UNIT2 BENCH WORK AND FITTING Structure 2.1 Introduction Objectives 22 Tools Used 23° Marking Tools 24° Measuring Instruments 25 Fitting Job 1 2.6. Fitting Job 2 INTRODUCTION In engineering, bench work and fiting have important roles to play to complete and finish a job to the desired accuracy. The term bench work generally denotes the production of our article by hand on the bench. Fitting isthe assembling together of parts and removing metals (o secure the necessary fit, and may or may not be carried out at the bench, ‘The main operations commonly performed in bench and fiting work may be classified (a) Chipping ©) Filing (©) Scrapping (@) Grinding (©) Sawing () Marking (®) Drilling (6) Reaming @ Tapping @ Dieing Objectives ‘After studying this unit, you should be able to ‘© know the tools used in bench work and fiting, ‘perform the experiments on bench vice, © perform sawing operation, and © measure with micro-meter, vernier gauge, etc. 2 TOOLS US Vices ‘The vice is the most common tool for holding work. Various types of vices are used for various purposes. They include bench vice, leg vice, pipe vice, hand vice, pin vice and toolmaker’s vice. 31Workshop Technology Laboratory Bench Vice “The most commonly used in the engineer's parallel join bench coach screws. ‘or with nuts and bolts. The vice essentially consists ofa cost iron body, 8 Fixed jaw, both made of cast steel, « handle, a square headed serew, and a nut all made of mild steel. Separate cast iron plates known as jaw plates are fixed to the jaws by means of set screws. Protective grips or clamps which ‘can be made of lead, fibre-tn plate, etc. are usually fitted over the jaws, "The width suitable for common work varies from 80 to 140 mm the ‘maximum opening being 95-180 mm, Pipe Vice awe. Pin Vice Leg Vice “The leg vice is used by blacksmiths but its also suitable for heavy hammering, chipping and cutting in the fitters work. The vice is secured 10 the top ofthe strap which is fastened to a plate bolted tothe bench top. The leg ofthe vice is fastened to the bench leg with staples and its end fit into a hhoke in the floor. This is suitable for heavy work Pipe Vice ‘The pipe vice is used for holding round section metal, t rips the work at four points on its surface. es, pipes, ete. I Hand Vice ‘The hand vice is used for gripping screws, evets, beep, small drills and other similar objects which are to be conveniently held in the bench-vice. "The length varies from 125-150 mm and jaw width from 40-44 mm, Pin Vice “The pin vice is used for holding round material of small diameters such as wire and pins during working. It also forms a very useful handle for small, fils.Bench Work and Fiting Toolmakers Vice ‘The toolmaker’s vice is particularly useful for holding small work which requires filing or drilling and for such work 2s laying out smal jobs on the surface plates, These are made of mild stet. Files A file isa hardened piece of high grade steel with slanting row of teth, tt is used to-cut, smooth, or fit metal parts, The tong is the pointed part which is fitted into the handle-The point is the end opposite tothe tang. The hee! is next tothe handle, "The safe edge o side ofa file is that which has no teeth Flat Fite Itis tapered in width and thickness and one of the most commonly used files for generate work. They are always double cut on faces and single cut on the edges. 7 ‘6 Flat Fle Hand File Its parallel in its width and tapered in thickness. A hand file is used for finishing flat surfaces. It has one edge and therefore it is useful where the flat file cannot be used. aa Hand File Square Fite Tt is square in cross section double cut and tapered towards the point. This is used for filing square corners enlarging square or rectangular openings as splines and key ways, _ Square Fle _ Round Fite ‘They are round in cross-section and usually tapered when they are termed rabtailed. When parallel, they are described as parallel round. Round files are used for or filing curved Surfaces and enlarging round holes and forming fillets, They may be single cut or double cutWorkshop Technulogs aboratory ular Files Three square or triangular file is taper xd, double cut and the shape is that of. aan equilateral triangle. They are used for rectangular eu and filing corners less than 90, — Teanga Fle Half Rounded File “This is taper double evt and its eros ection is nota hal circle but oly about one-third ofa circle, This file is used for round euts and filing curved surfaces, Half Round Fie Hammer Hammers are used to strike a job or a tool. They ate made of forged steel of various sizes and shapes to suit various purposes. a Hammer Ball Pen Hammers This is the most common form of hammer and is sometimes called engineer's hammer of chipping hammer. The peen has a shape of ball, which is hardened and polished, Cross Peen Hammer This is similar to ball pcen hammer in shape and size except thatthe pen hich is across the shaft or eye, This is mainly used for bending, stretching hammering into shoulders inside curves, et Steaight Peen Hammer This hammer has a peen straight with the shaf, ie. parallel tothe axis of the shaft. This is used for stretching or peening metal Soft Hammer ‘Where its nevessary to strike the metal a bfow with minimum damage to the surface. « soft hammer called mallet is used. Maliet's heads go by the rhumbers oF by the diemeter of the head. Chisel ‘Cold chivels are used for cutting and chipping away pices of metal and ane made of carbon stce! uswally rectangular. hexagonal or octagonal in cross section. They ged 10 shape thly ground and then