Safe Use of Punches in Engineering
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Questions and Answers

What type of material are letter and figure punches made of?

  • Hardened and tempered steel (correct)
  • High-carbon tool steel
  • Nylon
  • Brass

    • What is the purpose of grinding off mushroomed material from the shank end of a punch?

  • To improve durability
  • To prevent rust
  • To maintain grip
  • To prevent eye injury (correct)

    • What type of joints do pliers have?

  • Fixed, toggle, and slip (correct)
  • Fixed, rotating, and slip
  • Toggle, rotating, and slip
  • Slip, toggle, and rotating

    • What determines the classification of pliers?

    <p>Type and length</p> Signup and view all the answers

    What is the purpose of multi-grip pliers?

    <p>To tighten packing gland nuts</p> Signup and view all the answers

    What feature of multi-grip pliers allows for a great deal of force to be applied?

    <p>Length of handles</p> Signup and view all the answers

    What is a characteristic of the jaws of pliers?

    <p>They have a great variety of shapes</p> Signup and view all the answers

    What is a common length range for interlocking joint pliers?

    <p>5 in. to 20 in.</p> Signup and view all the answers

    What is the primary reason for removing the mushroom shape from a punch shank?

    <p>To prevent the punch from splitting or chipping</p> Signup and view all the answers

    What is the main purpose of a prick punch?

    <p>To transfer dimensions and locations onto sheet metal</p> Signup and view all the answers

    What happens to the shank end of a punch when it is continuously hammered?

    <p>It deforms to a mushroom shape</p> Signup and view all the answers

    Why should prick punches not be used to drive a pin or rivet from a hole?

    <p>They may scar the material and have delicate points</p> Signup and view all the answers

    What is the correct way to prevent mushrooming on a punch shank?

    <p>By keeping the shank free of burrs</p> Signup and view all the answers

    What is the primary benefit of a crowned shape on a punch shank?

    <p>It minimizes the chance of the punch splitting or chipping</p> Signup and view all the answers

    What is the purpose of the spiral rod in the handle of lockwire pliers?

    <p>To twist the wire</p> Signup and view all the answers

    What type of pliers is typically used for electrical and electronic work?

    <p>Needle nose pliers</p> Signup and view all the answers

    What is the purpose of putting a 'pig tail' or curl on the end of the wire?

    <p>To avoid injury to personnel</p> Signup and view all the answers

    What type of pliers is used for fitting and removing circlips?

    <p>Circlip pliers</p> Signup and view all the answers

    What is the angle of the cutting edge of a flat chisel?

    <p>70°</p> Signup and view all the answers

    What is the range of sizes of flat cold chisels?

    <p>8 - 17 mm</p> Signup and view all the answers

    What is the purpose of the built-in cutters in lockwire pliers?

    <p>To cut the wire</p> Signup and view all the answers

    What type of pliers has long, thin jaws that are bent at a right angle to the handle?

    <p>Needle nose pliers</p> Signup and view all the answers

    How does the convex shape of a flat chisel's cutting edge help in reducing stress?

    <p>By directing the greatest stress from a hammer blow into the centre of the chisel</p> Signup and view all the answers

    Why are cold chisels not commonly used in aircraft maintenance?

    <p>Because they are not suited to most aviation maintenance tasks</p> Signup and view all the answers

    What is the main difference between a chisel and a file?

    <p>A chisel has a single cutting edge, while a file has multiple cutting edges</p> Signup and view all the answers

    How do files remove material?

    <p>By pushing the file across the material, which causes the teeth to penetrate the surface and remove small chips of material</p> Signup and view all the answers

    What is the importance of knowing the correct file for the job?

    <p>Because there is a large range of types, shapes and sizes of files, and knowing the correct one is crucial for the job</p> Signup and view all the answers

    What determines the depth of the cut when using a cold chisel?

    <p>The angle between the chisel and the work</p> Signup and view all the answers

    What is a characteristic of a file's teeth?

    <p>They are small and pointed, acting like small chisels</p> Signup and view all the answers

    Why are files generally manufactured from high-carbon steel?

    <p>Because high-carbon steel is suitable for most filing tasks</p> Signup and view all the answers

    What is the main purpose of the tang on a file?

    <p>To facilitate the handling of the file</p> Signup and view all the answers

    What part of the file is not hardened like the body of the file?

