FITTING

INTRODUCTION

Machine tools are capable of producing work at a faster rate, but, there are occasions when
components are processed at the bench. This involves a certain amount of hand fitting. The assembly of
machine tools involves certain amount of bench work. The accuracy of work done depends upon the
experience and skill of the fitter.
The term ‘bench work’ refers to the production of components by hand on the bench, where as
fitting deals which the assembly of mating parts, through removal of metal, to obtain the required fit.
Both the bench work and fitting requires the use of number of simple hand tools and considerable
manual efforts. The operations in the above works consist of filing, chipping, scraping, sawing drilling,
and tapping.

HOLDING TOOLS:

1. BENCH VICE
The bench vice is a work holding device. It is the most commonly used vice in a fitting shop. It is fixed
to the bench with bolts and nuts. The vice body consists of two main parts, fixed jaw and movable jaw.
When the vice handle is turned in a clockwise direction, the sliding jaw forces the work against the fixed
jaw. Jaw plates are made of hardened steel. Serrations on the jaws ensure a good grip. Jaw caps made of
soft material are used to protect finished surfaces, gripped in the vice.
2. V‐BLOCK
V‐block is rectangular or square block with a V‐groove on one or both sides opposite to each other.
The angle of the ‘V’ is usually 90° V‐block with a clamp is used to hold cylindrical work securely,
during layout of measurement, for measuring operations or for drilling for this the bar is faced
longitudinally in the V‐Groove and the screw of V‐clamp is tightened. This grip the rod is firm with
its axis parallel to the axis of the v‐groove.

3. C – CLAMP
This is used to hold work against an angle plate or v‐block or any other surface, when gripping is
require Its fixed jaw is shaped like English alphabet ‘C’ and the movable jaw is round in shape and
directly fitted to the threaded screw at the end .The working principle of this clamp is the same as
that of the bench vice.
MARKING AND MEASURING TOOLS:

1. SURFACE PLATE
The surface plate is machined to fine limits and is used for testing the flatness of the work piece. It is
also used for marking out small box and is more precious than the marking table. It is specified by
length, width, height and grade. Handles are provided on two opposite sides, to carry it while
shifting from one place to another

2. ANGLE PLATE
The angle plate is made of cast iron. It has two surfaces, machined at right angles to each other.
Plates and components which are to be marked out may be held against the upright face of the angle
plate to facilitate the marking.

3. SCRIBER
A Scriber is a slender steel tool, used to scribe or mark lines on metal work pieces. It is made of
hardened and tempered High Carbon Steel. The Tip of the scriber is generally ground at 12 to15
degree.
 4. TRY SQUARE
It is used for checking the trueness of an object and also for marking. The blade of the try square is
made of hardened steel and stock of cast iron or steel.

5. ODD LEG CALIPER

This is also called ‘Jenny Caliper’ or Hermaphrodite. This is used for marking parallel liners from a
finished edge and also for locating the center of round bars; it has one leg pointed like a divider and
the other leg bent like a caliper. It is specified by the length of the leg up to the hinge point.

6. DIVIDER
It is basically similar to the calipers except that its legs are kept straight and pointed at the measuring
edge. This is used for marking circles, arcs laying out perpendicular lines, by setting lines. It is made of
case hardened mild steel or hardened and tempered low carbon steel. Its size is specified by the length of
the leg.
 7. PUNCHES
These are used for making indentations on the scribed lines, to make them visible clearly. These are
made of high carbon steel. A punch is specified by its length and diameter.

 Dot Punch is used to lightly indent along the layout lines, to locate center of holes and to
provide a small center mark for divider point, etc. for this purpose, the punch is ground to a
conical point having 60° included angle.
 Center Punch is similar to the dot punch, except that it is ground to a conical point having 90°
included angle. It is used to mark the location of the holes to be drilled.

