Aviation Engines Part 28

It is known as the "Spartan" hammer and is a tool steel drop forging in one piece having the working surfaces properly hardened and tempered while the metal is distributed so as to give a good balance to the head and a comfortable grip to the handle. The hammer head provides a positive and comfortable T-handle when the tool is used as a screw driver or "tommy" bar. Machinist's hammers are provided with three types of heads, these being of various weights. The form most commonly used is termed the "ball pein" on account of the shape of the portion used for riveting. The straight pein is just the same as the cross pein, except that in the latter the straight portion is at right angles to the hammer handle, while in the former it is parallel to that member.

FORMS OF WRENCHES

Wrenches have been made in infinite variety and there are a score or more patterns of different types of adjustable socket and off-set wrenches. The various wrench types that differ from the more conventional monkey wrenches or those of the Stillson pattern are shown at Fig. 164. The "perfect handle" is a drop forged open end form provided with a wooden handle similar to that used on a monkey wrench in order to provide a better grip for the hand. The "Saxon" wrench is a double alligator form, so called because the jaws are in the form of a V-groove having one side of the V plain, while the other is serrated in order to secure a tight grip on round objects. In the form shown, two jaws of varying sizes are provided, one for large work, the other to handle the smaller rods. One of the novel features in connection with this wrench is the provision of a triple die block in the centre of the handle which is provided with three most commonly used of the standard threads including 5/16-inch-18, 3/8-inch-16, and 1/2-inch-13. This is useful in cleaning up burred threads on bolts before they are replaced, as burring is unavoidable if it has been necessary to drive them out with a hammer. The "Lakeside" wrench has an adjustable pawl engaging with one of a series of notches by which the opening may be held in any desired position.

[Ill.u.s.tration: Fig. 164.--Wrenches are Offered in Many Forms.]

Ever since the socket wrench was invented it has been a popular form because it can be used in many places where the ordinary open end or monkey wrench cannot be applied owing to lack of room for the head of the wrench. A typical set which has been made to fit in a very small s.p.a.ce is shown at D. It consists of a handle, which is nickel-plated and highly polished, a long extension bar, a universal joint and a number of case hardened cold drawn steel sockets to fit all commonly used standard nuts and bolt heads. Two screw-driver bits, one small and the other large to fit the handle, and a long socket to fit spark-plugs are also included in this outfit. The universal joint permits one to remove nuts in a position that would be inaccessible to any other form of wrench, as it enables the socket to be turned even if the handle is at one side of an intervening obstruction.

The "Pick-up" wrench, shown at E, is used for spark-plugs and the upper end of the socket is provided with a series of grooves into which a suitable blade carried by the handle can be dropped. The handle is pivoted to the top of the socket in such a way that the blades may be picked up out of the grooves by lifting on the end of the handle and dropped in again when the handle is swung around to the proper point to get another hold on the socket. The "Miller" wrench shown at F, is a combination socket and open end type, made especially for use with spark-plugs. Both the open end and the socket are convenient. The "Handy" set shown at G, consists of a number of thin stamped wrenches of steel held together in a group by a simple clamp fitting, which enables either end of any one of the four double wrenches to be brought into play according to the size of the nut to be turned. The "Cronk" wrench shown at H, is a simple stamping having an alligator opening at one end and a stepped opening capable of handling four different sizes of standard nuts or bolt heads at the other. Such wrenches are very cheap and are worth many times their small cost, especially for fitting nuts where there is not sufficient room to admit the more conventional pattern. The "Starrett" wrench set, which is shown at I, consists of a ratchet handle together with an extension bar and universal joint, a spark-plug socket, a drilling attachment which takes standard square shank drills from 1/8-inch to 1/2-inch in diameter, a double ended screw-driver bit and several adjustments to go with the drilling attachment. Twenty-eight a.s.sorted cold drawn steel sockets similar in design to those shown at D, to fit all standard sizes of square and hexagonal headed nuts are also included. The reversible ratchet handle, which may be slipped over the extension bar or the universal joint and which is also adapted to take the squared end of any one of the sockets is exceptionally useful in permitting, as it does, the instant release of pressure when it is desired to swing the handle back to get another hold on the nut. The socket wrench sets are usually supplied in hard wood cases or in leather bags so that they may be kept together and protected against loss or damage. With a properly selected socket wrench set, either of the ratchet handle or T-handle form, any nut on the engine may be reached and end wrenches will not be necessary.