bardewed and temperedBench Work and Fiting Fiat Chisel This isthe most common of all kinds of chisels used in engineering. [tis ‘generally used for chipping operations, It may be used for removing surplus mtal from surfaces of jobs, The flat chisels should be dravn to the shape ‘and the cutting edge should be slightly curved. Flat Chisel Cross-cw Chisel The cross-cut chisel or cope chisel as its sometimes calle is used for cutting troove in large surfaces previous to using the flat chisel and i is also used ccuiting key ways in wheels and shatts Half Round Chisel A half round chisel is used for cutting oil-warp or groves in, bosses and pulley bearings, etc, They are also used for settling over pilot holes. Whee hole is to be drilled a smaller ora pilot hole is chilled firs. — — Half Round Chisel Diamond Point Chisel ‘The diamond point chisel is used for cutting “V" and equating small holes. The chisel is drawn toa square sector and end is ground off at an angle producing a “diamond” shape rar a E | \ {i ai | { Diamond Point Chisel‘Workshop Technology Side Chisel boratory Aside chisel is useful in chipping and removing the sueplus metal in cotter ‘ways and sets, which may have to be cut by hand after having been drilled. ‘The shank of this chisel is bent out alittle sideways and then vertically down again, = Side Chis Scraper Scraping means shaving or parting off thin slices or lakes of metal to make a fine, smooth surface. This is done with tools called serapers which have very hard cutting edges are usually left very hard. Old files makes excellent scrapers. Flat Scrapper ‘The flat scraper isthe most common and the most easily made. The cutting edge is at end. It should most easily made. It should be curved a little looking at the broad side. A flat scrapper is used for producing a perfectly flat surface Flat Scraper Triangular Scraper ‘The triangular scraper has three cutting edges and is made from a triangular file, Iis used to scrap round or curved surfaces and to remove sharp comers and burs, Half Round Seraper AA half round scraper is trig-shaped like a half round file. In fact they are ‘often made from old half round files. They are used to scrape round or curved surfaces, Hacksaw ‘The hacksaw is used for sawing all metals except hardened steel. A hacksaw ‘consists of a frame handle prop tightening screw and nut blade. The frame is made to hold the blade tightly. They are made in two types: the solid frame in which length can't be changed and the adjustable frame which has a back that can be lengthened or shortened to hold blades of different length. Solld Frame HacksaseHacksaw blades are made of special steels for hand saws either high carbon steel Bench Work and Fitting low alloy ste! or high speed steels is used. All hard blades made of high speed steel are used for cutting the harder metals such as alloy steels while flexible blades are less iable to break and are used for general work. Power Hacksaw ‘The power hacksaw is very similar to the hand hacksaw withthe addition of ‘suitable driving mechanism the drive is either given a belt from a line shaft ‘or by an enclosed motor. Suitable mechanisms are provided whereby length of the stoke and the weight applied may be varied MARKING TOOLS ‘The following tools are used for making (@) Surface plate () Serer (©) Punch (@) _V-block (©) Angle plate (Try square face Plates ‘The surface plate is used for testing flatness of work itself and is also used for making out work, This is used for small pieces of work while marking out table is used for larger jobs. Surface tables are made of gray cast iron and of solid design or with ribs. They should be well and reflection free illuminated and rest horizontally on a firm support, the height being about 800 mm from the floor. Seriber ‘The scriber isa piece of hardened steel about 150 to 300 mm in length and 3 to 5 mm in diameter pointed at one of both ends like a needle. It is held like a pencil to scratch or scribe lines on metal. The bent end is used to stretch line in places, Where the straight and cannot reach. The ends are sharpened on an oilstone when necessary. — = Punch AA punch is used in a bench work for marking work locating centers ete. in a more permanent manner. The two types of punches are 31Workshop Technology Laboratory 38 Prick Punch ‘The prick punch is a sharply pointed tool. The tapered point of the punch is sharply angled at usually 40. It is used to make small punch marks on layout Tines in order to make them last longer Prick Punch Centre Punch ‘The centre punch looks like a prick punch. Its point has an angle more obtuse than that of the prick punch point this angle usually being 60°. The centre punch is used only to make the prick punch marks larger atthe centres of holes that are to be drilled. Contee seh Block ‘The V-block of steel with V-shaped grooves. Roundly shaped workpieces which are to be marked or drilled are firmly supported in a horizontal position and c: rotate easily Angle Plates ‘The angle plates which is made of grey cast iron has two plane surfaces at right angles to each other. This is used in conjunction withthe surface plate for supporting workin the perpendicular position. It has various slots init to enable the work to be held firmly by bolts and damps. ‘Tey Square ‘The try square is made of one-piece, both blade and beam. This is used when itis necessary to get another edge or sueface exactly at right angles to an already trued edge or surface and also for laying out work. The sides and edges of any square may be tested by placing the beam of the square against the