MEM05 Cluster Learner Resource - Learner Guide

MEM05 Metal and Engineering
Training Package
MEM05 Cluster Learner Resource:
M
PL
MEM18001C Use hand tools

MEM18002B Use power
tools/hand held operations
MEM05005B Carry out mechanical
cutting
3 Learner guides
SA
Version 1
Training and Education Support

Industry Skills Unit
Meadowbank
ISBN: 978 1 74236 485 8

Product Code: 5777

Training Package
MEM18001C
M
PL
Use hand tools
Learner guide
SA
Version 1

Meadowbank
Acknowledgments
The TAFE NSW Training and Education Support Industry Skills Unit, Meadowbank
would like to acknowledge the support and assistance of the following people in the
production of this learner resource guide:
Writer
Jim Miles (from existing TAFE resources)
TAFE NSW
Reviewer
Project Manager
Stephen Davies
Education Programs Manager
TAFE NSW
Enquiries
PL
E
Ed Harkness Illawarra Institute

Mark Pollard South Western Sydney Institute
Enquiries about this and other publications can be made to:
SA
Training and Education Support Industry Skills Unit, Meadowbank

Meadowbank TAFE
Level 3, Building J
See Street
MEADOWBANK NSW 2114
Tel: 02-9942 3200 Fax: 02-9942 3257
TAFE NSW (Training and Education Support, Industry Skills Unit

Meadowbank) 2012
Copyright of this material is reserved to TAFE NSW Training and Education
Support, Industry Skills Unit Meadowbank. Reproduction or transmittal in whole
or in part, other than for the purposes of private study or research, and subject to
the provisions of the Copyright Act, is prohibited without the written authority of
TAFE NSW Training and Education Support, Industry Skills Unit Meadowbank.
TAFE NSW (Training & Education Support Industry Skills Unit Meadowbank), 2012
Table of Contents
Introduction.................................................................................... 7
1. General introduction.............................................................................. 7
2. Using this learner guide ......................................................................... 7
3. Prior knowledge and experience.............................................................. 9
4. Unit of competency overview.................................................................. 9
5. Assessment........................................................................................ 11
Topic 1: Hand tools....................................................................... 15

Hammers............................................................................................... 16
Cutting tools........................................................................................... 17
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Chisels............................................................................................... 17
Files................................................................................................... 19
Hacksaws........................................................................................... 25
Snips................................................................................................. 27
Cutters and strippers............................................................................ 28
Hand Taps.......................................................................................... 29
Dies................................................................................................... 30
SA
Mechanical tools...................................................................................... 31
Spanners............................................................................................ 31
Screwdrivers....................................................................................... 37
Hexagon wrenches............................................................................... 39
Pliers................................................................................................. 40
Pipe wrenches..................................................................................... 41
Care of hand tools................................................................................... 42
Safe use of hand tools............................................................................. 42
Review Questions ......................................................................... 43

Practical jobs, projects, instruction and demonstration ................ 45
Practical assessment................................................................................ 45
Job 1: Hand tool identification.................................................................. 47
Job 2: Hacksaw use................................................................................ 48
Job 3: Using metal removal hand tools...................................................... 49

Job 4: Multi-purpose gauge..................................................................... 50
Job 5: Toolbox square............................................................................. 51
Job 6: Cutting sheet metal....................................................................... 52
Job 7: Sharpening tools.......................................................................... 53
Job 8: Drill and tool gauge....................................................................... 54
SA
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Resource Evaluation Form............................................................. 55
Topic 1: Hand tools

