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Cut pattern:: Uses: Cross section Picture Name

Flat file

Half -round

Round file

Three square ( triangle )

Needle files

Question 1

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Question 2 The graph shown below is the data collected for the cutting speed of six different material workpiece. a. Define “cutting speed” b. Analyze the graph, compare and determine why the cutting speed is shown to be increasing.

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c. Establish three examples of a material workpiece and show the order of the cutting speed from the lowest cutting speed to the highest.

Question 3 a. Define what a drilling process entails. b. By an aid of a sketch (drill bit and workpiece), outline and explain the direction of the tool feed, the rotating motion of the tool including its

orientation in relation to the axis of rotation towards the workpiece.

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Worksheet (module1,2,3)

1. Mark (T) for true and (F) for false statements.

No. Statement T / F

1 The meter is the basic unit of length in the imperial system

2 The yard is the basic unit of length in the metric system

3 The vernier caliper can take measurements to accuracy of ± 0.02

mm

4 No gap between the work piece and RULE means the work piece

edge is FLAT.

5 Gap between the work piece and the RULE means the work piece edge is NOT FLAT.

6 The Vernier caliper with 10 divisions in Vernier scale is accurate

to ±0.1 mm

7 The Vernier caliper with 50 divisions in Vernier scale is accurate

to ±0.05 mm.

8 Stem of vernier caliper is used to measure outer dimensions

9 Outside jaws of vernier caliper are used to measure external

lengths

10 Inside jaws are used to measure internal lengths

11 The main scale of the vernier caliper is a movable part while

vernier scale is the fixed part.

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12 Scribers are used to mark circle on work pieces

13 A center punch has a point angle of 90°

14 A prick punch produces a bigger indentation than a center punch

15 A prick punch has a point angle of 90°

16 The engineer’s square is used for checking the straightness of a

work piece

17 The micrometer can take measurements to accuracy of ± 0.05

mm

18 A surface gauge is used for scribing lines and checking parallel surfaces and heights

19 The spring dividers are used for scribing arcs and circles

20 The Vee blocks are used for holding circular work pieces

21 The sizes of metric spanners are identified by the distance across

flats of a nut.

22 The flathead screw driver is identified by its point size.

23 The crosshead screwdriver is identified by its length.

2. Select the correct answer (A, B, C or D).

1- Always look at ____________to the rule to help you measure correctly

A. 30°

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B. 60°

C. 90°

D. 40°

2- The steel rule can take linear measurements to accuracy of ____________

A. ± 0.01 mm

B. ± 0.1 mm

C. ± 0.5 mm

D. ± 0.002 mm

3- The vernier caliper can take measurements to accuracy of ____________

A. ± 0.02 mm

B. ± 0.005 mm

C. ± 0.0002 mm

D. ± 0.0001 mm

4- ____________ is used as a datum surface for marking out and for measuring purposes.

A. Scriber

B. Divider

C. Surface plate

D. V-block

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5- _____________ is used for checking the straightness of a work piece.

A. Engineer’s square

B. Divider

C. Surface plate

D. V-block

6- A __________ produces a smaller indentation than a center punch.

A. Engineer’s square

B. prick punch

C. Surface plate

D. V-block

7- ___________ used for scribing arcs and circles

A. Engineer’s square

B. prick punch

C. Surface plate

D. Spring divider

8- The ends of open-ended spanners are generally oriented at an angle of____ to the axes.

A. 30º

B. 60º

C. 15º

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D. 90º

9- _______ is spanner that has a moving jaw to fit different bolt/nut sizes.

A. Open-ended spanner

B. Adjustable spanner

C. Ring spanner

D. Combination spanner

10- ___________ is used on socket head cap screws and grub screws.

A. Allen key

B. Spanner

C. Pliers

D. Hammer

11. Which tool of the following is used to scratch lines on metal?

A

B

C

D

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12. How can scratches on metal be made to appear more clearly?

