GCSE
Resistant Materials
Topic 2 : Tools, Equipment and Safety
Produced by David Bunce
Student Workbook 2
Name ________________________________________
Tools, Equipment and Safety
It is very important that you are able to identify the different hand tools, power tools, fixed
equipment and specialised machinery available for use around the workshop. You should be
able to :
•
•
•
Name the tool, equipment or machinery
Identify what the tool, equipment or machinery is used for.
Use the tool, equipment or machinery correctly and safely.
As there are over 100 different items in our workshop and you will not be able cover all of the
above in one or two lessons. However, during the course of this first year (10) you need to
familiarise yourself with all of the tools and equipment available in order to gain the
confidence to use these (on your own) at a later date, correctly and safely.
Most tools and equipment you see can be placed in one of the following FOUR categories.
1.
2.
3.
4.
Hand Held Tools
Hand Held Power Tools
Fixed Equipment (general purpose)
Specialised Machinery
1. Hand Held Tools
• General Tools (Screwdrivers Spanners, Hammers, Mallets) etc
• Measuring Tools (Ruler, Measuring Tape, Micrometer, Vernier Caliper) etc
• Marking Out Tools (Marking Gauge, Scriber, Centre Punch, Tri-Square, Dividers) etc
• Cutting Tools (Saws, Chisels, Files, Planes, Drills, Tin Snips, Taps and Dies) etc
• Holding Tools (Vices, Mole Grips, Pliers, G-Clamps)
2. Hand Held (portable) Power Tools
Electric Drill, Electric Sander, Electric Grinder, Electric Circular Saw. Electric Jig Saw,
Soldering Iron etc
3. Fixed Equipment (general purpose)
Guillotine, Vices, Electric Pillar Drill, Electric Sander, Electric Circular Saw, Electric Jig Saw,
Electric Band Saw, Electric Polisher etc
4. Specialised Machinery
CNC Router, CNC Mill, CNC Lathe, Mig Welding Equipment, Gas Welding Equipment,
Vacuum Forming Machine, Laser Cutting Machine, Hot Wire Cutter, Plastic Bending
Machine, Wood Turning Lathe etc
A great website
http://www.thesitebox.com/hand-tools/woodworking-tools.aspx
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Name of tool,
equipment or
machine
General Tools
Ball pein
hammer
Images
Used for
A ball pein hammer has a
rounded pein on rear face. It’s
a heavy duty hammer usually
used with metal
Cross pein
hammer
A cross pein hammer has a
wedge shaped pein on the
rear face. Used to hammer
small pins and nails.
Claw hammer
A claw hammer is a heavy
duty hammer used for
hammering larger nails into
timber. The claw (at the rear)
is used to remove nails
Wooden mallet
Wooden mallets are normally
made from beech and used
with wood chisels or
assembling wood joints.
Rubber mallet
Rubber and nylon hammers
are the modern version of a
wooden mallet. Used for
assembling wood joints and
bending/shaping some softer
metals
A combination spanner
comes in a large range of
sizes and has an open ended
spanner at one end and a ring
spanner at the other. Use with
nuts and bolts
Side cutting pliers have a
sharp cutting edge and are
used to cut and strip electrical
wire.
Combination
spanner
Side cutting
pliers
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Measuring and Marking Out Tools
Ruler
A steel rule is used for
measuring and marking out
and is accurate to 1mm
Vernier gauge
A modern digital vernier
gauge is accurate to
0.01mm and is a very useful
measuring instrument, that
is easy to use. Used for
measuring both inside and
outside dimensions
Micrometer
A micrometer is a precision
measuring instrument that is
accurate to 0.01mm
Mortise gauge
(marking gauge)
A mortise gauge is used for
marking parallel lines (in
wood), which is ideal when
making joints in several
pieces of timber
Tri-square
A tri square is used to
ensure that objects have
been cut, filed or glued
accurately to an angle of 90º
4
Centre punch
(dot punch)
A centre or dot punch is
used to mark where holes
need to be drilled in metal
objects
Scriber
A scriber is used when
marking out metal objects
before cutting and drilling. It
has a sharp tip which is
used to lightly scribe
(scratch) the metal surface
Sliding bevel
A sliding bevel is used to
indicate where wood needs
to be cut. It is adjustable
and can be set at all angles
Dividers
Dividers are used for making
simple comparisons, but not
used as an accurate
measuring tool
(non-indicating)
Odd leg callipers
Odd leg callipers are used
to mark out lines and can be
used in a variety of ways.
