Layout and Measuring Tools - AVIA-1064

Layout and Measuring Tools AVIA-1064 1 Layout and Measuring Tools Rules made of steel are either: – Rigid or flexible will bend but should not be bent intentionally as it may be broken rather easily Reading: General Chapter 11 https:/...

Layout and Measuring Tools AVIA-1064 1 Layout and Measuring Tools Rules made of steel are either: – Rigid or flexible will bend but should not be bent intentionally as it may be broken rather easily Reading: General Chapter 11 https://www.faa.gov/regulations_policies/handb ooks_manuals/aviation/amtg_handbook.pdf 2 Layout and Measuring Tools Rulers the unit of measure most commonly used is the inch may be divided into smaller parts by means of either: decimal divisions divisions of one tenth of an inch divisions of one hundredth of an inch divisions of one thousandth of an inch divisions of one ten thousandth of an inch  Layout and Measuring Tools Rulers fraction divisions the fractional divisions for an inch are found by dividing the inch into equal parts: – halves (1⁄2) – quarters (1⁄4) – eighths (1⁄8) – sixteenths (1⁄16) – thirty-seconds (1⁄32) – sixty-fourths (1⁄64) may be expressed in decimals – called decimal equivalents of an inch – Example:1⁄8 inch is expressed as 0.125 (one hundred twenty-five ten-thousandths of an inch) 4 Layout and Measuring Tools Rules manufactured in two basic styles those divided or marked in common fractions those divided or marked in decimals or divisions of one one hundredth of an inch may be used as either: a measuring tool a straightedge [Figure 9-31] 5 Layout and Measuring Tools Scales available in various lengths with the 6-inch and 12-inch scales being the most common and affordable very useful with fractions on one side and decimals on the other to obtain an accurate measurement: measure with the scale held on edge from the 1-inch mark instead of the end use the graduation marks on the side to set a divider or compass [Figure 4-3] Layout and Measuring Tools Scriber designed to serve in the same way as a pencil or pen used to scribe or mark lines on metal surfaces made of tool steel – 4 to 12 inches long has two needle pointed ends – one end is bent at a 90° angle for reaching and marking through holes – [Figure 9-33] Layout and Measuring Tools Scriber Caution used to mark or score metal to show where it is to be cut should only be used when marks will be removed by either drilling or cutting because it makes scratches that weaken the material and could cause corrosion Layout and Measuring Tools Dividers and Pencil Compasses have two legs joined at the top by a pivot used for scribing circles and arcs and transferring measurements from the rule to the work Layout and Measuring Tools pencil compasses: have one leg tapered to a needle point the other leg has a pencil or pencil lead inserted Pencils on Aluminum are not acceptable Unless the aluminum skin is primed first Graphite on Aluminum leads to corrosion Layout and Measuring Tools Calipers used for measuring diameters and distances or for comparing distances and sizes three common types: inside, outside and hermaphrodite inside calipers have outward curved legs for measuring inside diameters such as: – diameters of holes – the distance between two surfaces – the width of slots – other similar jobs Layout and Measuring Tools Calipers-Outside calipers used for measuring outside dimensions example: the diameter of a piece of round stock 12 Layout and Measuring Tools Marking Tools Pens fiber-tipped pens are the preferred method of marking lines and hole locations directly on aluminum because the graphite in a No.2 pencil can cause corrosion when used on aluminum make the layout on the protective membrane if it is still on the material cover the material with masking tape and then mark on the tape Precision Measuring Instruments AVIA-1064 14  Micrometer Calipers types of micrometer calipers each designed for a specific use outside micrometer is the most common type used to measure outside dimensions of shafts thickness of sheet metal stock diameter of drills many other applications inside micrometer depth micrometer thread micrometer Precision Measuring Used for more precise measurements Instruments 15  Micrometer Parts fixed parts: the frame the barrel (sleeve) the anvil movable parts: the thimble rotates the spindle turning the thimble provides an opening between the anvil and the end of the spindle where the work is measured the size of the work is indicated by the graduations Precision Measuring on the barrel and thimble the spindle moves in the Instruments threaded portion inside the barrel 16  Dial indicator Precision Measuring measures variations in a surface Instruments – using an accurately machined probe – mechanically linked to a circular hand – movement indicates thousandths of an inch – or is displayed on a liquid crystal display (LCD) screen Measuring Crankshaft runout 6:53 17  Precision Measuring Instruments Slide Calipers-sometimes called Vernier Calipers used to measure the length of an object provides greater accuracy than the ruler measures both inside and outside dimensions with specially formed jaws Some also contain a depth gauge for measuring the depth of blind holes caliper jaw slides along a graduated scale its jaws then contact the inside or outside of the object to be measured measurement is then read on the scale located on the body of the caliper the LCD screen  Slide Calipers Precision Measuring – scale located on the body of the caliper Instruments – LCD screen 19 Precision Measuring Instruments Slide Calipers 20 Tool Storage and Control AVIA-1064 21  Taken from http://www.aviationpros.com/article/10385420/tool-control http://www.aviationpros.com/article/10385420/tool-control It’s a matter of fact – tool control affects safety Tool Storage and Control Leaving a tool in an aircraft or engine is not just an inconvenience, it is a safety risk. https://www.youtube.com/watch?v=d d0Z2PKUA-g FOD - 10 min They realize that establishing most aircraft maintenance and enforcing a tool control businesses enforce some sort program can provide of tool control procedures. numerous benefits, foremost of which is safety. 