USE AND CARE OF FILES

Mention has been previously made of the importance of providing a complete set of files and suitable handles. These should be in various grades or degrees of fineness and three of each kind should be provided.

In the flat and half round files three grades are necessary, one with coa.r.s.e teeth for roughing, and others with medium and fine teeth for the finishing cuts. The round or rat tail file is necessary in filing out small holes, the half round for finishing the interior of large ones.

Half round files are also well adapted for finishing surfaces of peculiar contour, such as the inside of bearing boxes, connecting rod and main bearing caps, etc. Square files are useful in finishing keyways or cleaning out burred splines, while the triangular section or three-cornered file is of value in cleaning out burred threads and sharp corners. Flat files are used on all plane surfaces.

[Ill.u.s.tration: Fig. 165.--Ill.u.s.trating Use and Care of Files.]

The file brush shown at Fig. 165, A, consists of a large number of wire bristles attached to a substantial wood back having a handle of convenient form so that the bristles may be drawn through the interstices between the teeth of the file to remove dirt and grease. If the teeth are filled with pieces of soft metal, such as solder or babbitt, it may be necessary to remove this acc.u.mulation with a piece of sheet metal as indicated at Fig. 165, B. The method of holding a file for working on plain surfaces when it is fitted with the regular form of wooden handle is shown at C, while two types of handles enabling the mechanic to use the flat file on plain surfaces of such size that the handle type indicated at C, could not be used on account of interfering with the surface finished are shown at D. The method of using a file when surfaces are finished by draw filing is shown at E. This differs from the usual method of filing and is only used when surfaces are to be polished and very little metal removed.

SPLIT PIN REMOVAL AND INSERTION

One of the most widely used of the locking means to prevent nuts or bolts from becoming loose is the simple split pin, sometimes called a "cotter pin." These can be handled very easily if the special pliers shown at Fig. 166, A, are used. They have a curved jaw that permits of grasping the pin firmly and inserting it in the hole ready to receive it. It is not easy to insert these split pins by other means because the ends are usually spread out and it is hard to enter the pin in the hole.

With the cotter pin pliers the ends may be brought close together and as the plier jaws are small the pin may be easily pushed in place. Another use of this plier, also indicated, is to bend over the ends of the split pin in order to prevent it from falling out. To remove these pins a simple curved lever, as shown at Fig. 166, B, is used. This has one end tapering to a point and is intended to be inserted in the eye of the cotter pin, the purchase offered by the handle permitting of ready removal of the pin after the ends have been closed by the cotter pin pliers.

COMPLETE CHISEL SET

[Ill.u.s.tration: Fig. 166.--Outlining Use of Cotter Pin Pliers, Spring Winder, and Showing Practical Outfit of Chisels.]

A complete chisel set suitable for repair shop use is also shown at Fig.

166. The type at C is known as a "cape" chisel and has a narrow cutting point and is intended to chip keyways, remove metal out of corners and for all other work where the broad cutting edge chisel, shown at D, cannot be used. The form with the wide cutting edge is used in chipping, cutting sheet metal, etc. At E, a round nose chisel used in making oil ways is outlined, while a similar tool having a pointed cutting edge and often used for the same purpose is shown at F. The centre punch depicted at G, is very useful for marking parts either for identification or for drilling. In addition to the chisels shown, a number of solid punches or drifts resembling very much that shown at E, except that the point is blunt should be provided to drive out taper pins, bolts, rivets, and other fastenings of this nature. These should be provided in the common sizes. A complete set of real value would start at 1/8-inch and increase by increments of 1/32-inch up to 1/2-inch. A simple spring winder is shown at Fig. 166, H, this making it possible for the repairman to wind coil springs, either on the lathe or in the vise. It will handle a number of different sizes of wire and can be set to s.p.a.ce the coils as desired.

DRILLING MACHINES

[Ill.u.s.tration: Fig. 167.--Forms of Hand Operated Drilling Machines.]