A By using pen

B By using chalk

C By covering a metal with marking blue

D By using pencil

13. How is the pivoting leg of a pair of dividers stopped from sliding over the surface of metal?

A By using scriber

B By using prick punch

C By using height gauge

D By using caliper

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3. Fill in the blanks by selecting your answer from the following list:

Crosshead/Phillips Micrometer Dial

vernier

caliper

Goggle Safety

boot

Chuck

Ball peen

hammer

Long nose

plier

Flathead/slotted

Vernier

caliper

a. _____________ is used to protect our eyes from injuries.

b. _______________ is used to strike punches and chisels.

c. ________________ will protect your feet if you accidentally drop something.

d. ____________ has inside, outside jaws and stem to measure different dimensions.

e. ________________ has indicator which can gives you the reading directly.

f. __________ is used to measure even smaller dimensions than the vernier calipers.

g. _____________ is used by electricians to bend, re-position and cut wire.

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h. The two most common screw drivers are: ________________ and __________________.

4.

1- Read the micrometers and the vernier calipers illustrated bellow:

A)

Accuracy = 0.01 mm

Reading is _________________mm

B)

Accuracy = 0.01 mm

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Reading is ______________ mm

C)

Accuracy = 0.01 mm

Reading is ______________ mm

D)

Accuracy = 0.02 mm

Reading is _____________ mm

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E)

Accuracy = 0.1 mm

Reading is _______________ mm

F)

Accuracy = 0.1 mm

Reading is _____________ mm

2. Read the rule illustrated bellow:

A- 7 mm

B- 27 mm

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C- 44 mm

5.

1. Identify the main parts of the vernier caliper illustrated bellow:

Stem Outside jaws Vernier scale

Screw clamp Main scale Inside jaws

1-

2-

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3-

4-

5-

6-

6. Identify the main parts of the micrometer illustrated bellow:

Stem Frame Thimble

Sleeve Lock Inside jaws

Ratchet Anvil Spindle

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1-

2-

3-

4-

5-

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6-

7-

7. Find out five mistakes in the safety dress shown in the picture:

1-

2-

3-

4-

5-

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8. Identify the three types of the vernier caliper illustrated bellow:

A.

B.

C.

9. Select the correct words from the list to fill in the following blanks:

1 2 3 4

Inside jaws Stem Outside jaws Screw clamp

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A- __________ used to

measure external dimensions.

B- _________ used to measure

inner dimensions.

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C- _________ used to measure

the depth.

A B C

Name Marking out tools Definition

- Used for checking the

__________ of a work piece. - Also be used for marking

____________

Used to ____________ on metal

Used for scribing ________ and

__________

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Used to _________ punches and

chisels

Forms an _______ in which the tip of the drill will fit. has a point angle

of _______

Produces a ___________ than a

center punch. has a point angle of

____________

Used as a __________ for

___________ and for

____________purposes

Used to assist in ___________ the ____________ to the table

Used for: 1. _________ on work pieces

2. checking _______________

3. Checking ______________

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_______

Used for ___________ work pieces

11. Match the following.

Match the marking out tools in column B with their correct functions in column A, Write your answer in the

box below?

Column A 1 2 3 4 5

Column B

Column A Column B

1) Is used for checking the

straightness of a workpiece.

A)

2) Is used to scratch lines

B)

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3) Is used for making indents that

position the drill points and stop

them slipping

C)

4) Is used for supporting or

setting up work vertically.

D)

5) Is used for scratching lines

parallel to a surface.

E)

Match the hand tools in column B with their correct names in column A,

Write your answer in the box below?

Column A 1 2 3 4 5 6 7 8

Column B

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Column A Column B

1) Combination pliers

A)

2) Adjustable spanner

B)

3) Allen key

C)

4) Crosshead screwdriver

D)

5) Open-ended spanner

E)

6) Ring spanner

F)

7) Pipe wrench

G)

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8) Flathead screwdriver

H)

Worksheet (module-4)

1. Mark (T) for true and (F) for false statements.

No. Statement

T

/ F

1

Hack sawing is a process of cutting metals to size

2

Different standard lengths of blades can be fitted to solid hacksaw frame.