    <p>The tang</p> Signup and view all the answers

    What is the purpose of a safe edge on a file?

    <p>To permit a corner to be cleaned out without damage to adjacent faces</p> Signup and view all the answers

    What determines the rate of cutting and the finish given to the work by a file?

    <p>The depth and spacing of the file's cutting teeth</p> Signup and view all the answers

    What is the smoothest grade of cut on a file?

    <p>Dead smooth</p> Signup and view all the answers

    What is the purpose of varying the direction of the cutting motion when filing?

    <p>To produce flat or curved surfaces</p> Signup and view all the answers

    What is the term for the arrangement of cutting teeth on a file?

    <p>Type of cut</p> Signup and view all the answers

    What is the primary purpose of using a file in a maintenance practice?

    <p>To alter the size of a part by removing a considerable amount of material</p> Signup and view all the answers

    What is the primary objective of the applicant's knowledge in this subject?

    <p>To apply theoretical knowledge in a practical manner</p> Signup and view all the answers

    What is expected of the applicant in terms of theoretical knowledge?

    <p>To know the theory of the subject and its interrelationships with other subjects</p> Signup and view all the answers

    What is the purpose of the applicant being able to read, understand, and prepare sketches and schematics?

    <p>To describe the subject using theoretical fundamentals and specific examples</p> Signup and view all the answers

    What is expected of the applicant in terms of applying knowledge in a practical manner?

    <p>To combine and apply separate elements of knowledge in a logical and comprehensive manner</p> Signup and view all the answers

    What is the primary purpose of the applicant being able to interpret results from various sources and measurements?

    <p>To apply corrective action where appropriate</p> Signup and view all the answers

    What is the expected outcome of the applicant's ability to apply knowledge in a practical manner?

    <p>To combine theoretical and practical knowledge to achieve a practical solution</p> Signup and view all the answers

    What is an important safety precaution to take when using a hammer or mallet?

    <p>Wearing eye and face protection</p> Signup and view all the answers

    What is the typical weight range of a ball pein hammer?

    <p>28 grams (1 oz) to 1-1.5 kg (2-3 lb)</p> Signup and view all the answers

    What is the purpose of the ball end of a ball pein hammer?

    <p>Peening over rivets in commercial sheet metal work</p> Signup and view all the answers

    What is the benefit of using the full face of the hammer when striking?

    <p>It reduces the risk of marring the work</p> Signup and view all the answers

    Why is it important to inspect a hammer or mallet before use?

    <p>To ensure the handle is secure and in good condition</p> Signup and view all the answers

    What is the benefit of keeping the face of a hammer or mallet smooth and free of dents?

    <p>It reduces the risk of marring the work</p> Signup and view all the answers

    How should you hold your arm when swinging a hammer?

    <p>With your elbow bent and your wrist straight</p> Signup and view all the answers

    What is the benefit of using a cross pein hammer?

    <p>It has a narrow end for access to limited working surfaces</p> Signup and view all the answers

    What is the primary objective of a Level 1 knowledge level in an aircraft maintenance licence?

    <p>To be able to give a simple description of the whole subject</p> Signup and view all the answers

    What is the characteristic of a Level 2 knowledge level in an aircraft maintenance licence?

    <p>Ability to apply theoretical knowledge in practical situations</p> Signup and view all the answers

    What is the requirement for Category C applicants in terms of knowledge levels?

    <p>They must meet either the category B1 or B2 knowledge levels</p> Signup and view all the answers

    What is the purpose of knowledge level indicators in an aircraft maintenance licence?

    <p>To indicate the level of knowledge required for each subject</p> Signup and view all the answers

    What is the primary focus of a Level 1 knowledge level in an aircraft maintenance licence?

    <p>Basic elements of the subject</p> Signup and view all the answers

    What is the characteristic of a Level 2 knowledge level in terms of mathematical formulae?

    <p>Ability to use mathematical formulae in conjunction with physical laws</p> Signup and view all the answers

    What is the purpose of the knowledge level indicators in Category A, B1, and B2 aircraft maintenance licences?

    <p>To indicate the level of knowledge required for each category</p> Signup and view all the answers

    What is the primary difference between Level 1 and Level 2 knowledge levels in an aircraft maintenance licence?