Drilling machines may be of two kinds, hand or power operated. For drilling small holes in metal it is necessary to run the drill fast, therefore the drill chuck is usually driven by gearing in order to produce high drill speed without turning the handle too fast. A small hand drill is shown at Fig. 167, A. As will be observed, the chuck spindle is driven by a small bevel pinion, which in turn, is operated by a large bevel gear turned by a crank. The gear ratio is such that one turn of the handle will turn the chuck five or six revolutions. A drill of this design is not suited for drills any larger than one-quarter inch. For use with drills ranging from one-eighth to three-eighths, or even half-inch the hand drill presses shown at C and D are used. These have a pad at the upper end by which pressure may be exerted with the chest in order to feed the drill into the work, and for this reason they are termed "breast drills." The form at C has compound gearing, the drill chuck being driven by the usual form of bevel pinion in mesh with a larger bevel gear at one end of a countershaft. A small helical spur pinion at the other end of this countershaft receives its motion from a larger gear turned by the hand crank. This arrangement of gearing permits of high spindle speed without the use of large gears, as would be necessary if but two were used. The form at D gives two speeds, one for use with small drills is obtained by engaging the lower bevel pinion with the chuck spindle and driving it by the large ring gear. The slow speed is obtained by shifting the clutch so that the top bevel pinion drives the drill chuck. As this meshes with a gear but slightly larger in diameter, a slow speed of the drill chuck is possible. Breast drills are provided with a handle screwed into the side of the frame, these are used to steady the drill press. For drilling extremely large holes which are beyond the capacity of the usual form of drill press the ratchet form shown at B, may be used or the bit brace outlined at E. The drills used with either of these have square shanks, whereas those used in the drill presses have round shanks. The bit brace is also used widely in wood work and the form shown is provided with a ratchet by which the bit chuck may be turned through only a portion of a revolution in either direction if desired.

DRILLS, REAMERS, TAPS AND DIES

In addition to the larger machine tools and the simple hand tools previously described, an essential item of equipment of any engine or plane repair shop, even in cases where the ordinary machine tools are not provided, is a complete outfit of drills, reamers, and threading tools. Drills are of two general cla.s.ses, the flat and the twist drills.

The flat drill has an angle between cutting edges of about 110 degrees and is usually made from special steel commercially known as drill rod.

A flat drill cannot be fed into the work very fast because it removes metal by a sc.r.a.ping, rather than a cutting process. The twist drill in its simplest form is cylindrical throughout the entire length and has spiral flutes which are ground off at the end to form the cutting lip and which also serve to carry the metal chips out of the holes. The simplest form of twist drill used is shown at Fig. 168, C, and is known as a "chuck" drill, because it must be placed in a suitable chuck to turn it. A twist drill removes metal by cutting and it is not necessary to use a heavy feed as the drill will tend to feed itself into the work.

[Ill.u.s.tration: Fig. 168.--Forms of Drills Used in Hand and Power Drilling Machines.]

Larger drills than 3/4-inch are usually made with a tapered shank as shown at Fig. 168, B. At the end of the taper a tongue is formed which engages with a suitable opening in the collet, as the piece used to support the drill is called. The object of this tongue is to relieve the tapered portion of the drill from the stress of driving by frictional contact alone, as this would not turn the drill positively and the resulting slippage would wear the socket, this depreciation changing the taper and making it unfit for other drills. The tongue is usually proportioned so it is adequate to drive the drill under any condition. A small keyway is provided in the collet into which a tapering key of flat stock may be driven against the end of the tongue to drive the drill from the spindle. A standard taper for drill shanks generally accepted by the machine trade is known as the Morse and is a taper of five-eighths of an inch to the foot. The Brown and Sharp form tapers six-tenths of an inch to the foot. Care must be taken, therefore, when purchasing drills and collets, to make sure that the tapers coincide, as no attempt should be made to run a Morse taper in a Brown and Sharp collet, or vice versa.

Sometimes cylindrical drills have straight flutes, as outlined at Fig.

168, A. Such drills are used with soft metals and are of value when the drill is to pa.s.s entirely through the work. The trouble with a drill with spiral flutes is that it will tend to draw itself through as the cutting lips break through. This catching of the drill may break it or move the work from its position. With a straight flute drill the cutting action is practically the same as with the flat drill shown at Fig. 168, E and F.

If a drill is employed in boring holes through close-grained, tough metals, as wrought or malleable iron and steel, the operation will be facilitated by lubricating the drill with plenty of lard oil or a solution of soda and water. Either of these materials will effectually remove the heat caused by the friction of the metal removed against the lips of the drill, and the danger of heating the drill to a temperature that will soften it by drawing the temper is minimized. In drilling large or deep holes it is good practice to apply the lubricating medium directly at the drill point. Special drills of the form shown at Fig.

168, B, having a spiral oil tube running in a suitably formed channel, provides communication between the point of the drill and a suitable receiving hole on a drilled shank. The oil is supplied by a pump and its pressure not only promotes positive circulation and removal of heat, but also a.s.sists in keeping the hole free of chips. In drilling steel or wrought iron, lard oil applied to the point of the drill will facilitate the drilling, but this material should never be used with either bra.s.s or cast iron.