straight edge. ji a a Try Square 2.4 MEASURING INSTRUMENTS _ Steel Rule Ikis one of the most useful tools for taking linear measurements of blanks and articles to an accuracy of range from 1.0 10 0.5 mm. It consists of a strip of| hardened stee! having line graduations etched or engraved at interval of fraction of «standard unit of length, Depending upon the interval at which the graduations are ‘made the scale can be manufactured in different sizes and styles Se a Steel Rule___ Divider Bench Work and Fitting ‘The tool is used for transferring dimensions, Scribing circles, and doing general layout work. In practice one point is placed in the centre top making the exact centre, and the circle or arc may then be seribed on the joint with the other point. ‘The size is measured by the greatest distance it can be opened between the leap. Thus a 100 mm divider open 100 mm between the points. Steel scale must also be used with tis instrument. Dinider Micrometer “The micrometer is primarily used to measure dimensions like diameters of shafts, screw threads, diameter of holes, thickness of parts ete. to an accuracy of 0.01 mam. ‘The frame is made of steel, cast steel, malleable cast iron or light alloy. The reading is taken with the help of two scales like (@) Main scales, and (©) Circular sate ‘The least count of the micrometer is 0.01 mm. Itis of three types like (External, (b) — Screw-thread, and (©) Internal/nside, anaue i SPINE FRICTION OR RATCHET DANE MEASORING Mactometer Varnier Caliper Iis primarily used for measuring both inside and outside diameters of shafts, thickness, of pars etc to an accuracy of about 0.02 mm by a vernier scale attached fo the caliper. A vernier scale is the name given to any scale making use of the difference between two scales which are nearly, but not quite alike, for ‘obtaining smal difference. The instruction comprises of a beam or main scale which carries the fixed graduations, two measuring jaws, a verier head having a vvernier scale engraved on it and an auxiliary head of a vernier clan which is used for a specific dimensions by a micrometer serew. The vernier head and the auxiliary head can be Jocked to the main scale by the knurled screw.Workshop Technology 2,5 FITING JOB 1 Laboratory —— Aim, ‘To prepare 2 smooth rectangular blocks of mild steel having dimensions 5.5 x5 x 0.4 om’ from the given piece of metal. ‘Tools Required Bench Vice, hacksaw, trysquare, hand file, surface plate and scale and a scriber Procedure } (a) Placed the workpieces on the table and using scriber drawn straight lines paralle! om it $5 mm apart (b) Fixed the workpieces firmly in the jaws of the vice. (©) Cat along the marked line using a hacksaw, b (a) Thecut out workpieces was now again placed firmly between the jaws of the vice in such a way that a small portion of one of its edges is above the level of the jaw. (©) Now filing was done by using a hand file. (8) Using try, square, it should be ensured that all the edges of the workpieces are at the right angles to adjacent edges. (a) Placed the work on one of the faces on the surface plate and moved it along its surface to check the area om the work where strain has accumlated. File them properly Precautions (@) While filing caution should be taken thatthe file moves in straight strokes and not slanting in any condition (b) While fiting, dimensions should be checked again and again then required single hand file should be used so thatthe piece of proper dimensions is obtained, (©) The piece should be fixed straight inthe jaws ofthe bench vice otherwise error in shape might occur. 40“FITING JOB2—_ 6 Aim To prepare two metal pieces as male and female socket as per required specifications. Apparatus (a) Bench Vice (©) Hacksaw (© Try Square (@ FlaFite (©) Half-round file (Steel Seale (@) Divider (b) Surface Plate (Vernier Height gauge @ Punch (k) Hand Hammer Material Used Mild Steel Procedure “The following steps are catried for pre ration of pieces (@) A steel of mild steel is taken and mounted on a bench vice. (b) Two piece of dimensions given were cut with the help of a hacksaw keeping in consideration the allowances. (©) One surface and the edges of the two pieces were filed and it was made sure that the adjacent edges are perpendicular to each other (with the help of try square). (@ A paste of erushed chalk and water was applied und allowed to dry up to give a plain white surface easy for marking, (©) The marking was then carried out on two workpieces with the help of surface plate. Scale and vernier height gauge. The quachants were then marked with the help of a divider at the corners. The marking were made more prominent withthe help of punch and hammer. (@) Therequired cutting is done with the hacksaw. (b) Surface are made smooth by filing first the hand file is used to smoothen the rough surface and then the half round file is used to give ‘fine surface finish Precautions to he Taken (2) The teeth of the hacksaw should be facing forward (b) The piece should be fixed straight in the juws of the bench vice otherwise ‘error in shape might occur (©) Marking should be done with great care. (@) While Sawing allowances should be made for filing, ‘Bench Work and FittingWorkshop Technology (©) While filing, caution should be taken that the file moves in straight strokes, Laboratory and not slanting in any conditions. (f) All the edges should be smooth. While filing, dimensions shoutd be checked again and again and half round file should be used so that piece of proper dimension is obtained. Workpieces and tools should be regulary oiled to avoid rusting.