Introduction
Tools are common place in our lives today and it is easy to overlook that they can
cause injury in untrained hands. With the introduction of the Work Health and
Safety Laws (WHS) all tools are manufactured with the operators safety in mind.
Some hand tools are common to a number of occupations while others are generally
only used in specific fields. As a number of common hand tools are used across
a broad range of occupations and trades in manufacturing and engineering it is
important to learn their purpose and application. It is also necessary to know how to
select and safely use them for a given task. Quality hand tools are often expensive
so it is also important that users know how to properly maintain them.
Workshop safety
PL
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The Work, Health and Safety Act 2011 (WHS Act) and WHS Regulations are
enforced throughout all Australian States and Territories. This legislation is aimed
at providing consistency, certainty and clarity across Australia making it easy to
understand workplace health and safety responsibilities. Consequently this act and
its regulations requires both employers and employees to take every reasonable
step to work safely and responsibly in the workplace.
There are no short cuts to working safety, its everyones responsibility to manage
and minimise potential risks in the workplace, report faulty equipment as well as
unsafe environments. Detailed information relating to the WHS Act and regulations
can be found on:
SA
WorkCover Authority of NSW website; www.workcover.nsw.gov.au

Or on
Safe Work Australia; www.safeworkaustralia.gov.au
TAFE NSW (Training & Education Support, Industry Skills Unit Meadowbank), 2012
Page 15 of 58
Hammers
Hammers are impact tools used to impart a force either directly, or indirectly
through another tool such as a chisel or punch, to a workpiece The most common
hammers used by the mechanical tradesperson are the ball pein (engineers), cross
pein and soft faced hammers.
Ball pein hammers
The Ball Pein or engineers hammer is the most common
of the hammers used by mechanical tradespeople. It has
a slightly convex face for striking tools such as punches,
chisels, centre punches or the workpiece itself.
The opposite end of the hammer head is a hemispherical
ball pein used to dome or shape the shanks of rivets or to
stretch the surface of a metal workpiece to straighten it.
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All hard faced hammers are made from

tool steel by a drop forging process. After forging, the
hammer is carefully
heat-treated so that the face and the pein are hardened
and tempered while the metal around the eye is left soft.
SA
Because the hammer head has been heat treated it must

not be subjected to high temperatures, otherwise the
Ball pein
hardness of the face and pein will be lowered.
hammer
The engineers hand hammer is made in a range of sizes.
The smallest weighs around 100 g and the largest 1500 g.
The hammer size best suited to a fabricators work weighs
about 600 g while a 200 g hammer would suit most marking-off purposes.
The weight of the hammer must be chosen to suit the job. For example, where
a heavy blow is required in a confined space, a heavy hammer should be used
because its larger mass will be able to deliver a greater amount of energy to the
workpiece or tool without being made to move fast. But for normal conditions the
heavy hammer would be too tiring to use.
Hammer handles should be in good condition and of a size that is comfortable to
use. It should be square with the head and fit tightly into the head.
The hammer should not be used if either the head or the handle is damaged,
because it may cause injury to either the user, or the people around the user.
Page 16 of 58
Cross pein hammers
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This is a special purpose engineering hammer that comes in a variety of masses

up to 450 g (1 lb) metal. The cross pein hammer is used in confined spaces or for
straightening or stretching when the is peined at right angles to the direction of
stretch or curve.
Cross pein
hammer
Cutting tools
Chisels
SA
Cold chisels are forged from medium carbon steel. Only the point of the chisel is
hardened and tempered, the body being left soft. If the head of the chisel were
hard it would chip or shatter as a result of hammer blows.
The point of the chisel should be formed into a cutting edge similar in nature to
other cutting edges in that it requires the edge to be sharp.
Point
angle

Cold chisel

Correct cutting position

and angle
Page 17 of 58
Because chisels are subjected to continual impact loads,

they are likely to show signs of metal fatigue or
cracking after a period of use. In this condition they
can become dangerous as small pieces of metal or
splinters may fly off at high speed causing injury to the
operator or to people standing nearby.
Grind head along

dotted lines
Grind head along
dotted lines
A new chisel should be used lightly until it is proved to

be sound and only then should heavy blows be used on
it.
A major problem associated with the use
of chisels is the mushrooming of the head due to the
fact that the head is soft and constant hammering on
the head distorts the metal as shown opposite. The
head of the chisel should be kept in good repair by
keeping the chamfer ground cleanly as shown.
Correctly prepared
Correctly prepared
chisel head chisel head
Restored
head
Restored
head
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Chisel types
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When resharpening a chisel care must be taken not

