FILES AND FILING

Uses

Files are tools used for shaping metals by removing very small amounts of metals. Files shape
metals by removing small amounts of chips. A file is a piece of hardened steel having a series of
teeth, in the form of grooves, cut across its face.

The teeth formed by the grooves act on the material as a series of small cutting tools
when the file is passed over the surface.
File manufacture
The file manufacturing process consists of:
 forging to shape
 annealing
 grinding of the faces
 cutting of the teeth
 hardening
 tempering.

Materials: Files for general purpose us are made of high carbon steel

Types

There are many different types of files in engineering workshops. Generally, files are known by
their geometrical shapes. These are:

 Hand file
 Flat file
 Round file
 Half round file
 Square file
 Triangular file

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 PARTS OF A FILE

Figure 1 Parts of a file

The figure above shows the principal parts of a file. Some files have two faces; others, like the
half round file, have only one face, the curved side being referred to as the back. The length is
measured from the point to the heel and does not include the tang. The common types of files are
made in various lengths.

Parts and Uses

Handle : Is made of wood or plastic. Protects user from the tang
Ferrule: Prevents wooden handles from splitting.

Files are classified by the length of their blade

Types of Files

Flat file – used for filing large, flat surfaces. It tapers towards the tip

Figure 2 Flat file

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Hand file – has one safe edge and can file up to a shoulder without
marking it. The safe edge is the edge without teeth

Figure 3 Hand file

Pillar file – is narrowed and thicker than the hand file, and is used where greater pressure per unit
area is required to make the file bight.

Figure 4 Pillar File

Warding file – thinner than the flat file, used for filing out narrow slots.

Figure 5 Warding File

Square File - Is used for opening up square holes as well as filing corners

Figure 6 Square File

Round file Round file – for opening up round holes.

Figure 7 Round File

Half round file – used to file curved/concave surfaces.

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 Figure 8 Half round File

Cut of a file

The cut of a file is the way in which the teeth of a file are cut eg single cut , double cut rasp cut
etc.

Single cut files give a finer finish, but do not remove the metal as quickly as double cut
files. They are used for draw filing, lathe filing and for filing brass and similar metals.
Double cut files have two rows of cuts at an angle to and crossing each other. They are
used for general purpose filing on steel and cast iron.
Dreadnought cut files have coarse, curved teeth and are used for cutting soft metals
such as aluminium and lead.

a Single cut files b Double cut files c dreadnought cut file

Figure 9 Types of file cuts

The Grade of a file

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The grading of a file is also associated with its name. It is the number of teeth on a file per 25mm
distance. The grade is the coarseness of the teeth, that is the distance apart which the teeth have
been cut on the file. We can list the name and teeth per 25 mm of each as follows.

Types of Grades
The following are the types of file grades:
 Dead smooth
 Smooth
 Second cut
 Bastard
 Rough

Grading and coarseness

The grading of a file is also associated with its name. The grade is the coarseness of
the teeth, that is the distance apart which the teeth have been cut on the file. We can
list the name and teeth per 25 mm of each as follows.
 Dead smooth – 70/80 teeth per 25 mm
 Smooth – 50/60 teeth per 25 mm
 Second cut – 30/40 teeth per 25 mm
 Bastard – 20/25 teeth per 25 mm.
Safe edge is the term used for the edge of the file which has no teeth cut on it. It is
used to place against the finished work in order to stop further removal of metal taking
place.
Pinning
Pinning refers to the tendency of the file grooves to pick up waste material between the
teeth, forming hard pins that scratch the material. As soon as the slightest indication
of pining is observed, the file should be cleaned with a file brush (Fig 9 b ). Another
method is to use chalk on the surface of the file.

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 Figure (9 b) Cleaning the teeth of a file with a file wire brush or file card
Holding the file
It is most important for the beginner to learn the correct manner of holding a file. It is
just as easy to learn the correct way as it is to learn the wrong way, however it will be
harder to forget the wrong way and learn the correct way. In moving a file endways
across the work, commonly called cross filing, the file is held as shown in Fig below.

Cross filing process

For heavy filing, the file should be held like in the figure below

For light filing the file should be held like in figure below

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 Figure 10 Cross Filing processes
For finishing, the file should be held like in the figure below

Draw filing is a finishing process and the file should be held in the manner shown below. The
file should be held at 900 the edges of the workpiece

Figure 11 The draw filing process

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Filing Processes of different profiles

Narrow surfaces
The file should be kept parallel with the work and the stroke carried fully across the
surface.
Filing of holes
In filing circular holes, a round file that is nearly the size of the hole should be used. If a
small file is used there will be a tendency to produce a number of small ridges.
Filing of curves
When filing is to be done on an internally curved surface, a half round file is used. As
in the case of circular filing, there is a tendency to file unevenly and a file of as large
a curvature as is obtainable should be used. The file should be moved along the
circumference as well as across the work.

Filing corners
When it is necessary to form a sharp corner or to file to a finished surface that stands
at right angles to a finished surface, a safe edge file is used.
Draw filing
When filing by moving the file sideways across the work it is called draw filing, as
shown in Fig The file is held in both hands with the motion being at right angles to
its length. Draw filing is used in finishing work.
Process of Draw filing.
 A flat file of fine cut is used for this operation.
 It should be ensured before use that the file teeth are free from metal particles,
 Otherwise a numbers of scratches will be produced on the surface. It is usual to employ
a file card quite frequently for cleaning the file teeth both before use as well as during
use.
 For draw filing operation the file is held flat on the surface between the two hands.
 The file must move forward and backward. Flatness and evenness of the surface should
be checked quite frequently during the operation.

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For final finishing, it is a common practice to rub a chalk piece over the entire surface of the file.
This helps in producing a finely finished surface.

Precautions when using a file

 Select the correct type of file for the job in hand.
 Never use a file without first fitting a file handle over the tang.
 Never hit a file against a hard surface, as damage will occur to the teeth or the file may
shatter.
Filing

 Similar to the saw blades, most of the files have their teeth pointing away from the
operator such that they cut during the forward stroke.
 The pressure of the hand in filing should also be applied only during the forward stroke
and relieved during the return stroke.
 Beginners particularly should be careful enough to practice correct movement of file.
 It should always be more in a perfect horizontal plane for obtaining a truly plane and
smooth surface.
 As far as possible, try to use full length of the file during the operation.
 Moving the file diagonally on a flat surface always yields best results. A coarse pitched
file should be employed when enough metal is to be removed, followed by finishing with
a smooth file.
Draw filing

When the surface is to be finally finished by filing only and no other operation, like scraping, is
to follow the filing operation, a special method of filing, called Draw filing, is employed for
finishing the surface.

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 Figure 12 Uses of various types of files

EXERCISE

1 Briefly describe how files are manufactured. (5)

2 Use sketches to illustrate the practical use of each of the following files:

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 i Hand file

ii Flat File

iii Triangular File

iv Round File

v Warding file

iv Half round file (12)

3 Name the most ideal material used in the manufacture of files and justify your answer ( 5)

4 (a) Illustrate how files are specified (3)

(b) Name three grades of files (3)

5 Illustrate the use of a safe edge on a hand file (2)

Due Date 28/05/2021

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