PRACTICAL: 3
Fitting
Aim: To study different instruments/tools used in the fitting shop and make a job as per the
given drawing.
3.1 Introduction:
Machine tools are capable of producing work at a faster rate, but, there are occasions
when components are processed at the bench. Sometimes, it becomes necessary to replace
or repair component which must be fit accurately with another component on reassembly.
This involves a certain amount of hand fitting. The assembly of machine tools, jigs,
gauges, etc, 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.
3.2 Tool used in Fitting Shop:
Tools used in fitting shop are classified as follows:
1. Holding Tools
2. Marking and Measuring Tools
3. Cutting Tools
4. Miscellaneous Tools
3.3 Holding Tools
3.3.1 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. The size of the vice is specified by the length of the jaws. The vice body is
made of cast Iron which is strong in compression, weak in tension and so fractures
under shocks and therefore should never be hammered.
3.3.2 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 900. 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.
3.3.3 C – Clamp
This is used to hold work against an angle plate or V-block or any other surface,
when gripping is required. Its fixed jaw is shaped like English alphabet ‘C’ and
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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.
3.4 Marking & Measuring Tools
3.4.1 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. The degree of the finished depends upon whether it is designed
for bench work in a fitting shop or for using in an inspection room; the surface
plate is made of Cast Iron, hardened Steel or Granite stone. 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.
3.4.2 Try Square
It is measuring and marking tool for 900 angle .In practice, it is used for checking
the squareness of many types of small works when extreme accuracy is not
required .The blade of the Try square is made of hardened steel and the stock of
cast Iron or steel. The size of the Try square is specified by the length of the blade.
3.4.3 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 12o to 15o. It is generally available in lengths, ranging from
125 mm to 250 mm. It has two pointed ends the bent end is used for marking lines
where the straight end cannot reach.
3.4.4 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.
3.4.5 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.
3.4.6 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 (say as 150’ 12.5mm). It consists of a cylindrical knurled body,
which is plain for some length at the top of it. At the other end, it is ground to a
point. The tapered point of the punch is hardened over a length of 20 to 30mm.
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.
3.4.7 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
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measurements. These are made of Case hardened mild steel or hardened and
tempered low carbon steel. While using, but the legs of the caliper are set against
the surface of the work, whether inside or outside and the distance between the
legs is measured with the help of a scale and the same can be transferred to
another desired place. These are specified by the length of the leg. In the case of
outside caliper, the legs are bent inwards and in the case of inside caliper, the legs
bent outwards.
3.5 Cutting Tools
3.5.1 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 (cm). Blades having lesser number of teeth per cm are used for
cutting soft materials like aluminum, brass and bronze. Blades having larger
number of teeth per centimeter are used for cutting hard materials like steel and
cast Iron.
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 unskilled or semi skilled persons.
The teeth of the hacksaw blade are staggered, as shown in figure and known as a
‘set of teeth’. These make slots wider than the blade thickness, preventing the
blade from jamming.
3.5.2 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°.
3.5.3 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.
3.5.4 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.
3.5.5 Dies and Die Holders
Dies are the cutting tools used for making external thread. Dies are made either
solid or split type. They are fixed in a die stock for holding and adjusting the die
gap. They are made of Steel or High Carbon Steel.
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3.5.6 Bench Drilling Machine
Holes are drilled for fastening parts with rivets, bolts or for producing internal
thread. Bench drilling machine is the most versatile machine used in a fitting shop
for the purpose. Twist drills, made of tool steel or high speed steel are used with
the drilling machine for drilling holes.
Following are the stages in drilling work
Select the correct size drills, put it into the check and lock it firmly
• Adjust the speed of the machine to suit the work by changing the belt on
the pulleys. Use high speed for small drills and soft materials and low
speed for large diameter drills and hard materials.
• Layout of the location of the hole and mark it with a center punch.
• Hold the work firmly in the vice on the machine table and clamp it directly
on to the machine table. 5. Put on the power, locate the punch mark and
apply slight pressure with the Feed Handle.
• Once Drilling is commenced at the correct location, apply enough pressure
and continue drilling.
• When drilling steel apply cutting oil at the drilling point.
• Release the pressure slightly, when the drill point pierces the lower surface
of the metal. This prevents the drill catching and damaging the work or
drill.
• On completion of drilling retrace the drill out of the work and put off the
power supply.
3.6 Finishing Tools
3.6.1 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.