to raise the temperature of the cutting edge above
the tempering temperature. Ideally when grinding
a chisel's cutting edge no tempering colours should
show on the surface other than a very light straw
colour, otherwise the intergrity of the chisel may be
compromised. Depending upon the type of chisel
used a general guide is to use a 60 point angle as
illustrated above.
Mushroomed head
Mushroomed head
Flat
Diamond Point
Cross cut
Round nose
Side Cutting
Gouge or C
Common types of chisels
Page 18 of 58
Unsafe or faulty hand tools

Damaged hand tools
Chisels, wedges and drift pins are impact tools and due to constant use these tools
form mushroom heads if not maintained. An impact tool must be kept free of
mushroom heads as they may cause injury to the user or to others as the head will
eventually shatter on impact causing metal fragments to fly off in any direction.
Worn hand tools
A tool with a damaged wooden handle such as a hammer can pose risks to the user
or those close by. Should the handle be loose, cracked or splintered the head could
fly off causing injury. Equally, a wrench with worn or sprung jaws can cause slipping
and result in injury to the user.
Description of a file
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Files
Files are made from a high carbon tool steel and pass through a process which
includes forging, dressing of the surfaces by filing or grinding, forming of the teeth
and heat treatment. Files are used to reduce or smooth the surface of metal or
other material.
Tang
Length
Edge
Face
Shoulder
Handle
SA
Point
Parts of a file
Convexity of a file
Face of file slightly convex along the length
The belly on a file

Most files are made with their faces slightly bellied or convex, along the length.
In their finished form, files are very hard and brittle and must not be used as levers,
packing or wedges, nor should they be hit, because of the danger of shattering. If
they do shatter, there is great likelihood of small pieces of the file seriously injuring
a person nearby.
Page 19 of 58

Training Package
MEM18002B
M
PL
Use power tools/hand held

operations
Learner guide
SA
Version 1

Meadowbank
MEM18002B Use power tools/hand held operations
Acknowledgments
The TAFE NSW Training and Education Support Industry Skills Unit, Meadowbank
would like to acknowledge the support and assistance of the following organisations
and people in the production of this learner guide.
Standards Australia:
AS 1788.2-1987 Abrasive wheels - Selection, care, and use
Writer:
Jim Miles (from existing TAFE resources)
Reviewer:
Project Manager:
Stephen Davies
Education Programs Manager
TAFE NSW
Enquiries
PL
E
Ed Harkness (Illawara Institute)

Meadowbank TAFE
Level 3, Building J
See Street
MEADOWBANK NSW 2114
SA
Tel: 02-9942 3200
Fax: 02-9942 3257
TAFE NSW (Training and Education Support, Industry Skills Unit

Meadowbank) 2012
Copyright of this material is reserved to TAFE NSW Training and Education
Support, Industry Skills Unit Meadowbank. Reproduction or transmittal in whole
or in part, other than for the purposes of private study or research, and subject to
the provisions of the Copyright Act, is prohibited without the written authority of
TAFE NSW Training and Education Support, Industry Skills Unit Meadowbank.
TAFE NSW (Training & Education Support Industry Skills Unit, Meadowbank) 2012
Table of Contents
Introduction.................................................................................... 7
1. General introduction.............................................................................. 7
2. Using this learner guide.......................................................................... 7
3. Prior knowledge and experience.............................................................. 9
4. Unit of competency overview.................................................................. 9
5. Assessment........................................................................................ 13
Scope of unit and performance criteria....................................................... 16
Topic 1: Portable power tools and accessories...............................19
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Portable power tools................................................................................ 19

Abrasive consumables.............................................................................. 22
Belt grinding (Linishing)........................................................................... 25
Pistol drills............................................................................................. 26
Saws..................................................................................................... 26
Nibblers................................................................................................. 27
Power hand shears ................................................................................. 27
SA
Pneumatic chipping hammers................................................................... 27

