FITTING
INTRODUCTION
Fitting consists of a handwork involved in fitting together components usually
performed at a bench equipped with a vice and hand tools. The matting components
have a close relation with each other, and when the function together is termed Fitting.
We have to use hand tools, precision tools and various operations, as well as the details
of the tool such as identification, material, parts, types, various uses, manipulation,
specification, care and maintenance etc.
MARKING AND MEASURING TOOLS
1. STEEL RULE:
A steel rule is a direct reading measuring instrument used to read an accuracy of
0.5mm. Available in various lengths, widths and thickness with several
graduations. They are made from high carbon steel, spring steel, stainless steel
and various alloy steel.
2. TRY SQUARE:
It is used for marking and measuring right angles (90°). It consists of a blade and
stock. Blade is made of tempered Steel, riveted at right angles to a stock made of
steel or cast iron. It is classified by the length of the blade from the edge of the
stock. It is also used for checking the flatness of the object.
3. SCRIBER:
A scriber is a pointed tool used for marking lines on metals. Scribers are made
from high carbon steel and the points are hardent and tempered.
Types: Straight Scriber, Bent type scriber, Offset scriber, Adjustable Scriber etc.
4. DIVIDER:
This tool consists of two pointed legs having a joint at the top end. There are
spring type and firm joint dividers. It is made from high carbon steel and the
points are hardent and tempered. It is used to scribe circles, arcs, parallel lines
and laying of distance. To divide straight or curved lines into number of equal
spaces. To find the centre of a round bars. To transfer the dimension from a rule
to job.
5. CALIPER:
It is a simple tool gauging legs. It is made of high carbon steel and the measuring
points are hardened and tempered.
Outside Caliper - They are used to measure the outer dimensions of the shafts,
pulleys and square bars etc.
Inside Caliper - They are used to measure the inner dimensions of holes, bores,
slots etc.
Jenny Caliper - They are used in layout work for locating and testing centre on
cylindrical and other sections laying of distance from an edge and to scribe
parallel lines.
6. VERNIER CALIPER:
The vernier Caliper is a precision instrument used for measuring both inside and
outside diameters of shafts, thickness of parts, etc. to an accuracy of 0.02 mm by
a vernier scale attached to the caliper.
7. OUTSIDE MICROMETER:
The outside micrometer is a precision instrument used to measure outside
dimensions like diameters of shafts, thickness of parts, etc. to an accuracy of 0.01
mm.
8. VERNIER HEIGHT GAUGE:
The vernier Height gauge is used to measure the height of parts to an accuracy of
0.02mm (0.001 inches). The vernier Height gauges are available for the following
lower and upper limits of measurements 0-200, 20 to 250, 30 to 400, 40 to 500,
60 to 800 and 60 to 1000. For making out the scriber is set for the specified
height and the lines are scribed by moving the scriber along the work piece.
9. ANGLE PLATE:
If the shape is such that it does not have a base, it has to be clamped to an angle
plate. The faces of this plates are provided with slots to fasten the work to the
plate by bolt and nut. Solid angular plates and adjustable angle plates are
available.
10. V-BLOCK:
This is a block of steel or cast Iron, which provide with V-shaped groove on it’s
top or bottom or both surfaces. All it’s faces are truly machined. It is used to hold
round bars during marking and drilling. The round bars clamped firmly on the V-
block by a U-clamp the slots cut at the 2 sides of the V-block.
11. PUNCHES:
Punches are important tools used for marking outward, locating centre for holes.
The punch marks are made along the marked out lines to make them clear till the
operation is over. Punches are made from carbon tool steel of length 90 to
150mm. The head is hardened and tempered. The point is ground to the proper
angle according to the purpose of the punch.
(a) Dot punch: are used to make dots or points along the scribed line.
(b) Centre Punch: are used for locating the centre of holes to be drilled to keep
the drilling correct position.
(c) Prick punch: Punches are using for the above said purposes. Its angle of
point is 30° or 40° so that their points are sharper.
12. SURFACE PLATE:
Surface plate is the basic tools used for marking. It is a plane table of fine grained
cast iron. Even though surface plates are made indifferent sizes and shapes, the
most common shapes are rectangular and square. The surface plate is specified
in it’s sizes.
CUTTING TOOLS
HACKSAW:
The hacksaw is used for sawing metals. A hand hacksaw consists of a frame,
handle, prongs, tightening screw and nut and blade. The frame is made to hold the blade
tightly. It is of two types;
The solid frame, in which the length cannot be changed, and the adjustable
frame, which has a back that can be lengthened or shortened to hold blades of different
length. Hack saw blades are made of alloy steel and a standard lengths 225, 250 &
300mm. Push type blades - those which cut in forward stroke only are generally used.
