Marking Tools for Drilling in Fitting
Marking Tools for Drilling in Fitting
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UNIT 2
Fitting
Learning Objectives
On completion of this unit a learner will be able to
• Explain various cutting tools used in fitting shop.
• Describe various work holding device used in fitting shop.
• List out various marking and measuring tools used in fitting.
• Explain about radial drilling machine.
2.0 Introduction
Although majority of the work can be finished to fairly good degree of
accuracy through various machining operations, but still needs some hand
operations to obtain desired finish and fit .These operations are usually carried
on bench by fitter. Hence fitting is the process of assembling various parts
manufactured in the machine shop. Also a fitter’s task is unavoidable when
different parts are to be assembled in position.
Hence various tools and equipments are required to perform operations to
finish the work to the desired shape and size in assembling the unit.
Tools used in fitting:
Tools used in fitting is classified into following groups:
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1. Cutting tools
2. Striking tools
3. Holding tools
4. Marking and measuring tools
In addition to the above tools ,the fitter needs other miscellaneous tools
such as screw drivers and spanners etc.
2.1 Cutting Tools
Cutting tools plays a most important role in removing excess metal from the
job to obtain desired finished part. The various cutting tools used in fitting are:
1. Chisels
2. Hacksaws
3. Files
4. Scrapers
5. Drill bits
6. Reamers
7. Taps
8. Dies and sockets
2.1.1 Chisels
Cold chisels are used for cutting thin sheets and to remove excess material
from large surfaces .In this case the surface finish and accuracy are usually poor.
Parts of chisel:It consists of following parts
a) Head
b) Body or shank
c) Point or cutting edge
Head : The head is tapered towards top and made tough to with stand
hammer blows
Body or Shank : The cross section of the shank is made hexagonal or
octagonal to have grip while working.
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Point or Cutting Edge : The cutting edge is hardened and tempered and
made to specified angle. The hardening followed by tempering makes the chisel
to maintain its sharp edge.
HEAD
SHANK
POINT
The shape of cutting edge is required to specify the chisel. The five most
important types of chisels are:
1. Flat chisel
2. Cross cut chisel
3. Half round chisel
4. Diamond point chisel
5. Side chisel
Flat Chisel: It is most common chisel used for chipping large surfaces and
cutting the sheets. It is also used to part off metal after chain drilling. The length
of a flat chisel varies from 100mm to 400mm and the width from 16mm to
32mm.
Cross Cut Chisel: The cross cut chisel or cape chisel is used for cutting
grooves and channels and keys ways in shafts and pulleys. Its cutting edge
wider than the supporting metal to provide clearance. The length of chisel varies
from 100mm to 400mm and width varies from 4mm to 12mm.
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Half Round Chisel : It is particularly useful for cutting oil ways ,cutting
curved grooves in bearings ,bosses and pulleys .They are also used for setting
over pilot holes. When a hole is to be drilled a pilot hole is drilled first.
Diamond Point Chisel.: Its edge is in the form of diamond used for cutting
V- grooves, cleaning corners and squaring small holes.
Side Chisel : This is used for chipping and removing the surplus metal in
rectangular slots. The shank of the chisel is bent out a little side way and vertically
down again.
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2.1.2 Hack Saw : It is a basic hand cutting tool used for cutting unwanted
material. It is used for cutting metals and making recesses priper to filing or
chipping. It is also used for cutting slots and contours.
Parts of Hack saw : It consists of the following parts.
1. Metal frame
2. Blade
3. Handle.
4. Wing nut
5. Screw
The frame is made to hold the blade tightly. They are made in two types.
a) The solid frame hack saw in which the length cannot be changed. b) The
adjustable frame in which the frame can be adjusted to hold the blades of different
lengths.
Wing
Handle Nut
Pin
Hacksaw Blade : It is thin, narrow steel strip made of high carbon steel
or low alloy steel or high speed steel. The balde has two pin holes at the ends
which fits over two pins which project from the stand that slides in and out of the
frame end. Tightening the wing nut at the front end tensions the blade sufficiently
to prevent it from flexing when cutting. The blade must be fitted such that teeth
pionts away from the handle so that cut takes on the forward stroke.
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Blade Length
Pin Hole Pin Hole
250 to 200 mm
2.1.3 FILES : File is a cutting tool with multiple teeth like cutting edges
used for producing smooth surface. The accuracy that can be acheived from
0.2 to 0.05 mm.
Wooden
Point or Tip Teeth Heel handle
Shoulder Feerule
Edge Face
Face
Handle
Heel
Tip
Edge
Shoulder
Ferrule
(b) Hand File : This is used where flat file is not suitable for filing flat
surfaces and has rectangular cross section with parallel edges throughout, but
thinkness is tapered towards point.
(c) Square file : This is in square cross section used for filing square and
rectangular holes and for finishing the bottom narrow slots.
(d) Round File : They are round in cross-section and usually tapered.
They are used for filing circular holes, curved surfaces and finishing fillets.
(e) Half Round File : This file is tapered double-cut and its cross-section
is not a half circle but only one third of a circle. This file is used for round cuts
and filing curved surfaces.