Power screwdrivers.................................................................................. 28
Pneumatic wrenches................................................................................ 28
Holding, securing and clamping work......................................................... 29
Review questions.................................................................................... 30
Topic 2: Grinding and drilling machines..........................................33

Bench and pedestal grinders..................................................................... 33
Removal, inspection and fitting new grinding wheel...................................... 35
Bench drill.............................................................................................. 38
Column drilling machines......................................................................... 39
Radial arm drilling machines..................................................................... 40
Topic 3: Care and routine maintenance of portable power tools.....43

Pneumatic tool safety.............................................................................. 44
Safety checks......................................................................................... 44
Electrical tagging.................................................................................... 45
Safety Regulations ................................................................................. 45
Standard Operating Procedures (SOPs)...................................................... 46
Safe use of power tools and machinery...................................................... 46
Housekeeping......................................................................................... 48
Suggested practical jobs................................................................51
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Job 1: Inspect, remove and replace grinding wheel(s).................................. 52

Job 2: Tool sharpening............................................................................. 54
Job 3: Lap joint assembly......................................................................... 55
Appendix A.....................................................................................59
Report form for abrasive wheel breakages.................................................. 59
SA
Resource Evaluation Form..............................................................61
Topic 1: Portable power tools and accessories

Portable power tools
Introduction
Portable hand-held power tools are extensively used by workers in engineering and
manufacturing industries. Due to their availability, design, cost and efficiency, many
tasks can be completed quickly using modern hand-held power tools.
The most common power tools found in engineering workshops and construction
sites include:
Angle grinders
Pistol drills
Hammer drills
Nibblers
Saws and jig saws.
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Power hand shears
Personal protective equipment (PPE)
Safety glasses
When using portable power tools you will need to wear a combination of the
following:
Boots or shoes, with steel cap and rubber soles
Ear protection (plugs, muffs)
SA
Hair net if required
Close fitting heavy drill cotton overalls, shirt or trousers.

Portable power tools can be operated using three types of power sources, they can be:
Electrically operated
Battery operated
Pneumatically operated.
Electric powered tools are the most commonly used; however; battery operated
power tools are gaining popularity, especially for pistol drills. An alternative is to use
pneumatically powered tools; these can be lightweight for the user but require an
air compressor to operate them.
Types of portable grinders
Three types of portable grinders used are:
Angle grinders
Die grinders
Straight grinders.
TAFE NSW (Training & Education Support, Industry Skills Unit Meadowbank) 2012
Page 19 of 64
Angle grinders
Hand held powered angle grinders are used to grind work where it is easier to take
the grinder to the job rather than the job to the grinder. These tools are commonly
used by operators to remove defects, rough edges, remove unwanted metal etc,
due to their portability and ease of operation.
Unlike the larger fixed bench and pedestal grinding machines, hand held angle
grinders have an adjustable guard to assist in streaming sparks and particles away
from the operator and the work.

Electric angle
Electric angle
grinder (100 mm) grinder (230 mm)
Die grinders
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These units have a side-handle which can be located on either the left or right
hand side of the machine to suit the operators needs. There is an extensive range
of purpose designed cutting and grinding discs to suit the work and material and
should only be used in accordance with the manufacturers specifications.
SA
When selecting a die grinder it is important to consider its intended use, the
attachments to be used and the amount of time that will be spent grinding down
materials i.e. thickness of area. Therefore, an incorrectly used die grinder will, more
than likely, wear out quickly from unnecessary overuse.
Pneumatic (air) die grinder

with burring tool
Typically this tool is used to remove metal spurs and other irregular surface
conditions where a cut has been made in metal pipe or tubing. This tool can also be
used to deburr, polish and/or buff the inside of cylindrical sections.
A cylindrical grinding/polishing attachment known as a grinding nose is selected by
the operator for the task and fitted to the die grinder in a similar fashion to that of a
drill bit.
Page 20 of 64
Rotary burrs
Rotary burring (cutting) tools are used on a wide range of pneumatic and electric
hand-held grinding tools. Some typical applications include::
Fast freehand stock removal
Weld preparation and surface removal
Dressing metal surfacess
Gaining access into tubes, pipes and other hollow
sections
Contouring metal profiles.
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Selection of rotary
burring tools
To achieve optimum performance of the tool it may be necessary to adjust the