    <p>Level of application of theoretical knowledge in practical situations</p> Signup and view all the answers

    What is the primary factor that determines the quality of a product in the aircraft maintenance environment?

    <p>The art of skill of a worker</p> Signup and view all the answers

    What is the importance of workmanship in the aircraft maintenance environment?

    <p>It is a critical aspect of safety as people put their lives in the hands of AMEs</p> Signup and view all the answers

    What is a standard in the context of aircraft maintenance?

    <p>An agreed way of doing something</p> Signup and view all the answers

    Why are standards important in the aircraft maintenance environment?

    <p>They provide a way to ensure consistency and safety</p> Signup and view all the answers

    What is the role of the AME in ensuring workmanship?

    <p>To ensure duty of care to oneself and others</p> Signup and view all the answers

    What is the relationship between workmanship and standards?

    <p>Workmanship is a measure of standards</p> Signup and view all the answers

    Why is it important to have a standard of workmanship in the aircraft maintenance environment?

    <p>To ensure the safety of the aircraft and its passengers</p> Signup and view all the answers

    What is the impact of poor workmanship on the aircraft maintenance environment?

    <p>It can lead to a compromise in safety</p> Signup and view all the answers

    What is the purpose of letter and figure punches?

    <p>To stamp identifying symbols, letters or numbers on work</p> Signup and view all the answers

    What is common to all types of joints in pliers?

    <p>They all have a pivot, hinge or fulcrum pin</p> Signup and view all the answers

    What is unique about multi-grips pliers?

    <p>They have several curved grooves that make up a series of interlocking joints</p> Signup and view all the answers

    What is a common feature of the handles of pliers?

    <p>They are all provided with handles shaped to give an efficient grip</p> Signup and view all the answers

    What is the benefit of keeping the working edges of punches sharp?

    <p>It prevents eye injury from mushroomed material</p> Signup and view all the answers

    What is a characteristic of the jaws of pliers?

    <p>They come in a great variety of shapes designed for different tasks</p> Signup and view all the answers

    What is the purpose of the length of the handles of multi-grips pliers?

    <p>To allow for a great deal of force to be applied to the jaws</p> Signup and view all the answers

    What is common to all types of pliers?

    <p>They all have a pair of legs joined by a pivot, hinge or fulcrum pin</p> Signup and view all the answers

    Study Notes

    Safe Use of Punches

    • Safe use of punches depends on hitting them squarely and keeping their heads free of burrs that lead to mushrooming.
    • Mushrooming occurs when a punch shank has been continuously hammered, causing the shank end to deform into a mushroom shape.
    • The mushroom shape should be removed and returned to its original crowned shape using a bench grinder to minimize the chance of the punch splitting or chipping.

    Punches

    • Prick punches are small, sharp-pointed punches used to transfer dimensions and locations onto sheet metal for drilling.
    • Prick punches should never be used to drive a pin or rivet from a hole, as they can scar the material and have relatively delicate points.
    • Letter and figure punches are made of hardened and tempered steel and are used to stamp identifying symbols, letters, or numbers on work.
    • All working edges of punches should be kept sharp, and all mushroomed material should be ground off the shank end to prevent eye injury.

    Holding Tools

    • Pliers are a group of tools that have a pair of legs joined by a pivot, hinge, or fulcrum pin.
    • Pliers can have three types of joints: fixed, toggle or compound, and slip.
    • Pliers are made of high-carbon tool steel or alloy steel, are classified by type and length, and are provided with handles shaped to give an efficient grip.

    Specific Types of Pliers

    • Multi-grips pliers are used to tighten the packing gland nut around a water pump shaft and have several curved grooves that make up a series of interlocking joints.
    • Needle nose pliers are used in aviation maintenance and are handy for electrical and electronic work due to their small size and ability to grip and hold small components and wires.
    • Circlip pliers are used for fitting and removing circlips in assembly and maintenance work.

    Chisels

    • Cold chisels are made from square or octagonal stock and have a flat cutting edge ground to an angle of approximately 70°.
    • The cutting edge of a flat chisel is slightly wider than the shank and is ground slightly convex to reduce stresses transmitted to the sides of the cutting edge.

