The main types of locksmith work

markup
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Rice. 30. Marking plate

Marking is the drawing of borders on the surface of the workpiece in the form of lines and points corresponding to the dimensions of the part according to the drawing, as well as axial lines and centers for drilling holes.

If the markup is made in only one plane, for example, on sheet material, then it is called planar. The marking of workpiece surfaces located at different angles to each other is called spatial. The blanks are marked on a special cast-iron plate (Fig. 30), called marking, mounted on a wooden table so that its upper plane is strictly horizontal.

Tools for marking-to and. When marking, use various marking tools.

Scriber (Fig. 31) is a steel rod with sharp hardened ends. With a scriber, thin lines are applied to the surface of the workpiece using a ruler, template or square.

Thickness gauges are used to apply horizontal lines on the workpiece parallel to the surface of the marking plate. Reismas (Fig. 32) consists of a base and a stand fixed in its center, on which there is a movable clamp with a scriber that rotates around its axis. The movable clamp can move along the rack and be fixed on it in any position with a clamping screw.

Rice. 31. Scribbler

The marking compass (Fig. 33) is used to draw circles and roundings on the marked workpiece.

Rice. 32. Reismas

Rice. 33. Marking compasses

For accurate marking, use a height gauge (Fig. 34). A bar with a millimeter scale is firmly fixed on a massive base. A frame with a vernier and a second micrometric feed frame move along the bar. Both frames are fixed on the rod with screws in any desired position. A replaceable scriber leg is attached to the frame with a clamp.

A marking caliper is used to draw circles of large diameters with direct sizing. A marking caliper (Fig. 35) consists of a rod with a millimeter scale printed on it and two legs, of which the leg is fixedly mounted on the rod, and the leg is movable and can move on the rod. The movable leg has a vernier. Hardened steel needles are inserted into both legs. The needle of the movable leg can move up and down and be clamped in the desired position with a screw.

Rice. 34. Height gauge

Rice. 35. Marking caliper

Rice. 36. Center Finder

The center finder is designed to determine the center of the end face of a cylindrical billet (Fig. 36). The center finder consists of a square with shelves located at an angle of 90° to each other, and a leg, the inner side of which divides the right angle of the square in half. To determine the center, the center finder is installed so that the square shelves touch the cylindrical surface of the workpiece. The scriber is drawn along the inner side of the leg, thus drawing a diameter line, then the center finder is rotated 90 ° and a second diametrical line is applied. The intersection point of these lines will be the center of the end face of the cylindrical blank.

A scale altimeter (Fig. 37) is used for marking in cases where it is necessary to set the tip of the scriber at a certain height. It consists of a fixed scale bar attached to a cast-iron square, a movable ruler moving along guide bases, and a fine-line targeting engine. When marking, the sighting engine is set so that its thin line coincides with the main axis of the workpiece, and is fixed in this position. After that, the zero division of the movable ruler is placed against the thin line of the sighting engine and the distance (height) from the main axis of the workpiece to other axes is read on the movable ruler.

The center punch is used to make small indentations on the marking lines of the workpiece, so that these lines are clearly visible and not erased during the processing of the workpiece. The punch (Fig. 38) is made of tool steel in the form of a rod, the middle part of which has a notch. The working part of the lower end of the center punch is sharpened at an angle of 45-60 ° and hardened, and the upper end is a striker, which is hit with a hammer when punching.

Marking devices. In order to protect the surface of the marking plate from scratches, nicks, as well as to create a stable position when marking parts that do not have a flat base, and to facilitate the marking process, cast iron linings are used (Fig. 39, a), jacks (Fig. 39 , b) and marking boxes (Fig. 39, c) of various shapes. Squares, clamps and adjustable wedges are also used.

The markup process is carried out as follows. The surfaces of the marked workpieces are cleaned of dirt, dust and grease. Then cover with a thin layer of chalk diluted in water with the addition of linseed oil and desiccant or wood glue. Well-treated surfaces are sometimes covered with a solution of copper sulphate or quick-drying paints and varnishes. When the applied layer of chalk or paint dries, you can start marking. The markup can be made according to a drawing or a template.

Rice. 37. Scale altimeter

Rice. 38. Punch

The process of marking the workpiece according to the drawing is performed in the following sequence:
- the prepared workpiece is installed on the marking plate;
- the main lines are applied to the surface of the workpiece, by which it is possible to determine the position of other lines or centers of holes;
- apply horizontal and vertical lines in accordance with the dimensions of the drawing, then find the centers and draw circles, arcs and oblique lines;
- along the lines drawn with a center punch, small recesses are knocked out, the distance between which, depending on the state of the surface and the size of the workpiece, can be from 5 to 150 mm.

Rice. 39. Devices for marking:
a - linings, b - doykratiki, c - marking boxes

For planar marking of identical parts, it is more advisable to use a template. This method of marking consists in the fact that a steel template is applied to the workpiece and its contours are circled on the workpiece with a scriber.

metal cutting

Bench cutting is used to remove excess metal in cases where high precision processing is not required, as well as for rough leveling of rough surfaces, for cutting metal, cutting down rivets, for cutting keyways, etc.

Cutting tools. The tools for cutting metal are chisels and crosscutters, and the percussion tool is a hammer.

The chisel (Fig. 40, a) is made of U7A tool steel and, as an exception, U7, U8 and U8A. Chisel blade width from 5 to 25 mm. The angle of sharpening the blade is selected depending on the hardness of the metal being processed. For example, for cutting cast iron and bronze, the sharpening angle should be 70°, for cutting steel 60°, for cutting brass and copper 45°, for cutting aluminum and zinc 35°. The chisel blade is sharpened on an emery wheel so that the chamfers have the same width and the same angle of inclination to the chisel axis. The sharpening angle is checked with a template or goniometer.

Rice. 40. Tools for cutting metal:
a - a chisel, b - a cross-cutting tool, c - a locksmith's hammer

Kreutzmeysel (Fig. 40, b) is used for cutting keyways, cutting rivets, pre-cutting grooves for subsequent cutting with a wide chisel.

To prevent jamming of the crosscut when cutting through narrow grooves, its blade must be wider than the retracted part. The sharpening angles of the crosscut blade are the same as those of the chisel. The length of the crosscut is from 150 to 200 mm.

Locksmith hammer (Fig. 40, b). When cutting, hammers weighing 0.5-0.6 kg are usually used. The hammer is made of tool steel U7 and U8, and its working part is subjected to heat treatment (hardening followed by tempering). Hammers come with round and square heads. Hammer handles are made of hard wood (oak, birch, maple, etc.). The length of the handles of medium weight hammers is from 300 to 350 mm.

To increase labor productivity, mechanization of felling has recently begun to be carried out by using pneumatic hammers operating under the action of compressed air coming from a compressor unit.

The manual cutting process is as follows. The workpiece or part to be chopped off is clamped in a vice so that the marking line for cutting is at the level of the jaws. Cutting is carried out in a chair vice (Fig. 41, a) or, in extreme cases, in a heavy parallel vice (Fig. 41.6). When cutting, the chisel should be in an inclined position to the cut off surface of the workpiece at an angle of 30-35 °. The hammer is struck in such a way that the center of the hammer striker hits the center of the chisel head, and you need to carefully look only at the chisel blade, which should be moved exactly along the marking line for cutting the workpiece.

Rice. 41. Vise:
a - chair, 6 - parallel

When cutting, a thick layer of metal is cut down in several passes of a chisel. To remove metal with a chisel from a wide surface, grooves are first cut down with a crosscut, then the resulting protrusions are cut down with a chisel.

To facilitate work and obtain a smooth surface when cutting copper, aluminum and other viscous metals, periodically moisten the chisel blade with soapy water or oil. When cutting cast iron, bronze and other brittle metals, chipping often occurs on the edges of the workpiece. To prevent chipping, chamfers are made on the ribs before cutting.

Sheet material is cut on an anvil or on a plate with a chisel with a rounded blade, and do I do it first? notch with light blows along the marking line, and then cut the metal with strong blows.

The main equipment of the locksmith's workplace is a workbench (Fig. 42, a, b), which is a solid, stable table 0.75 high and 0.85 m wide. The workbench cover must be made of boards with a thickness of at least 50 mm. From above and from the sides, the workbench is upholstered with sheet steel. A chair or heavy parallel vice is installed on the workbench. The table has drawers for storing metalwork tools, drawings and workpieces and parts.

Before starting work, the locksmith must check the locksmith's tools. Defects found in the tools are eliminated or replaced by a serviceable tool that is unsuitable for work. It is strictly forbidden to work with a hammer with an oblique or knocked down surface of the striker, to work with a chisel with an oblique or knocked down head.

Rice. 42. Locksmith's workplace:
a - single workbench, b - two-man workbench

To protect the eyes from fragments, the locksmith must work with glasses. To protect others from flying fragments, a metal mesh is installed on the workbench. The workbench must be firmly planted on the floor, and the vise must be well secured to the workbench. It is impossible to work on poorly installed workbenches, as well as on a loose vice, as this can lead to injury to the hand, and it also quickly tires.

Metal straightening and bending

Locksmith editing is usually used to align the curved shape of workpieces and parts. Dressing is carried out manually or on straightening rolls, presses, straightening and angle straightening machines, etc.

Manual dressing is carried out on a straight cast-iron plate or on a blacksmith's anvil with metalworkers' wooden or metal hammers. Thin sheet material is corrected on the correct plates. When straightening sheet material with a thickness of less than 1 mm, wooden or steel bars are used to smooth the sheets on a straightening plate. When editing sheets with a thickness of more than 1 mm, wooden or metal hammers are used.

When manually editing the sheet material, all the bulges are first identified and marked with chalk, then the sheet is placed on the correct plate so that the bulges are on top. After that, they begin to strike with a hammer from one edge of the sheet in the direction of the bulge, and then from the other edge. Hammer blows should not be very strong, but frequent. The hammer should be held firmly and hit the sheet with the central part of the striker, avoiding any distortions, since dents or other defects may appear on the sheet if the blows are incorrect.

The strip material is corrected on the right plates by hammer blows; round bar material is straightened on a special straightening and sizing machine.

Dents on the wings, hood and body of the car are first straightened with curly levers, then a blank or mandrel is installed under the dent and the dent is straightened with blows of a metal or wooden hammer.

Metal bending is used to obtain the required shape of products from sheet, bar material, as well as from pipes. Bending is carried out manually or mechanically.

When bending by hand, a pre-marked metal sheet is installed in a fixture and clamped in a vice, after which the part protruding from the fixture is struck with a wooden hammer.

Pipes are bent manually or mechanically. Large pipes (such as silencer pipe) are usually bent with preheating at the bends. Pipes of small sizes (pipes of power systems and brake) are bent in a cold state. In order for the pipe walls not to flatten during bending, and the cross section does not change at the bending points, the pipe is pre-filled with fine dry sand, rosin or lead. To get a normal rounding, and the pipe was round at the bend (without folds and dents), you need to choose the right bending radius (a larger diameter of the pipe corresponds to a larger radius). For cold bending, pipes must be pre-annealed. The annealing temperature depends on the pipe material. For example, copper and brass pipes are annealed at a temperature of 600-700 °C, followed by cooling in water, aluminum at a temperature of 400-580 °C, followed by air cooling, steel at 850-900 °C, followed by cooling in air.

Rice. 43. Roller pipe bender

Pipe bending is carried out using various devices. On fig. 43 shows a roller fixture. Mechanical bending of pipes is carried out on pipe bending, edge bending machines, universal bending presses.

metal cutting

When cutting metal, various tools are used: wire cutters, scissors, hacksaws, pipe cutters. The use of a particular tool depends on the material, profile and dimensions of the workpiece or part being processed. For example, wire cutters are used for cutting wire (Fig. 44, a), which are made from tool steel grade U7 or U8. The jaws of the cutting pliers are subjected to hardening followed by low (heating up to 200 ° C and slow cooling) tempering.

Rice. 44. Tools for cutting metal: a - wire cutters, b - chair scissors, c - lever scissors

For cutting sheet material, manual, chair, lever, electric, pneumatic, guillotine, disk shears are used. Thin sheet material (up to 3 mm) is usually cut with hand or chair scissors (Fig. 44, b), and thick (from 3 to 6 mm) - lever (Fig. 44, c). Such scissors are made of carbon tool steel U8, U10. The cutting edges of scissors are hardened. The angle of sharpening of the cutting edges of scissors usually does not exceed 20-30°.

When cutting with scissors, a pre-marked metal sheet is placed between the blades of the scissors so that the marking line coincides with the upper blade of the scissors.

Electric and pneumatic scissors are becoming more and more widely used. In the body of electric scissors there is an electric motor (Fig. 45), the rotor of which, by means of a worm gear, rotates an eccentric roller, to which a connecting rod is connected, which drives the movable knife. The lower fixed knife is rigidly connected to the body of the scissors.

Rice. 45. Electric scissors I-31

Pneumatic scissors work under the influence of compressed air.

Mechanically driven guillotine shears cut steel sheets up to 40 mm thick. Circular shears cut sheet material up to 25 mm thick in straight or curved lines.

For cutting small workpieces or parts, manual and electromechanical hacksaws are used.

A hand saw (Fig. 46) is a steel sliding frame, called a machine, in which a steel hacksaw blade is reinforced. The hacksaw blade has the shape of a plate up to 300 mm long, 3 to 16 mm wide and 0.65 to 0.8 mm thick. The teeth of the hacksaw blade are bred in different directions so that the width of the cut formed during cutting is 0.25-0.5 mm larger than the thickness of the hacksaw blade.

Hacksaw blades come with small and large teeth. When cutting parts with thin walls, thin-walled pipes and thin profile rolled products, blades with fine teeth are used, and for cutting soft metals and cast iron - with large teeth.

The hacksaw blade is installed in the machine with the teeth forward and tensioned so that it does not warp during operation. Before starting work, the workpiece or part to be cut is installed and clamped in a vice so that the marking line (cut line) is located as close as possible to the vise jaws.

During operation, the locksmith should hold the hacksaw by the handle with his right hand, and his left hand should lie on the front end of the machine. When moving the hacksaw away from you, a working stroke is made. With this move, you need to press, and when you move the hacksaw back, i.e., when you move it towards yourself, an idle stroke occurs, at which pressure should not be done.

The work of a manual hacksaw is unproductive and tiring for the worker. The use of electromechanical hacksaws dramatically increases labor productivity. The device of an electromechanical hacksaw is shown in fig. 47. In the body of the hacksaw there is an electric motor that rotates the shaft on which the drum is mounted.

Rice. 47. Electromechanical hacksaw

The drum has a spiral groove along which the pin, fixed in the slider, moves. A hacksaw blade is attached to the slider. When the electric motor is running, the drum rotates, and the hacksaw blade attached to the slider, reciprocating, cuts the metal. The bar is designed to stop the tool during operation.

Hacksaw blade.

Rice. 46. ​​Hacksaw:
1 - machine, 2 - fixed earring, 3 - handle, 4 - hacksaw blade, 5 - magnifying glass, 6 - lamb, 7 - movable earring

Rice. 48. Pipe cutter

A pipe cutter is used to cut pipes. It consists of a bracket (Fig. 48) with three disc incisors, of which the incisors are fixed, and the incisor is movable, and a handle mounted on the thread. When working, the pipe cutter is put on the pipe, by turning the handle, the movable disk is moved until it comes into contact with the surface of the pipe, then, rotating the pipe cutter around the pipe, they cut it.

Pipes and profile material are also cut with band or circular saws. The device of the band saw LS-80 is shown in fig. 49. On the saw bed there is a table with a slot designed for the passage (tape) of the saw blade. In the lower part of the bed there is an electric motor and the drive pulley of the saw, and in the upper part of the bed there is a driven pulley. Using the handwheel, the saw blade is pulled.

In circular saws, instead of a cutting band, there is a cutting disc. A feature of circular saws is the ability to cut profile metal at any angle.

Thin grinding wheels are also used for cutting hardened steel and hard alloys.

filing metal

Filing is one of the types of metalworking, which consists in removing a layer of metal from a workpiece or part to obtain the desired shapes, sizes and surface finish.

This type of processing is performed with a special metalwork tool called a file. Files are made from tool steels U12, U12A, U13 or U13A, ShKh6, ShKh9, ShKh15 with obligatory hardening. According to the shape of the cross section, the files are divided into flat (Fig. 50, a), semicircular (Fig. 50.6), square (Fig. 50, c), trihedral (Fig. 50, d), round (Fig. 50, e ) and etc.

By type of notch, files come with single and double notches (Fig. 51, a, b). Files with a single notch are used for filing soft metals (lead, aluminum, copper, babbit, plastics), files with a double notch are used for processing hard metals. Depending on the number of notches per 1 lin. cm, files are divided into six numbers. No. 1 includes files with a large notch with a number of teeth from 5 to 12, the so-called "bastard files". Files with a notch No. 2 have a number of teeth from 13 to 24, they are called "personal". The so-called "velvet" files have a fine notch - No. 3, 4, 5, 6, are made with a number of teeth from 25 to 80.

Rice. 49. Band saw LS-80

Rice. 50. Files and their application (left):
a - flat, o - semicircular, c - square, d - trihedral, d - round

For rough filing, when it is required to remove a metal layer from 0.5 to 1 mm, bastard files are used, which can remove a metal layer with a thickness of 0.08-0.15 mm in one stroke.

