Metal cutting. Manual metal processing. Locksmithing

The need for processing of metal products and structures occurs in a variety of areas. The mechanic uses a wide range of tools for solving such problems, among which are all kinds of carvers, drills, hacksaws and abrasive equipment. The initial level is represented by a file, which is used both for domestic purposes and in specialized workshops. Operations delicate, soft processing allow you to maximize the characteristics of the workpiece to the desired indicators. However, in order to realize the qualitative filing of metal, it is necessary to approach the selection of the working tool responsibly.

Objectives of filing

During the processing of this kind, the top layer of the metal surface is removed. Depending on the characteristics of the tool used, this layer can be from one to several millimeters. As a rule, plumbing in this direction helps to form the optimal quality of the billet for its subsequent application in structures or as an independent object. The working process allows to give the product a certain shape, dimensions, and also provide a curved or straight surface for the purpose of subsequent adaptation to the part or structure.

Scales of work may vary depending on the application of the final object. For example, for small elements, a vise and an abrasive tool with minimal mechanical impact are used. Conversely, large metal billets can be serviced directly at the site of their assembly and even operation.

File device

The file in appearance is a small bar provided with small teeth. The incisions are performed according to different schemes and differ in size. Thus, single ones are placed at an angle of about 80 ° relative to the tool edge. A double notch is also used. In this case, an angle of 55 ° is provided in the lower part and 70 ° in the upper part. Teeth determine the effectiveness of the abrasive action that a particular file provides. GOST under number 1465-80 also provides that the base should be made of tool steels of grade У13. In addition to the working part, the file has a shank that can act as a handle. But there are also models, in which the entire metal surface is represented by serrated incisions.

Varieties of files

The files are divided into many parameters, among which are the length, shape, number of incisions per cm, etc. Thus, there are fight models with large teeth on the surface. Accordingly, such a tool is suitable for performing rough machining of parts. The opposite of the fighting models are velvet files, distinguished by a small notch. If you want to accurately feed the workpieces for point introduction of the element into the mechanism, then use small teeth. Distinguish between the tool and the types of surfaces. In particular, a flat file can be called a basic model, although the spectrum of problems solved by it is essentially limited. The technology of manufacturing such models is the simplest, and is due to their low price and wide distribution. However, a spherical file, also represented in different variations, is considered more technologically and universally applicable. For example, distinguish round, semicircular, rhomboid and rectangular versions.

Requirements for the production of files

Regardless of the device and the configuration of the location of the faces, there are general requirements for the files. A quality tool should have sufficient hardness and sharpness of notches to ensure optimal adhesion to the base plate. There are also regulations that regulate the layout of the incisions themselves. Special requirements apply to a narrow file. GOST 1465-80 prescribes to make it in such a way that a single notch has an angle of 65 °. In this case, the number of teeth on the narrow sides should correspond to the number of base incisions located on the wide sides.

The large narrow side of the files of the hacksaw type is provided with notches only on parallel running areas. Separate requirements concern the rounded tool. Semicircular models should be made with cut teeth, although there are exceptions, when a traditional notch is used for this type.

The working process

First of all, conditions for the technical implementation of the event are prepared. The main requirement for its organization is the reliable fixation of the workpiece. Most often for this purpose use a vice, which allows to give the element a stable position. Work begins with preliminary stripping. If there are traces of rust or scale on the surface of the material, they are eliminated with a shot file. That is, in this part, rough metal filing is used, in which it is desirable to use an old tool, since working with problem surfaces quickly wears files.

Then you can start roughing. Depending on the state of the workpiece at this time, a more efficient and accurate tool is selected. At the same time, it is worth taking care of the vice, which may suffer during the sawing process. Protect the jaws with special brass, copper or aluminum linings. The choice of material also depends on the nature of the treatment - the more intense and coarser, the harder the patch.

Recommendations on the technique of filing

Vices are set so that their sponges are at the level of the elbow. During filing, you should stand half-turned to the equipment - about 20 cm from the edge of the table. The body is kept straight, but with a rotation of 45 ° relative to the longitudinal axis of the vise. The optimal location of the legs is on the width of the shoulders, while the left leg can be turned in the direction of the tool's forward movement. This position provides the most stable position of the body, which allows you to perform free filing of metal, even with a slight inclination of the body forward to control the quality of work. During the operation, the file is held with the right hand so that the pen's head rests against the palm of your hand.

Mechanization of filing

Recently, many representatives of the traditional hand tools have successfully moved into the form of electrical devices that have higher technical and operational indicators. The plumbing business was also modernized, as a result of which the masters acquired pneumatic devices for sawing metal. In general, the concept of manual processing has been retained, but the power effect is provided by the electric motor. The nozzles with abrasive surfaces also serve as working elements.

In addition to the pneumatic tool, battery batteries as well as network devices became widespread. For example, the tape file is equipped with cutting blades that effectively perform accurate and dot finishing of various metal surfaces. The advantages of mechanized devices include processing quality, high speed and process safety. However, high accuracy in maintaining complex shapes of blanks is still achieved only if traditional files are used.

Checking the quality of work

The correctness of the processing performed is evaluated using a ruler or a gon. Thus, the supervising master checks the presence of gaps. This version of control is used in the event that the goal was to obtain an even and clean surface. If metal filing was performed for the subsequent integration of the element into the design with grooves, then the quality of work can be assessed by a natural comparison of the parameters.

Conclusion

In a wide range of cutting tools, the file is one of the safest. Nevertheless, in working with him, do not forget about some rules that will prevent unpleasant consequences. Thus, manual metal working should be carried out only under condition of stable position of the workpiece. The absence of swaying will favorably affect both safety and quality of work. Also during processing it is not necessary to remove the shavings with your hands. For this purpose, special brushes or industrial vacuum cleaners are used. By the way, the electric belt and pneumatic tools, depending on the modification, may provide for the possibility of additional equipment with dust extraction systems.