22  What’s involved? At a minimum, tool control is a method to quickly determine that all tools are accounted for at the end of a maintenance task. Tool Storage and Control This can only be done if each tool has a specific place where it is stored that allows for quick identification if the tool is missing. List some ways we can do this 23  Tool shadowing Tool Storage and Control This involves specifying a specific space for each tool It should be designed in such a way as to quickly determine if a tool is missing A popular method is to use some type of foam product and cut out spots for each tool In a tool room environment, walls can be used with pegboard and hooks The item is then outlined and shadowed 24 Tool Storage and Control Tool identification Tools can be marked using a variety of methods such as: Coloured Tape Vibra-peen tool Laser tool marking Electro engraving 3M RFID Radio Frequency ID API is another company that uses a handheld reader system Use of permanent markers is not very effective and is not recommended. 25 Tool Storage and Control Tool identification If your company requires mechanics to mark their personal tools in a uniform method, be careful of the requirement. It would be best to use mechanics’ initials. Anything that will show ownership. Company specific numbers such as employee numbers should be avoided. If the mechanic changes jobs to another company, these numbers will not be relevant, and he or she may have to mark them all over again. 26 Tool Storage and Control Tool identification Marking tools serves two purposes. First of all, it ensures that if a tool is found it is returned to the owner. Second, it helps assure compliance with missing tool reporting. It makes employees become more vigilant in reporting missing tools vs. just going to the closest tool truck or store to buy a replacement.  Tool inventory A tool inventory should be accomplished on a regular basis so that any missing tools can quickly be identified and searched for before they affect the safety of an aircraft. Tool Storage and Control This can be done after each work task or at least once a day. Many companies choose to do it at the beginning and end of each shift. 28 Tool Storage and Control Missing tool reporting An important part of any tool control program is a process for missing tool reporting In order to achieve the goal of accounting for all tools to ensure a safe product for the customer, a culture must be present that encourages employees to report any missing tool Tool Storage and Control Missing tool reporting This procedure should be clear as to how often tools need to be inventoried, how the employee should report a missing tool, and the steps to be taken once a missing tool is reported. An important part of this is the person who has the authority to release the aircraft in the event a missing tool is not found. Questions What is this? Dial indicator Used for measuring? Out of round items like Crankshaft runout How precise is it? movement indicates thousandths of an inch 31 Questions What is this? Micrometer caliper Slide Calipers 32 Questions If I was measuring a precise measurement such as.3145” (inches), what measuring tool would I use? A) 0-1 inch micrometer B) 25 foot measuring tape C) a 12 inch Ruler D) a veneer caliper Not Spelled Veneer (Vernier) 33 General Purpose Tools AVIA-1064 34 General Purpose Tools Hammers and Mallets Metal head hammers -usually sized according to the weight of the head without the handle soft-faced hammer has a striking surface made of wood brass lead rawhide hard rubber plastic intended for use in forming soft metals or striking surfaces that are easily damaged wood and leather mallets used in aviation To prevent marring the surface of a part to prevent quickly ruining this type of hammer it should not be used for striking punch heads, bolts or nails General Purpose Tools Hammers and Mallets mallet head made of – hickory – rawhide – rubber handy for shaping thin metal parts without causing creases or dents with abrupt corners. General Purpose Tools Hammers and Mallets Ball peen hammer – Hardened steel – For shaping metal – Striking steel punch – Striking cold chisel Claw hammer-Used in construction not aviation 37 Image result for tri wing screwdriver Screwdrivers can be classified by its shape type of blade General Purpose Tools blade length made for only one purpose for loosening or tightening screws or screw head bolts should not be used for chiseling or prying General Purpose Tools Screwdrivers common screwdriver select the largest screwdriver whose blade will make a good fit in the screw must fill at least 75 percent of the screw slot if the screwdriver is the wrong size, it cuts and burrs the screw slot, making it worthless damage may be so severe that the use of screw extractor may be required may slip and damage adjacent parts of the structure used only where slotted head screws or fasteners are found on aircraft An example of a fastener – camlock style fastener that is used to secure the cowling on some aircraft  General Purpose Tools Screwdrivers recessed head screws Phillips – slightly larger center in the cross – screwdriver is blunt on the end Reed & Prince – head forms a perfect cross – screwdriver is pointed on the end – screwdrivers are not interchangeable – use of the wrong type screwdriver results in mutilation of the screwdriver and the screw head only the proper recessed head screwdriver of the correct size most common