In cases where, after preliminary rough filing with bastard files, clean and accurate processing of the workpiece or part is required, personal files are used, which can be used to remove a layer of metal with a thickness of 0.02-0.03 mm in one stroke.

Rice. 51. Notch files:
a - single, b - double

Velvet files are used for the most precise processing and giving the treated surface a high purity. For finishing and other special work, files called “needle files” are used. They have the smallest notch. For filing soft materials (wood, leather, horns, etc.), files are used, which are called rasps.

The choice of file depends on the hardness of the surface to be treated and the shape of the workpiece or part. To increase the service life of the files, it is necessary to take measures to protect them from water, oil, dirt. After work, the notch of the files should be cleaned with a metal brush from dirt and sawdust stuck between the teeth of the notch. For storage, the files are placed in tool boxes in one row, preventing them from touching each other. To prevent oiling of the file during operation, the notch is rubbed with oil or dry charcoal.

Filing techniques. The productivity and accuracy of filing depend mainly on how coordinated the movements of the right and left hands are, as well as on the pressure on the file and the position of the locksmith's body. When filing, the fitter stands on the side of the vise at a distance of approximately 200 mm from the edge of the workbench so that the movement of his hands is free. The position of the locksmith's body is straight and rotated by 45° in relation to the longitudinal axis of the vise.

The file is taken by the handle with the right hand so that the thumb is located on top along the handle, and the remaining fingers clasp it from below. The left hand should rest with the palm across the top surface of the front end of the file.

The movement of the file must be strictly horizontal, and the pressure force of the hands must be adjusted depending on the fulcrum of the file on the surface being processed. If the fulcrum is in the middle of the file, then the pressing force with both hands should be the same. When moving the file forward, you need to increase the pressure of the right hand, and, on the contrary, reduce the left hand. The movement of the file back should be without pressure.

When filing on the surface to be treated, there are traces of the teeth of the file, called strokes. The strokes, depending on the direction of movement of the file, can be longitudinal or cross. The quality of filing is determined by how evenly spaced strokes. To obtain a pra-ail sawn surface, evenly covered with strokes, cross filing is used, which consists in first filing with parallel strokes from right to left, and then from left to right (Fig. 52, a).

After rough filing, the quality of the work is checked against the light with a straightedge, which is applied along, across and diagonally to the processed plane. If the clearance is the same or not at all, the filing quality is considered good.

A more accurate way is to check “for paint”, which consists in the fact that a thin layer of paint (usually blue or soot diluted in oil) is applied to the surface of the test plate and the part is applied to it with a treated surface, and then, by lightly pressing on the part, they move it is all over the plate and removed. If traces of paint are evenly distributed over the entire surface of the part, it is considered that filing is done correctly.

Thin round parts are filed as follows. A wooden block with a trihedral cut is clamped in a vice, in which the sawn part is placed, and its end is clamped in a hand vise (Fig. 52, b). When filing, hand vises, together with the part fixed in them, are gradually turned with the left hand.

When filing several planes located relative to each other at an angle of 90 °, proceed as follows. First, wide opposite planes are processed with cross filing and checked for parallelism. After that, one of the narrow planes is filed with longitudinal strokes. The quality of its processing is checked with a ruler for clearance, the angles formed with a wide plane - a square. Then the remaining planes are sawn off. Narrow planes for mutual perpendicularity are checked with a square.

When filing parts made of thin sheet metal, first they process wide planes on surface grinders, then the parts are combined into packs and their edges are filed using the usual methods.

Sawing straight shaped armholes usually begins with the manufacture of liners, and only after that proceed to the armholes. First, the outer edges of the armhole are filed, then the center and contours of the armhole are marked, after marking, a round hole is drilled so that the edges of the hole are at least I-2 mm away from the marking lines. After that, a preliminary filing of the hole (armhole) is performed and trimming with a needle file is made in its corners.

Rice. 52. Filing surfaces:
a - wide flat, b - cylindrical

Then they proceed to the final processing, filing first two mutually parallel sides of the armhole, after which the adjacent side is filed according to the template, and then the next opposite, parallel to it. Mark the armhole a few hundredths of a millimeter smaller than the size of the liner. When the armhole is ready, make an adjustment (exact fit of the parts to each other) along the liner.

After fitting, the liner should fit into the armhole and have no gaps in the places of contact with it.

Identical parts are made by filing along a copier-conductor. The copier-conductor is a device, the contour of the working surfaces of which corresponds to the contour of the manufactured part.

For filing along the copier-conductor, the workpiece is clamped together with the copier in a vice (Fig. 53) and the parts of the workpiece protruding beyond the contour of the copier are filed. This processing method increases labor productivity when filing parts made of thin sheet material, which are clamped into a vise several pieces at once.

Mechanization of the sawing process. At repair enterprises, manual filing is replaced by mechanized, performed at filing stations. machine tools with the help of special devices, electric and pneumatic grinders. Light portable machines include a very convenient I-82 electric grinder (Fig. 54, a) and a ShR-06 pneumatic grinder (Fig. 54.6), on the spindle of which there is an abrasive wheel. The spindle is driven by a pneumatic rotary motor.

For filing surfaces in hard-to-reach places, a mechanical file is used (Fig. 54, c), powered by an electric drive with a flexible shaft that rotates the tip /. The rotation of the tip is transmitted through the roller and the worm gear to the eccentric 2. During rotation, the eccentric informs the plunger 3 and the file attached to it reciprocating motion.

Sawing safety. The sawn workpiece must be securely clamped in a vice so that during operation it cannot change its position or jump out of the vice. Files must be with wooden handles, on which metal rings are mounted. The handles fit firmly onto the file shanks.

The shavings formed during filing are removed with a hair brush. It is strictly forbidden for a mechanic to remove chips with his bare hands or blow them off, as this can lead to injury to hands and eyes.

Rice. 53. Filing on a copier:
1 - copier strip, 2 - removable layer

Rice. 54. Tools for mechanized filing:
a - electric grinder I-82, 6 - pneumatic grinder ShR-06, c - mechanical file

When working with portable electric tools, you must first check the reliability of their grounding.

scraping

Scraping is the process of removing a very thin layer of metal from an insufficiently flat surface with a special tool - a scraper. Scraping is the final (precise) finishing of the surfaces of mating machine parts, plain bearing shells, shafts, calibration and marking plates, etc. to ensure a snug fit of the connection parts.

Scrapers are made from high-carbon tool steel U12A or U12. Often scrapers are made from old files, having removed a notch from them with an emery wheel. The cutting part of the scraper is hardened without subsequent tempering in order to give it high hardness.

The scraper is sharpened on an emery wheel so that the strokes from sharpening are located across the blade. To avoid strong heating of the blade during sharpening, the scraper is periodically cooled in water. After sharpening, the blade of the scraper is adjusted on grinding whetstones or on abrasive wheels, the surface of which is coated with machine oil.

Scrapers come with one or two cutting ends, the first are called one-sided, the second - two-sided. According to the shape of the cutting end, the scrapers are divided into flat (Fig. 55, a), trihedral (Fig. 55, b) and shaped.

Flat one-sided scrapers come with a straight or bent down end; they are used for scraping flat surfaces of grooves and grooves. For scraping curved surfaces (when processing bushings, bearings, etc.), trihedral scrapers are used.

Shaped scrapers are designed for scraping shaped surfaces, grooves with complex profiles, grooves, grooves, etc. A shaped scraper is a set of steel plates, the shape of which corresponds to the shape of the treated surface. The plates are mounted on a metal holder. scraper and fixed on it with a nut.

The quality of surface treatment by scraping is checked on a surface plate.

Depending on the length and width of the processed flat surface, the scraping allowance should be from 0.1 to 0.4 mm.

The surface of a part or workpiece before scraping is processed on metal-cutting machines or by filing.

After pre-treatment, scraping begins. The surface of the calibration plate is covered with a thin layer of paint (red lead, blue or soot diluted in oil). The surface to be treated is carefully wiped with a cloth, carefully placed on the surface plate and slowly moved over it in a circular motion, after which it is carefully removed.

As a result of such an operation, all areas protruding on the surface are painted and clearly distinguished by spots. Painted areas (spots) together with the metal are removed with a scraper. The surface to be treated and the reference plate are then cleaned and the plate is recoated with a layer of paint, and the workpiece or part is again placed on it.

Rice. 55. Manual scrapers:
a - straight flat one-sided and flat one-sided with a bent end, b - trihedral

Newly formed spots on the surface are again removed with a scraper. Spots during repeated operations will be made smaller, and their number will increase. Scrap until the spots are evenly distributed over the entire surface to be treated, and their number meets the specifications.

When scraping curved surfaces (for example, a bearing shell), instead of a calibration plate, a shaft neck is used, which must be in conjunction with the machined surface of the bushing. In this case, the bearing shell is placed on the shaft neck, covered with a thin layer of paint, carefully turned around it, then removed, clamped in a vise and scraped over the spots.

When scraping, the scraper is set in relation to the surface to be treated at an angle of 25-30° and is held with the right hand by the handle, pressing the elbow to the body, and with the left hand they press the scraper. Scraping is done with short movements of the scraper, and if the scraper is flat straight, then its movement should be directed forward (away from you), with a flat scraper with the end bent down, the movement is done backward (towards you), and with a trihedral scraper - sideways.

At the end of each stroke (movement) of the scraper, it is torn off from the surface to be treated so that burrs and ledges do not result. To obtain a smooth and precise surface to be treated, the scraping direction is changed each time after checking for paint so that the strokes intersect.

The scraping accuracy is determined by the number of evenly spaced spots on an area of ​​25X25 mm2 of the treated surface by applying a control frame to it. The average number of spots is determined by checking several areas of the treated surface.

Manual scraping is very laborious and therefore it is replaced at large enterprises by grinding, turning, or it is carried out by mechanized scrapers, the use of which facilitates work and dramatically increases its productivity.

Rice. 56. Mechanized scraper

The mechanized scraper is driven by an electric motor (Fig. 56) through a flexible shaft connected at one end to the gearbox and at the other to the crank. When the electric motor is turned on, the crank begins to rotate, imparting a reciprocating motion to the connecting rod and the scraper attached to it. In addition to the electric scraper, pneumatic scrapers are used.

Lapping

Lapping is one of the most accurate methods of final finishing of the treated surface, providing high processing accuracy - up to 0.001-0.002 mm. The lapping process consists in removing the thinnest layers of metal with abrasive powders, special pastes. For lapping, abrasive powders made of corundum, electrocorundum, silicon carbide, boron carbide, etc. are used. Lapping powders are divided into grinding powders and micropowders according to their grain size. The former are used for rough grinding, the latter for preliminary and final finishing.

To grind the surfaces of mating parts, for example, valves to seats in engines, nipples to valve sockets, etc., GOI (State Optical Institute) pastes are mainly used. GOI pastes rub any metals, both hard and soft. These pastes are available in three types: coarse, medium and fine.

Coarse GOI paste is dark green (almost black), medium is dark green, and fine is light green. Lapping tools are made of gray fine-grained cast iron, copper, bronze, brass, and lead. The shape of the lap must match the shape of the surface to be lapped.

Lapping can be done in two ways: with and without a lap. The processing of surfaces that are not mating with each other, for example, gauges, templates, squares, tiles, etc., is carried out using a lap. The mating surfaces are usually lapped together without the use of a lap.

Laps are movable rotating discs, rings, rods or fixed plates.

The process of grinding non-conjugated planes is as follows. A thin layer of abrasive powder or a layer of paste is applied to the surface of the flat lap, which is then pressed into the surface with a steel bar or rolling roller.

When preparing a cylindrical lap, the abrasive powder is poured in an even thin layer on a hardened steel plate, after which the lap is rolled along the lap until the abrasive powder is pressed into its surface. The prepared lap is inserted into the workpiece and is moved along its surface with light pressure, or, conversely, the workpiece is moved along the surface of the lap. Abrasive powder grains pressed into the lap cut off a metal layer 0.001-0.002 mm thick from the lapped surface of the part.

The workpiece must have a lapping allowance of not more than 0.01-0.02 mm. To improve the quality of grinding, lubricants are used: engine oil, gasoline, kerosene, etc.

Mating parts are lapped without lapping. A thin layer of the appropriate paste is applied to the surfaces of the parts prepared for lapping, after which the parts begin to move one over the other in a circular motion in one direction or the other.

The manual lapping process is often replaced by a mechanized one.

Automotive repair shops use rotaries, electric drills, and pneumatic machines to grind valves into seats.

The valve is ground to its seat as follows. The valve is installed in the guide bushing of the cylinder block, having previously put a weak spring and a felt ring on the valve stem, which protects the guide bushing from getting lapping paste into it. After that, the working chamfer of the valve is lubricated with GOI paste and they begin to rotate the valve with a manual or electric drill, making one third of a turn to the left, and then two or three turns to the right. When changing the direction of rotation, it is necessary to loosen the pressure on the drill so that the valve, under the action of a spring put on its stem, rises above the seat.

The valve is usually rubbed first with a coarse paste, and then medium and fine. When a dull gray band in the form of a ring without spots forms on the working face of the valve and seat, the lapping is considered complete. After lapping, the valve and seat are thoroughly flushed to remove any remaining particles of lapping paste.

Drilling is used to obtain round holes in workpieces or parts. Drilling is carried out on drilling machines or a mechanical (manual), electric or pneumatic drill. The cutting tool is a drill. Drills are divided into feather drills, spiral drills, center drills, drills for drilling deep holes and combined drills. In plumbing, mainly twist drills are used. Drills are made from tool carbon steels U10A, U12A, as well as from alloyed chromium steels 9XC, 9X and high-speed P9 and P18.

A twist drill (Fig. 57) has the shape of a cylindrical rod with a conical working end, which has two helical grooves on the sides with an inclination of 25-30 ° to the longitudinal axis of the drill. Through these grooves, the chips are discharged to the outside. The tail part of the drill is made cylindrical or conical. The angle of sharpening at the top of the drill can be different and depends on the material being processed. For example, for processing soft materials, it should be from 80 to 90 °, for steel and cast iron 116-118 °, for very hard metals 130-140 °.

Drilling machines. In repair shops, single-spindle vertical drilling machines are most widely used (Fig. 58). The workpiece or part to be machined is placed on a table that can be raised and lowered with a screw. The table is fixed on the bed with the handle at the required height. The drill is installed and fixed in the spindle. The spindle is driven by an electric motor through a gearbox, automatic feed is carried out by a feed box. The vertical movement of the spindle is carried out manually by a flywheel.

A hand drill (fig. 59) consists of a spindle on which the cartridge is located, a bevel gear (consisting of large and small gears), a fixed handle, a movable handle and a breastplate. The drill is inserted into the chuck and fixed. When drilling, the locksmith holds the drill with his left hand by the fixed handle, and with his right hand rotates the movable handle, resting his chest on the bib.

Rice. 57. Twist drill:
1 - working part of the drill, 2 - neck, 3 - shank, 4 - foot, l - groove, 6 - pen, 7 - guide chamfer (ribbon), 8 - rear sharpening surface, 9 - cutting edges, 10 - jumper, 11 - cutting part

Rice. 58. Single spindle vertical drilling machine 2135

Pneumatic drill (Fig. 60, a) works under the action of compressed air. It is easy to use due to its small size and weight.

An electric drill (Fig. 60, b) consists of an electric motor, gear and spindle. A chuck is screwed onto the end of the spindle, in which the drill is clamped. On the casing there are handles, in the upper part of the body there is a bib for emphasis during work.

Drilling is carried out either according to the marking, or according to the conductor. When drilling along the markup, the hole is first marked, then it is punched around the circumference and in the center. After that, the workpiece is fixed in a vice or other device and drilling is started. Drilling according to the markup is usually carried out in two steps. First, a hole is drilled to a depth of a quarter of the diameter. If the resulting hole (non-through) matches the marked one, then drilling is continued, otherwise the installation of the drill is corrected and only after that drilling is continued. This method is of the greatest use.

Rice. 59. Hand drill

Rice. 60. Pneumatic (a) and electric (b) drills:
1 - rotor, 2 - stator, 3 - cartridge, 4 - spindle, 5 - gearbox, 6 - trigger

Drilling a large number of identical parts with high accuracy is carried out according to the jig (a template with accurately made holes). The jig is applied to the workpiece or part to be processed, and drilling is performed through the holes in the jig. The jig does not allow the drill to deviate, so that the holes are accurate and located at the right distance. When drilling a hole for a thread, it is necessary to use reference manuals to select the drill diameter in accordance with the type of thread, as well as taking into account the mechanical properties of the material being processed.

Causes of drill breakage. The main causes of drill breakage during drilling are: deviation of the drill to the side, the presence of shells in the workpiece or part, clogging of the grooves on the drill with chips, improper sharpening of the drill, poor heat treatment of the drill, blunt drill.

Drill sharpening. The sharpening of the drill has a great influence on the productivity and quality of drilling. Drills are sharpened on special machines. In small workshops, drills are sharpened by hand on emery grinders. Drill sharpening control is carried out with a special template having three surfaces a, b, c, (Fig. 61).

Hole countersinking - subsequent (after drilling) processing of holes, which consists in removing burrs, chamfering and obtaining a conical or cylindrical recess at the inlet of the hole. Countersinking is carried out with special cutting tools - countersinks. According to the shape of the cutting part, the countersink is divided into cylindrical and conical (Fig. 62, a, b). Conical countersinks are used to obtain conical recesses in holes for rivet heads, countersunk screws and bolts. Conical countersinks can be with an angle at the top of 30, 60 and 120°.

