Filing a workpiece - English

Summary

This tutorial covers the essential steps and techniques for filing a workpiece, from understanding what filing is, to selecting the right tools and methods. It explains various types of files, their specific uses, and outlines the filing process, including cutting excess material, filing techniques (such as straight, draw, and diagonal filing), and checking for flatness and squareness. It also highlights common filing mistakes and safety tips. The tutorial emphasizes the importance of precision and the correct use of tools like the try-squareandVerniercalipertoachieveanaccurateresult.

Takeaways

• 🧰 Filing is a process of removing excess material from a workpiece using a file.
• 📌 Different files are used for different purposes, such as flat, smooth, safe edge, square, half round, and round files.
• 📏 Accurate measurement is essential before filing; the example job requires a 5×3 inch workpiece.
• ✍️ Marking medium (chalk/ink) and a jenny calliper are used to mark the cutting line on the workpiece.
• 🔨 A punch and ball pein hammer are used to create punch marks along the marked line for guidance.
• 🪚 A hacksaw is used to cut off excess material before starting the filing operation.
• 🪛 The workpiece must be securely clamped in a bench vice to ensure safe and accurate filing.
• 🧤 Always use a file with a properly fitted handle to avoid hand injuries.
• 🧼 Files should be clean and free from rust to prevent damaging the workpiece and bruising hands.
• 🧍 Proper filing posture matters: stand perpendicular to the vice with left leg forward and right leg back for stability.
• 🪵 Three filing methods are demonstrated: straight forward filing, draw filing, and diagonal/cross filing.
• 📐 Flatness and squareness should be checked using a try-square against a light source and at multiple points.
• 📏 Thickness consistency should be checked at least three locations using a vernier calliper.
• ⚠️ Common mistakes include filing at an angle and filing onlytheedgeswhileskippingthecenter.

Q & A

What is filing and why is it important in manufacturing?

Filing is a process of removing excess material from a workpiece using a file. It is essential in shaping, smoothing, and refining the surface of a material, often used to achieve precise dimensions and finishes in manufacturing.

What tools are required for filing a workpiece?

The required tools for filing a workpiece include a file, workpiece to be filed, bench vice, Vernier calliper, try square, hack saw, punch, and a ball pein hammer.

What types of files are used for different filing purposes?

There are several types of files used for different purposes: Flat file (for rectangular cross-sections), smooth file (for smooth surfaces), safe edge file (for filing right-angled parts), square file (for square corners or holes), half-round file (for semi-spherical surfaces), and round file (for developing holes or round grooves).

What is the correct method for cutting excess material from a workpiece before filing?

To cut excess material from a workpiece, first apply a marking medium like chalk or ink, then use a jenny calliper to mark the cutting line. Use a punch and ball pein hammer to mark the line, and then securely hold the workpiece in the bench vice. Finally, use a hacksaw to remove the excess material.

What safety precautions should be followed when using a file?

Always ensure that the file has a proper handle securely fitted, and that the file is clean to avoid injuries and damage to the workpiece. Never use a rusty file, as it can damage both the workpiece and the user's hands.

What is the ideal body position for filing a workpiece?

The ideal body position for filing is to stand perpendicular to the bench vice, with your left leg forward and right leg back for stability. This positioning helps maintain balance and control while filing.

What are the three methods of filing, and how are they performed?

The three methods of filing are: Straight forward filing (moving the file lengthwise across the workpiece), Draw filing (pulling the file towards the body with even pressure), and Diagonal filing (moving the file diagonally from one corner to another on the workpiece).

How can flatness and squareness of the workpiece be checked after filing?

To check flatness, place a try-square on the workpiece and check for light gaps at three different points. If there’s a gap, it indicates unevenness. To check squareness, ensure the try-square is placed on two adjacent sides of the workpiece at 90 degrees to each other.

How can the thickness of the workpiece be verified during the filing process?

The thickness of the workpiece can be measured using a Vernier calliper. Measure the thickness at at least three different points to ensure consistency and uniformity across the entire workpiece.

What are the common mistakes to avoid while filing a workpiece?

Common mistakes include filing at an incorrect angle or filing only at the edges, leaving the center untouched. Both errors can lead to an uneven or improperly shaped workpiece.