4 - FITTING AND SHEET METAL TOOLS

1) Purpose of Bench Vice.

It is used for holding the work and is fixed to the bench with screws, and with
nuts and bolts.

2) Main parts of Hack saw.

The parts of Hack saw
[Link] frame
[Link] handle
[Link] screw and nut

3) Types of vices used to hold the work in fitting.

1. Bench vice
2. Pipe vice
3. Hand vice
4. Pin vice
5. Tool maker's vice
6. Leg vice

4) Use of following tools

(i) Pipe vice (ii) Hand vice ( iii) Pin vice

(i) Pipe vice- It is used for holding pipes, shafts, tubes or round jobs.
(ii) Hand vice- The hand vice is used for gripping screws, rivets, keys,
small drills and which are held convently in the bench vice.
(iii) Pin vice - The pin vice is used for holding round material of small diameter
like wires, pins and holding for small files.

5) Types of Fitting operations.

The operations involved in fitting are
1. Sawing
2. Filing
3. Chipping
4. Scraping
5. Drilling
6. Reaming
7. Tapping
8. Dieing

6) Tapping and Reaming operations.

Tapping :
Tapping is the process of cutting an internal thread with a tap. For tapping, tap
must be positioned and is turned into the hole with tap wrench. It is important to
 reverse the tool after the cut has been made. This ensures easy removal of tap
from the work. The thread can be finished by using standard set of taps. Except for
cast iron and brass, the cutting fluid should be applied to improve the surface finish
of threads being cut

Reaming :
Reaming is a process is the process of finishing a drilled hole to accurate size with a
smooth finish. In hand reaming, tang of reamer is held in tap wrench and rotated at
proper speed. Reamer should be properly inserted in the hole and should not feed
too fast. When reaming any material except cast iron, proper cutting fluid should
be applied to remove the chips and assist in obtaining a good finish.

7) Scrapping and Drilling operations.

Scrapping
Scrapping is the finishing operation used to finish the work surface to high degree
of accuracy. It involves cutting thin layers of metal at selected high spots. To
identify the high spot the work surface is rubbed to and fro on the surface plate
which is coated with Prussian blue or a paste of red lead. The high spots will be
clearly revealed by the Prussian blue adhering to them. These high spots will be
removed by scrapper. The process is repeated until the true surface obtained.

Drilling
Drilling is the operation of producing the hole with a drill . In drilling, hole position is
commonly marked with centre punch and work is clamped in position on machine
vice. The taper shank drill or drill chuck is inserted in a drilling machine spindle, and
can be rotated by an electric motor. The feed can be controlled by hand lever. The
accuracy and surface finish of drilled holes is poor, and can be improved by using
drill jig.

8) Differentiate between tapping and dieing.

Tapping:- Tapping is a process of cutting internal threads in a metal by using hand
tool known as Tap.

In tapping, first suitable hole is drilled in the work. Then the work is clamped in vice
with the hole in the upright position. The square end of the tap is clamped by a
tap wrench and tap placed into the hole. A steady downward pressure on the
wrench is applied with one hand to get a good start and then tap is turned by two
hands for cutting threads.

The three taps are used one after the other in the process of tapping
First or taper tap for starting threads.
Second or intermediate tap for cutting the threads, and
Finishing or bottoming tap for finishing the threads.

Dieing:-
Cutting external threads on round rod or bolt with a die and stock is called dieing or
external threading.

In dieing the die is held in die stock, and the work is placed in a vice. When starting
the thread, care must be taken to ensure that the die is square with the axis of the
work being threaded otherwise it may result drunken thread.

When cutting , die should be turned backward and forward as in tapping, using
plenty if lubricant. When sufficient length of threads has been made, the stock is
screwed back and the adjusting screw is tightened up further and same process
repeated , until the correct depth has been reached.
9) Filing methods used in fitting shop.
The three methods of filing are:
1. Cross filing
2. Straight filing
3. Draw filing

1. Cross filing :Cross filing is the most common method of filing and used to remove
large amounts of metal. The file is moved diagonally from left to right or from right
to left.

[Link] filing :Straight filing is used to obtain a flat surface on a short workpiece.
It produce smooth surface than cross filing.

[Link] filing :Draw filing is used to produce a fine finish on a narrow surface. A smooth
flat file is placed across the work and is then moved forward and backward. The
main purpose of a draw filing is to obtain a perfectly smooth level surface.
10) External threading process in fitting.
A Tool is used for external threads on bars or tubes, such as on a bolt , is called
a die. It is a round or square block of hardened steel with a hole containing threads
and flutes which form cutting edges. After hardening and sharpening of the cutting
edges the die is screwed on to the bar upon which the thread is to be cut.