Cylindrical countersinks process the planes of bosses, recesses for the heads of screws, bolts, screws, washers. A cylindrical countersink has a guide pin that fits into the hole being machined and ensures the correct direction of the countersink. Countersinks are made from carbon tool steels U10, U11, U12.

Countersinking is the subsequent processing of holes before reaming with a special tool - a countersink, the cutting part of which has more cutting edges than a drill.

According to the shape of the cutting part, countersinks are spiral and straight, according to their design they are divided into solid, mounted and with plug-in knives (Fig. 63, a, b, c). According to the number of cutting edges, countersinks are three- and four-toothed. One-piece countersinks have three or four cutting edges, mounted ones have four cutting edges. Reaming is performed on drilling machines, as well as pneumatic and electric drills. Zenkers are fixed in the same way as drills.

Reaming is the finishing of a hole by a special cutting tool called a reamer.

When drilling a hole, an allowance for the diameter for rough reaming is not more than 0.2-0.3 mm, and for finishing - 0.05-0.1 mm. After reaming, the accuracy of the hole size increases to the 2-3rd class.

Rice. 61. Template for controlling the sharpening of drills

Rice. 62. Countersinks:
a - cylindrical, b - conical

According to the method of actuation, reamers are divided into machine and manual, according to the shape of the processed hole - into cylindrical and conical, according to the device - into solid and prefabricated. Reamers are made from tool steels.

Cylindrical solid reamers come with a straight or helical (spiral) tooth, and therefore the same grooves. Cylindrical reamers with a spiral tooth can be with right or left grooves (Fig. 64, a, b). The reamer consists of a working part, a neck and a shank (Fig. 64, c).

Rice. 63. Zenkers:
a - solid, b - mounted, i - with plug-in knives

Rice. 64. Cylindrical reamers:
a - with a right helical groove, b - with a left helical groove, c - main parts of the reamer

The cutting, or intaking, part is made conical, it performs the main work of cutting to remove the allowance. Each cutting edge forms with the reaming axis the main angle in plan Ф (Fig. 64, c), which is usually 0.5-1.5 ° for manual reamers, and 3-5 ° for machine reamers - for processing hard metals and 12- 15° - for processing soft and viscous metals. .

The cutting edges of the intake part form an angle at the top of 2 cf. with the revolving axis. The end of the cutting part is chamfered at an angle of 45°. This is necessary to protect the tops of the cutting edges from nicks and chipping during operation.

The calibrating part of the reamer almost does not cut, it consists of two sections: a cylindrical section, which serves to calibrate the hole, the direction of the reamer, and a section with a reverse taper, designed to reduce the friction of the reamer against the surface of the hole and protect the hole from development.

The neck is the section of the reamer between the working part and the shank. The neck diameter is 0.5-1 mm less than the diameter of the calibrating part. Machine reamers have conical shanks, while manual reamers have square shanks. Reamers come with uniform and uneven tooth pitch. Machine reamers are fixed in the machine spindle with the help of conical sleeves and cartridges, manual reamers are fixed in a wrench, with the help of which the reaming is performed.

Conical reamers are used to ream conical holes for Morse taper, for metric taper, for pins with a taper of 1:50. Conical reamers are made in sets of two or three pieces. A set of three reamers consists of rough, intermediate and finishing (Fig. 65, a, b, c). In a set of two reamers, one is transitional and the other is finishing. Conical reamers are made with a cutting part along the entire length of the tooth, which is also a calibrating part for finishing reamers.

Deployment by hand and on machines. Manual deployment is carried out using a wrench, in which the development is fixed. With manual deployment, small workpieces or parts are fixed in a vice, and large ones are processed without fixing.

After fixing the workpiece or part, the cutting part of the reamer is inserted into the hole in such a way that the axes of the reamer and the hole coincide. After that, slowly rotate the scan clockwise; it is impossible to rotate the scan in the opposite direction, as scuffing may result. With machine deployment on machines, they proceed in the same way as when drilling.

Rice. 65. Tapered Reamers:
a - rough, b - intermediate, c - finishing

When reaming holes in steel blanks or parts, mineral oils are used as a lubricant; in copper, aluminum, brass parts - soap emulsion. In cast iron and bronze blanks, holes are drilled dry.

The choice of reamer diameter is of great importance for obtaining the required hole size and surface finish. In this case, the thickness of the chips removed by the tool is taken into account (Table 2).

Using this table, you can choose the diameter of the reamer and countersink.

Example. It is necessary to manually unroll a hole with a diameter of 50 mm. To do this, take a finishing reamer with a diameter of 50 mm, and a rough reamer 50-0.07 = 49.93 mm.

When choosing a machine finishing reaming, one should take into account the size of the development, i.e., an increase in the diameter of the hole during machine reaming.

When processing holes with a drill, countersink and reamer, the following basic safety rules must be observed:

perform work only on serviceable machines with the necessary guards;

before starting work, tidy up clothes and headgear. When working, clothing should fit the body without fluttering floors, sleeves, belts, ribbons, etc., it should be tightly buttoned.

Long hair should be matched with a headdress:
- a drill, countersink, reamer or fixture is accurately installed in the machine spindle and firmly fixed;
- It is strictly forbidden to remove chips from the resulting hole with your fingers or blow them off. It is only allowed to remove chips with a hook or brush after the machine has stopped or when the drill is retracted;
- the workpiece or part to be processed must be installed motionless on the table or plate of the machine in the fixture; you can not hold it with your hands during processing;
- you can not install the tool during the rotation of the spindle or check the sharpness of the rotating drill by hand;
- when working with an electric drill, its body must be grounded, the worker must be on an insulated floor.

Threading

Threading is the process of obtaining helical grooves on cylindrical and conical surfaces. A set of turns located along a helical line on a product is called a thread.

The thread is external and internal. The main elements of any thread are profile, pitch, height, outer, middle and inner diameters.

Rice. 66. Thread elements

The thread profile is the shape of the section of the coil passing through the axis of the bolt or nut (Fig. 66). A thread (coil) is a part of a thread formed during one complete revolution of the profile.

The thread pitch is the distance between two similar points of adjacent turns, measured parallel to the axis of the thread, the axis of the bolt or nut.

Thread height is defined as the distance from the top of the thread to the bottom.

The top of the thread is the section of the thread profile that is at the greatest distance from the axis of the thread (the axis of the bolt or nut).

The base of the thread (depression) is the section of the thread profile located at the smallest distance from the axis of the thread.

The angle of the thread profile is the angle between the two sides of the thread profile.

The outer diameter of the thread is the largest diameter measured at the top of the thread in a plane perpendicular to the axis of the thread.

Rice. 67. Thread systems:
a - metric; b - inch, c - pipe

The average thread diameter is the distance between two lines parallel to the axis of the bolt, each of which is at a different distance from the top of the thread and the bottom of the valley. The width of the turns of the external and internal threads, measured along a circle of average diameter, is the same.

The inside diameter of a thread is the smallest distance between opposite thread roots, measured in a direction perpendicular to the thread axis.

Profiles and thread systems. Various thread profiles are used in machine parts. The most common are triangular, trapezoidal and rectangular profiles. By appointment, the threads are divided into fastening and special. A triangular thread is used to fasten parts together (threads on bolts, studs, nuts, etc.), it is often called a fastener. Trapezoidal and rectangular threads are used on parts of motion transmission mechanisms (screws for locksmith disks, lead screws for screw-cutting lathes, lifts, jacks, etc.). R. There are three thread systems: metric, inch and pipe. The main one is the metric thread, which has a profile in the form of an equilateral triangle with an angle at the apex of 60 ° (Fig. 67, a). To avoid jamming during assembly, the tops of the threads of bolts and nuts are cut off. Metric thread sizes are given in millimeters.

The pipe thread is a fine inch thread. It has the same profile as the inch one, with an angle at the top of 55 ° (Fig. 67, c). Pipe threads are mainly used for gas, water pipes and couplings connecting these pipes.

Tools for cutting external threads. For cutting external threads, a die is used, which is a piece or split ring with a thread on the inner surface (Fig. 68, a, b). The chip grooves of the die are used to form cutting edges, as well as to exit the chips.

By design, the dies are divided into round (lerks), sliding and special for cutting pipes. Round dies are solid and split. One-piece round dies have great rigidity, they give a clean thread. Split dies are used for cutting threads of low accuracy.

Sliding dies consist of two halves, which are called half dies. On the outer sides of the half dies there are grooves with an angle of 120° for fixing the half dies in the die. Each half die is marked with a thread diameter and numbers 1 and 2, which guide them when installing them in a die. Dies are made from tool steel U £ 2 "

Threading by hand with dies is carried out with the help of knobs and screw caps. When working with round dies, special knobs are used (Fig. 68, c). The frame of such a star has the shape of a round die. A round plate is installed in the hole of the frame and fixed with three locking screws having conical ends, which enter into special recesses on the plate. The fourth screw, which is included in the cut of the adjustable die, sets the outer size of the thread.

Rice. 68. Tools for cutting external threads:
a - a split die, b - a sliding die, c - a collar, d - a screw cap with an oblique frame

Sliding dies are installed in a die with an oblique frame (Fig. 68, d), which has two handles. Both half-plates are installed in a frame. With an adjusting screw, half-dies are brought together and set to obtain a thread of the desired size. A cracker is inserted between the extreme half-deck and the adjusting screw, which ensures uniform distribution of the screw pressure on the half-dice.

The thread is cut by hand and on machines. In plumbing, hand tools are more often used. External thread cutting with sliding dies is as follows. The blank of a bolt or other part is clamped in a vice and lubricated with oil. Then, a die with dies is applied to the end of the workpiece and the dies are brought together with an adjusting screw so that they cut into the workpiece by 0.2-0.5 mm.

After that, they begin to rotate the screw, turning it 1-2 turns to the right, then half a turn to the left, etc. This is done until the thread is cut to the required length of the part.

Then the die is rolled along the thread to its original position, the dies are brought closer together with the adjusting screw and the cutting process is repeated until a complete thread profile is obtained. After each pass, it is necessary to lubricate the cut part of the workpiece. Thread cutting with solid dies is performed in one pass.

Rice. 69. Locksmith taps:
a - the main parts of the tap, b - a set of taps: 1 - rough, 2 - medium, 3 - finishing

Tools for cutting internal threads. The internal thread is cut with a tap both on machines and manually. In plumbing, they mainly use the manual method.

The tap (Fig. 69, a) is a steel screw with longitudinal and helical grooves that form cutting edges. The tap consists of a working part and a shank. The working part is divided into intake and calibrating parts.

The intaking part of the tap is called the front conical part, which performs the main cutting work. The calibrating part is used to guide the tap in the hole when cutting and calibrating threads. The teeth of the threaded part of the tap are called cutting feathers. The shank serves to secure the tap in the chuck or in the collar. The shank ends in a square. According to their purpose, taps are divided into locksmith, nut, machine, etc.

Taps are used for threading by hand, they are available in sets of two or three pieces. A set of taps "" for cutting metric and inch threads consists of three pieces: rough, medium and fine (Fig. 69, b). The intake part of the rough tap has 6-8 turns, the middle tap has 3-4 turns and the finishing tap has 1.5-2 turns. With a rough tap, pre-cutting is performed, the thread is made more accurate with a medium tap, and the final cut is carried out with a finishing tap and the thread is calibrated.

According to the design of the cutting part, taps are cylindrical and conical. With a cylindrical design, all three taps of the set have different diameters. Only the finishing tap has a full thread profile, the outer diameter of the middle tap is less than the finishing tap by 0.6 of the thread height, and the diameter of the rough tap is less than the diameter of the finishing tap by the full height of the thread. Taps with a cylindrical design of the cutting part are mainly used for threading in blind holes.

With a conical design, all three taps have the same diameter, full thread profile with different chamfer lengths. These taps are used for cutting threads in through holes. Taps are made from tool carbon steels U10, U12. Threads are cut by hand using a wrench with a square hole.

The workpiece or part is fixed in a vice, and the tap - in the collar. The threading process is as follows. The rough tap is installed vertically in the prepared hole and, with the help of a wrench, they begin to rotate it clockwise with light pressure. After the tap crashes into the metal, the pressure is stopped and the rotation continues.

Periodically, it is necessary to check the position of the tap with a square in relation to the upper plane of the workpiece. The tap should be turned 1-2 turns clockwise and then half a turn counterclockwise. This should be done for

so that the chips obtained during cutting are crushed and thereby facilitate the work.

After the rough tap, cutting is done with a medium tap and then with a finish tap. To obtain a clean thread and cool the tap during cutting, lubricant is used. When cutting threads in steel blanks, mineral oil, drying oil or emulsion is used as lubricating and cooling liquids, in aluminum - kerosene, in copper - turpentine. In cast iron and bronze blanks, the threads are cut dry.

When cutting threads in workpieces made of soft and ductile metals (babbitt, copper, aluminum), the tap is periodically turned out of the hole and the grooves are cleaned of chips.

When working with a tap, various defects are possible, for example, breakage of the tap, torn thread, thread stripping, etc. The reasons for these defects are: a blunt tap, clogging of the tap grooves with chips, insufficient lubrication, improper installation of the tap in the hole and selection of the hole diameter, as well as the inattentive attitude of the worker .

Klepka

When repairing machines and assembling them, a mechanic has to deal with various connections of parts. Depending on the assembly method, the connections can be detachable and one-piece. One of the ways to assemble parts into a permanent connection is riveting.

The riveting is made by means of rivets in the manual or machine way. The riveting is cold and hot.

The rivet is a cylindrical rod with a head at the end, which is called a mortgage. In the process of riveting the rod, a second head is formed, called the closing head.

Rice. 70. The main types of rivets and rivet seams:
heads: a - semicircular, 6 - countersunk, c - semi-secret, d - step of the rivet connection; seams; d - overlap, e - butt with one overlay, g - butt with two overlays

According to the shape of the embedded head, rivets come with a semicircular head, with a semi-counterhead head, with a countersunk head (Fig. 70, a, b, c), etc.

The connection of parts made with rivets is called a rivet seam.

Depending on the location of the rivets in the seam in one, two or more rows, rivet joints are divided into single-row, double-row, multi-row.

The distance t between the centers of the rivets of one row is called the pitch of the rivet connection (Fig. 70, d). For single-row seams, the pitch should be equal to three rivet diameters, the distance a from the center of the rivet to the edge of the parts to be riveted should be equal to 1.5 rivet diameters with drilled holes and 2.5 diameters with punched holes. In double-row seams, the pitch is taken equal to four rivet diameters, the distance from the center of the rivets to the edge of the parts to be riveted is 1.5 diameters, and the distance between the rows of rivets should be equal to two rivet diameters.

Rivet joints are performed in three main ways: overlap, butt with one overlay and butt with two overlays (Fig. 70, e, f, g). According to their purpose, rivet seams are divided into strong, dense and strong-dense.

The quality of the rivet seam depends to a large extent on whether the rivet is correctly selected.

Equipment and tools used in manual and mechanized riveting. Manual riveting is carried out using a locksmith's hammer with a square head, support, stretching and crimping (Fig. 71). Hammers are available in weights from 150 to 1000 g. The weight of the hammer is selected in accordance with the diameter of the rivet rod,

The support serves as a support for the insert head of the rivet during riveting, the tension - for a closer approach of the parts to be riveted, the swaging is used to give the correct shape to the locking head of the rivet.

Mechanized riveting is carried out by pneumatic structures. Pneumatic riveting hammer (Fig. 72) is powered by compressed air and is driven by a trigger. When the trigger is pressed, valve 9 opens and compressed air, flowing through the channels to the left side of the barrel chamber, activates the drummer, which strikes the crimp.

Rice. 71. Auxiliary tools used for riveting:
1 - crimp, 2 - support, 3 - stretch

After the impact, the spool blocks the flow of air into channel 3, connecting it with the atmosphere, and compressed air is sent through channel 4 to the right side of the barrel chamber, while the striker is thrown off channel 4, the gold-to-action is blocked, etc. The work of the pneumatic is performed by two people , one produces riveting with a hammer, and the other is an assistant.

Rice. 72. Pneumatic riveting hammer P-72

The riveting process is as follows. A rivet is inserted into the hole and set with a mortgage head on a support clamped in a vice. After that, a tension is set on the rivet rod. The tension head is hit with a hammer, as a result of which the parts to be riveted come together.

Then they begin to rivet the rivet rod with hammer blows, inflicting alternately direct and oblique blows directly on the rod. As a result of riveting, the closing head of the rivet is obtained. To give the correct shape to the closing head, a crimp is put on it and the final processing of the head is performed by hammer blows on the crimp, giving it the correct shape.

For rivets with a countersunk head, the hole is pre-treated with a cone countersink. The countersunk head is riveted with direct hammer blows directed exactly along the axis of the rivet.

The most common riveting defects are the following: bending of the rivet shaft in the hole, resulting from the fact that the diameter of the hole was very large; deflection of the material due to the fact that the diameter of the hole was small; displacement of the insert head (obliquely drilled hole), bending of the closing head, resulting from the fact that the rivet shaft was very long or the support was not installed along the axis of the rivet; undercutting of the part (sheet) due to the fact that the crimping hole was larger than the rivet head, cracks on the heads of the rivets that appear when the material of the rivets is insufficiently plastic.

