DRILLING, TAPPING &

THREADING (DTT)

Facilitator Guide

TABLE OF CONTENTS

INTRODUCTION PAGE 1 HOW TO USE THIS PACKAGE PAGE 2 PROGRAMME DTT-1 PAGE 3 PROGRAMME DTT-2 PAGE 4 PROGRAMME DTT-3 PAGE 5 PROGRAMME DTT-4 PAGE 6 MODEL ANSWERS THEORETICAL EXERCISE DTT-1 PAGE 7 CRITERION TEST DTT-1 A PAGE 9 CRITERION TEST DTT-1 B PAGE 10 CRITERION TEST DTT-2 PAGE 11 CRITERION TEST DTT-3 PAGE 12 CRITERION TEST DTT-4 PAGE 13

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INTRODUCTION This learner-directed series of programmes is aimed at assisting learners, in the metal working disciplines, to acquire the basic skills of producing accurately positioned and correctly threaded holes. The tools and equipment demonstrated in this package are of typical style and design. Most of the tools are obtainable from your local stockist. It is strongly recommended that learners are already competent, or, have attained mastery in the following: 1. Basic Hand Tools - Tech AV BHT 2. Bench Grinding Machines - Tech AV BGM THIS PACKAGE COMPRISES 1. This Facilitator's Guide. 2. Video programme. 3. A Learner's Guide. 4. SOMTA User Guide booklet. 5. Loose leaf criterion-test sheets.

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HOW TO USE THIS PACKAGE

The design of this package is such that it can be incorporated into any existing training system. Modern modular trends allow learners to work at their own pace and this package caters ideally for this system. The workbooks should be read first and then the videos viewed. During each video you will notice either a discussion or a practical prompt accompanied with music. Upon these cues/prompts the learner is advised to the video and embark upon one or more of the following: 1. Discussion with the Instructor/Course Controller. 2. Practical exercise as suggested in the workbook. 3. Practical exercise in a workshop or training centre. After the learner has worked through each programme (beginning at DTT-1) he or she may elect to perform a CRITERION TEST which is assessed against the mark sheets (Supplied as loose leaf issue). When the learner has successfully completed a criterion test then he or she is deemed competent in that particular skill. Please enter the result of any practical criterion test on learner's progress summary in the learner's workbook.

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PROGRAMME DTT-1 DRILLS AND DRILLING

LEARNING OBJECTIVE At the end of the training session learners will demonstrate the ability to create accurately positioned holes into metal stock using conventional fixed and portable power machines in combination with H.S.S. twist drills. TRAINING AIDS REQUIRED

o 1 x Belt driven bench or pedestal drilling machine. o 1 x Portable hand held drilling machine (10 mm chuck). o 1 x Centre-punch. o 1 x Prick-punch. o 1 x 250 g Ball-pein hammer. o 1 x Small engineers square. o Necessary spanners to secure platform vice. o Necessary lubricant or cutting fluid. o Prepared mild steel metal stock. o Safety goggles. o Set of twist drills (± 2 -13 mm).

Estimated Learning Time: - 3 - 4 hours. SUMMARY OF SUBJECT MATTER

o Identification, parts and functions of portable and fixed drilling machines. o Safety checks on machines. o Correct operation of hand held (portable) machine. o Preparation of fixed type (bench) machine. o Setting up work piece. o Setting rotational speed. o Installation of straight and taper shank drills. o Squaring up. o Setting drilling depth. o Drilling processes. o Drawing onto centre (i.e. ensuring correct centre). o Removal and storage of drills.

ADDITIONAL RESOURCE MATERIAL SOMTA User Guide booklet (included in this package).

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PROGRAMME DTT-2 DRILL POINT SHARPENING

LEARNING OBJECTIVE At the end of this training session learners will demonstrate the ability to dress the tip of a H.S.S. twist drill, to conform to "standard-point" geometry, using the "off-hand" method on a conventional bench mounted grinding machine. TRAINING AIDS REQUIRED 1. Assorted drills that require dressing. 2. A bench mounted grinding machine with a property dressed medium or time grit

aluminium oxide type wheel. 3. Safety goggles. 4. Standard drill-point gauge (118°). 5. An engineer's square or protractor gauge. Estimated Learning Time: - 1 - 2 hours. SUMMARY OF SUBJECT MATTER

o Standard terminology of conventional twist-drills. o Different point designs for material types. o Static demonstration of point to emery wheel contact. o Dynamic demonstration of point grinding procedure. o Assessment of point angles and corrective action.

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PROGRAMME DTT-3 HAND TAPPING

LEARNING OBJECTIVE At the end of this training session learners will demonstrate the ability to produce well cut threads into pre-drilled holes (mild steel stock) using conventional fluted "hand-taps". TRAINING AIDS REQUIRED

o Tapping drill set. o H.S.S. Hand taps of required thread type. o Tap wrench. o Engineer's set-square. o Cutting paste. o Bench vice on workbench. o Paintbrush for cleaning purposes. o Prepared mild-steel work pieces.

