TO Category:
Locksmith work - general
Basic plumbing operations and their purpose
Locksmith operations are related to the processes of cold metal cutting. They are carried out both manually and with the help of a mechanized tool. The purpose of locksmith work is to give the workpiece the shape, size and surface finish specified by the drawing. The quality of the locksmith work performed depends on the skills of the locksmith, the tool used and the material being processed.
The metalworking technology contains a number of operations, which include: marking, cutting, straightening and bending of metals, cutting metals with a hacksaw and scissors, filing, drilling, countersinking and reaming holes, threading, riveting, scraping, lapping and finishing, soldering and tinning , bearing casting, bonding, etc.
In the manufacture (processing) of metal parts by the locksmith method, the main operations are performed in a certain order, in which one operation precedes the other.
First, locksmith operations are performed to manufacture or correct the workpiece: cutting, straightening, bending, which can be called preparatory. Next, the main processing of the workpiece is performed. In most cases, these are cutting and sawing operations, as a result of which excess
layers of metal and it receives the shape, dimensions and condition of the surfaces, close or coinciding with those indicated in the drawing.
There are also such parts of machines, for the processing of which the operations of scraping, grinding, finishing, etc., are also required, in which thin layers of metal are removed from the manufactured part. In addition, during the manufacture of a part, it can, if necessary, be connected to another part, together with which it is subjected to further processing. For this, drilling, countersinking, threading, riveting, soldering, etc.
All of these types of work relate to the main operations of locksmith processing.
Depending on the requirements for finished parts, additional operations can also be performed.
Their purpose is to impart new properties to metal parts: increased hardness or ductility, resistance to destruction in the environment of gases, acids or alkalis. Such operations include: tinning, enamel coating, hardening, annealing, electrohardening, etc.
When determining the sequence of processing, it is taken into account in what form the parts (blanks) arrive; coarser processing always precedes the final (finishing).
Fitting and assembly work at a machine-building enterprise is a set of operations for connecting parts in a strictly defined sequence to obtain a mechanism or machine that meets the requirements for them. technical requirements. When assembling, all the main types of locksmith work are used, including fitting the assembled parts into assemblies, followed by adjustment and checking the correct operation of mechanisms and machines. The assembly quality of the machine affects its durability and reliability in operation, since the fewer errors are allowed during assembly, the greater the performance and the better specifications machines and mechanisms.
Maintenance and repair work is aimed at maintaining the efficiency of the equipment. Repair of equipment is carried out at enterprises primarily in order to eliminate defects in machines that impede their normal operation. Worn parts are replaced during repair with new ones or restored to their original dimensions in various ways.
Technological progress and related equipment of enterprises with the latest technology, as well as the introduction into production processes advanced technology impose new requirements on existing equipment, therefore, simultaneously with the repair of machines at plants and factories, a lot of work is being done to modernize (update) it. Modernization of equipment is aimed at increasing the speed and productivity of machines, the power of their engines, reducing the time of idling and auxiliary operations, creating a narrow specialization, as well as expanding the technological capabilities of certain types of equipment and increasing the wear resistance of machine parts. Work on the modernization of equipment is carried out at the plant according to a specific plan.
The volume of locksmith processing to a large extent characterizes the technical level of the technology used and depends on the nature of production. At machine-building plants that produce heterogeneous products in small quantities (single production), specific gravity locksmith work is especially great. Here, the locksmith is obliged to perform a wide variety of locksmith work, that is, to be a universal locksmith. If necessary, he repairs and installs machine tools, manufactures fixtures, etc.
In serial production, where homogeneous parts are manufactured in large batches, the accuracy of machining increases and, accordingly, the volume of locksmith work decreases somewhat. The work of locksmiths continues to be necessary even in mass production factories, where homogeneous products are produced in large quantities and for a long time (a year, two, etc.).
In all factories and factories, regardless of the type of production, locksmiths are needed for the manufacture of dies, fixtures and tools, for repairs and installation industrial equipment, sanitary works, industrial ventilation, etc. You can’t do without locksmiths in a modern agriculture; here they repair tractors, combines and other equipment.
The metalworking technology contains a number of basic operations, such as marking, cutting, straightening and bending metals, cutting metals, filing, drilling, countersinking, countersinking and reaming holes, threading, riveting, lapping and finishing, soldering, etc. Most of these operations are for metal cutting.
3.1 Markup
Marking is the operation of drawing lines (marks) on the surface of the workpiece, showing, according to the drawing, the contours of the part or place to be processed. Markup is divided into:
Linear (one-dimensional) - along the length of bars, rolled products, strip steel,
Planar (two-dimensional) - for sheet metal blanks,
Spatial (volumetric, three-dimensional) - for bulk blanks.
Special marking tools include scribers, center punches, marking compasses, thickness gauges. In addition to these tools, hammers, marking plates and auxiliary devices are used: linings, jacks, etc.
| Figure 6 Scribe | Scribers (Figure 6) are used to draw lines on the marked surface of the workpiece. They are made from tool steel U10 or U12 (hardness HRC 58-62). Center punches (Figure 7) are used to apply recesses (cores) on pre- |
| Figure 7 Punch |
|
| marked lines so that the lines are clearly visible and not erased during the processing of parts. A center punch is a rod made of tool carbon steel U7, U8 (HRC 52-57) with a length of 100-160 mm and a diameter of 8-12 mm. The sharpening angle is usually 60, with more accurate markings - 30-45 °, for the centers of future holes - 75 °. Marking (locksmith) compasses are similar in design to drawing compasses. The thickness gauge (Figure 8) is used to apply parallel vertical and horizontal marks. Recently, a height gauge with a sharp tip is more often used. Planar and especially spatial marking of workpieces is carried out on marking plates. The marking plate is a cast iron, horizontal working surface and the side faces of which are very accurately processed. A template is a device by which parts are made or checked. |
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after processing. Template marking is used in the manufacture of large batches of identical parts. It is expedient because the time-consuming and time-consuming markup according to the drawing is carried out only once during the manufacture of the template. All subsequent operations of marking blanks consist in copying the outlines of the template. In addition, the manufactured templates can be used to inspect the part after the workpiece has been machined.