speed of rotation. For instance if the speed of rotation is below the cutting tools
optimum speed it may cause chipping. Harder metals and extra long burrs will
require slower speeds. Running the tool at excessive speed will cause tooth wear
and caution should be used to avoid tools from becoming too hot.
SA
Should the braze weld holding the head of the shank become too heated it could
loosen, causing the head to detach. An operator should apply a constant light force
and movement during use of the tool and replace worn collets as they can cause
chipping of the workpiece.
Burring tools can be used to grind and finish many different types of metals, such as:
Aluminium
Brass/bronze
Copper
Titanium alloys
Cast Iron
Carbon and alloy steels
Bronze
Nickel and nickel alloys
Stainless steel
Zinc alloys.
Page 21 of 64
Straight grinder
Straight or barrel grinders are ideal for grinding steel pipe and tube and also buffing
and polishing applications. Buffing and polishing of stainless steel and aluminium is
done using a combination of rag and sisal mops.
Electric straight
grinder
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Abrasive consumables
A range of abrasive consumables, such as grinding discs, cut-off wheels, sand
papers and sanding discs, are commonly available as well as the products listed
below:
Resinoid-bonded cut-off wheels
Industrial wire brushes
Flap discs and Flap wheels
Rotary burrs
Abrasive belts
SA
Polishing tools
Vitrified grinding products
Sticky back discs.
Selection of abrasives
Angle grinders fitted with abrasive cut-off wheels can be used to cut bar, tube and
plate. Thin cut-off wheels are designed to suit either a depressed or flush centre
mounting and are generally made from carborundum, which is a compound of
silicon and carbon. Typical applications for these cut-off wheels include cutting:
Thin-walled tube
Sheet metal items made of steel and stainless steel
Nonferrous metals
Composite materials.
Page 22 of 64
Resinoid-bonded cut-off wheels

These wheels are designed for use with hand held grinding machines and are
generally suitable for use with a variety of metals and cutting applications, such
as steel pipe, bar and plate. They should not be used on non-ferrous metals such
as aluminium and brass as soft materials will clog the disc and may cause it to
overheat and shatter.
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The wheels are fibreglass reinforced for strength and are required to run at cutting
speeds of up to 80 m/s (metres per second). Manufacturers recommend a wheel
thickness in the range of 2 - 3.2 mm for cutting and depressed centre wheels with a
thickness of 4 - 10 mm for grinding.
Abrasive cut-off wheels
SA
Reinforced cutting and grinding discs are generally made of corundum (aluminium
oxide), have a medium to hard bond and are less brittle than vitrified wheels.
They are also typically flat and are coloured black but are available in a raised hub
variety. These discs can also include the following materials:
Aluminium oxide
White aluminium oxide
Single crystal aluminium
Zirconia aluminium
Green silicon carbide
Black silicon carbide.
Industrial wire wheel brushes

Specially designed wire brushes can be fitted to angle grinders. These brushes are
used to clean metal surfaces prior to priming or painting.

Wire wheel brushes
Wire cut wheel for
for angle grinders
angle grinders
Page 23 of 64

Training Package
M
PL
MEM05005B
Carry out mechanical
cutting
Learner guide
SA
Version 1

Meadowbank
MEM05005B Carry out mechanical cutting
Acknowledgments
The TAFE NSW Training and Education Support Industry Skills Unit, Meadowbank would like
to acknowledge the support and assistance of the following people in the production of this
learner resource guide:
Standards Australia
Writer
Jim Miles (from existing TAFE Resources)
Reviewer
Ed Harkness (Illawarra Institute)
Project Manager:
Enquiries
M
PL
Stephen Davies
Educational Program Manager
TAFE NSW
SA