Most commonly it is used to
scribe (scratch) parallel lines
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Mitre box
A mitre block is used to
accurately cut wood at exact
angles (eg 45°) for right
angle joints. A mitre block is
usually made from wood or
very hard plastic
Sawing Jig
A sawing jig also enables
timber to be cut at specific
angles very accurately, but
is larger than a mitre block
which enables larger pieces
of wood to be cut.
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Cutting Tools (Wasting)
Tenon saw
Coping saw
Hacksaw
Ripsaw
Cross cut saw
A tenon saw is a small saw
with a brass back which
keeps the blade very
straight. Ideal for cutting
small pieces of wood in a
straight line. Most saws cut
when they are pushed away
from the user.
A coping saw cuts when
pulled and has a small
detachable blade which is
easily removed. This saw is
ideal for cutting round
curves.
A hacksaw also has a
detachable blade which is
easily changed and is used
for cutting small metal items.
The number of teeth per
inch (tpi) depends on the
material you are cutting. As
a simple rule softer metals
like brss and aluminium
would have slightly larger
teeth than the blades used
for steel
A rip saw has large teeth
like chisels that cut along
the grain and is used for
cutting large pieces of wood.
The blade does flex slightly.
A cross cut saw usually has
smaller teeth than a rip saw
(cut at 60°) and is used
when cutting across the
grain of wood. The blade
does flex slightly.
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Block plane
A block plane is used for
planning the end grain of a
piece of wood
Smoothing plane
A smoothing plane is used
to get a smooth finish on
timber before abrasive
paper is used for the final
smooth finish
Spoke shave
A spoke shave is used to
smooth curved edges
Bevel edged
chisel (for wood)
A bevel edges chisel can be
used to cut and trim would
where the
Mortise chisel
(for wood)
Mortise chisels are strong
withstraight sides and are
used for chopping deep
holes in timber (eg slots for
mortise joints)
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Gouge chisel
(for wood)
A gouge chisel has a curved
blade for carving
Centre bit (drill)
A centre bit drill is used to
accurately mark the point
where drilling needs to be
done on a pillar drill or lathe
Twist drill
Twist drills come in a variety
of sizes and are usually
used for drilling holes in
metal, wood or plastic.
Some twist drills are referred
to as masonry drills and are
used for drilling holes in
brick or concrete wall. These
drills have a special
hardened tip
Countersink drill
A countersink drill is used to
after a hole has been made
with a normal twist drill to
provide a tapered hole so a
countersunk screw head
can sit below the surface of
the material
Chuck Key
A chuck key is required to
secure a drill bit in place in
the chuck of a pillar drill or
portable drill
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Hole Cutter
Hole cutters come in a
variety of sizes and are
used for cutting large
diameter holes
Taps and Dies
Taps and dies come in large
sets and are used for cutting
threads. Taps are used for
cutting internal threads and
dies are used for cutting
external threads
Engineering
Files
Engineers files come in all
shapes and sizes with
different size cutting teeth.
They are used for shaping
and smoothing metal
Rasps
Rasps look similar to files
but have very coarse teeth
and are usually used on
wood.
Tin Snips
Tin snips are like very strong
scissors that are used for
cutting thin tin or steel sheet
metal
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Vices and Cramps (Holding Tools)
Woodworking
vice
Engineers vice
A woodworking vice is used
to hold wood or plastic while
it is being drilled, cut, planed
or shaped
An engineers vice is used to
hold metal objects while it is
being drilled, cut or shaped.