Safety engineering. When performing riveting work, the following safety rules must be observed: the hammer must be securely mounted on the handle; hammer heads, crimps should not have potholes, cracks, as they can split during the riveting process and injure both the riveting worker and the workers nearby with fragments; when working with a pneumatic hammer, it must be adjusted. When adjusting, do not try the hammer while holding the swage with your hands, as this can lead to serious injury to the hand.

Pressing and pressing

When assembling and disassembling assemblies consisting of fixed parts, the pressing and pressing operations are used, carried out using presses and special pullers.

Pressing out is often done using screw pullers. The puller for pressing out the bushings is shown in fig. 73. It has a grip that is pivotally connected to the end of the screw. To secure the sleeve being pressed out in it, the gripper is tilted and inserted into the sleeve.

Rice. 73. Puller for pressing bushings

Pullers are special and universal. Universal pullers can be used to press out parts of various shapes.

In car repair shops, when disassembling and assembling cars, presses of various designs are used for pressing and pressing out: hydraulic (Fig. 74), bench rack, bench screw (Fig. 75, a, b). Bench rack and bench screw are used for pressing out bushings, fingers and other small parts. Pressing and pressing of large parts is carried out using hydraulic presses.

When pressing in and out with a hydraulic press, proceed as follows. First of all, by turning the handle (see Fig. 74), a lifting table is installed in such a way that the part being pressed or pressed out passes freely under the rod, and fixed with pins.

By rotating the flywheel, the rod is lowered to the stop with the part. After that, with the help of a lever, a pump is activated, pumping oil from the tank into the press cylinder. Under oil pressure, the piston and the rod connected to it are lowered. Moving, the rod presses (or presses out) the part. After the work is done, the valve is opened and the piston springs up along with the stem. The oil from the cylinder is passed back to the reservoir.

Rice. 74. Hydraulic press:
1 - lifting table, 2 - table lifting handle, 3 - rollers for winding the cable, 4 - lifting spring, 5 - pressure gauge, 6 - cylinder, 7 - release valve, 8 - pump lever, 9 - oil tank, 10 - rod , 11 - flywheel, 12 - pressed part, 13 - frame

Rice. 75. Mechanical presses:
a - bench rack, 6 bench screw

In all cases of pressing, to protect the surface of parts from damage and jamming, they are pre-cleaned from rust, scale and lubricated with oil. On the parts prepared for pressing, there should be no nicks, scratches and burrs.

Soldering

Soldering is a method of connecting metal parts to each other using special alloys called solders. The soldering process consists in the fact that the parts to be soldered are applied one to the other, heated to a temperature slightly higher than the melting point of the solder, and liquid molten solder is introduced between them.

To obtain a high-quality solder joint, the surfaces of the parts are cleaned of oxides, grease and dirt immediately before soldering, since the molten solder does not wet the contaminated areas and does not spread over them. Cleaning is carried out by mechanical and chemical methods.

The surfaces to be soldered are first subjected to mechanical cleaning of dirt, rust with a file or scraper, then they are degreased by washing them in a 10% solution of caustic soda or in acetone, gasoline, denatured alcohol.

After degreasing, the parts are washed in a bath of running water and then pickled. Brass parts are etched in a bath containing 10% sulfuric acid and 5% chromium peak, 5-7% hydrochloric acid solution is used for etching steel parts. At a solution temperature of not more than 40°C, parts g are kept in it from 20 to 60 minutes. ~~ After etching, the parts are thoroughly washed first in cold, then in hot water.

Before soldering, the working part of the soldering iron is cleaned with a file and then tinned (coated with a layer of tin).

When soldering, tin-lead-whist, copper-zinc are of the greatest use. copper, silver and copper-phosphorus solders.

To eliminate the harmful effects of oxides, fluxes are used that fuse and remove oxides from the surfaces to be soldered and protect them from oxidation during the soldering process. The flux is chosen in accordance with the properties of the metals to be soldered and the solders used.

Solders are divided into soft, hard. Soft solders solder steel and copper alloys. Steel parts are tinned before soldering with soft solders. Only under this condition is a reliable soldered connection guaranteed.

The most common soft solders are tin-lead alloys of the following grades: POS-EO, POS-40, POS-ZO, POS-18. Solders are available in the form of rods, wires, tapes and tubes. Zinc chloride, ammonium chloride (ammonia), rosin (when soldering copper and its alloys), 10% aqueous solution of hydrochloric acid (when soldering zinc and galvanized products), stearin (when soldering low-melting alloys) are used as fluxes when soldering with soft solders. lead).

For soldering critical parts made of cast iron, steel, copper alloys, aluminum and its alloys, hard solders are used, mainly copper-zinc and silver of the following grades: PMC-36, PMC-48, PMC-54, PSr12, PSr25, PSr45 (melting point of hard alloys from 720 to 880 °C).

For soldering aluminum and its alloys, for example, solder of the following composition is used: 17% tin, 23% zinc and 60% aluminum. Borax, boric acid and their mixtures are used as fluxes. When soldering aluminum, a flux is used, consisting of a 30% solution of an alcohol mixture, which includes 90% zinc chloride, 2% sodium fluoride, 8% aluminum chloride.

When soldering with hard solders, the parts are fixed in special devices in such a way that the gap between the parts does not exceed 0.3 mm. Then flux and solder are applied to the place to be soldered, the part is heated to a temperature slightly higher than the melting of the solder. The melted solder fills the gap and forms a strong joint when cooled.

Car maintenance

Plumbing: A Practical Guide for a Locksmith Kostenko Evgeny Maksimovich

1.1. plumbing

1.1. plumbing

Plumbing - This is a craft consisting in the ability to work metal in a cold state with the help of hand tools (hammer, chisel, file, hacksaw, etc.). The purpose of plumbing is the manual manufacture of various parts, the performance of repair and installation work.

Locksmith - This is a worker who performs metal processing in a cold state, assembly, installation, dismantling and repair of all kinds of equipment, machines, mechanisms and devices using hand tools, simple auxiliary tools and equipment (electric and pneumatic tools, simple machines for cutting, drilling, welding, bending, pressing, etc.).

The processing or assembly process (in relation to locksmith work) consists of separate operations strictly defined by the developed technological process and performed in a given sequence.

Under operation is understood as a complete part of the technological process, performed at one workplace. Individual operations differ in the nature and scope of the work performed, the tools used, fixtures and equipment.

When performing locksmith work, operations are divided into the following types: preparatory (related to preparation for work), basic technological (related to processing, assembly or repair), auxiliary (dismantling and assembly).

TO preparatory operations include: familiarization with the technical and technological documentation, selection of the appropriate material, preparation of the workplace and tools necessary to perform the operation.

Main Operations are: parting off the workpiece, cutting, off-sawing, drilling, reaming, threading, scraping, grinding, lapping and polishing.

TO support operations include: marking, punching, measuring, fixing the workpiece in a fixture or bench vise, straightening, bending material, riveting, shading, soldering, gluing, tinning, welding, plastic and heat treatment.

TO dismantling operations includes all operations associated with dismantling (using a manual or mechanized tool) the machine into kits, assembly units and parts.

IN assembly operations includes the assembly of parts, assembly units, kits, assemblies and the assembly of machines or mechanisms from them. In addition to assembly work, assembly operations include monitoring the compliance of the main mounting dimensions of the technical documentation and the requirements of technical control, in some cases, the manufacture and fitting of parts. Assembly operations also include the adjustment of assembled assembly units, kits and assemblies, as well as the entire machine as a whole.

This text is an introductory piece.

State budgetary professional educational institution "Trubchevsky Polytechnic College"

Research work

"Plumbing Yesterday and Today"

Fulfilled

Fomuk Nikita Sergeevich

2nd year student

GBPOU Trubchevsky

Polytechnic College"

Supervisor

production master

learning

Alymov Vladimir Nikolaevich

Trubchevsk 2016

Content

Introduction 3-4

Main part.

The history of plumbing in the Bryansk region 5-6

Plumbing History 6-8

The role and place of metalwork in industrial production 8-10

Locksmith training in our technical school 10-11

Organization of the locksmith's workplace 11-14

The main types of plumbing operations. 14-16

Conclusion 17

Sources used 18

Applications 19-21

Introduction.

Our region is one of the oldest areas of plumbing. The metalwork craft received special development after the Great October Revolution. Our scientists, engineers, technicians and workers have done a lot to replace heavy, inefficient manual labor with work by machine mechanisms. With the advent of metal-cutting machine tools and their improvement, the role and share of manual labor gradually decreased, which began to be replaced by the labor of planers, turners, millers, grinders, etc. But one of the leading professions is a locksmith. The work of a locksmith is still valued - a master who is required to be able to perform all types of manual metal processing.

Purpose of the study: 1) to realize the importance of the development of plumbing; 2) get acquainted with the profession of a locksmith;

3) find out what qualities a locksmith should have?

4) What, first of all, should a locksmith know and be able to do?

5) What are the main types of plumbing operations, and where are they used?

The object of my research is plumbing yesterday and today, the history of the development of plumbing.

The subject of my research is a plumbing analysis.

To achieve the goal, I plan to solvethe following tasks:

1. Collect and study the history of the development of plumbing;

2. Analyze how students learn plumbing;

3. Find out what qualities a locksmith should have, what he should know and be able to do;

4. Learn about the main types of plumbing operations and their application?

5. Help my peersengage in plumbing operations.

6. Find out with the help of a questionnaire whether the students of our technical school are familiar with locksmith work, and present the results.

The tasks set allowed us to formulate the research hypothesis: study locksmithing, learn more about the profession of a locksmith. And not all students of our technical school know about it.The study was conducted by sampling from textbooks, reference books on plumbing.

In my work I used the followingmethods:

interview method; method of text interpretation;

method of analysis and generalization; method of emotional impact through the performance of plumbing work.

Stages of work:

Questioning of students of 2-3 courses; work with textbooks, plumbing reference books, text interpretation; processing, systematization of information; registration of research results; presentation of the work; dissemination of information about the study.

Research results:

collect and systematize information about the profession of a locksmith and the types of locksmith work; make a presentation of the work in front of classmates;

reflect the results of the survey in the diagram. (Appendix No. 1)

When analyzing all the collected material, it was revealed that the profession of a locksmith is very important and in demand in the labor market.

The practical significance of the study lies in the fact that it can be used in the lessons of industrial training, in the teaching of locksmith practice. I think the work will also be important to those who are interested in locksmithing.

At the beginning of the work, a problem was posed, goals and objectives were defined. Then the information gathering process began. We worked in the regional and technical school libraries, used Internet data. The received information was analyzed and systematized. After that, the best ideas were worked out. At the last stages of work, we evaluated the achievements of our activities.

The result of the work: theoretical component and presentation.

To a person who has never worked with a locksmith tool before, it may seem at first glance that you will never master locksmith skills. However, in reality, everything is not so complicated: almost everyone who has the desire to work with their hands and head, and not run with every minor breakdown to a specialized workshop, can learn plumbing within the necessary limits for homework. Only the first step is difficult, therefore, having learned to eliminate minor malfunctions, you can understand more complex plumbing work.

These works can be learned in locksmith practice. There is such a practice in our technical school, where students master the basic operations of metalworking, equipment, tools, devices used in metalworking, instill skills in performing the main types of metalworking. Training should be carried out taking into account the knowledge gained during theoretical training. Students improve the acquired knowledge, skills and abilities.

The history of the development of plumbing in the Bryansk region.

Excavations of cities, villages, castles, fortresses, rural settlements and mounds of the era of Ancient Rus' on the territory of the Bryansk region provided rich material for characterizing crafts, mining and manufacturing industries. Numerous craft workshops and other production facilities of metallurgists and blacksmiths were found on these archaeological sites.

Production waste, blacksmith slag, and the tools for metal processing themselves, which make up a significant proportion of the things found in the settlements, indicate that most of these products were made by local artisans.

Almost all the tools of the craftsman-metallurgist were found: anvils, pincers, sledge hammers, handbrakes, files, chisels, punches, drills, cutters. (Fig. 1)

Two hand hammers were found in Zaruba, the third hammer with a pointed edge was used to cut iron. The blacksmith's essential tool is the tongs with which he holds the red-hot iron. Such a tool is also known in the collections of Vshchizh. Findings of metalwork chisels, punches and files for metal are more frequent. Jeweler's tools include small jewelry anvils, jewelry hammers, chisels, and tweezers. In the second floor. In the 18th century, when iron production in the Bryansk region reached especially significant volumes, only in its western and southwestern regions there were about 100 ores, each producing about 500 pounds of iron per year.

History of plumbing

The history of the development of plumbing and plumbing tools began many centuries ago. In ancient times, all artisans involved in metal processing were called blacksmiths. When such a branch of blacksmithing as cold forging of metal arose, locksmiths appeared - locksmiths. It is to the locksmiths that we owe the appearance of the word "locksmith". The fact is that at the beginning of the XVIII century. locksmiths began to be called Schlossers (in German Schlosser - locksmith). Over time, as is often the case in the Russian language, the foreign word became Russified and acquired a different meaning, which has to this day - "locksmith". The first meaning of the word locksmith was "locksmith".

The meaning of the word locksmith according to Efremova:
Locksmith - dealing metal processing, assembly of machinery and equipment, repair of metal products.
The meaning of the word locksmith according to Ozhegov:
Locksmith - - processing, assembly and repair of metal products, parts.
The meaning of the word locksmith according to Ushakov's dictionary:
Locksmith - locksmith, pl. locksmith and (outdated) locksmiths, m. (German: Schlosser). hand-crafted metalproducts, and by assembly.

The meaning of the word locksmith according to Dahl's dictionary:
Locksmith - m. from German. master; craftsman who makes small iron and copper engaged in cold forging, riveting, drill, sawing. unlocks, and they bow to him! plumbing Locksmith tools. Slesarskaya plumbing

Plumbing.

The metalwork craft received special development after the 1917 revolution. Our scientists, engineers, technicians and workers have done a lot to replace heavy, inefficient manual labor with the work of machine mechanisms. With the advent of metal-cutting machine tools and their improvement, the role and share of manual labor gradually decreased, which began to be replaced by the labor of planers, turners, millers, grinders, etc.

But one of the leading professions is a locksmith. The work of a locksmith is still valued - an indispensable craftsman who performs manual work that cannot be performed by a machine. The quality of the locksmith's work largely depends on the locksmith's tool and the ability to use it correctly. The fitting and assembly tool must be of high quality and reliable, and a novice locksmith needs, first of all, to study the tool that he will have to use.

In the cold manual processing of metals, a locksmith most often uses such fitting and assembly tools as hammers, chisels, hacksaws, files, etc. other.

The profession of a "mechanic" includes training in three specialties: a mechanical assembly worker, a repairman, and a toolmaker.

The role and place of metalwork in industrial production

Locksmith craft, associated with the processing of various materials, is the most ancient of the crafts. Even before the "bronze" and "iron" ages, ancient craftsmen made utensils and weapons, jewelry and tools for cultivating the land with stone axes. They became the forerunners of modern locksmiths.

With the advent of metals (bronze and then iron), the profession of a blacksmith began to predominate. For centuries, blacksmiths were the main manufacturers of tools (scythes, sickles, axes), weapons (swords, shields, spears, helmets), household items. The manufacture of locks and weapons required special skill, so specialists in more precise and fine metal processing gradually emerged from the blacksmiths. These specialists were locksmiths, who were called locksmiths.

With the development of technology and production technology, manual processing of the material was replaced by machine processing. At first, the maintenance of machines was carried out by people, and then it became automated.

At the present stage, the operation of machines is controlled using computers operating according to a predetermined program, capable of independently readjusting them when working conditions change.

However, the profession of "locksmith" has not lost its significance, since manual skills are still highly valued today.

The profession of "locksmith" at a modern machine-building enterprise is one of the most common. On the "zero" cycle of construction enterprises are workingplumbers Andelectrical fitters laying underground energy routes. The building of the enterprise is erected by metalwork fitters. After the completion of construction, equipment is supplied, which is installedfitters , and then adjusted by adjusters, in whose work a large amount of locksmith work. The parts of future machines manufactured in workshops and subdivisions go to assembly shops, whereassembly fitters Thousands of parts are assembled and debugged into finished products. All these works require special tools, fixtures and other equipment, which are madetoolmakers . And finallyrepairmen ensure the smooth operation of the equipment of the enterprise. In a word, without a locksmith - not a step!

Each of these groups of locksmiths is characterized by knowledge and professional skills specific to their work. However, the main base for each locksmith is the possession of general locksmith operations, which are the "frame", "bricks" of locksmith skills. These include marking, cutting, straightening, bending, cutting, filing, drilling, countersinking and reaming holes, threading, scraping, lapping and finishing, riveting and soldering. These operations are performed with manual and mechanized tools, which every locksmith should be able to use.

A modern locksmith must also have the skills to perform simple work on metal-cutting machines (screw-cutting lathes, universal milling, surface grinding, cross-cutting), which allows replacing tedious manual processing of parts, facilitating and improving the quality of work performed.

Locksmith work is widely used in various sectors of the national economy. Therefore, a locksmith must be well versed in the drawings, know the equipment and tools used, be able to perform locksmith work, be disciplined, and independently solve production problems.

For this, they organize excursions and industrial practice at factories, in repair shops. In production, you will get acquainted with many metal-cutting machines, and you will be able to work on some on your own.

Locksmith work is the processing of metals, usually supplementing machine machining or completing the manufacture of metal products by connecting parts, assembling machines and mechanisms, as well as their regulation. Locksmith work is performed using manual or mechanized locksmith tools or on machines.

