Aviation Hand Tools PDF

Hammers The Hammer Hammers include different types and weights of hammers and mallets, each with a very specific use. Since misuse of pounding tools can result in damage to aircraft components and injury to personnel, it is important that you always use these tools properly. Before using any hammer...

Hammers The Hammer Hammers include different types and weights of hammers and mallets, each with a very specific use. Since misuse of pounding tools can result in damage to aircraft components and injury to personnel, it is important that you always use these tools properly. Before using any hammer or mallet, you should make sure you have the appropriate eye and face protection. Furthermore, you should inspect the tool for any damage that could affect safety. For example, before using a hammer or mallet, make sure the handle is secure and in good condition. When striking a blow with a hammer, think of your forearm as an extension of the handle. In other words, swing the hammer by bending your elbow, not your wrist. Always strike the work squarely using the full face of the hammer. To avoid marring the work, keep the face of a hammer or mallet smooth and free of dents. Hammers 2023-11-24 B-07b Maintenance Practices CASA Part 66 - Training Materials Only Page 42 of 498 Ball Pein Hammers The ball pein hammer ranges in weight from 28 grams (1 oz) to 1 - 1.5 kg (2–3 lb). One hammer face is always flat, while the other is formed into the shape of a ball. The flat hammer face is used for working metal and driving, but should not be used to drive a nail. The ball end of the hammer is typically used to peen over rivets in commercial sheet metal work. However, this is not the method used for securing rivets in aircraft sheet metal work. Ball pein hammers Cross Pein The narrow cross pein helps gain access to limited working surfaces. Cross pein hammer 2023-11-24 B-07b Maintenance Practices CASA Part 66 - Training Materials Only Page 43 of 498 Straight Pein The straight pein has a similar form and function to the cross pein, but with a vertical rather than horizontal edge. Straight pein hammer Sledgehammers The metal head of a sledgehammer has two flat faces and is sized according to the weight of the head without the handle. For example, the head of a 5-lb sledgehammer weighs 5 lb. This tool is sometimes used in aircraft maintenance, typically when a lot of heavy driving force is needed, such as when driving heavy pins and stakes. Sledgehammer 2023-11-24 B-07b Maintenance Practices CASA Part 66 - Training Materials Only Page 44 of 498 Panel or Body Hammers Body or panel hammers have large, smooth faces and are lightweight. They are specifically used to remove small dents and to smooth (planish) or stretch sheet metal. Planishing (from the Latin planus, "flat") is a metalworking technique that involves finishing the surface by finely shaping and smoothing sheet metal. Other types of body hammers include riveting, setting and stretching hammers. Panel hammer 2023-11-24 B-07b Maintenance Practices CASA Part 66 - Training Materials Only Page 45 of 498 Special Purpose Hammers There are many types of special purpose hammer. The most common in engineering workshops are soft head/face hammers. Soft head hammers are used: to seat or position work for machining to strike surfaces without damaging them to strike full impact blows without danger from rebound. Materials used with soft head hammers include: brass copper aluminium wood rubber plastic rawhide. Copper face rawhide hammer 2023-11-24 B-07b Maintenance Practices CASA Part 66 - Training Materials Only Page 46 of 498 Plastic soft faced hammer Slide Hammer Slide hammers are used with pullers to ‘shock’ components apart. They are common in aircraft maintenance and range in weight from a few grams to several kilograms. Slide hammer kit 2023-11-24 B-07b Maintenance Practices CASA Part 66 - Training Materials Only Page 47 of 498 Hammer Safety Safety First Before using any hammer: Ensure that the head is secure and the wedge is in place. Check the head for splits or burrs, which could allow fragments to fly. Check that there are no splits in the handle. Use a clean, dry cloth to wipe your hands and the handle of the hammer. Remove any oil, grease or dampness, which can cause the handle to slip from your hand or the striking face to slip from the work. Top view of ball pein hammers Caution: Never strike one hammer against another because they may shatter. Flying particles may cause injury, especially to the eyes. 2023-11-24 B-07b Maintenance Practices CASA Part 66 - Training Materials Only Page 48 of 498 Punches The Punch Punches are hand tools that you hit with a hammer. Different punches are made: To mark positions in work To stamp identification marks To drive parts that cannot be hit directly with a hammer To cut holes in thin or soft material. Safe use of punches depends particularly on: Hitting them squarely Keeping their heads free of burrs that lead to mushrooming. Toolbox containing