It has an adjustable spring loaded trip mechanism
What is an automatic centre punch used for and what is its tip angle?
- used to indent where drilling is to be done
- general work 90 °
- light work 60 °
How do you drive out a bolt or a pin?
- start with a starting/ taper punch
- finish with a pin punch
How do you drive out a bolt or a pin?
- start with a staring/ taper punch
- finish with a pin punch
How is a pin punch selected to take out rivets?
Match punch face diameter to the diameter of the rivets shank
When are beryllium- copper and brass punches used?
- where damage may occur if using a hardened steel punch
- environments where there’s a risk of sparking
What direction do yellow, green and red aviations snips cut?
Yellow: Striaght
Green: curve right
Red: curve left
How should cuts be made when using aviation snips? (Since they don’t remove any material and minute fractures can occur along the cut)
About 0.8mm from the layout line and must be finished by hand filing down the line
What is the size range of a full size hacksaw?
6-16 inches, most common is 12 inches
How many teeth per inch are in coarse hacksaw blades?
14 teeth per inch when cutting steel
18 teeth per inch for solid stick ali, bearing metal, tool steel and cast iron
How many teeth are in a medium pitch hacksaw blade?
24 teeth per inch
When cutting thick walled tubing, pile, brass, copper, channel and angle iron
How many teeth are there per inch of a fine hacksaw blade? If
32 teeth per inch
When cutting thin walled tubing and sheet metal
What is the cutting direction on a full size hacksaw blade?
On the forward stroke
Which direction do the teeth in a junior hacksaw face?
Towards the handle
What is the cutting direction of a junior hacksaw?
- towards the operator
- this is because the saw frame is springy and compressed the blade if force is applied when the saw is pushed away
What direction do the teeth in a mini hacksaw generally face?
Face forward
(Used for confined spaces)
What speed should you hacksaw at?
Not more than 40-50 strokes per minute
What are files made from?
High grade carbon steels that are tempered to give its strength and durability
What special treatment do tangs (type of file) undergo and why?
Further heat treatment to make it softer and less brittle
How are files classified?
- length from point to base of the tang/ top of the heel
What does the “shape of the file” refer to?
It’s cross sectional shape
How are flat files tapered?
Tapered in width and thickness for the last 1/3 of their length towards the tip
What is a hand files shape?
- rectangular in cross section
- tapered in thickness
- parallel for their full length
- one safe edge and one single cut
- both faces will have double cut teeth
What cut do square and triangular files have?
Double cut teeth on all edges
What is the difference between round and rat tail files?
Rat tail files are tapered towards the tip
What is the cut in both sides of the half round file?
- flat face is double cut
- half round face is single cut
What angle are the teeth cut in a single cut file?
65 °- 85 °
What angles are teeth of double cut files?
First set: 40-50 °
Second set: 70-80 °
What allows the cutting stroke of the file to be forward stroke only?
Negative rake (sloping backwards of the teeth)
What are the grade of cuts commonly used?
- bastard cut
- second cut
- smooth cut
- Rasp cut (removes the most material)
What are the three parts of a drill bit?
Shank
Body
Point
What are the flutes in a drill bit for?
- Permit removal of swarf
- allows cutting fluid to reach the cutting lips
What determines the size of a drill bit?
The margin (narrow surface along the flutes)
What provides the torsional strength to a drill bit?
The land (bit between the flutes)
What does the point of the drill consist of?
Cutting edge, flank, face, web and chisel edge
What drill point angle do aluminium and mild steel bits have?
118 degrees
What drill point angle do aluminium and mild steel bits have?
118 °
What’s drill point angle do alumium, high tensile steel, stainless steel, sheet steel use?
135 °
What drill bits use a drill angle ion 30-70 °?
Hard rubber and fibre 60 °
Plastic materials: deeper it is the higher the angle required
What standards are used to size drills?
ANSI American National Standards Insitute
ISO International Organisation for Standardisation
What does a split point twist drill bit have that helps stop wandering?
Reduction of web thickness at the point
(Same concept as centre punching being done w smaller diameter)
What are the advantages of a split point drill bit?
- faster drilling
- requires less force to cut through material = less heat and stress
- create smaller or less chips so reduced risk of holes clogging up and bits breaking
How many lips can a standard countersink have?
One, three or multiple
What are the types of reamers?
- hand reamers
- machine reamers
What is the cylindrical part of a straight reamer for?
Merely grooves cut for the full length of the reamer body
For chips to escape and lubricant to reach the cutting edge
What does the cutting on a reamer?
the end of the reamer
What should you never do when taking out the reamer after cutting?
Do not reverse the cut/ rotation of the reamer
What is used to drive a machine reamer? How is it removed?
Driven by a morse taper shank NOT a square drive
A key drift has to be used to remove it
How is a straight shank reamer shaped?