The sizes to be provided depend upon the nature of the work and the amount of money that can be invested in drills. It is common practice to provide a set of drills, such as shown at Fig. 169, which are carried in a suitable metal stand, these being known as number drills on account of conforming to the wire gauge standards. Number drills do not usually run higher than 5/16 inch in diameter. Beyond this point drills are usually sold by the diameter. A set of chuck drills, ranging from 3/8 to 3/4 inch, advancing by 1/32 inch, and a set of Morse taper shank drills ranging from 3/4 to 1-1/4 inches, by increments of 1/16 inch, will be all that is needed for the most pretentious repair shop, as it is cheaper to bore holes larger than 1-1/4 inches with a boring tool than it is to carry a number of large drills in stock that would be used very seldom, perhaps not enough to justify their cost.

[Ill.u.s.tration: Fig. 169.--Useful Set of Number Drills, Showing Stand for Keeping These in an Orderly Manner.]

In grinding drills, care must be taken to have the lips of the same length, so that they will form the same angle with the axis. If one lip is longer than the other, as shown in the flat drill at Fig. 168, E, the hole will be larger than the drill size, and all the work of cutting will come upon the longest lip. The drill ends should be symmetrical, as shown at Fig. 168, F.

[Ill.u.s.tration: Fig. 170.--Ill.u.s.trating Standard Forms of Hand and Machine Reamers.]

It is considered very difficult to drill a hole to an exact diameter, but for the most work a variation of a few thousandths of an inch is of no great moment. Where accuracy is necessary, holes must be reamed out to the required size. In reaming, a hole is drilled about 1/32 inch smaller than is required, and is enlarged with a cutting tool known as the reamer. Reamers are usually of the fluted form shown at Fig. 170, A.

Tools of this nature are not designed to remove considerable amounts of metal, but are intended to augment the diameter of the drill hole by only a small fraction of an inch. Reamers are tapered slightly at the point in order that they will enter the hole easily, but the greater portion of the fluted part is straight, all cutting edges being parallel. Hand reamers are made in either the straight or taper forms, that at A, Fig. 170, being straight, while B has tapering flutes. They are intended to be turned by a wrench similar to that employed in turning a tap, as shown at Fig. 172, C. The reamer shown at Fig. 170, C, is a hand reamer. The form at D has spiral flutes similar to a twist drill, and as it is provided with a taper shank it is intended to be turned by power through the medium of a suitable collet.

As the solid reamers must become reduced in size when sharpened, various forms of inserted blade reamers have been designed. One of these is shown at E, and as the cutting surfaces become reduced in diameter it is possible to replace the worn blades with others of proper size.

Expanding reamers are of the form shown at F. These have a bolt pa.s.sing through that fits into a tapering hole in the interior of the split reamer portion of the tool. If the hole is to be enlarged a few thousandths of an inch, it is possible to draw up on the nut just above the squared end of the shank, and by drawing the tapering wedge farther into the reamer body, the cutting portion will be expanded and will cut a larger hole.

Reamers must be very carefully sharpened or there will be a tendency toward chattering with a consequent production of a rough surface. There are several methods of preventing this chattering, one being to separate the cutting edges by irregular s.p.a.ces, while the most common method, and that to be preferred on machine reamers, is to use spiral flutes, as shown at Fig. 170, D. Special taper reamers are made to conform to the various taper pin sizes which are sometimes used in holding parts together in an engine. A taper of 1/16 inch per foot is intended for holes where a pin, once driven in, is to remain in place. When it is desired that the pin be driven out, the taper is made steeper, generally 1/4 inch per foot, which is the standard taper used on taper pins.

[Ill.u.s.tration: Fig. 171.--Tools for Thread Cutting.]

When threads are to be cut in a small hole, it will be apparent that it will be difficult to perform this operation economically on a lathe, therefore when internal threading is called for, a simple device known as a "tap" is used. There are many styles of taps, all conforming to different standards. Some are for metric or foreign threads, some conform to the American standards, while others are used for pipe and tubing. Hand taps are the form most used in repair shops, these being outlined at Fig. 171, A and B. They are usually sold in sets of three, known respectively as taper, plug, and bottoming. The taper tap is the one first put into the hole, and is then followed by the plug tap which cuts the threads deeper. If it is imperative that the thread should be full size clear to the bottom of the hole, the third tap of the set, which is straight-sided, is used. It would be difficult to start a bottoming tap into a hole because it would be larger in diameter at its point than the hole. The taper tap, as shown at A, Fig. 171, has a portion of the cutting lands ground away at the point in order that it will enter the hole. The manipulation of a tap is not hard, as it does not need to be forced into the work, as the thread will draw it into the hole as the tap is turned. The tapering of a tap is done so that no one thread is called upon to remove all of the metal, as for about half way up the length of the tap each succeeding thread is cut a little larger by the cutting edge until the full thread enters the hole. Care must be taken to always enter a tap straight in order to have the thread at correct angles to the surface.

