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		Manual Sawing - Course: Technique for manual working of materials. Instruction examples for practical vocational training (Institut für Berufliche Entwicklung, 31 p.)
			(introduction...)
			Introduction
			Instruction example 4.1. Spacers and pin drifts
			Instruction example 4.2. Stands and supports
			Instruction example 4.5. Container
			Instruction example 4.4. Vee-shaped attachment
			Instruction example 4.5. Steel square
			Instruction example 4.6. Angle-steel frame table
			Instruction example 4.7. Wall-shelf bracket

Instruction example 4.1. Spacers and pin drifts

To practise simple cutting-off of sectional steel and other materials.

Material

- Flat steel (340 MPa)
Thickness: 15 mm
Width: 25 mm
- Flat aluminium bars
Thickness: 5 mm
Width: 40 ram
- Round copper and brass bars e.g. 6 and 10 mm diameter, any length.

Figure

Hand tools

Steel scriber, mark-out punch, engineers’ hammer, hand hacksaw with various saw blade types (coarse and normal tooth pitch), smooth-cut file 200 mm (flat).

Measuring and testing tools

Steel measuring tool, try square.

Accessories

Vice, cutting oil, horizontal Vee-shaped attachments.

Required previous knowledge

Reading of drawings, measuring and testing, scribing and prick-punching.

Sequence of operations

Comments

1. Arrange the working place, prepare the working materials.

- Check for completeness.

2. Scribe and prick-punch flat steel to 120 length.

- Part (1)
Datum edge to be flat and at right angle (try square).

3. Clamp workpiece in vice and start sawing with small starting-cut sawing angle.

- Use saw blade with normal tooth pitch.
- File guiding kerf, it necessary.

4. Saw-off with constant cutting movement, then remove burrs.

- Provide saw blade with cutting oil.
- Use total length of saw blade.

5. Prepare and saw-off flat aluminium bar in the same manner.

- Part (2)
- Use saw blade with coarse tooth pitch.

6. Scribe round copper and brass bars and clamp them in vice.

- Parts (3) and (4)
- Use suitable attachments for horizontal clamping.

7. Saw-off at scribed line in one pass and remove burrs.

8. Final inspection.

- Straightness of cut.

To continue practising, if necessary

Saw-off other flat stock and round bars of different diameters.

Spacers and pin drifts

Sequence of operations	Comments
1. Arrange the working place, prepare the working materials.	- Check for completeness.
2. Scribe and prick-punch flat steel to 120 length.	- Part (1) Datum edge to be flat and at right angle (try square).
3. Clamp workpiece in vice and start sawing with small starting-cut sawing angle.	- Use saw blade with normal tooth pitch. - File guiding kerf, it necessary.
4. Saw-off with constant cutting movement, then remove burrs.	- Provide saw blade with cutting oil. - Use total length of saw blade.
5. Prepare and saw-off flat aluminium bar in the same manner.	- Part (2) - Use saw blade with coarse tooth pitch.
6. Scribe round copper and brass bars and clamp them in vice.	- Parts (3) and (4) - Use suitable attachments for horizontal clamping.
7. Saw-off at scribed line in one pass and remove burrs.
8. Final inspection.	- Straightness of cut.