cross point screwdrivers are the Number 1 and Number 2 Phillips 40 http://public.snapon.com/R_RRD/Objects_lg/images/SSDMR4BO.jpg General Purpose Tools Screwdrivers Replaceable tip screwdrivers allow for the quick changing of a screwdriver tip economical replacement of the tip when it becomes worn wide variety of screwdriver tips, including Flat Crosspoint Torx Robertson When using a screwdriver on a small part, always hold the part in the vise or rest it on a workbench Do not hold the part in the hand, as the screwdriver may slip and cause serious personal injury 41  General Purpose Tools Screwdrivers cordless hand-held power screwdriver has replaced most automatic or spiral screwdrivers care must be exercised if the slip clutch is set for too high a setting when installing a screw, the screwdriver tip will slip rotate on top of the screw head, damaging it slip out of the screw head, damaging the surrounding material break off the screwdriver tip, resulting in flying particles damaged screw head to avoid cross-threaded screws into the nuts or nutplates should be started by hand 42  http://www.bloomertool.com/images/370.JPG General Purpose Tools Pliers and Plier-Type Cutting Tools most frequently in aircraft repair work are Diagonal needle nose duckbill size of pliers indicates their overall length ranging from 5 to 12 inches General Purpose Tools Pliers and Plier-Type Cutting Tools Roundnose pliers used to crimp metal not made for heavy work too much pressure will spring the jaws often wrapped to prevent scarring the metal General Purpose Tools Pliers and Plier-Type Cutting Tools Needle nose pliers half round jaws of varying lengths used to hold objects and make adjustments in tight places General Purpose Tools Pliers and Plier-Type Cutting Tools Duckbill pliers resemble a “duck’s bill” – jaws are thin, flat, and shaped like a duck’s bill – used exclusively for twisting safety wire 46  General Purpose Tools Pliers and Plier-Type Cutting Tools Diagonal pliers – usually referred to as – diagonals or sidecutters – a short-jawed cutter – blade set at a slight angle on each jaw – can be used to cut – wire – rivets – small screws – cotter pins – also used in removing or installing safety wire – used extensively in aviation for the job of safety wiring 47  General Purpose Tools Pliers and Plier-Type Cutting Tools Flushcut a short-jawed cutter blade set with no angle on each jaw can be used to cut Tie wraps , zip ties Light electrical wire NEVER used to cut lock wire 48  General Purpose Tools Punches – usually made of carbon steel, hardened and tempered – used to locate centers for drawing circles or to start holes for drilling – Used to punch holes in sheet metal, to transfer location of holes in patterns, and to remove damaged rivets, pins or bolts General Purpose Tools Punches – two types generally used – solid – classified according to the shape of their points – hollow 50  General Purpose Tools Prick punches – used to place reference marks on metal – often used to transfer dimensions from a paper pattern directly on the metal – place the paper pattern directly on the metal – go over the outline of the pattern with the prick punch, tapping it lightly with a small hammer, making slight indentations on the metal at the major points on the drawing indentations can then be used as reference marks for cutting the metal should never be struck with a heavy blow as it may bend the punch and cause excessive damage to the material being worked 51 General Purpose Tools Punches Center punch – large indentations in metal are necessary to start a twist drill – This helps the drill stay on the mark as it goes through the metal – drills have the tendency to wander on a flat surface – The Punch should never be struck with enough force to dimple the material around the indentation or to cause the metal to protrude through the other side of the sheet – has a heavier body than a prick punch – ground to a point with an angle of about 60° 52 General Purpose Tools Automatic Center Punch performs the same function as an ordinary center punch uses a spring tension mechanism to create a force enough to make an indentation without the need for a hammer mechanism automatically strikes a blow of the required force when placed where needed and pressed has an adjustable cap for regulating the stroke point can be removed for replacement or sharpening never strike an automatic center punch with a hammer General Purpose Tools drive punch often called a tapered punch used for driving out damaged rivets pins bolts size of the punch is determined by the width of the face (1) usually 1⁄8 inch to 1⁄4 inch 54 General Purpose Tools Pin punches often called drift punches similar to drive punches used for the same purposes has a straight shank sized by the diameter of the face in thirty-seconds of an inch range from 1⁄16 to 3⁄8 inch in diameter 55 General Purpose Tools Wrenches most often used in aircraft maintenance are made from chrome- vanadium steel are almost unbreakable 56 General Purpose Tools Open-end wrenches may have their jaws parallel to the handle or at an angle of up to 90° most are set at an angle of 15° solid, nonadjustable open parallel jaws on one or on both ends are designed to fit on a nut, bolt head, or other object, which makes it possible to exert a turning action 57 General Purpose Tools Wrenches Box-end wrenches popular tools because of their usefulness in close quarters they box, or completely surround, the nut or bolt head made with 12 points so they can be used in places having as little as 15° swing It is by reversing (turning the wrench over) the position of the wrench that a 15° arc may be made with the wrench handle  General Purpose Tools Wrenches ideal to break loose tight nuts or pull tight nuts tighter time is lost turning the nut off the bolt once the