Soft aluminium inserts can
be used (in the vice jaws) to
prevent damage to the
surface of the metal
Machine vice
A machine vice is used for
holding items securely whilst
they are being drilled.
G cramp
A G cramp is normally used
for holding items to a bench
whilst gluing, drilling or
cutting. Can also be used to
hold items together, while
inserting screws etc
Sash cramp
A sash cramp is a large
adjustable clamp usually
used for holding items
together after they have
been glued
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Mole grips
(vice grips)
Mole grips are used for
holding items securely whilst
they are being drilled or cut.
A variety of jaw shapes
enables a wide range of
shapes to be held (eg
tubing)
Engineers pliers
Engineers pliers are used
for holding all types of small
objects. The are very useful
for working objects loose (eg
bolts, pins etc) that may
have become seized.
Fixed and Hand Held Equipment (General Purpose)
A band saw is a circular
Band saw
blade that passes
vertically through a flat
bed. Its ideal for cutting
small flat pieces of wood.
This machine can be very
dangerous
Hand held
jig saw
A hand held jigsaw is
used to cut flat wood in
straight or curved lines.
This machine can be very
dangerous
Scroll saw
A scroll saw has a
detachable blade which
enables it to be passed
through a small hole. It
can then cut out small
curved shapes quickly
and accurately. This
machine can be very
dangerous.
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Belt sander
Belt sanders can be flat
(as shown) or vertically
mounted. They are used
to sand the edges of
wood to to a smooth
finish
Hand held
sanders
Hand held sanders are
used for finishing timber
to a smooth finish prior to
applying wood stain or
varnish.
Orbital sander
Belt Sander
Bench
mounted
shears
Bench mounted shears
are used for cutting sheet
metal.
These shears can be
very dangerous and are
often locked.
Pillar drill
A pillar drill is a large
heavy duty machine used
for drilling holes. The
chuck can enable drill bits
to be used that are up to
20mm diameter.
Circular saw
machine
A circular saw machine is
a heavy duty how
powered machine that is
used for cutting up large
sheets of timber or man
made board in straight
lines. This machine can
be very dangerous
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Hand held
circular saw
Power
hacksaw
A hand held saw is also
used for cutting timber in
straight lines, but has the
advantage of portable
which is very useful for
site work. This machine
can be very dangerous
and must be used under
supervision
A power hacksaw is a
heavy duty machine
design to cut up metal
tubing and box section
steel.
This machine can be very
dangerous and must be
used under supervision
Hand held
angle grinder
An angle grinder is used
to cut through metal or to
smooth welded metal
joints. It can be very
dangerous and needs to
be used with extreme
care.
Hand held drill
A very popular piece of
equipment used for
drilling holes. The chuck
size usually opens to
10mm diameter. 2 speed
settings and a hammer
action enable holes to be
drilled in masonry with
the appropriate drill bit.
This is very similar to a
normal hand held drill,
but is low voltage and far
more portable. The main
disadvantages are that it
has to be recharged and
has far less power than a
conventional mains
powered drill.
Hand held
portable drill
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Specialised Equipment
CNC router
CNC lathe
CNC mill
A CNC router is a 3 axis
machine (sideways, front to
back and up/down) used for
cutting out shapes or
making holes in wood and
soft metal very accurately.
It requires a computer and
software.
The advantage of using
CNC is that it enables
identical pieces to be
manufactured quickly and
accurately.
A CNC mill is very similar to
a router and is also a 3 axis
machine (sideways, front to
back and up/down) The
main difference is that a mill
enables far more complex
shaped to be machined to a
very high degree of
accuracy. It requires a
computer and software
The advantage of using
CNC is that it enables
identical pieces to be
manufactured quickly and
accurately.
A CNC lathe is also a 3 axis
machine (sideways, front to
back and up/down) that
enables metal or hard
plastic (like nylon) to be
machined into intricate
shapes very accurately. It
requires a computer and
software. The advantage of
using CNC is that it enables
identical pieces to be
manufactured quickly
accurately
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Laser cutter
A laser cutter is a 2 axis
machine that only enables
cutting in 2 axis (sideways
and front to back). It is used
to accurately cut plastic and
thin wood up to 10mm thick
Vacuum former
A vacuum forming machine
is used to manufacture a
variety of shapes in plastic.