(f) Triangular File : The cross section of file is like equilateral triangle
used for filing grooves, slots , holes and sharp corners.
(g) Knife Edged File : Its shape is like a knife used to file narrow slots,
grooves and sharp corners. Its width and thickness are tapered towards point in
the form of knife.
2.1.4 Scrapers : These are used to shaving off thin slices of metal to make a
fine and smooth surface which is not possible with a file or chisel. This is made
of good quality forged steel and its cutting edge is usually made thin, made from
old files.
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Parts of Scrapers
1. Cutting edge with rounded corners. 2. Blade 3. Tang
4. Wooden handle.
This type of scraper is used for scapping plane surfaces or slots and the
cutting edge at the ends of the balde is curved. The corners are rounded to
prevent deep scratches on finished surface. It also helps to scrap the metal
exactly at the desired spot.
(b) Triangular Scraper
It has three cutting edges and is made from old triangular files used to scrap
round or curved surfaces and to remove sharp corners.
(c) Half round Scraper :
It is used for finishing curved surfaces and chamfering holes and removing
burrs.
2.1.5 Drill Bits
A drill is a cutting tool for making through hole in a metal piece and usually
it has two cutting edges set an angle with axis. It does not produce accurate
hole. There are three types of drills.
(a) Flat Drill (b) Straight Fluted Drill (c) Twist Drill
(a) Flat Drill : It is a simple drill used for producing holdes in softer materials
like wood and plastic. This is made of high carbon steel and has two cutting
edges.
(b) Straight Fluted Drill : It has two cutting edges and two straight flutes
used for drilling brass and non-ferrous metals.
(c) Twist Drill : This is most commonly used cutting tool in workshop. It
has two cutting edges and two helical grooves which admits coolant and allows
the chips to escape during the drilling. These are made of high speed steel.
Neck
Body Cutting
Shank
Edge
2.1.6 Reamers : A drill does not produce accurate hole and it must be
finished by finishing tool called reamer. When an accurate hole with a smoother
finish a required a reamer is used. Hence the reamer can only follow the drilled
hole and removes very small amount of metal to make it smooth
There are two types of reamers
(a) Hand Reamers
(b) Machine Reamers
(a) Hand Reamer : This reamer is turned by hand called hand [Link]
shank has a square tang so that a tap wrench can be used to turn the reamer in
to work. These are available with straight or helical flutes.
(b) Machine Reamers : These are used to turn by the machine called
machine reamers. Its shank is tapered which fits directly in the internal taper of
the machine spindle. These are also available with straight shanks which are
held and driven by drill chuck.
2.1.7 Taps : A tap is a screw like tool which has threads like a bolt and
three or four flutes cut across the threads which is used to produce internal
threads. The edge of the thread formed by the flutes are the cutting edges. The
lower part of the tap is some what tapered so that it can well attack the walls of
the drill hole.
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Hand taps are usually made in sets of three (1) Taper tap (2) Second tap
(3) Bottom tap.
(1) Taper Tap : In this tap about six threads are tapered and is used to
start the thread, so that the threads are formed gradually as the tap is turned into
the hole.
(2) Second tap : It is tapered back from the edge about three or four
threads used after taper [Link] has been used to cut the threads as far as possible
(3) Bottom Tap : It has full threads for the whole of its length. This is used
to finish the work prepared by the other two taps.
2.1.8 Dies
It is a circular disc of harderned tool steel used to make external threads on
a round rod or bolts with a die and stock. Die has a hole containing threads and
flutes which form cutting edges. These are mainly two types
1. Solid Die 2. Adjustable Die.
1. Solid Die : It is one which has fixed dimension and cannot be adjusted
for smaller or large diameter. It is used for recutting damaged threads and may
be driven by suitable wrench.
2. Adjustable Die : It can be set to cut larger and smaller diameters. It
has a split through one side and a slight adjustment is possible with the help of
set screw.
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2.1.9 Sockets
It is used for the drills whose taper is larger than spindle hole taper. It is
much larger than sleeve. Its taper shunk conforms to the spindle hole taper and
fits in to it.
Face
Fig. 2.29 Parts of Hand Hammer
A hammer consists of four parts namely Face, Peen, Cheek and eye hole.
Face : It is the striking portion polished well and is given slight convexity to
avoid spoilage of the surface of the metal to be hammered.
Peen : It is the other end of the head and is made into different shapes to
suit various operations.
Cheek : Middle portion of the hammer head.
Eye-Hole : It is made oval or elliptical in shape to accommodate the handle..
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Depending upon the shape of the peen, hand hammers are classified as 1)
Ball peen hammer 2) Cross peen hammer 3) Straight peen hammer.
1. Ball Peen Hammer : It has a flat striking face and ball shaped peen
which is hardened and polished. This hammer is chiefly used for chipping and
riverting.
2. Cross - Peen Hammer : It has wedged shape peen across the eye. It
is used for bending, stretching, hammering into shoulders.
4. Soft Hammer or Mallet : These are soft hammers used give light
blows where the work surface must not be damaged . They are made of either
rubber, plastic or wood.