nut is broken loose only when there is sufficient clearance to rotate the wrench in a complete circle can this tedious process be avoided after a tight nut is broken loose can be unscrewed more quickly with an open-end wrench 59 General Purpose Tools a combination wrench can be used has a box end on one end and an open-end wrench of the same size on the other 60 General Purpose Tools Socket and ratchet is made of two parts the socket – which is placed over the top of a nut or bolt head – four, six, or twelve-sided recess – detachable handles – usually come in sets – fit several types of handles The handle, ratchet, which is connected to the socket 61 General Purpose Tools Wrenches adjustable wrench handy utility tool smooth jaws When using any adjustable wrench exert the pull on the side of the handle attached to the fixed jaw of the wrench minimize the possibility or rounding off the fastener fit the wrench to the bolt or nut to be turned 62 General Purpose Tools Special Wrenches crowfoot normally used when accessing nuts that must be removed from studs or bolt that cannot be accessed using other tools mounts using the standard square adapter 63 General Purpose Tools Special Wrenches flare nut has the appearance of a box-end wrench has been cut open on one end opening allows the wrench to be used on the B-nut of a fuel, hydraulic, or oxygen line mounts using the standard square adapter can be used in conjunction with a torque wrench 64  Questions Which one of these is wrong? A) socket and rachet to remove a bolt B) Centre punch for marking holes C) Duck Bill Pliers used for lockwiring D) Hammer and Flat head screwdriver as a chisel D) Hammer and Flat head screwdriver as a chisel 65  Questions What is this? Adjustable wrench Ratcheting wrench 66  Questions What is this? Box-end wrench Open-end wrench 67 General Purpose Tools Torque Wrench Used when definite pressure must be applied to a nut or bolt as it is installed a calibrated torque wrench must be used a precision tool consisting of a – torque indicating handle – appropriate adapter or attachments It measures the amount of turning or twisting force applied to a nut, bolt, or screw General Purpose Tools Torque Wrench Before each use must be visually inspect for damage – bent pointer – cracked or broken glass (dial type) – signs of rough handling must be tested at periodic intervals to ensure accuracy If damaged the wrench must be tested Always return to zero setting when done using General Purpose Tools Torque Wrench Types of commonly used torque wrenches Direct visual read deflecting beam dial indicating micrometer preset to the desired torque when this torque is reached operator notices a sharp impulse or breakaway “click” electronic setting types Metal Cutting Tools AVIA-1064 Reading General Chapter 9 & 11 71 Metal Cutting Tools Common types of Hand Snips Straight-used for cutting straight lines when the distance is not great enough to use a squaring shear Used for cutting outside curves Curved-used for cutting the inside of curves or radii Aviation Snips-designed especially for cutting heat treated aluminum alloy and stainless steel 72 Metal Cutting Tools are available in three types those which cut from right to left those which cut from left to right those that cut straight cuts should be made about 1/32 inch from the layout line finished by hand filing down to the line Red=Straight, Left hand curve and circles Yellow=Straight and outside curves Green=Straight, Right hand curves and circles Metal Cutting Tools common hacksaw has a frame handle two styles pistol grip straight blade  7 5 Metal Cutting Tools Hacksaws blade have holes in both ends are mounted on pins attached to the frame mount the blade with the teeth pointing forward, away from the handle made of steel different lengths different teeth per inch, 14,18,24,32  76 Metal Cutting Tools When using a hacksaw, observe the following procedures Select the appropriate blade for the job Indicate the starting point by nicking the surface with the edge of a file break any sharp corner that might strip the teeth This mark will also aid in starting the saw at the proper place Hold the saw at an angle that will keep at least two teeth in contact with the work at all times Start the cut with a light, steady, forward stroke just outside the cutting line At the end of the stroke, relieve the pressure and draw the blade back The cut is made on the forward stroke slow and steady Metal Cutting Tools Deburring Tool This type of tool is used to remove a burr from an edge of a sheet or to deburr a hole Drills AVIA-1064 78 Drills Generally four types of portable drills used in aviation Hand drill used for holes 1/4 inch in diameter and under commonly called an “egg beater” 79 Drills Electric power drills available in various shapes and sizes sparks from an electric motor are a fire or explosion hazard less common in aviation – due to the risk of the cord being cut by the edge of sheets of aluminum Drills Pneumatic power drills available in various shapes and sizes most common in aviation preferred for use around flammable materials 81 Drills Battery powered electric drills available in various shapes and sizes sparks from an electric motor are a fire or explosion hazard – not to be used around fuel or flammable materials 82 Drill Bits Twist Drills a pointed tool rotated to cut holes in material made of a cylindrical hardened steel bar made of – carbon steel for general work relatively inexpensive – high-speed alloy steel (HSS) used for the tough materials such as stainless steels more expensive 83 Drills spiral flutes (grooves) running the length of the body one to four spiral flutes two flutes are used for most drilling three or four flutes are used to follow smaller drills or to enlarge holes 84 Drills the shank is the end that fits into