1.

Types and Uses of Hand Tools:

Hand tools are fundamental in various trades. Proficiency in using the right tool enhances safety,
efficiency, and precision in workmanship. It is important to know the basics and usage of a variety of
hand and power tools so you can pick the right tool for the right job.

1.1 Vice
A vice is essential for firmly holding workpieces in place during various operations such as cutting,
filing, and assembly.

Bench Vice:
It is the most common vice in mechanical maintenance workshops and used to grip a job so that
cutting/sawing or other job can be performed on it. Parts include a body, slide, fixed jaw, moving jaw,
screw, handle, and sometimes a quick-release mechanism. The handle used to turn the screw and
move the moving jaw.

The jaw faces are hard, rough and serrated to properly grip the job/work. They can damage the work if
guards are not used properly. If you are filing or sawing with your work sticking too far from the jaws,
the work vibrates and gives a poor cut. Hence it is important to grip your work properly in the vice.

Pipe Vice:
Pipe vice is specifically designed to hold round bars and pipes securely. It features V-shaped jaws
that provide a strong grip, preventing slippage during cutting or threading operations.
1.2 Files
Files are used for precision material removal, smoothing edges, deburring, and shaping workpieces
to achieve desired dimensions and finishes.

Types of Cuts:
A file’s grade of cut depends on the coarseness of the cutting edges or teeth: A coarse grade has
larger teeth and removes more material—it gives a rougher finish; a fine grade has smaller teeth and
removes less material—it gives a smoother finish. Further types of cuts are

• Single-cut: Features a single row of parallel teeth, ideal for working with harder metals.
• Double-cut: Has two sets of intersecting teeth, providing faster material removal for rough
shaping and general-purpose work.
• Rasp: Features individual, protruding teeth, designed for coarse material removal from
wood, leather, and other soft materials.
File Shapes:
How to use files:
• Push forward with the hand holding the handle and push down on the tip of the file with the
other hand.
• Only push down on the forward (away from you) stroke. The file only cuts on the forward
stroke. Pushing down on the back stroke wastes your energy and damages the file’s teeth.
• Use slow, even strokes. Filing too quickly makes the teeth hot, and they become blunt.
• Move the file at an angle across your work using the full length of the file. Change the
direction every few strokes. This helps clear the teeth of cut material

1.3 Chisels
Chisels are used for cutting, shaping, and removing metal by applying impact force with a hammer or
mallet. Chisels remove more metal than files, but they produce a rough surface that you must
normally finish with a file.

Types of Chisels:
Chisels are classified based on their cutting edges:
Using Chisels:
• Always wear safety glasses to protect against flying chips.
• Hold the chisel securely at the correct angle to the work
• Ensure the chisel is sharp and the workpiece is securely held in a vice.
• Use a hammer of appropriate size and strike the chisel head squarely to avoid glancing blows.
• After using chisel for a long time, the soft head of a chisel becomes flattened and forms a
‘mushroom head’. The mushroom head is brittle, and small pieces can break off if you
continue hammering it. Hence it is important to inspect chisel before usage and never use
chisel that has a mushroom head.
1.4 Hammers
Hammers are used for delivering impact force to drive nails, shape metal, and assemble
components. Most hammer heads are made of steel with hardened surfaces where the hammer
blow is taken. The handle is normally wood, fits into a tapered hole in the hammer head and is held
securely by a wedge.

Types of Hammers:
The size of hammer is identified by the weight of its head starting from 2 pounds upto 40 pounds (18
kg) even.

• Ball peen: Used for metalworking, shaping, and riveting.

• Claw: Designed for driving and removing nails in woodworking.
• Sledge: Heavy hammer used for demolition and heavy-duty tasks.
• Soft-faced: Made of materials like rubber, plastic, or copper, used to prevent damage to
delicate surfaces.