3.2 Straightening and bending of metals
Editing is an operation to eliminate defects in workpieces and parts in the form of concavity, convexity, waviness, warpage, curvature, etc. Its essence lies in the compression of the convex metal layer and the expansion of the concave one.
The metal is straightened both cold and hot. The choice of one or another method of dressing depends on the amount of deflection, dimensions and material of the workpiece (part).
Dressing can be manual (on a steel or cast iron straightening plate) or machine (on straightening rollers or presses).
The correct plate, as well as the marking one, must be massive. Its dimensions can be from 400400 mm to 15003000 mm. Plates are installed on metal or wooden supports, which ensure the stability of the plate and the horizontal position of its position.
For straightening hardened parts (straightening), straightening headstocks are used. They are made from steel and hardened. The working surface of the headstock can be cylindrical or spherical with a radius of 150-200 mm.
Manual dressing is carried out with special hammers with a round, radius or plug-in soft metal striker. Thin sheet metal is ruled with a mallet (wooden mallet).
They check the dressing "by eye", and with high requirements for the straightness of the strip - with a curved ruler or on a test plate.
Shafts and round blanks large sections are ruled with a manual screw or hydraulic press.
Bending of metals is used to give the workpiece a curved shape according to the drawing. Its essence lies in the fact that one part of the workpiece is bent relative to the other at any given angle. Manual bending is done in a vice using locksmith's hammer and various fixtures.
Bending of thin sheet metal is done with a mallet.
With plastic deformation of the metal during the bending process, the elasticity of the material must be taken into account: after the load is removed, the bending angle slightly increases.
The manufacture of parts with very small bending radii is associated with the risk of rupture of the outer layer of the workpiece at the bend. The size of the minimum allowable bending radius depends on the mechanical properties of the workpiece material, on the bending technology and surface quality.
Pipe bending is carried out with or without filler (usually dry river sand). The filler protects the pipe walls from the formation of folds and wrinkles (corrugations) in the places of bending.
studfiles.net
GBPOU RM "Saransk Polytechnic College", Ruzaevka.
Abstract for the lesson "Basic plumbing operations in welding production"
File: lesson summary
Routing No. 1 PM05. "Performance of work according to the profession of a worker"
Subject: General information on locksmith operations used in assembly and welding production.
Objective: To become familiar with the basic locksmith operations used in the manufacture of a welded product.
The type of lesson is a practical lesson.
Lesson teaching method - partial search
Lesson Objectives:
Educational:
The student must be able to:
Correctly determine the loads on welds; - draw up diagrams of loads on welds.
Educational:
To educate students in the ability to independently make technical decisions, attentiveness, respect for the chosen profession.
Developing:
To form in the trainees an information-professional outlook, the desire to learn new things.
Arouse interest in the discipline, reveal the relationship of the discipline with other professional disciplines.
The form of education is group.
The teaching method is practical.
Material - technical and didactic equipment of the lesson: - multimedia installation, materials of the electronic textbook, guidelines for the performance of work
During the classes
1. Actualization of basic knowledge, abilities, skills and personality traits
Checking the availability of students on the payroll - a report; - Setting the objectives of the lesson; - Issuing individual tasks for practical work.
2. Formation of new knowledge, skills and personality traits
Locksmithing is the processing of metals, usually in addition to machining or completing fabrication. metal products connection of parts by welding, assembly of machines and mechanisms, as well as their regulation. Locksmith work is performed using manual or mechanized metalwork tool or on machines.
Locksmith works are used in various types of production and they are united by a single technology for their implementation.
The main plumbing operations can be divided into several groups according to their purpose:
Fig.1 The main groups of locksmith operations
The operations of each group have their own class of accuracy, therefore, in the process of work, it should be clearly understood what processing accuracy is required in the final result of performing metalwork. At enterprises or in workshops that produce a variety of welded products, the versatility of performing various metalwork operations is required.
The quality of the welded joint largely depends on the preparation of the metal and the assembly of the product for welding.
The base metal intended for the manufacture of welded structures is cleaned, marked into separate parts, and the necessary edge profiling is performed.
Cleaning is an operation that is used to remove preservatives, contaminants, cutting fluids, rust, scale, burrs and burrs from the surface of the metal, which impede the welding process, cause defects in welds and prevent application protective coatings.
Straightening is an operation to eliminate deformations of rolled sheet steel and profile metal, straightening workpieces of parts with dents, bulges, waviness, warping, curvature, etc. The metal is straightened both in a cold and in a heated state. The choice of method depends on the deflection, dimensions and material of the product.
Marking - transferring the dimensions of the part in full size from the drawing to the metal. In addition, when welding, marking lines (risks) are applied to the surface of the workpiece, which determine the installation location of individual parts when assembling units and structures.
Distinguish:
1. Planar markings.
2. Spatial markup.
Metal cutting is the operation of cutting metal into pieces.
Depending on the shape and size of the blanks or parts, cutting is carried out manually - with hand shears, hand saws, lever shears. Cutting can also be carried out with oxygen cutters along the intended line of the contour of the part manually or with gas cutting machines for special purposes. Cutting on mechanized machines is more productive and has a high quality cut. However, it is advisable to perform mechanical cutting when preparing parts of the same type, mainly with a rectangular section.
Bending is a method of metal forming by pressure, in which a workpiece or part of it is given a curved shape.