In cutting external threads on small rods or on small pieces, such as bolts and studs, it is not always economical to do this work in the lathe, especially in repair work. Dies are used to cut threads on pieces that are to be placed in tapped holes that have been threaded by the corresponding size of tap. Dies for small work are often made solid, as shown at Fig. 171, C, but solid dies are usually limited to sizes below 1/2 inch. Sometimes the solid die is cylindrical in shape, with a slot through one side which enables one to obtain a slight degree of adjustment by squeezing the slotted portion together. Large dies, or the sizes over 1/2 inch, are usually made in two pieces in order that the halves may be closed up or brought nearer together. The advantage of this form of die is that either of the two pieces may be easily sharpened, and as it may be adjusted very easily the thread may be cut by easy stages. For example, the die may be adjusted to cut large, which will produce a shallow thread that will act as an accurate guide when the die is closed up and a deeper thread cut.

[Ill.u.s.tration: Fig. 172.--Showing Holder Designs for One- and Two-Piece Thread Cutting Dies.]

A common form of die holder for an adjustable die is shown at Fig. 172, A. As will be apparent, it consists of a central body portion having guide members to keep the die pieces from falling out and levers at each end in order to permit the operator to exert sufficient force to remove the metal. The method of adjusting the depth of thread with a clamp screw when a two-piece die is employed is also clearly outlined. The diestock shown at B is used for the smaller dies of the one-piece pattern, having a slot in order that they may be closed up slightly by the clamp screw. The reverse side of the diestock shown at B is outlined below it, and the guide pieces, which may be easily moved in or out, according to the size of the piece to be threaded by means of eccentrically disposed semi-circular slots in the adjustment plate, are shown. These movable guide members have small pins let into their surface which engage the slots, and they may be moved in or out, as desired, according to the position of the adjusting plate. The use of the guide pieces makes for accurate positioning or centering of the rod to be threaded. Dies are usually sold in sets, and are commonly furnished as a portion of a complete outfit such as outlined at Fig.

173. That shown has two sizes of diestock, a tap wrench, eight a.s.sorted dies, eight a.s.sorted taps, and a small screw driver for adjusting the die. An automobile repair shop should be provided with three different sets of taps and dies, as three different standards for the bolts and nuts are used in fastening automobile components. These are the American, metric (used on foreign engines), and the S. A. E. standard threads. A set of pipe dies and taps will also be found useful.

[Ill.u.s.tration: Fig. 173.--Useful Outfit of Taps and Dies for the Engine Repair Shop.]

MEASURING TOOLS

The tool outfit of the machinist or the mechanic who aspires to do machine work must include a number of measuring tools which are not needed by the floor man or one who merely a.s.sembles and takes apart the finished pieces. The machinist who must convert raw material into finished products requires a number of measuring tools, some of which are used for taking only approximate measurements, such as calipers and scales, while others are intended to take very accurate measurements, such as the Vernier and the micrometer. A number of common forms of calipers are shown at Fig. 174. These are known as inside or outside calipers, depending upon the measurements they are intended to take.

That at A is an inside caliper, consisting of two legs, A and D, and a gauging piece, B, which can be locked to leg A, or released from that member by the screw, C. The object of this construction is to permit of measurements being taken at the bottom of a two diameter hole, where the point to be measured is of larger diameter than the portion of the hole through which the calipers entered. It will be apparent that the legs A and D must be brought close together to pa.s.s through the smaller holes.

This may be done without losing the setting, as the guide bar B will remain in one position as determined by the size of the hole to be measured, while the leg A may be swung in to clear the obstruction as the calipers are lifted out. When it is desired to ascertain the measurements the leg A is pushed back into place into the slotted portion of the guide B, and locked by the clamp screw C. A tool of this form is known as an internal transfer caliper.

[Ill.u.s.tration: Fig. 174.--Common Forms of Inside and Outside Calipers.]