Locksmith training in our technical school.

Locksmith practice in our technical school is carried out in workshops, in which an individual workplace is equipped for each student,

equipped with a set of tools and accessories.
The practice is carried out by masters of industrial training, who have higher specialized education and experience in metalwork metalworking, as well as who own the methodology of industrial training.
When issuing a task to students, the master explains to them the purpose and content of the task, provides them with technological maps, materials, blanks, drawings, and also talks about the equipment, fixtures, tools used, explainsrules for their use and show the most rational safe methods of performing work.

Students are allowed to work only after passingintroductory safety briefingand initial training at the workplace.If students violate labor protection requirements that can lead or have led to an accident, fire, accident, injury or explosion, then an unscheduled briefing is carried out..

Issuing tasks to students for the manufacture of complex productsmasterconducts as they acquire the necessary skills to perform simple operations, guided by the individual abilities of the student. For each completed work, the master gives students a mark on a five-point system.
Along with instilling practical skills in students, the master systematically educates them in love for their profession, careful attitude to tools and equipment.
Students who missed one or more classes in metalwork practice are required to work out the time set by the curriculum, regardless of the number of hours missed and the reasons for the absence, outside of school hours.

During the period of metalwork practice, students learned how to use measuring tools;correct marking of parts; to properly cut metal; metal cutting; to make straightening and bending of metal; manual filing of metal; drilling, countersinking, reaming.

Among student groups2-3 courses, we conducted a study on the importance of locksmith work. (Appendix No. 1)

Workplace organization

The workplace should occupy the area necessary for the rational placement of equipment on it and the free movement of the locksmith during work. The distance from the workbench and racks to the locksmith should be such that he can use mainly the movement of his hands and, if possible, avoid turning and bending the body. The workplace should have good individual lighting.

The workplace is understood as a part of the workshop, which is assigned to a specific employee or employees in the case of shift work of a particular production. The workplace is designed to perform work of a certain type and must be equipped with equipment, fixtures, tools and materials necessary for their implementation.

locksmith workbench - the main equipment of the workplace. It is a stable metal or wooden table, the lid (tabletop) of which is made of boards 50 ... 60 mm thick of hardwood and covered with sheet iron. Single workbenches are the most convenient and common, since on multi-seat workbenches, when several people work at the same time, the quality of precision work is reduced. (fig.2)

The workbench contains the tools necessary to complete the task. The drawings are placed on the tablet, and the measuring tools are placed on the shelves.

Under the tabletop of the workbench are drawers, divided into a number of cells for storing tools and documentation.

To protect workers from possible injuries when performing operations associated with the formation of chips, a replaceable protective screen 5 made of mesh or organic glass is installed on the workbench. (fig.2)

To fix the workpieces, a vise is installed on the workbench. Depending on the nature of the work, parallel, chair and hand vices are used.

The most widespread are parallel swivel and non-swivel vices, in which the jaws remain parallel during divorce. The rotary part of the vise is connected to the base with a center bolt, around which it can be rotated at any angle and fixed in the required position with the help of a handle. To increase the service life of the vise, steel overhead sponges are attached to the working parts of the jaws. (fig.3)

The vice consists of a base plate 1 and a rotary part 2. The movement of the movable jaw 4 is provided by a screw pair (lead screw 7 and lead screw nut 5), and the parallelism of this movement is provided by a guide prism 6. To rotate the upper part of the vise relative to the base plate 1 must be loosened at using the handle 11 bolts 10, and you can turn the vise. (fig.3)

Chair vise is rarely used, only to perform work related to shock loading (withcutting, riveting, etc.). Chair vise (Fig. 4) have a very limited scope. They are designed to perform heavy work associated with large shock loads, such as cutting, bending, riveting.

When processing small parts, use a hand vise.

The choice of the height of the vice according to the height of the worker and the rational placement of the tool on the workbench contribute to a better formation of skills, an increase in labor productivity and reduce fatigue.

When choosing the height of the vise installation, the left hand bent at the elbow is placed on the vise jaws so that the ends of the straightened fingers of the hand touch the chin. Tools and devices are arranged so that it is convenient to take them with the appropriate hand: what is taken with the right hand - hold on the right, what is taken with the left - on the left.

A protective screen made of metal mesh or durable plexiglass is installed on the workbench to retain pieces of metal that fly off during cutting.

Blanks, finished parts and fixtures are placed on racks installed in the area allotted for them.

The workplace must have working and control and measuring tools necessary to perform a given operation. There are certain requirements for the placement of tools, blanks and materials in the workplace:

The workplace should contain only those tools, materials and blanks that are necessary to perform this work;

Tools and materials that the worker uses frequently should be located closer to him to the right and left of the worker by approximately 350 mm;

Tools and materials used less often should be located in zones approximately 500 mm;

tools and materials that are rarely used should be kept away.

The main types of plumbing operations.

locksmith work - this is the manual processing of materials, the fitting of parts, the assembly and repair of various mechanisms and machines.

felling - a locksmith operation, during which excess metal layers are removed from the workpiece with a cutting and impact tool, grooves and grooves are cut out, or the workpiece is divided into parts. The cutting tool is a chisel, a cross-cutting tool, and a hammer is a percussion tool.

cutting is the operation of separating metals and other materials into parts. Depending on the shape and size of the blanks, cutting is carried out with a hand saw, hand or lever scissors.

Hand saw consists of a steel solid or sliding frame and a hacksaw blade, which is inserted into the slots of the heads and secured with pins. A handle is fixed on the shank of the fixed head. A movable head with a screw and a wing nut is used to tension the hacksaw blade. The cutting part of the hacksaw is a hacksaw blade (a narrow and thin plate with teeth on one of the ribs) made of steel grades U10A, 9XC, P9, P18 and hardened. Hacksaw blades are used with a length (distance between holes) of 250-300 mm. The teeth of the blade are spread (bend) so that the width of the cut is slightly greater than the thickness of the blade.

Metal dressing - an operation in which irregularities, dents, curvature, warpage, waviness and other defects in materials, workpieces and parts are eliminated. Editing in most cases is a preparatory operation. Straightening has the same purpose as straightening, but defects are corrected in hardened parts.

bending widely used to give blanks a certain shape in the manufacture of parts. For manual straightening and bending, correct plates, straightening headstocks, anvils, vices, mandrels, sledgehammers, metal and wooden hammers (mallets) and special devices are used.

Klepka - locksmith operation of joining two or more parts with rivets. Rivet connections are one-piece and are used in the manufacture of various metal structures.

The riveting is performed in a cold or hot (if the rivet diameter is more than 10 mm) state. The advantage of hot riveting is that the rod fills the holes in the parts to be joined better, and when cooled, the rivet pulls them together better. When riveting in a hot state, the diameter of the rivet should be 0.5 ... 1 mm smaller than the hole, and in a cold state, by 0.1 mm.

Manual riveting is performed with a hammer, its mass is chosen depending on the diameter of the rivet, for example, for rivets with a diameter of 3 ... 3.5 mm, a hammer weighing 200 g is required.

filing - a locksmith operation, in which a layer of metal is cut from the surface of the part with files to obtain the required shape, size and surface roughness, to fit the parts during assembly and prepare the edges for welding.

Files are steel (steel grades U13, U13A; ShKh13 and 13Kh) hardened bars of various profiles with teeth cut on the working surfaces. The teeth of the file, having the shape of a sharpened wedge in cross section, cut off layers of metal in the form of chips (sawdust) from the workpiece.

Shabreniy the operation of scraping thin layers of metal from the surface of a part with a cutting tool is called - scraper. This is the final processing of precision surfaces (machine guides, control plates, plain bearings, etc.) to ensure tight mating. Scrapers are made of U10 and U12A steels, their cutting ends are hardened without tempering to a hardness of HRC 64...66.

Lapping and polishing – surface treatment operations with especially fine-grained abrasive materials using lapping.

These operations achieve not only the required shape, but also the highest accuracy (5 ... 6th grade), as well as the lowest surface roughness (up to 0.05 microns).

Fitting and assembly work - these are assembly and dismantling works performed during the assembly and repair of machines. Various connections of parts performed during the assembly of machines are divided into two main types: movable and fixed. When performing locksmith and assembly work, a variety of tools and devices are used: wrenches (simple, socket, sliding, etc.), screwdrivers, punches, pullers, devices for pressing and pressing out.

Conclusion.

Everything that surrounds a person, with the exception of nature itself, has been created over thousands of years by his hands.

No wonder at all times the masters repeated that the material is no more stupid than the craftsman and sometimes he can tell himself what it is intended for. Perhaps this is one of the mysteries of the eternity of all the crafts that once appeared on Earth.

And if the most ancient of objects and weapons have survived to the present day, is this not the brink of eternity, in which the master himself remains forever - a person inspired by his craft?

Our ancestors, who lived long ago and recently, left us a priceless gift as a legacy - this is their rich experience, the skillful craftsmanship of craftsmen and diligence.

Having completed this work, we were convinced that today locksmith work is an indispensable part of a person’s daily life, they have entered the life of modern people.

A locksmith must have accuracy, accuracy and again accuracy. Because any of the plumbing operations: marking or cutting metal, filing or drilling, threading or soldering require accuracy, since an error of just 1 mm can lead to damage to the workpiece.

The locksmith, first of all, must know the methods of metal processing, which allow him to bring the quality of the locksmith work he performs to the required level on a lathe, milling machine of an industrial design.

Used sources

Main sources:

1. Pokrovsky B.S. Plumbing Fundamentals: A Textbook for the Beginnings. prof. education. - M .: JIC "Academy", 2007. - 272 p.

2. Pokrovsky B.S. General plumbing course: Proc. allowance. - M .: JIC "Academy", 2007 - 80 p.

3. Novikov V.Yu. "Mechanic-repairman" Proc. allowance. - M .: JIC "Academy", 2004

Additional sources:

4. Pokrovsky B.S. Locksmith basics. Workbook. - M .: JIC "Academy", 2008.

5. Ganevsky G.M., Goldin I.I. "Tolerances, landings and technical measurements" Textbook for the beginning. prof. education. - M .: JIC "Academy", 2007.

Internet resources:

Normative and technical literature "TRANSINFO"

Application

Questioning.

Students of the Trubchevsk Polytechnic College took part in the surveyII - IIIcourse (125 people.

The results of the survey on the topic "Do you know plumbing"

1. Name what locksmith tools do you know? -

125 people know (100%)

2.Can you apply locksmith tools? -

125 people (100%)

3.What locksmith operations can you do? -

Can perform any plumbing operations -

98 people (79%)

Can perform some locksmith operations, but not all.-

27 people (21%)

Conclusion: almost all students of 2-3 courses can perform plumbing

work.

Fig.1

Blacksmith's iron products from Chashin Kurgan and Pokrovskaya Gora - nails, knives, staples, hooks, keys. Bryansk Regional Museum.

Fig.2

Single locksmith workbench: a - general view: 1 - screw for raising and lowering the adjustable vice; 2 - tool box; 3 - plane-parallel vice; 4 - tool shelf; 5 - protective screen; 6 - tablet for the tool; 7 - a side from a steel corner; 8 - the handle of the drive for the vertical movement of the vise; b - the location of locksmith tools on a workbench.

Fig.3

Parallel swivel vise: 1 - base plate; 2 - turning part; 3 - fixed sponge; 4 - movable sponge; 5 - lead screw nut; 6 - guiding prism; 7 - lead screw; 8 - T-shaped circular groove; 9 - axis; 10 - bolt; 11 - handle; 12 - the nut with the bolt 10 will move freely in the circular T-slot 8. The upper part of the vise after installation in the desired position is fixed with the handle 11.

Fig.4

Chair vise: 1 - workbench; 2 - fastening bar; 3 - fixed sponge; 4 - movable sponge; 5 - clamping screw; 6 - handle; 7 - flat spring; 8 - rod.

transcript

2 1. GENERAL INFORMATION ABOUT FITTING WORK 1.1. Plumbing Plumbing is a craft that consists in the ability to process metal in a cold state with the help of manual plumbing tools (hammer, chisel, file, hacksaw, etc.). The purpose of plumbing is the manual manufacture of various parts, the performance of repair and installation work. A locksmith is a worker who performs metal processing in a cold state, assembly, installation, dismantling and repair of all kinds of equipment, machines, mechanisms and devices using hand tools, simple auxiliary tools and equipment (electric and pneumatic tools, simple machines for cutting, drilling , welding, bending, pressing, etc.). The processing or assembly process (in relation to locksmith work) consists of separate operations strictly defined by the developed technological process and performed in a given sequence. An operation is understood as a complete part of the technological process performed at one workplace. Individual operations differ in the nature and scope of the work performed, the tools used, fixtures and equipment. When performing locksmith work, operations are divided into the following types: preparatory (related to preparation for work), basic technological (related to processing, assembly or repair), auxiliary (dismantling and assembly). The preparatory operations include: familiarization with the technical and technological documentation, selection of the appropriate material, preparation of the workplace and tools necessary to perform the operation. The main operations are: cutting off the workpiece, cutting, sawing off, drilling, reaming, threading, scraping, grinding, lapping and polishing.

3 Auxiliary operations include: marking, punching, measuring, fixing the workpiece in a fixture or bench vise, straightening, bending material, riveting, shading, soldering, gluing, tinning, welding, plastic and heat treatment. Dismantling operations include all operations associated with the dismantling (using a manual or mechanized tool) of the machine into kits, assembly units and parts. Assembly operations include the assembly of parts, assembly units, kits, assemblies and the assembly of machines or mechanisms from them. In addition to assembly work, assembly operations include monitoring the compliance of the main mounting dimensions of the technical documentation and the requirements of technical control, in some cases, the manufacture and fitting of parts. Assembly operations also include the adjustment of assembled assembly units, kits and assemblies, as well as the entire machine as a whole. Professional specialization A specialist in a particular profession is a worker who performs a narrow range of work. Narrow specialization gives the employee the opportunity to know and perform the assigned operations deeper and more accurately. In the locksmith profession, there is a professional specialization associated with the maintenance and repair of specialized machines, equipment and various kinds of tools, for example: maintenance and repair of railway equipment, metallurgical equipment, automobile, tractor and agricultural machines, urban water supply and sewerage systems, etc. The difference between a workshop and a specialized locksmith shop is that there is no specialization in a locksmith shop. It performs all operations related to the plumbing profession. Locksmith shop in the local area

4 industry, maintenance and repair has a limited number of workers performing all possible types of work. Specialized locksmith sections in the factory shops have a large number of workers of various specialties who perform only locksmith work in accordance with the production and technological process of the shop. A professional team is a group of workers of one or more professions and different specialties, which specializes in performing work that is similar in nature. For example, locksmith work in the repair of vehicles, locksmith work in plumbing and sewerage work, etc. At present, such brigades are developing a combination of professions, which allows workers to perform a wider range of work. In repair and specialized workshops, workers of the following professions can work: locksmiths, blacksmiths, tinsmiths, mechanics for repairing cars, household appliances, electromechanics, welders, boilermakers, chasers, precision machine mechanics, foundry workers, etc. Locksmiths of various specialties can work at industrial enterprises: a toolmaker, a fitter, a fitter, a scriber, a fitter, an adjuster, an equipment repairman, a mechanic for the repair of electrical equipment, sanitary equipment, industrial heating networks, etc. Workplace of a mechanic At the workplace, a mechanic performs operations related to his profession. The workplace is equipped with the equipment necessary for carrying out plumbing work. The locksmith's workplace can be located both indoors and outdoors in accordance with the layout of the production facility and the technology of the production process.

5 The area of ​​the locksmith's workplace depends on the nature and volume of the work performed. At industrial enterprises, a locksmith's workplace can occupy 4-8 m 2, in workshops at least 2 m 2. A locksmith's workplace in an enclosed space is, as a rule, permanent. The outdoor workstation can be moved depending on the production environment and climatic conditions. A workbench equipped with appropriate devices, primarily a bench vise, must be installed at the locksmith's workplace. The locksmith performs most of the operations at the locksmith's workbench using a vise. The workplace of an assembly fitter or equipment repair fitter can be located at the assembly site. In addition to the main workplace (behind the workbench), the locksmith may have auxiliary workplaces, for example, at the marking, lapping or control plates, at the forge or anvil, at the welding machine, drilling machine, power saw, hand press, straightening plate, etc. e. The auxiliary workplace becomes the main one if the work is of a special nature, for example, the workplace at the drilling machine, which is serviced by a driller, the workplace at the lapping plate, at which the lapper works, the workplace at the welding machine, on which a locksmith-welder works, etc. Locksmith workshop A locksmith workshop is a room specially designed for locksmith work and equipped with the necessary equipment, fixtures, tools and technical equipment. The locksmith workshop must be equipped with workbenches (according to the number of employees), tools, a dressing plate, a lapping plate, a mechanical plate, lever shears, a drilling machine, hand-held drilling tools, a sharpening machine,

6 electric portable grinder, screw press, jacks, forge with anvil. In large workshops, lathes, planers, sometimes milling and grinding machines, as well as an electric welding machine, gas welding equipment, a heat treatment furnace, a bath for cooling parts subjected to heat treatment, and auxiliary equipment can be installed. The acetylene generator is placed in a separate room, since its improper operation can lead to an explosion with serious consequences. The staff of a locksmith shop usually consists of a foreman, locksmiths and apprentices. The nature of the work is the performance of services and repairs, less often the production of products of a certain profile. The locksmith section of the workshop The locksmith section at an industrial enterprise is an independent production unit of the workshop, which occupies a significant area and is equipped with workbenches, tools, basic and auxiliary equipment. The staff of the site consists of several tens or even several hundred people. Depending on the size of the enterprise, independent assembly and locksmith shops can be organized, which may include production units (tool pantry, pantry of materials and components, control department and a number of other production and auxiliary units). Separate parts of machines and devices manufactured at other sites are delivered to the fitter and assembly site. From these parts, site workers assemble assembly units, kits or units from which machines are mounted. The products of the metalworking section of the workshop can be presented in the form of parts. However, the site, as a rule, does not perform other services for servicing the workshop or plant.