A hard mould is usually
produced from a high
density fibre board. The
plastic is heated until soft
and then the mould is forced
into the plastic. A vacuum
pump ensures that the
plastic is formed tightly
around the mould to
produce a plastic product
(shell).
A hot wire cutter is used to
cut through plastic or foam.
It can be used to cut foam
quite accurately in lots of
different shapes. It is used
mainly for modelling
products before
manufacture.
Hot wire cutter
(for plastic)
Wood turning
lathe
A wood turning lathe is used
to shape circular or square
wood into more ornate
round objects like candle
holders and table legs.
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Safety
Many of the hand held tools around the workshop have sharp edges (eg saws, chisels, drills,
planes etc). If you use these tools incorrectly or handle them carelessly, they can easily
cause damage and spoil your work and/or injure yourself or other people.
Hand held power tools can be even more dangerous and it is very important that you
understand how to use the tools correctly and safely. Using all tools correctly comes with
practice in order develop skills and gain confidence. Your teacher will demonstrate the
correct operating procedure and highlight all of the safety features that need to be observed.
However, there are some very important common safety rules that need to be observed at all
times
General Safety Rules
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•
•
•
•
•
•
•
•
•
Always carry sharp tools with the sharp edge facing downwards
Never run in the workshop
Always wear aprons to protect your clothes
Roll up your sleeves
Remove your tie (if applicable)
Tie back you hair (if applicable)
Wear goggle when necessary (eg operating power tools
Where a dust mask when necessary (eg operating sanding tools)
Wear firm flat shoes
Know where the stop buttons are for every machine.
Keep your work area clean and tidy
Specific Safety Rules
Specific safety rules and correct operating procedures apply to almost every single tool and
all equipment that you will use in the workshop. Some are very simple (and in most cases
very obvious), others are more detailed and specific to that particular piece of equipment.
For example, the safety rules for using a screwdriver correctly will be easier to follow than
operating a fixed pillar drill or MIG welding machine. In ALL cases you must know these
safety rules before you start work. IF IN DOUBT > ASK
Safety Signs
Around the workshop you will notice a variety of safety signs and notices. These signs are
usually colour coded and divided into FOUR categories.
RED = Prohibition (Stop/Do Not)
YELLOW = Caution (Warning of Danger)
BLUE = Mandatory (You must do)
GREEN = Information (Go this way)
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Examples of Safety Signs
YELLOW = Caution
(Warning of Danger)
RED = Prohibition
(Stop / Do )
BLUE = Mandatory
(You must do)
GREEN = Information
(Go this way)
Recognising Hazards and Risks
There is a very old saying that ‘prevention is better than cure’ . This applies to many aspects
of life, but is particularly relevant to safety in the workshop. Preparing yourself correctly to
start work should ensure that the job is carried out safely. This may involve wearing personal
protective equipment (PPE) like goggles or gloves. Ensuring that the work-piece in fixed
securely (eg in a vice), checking the tool you are using for signs of wear or damage. This will
then be followed by carrying out the task. Again, knowing how to use the tool correctly
(before you start) is essential. At a later date, we will look at some statistics of accidents at
work and you will be surprised how many accidents happen carrying out the most simple
task.
Obviously, certain tasks carry a much higher risk (of injury) than other tasks and it is
important that you understand how to carry out a RISK ASSESSMENT, in order to
understand and appreciate how and why accidents happen with all types of tools and
equipment.
We will look at risk assessments in more detail at a later date, but there are five principles
associated with a risk assessment.
1. Identify potential hazards
2. Decide who might be harmed and how
3. Evaluate the level of risk and decide whether existing precautions are adequate or
more should be done.