The Two types of DIES are

1. Solid Die, and
2. Adjustable Die

1. Solid Die-- It has circular, square or hexgonal shape with fixed dimensions, cuts
only one size of threads. It is generally used to rectify damage and knocks on
existing screw such as studs and bolts.

2. Adjustable Die, is one, which can be adjusted and set to cut larger or smaller
diameters. A circular adjustable die ,is very common. The die is split through one
side and slight adjustment is made by means of the set screw shown. If the screw
is tightened up, the die is opened up slightly, while unscrewing will cause the die
to spring in. The size of a die is specified by the outside diameter of the thread to
be cut and pitch of the thread

11) Chipping and scraping operations in fitting.

Chipping: - Chipping is a term applied to the removal of metal with the cold chisel
and hammer. Chipping is adapted when high accuracy is not required. For chipping,
the work is held rigidly in a vice and the cut is directed towards fixed jaw of vice. The
process includes cutting key ways, oil grooves and repairing sharp corners. In
chipping the surplus metal is removed in small layers as the chisel is struck with a
hammer. The chisel must be held in position by one hand and the hammer by other
hand. The chippping should not continue to the edge of the surface and when
approaching edge, it should be commenced from other side.

Scraping:-Scraping means shaving or parting off slices or flakes of metal to make

a fine, smooth surface . It is used for producing a truer flat surface than can be
produced by machining or filing

During scraping, the handle of the scraper is held in the right hand with thumb and
first finger pointing in the direction of cutting edge, and blade should be held in the
left hand, close the cutting edge, and scraper should be held at some inclination to
the workiece.

To identify the high spot the worksurface is rubbed to and fro on the surface plate with
prussian blue or red lead. Thus the high spots on the work will be marked with the
coated material. These spots are scraped with moving the scraper in circular
direction.

12) Types of drills used in fitting.

The following types of drills are more commonly used
1. Flat drill
2. Straight fluted drill
3. Twist drill

13) Explain hand reamer and machine reamer with the neat sketch.
Hand reamer: The hand reamer is shown in figure. The shank has a square tang
so that a tap wrench can be used to turn the reamer into the work. Hand reamers
are available with straight or helical flutes. Hand reamers are made of high
Carbon steel because cutting speed in hand reaming is low.

Machine reamer: Machine reamer is shown in figure. It has a taper shank, which
fits directly in the internal taper of machine spindle. Machine reamers are also
available with straight shanks , which are held and driven by drill chuck. These
are made with straight or helical flute. The helical fluted reamers provide better
surface finish and are particularly suited for interrupted holes.
14) Marking tools used in the fitting section.
The following tools are used for marking on metals
1. Scriber
2. Divider
3. Jenny caliper
4. Scribing block
5. Angle plate
6. V block
7. Try square
8. Surface plate
9. Straight edge

15) Types of punches used in fitting.

Different types of punches
1. Prick punch
2. Centre punch
3. Number punch
4. Letter punch

16 Differentiate between Prick punch and Centre punch.

Prick punch
Center punch
Prick punch is used for marking Center punch is used to mark the
small dots along the layout lines centers of holes to be drilled
Prick punch point angle is 400 Center punch point angle is 600 or 900

17) What is a surface plate? How is it protected?

The surface plate is made of cast iron. It provides a true flat surface for layout work
and reference surface on which work may be mounted for inspection. Work pieces
and accessories must be cleaned before being placed on the surface plate. When
used for testing flatness the top of the plate should be coated with thin layer of
prussion blue or paste or paste of red lead in oil. When not in use surface plate must
be protected by a wooden cover .
18) Measuring tools used in sheet metal work.
Measuring tools used in sheet metal:
1. Scale
2. Steel square or Set sqaure
3. Circumference rule

19) Name the tool used to mark layout lines on metal surfaces?
Scriber is used for marking layout lines on metal surfaces.

20) Types of tools used in sheet metal work.

1. Snips
2. Stakes
3. Hand hammer
4. Hand groover
5. The Rivet set
6. Soldering iron
7. Hand seamer
8. Set square
9. Circumference rule
10. Divider

21) What is a mallet?

Mallet is a hammer made of hard wood, is used for operating chisels and gouges.

22) Types of snips used in sheet metal work.

[Link] snip [Link] or curved snip 3. Double shear
4. Bench shear [Link] shear.

23) Bench shear used in sheet metal work.