7 The locksmith section of the workshop must be equipped with workbenches equipped with a vice, manual and mechanical drilling machines, tool sharpening machines, power saws, lever shears, straightening and lapping plates, marking plate, portable electric grinders, machines and tools for soldering, tools mechanization of lifting and transport operations, racks and containers for parts, waste containers, tool pantry. Depending on the production needs and the type of products manufactured by the enterprise, the locksmith shop can be equipped with pneumatic chisels and hammers, stamping and straightening presses, coating equipment, jacks, compressors, machine tools, cranes, equipment for gas and electric welding Labor protection, safety and occupational health Work is safe if it is performed in conditions that do not threaten the life and health of workers. At industrial enterprises, the heads of the enterprise, workshop, section (director, foreman, foreman) bear full responsibility for labor protection and safety. Each enterprise should organize a labor protection department that monitors compliance with the conditions for safe work and implements measures to improve these conditions. Employees are required to comply with the requirements of labor protection instructions. Before starting work, the employee must be instructed in labor protection. Occupational hygiene is a section of preventive medicine that studies the impact of the labor process and factors of the working environment on the human body in order to scientifically substantiate the standards and means of preventing occupational diseases and other adverse effects of working conditions on workers.

8 An employee starting work must be healthy and neatly dressed. Hair must be tucked under a headdress (beret, scarf). Locker rooms must have adequate lighting in accordance with current regulations. Distinguish between natural (daylight) and artificial (electric) lighting. Electric lighting can be general and local. The floor in the locksmith's room should be laid out from end checkers, wooden beams or asphalt masses. Contamination of the floor with oil or grease should be avoided as this may cause an accident. In order to avoid accidents at the enterprise and at the workplace, safety requirements must be observed. All moving and rotating parts of machines, equipment and tools must have protective screens. Machinery and equipment must be properly grounded. Sources of electricity must comply with current technical requirements. In the places where fuses are installed, special protective equipment must be used. Maintenance and repair of equipment and fixtures must be carried out in accordance with the instructions for use and repair. The tool must be correct. Informational (for example, “Water for drinking”, “Changing room”, “Toilets”, etc.), warning (for example, “Attention train”, “Stop! High voltage”, etc.) and prohibitive ( for example, “No smoking!”, “Grinding without glasses is prohibited”, etc.) pointers. Steel and hemp ropes of various handling equipment and accessories, seat belts should be systematically tested for strength. Fire and access roads, walkways for pedestrians (both on the territory of the enterprise and inside the premises) must be safe for traffic.

9 Do not use damaged ladders. Open channels and manholes should be well marked and protected. At the enterprise and at the workplace, the thoughts of the employee should be focused on the work entrusted to him, which must be completed quickly and efficiently. At work, violations of labor and production discipline, alcohol consumption are unacceptable. At the end of the work, you should tidy up the workplace, put the tools and accessories in the tool box, wash your hands and face with warm soapy water or take a shower. Overalls should be put away in a closet specially designed for this purpose. Each site or workshop must be equipped with a first aid kit (first aid station). The first aid kit should contain sterile bandages, cotton wool, disinfectants, plasters, bandages, tourniquets, sterile bags, triangular scarves, tires and stretchers, valerian drops, painkillers, cough tablets, ammonia, iodine, pure alcohol, drinking soda. Teams (links) of rescuers or sanitary instructors are formed from among specially trained workers at an enterprise or in a workshop. The rescuer or health instructor provides the victim with first aid in case of accidents, calls for emergency assistance, transports the victim home, to the clinic or hospital and does not leave the victim until the necessary medical care is provided to him. Employees of enterprises and locksmith shops working with metal most often experience the following occupational injuries: cuts or damage to the surface of tissues with a sharp tool, eye damage from metal fragments or shavings, burns, electric shock. A burn is damage to body tissues that have been in direct contact with a hot object, steam, hot liquid, electric current, acid.

10 There are three degrees of burns: the first degree is reddening of the skin, the second is the appearance of blisters, the third is necrosis and charring of tissues. For minor burns (first degree), first aid is provided with cleansing agents. Do not compress with oil or any ointment, as this can lead to further irritation or infection, which will require long-term treatment. The burnt area should be bandaged with a sterile bandage. A victim with first, second and third degree burns should be immediately sent to the hospital. In case of electric shock, the victim is first of all released from the source of damage (to do this, it is necessary to break the connection, turn off the voltage or drag the victim away from the place of damage, while wearing dielectric shoes and gloves) and lay on a dry surface (boards, doors, blanket, clothes), unfasten clothing that squeezes the throat, chest and stomach. Clenched teeth must be unclenched, tongue extended (preferably with a handkerchief) and a wooden object placed in the mouth to prevent the mouth from spontaneously closing. After that, begin to do artificial respiration (15 18 shoulder movements or breaths per minute). Artificial respiration should be interrupted only on the recommendation of a doctor or if the victim begins to breathe on his own. The most effective method of artificial respiration is the mouth-to-mouth and mouth-to-nose method. In the event of a fire, stop work, turn off electrical installations, equipment, ventilation, call the fire brigade, inform the management of the organization and start extinguishing the fire with the available fire extinguishing equipment. Safety measures when performing certain types of work are briefly discussed in the relevant sections. 2. BASICS OF THE TECHNOLOGY OF FITCHWORK WORK 2.1. technological process

11 Technological process is a part of the production process that is directly related to changing the shape, size or physical properties of materials or semi-finished products to obtain a product of the required configuration and quality. The technological process is also defined as a part of the production process, containing actions to change and then determine the state of the subject of production. The technological process consists of operations. An operation is a part of the technological process performed by a mechanic at one workplace with or without the use of mechanized or manual tools, mechanisms, devices when processing one part. Examples of operations: making a groove for lubrication on a plain bearing, cutting a helical surface on a rod, cutting a thread in a hole, etc. The elements of a technological operation are installation, technological transition, auxiliary transition, working stroke, auxiliary stroke, position. Set the part of the technological operation, performed with the constant fixing of the workpiece or assembly unit to be assembled. For example, drilling one or more holes of different diameters in a part while fixing the part unchanged, cutting a thread on a rod. A technological transition is a completed part of an operation, characterized by the constancy of the tool used and the surfaces formed during processing or connected during assembly. For example, drilling a part with a drill of the same diameter or connecting a sleeve to a shaft. Auxiliary transition part of the operation without changing the geometry of the machined surface or the position of the assembled parts, necessary to perform the technological transition (setting the workpiece, changing tools, etc.).

12 The working stroke is the completed part of the operation associated with a single movement of the tool relative to the workpiece, necessary to change the geometry of the part. The auxiliary stroke is not associated with a change in the geometry of the part, but is necessary for the implementation of the working stroke. A position is a fixed position occupied by a fixed workpiece or assembly unit, together with a fixture, relative to a tool or a fixed piece of equipment to perform a specific part of an operation. A process flow chart is a process document containing a description of the process of manufacturing, assembling or repairing a product (including control and movement) for all operations of one type of work performed in one workshop, in a process sequence, indicating data on technological equipment, material and labor standards. It also defines the place of work, the type and size of the material, the main surfaces of the workpiece and its installation, working tools and fixtures, as well as the duration of each operation. The technological process is developed on the basis of a drawing, which for mass and large-scale production must be made in great detail. With make-to-order production, often only a route workflow is given, listing the operations required for processing or assembly. The time required for the manufacture of a product in case of a single and small-scale production is set approximately on the basis of timing or accepted standards, and in large-scale and mass production on the basis of design and technical standards. Basing is called giving the workpiece or product the required position relative to the selected coordinate system. A base is a surface, a combination of surfaces, an axis or a point that belongs to a workpiece or product and is used for basing.

13 By purpose, the bases are divided into design, main, auxiliary, technological and measuring. The design base is used to determine the position of a part or assembly unit in a product. The main base is a design base that belongs to a given part or assembly unit and is used to determine its position in the product. For example, the main bases of a shaft assembled with bearings are its bearing journals and a thrust collar or flange. An auxiliary base is a design base belonging to a given part or assembly unit and used to determine the position of the product attached to them. For example, when connecting a shaft to a flanged bushing, the auxiliary base can be the shaft bore diameter, its collar and key. The technological base is a surface, a combination of surfaces or an axis used to determine the position of a workpiece or product in the manufacturing or repair process. For example, a part base plane and two base holes. The measuring base is used to determine the relative position of the workpiece or product and measuring instruments Universal measuring tool

14 Fig. 1. Universal measuring tools: a measuring metal ruler; b - caliper; in calipers normal; d inside gauge normal d caliper depth gauge; e goniometer universal; 90" flat square Universal measuring tools for dimensional control used in plumbing include a folding measuring metal ruler or metal tape measure, a universal caliper, a normal caliper for external measurements, a normal internal caliper for measuring diameter, a simple caliper depth gauge, a universal goniometer, a square 90, as well as compasses (Fig. 1).Simple special tools for measuring dimensions used in plumbing include an angle ruler with two

15 with a side bevel, a rectangular ruler, a threaded template, a probe, a one-sided assembly plug, a two-sided limit plug, a one-sided limit bracket and a two-sided limit bracket (Fig. 2). The universal caliper is a measuring tool used for internal and external measurements of length, diameter and depth. It consists of a guide rod made integral with a jaw having two supporting surfaces (lower for external and upper for internal measurements), a slider that is integral with the lower movable jaw for external measurements and the upper movable jaw for internal measurements, a clamping frame and retractable depth gauge rail. The guide rod is marked with millimeter divisions.

16 Fig. 2. Simple special tools for dimensional control: a ruler is angled with double-sided bevel; b the ruler is rectangular; c - threaded template; g dipstick; d cork team one-sided; e cork team double-sided limit; g bracket limit one-sided; z limiting double-sided bracket On the lower part of the slider, divisions of the vernier are given. Single-sided and double-sided calipers differ from the universal caliper in design. The measuring range of calipers of different sizes is from 0 to 2000 mm. Nonius is the divisions marked on the bottom of the caliper slider.

17 When counting with a vernier, to the number of whole divisions of the bar located below zero on the vernier scale, add the number of tenths or hundredths of a millimeter, which corresponds to the number of intervals on the vernier scale up to the stroke of this scale, coinciding with one of the strokes of the bar scale. Depending on the graduation of the vernier with a vernier caliper, dimensions can be measured with an accuracy of 0.1, 0.05 or 0.02 mm. A vernier caliper with a measurement accuracy of up to 0.1 mm has a vernier with ten divisions over a length of 9 mm, i.e. the distance between the divisions of the vernier is 0.9 mm. A vernier caliper with a measurement accuracy of up to 0.05 mm has a vernier with twenty divisions over a length of 19 mm, i.e. the distance between the divisions of the vernier is 0.95 mm. A vernier caliper with a measurement accuracy of up to 0.02 mm has a vernier with fifty divisions over a length of 49 mm, i.e. the distance between divisions is 0.98 mm. A caliper is a measuring tool used in plumbing to measure and scale a part. There are the following types of calipers and inside gauges: normal for external or internal measurements; spring for external or internal measurements. The caliper may have a scale for internal measurements. The compass is used to draw circles, curved lines, or to sequentially transfer the position of points on a line when marking out parts. There are spring compasses and compasses with an arc setting. An angle template, called a square, is used to check or draw angles on the plane of the workpiece. Squares are flat (regular and curved), as well as flat with a wide base. The 90° square is a right angle steel template. Often, steel squares with an angle of 120, 45 and 60 are used.

18 Rectangular and faceted rulers are a simple handyman's auxiliary tool for checking the flatness or straightness of a surface. Rectangular rulers include solid rectangular ones with a wide working surface of an I-section and bridge rulers with a wide working surface. Faceted rulers come with a double-sided bevel, triangular, tetrahedral. Faceted rulers are made with high precision. Templates often used by a locksmith include squares, thread templates, feelers, templates for shaped surfaces Measuring tools and instruments for precise measurements Instruments and instruments for precise measurements include single or double-sided calipers, reference and angle tiles, micrometers for external measurements , inside micrometers, micrometer depth gauges, indicators, profilometers, projectors, measuring microscopes, measuring machines, as well as various types of pneumatic and electrical devices and auxiliary devices. Measuring indicators are intended for comparative measurements by determining deviations from a given size. In combination with appropriate fixtures, indicators can be used for direct measurements. Measuring indicators, which are mechanical pointer devices, are widely used to measure diameters, lengths, to check the geometric shape, alignment, ovality, straightness, flatness, etc. In addition, indicators are often used as an integral part of devices and devices for automatic control and sorting . The scale interval of the indicator is usually 0.01 mm, in some cases 0.002 mm. A variety of measuring indicators are minimeters and microcators.

19 Measuring fixtures are designed to measure large items. Measuring projectors are devices belonging to the group of optical, based on the use of the method of non-contact measurements, i.e. measurements of the dimensions of not the object itself, but its image reproduced on the screen in multiple magnification. Measuring microscopes, like projectors, belong to the group of optical instruments that use a non-contact measurement method. They differ from projectors in that the observation and measurement is not performed on the image of the object projected on the screen, but on an enlarged image of the object observed in the eyepiece of the microscope. The measuring microscope is used to measure the lengths, angles and profiles of various products (threads, teeth, gears, etc.). Rice. 3. Auxiliary measuring devices: a measuring plate; b measuring ruler; into a prism; g measuring

20 rolling pin; d sine ruler; e level; g measuring stand; h - wedges for measuring holes Auxiliary measuring devices include: plates, rulers, prisms, measuring rolling pins, sine rulers, levels, measuring racks and wedges for measuring holes (Fig. 3). All measuring instruments are highly accurate and require careful maintenance. Ensuring proper conditions of use and storage is a guarantee of durability and accuracy. Improper handling leads to premature wear and tear, impossibility of operation and even damage to measuring instruments. During the operation of the measuring tool and devices, mechanical damage, sudden temperature changes, magnetization, and corrosion are unacceptable. Necessary requirements for the operation of measuring tools and instruments are cleanliness, qualified maintenance and, above all, a good knowledge of the construction and operating conditions of measuring instruments , punches, center punch, files, needle files, flat wrenches, universal wrench, end wrench, consignment note, lever wrench for pipes, hook for pipes, chain pipe, various tongs, pliers, round teeth, hand and bench drills, drills, reamers, taps metalwork, dies, metalwork manual vise, screwdrivers, clamps, grippers, pipe bending plate, pipe cutter, hand shears for tin, mandrel with a blade for cutting material, knobs and mandrels for dies, scrapers and tools for inducing a decorative pattern, lapping plate and laps, soldering irons, blowtorch, pneumatic hammer, bearing puller, marking plate, marking tool and screw clamps.

21 The main machines, auxiliary equipment and fixtures used in locksmith work include: turning, milling, planing, drilling, grinding machines, a screw press, a forge with an anvil and a set of blacksmith tools, equipment and tools for soldering, mechanical riveting and thermal processing, manual hoist, table vice, containers for finished products, parts and waste, as well as cleaning materials. Auxiliary locksmith tools and auxiliary materials are: a hand brush, a metal brush for cleaning files, a marking tool, cleaning materials, chalk, vice cheek pads, wooden pads, oils and lubricants, steel numerical and alphabetic markers, a rasp for wood, a fitter's knife, wooden mallet, rubber mallet, emery cloth, brushes, spoon for melting tin, crucible for melting low-melting alloys of non-ferrous metals, oil and insulating tape, red lead, paints. Locksmith workbenches can be of different designs, single and double, permanent and mobile. They can be made of wood or metal; also make combined workbenches made of wood and metal. The slab of the locksmith's workbench is always made of solid wood. At the bottom of the table (under the stove) is a drawer for tools. Depending on the design of the table, a cabinet with shelves is located on the right (or left) side of the drawer. A single locksmith workbench usually has the following dimensions: length 1200 mm, width 800 mm, height mm. Multi-seat workbenches (Fig. 4) are installed in large metalwork areas or in metalwork shops. The length of the double table is mm. The distance between the axes of the vise on two or multi-place workbenches is mm. If the locksmith's area does not have natural overhead lighting, the locksmith's workbench should be installed near the windows.