Cutting is a plumbing operation in which, with the help of a cutting tool (chisel, etc.) and a percussion tool (locksmith's hammer), excess layers of metal are removed from the surface of the workpiece or part or the workpiece is cut into pieces. In addition, cutting is used when it is necessary to remove burrs, defects or remove part of the metal.
Filing is the removal of a layer of metal from the surface of the workpiece being processed by means of a special cutting tool - a file.
With the help of files, a mechanic gives the parts the required shape and dimensions, fits the parts to each other, prepares the edges of the parts for welding, and performs other work.
3. Summing up the lesson (5 min)
Monitoring the performance of the task by all students of the group, analysis of the performance of the work, comments on the progress of the work and obtaining specific results.
4. Homework (5 min): the material of the electronic textbook on the topic, the repetition of previously studied material.
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Basic locksmith operations and tools used
Editing is an operation by which irregularities, curvature or other imperfections in the shape of workpieces are eliminated.
The main equipment for manual straightening of metals are steel or cast iron straightening plates. Used as a manual dressing tool steel hammers with a round striker; hammers made of soft materials are used for straightening finished surfaces, as well as for straightening workpieces and parts made of non-ferrous metals and alloys.
Cutting is an operation of cold working of metals by cutting. Locksmith and pneumatic hammers serve as percussion tools for cutting, and chisels, crosscutters and groovers serve as cutting tools.
Chisel. The metalwork chisel is made of tool carbonaceous steel. It consists of three parts: shock, middle and working.
The impact part is made tapering upwards, and its top (striker) is rounded; for the middle part of the chisel is held during cutting; the working part has a wedge-shaped shape. The angle of sharpening is selected depending on the hardness of the material being processed.
For the most common materials, the following taper angles are recommended: for hard materials (hard steel, cast iron) - 70°;
for materials of medium hardness (steel) - 60 °;
for soft materials (copper, brass) – 45°;
For aluminum alloys– 35°.
Kreutzmeisel. To cut out narrow grooves and grooves, a chisel with a narrow cutting edge is used - a cross-cutting tool. Such a chisel can also be used to remove wide layers of metal: first, grooves are cut with a narrow chisel, and the remaining protrusions are cut down with a wide chisel.
Locksmith hammers. Bench hammers used in cutting metals are of two types: with a round and with a square striker. The main characteristic of a hammer is its mass. For cutting metals, hammers weighing 400 ... 600 g are used.
To facilitate labor and increase its productivity, mechanized tools are used. Among them, the pneumatic chipping hammer is the most widely used.
metal cutting
For cutting metal, a hacksaw is used, the cutting part of which is a blade. The choice of blade depends on the material of the workpiece, its shape and size. Pipe cutters are used to cut pipes manually. For cutting sheet metal up to 1.5 mm thick, straight-cutting or for curly cutting scissors. The wire is cut with needle nose pliers or power scissors.
filing
Sawing is an operation in which a layer of metal is removed from the surface of the workpiece using a cutting tool - a file.
The purpose of filing is to give parts the required shape, size and desired surface roughness.
Files differ in the number of notches, section profile and length.
According to the number of teeth cut per 10 mm length, files are divided into 6 classes (0, 1, 2, 3, 4.5).
Depending on the work performed, files are divided into the following types: general purpose and for special works, machine, needle files and rasps.
1) General purpose locksmith files according to GOST 1465-69 are made in eight types: flat, square, trihedral, semicircular, rhombic and hacksaw files with a length of 100 to 400 mm with a notch No. 0-5.
Locksmith's files for special work are designed to remove very large allowances when filing grooves, shaped and curved surfaces; for processing non-ferrous metals, non-metallic materials, etc. Depending on the work performed, files of this type are divided into grooved, flat with oval ribs, bars, double-ended, etc.
2) According to their design, machine files are divided into rod, disk, shaped heads and lamellar ones. In the process of operation, the rod files are reciprocated, the disk files and shaped heads are rotated, and the lamellar files are in continuous motion along with a continuously moving metal tape.
3) According to GOST 1513-67, needle files are made in ten types: flat, trihedral, square, semicircular oval, hacksaw, etc. 40, 60 and 80 mm long with a notch of 5 numbers. The length of the file is determined by the length of the working part. Ribs of flat files have a single or double notch. The sides and upper edge of the hacksaw files have a double notch.
Files are used for filing small surfaces and narrow places that are inaccessible for machining with metalwork files.
4) Rasps according to GOST 6876-54 are made in several types: general purpose, shoe and ungulate.
Depending on the profile, general-purpose rasps are divided into flat, round and semi-circular with a notch No. 1-2 and a length of 259 to 350 mm.
Holemaking
Drilling is carried out on drilling machines or using handheld devices. The main cutting part is the drill, which has two cutting edges. When drilling holes with a diameter of more than 20 mm, pre-drilling the holes with a drill of a smaller diameter is used, then it is drilled to size with a drill of a larger diameter.
After drilling, stamping, cast to obtain a more accurate hole, they are reamed. Depending on the accuracy and purpose of the holes for their processing, countersinks of two numbers are made: No. 1 - for pre-treatment of holes and No. 2 - for final processing. Structurally, countersinks are of two types: solid hole processing from 10 to 40 mm and mounted - from 32 to 80 mm.
Reaming is used to obtain holes with a more precise shape and low roughness. The operation is carried out using a multi-blade tool - a reamer. Depending on the shape, cylindrical and conical reamers are distinguished. According to the method of application - manual and machine, according to the design - one-piece, mounted, sliding (adjustable) and combined, right and left.
Made part:
Detail sketch:
 |
Progress:
1. Processing with a bastard file sharp corners blanks.
2. Marking with a caliper and gauge.
3. Punching along the marking contour for drilling.
4. Drilling.
5. Beating off excess material with a chisel.
6. Processing with files until the required dimensions are obtained.
7. Reaming the central hole with one thread. thread cutting,
8. Polishing with sandpaper.
welding area
infopedia.su
Locksmith operation - The Big Encyclopedia of Oil and Gas, article, page 1
locksmith operation
Page 1
Locksmith operations must be carried out very carefully, using only well-sharpened tools.