hammers, punches and chisels 2023-11-24 B-07b Maintenance Practices CASA Part 66 - Training Materials Only Page 49 of 498 Mushrooming After a punch shank has been continuously hammered, the shank end typically deforms to the shape of a mushroom. When this happens, the mushroom shape should be removed and returned to its original crowned shape using a bench grinder. The crowned shape minimises the chance of the punch splitting or chipping by allowing the hammer to hit it squarely. Original crowned shape of a punch shank end Mushroom due to repeated hammering on a punch shank end 2023-11-24 B-07b Maintenance Practices CASA Part 66 - Training Materials Only Page 50 of 498 Prick Punches Prick punches are small, sharp-pointed punches used to transfer dimensions and locations onto sheet metal for drilling. To mark sheet metal work, place the prick punch in the desired position and then tap the head of the punch with a small hammer. Because prick punches scar the material and have relatively delicate points, they should never be used to drive a pin or rivet from a hole. For example, the witness marks may be used to locate pivot points of dividers for scribing lines or arcs. Prick punch Prick punch use 2023-11-24 B-07b Maintenance Practices CASA Part 66 - Training Materials Only Page 51 of 498 Centre Punches Centre punches are similar to prick punches, but they are generally larger, are ground to a shallower angle and are hit harder. Centre punches are used to: Make deeper witness marks on scribed lines Locate a centre position and make it easier for a drill point to start cutting accurately in that position Mark relative positions of adjacent parts that have to be removed and replaced. Automatic centre punch (left) and solid steel centre punch (right) 2023-11-24 B-07b Maintenance Practices CASA Part 66 - Training Materials Only Page 52 of 498 Centre punch use Starter Drift and Pin Punches A starter drift punch is hit hard with a hammer to jar loose taper and parallel pins. A starter drift punch tapers towards a slightly concave end that will not spread the end of a pin. A pin punch is hit with a hammer to drive loosened locating or locking pins, dowels and rivets out of their holes. The ends of these punches are circular and flat. Parallel pin punch set 2023-11-24 B-07b Maintenance Practices CASA Part 66 - Training Materials Only Page 53 of 498 Pin punch use When working on aircraft, care must be taken not to damage the component by using steel punches and drifts – a better choice is a soft drift material such brass, aluminium or nylon. Brass (left) and Nylon (right) punches 2023-11-24 B-07b Maintenance Practices CASA Part 66 - Training Materials Only Page 54 of 498 Letter and Figure Punches These hardened and tempered steel punches are used to stamp identifying symbols, letters or numbers, as required, on work. Number/letter punches Caution: All working edges of punches should be kept sharp. All mushroomed material should be ground off the shank end to prevent eye injury. 2023-11-24 B-07b Maintenance Practices CASA Part 66 - Training Materials Only Page 55 of 498 Holding Tools Pliers Pliers include a group of tools which have a pair of legs joined by a pivot, hinge or fulcrum pin. These tools may have three types of joints: Fixed Toggle or compound Slip. Pliers are: Made of high-carbon tool steel or alloy steel that is forged, machined and heat treated 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. Pliers 2023-11-24 B-07b Maintenance Practices CASA Part 66 - Training Materials Only Page 56 of 498 Multi-Grips Multi-grips pliers are used to tighten the packing gland nut around a water pump shaft. They have several curved grooves that make up a series of interlocking joints. Furthermore, the length of the handles allows a great deal of force to be applied to the jaws. Interlocking joint pliers are available in lengths from around 5 in. up to about 20 in. Multi-grips Vise-Grip Locking Pliers Vise-Grip is the registered trade name of the Petersen Manufacturing Company for a special compound-action type pliers. The opening of these jaws is adjustable by a knurled screw located in the end of the pliers’ handles. When these handles are squeezed together, compound leverage multiplies the effort and applies a tremendous force to the jaws. A toggle action clamps the jaws together so they will not open when the handles are released. The jaws are released by a small lever in one of the handles. Vise-Grip pliers come in a wide variety of lengths and jaw styles. Some are designed to hold pipes, some to cut wire and others to pinch off hoses. Special forms of Vise-Grip pliers are made with sheet metal bending jaws, while others are made with jaws that serve as welding clamps or C-clamps. Locking pliers 2023-11-24 B-07b Maintenance Practices CASA Part 66 - Training Materials Only Page 57 of 498 Duckbill Pliers A special type of pliers used in aviation is the duckbill pliers. These long-handled, flat-nosed pliers are typically used to twist and help remove safety wire. The