Departments› Automotive Mechatronics Technology› Module I› Workshop Technology Principles› Ch 4: Use hand tools to cut and file parts
Automotive Mechatronics Technology  ·  Level 6
Workshop Technology Principles
Chapter 4: Use hand tools to cut and file parts
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⚑ What you will be able to do

By the end of this chapter, you will be able to:

  • Select the right hand tools based on the operation plan for the job.
  • Cut the work piece accurately to the specifications required by the job.
  • File the work piece carefully to meet the job’s specifications.
  • Produce parts accurately following the specifications required for the job.

These skills are essential because they help you create quality parts that fit perfectly and work safely in real-world projects.

Chapter Practical Activities

Practical 1: Cutting metal rods to specified lengths using a hacksaw

Automotive Mechatronics Technology · Level 6
Workshop Technology Principles
PRACTICAL ASSESSMENT
TIME: 3 HOURS
⬇ PDFCandidate Instructions (Candidate Tool)

Type: Individual

INSTRUCTIONS TO CANDIDATE:
1.  You are required to perform the following task:
i.  Cut two mild steel rods 12mm diameter to lengths of 150mm and 220mm.
2.  You have been provided with the following resources for the practical task:
Tools & EquipmentMaterials
Hacksaw frame with bladeMild steel rods 12mm diameter
Try squareSafety gloves
Marking gaugeSafety boots
Center punchOverall/overcoat
Bench viceEye protection goggles
Metal file
⬇ PDFResources Required (Cutting List)
S/NItemQuantity
1Mild steel rods 12mm diameter2 pcs per Candidate
2Hacksaw frame with blade1 set per Candidate
3Try square1 pc per Candidate
4Marking gauge1 pc per Candidate
5Center punch1 pc per Candidate
6Bench vice1 pc per Candidate
7Metal file1 pc per Candidate
8Safety gloves1 pair per Candidate
9Safety boots1 pair per Candidate
10Overall/overcoat1 pc per Candidate
11Eye protection goggles1 pair per Candidate
⬇ PDFAssessor Guide
Items to be EvaluatedMarks AvailableMarks ObtainedComments
TASK 1: Preparation and Safety
Wore all required personal protective equipment (safety gloves, boots, goggles, overall)
(Award 1 mark for each PPE worn or zero)		4
Assembled tools and materials at workplace correctly
(Award 1 mark or zero)		1
Checked and secured the mild steel rod in the bench vice properly
(Award 1 mark or zero)		1
Sub-Total6
TASK 2: Marking and Cutting
Measured and marked the first rod accurately at 150mm using try square and marking gauge
(Award 2 marks or zero)		2
Center punched the marked cutting points on both rods
(Award 1 mark or zero)		1
Measured and marked the second rod accurately at 220mm
(Award 2 marks or zero)		2
Used hacksaw to cut the rods along the marked lines with correct technique
(Award 3 marks or zero)		3
Smoothed the cut edges using a metal file
(Award 2 marks or zero)		2
Sub-Total10
PRODUCT CHECKLIST
Both rods cut to specified lengths within ±1mm tolerance (150mm and 220mm)
(Award 3 marks or zero)		3
Cut edges are smooth, free from burrs and square to rod axis
(Award 3 marks or zero)		3
Rods are free from deformation or damage after cutting
(Award 2 marks or zero)		2
Sub-Total8
GRAND TOTAL24
ASSESSMENT OUTCOME:   ☐ Competent    ☐ Not Yet Competent (competent if at least 50%)

Practical 2: Filing Flat Metal Surface to Specified Dimensions

Automotive Mechatronics Technology · Level 6
Workshop Technology Principles
PRACTICAL ASSESSMENT
TIME: 4 HOURS
⬇ PDFCandidate Instructions (Candidate Tool)