3

A particular standard length of blade can be fitted to an adjustable

hacksaw frame.

4

The hacksaw blade is classified by its length and the teeth pitch.

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5

A coarse pitch blade has more teeth per 25 mm than a fine pitch

blade.

6

Fast blunting can be occurred if wrong teeth number is chosen.

7

Fast blunting is the result of low pressure.

8

The breaking of blade teeth is the result of un tightened work piece.

9

Curved cutting can be occurred if material is insufficiently tightened

10 Breaking of saw blade is the result of Jammed material.

Fill in the blanks. Select your answer from the list bellow.

Adjustable hacksaw Forward Fine blade Alternate

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Coarse blade Wave Hack sawing Solid hacksaw

Jamming Three Pitch Fine

50 Backward 40 Two

1- ______________ is a process of cutting metals to size.

2- A particular standard length of blade can be fitted to a ________________ frame

3- ________________ frame allows different standard lengths of blades to be fitted.

4- A ____________ is the number of teeth per 25 mm.

5- A _____________ is used to cut thick and soft work piece.

6- A ________________ is used to cut thin and hard work piece.

7- ______________ and _________________ are the most common types of saw blade set.

8- A hacksaw cuts best at about _________ to _________ strokes per minutes.

9- At least ___________ or ________ teeth should be cutting all the time.

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10- Blade setting helps to prevent the blade from ___________ when cutting the metal.

11- Hacksaws cut on the _______ stroke, not on the __________ stroke.

12- A ____________ pitch blade has more teeth per 25 mm than a coarse pitch blade.

Circle the most correct answer:

1. Which of the following saw blade has coarse pitch teeth?

a) 32 teeth per 25 mm.

b) 18 teeth per 25 mm.

c) 14 teeth per 25 mm.

d) 20 teeth per 25 mm

2. Which of the following saw blade has fine pitch teeth?

a) 32 teeth per 25 mm.

b) 18 teeth per 25 mm.

c) 14 teeth per 25 mm.

d) 20 teeth per 25 mm

3. The pitch of saw blades is expressed as:

a) The length from hole-to-hole centre of the blade.

b) The material of the blade.

c) The number of teeth per linear inch.

d) None of the above

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4. If wrong teeth number of blade is chosen the result is:

a) Curved cutting

b) Breaking of saw blade

c) Fast blunting of teeth

d) None of the above

5. While hack sawing, if material is not tightened well the result is:

a) Teeth breaking.

b) Breaking of saw blade.

c) Curved cutting

d) All of the above

Give only one cause for each saw blade defect:

Causes Defects Figures

1- ---------------------

Fast blunting

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1- ----------------------

Teeth breaking

1- ----------------------

Breaking of saw blade

1- ---------------------

Curved cutting

Answer:

Select one of the following causes:

Fast blunting:

Teeth breaking:

Breaking of saw blade:

Curved cutting:

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- Identify the following types of blade set:

Identify the following types of hacksaw frames:

a- ______________

b- ________________

(a)

(b)

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____________________ _______________

Name the parts shown by the arrows.

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Reorganize the following steps in order to cut the work piece

illustrated bellow. Put your answer in the list bellow:

Install the hacksaw blade.

Use the blade check list to ensure proper installation.

Mount the work piece firmly on the vice.

Use the hacksaw to cut the work piece.

Choose the correct blade.

Wear the safety clothes and equipment required.

130

80

102

64 Sawing lines

All Dimensions are in mm

Arrange the steps in the correct order respectively:

1- Choose the correct blade

2- Install the hacksaw blade

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3- Wear the safety clothes and equipment required.