22 in such a way that natural light (through windows) falls directly or at an angle from the left side of the workplace. Rice. 4. Double locksmith workbench Locksmith vise according to the design is divided into parallel with a movable back or front cheek and chair (Fig. 5). Rice. 5. Locksmith vise: a parallel; b chair

23 The group of parallel vise includes stationary, rotary, mobile and portable vise. Manual locksmith vise belong to the group of chair vise. Parallel bench vices differ from chair vices primarily in the mutual arrangement of the cheeks: in parallel bench vices, the cheeks diverge in parallel and cover the object with the entire surface; the cheeks of the chair vise diverge at an angle, and the object is fixed only by the lower surface of the cheeks. Chair vices are made from steel forgings, making them impact resistant. Used in blacksmithing, less often in plumbing. Locksmith parallel vices are made of cast iron, so they are not resistant to impacts. Replaceable corrugated jaws of the cheeks are made of steel and hardened. Parallel vices are mainly used for locksmith work and are used to perform operations related to manual metal processing with files, saws, chisels or other tools without significant effort and shock. They are also used in cases where the workpiece must be securely fixed without damaging the clamping surface. This is ensured by a clamp over the entire surface of the cheeks and the use of interchangeable soft metal pads. Parallel vice consists of the following parts: fixed and movable jaws, base, threaded bushing, screw. The fixed cheek of the non-rotating vice is integral with the base. The base has holes for attaching a vise to the table. The fixed cheek has a bushing with a thread cut inside. A screw having a rectangular or trapezoidal thread passes through a smooth hole in the movable cheek and is screwed into the threaded bushing of the fixed cheeks. The thickened cylindrical part of the screw has a hole into which the handle is inserted. By screwing in or unscrewing the screw, you can reduce or spread the cheeks of the vise. The chair vise consists of a fixed and movable cheeks, a bracket and a holder that serve to attach the vise to the table,

24 female threaded bushings, ball head screws and handles. The size of the vise is determined by the width of the jaws, cheeks, the largest distance they can diverge, as well as the weight of the vise. Locksmith's parallel stationary vise has a cheek width within mm, the distance at which the cheeks diverge from 45 to 180 mm, weight from 3 to 40 kg. Side plates made of soft metals (copper, aluminium, lead), wood, rubber, artificial and similar materials differ significantly in hardness from the materials of the processed objects. They protect the surfaces of these objects from damage or change in shape. The side plates are used only for parallel vice jaws. A screw clamp (clamp) is an auxiliary locksmith fixture made of steel. The design of the clamps varies depending on their purpose. Clamping of the processed or assembled parts is carried out using a screw (Fig. 6). Depending on the nature of the operations (processing, assembly), the clamps play the role of either the main clamp or an additional clamp when processing the part in a vice. Used for small plumbing jobs. Wrenches are used to tighten and loosen nuts and bolts, as well as to hold the bolt when tightening the nuts. There are two types of keys: unregulated and adjustable universal. Rice. 6. Screw clamps

25 keys have a key opening that can be changed within certain limits. Unregulated wrenches are divided into flat one-sided and two-sided (Fig. 7, a and b), overhead one-sided straight and double-sided curved (Fig. 7, c and d), straight and curved end (Fig. 7, e and f), as well as hook (Fig. 7, g). Universal wrenches are divided into adjustable wrenches with a head (Fig. 7, h, i), lever wrenches (Fig. 7, j), as well as special ones. The group of special wrenches includes ratchet wrenches for nuts, crank wrenches, wrenches for bolts with a hexagonal or square socket, pipe, hook, lever and chain wrenches, as well as socket wrenches with interchangeable heads. Rice. 7. Wrenches Tongs are used for auxiliary locksmith work. They can bend thin metal materials, as well as hold parts at

26 handling and assembly, unscrewing and tightening nuts of small sizes. Depending on the purpose and design, the following types of tongs are distinguished: ordinary pliers (Fig. 8, a), combined pliers, round teeth (Fig. 8, b), adjustable straight and curved (Fig. 8, c) tongs, needle nose pliers (nippers) flat and end, articulated cutters. The group of pliers also includes universal pipe pliers and nail pliers (Fig. 8, d). Rice. 8. Locksmith's tongs The puller is a locksmith's tool for removing gears, couplings, pulleys, bearings, levers, etc. from the shafts. The puller for bearings consists of two or three clamps (cheeks) and a clip connecting the shoulders of the clamps, bushings with internal thread , as well as from a screw with a hex or square head or a handle. The locksmith's manual jaw hoist belongs to the locksmith's auxiliary equipment and is used to lift and move heavy parts or materials. The direction of movement can be arbitrary. Tali are also used for repair and assembly work. The lifting capacity of the hoists is up to 1.5 tons. The planer performs roughing of flat surfaces of products in order to reduce manual processing of these surfaces with a file to a minimum. Cross-cutting machine consists of a cast bed, table and slider. In bed

27 drive mechanisms are located. The slider, located in the upper part of the bed, with the help of a special mechanism, is reciprocated along the guides of the bed (working and idling). At the end of the slider there is a swivel head of the support with a holder for the planer. On the vertical guides of the frame, a machine table is installed on the bracket, which is driven by a lead screw. A parallel vice or clamping fixture is attached to the table to clamp the workpieces. Auxiliary tools and materials, depending on the needs of the technological process and production conditions, have different purposes. They serve to clean the surfaces of objects or tools for their preservation, lubrication, painting, etc. With the help of auxiliary materials, you can give the product an aesthetic, pleasant appearance. An auxiliary tool can be used when processing a product, disassembling or assembling it, and also have a different purpose, depending on the need and nature of the operations performed Marking Marking is the operation of drawing lines and dots on a workpiece intended for processing. Lines and dots indicate processing boundaries. There are two types of markup: flat and spatial. The marking is called flat when lines and points are applied to a plane, spatial when marking lines and points are applied to a geometric body of any configuration. Spatial marking can be done on a marking plate using a marking box, prisms and squares. With spatial marking, prisms are used to rotate the marked workpiece. For flat and spatial marking, a drawing of a part and a workpiece for it, a marking plate, a marking tool are required

28 and universal marking devices, measuring tools and auxiliary materials. Marking tools include: scriber (with one point, with a ring, double-sided with a curved end), marker (several types), marking compasses, punches (regular, automatic for stencil, for a circle), calipers with a conical mandrel, hammer, center compass , rectangle, prism marker. Marking devices include: marking plate, marking box, marking squares and bars, stand, thickness gauge with scriber, thickness gauge with moving scale, centering device, dividing head and universal marking grip, rotary magnetic plate, double clamps, adjustable wedges, prisms , screw supports. Measuring tools for marking are: a ruler with divisions, a gauge, a thickness gauge with a moving scale, a vernier caliper, a square, a goniometer, calipers, a level, a control ruler for surfaces, a probe and reference tiles. Auxiliary materials for marking include: chalk, white paint (a mixture of chalk diluted in water with linseed oil and the addition of a compound that prevents the oil from drying out), red paint (a mixture of shellac and alcohol with the addition of a dye), lubricant, detergents and etching materials, wooden blocks and slats, a small tin for paints and a brush. Simple marking and measuring tools used in plumbing work are: a hammer, a scriber, a marker, an ordinary center punch, a square, a compass, a marking plate, a ruler with divisions, a caliper and a caliper. Flat or spatial marking of the part is carried out on the basis of the drawing. Before marking, the workpiece must undergo mandatory preparation, which includes the following operations: cleaning the part from dirt and corrosion (do not do it on the marking plate); degreasing

29 details (do not produce on a marking plate); inspection of the part in order to detect defects (cracks, shells, curvatures); verification of overall dimensions, as well as allowances for processing; determination of the marking base; covering with white paint the surfaces to be marked and applied to them with lines and dots; definition of the axis of symmetry. If a hole is taken as the marking base, then a wooden cork should be inserted into it. The marking base is a specific point, axis of symmetry or plane, from which, as a rule, all dimensions on the part are measured. Punching is the operation of applying small dots of depressions on the surface of a part. They define centerlines and hole centers required for machining, certain straight or curved lines on the product. Piercing is done in order to designate persistent and noticeable signs on the part that determine the base, processing boundaries or the place of drilling. The punching operation is performed using a scriber, a center punch and a hammer. Marking using a template is used in the manufacture of a significant number of identical parts. A template made of tinplate 0.5–2 mm thick (sometimes stiffened with a corner or a wooden lath) is superimposed on the flat surface of the part and outlined with a scriber along the contour. The accuracy of the applied contour on the part depends on the degree of accuracy of the template, the symmetry of the scriber tip, and also on the way the scriber tip advances (the tip must move perpendicular to the surface of the part). A template is a mirror image of the configuration of parts, lines and dots to be applied to the surface of the part. Marking accuracy (accuracy of transferring dimensions from a drawing to a part) depends on the degree of accuracy of the marking plate, auxiliary devices (gons and marking boxes), measuring tools, the tool used to transfer dimensions, on the degree of accuracy of the marking method, as well as on

30 marker qualifications. The marking accuracy is usually from 0.5 to 0.08 mm; when using reference tiles from 0.05 to 0.02 mm. When marking, be careful with pointed scribers. To protect the hands of the worker before marking, it is necessary to put on a cork, a wooden or plastic case on the tip of the scriber. To install heavy parts on the marking plate, use hoists, telphers or cranes. Oil or other liquid spilled on the floor or marking plate can cause an accident Chopping, cutting, trimming and profile cutting of parts from sheet material Bench chisel (Fig. 9) is a tool made of U7A or U8A tool carbon steel with a rectangular or rounded profile, one end which is wedge shaped. Chisel dimensions: length mm, thickness 8-20 mm, width mm. A metalwork chisel is used for cutting or removing a layer of metal when machining accuracy is not required. They can also cut, cut and cut material. Rice. 9. Bench chisel Depending on the type of material being cut or cut, the angle of sharpening of the chisel is: 60 for steel, 70 for cast iron and bronze, 45 for copper and brass, 35 for zinc and aluminum. The material to be cut (tin, strip iron, steel tape, profile, rod) should be placed on a steel plate or on an anvil so that it rests with its entire surface on the surface of the plate or anvil. The material to be

31 chop off the workpiece, can be fixed in a vise. If the metal is longer than a slab or anvil, its overhanging end must be supported by appropriate supports. A sheet or piece of tin with the contour of the element marked on it is placed on a steel plate to cut the tin. The tip of the chisel is placed at a distance of 1-2 mm from the marked line. By hitting the chisel with a hammer, the tin is cut. By moving the chisel along the contour and at the same time hitting it with a hammer, the shaped element is cut out along the contour and separated from the tin sheet. The cutting of an element from a thick sheet material is performed first on one side of the sheet, then it is turned over to the other side and cut out completely (by moving the chisel along the resulting trace from the tip of the chisel). The cut out element along the contour is processed with a hand file. Warped or dented tin before marking should be straightened on the plate with a rubber or wooden mallet. Before laying the sheet on the slab during straightening, marking and cutting, the slab should be thoroughly cleaned and wiped. The tin should adhere to the plate with its entire surface. A blunt or chipped chisel and a chipped or riveted hammer must not be used. A chisel is used to cut material in cases where it is difficult or impossible to use scissors or a saw due to the complexity of the required configuration of the part, when there are no (at all or at the moment) the necessary scissors, when the material being cut is too hard. When cutting viscous materials (thick tin or strip iron), in order to protect the chisel from jamming, the cutting part of the chisel should be lubricated with oil or soap and water, which reduces friction and makes it possible to obtain a smooth cut surface. Trimming is the removal of the edge of the material with a chisel, as well as the removal of sagging and sprues on the surface of the castings. Kreutzmeisel is a metalwork tool, similar to a chisel, but having a narrow or shaped (groove) cutting part. He serves

32 for cutting rectangular or shaped grooves. It is made of U7A or U8A tool carbon steel. Kreuzmeysel dimensions: length mm, width mm, thickness 8 16 mm; groove dimensions: length mm, width 6 25 mm, thickness 6 16 mm. There are several types of crosscuts: rectangular, semicircular and special (Fig. 10). Cutting is the execution of grooves, recesses, as well as auxiliary grooves when cutting a large surface with the help of a crosscut. Rice. 10. Kreuzmeysel: a rectangular; b semicircular (groove) A chisel is used for cutting, a cross maker is used for cutting. The chisel is made of carbon tool steel U7A or U8A with a carbon content in the range of 0.65-0.74% (U7A steel) and 0.75-0.84% ​​(U8A steel). After heating one end of the chisel billet to a temperature of C, it is forged, giving it the shape of a point. After forging (obtaining a wedge), this part of the workpiece is pre-sharpened and heated again to the hardening temperature (C; flame color is cherry), after which the tip is lowered into water to a depth of 15 mm for two seconds in order to harden it. After hardening, the workpiece, while still heated, is cleaned of scale on a steel plate or with a file, while observing the color of the plaque that gradually appears on the tip during cooling. Holidays are carried out at a temperature of C (the color of the plaque from

33 light straw to violet blue). The chisel head is tempered, depending on the grade of steel, at a temperature of C (the color of the coating is from dark blue to gray). The second tempering method is based on the complete cooling of the tool after quenching, cleaning it and reheating it to the appropriate tempering temperature (the temperature and colors of the coating are given above), upon reaching which the tool cools rapidly. After tempering, the cutting part is sharpened. The hardness of the working part of chisels and crosscuts at a length of 0.3 0.5 of the conical part HRC 52 57, the impact part at a length of mm HRC (methods for determining and designating the hardness of metals are discussed in clause 4.3). For mechanical cutting, a manual pneumatic hammer with a chisel inserted into it is used. The pneumatic hammer is driven by compressed air. Pneumatic hammers are also used in riveting and construction work. They provide (depending on the design) from 750 to 3000 beats per minute. They are used both indoors and outdoors during installation and construction work. The heads of chisels and crosscuts have beveled, rounded end surfaces. In case of blunting or damage to the point, the cutting part of the chisel should be sharpened to the appropriate angle. After work, the tool must be cleaned of dirt and wiped with a cleaning cloth soaked in oil. In case of non-compliance with safety requirements when cutting, cutting and cutting, a locksmith most often receives injuries to his hands or face from fragments of the processed materials or tools. Work with a chisel or cross-cutting tool should be in goggles and gloves. The workplace of a locksmith working with a chisel must be fenced with a protective net

34 manual screw presses, hydraulic presses, windrowers and gates. Metal bending, depending on its thickness, configuration or diameter, is performed with a hammer using locksmith tongs or blacksmith tongs on a dressing plate, in a vice or in molds or on an anvil. You can also bend metal in various bending fixtures, bending machines, dies on bending presses and other equipment. A hammer is a percussion instrument consisting of a metal head, a handle and a wedge fig. eleven). Rice. 11. Locksmith's hammer: a metal head; b handle; The wedge Hammer is widely used in various plumbing operations; this is one of the main tools in the performance of plumbing work. The metal part consists of the following elements: a clinoid part, a slightly rounded butt (shock part) and a hole. The handle for the hammer is made of hard wood with a section and length depending on the size of the hole in the hammer and on its weight. After fitting the hammer onto the handle, a wooden or metal wedge is driven into it to prevent the hammer from falling off the handle.

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Annotation The manual contains the necessary information on the technology of locksmith work, including all the basic operations in the manufacture of metal products, installation, dismantling and repair of equipment. Given

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П/п 15.01.35 Master of locksmith works in accordance with the Federal State Educational Standard according to TOP-50 Logistics and technical support of the educational process Name of equipment Short annotation Price, in rub. 1. A set of training equipment

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Metal marking is the operation of applying lines (marks) to the workpiece, which determine, according to the drawing, the contours of the part and the places to be processed. Marking is planar and spatial. Planar markings

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Chapter 1
introductory course

1.1. The concept of plumbing. Its relevance in modern conditions

The main material in the metalworking industry and mechanical engineering are metals. People have been mining and processing metals since ancient times. Metals were used to make weapons, tools, household items. Swords, shields, axes, sickles, scythes, vessels for cooking food, and various decorations were made from it. In ancient Rus', metal products were made by blacksmiths. The development of blacksmithing led to a division of labor among artisans. Some blacksmiths performed large and rough work, others did small and fine work, there appeared blacksmiths-nail-makers and staplers, ring-makers and money-makers, armor-makers and archers. A new branch of the blacksmith's craft arose - cold forging of metal, that is, forging without heating the metal. On the basis of the division of labor in blacksmithing and the use of cold forging, a new craft began to take shape - metalwork. The most typical representatives of this branch were lockmakers. They were called "schlossers" from the German word "der Schloss - castle". Over time, the foreign word acquired a different meaning. This is how the name of the profession appeared - a locksmith. With the advent of metal-cutting machines and their improvement, the role and share of manual labor was reduced, which began to be replaced by the labor of planers, turners, millers, and grinders. But one of the leading professions is a locksmith. The work of a master locksmith is still valued, from which the ability to perform all types of manual metal processing is required.
In modern mechanical engineering, the role of locksmith work is quite large. Not a single machine (mechanism, device) can be assembled and adjusted without the participation of locksmiths. Mastering the qualifications of a locksmith is important for increasing the productivity of workers in many specialties. In working with metal and machines, there is a constant need to use such plumbing operations as straightening, cutting and chopping metals, threading, soldering, lapping and fitting parts, the ability to make and restore a working tool. Locksmith work covers various industries. Therefore, universal locksmiths began to be subdivided according to the types of work: repair fitters, tool fitters, instrument fitters, etc. Among the types of such work, a significant place is occupied by fitters of various machine tools, semi-automatic and automatic machines. The study of plumbing is necessary for agricultural machine operators, machine operators in road construction, and car drivers. Tractor operators, combine operators, crane operators, and drivers who have mastered the plumbing business quickly and better adjust the machines, eliminate and prevent any kind of downtime, and independently repair the serviced mechanisms. As a result of the use of mechanized tools, fixtures and machine tools, the profession of a locksmith began to approach the professions of machine operators. Now the locksmith is required to be able to work on planing, grinding, lapping and other machines. The volume of locksmith processing is characterized by the level of technology and depends on the type of production. At enterprises producing dissimilar products in small quantities, versatility is required from locksmiths. A locksmith at such an enterprise performs work of varying complexity. He manufactures tools and individual parts from start to finish, adjusts the parts to each other and assembles them into products, and, if necessary, solders, tins, repairs and assembles machine tools, and makes fixtures. There is a lot of manual work at such enterprises, so locksmiths make up the main workforce. A large share of manual work in mass production enterprises, where homogeneous parts are manufactured in large batches, increases the accuracy of machining and reduces the amount of locksmith work. All manual work is performed by a locksmith, which increases his importance in the manufacture of parts. The work of a locksmith continues to be necessary in mass production enterprises, where homogeneous products are produced in large quantities and for a long time. Manual processing is less productive than mechanical processing and requires great physical effort on the part of the worker. Therefore, where possible, manual processing is replaced by mechanical processing. In such establishments, skilled locksmiths perform manual work that cannot be replaced by machine work, such as product assembly. At enterprises, locksmiths are needed to install industrial steam pipelines and install heating systems, as well as to perform plumbing, gas, sanitary and technical work. From all of the above, we can conclude that in any production or economy where there are machines, mechanisms, fixtures and various devices made of metal, the work of a locksmith is necessary.

