CHAPTER 12 STEELWORKER TOOLS AND EQUIPMENT In the shop and out on a jobsite, you will be using grinders, portable power drills, compressors, saws, and various other tools. As a Steelworker you need to be thoroughly familiar with the operation and maintenance of these tools as well as all applicable safety precautions. BENCH AND PEDESTAL GRINDERS The common bench and pedestal grinders are the simplest and most widely used grinding machines. The grinding work done with them is called OFFHAND GRINDING. Offhand grinding is used for work on pieces that can be held in the hands and controlled until ground to the desired shape or size. This work is done when the piece king ground does not require great precision or accuracy. The bench grinder (fig. 12-1) is attached to a Figure 12-2.—The pedestal grinder (dry type). bench or table. The grinding wheels mount directly onto the motor shaft. One wheel is coarse for rough grinding, and the other is fine for finish grinding. The pedestal grinder, inmost cases, is larger than the bench grinder and is equipped with a base and pedestal fastened to the floor. The DRY TYPE (fig. 12-2) has no arrangement for cooling the work while grinding other than a water container into which the piece can be dipped to cool it. The WET TYPE (fig. 12-3) is equipped with a built-in coolant system that keeps the wheels constantly drenched with fluid. The coolant washes away particles of loose abrasive material, as well as metal, and keeps the piece cool. Figure 12-3.—Pedestal grinder (wet type) wttb a built-in coolant system Bench and pedestal grinders are dangerous if they are not used correctly They must never be used unless fitted with guards and safety glass EYE SHIELDS (fig. 12-4). Even then you must wear goggles or safety glasses. A TOOL REST is furnished to support the Figure 12-1.—The bencb grinder, Eye shields have not been work while grinding. It should be adjusted to come mounted. within one eighth of an inch from the wheels. This will 12-1 Figure 12-6.—Mechanical wheel dresser. remove the glaze that occurs after heavy use. This is done by holding the dresser firmly against the wheel with both hands, using the tool rest for support. Then, as the wheel turns, move the dresser back and forth across the surface (fig. 12-7). For maximum Figure 12-4.—Eye shields for bench and efficiency and safety in operating the grinder, you pedestal type of grinders. should observe the following rules: 1. Use the face of the wheel, never the sides. prevent work from being wedged between the tool rest and the wheel. Turn the wheel by hand after 2. Move the work back and forth across the face adjusting the tool rest to ensure there is satisfactory of the wheel. Even wear results because this action clearance completely around the wheel (fig. 12-5). prevents the wheel from becoming grooved. The grinding wheels themselves can be sources 3. Keep the wheel dressed and the tool rest of danger and should be examined frequently, based properly adjusted. upon usage, for irregularities and soundness. You can test a new wheel by suspending it on a string or wire Do not shape soft metals, like aluminum, brass, and tapping the side of the wheel with a light metal and copper, that tend to load (clog) the abrasive rod. A solid wheel will give off a distinct ringing wheel. These metals should be shaped by other sound, A wheel that does not give off such a sound methods, such as tiling, sanding, and chipping. must be assumed to be cracked and should be discarded. Under no circumstances should it be used. PNEUMATIC POWER TOOLS Since it is not practical to check the wheels by this manner every time you use the grinder, make it a The portable power tools that are available for use habit never to stand in front of a grinder when it is are either powered by electric motors or by air first turned on. A cracked wheel can disintegrate and (pneumatic) motors. Whether powered by electricity become projectiles quickly. or compressed air, the tools are basically the same and the procedures for using them are the same. This The wheel must also run true and be balanced on section will deal with pneumatic tools since these the shaft. A WHEEL DRESSER (fig. 12-6) should be require unique maintenance and servicing on the used to bring abrasive wheels back to round and jobsite or in the shop. NOTE: All low-pressure compressed air systems should have a filter, a regulator, and a lubricator assembly installed at the outlet. This assembly will ensure delivery of clean, regulated mist lubricated compressed air for the operation of pneumatic tools. Figure 12-5.