Locksmith operations performed on the conveyor are, if possible, mechanized.
Locksmith operations consist in the processing and fitting of parts manually using the simplest tools and fixtures. For many years locksmith operations were not mechanized, and therefore were very labor intensive.
Locksmith operations during assembly consist in the processing and fitting of parts with the simplest tools. The need for locksmith operations is caused by the imperfection of the machining of parts and the lack of interchangeability of parts during assembly.
The listed plumbing operations are preparatory, they are performed before the assembly of parts into assemblies.
Locksmith operations repair electrical equipment electrician performs with.
The locksmith performs the repair of electrical equipment with the help of a locksmith (Fig. 2), metal-cutting (Fig. 3) and measuring (Fig. 4) tools.
A locksmith operation is a completed part of the technological process of processing a workpiece or part, performed simultaneously and continuously until the transition to the processing of the following workpieces or parts. The concept of a locksmith operation is conditional, since the same locksmith operation carried out at different enterprises or in different conditions, is determined differently from the point of view of the technology of its implementation.
The most common locksmith operations during the preparation of pipes for assembly are threading and bending.
Performing locksmith operations for the processing of individual parts, they must be firmly fixed in a vice. The bench vice must be in perfect working order, firmly clamp the products, there should be no noticeable notch wear on the jaws.
Many locksmith operations in electrical machines differ significantly from similar operations in mechanical engineering.
Many locksmith operations in electrical machines differ significantly from similar operations in general engineering.
Variety of locksmith operations causes improvement and specialization clamping fixtures, some of which are shown in Fig.
Pages: 1 2 3 4
www.ngpedia.ru
- Locksmith and tool work
Locksmith operations before assemblyLocksmith and tool work
Locksmith operations before assemblyBefore assembling the fixture, the completeness, workmanship and degree of readiness of the parts received for assembly are established. After making sure that the parts correspond to the drawing and the technological process, they proceed to their metalwork.
Locksmith processing them consists in blunting sharp edges, removing burrs, filling threads, in assembling individual assemblies installed in assembled form, in creating the required connection and smooth running of parts and assemblies, in scraping or grinding the reference planes and planes of connection with the fixture body. Most of the above works are carried out by conventional plumbing techniques.
The processing of hardened surfaces of parts in many cases is carried out not by the mechanical, but by the assembly section of the shop. The reason for this is that grinding operations are usually interspersed with metalwork operations, and sometimes carried out by the same toolmakers. The hardened surfaces of fixture parts are ground on machines, mechanized tools or manually.
Grinding in progress abrasive wheels, heads and bars. Manual grinding with bars is performed if the surface of the part cannot be processed on the machine. For it, abrasive bars of various shapes and sizes (GOST 2456-52) are used, made from both artificial and natural abrasive materials. It is known that in manual grinding, the cutting speed (the speed of movement of the bar) is many times less than the cutting speed when grinding on machine tools or mechanized tools. In this regard, abrasive stones are selected with a higher hardness than grinding wheels. Hand grinding, as a rule, is carried out first with coarse-grained and hard, and then with fine-grained and softer bars.
The surfaces of the bars during manual grinding wear out quickly, become clogged or lose their shape. To restore the shape and performance of the bars, they are periodically corrected on special plates, caricatured with grinding powders. When straightening, the bar is placed on the surface of the slab and moves in different directions with some pressure. Ate, several movements along the surface of the plate, the plane of the bar becomes geometrically correct, and its edges become sharp and suitable for further work.
Abrasive bars produce grinding of shaped surfaces of copiers, installations and other parts, as well as supporting surfaces of assembled devices. How to get shaped surfaces, exact planes and angles are similar to the techniques described earlier. However, due to the fact that the accuracy of these surfaces is rougher than the equivalent surfaces of the measuring tool, in the manufacture of fixtures they rarely resort to pattern finishing, and more often they are limited to polishing the surfaces with abrasive sand after mechanical or manual grinding.
The largest volume of preparatory locksmith operations falls on the locksmith processing of the body of the device. As stated earlier, the base and datum planes of the case are machined before it is sent to the assembly. In the assembly area, these surfaces are again inspected, checked for correctness, and damaged. The check is carried out “for paint” using a control plate. The main and technological bases of the corps are subjected to the same check.
The accuracy of the fixture requires a reliable connection of the body and the nodes installed on it. Therefore, their connecting surfaces are carefully processed within VV 6 - WV 8 by grinding or scraping. In addition to the necessary cleanliness of the surface, these planes are required to be strictly parallel and perpendicular to the base and bases of the body.
pereosnastka.ru
The main types of plumbing operations.
Production Main types of plumbing operations.
Markup.
Locksmith's workplace.
Topic 25. Basics of plumbing.
1. Locksmith work - ϶ᴛᴏ manual processing of materials, fitting parts, assembly and repair of various mechanisms and machines.
A workplace is a part of the production area with all the equipment, tools and materials located on it, which are used by a worker or a team of workers to complete a production task.
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.
Locksmith workbench (Fig. 36) - the main equipment of the workplace. It is a stable metal or wooden table, the lid (table top) of which is made of boards 50 ... 60 mm thick hard rock wood 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.
Rice. 36 Single locksmith workbench:
1 - frame; 2 - countertop; 3 - vice; 4 - protective screen; 5 - tablet for drawings; 6 - lamp; 7 - shelf for tools; 8 - tablet for a working tool; 9 - boxes; 10 - shelves; 11 - seat
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 workbench top are drawers, divided into a number of compartments for storing tools and documentation.