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Body
Fig. 2.41 Single point Scriber Fig. 2.42 Double point Scriber
2.4.4 Angle plate : This is used in conjunction with the surface plate for
supporting work in the perpendicular position. It is madeof grey cast iron has
two plane surfaces at right angles to each other. It has various slots in it to enable
the work to be held firmly by bolts and clamps.
2.4.5 Punches : Punches are used in a bench work for marking out work,
locating centres, etc in permanent manner. It is made of tool steel, hardened
and tempered . The shank is knurled to provide grip.
Punches are two types
1. Prick punch 2. Centre punches.
Prick punch is sharply pointed tool used for marking small dots along the
layout lines in order to make them last longer. Centre punch has an angle more
than abtuse and used to mark the centres of holes to be drilled.
2.4.6 Try Square : It is made of steel and consist of a blade and a stock
made in one piece set at right angle to each other. It is used to test trueness of
mutually perpendicular surfaces and for making straight lines at right angle to
each other.
BLADE
STOCK
In addition to the above tools, the following tools are widely used in fitting.
1) File Card 2) Screw driver
3) Spanner 4) Pliers
1. File Card
It is the short wire brush used to remove small chips called pins, and to
clean the file. While filing these chips are deposited between the teeth of file
which reduces cutting ability and casuing scratches on work piece.
2. Screw Driver
Screw driver is used for tightening and loosening the screws. It is made in
variety of shapes to suit various job operations.
3. Spanners
These are also called wrenches, are used for tightening or loosening nuts
and bolts. The following types of spanners are widely used in fitting.
a. Single end Spanner
b. Double end Spanner
c. Adjustable Spanner
d. Box Spanner
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4. Pliers
These are used for holding small jobs which are difficult to held by hand.
They are used for bending and cutting the wires. The following types of pliers
are most common.
1. Cutting pliers 2. Nose Pliers
b. Calipers
These are used for measuring and transferring the inside or outside
dimensions for components. These are also used for comparing the sizes with
existing standards. The following types of calipers are most widely used in
workshops
1. Outside Calipers 2. Inside Calipers
1. Outside Calipers
It is used for measuring outside dimensions of cylindrical shapes and the
thickness of metal pieces. It has two steel legs bent inwards.
2. Inside Calipers
It is used to measure the diameter of holes and width of key ways or
recesses. Its legs are bent outwards.
3) Depth Gauge
It is used to measure the bling holes, slots, recesses and height of projections.
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4. Vernier Calipers
These are widely used for precision measurement of length, thickness, depth
and inside and outside diameters. With vernier caliper we can achieve accuracy
upto 0.02 mm.
5. Micrometer
Micrometer is a precision tool used to measure external or internal dimensions
such as diameters and thickness, with an accuracy upto 0.01 mm.
Distance
Measured
Handle
6. Gauge Block
They are used to check the accuracy of gauges to set comparators, sine
bars and to make machine tool setups.
Vernier Slide
Fine Adjustment
Beam
7. Dividers
These are used for transferring dimensions and scrubing circles and arcs on
work surface. These are also used for dividing straight and curved lines.
2.7 Drilling Machines
Drilling is a process of making holes in a work piece and is carried out by
driving a rotating tool called “drill” into a rigidly held work peice. To accomplish
the drilling two things are required i.e. drilling macine and drilling tools. A drilling
machine is used for drilling holes. However it can perform operations other than
drilling such as reaming, boring, lapping etc.
Types of Drilling Machine
1) Portable drilling machine
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c. Sleeve : It is used to hold the taper shank drills whose taper is less than
taper hole of the spindle.
Taper Shank
Taper hole
d. Socket : It is used for the drilling whose taper is larger than spindle hole
taper. It is much longer than sleeve. Its taper shank confirms to the spindle hole
taper and fits into it.
2.9 Drilling Operations
The following operations are generally performed on drilling machine.
a) Drilling b) Reaming c) Boring
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Summary
1. Fitting is the process of assembling various parts manufactured in the
machine shop.
2. In fitting the hand tools are classified as cutting tools, marking tools,
striking tools,holding tools, measuring and checking instruments.
3. Chisels are used to cut thin sheets and to remove excess material in the
form of layers
4. Hacksaw is abasic hand cutting tool used to remove excess metal from
the job
5. Files are used to remove excess metal from the job in the form of pow-
der to make it smooth
6. Scrapers are used to remove excess metal in form of thin layers at se-
lected spots to make it truly flat surface
7. Drilling is the process of making circular holes on the metal piece by
rotating the tool against work piece
8. Reamer is a tool used to finish the already drilled hole on cylindrical
holes
[Link] is acutting tool used to cut internal threads and dies are used to cut
external threads on the cylindrical rods and pipes
10. Striking tools are hammers used to strike the work or tool
11. Holding devices are used to hold work tightly to prevent slipping during
cutting operations.
Activity
1. A learner should collect L-shape M S flat.
2. A learner should collect T-shape MS flat.
Short Answer Type Questions
1. What is the use of a file.
2. What is the purpose of chisel.
3. Define scrappers.
4. Differentiate tap and die.
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