4. Record the findings of the risk assessment
5. Review and revise the assessment at regular intervals (keep records)
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Risk Assessment
A Risk Assessment is nothing more than a careful examination of what could cause
harm to people and whether sufficient safety precautions have been taken. (in simple
terms identifying RISK !!)
Every employer should take every precaution necessary to prevent injury or illness. Accidents
not only ruin individual’s lives but can affect their family and friends. Bad accidents can also
affect a business, where they may be a temporary or permanent shut down. A bad accident
may also result in damage to expensive equipment and machinery which may cost thousands
of pounds to repair. In extreme cases an employer could be prosecuted or even given a jail
sentence if they have not provide adequate safety training and equipment.
Before we start looking more closely at Risk Assessments
of the workshop and individual tools and equipment. It is
very important to understand that most accidents in the
workplace occur due to slips and trips where people
have fallen over. Many of these accident could have
been prevented if the workplace was kept more tidy
and spilt oil or water cleaned up immediately.
You should NEVER have the attitude that picking something up of cleaning up some split
liquid is somebody else’s job. If you are in that workspace IT IS YOUR JOB ! You are
responsible for the health and safety of your friends and work colleagues as well as yourself.
The second highest cause of accidents is NOT wearing
adequate personal protective equipment
(eg gloves, goggles, work boots etc). Again, it is your
responsibility to ensure that you wear googles when
using sanding, cutting or grinding. You only have one
pair of eyes and a small fragment of metal rotating at
2000 rpm could easily be thrown up and enter your
eye at 100 mph.
Even if someone else is carrying out a dangerous activity, it is your responsibility to notify that
person of the dangers, which could also cause harm to you.
Another common cause of accidents is lack of training, where someone operates a piece of
equipment incorrectly, before they have carried out adequate set-up or safety checks.
Again, a good employer should ensure that you have received adequate training, but it is also
important that you DO NOT operate any equipment unless you have been shown how to
operate that equipment or tool safely.
In the UK the HASAWA (Health and Safety at Work Act) was introduced by the government
to raise the standards of health and safety in the workplace.
Assessing the risk associated with different workshop tasks comes with experience, but some
simple steps can be followed to make the process quite straightforward if the following steps
are followed.
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Carrying out a risk assessment
Step 1
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•
•
Identify potential hazards
Who may be exposed to the hazard
What control measures are already in place
Step 2
•
Assess the level of risk using a risk graph (see below)
Step 3
Evaluate the risk
Decide :
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•
•
•
If existing controls are adequate
What action is recommended
The time frame to eliminate the risk
Review date
IT IS VERY IMPORTANT TO KEEP RECORDS OF ANY RISK ASSESSMENTS AND
REVIEW THAT THE ACTIONS RECOMMENDED WITHIN THE GIVEN TIME FRAME
No
1
Hazard
Using a
hot glue
gun
Hot glue
gun tip and
hot glue
coming
into
contact
with the
skin
Who might
be harmed
Operator
Existing control
measures
Tools checked for
serviceability
weekly.
Demonstration of
correct use by
teacher before
students are
allowed to use this
equipment.
Level of
Risk
Medium
Future actions required
Time
frame
Demonstration of use
before each lesson.
Emphasise the importance
of correct handling of the
glue gun and using the
stand when not in use.
ONE
WEEK
Ensure safety warning is
attached to all glue guns l
First aid box
checked weekly
This type of risk assessment should be carried out on every piece of equipment in the
workshop. Each item should have been given a low, medium or high level of risk.
Tools and equipment with high levels of risk, should NOT be used until any safety issues
ghave been rectified (eg machine guards fitted etc)
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The action required and the time frame depends on the LEVEL OF RISK. This risk graph and
table will help you establish the level of risk, based on accident likelihood and severity. If it is
not possible to carry out the action immediately for high risk activities, that activity should be
STOPPED.
When you establish the overall level of risk.
You need to consider, both :
• Likelihood of accident
• Severity of accident
Existing Control Measures are also important to consider.
As a general rule, if the EXISTING CONTROL MEASURES are very
good this should significantly reduce the likelihood of an accident.
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