the chuck of a hand or power drill the body is the metal column forming the core of the drill body clearance area is slightly smaller in diameter than the margin to reduce the friction between the drill and the sides of the hole  Drills diameter of a twist drill by fractions classified by sixteenths of an inch (from 1/16 to 3 ½ inch), by thirty-seconds (from 1/32 to 2 ½ inch), or by sixty-fourths (from 1/64 to 1 ¼ inch) letters letter system is used with decimal equivalents: A (0.234 inch) to Z (0.413 inch) numbers most accurate measurement: No 80 (0.0314 inch) to No 1 (0.228 inch) Reamers Reamers used to smooth and enlarge holes to exact size Hand reamers have square end shanks that they can be turned with a tap wrench or similar handle types of reamers are illustrated in Figure 9-23 hole must be drilled about 0.003 to 0.007 inch undersize cut that removes more than 0.007 inch places too much load on the reamer should not be attempted 87 Reamers When reaming a hole rotate the reamer in the cutting direction only Do not back a reamer out of a hole by rotating it opposite the cutting direction Turn the reamer steadily and evenly to prevent Chattering or marking and scoring of the hole walls There are a variety or reamer types for different applications Taps and Dies Taps and Dies A tap is used to cut threads on the inside of a hole a die is for cutting external threads on round stock made of hard tempered steel and ground to an exact size four types of threads that can be cut with standard taps and dies National Coarse (UNC) National Fine (UNF) National Extra Fine (UNEF) National Pipe (NPT) 89 Taps and Dies Hand taps usually provided in sets of three taps each diameter and thread series contains taper tap plug tap bottoming tap The taps in a set identical in diameter and cross section only difference is the amount of taper 90 Drills and Such Dies classified as adjustable round split die Solid dies 91 Drills and Such adjustable round split die has an adjusting screw that can be tightened so that the die is spread slightly adjusting the die allows control of the diameter and fit plain round split die Drills and Such types of wrenches turning taps – T-handle – adjustable tap wrench turning dies – diestock for round split die https://youtu.be/06oDaoxaL_4 (3 min)  Files AVIA-1064 94 Files Files made of high-grade tool steels hardened and tempered variety of shapes and sizes known either by the cross section or type of application Files Files are used to square ends round corners remove burrs and slivers from metal straighten uneven edges file holes and slots smooth rough edges 96  Files are catalogued in Files three ways: Length Shape Cut Files have three distinguishing features their length, not including the tang their kind or name, that relates to the coarseness of the teeth 97 their cut  Files 98 Files Shape Refers to the physical cross section of the file Circular Rectangular Triangular a variation thereof Files two types of cuts single cut single row of teeth double cut has two rows of teeth that cross each other the angle of the first row is 40° to 45 used principally for finishing flat surfaces and similar work 99 Files Cut Refers to both the character of the teeth and the coarseness rough, coarse for use on heavier classes of work bastard and second cut, smooth and dead smooth for finishing work 100 10 1 Files recommended methods for using files Before attempting to use a file: place a handle on the tang of the file essential for proper guiding and safe use  File Card/Wire Brush Particles of metal collect between the teeth of a file Files remove them with a file card or wire brush Draw the brush across the file the bristles pass down the gullet between the teeth 102 Aircraft Specific Hand Tools AVIA-1064 103  have six to eight twists per inch of wire Aircraft Specific Hand be pulled tight while being installed install the safety wire around the head of the fastener Tools twist it in such a manner that the loop of the wire is pulled close to the Lockwire Wire contour of the unit being safety wired in the direction that would have the tendency to tighten the fastener 104 Aircraft Specific Hand Tools Chassis Punch A chassis punch is used to make holes in sheet metal parts for the installation of instruments and other avionics appliance, as well as lightening holes in ribs and spars Sized in 1/16 of an inch, they are available in sizes from 1/2 inch to 3 inches  Aircraft Specific Hand Tools Hole Duplicator or hole finders available in a variety of sizes and styles holes in a replacement sheet or in a patch – must be drilled to match existing holes in the structure – hole duplicator simplifies this process 106 Aircraft Specific Hand Tools 107 Aircraft Specific Hand Tools Hardwood Form Blocks hardwood form blocks constructed to duplicate practically any aircraft structural or nonstructural part wooden block or form is shaped to the exact dimensions contour of the part to be formed Airframe Vol 1 427 108 Aircraft Specific Hand Tools Sheet Metal Holding Devices Used for work with sheet metal during the fabrication process to hold the work together variety of holding devices clamps vises temporary fasteners selected for type of operation being performed metal being used determine the holding style needed  Temporary clamps Aircraft Specific Hand such as the carriage clamp (commonly called the C-clamp) used to position components while fixing them together Tools C-Clamps Clamps and vises shaped like a large C can leave marks on aluminum 110 Aircraft Specific Hand Tools Clamps and Vises Vises A clamping device that holds the work piece in place allows work to be done on it with tools such as saws and drills To avoid marring metal, add some type of padding ready-made rubber jaw pad 111  Reusable Sheet Metal Fasteners temporarily hold drilled sheet