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Category A/B1
MODULE 7
Sub Module 7.2
WORKSHOP PRACTICES
Contents
MAINTAINING TOOLS --------------------------------------------------- 1
TOOL CATEGORIES ----------------------------------------------------- 1
CARE OF TOOLS --------------------------------------------------------- 2
CONTROL OF TOOLS --------------------------------------------------- 5
USE OF WORKSHOP MATERIALS ---------------------------------- 8
DIMENSIONS -------------------------------------------------------------11
TOLERANCES AND ALLOWANCES --------------------------------15
STANDARDS OF WORKMANSHIP ---------------------------------18
CALIBRATION OF TOOLS AND EQUIPMENT -------------------19
CALIBRATION STANDARDS -----------------------------------------28
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MAINTAINING TOOLS
All the tools used for aircraft maintenance have to be of the
highest quality to ensure expert maintenance of aircraft to the
level prescribed by the manufacturer. At the most fundamental
level, woodshop tool maintenance simply means keeping your
tools operating as well as they did when you took them out of
the box. That's a minimum requirement for running a safe,
successful shop. But a good tool maintenance regimen can take
you even further. Taking a few extra steps in caring for work
surfaces, cutting edges, alignment mechanisms and moving
parts can work wonders for the performance of your tools. Add
in a few affordable power tool upgrades and you can improve
the performance of your woodworking machinery beyond likenew condition. Below, we'll show you how easy it can be to go
beyond the basics in keeping the tools in your shop sharp, true,
clean, and running smooth
TOOL CATEGORIES
A maintenance organization usually has two basic categories of
tools in use.
Personal Tools Tools that are issued to the maintenance
personnel permanently on individual basis depending on the
function they perform in the organization. These tools will form a
personal toolkit comprised of tools that are of general nature
and required by a considerable number of persons frequently.
These tools are selected for their familiarity and personal
quality, their low cost and convenience.
ISO 9001:2008 Certified
PTC/CM/B1.1 Basic/M7/01
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CARE OF TOOLS
Personal tools
Most of the tools are manufactured from alloy steels and are
susceptible to corrosion. To reduce this susceptibility to
corrosion most tools are manufactured with a corrosion resistant
exterior finish and mechanisms that are sealed against
moisture. Therefore the corrosion resistance is dependent on
the integrity of such protections provided.
Despite efforts to reduce corrosion and associated degradation,
corrosion and wear still takes its toll unless cleaning and reprotection such as lubrication is carried out on regular basis.
Workshop fixtures and equipment supplied and installed by the
appropriate department are maintained and repaired by that
organization, and must not be interfered with by personnel,
except for general cleaning, re-painting externally, etc.
Other equipment and machinery must be systematically
cleaned, lubricated and adjusted by competent workshop
personnel; the following points have a general application.
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Drilling machine
The drilling machine should be cleaned and lubricated regularly;
during this process the clamping screws of the drilling table
should be slackened several turns to enable the threads and
thrust faces to be lubricated.
A piece of planed hardwood should be kept on the drilling table
to protect the machined face when drilling sheet metals, etc.
Grinder
The grinding machine must be kept clean and as free from
abrasive dust as possible. The bearings should be lubricated
regularly, but care must be taken to prevent oil or grease
coming in contact with the grinding wheels. The tool rests
should be kept in adjustment at a position as near as possible to
the grinding wheels. These wheels should be turned up, as
required, by a wheel dresser; the resulting abrasive dust should
be carefully removed after the operation has been completed,
and the tool rests must then be reset.
Vices
Motor drives
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CONTROL OF TOOLS
3
by
most
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7.2 - 7
require control of issue and use, though they may not, normally,
require stringent safety precautions.
A huge range of liquids can be used in the workshop situation,
some of which are harmless and some of which are extremely
toxic. It is vital that the work-force make themselves aware of
the risks involved when dealing with ANY materials, and
especially when working within enclosed areas.
USE OF WORKSHOP MATERIALS
Obviously all liquids must only be used for the purpose for
which
they
For Training Purpose Only
PTC/CM/B1.1 Basic/M7/01
7.2 - 8
Rev. 00
Mar 2014
DIMENSIONS
Information is communicated from one person to another
primarily through spoken and written word. Such communication
requires the use of previously defined, basic characters, the
complete set of which is commonly known as an alphabet.