To fix the workpieces, a vise is installed on the workbench. Given the dependence 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 to 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. Chair vise they are rarely used, only for work related to shock loading (when cutting, riveting, etc.). 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 installation of the vise bent at the elbow left hand put on the vice jaws so that the ends of the straightened fingers of the hand touch the chin. Tools and fixtures are arranged so that it is convenient to take them with the appropriate hand: what is taken right hand- hold on the right, what they take 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.
2. Marking - the operation of drawing lines (marks) on the workpiece that determine (according to the drawing) the contours of the part and the places to be processed. Marking is used for individual and small-scale production.
Marking is carried out on marking plates cast from gray cast iron, aged and precisely machined.
Lines (risks) with a planar marking are applied with a scriber, with a spatial marking, with a scriber fixed in the thickness gauge collar. Scribers are made from steel grades U10 and U12, their working ends are hardened and sharpened sharply.
The center punch is intended for drawing indentations (cores) on pre-marked lines. It is made from steel grades U7, U7A, U8 and U8A.
The marking compass is used to draw circles, divide angles and apply linear dimensions to the workpiece.
3. The main types of plumbing operations.
Cutting is a metalwork 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 - ϶ᴛᴏ the operation of separating metals and other materials into parts. Taking into account the dependence on the shape and size of the workpieces, 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 (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 is 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 is 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.
Riveting is a metalwork 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 with a mass of 200 ᴦ is required.
Sawing is a plumbing operation in which a layer of metal is cut off from the surface of a part with files to obtain the required shape, size and surface roughness, to fit parts during assembly and prepare 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.
Scraping is the operation of scraping thin layers of metal from the surface of a part with a cutting tool - a 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 finishing - operations of surface treatment 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 - ϶ᴛᴏ installation and dismantling work performed during the assembly and repair of machines. Various connections of parts performed during assembly of machines are divided into two basic 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.
Locksmith. Plumbing practicelocksmith
A specialist in the processing of metal blanks, the manufacture and repair of metal parts or products, and many other types of work performed using manual and mechanized tools, mainly in the process of assembling and adjusting instruments, mechanisms, machines, and equipment. The range of locksmith work is so wide and varied that in the manufacturing sector, locksmiths, as a rule, specialize in one profile: for example, plumbers, tool makers, pattern makers, assemblers, machine tool mechanics, car mechanics, etc.
The word "locksmith" is of German origin. Translated into Russian, it means "specialist in the manufacture of locks." Obviously, historically, the locksmith profession has its origins, its roots in housework. Indeed, during the repair and improvement of a city apartment, the construction of a rural house, there is a constant need for a variety of metal products: strips, brackets, overlays, squares for frames, all kinds of fasteners, etc. Not all of these products and not always available for sale. But even if there is, it is often more profitable to make them yourself than to buy in a store. In addition, individual products may be of original design, i.e. are suitable only for this particular case and, of course, they cannot be purchased in a store or on the market. The manufacture of such products requires significant skills in metal processing with manual and mechanized tools at home. These skills are based on knowledge of the properties of metals, the technology of their processing, working and measuring tools and working methods.
Together with Gem, and in farmhouse, and a city apartment uses a different Appliances: devices, mechanisms, machines. In order for these devices to work well and reliably, it is necessary to constantly monitor their serviceability, timely carry out routine inspections, clean and lubricate rubbing parts, replace worn parts, i.e. carry out appropriate repairs. All this also requires skills in the processing of metals and other materials. Moreover, the repair of equipment requires knowledge of this equipment itself, the laws and principles of its operation, i.e. certain general technical literacy. Therefore, in this case, the home craftsman acts as a repairman.
Basic plumbing operations
Plumbing technology includes the performance of individual plumbing operations in the manufacture or repair of metal parts or products. A locksmith operation is understood as the impact on a metal workpiece with a manual or mechanized tool in order to obtain a finished part or connect parts into a whole product. These are, for example, filing workpieces, drilling holes, etc.
Locksmith operations can be divided into processing, assembly, finishing and auxiliary. With the help of processing operations, the shape and size of the workpieces are changed. These include cutting metal chisel, metal cutting scissors or hacksaw straightening and bending of metals, metal filing, threading etc. Assembly operations are, for example, the execution threaded connections. Among the finishing operations, a significant place is occupied by grinding and polishing the surfaces of workpieces. Ancillary operations include markup, control operations. The simplest control and measuring tools used when performing plumbing operations at home are measuring ruler, locksmith square, calipers. An ordinary school protractor can be used to measure angles. These tools are familiar to everyone from school.
The production of a product usually begins with a markup. It is carried out with the help of a measuring instrument. Such a tool is also used when performing other plumbing operations; for example, each processing operation must be followed by a check of the correctness of its execution using various control and measuring tools.
Metal blanks and parts are not only cut, but also connected to each other. For this, in addition to threaded connections, apply riveting, soldering And welding, although the latter, like heat treatment of metals, are usually not classified as locksmith work.
The techniques and tools used when working with metal are also suitable for working with plastics. So, for example, the most common and accessible plastic material - organic glass - can be sawn with a hacksaw, jigsaw, filed, cut with a homemade cutter, drilled, etc.; in a heated state, organic glass can be bent, cut with scissors, given various shapes under pressure, using wooden bars like a die and a punch. Gasket washers are machined from getinaks; foil (one- and two-sided) getinaks suitable for home-made printed circuit boards, instrument cases, shielded blocks (in this case, the walls and partitions of the blocks are connected by soldering). Textolite rods can be used to machine mounting racks, bushings, rollers, tool handles and other details. Bakelite plates are cut out, and then sawed and drilled circuit boards for electrical devices.