Meadowbank TAFE
Level 3, Building J
See Street
MEADOWBANK NSW 2114
Tel: 02-9942 3200
Fax: 02-9942 3257
The State of New South Wales, Department of Education and Training,

TAFE NSW, Training and Education Support Industry Skills Unit,
Meadowbank, 2009.
Copyright of this material is reserved to TAFE NSW Training and Education Support
Industry Skills Unit, Meadowbank. Reproduction or transmittal in whole or in part,
other than for the purposes of private study or research, and subject to the
provisions of the Copyright Act, is prohibited without the written authority of, TAFE
NSW. Training and Education Support Industry Skills Unit, Meadowbank.
Table of contents
Introduction ......................................................................................... 7
1.
General introduction ...............................................................................7
2.
Using this learner guide ..........................................................................7
3.
Prior knowledge and experience ...............................................................9
4.
Unit of competency overview ...................................................................9
Topic 1: Mechanical cutting and associated safety ............................. 17
Safe working procedures (SWP) ..................................................................... 20
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Review questions .......................................................................................... 21
Topic 2: Shearing equipment.............................................................. 22

Guillotines ................................................................................................... 22
Universal metal worker (Punch and shears) ..................................................... 23
Universal sheetmetal nibbling machine (Nibbler) .............................................. 25
Bench shears ............................................................................................... 26
SA
Topic 3: Metal sawing equipment ....................................................... 29

Cold Cut-Off Saw .......................................................................................... 29
Abrasive cut-off saws .................................................................................... 30
Horizontal bandsaws ..................................................................................... 32
Vertical band saw ......................................................................................... 34
Topic 4: Cutting tools and materials ................................................... 37

Metals cut by mechanical cutting equipment .................................................... 37
Suggested practical jobs/projects ..................................................... 43

Job 1: Face plate .......................................................................................... 44
Job 2: Angle connection ................................................................................ 45
Job 3: Angle bracket ..................................................................................... 47
Project 1: Fabricated paper tray ..................................................................... 49
Project 2: Fabricated toolbox ......................................................................... 51
Project 3: Sash Clamp ................................................................................... 53
SA
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Resource Evaluation Form .................................................................. 55
Topic 1: Mechanical cutting and associated safety

The Work, Health and Safety Act 2011 (WHS Act) and WHS Regulations are enforced
throughout all Australian States and Territories. This legislation is aimed at providing
consistency, certainty and clarity across Australia making it easy to understand
workplace health and safety responsibilities. Consequently this act and its regulations
requires both employers and employees to take every reasonable step to work safely
and responsibly in the workplace.
There are no short cuts to working safety, its everyones responsibility to manage and
minimise potential risks in the workplace, report faulty equipment as well as unsafe
environments. Detailed information relating to the WHS Act and regulations can be found
on:
WorkCover Authority of NSW website; www.workcover.nsw.gov.au

Or on
M
PL
Safe Work Australia; www.safeworkaustralia.gov.au
Welding operators must know about the principles governing the welding operation,
equipment used and workplace health and safety precautions required. The following
points need to be taken into account when working in a welding environment.
Mechanical cutting of plates, sheets and rolled sections is an integral part of metal
fabrication. Together with forming, welding, and thermal cutting, mechanical cutting
plant and equipment play a vital role in fabrication industries.
SA
A wide variety of mechanical cutting equipment is used by fabricators in both the light
and heavy industries. Mechanical cutting can be achieved through either a shearing
action such as a guillotine, or by a sawing action such as a cut-off saw.
Typical cutting machinery used by fabricators include:
Guillotines
Universal metal workers (punch and shears)

Universal sheet metal nibbling machines
Hand shears (bench lever type)
Cold cut-off saws
Abrasive cut-off saws
Power hacksaws
Bandsaws.
Tradespeople and workers in fabrication industries must know how to set up and safely
operate mechanical cutting equipment used in their workplaces. To keep machinery in
reliable and good working condition, it is important that operators understand the
equipments operating capacity and work within the machines limits.
Page 17 of 58
Advantages of mechanical cutting