4- Use the hacksaw to cut the work piece

5- Use the blade check list to ensure proper installation

6- Mount the work piece firmly on the vice

Worksheet (module-5)

No. Statement

T /

F

1 Hand file is a half-round in section and parallel in width

2 Flat file is a rectangular in section and tapered in width

3 A double cut file has one set of teeth cut at 70 degrees

4

Files with a rougher grade of cut give a poor surface finish

5 A file with a short length would have a coarser pitch than a longer one

6 The pining can be removed with a handle of file

7 The pining can be removed with a file card

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8- Which file of the following is used for filing corners or angles less than 90°?

A

B

C

D

9- Files are categorized according to Length and _______.

A Shape

B Grade

C Cut patterns

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D All of the above

10-Which one of the following files is used for filling internal and external curves?

A

B

C

D

11-Which of the following file grades is commonly used in the Work shop?

a single cut file

b double cut file

c rasp file

d all of the above

12- The purposes for the safe edge are to avoid the _______.

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a damage of the file handle

b damage of the file teeth

c damage of the work piece

d damage of the file tip

Fill in the blanks. Select your answer from the list bellow.

Rasp file Half-round file Hand file File Flat file

1- _______________ has double cut teeth on two faces and single cut teeth on two

Side.

2- _____________ is commonly used for the cutting off soft materials such as wood, PVC and rubber.

3- A ____________ is a metalworking tool used to cut fine amount of material from a work piece

4- ___________ is a rectangular in section and parallel in width.

5- ________________ is used for forming radii and grooves.

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Match the pictures in column B with their correct names in column A, Write your answer in the box below?

Column A 1 2 3 4 5

Column B

Column A Column B

1) Half round file

A)

2) Needle file

B)

3) Square file

C)

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4) Triangular file

D)

5) Round file

E)

Match the items in column B with their correct names in

column A, Write your answer in the box below?

Column A 1 2 3 4 5 6

Column B

Column A

Column B

1) File card

A)

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2) Hand file

B)

3) First cut file

C)

4) Second cut file

D)

5) Bastard file

E)

6) Draw filing F)

Worksheet (module-6)

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No. Statement

T

/

F

1 The most common tool used to cut a hole is the twist drill

2 The twist drill is made of Aluminum

3

Most of small drills up to 13 mm in diameter have tapered shanks.

4

Most of small drills up to 13 mm in diameter have straight shanks.

5 Most drills that are larger than 13 mm are tapered.

6 Most drills that are larger than 13 mm are straight.

7 drill gauges are used to determine and check the drill diameters

8 Chuck is mainly used for drills with tapered shanks

9 Chuck is mainly used for drills with straight shanks

10 Vises are used to hold the drill twist

11 Vises are used to hold the work piece

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Twist drill Drift Drilling Vices

Straight Drill gauges Friction Hardness

Tapered Cutting tool material Speed

Harder Softer Chuck

1- ________________________ is used to create round holes

2- The most common tool used to cut a hole is the ___________________

3- Most of small drills up to 13 mm in diameter have ___________ shanks

4- Most drills more than 13 mm in diameter have ______________shanks

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5- ______________ are used to determine and check the drill diameters

6- The ____________ is mainly used for drills with straight shanks.

7- The drill is locked in the spindle with _____________ and is removed from the spindle by using a _______

8- __________are used to hold the work piece during the drilling process.

9- The ________________are used to hold a round work piece.

10- Cutting speeds depend on the type of ___________ and the type of _________________

11- ___________ a great impact on selecting the cutting speed.

12- The _____________ the work material, the slower the cutting speed.

13- The ________________ the work material, the faster the cutting speed.

Identify the following process:

Filling Drilling Sawing

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A-

B-

C-

A B C

Name the parts of the floor

press drill machine

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Name the parts of twist drill

illustrated bellow:

Identify the following objects and their usages

Name Usage Figure

Drill gauge

To create a hole

Chuck

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Drift

To hold the work

piece

T-bolt