Tools and fixtures for various plumbing operations
| Operation | Tools and fixtures |
| Measurement and layout | Steel ruler, scale ruler, vernier caliper, measuring compasses (with sharp ends), calipers, square, goniometer, scriber, center punch |
| Hole drilling | Drill with manual drive or electric drill twist drills, countersink, countersink, reamer |
| Fastening and clamping | Bench and manual vices, clamps, round nose pliers, pliers, pliers |
| percussion work | Hammer, mallet |
| Riveting (manual) | Support, stretch, crimp |
| Cutting and cutting metal | Chisel, cross-mechanic, hand scissors for cutting sheet metal, hacksaw, slotting, lever shears |
| filing | Files: bastard, personal, velvet; square, flat, trihedral, round, rhombic |
| Threading | Sets of taps and dies, devices for threading (knobs, die holders, die cutters) |
| Screwing and unscrewing | screwdriver sets, wrenches, wrench |
| Soldering and tinning | Soldering tools (soldering iron, blowtorch, soldering torch), scraper, cleaner, wire brush, soldering flares |
Workplace of a home locksmith
At home, to perform locksmith work, it is desirable to have a separate locksmith workbench - metal or upholstered sheet metal wooden table with toolboxes. If there is no special workbench, then it is easiest to adapt an old utility table as a workplace. A large load on the table during work, as a rule, requires a stronger base. If necessary, the legs of the table are strengthened from the outside or inside using screwed wooden planks or metal corners. From the sides and back, the legs of the table are reinforced crosswise with screwed boards. The normal thickness of the utility table cover is about 20 mm, but this may not be enough for locksmith work. It is recommended to make a second cover (plate) from boards 30 mm thick and fasten it from below with screws to the old cover. The plate should protrude from the edges of the table on all sides by approximately 50 mm so that you can fix a clamp or grinding machine, screw vise, etc. To the plate - from below, from the side or (and) from the front - metal corners are screwed so that the part can be processed. Despite solid construction, the desktop may become loose and shift during operation. Therefore, it is advisable to put it in the corner of the room and attach it with metal corners or strips to the floor or wall; the cover can be screwed to the plank on the wall. Electric current to the workplace should be supplied through two separate electrical circuits: one - for electric tools and machine tools, the other - for lighting (light on workplace must fall in front!). Several sockets mounted on the wall allow you to use different devices at the same time.
Of the devices, the craftsman will first of all need stationary and manual vise, anvil, leveling plate, and thread cutting tools- die holders, knobs, klupps. A set of locksmith tools necessary in the home workshop: hammers, used as percussion instrument when cutting, bending, straightening, riveting; pincers - for capturing, holding, moving workpieces, cutting wire and other operations; set files - for filing metals; chisel - for cutting metals, cutting old rivets, etc.; taps And dies - for cutting internal and external threads, respectively; drill- for drilling holes; hacksaws for metal and scissors - for cutting metal. The set of tools and fixtures required for a home workshop is shown in the summary table.
The workplace should provide an opportunity to perform a variety of locksmith work (and not only locksmith). The replenishment of the workshop with tools, various devices and materials necessary for work usually occurs gradually, depending on the type of work performed, as well as on the tastes and inclinations of the master. Ready-made tool kits can be bought at the store. For those who start small and want to purposefully expand the available arsenal of tools, it is useful, and in some cases necessary, to direct their efforts to the manufacture of individual tools and devices on their own. Home-made tools and devices are not in everything equivalent to industrial counterparts, however, they are quite suitable for the needs of a home craftsman.
Here are some typical examples homemade tools and fixtures. Not every craftsman has an anvil or a straightening plate in his house. They can be successfully replaced with appropriately processed pieces of a railway rail, channel, I-beam (Fig. 1).
Rice. 1. Homemade fixtures for a locksmith workshop: 1, 2 - raw and processed pieces of an I-beam; 3 - processed piece of channel; 4 - processed piece of rail.
Mouthpieces - a safety device for a vise when clamping soft, fragile parts or parts with a polished surface. Material: sheet aluminum 1...2 mm thick. The dimensions of the muffs are determined by the dimensions of the vise. A line is drawn on the workpiece with a scriber or pencil, from which all dimensions are counted or set aside (Fig. 2). Hand-held metal shears can be used to cut soft aluminum. A hacksaw is used to cut hard aluminum. In order for the hacksaw blade not to slip off the marking line, an auxiliary line is made near this line with a trihedral file and sawed along it. The workpiece during cutting must be fixed in a vice with the help of squares. The workpiece is bent, fixing it in a vice, with the blows of a mallet, the angle between the sides of the muffs is adjusted to 90 ° C.
Rice. 2. Muffs: 1 - marking of the blank of the muffs; 2 - clamping the workpiece in a vice with the help of caps when cutting it with a hacksaw; 3- general form muffs.
Scriber - a tool for drawing marking lines. Material: steel rod with a diameter of 3 or 4 mm and a length of approximately 200 mm. With the help of round-nose pliers (Fig. 3), an eyelet with a diameter of about 25 mm is bent. The working end of the scriber is sharpened with a fine-grained emery fugue. The point is hardened: heated on a gas burner until it acquires a cherry-red color (temperature approximately 700 ... 800 ° C), dipped in water, as a result it becomes so brittle (hard) that it can break off. The hardness is reduced by tempering: after stripping with fine-grained sandpaper, the point is again heated to a light yellow tint (temperature approximately 200 ° C), dipped again in water and then cleaned with fine-grained sandpaper.
Rice. 3. Scribe: 1 - appearance; 2 - bending the eye with round-nose pliers.
Gauge (template) for checking sharpening - a device for checking the angle of sharpening a center punch or chisel. Material: sheet steel approx. 2 mm thick. Having finished marking, a workpiece is cut out with a hacksaw, corner cuts are cut out in it (Fig. 4), which are then processed (finished) with a file. To check the accuracy of filing, triangles are first cut out of cardboard, which correspond in size to the slots of the caliber. Triangles are inserted into the slots of the caliber and viewed through the light: if the cuts are correct, then only thin uniform strips of weak light between the walls of the slot and the sides of the triangles will be visible.