Estimated Learning Time: - 2 - 3 hours. SUMMARY OF SUBJECT MATTER

o Hand tapping tools overview. o Tap terminology (nomenclature). o Purpose of 1st, 2nd and 3rd tap. o Establishing tapping drill size by:

a) Chart. b) Calculation.

o Setting up work piece. o Tapping procedures for open and blind holes. o Tapping non-ferrous material.

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PROGRAMME DTT-4 HAND TREADING

LEARNING OBJECTIVE At the end of this training session learners will demonstrate the ability to create threads on suitable round stock metal using "split-dies" and stocks. TRAINING AIDS REQUIRED o Assorted split-dies and stocks. o Cutting paste (for steel). o Stock round bar (e.g. 10 mm MIS). o Bench vice. o Steel rule. o Pipe vice. o Conduit stocks and dies (for 20 mm conduit). o Conduit or galvanised 20 mm pipes. o Die nuts and spanner. o De-burring tool. Estimated Learning Time: - 3 - 4 hours. SUMMARY OF SUBJECT MATTER o Identification of split-dies and stock body. o Installation of die into stock. o Setting up work piece and chamfering. o Threading procedures. o Finishing the threads. o Pipe threading procedures. o Some tips for threading aluminium and brass.

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MODEL ANSWERS THEORETICAL EXERCISE DTT-1 - DRILLING

Answer the following questions without reference to your notes - check your answers afterwards. 1. List all the relevant aspects of safety that must be considered and obeyed when using portable electric drilling machines.

o Only use hammer action with masonry. o Check machine over before using. o Return faulty machine to repair. o Always protect eyes with goggles. o Cables not to be over walkways, vehicles accesses or sharp edges. o Never work in wet conditions. o Wear insulated shoes. o Carry machine by its body -not the cord. o Allow drill to cool before removing it.

2. Describe how to fit a parallel (straight) shank drill into a chuck. 1. Fit in such a way that only the shank is gripped. 2. Check that ± 1/3 of shank is visible below chuck jaws. 3. Secure firmly and then remove chuck key. 4. If drill does not run true -check for scored shank or if drill is bent. 3. Describe how to fit a Morse Taper Shank bit to the fixed machine. 1. Ensure shank is clean and dry.

2. Insert shank into spindle sleeve, twist it to engage between slot in the sleeve.

3. Secure by pulling down onto a piece of timber. 4. What very important safety rule applies when you want to change belt positions on

bench machine? Always isolate the power supply first. 5. During the drilling operation you should be wearing what? Suitable eye protection -goggles. 6. After removal of a bit from a machine what must you always do? Ensure that you have removed the key or the taper drift.

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SELF CHECK

Q1. Total no. correct out of 9 =

Q2. Total no. correct out of 4 =

Q3. Total no. correct out of 3 =

Q4. Tick right or wrong R W

Q5. Tick right or wrong R W

Q6. Tick right or wrong R W

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DRILLING TAPPING & THREADING CRITERION TEST - PRACTICAL

LEARNER: ____________________________________ DATE: ______________________ TASK: HAND POWERED DRILLING DTT-1A ITEM CRITERIA YES NO

Preparation. Hammer action off.

Preparation. Safety checks done on machine.

Preparation. Cables safely laid out.

Preparation. Safety goggles worn.

Preparation. Drill fitted - 1/3 of shank visible.

Drilling. Correct speed range for drill size.

Machine at 90⁰ to work surface.

Machine correctly held / supported.

Product. Holes produced on centre.

Completion. Tools / equipment cleaned.

Chuck key stored correctly.

ASSESSED BY: _______________________________ CAPACITY: _____________________ CRITERION ATTAINED: YES NO ATTEMPT NO.: ________________

ENTER RESULT ONTO LEARNER PROGRESS SUMMARY.

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DRILLING TAPPING & THREADING CRITERION TEST - PRACTICAL

LEARNER: _____________________________________ DATE: _______________________ TASK: FIXED MACHINE DRILLING DTT-1B ITEM CRITERIA YES NO

Preparation. Drill correctly installed.

Preparation. Correct size selected.

Preparation. Work table and machine vice cleaned.

Preparation. Work piece secure and square.

Preparation. All locks / clamps secured.

Preparation. Correct speed selected on spindle.

Preparation. Power isolated for adjustment.

Drilling. Safety goggles worn.

Cutting / cooling fluid used.

Breaks off long swarf during operation.

Product. Holes on centre.

Holes as per drawing (size / location).

Completion. Tools / equipment cleaned.

Key or taper drifts removed.