Although mechanical cutting equipment is expensive to purchase, a metal fabrication
company would expect equipment to last for many years. Fabricators from such
companies make up material or cutting lists of parts to be mechanically cut from job
plans and instructions. By setting backstops or back gauges on mechanical cutting
equipment such as a guillotine, parts can be cut quickly, accurately and to size.
Machine backstops also allow repetitive work and large quantities of parts to be cut
efficiently, to consistent accuracy, saving time and improving productivity.
Unlike thermal cutting processes such as fuel gas and plasma cutting, mechanical cutting
equipment does not use heat to cut parts, which means there is little or no distortion .
Mechanical cutting safety and safe operating procedures
Safe Operating Procedures
Mechanical cutting equipment is extremely dangerous and it is important that operators

are provided with training and instruction in the safe and proper use of the equipment.
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A Safe Operating Procedure (SOP) is a set of written instructions that identifies health
and safety issues that may arise from the jobs and tasks associated with the equipment
being operated.
SOPs are placed on a machine in a location accessible to the operator and others
working in the area. Information found on a SOP sheet would include:
Tasks to be undertaken that may pose risks
Equipment and substances used in these tasks
Control measures that have been built into these tasks
Training or qualifications needed to undertake the task
Personal protective equipment to be worn
Action to be undertaken to address safety issues that may arise while undertaking
the task.
SA
Machinery safety (Engineering controls)

Mechanical cutting equipment and machinery are fitted with safety devices designed to
allow the operator to use the machine in a safe manner. Safety devices on a machine
may include:
Emergency stop buttons to cut power to the machine in the event of an emergency
Guards and shields to cover blades and cutting tools
Guards which cover a machines moving parts
Electronic sensors to cut power to a machine if activated by a person entering a
restricted area
Cages to restrict entry to an area whilst a machine is operating.
When hazards associated with mechanical cutting equipment cannot be eliminated or

sufficiently reduced by engineering controls or safe working procedures alone, operators
must wear Personal Protective Equipment (PPE) to improve protection.
Page 18 of 58
PPE includes safety glasses or goggles, earplugs or earmuffs, protective gloves,

respirators and dust masks, overalls or other close-fitting clothing as well as safety
shoes or boots with steel toe-caps to protect feet should heavy items accidentally be
dropped.
An important safety consideration to people working in fabrication industries is
that young workers have a much higher risk of being injured at work than older
workers. Therefore safety, supervision and instruction are vital to the training
of younger workers.
Safety regulations
Safe guarding of mechanical cutting equipment used in fabrication industries is regulated

by statutory authorities such as WorkCover NSW and Australian Safety and
Compensation Council (Formerly known as the National Health and Safety Commission).
These State and federal government safety authorities will investigate serious workplace
accidents and can issue heavy fines if neglect toward workplace safety is proven to be
the cause of an accident.
SA
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In addition to the types of mechanical cutting equipment used in fabrication and related
industries, applications of each machine and specific safety requirements for operating
them are listed in this resource.
Page 19 of 58
Safe working procedures (SWP)

You must follow these rules when you enter a fabrication workshop:
Act safely and responsibly at all times
Follow all workplace procedures
You are responsible for tools while in your care
Use storage facilities as directed
Observe all safety requirements such as:

wearing protective clothing
wearing safety footwear
wearing eye protection as required
using hearing protection as required
wearing hair protection if required
using any other safety items as required for specific areas
ensure all guards are correctly positioned and working
consider the safety of others when using tools and equipment
NOT use any equipment unless you have been trained in its safe and
correct use.
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IF IN DOUBT, ASK your teacher before attempting to operate any machine or

carry out a task
Work must be held securely before performing any operation
Identify all relevant WARNING signs e.g., turn power off at main switch before
making any adjustment such as changing speeds on a belt-driven pedestal drill
Do not use any equipment or machines with signs indicating DANGER or DO