8. CALIPERS
They are indirect measuring tools used to measure or transfer linear dimensions. These are used with the
help of a steel Rule to check inside and outside measurements and are specified by the length of the leg..
They are made of Case hardened mild steel or hardened and tempered low carbon steel.
a. VERNIER CALIPERS
These are used for measuring outside as well as inside dimensions. It may also be used as a depth
gauge. It has two jaws. One jaw is formed at one end of its main scale and the other jaw is made part of
the vernier scale. Least count may be defined as the minimum dimension which can be measured by the
device.
b. VERNIER HEIGHT GAUGE
The vernier height gauge clamped with a scriber it is used for layout work. An offset scriber is used
when it is required to take measurements from the surface on ehich the gauge is standing. The accuracy
is same as vernier calipers. Its size is specified by the maximum height that can be measured it. It is
made of nickel-chromium steel.

CUTTING TOOLS:

1. HACK SAW
The Hack Saw is used for cutting metal by hand. It consists of a frame, which holds a thin blade, firmly
in position. Hacksaw blade is specified by the number of teeth for centimeter. Hacksaw blades have a
number of teeth ranging from 5 to 15 per centimeter. Hacksaw blades are classified as (i) All hard and
(ii) flexible type. The all hard blades are made of H.S.S, hardened and tempered throughout to retain
their cutting edges longer. These are used to cut hard metals. These blades are hard and brittle and can
break easily by twisting and forcing them into the work while sawing. Flexible blades are made of H.S.S
or low alloy steel but only the teeth are hardened and the rest of the blade is soft and flexible. These are
suitable for use by un‐skilled or semi‐skilled persons.
 2. CHISELS
Chisels are used for removing surplus metal or for cutting thin sheets. These tools are made from 0.9%
to 1.0% carbon steel of octagonal or hexagonal section. Chisels are annealed, hardened and tempered to
produce a tough shank and hard cutting edge. Annealing relieves the internal stresses in a metal. The
cutting angle of the chisel for general purpose is about 60°.

3. TWIST DRILL
Twist drills are used for making holes. These are made of High speed steel. Both straight and
taper shank twist drills are used. The parallel shank twist drill can be held in an ordinary self –centering
drill check. The tapper shank twist drill fits into a corresponding tapered bore provided in the drilling
machine spindle.

4. TAPS AND TAP WRENCHES

A tap is a hardened and steel tool, used for cutting internal thread in a drill hole. Hand Taps are usually
supplied in sets of three in each diameter and thread size. Each set consists of a tapper tap, intermediate
tap and plug or bottoming tap. Taps are made of high carbon steel or high speed steel.
FINISHING TOOLS:

1. REAMERS
Reaming is an operation of sizing and finishing a drilled hole, with the help of a cutting tool called
reamer having a number of cutting edges. For this, a hole is first drilled, the size of which is slightly
smaller than the finished size and then a hand reamer or machine reamer is used for finishing the hole to
the correct size.
Hand Reamer is made of High Carbon Steel and has left‐hand spiral flutes so that, it is prevented
from screwing into the whole during operation. The Shank end of the reamer is made straight so that it
can be held in a tap wrench. It is operated by hand, with a tap wrench fitted on the square end of the
reamer and with the work piece held in the vice. The body of the reamer is given a slight tapper at its
working end, for its easy entry into the whole during operation, it is rotated only in clock wise direction
and also while removing it from the whole.

2. FILES
Filing is one of the methods of removing small amounts of material from the surface of a metal part. A
file is hardened steel too, having small parallel rows of cutting edges or teeth on its surfaces. Files are
classified according to their shape, cutting teeth and pitch or grade of the teeth.
MISCELLANEOUS TOOLS:

1. BALL- PEEN HAMMER

Ball‐ Peen Hammers are named, depending upon their shape and material and specified by their weight.
A ball peen hammer has a flat face which is used for general work and a ball end, particularly used for
riveting.

2. CROSS- PEEN HAMMER

It is similar to ball peen hammer, except the shape of the peen. This is used for chipping, riveting,
bending and stretching metals and hammering inside the curves and shoulders.
 3. STRAIGHT‐PEEN HAMMER

This is similar to cross peen hammer, but its peen is in‐line with the hammer handle. It is used for
swaging, riveting in restricted places and stretching metals.