Two types of hacksaw blades are available, all hard and flexible. The all hard blade is
hardened throughout and being more rigid - it is aid to an accurate sawing in hard
metals. It requires skill to use, as it is easily broken. The flexible blade is hardened on
the cutting edge only. They are suitable for general work for cutting.
CHISELS:
Chisels are used for cutting and chipping away pieces of metal and are made of
carbon steel usually of rectangular, hexagonal cross section. They are forged to shape
roughly ground and then hardent and tempered. The edge is correct to the cutting angle.
Care being taken not to overheat the steel and draw the temper. The cutting angles
given to the chisel is determined mainly by the nature of the metal to be chip. It varies
between 350 and 700. It is generally specified by the length and width of the cutting
edge.
TYPES:-
1. FLAT CHISEL:
The flat chisel is the most common of all the chisels used in engineering. It is the
chisel which is used for most of the general chipping operation. It may be used
for removing surplus metal from surface of jobs.
2. CROSS CUT CHISEL:
The cross cut chisel or cape chisel as it is sometimes called, is used cutting
grooves in large surfaces. The cutting edge is slightly wider than the supporting
metal to provide clearance length of this chisel various from 100 to 400mm, and
width of the edge varies from about 4 to 12 mm.
3. HALF ROUND CHISEL:
A half round chisel is particularly useful for cutting oil ways or grooves in
bearing, pulleys, and bushes. They are also used for setting over pilot holes.
4. DIAMOND POINT CHISEL:
It is made square at the point and then bevelled to make a cutting edge. It is used
to make a cutting edge. It is used for cutting grooves and square corners.
5. SIDE CHISEL:
It is ground and bevelled on one side only. It is used for cutting sides where flat
chisels cannot enter.
FILES:
The most widely used hand tool in an engineering shop is the file. A file is a
hardened piece of high grade steel with standing row of teeth. The cuts all metals except
hardened steel. The file consists of the following parts, tang, heel, face, edge, and point.
Files are classified according to four principal factors, sizes, shape, grade and types of
cut of teeth.
Size: The size of the file is its length. This is the distance from the point to the heel.
Shape: The shape of a file is its general outline and cross section, commonly used
shapes are as follows
a) Flat file: This is tapered in width and thickness and one of the most
commonly used file to general work. They are always double cut on faces and
single cut on edges.
b) Hand file: This is parallel in its width and tapered in thickness. It is used for
finishing flat surfaces. It has one safe edge.
c) Square file: This square in cross section, double cut and tapered towards the
point used for filing square corners, enlarging square or rectangular openings.
d) Round file: They are round in cross section and usually tapered towards the
point.
e) Half Round file: Its tapered, double cut, and its cross section is not a half
circle but only about 1/3 of a circle. This file is used for round cuts and filing
curved surfaces.
f) Triangular file: It is triangular in shape and it is used for filing sharp corners
and angles.
g) Knife edge file: It is shaped like knife edge, tapered in width and thickness
and double cut. They are used for filing narrow slots, notches and grooves.
h) Needle file: It is made in sizes from 100mm to 200mm of various shapes and
cuts are extremely delicate and are used for fine work.
Grade: It is the coarseness is spacing between the rows of teeth, they are Rough,
Bastard, Second cut, smooth, dead smooth and super smooth.
Cut: Cut of files are classified into two groups: Single-cut, and Double-cut On single cut
files, the teeth are cut parallel across the file at an angle of about 600 to the centre of the
file. Double-cut file at an angle of teeth, the over-cut teeth being cut at about 600, and
the up-cut at 750 to 800 to the centre line
STRIKING TOOLS
Hammers are used to strike a job or a tool. They are made of forged steel of
various sizes and shapes to suit various purposes. A hammer consists of 4 parts namely,
peen, head, eye and face. The eye is made oval or elliptical inside in shape and
accommodate the handle. Hammers are classified according to the shape and peen.
1. BALL PEEN HAMMER:
This is the most common hammer. The peen has a shape of a ball which is
hardened and polished; size varies from 0.11 to 0.91 Kgs.
2. CROSS PEEN HAMMER:
This is similar to ball peen hammer in shape and size except the peen which is
across the shaft or eye.
3. STRAIGHT PEEN HAMMER:
This hammer has a peen straight with the shaft or parallel to the axis of the shaft.