Type: Individual

INSTRUCTIONS TO CANDIDATE:
1.  You are required to perform the following task:
i.  File the flat surface of a mild steel plate 150mm x 100mm x 6mm to achieve a smooth, level finish within ±0.2mm thickness tolerance.
2.  You have been provided with the following resources for the practical task:
Tools & EquipmentMaterials
Hand file (second cut) 250mm lengthFlat mild steel metal plate 150mm x 100mm x 6mm
Marking scriber
Try square 150mm
Caliper vernier 150mm
Clamp or bench vice
⬇ PDFResources Required (Cutting List)
S/NItemQuantity
1Flat mild steel metal plate 150mm x 100mm x 6mm1 Pc per Candidate
2Hand file (second cut) 250mm length1 Pc per Candidate
3Marking scriber1 Pc per Candidate
4Try square 150mm1 Pc per Candidate
5Surface plate or flat reference surface1 Pc per Workstation
6Caliper vernier 150mm1 Pc per Candidate
7Clamp or bench vice1 Pc per Workstation
8Safety goggles1 Pair per Candidate
9Protective gloves1 Pair per Candidate
10Overall1 per Candidate
⬇ PDFAssessor Guide
Items to be EvaluatedMarks AvailableMarks ObtainedComments
TASK 1: Preparation and Safety
Wore safety PPE correctly (goggles, gloves, overall)
(Award 1 mark for each correctly worn PPE)		3
Assembled tools and materials at the workstation
(Award 1 mark for complete and proper setup)		1
Clamped the metal plate securely in the bench vice
(Award 1 mark for correct and secure clamping)		1
Checked and marked the surface to be filed using marking scriber and try square
(Award 1 mark each for neat marking and correct layout)		2
Sub-Total7
TASK 2: Filing Process
Used hand file with correct grip and stroke technique
(Award 2 marks for proper filing technique)		2
Filed the surface evenly to remove high spots
(Award 2 marks for uniform filing and surface leveling)		2
Stopped filing periodically to check thickness using vernier caliper
(Award 2 marks for accurate thickness monitoring)		2
Ensured the surface was smooth and free from deep scratches
(Award 1 mark for surface finish quality)		1
Sub-Total7
TASK 3: Final Checking and Cleanup
Verified final thickness of the plate is within ±0.2mm tolerance
(Award 2 marks for meeting thickness specification)		2
Checked flatness and squareness of the filed surface with try square and surface plate
(Award 2 marks for correct flatness and squareness)		2
Cleaned and returned tools to their proper place
(Award 1 mark for proper housekeeping)		1
Sub-Total5
PRODUCT CHECKLIST
Flat surface filed to dimensions 150mm x 100mm with thickness 6mm ±0.2mm
(Award 3 marks if all dimensions are within tolerance)		3
Surface is smooth, level, and free from deep scratches or gouges
(Award 2 marks for good surface finish)		2
Edges and corners are square and sharp as per working drawing
(Award 2 marks for correct edge and corner finish)		2
Sub-Total7
GRAND TOTAL26
ASSESSMENT OUTCOME:   ☐ Competent    ☐ Not Yet Competent (competent if at least 50%)
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🔒Cut wooden dowels to specified lengths using a handsawPractical 3
🔒Filing edges to remove burrs from cut metal partsPractical 4
🔒Cutting a Rectangular Shape from Sheet Metal Using Tin SnipsPractical 5
🔒Filing a curved metal surface using a round filePractical 6
🔒Cutting Plastic Pipes to Length Using a HacksawPractical 7
🔒Filing Slots and Grooves in Mild Steel WorkpiecesPractical 8
🔒Cutting bolts to specified lengths using a hacksawPractical 9
🔒Filing a Metal Workpiece to Exact DimensionsPractical 10
Am I competent?

At the start of this chapter we promised you would be able to:

  • Select the right hand tools based on the operation plan for the job.
  • Cut the work piece accurately to the specifications required by the job.
  • File the work piece carefully to meet the job’s specifications.
  • Produce parts accurately following the specifications required for the job.

Tick each one you can genuinely do.

So, are you there yet?

You're competent when you can confidently do 50% or more of what this chapter promised.

Sign in to record how you're doing.

← Ch 3: Measure and mark-out dimensions on… Ch 5: Use drills to make holes →