ASSESSED BY: ________________________________ CAPACITY: ____________________ CRITERION ATTAINED: YES NO ATTEMPT NO.: ________________

ENTER RESULT ONTO LEARNER PROGRESS SUMMARY.

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DRILLING TAPPING & THREADING CRITERION TEST - PRACTICAL

LEARNER: _____________________________________ DATE: _______________________ TASK: DRILL BIT DRESSING DTT-2 ITEM CRITERIA YES NO

Preparation. Grinding wheel ground flat.

Tool rest correctly set.

Cooling water available.

Grinding. Goggles worn.

Point cooled frequently.

Product. Point angles correct (to gauge).

Lip lengths equal.

Relief angles correct.

Completion. Tools & equipment cleaned.

Drill stored correctly.

ASSESSED BY: _______________________________ CAPACITY: _____________________ CRITERION ATTAINED: YES NO ATTEMPT NO.: ________________

ENTER RESULT ONTO LEARNER PROGRESS SUMMARY.

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DRILLING TAPPING & THREADING CRITERION TEST - PRACTICAL

LEARNER: _____________________________________ DATE: _______________________ TASK: HAND TAPPING DTT-3 ITEM CRITERIA YES NO

Preparation. Correct tapping drills used (explained).

Preparation. Work piece set square in vice.

Preparation. Necessary tools and equipment selected.

Tapping. Cutting paste used (if steel).

Tap squared up correctly.

Taper tap used initially.

Taps used in correct sequence.

Cuttings cleared between changes.

Product. Threads clean.

Threads straight.

Threads to size.

Completion. Work clean.

Taps cleaned / stored.

All tools equipment stored.

ASSESSED BY: ________________________________ CAPACITY: ____________________ CRITERION ATTAINED: YES NO ATTEMPT NO.: ________________

ENTER RESULT ONTO LEARNER PROGRESS SUMMARY.

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DRILLING TAPPING & THREADING CRITERION TEST - PRACTICAL

LEARNER: _____________________________________ DATE: _______________________ TASK: THREADING DTT-4 ITEM CRITERIA YES NO

Preparation. Work piece chamfered.

Work piece set into vice correctly.

Correct dies and stock selected.

Die fitted right way up in stock.

Die adjusted correctly - initial cut.

Threading. Cutting pasts used on steel.

Initial cut set level.

Threads checked against a new nut.

Dies re-set / adjusted correctly.

Swarf / cutting cleared frequently.

Product. Thread cut to specific length.

Threads well formed.

Threads level (not drunken).

Nut fits snugly.

Completion. Tools / equipment cleaned.

Pipes de-burred.

Tools / equipment stored.

ASSESSED BY: ________________________________ CAPACITY: ____________________ CRITERION ATTAINED: YES NO ATTEMPT NO.: ________________

ENTER RESULT ONTO LEARNER PROGRESS SUMMARY.

(DTT)

Total 2: Total 3: Check Box1: OffCheck Box2: OffCheck Box3: OffCheck Box4: OffTotal 1: Check Box5: OffCheck Box6: OffCheck Box7: OffCheck Box8: OffCheck Box9: OffCheck Box10: OffCheck Box11: OffCheck Box12: OffCheck Box13: OffCheck Box14: OffCheck Box15: OffCheck Box16: OffLearner 1: Date 1: Assessed 1: Capacity 1: Attempt 1: Learner 2: Date 2: Assessed 2: Capacity 2: Attempt 2: Learner 3: Date 3: Capacity 3: Assessed 3: Attempt 3: Learner 4: Date 4: Assessed 4: Capacity 4: Attempt 4: Learner 5: Date 5: Assessed 5: Capacity 5: Attempt 5: Group1: OffGroup2: OffGroup3: OffGroup4: OffGroup5: OffGroup6: OffGroup7: OffGroup8: OffGroup9: OffGroup10: OffGroup11: OffGroup12: OffGroup13: OffGroup14: OffGroup15: OffGroup16: OffGroup17: OffGroup18: OffGroup19: OffGroup20: OffGroup21: OffGroup22: OffGroup23: OffGroup24: OffGroup25: OffGroup26: OffGroup27: OffGroup28: OffGroup29: OffGroup30: OffGroup32: OffGroup33: OffGroup34: OffGroup35: OffGroup36: OffGroup37: OffGroup38: OffGroup39: OffGroup40: OffGroup41: OffGroup42: OffGroup43: OffGroup44: OffGroup45: OffGroup46: OffGroup47: OffGroup48: OffGroup49: OffGroup50: OffGroup51: OffGroup52: OffGroup53: OffGroup54: OffGroup55: OffGroup56: OffGroup57: OffGroup58: OffGroup59: OffGroup60: OffGroup61: OffGroup62: OffGroup63: OffGroup64: OffGroup65: OffGroup66: OffGroup67: Off