Filing
Pa g e 1
LESSON PLAN
Basic Cutting Processes 1
PRT 01.10
Benchwork Workshop
Location
Chapter
Filing
Prepared by
ADIB
AZIHA
HASNIZAM
Objectives
1.
2.
Identify and describe the most common shapes and sizes of files
3.
Identify the cuts and coarseness of files and describe their intended use
4.
References
Media
1.
1.
Overhead projector
Chapter 2
1.
FILING
General
The file
1.1.
Classification of Files
A. single-cut
B. double cut
C. rasp-cut
D. curved-cut
1.2.
Hand file
A hand file is used for general surfacing work. Both faces are double-cut. The edge may be
single-cut, or one edge may be left uncut to provide a "safe" edge for use when filing up to a
shoulder as shown in the diagram.
1.3.
File selection
Many factors must be considered in selecting the file if maximum efficiency is to be attained.
1. The nature of work (flat, concave, convec, notched etc)
2. Kind of material
3. Amount of material to be removed
4. Surface finish and accuracy demanded
There is almost no limit to the numbers of different kinds, shapes and cuts of files that are
manufactured.
Of the many file shapes available, the most commonly used are flat, square, 3-square, knife,
half round, round and crossing files.
1.4.
1.
File safety
A file should NEVER be used without a handle. This applies especially to
lathe work because the tang can be driven right through a person's hand by
force exerted by the moving parts of the machine.
2.
Clean files with a file card, NOT your hand. The chips can penetrate your
hand and cause a painful infection.
3.
4.
Do NOT clean the surface being filed with your finger. Short burrs are formed
in filing and can cause serious cuts.
5.
Never hammer on or with a file. It may shatter and chips can fly in all
directions.
6.
1.5.
File handle
1.6.
It is important to clamp to workpiece tightly; this is usually done in a bench vice by gripping
the workpiece as near to the vice jaws as possible.
Picture (a)
Picture (b)
The front jaw is movable, the back jaw is fixed.
1.7.
Protective pads
The surface of the workpieces should be protected by covering the hardened rice jaws with
protective "soft" jaws. These soft jaws can be made of copper, aluminium lead, press-board
or wood.
1.8.
1.9.
Height of vice
1.11.
The right hand grips the file handle so that the end of the handle presses against the ball of
the thumb.
The left hand presses on the file blade with the ball of the thumb.
1.12.
Positioning of feet
1.13.
Positioning of body
1.14.
Forward stroke with pressure. Return stroke without pressure (use the whole length of the
file).
1.15.
a) The file should be moved with equal pressure along the entire length of the file. However,
do not push the file forward so that the handle hits against the work. This could remove the
handle and cause accidents.
b) To minimize vibrations, sheet metal should be filed at an angle.
c) Never touch the surface to be filed with your hands, as this leaves a film of lubricant on
the face of the work which impairs the action of the file.
d) Scoring can be minimized by rubbing chalk over the body of the file.
Regular forward stroke motion to both sides produces even removal of filings.
1.16.
Radius filing
1.17.
Work technique
File provisional surfaces diagonally at right angles to the broad surface. Turn the file about
its longitudinal axis when round filing at right angles to the radius.
Guide the file-see-saw motion-in synchronization with the radius. Re-clamp the workpiece
repeatedly so that a circular shape is produced. Check the radius with the radius gauge.
Turn the file about its lateral axis when round filing in synchronization with the radius.
1.18.
1.19.
Basic principles
Round filing of internal surfaces requires the use of rounded files, the radius of which must
be smaller than that of the radius of the workpiece to be filed.
1.20.
Work process
1.21.
Work technique
Guide the file straight as in flat filing, turning it at the same time about its longitudinal axis. To
achieve an even radius, an additional sideways feed is necessary. The sideways feed should
not be too great otherwise serrations will be produced.
1.22.
Diagonal filing
The file is used across the work surface at an angle of 45. Change the direction of filing by
90 each time. The resulting shades on the workpiece surface show up the unevenness of
the surface.
1.23.
Transverse filing
The file is used at right angles to the longer edge of the workpiece.
1.24.
Longitudinal filing
De-burring the filed edge in a longitudinal direction (do not file the chamfer).
1.25.
File brush
Cleaning the file is necessary because "dirty" files produce messy finishes (serrations) or do
not bite at all. Only use the file brush in the direction of the over-cut. Stubborn chips should
be removed with a file cleaner (brass or cooper sheet).
The chalk settles into the base of the file teeth and thus reduces the penetration of the teeth.
Chips which could otherwise damage the smooth surface of the workpiece do embed
themselves into the chalk. The file should, therefore, be cleaned more often and recoated
with chalk.
1.28.
Which cut of file is intended to cut steel, cast iron and hard plastics?
1.29.