—Properly spaced tool rest. Figure 12-7.—Using a wheel dresser. 12-2 CAUTION can also punch holes. The size of the angles and plates that can be safely handled by the machine depends Before operating a pneumatic tool, inspect upon its capacity. It is manufactured in various sizes the air hose and check it for leaks or damage. and capacities, and each machine has a capacity plate Blow air through the air hose to free it of foreign either welded or riveted on it. This guide should be material before connecting it to the tool. Keep strictly adhered to. The pressure and power the the air hose clean and free from lubricants. machine develops demand extreme caution on the part Never point the air hose at another person. of the operator. VERTICAL BAND SAWS Pneumatic tools must have complete lubrication. The moving parts of pneumatic tools are fitted very While the vertical band saw is designed primarily closely, and they must be lubricated correctly or they for making curved cuts, it can also be used for straight will wear quickly and fail to work. cutting. Unlike the circular saw, the band saw is frequently used for freehand cutting. Valves and pistons on pneumatic hammers require a light machine oil. Since the compressed air comes The band saw has two large wheels on which a directly in contact with these parts, it has a tendency continuous narrow saw blade, or BAND, turns, just as to drive the lubricant out through the exhaust. a belt is turned on pulleys. The LOWER WHEEL, located below the WORKING TABLE, is connected When working continuously with a pneumatic to the motor directly or by means of pulleys or gears tool, you should regularly check the lubricator to and serves as the driver pulley. The UPPER WHEEL ensure there is ample lubricant available. Next, empty is the driven pulley. the filter assembly as needed. The saw blade is guided and kept in line by two On low-pressure compressed air systems that do sets of BLADE GUIDES: one fixed set below the not have the filter, the regulator, and the lubricator table and one set above with a vertical sliding assembly installed, you should disconnect the air hose adjustment. The alignment of the blade is adjusted by every hour or so and squirt a few drops of light oil into a mechanism on the back side of the upper wheel. the air hose connection. Do NOT use heavy oil TENSIONING of the blade—tightening and because the oil will cause precision parts to either fail loosening-is provided by another adjustment located or to have operating troubles. If this occurs, you have just back of the upper wheel. to clean your tool in cleaning solvent to loosen the gummy substance that results. Blow out the tool with Cutoff gauges and ripping fences are sometimes air, lubricate it with light oil, and go back to work. provided for use with band saws. However, you will do most of your work freehand with the table clear Keep your pneumatic tools clean and lubricated because accurate cuts are difficult to make with a band and you will have few operating problems. saw when gauges or fences are used. SHOP MACHINERY The size of a band saw is designated by the diameter of the wheels. Thus the 14-inch model (fig. Prefabrication of steel parts and assemblies is 12-9) has 14-inch wheels. Common sizes are 14-, 16-, typically accomplished in a steel shop where heavy 18-, 20-, 30-, 36-, 42-, and 48-inch machines. The steel working machinery is accessible. The steel shop 14-inch size is the smallest practical band saw. With is tasked with manufacturing and fabricating items, the exception of capacity, all band saws are much alike such as sheet-metal ducts, pipeline section fittings, in maintenance, operation, and adjustment. plates, and angles. In the following sections, we will Blades, or bands, for bandsaws are designated by discuss some of the common types of machinery found POINTS (tooth point per inch), THICKNESS (gauge), in a well-equipped steel shop. and WIDTH. The required length of the blade is found by adding the circumference of one wheel to twice the COMBINATION IRON WORKER distance between the wheel centers. Length can vary within a limit of twice the tension adjustment range. The combination iron worker is likely the most valuable and versatile machine in a shop. The Vertical band saws are comparatively simple combination punch, shear, and coper (fig. 12-8) is machines to operate. Each manufacturer publishes a capable of cutting angles, plates, and steel bars, and it technical manual for their machine. Refer to the 12-3 Figure 12-8.—Combination punch, shear, and coper.