metal parts accurately in position for riveting or Aircraft Specific Hand drilling keeps the holes in the separate sheets aligned Tools sheet metal parts are not held tightly together most commonly used sheet metal holder is the Cleco (also spelled Cleko) fastener 112  Aircraft Specific Hand Clecos Reusable sheet metal fasteners, “Cleco’s”, are colour coded to Tools allow for easy size recognition Silver used for 3/32” rivets (#40) holes Copper used for 1/8” rivets (#30) holes Black used for 5/32” rivets (20-21) holes Gold used for 3/16” rivets (#10-11) holes 113 Aircraft Specific Hand Tools Hex Nut and Wing Nut Temporary Sheet Fasteners used to temporarily fasten when higher clamp up pressure is required Wing nut sheet metal fasteners characterized by wing shaped protrusions identical to Cleco wing nut fasteners hex nut can be used with pneumatic Cleco installers tightened with a hex nut runner 114 Aircraft Specific Hand Tools Rivet Cutter used to trim rivets when rivets of the required length are unavailable 115  Bucking Bar sometimes called a Aircraft Specific Hand dolly bucking iron Tools bucking block is a heavy chunk of steel whose counter vibration during installation contributes to proper rivet installation 116 Aircraft Specific Hand Tools come in a variety of shapes and sizes weights ranges from a few ounces to 8 or 10 pounds depending upon the nature of the work 117  when selecting a bucking bar first consideration is shape If it does not have the correct shape it deforms the rivet head Aircraft Specific Hand if the bar is too light it does not give the necessary bucking weight the material may become bulged toward the shop head Tools if the bar is too heavy force may cause the material to bulge away from the shop head Vibration dampened bucking bars 118 Aircraft Specific Hand Tools Bucking Bar must be kept clean, smooth and well polished edges should be slightly rounded to prevent marring the material surrounding the riveting operation 119 Aircraft Specific Hand Tools Hand Rivet Set equipped with a die for driving a particular type rivet available to fit every size and shape of rivet head made of 1/2-inch carbon tool steel 6 inches in length knurled to prevent slipping in the hand the face of the set is hardened and polished 120 Aircraft Specific Hand Tools Sets for universal rivets are recessed (or cupped) and fit the rivet head When selecting the correct set, be sure it provides the proper clearance between the set and the sides of the rivet head the surfaces of the metal and the set 121  Aircraft Specific Hand Sets for Flush or flat rivets are used for countersunk and flathead rivets Tools To seat flush rivets properly sets are at least 1 inch in diameter Installing Aircraft Rivets 122 Aircraft Specific Hand Tools Special draw sets are used to draw up the sheets to eliminate any opening between sheets before the rivet is bucked set has a hole 1/32-inch larger than the diameter of the rivet shank Occasionally the draw set and rivet header are incorporated into one tool header part consists of a hole shallow enough for the set to expand the rivet and head when struck with a hammer 123  Countersinking Tool Aircraft Specific Hand a tool that cuts a cone-shaped depression around the rivet hole allows the rivet to set flush with the surface of the skin Tools made with angles to correspond with the various angles of countersunk rivet heads standard countersink has a 100-degree angle 124 Aircraft Specific Hand Tools Countersinking Tool, Special micro-stop countersinks commonly called stop countersinks can be adjusted to any desired depth cutters to allow interchangeable holes with various countersunk angles to be made some have a micrometer set mechanism in 0.001-inch increments for adjusting their cutting depths 125 Aircraft Specific Hand Tools Dimpling Dies dimpling is done with a male and female die punch and die set-male die has a guide for the size of the rivet hole same degree of countersink as the rivet female die has a hole into which the male guide fits corresponding degree of countersink 126 Aircraft Specific Shop Tools Cable Tensiometer used to determine the amount of tension on a cable 98 percent accurate tension is determined by measuring the amount of force needed to make an offset in the cable between two hardened steel blocks called anvils riser or plunger is pressed against the cable to form the offset 127 12 8 Aircraft Specific Shop Tools Cable Tensiometer different numbered risers are used with different size cables They are identified with a number and easily inserted into the tensiometer Different height riser blocks used on a tensiometer enable the tensiometer to adapt to different cable sizes Aircraft Specific Shop Tools dial reading is converted to pounds of tension as follows using a No 2 riser to measure the tension 5/32” diameter cable reading of 30 is obtained actual tension (see chart) of the cable is 70 lbs 129  Cable Tensiometer To use the chart, determine the size of the cable that is to be adjusted and the ambient air temperature For example assume that the cable size is 1/8” diameter Aircraft which is a 7-19 cable ambient air temperature is 85 °F Specific Shop Follow the 85 °F line upward to where it intersects Tools the curve for 1/8” cable extend a horizontal line from the point of intersection to the right edge of the chart The value at this point indicates the tension (rigging load in pounds) to establish on the cable The tension for this example is 70 pounds 131  Screwdriver types A is called what? Phillips B is called what? Torx C? Security T D? Allen wrench or Allen key 132 Aircraft Specific Hand What are these called? Tools What do the colours mean? 133 Aircraft Specific Shop Tools AVIA-1064 134 Aircraft Specific Shop Tools Universal Propeller Protractors Used for measuring angles in degrees