1.5 Hacksaws
Hacksaws are used for cutting metal roughly to a size, utilizing a fine-toothed blade stretched across
a frame. Hacksaws have two main parts: the frame and the blade. The teeth of a hacksaw blade are
‘set’ to either side so that they cut a slot that is wider than the rest of the blade. This stops the blade
from sticking in the saw cut. The teeth of a blade must always be hard so that they can cut other,
softer materials. Hacksaw blades are hard, and the teeth are brittle. Avoid anything that will chip the
teeth. Keep hacksaws on a rack, not in a drawer with other tools.

Types of Hacksaw Blades:

Hacksaw blades are identified by their length and either the number of teeth per 25mm (or per inch),
or the pitch of the teeth. The more teeth per inch, the smaller the teeth and the smaller the pitch

• Fine: High tooth count (e.g., 32 TPI) for thin materials and precise cuts.
• Medium: Moderate tooth count (e.g., 24 TPI) for general-purpose cutting.
• Coarse: Low tooth count (e.g., 18 TPI) for thicker materials and faster cuts.

How to use hacksaw:

• Always check that the hacksaw blade teeth point forward before you start sawing.
• The blade should cut only on the forward stroke.
• Make sure that the blade is tightened to the correct tension.
• Mark a line on your work where you want to cut.
• Hold the work in a vice so that the cutting line is close to the jaws to avoid vibration.
• Position the blade on the waste side of the cutting line.
• Use the full length of the blade when you cut. Use steady, even strokes, about one complete
forward and back stroke each second.
• Only push down on the forward stroke.
1.6 Spanners & Wrenches
Spanners and wrenches are used for gripping, tightening and loosening nuts, bolts, and fasteners.
The key difference between a spanner and a wrench is that wrenches have an adjustable jaw while
spanners come in a range of fixed sizes.

Types of Spanners:
Open-ended spanner features open jaws that fit onto two opposite sides of a nut or bolt head. It can
slip off the nut, especially if it is worn or damaged and you need more space to operate the spanner.

Ring spanner encloses the nut or bolt head completely, providing a more secure grip and reducing
the risk of slippage as it contacts all the corners of the nut or bolt head.

Combination spanner has an open-ended spanner on one end and a ring spanner on the other,
offering versatility for various tasks.
Box spanners are made from a tube, shaped at the end to fit over a hexagonal nut. They can reach
nuts that are difficult to reach with open-ended or ring spanners and are useful for recessed nuts.
Box spanners have a hole to take a handlebar for turning the spanner.

A socket wrench uses a closed socket format to turn the nut or bolt. There is a hole, usually square,
at one end to take a driving attachment. Sockets fit onto the nut like a ring spanner. A ratcheting socket
wrench is the most common type of socket wrench, it includes a reversible mechanism which allows
the user to pivot the tool back and forth to turn its socket instead of removing and repositioning a
wrench to do so.
Torque wrench is used to apply a specific torque to a fastener such as a nut, bolt, or lag screw. It has
an internal mechanism which will indicate (by 'clicking' or specific movement of the tool handle) when
a specified (adjustable) torque value has been reached during application. When assembling a
equipment, you will often be told to ‘torque up the bolts’ to a value given by the manufacturer. The
torque is given in units of torque, Newton-metres (Nm) or foot-pounds (ft-lb).

Adjustable spanner has a fixed jaw and a movable jaw. You can adjust the movable jaw with a screw
to fit a range of different nut sizes. This can be very useful, but you must use it carefully. If it is not
adjusted correctly, or if it is worn, it can easily slip off the nut. Only use an adjustable spanner when
you do not have the correct size of an ordinary wrench.

Allen keys, or hex keys, are hexagonal shaped tools for tightening and loosening socket-head screws.
It is most commonly L-shaped, providing two arms of different lengths for either greater reach or
more torque, and is available in various sizes to match different fasteners.
1.8 Screwdrivers
A screwdriver is a hand tool with a handle, shaft, and tip designed to turn screws by fitting into their
heads with various types designed to match different screw head designs.

Types of Screwdrivers Tips:

1.9 Pliers
Pliers are used to grip things that are too small to hold securely in your fingers. You can also apply
more gripping force with pliers as they use a lever action. This is useful for bending small items.
Types of Pliers:
Combination pliers are for general use. They are for gripping and for cutting wires.