- shank is smooth and parallel with no square or morse taper drive
- can have straight or helical flutes
- Used in a drill
Is the spiral or straight fluted reamer less likely to chatter?
Spiral
What reamers are tapered?
Spiral and straight fluted reamer
What reamers are used to complete the reaming of blind holes?
- bottoming tapers
- have no taper
What is a tap used for?
Cut threads in the inside of a hole
What is a die used for?
Cutting external threads Ona round bar
What are identical in all taps in a set?
Identical in diameter and cross section
What is the only difference between all the tapers in a set?
The amount of taper
What are the three taps in a set used for?
- taper tap
- plug tap
- bottoming tap
What is the taper tap used for? How much is it tapered?
- only tap needed for tapping holes that extend through thin sections
- tapered back for six to seven threads
What is a plug type tap used for?
Helps the taper tap for thicker materials
What is a bottoming tap used for?
- to cut full threads (so not tapered) to the bottom of a blind hole
What tool is used to hold and turn a tap?
A tap wrench tool
What are the two types of dies.
- solid dies
- adjustable dies
What cut do solid dies produce?
- a nominal thread w consistent depth
- accuracy is dependent on die precision and wear
How is the die adjusted on an adjustable die?
By turning the integrated screws
How to adjustable dies remove chips?
Have cavities
What is the “stock” in an adjustable die?
The tool used to hold and turn a threading die when producing external threads by hand
What are the three interchangeable basic requirements of electric tools?
- Either have a three wire cord w ground or be grounded or
- Be double insulated or
- Be powered by a low voltage isolation transformer
Why is double insulation the most convenient way to protect against electrical shock?
The user and tools protected in two ways:
1) by the normal insulation on the wires inside
2) by the housing that can’t conduct electricity
How is a pillar drill driven?
- by an electric motor through a speed changing mechanism (can be a belt transmission or a gear transmission)
Are drills run faster or slower when cutting softer materials?
Faster
How is an abrasive wheel tested? What is the sign of an undamaged wheel?
- tapped gently w a light non- metallic instrument
- An undamaged wheel makes a clear metallic tone or “ring”
What is the main advantage of pneumatic tools over electric?
Safety
What pressure is the air supply to pneumatic tools?
Generally 90-110 psi
How is collected moisture, in air compressors for pneumatic tooling, countered?
The compressor will have a water drain
What head angles are available in angle drills?
30 °
45 °
90 °
What is a collet? (Angled drills)
- a sleeve w a cylindrical inner surface and conical outer surface
- used to connect drill bits to the small drill head size of angled drills
What does a drill stop do?
- regulates hole depth, cushions the breakthrough, eliminates surface marks and reduces drill breakage
Where can you find the manufacturers recommended capacity for a rivet gun?
On the barrel
What supplies the force to a pneumatic drill to buck the rivet?
An air driven hammer inside the barrel
What are the four types of micrometers?
Internal
External
Depth
Thread
Give a description of a micrometer:
Circular frame with a cylindrical extension (barrel) at its right end
Hardened anvils inside at the left end
Watch a how to read imperial and metric micrometer video
👍
How can a micrometer be calibrated?
Insert a standard or gauge block between the anvil and spindle
Gently close the spindle on to the block
Match the zero mark on the thimble with the sleeve datum line with a wrench
What can an internal micrometer have to make it more accurate?
symmetrically positioned anvils
How do you do a zero error check on a Veronica calliper type?
- don’t over tighten the jaws
- tighten the lock screws
How do you carry out a zero error check on a digital and dial type Vernia?
Close the jaws and tighten the lock screws
Check that zero divisions on all scales align
What are three disadvantages of a dial calliper?
- easily damaged
- more difficult to read
- on,y come in one unit not both
What tool can be used to measure the alignment of shafts or check the smoothness of surfaces?
Dial test indicator (DTI)
Where the two types of DTIs?
Plunger DTI
Lever DTI
What ATA chapter covers servicing?
Chapter 12
What has to be done to hoses from all liquid and gas servicing trolleys when not in use?
They’ve got to be blanked
What can the lubricants used on aircraft be broken down in to?
- greases
- oils
- specialty lubricants
What two broad areas are lubricants used in?
- airframe systems
- engine and gearbox systems
Describe the valve of a grease nipple.
- one way valve that isolated the grease in the line and stops it from coming back out
- spring loaded to prevent the loss of lubricant
What are the most commonly used grease nipple fittings?
Zerk fittings
Flush type where clearance is a problem
What is needed when adding grease via a flush nipple?
An injector needle
( the tip of the injector needle deseats the ball valve by applying gentle pressure)
What is general servicing oil applied by?
Oil cans
What are specialty lubricants applied by?
Aerosol
What are hydraulic and engine oils applied by?
Dedicated equipment
What should be done to aerosols before use?
Shake it until the pea is moving with no resistance
On what type of aircraft are mineral based hydraulic oils used?