jaws of duckbill pliers have serrations to grip safety wire, while the handles are long enough to provide a good tight grip on the wire while it is being twisted. Duckbill pliers Lockwire Pliers/Safety Wire Pliers A special tool used by aircraft engineers is the lockwire pliers. This tool combines the features of sidecutters with those of the duckbills. Lockwire pliers have a special twister built into the handle that quickly and efficiently twists lockwire. To lockwire something, cut the length of wire needed and insert it into whatever is being safetied. Cross the wire close to the head of the object being safetied and grip the ends of wire with the flat serrated jaws. After locking the handles together, pull the knob in the pliers handle and a spiral rod in the handle will rotate the pliers, twisting the wire. When twisting is completed and the wire is secured, cut off the ends of the wire with the built-in cutters and put a ‘pig tail’ or curl on the end of the wire to avoid injury to personnel. Lockwire pliers/safety wire pliers 2023-11-24 B-07b Maintenance Practices CASA Part 66 - Training Materials Only Page 58 of 498 Needle Nose Pliers Several different designs of needle nose pliers are used in aviation maintenance. Needle nose pliers come in handy for electrical and electronic work because they are typically small enough to grip and hold small components and wires. Some needle nose pliers have long, thin jaws that are bent at a right angle to the handle. This allows the pliers to grip a component and hold it while keeping your hand out of the way. Needle nose pliers 2023-11-24 B-07b Maintenance Practices CASA Part 66 - Training Materials Only Page 59 of 498 Circlip Pliers The circlip pliers shown below are used for fitting and removing circlips in assembly and maintenance work. Some types are made to suit inside or outside circlips, and the noses can be straight or bent. Circlip pliers 2023-11-24 B-07b Maintenance Practices CASA Part 66 - Training Materials Only Page 60 of 498 Chisels Cold Chisels Flat cold chisels are made from square or octagonal stock, ranging from 8 - 17 mm (5/16 - 11/16 in.) across. The cutting edge of a flat chisel is forged so it is slightly wider than the shank and is ground to an angle of approximately 70°. To use a cold chisel, hold the cutting edge flat against the material and control the depth of the cut by varying the angle between the chisel and the work. The cutting edge of a flat chisel is ground slightly convex so that the greatest stress from a hammer blow is directed into the centre of the chisel. This reduces the stresses that are transmitted to the sides of the cutting edge. Flat cold chisel set Cold chisels are not regularly used in aircraft maintenance as they are not suited to most aviation maintenance tasks. In fact, most engineers probably do not have one in their toolbox and have not used one in their careers. 2023-11-24 B-07b Maintenance Practices CASA Part 66 - Training Materials Only Page 61 of 498 Files Files and Filing Next to the chisel, the simplest cutting tool is the file. A file differs from a chisel in that it has a large number of cutting edges or points rather than a single cutting edge. A file is pushed across a material by hand, and as it moves, the teeth act like small chisels, removing small chips of material. Files are generally manufactured from high-carbon steel. They are available in a variety of lengths, sections, cuts and grades to suit almost every requirement. A file’s large numbers of small teeth can cut softer materials. Pressure on the file makes its teeth penetrate the surface to be filed. When the file is moved in the cutting direction, small particles are removed from the surface being filed. The file is one of the most commonly used tools, but as there is such a large range of types, shapes and sizes, you must know the correct file for the job at hand. 2023-11-24 B-07b Maintenance Practices CASA Part 66 - Training Materials Only Page 62 of 498 Parts of a File To obtain the best results, you should be familiar with the parts of a file: The tang, on which a handle should always be fitted, is not hardened like the body of the file. The heel is the portion between the tang and the teeth. The faces are the main surfaces on which the teeth are cut. The edges are two sides, mainly on flat files, on which teeth may or may not be cut. The point is the end opposite the tang. The back is the convex side of a half-round or similar file. A safe edge is an edge on which no teeth are cut. This permits a corner to be cleaned out without damage to adjacent faces. Parts of a file Files can provide either: A roughing process to alter the size of a part by removing a considerable amount of material A finishing process to smooth a surface without removing much material. Flat or curved surfaces may be produced by varying the direction of the cutting motion. Both the shape of the teeth and the number of teeth affect the surface finish obtained by filing. 