various types are used to determine the travel of flight control surfaces can be used to measure aileron elevator wing flap travel Reading: Airframe Vol 1, 4-26 Aircraft Specific Shop Tools Drill Press Used for drilling holes that require a high degree of accuracy serves as an accurate means of locating and maintaining the direction of a hole that is to be drilled and provides the operator with a feed lever that makes the task of feeding the drill into the work easier The upright drill press is the most common of the variety of drill presses available 136 Aircraft Specific Shop Tools Drill Press using a drill press height of the drill press table is adjusted to accommodate the height of the part When the height of the part is greater the table is lowered When the height of the part is less the table is raised After the table is properly adjusted the part is placed on the table the drill is brought down to aid in positioning the metal so that the hole to be drilled is directly beneath the point of the drill 137 Aircraft Specific Shop Tools Drill Press The part is then clamped to the drill press table to prevent it from slipping during the drilling operation Parts not properly clamped may bind on the drill and start spinning causing serious cuts on the operator’s arms or body, or loss of fingers or hands Always make sure the part to be drilled is properly clamped to the drill press table before starting the drilling operation Aircraft Specific Shop Tools AVIA-1064 Shop tools Power tools 139  Aircraft Specific Shop Tools Bar folder - used for turning or bending the edges of sheet metal  Cornice Brake a brake is similar to a bar folder because it is also used for turning or bending the edges of sheet metal Aircraft more useful than the bar folder because its design allows the sheet metal to be folded and formed Specific Shop to pass through the jaws from front to rear without obstruction Tools the bar folder can form a bend or edge only as wide as the depth of its jaws any bend formed on a bar folder can also be made on the cornice brake 141  Cornice Brake in making ordinary bends with the cornice brake: if other bends are to be made. the clamping bar is lifted, and the sheet is moved to the correct position for bending Aircraft Specific Shop Tools 142  Cornice Break Pt 1 1:18 Cornice Break Pt 2 0:36 Cornice Break Pt 3 1:04 Aircraft Specific Shop Tools 143 Aircraft Specific Shop Tools Box and Pan Brake often called the finger brake because it is equipped with a series of steel fingers of varying widths simply remove the fingers that are in the way use only the fingers required to make the bend the fingers are secured to the upper leaf by thumbscrews all the fingers not removed for an operation must be: – securely seated – firmly tightened – before the brake is used Aircraft Specific Shop Tools Box and Pan Brake (finger brake) the radius of the nose on the clamping fingers is usually rather small frequently requires nose radius shims to be custom made for the total length of the bend Using a box brake to make a metal box 4:59 Aircraft Specific Shop Tools Box and Pan Brake 146 Power Equipment and Tools AVIA-1064 147 Power Equipment and Tools Kett Saw 148  Pneumatic Circular Cutting Saw Power Equipment and useful for cutting out damage Tools similar to the kett saw 149 Power Equipment and Tools Die Grinder a handheld tool that turns either a mounted cutoff wheel, a rotary file or a sanding disk at high speeds usually powered by compressed air electric die grinders are also used pneumatic die grinders run at 12,000 to 20,000 revolutions per minute (rpm) with the rotational speed controlled by the operator operator uses a hand or foot-operated throttle to vary the volume of compressed air 15 0 Power Equipment and Tools Die Grinder available in: – straight models – 45° models – 90° models excellent for: – weld breaking – smoothing sharp edges – deburring – porting – general high-speed: polishing grinding cutting https://www.youtube.com/watch?v=9bMQDcFTO8o https://www.youtube.com/watch?v=nSmPX-4NIik https://www.youtube.com/watch?v=yHaCLaTbS8Y  Cut-off Wheel a thin abrasive disc Power Equipment and driven by a high-speed pneumatic die-grinder Tools used to cut out damage on: aircraft skin stringers comes in different thicknesses and sizes Power Equipment and Tools Squaring Shear 153  Power Equipment and Tools Squaring Shear to make a cut with a foot shear: – move the upper blade down – by placing the foot on the treadle and pushing downward a spring raises the blade and treadle once: – the metal is cut – foot pressure removed 15 4 Power Equipment and Tools Band Saw consists of a toothed metal band continuously driven around the circumferences of the two wheels used to cut: aluminum steel composite parts 15 5 Power Equipment and Tools Disk Sander and Belt Sander have powered abrasive-covered disks or belts the sander unit: uses abrasive paper of different grits to trim metal parts used for smoothing or polishing surfaces quicker to use a disk sander than to file a part to the correct dimension the combination disk and belt sander: has a vertical belt sander coupled with a disk sander often used in a metal shop [Figure 4-29] 156  Portable Power Drills operate by electricity or compressed air when using the portable power drill: Power Equipment and – hold it firmly with both hands – before drilling: Tools – always wear safety goggles while drilling – be sure to place a backup block of wood under the hole to be drilled to add support to the metal structure 157  Portable Power Drills the drill bit should be: Power Equipment and inserted in the chuck tested for trueness or vibration Tools this may be visibly checked by running the motor freely a drill bit that wobbles is slightly bent and should not be used since such a condition causes enlarged holes 158  159 