Flat-nose pliers are for gripping smaller objects.

Circlip pliers are special purpose pliers. The jaws have ends designed to fit the small holes in a
circlip.

2. Types and Uses of Power Tools:

Power tools are mechanical devices that operate using an external power source such as electricity,
batteries, compressed air, rather than relying solely on manual human effort. They are available in
both portable (handheld) and stationary forms, enabling a wide range of tasks from drilling and cutting
to grinding and fastening.

Power tools are indispensable in modern industry due to several key benefits:

• Increased Efficiency: Power tools allow tasks to be completed much faster compared to
manual tools, significantly improving productivity in industrial settings.

• Enhanced Precision: These tools deliver consistent, accurate results, which is critical for
maintaining quality standards in manufacturing and construction.

• Reduced Physical Strain: By mechanizing labour-intensive processes, power tools minimize

worker fatigue and the risk of repetitive strain injuries.

• Versatility: Many power tools can perform multiple functions with interchangeable
attachments, making them adaptable to various industrial applications.

Portable Drills:
Portable drills are lightweight, hand-held power tools designed for drilling holes and driving screws.
They are available in both corded (plugged into mains electricity) and cordless (battery-powered)
versions, with modern models often featuring keyless chucks for quick bit changes, variable speed
controls, and torque settings for different applications. Some portable drills are also air-operated,
using filtered and lubricated compressed air supply at pressures upto 100 psig.

Angle Grinders:
An angle grinder, also known as a side grinder or disc grinder, is a handheld power tool designed for
grinding (abrasive cutting), cutting, and polishing a variety of materials. It features a rotating abrasive
disc powered by an electric motor or compressed air, with an adjustable guard and a side handle for
two-handed operation, ensuring both safety and control during use. Angle grinders are highly valued
in metal fabrication, construction, and maintenance due to their versatility and efficiency.
Impact Wrench:
An impact wrench, also known as an impact gun, is a power tool specifically designed to deliver very
high torque output with minimal user effort. It achieves this by storing energy in a rotating mass
(hammer mechanism) and then suddenly releasing it to the output shaft (anvil) in powerful, rapid
bursts. This mechanism allows the tool to loosen or tighten stubborn bolts and nuts that would be
difficult or impossible to move with conventional tools. Air impact wrenches come in various drive
sizes, each tailored to specific tasks. The most common sizes include 1/4″, 3/8″, 1/2″, 3/4″ and larger
options like 1″ and 1-1/2″

Types of Impact Wrenches

• Pneumatic (Air-powered): Most common in industrial settings, powered by compressed air.

• Electric: Includes both corded and cordless (battery-powered) models, increasingly popular
for portability.

• Hydraulic: Used in specialized heavy-duty applications

• Store tools in a dry, organized manner to prevent rust, corrosion, and damage.

3. Drilling, Tapping, and Grinding Basics

Drilling Basics
• Use a drill press or hand drill with adjustable speed settings for different materials and drill
bit sizes.
• Select the correct drill bit size and type based on the hole size and material.
 • Secure the workpiece with clamps or a vice to prevent movement during drilling.
• Apply cutting oil or lubricant to reduce friction and heat buildup, especially when drilling
metal.
• Use appropriate speed for the material being drilled to prevent overheating and damage the
drill bit.

Tapping Basics
• Use a tap and die set to create internal threads in holes for fasteners.
• Drill the correct size hole according to the tap size chart to ensure proper thread
engagement.
• Use cutting oil or lubricant to ease the tapping process and prevent thread damage.
• Turn the tap slowly and evenly, applying downward pressure while rotating.
• Back off the tap periodically to break chips and prevent binding.

Grinding Basics
• Use a bench grinder or angle grinder with appropriate safety guards and eye protection.
• Wear safety glasses and a face shield to protect against flying sparks and debris.
• Select the correct grinding wheel based on the material and grinding operation.
• Keep the workpiece moving across the grinding wheel to prevent overheating and uneven
material removal.
• Avoid applying excessive pressure, which can cause the grinding wheel to shatter or the
workpiece to overheat.