Rice. 4. Caliber (template) for checking sharpening (1); checking the chisel sharpening angle with a gauge (2).
Screwdrivers with bent ends (Fig. 5) are used to tighten and unscrew screws in cases where it is inconvenient or impossible to do with an ordinary screwdriver. Material: tool steel bar with a diameter of 7 mm or a nail of the same diameter. Sawing off the workpiece desired length, both ends of it are bent (steel is recommended to be bent in a heated state), sawn off, then quenched and tempered in the same way as the scriber.
Rice. 5. Screwdriver with bent ends, made of a steel bar (1) and a nail (2).
materials
Strips of steel sheet, parts of end-of-life bicycles, baby carriages, electric stoves, refrigerators, wall clocks and other appliances, old screws, nuts, metal angles, tubes, rods, springs, pieces of wire, etc. - all this can be used by a home mechanic in the manufacture of various parts and products. Thrift and a developed ability to determine the usefulness of one or another "junk" thing are the necessary qualities of a home craftsman. It is important, without turning the home workshop into a cluttered closet, to determine the place for each future workpiece so that you can easily find it at the right time.
The home locksmith most often has to deal with the processing of various steel blanks. On sale if they are, then in a limited range. It is necessary, as a rule, to use secondary raw materials. In this case, it is important, firstly, to be able to determine the steel grade at home, and secondly, to know what steel of this grade is suitable for, thirdly, by heat treatment, learn to give the material the required mechanical properties(hardness, plasticity, etc.).
The steel grade can be determined quite accurately by the resulting beam of sparks on the emery wheel. The presence of alloyed additives significantly changes the properties of the steel itself. For example, the content of both chromium and nickel in steel increases its toughness and hardness; the presence of one nickel makes steel not only viscous, but also gives it the ability to endure large shock loads; alloyed additives of chromium and silicon make the steel tougher and easier to heat treat.
When using recycled materials, it is important to know the steel grades used to make the most common tools. Sometimes you can make a new, necessary one out of a tool that has become unusable. The following is a list of steel grades used for the manufacture of some tools:
Irons from carpentry tools 9HF
Chisels, screwdrivers, stamps for U7A steel
Cores, woodworking tools U10, U10A
Hammers, sledgehammers, trowels, carpentry tools U7
Taps UP, R9, 9XC
Needle files U10-U12
Files U10-U13, ShKh6
Hacksaw blades R9, R18, ShKh15
Hacksaw blades are manual. . . . U8-U12
Hacksaws for wood U8GA
Planer knives 9X5VF
Circular saws 85HF
Saws for sawmill frames 85XV
Cross saws U8GA, U10
Rip saws 85X
Dies 9XC
Bow saw blades U8GA, 85HF
Punches, dies, punches U8, U8A
Manual reamers R9, 9XC
Machine reamers P9, P18
Cutters for hard metals U13, U13A
Turning and planing cutters U10, U10A
Twist drills for wood 9XC, 9X5VF
Drills for metal P9, P18
Milling cutters P9, P18
Scrapers U12, U12A
When processing metal blanks, a home craftsman needs to master the methods of heat treatment of metals. For example, unhardened (“raw”) steel is quite ductile: it can be sawn, filed, forged, chopped, straightened, etc. Hardened steel is extremely hard and can only be machined with abrasive tools.
Not all metals and metal alloys can be combined to create any structures. Some metals and alloys are incompatible with each other: at their joints, when moisture enters, so-called galvanic (electrical) pairs are formed, which cause increased corrosion of the metal (alloy), weaken the mechanical strength of the joints and break electrical contacts. For example, unalloyed steel is incompatible with copper and copper alloys and is compatible with aluminum, tin, chromium, zinc; copper is incompatible with aluminum and aluminum alloys, zinc and is compatible with tin, nickel, chromium; zinc is incompatible with copper and copper alloys and is compatible with steel, aluminium, tin, nickel, chromium. Taking into account this property of metals, in particular screws, rivets and other fixing material used to connect metal parts should be selected from metals that are homogeneous or compatible with these parts.
Lit.: Hirte W., DIY 1000 things, trans. from German., M., 1970; Verkhovtsev O.G., Lyutov K.P., To an amateur master in electrical engineering and electronics, L., 1984; Makienko N.I., General course of plumbing, 2nd ed., M., 1984; Arbuzov M.O., Reference book of a young repairman, M., 1985; Starichkov B.C., Workshop on metalwork, 4th ed., M., 1985; Syuch Y., ABC of a home master, trans. from Hung., M., 1985; House and estate, M., 1989; Mokretsov A.M., Elizarov A.I., Plumbing Practice, M., 1989; Handbook of labor training. A guide for students in grades 5-7, M., 1992; Erlykin L.A., House and plot. Book set "With your own hands", book. 3, M., 1993.
Locksmith profession.
Locksmith work is understood as work performed by hand and mechanized tools and completing the manufacture of most products through fitting and finishing work, connecting various parts into assembly units, kits and complexes and adjusting them.
Assembly fitters assemble various machines and mechanisms. Maintenance and their repair during operation is carried out by repairmen. Locksmiths - toolmakers provide production with the necessary tools, facilitate and improve machining. Locksmiths for the installation of equipment, instruments, communications securely install them and the proper place, let down different kinds energy and necessary for the production of basic and auxiliary materials. All these workers are united by the ability to perform various plumbing operations. This is what they learn in the general locksmith course.