NOT USE
Note the locations of first aid and nurse stations
Know emergency exits and evacuation procedures
Know the locations of fire extinguishers
Know the position and use of emergency stop buttons
Clean machines and work areas that have been used. This task includes sweeping
the floor
Remain in the area until all tools and equipment has been accounted for
Do not leave the area without permission from your teacher.
SA
Page 20 of 58
Review questions
These questions have been included to help you revised what you have learnt in Topic 1:
Mechanical cutting and associated safety.
3.
4.
________________________________________________________________
________________________________________________________________
________________________________________________________________
________________________________________________________________
________________________________________________________________
________________________________________________________________
________________________________________________________________
List five (5) types of mechanical cutting machines typically used in fabrication
workshops.
________________________________________________________________
________________________________________________________________
________________________________________________________________
________________________________________________________________
________________________________________________________________
Give an advantage associated with mechanical cutting.
5.
State three (3) items of personal protective equipment (PPE) that must be worn
when using mechanical cutting machines.
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2.
List four (4) safety control devices (engineering controls) that could be fitted to
mechanical cutting equipment that provide safety for the operator and those working
nearby.
SA
1.
________________________________________________________________
Explain the purpose of an SOP and list three (3) items of information you would find
on them.
Purpose: __________________________________________________________
________________________________________________________________
________________________________________________________________
________________________________________________________________
Page 21 of 58

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MEM05 Metal and Engineering

MEM05 Cluster Learner Resource:

MEM18001C Use hand tools

Training and Education Support

ISBN: 978 1 74236 485 8

MEM05 Metal and Engineering

Use hand tools

Training and Education Support

MEM18001C Use hand tools

Ed Harkness Illawarra Institute

Enquiries about this and other publications can be made to:

Training and Education Support Industry Skills Unit, Meadowbank

TAFE NSW (Training and Education Support, Industry Skills Unit

MEM18001C Use hand tools

Topic 1: Hand tools....................................................................... 15

Review Questions ......................................................................... 43

MEM18001C Use hand tools

Job 3: Using metal removal hand tools...................................................... 49

Resource Evaluation Form............................................................. 55

MEM18001C Use hand tools

Topic 1: Hand tools

WorkCover Authority of NSW website; www.workcover.nsw.gov.au

Safe Work Australia; www.safeworkaustralia.gov.au

MEM18001C Use hand tools

All hard faced hammers are made from

Because the hammer head has been heat treated it must

MEM18001C Use hand tools

Cross pein hammers

This is a special purpose engineering hammer that comes in a variety of masses

Correct cutting position

MEM18001C Use hand tools

Because chisels are subjected to continual impact loads,

Grind head along

A new chisel should be used lightly until it is proved to

When resharpening a chisel care must be taken not

Common types of chisels

MEM18001C Use hand tools

Unsafe or faulty hand tools

Face of file slightly convex along the length

The belly on a file

MEM05 Metal and Engineering

Use power tools/hand held

Training and Education Support

MEM18002B Use power tools/hand held operations

AS 1788.2-1987 Abrasive wheels - Selection, care, and use

Jim Miles (from existing TAFE resources)

Ed Harkness (Illawara Institute)

Enquiries about this and other publications can be made to:

Training and Education Support Industry Skills Unit, Meadowbank

Tel: 02-9942 3200

Fax: 02-9942 3257

TAFE NSW (Training and Education Support, Industry Skills Unit

MEM18002B Use power tools/hand held operations

Topic 1: Portable power tools and accessories...............................19

Portable power tools................................................................................ 19

Pneumatic chipping hammers................................................................... 27

Topic 2: Grinding and drilling machines..........................................33

MEM18002B Use power tools/hand held operations

Topic 3: Care and routine maintenance of portable power tools.....43

Suggested practical jobs................................................................51

Job 1: Inspect, remove and replace grinding wheel(s).................................. 52

Resource Evaluation Form..............................................................61

MEM18002B Use power tools/hand held operations

Topic 1: Portable power tools and accessories