3.6.2 Files
File is also a multi tooth tool. It is used to remove material by rubbing it on the
metal. Files are available in a number of sizes, shapes and degree of coarseness.
Classification of files on the basis of grade:
(i) Rough (20 Teeth per inch)
(ii) Bastard (30 Teeth per inch)
(iii) Second cut (40 Teeth per inch)
(iv) Smooth file (50-60 Teeth per inch)
(v) Dead smooth (100 Teeth per inch)
Rough and bastard are the big cut files. These are used for rough cutting where the
material removing is more. These files have bigger teeth.
Dead smooth and smooth files have smaller teeth and are used for finishing work.
Second cut file has the degree of finish midway between bastard and smooth file.
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[Link] Classification on the Basis of Shape and Size
File are available in a number of shape and sizes. The lengths of files vary from 4”
to 14”. The shapes are available are (1) Square (2) Triangular or three Square (3)
Round (4) Half round (5) Flat (6) Hand file (7) Knife edge (8) Diamond file
[Link] Classification on the Basis of Number of Cuts
Files are classified into two categories i.e., single cut and double cut files. In single
cut the teeth are cut in parallel rows at an angle 60 ﹾto the face. Another row of teeth is
added in opposite direction in case of double cut files. Material removing rates is
more in double cut file than in single cut file.
[Link] Pitch
The number of teeth in one centimeter is called the pitch of the file. The number of
teeth varies from 10 to 40 in one centimeter.
[Link] Use of File
The file should be used in perfect horizontal position. Most of the files have their
teeth pointing forward. So the pressure should be applied on the forward only. The
work is held in a vice after marking. Keeping right hand on the handle and left hand
on the front end, file is moved to and fro with a speed of 15 to 25 strokes per minute.
Rough files are used where material removing is more and fine files are used for
finishing works.
[Link] Care of Files
The following points should be kept in mind while using and storing the files.
1. The teeth should be protected from excessive wearing.
2. Files should be stored in wooden rack.
3. Files cleaner should be used for cleaning the files.
4. When not in use, files should be coated with oil.
[Link] Soft Edge File
It is a file having one edge without teeth. Soft edge file is used in complex shaped
workpiece in order to avoid cutting with upper side of the file.
[Link] Types of Filling
There are several methods of filing, each with a specific purpose. With reference to
the figure, the following may be noted:
1. Holding the file: For heavy work and to remove more metal, a high pressure is
used. For light and fine work, a light pressure is applied.
2. Filing internal curves: A part of half round file only makes contact as shown
during filing operation. Movement of the file is indicated by arrows.
3. Cross filing: It is the most common method of filing. Cross filing is carried out
across two diagonals, to produce medium surface finish. It is used when large
amounts of metal is to be removed. By cross filing ‘rounding’ the surface is reduced.
4. Straight filing: When a short length of workpiece is required to have a flat surface,
straight filing is used. File marks made during cross filing may be removed, to
produce a relatively smooth surface.
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5. Draw filing: It is done to get a finely finished surface. It produces a smoother
surface finish than straight filing. A smooth or dead smooth flat file is used for this
3.7 Finishing Tools
3.7.1 File Card
It is a metal brush, used for cleaning the files, to free them from filings, clogged in
between the teeth.
3.7.2 Spirit level
It is used to check the leveling of machines.
3.7.3 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.
3.7.4 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.
3.7.5 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
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Assignment : 3
1. Explain Bench Work and Fitting?
2. State the different processes done in fitting shop.
3. List down the various types of tools used in fitting shop.
4. List down the different types of marking and measuring tools used in fitting shop.
5. Explain the process and types of filing?
6. What are the different types of files? Explain each of them.
7. To make a fitting job as per given drawing.
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Drawing
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Shop : Fitting
Size of Raw Material : M.S. Plate 50 x 50 x 3 mm
Finished Size : 45 x 45 x 3 mm
Date of Material Issued :
Instruments Used : Try square
Dot punch
Center Punch
Marking Square gauge
Steel rule
Hacksaw Frame
Hacksaw Blade
Rough & Smooth File (Flat)
Ball Pen Hammer
Date Period Signature of Instructor Starting Date & Signature
Finished Date & Signature
Remarks
Date of Submission___________________
Signature___________________
Rubric-wise marks obtained:
Evaluation Understanding Quality of Attendance and Involvement Total
Parameters of the topic laboratory work in laboratory session (20 Marks)
(7Marks) (7 Marks) (6 Marks)
Marks
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