HOLDING DEVICES:
VICE: Vice the most common tool for holding the work various types of vices are used
for various purposes.
1. BENCH VICE:
The most commonly used vice is engineer’s parallel jaw bench vice. It must be
firmly fixed to a bench with nuts and bolts or screws. The vice essentially
consists of a cast iron body. A fixed jaw, a movable jaw both made of cast steel, a
handle, a square the ended screw and a nut all made of mild steel, separated cast
steel plated called jaw plates are fixed to the jaws by means of set screws and
they can be replaced when worn. The holding faces of Jaw plate, have teeth to
hold the work firmly. The movement of the vice is caused by the movement of
the screw through the nut fixed under the movable jaw. The size of the vice is
known, by the width of it’s jaws.
2. LEG VICE:
The leg vice used by black smith is suitable for heavy hammering, chipping and
cutting in fitters work.
3. PIPE VICE:
Pipe vice is used for holding round metals, tubes, pipes etc. In this case the screw
is vertical and the movable jaw works vertically. It grips the work at 4 points on
its’s surfaces.
4. HAND VICE:
The hand vice is used for gripping screws rivets, keys, small drills and other
similar objects which are too small to be conveniently held, in the bench vice. It
consists of two legs mad of mild steel which hold the jaws at the top and hinged
together at the bottom a flat spring held between the legs tends to keep the jaws
open. The jaws can be open and close by a wing nut which moves through a
screw that is fastened to one leg and passes through other.
5. PIN VICE:
Pin vice is used for holding round materials of smaller diameter such as wire and
pins during working. It also forms handles for small files. It consists of a handle
and tapered nose covering a small collect chuck at its end. The chuck carries the
jaws which are operated by turning the handle.
Exercise No.1 Date:
FILING PRACTICE
Exercise No: 1
FILING PRACTICE
Aim :
To practice filing and make the shape as per given figure.
Materials required :
MS flat plate of size 50 x 50 x 6 mm.
Tools required :
Flat file, hacksaw frame with blade, try square, steel rule, & scriber.
Operations to be carried out :
Measuring, marking, cutting, filing & finishing.
Procedure :
Make sure the required length of flat plate using a steel rule and
scriber.
Cut the work piece with hacksaw blade with frame.
Hold the work piece in the bench vice and file its one edge to get a flat
edge.
Check its flatness using a steel rule and try square.
File adjacent side and check the angle (90°) with a try square.
File the other two edges of the work piece to get the dimension as per
figure
Check the work for inspection
Result :
Exercise No.2 Date:
HACKSAW CUTTING PRACTICE
(All dimensions are in
‘mm’)
Exercise No: 2
HACKSAW CUTTING PRACTICE
Aim :
To make a hacksaw cutting practice.
Materials required :
MS flat plate of size 50 x 50 x 6 mm.
Tools required :
Flat file, hacksaw frame with blade, try square, steel rule,
scriber, surface plate, V-block, vernier height gauge, ball peen
hammer, center punch, triangular file, & smooth file.
Operations to be carried out :
Measuring, chalk applying, marking, cutting, filing & finishing.
Procedure :
Cut the MS flat of size 50 x 50 x 6 mm using hacksaw frame with
blade.
File and finish the two adjacent sides up to 90º.
Apply chalk on the one side of the work piece.
Mark the dimensions as per the drawing using surface plate, V-block
& vernier height gauge.
Punch the witness mark through the required lines.
Cut the work piece in to V-shape and square shape and straight line
cutting.
File and finish the work for inspection.
Result :
Exercise No.3 Date:
L - JOINT
Exercise No: 3
L - JOINT
Aim :
To make a L – joint.
Materials required :
MS flat plate of size 65 x 50 x 6 mm.
Tools required :
Flat file, hacksaw frame with blade, try square, steel rule,
scriber, surface plate, Vblock, vernier height gauge, ball peen
hammer, center punch, triangular file, & smooth file.
Operations to be carried out :
Measuring, chalk applying, marking, cutting, filing & finishing.
Procedure:
Cut the MS flat of size 65 x 50 x 6 mm using hacksaw frame with
blade.
File and finish the two adjacent sides up to 90º.
Apply chalk on the one side of the work piece.
Mark the dimensions as per the drawing using surface plate, V-block
& vernier height gauge.
Punch the witness mark through the required lines.
Separate metal into two pieces by hack sawing.
File and finish the work using flat file and triangular file.
File and finish the all edges, surface & check the dimensions.
Remove the burrs and apply thin coat of lubricating oil.
Result :