Likewise, the scientific community has, in effect, established an
alphabet of its own. The elements, or most basic parts of this
communication system, are known as dimensions.
Common dimensions
The following are a few common dimensions and their
definitions:
The length of an object is the distance between its ends, its
linear extent as measured from end to end.It is usually
represented by the capital letter L.
Mass (M) is the amount of matter in an object. Every object has
a mass that does not change as the object is moved from one
place to another.
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Derived dimensions
Fundamental dimensions
The most elementary dimensions, like length (L), mass (M), and
time (T), are known as fundamental dimensions.
Fundamental units
Quantity
Standard
Unit
Symbol
Length
meter
Mass
kilogram
kg
Time
second
Electric Current
ampere
Temperature
Kelvin
Luminous
Intensity
Candela
Cd
Matter
mole
mol
Plane Angle
Radian
rad
Steradian
sr
9
Solid Angle
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Velocity (LT-1), acceleration (LT-2), and pressure (ML1T-2), on the other hand, are examples of derived
dimensions obtained by combining different fundamental
dimensions (i.e., M, L, and T).
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Symbol
Quantity
hertz
Hz
frequency
Newton
force, weight
Pascal
joule
watt
Pa
J
W
pressure, stress
energy, work, heat
power, radiant flux
coulomb
volt
voltage,
electrical
potential
difference, electromotive force
farad
ohm
s-1
mkg/s2
N/m2
Nm = CV = Ws
J/s = VA
sA
mkgs2
m1kgs2
m2kgs2
m2kgs3
sA
W/A = J/C
m2kgs3A1
electric capacitance
C/V
m2kg1s4A2
V/A
m2kgs3A2
Siemens
electrical conductance
1/
m2kg1s3
A2
Weber
Wb
magnetic flux
J/A
m2kgs2
A1
tesla
Henry Certified
H
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inductance
Vs/m2 =
Wb/m2 =
N/(Am)
Vs/A = Wb/A
kgs2
A1
m2kgs2
For
Training Purpose Only
A2
Rev. 00
Mar 2014
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Bilateral Tolerance
ISO 9001:2008 Certified
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7.2 - 17
Unilateral Tolerance
For Training Purpose Only
Rev. 00
Mar 2014
STANDARDS OF WORKMANSHIP
Whilst the standards of workmanship, during the hand-working
of metals and other materials, is controlled by the craftsperson,
once machinery is used in the manufacturing process, then the
standards of finish and workmanship depend upon the
allowances set by the designer and on the type of machinery
being used.
With hand tools, there are standards of finish, but these depend
upon the skill of the craftsperson and, again, on the tools being
used. For example, when filing metal, different grades of files
are used, to obtain a comparatively smooth surface finish while
other methods, such as abrasive papers, pastes and polishes,
are then used, to provide the final finish.
When sawing, the same procedures apply in that blades with
finer teeth will give a better finish to the sawn edges, which may
then be further smoothed, using an appropriate selection of
files.
When drilling a hole, the conventional twist drill will only produce
a finish of a certain standard. If a finer finish, to the inside of the
hole, is required, then a reamer would be used, to smooth the
material inside the hole, so that, if a tight fitting pin is to be fitted
through the hole, there will be better surface contact.
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Instrument classification
application thus involves balancing the measurementresolution requirements carefully against cost.
Fig. 2.3
Fig. 2.4
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Static calibration
All inputs (desired, interfering and modifying) except one are
kept at some constant values. Then the input under study is
varied over some range of constant values. The input-output
relationship is valid under the stated constant conditions of all
the other inputs.
Measurement method: ideal situation all other inputs are
held constant
Measurement process: physical realization of the
measurement method
CALIBRATION STANDARDS
History
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As specified in BS 5750,
The supplier shall provide, control, calibrate and maintain
inspection, measuring and test
equipment
suitable
to
demonstrate the performance of the product to the specified
requirements. Equipment shall be used in a manner, which
ensures that measurement uncertainty is known.
STANDARD PROCEDURE
BS 5750 lays down procedures to be followed when selecting,
using, calibrating, controlling and maintaining measurement
standards and measuring equipment. A summary of the
requirements is given below:
1
Requirement
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the environmental
calibration;
conditions
required
for
of
For Training Purpose Only
Rev. 00
Mar 2014