1.2. Locksmith's workplace

Workplace - part of the production area on which the equipment, inventory, tools and materials needed to complete the production task are located. It is equipped in such a way that it is convenient for the locksmith to work. The size of the locksmith's workplace depends on the nature of the work performed and must be at least 1.6 sq. m. The workplace should be well lit with diffused natural light. Based on this condition, locksmith sites and workbenches, as a rule, are located at the windows of the southern and southwestern sides of the workshop. Workplaces of locksmiths are equipped locksmith workbenches, on which the locksmith has the tools, fixtures, materials, parts, drawings, etc. necessary for work. A workbench is a stable metal or wooden table. Covers of workbenches can be covered with linoleum to protect parts from damage. For greater stability, the legs of the workbench are located at a distance of 1.5–1.6 m from each other. The height of the workbench varies between 0.8–0.9 m, and the length is 1.5 m. If several people work at the workbench, then its length increases. Each workbench, depending on the number of jobs, has a tool storage box.
Workbenches can be individual, double and multi-seat - for the simultaneous work of several locksmiths. The most common workbenches are single (individual) and double. The covers of the workbenches are equipped on three sides with boards 60–80 mm high, which are designed to keep objects located on the workbench from falling. When performing precise work, general lighting may not be enough, therefore, an electric lamp with adjustable light direction is installed at each locksmith's workplace.
On the workbenches, a metalwork vice is installed in which the workpieces are fastened. For fixing large parts, parallel rotary and fixed vices with jaws 120-150 mm long are used, and for processing small parts, parallel rotary vices with jaws 60 mm long are used. A chair vice is used for cutting sponges, since parallel vices are not strong enough to perform these works. Cases of parallel vices of all types are cast from gray cast iron. Hardened plates are screwed to the jaws of the vise, which have a cross notch that serves to increase friction between the jaws and the part clamped in them. To increase the efficiency of the production process, pneumatic spring vise is used. A feature of the vise is that the working force when clamping the part is created in them by springs, and the short-term acting force to release the part is produced by compressed air. The design of the vise provides for the regulation of the distance between the jaws, as a result of which the magnitude of the clamping force may change.
Proper placement of the tool on the workbench plays an important role in the production of plumbing work. The following arrangement of the tool is considered optimal. All tools and fixtures that are taken with the left hand are located on the left side of the workbench, those that are taken with the right hand are on the right side. Close to the locksmith are the items that he uses most often. Such an arrangement should be unchanged so that the employee can take the necessary item without spending a lot of time searching for it. It is necessary to store the tool in drawers or a cabinet in such a way that the cutting tool does not deteriorate, and the measuring tool does not receive nicks and scratches from impacts. To do this, transverse shelves 150-160 mm wide are made in the sliding tool box of the workbench. Each cell is intended for one type of tool. In one of the tool boxes, along its sides, 3-4 stepped strips are nailed, on which files are placed, while large files are placed on the lower steps, and small ones on the upper ones. The bottom of the box is divided into several cells for storing drills, reamers, taps and dies. The rest of the area of ​​the box contains a coarser tool: hammers, chisels, cross-cutters.
After finishing work, the files are cleaned of sawdust and dirt with a wire brush, and then wiped with a clean rag or napkin. The working parts of the cutting and measuring tools are lubricated with a thin layer of petroleum jelly. Locksmith tools, which are rarely used, are stored in the tool pantry.

Control questions

1. How did plumbing come about?
2. What are the main ways of plumbing development at the present time?
3. What is the name of the main workplace of a locksmith and its main characteristics.
4. How to properly equip the locksmith's workplace?

Section I
Locksmith processing of parts

Chapter 2
Dimensional processing of parts

2.1. Basic plumbing operations: purpose, essence, techniques and sequence of execution

Under locksmith work is meant the processing of metals in a cold state, performed by locksmiths manually using various tools. Locksmith processing complements machine tool machining or is the final operation in the manufacture of metal products by connecting parts, assembling machines and mechanisms, and also adjusting them. Locksmith work consists of a variety of technological operations, which include: marking, cutting, straightening and bending metals, cutting metals with a hacksaw and scissors, filing metal, drilling, countersinking and reaming, threading, riveting, scraping, grinding and finishing, soldering, tinning . Some of the listed operations can also be performed in the hot state of metals (cutting, riveting, bending). Many locksmith operations are performed not only manually, but also mechanically.
Blanks for machine parts are sent for processing to mechanical and locksmith shops in the form of forgings of sectional metal. Depending on the purpose of the parts, some workpieces remain unprocessed, others are processed partially or completely. During processing, a layer of metal is removed from the surface of the workpiece, as a result of which its size is reduced. The difference between the workpiece size before and after machining is the machining allowance. To know the optimal dimensions for processing, the workpiece must be marked. markup called the operation of applying marking lines to the workpiece to be processed, defining the contours of the future part or the place to be processed. Marking is carried out accurately and accurately, because mistakes made during marking can lead to the fact that the manufactured part turns out to be a marriage. It is also possible that an inaccurately cast reject workpiece can be corrected by careful marking, redistributing the allowances for each marking surface. The accuracy achieved with conventional marking methods is approximately 0.5 mm. With careful marking, it can be increased to hundredths of a millimeter.
Marking is used mainly in single and small-scale production. At factories of large-scale and mass production, the need for marking is eliminated due to the use of special devices - conductors, stops, etc.
Depending on the shape of the marked blanks and parts, the marking is divided into planar and spatial. Planar marking is performed on the surfaces of flat parts, on strip and sheet material and consists in applying contour parallel and perpendicular lines, circles, arcs, angles, axial lines, various geometric shapes according to specified sizes or contours of various holes according to templates onto the workpiece.
It is impossible to mark out even the simplest body with the methods of planar marking, if its surfaces are not rectilinear. With planar marking, it is impossible to apply horizontal risks to the lateral surface of the body of revolution, perpendicular to its axis, since it is impossible to attach a marking tool in the form of a square or a ruler to it and draw parallel lines.
Spatial markup- common in mechanical engineering, differs from planar. The difficulty of spatial marking is that it is necessary not only to mark individual surfaces of the part located in different planes and at different angles to each other, but to link the marking of these individual surfaces to each other.
For marking, the workpiece is inspected, checked for defects (shells, cracks, bubbles). After that, the surface intended for marking is cleaned of scale and molding earth residues. Irregularities are removed from the part and the surface is painted. The coloring of the workpiece is carried out so that the marking lines are clearly visible during processing. Black, i.e., untreated, as well as roughly processed surfaces are painted with chalk, quick-drying paints or varnishes. Chalk (powder) is diluted in water to the density of milk, and a little linseed oil and a desiccant are added to the resulting mass. It is not recommended to rub the surface to be marked with a piece of chalk, as the chalk quickly crumbles and the marking lines disappear. For painting cleanly treated surfaces, copper sulphate is used in solution or in pieces. A solution of copper sulfate (two or three teaspoons per glass of water) is applied to the surface with a brush or cloth; lump vitriol rub the surfaces moistened with water. In both cases, the surface is covered with a thin and durable copper layer, on which marking lines are clearly visible. Before applying marking marks to a painted surface, a base is determined from which risks will be applied. In planar marking, the outer edges of flat parts, strip and sheet material, as well as various lines applied to the surface, for example, center, middle, horizontal, vertical or inclined, can serve as bases. If the base is the outer edge (lower, upper or side), then it must first be aligned.
The risks are usually applied in the following order: first all the horizontal risks are drawn, then the vertical ones, then the inclined ones, and finally the circles, arcs and roundings.
Since the risks during operation are easy to wipe with your hands and then they will become poorly visible, small depressions are filled along the lines of the risks with a center punch. These recesses - cores should be shallow and divided by a risk in half. Distances between center punches are determined by eye. On long lines of a simple outline, these distances are taken from 20 to 100 mm; on short lines, as well as in corners, bends or roundings - from 5 to 10 mm. On the machined surfaces of precision products, cores are not made along the marking lines.
felling metal processing is called a cutting and percussion tool, as a result of which excess layers of metal are removed or metal is cut into pieces, intended for further processing. As a cutting tool in plumbing, a chisel or cross-cutting tool is used, and as a percussion tool, simple or pneumatic hammers. With the help of cutting it is possible to perform: removal of excess metal layers from the surfaces of workpieces; leveling uneven and rough surfaces; removal of hard crust and scale; cutting edges on forged and cast blanks; chopping after assembling the protruding edges of the sheet material, the ends of the strips and corners; cutting into parts of sheet and varietal material; punching holes in sheet material along the outlined contours; cutting edges into a joint for welding; cutting off the heads of rivets when they are removed; cutting out oil grooves and keyways.
Cutting is done in a vice, on a plate or on an anvil; bulky parts can be processed by felling at their location. A chair vise is best suited for chopping; it is not recommended to perform cutting on parallel vices, since their main parts - sponges made of gray cast iron, may not withstand strong blows and break.
The part to be cut must be fixed in place. Therefore, small parts are clamped in a vise, and large parts are placed on a workbench, stove or anvil, or placed on the floor and well strengthened. Regardless of the place of felling, the installation of parts in height must be done in accordance with the growth of the worker. Starting cutting, the locksmith prepares his workplace. Taking out a chisel and a hammer from the workbench box, he puts the chisel on the workbench on the left side of the vise with the cutting edge towards him, and the hammer on the right side of the vise with the striker pointing towards the vise. When chopping, one must stand straight and steady at the vise, so that the body is to the left of the axis of the vise. The left leg is put half a step forward, and the right one, which serves as the main support, is slightly set back, spreading the feet at an angle. Hold the chisel in your hands freely, without excessive clamping. During cutting, they look at the place of cutting, and not at the impact part of the chisel, which is hit with a hammer. The cabin is made with a sharply sharpened chisel; a blunt chisel slips off the cut surface, which leads to a decrease in the quality of the felling. The depth and width of the metal layer removed by the chisel depend on the physical strength of the worker, the size of the chisel, the weight of the hammer and the hardness of the metal being processed. The hammer is chosen by weight, the size of the chisel - by the length of its cutting volume. For every millimeter of the length of the cutting edge of the chisel, 0.04 kg of hammer weight is required. Hammers weighing 0.6 kg are usually used for cutting. Depending on the order of operations, cutting can be rough and finish. During rough cutting, with strong blows of a hammer, a layer of metal with a thickness of 1.5 to 2 mm is removed in one pass. When finishing felling, a layer of metal with a thickness of 0.5 to 1.0 mm is removed per pass, inflicting lighter blows.
To obtain a clean and smooth surface when cutting steel and copper blanks, it is recommended to moisten the chisel with machine oil or soapy water; cast iron should be cut without lubrication. Brittle metals (cast iron, bronze) must be cut from the edge to the middle. In all cases, when approaching the edge of the part, the surface should not be cut to the end, 15–20 mm should be left to continue cutting from the opposite side. This prevents chipping of corners and edges of the workpiece. At the end of metal cutting, the hammer blow on the chisel is weakened. Cutting in a vice is carried out either according to the level of the vise jaws, or above this level - according to the intended risks. According to the level of the vice, thin strip or sheet metal is most often cut, above the level of the vice (by risks) - wide surfaces of the workpieces. When chopping wide surfaces, to speed up work, use a cross cutter and a chisel. First, grooves of the required depth are cut with a crosscut, and the distance between them should be equal to 3/4 of the length of the cutting edge of the chisel. The resulting protrusions are cut down with a chisel. In order to properly cut, you need to have a good command of the skills of working with a chisel and a hammer, that is, to hold the chisel and hammer correctly, move your hand, elbow and shoulder correctly, and hit the chisel with a hammer accurately, without a miss.
Carrying out manual felling is a physically demanding and lengthy work. Cutting is facilitated by the use of a pneumatic hammer. The pneumatic hammer consists of a cylinder, a piston moving in the cylinder, and an air distribution device. When the hammer is working, the piston moves very quickly back and forth under the action of compressed air supplied by a hose at a pressure of 50–60 kPa. During the working movement, the piston plays the role of a hammer striker, striking the cutting tool (chisel or crosscut). The reverse movement of the piston is provided by an automatically operating device. During the working stroke of the piston 1, compressed air enters through the channel 5 to the right side of the cylinder; from the left side of the cylinder, the air at this time is displaced through channel 7, annular groove 6 and channel 4 into the atmosphere. At the end of the working stroke, compressed air, passing through channel 3, shifts spool 2 to the right (shown in the lower projection) and goes through the channel 7, producing a reverse stroke of the piston; air escapes from the right side of the cylinder through the channel 8. At the end of the return stroke, the channel is blocked by the piston, the air in the right side of the cylinder begins to compress and moves the spool to the left - the working stroke begins again. The hammer is activated by pressing the trigger 9 .
When cutting, hold the pneumatic hammer with both hands: with the right hand on the handle, and with the left hand on the end of the trunk and guide the chisel along the cutting line. The pneumatic hammer must be properly maintained. Each time before starting work, it is necessary to inspect the hammer and make sure that it is in good condition. It is necessary to monitor the cleanliness of the hole in the barrel sleeve where the tool shank is inserted, and the cleanliness of the shank itself. The hammer sleeve must fit snugly into the hole.
After making sure that the hammer and the working tool are in good condition, the hammer is lubricated. For lubrication use turbine oil grade L, spindle or transformer oil. After pouring oil into the hammer, pull the trigger. The oil passes into the internal parts of the hammer and lubricates them. After lubrication, a hose is attached to the hammer through which air is supplied; the hose should not be longer than 12 m. Before fastening, the hose is carefully blown with air.
After attaching the hose to the hammer, turn on the air. It is not allowed to disconnect the hose from the hammer when the access of compressed air is still not closed, since in this case the hose may suddenly escape from the hands and hit the worker.
Getting started, you must first test the hammer at low speed with an incomplete pull of the trigger. After every 2-3 hours of operation, the hammer is lubricated. When cutting with a pneumatic hammer, goggles and gloves must be worn. At the end of the work, the hammer is handed over to the pantry.
metal cutting- the operation of dividing the metal into parts. Depending on the shape and size of the workpieces or parts, cutting is carried out manually (hand scissors, hand saws, lever scissors) or mechanically (using power saws, circular saws, etc.). Round blanks are manually cut with a hand saw, and mechanically - on special machines. The essence of the process of cutting with scissors is the separation of metal parts under the pressure of cutting knives. The sheet to be cut is placed between the upper and lower knives. The upper knife, descending, presses on the metal and cuts it. The angle of sharpening depends on the amount of pressure experienced by the blades. The harder the metal, the greater the angle of sharpening of the blade: for soft metals it is 65°, for medium hard metals it is 70–75°, and for hard metals it is 80–85°. To reduce the friction of the blades on the metal being cut, they are given a small back angle of 1.5–3°.
Manual cutting of metal can be done with hand scissors or hand saws. Manual scissors are used for cutting steel sheets with a thickness of 0.5–1.0 mm and from non-ferrous metals - up to 1.5 mm. Hand shears are made with straight and curved cutting blades. According to the location of the cutting edge of the blade, hand scissors are divided into right and left. For the right scissors, the bevel of the cutting part of the half is on the right side, and for the left, on the left. The length of the scissors is 200, 250, 320, 360 and 400 mm, and the cutting part (from sharp ends to the hinge), respectively, 55–65; 70–82; 90–105; 100–120 and 110–130 mm. Well-sharpened and adjusted scissors should cut paper. Scissors are held in the right hand, covering the handles with four fingers and pressing them to the palm; the little finger is placed between the handles of the scissors. The compressed index, ring and middle fingers unclench, straighten the little finger and, with its effort, pull the lower handle of the scissors to the required angle. Holding the sheet with your left hand, feed it between the cutting edges, directing the upper blade exactly in the middle of the marking line, which should be visible when cutting. Then, squeezing the handle with all fingers of the right hand, except for the little finger, cutting is carried out. Cutting with the right scissors is carried out in a clockwise direction, with the left scissors - counterclockwise. Cutting sheet metal in a straight line and along a curve (circles and roundings) without sharp turns is performed with right scissors. For rectilinear cutting of metal of small thickness, hand-held scissors are used, one handle of which is clamped in a vice.