The degree and type of professional training, the availability of knowledge, skills and abilities and the suitability to perform work of a certain content and complexity determine the qualifications of the worker. It is estimated by the tariff category, which is assigned to the worker by the qualification commission. The basis for this is the qualification characteristic given in special, tariff-qualification reference books. It specifies what a worker “should be able to” and what “should know” in order to receive the appropriate wage category in his specialty.
Basic plumbing operations.
Consider the basic plumbing operations using the example of processing simple parts - a guide key (Fig. 1). Like wine from the drawing, all surfaces of the key are machined, it has three holes: two stepped fixing screws and one with a thread.
The key is made of keyed steel - a bar of rectangular section. To obtain a workpiece of the desired length, produce markup – scriber put on the surface of the mug lines defining the shape and size of the part. Further chisel(operation is called felling) or hacksaw (cutting) the workpiece is separated. During the cutting process, the workpiece can be bent. She needs to be corrected. Often you want to do the opposite work: bend having a workpiece, to give it a complex shape. Then perform bending.
The listed operations cannot be obtained correct form part surfaces and specified dimensions. They are preliminary, preparatory. Their goal is to prepare the workpiece for further processing, to ensure and accelerate it by removing large layers of metal. To give the key desired shape and dimensions of the workpiece cast off . Hole ø 11 mm and thread M10 receive drilling , and the local expansion of the hole size up to ø 17 mm - reaming. Thread cut in a drilled hole tap. When the hole needs to be accurately sized, it deploy . Except
considered, there are other operations: sawing And fitting- obtaining holes of complex shape and very precise processing of two parts to be joined; scraping And lapping- accurate final operations, providing high accuracy, tightness of joints; riveting, soldering And gluing- operations that allow you to connect parts to each other to form permanent joints.
As can be seen from the foregoing, all operations for the manufacture of any product must be performed in a certain
sequences. Together they make technological process detail processing.
The technology of locksmith processing contains a number of basic operations, such as marking, cutting, straightening and bending of metals, cutting of metals, filing, drilling, countersinking, countersinking and reaming of holes, threading, riveting, lapping and finishing, soldering and others. Most of these operations relate to the processing of metals by cutting.
3.1 Markup
markup called the operation of applying lines (risks) to the surface of the workpiece, showing, according to the drawing, the contours of the part or place to be processed. Markup is divided into:
Linear (one-dimensional) - along the length of bars, rolled products, strip steel,
Planar (two-dimensional) - for sheet metal blanks,
Spatial (volumetric, three-dimensional) - for bulk blanks.
Special marking tools include scribers, center punches, marking compasses, thickness gauges. In addition to these tools, hammers, marking plates and auxiliary devices are used: linings, jacks, etc.
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Figure 6 Scribe |
Scribers (Figure 6) are used to draw lines on the marked surface of the workpiece. They are made from tool steel U10 or U12 (hardness HRC 58-62). Center punches (Figure 7) is used to apply recesses (cores) on pre- |
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Figure 7 Punch |
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marked lines so that the lines are clearly visible and not erased during the processing of parts. Kerner - this is a rod made of tool carbon steel U7, U8 (HRC 52-57) with a length of 100-160 mm and a diameter of 8-12 mm. The sharpening angle is usually 60, with more accurate markings - 30-45 °, for the centers of future holes - 75 °. Marking (locksmith) compasses the device is similar to drawing compasses. Reismus (Figure 8) is used to apply parallel vertical and horizontal marks. Recently, a height gauge with a sharp tip is more often used. Planar and especially spatial marking of workpieces is carried out on marking plates. Marking plate is a cast iron casting, the horizontal working surface and the side edges of which are very accurately machined. Template called a device by which parts are made or checked |
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after processing. Template marking is used in the manufacture of large batches of identical parts. It is expedient because the time-consuming and time-consuming markup according to the drawing is carried out only once during the manufacture of the template. All subsequent operations of marking blanks consist in copying the outlines of the template. In addition, the manufactured templates can be used to inspect the part after the workpiece has been machined.
3.2 Straightening and bending of metals
edit called an operation to eliminate defects in workpieces and parts in the form of concavity, convexity, waviness, warpage, curvature, etc. Its essence lies in the compression of the convex metal layer and the expansion of the concave one.
The metal is straightened both cold and hot. The choice of one or another method of dressing depends on the amount of deflection, dimensions and material of the workpiece (part).
Dressing can be manual (on a steel or cast iron straightening plate) or machine (on straightening rollers or presses).
Right Stove , as well as marking, should be massive. Its dimensions can be from 400400 mm to 15003000 mm. Plates are installed on metal or wooden supports, which ensure the stability of the plate and the horizontal position of its position.
For straightening hardened parts (straightening) use straightening grandmas. They are made from steel and hardened. The working surface of the headstock can be cylindrical or spherical with a radius of 150-200 mm.
Manual dressing is carried out with special hammers with a round, radius or plug-in soft metal striker. Thin sheet metal rule mallet(with a wooden mallet).
They check the dressing "by eye", and with high requirements for the straightness of the strip - with a curved ruler or on a test plate.
Shafts and round blanks of large cross section are corrected using a manual screw or hydraulic press.
bending metal is used to give the workpiece a curved shape according to the drawing. Its essence lies in the fact that one part of the workpiece is bent relative to the other at any given angle. Manual bending is carried out in a vice using a bench hammer and various devices.
Bending of thin sheet metal mallet .
With plastic deformation of the metal during the bending process, the elasticity of the material must be taken into account: after the load is removed, the bending angle slightly increases.
The manufacture of parts with very small bending radii is associated with the risk of rupture of the outer layer of the workpiece at the bend. The size of the minimum allowable bending radius depends on the mechanical properties of the workpiece material, on the bending technology and surface quality.
Pipe bending is carried out with or without filler (usually dry river sand). The filler protects the pipe walls from the formation of folds and wrinkles (corrugations) in the places of bending.