2023-11-24 B-07b Maintenance Practices CASA Part 66 - Training Materials Only Page 63 of 498 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. Grade of Cut The cut of the file refers to how fine its teeth are. They are defined as (from roughest to smoothest): rough, middle, bastard, second cut, smooth, and dead smooth. Type of Cut Various arrangements of cutting teeth are provided to give the most satisfactory results when you work on different metals. These arrangements are known as cuts. Details of the more widely used cuts are as follows: Single-cut Double-cut Dreadnaught (curved teeth) Rasp. Single-cut file has one set of parallel teeth while a cross-cut or double-cut file has a second set of cuts forming diamond shaped cutting surfaces. 2023-11-24 B-07b Maintenance Practices CASA Part 66 - Training Materials Only Page 64 of 498 Cut Usages Although there are rougher cuts, the following are the three standard cuts in regular use. Bastard Cut The coarse bastard grade of file removes material quickly. It is intended for roughing out. Second Cut The second cut grade is finer than the bastard grade. It cuts more slowly, but gives a smoother finish to the work. Smooth Cut A smooth file cuts quite slowly and imparts a good finish to the work. It should be used for finishing work. File cuts and cut types 2023-11-24 B-07b Maintenance Practices CASA Part 66 - Training Materials Only Page 65 of 498 File Types and Profiles Flat Files The flat is the most commonly used section for general filing. In most cases, the blade is a rectangular shape, but tapered and bellied blades are also available if required. © Commonwealth of Australia 2009 Flat file Hand Safe Edge Files The only difference between flat and parallel files is that they have one safe edge, that is, an edge without teeth. They are used for filing near 90° shoulders to avoid damaging the finished surface of the shoulder. © Commonwealth of Australia 2009 Hand safe edge file 2023-11-24 B-07b Maintenance Practices CASA Part 66 - Training Materials Only Page 66 of 498 Half-Round Files Half-round files are shaped like segments of a circle. They are double-cut on the flat side. The teeth on the convex side may be either double- or single-cut, depending on the grade and length of file. They are used for enlarging large, round holes and for filing concave surfaces. The flat side may be used for filing in corners and grooves where the angle is less than 60°. © Commonwealth of Australia 2009 Half-round file 2023-11-24 B-07b Maintenance Practices CASA Part 66 - Training Materials Only Page 67 of 498 Round Files A round file is suitable for filing small radii and is used with bellied, tapered and parallel blades, the bellied shape being the most common. Most round files are single-cut in a spiral fashion. The smaller sizes of round taper files are called rat tails. They must be used with an additional rolling motion to prevent grooving the work. They are used for enlarging round holes and finishing fillets and other concave surfaces. © Commonwealth of Australia 2009 Round file 2023-11-24 B-07b Maintenance Practices CASA Part 66 - Training Materials Only Page 68 of 498 Three-Square Files Three-square files have a cross-section that is an equilateral triangle. They are usually of bellied form and have limited use in clearing out square corners and filing acute internal angles greater than 60°. © Commonwealth of Australia 2009 Three-square file Square Files All three of the usual shapes are associated with files of square cross-section. They are suitable for internal work, such as filing keyways, and for enlarging square and rectangular holes. © Commonwealth of Australia 2009 Square file 2023-11-24 B-07b Maintenance Practices CASA Part 66 - Training Materials Only Page 69 of 498 Warding Files Warding files are very thin and taper markedly in width. They are used for very narrow slotting. © Commonwealth of Australia 2009 Warding file 2023-11-24 B-07b Maintenance Practices CASA Part 66 - Training Materials Only Page 70 of 498 Sheet Metal Shears Aviation Snips The popular tin snips are useful in aircraft maintenance work for cutting the metal to its rough shape and size, but for accurate work, it is best to use aviation snips. Aviation snips have serrated cutting edges and leverage multiplication that allows relatively thick sheet metal to be cut without requiring excessive handle force. They come in sets of three, and the handles are colour coded: yellow cuts straight, green cuts to the right and red cuts to the left. Aviation snips 2023-11-24 B-07b Maintenance Practices CASA Part 66 - Training Materials Only Page 71 of 498 Cutting Pliers Diagonal cutting pliers (or side cutters) are: Made with jaws set at an angle Obtainable with bare or insulated handles Used for shearing off wires in confined spaces and cutting off wires close to electrical terminals Useful for pulling, cutting to length and spreading cotter pins. Diagonal side-cutters Side cutter use 2023-11-24 B-07b Maintenance Practices CASA Part 66 - Training Materials Only Page 72 of 498