    Files

    • Files are cutting tools that have a large number of cutting edges or points rather than a single cutting edge.
    • Files are pushed across a material by hand, and as they move, the teeth act like small chisels, removing small chips of material.
    • Files are generally manufactured from high-carbon steel and are available in a variety of lengths, sections, cuts, and grades to suit almost every requirement.

    Parts of a File

    • The parts of a file include the tang, heel, faces, edges, point, and back.
    • A safe edge is an edge on which no teeth are cut, permitting a corner to be cleaned out without damage to adjacent faces.

    File Characteristics

    • The rate of cutting and the finish given to the work are mainly determined by the depth and spacing of the file's cutting teeth.
    • The grade of cut refers to how fine the file's teeth are, ranging from rough to smooth.
    • The type of cut refers to the arrangement of cutting teeth, which is provided to give the most satisfactory results when working on different metals.

    Category B1 and B2 Licences

    • CASA B-07b: Maintenance Practices - General

    Knowledge Levels

    • Category A, B1, B2, and C Aircraft Maintenance Licence
    • Basic knowledge levels for categories A, B1, and B2 are indicated by knowledge level indicators (1, 2, or 3) against each applicable subject
    • Category C applicants must meet either the category B1 or category B2 basic knowledge levels

    Knowledge Level Indicators

    • Level 1:
      • Familiarity with basic elements of the subject
      • Ability to give a simple description of the whole subject using common words and examples
      • Ability to use typical terms
    • Level 2:
      • General knowledge of theoretical and practical aspects of the subject
      • Ability to apply knowledge
      • Ability to understand theoretical fundamentals of the subject
      • Ability to give a general description of the subject using theoretical fundamentals and specific examples
      • Ability to use mathematical formulae in conjunction with physical laws
      • Ability to read and understand sketches, drawings, and schematics describing the subject
      • Ability to apply knowledge in a practical manner using detailed procedures
    • Level 3:
      • Detailed knowledge of theoretical and practical aspects of the subject
      • Capacity to combine and apply separate elements of knowledge in a logical and comprehensive manner
      • Ability to know the theory of the subject and interrelationships with other subjects
      • Ability to give a detailed description of the subject using theoretical fundamentals and specific examples
      • Ability to understand and use mathematical formulae related to the subject
      • Ability to read, understand, and prepare sketches, simple drawings, and schematics describing the subject
      • Ability to apply knowledge in a practical manner using manufacturer's instructions
      • Ability to interpret results from various sources and measurements and apply corrective action where appropriate

    Standards of Workmanship

    • Workmanship refers to the degree of skill with which a product is made or a job is done
    • Factors affecting workmanship include:
      • The art of skill of a worker
      • The quality of the product
      • The product or result of the labour and skill of a worker
      • Attitudes of the AME, team, and organisation
      • Duty of care (self, others, and equipment)
      • Working done according to a standard

    Tools

    • Hammers:
      • Include different types and weights of hammers and mallets
      • Each type has a specific use
      • Importance of using hammers properly to avoid damage to aircraft components and injury to personnel
    • Ball Pein Hammers:
      • Range in weight from 28 grams (1 oz) to 1-1.5 kg (2-3 lb)
      • One hammer face is flat, while the other is formed into the shape of a ball
      • Flat hammer face is used for working metal and driving, but should not be used to drive a nail
      • Ball end is used to peen over rivets in commercial sheet metal work
    • Cross Pein:
      • Narrow cross pein helps gain access to limited working surfaces
    • Letter and Figure Punches:
      • Used to stamp identifying symbols, letters, or numbers on work
      • Made of hardened and tempered steel
      • Caution: All working edges of punches should be kept sharp, and all mushroomed material should be ground off the shank end to prevent eye injury
    • Pliers:
      • Include a group of tools with a pair of legs joined by a pivot, hinge, or fulcrum pin
      • Classified by type and length
      • Provided with handles shaped to give an efficient grip for the hand
      • Made with a great variety of jaw shapes designed for cutting, holding, gripping, pulling, pushing, twisting, or turning
    • Multi-Grips:
      • Used to tighten the packing gland nut around a water pump shaft
      • Have several curved grooves that make up a series of interlocking joints
      • Length of handles allows a great deal of force to be applied to the jaws

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    Description

    Learn about the safe usage of punches, including preventing mushrooming and proper maintenance techniques. Understand the importance of keeping punch heads free of burrs and how to remove deformations.

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