Power Equipment and Tools Portable Power Drills the drill should always be held at right angles to the work regardless of the position or curvatures tilting the drill at any time when drilling into or withdrawing from the material may cause elongation (egg shape) of the hole Power Equipment and Tools Portable Power Drills when drilling through sheet metal, small burrs are formed around the edge of the hole burrs must be removed to allow rivets or bolts to fit snugly and prevent scratching burrs may be removed with either a – bearing scraper – countersink should be rotated by hand – drill bit larger than the hole (should be rotated by hand) 160 Power Equipment and Tools Pneumatic Drill Motors the most common type of drill motor for aircraft repair work recommended for use on repairs around flammable materials where potential sparks from an electric drill motor might become a fire hazard they are light weight and have sufficient power and good speed control 161  Pneumatic Drill Motors available in many different sizes and models Power most drill motors used for aircraft sheet metal work are rated at Equipment and 3,000 rpm but if drilling deep holes or drilling in hard materials such as corrosion resistant steel or titanium Tools a drill motor with more torque and lower rpm should be selected to prevent damage to tools and materials 162 Power Equipment and Tools Right Angle and 45° Drill Motors used for positions that are not accessible with a pistol grip drill motor right angle drill motors-most use threaded drill bits that are available in several lengths heavy-duty right-angle drills are equipped with a chuck similar to the pistol grip drill motor 163 Power Equipment and Tools Two Hole special drill motors that drill two holes at the same time used for the installation of nutplates by drilling two holes at the same time: the distance between the holes is fixed the holes line up perfectly with the holes in the nutplate 164 Power Equipment and Tools Pneumatic Rivet Gun the most common rivet upsetting tool used in airframe repair work available in many sizes and types [Figure 4-86] the manufacturer’s recommended capacity for each gun is usually stamped on the barrel they operate on air pressure of 90 to 100 pounds per square inch 165  Pneumatic Rivet Gun they are used in conjunction with Power interchangeable rivet sets each set is designed to fit the specific type Equipment and of rivet and the location of the work the shank of the set is designed to fit into Tools the rivet gun an air driven hammer inside the barrel of the gun supplies force to buck the rivet 166 Power Equipment and Tools  Pneumatic Rivet Gun a rivet gun should upset a rivet in 1 to 3 seconds an aircraft technician learns the length of time needed to hold down the trigger a rivet gun with the correct header (rivet set) must be held: snugly against the rivet head perpendicular to the surface Power Equipment and Tools 168 Power Equipment and Tools Pneumatic Rivet Gun while a bucking bar of the proper weight is held against the opposite end the force of the gun must be absorbed by the bucking bar not the structure being riveted the rivet is driven when the gun is triggered always make sure the correct rivet header and the retaining spring are installed Power Equipment and Tools Pneumatic Rivet Gun the riveting action should start slowly and be one continued burst if the riveting starts too fast: – the rivet header might slip off the rivet and damage either: – the rivet (smiley) – the skin (eyebrow) try to drive the rivets within 3 seconds the rivet will work harden if the driving process takes too long 170  Power Equipment and Tools Pneumatic Rivet Gun rivet header might slip off the rivet and damage either: the rivet (smiley) the skin (eyebrow) 171  Pneumatic Rivet Gun the dynamic of the driving process has the gun hitting/vibrating the rivet and material it causes the bar to bounce/ counter vibrate these opposing blows (low frequency vibrations)squeeze the rivet causing it to swell and then form the upset head Power Equipment and Tools 172 Power Equipment and Tools Pneumatic Rivet Gun some precautions to be observed when using a rivet gun are: never point a rivet gun at anyone at any time a rivet gun should be used for one purpose only: to drive or install rivets never depress the trigger mechanism unless the set is held tightly against a block of wood or a rivet always disconnect the air hose from the rivet gun when it is not in use for any appreciable length of time or you are changing a snap Power Equipment and Tools Pneumatic Rivet Gun significant changes have been made in rivet gun ergonomics while traditional tooling has changed little in the past 60 years reduced vibration rivet guns and bucking bars have been developed to reduce the incidence of carpal tunnel syndrome and enhance operator comfort 174 Power Equipment and Tools 175  Rivet Sets/Headers rivet headers are made in a variety of styles the short, straight header is best when the gun can be brought close to the work offset headers may be used to reach rivets in obstructed places long headers are sometimes necessary when the gun cannot be brought close to the work due to structural interference, rivet headers should be kept clean Power Equipment and Tools 176 Power Equipment and Tools Rivet Sets/Headers 177 Power Equipment and Tools Compression Riveting - Hand is method of riveting can be used only over the edges of sheets or assemblies where conditions permit where the reach of the rivet squeezer is deep enough Power Equipment and Tools Compression Riveting-pneumatic 17 9 Power Equipment and Tools Microshavers used if the smoothness of the material such as skin requires that all countersunk rivets be driven within a specific tolerance [Figure 4-89] this tool has: a cutter a stop contains the cutting portion