Usually non pressurised and not operating in such harsh extremes
Can be poured straight from the can
On what aircraft are phosphate ester based hydraulic fluids used?
Used on almost all pressurised aircraft with systems that require minimum 3000 psi
operate in harsh environments
What is the application method when using phosphate ester based hydraulic fluids?
Can’t be directly poured as the ac system will be pressurised
Pressurised application
What is a common hand pump used to top up systems for almost all oils?
Risbridger- connects to a standard can
How does a permanent magnet moving coil measure current?
- It’s pointer deflects a certain amount according to the current flowing through its coil across a permanent magnet
How does the spring, that balances the forces when using a permanent magnet moving coil, compensate an increase in temperature?
The springs are made of phosphor bronze metal, which had a positive temperature coefficient
As the temp changes it allows the need,e to remain stationary
What are two features used that increase the accuracy and efficiency of the permanent magnet moving coil meter?
- Iron core placed inside the coil to concentrate magnetic fields- produces eddy cuffent that will give some damping and reduce oscillations too
- Curved pole pieces are attached to the magnet- ensures the turning force increases steadily as the current increases
What is full scale current?
The amount of current that must flow through the meter coil to cause a full scale deflection
What is the relationship between meter sensitivity and the full scale current value?
Meter sensitivity value is the reciprocal of the full scale current value
Is an ammeter connected in series or parallel w a circuit?
In series
How do you connect a DC ammeter?
+ terminal must be connected with the positive side of the circuit
- terminal connected to the negative side
What is a shunt?
A type of resistor connected in parallel with a meter
Increase the amount of current the meter can measure
What is the current sensitivity (amount of current that can be measured) and resistance of a standard moving coil meter?
Current sensitivity of 1 mA
Resistance if 50 ohms
How is a multi range ammeter capable of measuring several different maximum current ranges?
It has multiple shunts in the meter case that can be switched on or off depending on what you’re reading
How does a voltmeter work?
The resistor in it limits the current flow to a value, which results in a full scale deflection
What is resistance measured in?
Ohms
How is the amount of resistance required to be connected in series with a voltmeter calculated?
Using V= IR
How is a voltmeter connected with the load to be measured?
In parallel
Plus terminal connected to positive side and vice versa
How does a multi range voltmeter work?
Has a selector switch that operates multipliers or resistors (voltmeter version of a shunt)
How do you select the current voltmeter range?
- select the range that results in a needle deflection in the centre third of the scale
What is an ohmmeter?
- moving coil meter that has a small battery providing voltage that creates the current to operate movement
- measures resistance of a load
What is the ohmmeters pointer deflection controlled by?
Amount of battery current passing through the moving coil
What allows for calibration in an ohmmeter?
A variable resistor (rheostat)
How should ohmmeters be connected to a circuit?
With the circuit DE ENERGISED
What happens to an ohmmeters deflection when resistors have a larger value?
More resistance —>
current flowing in the moving coil of the ammeter decreased —>
deflection will decrease —>
scale indication would read a higher circuit resistance
If the pointer on an ohmmeter scale is at 20ohms, and the range switch is set at R x 100, what is the actual resistance measurement?
2 killiohms
What is the difference in function between a shunt and series ohmmeter?
In a shunt ohmmeter resistance is measured in parallel w the meter movement
In a series ohmmeter resistance is measured in series with the internal resistors and and the meter movement
What’s the key difference in the scales of a shunt and series ohmmeter?
Series: 0 is on the right and infinity on the left
Shunt: 0 is on the left and infinity on the right
How is a shunt ohmmeter made multi range?
Resistors of different values are used
What are shunt ohmmeters generally used for?
Generally limited to measuring resistances up to 400 ohms
Must be switched to off position after use
How can you use a moving coil meter to measure AC?
- must use a rectifier to convert AC to DC
- a full wave rectifier in AC voltmeters is better than half wave as it’s more sensitive
- most frequently used is the bridge type rectifier
What is a multimeter and what can it be used for?
- a moving coil meter connected to different external resistor networks
- can measure voltage, current or resistance
What is one of the most common multimeters used in aircraft maintenance?
The AVOmeter
How much current can a digital multimeter measure?
AC and Dc to 10A
20A overload for 30secs max
How much voltage can a digital multimeter measure?
AC and DC up to 600V
What is the name of one of the most common digital multimeters?
Fluke 115
How must the leads in a digital multimeter be connected and disconnected?
- Connect the common test lead before connecting the live lead
- disconnect the live lead before removing the common test lead
What must be done before connecting or disconnecting a multimeter?
De- energise and discharge of the circuit
What precaution must be taken when measuring resistance with a multimeter?
To never apply power to the circuit!
What is the primary and secondary winding on a current clamp (used to measure current)?
Primary winding: subject conductor
Secondary winding: the coil in the clamp
