1. A decent Allen key should be too hard for a file to have any impact. You need something like an oilstone, such as Screwfix item 4851V. Better still if you can get a diamond stone, but a good deal more expensive. Note that the oilstone will require a lubricant such as "3 in 1" oil. The diamond will work with water.
2. Standard grub screws are usually M5 to take a 2.5 mm Allen key, or M6 to take a 3.0 mm Allen key. However, once you remove one:
2.1 Measure the diameter accurately across the threads in mm. 5.0 mm is an M5 thread, 6.0 mm is M6 and so on.
2.2 Measure the length of the grub screw from tip to base.
2.3 They come in four main tip types, flat, cup, point and dog. Make sure you get one to match. Most likely flat or point.
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