Bench shear : Bench shear is heavier than plain hand shears (straight and bent
snips) and are used for cutting metal sheets upto 2 mm thick. The one arm of the
shear is fixed in vice and the other is moved by hand for cutting the sheet. The use
of bench shear is illustrated in Fig.

24) Write a short note on snips used in sheet metal work.

1. Straight snip: It has a straight blade and used for cutting along the straight
lines and for trimming the edges.
2. Bent or curved snip: It has a curved blade and used for cutting circles and
irregular [Link] is also used for trimming the cylindrical edges.
3. Double shears: Double shears are used for cutting thin cylinders,stove pipes
and for cutting holes on light gauge metals.
4. Bench shear: Bench shear is heavier than plain hand shears and are used
for cutting metal sheets upto 2mm thick.
5. Block shear: One arm of the shear is bent down at right angle and is fixed
in the wooden block or [Link] other arm is operated by the [Link] is used
for cutting thicker metal sheets.

25) Cutting tools used in sheet metal.

Cutting Tools used in Sheet Metal

1. Straight snip
2. Bent or curved snip
3. Double shear
4. Bench shear
5. Block shear.

1. Straight snip: It has a straight blade and used for cutting along the straight
lines and for trimming the edges.

2. Bent or curved snip: It has a curved blade and used for cutting u Tavoit circles
and irregular shapes. It is also used for trimming the cylindrical edges

3. Double shears : Double shears are used for cutting thin cylinders stove
pipes and for cutting holes on light gauge metals

4. Bench shear : Bench shear is heavier than plain hand shears (straight and
bent snips) and are used for cutting metal sheets upto 2mm thick. The one
arm of the shear is fixed in vice and the other is moved by hand for cutting
the sheet.

5. Block shear: The block shear has One arm of the shear is bent down at right
angle and is fixed in the wooden block or table. The other straight arm is
operated by the hand. It is used for cutting thicker metal sheets.

26) Types of stakes used in sheet metal:

1. Double seaming stakes 2. Blow horn stake 3. Break horn stake
 4. Bevel edge square stake 5. Conductor stake 6. Funnel stake
7. Moon stake 8. Matched stake 9. Creasing stake
10. Needle case stake 11. Hallow mandrel stake

The following types of stakes are most generally used sheet metal :

The double seaming stake has two horns and it is used to double seam for
vessels.

The blow horn stake has a short- t a p e r e d horn at one end, and a long
tapered one at the other end. It is used for forming or seaming funnel.

The break horn stake has a square tapered horn on one side and round
tapered horn on the opposite side. It is used for shaping round and square
surfaces, bending edges and making corners.

The bevel edged square stake has a bevelled square head with a offset shank.
It is used to form corners and edges.

The conductor stake has two cylindrical horns having different diameters It is
used for forming pipes and cylindrical pieces.

The funnel stake is used for forming conical shapes and for making wire rings.

The half moon stake is used for folding edges of cylindrical shaped articles.

The hatchet stake has a horizontal sharp straight edge and can beused for
making straight, sharp bends and for folding and bending edges.

The creasing stake has a tapering square horn with a grooved slots on one
end and a tapered round horn on other end. The square horn is used for
wiring and beading, and the round horn is used for forming conical shapes.

The needle case stake has a round horn on one side, and a rectangular horn
on other side. It is used for forming small tubes, wire rings and bending metals.

The hollow mandrel stake is a horizontal metal piece with a flat surface on
one side and a round section on the other. The round section has a slot which
facilitates fixing of the stake at different position on the bench. It is used for
riveting, seaming and forming,

27) Types of sheet metal joints.

Sheet metal joints:
1. Lap seam
[Link] seam
 [Link] seam
[Link] seam
[Link] seam
[Link] or burred seam

28) Types of metals used as sheet in sheet metal work.

The following metals are used in sheet metal work.
1. Galvanised Iron (Zinc coated steel)
2. Black Iron (uncoated metal sheet)
3. Tin plate (Tin coated steel or iron)
4. Stainless steel (corrosion resistant alloy of chromium and nickel).
5. Copper, and
6. Aluminium.

29) What is meant by sheet metal work? List any two applications.
The Sheet metal work deals with the production of components in a wide variety
of shapes and sizes from sheet metal with aid of hand tools or Machines. The
applications of Sheet metal to make boxes, trays and similar objects or is rolled to
form cylinders.

30) U se of conductor stake and double seaming stake.

The conductor stake is used for forming pipes and cylindrical pieces.

CONDUCTOR STAKE

The double seaming stake is used to make double seam for vessels.

DOUBLE SEAMING STAKE